C-10, C-12, 3406E, C-15, and C-16 Truck Engine Electrical System[1].pdf

©2001 CaterpillarAll Rights Reserved

Printed in U.S.A.

RENR2237-02May 2001

C-10, C-12, 3406E, C-15, and C-16Truck Engine Electrical SystemCPD1-UP1MM1-UP2KS1-UP2WS1-UP

6NZ1-UP7CZ1-UP

3CS1-UP

FuelTemperatureSensor

EngineGroundStud

CrankshaftPositionSensor

CamshaftPositionSensor

OEMVehicleHarnessConnectorJ1/P1

EngineHarnessConnectorJ2/P2

EngineGroundStud

OilPressureSensor

ElectronicUnitInjectorConnector

AtmosphericPressureSensor

EngineControlModule(ECM)

C-10 and C-12 Left Side View

C-15 and C-16 Left Side View3406E Left Side View

CoolantTemperatureSensor

InletManifoldAirTemperatureSensor

BoostPressureSensor


C-10 and C-12 Front Right Side View C-10 and C-12 Front Top View

C-15 and C-16 Front Top View

BoostPressureSensor


InletManifoldAirTemperatureSensor

EngineGroundStud





CrankshaftPositionSensor Engine

HarnessConnectorJ2/P2


3406E Right Side View 3406E Front View

OilPressureSensor


BoostPressureSensor


InletManifold AirTemperatureSensor

EngineGroundStud



EngineHarnessConnectorJ2/P2

CrankshaftPositionSensor Atmospheric

PressureSensor

OilPressureSensor




InletManifold AirTemperatureSensor

C-10, C-12, 3406E, C-15, and C-16 ENGINE HARNESS WIRING DIAGRAM

C-10, C-12, 3406E, C-15, and C-16 OEM VEHICLE HARNESS WIRING DIAGRAM

ENGINE FUEL TEMPERATUREENGINE TEMPERATURE SENSOR COMMON

12

995-BUG833-PK

J100 P100

ENGINE COOLANT TEMPERATUREENGINE TEMPERATURE SENSOR COMMON

ENGINE INTAKE MANIFOLD AIR TEMPERATUREENGINE TEMPERATURE SENSOR COMMON

J103 P103

C967-BUG833-PK

12

A751-YLG833-PK

995-BUC967-BUA751-YL

G833-PKG832-ORG827-BU

12

J105 P105

E963-BKE964-WH

E965-BUE966-YL

12

J401 P401

CRANK SPEED/TIMING-CRANK SPEED/TIMING+

CRANKSHAFTPOSITION SENSOR

E963-BKE964-WH

E965-BUE966-YL

CAMSHAFTPOSITION SENSOR

CAM SPEED/TIMING-CAM SPEED/TIMING+

J402 P402

12

INJECTOR COMMON CYLINDERS 1 & 2INJECTOR COMMON CYLINDERS 3 & 4INJECTOR COMMON CYLINDERS 5 & 6INJECTOR CYLINDER 6INJECTOR CYLINDER 5INJECTOR CYLINDER 4INJECTOR CYLINDER 3INJECTOR CYLINDER 2INJECTOR CYLINDER 1RETARDER SOLENOID MED/HIRETARDER SOLENOID LOW/HIRETARDER SOLENOID COMMON

P1 J1

ENGINE HARNESS CONNECTOR

4445465554393837361011 9

ENGINE RETARDERSOLENOID CYLINDERS

3 & 4 NOTE H


5 & 6 NOTE H


1 & 2 NOTE H

P2 J2

TO ECMMOUNTINGBOLT

54227172223265060

304753 4

41 1

5156576768697065665231

INPUT #17ENGINE BOOST PRESSUREENGINE ATM PRESSUREENGINE OIL PRESSURE

ENGINE PRESSURE SENSOR COMMONENGINE PRESSURE SENSOR +5V

4014242516 3 2

819121343202161626364282915

CRANK SPEED/TIMING NEGATIVECRANK SPEED/TIMING POSITIVE

CAM SPEED/TIMING NEGATIVECAM SPEED/TIMING POSITIVE

ENGINE COOLANT TEMPERATUREENGINE INTAKE MANIFOLD AIR TEMPERATUREENGINE FUEL TEMPERATURE

ENGINE TEMPERATURE SENSOR COMMONINPUT SENSOR COMMON #4INPUT SENSOR COMMON #3

3235333418

5958 6 7

4948

SPEEDOMETERNOTE ENOTE H

ECM GND STRAP

SENSOR ACCELERATORPEDAL POSITION

BKRDWH

J403 P403

ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON+8 V

ACCELERATOR PEDAL POSITION

BAC

C977-BU

E716-GYG879-ORC983-WHC984-YL

H795-PK

H795-PK

A/C HIGH PRESSURE SWITCHN/C

E971-GN

G883-GN

450-YL

451-BR

SIGNAL+

SIGNAL-

TACHOMETERNOTE ENOTE H

INPUT #16

CLUTCH PEDAL POSITION SWITCH

E793-BUE794-YL

INPUT #11 (NOTE L)INPUT #15 POSITIVE

RETARDER SOLENOID LOW/HI SWITCH+5VENGINE COOLANT LEVEL NORMAL (NOTE G)ENGINE COOLANT LEVEL LOW (NOTE G)RETARDER SOLENOID MED/HI SWITCH

