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

SENR9575-01
July 2001

Engine Coolant Customer Service Tool Fuel Fuel Atmospheric Electronic Control Module (ECM) Caterpillar Supplied
Customer J63
Service Tool Fuel Fuel Temperature Connector Connector Temperature Pressure Pressure Engine Service
Turbo Outlet Connector Connector Pressure Temperature Sensor J61 J63 Sensor Sensor Sensor Tool Connector
Pressure J61 J63 Sensor Sensor Electronics
Electronics
Sensor Ground 6 Electronic J2 J1 Termination
Ground
(Intake Stud Unit Injectors Resistor (J1939)
Stud
Manifold Air)
Electronics
Ground Stud
Intake Manifold
Air Temperature
Sensor
Customer
J61 Connector
J300/P300
Battery + -
P61 Disconnect Battery
Switch 12 or 24VDC
P400
Breaker
Secondary Timing Calibration SMMS
Speed/Timing Probe Connector
Sensor
ECM
(Camshaft) J401/P401
TC Probe Ground
Primary Keyswitch
Connector Strap Speed/Timing Sensor
P400
(Crankshaft) 15 Amp
J402/P402 Breaker 15 Amp
Secondary Breaker
Electronic Speed/Timing Sensor
Control (Camshaft)
Module
Electronic
(ECM) P209/J209
Control OEM Installed Switches:
Fuel

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

Module Pressure Sensor PTO Enable
(ECM) PTO Ramp Up/Down
P203/J203 PTO Interrupt

Industrial Engine
ECM Remote Shutdown
Atmospheric
Ground Pressure Sensor Starting Aid Override
Strap Overspeed Verify

Electrical System
P201/J201 Intermediate Engine Speed
TC Probe Engine Oil ECM ECM
Connector Pressure Connector Connector Engine Oil Maintenance Due Reset
P400 Sensor J2/P2 J1/P1 Pressure Sensor Torque Limit
Primary
Speed/Timing Atmospheric Engine Oil ECM ECM J403/P403
P200/J200
Sensor Pressure
Sensor
Pressure Connector Connector LEFT SIDE VIEW BDL1-UP Turbo Outlet
Throttle
(Crankshaft) Sensor J2/P2 J1/P1 Position Sensor
BEM1-UP Pressure Sensor
(Intake Manifold Air)
LEFT SIDE VIEW
Secondary Turbo Outlet
Pressure
BFM1-UP Engine Coolant
J100/P100

Speed/Timing P800/J800
Sensor
Intake Manifold
Air Temperature
Sensor BCX1-UP Temperature Sensor Coolant
(Camshaft) (Intake Manifold Air) Level Sensor
Sensor J105/P105
Primary
Fuel
Speed/Timing P220/J220
Temperature Sensor
Sensor
Auxiliary
(Crankshaft) J103/P103 Pressure Sensor
Intake Manifold Air
Temperature Sensor
P142/J142
Engine Coolant
Auxiliary
Temperature
Temperature Sensor
Sensor
NOTE: Warning Lamp
Components within
this area are Inlet Air Shutoff
Diagnostic Lamp Solenoid
recommendations
Inlet Air Shutoff Relay
Maintenance
Due Lamp
Ether Start Valve
Termination Ether Start Valve Relay Solenoid
Resistor (J1939)

Customer Installed J66

Engine Monitoring
Service Tool
10 15

FRONT VIEW TOP VIEW System (EMS)

5 20

FRONT VIEW Connector 0 25

Display Modules

© 2001 Caterpillar Printed in U.S.A.

