Connector Tables for Harness 219-7461
ENGINE COOLANT TEMPERATURE SENSOR P100
TURBO OUTLET PRESSURE SENSOR (BOOST) (INTAKE MANIFOLD AIR) P200
FUEL HARNESS CONNECTOR P93
ATMOSPHERIC PRESSURE SENSOR J203
EJ-S4
(CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR P402
INTAKE MANIFOLD AIR TEMPERATURE SENSOR P103
EJ-S2
EJ-S3
Harness 219-7461 Connector and Splice Locations
TIMING CALIBRATION (TC) PROBE CONNECTOR P400
EJ-S1
ENGINE OIL PRESSURE SENSOR J201
(CRANKSHAFT POSITION) PRIMARY ENGINE SPEED/TIMING SENSOR P401
ELECTRONIC CONTROL MODULE P2
TERM/PLUG 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 8T-8737 180-9340 8T-8737 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 180-9340 8T-8737 180-9340 8T-8737 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 180-9340 8T-8737 8T-8737 8T-8737 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 8T-8737 8T-8737 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 180-9340 180-9340 180-9340 180-9340 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 180-9340 180-9340 8T-8737
CLR-GA YL-18 PK-18 WH-18 PU-18 WH-18 GN-18 PK-18
QTY 1 1 200mm
CLR-GA BU-18 PK-18 QTY 1 1 200mm
CLR-GA BU-18 PK-18 QTY 1 1 200mm
CLR-GA WH-18 GN-18 PK-18 QTY 1 1 200mm
CLR-GA WH-18 GN-18 GY-18 QTY 1 1 200mm
P93 WIRE NAME F421-A13 G833-A46 T725-A32 N707-A31 G828-A35 G829-A36 C991-A33
POS 1 2 3 4 5 6 7 8 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
P100 WIRE NAME POS 995-A12 1 G833-A44 2 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
P103 WIRE NAME POS C967-A15 1 G833-A45 2 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
P200 WIRE NAME POS G828-A39 A G829-A41 B R746-A20 C ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
TERM/PLUG 180-9340 180-9340 180-9340 180-9340 180-9340 180-9340 180-9340 8T-8737 P/N 155-2264 155-2259 110-3202
TERM/PLUG 180-9340 180-9340
CLR-GA OR-18-XLPE WH-18-XLPE
POS 1 2 3 4 5 WH-18-XLPE T859-A37 6 GN-18-XLPE T961-A28 7 PU-18-XLPE T957-A16 8 GY-18-XLPE T858-A23 9 YL-18-XLPE T958-A17 10 BR-18-XLPE T959-A18 11 BU-18-XLPE T960-A19 12 ACCESSORY TABLE QTY PART NAME 1 PLUG_AS. 1 WEDGE 200mm PAINT/PRO
CLR-GA WH-18 YL-18
P/N 155-2269 155-2261 110-3202
TERM/PLUG 180-9340 180-9340 P/N 155-2269 155-2261 110-3202
QTY 1 1 200mm
CLR-GA BK-18 WH-18
TERM/PLUG 180-9340 180-9340 180-9340
QTY 1 1 200mm
CLR-GA BU-18 YL-18
P/N 155-2267 155-2276 110-3202
J201 WIRE NAME POS TERM/PLUG G828-A38 A 180-9339 G829-A43 B 180-9339 994-A10 C 180-9339 ACCESSORY TABLE PART NAME P/N RECEPTACLE_AS. 3E-3370 WEDGE 3E-3371 PAINT/PRO 110-3202
P300 WIRE NAME T860-A34 T962-A29
QTY 1 1 200mm
P400 WIRE NAME POS G856-A22 1 G857-A30 2 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
P401 WIRE NAME POS E963-A27 1 E964-A26 2 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
P402 WIRE NAME POS E965-A48 1 E966-A49 2 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
Harness And Wire Electrical Schematic Symbols
RENR8045-03 December 2007
TERM/PLUG 180-9340 180-9340 8T-8737 8T-8737 8T-8737 180-9340 180-9340 180-9340 180-9340 180-9340 180-9340 180-9340
Symbols
T
Pressure Symbol
Temperature Symbol
Level Symbol
Symbols and Definitions
P/N 155-2252 155-2258 110-3202
Fuse - A component in an electrical circuit that will open the circuit if too much current flows through it. 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.
TERM/PLUG 180-9340 180-9340
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.
P/N 155-2269 155-2261 110-3202
Ground (Wired): This indicates that the component is connected to a grounded wire. The 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.
TERM/PLUG 180-9340 180-9340 P/N 155-2269 155-2261 110-3202
TERM/PLUG 180-9340 180-9340 P/N 155-2269 155-2261 110-3202
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.
C11 and C13 Industrial Engine Electrical System
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.
T
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.
A5K1-UP B5K1-UP LGK1-UP GLS1-UP
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. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is 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.
Harness and Wire Symbols CLR-GA WH-18 GN-18 GY-18 QTY 1 1 200mm
J203 WIRE NAME POS TERM/PLUG G828-A40 A 180-9339 G829-A42 B 180-9339 R747-A6 C 180-9339 ACCESSORY TABLE PART NAME P/N RECEPTACLE_AS. 3E-3370 WEDGE 3E-3371 PAINT/PRO 110-3202
1 2
1 2
Deutsch connector: Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
Part Number for Connector Plug
C-C4 AG-C3 130-6795 130-6795
Harness Connector Serialization Code: The "C" stands for "Connector" and the number indicates which connector in the harness. (C1, C2, C3, .....)
L-C12 3E-5179
AG-C4 111-7898
Part Number For Connector Recepticle
1
325-AG135 PK-14 Socket
Pin
Sure-Seal connector: Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Harness Identification Letter(s): (A, B, C, ..., AA, AB, AC, ...)
Wire, Cable, or Harness Assembly Identification: Includes Harness Identification Letters and Harness Connector Serialization Codes
5A
Receptacle Pin or Socket Number
Single Wire Connector
9X-1123
200-L32 BK-14
2
Harness identification code: This example indicates wire 135 in harness "AG".
Circuit Identification Number
Ground Connection
Printed in U.S.A.