INPUT #15 NEGATIVEVEHICLE SPEED IN POSITIVE (NOTE F)VEHICLE SPEED IN NEGATIVE

INPUT #8 (NOTE L)

20A

NOTE H

14 AWG GXL14 AWG GXL14 AWG GXL14 AWG GXL

ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON+8VACCELERATOR PEDAL POSITION

226323 24954

PASSIVEMAGNETIC

VEHICLE SPEEDSENSOR

G808-BUG809-GN

H795-PK

H795-PK

E717-GN

E716-GY

SET/RESUME SWITCH

NOTE J

ENGINEBLOCK

4124

E971-GNG834-PU

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED

CLUTCH PEDAL POSITION SWITCH N/C

SERVICE BRAKE PEDAL POSITION SWITCH N/C

(PEDAL RELEASED POSITION)

626461

COOLING FAN SOLENOID

CRUISE CONTROL ON/OFF SWITCH

CHECK ENGINE LAMP

GNYLOR

ENGINE BOOST PRESSUREENGINE PRESSURE SENSOR COMMON

ENGINE PRESSURE SENSOR +5VP200 J200

ABC

WARNING LAMP

TO J1922 DATA LINK CONNECTORTO J1922 DATA LINK CONNECTOR

+BAT.-BAT.

J1587 DL NEGATIVEJ1587 DL POSITIVE

TO J1939 DATA LINK CONNECTOR

TO J1939 DATA LINK CONNECTORTO J1939 DATA LINK CONNECTOR

12

D

H795-PK

EC

405155

NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED

F

CAB DIAGNOSTIC TOOL CONNECTOR

BA

5 466

2532336968

VEHICLE HARNESS CONNECTOR

TO VEHICLECOMPONENTS

P2 J2

H795-PKC985-BUC986-BR

L994-YL659-PK

K998-BUG880-PKJ906-BRG881-BU

G882-WH

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

SERVICE BRAKE PEDAL POSITION SWITCHINPUT SENSOR COMMON #1INPUT #5 (NOTE L)INPUT #6 (NOTE L)INPUT #7 (NOTE L)

SIGNAL-

SIGNAL+

START

ONOFF

BS

C

NOTE H

R

451847 646

C992-PUL901-GYG842-GYG843-ORG844-PK

H795-PK

45.5

mA

MA

X

INJECTORCYLINDER

NO.6

INJECTORCYLINDER

NO.5

C974-PUC973-GNE718-PKE991-GY

G836-WH

GS

MTRBAT

STARTERMOTOR

(12V)

CRUISE CONTROL ON/OFF SWITCHINPUT #3 (NOTE L)INPUT #4 (NOTE L)

5960 7

BATTERY 2

C975-WHK982-YL

G841-GN

N/ORELAY

H795-PKC985-BUC986-BR

SETRESUMEINPUT #1 (NOTE L)INPUT #2 (NOTE L)

C978-BRC979-OR

C977-BU

C992-PU

C975-WH

35445658

C978-BRC979-ORK999-GNK980-PK

C973-GN

C974-PUKEY SWITCH

659-PK

GROUND

L994-YL

ALTERNATOR

- 12V+- 12V+ +

P1 J1

12V

INJECTORCYLINDER

NO.4

INJECTORCYLINDER

NO.3

-

BATTERY 3 BATTERY 1

G884-YLA746-PKA747-GY

994-GY

G829-GNG828-WH

L983-WHL984-ORL985-YL

A706-GYA705-BUA704-GNA703-BRA702-PUA701-GYJ700-BRJ701-GNJ702-BK

NOTE J: ENGINE BLOCK MUST HAVE A DIRECT WIRE CONNECTIONTO BATTERY(-). THIS CONNECTION CAN BE MADE AT THESTARTER(-) TERMINAL OR MAINFRAME GROUND LUG

NOTE M: J1922 AND J1939 DATA LINKS MUST BE PROGRAMMED FOR ECM TOINTERACT ON DATA LINK, J1939 MUST NOT BE PROGRAMMED UNLESS USED IF PROGRAMMED WITHOUT PROPER CONNECTION A DIAGNOSTIC CODE WILL RESULT