All Rights Reserved
 P300/J300
L983/WH 12 L983/WH
ECM L984/OR 10 L984/OR
GROUND L985/YL 8 L985/YL
STRAP A706/GY 6 A706/GY
ECM
MOUNTING A705/BU 5 A705/BU
BOLT A704/GN 4 A704/GN
A703/BR 3 A703/BR
A702/PU 2 A702/PU
A701/GY 1 A701/GY J61 Customer Pin Out
J2/P2 11
INJECTOR COMMON 1 & 2 44 L983/WH 9
INJECTOR COMMON 3 & 4 45 L984/OR 7 CYL CYL CYL CYL CYL CYL
No. Function Wire Ident
INJECTOR COMMON 5 & 6 46 L985/YL NO.6 NO.5 NO.4 NO.3 NO.2 NO.1 1 +Bat. (Unswitched) 150/OR
INJECTOR 6 55 A706/GY
INJECTOR 5 54 A705/BU P400 TIMING 2 Torque Limit Switch M909/GN
INJECTOR 4 39 A704/GN G810/PU 2 CALIBRATION
INJECTOR 3 38 A703/BR G811/YL 1 PROBE 3 N/C¹ T936/GN
INJECTOR 2 37 A702/PU CONNECTOR
INJECTOR 1 36 A701/GY 4 Inlet Air Shutoff Solenoid Relay G971/BR
TIMING CALIBRATION PROBE - 23 G810/PU 5 Solenoid Common G969/YL
TIMING CALIBRATION PROBE + 22 G811/YL P401/J401 PRIMARY ENGINE
PRIMARY (CRANK) SP/TMG SIG - 49 P920/BR P920/BR 1 SIGNAL - SPEED/TIMING SENSOR 6 Cat Data Link - 892/BR
PRIMARY (CRANK) SP/TMG SIG + 48 F732/PK F732/PK 2 SIGNAL + (CRANKSHAFT)
SECONDARY (CAM) SP/TMG SIG - 59 998/BR (189-9266) 7 Cat Data Link + 893/GN
SECONDARY (CAM) SP/TMG SIG + 58 999/WH
ENGINE COOLANT TEMP. SNSR 32 995/BU P402 J402 SECONDARY ENGINE 8 Digital Sensor Power (+8V) 167/OR
PASSIVE SNSR COMMON 18 R993/BR 998/BR 1 1 SIGNAL - SPEED/TIMING SENSOR
HARNESS EXTENSION (CAMSHAFT) 9 Digital Sensor Return A274/BK
ANALOG SNSR POWER (+5V) 2 997/OR 999/WH 2 2 SIGNAL +
NOTE U (189-9801 NOTE N)
ANALOG SNSR COMMON 3 993/BR 10 Throttle Position Sensor A307/GY
TURBO OUTLET PRESS. SNSR 40 A746/PK (188-7513 NOTE P)
ATMOSPHERIC PRESS. SNSR 14 A747/GY P100/J100 11 Auxiliary Temperature Sensor G488/GN
ENG OIL PRESS. SNSR 24 994/GY 995/BU 1 SIGNAL ENGINE COOLANT
FUEL TEMP. SNSR 33 F421/YL R993/BR 2 COMMON TEMPERATURE SENSOR 12 Maintenance Due Reset Switch F426/BU
(130-9811)
FUEL PRESS. SNSR 16 413/BR 13 Maintenance Due Lamp F424/YL
INTAKE MANIF. AIR TEMP. SNSR 35 C967/BU J200/P200
UNUSED 1 997/OR A +5V TURBO OUTLET 14 Analog Sensor Power (+5V) 125/OR
UNUSED 4 A746/PK C SIGNAL PRESSURE SENSOR
UNUSED 5 993/BR B RETURN (INTAKE MANIFOLD AIR) 15 Analog Sensor Return T993/BR
UNUSED 6 (161-9929)
16 J1939 Shield A234/BK
UNUSED 7 J203/P203
ATMOSPHERIC PRESSURE
UNUSED 8 997/OR A +5V
SENSOR
17 J1939 Data + K900/YL
UNUSED 9 A747/GY C SIGNAL
UNUSED 10 993/BR B RETURN (161-9925 NOTE S) 18 J1939 Data - K990/GN
UNUSED 11 (163-8530 NOTE T)
UNUSED 12 J201/P201 19 PTO Interrupt Switch M904/OR
UNUSED 13 997/OR A +5V ENGINE OIL PRESSURE 20 N/C¹ 450/YL
UNUSED 15 994/GY C SIGNAL SENSOR
UNUSED 17 993/BR B RETURN (161-9931) 21 N/C¹ 451/BR
UNUSED 19
UNUSED 20 22 Ether Start Valve Relay 382/PK
UNUSED 21 P105/J105
UNUSED 25 F421/YL 1 SIGNAL FUEL TEMPERATURE 23 N/C¹ J983/YL
UNUSED 26 R993/BR 2 COMMON SENSOR
(130-9811) 24 Diagnostic Lamp F404/RD
UNUSED 27
UNUSED 28 J209/P209 25 Warning Lamp F420/GN
UNUSED 29 997/OR A +5V
FUEL PRESSURE SENSOR 26 +Bat. (Switched) 120/YL
UNUSED 30 413/BR C SIGNAL
(161-9931)
UNUSED 31 993/BR B RETURN
UNUSED 34
27 Remote Shutdown Switch F716/WH
UNUSED 41 P103/J103
INTAKE MANIFOLD AIR 28 Intermediate Engine Speed Switch G968/WH
UNUSED 42 C967/BU 1 SIGNAL
TEMPERATURE SENSOR
UNUSED 43 R993/BR 2 COMMON 29 PTO Enable Switch 381/PU
(130-9811)
UNUSED 47
UNUSED 50 30 PTO Ramp Up/Set Switch G955/GN
UNUSED 51
31 +Bat. (Unswitched) 150/OR
UNUSED 52
UNUSED 53 32 +Bat. (Unswitched) 150/OR
UNUSED 56
UNUSED 57 33 Auxiliary Pressure Sensor G469/BU
UNUSED 60
UNUSED 61 34 N/C¹ H407/YL
UNUSED 62 Customer Connector J61 35 N/C¹ E798/PK
UNUSED 63
UNUSED 64 36 Coolant Level Sensor E452/WH
UNUSED 65 Customer Connector P61
UNUSED 66 37 N/C¹ H405/BU
UNUSED 67
UNUSED 68
38 Starting Aid Override Switch M910/OR
1 2 3 4 5 6 7 8 9 10 10 9 8 7 6 5 4 3 2 1
UNUSED 69 39 PTO Ramp Down/Resume Switch G967/WH
UNUSED 70 11 12 13 14 15 16 17 18 19 20 20 19 18 17 16 15 14 13 12 11
40 75% Overspeed Verify Switch 387/PK
21 22 23 24 25 26 27 28 29 30 30 29 28 27 26 25 24 23 22 21

