Printed in U.S.A. RENR4930 December 2002 3500B Engi ne f or Pow er Modul es El ec t r i c al Syst em Engine: 1FZ1-UP Power Module: BLM1-UP 1GZ1-UP 1HZ1-UP BNR1-UP BPD1-UP Related Electrical Service Manuals Form Number Alternator: 5N-5692 SENR4978 Electric Starting Motor: 8N-3896 SENR3860 Electric Starting Motor: 7C-0527 SENR3581 Title Resistor and Solenoid Specifications Part No. Component Description Resistance (Ohms) 134-2540 Resistor: Smartlink Connector 120 189-5746 Resistor: LH Mag Pick Up 142 189-5746 Resistor: Timing Calibration Connector 142 9X-5484 Resistor: Diode/Resistor 20 0.2 8C-6099 Solenoids: Ether #1 and #2 3.33 - 4.07 At roomtemperature unless otherwise noted. Off Machine Switch Specification Part No. Function Actuate Deactuate Contact Position 3N-1400 Prelube Pressure 9 to 2 kPa (1.3 to .29 psi.) 7 kPa (1 psi.) Normally Open T Normally open switch that will close with an increase of a specific condition (temp-press-etc.). Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition. Normally closed switch that will open with an increase of a specific condition. Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition. The circle indicates that the component has screwterminals and a wire can be disconnected fromit. No circle indicates that the wire cannot be disconnected fromthe component. This indicates that the component has a wire connected to it that is connected to ground. This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine. Electrical Schematic Symbols And Definitions Pressure Symbol Temperature Symbol Level Symbol Flow Symbol A AA 2 A AA 1 2 325-PK-14 C A 325-PK-14 200-BK-14 T FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. 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. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. 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. Harness And Wire Electrical Schematic Symbols Socket Pin Pin or Socket Number Wire, Cable, or Harness Assembly Identification Single Wire Connector Circuit Number Identification Wire Gauge Wire Color Plug Receptacle 9X-1123 Component Part Number Electrical Schematic Symbols And Definitions 1 1 1 2 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets. Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch 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. AI R CLEANER UNFI LTERED OI L PRESSURE FRONT VI EW TURBO OUTLET PRESSURE ATMOS PRESSURE ENGI NE OI L PRESSURE AI R SHUT- OFF ELECTRI C STARTER AI R CLEANER STARTI NG AI D UNFI LTERED FUEL PRESSURE FI LTERED FUEL PRESSURE FI LTERED OI L PRESSURE LEFT SI DE VI EW AFTERCOOLER TEMP ELECTRI C STARTER ENGI NE SPEED TI MI NG LEFT HAND TURBO EXHAUST UNFI LTERED OI L