©
2001 Caterpillar
All Rights Reserved
Printed in U.S.A.
RENR2237-02
May 2001
C-10, C-12, 3406E, C-15, and C-16
Truck Engine Electrical System
CPD1-UP
1MM1-UP
2KS1-UP
2WS1-UP
6NZ1-UP
7CZ1-UP
3CS1-UP
Fuel
Temperature
Sensor
Engine
Ground
Stud
Crankshaft
Position
Sensor
Camshaft
Position
Sensor
OEM
Vehicle
Harness
Connector
J1/P1
Engine
Harness
Connector
J2/P2
Engine
Ground
Stud
Oil
Pressure
Sensor
Electronic
Unit
Injector
Connector
Atmospheric
Pressure
Sensor
Engine
Control
Module
(ECM)
C-10 and C-12 Left Side View
C-15 and C-16 Left Side View
3406E Left Side View
Coolant
Temperature
Sensor
Inlet
Manifold
Air
Temperature
Sensor
Boost
Pressure
Sensor
Atmospheric
Pressure
Sensor
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
Boost
Pressure
Sensor
Electronic
Unit
Injector
Connector
Inlet
Manifold
Air
Temperature
Sensor
Engine
Ground
Stud
Camshaft
Position
Sensor
OEM
Vehicle
Harness
Connector
J1/P1
Fuel
Temperature
Sensor
Atmospheric
Pressure
Sensor
Crankshaft
Position
Sensor
Engine
Harness
Connector
J2/P2
Engine
Control
Module
(ECM)
3406E Right Side View
3406E Front View
Oil
Pressure
Sensor
Coolant
Temperature
Sensor
Boost
Pressure
Sensor
Electronic
Unit
Injector
Connector
Inlet
Manifold Air
Temperature
Sensor
Engine
Ground
Stud
Camshaft
Position
Sensor
OEM
Vehicle
Harness
Connector
J1/P1
Engine
Harness
Connector
J2/P2
Crankshaft
Position
Sensor
Atmospheric
Pressure
Sensor
Oil
Pressure
Sensor
Engine
Control
Module
(ECM)
Coolant
Temperature
Sensor
Fuel
Temperature
Sensor
Inlet
Manifold Air
Temperature
Sensor
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 TEMPERATURE
ENGINE TEMPERATURE SENSOR COMMON
1
2
995-BU
G833-PK
J100 P100
ENGINE COOLANT TEMPERATURE
ENGINE TEMPERATURE SENSOR COMMON
ENGINE INTAKE MANIFOLD AIR TEMPERATURE
ENGINE TEMPERATURE SENSOR COMMON
J103 P103
C967-BU
G833-PK
1
2
A751-YL
G833-PK
995-BU
C967-BU
A751-YL
G833-PK
G832-OR
G827-BU
1
2
J105 P105
E963-BK
E964-WH
E965-BU
E966-YL
1
2
J401 P401
CRANK SPEED/TIMING-
CRANK SPEED/TIMING+
CRANKSHAFT
POSITION SENSOR
E963-BK
E964-WH
E965-BU
E966-YL
CAMSHAFT
POSITION SENSOR
CAM SPEED/TIMING-
CAM SPEED/TIMING+
J402 P402
1
2
INJECTOR COMMON CYLINDERS 1 & 2
INJECTOR COMMON CYLINDERS 3 & 4
INJECTOR COMMON CYLINDERS 5 & 6
INJECTOR CYLINDER 6
INJECTOR CYLINDER 5
INJECTOR CYLINDER 4
INJECTOR CYLINDER 3
INJECTOR CYLINDER 2