31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
¹ This terminal is for future expansion. Install an 8T-8737 Seal Plug.

Terminal Side
Terminal Side

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

C OFF (NOTE B)
SMMS ON B
S ST 1
2 INLET AIR SHUTOFF
SOLENOID RELAY
R INLET AIR SHUTOFF (NOTE V)
SOLENOID (NOTE V)
CB
KEYSWITCH 15A
J1/P1
14 AWG P142/J142
UNUSED 1 AUXILIARY
A +8V
UNUSED 6 CB 14 AWG TEMPERATURE
C SIGNAL
UNUSED 7 (NOTE D) SENSOR
B RETURN
UNUSED 12 (131-0427)
UNUSED 13 +
UNUSED 14
P800/J800
UNUSED 16 COOLANT LEVEL
ALTERNATOR A +8V
UNUSED 17 G S SENSOR
C SIGNAL
UNUSED 18 (165-6634)
GND B RETURN
UNUSED 19 MTR BAT OFF ENGINE
CB
UNUSED 20
(NOTE D)
UNUSED 24
STARTING P220/J220
UNUSED 25 AUXILIARY
MOTOR A +5V
UNUSED 26 PRESSURE
C SIGNAL
UNUSED 31 SENSOR
B RETURN
UNUSED 32 (161-9932)
UNUSED 33 15A
UNUSED 35 14 AWG
UNUSED 36 J403/P403
10 AWG C SIG THROTTLE
UNUSED 37 BATTERY
CB A + BAT. POSITION
UNUSED 51 DISCONNECT
+ - B - BAT. SENSOR
UNUSED 55 SWITCH
(161-8906)
UNUSED 57
4 AWG BATTERY
UNUSED 62
(NOTE B)
UNUSED 64
UNUSED 69
PWM OUTPUT 3 43 E798/PK
TACHOMETER - 39 451/BR J61/P61 ETHER START
14 AWG VALVE RELAY ETHER
+BAT.(UNSWITCHED) 48 150/OR 1 +BAT. (UNSWITCHED)
AIR SHUTOFF SOLENOID 11 G971/BR 4 INLET AIR SHUTOFF SOLENOID RELAY (NOTE V) 1 START
SOLENOID COMMON 67 G969/YL 5 SOLENOID COMMON 2 VALVE
AUXILIARY TEMP SNSR 68 G488/GN 11 AUXILIARY TEMP SNSR (NOTE V)
COOLANT LEVEL SNSR 46 E452/WH 36 COOLANT LEVEL SNSR STARTING AID OVERRIDE SW
DIG SNSR PWR (+8V) 4 167/OR 8 DIG SNSR PWR (+8V)
DIG SNSR RETURN 5 A274/BK 9 DIG SNSR RETURN MAINTENANCE DUE RESET SW
AUXILIARY PRESS. SNSR 15 G469/BU 33 AUXILIARY PRESS. SNSR
THROTTLE POSITION SNSR 66 A307/GY 10 THROTTLE POSITION SNSR TORQUE LIMIT SW
ANLG SNSR PWR (+5V) 2 125/OR 14 ANLG SNSR PWR (+5V)
ANLG SNSR RETURN 3 T993/BR 15 ANLG SNSR RETURN REMOTE SHUTDOWN SW (NOTE K)
ETHER START VALVE RELAY 21 382/PK 22 ETHER START VALVE RELAY
STARTING AID OVERRIDE SW 22 M910/OR 38 STARTING AID OVERRIDE SW INTERMEDIATE ENGINE SPEED SW
MAINTENANCE DUE RESET SW 23 F426/BU 12 MAINTENANCE DUE RESET SW
