SENR9590-01

July 2001

Electronic Control Module (ECM) J63 Caterpillar Supplied

Engine Service
Tool Connector
6 Electronic J2 J1 J1939
Unit Injectors Terminating
Injection Turbo Outlet Resistor
Actuation Inlet Air Pressure Sensor
Pressure Heater Engine Oil (Intake Manifold Air) Electronics
Atmospheric Ground Stud
Sensor Relay Temperature
Pressure
Sensor
Injector Sensor
ECM AMP Connectors Harness Intake Manifold Caterpillar Supplied P300/J300 J61 Customer
Connector
Connector Air Temperature Service Tool
Injection
P300/J300 Sensor Connector P61 Battery
Actuation Disconnect
J63
Pressure Engine Coolant Switch + -
Temperature Battery
Control Valve Customer P400
Timing Calibration 12 or 24VDC
(IAPCV) Sensor Connector Inlet Air Heater Breaker
Probe Connector
J61
SMMS
Primary Engine J401/P401 Breaker
Speed/Timing Sensor
Electronics Secondary Engine
Ground Speed/Timing Sensor Keyswitch
Injector Stud J402/P402
Harness
15 Amp
Grommet Injection Actuation J500/P500 Breaker 15 Amp
Pressure Control Breaker
Valve (IAPCV)
ECM Side ECM Connector P1 Harness Side
Fuel

3126B
Pressure P204/J204
Injection Actuation OEM Installed Switches:
Sensor Pressure Sensor
PTO Enable

Industrial Engine
P209/J209 PTO Ramp Up/Down
Fuel PTO Interrupt
Pressure Sensor
Remote Shutdown

Electrical System
Timing Calibration Starting Aid Override
P203/J203
Probe Atmospheric Overspeed Verify
Connector Pressure Sensor Intermediate Engine Speed
P400 Maintenance Due Reset
J201/P201
Primary
Speed/Timing Electronic
BEJ1-UP Engine Oil
Pressure Sensor
Torque Limit

Sensor Control DCS1-UP Turbo Outlet J200/P200

J403/P403
Throttle
Module Position Sensor
(Intake Manifold Air)
(ECM) Pressure Sensor
J100/P100 P800/J800
Engine Coolant Coolant
Secondary Temperature Sensor Level Sensor
Speed/Timing
Sensor ECM P101/J101
Engine Oil P220/J220
Ground Auxiliary
ECM Temperature Sensor
Strap Pressure Sensor
Connector
J2/P2 J103/P103
Intake Manifold Air
Fuel Intake Manifold Temperature Sensor P142/J142
Pressure Engine Oil ECM Auxiliary
Air Temperature
Sensor Pressure Connector Temperature Sensor
ECM Side ECM Connector P2 Sensor
Harness Side (Optional Location) Sensor (Optional Location) J1/P1 Warning Lamp

Diagnostic Lamp Inlet Air Shutoff Relay

Engine Oil Inlet Air Shutoff
Solenoid
Pressure NOTE:
Maintenance
Sensor Due Lamp Inlet Air Heater
Components within Relay
(Optional Location) Inlet Air Heater
this area are J1939
recommendations Terminating Air Inlet
Resistor To ECM J2/P2 Ground Stud

LEFT SIDE VIEW Customer Installed J66 Engine Monitoring

Service Tool System (EMS)
10 15

5 20

Connector 0 25 Display Modules

© 2001 Caterpillar Printed in U.S.A.

