卡特C9发动机技术5

C-9 LAB EXERCISES
(Student's Copy)
Index of Labs
Lab A: C-9 Systems Component Identification
Lab B: C-9 Systems Operation
Lab C: Fuel Injection System Component Removal and Installation Lab D: Fuel Injection System Testing and Adjusting
Lab E: Electrical/Electronic Component Removal and Installation Lab F: Electronic System Power Supply Testing
Lab G: Electrical/Electronic Component Testing and Adjusting Lab H: General System Diagnostics
Lab A: C-9 Systems Component Identification
Shop Exercise Using the lab worksheets and the system schematics, identify the
following components where visible:
Cooling System
Thermostat and housing
Coolant temperature sensor
Water pump
Bypass line
Lubrication System
Oil pressure sensor
Oil pump
Oil filter
Oil cooler
Oil breather
Air Intake and Exhaust System
Atmospheric pressure sensor
Turbocharger inlet pressure sensor, if installed
Turbocharger outlet pressure sensor
Inlet manifold heater and relay
Air filters
Turbocharger compressor
Turbocharger turbine
Wastegate, if installed
Fuel Delivery System
Unit injector
Transfer pump
Priming pump
Primary filter
Water separator
Secondary filter
Fuel pressure regulating valve
EXERCISE INSTRUCTOR NOTE
Lab A: C-9 Systems Component Identification (continued)
Electronic Control System
ECM and 70 pin connectors
Personality module
Speed/timing sensors
HEUI hydraulic pump
Pump control valve
Hydraulic pressure sensor
Analog and digital sensors
Electronic unit injector
Service tool connector
Machine interface connector
System power supplies
Data links
Shutdown systems
System power supplies
Ground stud
After component identification, state the function and location of each
component listed on the worksheet either written or orally. All engine MATERIALS NEEDED
locations are referenced from the rear of the engine.
C-9 engine or
Machine or truck with C-9 engine
Cooling, lubrication, air intake and exhaust system schematics
Lab A Worksheets
Lab A Worksheets
COOLING SYSTEM _____ Thermostat and Housing
Function:
Location:
_____ Coolant Temperature Sensor
Function:
Location:
_____ Water pump
Function:
Location:
_____ Bypass Line
Function:
Location:
Lab A: Worksheets
LUBRICATION SYSTEM _____ Oil pressure Sensor
Function:
Location:
_____ Oil pump
Function:
Location:
_____ Oil filter
Function:
Location:
_____ Oil cooler
Function:
Location:
_____ Oil breather
Function:
Location:
Lab A: Worksheets
AIR INTAKE AND EXHAUST SYSTEM _____ Atmospheric Pressure Sensor
Function:
Location:
______ Turbocharger Outlet Pressure Sensor
Function:
Location:
_____ Inlet Manifold Heater and Relay
Function:
Location:
_____ Turbocharger Compressor
Function:
Location:
_____ Turbocharger Turbine
Function:
Location:
Lab A: Worksheets
FUEL DELIVERY SYSTEM _____ Transfer Pump
Function:
Location:
_____ Priming Pump
Function:
Location:
_____ Primary Filter and Water Separator
Function:
Location:
_____ Secondary Filter
Function:
Location:
_____ Unit Injector
Function:
Location:
_____ Fuel Pressure Regulating Valve
Function:
Lab A: Worksheets
FUEL DELIVERY SYSTEM _____ Cylinder Head Fuel Passage
Function:
Location:
_____ ECM Fuel Cooling Passage (if so equipped)
Function:
Location:
Lab A: Worksheets
FUEL CONTROL SYSTEM _____ ECM and 70 Pin Connectors
Function:
Location:
_____ HEUI Hydraulic Pump
Function:
Location:
_____ Hydraulic Pump Control Valve (IAPCV)
Function:
Location:
_____ Hydraulic Manifold
Function:
Location:
_____ Hydraulic Pressure Sensor
Function:
Location:
_____ Hydraulic Oil Temperature Sensors
Function:
Lab A: Worksheets
FUEL CONTROL SYSTEM _____ Speed/Timing Sensors
Function:
Location:
