SENR9575-05 November 2007

P300 UNIT INJECTOR HARNESS CONNECTOR

Harness And Wire Electrical Schematic Symbols

Symbols

INTAKE MANIFOLD AIR TEMPERATURE P103

SPLICE G828 SPLICE G829

ENGINE COOLANT TEMPERATURE P100

FUEL TEMPERATURE P105

FUEL PRESSURE J209

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Circuit Breaker Symbol

Symbols and Definitions

Fuse - A component in an electrical circuit that will open the circuit if too much current flows through it.

ATMOSPHERIC PRESSURE P203

ENGINE OIL PRESSURE J201

ATMOSPHERIC PRESSURE J203 INTAKE MANIFOLD AIR TEMPERATURE P103

Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates that the component has screw terminals and a wire can be disconnected from it. Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). No circle indicates that the wire cannot be disconnected from the component. Ground (Wired): This indicates that the component is connected to a grounded wire. The grounded wire is fastened to the machine.

SPLICE G833

FUEL TEMPERATURE P105

FUEL PRESSURE J209

ELECTRONIC CONTROL MODULE P2 SECONDARY ENGINE SPEED/TIMING (CAMSHAFT) P402 TIMING CALIBRATION(TC) PROBE CONNECTOR P400

TURBO OUTLET (INTAKE MANIFOLD AIR) PRESSURE P200

ENGINE COOLANT TEMPERATURE P100

TURBO OUTLET (INTAKE MANIFOLD AIR) PRESSURE J200

Ground (Case): This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. Sender: A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. Solenoid: A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.

SECONDARY ENGINE SPEED/TIMING (CAMSHAFT) P402

P300 UNIT INJECTOR HARNESS CONNECTOR

SPLICE R993

SPLICE 993

SPLICE 997

PRIMARY ENGINE SPEED/TIMING (CRANKSHAFT) P401

ENGINE OIL PRESSURE P201

CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES 226-5758 AND 243-6620 (C-10/C-12) INTEGRAL SENSORS

PRIMARY ENGINE SPEED/TIMING (CRANKSHAFT) P401

ELECTRONIC CONTROL MODULE P2

C-10, C-12, C-15 and C-16 Industrial Engine Electrical System

Z2B1-UP Z2C1-UP BDL1-UP BEM1-UP BFM1-UP BCX1-UP

CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES 191-5204, 238-1773, AND 237-7595 (C-15/C-16)

Harness and Wire Symbols

1 2
Deutsch connector: Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
Wire, Cable, or Harness Assembly Identification: Includes Harness Identification Letters and Harness Connector Serialization Codes Part Number for Connector Plug

1 2

Sure-Seal connector: Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets.
Harness Identification Letter(s): (A, B, C, ..., AA, AB, AC, ...) Harness Connector Serialization Code: The "C" stands for "Connector" and the number indicates which connector in the harness. (C1, C2, C3, .....)

C-C4 AG-C3 130-6795 130-6795

Pin Single Wire Connector Socket

AG-C4 111-7898 1
Receptacle

L-C12 3E-5179

Part Number For Connector Recepticle

325-AG135 PK-14

5A
Pin or Socket Number

9X-1123

Fuse (5 Amps)
Component Part Number

INTAKE MANIFOLD AIR TEMPERATURE P103

Plug Harness identification code: This example indicates wire 135 in harness "AG".
SPLICE 997 SPLICE 993

2
Ground Connection Circuit Identification Number

200-L32 BK-14
Wire Color Wire Gauge

FUEL TEMPERATURE P105

SPLICE R993

2007 Caterpillar All Rights Reserved

TIMING CALIBRATION(TC) PROBE CONNECTOR P400
INJECTOR HARNESS CONNECTOR J300

Printed in U.S.A.

TURBO OUTLET (INTAKE MANIFOLD AIR) PRESSURE J200 ENGINE COOLANT TEMPERATURE P100

ATMOSPHERIC PRESSURE J203

FUEL PRESSURE J209

ELECTRONIC CONTROL MODULE P2

174-0502

160-7689

SECONDARY ENGINE SPEED/TIMING (CAMSHAFT) P402

P300 UNIT INJECTOR HARNESS CONNECTOR ENGINE OIL PRESSURE J201

A
D788 D786 D788 D787 SPLICE D786 D788 D786

155-2269
SPLICE D790 A701 A702
2 1

PRIMARY ENGINE SPEED/TIMING (CRANKSHAFT) P401

A706 D791

A705 D791 D790

A704

A703 D790

D789

D789
2 1

160-7690

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 189-6594 (C-10/C-12) PIGTAIL SENSORS
3E-3370
SPLICE D791 SPLICE D788 SPLICE D789

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 122-1486 (C-15/C-16)