INJECTOR CYLINDER 1
RETARDER SOLENOID MED/HI
RETARDER SOLENOID LOW/HI
RETARDER SOLENOID COMMON
P1 J1
ENGINE HARNESS CONNECTOR
44
45
46
55
54
39
38
37
36
10
11
9
ENGINE RETARDER
SOLENOID CYLINDERS
3 & 4 NOTE H
ENGINE RETARDER
SOLENOID CYLINDERS
5 & 6 NOTE H
ENGINE RETARDER
SOLENOID CYLINDERS
1 & 2 NOTE H
P2 J2
TO ECM
MOUNTING
BOLT
5
42
27
17
22
23
26
50
60
30
47
53
4
41
1
51
56
57
67
68
69
70
65
66
52
31
INPUT #17
ENGINE BOOST PRESSURE
ENGINE ATM PRESSURE
ENGINE OIL PRESSURE
ENGINE PRESSURE SENSOR COMMON
ENGINE PRESSURE SENSOR +5V
40
14
24
25
16
3
2
8
19
12
13
43
20
21
61
62
63
64
28
29
15
CRANK SPEED/TIMING NEGATIVE
CRANK SPEED/TIMING POSITIVE
CAM SPEED/TIMING NEGATIVE
CAM SPEED/TIMING POSITIVE
ENGINE COOLANT TEMPERATURE
ENGINE INTAKE MANIFOLD AIR TEMPERATURE
ENGINE FUEL TEMPERATURE
ENGINE TEMPERATURE SENSOR COMMON
INPUT SENSOR COMMON #4
INPUT SENSOR COMMON #3
32
35
33
34
18
59
58
6
7
49
48
SPEEDOMETER
NOTE E
NOTE H
ECM GND STRAP
SENSOR ACCELERATOR
PEDAL POSITION
BK
RD
WH
J403 P403
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON
+8 V
ACCELERATOR PEDAL POSITION
B
A
C
C977-BU
E716-GY
G879-OR
C983-WH
C984-YL
H795-PK
H795-PK
A/C HIGH PRESSURE SWITCH
N/C
E971-GN
G883-GN
450-YL
451-BR
SIGNAL+
SIGNAL-
TACHOMETER
NOTE E
NOTE H
INPUT #16
CLUTCH PEDAL POSITION SWITCH
E793-BU
E794-YL
INPUT #11 (NOTE L)
INPUT #15 POSITIVE
RETARDER SOLENOID LOW/HI SWITCH
+5V
ENGINE COOLANT LEVEL NORMAL (NOTE G)
ENGINE COOLANT LEVEL LOW (NOTE G)
RETARDER SOLENOID MED/HI SWITCH
INPUT #15 NEGATIVE
VEHICLE SPEED IN POSITIVE (NOTE F)
VEHICLE SPEED IN NEGATIVE
INPUT #8 (NOTE L)
20A
NOTE H
14 AWG GXL
14 AWG GXL
14 AWG GXL
14 AWG GXL
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON
+8V
ACCELERATOR PEDAL POSITION
22
63
23
2
49
54
PASSIVE
MAGNETIC
VEHICLE SPEED
SENSOR
G808-BU
G809-GN
H795-PK
H795-PK
E717-GN
E716-GY
SET/RESUME SWITCH
NOTE J
ENGINE
BLOCK
41
24
E971-GN
G834-PU
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED
CLUTCH PEDAL POSITION SWITCH N/C
SERVICE BRAKE PEDAL POSITION SWITCH N/C
(PEDAL RELEASED POSITION)
62
64
61
COOLING FAN SOLENOID
CRUISE CONTROL ON/OFF SWITCH
CHECK ENGINE LAMP
GN
YL
OR
ENGINE BOOST PRESSURE
ENGINE PRESSURE SENSOR COMMON
ENGINE PRESSURE SENSOR +5V
P200 J200
A
B
C
WARNING LAMP
TO J1922 DATA LINK CONNECTOR
TO J1922 DATA LINK CONNECTOR
+BAT.
-BAT.