All Rights Reserved
 P306/J306
INJECTOR HARNESS
B
GROMMET A
J300/P300 P305/J305
7 L985/YL B
ECM 6 A706/GY A
GROUND 8 L985/YL P304/J304
STRAP 5 A705/BU B INJECTOR
ECM
MOUNTING 9 L984/OR A CYLINDER
BOLT 4 A704/GN P303/J303 NO.6
10 L984/OR B INJECTOR
3 A703/BR A CYLINDER
11 L983/WH P302/J302 NO.5
J2/P2 2 A702/PU B INJECTOR
INJECTOR COMMON 5 & 6 46 L985/YL 12 L983/WH A CYLINDER
INJECTOR COMMON 3 & 4 45 L984/OR 1 A701/GY P301/J301 NO.4
INJECTOR COMMON 1 & 2 44 L983/WH B INJECTOR J61 Customer Pin Out
INJECTOR 6 55 A706/GY A CYLINDER
INJECTOR 5 54 A705/BU NO.3
INJECTOR 4 39 A704/GN INJECTOR No. Function Wire Ident
INJECTOR 3 38 A703/BR P400 TIMING CYLINDER
NO.2
1 +Bat. (Unswitched) 150/OR
INJECTOR 2 37 A702/PU G857/YL 2 CALIBRATION
INJECTOR 1 36 A701/GY G856/WH 1 PROBE INJECTOR 2 Torque Limit Switch M909/GN
TIMING CALIBRATION PROBE - 23 G857/YL CONNECTOR CYLINDER
TIMING CALIBRATION PROBE + 22 G856/WH NO.1 P401/J401 3 N/C¹ T936/GN
PRIMARY SP/TMG SIG - 49 E963/BK E963/BK 1 SIGNAL - PRIMARY
PRIMARY SP/TMG SIG + 48 E964/WH E964/WH 2 SIGNAL + SPEED/TIMING SENSOR 4 Inlet Air Shutoff Solenoid Relay G971/BR
SECONDARY SP/TMG SIG - 59 E965/BU 5 Solenoid Common G969/YL
SECONDARY SP/TMG SIG + 58 E966/YL (169-3300)
COOL. TEMP. SNSR 32 995/BU P402/J402 6 Cat Data Link - 892/BR
PASSIVE SNSR COMMON 18 G833/PK E965/BU 1 SIGNAL - SECONDARY
ANALOG SNSR POWER (+5V) 2 G828/WH E966/YL 2 SIGNAL + SPEED/TIMING SENSOR 7 Cat Data Link + 893/GN
ANALOG SNSR COMMON 3 G829/GN
TURBO OUTLET PRESS. SNSR 40 A746/PK
8 Digital Sensor Power (+8V) 167/OR
ATMOSPHERIC PRESS. SNSR 14 A747/GY P100/J100 9 Digital Sensor Return A274/BK
ENGINE COOLANT
ENG OIL PRESS. SNSR 24 994/GY 995/BU 1 SIGNAL
TEMPERATURE SENSOR
G833/PK 2 COMMON
(130-9811)
10 Throttle Position Sensor A307/GY
FUEL PRESS. SNSR 16 413/BR
INTAKE MANIF. AIR TEMP. SNSR 35 C967/BU P200/J200 11 Auxiliary Temperature Sensor G488/GN
INJ. ACTUATION PRESS. SNSR 27 G849/BR G828/WH A +5V TURBO OUTLET
IAP CONTROL VALVE + 61 G854/PK A746/PK C SIGNAL PRESSURE SENSOR 12 Maintenance Due Reset Switch F426/BU
G855/PU (INTAKE MANIFOLD AIR)
IAP CONTROL VALVE - 62 G829/GN B RETURN
(161-9928)
13 Maintenance Due Lamp F424/YL
ENGINE OIL TEMP. SNSR 34 401/BU
J203/P203 14 Analog Sensor Power (+5V) 125/OR
G828/WH A +5V ATMOSPHERIC PRESSURE
UNUSED 1 A747/GY C SIGNAL SENSOR 15 Analog Sensor Return T993/BR
UNUSED 4 G829/GN B RETURN (161-9925 NOTE S)
(163-8530 NOTE T) 16 J1939 Shield A234/BK
UNUSED 5
UNUSED 6 P201/J201 17 J1939 Data + K900/YL
UNUSED 7 G828/WH A +5V ENGINE OIL PRESSURE
UNUSED 8 994/GY C SIGNAL SENSOR 18 J1939 Data - K990/GN
UNUSED 10 G829/GN B RETURN (161-1705)
UNUSED 11 19 PTO Interrupt Switch M904/OR
UNUSED 13 J209/P209 20 N/C¹ 450/YL
UNUSED 15 G828/WH A +5V
FUEL PRESSURE SENSOR
UNUSED 17 413/BR C SIGNAL
(161-9931) 21 N/C¹ 451/BR
UNUSED 19 G829/GN B RETURN
UNUSED 20 22 N/C¹ 382/PK
UNUSED 21 P103/J103
UNUSED 25 C967/BU 1 SIGNAL
INTAKE MANIFOLD AIR 23 N/C¹ J983/YL
TEMPERATURE SENSOR
UNUSED 26 G833/PK 2 COMMON 24 Diagnostic Lamp F404/RD
(130-9811)
UNUSED 28
UNUSED 29 25 Warning Lamp F420/GN
UNUSED 30 J204/P204
UNUSED 31 G828/WH A +5V INJECTOR ACTUATION 26 +Bat. (Switched) 120/YL
UNUSED 33 G849/BR C SIGNAL PRESSURE SENSOR
UNUSED 41 G829/GN B RETURN (167-1708) 27 Remote Shutdown Switch F716/WH
UNUSED 42 28 Intermediate Engine Speed Switch G968/WH
UNUSED 43 P500/J500
INJECTOR ACTUATION
UNUSED 47 G854/PK 1 SIGNAL + 29 PTO Enable Switch 381/PU
SIGNAL - PRESSURE CONTROL VALVE
UNUSED 50 G855/PU 2
UNUSED 51
(IAPCV) 30 PTO Ramp Up/Set Switch G955/GN
UNUSED 52 J101/P101
ENGINE OIL 31 +Bat. (Unswitched) 150/OR
UNUSED 53 401/BU 1 SIGNAL
TEMPERATURE SENSOR
UNUSED 56 G833/PK 2 COMMON
(191-6587)
32 +Bat. (Unswitched) 150/OR
UNUSED 57
33 Auxiliary Pressure Sensor G469/BU
UNUSED
UNUSED
60
63
Customer Connector J61
UNUSED 64 34 N/C¹ H407/YL
UNUSED 65 Customer Connector P61 35 N/C¹ E798/PK
UNUSED 66
UNUSED 67 36 Coolant Level Sensor E452/WH
UNUSED 68
UNUSED 69 1 2 3 4 5 6 7 8 9 10 10 9 8 7 6 5 4 3 2 1 37 N/C¹ H405/BU
UNUSED 70 11 12 13 14 15 16 17 18 19 20 20 19 18 17 16 15 14 13 12 11
38 Starting Aid Override Switch M910/OR
IAH RELAY RETURN 9 C987/RD 21 22 23 24 25 26 27 28 29 30 30 29 28 27 26 25 24 23 22 21
39 PTO Ramp Down/Resume Switch G967/WH
INLET AIR HEATER 12 G850/BU 31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
40 75% Overspeed Verify Switch 387/PK