P/N 227-4002 211-6807 110-3202
Connector Table for Harness 264-2354 P-1 CLR-GA
GROUND M2
Connector Tables for Harness 240-8721 HARNESS INTERFACE J93
NOT USED
Harness 240-8721 Connector Locations FUEL PRESSURE J209
CLR-GA YL-18 PK-18 WH-18 PU-18 WH-18 GN-18 PK-18
QTY 1 1 200mm
POS 1 2 3 4 5 6 7 8 ACCESSORY TABLE PART NAME RECEPTACLE_AS. WEDGE PAINT/PRO
TERM/PLUG 180-9339 180-9339 180-9339 180-9339 180-9339 180-9339 180-9339 8T-8737
CLR-GA WH-18 GN-18 PK-18 QTY 1 1 200mm
TERM/PLUG 180-9339 180-9339 180-9339 P/N 3E-3370 3E-3371 110-3202
CLR-GA YL-18 PK-18 QTY 1 1 200mm
P105 WIRE NAME POS F421-L1 1 G833-L2 2 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
TERM/PLUG 180-9340 180-9340 P/N 155-2269 155-2261 110-3202
CLR-GA WH-18 PU-18 QTY 1 1 200mm
NOT USED WIRE NAME POS T725-L3 1 N707-L4 2 ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
E-S5
TERM/PLUG 180-9340 180-9340
E-S7 E-S6
E-S8
P/N 155-2269 155-2261 110-3202
E-S4
E-S1
ENGINE COOLANT TEMPERATURE SENSOR P100
FUEL PRESSURE SENSOR J209
P/N 3E-3388 3E-3389 110-3202
ENGINE OIL PRESSURE SENSOR J201
FUEL TEMPERATURE SENSOR P105
INTAKE MANIFOLD AIR TEMPERATURE SENSOR P103
GROUND M1 TIMING CALIBRATION(TC) PROBE CONNECTOR P400
ATMOSPHERIC PRESSURE SENSOR J203
ELECTRONIC CONTROL MODULE P-1 INJECTOR HARNESS CONNECTOR J300
Harness 240-8721 Connector Locations Harness 240-8721 Connector Locations
J-S1
NO.5 CYLINDER INJECTOR
J-S3
(CRANKSHAFT POSITION) PRIMARY ENGINE SPEED/TIMING SENSOR P401
Connector Table for Harness 230-0960 J300 CLR-GA WIRE NAME POS TERM/PLUG OR-16-NW T860-J8 1 180-9339 WH-16-NW T962-J16 2 180-9339 3 8T-8737 4 8T-8737 5 8T-8737 WH-16-NW T859-J9 6 180-9339 GN-16-NW T961-J15 7 180-9339 PU-16-NW T957-J13 8 180-9339 GY-16-NW T858-J7 9 180-9339 YL-16-NW T958-J14 10 180-9339 BR-16-NW T959-J18 11 180-9339 BU-16-NW T960-J17 12 180-9339 ACCESSORY TABLE QTY PART NAME P/N 1 RECEPTACLE_AS. 3E-7990 1 WEDGE 3E-5180
TERM/PLUG
CLR-GA
WIRE NAME
POS
1
8T-8737
OR-14
150-E16
1
TERM/PLUG 126-1767
2
180-9340
GN-18
M909-E17
2
180-9339
OR-18
125-E29
BR-18
T993-E30
3
180-9340
GN-18
T936-E18
3
180-9339
OR-18
167-E23
4
180-9340
BR-16
G971-E19
4
180-9339
BK-18
A274-E24
5
180-9340
YL-14
G969-E20
5
126-1767
BU-18
F426-E27
6
180-9340
BR-18
892-E21
6
180-9339
GN-18
M909-E17
7
180-9340
GN-18
893-E22
7
180-9339
GN-18
893-E3
8
180-9340
OR-18
167-E23
8
180-9339
BR-18
892-E4
9
180-9340
BK-18
A274-E24
9
180-9339
PK-16
382-E37
10
180-9340
GY-18
A307-E25
10
180-9339
BR-16
G971-E19
11
180-9340
BR-16
G488-E26
11
180-9339
12
8T-8737
BU-18
F426-E27
12
180-9339
13
8T-8737
YL-18
F424-E28
13
180-9339
14
8T-8737
OR-18
125-E29
14
180-9339
BU-18
G469-E48
15
180-9340
BR-18
T993-E30
15
180-9339
BR-16
G488-E26
16
180-9340
BK
A234-E31
16
133-0967
17
8T-8737
YL
K900-E32
17
180-9339
18
8T-8737
GN
K990-E33
18
180-9339
19
8T-8737
OR-18
M904-E34
19
180-9339
20
8T-8737
GN-14
C912-E35
20
126-1767
21
8T-8737
BU-18
A741-E36
21
180-9339
PU-18
A742-E9
22
180-9340
PK-16
382-E37
22
180-9339
GY-18
E716-E49
23
180-9340
OR-18
A743-E38
23
180-9339
24
8T-8737
RD-18
F404-E39
24
180-9339
25
8T-8737
GN-18
F420-E40
25
180-9339
26
8T-8737
YL-18
120-E41
26
180-9339
27
8T-8737
WH-18
F716-E42
27
180-9339 180-9339
RD-18
F404-E39
28
180-9340
WH-18
G968-E43
28
GN-18
F420-E40
29
180-9340
PU-18
381-E44
29
180-9339
YL-18
F424-E28
30
180-9340
GN-18
G955-E45
30
180-9339
GN-18
T936-E18
31
180-9340
OR-14
150-E46
31
126-1767
32
8T-8737
OR-14
150-E47
32
126-1767
33
8T-8737
BU-18
G469-E48
33
180-9339
GN
K990-E5
34
180-9340
GY-18
E716-E49
34
180-9339
OR-18
A743-E38
35
180-9340
GN-18
E717-E50
35
180-9339
36
8T-8737
WH-18
E452-E51
36
180-9339
37
8T-8737
OR-14
150-E1
37
126-1767
38
8T-8737
PU-18
A742-E9
38
180-9339
39
8T-8737
WH-18
G967-E54
39
180-9339
PK-18
387-E55
40
180-9339
GN-18
E717-E50
40
180-9340
OR-18
M904-E34
41
180-9340
BK
A234-E52
42
133-0969
QTY
PART NAME
P/N
43
8T-8737
1
RECEPTACLE AS.
9X-1343 126-1771
ACCESSORY TABLE
WH-18
F716-E42
44
180-9340
1
CAP-DUST
WH-18
G968-E43
45
180-9340
50mm
TUBE
5P-0702
46
8T-8737
50mm
TUBE
125-7876
1
BOOT
6I-4348
47
8T-8737
OR-14
150-E16
48
126-1768
WH-18
E452-E51
49
180-9340
YL
K900-E2
50
180-9340
CLR-GA
WIRE NAME
POS
51
8T-8737
YL-18
120-E15
A
180-9339
BK-14-GXL
229-E56
B
126-1767
J-63 TERM/PLUG
OR-14
150-E46
52
126-1768
OR-14
150-E47
53
126-1768
BK
A234-E62
C
133-0967
PK-18
387-E55
54
180-9340
GN-18
893-E8
D
180-9339
OR-14
150-E1
55
126-1768
BR-18
892-E7
E
180-9339
PU-18
381-E44
56
180-9340
GN
K990-E13
F
180-9339
57
8T-8737
YL
K900-E11
G
180-9339
GN-18
G955-E45
58
180-9340
H
8T-8737
BU-18
A741-E36
59
180-9340
J
8T-8737
WH-18
G967-E54
60
180-9340
BK-14-GXL
229-E59
61
126-1768
QTY
PART NAME
P/N
62
8T-8737
1
RECEPTACLE
8T-8736
63
BK-14-GXL
229-E57
ACCESSORY TABLE
126-1768
50mm
TUBE
5P-0702
64
8T-8737
50mm
TUBE
125-7876
BK-14-GXL
229-E58
65
126-1768
1
CAP
8C-6354
GY-18
A307-E25
66
180-9340
300mm
WIRE
5P-9074
YL-14
G969-E20
67
126-1768
100mm
TUBE
113-7027
GN-14
C912-E35
68
126-1768
BK-14-GXL
299-E10
69
126-1768
YL-18
120-E6
70
180-9340
ACCESSORY TABLE QTY
PART NAME
P/N
1
PLUG AS.