J1587 DL NEGATIVE
J1587 DL POSITIVE
TO J1939 DATA LINK CONNECTOR
TO J1939 DATA LINK CONNECTOR
TO J1939 DATA LINK CONNECTOR
1
2
D
H795-PK
E
C
40
51
55
NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED
F
CAB DIAGNOSTIC TOOL CONNECTOR
B
A
5
4
66
25
32
33
69
68
VEHICLE HARNESS CONNECTOR
TO VEHICLE
COMPONENTS
P2 J2
H795-PK
C985-BU
C986-BR
L994-YL
659-PK
K998-BU
G880-PK
J906-BR
G881-BU
G882-WH
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS
SERVICE BRAKE PEDAL POSITION SWITCH
INPUT SENSOR COMMON #1
INPUT #5 (NOTE L)
INPUT #6 (NOTE L)
INPUT #7 (NOTE L)
SIGNAL-
SIGNAL+
START
ON
OFF
B
S
C
NOTE H
R
45
18
47
6
46
C992-PU
L901-GY
G842-GY
G843-OR
G844-PK
H795-PK
45.5mA MAX
INJECTOR
CYLINDER
NO.6
INJECTOR
CYLINDER
NO.5
C974-PU
C973-GN
E718-PK
E991-GY
G836-WH
G
S
MTRBAT
STARTER
MOTOR
(12V)
CRUISE CONTROL ON/OFF SWITCH
INPUT #3 (NOTE L)
INPUT #4 (NOTE L)
59
60
7
BATTERY 2
C975-WH
K982-YL
G841-GN
N/O
RELAY
H795-PK
C985-BU
C986-BR
SET
RESUME
INPUT #1 (NOTE L)
INPUT #2 (NOTE L)
C978-BR
C979-OR
C977-BU
C992-PU
C975-WH
35
44
56
58
C978-BR
C979-OR
K999-GN
K980-PK
C973-GN
C974-PU
KEY SWITCH
659-PK
GROUND
L994-YL
ALTERNATOR
-
12V
+
-
12V
+ +
P1 J1
12V
INJECTOR
CYLINDER
NO.4
INJECTOR
CYLINDER
NO.3
-
BATTERY 3 BATTERY 1
G884-YL
A746-PK
A747-GY
994-GY
G829-GN
G828-WH
L983-WH
L984-OR
L985-YL
A706-GY
A705-BU
A704-GN
A703-BR
A702-PU
A701-GY
J700-BR
J701-GN
J702-BK
NOTE J: ENGINE BLOCK MUST HAVE A DIRECT WIRE CONNECTION
TO BATTERY(-). THIS CONNECTION CAN BE MADE AT THE
STARTER(-) TERMINAL OR MAINFRAME GROUND LUG
NOTE M: J1922 AND J1939 DATA LINKS MUST BE PROGRAMMED FOR ECM TO
INTERACT ON DATA LINK, J1939 MUST NOT BE PROGRAMMED UNLESS USED
IF PROGRAMMED WITHOUT PROPER CONNECTION A DIAGNOSTIC
CODE WILL RESULT
G835-OR
G808-BU
G809-GN
G845-PU
J1587 DATA LINK NEGATIVE
J1587 DATA LINK POSITIVE
J1939 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
-BATTERY
INPUT #9
INPUT #10
INPUT SENSOR COMMON #2
INPUT #14
52
53
65
67
27
26
3
17
E717-GN
101-RD
101-RD
229-BK
229-BK
G933-YL
C453-YL
993-BR
F713-OR
9
8
42
34
50
1
14
48
43
TACHOMETER POSITIVE
TACHOMETER NEGATIVE
OUTPUT #5
OUTPUT #6
OUTPUT #7
OUTPUT #8
38
39
11
19
20
21
57
450-YL
451-BR
G837-YL
G838-BR
G839-BU
G840-PU
L983-WH
L984-OR
L985-YL
A706-GY
A705-BU
A704-GN
A703-BR
A702-PU
A701-GY
J700-BR
J701-GN
J702-BK
NOTE C
NOTE F
GN
YL
OR
ENGINE OIL PRESSURE
ENGINE PRESSURE SENSOR COMMON
ENGINE PRESSURE SENSOR +5V
P201 J201
A
B
C
994-GY
G829-GN
G828-WH
A747-GY
G829-GN
G828-WH
C
B
A
P203 J203
ENGINE ATMOSPHERIC PRESSURE
ENGINE PRESSURE SENSOR COMMON
ENGINE PRESSURE SENSOR +5V
GN
YL
OR
SPEEDOMETER POSITIVE
