C-9 LAB EXERCISES(Student's Copy)Index of LabsLab A: C-9 Systems Component IdentificationLab B: C-9 Systems OperationLab C: Fuel Injection System Component Removal and Installation Lab D: Fuel Injection System Testing and AdjustingLab E: Electrical/Electronic Component Removal and Installation Lab F: Electronic System Power Supply TestingLab G: Electrical/Electronic Component Testing and Adjusting Lab H: General System DiagnosticsLab A: C-9 Systems Component IdentificationShop Exercise Using the lab worksheets and the system schematics, identify thefollowing components where visible:Cooling SystemThermostat and housingCoolant temperature sensorWater pumpBypass lineLubrication SystemOil pressure sensorOil pumpOil filterOil coolerOil breatherAir Intake and Exhaust SystemAtmospheric pressure sensorTurbocharger inlet pressure sensor, if installedTurbocharger outlet pressure sensorInlet manifold heater and relayAir filtersTurbocharger compressorTurbocharger turbineWastegate, if installedFuel Delivery SystemUnit injectorTransfer pumpPriming pumpPrimary filterWater separatorSecondary filterFuel pressure regulating valveEXERCISE INSTRUCTOR NOTELab A: C-9 Systems Component Identification (continued)Electronic Control SystemECM and 70 pin connectorsPersonality moduleSpeed/timing sensorsHEUI hydraulic pumpPump control valveHydraulic pressure sensorAnalog and digital sensorsElectronic unit injectorService tool connectorMachine interface connectorSystem power suppliesData linksShutdown systemsSystem power suppliesGround studAfter component identification, state the function and location of eachcomponent listed on the worksheet either written or orally. All engine MATERIALS NEEDEDlocations are referenced from the rear of the engine.C-9 engine orMachine or truck with C-9 engineCooling, lubrication, air intake and exhaust system schematicsLab A WorksheetsLab A WorksheetsCOOLING SYSTEM _____ Thermostat and HousingFunction:Location:_____ Coolant Temperature SensorFunction:Location:_____ Water pumpFunction:Location:_____ Bypass LineFunction:Location:Lab A: WorksheetsLUBRICATION SYSTEM _____ Oil pressure SensorFunction:Location:_____ Oil pumpFunction:Location:_____ Oil filterFunction:Location:_____ Oil coolerFunction:Location:_____ Oil breatherFunction:Location:Lab A: WorksheetsAIR INTAKE AND EXHAUST SYSTEM _____ Atmospheric Pressure SensorFunction:Location:______ Turbocharger Outlet Pressure SensorFunction:Location:_____ Inlet Manifold Heater and RelayFunction:Location:_____ Turbocharger CompressorFunction:Location:_____ Turbocharger TurbineFunction:Location:Lab A: WorksheetsFUEL DELIVERY SYSTEM _____ Transfer PumpFunction:Location:_____ Priming PumpFunction:Location:_____ Primary Filter and Water SeparatorFunction:Location:_____ Secondary FilterFunction:Location:_____ Unit InjectorFunction:Location:_____ Fuel Pressure Regulating ValveFunction:Lab A: WorksheetsFUEL DELIVERY SYSTEM _____ Cylinder Head Fuel PassageFunction:Location:_____ ECM Fuel Cooling Passage (if so equipped)Function:Location:Lab A: WorksheetsFUEL CONTROL SYSTEM _____ ECM and 70 Pin ConnectorsFunction:Location:_____ HEUI Hydraulic PumpFunction:Location:_____ Hydraulic Pump Control Valve (IAPCV)Function:Location:_____ Hydraulic ManifoldFunction:Location:_____ Hydraulic Pressure SensorFunction:Location:_____ Hydraulic Oil Temperature SensorsFunction:Lab A: WorksheetsFUEL CONTROL SYSTEM _____ Speed/Timing SensorsFunction:Location:_____ Timing WheelFunction:Location:_____ Timing Calibration ProbeFunction:Location:_____ Throttle Position SensorFunction:Location:_____ Shutdown SwitchFunction:Location:_____ User Defined ShutdownFunction:Lab A WorksheetsFUEL CONTROL SYSTEM _____ CAT Data LinkFunction:Location:_____ CAN Data LinkFunction:Location:_____ Service Tool ConnectorFunction:Location:_____ Analog Power SupplyFunction:Location:_____ Digital Power SupplyFunction:Location:_____ Ground StudFunction:Location:Lab B: C-9 Systems OperationShop ExerciseUsing the system schematics, trace the flow through the systems and EXERCISEidentify the following components on the schematics:Cooling SystemThermostat and housingCoolant temperature sensorWater pumpBypass lineLubrication SystemOil pressure sensorOil pumpOil filterOil coolerOil breatherAir Intake and Exhaust SystemAtmospheric pressure sensorTurbocharger inlet pressure sensor, if installedTurbocharger outlet pressure sensorInlet manifold heater and relayAir filtersTurbocharger compressorTurbocharger turbineWastegate, if installedFuel Delivery SystemUnit injectorTransfer pumpPriming pumpPrimary filterWater separatorSecondary filterFuel pressure regulating valveLab B: C-9 Systems Operation (continued)Electronic Control SystemECM 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 studCooling, lubrication, air intake, exhaust, fuel system and electronic systems schematicsMATERIALS NEEDEDEXERCISELab C: Fuel Injection System Component Removal and InstallationShop ExerciseRemove and install the following components following Service Manual procedures:Transfer PumpFuel Pressure Regulating Valve Primary Filter Secondary Fuel Filter Hydraulic Unit Injector Hydraulic (HEUI) PumpNote 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 ManualCommunication Adapter and Cables Caterpillar MultimeterInjector removal installation tool Mechanic's tool box with hand toolsMATERIALS NEEDEDEXERCISELab D: Fuel Injection System Testing and AdjustingClass 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 ETRetrieve Active and Logged Faults for injectors Injector Solenoid TestManual Cylinder Cutout Test with no loadManual Cylinder Cutout Test with a constant load applied Automatic Cylinder Cutout Test Cylinder Cutout with torque stall test Injector Actuation Pressure TestA machine or truck with a C-9 Engine and/or C-9 engine PC with ET/STW software installed Engine Service ManualCommunication Adapter and Cables Caterpillar MultimeterInjector removal installation tool Mechanic's tool box with hand tools Lab D WorksheetsEXERCISEMATERIALS NEEDEDLab E: Electrical/Electronic Component Removal and InstallationNOTE: 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 ECMEngine Service ManualAn operable training engine and/or a C-9 powered machine or truck PC with ET/STW software installed Communication Adapter and Cables Caterpillar MultimeterMechanic's tool box with hand toolsMATERIALS NEEDEDEXERCISELab F: Electronic System Power Supply TestingClass 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 supplyThe 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 ETinjection 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 MultimeterMechanic's tool box with hand tools Lab F WorksheetMATERIALS NEEDEDEXERCISELab 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 ManualAn operable training engine and/or a C-9 powered machine or truckPC with ET/STW software installedCommunication Adapter and CablesCaterpillar MultimeterMechanic's tool box with hand toolsLab G WorksheetsMATERIALS NEEDED EXERCISEINSTRUCTOR NOTELab 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 truckEngine Service ManualPC with ET/STW software installedCommunication Adapter GroupCaterpillar MultimeterMechanic's tool box with hand toolsLab H WorksheetsMATERIALS NEEDED EXERCISELOW POWER OR FAILURE TO START COMPLAINTSReview 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 shortAnalog sensor power supply faultBoost pressure sensor faultInjector faultCoolant/oil temperature lowHydraulic pressure sensor faultHydraulic leakPump control valve faultAt 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.。