160-7689
50mm
TUBE
5P-0702
50mm
TUBE
125-7876
200mm
PAINT/PRO
110-3202
1
ENDBELL
237-0336
P-154 CLR-GA
WIRE NAME
POS
TERM/PLUG
YL
K900-E12
A
180-9340
GN
K990-E14
B
180-9340
BK
A234-E63
C
133-0969
ACCESSORY TABLE QTY
PART NAME
P/N
1
PLUG AS.
174-0502
50mm
TUBE
5P-0702
50mm
TUBE
125-7876
200mm
PAINT/PRO
110-3202
1
WEDGE
155-2266
Harness 230-0960 Connector and Splice Locations
NO.4 CYLINDER INJECTOR J-S2
FRONT ENGINE VIEW
POS
E-S3
Harness 264-2354 Connector and Splice Locations (CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR P402
J-61
WIRE NAME
P-154
E-S2
E-S9
TERMINATION RESISTOR
CUSTOMER CONNECTOR J-61
TURBO OUTLET PRESSURE SENSOR (BOOST) (INTAKE MANIFOLD AIR) P200
Wire Gauge
Wire Color
© 2007 Caterpillar All Rights Reserved
SERVICE TOOL CONNECTOR J-63
J209 WIRE NAME POS G828-L5 A G829-L6 B C991-L7 C ACCESSORY TABLE PART NAME PLUG_AS. WEDGE PAINT/PRO
Fuse (5 Amps) Component Part Number
Plug
FUEL TEMPERATURE P105
J93 WIRE NAME F421-L1 G833-L2 T725-L3 N707-L4 G828-L5 G829-L6 C991-L7
Circuit Breaker Symbol
Flow Symbol
NO.3 CYLINDER INJECTOR NO.2 CYLINDER INJECTOR
NO.1 CYLINDER INJECTOR
LEFT SIDE ENGINE VIEW
NO.6 CYLINDER INJECTOR
30 Page, (Dimensions: 39 inches x 28 inches)
INJECTOR HARNESS CONNECTOR P300
POS 1 2 3 4 5 6 7 8 9 10 11 12 BU-18 995-A12 13 14 PK-18 R746-A20 15 16 GN-18 G829-A2 17 18 19 20 21 22 23 24 BK-18 E963-A27 25 WH-18 G856-A22 26 27 GY-18 994-A10 28 29 PK-18 G833-A47 30 31 32 33 34 WH-18 E964-A26 35 YL-18 G857-A30 36 37 38 39 PK-18 C991-A33 40 41 42 43 44 45 YL-18 E966-A49 46 BU-18 E965-A48 47 48 49 50 51 52 53 54 55 BU-18 C967-A15 56 GY-18 R747-A6 57 58 59 60 61 YL-18 F421-A13 62 63 64 WH-18 T725-A32 65 66 67 68 69 70 71 WH-18 G828-A1 72 73 74 75 76 77 78 79 80 81 82 PU-18 N707-A31 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 OR-18-XLPE T860-A34 99 100 101 102 103 GY-18-XLPE T858-A23 104 WH-18-XLPE T962-A29 105 BR-18-XLPE T959-A18 106 GN-18-XLPE T961-A28 107 BU-18-XLPE T960-A19 108 109 110 111 112 113 114 WH-18-XLPE T859-A37 115 PU-18-XLPE T957-A16 116 117 YL-18-XLPE T958-A17 118 119 120 ACCESSORY TABLE QTY PART NAME 1 PLUG AS. 1 ENDBELL 200mm PAINT/PRO
RENR8045-03
CLR-GA
P2 WIRE NAME
P2 2274002
ENGINE COOLANT TEMPERATURE INTAKE MANIFOLD AIR PRESSURE PRESSURE SENSOR RETURN
PRIMARY ENGINE SPEED/TIMING (-) TIMING CALIBRATION (TC) PROBE (+) ENGINE OIL PRESSURE TEMPERATURE SENSOR RETURN
PRIMARY ENGINE SPEED/TIMING (+) TIMING CALIBRATION (TC) PROBE (-)
FUEL PRESSURE
SECONDARY ENGINE SPEED/TIMING (+) SECONDARY ENGINE SPEED/TIMING (-)
INTAKE MANIFOLD AIR TEMPERATURE ATMOSPHERIC PRESSURE
FUEL TEMPERATURE NOT USED
PRESSURE SENSOR SUPPLY +5V
NOT USED
INJECTOR 5&6 HIGH
INJECTOR 1&2 HIGH INJECTOR 6 LOW INJECTOR 3 LOW INJECTOR 5 LOW INJECTOR 4 LOW
INJECTOR 3&4 HIGH INJECTOR 1 LOW INJECTOR 2 LOW
P400 1552269 G856-A22 WH-18 G857-A30 YL-18
995-A12 C967-A15 G833-A45 G833-A44 G856-A22 G857-A30 995-A12 BU-18
G828-A40 G828-A35 G828-A38 G828-A39
A-S1
G828-A1 WH-18
2
1
R746-A20 PK-18 G829-A2 GN-18
BU-18 BU-18 PK-18 PK-18 WH-18 YL-18
995-A12 BU-18 G833-A44 PK-18
WH-18 WH-18 WH-18 WH-18
P402 1552269 E965-A48 BU-18 E966-A49 YL-18
2
994-A10 G828-A38 G828-A40 G828-A39 G829-A41 G829-A43 G829-A42 E963-A27 E964-A26 E965-A48 E966-A49 R746-A20 R747-A6
G829-A3 GN-18 A-S4
G829-A42 GN-18 G829-A43 GN-18
2
1
G833-A47 PK-18 A-S3
G833-A47 PK-18 E964-A26 WH-18 G857-A30 YL-18
G833-A44 PK-18 G833-A45 PK-18 G833-A46 PK-18
2
1
GY-18 WH-18 WH-18 WH-18 GN-18 GN-18 GN-18 BK-18 WH-18 BU-18 YL-18 PK-18 GY-18
E966-A49 YL-18 E965-A48 BU-18
ENGINE COOLANT TEMPERATURE SENSOR 130-9811
SIGNAL RETURN
INTAKE MANIFOLD AIR TEMPERATURE SENSOR 130-9811
C967-A15 BU-18 G833-A45 PK-18
1 2
BATTERY
2
(CRANKSHAFT POSITION) PRIMARY ENGINE SPEED/TIMING SENSOR 201-6615
SIGNALSIGNAL+
BK-18 WH-18
1
A B C
OR-18 YL-18 GN-18
+5 VOLTS RETURN SIGNAL
ANALOG SENSOR POWER(+5V) ANALOG SENSOR RETURN DIGITAL SENSOR PWR +8V DIGITAL SENSOR RETURN MAINTENENCE DUE RESET SWITCH TORQUE LIMIT SWITCH CAT DATA LINK + CAT DATA LINK ETHER START SOLENOID AIR SHUTOFF SOLENOID
J203 3E3370 A B C
OR-18 YL-18 GN-18
+5 VOLTS RETURN SIGNAL
J201 3E3370
