controles electronicos del motor

8/12/2019 Controles Electronicos Del Motor

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Service Training July 2002

ELECTRONIC ENGINE CONTROLS

Nigel Wilkinson


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C-9 ENGINESYSTEMS AND CONTROLS

SLIDES AND SCRIPT

AUDIENCE

Level II--Service personnel who understand the principles of engine systems operation, diagnostic

equipment, and procedures for testing and adjusting.

CONTENT

This presentation is designed to prepare a service technician to identify the components, explain their

function, and service the C-9 Engine in all machine and industrial applications.

OBJECTIVES

After learning the information in this presentation, the serviceman will be able to:

1. Locate and identify the major components in the C-9 engine systems.

2. Explain the functions of the major components in the C-9 engine systems.

3. Trace the flow of fuel and oil through the fuel system.

4. Trace the flow of current through the engine electrical system.

PREREQUISITES

Interactive Video Course "Fundamentals of Electrical Systems" (CD ROM) TEMV9002

Service Technician Workbench Tutorial (CD ROM included with STW software) NEHS0812

Caterpillar Machine Electronics Course (Five Modules) SEGV3001 - SEGV3005

Caterpillar HEUI HI300B Fuel System (CD ROM) RENR1392

Prior training in systems operation and testing and adjusting procedures for electronic engines should be

completed before participating in this training session. Additionally, the participants should have PC

skills including training in the current Windows operating system and the most current Electronic

Technician (ET) software.

Three serviceman's handouts are provided with this STMG. However, as this publication is available

electronically, it can be printed in color and used selectively or totally, in the class as a handout. This

feature will enable the student to follow the presentation and make notes in the book.

This publication is not available in paper form and is only available from the intranet at this time.

Estimated Time: 8 Hours

Visuals: 72 Electronic Slides

Date: 07/2002

2002 Caterpillar Inc.


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SUPPLEMENTARY TRAINING MATERIAL

Brochure "Service Technician Workbench" NELG5028

Brochure "Caterpillar Electronic Technician" NEDG6015

Service Technician Workbench Tutorial (Included with STW software) NEHS0812

Caterpillar HEUI Fuel System (Interactive CD ROM) RENR1392

RECOMMENDED C-9 ENGINE TOOLING

Software and Manuals

Caterpillar Service Tool Software/Getting Started Guide - Service Technician Workbench NEHS0796

or Caterpillar Service Tool Software/Getting Started - Caterpillar Electronic Technician JEBD3003

Caterpillar Service Tool Software/Users Manual- Communication Adapter II NEHS0758

Mechanical Tools

C-9 Tool Kit (contains all C-9 special tools) 196-3165

Engine Turning Tool 9S-9082

Engine Turning Tool (for tractors) 208-0888

Electronic Tools

Laptop computer

Communication Adapter II (Group) 171-4400

Cable, PC to Communication Adapter 96-0055Cable, Communication Adapter to Machine 160-0133

Caterpillar Digital Multimeter 146-4080

Three Pin DT Breakout Harness 7X-6370

Cable Probes 7X-1710

Auxiliary ECM Power Supply Harness 167-9225

Timing Calibration Probe (Magnetic Pickup) 6V-2197

Timing Calibration Probe Adapter Sleeve 7X-1171

Timing Calibration Probe Cable 7X-1695

REFERENCES

Systems Operation Testing and Adjusting "C-9 Industrial Engines" SENR9598-02

Systems Operation Testing and Adjusting "C-9 Engine for Caterpillar Built Machines" SENR9501

Troubleshooting Manual "C-9 Engine for Caterpillar Built Machines" D6R Tractor SENR9503

Disassembly and Assembly "C-9 Engines for Caterpillar Built Machines" SENR9502

Specifications Manual "C-9 Engines for Caterpillar Built Machines" SENR9500

Diagnostic Cables and Harnesses NEHS0822

C-9 Engine - 3 -

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C-9 Engine - 4 -

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TABLE OF CONTENTS

INTRODUCTION TO SYSTEMS OPERATION

Introduction ......................................................................................................................5