9X-1343

5 15 25 35

6 16 26 36

10 20 30 40

155-2267

11 21 31

CATERPILLAR SUPPLIED ENGINE SERVICE TOOL CONNECTOR J63

8T-8736

E
A B

C A B J H

F G

SPLICE 120 SPLICE 892 SPLICE 893 SPLICE D788

INJECTOR HARNESS CONNECTOR J300

SPLICE D786
12 11 10 9 8 7

155-2252

GROUND
229 D786 SPLICE D791 D787 D786 SPLICE D789
1 2 3 4 5 6

GROUND
229

SPLICE D790 SPLICE A234 K990 K900

D788

D788

D788

TERMINATION RESISTOR P154

D791 A706 A705

5 6

D791

D789 A702 A701

1 2

D789

3E-7990

A704

A703

CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES 189-6596, 191-1531, 238-1774, 242-7248, AND 243-6618 (ALL)

ELECTRONIC CONTROL MODULE P1

INJECTOR #6

INJECTOR #5

D790
4

D790

Related Electrical Service Manuals

INJECTOR #2 INJECTOR #1

Title
Installation Guide

Industrial Engine
C-10,C-12 C-10,C-12 C-10,C-12 C-15,C-16 C-15,C-16 C-15,C-16 C-10(Z2B),C-15(Z2C) C-10(Z2B),C-15(Z2C)

Form Number
12 11 10 9 8 7

REHS0871 SENR9573 SENR9576 REHS0871 RENR2347 SENR9576 SENR9953 RENR5061

6 5 4 3 2 1 7 8 9 10 11 12

INJECTOR #4

INJECTOR #3

System Operation Test and Adjust Troubleshooting Installation Guide System Operation Test and Adjust Troubleshooting System Operation Test and Adjust Troubleshooting

3E-8969

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 4P-9537 (C-10/C-12)

30 Page,

CUSTOMER CONNECTOR J61

169-8670

SENR9575-05

(Dimensions: 39 inches x 28 inches)

INJECTOR #6

INJECTOR #5

INJECTOR #4

INJECTOR #3

INJECTOR #2

INJECTOR #1

C-10 and C-12 Engine and Injector Harness (Pigtail Sensors)

ECM GROUND STRAP
ELECTRONIC CONTROL MODULE (ECM) ANALOG SENSOR POWER (+5V) ANALOG SENS0R COMMON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

NOT USED NOT USED

A702 PU-16 A703 BR-16 A704 GN-16 A705 BU-16 NO.5 CYLINDER INJECTOR NO.4 CYLINDER INJECTOR

A701 GY-16

INJECTOR HARNESS CONNECTOR P300 1552252 A701/GY A702/PU A703/BR A704/GN A705/BU A706/GY L985/YL L984/OR L983/WH 1 2 3 4 5 6 7 8 9 10 11 12 J300 3E7990 A701 A702 A703 A704 A705 A706 D788 D791 D787 D790 D786 D789

C-10 and C-12 Engine and Injector Harness (Integral Sensors)

NO.1 CYLINDER INJECTOR
ECM GROUND STRAP
ELECTRONIC CONTROL MODULE (ECM)

NOT USED NOT USED

A702 PU-16 A703 BR-16 A704 GN-16 A705 BU-16 NO.5 CYLINDER INJECTOR NO.4 CYLINDER INJECTOR NO.3 CYLINDER INJECTOR

A701 GY-16

NOT USED GY-16 PU-16 BR-16 GN-16 BU-16 GY-16 BK-16 YL-16 GN-16 OR-16 BR-16 WH-16

INJECTOR HARNESS CONNECTOR P300 1552252 A701/GY A702/PU A703/BR A704/GN A705/BU A706/GY J702/BK L985/YL J701/GN L984/OR J700/BR L983/WH 1 2 3 4 5 6 7 8 9 10 11 12 J300 3E7990 A701 A702 A703 A704 A705 A706 D788 D791 D787 D790 D786 D789

C-15 and C-16 Engine and Injector Harness

NO.1 CYLINDER INJECTOR
ECM GROUND STRAP ECM MOUNTING BOLT
P2 1607690 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 997/OR 993/BR

RETARDER MED/HI (SPECIFIC ARRANGEMENTS) RETARDER MED/HI (SPECIFIC ARRANGEMENTS)

A702 PU-16 A703 BR-16 A704 GN-16 A705 BU-16 NO.5 CYLINDER INJECTOR NO.4 CYLINDER INJECTOR NO.3 CYLINDER INJECTOR

A701 GY-16

ECM MOUNTING BOLT

P2 1607690 997/OR 993/BR

NO.6 CYLINDER INJECTOR A706 GY-16 D791 YL-16

NO.3 CYLINDER INJECTOR

NO.2 CYLINDER INJECTOR

NOT USED GY-16 PU-16 BR-16 GN-16 BU-16 GY-16 BK-16 YL-16 GN-16 OR-16 BR-16 WH-16

ECM MOUNTING BOLT

P2 1607690 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 G828/WH G829/GN

NO.6 CYLINDER INJECTOR A706 GY-16 D791 YL-16

NO.2 CYLINDER INJECTOR

INJECTOR HARNESS CONNECTOR P300 1552252 A701/GY A702/PU A703/BR A704/GN A705/BU A706/GY J702/BK L985/YL J701/GN L984/OR J700/BR L983/WH 1 2 3 4 5 6 7 8 9 10 11 12 J300 3E8969 A701 A702 A703 A704 A705 A706 D788 D791 D787 D790 D786 D789