G828-A38 WH-18 G829-A43 GN-18 994-A10 GY-18
A B C
OR-18 YL-18 GN-18
+5 VOLTS RETURN SIGNAL
ATMOSPHERIC PRESSURE SENSOR 194-6722
AUXILIARY PRESSURE SENSOR AUXILIARY TEMPERATURE SENSOR
ENGINE OIL PRESSURE SENSOR 194-6725
J209 3E3370 A G828-L5 WH-18 B G829-L6 GN-18 C C991-L7 PK-18
F421-A13 G833-A46 T725-A32 N707-A31 G828-A35 G829-A36 C991-A33
F421-A13 YL-18
YL-18 PK-18 WH-18 PU-18 WH-18 GN-18 PK-18
F421-A13 YL-18 G833-A46 PK-18 T725-A32 WH-18 N707-A31 PU-18 G828-A35 WH-18 G829-A36 GN-18 C991-A33 PK-18
FUEL PRESSURE SENSOR 194-6725
J93 3E3388 1 2 3 4 5 6 7 8
F421-L1 G833-L2 T725-L3 N707-L4 G828-L5 G829-L6 C991-L7
YL-18 PK-18 WH-18 PU-18 WH-18 GN-18 PK-18
DIAGNOSTIC LAMP WARNING LAMP MAINTENENCE DUE LAMP RETR LAMP (C11-C18)/EXH BK LAMP (C7-C9)
1552269
T725-L3 WH-18 N707-L4 PU-18
FUEL HARNESS CONNECTOR
T725-A32 WH-18
+5 VOLTS RETURN SIGNAL
OR-18 YL-18 GN-18
UNUSED RETR LO/HI SW (C11-C18)
P105 1552269 F421-L1 YL-18 G833-L2 PK-18
1 2
NOT USED
RETR MED/HI SW (C11-C18) PTO INTERRUPT SWITCH J1939 DATA LINK SHIELD
FUEL TEMPERATURE SENSOR 130-9811
SIGNAL RETURN
1 2
J1939 DATA LINK (-) UNUSED
REMOTE SHUTDOWN SWITCH INTERMEDIATE ENGINE SPEED SWITCH
G828-A1 WH-18
BATTERY (+) - UNSWITCHED COOLANT LEVEL SWITCH J1939 DATA LINK (+)
INJECTOR HARNESS CONNECTOR P300 1552252 T860-A34 OR-18-XLPE T962-A29 WH-18-XLPE
T859-A37 T961-A28 T957-A16 T858-A23 T958-A17 T959-A18 T960-A19
T860-A34 OR-18-XLPE
T858-A23 T962-A29 T959-A18 T961-A28 T960-A19
J300 3E7990 T860-J8 OR-16-NW T962-J16 WH-16-NW
1 2 3 4 5 6 7 8 9 10 11 12
WH-18-XLPE GN-18-XLPE PU-18-XLPE GY-18-XLPE YL-18-XLPE BR-18-XLPE BU-18-XLPE
T858-J1 GY-16-NW T957-J13 PU-16-NW
T858-J7 GY-16-NW
T859-J9 WH-16-NW
T859-J9 WH-16-NW T961-J15 GN-16-NW T957-J13 PU-16-NW T858-J7 GY-16-NW T958-J14 YL-16-NW T959-J18 BR-16-NW T960-J17 BU-16-NW
T860-J8 OR-16-NW
J-S1 1
2
T858-J1 GY-16-NW T858-J2 GY-16-NW
J-S2 1
T860-J6 OR-16-NW T860-J5 OR-16-NW
2
T957-J13 T958-J14 T959-J18 T960-J17 T961-J15 T962-J16
GY-18-XLPE WH-18-XLPE BR-18-XLPE GN-18-XLPE BU-18-XLPE
PTO RAMP UP/SET SWITCH UNUSED PTO RAMP DOWN/RESUME SWITCH BATTERY (-)
NO.2 CYLINDER INJECTOR
BATTERY (-)
T859-J3 WH-16-NW T859-J4 WH-16-NW
2
J-S3 1
T858-J2 GY-16-NW T958-J14 YL-16-NW
BATTERY (+) - UNSWITCHED BATTERY (+) - UNSWITCHED OVERSPEED VERIFY SWITCH BATTERY (+) - UNSWITCHED PTO ENABLE SWITCH
NO.1 CYLINDER INJECTOR
T859-J3 WH-16-NW T959-J18 BR-16-NW
PU-16-NW YL-16-NW BR-16-NW BU-16-NW GN-16-NW WH-16-NW
BATTERY (-) THROTTLE POSITION SENSOR SOLENOID COMMON NOT USED BATTERY (-) BATTERY (+) - KEY SWITCH
NO.3 CYLINDER INJECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
T859-A37 WH-18-XLPE T957-A16 PU-18-XLPE T958-A17 YL-18-XLPE
NO.5 CYLINDER INJECTOR
T860-J6 OR-16-NW T962-J16 WH-16-NW
NO.6 CYLINDER INJECTOR
BATTERY
1
1297163
1297164
125-E29 T993-E30 167-E23 A274-E24 F426-E27 M909-E17 893-E3 892-E4 382-E37 G971-E19
229-E56 BK-14-GXL
OR-18 BR-18 OR-18 BK-18 BU-18 GN-18 GN-18 BR-18 PK-16 BR-16
TWISTED WIRES
120-E6 YL-18
G469-E48 BU-18 G488-E26 BR-16
892-E4 BR-18 A742-E9 PU-18 E716-E49 GY-18
F404-E39 F420-E40 F424-E28 T936-E18
893-E3 GN-18
RD-18 GN-18 YL-18 GN-18
A234-E64 BK-18
E717-E50 GN-18 M904-E34 OR-18 A234-E52 BK-18 F716-E42 WH-18 G968-E43 WH-18 150-E16 OR-14 E452-E51 WH-18 K900-E2 YL-18 150-E46 150-E47 387-E55 150-E1 381-E44
E-S7
OR-14 OR-14 PK-18 OR-14 PU-18
G955-E45 GN-18 A741-E36 BU-18 G967-E54 WH-18 229-E59 BK-14-GXL
K900-E2 YL-18 K900-E60 YL-18
229-E57 BK-14-GXL 229-E58 BK-14-GXL A307-E25 GY-18 G969-E20 YL-14 C912-E35 GN-14 299-E10 BK-14-GXL 120-E6 YL-18
K990-E5 GN-18
K990-E61 GN-18
E-S5 E-S9
M904-E34 M909-E17 T993-E30 T936-E18
TWISTED WIRES
J-63 8T8736 120-E15 YL-18 229-E56 BK-14-GXL A234-E62 BK-18 893-E8 GN-18 892-E7 BR-18 K990-E13 GN-18 K900-E11 YL-18
ENGINE SERVICE TOOL CONNECTOR A B C D E F G H J
P142/J142 1 2
SIGNAL RETURN
AUXILIARY TEMPERATURE SENSOR
P800/J800 A C B
+8V SIGNAL RETURN
COOLANT LEVEL SENSOR OFF ENGINE
P220/J220 A C B
+5V SIGNAL RETURN
AUXILIARY PRESSURE SENSOR
J403/P403 C A B
SIG + BAT. - BAT.
DESIRED SPEED CONTROL (NOTE W)
BATTERY(-)
S
MTR
892-E7 BR-18 892-E21 BR-18
ETHER START VALVE
BAT.