Terminal Side ¹ This terminal is for future expansion. Install an 8T-8737 Seal Plug.
Terminal Side
C987/RD
G850/BU

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

C OFF (NOTE B)
SMMS ON B
S ST 1
2 INLET AIR SHUTOFF
SOLENOID RELAY
R INLET AIR SHUTOFF (NOTE V)
SOLENOID (NOTE V)
CB
KEYSWITCH 15A
J1/P1
14 AWG P142/J142
UNUSED 1 AUXILIARY
A +8V
UNUSED 6 CB 14 AWG TEMPERATURE
C SIGNAL
UNUSED 7 (NOTE D) SENSOR
B RETURN
UNUSED 12 (131-0427)
UNUSED 13 +
UNUSED 14
P800/J800
UNUSED 16 COOLANT LEVEL
ALTERNATOR A +8V
UNUSED 17 G S SENSOR
C SIGNAL
UNUSED 18 (165-6634)
GND B RETURN
UNUSED 19 MTR BAT OFF ENGINE
CB
UNUSED 20
(NOTE D)
UNUSED 24
STARTING P220/J220
UNUSED 25 AUXILIARY
MOTOR A +5V
UNUSED 26 PRESSURE
C SIGNAL
UNUSED 31 SENSOR
B RETURN
UNUSED 32 (161-9932)
UNUSED 33
15A
UNUSED 35 14 AWG
UNUSED 36 J403/P403
10 AWG C SIG THROTTLE
UNUSED 37 BATTERY CB
14 AWG A + BAT. POSITION
UNUSED 51 DISCONNECT
(NOTE B) CB B - BAT. SENSOR
UNUSED 55 SWITCH + -
14 AWG (161-8906)
UNUSED 57 BATTERY (NOTE B)
4 AWG
UNUSED 62
(NOTE B) 100A WITH 130A PEAK AT 11V
UNUSED 64 INLET AIR
UNUSED 69 HEATER
PWM OUTPUT 3 43 E798/PK GROUND INLET AIR RELAY
TACHOMETER - 39 451/BR J61/P61 STRAP HEATER
14 AWG
+BAT.(UNSWITCHED) 48 150/OR 1 +BAT. (UNSWITCHED) J501/P501
AIR SHUTOFF SOLENOID 11 G971/BR 4 AIR SHUTOFF SOLENOID RELAY 1 C987/RD
SOLENOID COMMON 67 G969/YL 5 SOLENOID COMMON AIR INLET
2 G850/BU
AUXILIARY TEMP SNSR 68 G488/GN 11 AUXILIARY TEMP SNSR GROUND STUD
COOLANT LEVEL SNSR 46 E452/WH 36 COOLANT LEVEL SNSR STARTING AID OVERRIDE SW
DIG SNSR PWR (+8V) 4 167/OR 8 DIG SNSR PWR (+8V)
DIG SNSR RETURN 5 A274/BK 9 DIG SNSR RETURN MAINTENANCE DUE RESET SW
AUXILIARY PRESS. SNSR 15 G469/BU 33 AUXILIARY PRESS. SNSR
THROTTLE POSITION SNSR 66 A307/GY 10 THROTTLE POSITION SNSR TORQUE LIMIT SW
ANLG SNSR PWR (+5V) 2 125/OR 14 ANLG SNSR PWR (+5V)
ANLG SNSR RETURN 3 T993/BR 15 ANLG SNSR RETURN REMOTE SHUTDOWN SW (NOTE K)
UNUSED 21 382/PK 22 NC
STARTING AID OVERRIDE SW 22 M910/OR 38 STARTING AID OVERRIDE SW INTERMEDIATE ENGINE SPEED SW
MAINTENANCE DUE RESET SW 23 F426/BU 12 MAINTENANCE DUE RESET SW