_____ Timing Wheel
Function:
Location:
_____ Timing Calibration Probe
Function:
Location:
_____ Throttle Position Sensor
Function:
Location:
_____ Shutdown Switch
Function:
Location:
_____ User Defined Shutdown
Function:
Lab A Worksheets
FUEL CONTROL SYSTEM _____ CAT Data Link
Function:
Location:
_____ CAN Data Link
Function:
Location:
_____ Service Tool Connector
Function:
Location:
_____ Analog Power Supply
Function:
Location:
_____ Digital Power Supply
Function:
Location:
_____ Ground Stud
Function:
Location:
Lab B: C-9 Systems Operation
Shop Exercise
Using the system schematics, trace the flow through the systems and EXERCISE
identify the following components on the schematics:
Cooling System
Thermostat and housing
Coolant temperature sensor
Water pump
Bypass line
Lubrication System
Oil pressure sensor
Oil pump
Oil filter
Oil cooler
Oil breather
Air Intake and Exhaust System
Atmospheric pressure sensor
Turbocharger inlet pressure sensor, if installed
Turbocharger outlet pressure sensor
Inlet manifold heater and relay
Air filters
Turbocharger compressor
Turbocharger turbine
Wastegate, if installed
Fuel Delivery System
Unit injector
Transfer pump
Priming pump
Primary filter
Water separator
Secondary filter
Fuel pressure regulating valve
Lab B: C-9 Systems Operation (continued)
Electronic Control System
ECM and 70 pin connectors Personality module Speed/timing sensors HEUI hydraulic pump Pump control valve Hydraulic pressure sensor Analog and digital sensors Electronic unit injector Service tool connector Machine interface connector System power supplies Data links Shutdown systems Ground stud
Cooling, lubrication, air intake, exhaust, fuel system and electronic systems schematics
MATERIALS NEEDED
EXERCISE
Lab C: Fuel Injection System Component Removal and Installation
Shop Exercise
Remove and install the following components following Service Manual procedures:
Transfer Pump
Fuel Pressure Regulating Valve Primary Filter Secondary Fuel Filter Hydraulic Unit Injector Hydraulic (HEUI) Pump
Note the importance of NOT filling the filter prior to installation.
A machine or truck with a C-9 Engine and/or C-9 engine Fuel Supply Circuit Schematic and sectional views (See Student Materials)
PC with ET/STW software installed Engine Service Manual
Communication Adapter and Cables Caterpillar Multimeter
Injector removal installation tool Mechanic's tool box with hand tools
MATERIALS NEEDED
EXERCISE
Lab D: Fuel Injection System Testing and Adjusting
Class or Shop Lab Exercise--This lab will verify that the student has the necessary skills to test the components after removal and installation. NOTE: Although helpful tips are provided to facilitate the labs, the Service Manual must be the final authority and source of information for the procedures. Demonstrate the following:
Input injector trim codes using ET
Retrieve Active and Logged Faults for injectors Injector Solenoid Test
Manual Cylinder Cutout Test with no load
Manual Cylinder Cutout Test with a constant load applied Automatic Cylinder Cutout Test Cylinder Cutout with torque stall test Injector Actuation Pressure Test
A machine or truck with a C-9 Engine and/or C-9 engine PC with ET/STW software installed Engine Service Manual
Communication Adapter and Cables Caterpillar Multimeter
Injector removal installation tool Mechanic's tool box with hand tools Lab D Worksheets
EXERCISE
MATERIALS NEEDED
Lab E: Electrical/Electronic Component Removal and Installation
NOTE: Although helpful tips are provided to facilitate the labs, the Service Manual must be the final authority and source of information for the procedures.