STARTING MOTOR
ST
NOTE D
(+)BATTERY (-)BATTERY J1939 SHIELD CAT DATA LINK(+) CAT DATA LINK(-) J1939(-) J1939(+)
NOTE D
S C
1 2
ALTERNATE ETHER VALVE WIRING
KEYSTART SWITCH
1
ALTERNATOR
ON OFF
P515 1552269
BK-18 BK-18
1 2
STARTING AID OVERRIDE SW
MAINTENANCE DUE RESET SW
P-154 1740502 K900-E12 YL-18 K990-E14 GN-18 A234-E63 BK-18
A234-E63 BK-18 A234-E31 BK-18 A234-E62 BK-18 BK-18 GY-18 PU-18 BU-18 OR-18 GN-14 GY-18 GN-18 RD-18 WH-18 GN-18 YL-18 BU-18 WH-18 BU-18 BR-16 GN-18 WH-18 WH-18 YL-14 BR-16
A B C
120
150-E16 M909-E17 T936-E18 G971-E19 G969-E20 892-E21 893-E22 167-E23 A274-E24 A307-E25 G488-E26 F426-E27 F424-E28 125-E29 T993-E30 A234-E31 K900-E32 K990-E33 M904-E34 C912-E35 A741-E36 382-E37 A743-E38 F404-E39 F420-E40 120-E41 F716-E42 G968-E43 381-E44 G955-E45 150-E46 150-E47 G469-E48 E716-E49 E717-E50 E452-E51 150-E1 A742-E9 G967-E54 387-E55
TWISTED WIRES
K900-E12 YL-18 K900-E11 YL-18 K900-E32 YL-18 K990-E14 GN-18 K990-E33 GN-18 K990-E13 GN-18 OR-18 GN-18 BR-18 GN-18
TERMINATION RESISTOR (134-2540) (NOTE B&C)
J-61 9X1343
OR-14 GN-18 GN-18 BR-16 YL-14 BR-18 GN-18 OR-18 BK-18 GY-18 BR-16 BU-18 YL-18 OR-18 BR-18 BK-18 YL-18 GN-18 OR-18 GN-14 BU-18 PK-16 OR-18 RD-18 GN-18 YL-18 WH-18 WH-18 PU-18 GN-18 OR-14 OR-14 BU-18 GY-18 GN-18 WH-18 OR-14 PU-18 WH-18 PK-18
14 AWG +BAT. (UNSWITCHED) 14 AWG +BAT. (UNSWITCHED) 14 AWG +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 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
P61 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
+BAT. (UNSWITCHED) TORQUE LIMIT SW RETARDER LAMP INLET AIR SHUTOFF SOLENOID RELAY SOLENOID COMMON CAT DATA LINK CAT DATA LINK + DIG SNSR PWR (+8V) DIG SNSR RETURN THROTTLE POSITION SNSR AUXILIARY TEMP SNSR MAINTENANCE DUE RESET SW MAINTENANCE DUE LAMP ANLG SNSR PWR (+5V) ANLG SNSR RETURN J1939 SHIELD J1939 DATA + J1939 DATA PTO INTERRUPT SW
TORQUE LIMIT SW
REMOTE SHUTDOWN SW (NOTE K)
INTERMEDIATE ENGINE SPEED SW
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 RETARDER LAMP 14 AWG +BAT. (SWITCHED) CAT DATA LINK CAT DATA LINK +
NC ETHER START VALVE NC DIAGNOSTIC LAMP WARNING LAMP +BAT. (SWITCHED) REMOTE SHUTDOWN SW INTERMEDIATE ENGINE SPEED SW PTO ENABLE SW PTO RAMP UP/SET SW +BAT. (UNSWITCHED) +BAT. (UNSWITCHED) AUXILIARY PRESS. SNSR RETARDER LO/HI SWITCH RETARDER MED/HI SWITCH COOLANT LEVEL SNSR NC STARTING AID OVERRIDE SW PTO RAMP DOWN/RESUME SW 75% OVERSPEED VERIFY SW
PTO RAMP UP/DOWN SWITCH MAINTENANCE DUE LAMP
CB 1A
ALTERNATE RETARDER WIRING
RETARDER LO/HI SWITCH
HI LO
RETARDER MED/HI SWITCH
1A
LOW RETARD SWITCH (ACTUATE ON CLOSE)
RETARDER SOLENOID ON/OFF SWITCH
RETARDER MED/HI SWITCH
1A
MEDIUM RETARD SWITCH (ACTUATE ON CLOSE)
J1939 SHIELD J1939 DATA + J1939 DATA -
ACTUATE BOTH SWITCHES FOR HIGH RETARD
MAX LENGTH 40 METERS
WARNING LAMP
CB
MED HI
DIAGNOSTIC LAMP
CB
RETARDER LO/HI SWITCH
LO MED
RETARDER LAMP
CB 1A
A B C D E F G H J
(153-2707) (NOTES B & E) MAX LENGTH 30 METERS C B A
1 2 3 4 5 6
229-C50 BK-16
+BATTERY J1939 DATA+ J1939 DATAJ1939 SHIELD GROUND
1 2 3 4 5 6
N782-G1 BU-18
N784-G3 WH-18 N785-G4 BU-18
N785-G20 BU-18
G-S11
RS485A RS485B GAUGE GROUND GAUGE V+
MAINTENANCE DUE LAMP 7N5876
DIAGNOSTIC LAMP 7N5876
3E3364 101-V1 RD-14 200-V2 BK-14
OPTIONAL WIRING 1
1297164 101-V1 RD-14
1
1297164 200-V2 BK-14
1297163
1
1
1
1
BU-18 GN-18 WH-18 BU-18
N782-G34 N783-G35 N784-G36 N785-G29
N782-G30 N783-G31 N784-G32 N785-G33
BU-18 GN-18 WH-18 BU-18
G-C6 1552273
229-C50 BK-16 120-C34 YL-16 F420-C8 GN-16 F404-C9 RD-16 F424-C41 YL-16 120-C36 YL-16
1552269 1 2
229-C54 BK-14
101-C39 RD-14 391-C33 PK-14 F404-C9 RD-16 F420-C8 GN-16 120-C45 YL-14 229-C50 BK-16 F424-C41 YL-16
120-C34 YL-16 F420-C8 GN-16 F404-C9 RD-16 120-C36 YL-16 F424-C41 YL-16
4
120-C45 YL-14
1
1
1275486
1275486
Diagnostic Code Flash Code SPN(1)/FMI Code or Event Code
1
1
1
1835-16
R C S B
OFF ON ST
1836-16
1 2
N/A
1836-03
REMOTE SHUTDOWN INTERMEDIATE ENGINE SPEED SWITCH BATTERY (+) - UNSWITCHED COOLANT LEVEL SWITCH J1939 DATA LINK (+)
PTO RAMP UP SWITCH PTO RAMP DOWN / RESUME SWITCH BATTERY (-) BATTERY (-) BATTERY (-) THROTTLE POSITION 1 (PWM) SOLENOID COMMON THROTTLE POSITION 2 (PWM) BATTERY (+) - KEY SWITCH
ELECTRONIC CONTROL MODULE
K900-C26 YL K900-C42 YL
893-C12 GN-16 892-C11 BR-16
K990-C24 GN K990-C43 GN
1
1
1
2
C-S2 K900-C27 YL 2
C-S3 K990-C25 GN 2
C-S4 120-C7 YL-14 120-C19 YL-14 120-C45 YL-14 1
K990-C32 GN K990-C15 GN K900-C14 YL K900-C13 YL
1
1
1
C-S7 A234-C46 BK 2
C-S5 K990-C43 GN 2
C-S6 K900-C42 YL 2
A B C
(+)BATTERY (-)BATTERY J1939 SHIELD CAT DATA LINK(+) CAT DATA LINK(-) J1939(-) J1939(+)
G967-C4 WH-16 229-C17 BK-14
13
1
23
14
31
24
39
32
47
40
57
48
70
58
168-00
168-00
System Voltage high
168-01
168-01
System Voltage low
168-02
168-02
System Voltage intermittent/erratic
268-02
Check Programmable Parameters
High Auxiliary Temperature Derate
58
639-09
247-09
J1939 Data Link communications
110-15
9
10
8
7
6
5
545-05
Ether Start Relay open/short to +batt
2417-05
Ether Injection Control Solenoid open/short to +batt
61
