KENR8775-00

01 Nov 12
VALVE FOR THE NOx REDUCTION SYSTEM
(NRS)
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 INJECTOR 5 INJECTOR 6
MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR

AIR INLET HEATER

MANIFOLD AIR TEMPERATURE SENSOR

CONTROL MODULES
INJECTOR DRIVER MODULE

INJECTOR CONTROL PRESSURE

SENSOR
CRANKSHAFT POSITION SENSOR

WATER IN FUEL SENSOR 1600 Series Industrial Engine

Electrical System
SOLENOILD FOR STARTER XGA
XGB
XGD
XGE
DRIVER FOR THE NRS
VALVE
ENGINE OIL TEMPERATURE SENSOR XGF
ELECTRONIC CONTROL MODULE XGH
HIGH CURRENT RELAY

INJECTOR PRESSURE REGULATOR

INJECTOR DRIVER MODULE

PIN LOCATION

COOLANT JACKET HEATER

24 17 STARTER RELAY

ENGINE FUEL PRESSURE SENSOR

ENGINE OIL PRESSURE SENSOR

Volume 1of 2:

INJECTION CONTROL PRESSURE SENSOR

LOCATED UNDER COVER

8
EXHAUST BACK PRESSURE SENSOR Harness And Wire Electrical Schematic Symbols
Symbols

X3 X2 X1 T

Pressure Temperature Level Flow Circuit Breaker

KENR8775-00 VOL 1of 2

INJECTION CONTROL PRESSURE SENSOR EXHAUST BACK PRESSURE SENSOR Symbol Symbol Symbol Symbol Symbol

Symbols and Definitions

Fuse: A component in an electrical circuit that will open the circuit if too much current flows
COOLANT TEMPERATURE SENSOR through it.
ELECTRONIC CONTROL MODULE
PIN LOCATION 24 17
Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
circle indicates that the component has screw terminals and a wire can be disconnected from it.

Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
No circle indicates that the wire cannot be disconnected from the component.

Ground (Wired): This indicates that the component is connected to a grounded wire. The
COOLANT SENSOR grounded wire is fastened to the machine.

Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine.

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
T
the gauge of the temperature or pressure.

CAMSHAFT POSITION Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
SENSOR It has a coil that makes an electromagnet when current flows through it. The
CAMSHAFT POSITION SENSOR
electromagnet can open or close the switch part of the relay.

Solenoid: A solenoid is an electrical component that is activated by electricity. It has a

8 coil that makes an electromagnet when current flows through it. The electromagnet
1 can open or close a valve or move a piece of metal that can do work.

ALTERNATOR Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is
X4 X3 X2 X1 activated by electricity and held latched 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.
NRS VALVE
Harness and Wire Symbols
ENGINE OIL TEMPERATURE SENSOR
Wire, Cable, or Harness Harness Identification Letter(s):
Assembly Identification: Includes (A, B, C, ..., AA, AB, AC, ...)
Harness Identification Letters and
Harness Connector Serialization Code:
Harness Connector Serialization
INLET AIR HEATER Codes (see sample).
The "C" stands for "Connector" and the
number indicates which connector in the
AG-C4 L-C12 harness (C1, C2, C3, ...).
L-C12
111-7898 3E-5179 3E-5179
Part Number: for Connector Plug 1
Part Number: for Connector Receptacle
INJECTION PRESSURE REGULATOR 2
Plug Receptacle
COOLANT JACKET HEATER MANIFOLD ABSOLUTE PRESSURE SENSOR Pin or Socket Number
5A
1 Deutsch connector: Typical representation
Component
of a Deutsch connector. The plug contains all Fuse (5 Amps) 9X-1123 Part Number
2 sockets and the receptacle contains all pins.
325-AG135 PK-14
1 Sure-Seal connector: Typical representation Harness identification code:
of a Sure-Seal connector. The plug and receptacle This example indicates wire group 325, Wire Gauge
2 contain both pins and sockets. wire 135 in harness "AG". Wire Color

WATER IN FUEL SENSOR MANIFOLD AIT TEMPERATURE SENSOR

© 2011 Caterpillar Printed in UK.

