C-10, C-12, C-15 & C-16 INDUSTRIAL ENGINES – ELECTRICAL SCHEMATIC

2001 Caterpillar

Printed in U.S.A.

SENR9575-01

July 2001

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

Industrial Engine

Electrical System

BDL1-UP

BEM1-UP

BFM1-UP

BCX1-UP

LEFT SIDE VIEW

FRONT VIEW

ECM

Connector

J1/P1

ECM

Connector

J2/P2

Secondary

Speed/Timing

Sensor

(Camshaft)

Primary

Speed/Timing

Sensor

(Crankshaft)

Turbo Outlet

Pressure

Sensor

(Intake

Manifold Air)

Customer

Connector

J61

Service Tool

Electronics

Ground

Stud

C-10 and C-12 Industrial EnginesC-15 and C-16 Industrial Engines

Connector

J63

Fuel

Pressure

Sensor

Fuel

Temperature

Sensor

TC Probe

Connector

P400

Engine Oil

Pressure

Sensor

Atmospheric

Pressure

Sensor

Engine Coolant

Temperature

Sensor

FRONT VIEW

LEFT SIDE VIEW

TOP VIEW

Engine Coolant

Temperature

Sensor

Fuel

Temperature

Sensor

Fuel

Pressure

Sensor

Atmospheric

Pressure

Sensor

Engine Oil

Pressure

Sensor

ECM

Electronic

Control

Module

(ECM)

ECM

Ground

Strap

ECM

Ground

Strap

Connector

J1/P1

ECM

Connector

J2/P2

Intake Manifold

Air Temperature

Sensor

Customer

Connector

J61

Service Tool

Connector

J63

TC Probe

Connector

P400

Electronic Control Module (ECM)

Battery

Disconnect

Switch

15 Amp

Breaker

15 Amp

Breaker

Keyswitch

Timing Calibration

Probe Connector

Engine Oil

Pressure Sensor

Turbo Outlet

Pressure Sensor

(Intake Manifold Air)

Intake Manifold Air

Temperature Sensor

Atmospheric

Pressure Sensor

Fuel

Pressure Sensor

Engine Coolant

Temperature Sensor

Fuel

Temperature Sensor

Secondary

Speed/Timing Sensor

(Camshaft)

Primary

Speed/Timing Sensor

(Crankshaft)

6 Electronic

Unit Injectors

Warning Lamp

NOTE:

Components within

this area are

recommendations

Diagnostic Lamp

Caterpillar Supplied

Engine Service

Tool Connector

Maintenance

Due Lamp

Customer Installed

Service Tool

Connector

Throttle

Position Sensor

Coolant

Level Sensor

Auxiliary

Temperature Sensor

Auxiliary

Pressure Sensor

Ether Start Valve

Solenoid

Inlet Air Shutoff

Solenoid

Inlet Air Shutoff Relay

Ether Start Valve Relay

Electronics

Ground Stud

J401/P401

J100/P100

J105/P105

J103/P103

P220/J220

P800/J800

J403/P403

OEM Installed Switches:

PTO Enable

PTO Ramp Up/Down

PTO Interrupt

Remote Shutdown

Starting Aid Override

Overspeed Verify

Intermediate Engine Speed

Maintenance Due Reset

Torque Limit

J66

J63

P61

Customer

Connector

SMMS

Engine Monitoring

System (EMS)

Display Modules

P142/J142

J402/P402

J300/P300

P209/J209

P203/J203

P201/J201

P200/J200

P400

Battery

12 or 24VDC

Intake Manifold

Air Temperature

Sensor

Secondary

Speed/Timing

Sensor

(Camshaft)

Primary

Speed/Timing

Sensor

(Crankshaft)

Turbo Outlet

Pressure

Sensor

(Intake Manifold Air)

Termination

Resistor (J1939)

Electronics

Ground

Stud

Termination

Resistor (J1939)

J61

Electronic

Control

Module

(ECM)

DEVICE

120

ABC

(165-0201)

TERMINATION

RESISTOR

(134-2540)

(NOTE B & C)

(NOTE B)

(165-0200)

BABC

ABC

MAX LENGTH 1 METER

NO.1

CYL

NO.3

CYL CYL

NO.2

PRIMARY ENGINE

SPEED/TIMING SENSOR

(CRANKSHAFT)