110-16
3
C-C13 1552269 391-C56 PK-14 229-C57 BK-14
1 2
DIODE 1893158
110-00
32 31 30 29 28
27 26 25 24 23
44 43 42 41 40 39
38 37 36 35 34 33 48 47 46 45
60 59 58 57
56 55 54 53
68 67 66 65
64 63 62 61
76 75 74 73
72 71 70 69
88 87 86 85 84 83
82 81 80 79 78 77
98 97 96 95 94
93 92 91 90 89
110 109 108 107 106 105
104 103 102 101 100 99
2
1
4
3
545-06
Ether Start Relay short to ground
111-17
E059
Low Engine Coolant Level Warning
Ether Injection Control Solenoid short to ground
111-18
E057
Low Engine Coolant Level Derate
1835-03
Auxiliary Pressure Sensor open/short to +batt
111-01
E058
Low Engine Coolant Level Shutdown
229-C28 BK-14 120-C45 YL-14 150-C1 OR-14 F716-C5 WH-16 150-C6 OR-14 150-C2 OR-14 F404-C9 RD-16 F420-C8 GN-16 G955-C3 GN-16 G967-C4 WH-16 F424-C41 YL-16 F426-C52 BU-16 229-C51 BK-16 229-C16 BK-14 229-C18 BK-14 229-C17 BK-14
120-C45 YL-14 150-C1 OR-14 150-C6 OR-14 150-C2 OR-14 F404-C9 RD-16 F716-C5 WH-16 F420-C8 GN-16 G955-C3 GN-16 G967-C4 WH-16 F424-C41 YL-16 F426-C52 BU-16 229-C51 BK-16 229-C16 BK-14 229-C18 BK-14 229-C17 BK-14
C-S8 1
2
229-C54 BK-14 229-C57 BK-14
229-C58 BK-14 C-S10 1
229-C18 BK-14
229-C28 BK-14
229-C16 BK-14
229-C59 BK-14
1835-04 1836-03 1836-04
Auxiliary Pressure Sensor short to ground
2
229-C30 BK-14
115 114 113 112 111
2
229-C50 BK-16 229-C29 BK-14 229-C44 BK-14
120-C7 YL-14 1607689 P1
Auxiliary Temperature Sensor open/short to +batt Auxiliary Temperature Sensor short to ground
111-02
Engine Coolant Level Sensor Loss of Signal Fuel Temperature open/short to +batt
174-04
63
ABBREV
COLOR
RD WH OR YL PK BK GY PU BR GN BU
RED WHITE ORANGE YELLOW PINK BLACK GRAY PURPLE BROWN GREEN BLUE
DESCRIPTION CIRCUIT CONNECTED CIRCUIT NOT CONNECTED ELECTRICAL CONNECTION TO MACHINE STRUCTURE INTERNAL ELECTRICAL CONNECTION TO SURFACE OF COMPONENT CONNECTOR
H#
CIRCUIT GROUPING DESIGNATION ATCH WIRE, CABLE, COMPONENT CIRCUIT CONNECTED BLADE, SPADE, RING OR SCREW TERMINAL SPLICE
94-15
41-03
8 Volt DC Supply short to +batt
678-04
41-04
8 Volt DC Supply short to ground
E096
15
16
20
21
25
26
30
31
35
36
40
174-16
Title
8T-8736
High Fuel Temperature Warning E363(2)
D E
High Fuel Temperature Derate
C A
F
High Fuel Temperature Shutdown
B
5 Volt Sensor DC Power Supply short to +batt 651-05
001-05
Injector Cylinder 1 open circuit
651-06
001-06
Injector Cylinder 1 short
651-11
001-11
Injector Cylinder #1 fault
652-05
002-05
Injector Cylinder 2 open circuit
652-06
002-06
Injector Cylinder 2 short
J
G
H
5 Volt Sensor DC Power Supply short to ground Engine Oil Pressure open/short to +batt 72
Engine Oil Pressure short to ground
100-10
100-10
Engine Oil Pressure abnormal rate of change
652-11
002-11
Injector Cylinder #2 fault
102-03
102-03
Boost Pressure Sensor short to +batt
653-05
003-05
Injector Cylinder 3 open circuit
102-04
102-04
Boost Pressure Sensor short to ground
653-06
003-06
Injector Cylinder 3 short
102-10
102-10
Boost Pressure Sensor abnormal rate of change
653-11
003-11
Injector Cylinder #3 fault
108-03
274-03
Atmospheric Pressure open/short to +batt
654-05
004-05
Injector Cylinder 4 open circuit
108-04
274-04
Atmospheric Pressure short to ground
654-06
004-06
Injector Cylinder 4 short
110-03
110-03
Engine Coolant Temperature open/short to +batt
654-11
004-11
Injector Cylinder #4 fault
110-04
110-04
Engine Coolant Temperature short to ground
655-05
005-05
Injector Cylinder 5 open circuit
28
91-13
91-13
Throttle Position calibration required
655-06
005-06
Injector Cylinder 5 short
32
91-08
91-08
Throttle Position signal abnormal
655-11
005-11
Injector Cylinder #5 fault
190-08
190-08
Engine Speed signal abnormal
656-05
006-05
Injector Cylinder 6 open circuit
723-08
342-08
Secondary Engine Speed signal abnormal
656-06
006-06
Injector Cylinder 6 short
Engine Overspeed Warning
656-11
006-11
Injector Cylinder #6 fault
Engine Overspeed Shutdown
1072-05
791-05
Low/High Retarder Solenoid Current Low (Open)
1072-06
791-06
Low/High Retarder Solenoid Current High (Short)
73
74
Form Number
Troubleshooting
RENR5042
Systems Operation / Testing and Adjusting
SENR9853
High Fuel Pressure Warning
High Inlet Air Temperature Shutdown
174-15
71
100-03
11
E539(2)
174-00 262-03
10
High Inlet Air Temperature Warning
1636-00
65
Low Engine Coolant Level Derate
6
9W-1951
D
E
NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL INSTALLATION DETAILS NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR TO TERMINATION RESISTOR) IS 40 METERS. NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION. NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939 SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS. 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 V: ARC SUPPRESSION DIODES ARE REQUIRED ON RELAY COILS AND SOLENOID COILS. NOTE W: WIRING FOR DESIRED SPEED CONTROL DETERMINED BY APPLICATION. FOR DESIRED SPEED CONTROL OPTIONS, REFER TO THE ELECTRONIC INSTALLATION GUIDE. NOTE X: EARLIER ENGINES MAY HAVE VARIATIONS IN SPLICING AND WIRING DESCRIPTIONS FOR HARNESS 254-2354.