All Rights Reserved

ENGINE OIL PRESSURE SENSOR

CRANKSHAFT POSITION SENSOR

ENGINE FUEL PRESSURE SENSOR

This document is printed from SPI². Not for RESALE

 8 7 6 5 4 3 2 1

Perkins 1606 Engine customer connection harness - P/N NS10070

Fuel Inj Pr. Lubrication Cooling Engine Timing Air Charging Connector Pin no. Nav Name Colour Notes

Mangmt EP System
Filter System System System Color Code for Schematic line
IDM1
IDM4
Main Pwr
Act Gnd
Red
Black
Switched by IDM8 via IDM Power Relay according to key-switch position

schematic lines description IDM6 Logic Pwr Red Switched by IDM8 via IDM Power Relay according to key-switch position
F
WIF ICP EOT EOP ECT CKP CMP MAT MAP IAT IDM IDM8 MPR Purple Ground for relay supplying IDM1 + 6
F
Left Bank IDM9 Key Pwr Orange Key Switch
EFP Red 24 Volts (VBatt) IDM10 Act Pwr Red Switched by X3-5 via ECM Power Relay according to key-switch position
Purple 48 Volts (Vinj) IDM16 Main Gnd Black
Blue 5 Volts (VREF) X3-3 KEYPWR Orange keyswitch
Green Signal Circuit X3-4 ECL Brown Coolant Level Switch
Dotted Green Frequency or switch function X3-5 MPR Purple Ground for relay supplying X4-1 + 2 and IDM10
X3-6 PWRGND Black
Brown Data Communication Link ECM X3 X3-7 PWRGND Black
Black Circuit Ground X3-12 CANH Yellow Shielded
X3-13 CANL Orange Shielded
Control Mode Selection Switch:
X3-19 RPRE Yellow 0 V = Load Share via AP1, 24 V = Standalone (AP1 ignored)
2 1 Note:
B A B A B A B A X4-1 VPWR Red Switched by X3-5 via ECM Power Relay according to key-switch position
B A C C 21 21 3 C 21 All Connector views are X4-2 VPWR Red Switched by X3-5 via ECM Power Relay according to key-switch position
21 C 21 21 X4-7 FSS Yellow Frequency Selection Switch: 0 V = 50 Hz, 24 V = 60 Hz
ECM looking into the X4-8 RSS Yellow Regulation Selection Switch: 0 V = Isoch, 24 V = Droop
X4-4 VREF2 Blue 5 Volts
harness side connector ECM X4
X4-18 AP1 Yellow Variable Throttle: 0.5 - 4.5 V, Nominal = 2.5 V
SIGRTN1 X1-6 X4-23 GSC White Injection disable: 0 V = Run, 5 V = Stop
X4-24 SIGRTN2 Blue
MAP X2-3 X4-20 ATA(+) Red Twisted pair
X4-21 ATA(-) Black Twisted pair
VREF1 X1-14 Note:
E MAT X2-14 For clarity of print 9-pin comms
A Red V.Batt
E
B Black Neg
socket
EBP/ EP X2-8 both engine Deutsch PN
C Black CAN Shield
F Orange CAN Low, shielded
CMP(+) X1-9 connectors are HD14-9-96P
G Yellow CAN High, shielded
(CAT PN 8T-
CMP(-) X1-10 shown together. 8736)
H Black ATA Neg, twisted pair
J Red ATA Pos, twisted pair
Intake Air VRSHD X1-11 The pin #s are
INTAKE AIR TO +24V
Heater HEATER POWER BATT.
CKP(+) X1-1 color coded.
RELAY CKP(-) X1-2 RED = X1
5 3 ECT X1-8 BLUE = X2
EOP X2-7
1