G835-ORG808-BUG809-GN

G845-PU

J1587 DATA LINK NEGATIVEJ1587 DATA LINK POSITIVEJ1939 DATA LINK SHIELD (NOTE K & NOTE M)J1939 DATA LINK NEGATIVE (NOTE K & NOTE M)J1939 DATA LINK POSITIVE (NOTE K & NOTE M)J1922 DATA LINK POSITIVE (NOTE M)J1922 DATA LINK NEGATIVE (NOTE M)

UNSWITCHED +BATTERY (NOTE D)UNSWITCHED +BATTERY (NOTE D)-BATTERY-BATTERYINPUT #9 INPUT #10 INPUT SENSOR COMMON #2INPUT #14

525365672726 317

E717-GN

101-RD 101-RD 229-BK 229-BK

G933-YLC453-YL 993-BR

F713-OR

9 8423450 1144843

TACHOMETER POSITIVETACHOMETER NEGATIVEOUTPUT #5OUTPUT #6OUTPUT #7OUTPUT #8

38391119202157

450-YL 451-BR

G837-YLG838-BRG839-BUG840-PU

L983-WHL984-ORL985-YL

A706-GYA705-BUA704-GNA703-BRA702-PUA701-GYJ700-BRJ701-GNJ702-BK

NOTE CNOTE F

GNYLOR

ENGINE OIL PRESSUREENGINE PRESSURE SENSOR COMMON

ENGINE PRESSURE SENSOR +5V

P201 J201

ABC 994-GY

G829-GNG828-WH

A747-GYG829-GNG828-WH

CBA

P203 J203

ENGINE ATMOSPHERIC PRESSUREENGINE PRESSURE SENSOR COMMON

ENGINE PRESSURE SENSOR +5V

GNYLOR

SPEEDOMETER POSITIVESPEEDOMETER NEGATIVEOUTPUT #2OUTPUT #3OUTPUT #4

LOMED

36371012131516

1210

8654321

1197

J300 P300

ENGINE TIMING CALIBRATION PROBE POSITIVEENGINE TIMING CALIBRATION PROBE NEGATIVE

ENGINE TIMING CALIBRATION PROBE POSITIVEENGINE TIMING CALIBRATION PROBE NEGATIVE

12

A746-PKG829-GNG828-WH

HI

ENGINE RETARDERSOLENOID SELECTOR SWITCH

NOTE H

2829303170

NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINEVOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETERSIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER.THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS

(PEDAL RELEASED POSITION)

G856-WHG857-YL

HI

CHECK ENGINE LAMPWARNING LAMPOUTPUT #1OUTPUT #9IGNITION KEY SWITCH

MEDLO

ENGINE RETARDERSOLENOID

ON/OFF SWITCH

INJECTORCYLINDER

NO.1

INJECTORCYLINDER

NO.2

NOTE H

INPUT #12INPUT #13

E793-BUE794-YLA249-BKK990-GNK900-YL

E721-WHE720-PK

NOTE L: SENSOR COMMON CONNECTION FOR INPUTS #1 THROUGH #8AND #11 MAY BE MADE TO EITHER J1-5 OR J1-18J1-18 IS FOR BODY BUILDER/AFTERMARKET INSTALLATIONS

OF EACH OTHER. FOR SPEEDOMETERS WITH A SINGLE SIGNAL INPUTTERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM THE ECM MAY BE USED.

NOTE F: AN ELECTRONIC SIGNAL MAY BE PROVIDED IN PLACE OF A PASSIVE MAGNETIC SENSOR, THE ELECTRONIC SIGNAL INPUT WILL BECONNECTED TO THE +SIGNAL PIN.

NOTE H: A DASHED LINE INDICATES AN OPTIONAL FEATURE NOT AVAILABLEON ALL SYSTEMS.

ENGINE BOOSTPRESSURE SENSOR

ENGINE ATMOSPHERICPRESSURE SENSOR

ENGINE OILPRESSURE SENSOR

ENGINE COOLANTTEMPERATURE SENSOR

ENGINE INTAKEMANIFOLD AIRTEMPERATURE SENSOR

ENGINE FUELTEMPERATURE SENSOR

J400 P400

TO +BATTERY

ALL SWITCHES ARE SHOWN IN THE OFF POSITIONUNLESS OTHERWISE SPECIFIED:ALL WIRES TO BE 18 AWG OR LARGER SAE J1128 TYPE SXLOR EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708