TORQUE LIMIT SW 40 M909/GN 2 TORQUE LIMIT SW OVERSPEED VERIFY SW
REMOTE SHUTDOWN SW 44 F716/WH 27 REMOTE SHUTDOWN SW
INTERMEDIATE ENG. SPEED SW 45 G968/WH 28 INTERMEDIATE ENGINE SPEED SW PTO INTERRUPT SW
OVERSPEED VERIFY SW 54 387/PK 40 75% OVERSPEED VERIFY SW
PTO INTERRUPT SW 41 M904/OR 19 PTO INTERRUPT SW PTO ENABLE SW
PTO ENABLE SW 56 381/PU 29 PTO ENABLE SW
1.5A DIGITAL OUT 4 HS 10 T936/GN 3 NC
PTO RAMP UP SW 58 G955/GN 30 PTO RAMP UP/SET SW
PTO RAMP DOWN SW 60 G967/WH 39 PTO RAMP DOWN/RESUME SW
MAINTENANCE DUE LAMP 30 F424/YL 13 MAINTENANCE DUE LAMP
PTO RAMP
DIAGNOSTIC LAMP 28 F404/RD 24 DIAGNOSTIC LAMP
UP/DOWN SWITCH
WARNING LAMP 29 F420/GN 25 WARNING LAMP
TACHOMETER + 38 450/YL 20 NC 14 AWG
+BAT. (SWITCHED) 70 120/YL 26 +BAT. (SWITCHED) MAINTENANCE
CB DUE LAMP
CAT DATA LINK - 9 892/BR 6 CAT DATA LINK -
CAT DATA LINK + 8 893/GN 7 CAT DATA LINK + 1A
-BAT. 65 229/BK 21 NC
PASSIVE/ACTIVE ANLG 8 27 J983/YL 23 NC
14 AWG
+BAT.(UNSWITCHED) 52 150/OR 31 +BAT. (UNSWITCHED) DIAGNOSTIC LAMP
14 AWG CB
+BAT.(UNSWITCHED) 53 150/OR 32 +BAT. (UNSWITCHED)
SWITCH INPUT 5 59 H407/YL 34 NC 1A
SWITCH INPUT 11 49 H406/GY 35 NC
SWITCH INPUT 10 47 H405/BU 37 NC
MAX LENGTH 40 METERS
J1939 SHIELD 42 A234/BK 16 J1939 SHIELD WARNING LAMP
CB
J1939 DATA + 50 K900/YL 17 J1939 DATA +
J1939 DATA - 34 K990/GN 18 J1939 DATA - 1A
-BAT. 61 229/BK
-BAT. 63 229/BK (153-2707) A + BAT.
(NOTES B & E) B - BAT.
MAX LENGTH 30 METERS C
ELECTRONIC CONTROL MODULE (ECM) E CAT DATA LINK -
C B A D CAT DATA LINK +
J63 F
G
120/YL A
+BAT.
J
229/BK B
-BAT.
H
893/GN D
CAT DATA LINK +
892/BR E
CAT DATA LINK - (J66)
A234/BK C
J1939 SHIELD CUST. SUPPLIED ENG
K990/GN F
J1939 DATA - SERVICE TOOL CONN
ELECTRONICS (165-0201)
K900/YL G
J1939 DATA + C B A B A C OPTIONAL
GROUND STUD H
NC
(NOTE A) J
NC
CAT SUPPLIED
ENGINE SERVICE TOOL
C B A (165-0200)
C B A CONNECTOR
MAX LENGTH 1 METER
(NOTE B)
TERMINATION DEVICE
RESISTOR
(134-2540) 120
120
(NOTE B & C)
TERMINATION
RESISTOR
(134-2540)
(NOTE B & C)
CAT DATA LINK +
CAT DATA LINK -
-BAT.
+BAT. (SWITCHED)

