SENR9697-01 Diagnostic Code Listing

August 2005 PID-FMI Description

Flash
PID-FMI Description
Flash
Intake Valve Codes Codes
Actuation Pressure
N/A No Diagnostic Codes Detected 55 0111-04 Coolant Level voltage low 12
Sensor
P1 0001-05 Cylinder #1 Injector current low 72 0111-11 Very Low Coolant Level 62
0001-06 Cylinder #1 Injector current high 72 0111-14 Low Coolant Level Warning
0002-05 Cylinder #2 Injector current low 72 0121-05 Low/High Retarder current low 14
Intake Valve 0002-06 Cylinder #2 Injector current high 72 0121-06 Low/High Retarder current high 14
Actuation Pressure 0003-05 Cylinder #3 Injector current low 73 0122-05 Med/High Retarder current low 14
Solenoid 0003-06 Cylinder #3 Injector current high 73 0122-06 Med/High Retarder current high 14
0004-05 Cylinder #4 Injector current low 73 0166-14 Rated Engine Power Special Instructions
0004-06 Cylinder #4 Injector current high 73 0168-01 Low ECM Battery Power 17
160-7690
0005-05 Cylinder #5 Injector current low 74 0168-02 ECM Battery Power Intermittent 51
0005-06 Cylinder #5 Injector current high 74 0171-03 Ambient Air Temperature voltage high
0006-05 Cylinder #6 Injector current low 74 0171-04 Ambient Air Temperature voltage low
0006-06 Cylinder #6 Injector current high 74 0171-11 Ambient Air Temperature Data Lost
0022-11 Primary to Secondary Engine Speed Calibration 42 0174-00 High Fuel Temperature Warning 65
0022-13 Engine Speed Signal Calibration Not Performed 42 0174-03 Fuel Temperature voltage high 13
P2
0030-08 PTO Throttle signal invalid 29 0174-04 Fuel Temperature voltage low 13
0030-13 PTO Throttle out of calibration 29 0190-00 Engine Overspeed Warning 35
0041-03 8 Volt Supply voltage high 21 0190-08 Primary Engine Speed Loss of Signal 34
0041-04 8 Volt Supply voltage low 21 0191-07 Transmission Not Responding 68
0043-02 Key Switch Fault 71 0224-11 Theft Deterrent Active 00
0052-11 Air Inlet Shutoff Shutdown 00 0224-14 Theft Deterrent Active with Engine Cranking 00
0054-05 Auxiliary Output #06 current low 66 0231-02 J1939 Data Incorrect 58
155-2252 0054-06 Auxiliary Output #06 current high 66 0231-12 J1939 Device Not Responding
0055-05 Auxiliary Output #07 current low 67 0232-03 5 Volt Supply voltage high 21
0055-06 Auxiliary Output #07 current high 67 0232-04 5 Volt Supply voltage low 21
12 11 10 9 8 7
0064-08 Secondary Engine Speed loss of signal 34 0246-11 Brake Pedal Switch #1 Fault
P681
P682 0071-00 Idle Shutdown Override 01 0247-11 Brake Pedal Switch #2 Fault
0071-01 Idle Shutdown 47 0252-11 Engine Software Incorrect 59

C15 On-highway Engine

0071-14 PTO Shutdown 47 0253-02 Check Customer or System Parameters 56
1 2 3 4 5 6
0084-00 Vehicle Overspeed Warning 41 0253-11 Check Transmission Customer Parameters 56
Intake Valve Actuation System Oil Pressure
0084-01 Vehicle Speed loss of signal 31 0283-05 97

Electrical System
Solenoid current low
Intake Valve Actuation System Oil Pressure
3E-8769 0084-02 Vehicle Speed signal invalid 36 0283-06 97
Solenoid current high
0084-08 Vehicle Speed signal out of range 36 0283-07 Intake Valve Actuation Oil Pressure not responding 91
0084-10 Vehicle Speed signal rate of change 36 0284-05 Engine Coolant Diverter current low 98
1 2 3 4 5 6 0084-14 Quick Stop Occurrence 0284-06 Engine Coolant Diverter current high 98

