Caterpillar C9 On-highway Engine Operation Testing Manual
Systems OperationTesting and Adjusting
C9 On-highway Engine
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential hazards This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information Safety precautions and warnings are provided in this manual and on the product If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION” The Safety Alert “WARNING” label is shown below
The message that appears under the warning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication, Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all-inclusive If a tool,
the procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or repair procedures that you choose
The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time These changes can affect the service that is given to the product Obtain the complete and most current information before you start any job Caterpillar dealers have the most current information available.
Caterpillar C9 On-highway Engine Operation Testing Manual
Table of Contents :
Systems Operation Section
General Information 4
Electronic Control System Components 6
Fuel System 13
Air Inlet and Exhaust System 16
Lubrication System 21
Cooling System 24
Basic Engine 26
Rear Power Take-Off (PTO) 28
Electrical System 28
Testing and Adjusting Section
Fuel System
Fuel System – Inspect 33
Air in Fuel – Test 33
Engine Speed – Check 34
Finding Top Center Position for No 1 Piston 35
Fuel Injector – Test 36
Fuel Quality – Test 36
Fuel System – Prime 37
Fuel System Pressure – Test 38
Gear Group (Front) – Time 40
Air Inlet and Exhaust System
Air Inlet and Exhaust System – Inspect 41
Turbocharger – Inspect 45
Inlet Manifold Pressure – Test 48
Exhaust Temperature – Test 49
Aftercooler – Test 49
Engine Crankcase Pressure (Blowby) – Test 52
Engine Valve Lash – Inspect/Adjust 53
Lubrication System
Engine Oil Pressure – Test 55
Excessive Bearing Wear – Inspect 58
Excessive Engine Oil Consumption – Inspect 58
Increased Engine Oil Temperature – Inspect 58
Cooling System
Cooling System – Check (Overheating) 60
Cooling System – Inspect 62
Cooling System – Test 62
Water Temperature Regulator – Test 67
Water Pump – Test 67
Basic Engine
Piston Ring Groove – Inspect 69
Connecting Rod Bearings – Inspect 69
Main Bearings – Inspect 69
Cylinder Block – Inspect 69
Flywheel – Inspect 70
Flywheel Housing – Inspect 71
Vibration Damper – Check 73
Electrical System
Alternator – Test 74
Battery – Test 74
Caterpillar C9 On-highway Engine Operation Testing Manual