PRESSURE ATMOS PRESSURE ENGI NE COOLANT TEMP RI GHT HAND TURBO PRESSURE LEFT HAND TURBO I NLET PRESSURE AI R CLEANER TI MMI NG CALI BRATI ON REAR VI EW ALTERNATOR AI R SHUT- OFF AI R CLEANER AI R START SOLENOI D RI GHT SI DE VI EW TURBO EXHAUST TEMP CRANK CASE PRESSURE RI GHT AI R SHUTOFF 23 28 31 32 24 06 07 08 09 10 11 12 04 05 37 39 40 01 02 O3 13 14 33 34 15 27 16 18 19 21 22 25 26 29 30 17 20 35 36 38 852- TN- 14 852- TN- 14 382- PK- 14 926- RD F701- BR F720- GN 844- TN- 18 845- TN- 18 846- TN- 18 101- TN- 14 101- TN- 14 102- GN/YL 102- GN/YL- 14 102- GN/YL- 14 838- SHLD- 18 838- RD- 18 838- BK- 18 998- BR F701- BR F716- WH- 18 113- OR- 18 F715- PU- 18 F702- GN- 18 F722- OR- 18 E798- PK- 18 E797- WH- 18 F710- BR- 18 F707- WH- 18 M754- RD- 16 M753- BK- 18 M756- YL- 19 M755- GN- 19 M757- CU- 19 846- TN- 18 845- TN- 18 844- TN- 18 709- OR- 18 A235- BK- 18 G429- GN- 18 709- OR- 18 G429- GN- 18 A235- BK- 18 102- GN/YL- 14 102- GN/YL- 14 102- GN/YL RD- 6 F701- BR LEFT AI R SHUTOFF ETHER SOLENOI DS ETHER SOLENOI DS STARTER MOTOR MAGC SW. ENGI NE OI L TEMP. SENSOR ( VS) ENGI NE OI L TEMP. SENSOR ( SI G) ENGI NE OI L TEMP. SENSOR ( GND) ETHER AUTO/MANUAL COOLANT LEVEL SENSOR ( A) COOLANT LEVEL SENSOR ( B) COOLANT LEVEL SENSOR ( C) POWER ( +) POWER ( +) POWER ( - ) /LO POWER ( - ) POWER ( - ) LG MAGC PU ( SHLD) LH MAGC PU ( 2) LG MAGC PU ( 1) PRI MARY CAT DATA LI NK ( +) PRI MARY CAT DATA LI NK ( - ) SECONDARY CAT DATA LI NK ( - ) SECONDARY CAT DATA LI NK ( +) DI GI TAL SENSOR RETURN CRANK SI GNAL START/STOP/RUN 1 ECM PWR. SWI TCHED ( ON/OFF) ENGI NE SHUTDOWN SI GNAL RATED SPEED DROOP SPEED SHUTDOWN NOTI FY PWR. SHUTDOWN NOTI FY RET. ETHER PULL- I N ETHER HOLD- I N DEVI CENET V+ DEVI CENET V- DEVI CENET CAN_H DEVI CENET CAN_L DEVI CENET DRAI N J981- WH J982- OR 892- BR 893- GN 101-TN-14 101-TN-14 101- TN- 14 101- TN- 14 M757- CU- 19 M755- GN- 19 M756- YL- 19 M753- BK- 16 M754- RD- 16 NOTES BLOCK L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 EMCP POWER ( +) BATTERY POWER ( - ) ECM POWER ETHER PULL- I N / HOLD- I N PRELUBE PRESSURE SWI TCH AI R SHUTOFFS ENGI NE SPEED TI MI NG ANALOG SENSOR POWER OI L TEMPERATURE SENSOR CAT DATALI NK ECM ON/OFF \ START/STOP ETHER SOLENOI DS SENSOR I NPUTS SENSOR I NPUTS COOLANT LEVEL SENSOR SHUTDOWN NOTI FY DI GI TAL SENSOR POWER CYLI NDER I NJECTORS L19 TI MI NG CALI BRATI ON LH MAG PI CK UP L20 L21 DROOP/RATED SPEED L22 SMARTLI NK 155- 2269 PLUG ASSEMBLY 155- 2261 WEDGE ASSEMBLY 155- 2276 WEDGE ASSEMBLY 169- 8670 PLUG ASSEMBLY 134- 2540 RESI STOR RECEPTACLE 177- 0071 6V- 5049 9X3271 ( SMARTLI NK USE) J982- OR J981- WH J981- WH J982- GR CONNECTOR 133- 0970 GENERATOR 8T9834 L22 L22 L15 L4 L21 L10 L11 L20 