J681
J682
BXS1-UP 0091-08
0091-13
Throttle Position Invalid
Throttle Position out of calibration
32
32
0285-05
0285-06
Intake Valve Actuator #1 current low
Intake Valve Actuator #1 current high
92
92
0100-01 Low Oil Pressure Warning 46 0285-07 Intake Valve Actuator #1 not responding 92
12 11 10 9 8 7
0100-03 Oil Pressure voltage high 24 0286-05 Intake Valve Actuator #2 current low 92
0100-04 Oil Pressure voltage low 24 0286-06 Intake Valve Actuator #2 current high 92
0100-11 Very Low Oil Pressure 46 0286-07 Intake Valve Actuator #2 not responding 92
0102-03 Boost Pressure voltage high 25 0287-05 Intake Valve Actuator #3 current low 93
0102-04 Boost Pressure voltage low 25 0287-06 Intake Valve Actuator #3 current high 93
7E-6513 153-9693 0105-00 High Intake Manifold Air Temperature Warning 64 0287-07 Intake Valve Actuator #3 not responding 93
0105-03 Intake Manifold Air Temperature voltage high 38 0288-05 Intake Valve Actuator #4 current low 93
T301 P541 0105-04 Intake Manifold Air Temperature voltage low 38 0288-06 Intake Valve Actuator #4 current high 93
T302 Wire 1 P542
T303 P543 0105-11 Very High Intake Manifold Air Temperature 64 0288-07 Intake Valve Actuator #4 not responding 93
T304 P544 0108-03 Barometric Pressure voltage high 26 0289-05 Intake Valve Actuator #5 current low 94
T305 P545 A B B
T306 P546 0108-04 Barometric Pressure voltage low 26 0289-06 Intake Valve Actuator #5 current high 94
Wire 2
0110-00 High Coolant Temperature Warning 61 0289-07 Intake Valve Actuator #5 not responding 94
0110-03 Coolant Temperature voltage high 27 0290-05 Intake Valve Actuator #6 current low 94
Engine Coolant 0110-04 Coolant Temperature voltage low 27 0290-06 Intake Valve Actuator #6 current high 94
Diverter Solenoid 0110-11 Very High Coolant Temperature 61 0290-07 Intake Valve Actuator #6 not responding 94
3E-3370 155-2267
0111-01 Low Coolant Level Warning 62 0385-01 Low Intake Valve Actuation System Oil Pressure
0111-02 Coolant Level signal invalid 12 0385-03 Intake Valve Actuation System Oil Pressure voltage high 95
0111-03 Coolant Level voltage high 12 0385-04 Intake Valve Actuation System Oil Pressure voltage low 95
J201 B A
J203 P200 A B
J227
C
Right Side View C

155-2269
P100
P103
P105
P400
P401
P402 2 1
P531
P540 © 2005 Caterpillar Printed in U.S.A.
All Rights Reserved