RETARDER LO/HI (SPECIFIC ARRANGEMENTS)

ELECTRONIC CONTROL MODULE (ECM)

D790 OR-16 D791 YL-16 D790 OR-16

D789 WH-16
ANALOG SENSOR POWER (+5V) ANALOG SENS0R COMMON

D790 OR-16 D791 YL-16 D790 OR-16

D789 WH-16

ANALOG SENSOR POWER (+5V) ANALOG SENS0R COMMON

D789 WH-16
NOT USED NOT USED NOT USED

D789 WH-16
P401 1552269
RETARDER COMMON (NOTE Y) RETARDER MED/HI (NOTE Y) RETARDER LOW/HI (NOTE Y)

P400 1552269 A747/GY 413/BR R993/BR G811/YL G810/PU P920/BR F732/PK 998/BR 999/WH 995/BU R993/BR 997/OR 993/BR A746/PK A747/GY 994/GY F421/YL 413/BR C967/BU 1 2

ATMOSPHERIC PRESSURE FUEL PRESSURE PASSIVE SENSOR RETURN

3E3364 TIMING CALIBRATION (TC) PROBE CONNECTOR P920/BR F732/PK

J702/BK J700/BR J701/GN A747/GY 413/BR R833/BR E963/BK E964/WH E965/BU E966/YL 995/BU R833/BR G828/WH G829/GN A746/PK A747/GY 994/GY A751/YL 413/BR C967/BU E963/BK E964/WH

P401 1552269 1 2 P402 1552269

998/BR 999/WH

ATMOSPHERIC PRESSURE

1 2 P402 1552269

BK-18 WH-18

SIGNAL(-) SIGNAL(+)

(CRANKSHAFT POSITION) PRIMARY ENGINE SPEED/TIMING SENSOR 188-7511

J702/BK J700/BR J701/GN A747/GY 413/BR R993/BR

GY-16 PU-16 BR-16 GN-16 BU-16 GY-16 BK-16 YL-16 GN-16 OR-16 BR-16 WH-16
P400 1552269 3E3364 TIMING CALIBRATION (TC) PROBE CONNECTOR P920/BR F732/PK

NO.6 CYLINDER INJECTOR A706 GY-16 D791 YL-16

NO.2 CYLINDER INJECTOR

NO.1 CYLINDER INJECTOR

D790 OR-16 D791 YL-16 D790 OR-16

D789 WH-16

D789 WH-16

ATMOSPHERIC PRESSURE FUEL PRESSURE PASSIVE SENSOR RETURN

G811/YL G810/PU P920/BR F732/PK 998/BR 999/WH 995/LTBU R993/BR 997/OR 993/BR A746/PK A747/GY 994/GY F421/YL 413/BR C967/LTBU

1 2

P401 1552269 1 2 P402 1552269

998/BR 999/WH

BK-18 WH-18

SIGNAL(-) SIGNAL(+)

(CRANKSHAFT POSITION) PRIMARY ENGINE SPEED/TIMING SENSOR 188-7511

FUEL PRESSURE PASSIVE SENSOR RETURN

E965/BU E966/YL

1 2

SIGNAL(-) SIGNAL(+)

(CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR 189-9801

SIGNAL(-) SIGNAL(+)

(CRANKSHAFT POSITION) PRIMARY ENGINE SPEED/TIMING SENSOR 189-9266

TIMING CALIBRATION PROBE + TIMING CALIBRATION PROBE ENGINE OIL PRESSURE

G811/YL G810/PU 994/GY

1 2

SIGNAL(-) SIGNAL(+)

(CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR 189-9801

P100 1552269 995/BU R833/BR 1 2 SIGNAL COMMON

P100 1552269 995/BU R993/BR J200 3E3370 A 997/OR B 993/BR A746/PK C J203 3E3370 A 997/OR B 993/BR C A747/GY J201 3E3370 A 997/OR B 993/BR C 994/GY OR-18 YL-18 GN-18 1 2 SIGNAL COMMON +5V RETURN SIGNAL

TIMING CALIBRATION PROBE + TIMING CALIBRATION PROBE ENGINE OIL PRESSURE

994/GY

ENGINE COOLANT TEMPERATURE SENSOR 130-9811

TIMING CALIBRATION PROBE + TIMING CALIBRATION PROBE ENGINE OIL PRESSURE

G811/YL G810/PU 994/GY

1 2

BK-18 WH-18
P100 1552269

SIGNAL(-) SIGNAL(+)

(CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR 188-7513

C-10 and C-12 Engines

Intake Manifold Air Temperature Sensor P103 Turbo Outlet Pressure Sensor (Intake Manifold Air) P200(J200)