L17 L18 L5 L12 L9 L13 L21 L21 L14 L18 L17 L13 L11 L12 L20 L10 L15 L14 L4 L4 L10 AND HARNESS TO THERMOCOUPLE SMARTLI NK ADAPTER 1 2 B A C EMCP CB 30A 1 2 E797-WH E798-PK L4 SMARTLI NK C B A CONNECTORS 838- SHLD- 18 2 1 838- RD- 18 838- BK- 18 BK- 18 WH- 18 LH MAGC PU 189- 5746 L11 892- BR 893- GN H J 229-BK-14 229-BK-14 L16 150- RD- 14 150- RD- 14 BK- 6 BK- 6 RD- 6 B C A WH- 18 BK- 18 OR- 18 ANALOG RET SI GNAL +V ANALOG ENGI NE OI L TEMP. SENSOR 102- 0050 ( EMCP I I USE) 998- BR- 18 F718- BU- 18 F705- PK 200- BK 104- RD- 10 104- RD- 10 C465- OR- 10 2 1 PRELUBE PRESSURE SWI TCH 3N- 1400 NOTE A 7 A 4 PPR- M B 2 1 PPR- S 3 4 PRELUBE CONTROL ( 148- 8026) 200- BK- 6 200- BK- 10 314- PU- 10 200- BK- 10 109- RD- 6 109- RD- 6 200- BK- 6 + R ALT 45A POWER DI STRI BUTI ON BOX 2 1 1 MAG RELAY 2 1 CI RCUI T BREAKER 40A 1 60A ALT CB 2 ECM CB 15A 2 30A PRELUBE CB STARTER SMMS2 1 3 4 2 MAG SWI TCH MAG SWI TCH STARTER 3 4 1 2 SMMS1 ( 147- 3347/147- 3346) WH-18 BK-18 ADEM I I - J2 ADEM I I - J1 F722- OR L2 L19 I NJECTOR GP ( 16) 998- BR A713-GN SHUTDOWN NOTIFY RET. FUEL PRESSURE SNSR - UNFILTERED F737-YL ENGINE SHUTDOWN SIGNAL 'D' SW6 DIG SNSR RETURN ANA SNSR PWR (5V) 362704 39 33 21 17 11 05 10 06 30 12 31 18 37 22 38 28 1534 26 40 16 35 29 01 25 2409D- KEY PLUG AS. 101- 0205 32 TI MI NG CALI BRATI ON CONNECTOR 189- 5746 COOLANT TEMP SNSR 995-BU 1 2 F723-PK F724-PU L19 XXX-XX XXX-XX F701-BR 04062319 051112183339 4028 27 213529363026 2202081434 2425 13030907 38323137101516 17 01 L16 L19 START/RUN/STOP1 SW3 L15 A714-PK A715-GY A716-PU 20 G769-PU ANA SNSR RETURN SW7 (UNUSED) G770-WH BATTERY(+) BATTERY(+) BATTERY(-) BATTERY(-) START/RUN/STOP2 SW4 ETHER HOLD-IN D-OUT 3 - HIGH SIDE (UNUSED) TIMING CAL-FAN SPD(-) TIMING CAL-FAN SPD(+) D-OUT 2 - HIGH SIDE (UNUSED) PRELUBE PUMP DIG SNSR PWR (8V) SECONDARY CAT DATA LINK (+) SW9 (UNUSED) ENGINE SHUTDOWN SIGNAL 'C' SW2 OIL PRESSURE SNSR - UNFILTERED CAN DATA LINK (-) (UNUSED) HSDL SHIELD GROUND (UNUSED) CAN DATA LINK (+) (UNUSED) FUEL PRESSURE SNSR - FILTERED 150-RD-14 150-RD-14 F718-BU F716-WH F717-YL F707-WH XXX-XX 893-GN J982-OR XXX-XX F705-PK A700-OR J981-WH F715-PU XXX-XX E796-GN XXX-XX XXX-XX XXX-XX F725-WH F704-OR A700-OR 998-BR A B C YL GN-18 +V DIGTAL SIGNAL DIGITAL RET TURBO EXHAUST TEMP RH 163- 7882 TURBO EXHAUST TEMP LH 163- 7882 DIGITAL RET SIGNAL +V DIGITAL YL-18 YL YL CBA 998-BR A700-OR F703-GY L3 L3 L6 998-BR 997-OR 993-BR ECM ON/OFF - KEYSWITCH INPUT F724- PU F723- PK 998- BR A700- OR L7 SPD PWM 1B+ (UNUSED) SPD PWM 1B- (UNUSED) ETHER PULL-IN PRELUBE PRESSURE SWITCH D-OUT 5 - LOW SIDE (UNUSED) DROOP SPD SIG (TERM D) SW10 CAT DATA LINK (-) CAT DATA LINK (+) SECONDARY CAT DATA LINK (-) ENG SPEED/TIMING