Connector Tables for Harness 241-3150 -01 Connector Tables for Harness 241-3150 -01 Connector Tables for
Rear Intake Manifold P2 P100 Harness 229-7366 -02
Boost
Front
Valve Cover
Valve Cover
Connector
Air Temperature CLR-GA WIRE NAME POS TERM/PLUG CLR-GA WIRE NAME POS TERM/PLUG J227 P681
J682
Harness identification code Harness And Wire Symbols
Sensor 1 8T-8737 BU-18 995-A12 1 180-9340 CLR-GA WIRE NAME POS TERM/PLUG CLR-GA WIRE NAME POS TERM/PLUG This example indicates
Pressure Connector P682 CLR-GA WIRE NAME POS TERM/PLUG wire 135 in harness "AG".
WH-18 G828-A1 2 180-9340 PK-18 G833-A44 2 180-9340 BR-18 G826-A21 A 180-9339 PU-16 T957-A16 1 180-9340
Sensor P681 BR-16 K737-E1 1 180-9339 Wire, Cable, or Harness
Secondary GN-18 G829-A2 3 180-9340 ACCESSORY TABLE BU-18 G827-A50 B 180-9339 YL-16 T958-A17 2 180-9340
BU-16 K739-E2 2 180-9339 Assembly Identification
Engine 4 8T-8737 OR-18 T853-A11 C 180-9339 BR-16 T959-A18 3 180-9340
QTY PART NAME P/N GN-16 T961-E3 3 180-9339
Speed/Timing ACCESSORY TABLE BU-16 T960-A19 4 180-9340 WH-16 T962-E4 4 180-9339 J274 Part Number For
(Camshaft) Sensor
5 8T-8737 1 PLUG_AS. 155-2269 P174 J174 P274 Connector Assembly
6 8T-8737 200mm PAINT/PRO 110-3202 QTY PART NAME P/N GY-16 T858-A23 5 180-9340 OR-16 T860-E5 5 180-9339 130-6795 130-6795 111-7898 3E-5179
7 8T-8737 1 RECEPTACLE_AS. 3E-3370 WH-16 T859-A24 6 180-9340 YL-16 X986-E6 6 180-9339
1 WEDGE 155-2261
BU-18 T855-A34 8 180-9340 200mm PAINT/PRO 110-3202 BU-16 X983-A7 7 180-9340 BR-16 X984-E7 7 180-9339 325-AG135 PK-14 1 325-A135 PK-14
1 WEDGE 3E-3371 OR-16 X985-A14 8 180-9340 WH-16 T856-E8 8 180-9339
BU-16 K739-A3 9 180-9340
P103 GN-16 T857-E9 9 180-9339
BR-16 K737-A4 10 180-9340 BR-16 X987-A37 9 180-9340 Socket
CLR-GA WIRE NAME POS TERM/PLUG
BR-16 K737-A54 10 180-9340
OR-16 X989-E10 10 180-9339 Pin Wire Wire Receptacle
GN-16 K738-A5 11 180-9340
BU-18 C967-A15 1 180-9340 P400 PU-16 X988-E11 11 180-9339 Gauge Fuse
12 8T-8737 CLR-GA WIRE NAME POS TERM/PLUG GN-16 K738-A5 11 180-9340 12 8T-8737 Color
Engine Coolant PK-18 G833-A45 2 180-9340
BU-16 K739-A56 12 180-9340
13 8T-8737 WH-18 G856-A8 1 180-9340 ACCESSORY TABLE
Temperature ACCESSORY TABLE
ACCESSORY TABLE
Single Wire Ground Plug
GY-18 R747-A6 14 180-9340 QTY PART NAME P/N
Sensor QTY PART NAME P/N YL-18 G857-A9 2 180-9340
QTY PART NAME P/N
Connector Circuit Connection 2 200-L32 BK-14
15 8T-8737 ACCESSORY TABLE 1 RECEPTACLE_AS. 3E-8969
1 PLUG_AS. 155-2269
1 PLUG_AS. 155-2252 1 WEDGE 3E-5180 Number
16 8T-8737 QTY PART NAME P/N
Timing 200mm PAINT/PRO 110-3202
200mm PAINT/PRO 110-3202
Identification
17 8T-8737 1 PLUG_AS. 155-2269
Calibration PK-18 G833-A47 18 180-9340
1 WEDGE 155-2261
1 WEDGE 155-2258 T305
Pin or Socket 105-9344
1 RECEPTACLE_AS. 3E-3364
(TC) Probe
19 8T-8737 CLR-GA WIRE NAME POS TERM/PLUG Number
2 PLUG 8T-8737
Connector P105 P682 GN-16 T961-E3 1 Component
BU-16 X983-A7 20 180-9340 200mm PAINT/PRO 110-3202

SENR9697-01
P400 CLR-GA WIRE NAME POS TERM/PLUG CLR-GA WIRE NAME POS TERM/PLUG OR-16 T860-E17 2 Part Number
OR-16 X985-A14 21 180-9340 1 WEDGE 155-2261
YL-18 A751-A13 1 180-9340 BR-16 K737-A55 1 180-9340 ACCESSORY TABLE
WH-18 G856-A8 22 180-9340
BU-16 K739-A57 2 180-9340 QTY PART NAME P/N
YL-18 G857-A9 23 180-9340 PK-18 G833-A46 2 180-9340
P401 1 CONNECTOR_AS 7E-6513
GY-18 994-A10 24 180-9340 ACCESSORY TABLE GN-16 T961-A28 3 180-9340
CLR-GA WIRE NAME POS TERM/PLUG 50mm TUBE 112-8144
OR-18 T853-A11 25 180-9340 QTY PART NAME P/N WH-16 T962-A29 4 180-9340
1 PLUG_AS. 155-2269 BK-18 E963-A27 1 180-9340 OR-16 T860-A25 5 180-9340
26 8T-8737
WH-18 E964-A26 2 180-9340 YL-16 X986-A22 6 180-9340 T306
27 8T-8737 200mm PAINT/PRO 110-3202
ACCESSORY TABLE CLR-GA WIRE NAME POS TERM/PLUG
WH-16 T856-A31 28 180-9340 1 WEDGE 155-2261 BR-16 X984-A30 7 180-9340
QTY PART NAME P/N WH-16 T962-E4 1
GN-16 T857-A36 29 180-9340 WH-16 T856-A31 8 180-9340
OR-16 T860-E16 2
1 PLUG_AS. 155-2269 GN-16 T857-A36 9 180-9340
30 8T-8737 P200 ACCESSORY TABLE
200mm PAINT/PRO 110-3202 OR-16 X989-A51 10 180-9340
GY-18 T852-A32 31 180-9340 CLR-GA WIRE NAME POS TERM/PLUG QTY PART NAME P/N
1 WEDGE 155-2261 PU-16 X988-A52 11 180-9340 1 CONNECTOR_AS 7E-6513
BU-18 995-A12 32 180-9340 WH-18 G828-A39 A 180-9340