Lab Exercise ...................................................................................................................23

SYSTEM POWER SUPPLIES

Introduction ....................................................................................................................27

ECM Power Supply .......................................................................................................28

Injector and Compression Brake Power Supply ............................................................32

Hydraulic Pump Control Valve Power Supply ...............................................................33

Analog Sensor Power Supply ........................................................................................34

Digital Sensor Power Supply .........................................................................................35

Air Intake Heater Power Supply.....................................................................................36

Service Tool Power Supply.............................................................................................37Lab Exercise ...................................................................................................................38

ELECTRONIC CONTROL SYSTEM

Introduction.....................................................................................................................41

Fuel Injection .................................................................................................................44

Fuel Injection Control System .......................................................................................46

SYSTEM CALIBRATIONS

Introduction.....................................................................................................................53

Speed/Timing Sensor Calibration ..................................................................................53

Injector Calibration ........................................................................................................58

Pressure Sensor Calibration ...........................................................................................60

Oil Grade Detection ........................................................................................................61

Engine Warnings and Derates.........................................................................................63

Lab Exercise ...................................................................................................................64

ELECTRONIC SENSORS AND SYSTEMS

Introduction ....................................................................................................................67

Injector and Compression Brake Systems ......................................................................68Speed/Timing Sensors ....................................................................................................69

Analog Sensors and Circuits ..........................................................................................72

Digital Sensors and Circuits ...........................................................................................86

Engine Shutdown Systems .............................................................................................89

Cold Starting Aids .........................................................................................................90

Data Link Circuits ..........................................................................................................93


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TABLE OF CONTENTS

CONCLUSION ....................................................................................................................96

Lab Exercise ...................................................................................................................97

SLIDE LIST .........................................................................................................................98

STUDENT HANDOUTS ....................................................................................................99

C-9 Engine - 5 -

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Introduction

Manual contents

Introduction

- Use System

Operation manual

for reference

INTRODUCTION TO SYSTEMS OPERATION

Introduction

This presentation describes the C-9 Engine Structure, Air Intake and

Exhaust, Cooling, Lubrication, Electrical and Fuel Systems.

Each portion of the training manual is followed by a lab exercise to

reinforce the location and function of each component.

The training manual is laid out as follows:

Introduction to Systems Operation

System Power Supplies

Electronic Control System

System Calibrations

Electronic Sensors and Systems

INSTRUCTOR NOTE: The Systems Operation portion of the Systems

Operation Testing and Adjusting manual for C-9 Industrial Engines

(SENR9598-02) can be used to supplement the Slide/Text information.

A separate publication, Caterpillar C-9 Hydraulic Electronic Unit

Injection (HEUI) Fuel system CD ROM (RENR1392) should also be used

to describe the HEUI fuel system in detail.

C-9 Engine - 6 -

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Cylinder and valve

location

8.8 liters displacement

Inlet and exhaust

valve arrangement

The C-9 engine has an in-line six cylinder arrangement. The engine has a

bore of 112 mm (4.4 in) and a stroke of 149 mm (5.9 in). The engine

displacement is 8.8 liters.

Note the arrangement of the inlet and exhaust valves for identification

purposes.

C-9 Engine - 7 -

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123456

EXHAUSTVALVES

INLETVALVES

CYLINDER AND VALVE LOCATION

FIRING ORDER 1 5 3 6 2 4

BORE 112 MM (4.4 IN)STROKE 149 MM (5.9 IN)

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Major components

ECM

This view of an industrial engine, shows some of the major components

of the engine.

The major fuel system and electronic components are mounted on the left

hand side of the engine.

Note the ECM on the lower right hand side.

The Systems Operation portion of the Systems Operation Testing and

Adjusting manual for C-9 Industrial Engines (SENR9598-02) can be used

to locate the various components. Otherwise the appropriate Service

Manual for the application should be used.