ENGINE COOLANT TEMPERATURE SENSOR 130-9811 TURBO OUTLET PRESSURE SENSOR (INTAKE MANIFOLD AIR) 194-6724

P200 1552267 1698670 G828/WH G829/GN A746/PK 995/BU A751/YL C967/BU A701/GY A702/PU A703/BR A704/GN A746/PK

995/LTBU R993/BR J200 3E3370 997/OR A B 993/BR A746/PK C J203 3E3370 A B C J201 3E3370 A B C OR-18 YL-18 GN-18

1 2

SIGNAL COMMON +5V RETURN SIGNAL

EARLY LATE A +5V RETURN B SIGNAL C

ENGINE COOLANT TEMPERATURE SENSOR 130-9811 TURBO OUTLET PRESSURE SENSOR (INTAKE MANIFOLD AIR) 194-6724

ENGINE COOLANT TEMPERATURE FUEL TEMPERATURE INTAKE MANIF. AIR TEMPERATURE INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 TURBO OUTLET PRESSURE

995/BU F421/YL C967/BU A701/GY A702/PU A703/BR A704/GN A746/PK

ENGINE COOLANT TEMPERATURE FUEL TEMPERATURE INTAKE MANIF. AIR TEMPERATURE INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 TURBO OUTLET PRESSURE

TURBO OUTLET PRESSURE SENSOR (INTAKE MANIFOLD AIR) 161-1704

OR-18 YL-18 GN-18

+5V RETURN SIGNAL

ATMOSPHERIC PRESSURE SENSOR 194-6722

P203 1698670 G828/WH A G829/GN B A747/GY C P201 1698670 A G828/WH B G829/GN C 994/GY

ENGINE COOLANT TEMPERATURE FUEL TEMPERATURE INTAKE MANIF. AIR TEMPERATURE INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 TURBO OUTLET PRESSURE

995/LTBU F421/YL C967/LTBU A701/GY A702/PU A703/BR A704/GN A746/PK 997/OR 993/BR A747/GY

+5V RETURN SIGNAL

ATMOSPHERIC PRESSURE SENSOR 161-1703

OR-18 YL-18 GN-18

+5V RETURN SIGNAL

ATMOSPHERIC PRESSURE SENSOR 194-6722

INJECTOR COMMON 1 & 2 INJECTOR COMMON 3 & 4 INJECTOR COMMON 5 & 6 PRIMARY SPEED/TIMING + PRIMARY SPEED/TIMING -

L983/WH L984/OR L985/YL F732/PK P920/BR

OR-18 YL-18 GN-18 P105 1552269

+5V RETURN SIGNAL

ENGINE OIL PRESSURE SENSOR 194-6725

+5V RETURN SIGNAL P105 1552269

INJECTOR COMMON 1 & 2 INJECTOR COMMON 3 & 4 INJECTOR COMMON 5 & 6 PRIMARY SPEED/TIMING + PRIMARY SPEED/TIMING -

L983/WH L984/OR L985/YL E964/WH E963/BK A751/YL R833/BR J209 P209 3E3370 1698670 G828/WH A G829/GN B 413/BR C

ENGINE OIL PRESSURE SENSOR 161-1705

997/OR 993/BR 994/GY L983/WH L984/OR L985/YL F732/PK P920/BR F421/YL R993/BR

OR-18 YL-18 GN-18 P105 1552269 1 2

+5V RETURN SIGNAL

ENGINE OIL PRESSURE SENSOR 194-6725

INJECTOR COMMON 1 & 2 INJECTOR COMMON 3 & 4 INJECTOR COMMON 5 & 6 PRIMARY SPEED/TIMING + PRIMARY SPEED/TIMING -

F421/YL R993/BR P209 J209 1698670 3E3370 997/OR A B 993/BR C 413/BR

1 2

SIGNAL COMMON

FUEL TEMPERATURE SENSOR 130-9811

1 2

SIGNAL COMMON

FUEL TEMPERATURE SENSOR 130-9811

SIGNAL COMMON

FUEL TEMPERATURE SENSOR 130-9811

INJECTOR 5 INJECTOR 6 SECONDARY SPEED/TIMING + SECONDARY SPEED/TIMING -

A705/BU A706/GY 999/WH 998/BR

997/OR OR-18 YL-18 993/BR GN-18 A745/WH Extension harness used for specific fuel filter arrangements. Not present on all engines.

J209A 3E3370 A B C

+5V RETURN SIGNAL

FUEL PRESSURE SENSOR 194-6725

INJECTOR 5 INJECTOR 6 SECONDARY SPEED/TIMING + SECONDARY SPEED/TIMING -

A705/BU A706/GY E966/YL E965/BU

997/OR OR-18 YL-18 993/BR GN-18 A745/WH Extension harness used for specific fuel filter arrangements. Not present on all engines.