16 Page
YL-18 A751-A13 33 180-9340 12 8T-8737 50mm TUBE 112-8144
GN-18 G829-A41 B 180-9340
34 8T-8737 PK-18 R746-A20 C 180-9340 P402 ACCESSORY TABLE Connector Tables for
P543
BU-18 C967-A15 35 180-9340 ACCESSORY TABLE CLR-GA WIRE NAME POS TERM/PLUG QTY PART NAME P/N
CLR-GA WIRE NAME POS TERM/PLUG Harness 229-7365 -03
GY-16 T858-A23 36 180-9340 BU-18 E965-A48 1 180-9340 1 PLUG_AS. 155-2252 J681 T303
QTY PART NAME P/N YL-16 X986-E6 A 154-2389
WH-16 T859-A24 37 180-9340 YL-18 E966-A49 2 180-9340 200mm PAINT/PRO 110-3202 OR-16 X989-E13 B 154-2389 CLR-GA WIRE NAME POS TERM/PLUG CLR-GA WIRE NAME POS TERM/PLUG
1 PLUG_AS. 155-2267
OR-16 T860-A25 38 180-9340 ACCESSORY TABLE 1 WEDGE 155-2258 ACCESSORY TABLE PU-16 T957-J1 1 180-9339 BR-16 T959-J3 1
200mm PAINT/PRO 110-3202
QTY PART NAME P/N QTY PART NAME P/N YL-16 T958-J2 2 180-9339 WH-16 T859-J16 2
BR-16 X987-A37 39 180-9340 1 WEDGE 155-2276
1 PLUG_AS. 155-2269 1 PLUG 153-9693 BR-16 T959-J3 3 180-9339 ACCESSORY TABLE
PK-18 R746-A20 40 180-9340
1 SEAL 154-0877 BU-16 T960-J4 4 180-9339 QTY PART NAME P/N
BR-18 G826-A21 41 180-9340 200mm PAINT/PRO 110-3202
J201 1 CLIP 154-3769 GY-16 T858-J5 5 180-9339 1 CONNECTOR_AS 7E-6513
BU-18 G827-A50 42 180-9340 1 WEDGE 155-2261
CLR-GA WIRE NAME POS TERM/PLUG WH-16 T859-J6 6 180-9339 50mm TUBE 112-8144
43 8T-8737 BU-16 X983-J7 7 180-9339
WH-18 G828-A38 A 180-9339 P544
PU-16 T957-A16 44 180-9340
GN-18 G829-A43 B 180-9339 P531 OR-16 X985-J8 8 180-9339
T304
CLR-GA WIRE NAME POS TERM/PLUG BR-16 X987-J9 180-9339
YL-16 T958-A17 45 180-9340 CLR-GA WIRE NAME POS TERM/PLUG 9
GY-18 994-A10 C 180-9339 BR-16 X984-E7 A 154-2389 CLR-GA WIRE NAME POS TERM/PLUG
BR-16 T959-A18 46 180-9340 BU-18 T855-A34 1 180-9340 BR-16 K737-J10 10 180-9339
ACCESSORY TABLE OR-16 X989-E12 B 154-2389 BU-16 T960-J4 1
BU-16 T960-A19 47 180-9340 GN-16 K738-J11 11 180-9339
QTY PART NAME P/N YL-18 H807-A35 2 180-9340 ACCESSORY TABLE WH-16 T859-J15 2
BU-16 K739-J12 12 180-9339
WH-18 E964-A26 48 180-9340 ACCESSORY TABLE QTY PART NAME P/N ACCESSORY TABLE
1 PLUG_AS. 3E-3370 ACCESSORY TABLE
BK-18 E963-A27 49 180-9340 QTY PART NAME P/N 1 PLUG 153-9693 QTY PART NAME P/N
200mm PAINT/PRO 110-3202 QTY PART NAME P/N
50 8T-8737 1 PLUG_AS. 155-2269 1 SEAL 154-0877 1 CONNECTOR_AS 7E-6513
1 WEDGE 3E-3371 1 RECEPTACLE_AS. 3E-8969
51 8T-8737 1 CLIP 154-3769 50mm TUBE 112-8144
200mm PAINT/PRO 110-3202 1 WEDGE 3E-5180
52 8T-8737 1 WEDGE 155-2261
YL-18 H807-A33 53 180-9340 J203 P545 P541
T301