SPEEDOMETER NEGATIVE
OUTPUT #2
OUTPUT #3
OUTPUT #4
LO
MED
36
37
10
12
13
15
16
12
10
8
6
5
4
3
2
1
11
9
7
J300 P300
ENGINE TIMING CALIBRATION PROBE POSITIVE
ENGINE TIMING CALIBRATION PROBE NEGATIVE
ENGINE TIMING CALIBRATION PROBE POSITIVE
ENGINE TIMING CALIBRATION PROBE NEGATIVE
1
2
A746-PK
G829-GN
G828-WH
HI
ENGINE RETARDER
SOLENOID SELECTOR SWITCH
NOTE H
28
29
30
31
70
NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE
VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER
SIGNALS 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-WH
G857-YL
HI
CHECK ENGINE LAMP
WARNING LAMP
OUTPUT #1
OUTPUT #9
IGNITION KEY SWITCH
MED
LO
ENGINE RETARDER
SOLENOID
ON/OFF SWITCH
INJECTOR
CYLINDER
NO.1
INJECTOR
CYLINDER
NO.2
NOTE H
INPUT #12
INPUT #13
E793-BU
E794-YL
A249-BK
K990-GN
K900-YL
E721-WH
E720-PK
NOTE L: SENSOR COMMON CONNECTION FOR INPUTS #1 THROUGH #8
AND #11 MAY BE MADE TO EITHER J1-5 OR J1-18
J1-18 IS FOR BODY BUILDER/AFTERMARKET INSTALLATIONS
OF EACH OTHER. FOR SPEEDOMETERS WITH A SINGLE SIGNAL INPUT
TERMINAL, 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 BE
CONNECTED TO THE +SIGNAL PIN.
NOTE H: A DASHED LINE INDICATES AN OPTIONAL FEATURE NOT AVAILABLE
ON ALL SYSTEMS.
ENGINE BOOST
PRESSURE SENSOR
ENGINE ATMOSPHERIC
PRESSURE SENSOR
ENGINE OIL
PRESSURE SENSOR
ENGINE COOLANT
TEMPERATURE SENSOR
ENGINE INTAKE
MANIFOLD AIR
TEMPERATURE SENSOR
ENGINE FUEL
TEMPERATURE SENSOR
J400 P400
TO +BATTERY
ALL SWITCHES ARE SHOWN IN THE OFF POSITION
UNLESS OTHERWISE SPECIFIED:
ALL WIRES TO BE 18 AWG OR LARGER SAE J1128 TYPE SXL
OR EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708
PID-FMI Description
Flash
Codes
PID-FMI Description
Flash
Codes
0-00 No Detected Faults 55 105-04 Intake Manifold Temp Sensor Short Circuit 38
1-11 Cylinder 1 Fault 72 105-11 Very High Intake Manifold Temp Warning 64
2-11 Cylinder 2 Fault 72 108-03 Atmospheric Pressure Sensor Open Circuit 26
3-11 Cylinder 3 Fault 73 108-04 Atmospheric Pressure Sensor Short Circuit 26
4-11 Cylinder 4 Fault 73 110-00 High Coolant Temp Warning 61
5-11 Cylinder 5 Fault 74 110-03 Coolant Temp Sensor Open Circuit 27
6-11 Cylinder 6 Fault 74 110-04 Coolant Temp Sensor Short Circuit 27
22-11 Cam Sensor to Crank Sensor Calibration 42 110-11 Very High Coolant Temp Warning 61
22-13 Check Timing Sensor Calibration 42 111-01 Low Coolant Level Warning 62
30-08 Invalid PTO Throttle Signal 29 111-02 Coolant Level Sensor Fault 12
30-13 PTO Throttle Sensor Calibration 29 111-11 Very Low Coolant Level 62
41-03 8 Volt Supply Above Normal 21 121-05 Retarder Solenoid Lo/Hi Open Circuit 14