EOT X2-1
ICP
2

2 1

X1-20
1845347C1
Control Notes:
EFP X2-16 1. RPRE X3-19 (Genset Type Select)
MAIH
WIF X2-9 Open (0v): Load Share (Throttle Control)
MAIH Closed (24v): Stand Alone (Pre- Set RPM)
X1-17
2. GFSS X4-07 (Frequency Select)
Exhaust 3 CAN2 H CAN2H X2-6 Open(0v): 50 Hz/ 1500 RPM
4 CAN2 L CAN2L X2-13 Closed (24v): 60 Hz/ 1800 RPM
D Gas Recirc. 2 PWR GND CAN2SH X2-12 3. GRSS X4-08 (Regulation Type/ Load Share Only) D
Open (0v): Isochronous Regulation
Control 1 VPWR Closed (24v): Droop Regulation
5 4. Throttle X4-18
IPRF X2-24 0.5v = 0% Throttle THIS SCHEMATIC IS FOR THE 1606A and the 1606D INDUSTRIAL ENGINE
ELECTRICAL SYSTEM
IPR X1-12 4.5v = 100% Throttle
Hall (Sh) 9 CKPO X1-19 5. GSC X4-23
CMPO X1-24 0.0v = Run
2 Hall W 15 BNO2 X1-16
5.0v = Engine Shutdown Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

3 Hall V 14
KENR8775-00 VOL 2 of 2

IAT X1-07
4 Hall U 13 X3-5
5 Gnd (Hall) 16 X3-10
1 2
1 +5Vdc (Hall) 12 CAN X3-30 3 4
X3-31 X3-4 ECL +5V
6 Mot W 8 Monitor
7 X3-32
Mot V 7 Connector X3-7 X3-12 CANH
8 Mot U 6 Cover X3-27 X3-13 CAN Bus
IPR CANL
X3-8 X3-15 CAN2SH
EGR Valve EGR Valve X3-4, 23
C Controller X3-24, 25 C
Inj Pr X3-1,2,3
X3-22,26
FOR REGULATED ENGINES ONLY See Control Notes 1
Control X3-28 +24V Ignition Switch
X3-19 RPRE
Conn.#2 X3-29 CRANK (START)
R 4 97OS1 X1-19 RUN
Y X3-3 KEYPWR (KL.15) +24V
1 97CS1 X1-20 X3-5 OFF
BK X1-5 MPR Batt
2 97CG1 ACCESORY
BL 3 97OG1 X1-2 X3-6 & 7 PWRGND
R 8 97OS2 X1-23 See Control Notes 2
Y 5 97CS2 X1-24 GFSS +24V
BK NOTE: X4-07
6 97CG2 X1-6 See details X4-08 GRSS +24V Note:
Front BL 7 97OG2 X1-1
R at right for See Control Notes 4 KL.15 is high when
4 97OS3 X1-17
Y X4-18 AP 1 switch is on Accesory,
1 1 97CS3 X1-18 vehicle See Control Notes 3
BK X4-24
2 97CG3 X1-8 connectors SIGRTN2 Run or Crank
BL
2 3 97OG3 X1-3 See Control Notes 5
R Conn.#3 97DW X4-23 GSC +5V
B 8 97OS4 X2-21 B
3 Y X4-4 VREF2
5 97CS4 X2-22
BK 6 ECM Power
4 BL
97CG4 X2-5 X4-21 ATA(-)
7 97OG4 X2-1 ATA Bus Relay
R X4-20 ATA(+) 85
5 4 97OS5 X2-17
Y 10 Amp 87
1 97CS5 X2-18 30
BK 97CG5 X4-1 & 2 VPWR
6 2 X2-6
BL 3 97OG5 X2-2 5
Flywheel R 8 97OS6 X2-19 25 Amp 86
Y 5 97CS6 X2-20 7
X1 X2 BK 3 2
6 97CG6 X2-8 BNO2 11 BNC +24V
BL 97OG6 X2-4 4
7 Act Gnd
INJECTOR: A-B-C-D-E-F Act Pwr
Conn.#4 10 IDM Power
FIRING ORDER: 1-5-3-6-2-4 IDM
2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3
KeyPwr 9 Relay
MPR 8 10 Amp 87 85
Logic Pwr 6 +24V
30
Main Pwr 1 Batt
Injector Pinout I345 Regulated
Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Main Gnd 16 86MEDIA NUMBER: kENR8775-00
A 1 - Closed Coil Power
ATA(+) A
2 - Open Coil Power #1 #2 #3 #4 #5 #6 2
3 - Open Coil Ground FUEL INJECTORS ATA(-) 3
4 - Close Coil Ground

8 7 6 5 4 3 2 1

This document is printed from SPI². Not for RESALE