(189-9266)

TURBO OUTLET

PRESSURE SENSOR

(INTAKE MANIFOLD AIR)

(161-9929)

ENGINE COOLANT

TEMPERATURE SENSOR

(130-9811)

SECONDARY ENGINE

SPEED/TIMING SENSOR

(CAMSHAFT)

(189-9801 NOTE N)

(188-7513 NOTE P)

CYL

NO.4

CYL

NO.5

1P920/BR

P401/J401

CYL

NO.6

+5V

1998/BR

999/WH

F732/PK

997/OR

A746/PK

993/BR

995/BU

R993/BR

J200/P200

P100/J100

P402

HARNESS EXTENSION

NOTE U

J402

SIGNAL

RETURN

SIGNAL

COMMON

SIGNAL -

SIGNAL +

SIGNAL -

SIGNAL +

ENGINE OIL PRESSURE

SENSOR

(161-9931)

ATMOSPHERIC PRESSURE

SENSOR

(161-9925 NOTE S)

(163-8530 NOTE T)

FUEL TEMPERATURE

SENSOR

(130-9811)

INTAKE MANIFOLD AIR

TEMPERATURE SENSOR

(130-9811)

FUEL PRESSURE SENSOR

(161-9931)

+5V

A997/OR

994/GY

997/OR

A747/GY

993/BR

1F421/YL

R993/BR

997/OR

993/BR B

J209/P209

P105/J105

J201/P201

J203/P203

413/BR

993/BR

C967/BU

R993/BR

P103/J103

SIGNAL

RETURN

SIGNAL

RETURN

SIGNAL

RETURN

SIGNAL

COMMON

SIGNAL

COMMON

L983/WH

L984/OR

L985/YL

A706/GY

A705/BU

L983/WH

L984/OR

L985/YL

A706/GY

A705/BU

P300/J300

A704/GN

A703/BR

A702/PU

A701/GY

TIMING

CALIBRATION

PROBE

CONNECTOR

A704/GN

A703/BR

A702/PU

A701/GY

G810/PU

G811/YL

P400

J2/P2

INJECTOR COMMON 1 & 2

INJECTOR COMMON 3 & 4

INJECTOR COMMON 5 & 6

INJECTOR 6

INJECTOR 5

INJECTOR 4

INJECTOR 3

INJECTOR 2

INJECTOR 1

TIMING CALIBRATION PROBE -

TIMING CALIBRATION PROBE +

PRIMARY (CRANK) SP/TMG SIG -

UNUSED

PRIMARY (CRANK) SP/TMG SIG +

SECONDARY (CAM) SP/TMG SIG -

SECONDARY (CAM) SP/TMG SIG +

ENGINE COOLANT TEMP. SNSR

PASSIVE SNSR COMMON

ANALOG SNSR POWER (+5V)