TORQUE LIMIT SW 40 M909/GN 2 TORQUE LIMIT SW OVERSPEED VERIFY SW
REMOTE SHUTDOWN SW 44 F716/WH 27 REMOTE SHUTDOWN SW
INTERMEDIATE ENG. SPEED SW 45 G968/WH 28 INTERMEDIATE ENGINE SPEED SW PTO INTERRUPT SW
OVERSPEED VERIFY SW 54 387/PK 40 75% OVERSPEED VERIFY SW
PTO INTERRUPT SW 41 M904/OR 19 PTO INTERRUPT SW PTO ENABLE SW
PTO ENABLE SW 56 381/PU 29 PTO ENABLE SW
1.5A DIGITAL OUT 4 HS 10 T936/GN 3 NC
PTO RAMP UP SW 58 G955/GN 30 PTO RAMP UP/SET SW
PTO RAMP DOWN SW 60 G967/WH 39 PTO RAMP DOWN/RESUME SW
MAINTENANCE DUE LAMP 30 F424/YL 13 MAINTENANCE DUE LAMP
PTO RAMP
DIAGNOSTIC LAMP 28 F404/RD 24 DIAGNOSTIC LAMP
UP/DOWN SWITCH
WARNING LAMP 29 F420/GN 25 WARNING LAMP
TACHOMETER + 38 450/YL 20 NC 14 AWG
+BAT. (SWITCHED) 70 120/YL 26 +BAT. (SWITCHED) MAINTENANCE
CB DUE LAMP
CAT DATA LINK - 9 892/BR 6 CAT DATA LINK -
CAT DATA LINK + 8 893/GN 7 CAT DATA LINK + 1A
-BAT. 65 229/BK 21 NC
PASSIVE/ACTIVE ANLG 8 27 J983/YL 23 NC
14 AWG
+BAT.(UNSWITCHED) 52 150/OR 31 +BAT. (UNSWITCHED) DIAGNOSTIC LAMP
14 AWG CB
+BAT.(UNSWITCHED) 53 150/OR 32 +BAT. (UNSWITCHED)
SWITCH INPUT 5 59 H407/YL 34 NC 1A
SWITCH INPUT 11 49 H406/GY 35 NC
SWITCH INPUT 10 47 H405/BU 37 NC
MAX LENGTH 40 METERS
J1939 SHIELD 42 A234/BK 16 J1939 SHIELD WARNING LAMP
CB
J1939 DATA + 50 K900/YL 17 J1939 DATA +
J1939 DATA - 34 K990/GN 18 J1939 DATA - 1A
-BAT. 61 229/BK
-BAT. 63 229/BK (153-2707) A + BAT.
(NOTES B & E) B - BAT.
C
MAX LENGTH 30 METERS
ELECTRONIC CONTROL MODULE (ECM) E CAT DATA LINK -
C B A D CAT DATA LINK +
J63 F
G
120/YL A
+BAT.
J
229/BK B
-BAT.
H
893/GN D
CAT DATA LINK +
892/BR E
CAT DATA LINK - (J66)
A234/BK C
J1939 SHIELD CUSTOMER INSTALLED
K990/GN F
J1939 DATA - SERVICE TOOL CONN
ELECTRONICS (165-0201)
K900/YL G
J1939 DATA + C B A B A C
GROUND STUD H
NC
(NOTE A) J
NC
CAT SUPPLIED
ENGINE SERVICE TOOL
C B A (165-0200)
C B A CONNECTOR
MAX LENGTH 1 METER
(NOTE B)
TERMINATION DEVICE
RESISTOR
(134-2540) 120
120
(NOTE B & C)
TERMINATION
RESISTOR
(134-2540)
(NOTE B & C)
CAT DATA LINK +
CAT DATA LINK -
-BAT.
+BAT. (SWITCHED)