J209A 3E3370 A B C

+5V RETURN SIGNAL

FUEL PRESSURE SENSOR 194-6725

INJECTOR 5 INJECTOR 6 SECONDARY SPEED/TIMING + SECONDARY SPEED/TIMING -

A705/BU A706/GY 999/WH 998/BR

997/OR 993/BR 413/BR

J209 3E3370 A B C

OR-18 YL-18 GN-18 P103 1552269 1 2

+5V RETURN SIGNAL

FUEL PRESSURE SENSOR 194-6725

C967/LTBU R993/BR

SIGNAL COMMON

INTAKE MANIFOLD AIR TEMPERATURE SENSOR 130-9811

C967/BU R993/BR

P103 1552269 1 2

SIGNAL COMMON

INTAKE MANIFOLD AIR TEMPERATURE SENSOR 130-9811

C967/BU R833/BR

P103 1552269

TOP VIEW

1 2

SIGNAL COMMON

INTAKE MANIFOLD AIR TEMPERATURE SENSOR 130-9811

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS (NOTE B)

Engine Control Module

1 2
INLET AIR SHUTOFF SOLENOID (NOTE V)

Engine Coolant Temperature Sensor P100 Primary Engine Speed/Timing Sensor (Crankshaft) P401

Customer Connector J61

Service Tool Connector Electronics J63 Ground Stud

Fuel Temperature Sensor P105

Fuel Pressure Sensor J209

Atmospheric Pressure Sensor P203(J203)

CID
INLET AIR SHUTOFF SOLENOID RELAY (NOTE V)

Component
Injector #1 Injector #2 Injector #3 Injector #4 Injector #5 Injector #6 Timing Sensor 8 Volt DC Supply Throttle Position Fuel Pressure Engine Oil Pressure Engine Coolant Temperature System Voltage Intake Manifold Air Temp Fuel Temperature Data Link Communications Personality Module Electronic Control Module Engine Timing 5 Volt Sensor DC Power Supply Digital Sensor Supply Check Programmable Parameters Turbo Outlet Pressure Atmospheric Pressure Speed / Timing Sensor Loss of Secondary Engine Speed Ether Start Relay Auxiliary Pressure Sensor Event Code E004 E005 E006 E015 E016 E017

0001 0002 0003 0004

P142/J142 A B C

+8V RETURN SIGNAL +8V RETURN SIGNAL

AUXILIARY TEMPERATURE SENSOR

0005 0006 0022 0041 0091 0094 0100

BATTERY
BATTERY DISCONNECT SWITCH 120

P800/J800 A B C P220/J220 A B C

COOLANT LEVEL SENSOR OFF ENGINE

TERMINATION RESISTOR (134-2540) (NOTE B&C)

A B C P154 1740502

P1 1607689 ANALOG SENSOR POWER (+5V) ANALOG SENSOR RETURN DIGITAL SENSOR POWER (+8V) DIGITAL SENSOR RETURN CAT DATA LINK (+) CAT DATA LINK (-) RETARDER LAMP INLET AIR SHUTOFF SOLENOID RELAY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

J63 ENGINE SERVICE TOOL CONNECTOR 8T8736 (+)BATTERY 120/YL A (-)BATTERY 229/BK B J1939 SHIELD A234/BK C CAT DATA LINK(+) 893/PK D CAT DATA LINK(-) 892/WH E J1939(-) F K990/GN J1939(+) G K900/YL H J

BATTERY
1297163 1297163
1 1

OPTIONAL WIRING

+5V RETURN SIGNAL

AUXILIARY PRESSURE SENSOR

0110 0168 0172 0174 0247 0253 0254 0261 0262

Secondary Engine Speed/Timing Sensor (Camshaft) P402

1297164
NOTE D

1297164

J403/P403 A B C BATTERY(-) ETHER START VALVE ETHER START VALVE RELAY (NOTE V)

+ BATTERY - BATTERY SIGNAL

DESIRED SPEED CONTROL (NOTE W)

ECM Ground Strap

G MTR

S BAT.

FRONT VIEW

125/OR T993/BR 167/OR A274/BK

229/BK(63) 229/BK(61) 229/BK(65) ELECTRONICS GROUND STUD NOTE A 120/YL A234/BK K990/GN 120/YL

STARTING MOTOR

ST

B ON OFF S C R

NOTE D

NOTE D

1 2

ETHER START VALVE (NOTE V)

0263 0268 0273 0274 0320 0342

START RELAY (SMMS)

1 1

(Dimensions: 39 inches x 28 inches)