MAIN EMS MODULE

(NOTE G)
OPTIONAL EMS DISPLAY MODULES
SCROLL BACKWARD

TACHOMETER MODULE QUAD GAUGE MODULE

SCROLL FORWARD

(NOTE G) (NOTE G)
CAT DATA LINK +
CAT DATA LINK -

MODULE CLOCK

WARNING LAMP
AUXILIARY CKT
MODULE LOAD

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

+V MODULE

US/METRIC

15
WARNING

10 20
OPTIONAL REMOTE
5 25 TACHOMETER MODULE OR
+24V
-BAT

-BAT

QUAD GAUGE MODULE

RPM X100
0 30 (NOTES G & B)
14
15
25
34
35
20
23
13

33

10
11
12
16
17
18
19
21
22
24
26
27
28
29
30
31
32
36
37
38
39
40
1
2
5

7
4

3
6
8
9

1
2
3
4
5
6

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

(NOTE F)

MODULE DATA
+V MODULE
MODULE CLOCK
MODULE LOAD
-BAT
BACKLIGHT LAMP PWR

+24V 1
- BAT. 2
US/METRIC 3
SCROLL FORWARD 4 (NOTE H)
CAT DATA LINK - 5
CAT DATA LINK + 6 -V OUT +V OUT
UNUSED 7
WARNING LAMP 8 DC/DC CONVERTER
WARNING 9 (127-8853)
BACKLIGHT LAMP PWR 10 (NOTES B & L)
(+) BATTERY SUPPLY WIRES
SCROLL BACKWARD 11
12 -V IN +V IN
INPUT SIGNAL WIRES TO ECM
(NOTE B)
OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

CAT DATA LINK +
CAT DATA LINK - SIGNAL PLUS
-BAT.
(NOTES B & L)
+BAT. (SWITCHED) SIGNAL MINUS

(-) BATTERY / SENSOR RETURN

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING NOTE S: USE THIS SENSOR FOR ALL INDUSTRIAL APPLICATIONS
HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE OTHER THAN UNDERGROUND MINING
CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO ABBREVIATION
A MAIN EMS MODULE NOTE T: USE THIS SENSOR FOR UNDERGROUND MINING APPLICATIONS ONLY
ALT ALTERNATOR
NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL
NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS. NOTE V: ARC SUPPRESSION DIODES ARE REQUIRED ATA AMERICAN TRUCKING ASSOCIATION
INSTALLATION DETAILS
IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED. ON RELAY COILS AND SOLENOID COILS. CB CIRCUIT BREAKER
IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO CIS CUSTOMER IGNITION SWITCH
NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR
BATTERY (-) IS REQUIRED DIG DIGITAL
TO TERMINATION RESISTOR) IS 40 METERS
ECM ELECTRONIC CONTROL MODULE
NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION N/C NO CONNECTION
NOTE K: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-) NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES PWM PULSE WIDTH MODULATION
NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939 THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS WITHOUT CATERPILLAR ENGINEERING APPROVAL SM STARTING MOTOR
SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING SMMS START MOTOR MAG SWITCH
NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS UNLESS OTHERWISE SPECIFIED:
MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION ALL WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR
NOTE L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708 WIRE CODE
FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS
CUSTOMER SUPPLIED WIRING
SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN
1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN
CONSIDERING COMPONENT REMOVAL
Receptacle Wedge

Receptacle Wedge

Receptacle Wedge
Speed/Timing Sensor Connectors

HD Connector Receptacle

DT Connector Receptacle
150 Series Receptacle

Pin Contact
Socket Contact

Plug Wedge

Plug Wedge

Plug Wedge

DT Connector Plug
HD Connector Plug
IAPCV Connector
150 Series Plug

Sealing Plug