MAIN EMS MODULE

(NOTE G)
OPTIONAL EMS DISPLAY MODULES
SCROLL BACKWARD

TACHOMETER MODULE QUAD GAUGE MODULE

SCROLL FORWARD

(NOTE G) (NOTE G)
CAT DATA LINK +
CAT DATA LINK -

MODULE CLOCK

WARNING LAMP
AUXILIARY CKT
MODULE LOAD

MODULE DATA
CAT DATA LINK +
CAT DATA LINK -
-BAT.
+BAT. (SWITCHED)

+V MODULE

US/METRIC

15
WARNING

10 20
OPTIONAL REMOTE
5 25 TACHOMETER MODULE OR
+24V
-BAT

-BAT

QUAD GAUGE MODULE

RPM X100
0 30 (NOTES G & B)
14
15
25
34
35
20
23
13

33

10
11
12
16
17
18
19
21
22
24
26
27
28
29
30
31
32
36
37
38
39
40
1
2
5

7
4

3
6
8
9

1
2
3
4
5
6

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

(NOTE F)

MODULE DATA
+V MODULE
MODULE CLOCK
MODULE LOAD
-BAT
BACKLIGHT LAMP PWR

+24V 1
- BAT. 2
US/METRIC 3
SCROLL FORWARD 4 (NOTE H)
CAT DATA LINK - 5
CAT DATA LINK + 6 -V OUT +V OUT
UNUSED 7
WARNING LAMP 8 DC/DC CONVERTER
WARNING 9 (127-8853)
BACKLIGHT LAMP PWR 10 (NOTES B & L)
(+) BATTERY SUPPLY WIRES
SCROLL BACKWARD 11
12 -V IN +V IN
INPUT SIGNAL WIRES TO ECM
(NOTE B)
OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

CAT DATA LINK +
CAT DATA LINK - SIGNAL PLUS
-BAT.
(NOTES B & L)
+BAT. (SWITCHED) SIGNAL MINUS

(-) BATTERY / SENSOR RETURN

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING NOTE S: USE THIS SENSOR FOR ALL INDUSTRIAL APPLICATIONS
HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE OTHER THAN UNDERGROUND MINING
CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO ABBREVIATION
A MAIN EMS MODULE NOTE T: USE THIS SENSOR FOR UNDERGROUND MINING APPLICATIONS ONLY
ALT ALTERNATOR
NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL
NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS. NOTE U: HARNESS EXTENSION NOT USED FOR C-10 OR C-12. P402 CONNECTS ATA AMERICAN TRUCKING ASSOCIATION
INSTALLATION DETAILS
IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED. DIRECTLY TO J402 ON C-10 & C-12 ONLY. CB CIRCUIT BREAKER
IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO NOTE V: ARC SUPPRESSION DIODES ARE REQUIRED CIS CUSTOMER IGNITION SWITCH
NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR
BATTERY (-) IS REQUIRED ON RELAY COILS AND SOLENOID COILS. DIG DIGITAL
TO TERMINATION RESISTOR) IS 40 METERS
ECM ELECTRONIC CONTROL MODULE
NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION NOTE K: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-) N/C NO CONNECTION
PWM PULSE WIDTH MODULATION
NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939 THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS SM STARTING MOTOR
SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES SMMS START MOTOR MAG SWITCH
NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS WITHOUT CATERPILLAR ENGINEERING APPROVAL
MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION NOTE L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER
UNLESS OTHERWISE SPECIFIED: WIRE CODE
FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS ALL WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR
CUSTOMER SUPPLIED WIRING
SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708
1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR
NOTE N: USE THIS SENSOR FOR C-10 & C-12 ONLY ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN
ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN
NOTE P: USE THIS SENSOR FOR C-15 & C-16 ONLY CONSIDERING COMPONENT REMOVAL
Receptacle Wedge

Receptacle Wedge

Receptacle Wedge
Speed/Timing Sensor Connectors

HD Connector Receptacle

DT Connector Receptacle
150 Series Receptacle

ECM Side

ECM Side
Pin Contact

ECM Connectors
ECM Connector P2

ECM Connector P1
Socket Contact

Plug Wedge

Plug Wedge

Plug Wedge
HD Connector Plug

DT Connector Plug
IAPCV Connector
150 Series Plug

Harness Side

Harness Side
Sealing Plug