C B
A
F
J
G
H
IDENT. A E L J
3E-7990
1
2
3
4
5
6
9
8
7
HARNESS 219-7461 264-2354 240-8721 230-0960
CHG 06 03 01 01
(J2 / ENGINE HARNESS) (J1 / CUSTOMER HARNESS) (FUEL HARNESS) (INJECTOR HARNESS)
1
1
SYMBOL
Low Engine Coolant Level Shutdown
1636-15
Fuel Temperature short to ground
678-03
E2143(2)
111-01
64
1
1
75
12 11 10
76
F426-C52 BU-16
190-15
HI/LO IDLE 110-7884 229-C29 BK-14 229-C51 BK-16
2
35
THIS DIAGRAM IS FOR THE C11 AND C13 INDUSTRIAL ENGINES. (S/N A5K1-UP, B5K1-UP, LGK1-UP, AND GLS1-UP)
1
WIRING DIAGRAM (231-1979) (CHG04)-J2 (291-5540) (CHG00)-J1
155-2252
E362(2) 190-00
12
3
1
94-03
94-03
Fuel Pressure open/short to +batt
94-04
94-04
Fuel Pressure short to ground
1073-05
792-05
Med/High Retarder Solenoid Current Low (Open)
105-03
172-03
Intake Manifold Air Temp open/short to +batt
1073-06
792-06
Med/High Retarder Solenoid Current High (Short)
105-04
172-04
Intake Manifold Air Temp short to ground
637-13
261-13
Engine Timing calibration required
37
G967-C4 WH-16 G955-C3 GN-16 229-C50 BK-16 229-C54 BK-14 F424-C41 YL-16 F404-C9 RD-16 F420-C8 GN-16 120-C45 YL-14
11
10
9
8
COMPONENTS ARE SHOWN INSTALLED ON A FULLY OPERABLE ENGINE WITH KEY IN THE OFF POSITION AND ENGINE NOT RUNNING.
7
184
DASHED FONT INDICATES AN ATTACHMENT COMPONENT OR HARNESS. 1
2
3
4
5
6
CUSTOMER WIRING AND OPTIONAL FEATURE WIRING SHOWN ARE RECOMMENDED.
38 42
100-17
CIRCUIT BREAKER 6T-3643 15A
101-C39 RD-14
46
100-18 100-01
155-2264
174-0502
Low Engine Oil Pressure Warning E360(2)
Low Engine Oil Pressure Derate Low Engine Oil Pressure Shutdown
(1) Suspect Parameter Number (2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order to designate a warning, a derate, or a shutdown.
OPTIONAL CONTROL PANEL
111-18
Low Engine Coolant Level Warning
5
27
150-C38 OR-14
K900-C14 YL K990-C32 GN A234-C40 BK
CAT DATA LINK J1939 DATA LINK RS-232/RS-485 DATA LINK
Related Electrical Service Manuals 1
34
229-C53 BK-16
150-C2 OR-14 150-C1 OR-14 150-C6 OR-14
CONTROL PLUS FROM ECM CONTROL MINUS FROM ECM
9X-1343
26
MAINTENANCE CLEAR SWITCH 3N-5716
C-S11 1
111-17
100-04
391-C33 PK-14
1
SIGNAL PLUS TO ECM SIGNAL MINUS TO ECM
High Engine Coolant Temperature Shutdown
100-04
25
STOP SWITCH 111-1325 1
1
High Engine Coolant Temperature Derate
2417-06
174-03
100-03 24
C-S9
391-C56 PK-14
2
16 15 14 13 12 11
52 51 50 49
High Engine Coolant Temperature Warning E361(2)
4
22 21 20 19 18 17
SENSOR / ACTUATOR SUPPLY
ALTERNATOR AMERICAN TRUCKING ASSOCIATION CIRCUIT BREAKER CUSTOMER IGNITION SWITCH DIGITAL ELECTRONIC CONTROL MODULE NO CONNECTION PULSE WIDTH MODULATION STARTING MOTOR START MOTOR MAG SWITCH
COLOR ABBREVIATIONS
Description of Code
630-02
High Auxiliary Temperature Shutdown
ALT ATA CB CIS DIG ECM NC PWM SM SMMS
227-4002
56
1079-04
229-C30 BK-14
893-C12 GN-16 892-C11 BR-16 120-C7 YL-14 120-C45 YL-14 229-C28 BK-14
A234-C37 BK
G955-C3 GN-16
51
1079-03
229-C44 BK-14 229-C53 BK-16
229-C51 BK-16
E445(2)
262-04
391-C31 PK-14 F716-C5 WH-16
150-C2 OR-14 150-C6 OR-14
B
A
1
High Auxiliary Temperature Warning
620-04
K990-C15 GN
K900-C13 YL
High Auxiliary Pressure Derate
174-03
21
229-C28 BK-14 893-C12 GN-16 892-C11 BR-16
120-C7 YL-14 120-C45 YL-14 229-C28 BK-14 892-C11 BR-16 893-C12 GN-16 K900-C42 YL K990-C43 GN A234-C46 BK
(+) BATTERY SWITCHED
DEVICE
STARTING CIRCUIT
160-7689
155-2267
155-2269
Diagnostic Code Flash Code SPN(1)/FMI Code or Event Code
620-03
2
J154 3E3370
1743016
A B C D E F G H J
391-C31 PK-14
A234-C40 BK A234-C37 BK
120-C19 YL-14 229-C28 BK-14 A234-C23 BK 893-C12 GN-16 892-C11 BR-16 K990-C25 GN K900-C27 YL
391-C55 PK-14
A234-C22 BK A234-C46 BK
C-S1 A234-C23 BK
4
1
PTO ENABLE SWITCH
K900-C26 YL K990-C24 GN A234-C22 BK
F426-C52 BU-16
150-C1 OR-14
Description of Code
111-02
174-04
J63 ENGINE SERVICE TOOL CONNECTOR 9W1951
1
BATTERY (+) - UNSWITCHED BATTERY (+) - UNSWITCHED OVERSPEED VERIFY SWITCH
TERMINATION RESISTOR
A B C
F716-C5 WH-16
(8-10 AWG)
13
C-C2 1740502
5
(+) BATTERY
(-) BATTERY / SENSOR RETURN
1
RETARDER SOLENOID MED/HI PTO INTERRUPT J1939 DATA LINK SHIELD
TERMINATION RESISTOR
2
J1939 DATA LINK (-)
C-C11 1743016
A B C
2 3
(165-0200) MAX LENGTH 1 METER (NOTE B)
626-05
1835-04
A B C
6
120 TERMINATION RESISTOR (174-3016) (NOTE B & C)
1
120 119 118 117 116
P515 1552269 391-C55 PK-14 229-C30 BK-14
1 2 3 4
F404-C9 RD-16 F420-C8 GN-16 F424-C41 YL-16
2
62
K900-C47 YL K990-C48 GN A234-C49 BK
LAMP LAMP LAMP LAMP
(12-14 AWG)
High Auxiliary Pressure Shutdown
1836-00
1835-03
C-C8 1552267
DIAGNOSTIC WARNING MAINTENANCE OVERDUE RETARDER
E443(2)
1836-15
1836-04
START AID OVERRIDE RETARDER SOLENOID LO/HI SWITCH
3
626-06
DT TEE 1330970
AUXILIARY PRESSURE AUXILIARY TEMPERATURE
127-5486
1
BK-18 BK-18
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
129-7164
High Auxiliary Pressure Warning
1835-00
101-C20 RD-10
1275485
START RELAY
1
B A C
ABBREVIATION
KEYSWITCH 3E0156
120-C36 YL-16
150-C38 OR-14
1275485
ANALOG SENSOR POWER (+5V) ANALOG SENSOR RETURN DIGITAL SENSOR POWER (+8V) DIGITAL SENSOR RETURN MAINTENANCE CLEAR SWITCH TORQUE LIMIT SWITCH CAT DATA LINK (+) CAT DATA LINK (-) ETHER SOLENOID CONTROL AIR SHUTOFF SOLENOID
8
C
1835-15
BAT.