C-9 Engine - 8 -

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C-9 Engine - 9 -

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HEUI system

schematic

Similar to other HEUI

systems

Some system

differences

- New HEUI hydraulicpump

- No jumper tubes

- Two hydraulic oiltemperature sensors

- Water in fuel andfuel pressuresensors available

This visual is taken from the Caterpillar HEUI HI300B Fuel System CD

RENR1392. This CD will supply all the information on the HEUI fuel

system, electronics and related diagnostics.

This HEUI system is very similar to the 3408E, 3412E and 3126 HEUI

systems. There are a number of features which differ from other engines.

The hydraulic pump is a completely new design.

There are no jumper tubes on the injectors. Oil under pressure is feddirectly from the cylinder head to the injectors.

There are two Hydraulic Oil Temperature Sensors installed on the engine.

Optional water in fuel and fuel pressure sensors may be installed in the

fuel supply system.

See also Student Handout No. 1 for a dedicated fuel supply system

diagram.

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C-9 Engine - 10 -

07/02

HEUI system

hydraulic pump

Transfer pump

mounted on rear of

HEUI pump

This view shows a cutaway of the HEUI pump.

The hydraulic pump is a high pressure, variable delivery piston pump.

This pump provides the hydraulic power to actuate the injectors.

The fuel system transfer pump is mounted on the rear of the hydraulic

pump and will deliver 450 100 kPa (65 1.5 psi).

This pump is fully described in the CD RENR1392 (described on the

previous page).

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Cross flow cylinder

head

- Improves emissions

and fuel

consumption

The C-9 engine has a cross flow cylinder head. This feature allows for

improved emissions and fuel consumption by improving the combustion

airflow through the engine.

C-9 Engine - 11 -

07/02

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Air intake and exhaust

system schematic

Air intake heater

The air to air aftercooler is used in most applications, the exception is the

marine engine. By cooling the precharge air, this component increases

the mass flow of air through the engine, thus allowing more horsepower.

The air intake heater is used to aid starting and reduce white smoke in

cold conditions.

In most applications, the air intake heater has replaced the ether aid. In

extreme cold (Arctic) conditions, it is possible to use the ether aid in

conjunction with the air intake heater. At this time however, C-9 engines

are noT being built with an ether aid.

C-9 Engine - 12 -

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AIRINLET

EXHAUSTOUTLET

EXHAUSTMANIFOLD

EXHAUSTVALVE

INLETVALVE

COMPRESSORSIDE

TURBINESIDE

TURBOCHARGER

INTAKEHEATER

AIR TO AIRAFTERCOOLER

AIR INTAKE AND EXHAUST SYSTEM

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Turbocharger

components

The turbocharger is conventional and may be equipped with a Wastegate

(next page).

C-9 Engine - 13 -

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AIRINLET

COMPRESSORHOUSING

COMPRESSORWHEEL BEARING

OILOUTLETPORT

TURBINEHOUSING

BEARING TURBINEWHEEL

EXHAUSTOUTLET

EXHAUST INLET

OILINLETPORT

TURBOCHARGER

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Turbocharger

wastegate

Wastegate bypasses

exhaust around the

turbocharger

Some C-9 applications are equipped with a turbocharger wastegate.

If the engine is required to respond rapidly at low rpm, it may be

necessary to optimize the turbocharger for this speed. In this case, the

turbocharger may develop excessive boost at rated speed and load.

The wastegate redirects a portion of the exhaust gasses past the

turbocharger which effectively limits turbocharger speed and boost. This

feature also limits cylinder pressure, thus protecting the engine from

undue stress.

The wastegate is preset at the factory and no adjustments can be made.

C-9 Engine - 14 -

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Valve train

Camshaft mounted

high in the block

The C-9 Camshaft is mounted high up in the block to reduce the size of

the pushrods and therefore reduces the reciprocating mass of the valve

mechanism. This feature improves the ability of the engine to sustain an

overspeed without damage.