893/PK 892/WH T936/GN G971/BR

KEYSTART SWITCH
P515 1552269
1 2

Event Codes For ADEM III ECM

Condition Engine Overspeed Shutdown Fuel Filter Restriction Derate Fuel Filter Restriction Shutdown High Engine Coolant Temperature Derate High Engine Coolant Temperature Shutdown High Engine Coolant Temperature Warning High Inlet Air Temperature Derate High Inlet Air Temperature Warning Low Engine Oil Pressure Derate Low Engine Oil Pressure Shutdown High Fuel Temperature Derate High Fuel Temperature Shutdown High Fuel Temperature Warning Low Engine Coolant Level Derate Low Engine Coolant Level Shutdown Low Engine Coolant Level Warning Fuel Filter Restriction Warning High Fuel Pressure Low Engine Oil Pressure Warning Engine Overspeed Warning High Auxiliary Pressure High Auxiliary Temperature

ALTERNATOR

A234/BK K990/GN K900/YL 892/WH 893/PK M909/GN T936/GN G971/BR G969/YL 167/OR A274/BK A307/GY G488/GN F426/BU F424/YL 125/OR T993/BR M904/OR 382/PK F404/RD F420/GN F716/WH G968/WH 381/PU G955/GN G469/BU H407/YL E798/PK(H406/GY)NOTE Z E452/WH H405/BU M910/OR G967/WH 387/PK 150/OR(48) 150/OR(52) 150/OR(53) 450/YL 451/BR J983/YL

BK-18 BK-18

STARTING AID OVERRIDE SW

0545 1835

AUXILIARY PRESSURE SENSOR

G469/BU K900/YL 892/WH 893/PK 382/PK M910/OR F426/BU MAINTENANCE DUE RESET SW

ETHER START VALVE STARTING AID OVERRIDE SWITCH MAINTENANCE DUE RESET SWITCH

SENR9575-05

NOT DIAGNOSTIC WARNING MAINTENANCE DUE

USED LAMP LAMP LAMP

J983/YL F404/RD F420/GN F424/YL

J1939 DATA (-)

K990/GN

TACHOMETER + TACHOMETER TORQUE LIMIT SWITCH PTO INTERRUPT SWITCH J1939 SHIELD

REMOTE SHUTDOWN SWITCH INTERMEDIATE ENGINE SPEED SWITCH COOLANT LEVEL SENSOR RETARDER SOLENOID HI (NOTE M) +BATTERY (UNSWITCHED) RETARDER SOLENOID MED (NOTE M) J1939 DATA (+) +BATTERY (UNSWITCHED) +BATTERY (UNSWITCHED) 75% OVERSPEED VERIFY SWITCH PTO ENABLE SWITCH PTO RAMP UP/SET SWITCH RETARDER SOLENOID MED/LO/HI (NOTE M) PTO RAMP DOWN / RESUME SWITCH BATTERY (-) BATTERY (-) BATTERY (-) THROTTLE POSITION SENSOR SOLENOID COMMON AUXILIARY TEMPERATURE SENSOR +BATTERY (SWITCHED)
ELECTRONIC CONTROL MODULE (ECM)

(NOT USED)NOTE Z

450/YL 451/BR M909/GN M904/OR A234/BK E798/PK F716/WH G968/WH E452/WH H405/BU 150/OR(48) H406/GY K900/YL 150/OR(52) 150/OR(53) 387/PK 381/PU G955/GN H407/YL G967/WH 229/BK(61) 229/BK(63) 229/BK(65) A307/GY G969/YL G488/GN 120/YL

NOTE Z

30 Page, Color 2,

J61 P61 9X1343 +BAT. (UNSWITCHED) 1 150/OR(48) M909/GN 2 TORQUE LIMIT SW RETARDER LAMP(NOTE M) 3 T936/GN 4 G971/BR INLET AIR SHUTOFF SOLENOID RELAY 5 G969/YL SOLENOID COMMON 6 CAT DATA LINK 892/WH 7 893/PK CAT DATA LINK + 8 DIG SNSR PWR (+8V) 167/OR 9 A274/BK DIG SNSR RETURN 10 A307/GY THROTTLE POSITION SNSR 11 G488/GN AUXILIARY TEMP SNSR 12 F426/BU MAINTENANCE DUE RESET SW F424/YL 13 MAINTENANCE DUE LAMP 14 125/OR ANLG SNSR PWR (+5V) 15 T993/BR ANLG SNSR RETURN 16 J1939 SHIELD A234/BK 17 J1939 DATA + K900/YL 18 K990/GN J1939 DATA 19 M904/OR PTO INTERRUPT SW 20 450/YL 21 451/BR 22 382/PK ETHER START VALVE 23 J983/YL 24 DIAGNOSTIC LAMP F404/RD 25 WARNING LAMP F420/GN 26 120/YL +BAT. (SWITCHED) F716/WH 27 REMOTE SHUTDOWN SW 28 G968/WH INTERMEDIATE ENGINE SPEED SW 29 PTO ENABLE SW 381/PU 30 G955/GN PTO RAMP UP/SET SW 31 150/OR(52) +BAT. (UNSWITCHED) 32 150/OR(53) +BAT. (UNSWITCHED) 33 G469/BU AUXILIARY PRESS. SNSR 34 H407/YL RETARDER MED/LO/HI SW(NOTE M) 35 E798/PK(H406/GY) RETARDER MED SW(NOTE M) 36 E452/WH COOLANT LEVEL SNSR 37 H405/BU RETARDER HI SW(NOTE M) 38 M910/OR STARTING AID OVERRIDE SW 39 PTO RAMP DOWN/RESUME SW G967/WH 40 387/PK 75% OVERSPEED VERIFY SW CUSTOMER CONNECTOR