SIG +V SPEED/TIMING CRANKCASE PRESSURE SENSOR CRANK SIGNAL POUT 1 (UNUSED) TURBO INLET RH PRESSURE SNSR 1907 23 201408020313 POUT 1 & 2 RETURN (UNUSED) TURBO OUTLET PRESSURE SNSR ATMOS PRES SNSR TURBO INLET LH PRESSURE SNSR OIL PRESSURE SNSR - FILTERED A751-YL AFTERCOOLER TEMPERATURE SNSR RATED SPEED (TERM S) TURBO IN EXH LH TEMP SNSR TURBO IN EXH RH TEMP SNSR SHUTDOWN NOTIFY PWR. F702-GN F703-GY F704-OR F714-PK 994-GY F713-OR A747-GY A746-PK ( +) 113-OR 229-BK-14 229-BK-14 F724-PU F723-PK XXX-XX XXX-XX F710-BR C- KEY PLUG AS. 101- 0204 F719-BR F720-GN F722-OR 892-BR 999-WH 996-GN E795-YL ETHER AUTO/MANUAL SW8 L3 L2 L2 L8 L21 L11 L1 SOLENOID 1 POWER SOLENOID 2 POWER SOLENOID 3 POWER SOLENOID 4 POWER SOLENOID 5 POWER SOLENOID 6 POWER SOLENOID 7 POWER SOLENOID 8 POWER SOLENOID 9 POWER SOLENOID 10 POWER SOLENOID 11 POWER SOLENOID 12 POWER SOLENOID 13 POWER SOLENOID 14 POWER SOLENOID 15 POWER SOLENOID 16 POWER SOL 1&3 RETURN SOL 2&4 RETURN SOL 5&7 RETURN SOL 6&8 RETURN SOL 9&11 RETURN SOL 10&12 RETURN SOL 13&15 RETURN SOL 14&16 RETURN A701-GY A702-PU A703-BR A704-GN A705-YL A706-GY A707-PU A708-BR A709-OR A710-GY A711-PU A712-BR F726-YL F727-GN F728-BR F729-GN F730-GY F731-OR C ENGI NE SPEED/ TI MI NG SENSOR 129- 6628 OR-18 BK-18 WH-18 +V SPD/TIM SIGNAL DIGITAL RET BA 999- WH 996- GN 999-WH 998-BR 996-GN XXX-XX ( - ) 150- RD RECEPT AS. ( 16) 9X- 0352 YLYL 2 2 1 1122 1 A702-PU F727-GN A701- GY F727-GN 122 1 A704-GN F726- YL A706-GY F729-GN F729-GN A708-BR I NJECTOR GP ( 16) A703- BR A714- PK RD- 00 FOR 3512B/3516B ONLY 39 229- BK A B CA B CCBA 27 BK- 00 A POS NEG MOTOR BAT MTR S G ENGI NE COOLANT LEVEL SENSOR 165- 6634 L5 RES2 GND VS ALARM RD- 18 BK- 18 GN- 18 C B A BK- 00 17 304- WH- 18 200- BK- 18 05 1 RD- 00 2 926- RD 200- BK- 14 382- PK- 14 B A BK- 00 C AI R STARTER SOLENOI D 5N- 8980 1/2 MOTOR GP. 8N- 3896 ( 3512/6) 7C- 0527 ( 3508) 1/2 MOTOR GP. 8N- 3896 ( 3512/6) 7C- 0527 ( 3508) RD- 00 304- WH- 10 CUSTOMER SUPPLI ED RD- 16 RD- 16 2 1 RESI STOR 9X- 9584 RESI STOR 9X- 9584 + AI R SHUT- OFF SOLENOI D LH 8C- 6099 PRELUBE MOTOR AS. 3T- 7583 ETHER SOL #1 9X- 7137 DI ODE AS. 1W- 9070 G S MTR BAT MOTOR L9 852- TN- 14 200- BK- 14 ATTACHMENTS B 200- BK- 14 852- TN- 14 382- PK- 14 200- BK- 14 926- RD BK 1 2 DI ODE AS. 1W- 9070 382- PK BU 200- BK MOTOR AI R SHUT- OFF SOLENOI D RH 8C- 6099 CCBAA B C CB 1 2 RD- 16 RD- 16 AA B RES1 DI SCONNECT SWI TCH 7N- 0718 BU 2 1 BK ETHER SOL #2 9X- 7137 200- BK 382- PK C NEG C POS BA 998- BR 36 HARNESS AS. 119- 8959 RD-00 BK- 00 BK-00 30 L6 31 38 32 ENGI NE OI L PRESSURE SENSOR FI LTD 194- 6725 ANALOG RET SIGNAL +V ANALOG GN-18 YL-18 OR-18 993-BR 997-OR 994-GY E795-YL 997-OR 993-BR OR-18 WH-18 OR-18 +V ANALOG