C-9 Engine - 15 -

07/02

PUSH ROD

LIFTER

ROCKER ARM

BRIDGE

VALVE

SPRING

VALVE SYSTEM COMPONENTS

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Air intake heater and

temperature sensor

Heater controlled by

ECM

System warns of high

air intake temperature

The air intake system has a heater and a temperature sensor. The Air

Intake Temperature Sensor is used by the ECM in conjunction with the

Coolant Temperature Sensor to calculate the need for air intake heating.

The ECM controls the heater through a relay mounted above the intake

manifold.

The Intake Temperature Sensor is also used by the ECM to warn the

operator of excessive air intake temperatures.

This view shows a Challenger C-9 installation. Other C-9 applications

will vary slightly in the sensor installation.

The Service Manual, Systems Operation section, describes the various

modes of operation of this system. A description of the operation is also

included with the Electronic Sensors and Systems portion of this STMG.

C-9 Engine - 16 -

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Lubrication system

schematic

The lubrication system is conventional with the exception of the oil cooler

which is recessed (as shown on the next page) into the cylinder block.

C-9 Engine - 17 -

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OIL FILTER

OIL COOLER

HEUI PUMP

TOTURBOCHARGER

C-9 LUBRICATION SYSTEM

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Lubrication system

cross section

Oil cooler recessed

The lubrication oil supply system is shown here in this cross sectional

view of the cylinder block.

Note the oil cooler recessed into the block. This feature reduces the

overall width of the engine and reduces the possibility of leaks.

C-9 Engine - 18 -

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Cooling system

schematic

Water pump is belt

driven

The system is conventional with a full flow by-pass outlet thermostat.

The water pump is belt driven by a pulley from the crankshaft.

C-9 Engine - 19 -

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CYLINDERHEAD

CYLINDERBLOCK

OILCOOLER

WATERPUMP RADIATOR

BYPASSHOSE

EXPANSION TANKWATER TEMPERATUREREGULATOR HOUSING

COOLING SYSTEM

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Fractured rod

Use care when

handling mating

surfaces

Fractured rod

manufacturing

process

This visual shows the fractured rod. The rod is deliberately fractured

during the manufacturing process in order to provide a mating surface that

does not allow fretting or sideways movement between the two halves of

the rod.

NOTE: Care should be taken to avoid damage to the mating faces during

handling. The rod must be replaced if there is any damage to the mating

surfaces. If the surfaces are damaged, bearing crush will be insufficient

which can cause the bearing to spin in its bore.

The fracture process involves the following steps:

The bolt holes are fully drilled, and tapped prior to fracture.

The fracture process begins with rough boring the crank end prior to

fracture (approximately. 1 mm undersize).

A laser (or "V" broach) is then used to etch a "V" notch for

initiating the crack split line.

A wedge is used in a hydraulically activated expanding mandrill to

force apart the rod and cap at the split line.

C-9 Engine - 20 -

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After the rod is split, the bolts are inserted and the cap reassembled.

The bolts are tightened to about 90% of final torque, backed off,

and the cap removed.

The joint is then cleaned to remove any chips that may have brokenoff, before the cap and rod are reassembled and the bolts re-

tightened down again. This procedure is performed twice.

Once tightened, the cap is not separated from the rod again during

the rest of the machining process. (Note: A fixture or torque gun

would be required to loosen the bolts prior to dispatch, or during

piston sub-assembly).

The advantages associated with fracturing the split are primarily reducedmachining operations. Some examples are as follows:

No machining of joint faces necessary.

No deburring of joint face edges due to perfectly matched joint

faces.

Elimination of dowels or fitted bolts (fracture surface results in a

perfectly mated joint).

Near net shape forgings (may eliminate the need for additional

balance machining).

Single clamping fixture required for machining bolt holes (no

separate cap and rod machining - same for bearing tab slots).