14 AWG +BAT. (UNSWITCHED) 14 AWG +BAT. (UNSWITCHED) 14 AWG +BAT. (UNSWITCHED) INLET AIR SHUTOFF SOLENOID RELAY SOLENOID COMMON AUXILIARY TEMP SNSR COOLANT LEVEL SNSR DIG SNSR PWR (+8V) DIG SNSR RETURN AUXILIARY PRESS. SNSR THROTTLE POSITION SNSR ANLG SNSR PWR (+5V) ANLG SNSR RETURN ETHER START VALVE STARTING AID OVERRIDE SW MAINTENANCE DUE RESET SW TORQUE LIMIT SW REMOTE SHUTDOWN SW INTERMEDIATE ENGINE SPEED SW 75% OVERSPEED VERIFY SW PTO INTERRUPT SW PTO ENABLE SW PTO RAMP UP/SET SW PTO RAMP DOWN/RESUME SW MAINTENANCE DUE LAMP DIAGNOSTIC LAMP WARNING LAMP RETARDER LAMP(NOTE M) 14 AWG +BAT. (SWITCHED) CAT DATA LINK CAT DATA LINK +

TORQUE LIMIT SW

1836 Auxiliary Temperature Sensor The CID is a diagnostic code that indicates which component is faulty. The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.

Timing Calibration (TC) Probe Connector P400

Engine Oil Pressure Sensor P201(J201)

Electronic Control Module (ECM) ECM Connector P2/J2

LEFT SIDE VIEW

ECM Connector P1/J1

REMOTE SHUTDOWN SW (NOTE K)

Failure Mode Identifiers (FMI)

FMI No. Failure Description
Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Parameter failures. Parameter failures. Parameter not available. Module not responding. Sensor supply fault. Condition not met. Parameter failures. 0 1 2 3 4 5 6 7

E025 E027 E039 E040 E054 E055 E056 E057 E058 E059 E095 E096 E100 E190 E443 E445

INTERMEDIATE ENGINE SPEED SW

OVERSPEED VERIFY SW

(+) BATTERY (+) BATTERY SWITCHED STARTING CIRCUIT (-) BATTERY / SENSOR RETURN SENSOR / ACTUATOR SUPPLY SIGNAL PLUS TO ECM SIGNAL MINUS TO ECM CONTROL PLUS FROM ECM CONTROL MINUS FROM ECM CAT DATA LINK J1939 DATA LINK

PTO INTERRUPT SW

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL INSTALLATION DETAILS NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR TO TERMINATION RESISTOR) IS 40 METERS NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939 SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO A MAIN EMS MODULE NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS. IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED. IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO BATTERY (-) IS REQUIRED NOTE K: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-) THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS NOTE L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS 1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR

PTO ENABLE SW

8 9 10 11
PTO RAMP UP/DOWN SWITCH MAINTENANCE DUE LAMP

12 13 14 15 16 17

CB J1939 SHIELD J1939 DATA + J1939 DATA (153-2707) (NOTES B & E) MAX LENGTH 40 METERS 1A

CB 1A

DIAGNOSTIC LAMP

18 19 20

RETARDER MED/LO/HI SW NOTE M

MED/LO/HI RETARD SWITCH

CB 1A

WARNING LAMP

The FMI is a diagnostic code that indicates what type of failure has occurred.

C-10, C-12, C-15, and C-16 Customer Harness

RETARDER MED SW NOTE M RETARDER HI SW

HI RETARD SWITCH MED RETARD SWITCH

C B A

CB 1A

RETARDER LAMP NOTE M

C-15 and C-16 Engines

Customer Connector J61 Service Tool Connector J63 Electronics Ground Stud Fuel Pressure Sensor J209 Fuel Temperature Sensor P105 Intake Manifold Air Temperature Sensor P103

NOTE M: THE RETARDER FEATURE IS ONLY AVAILABLE ON SPECIFIC MODELS NOTE V: ARC SUPPRESSION DIODES ARE REQUIRED ON RELAY COILS AND SOLENOID COILS. NOTE W: WIRING FOR DESIRED SPEED CONTROL DETERMINED BY APPLICATION. FOR DESIRED SPEED CONTROL OPTIONS, REFER TO THE ELECTRONIC INSTALLATION GUIDE. NOTE Y: HARNESSES 237-7595 -00 AND 238-1773 -00 HAVE WIRES J700/BR, J701/GN, AND J702/BK INSTALLED. ALL OTHER C-15/C-16 ENGINE HARNESSES DO NOT INCLUDE THESE WIRES. NOTE Z: HARNESS 242-7248 -00 HAS WIRE H406/GY INSTALLED. ALL OTHER CUSTOMER HARNESSES HAVE WIRE E798/PK INSTALLED. H406/GY TERMINATES AT P1/49 AND J61/35. E798/PK TERMINATES AT P1/43 AND J61/35. NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES WITHOUT CATERPILLAR ENGINEERING APPROVAL UNLESS OTHERWISE SPECIFIED: ALL WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708 ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN CONSIDERING COMPONENT REMOVAL