ANALOG SNSR COMMON

TURBO OUTLET PRESS. SNSR

ATMOSPHERIC PRESS. SNSR

ENG OIL PRESS. SNSR

FUEL TEMP. SNSR

FUEL PRESS. SNSR

INTAKE MANIF. AIR TEMP. SNSR

UNUSED

UNUSED 17

UNUSED

UNUSED 51

L983/WH

L984/OR

L985/YL

A706/GY

A705/BU

A704/GN

A703/BR

A702/PU

A701/GY

G810/PU

G811/YL

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

UNUSED

UNUSED 63

No. Function Wire Ident

1 +Bat. (Unswitched) 150/OR

2 Torque Limit Switch M909/GN

3 N/C¹ T936/GN

4 Inlet Air Shutoff Solenoid Relay G971/BR

5 Solenoid Common G969/YL

6 Cat Data Link - 892/BR

7 Cat Data Link + 893/GN

8 Digital Sensor Power (+8V) 167/OR

9 Digital Sensor Return A274/BK

10 Throttle Position Sensor A307/GY

11 Auxiliary Temperature Sensor G488/GN

12 Maintenance Due Reset Switch F426/BU

13 Maintenance Due Lamp F424/YL

14 Analog Sensor Power (+5V) 125/OR

15 Analog Sensor Return T993/BR

16 J1939 Shield A234/BK

17 J1939 Data + K900/YL

18 J1939 Data - K990/GN

19 PTO Interrupt Switch M904/OR

20 N/C¹ 450/YL

21 N/C¹ 451/BR

22 Ether Start Valve Relay 382/PK

23 N/C¹ J983/YL

24 Diagnostic Lamp F404/RD

25 Warning Lamp F420/GN

26 +Bat. (Switched) 120/YL

27 Remote Shutdown Switch F716/WH

28 Intermediate Engine Speed Switch G968/WH

29 PTO Enable Switch 381/PU

30 PTO Ramp Up/Set Switch G955/GN

31 +Bat. (Unswitched) 150/OR

32 +Bat. (Unswitched) 150/OR

33 Auxiliary Pressure Sensor G469/BU

34 N/C¹ H407/YL

35 N/C¹ E798/PK

36 Coolant Level Sensor E452/WH

37 N/C¹ H405/BU

38 Starting Aid Override Switch M910/OR

39 PTO Ramp Down/Resume Switch G967/WH

40 75% Overspeed Verify Switch 387/PK

J61 Customer Pin Out

P800/J800

P142/J142

P220/J220

J403/P403

ECM

GROUND

STRAP

ECM

MOUNTING

BOLT

Harness Side

ECM Connector P1

ECM Connector P2

ECM Side

ECM Connectors

3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

26 27 28 29 30

36 37 38 39

Customer Connector J61

Terminal Side

Customer Connector P61

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36373839

DT Connector Receptacle DT Connector Plug

Plug Wedge

Receptacle Wedge

HD Connector Receptacle

HD Connector Plug

Pin Contact

Sealing Plug

Socket Contact

Speed/Timing Sensor Connectors

150 Series Receptacle

IAPCV Connector

150 Series Plug

ABBREVIATION

WIRE CODE

ALT ALTERNATOR

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

ATA AMERICAN TRUCKING ASSOCIATION

CUSTOMER SUPPLIED WIRING

NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL

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 C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR

TO TERMINATION RESISTOR) IS 40 METERS

INSTALLATION DETAILS

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

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 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 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 F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR

MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION

NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939

SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS

NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION

NOTE N: USE THIS SENSOR FOR C-10 & C-12 ONLY

OTHER THAN UNDERGROUND MINING

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

NOTE P: USE THIS SENSOR FOR C-15 & C-16 ONLY

NOTE T: USE THIS SENSOR FOR UNDERGROUND MINING APPLICATIONS ONLY

NOTE V: ARC SUPPRESSION DIODES ARE REQUIRED

ON RELAY COILS AND SOLENOID COILS.

NOTE U: HARNESS EXTENSION NOT USED FOR C-10 OR C-12. P402 CONNECTS

DIRECTLY TO J402 ON C-10 & C-12 ONLY.

NOTE S: USE THIS SENSOR FOR ALL INDUSTRIAL APPLICATIONS

AUXILIARY

TEMPERATURE

SENSOR

(131-0427)

AUXILIARY

PRESSURE

SENSOR

(161-9932)

THROTTLE

POSITION

SENSOR

(161-8906)

ETHER START

VALVE RELAY

(NOTE V)

+8V

SIGNAL

RETURN

SIG

+ BAT.

- BAT.

RETURN

+5V

SIGNAL

RETURN

SIGNAL

COOLANT LEVEL

SENSOR

(165-6634)

OFF ENGINE

INLET AIR SHUTOFF

SOLENOID RELAY

(NOTE V)

ETHER

START

VALVE

(NOTE V)

REMOTE SHUTDOWN SW (NOTE K)

TORQUE LIMIT SW

MAINTENANCE DUE RESET SW

STARTING AID OVERRIDE SW

PTO RAMP

UP/DOWN SWITCH

MAINTENANCE

DUE LAMP

PTO ENABLE SW

PTO INTERRUPT SW

OVERSPEED VERIFY SW

INTERMEDIATE ENGINE SPEED SW

4 AWG

(NOTE B)

OFF

KEYSWITCH

ALTERNATOR

SMMS

GND

BAT

15A

14 AWG

MTR

BATTERY

STARTING

MOTOR

10 AWG

J1/P1

UNUSED

(NOTE D)