The majority of the benefits with fractured split rods lie in the

manufacturing process. There are other benefits such as virtual

elimination of fretting on the joint face, with the rod being able to accept

higher loads, due to perfectly matched surfaces. In addition, one of the

reported benefits of fractured split rods is that they tend to have a higher

processing quality than conventional rods due to the reduced machining

steps and controlled machining process. From a cost standpoint, this

feature can result in a part cost that is significantly reduced.

C-9 Engine - 21 -

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Crankshaft oil flow

Oil flow to rod

bearings

Related failure

analysis publications

This visual shows the path of oil flow from the main bearings to the rod

bearings.

It can be seen that three main bearings (1, 4 and 7) do not feed any rod

bearings. Two more main bearings (2 and 6) supply oil to one rod bearing

each. Main bearing numbers 3 and 5 supply oil to two rod bearings each.

This information is important if a bearing failure analysis is performed.

For additional information in bearing failure analysis, please refer to the

following AFA (Applied Failure Analysis) publications:

STMG Engine Bearings (SERV8001)

Engine Bearing Failure Analysis (SEBV0544)

C-9 Engine - 22 -

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OIL GALLERY

MAINBEARINGS

(7)

ROD BEARINGS (6)

1234567

123456

CRANKSHAFT OIL FLOW

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Viscous crankshaft

vibration damper

The viscous crankshaft vibration damper is also used to reduce crankshaft

torsional vibrations. This damper uses a heavy ring enclosed within a

casing and suspended by a viscous oil to oppose torsional vibration

forces.

C-9 Engine - 23 -

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CRANKSHAFT

WEIGHT

CASE

VISCOUS VIBRATION DAMPER

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Lab exercise

INSTRUCTOR NOTE: The following exercises will reinforce the

material introduced in the preceding pages and will allow questions to be

answered.

Lab Exercise:

The following exercise will reinforce the material introduced in the

preceding slides and will allow questions to be answered.

At this time, it is recommended that each component be located on the

machine and the function of each component reviewed with the students.

A list of the components follows on the next page.

If an engine is available out of a machine, component identification will

be easier because some components are difficult to see.

Some additional (used/defective) components available for examination

on a table will be helpful.

The Systems Operation portion of the Systems Operation Testing and

Adjusting manual for C-9 Industrial Engines (SENR9598-02) can be used

to supplement the Slide/Text information.

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Electrical Component List

ECM and 70 Pin Connectors (2)

Timing Calibration Installation Location

Timing Calibration Connector

Speed Timing Sensors

Coolant Temperature Sensor

Inlet Air Temperature Sensor

Atmospheric Pressure Sensor

Turbocharger Outlet Pressure Sensor

Oil Pressure Sensor

Hydraulic Oil Temperature Sensors

Fuel Temperature Sensor

Machine Interface Connector

Engine and Machine Ground Bolts

Service Tool Connector

Throttle Position Sensor

Shutdown Switches

Battery Disconnect Switch

Mechanical (Fuel Delivery) Component List

Primary Filter and Water Separator

Water in Fuel Sensor (if installed)

Secondary Filter

Priming Pump

Transfer Pump

Pressure Regulator Valve

Injectors (6)

Cylinder Head Fuel Passage

ECM Fuel Cooling Passage and Connectors (if installed)

Mechanical Component List

Thermostat

By-pass hose

C-9 Engine - 25 -

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INSTRUCTOR NOTES

C-9 Engine - 26 -

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Seven system power

supplies


Introduction

The C-9 HEUI system has seven power supplies with various voltages as

shown.

EXTERNAL POWER SUPPLY

ECM power supply (machines) 24 Volts

Challenger Tractors and some industrial engines 12 Volts

Air intake heater (machines) 24 Volts

Service Tool Power Supply 24 Volts

INTERNAL POWER SUPPLIES

Injector and compression brake power supplies 70 Volts

Pump control valve PWM

Analog sensor power supply 5 Volts

Digital sensor power supply 8 Volts

These power supplies are described in detail in the following section.