41-04 8 Volt Supply Below Normal 21 121-06 Retarder Solenoid Lo/Hi Short Circuit 14
43-02 Ignition Key Switch Fault 71 122-05 Retarder Solenoid Med/Hi Open Circuit 14
54-05 Multi-Function Output #6 Open Circuit 66 122-06 Retarder Solenoid Med/Hi Short Circuit 14
54-06 Multi-Function Output #6 Short Circuit 66 168-02 Low or Intermittent Battery Power to ECM 51
55-05 Multi-Function Output #7 Open Circuit 67 171-03 Outside Air Temp Sensor Open Circuit 00
55-06 Multi-Function Output #7 Short Circuit 67 171-04 Outside Air Temp Sensor Short Circuit 00
64-12 Loss of Engine Cam Sensor RPM Signal 34 171-11 No Ambient Air Temp Data 00
71-00 Idle Shutdown Override 01 174-00 High Fuel Temp Warning 65
71-01 Idle Shutdown Occurrence 47 174-03 Fuel Temp Sensor Open Circuit 13
71-14 PTO Shutdown Occurrence 47 174-04 Fuel Temp Sensor Short Circuit 13
84-00 Vehicle Overspeed Warning 41 190-00 Engine Overspeed Warning 35
84-01 Loss of Vehicle Speed Signal 31 190-12 Loss of Engine Crank Sensor RPM Signal 34
84-02 Invalid Vehicle Speed Signal 36 191-07 Transmission Not Responding 68
84-08 Vehicle Speed Out of Range 36 224-11 Theft Deterrent Enabled 00
84-10 Vehicle Speed Rate of Change 36 224-14 Emergency Cranking With Theft Deterrent Enabled 00
84-14 Quick Stop Occurrence 00 231-11 J1939 Data Link Fault 58
91-08 Invalid Throttle Signal 32 232-03 5 Volt Supply Above Normal 21
91-13 Throttle Sensor Calibration 28 232-04 5 Volt Supply Below Normal 21
100-01 Low Oil Pressure Warning 46 244-02 Event Recorder Data Lost 02
100-03 Oil Pressure Sensor Open Circuit 24 246-11 Brake Switch #1 Fault 00
100-04 Oil Pressure Sensor Short Circuit 24 247-11 Brake Switch #2 Fault 00
100-11 Very Low Oil Pressure 46 249-11 J1922 Data Link Fault 58
102-00 Boost Pressure Sensor Stuck High 25 252-11 Incorrect Engine Software 59
102-03 Boost Pressure Sensor Open Circuit 25 253-02 Check Customer or System Parameters 56
102-04 Boost Pressure Sensor Short Circuit 25 253-11 Check Transmission Customer Parameters 56
105-00 High Intake Manifold Temp Warning 64 253-14 Truck Manufacturer Parameter Not Programmed 56
105-03 Intake Manifold Temp Sensor Open Circuit 38
Diagnostic Code Listing
HarnessSide
HarnesECM Connector P1
ECM Connector P2
sSide
ECMSide
ECMSide
ECM Connectors
DT Connector Receptacle DT Connector Plug
Plug Wedge
Plug Wedge
Plug Wedge
Receptacle Wedge
Receptacle 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
INPUT SIGNAL WIRES TO ECM
OUTPUT SIGNAL WIRES FROM ECM
SENSOR SUPPLY VOLTAGE
(+) BATTERY SUPPLY WIRES
SIGNAL PLUS
(-) BATTERY / SENSOR RETURN
SIGNAL MINUS