1
7
A
C
101-C39 RD-14
ALTERNATOR
6
155-2273
2
1
N785-G33 BU-18
S
NOTE D
3E-3388
B
1
2
391-C33 PK-14
STARTING MOTOR
(8-10 AWG)
3E-3370
Cross Reference for Diagnostic Codes
1297163
MTR
(12-14 AWG)
3E-3364
5 1
BATTERY
G
127-5485
N784-G32 WH-18
G-S16
BATTERY DISCONNECT SWITCH
BATTERY
129-7163
N783-G31 GN-18
G-S15
N785-G28 BU-18
120-C21 YL-16
WARNING LAMP 7N5876
N782-G30 BU-18
G-S14
N784-G27 WH-18
G-S12
G-C5 1552273
G-S13
N783-G26 GN-18
120-C35 YL-16
CAT DATA LINK + CAT DATA LINK -
1 2 3 4 5 6
RS485A RS485B GAUGE GROUND GAUGE V+ 1 2 3 4 5 6
RS485A RS485B GAUGE GROUND GAUGE V+ BU-18 GN-18 WH-18 BU-18
N782-G25 BU-18
G-S10
N784-G19 WH-18
G-S8
N785-G12 BU-18
G-S9
N783-G18 GN-18
G-S7
N784-G11 WH-18
G-S4
N782-G17 BU-18
G-S6
N783-G10 GN-18
G-S3
N782-G21 N783-G22 N784-G23 N785-G24
BU-18 GN-18 WH-18 BU-18 G-S5
N782-G9 BU-18
G-S2
G-C4 1552273
C B A
TACHOMETER 207-2825
VOLTMETER 207-2822
1 2 3 4 5 6
RS485A RS485B GAUGE GROUND GAUGE V+
G-S1
N783-G2 GN-18
G-C3 1552273
N782-G13 N783-G14 N784-G15 N785-G16
N782-G5 N783-G6 N784-G7 N785-G8
G-C1 1552273
RS485A RS485B GAUGE GROUND GAUGE V+
1 2 3 4 5 6
RS485A RS485B GAUGE GROUND GAUGE V+ 1 2 3 4 5 6
G-C2 1552273
BU-18 GN-18 WH-18 BU-18 120-C34 YL-16 K900-C47 YL K990-C48 GN A234-C49 BK
101-C10 RD-10
30 Page, (Dimensions: 39 inches x 24 inches)
RENR8045-03
CONTROL MODULE 210-4309
C-C7 1552273
ENGINE COOLANT TEMPERATURE 207-2823
ENGINE OIL PRESSURE 207-2824
+ BAT. - BAT.
(J66) CUSTOMER INSTALLED SERVICE TOOL CONN
ELECTRONIC CONTROL MODULE FUEL PRESSURE 211-0745
ETHER START VALVE (NOTE V)
1 2
ETHER START VALVE BATTERY(-)
ETHER START VALVE (NOTE V)
R
START RELAY (SMMS) 1
ETHER START VALVE RELAY (NOTE V)
B
893-E8 GN-18 893-E22 GN-18
E-S4 E-S8
G
OR-18 OR-14 OR-14 OR-14 OR-14 OR-18 PU-18 PK-16 PK-18
E-S2
A274-E24 A307-E25 A742-E9 A741-E36 A743-E38 C912-E35 E716-E49 E717-E50 F404-E39 E452-E51 F420-E40 F424-E28 F426-E27 F716-E42 G469-E48 G488-E26 G955-E45 G967-E54 G968-E43 G969-E20 G971-E19
K990-E5 GN-18 A743-E38 OR-18
120-E15 YL-18 120-E41 YL-18
E-S1
E-S3
A234-E52 BK-18
NOTE D
GROUND
E-S6
125-E29 150-E16 150-E46 150-E47 150-E1 167-E23 381-E44 382-E37 387-E55
NO.4 CYLINDER INJECTOR
T860-J5 OR-16-NW T961-J15 GN-16-NW
M2
1
ELECTRONIC CONTROL MODULE
T859-J4 WH-16-NW T960-J17 BU-16-NW
1297163
OPTIONAL WIRING
M1
229-E59 BK-14-GXL
1607689 P-1
G828-A40 WH-18 G829-A42 GN-18 R747-A6 GY-18
C967-A15 BU-18 R747-A6 GY-18
229-E57 BK-14-GXL 299-E10 BK-14-GXL 229-E58 BK-14-GXL
TURBO OUTLET PRESSURE SENSOR (BOOST) (INTAKE MANIFOLD AIR) 239-3478
P93 1552264
N707-A31 PU-18
BATTERY DISCONNECT SWITCH
1297164
INLET AIR SHUTOFF SOLENOID RELAY (NOTE V)
INLET AIR SHUTOFF SOLENOID (NOTE V)
(NOTE X)
P200 1552267 G828-A39 WH-18 G829-A41 GN-18 R746-A20 PK-18
994-A10 GY-18 995-A12 BU-18 C967-A15 BU-18 C991-A33 PK-18 E963-A27 BK-18 E964-A26 WH-18 E965-A48 BU-18 E966-A49 YL-18 F421-A13 YL-18 G856-A22 WH-18 G857-A30 YL-18 N707-A31 PU-18 R746-A20 PK-18 R747-A6 GY-18 T725-A32 WH-18
C991-A33 PK-18
SIGNAL RETURN
HARNESS 264-2354
G829-A2 GN-18
994-A10 GY-18
2
1 2
1 2
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS (NOTE B)
PROBE CONNECTOR
P103 1552269
(CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR 201-6616
SIGNALSIGNAL+
BK-18 WH-18
1
P401 1552269 E963-A27 BK-18 E964-A26 WH-18
A-S2
E963-A27 BK-18 G856-A22 WH-18
3E3364 TIMING/CALIBRATION(TC)
P100 1552269
G829-A36 GN-18 G829-A41 GN-18
1
1 2
-BAT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
1
8
2
7
3
6
4
5
A
B
C
ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN CONSIDERING COMPONENT REMOVAL. UNLESS OTHERWISE SPECIFIED, ALL WIRES TO BE 16 AWG OR LARGER, SAE 1128 TYPE SXL OR EQUIVALENT. NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES WITHOUT CATERPILLAR ENGINEERING APPROVAL.