C-9 Engine - 27 -

07/02

C-9 HEUI


ECM

Injectors and Compression Brake

Pump Control Valve

Analog Sensors

Digital Sensors

Air Intake Heater

Service Tool

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C-9 Engine - 28 -

07/02

24 Volt power supply

Power supply

components

Power supply

diagnostic message

J2 J1

6 DRIVERS

3 RETURNS

ENGINE RETARDER

SOLENOIDS

ECM

TIMING CALIBRATIONCONNECTOR

GROUNDBOLT

20 AMPBREAKER

MAINPOWERRELAY

KEY STARTSWITCH

24 V

20 AMP FUSE

CRANK WITHOUT INJECT PLUG

DISCONNECT SWITCH

ECM Power Supply

The power supply to the ECM and the system is provided by the 24 Volt

machine battery. The principle components in this circuit are:

- Battery

- Key Start Switch

- Main Power Relay

- 20 Amp Breaker

- 20 Amp Fuse

- Ground Bolt

- ECM Connector (P1/JI)

If the supply voltage exceeds 32.5 Volts or is less than 9.0 Volts, a

diagnostic message is logged. (See the Troubleshooting Guide for

complete details on voltage event logging.)

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C-9 Engine - 29 -

07/02

ECM power supply

circuit

ECM switched

connection

- Energizes ECM

48

52

53

70

ECM (C-9)

24 VOLTS DC

(+)

(-)

ENGINE BLOCK

GROUND BOLT

15 AMP

CIRCUIT BREAKER

BATTERY

R

C

S

B ST

OFF

ON

KEY SWITCH

P1 J1

(-) BATTERY

(-) BATTERY

(-) BATTERY

61

63

65(+) BATTERY

(+) BATTERY

(+) BATTERY

(+) SWITCHED POWER

(+) BATTERY SUPPLY WIRES

INPUT SIGNAL WIRES TO ECM

OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

SIGNAL PLUS

SIGNAL MINUS

(-) BATTERY / SENSOR RETURN

WIRE FUNCTION COLOR CODE

FUSE

20 A

DISCONNECT

SWITCH

ECM POWER SUPPLY CIRCUIT

This schematic shows the principle components for a typical C-9 power

supply circuit. Battery voltage is normally connected to the ECM.

However, an input from the key start switch turns the ECM ON.

Note the seven power connections on the ECM. There are three wires

permanently connected to the ECM battery positive and three to the

battery negative. This feature is used to reduce the amperage on the

individual pins. The actual current draw with the engine stopped with the

key off is very small.

There is also a switched connection from the battery positive (ECM

pin 70). The purpose of the "switched power" connection is to energize or

"wake up" the ECM. The key switch circuit energizes the whole ECM

from "sleep mode," which in turn activates power supplies, sensors,

actuators, injectors, data links etc.

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Battery disconnect

switch

Wiring harness

bypass

The battery disconnect may be either on the positive or the negative cable

depending on the application. The relevant Troubleshooting Guide will

show the location and the polarity of the switch.

The machine wiring harness can be bypassed for troubleshooting

purposes. These steps are described in the Troubleshooting Guide

procedure. A breakout harness can be used and is referenced under "C-9

Recommended Tooling" at the front of this book.

The supply voltage may be conveniently checked using the ET Status

Screen display.

NOTE 1: The Challenger Tractor engine and some industrial engines

may have a 12 Volt power supply.

NOTE 2: The Wire Function Color Code is shown here for the first time

and is used through the presentation.

C-9 Engine - 30 -

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C-9 Engine - 31 -

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P1/P2 70 pin ECM

connectors

P1/J1 machine

interface connector

13

23

31

39

47

57

70

1

14

24

32

40

48

58

1

14

2 3 4 5 6 8 9 10 11 12 13

58 59 60 61 62 63 65 66 67 68 69 70

24

40

48

23

31

47

57

36

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