Students will remove and install the following components:
Pressure Sensors Temperature Sensor Throttle Position Sensor Speed/Timing Sensors ECM
Engine Service Manual
An operable training engine and/or a C-9 powered machine or truck PC with ET/STW software installed Communication Adapter and Cables Caterpillar Multimeter
Mechanic's tool box with hand tools
MATERIALS NEEDED
EXERCISE
Lab F: Electronic System Power Supply Testing
Class or Shop Lab Exercise--Students will use the procedures provided in the Student Materials to complete the exercise.
Each student should demonstrate competence in all tasks in this lab.
Test the following power supply circuits following the service manual procedures:
ECM power supply HEUI pump control valve Analog sensor power supply Digital sensor power supply Intake heater power supply
The injector power supply can be verified by the solenoid test or any of the injector tests.
The pump control valve power supply can be verified using the ET
injection actuation pressure test. Other method use use the status screen and check the current flow through the solenoid or a VOM.
Service literature (see Preparation Checklist)
An operable training engine and/or a C-9 powered machine or truck PC with ET/STW software installed Caterpillar Multimeter
Mechanic's tool box with hand tools Lab F Worksheet
MATERIALS NEEDED
EXERCISE
Lab G: Electrical/Electronic Component Testing and Adjusting Class or Shop Lab Exercise--Students will use the procedures provided in the Student Materials to complete the exercise. Each student should demonstrate competence in all tasks in this lab.NOTE: Although helpful tips are provided to facilitate the labs, the Service Manual must be the final authority and source of information for the procedures. Students will perform a diagnostic test on the following components:Pressure Sensors (perform calibration using two methods)Temperature Sensor Throttle Position Sensor Speed/Timing Sensors (perform calibration) ECM (program with new personality module flash file)Engine Service Manual
An operable training engine and/or a C-9 powered machine or truck
PC with ET/STW software installed
Communication Adapter and Cables
Caterpillar Multimeter
Mechanic's tool box with hand tools
Lab G Worksheets
MATERIALS NEEDED EXERCISE
INSTRUCTOR NOTE
Lab H: General System Diagnostics The purpose of this lab is to evaluate the student's ability to identify the source of low power and failure to start problems and to determine whether the fault is in the electronics or the mechanical parts of the HEUI system. Shop Lab Exercise--Students will use the procedures provided in the Student Materials to complete the exercises. Each student should demonstrate competence in all tasks in this lab.Students will perform diagnostic evaluations on the following circuit conditions/faults:Coolant temperature open or short Oil pressure signal open Low hydraulic pressure Injector open or short Analog sensor power supply fault Turbo outlet pressure sensor fault C-9 powered machine or truck
Engine Service Manual
PC with ET/STW software installed
Communication Adapter Group
Caterpillar Multimeter
Mechanic's tool box with hand tools
Lab H Worksheets
MATERIALS NEEDED EXERCISE
LOW POWER OR FAILURE TO START COMPLAINTS
Review the low power or failure to start diagnostic procedures in the Troubleshooting Guide before conducting the lab.
The first task is to determine the source of the problem (machine/ truck or engine). Then, if the problem is in the engine, determine if it is electronic or mechanical.
A number of checks can identify if the engine is, or is not, the root cause:
Actual engine rpm and desired engine speed.
Caterpillar Monitoring System Check Engine Lamp for HEUI system faults.
Derate for Automatic Altitude Compensation.
Air/Fuel Ratio Control derate.
Check boost at full power and compare with normal boost in similar conditions.
Check "fuel" position (synonymous with rack) on ET and compare with rated fuel.
The combination of any or all of the following faults can be used to create and troubleshoot a low power or failure to start problem:
Injector open or short
Analog sensor power supply fault
Boost pressure sensor fault
Injector fault
Coolant/oil temperature low
Hydraulic pressure sensor fault
Hydraulic leak
Pump control valve fault
At the end of the session, students should describe why the engine has a low power problem or failure to start problem with each of the above faults.。