C B A

B A C

MAX LENGTH 30 METERS

-BAT. +BAT. (SWITCHED) CAT DATA LINK + CAT DATA LINK -

120 TERMINATION RESISTOR (174-3016) (NOTE B & C) (165-0200) MAX LENGTH 1 METER (NOTE B) DEVICE

A B C D E F G H J

+ BAT. - BAT. CAT DATA LINK + CAT DATA LINK -

(J66) CUSTOMER INSTALLED SERVICE TOOL CONN

Turbo Outlet Pressure Sensor (Intake Manifold Air) J200

MAIN EMS MODULE (NOTE G) TACHOMETER MODULE (NOTE G)

OPTIONAL EMS DISPLAY MODULES

QUAD GAUGE MODULE (NOTE G)

CAT DATA LINK + CAT DATA LINK -BAT. +BAT. (SWITCHED)

+24V -BAT CAT DATA LINK + CAT DATA LINK MODULE LOAD MODULE CLOCK +V MODULE MODULE DATA US/METRIC SCROLL FORWARD WARNING LAMP AUXILIARY CKT WARNING SCROLL BACKWARD

10

15

20 25

-BAT

5 0 RPM X100

30

OPTIONAL REMOTE TACHOMETER MODULE OR QUAD GAUGE MODULE (NOTES G & B) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Engine Coolant Temperature Sensor P100

Secondary Engine Speed/Timing Sensor (Camshaft) P402

Timing Calibration (TC) Probe Connector P400

Atmospheric Pressure Sensor J203 Electronic Control Module (ECM) Engine Oil Pressure Sensor J201 ECM Ground Strap

1 2 5 14 15 25 34 35 20 23 13 7 4 33 3 6 8 9 10 11 12 16 17 18 19 21 22 24 26 27 28 29 30 31 32 36 37 38 39 40

ABBREVIATION ALT ALTERNATOR ATA AMERICAN TRUCKING ASSOCIATION CB CIRCUIT BREAKER CIS CUSTOMER IGNITION SWITCH DIG DIGITAL ECM ELECTRONIC CONTROL MODULE N/C NO CONNECTION PWM PULSE WIDTH MODULATION SM STARTING MOTOR SMMS START MOTOR MAG SWITCH

1 2 3 4 5 6

(NOTE F) MODULE DATA +V MODULE MODULE CLOCK MODULE LOAD -BAT BACKLIGHT LAMP PWR

THIS SCHEMATIC IS FOR THE C-10, C-12, C-15, and C-16 INDUSTRIAL ENGINES WIRING DIAGRAMS- 201-0649 CHG04 AND 238-1775 CHG01 HARNESS TABLE PART NO. CHG. NAME 189-6594 05 J2/ENGINE(C-10/C-12 Pigtail Sensors) 226-5758 03 J2/ENGINE(C-10/C-12 Integral Sensors) 243-6620 00 J2/ENGINE(C-10/C-12 Specific Arrangements) 191-5204 238-1773 237-7595 189-6596 243-6618 191-1531 238-1774 242-7248 4P-9537 122-1486 132-3144 02 00 01 04 00 04 00 00 07 10 00 J2/ENGINE(C-15/C-16) J2/ENGINE(C-15/C-16 Retarder) J2/ENGINE(C-15/C-16 Specific Arrangements) J1/CUSTOMER(C-10/C-12) J1/CUSTOMER(C-10/C-12 Specific Arrangements) J1/CUSTOMER(C-15/C-16) J1/CUSTOMER(C-15/C-16 Retarder) J1/CUSTOMER(C-15/C-16 Specific Arrangements) INJECTOR(C-10/C-12) INJECTOR(C-15/C-16) FUEL PRESSURE EXTENSION(C-10/C-12)

+24V - BAT. US/METRIC SCROLL FORWARD CAT DATA LINK CAT DATA LINK + UNUSED WARNING LAMP WARNING BACKLIGHT LAMP PWR SCROLL BACKWARD

1 2 3 4 5 6 7 8 9 10 11 12 (NOTE B)

(NOTE H) -V OUT +V OUT

Primary Engine Speed/Timing Sensor (Crankshaft) P401

FRONT VIEW

DC/DC CONVERTER (127-8853) (NOTES B & L) -V IN +V IN

ECM Connector P2/J2

ECM Connector P1/J1

LEFT SIDE VIEW

(NOTES B & L)

CAT DATA LINK + CAT DATA LINK -BAT. +BAT. (SWITCHED)