SIGNAL DIGITAL RET CRANK CASE PRESSURE SENSOR 161- 9926 FUEL FI LTER PRESSURE SENSOR UNFI LTD 194- 6725 26 AFTER COOLER TEMP SENSOR 102- 2240 A751- YL ANALOG RET SIGNAL +V ANALOG GN-18 YL-18 OR-18 993-BR 997-OR F737-YL 993- BR 997- OR 995- BU E796- GN F714- PK F713- OR A746- PK 994- GY E795- YL F737- YL 997-OR 993-BR A751-YL OR-18 BK-18 WH-18 +V ANALOG SIGNAL ANALOG RET L7 L8 L8 F725-WH 997-OR 993-BR OR-18 YL-18 GN-18 +V ANALOG SIGNAL ANALOG RET FUEL FI LTER PRESSURE SENSOR FI LTD 194- 6725 F725- WH L6 A747-GY 997-OR 993-BR ATMOS PRESSURE SENSOR 161- 9926 ANALOG RET SIGNAL +V ANALOG GN-18 YL-18 OR-18 A747- GY OR-18 YL-18 GN-18 +V ANALOG SIGNAL ANALOG RET ENGI NE COOLANT TEMP SENSOR 102- 2240 ENGI NE OI L PRESSURE SENSOR UNFI LTD 194- 6725 RI GHT TURBO I NLET PRESSURE SENSOR 161- 9926 LEFT TURBO I NLET PRESSURE SENSOR 161- 9926 TURBO OUTLET PRESSURE SENSOR 194- 6724 ANALOG RET SIGNAL +V ANALOG GN-18 YL-18 OR-18 OR-18 YL-18 GN-18 +V ANALOG SIGNAL ANALOG RET ANALOG RET SIGNAL +V ANALOG YL BK-18 YL ANALOG RET SIGNAL +V ANALOG GN-18 YL-18 OR-18 CBA CBA 995-BU 993-BR 997-OR 997-OR 993-BR 993-BR 997-OR 993-BR 997-OR 993-BR 997-OR E796-GN F714-OR F713-PK A746-PK 16D- KEY PLUG AS. 101- 0205 37 SOLENOID 1 POWER SOLENOID 2 POWER SOLENOID 3 POWER SOLENOID 4 POWER CYLI NDER HEAD SOL 2 SOLENOID 5 POWER SOLENOID 6 POWER SOLENOID 7 POWER SOLENOID 8 POWER SOL 1&3 RETURN SOL 2&4 RETURN SOL 5&7 RETURN SOL 6&8 RETURN A701-GY A702-PU F729-GN CYLI NDER HEAD SOL 4 CYLI NDER HEAD SOL 6 CYLI NDER HEAD SOL 8 CYLI NDER HEAD SOL 10 CYLI NDER HEAD SOL 12 CYLI NDER HEAD SOL 1 L1 CYLI NDER HEAD SOL 3 CYLI NDER HEAD SOL 5 CYLI NDER HEAD SOL 7 CYLI NDER HEAD SOL 9 F728-BR CYLI NDER HEAD SOL 11 A710-GY F731-OR F731-OR A712-BR A711-PU F730-GY F730-GY A709-OR A707-PU F728-BR F728-BR A705-YL A703-BR F726-YL F726-YL A701-GY F727-GN F726-YL A708-BR A707-PU A705- YL F728- BR A707- PU A709- OR F730- GY A711- PU A712- BR F731- OR A710- GY A708- BR F729- GN A706- GY A704- GN F727- GN A702- PU G770- WH A716- PU A706-GY A705-YL A704-GN A703-BR YL A715- GY G769- PU A713- GN FOR 3508B ONLY L1 YL G769-PU A713-GN CYLI NDER HEAD SOL 13 CYLI NDER HEAD SOL 15 A715-GY G769-PU A714-PK G770-WH CYLI NDER HEAD SOL 14 CYLI NDER HEAD SOL 16 G770-WH A716-PU 122 1122 1 122 1 122 1 12 12 8C- 6354 COVER 8T- 8736 CONNECTOR SERVI CE A B C D E F G YL YL YLYLYL YL YLYLYL YL YLYLYL YL YLYLYL YL YLYLYL YL YL L7 893- GN 892- BR WH-18 BK-18 OR-18 OR-18 BK-18 WH-18 XXX-XX F703- GY F704- OR 109- RD- 6 5N- 5692 THI S WI RI NG DI AGRAM ( 193- 3042- 01) , I S FOR THE 3500B ENGI NE, USED I N POWER MODULES AI R SHUTOFF SWI TCH ( RH) 227- 7483 AI R SHUTOFF SWI TCH ( LH) 227- 7483 F715- PU- 18 F715-PU-18 F715-PU-18