PID-FMI DescriptionFlashCodes

PID-FMI DescriptionFlashCodes

0-00 No Detected Faults 55 105-04 Intake Manifold Temp Sensor Short Circuit 381-11 Cylinder 1 Fault 72 105-11 Very High Intake Manifold Temp Warning 642-11 Cylinder 2 Fault 72 108-03 Atmospheric Pressure Sensor Open Circuit 263-11 Cylinder 3 Fault 73 108-04 Atmospheric Pressure Sensor Short Circuit 264-11 Cylinder 4 Fault 73 110-00 High Coolant Temp Warning 615-11 Cylinder 5 Fault 74 110-03 Coolant Temp Sensor Open Circuit 276-11 Cylinder 6 Fault 74 110-04 Coolant Temp Sensor Short Circuit 2722-11 Cam Sensor to Crank Sensor Calibration 42 110-11 Very High Coolant Temp Warning 6122-13 Check Timing Sensor Calibration 42 111-01 Low Coolant Level Warning 6230-08 Invalid PTO Throttle Signal 29 111-02 Coolant Level Sensor Fault 1230-13 PTO Throttle Sensor Calibration 29 111-11 Very Low Coolant Level 6241-03 8 Volt Supply Above Normal 21 121-05 Retarder Solenoid Lo/Hi Open Circuit 1441-04 8 Volt Supply Below Normal 21 121-06 Retarder Solenoid Lo/Hi Short Circuit 1443-02 Ignition Key Switch Fault 71 122-05 Retarder Solenoid Med/Hi Open Circuit 1454-05 Multi-Function Output #6 Open Circuit 66 122-06 Retarder Solenoid Med/Hi Short Circuit 1454-06 Multi-Function Output #6 Short Circuit 66 168-02 Low or Intermittent Battery Power to ECM 5155-05 Multi-Function Output #7 Open Circuit 67 171-03 Outside Air Temp Sensor Open Circuit 0055-06 Multi-Function Output #7 Short Circuit 67 171-04 Outside Air Temp Sensor Short Circuit 0064-12 Loss of Engine Cam Sensor RPM Signal 34 171-11 No Ambient Air Temp Data 0071-00 Idle Shutdown Override 01 174-00 High Fuel Temp Warning 6571-01 Idle Shutdown Occurrence 47 174-03 Fuel Temp Sensor Open Circuit 1371-14 PTO Shutdown Occurrence 47 174-04 Fuel Temp Sensor Short Circuit 1384-00 Vehicle Overspeed Warning 41 190-00 Engine Overspeed Warning 3584-01 Loss of Vehicle Speed Signal 31 190-12 Loss of Engine Crank Sensor RPM Signal 3484-02 Invalid Vehicle Speed Signal 36 191-07 Transmission Not Responding 6884-08 Vehicle Speed Out of Range 36 224-11 Theft Deterrent Enabled 0084-10 Vehicle Speed Rate of Change 36 224-14 Emergency Cranking With Theft Deterrent Enabled 0084-14 Quick Stop Occurrence 00 231-11 J1939 Data Link Fault 5891-08 Invalid Throttle Signal 32 232-03 5 Volt Supply Above Normal 2191-13 Throttle Sensor Calibration 28 232-04 5 Volt Supply Below Normal 21100-01 Low Oil Pressure Warning 46 244-02 Event Recorder Data Lost 02100-03 Oil Pressure Sensor Open Circuit 24 246-11 Brake Switch #1 Fault 00100-04 Oil Pressure Sensor Short Circuit 24 247-11 Brake Switch #2 Fault 00100-11 Very Low Oil Pressure 46 249-11 J1922 Data Link Fault 58102-00 Boost Pressure Sensor Stuck High 25 252-11 Incorrect Engine Software 59102-03 Boost Pressure Sensor Open Circuit 25 253-02 Check Customer or System Parameters 56102-04 Boost Pressure Sensor Short Circuit 25 253-11 Check Transmission Customer Parameters 56105-00 High Intake Manifold Temp Warning 64 253-14 Truck Manufacturer Parameter Not Programmed 56105-03 Intake Manifold Temp Sensor Open Circuit 38

Diagnostic Code Listing

Harness

Side

Harnes

EC

M C

onnector P1

EC

M C

onnector P2

sS

ideE

CM

Side

EC

MS

ide

EC

M C

onnectors

DT

Connector R

eceptacleD

T C

onnector Plug

Plug W

edge

Plug W

edge

Plug W

edge

Receptacle W

edge

Receptacle W

edge

Receptacle W

edge

HD

Connector R

eceptacleH

D C

onnector Plug

Pin C

ontactS

ealing Plug

Socket C

ontact

Speed/T

iming S

ensor Connectors

150 Series R

eceptacle

IAP

CV

Connector

150 Series P

lug

INPUT SIGNAL WIRES TO ECM

OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

(+) BATTERY SUPPLY WIRES

SIGNAL PLUS

(-) BATTERY / SENSOR RETURN

SIGNAL MINUS

C-10, C-12, 3406E, C-15, and C-16 Truck Engine Electrical System[1].pdf

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Transcript of C-10, C-12, 3406E, C-15, and C-16 Truck Engine Electrical System[1].pdf