BATTERY

DISCONNECT

SWITCH

J61/P61

+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 RELAY

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

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

CAT DATA LINK -

CAT DATA LINK +

451/BR

150/OR

382/PK

125/OR

167/OR4

T993/BR

M910/OR

F426/BU

E798/PK

G971/BR

G969/YL

G488/GN

E452/WH

A274/BK

G469/BU

A307/GY

387/PK

381/PU

120/YL

892/BR

893/GN

450/YL

M909/GN

F716/WH

G968/WH

M904/OR

T936/GN

G955/GN

G967/WH

F424/YL

F404/RD

F420/GN

15A

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

ELECTRONIC CONTROL MODULE (ECM)

ANLG SNSR RETURN

ETHER START VALVE RELAY

STARTING AID OVERRIDE SW

MAINTENANCE DUE RESET SW

TORQUE LIMIT SW

REMOTE SHUTDOWN SW

INTERMEDIATE ENG. SPEED SW

OVERSPEED VERIFY SW

PTO INTERRUPT SW

PTO ENABLE SW

1.5A DIGITAL OUT 4 HS

PTO RAMP UP SW

PTO RAMP DOWN SW

MAINTENANCE DUE LAMP

DIAGNOSTIC LAMP

WARNING LAMP

TACHOMETER +

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

PWM OUTPUT 3

TACHOMETER -

+BAT.(UNSWITCHED)

AIR SHUTOFF SOLENOID

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)

A + BAT.

DIAGNOSTIC LAMP

WARNING LAMP

CAT DATA LINK -

CAT DATA LINK +

- BAT.B

(J66)

CUSTOMER INSTALLED

SERVICE TOOL CONN

(153-2707)

(NOTES B & E)

+BAT. (UNSWITCHED)

J1939 SHIELD

J1939 DATA +

J1939 DATA -

120

B AC

TERMINATION

RESISTOR

(134-2540)

(NOTE B & C)

150/OR

229/BK

-BAT.

J63

J983/YL

H407/YL

H406/GY

H405/BU

A234/BK

K900/YL

K990/GN

(NOTE A)

229/BK

893/GN

892/BR

A234/BK

K990/GN

K900/YL

ELECTRONICS

GROUND STUD

120/YL A

MAX LENGTH 40 METERS

-BAT.

CAT DATA LINK +

CAT DATA LINK -

J1939 SHIELD

J1939 DATA -

J1939 DATA +

+BAT.

PASSIVE/ACTIVE ANLG 8

+BAT.(UNSWITCHED)

SWITCH INPUT 5

SWITCH INPUT 11

SWITCH INPUT 10

J1939 SHIELD

J1939 DATA +

J1939 DATA -

CAT SUPPLIED

ENGINE SERVICE TOOL

CONNECTOR

MAX LENGTH 30 METERS

21 NC229/BK65-BAT.

-BAT.

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

-BAT.

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

-BAT.

QUAD GAUGE MODULE

(NOTE G)

OPTIONAL REMOTE

TACHOMETER MODULE OR

QUAD GAUGE MODULE

(NOTES G & B)

OPTIONAL EMS DISPLAY MODULES

RPM X100

TACHOMETER MODULE

(NOTE G)

MAIN EMS MODULE

(NOTE G)

(NOTE F)

(NOTE H)

+24V

- BAT.

US/METRIC

SCROLL FORWARD

CAT DATA LINK -

+V OUT

+V IN

-V OUT

-V IN

DC/DC CONVERTER

(127-8853)

(NOTES B & L)

UNUSED

WARNING LAMP

WARNING

SCROLL BACKWARD

(NOTE B)

BACKLIGHT LAMP PWR

CAT DATA LINK +

+24V

MODULE DATA

+V MODULE

MODULE CLOCK

MODULE LOAD

-BAT

US/METRIC

SCROLL FORWARD

CAT DATA LINK -

AUXILIARY CKT

WARNING LAMP

WARNING

SCROLL BACKWARD

BACKLIGHT LAMP PWR

MODULE DATA

+V MODULE

MODULE CLOCK

MODULE LOAD

-BAT

CAT DATA LINK +

INLET AIR SHUTOFF

SOLENOID (NOTE V)

¹ This terminal is for future expansion. Install an 8T-8737 Seal Plug.

INPUT SIGNAL WIRES TO ECM

OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

(+) BATTERY SUPPLY WIRES

SIGNAL PLUS

(-) BATTERY / SENSOR RETURN

SIGNAL MINUS