OR-16 X989-A51 54 180-9340 CLR-GA WIRE NAME POS TERM/PLUG CLR-GA WIRE NAME POS TERM/PLUG CLR-GA WIRE NAME POS TERM/PLUG
P540 CLR-GA WIRE NAME POS TERM/PLUG
PU-16 X988-A52 55 180-9340 WH-18 G828-A40 A 180-9339 WH-16 T856-E8 A 154-2389 BU-16 X983-J7 A 154-2389
CLR-GA WIRE NAME POS TERM/PLUG PU-16 T957-J1 1
GN-18 G829-A42 B 180-9339 PU-16 X988-E15 B 154-2389 BR-16 X987-J20 B 154-2389
56 8T-8737 GY-16 T858-J13 2
GY-18 R747-A6 C 180-9339 GY-18 T852-A32 1 180-9340 ACCESSORY TABLE ACCESSORY TABLE
57 8T-8737 ACCESSORY TABLE
YL-18 H807-A53 2 180-9340 QTY PART NAME P/N QTY PART NAME P/N
YL-18 E966-A49 58 180-9340 ACCESSORY TABLE QTY PART NAME P/N
ACCESSORY TABLE 1 PLUG 153-9693 1 PLUG 153-9693
BU-18 E965-A48 59 180-9340 QTY PART NAME P/N 1 CONNECTOR_AS 7E-6513
QTY PART NAME P/N 1 SEAL 154-0877 1 SEAL 154-0877
1 PLUG_AS. 3E-3370 50mm TUBE 112-8144
60 8T-8737 1 CLIP 154-3769 1 CLIP 154-3769
200mm PAINT/PRO 110-3202 1 PLUG_AS. 155-2269
61 8T-8737
200mm PAINT/PRO 110-3202
62 8T-8737 1 WEDGE 3E-3371 T302
1 WEDGE 155-2261 P546 P542
63 8T-8737 CLR-GA WIRE NAME POS TERM/PLUG
CLR-GA WIRE NAME POS TERM/PLUG CLR-GA WIRE NAME POS TERM/PLUG
Primary YL-16 T958-J2 1
64 8T-8737 GN-16 T857-E9 A 154-2389 OR-16 X985-J8 A 154-2389
J1 GY-16 T858-J14 2
Engine Speed/Timing YL-16 X986-A22 65 180-9340 PU-16 X988-E14 B 154-2389 BR-16 X987-J19 B 154-2389
Fuel ACCESSORY TABLE
(Crankshaft) Sensor BR-16 X984-A30 66 180-9340 ACCESSORY TABLE ACCESSORY TABLE
Temperature QTY PART NAME P/N
WH-16 T962-A29 67 180-9340 QTY PART NAME P/N QTY PART NAME P/N
Sensor 1 CONNECTOR_AS 7E-6513
P2/J2 1 PLUG 153-9693 1 PLUG 153-9693
GN-16 T961-A28 68 180-9340 50mm TUBE 112-8144
Engine Control 1 SEAL 154-0877 1 SEAL 154-0877
69 8T-8737
Engine Oil Module (ECM) 1 CLIP 154-3769 1 CLIP 154-3769
Atmospheric 70 8T-8737
Pressure
Pressure ACCESSORY TABLE
Sensor
Sensor QTY PART NAME P/N
1 PLUG_AS. 160-7690
4 STRAP 3S-2093
200mm PAINT/PRO 110-3202
Left Side View 1 ENDBELL 185-3599
 T301

Connector and Splice Locations for Harness 241-3150 -01 J227

7E6513
T957-J1 PU-16
T858-J13 GY-16 2
1
INJECTOR 1
239-4909
3E3370 T957-J1 PU-16 T957-J1 PU-16
INTAKE VALVE ACTUATION +5 VOLTS OR-16 A G826-A21 BR-18 T958-J2 YL-16 T958-J2 YL-16 P541
PRESSURE SENSOR GROUND YL-16 B G827-A50 BU-18 T959-J3 BR-16 T959-J3 BR-16
SIGNAL GN-16 C 1539693
224-4535 T853-A11 OR-18 T960-J4 BU-16 T960-J4 BU-16
P681 J681 J-S1 X983-J7 BU-16 A INTAKE VALVE ACTUATOR 1
1552252 3E8969 T858-J5 GY-16 T858-J13 GY-16 X987-J20 BR-16 B 221-9895
Intake Valve T858-J14 GY-16
Actuation Pressure A-S4 P540 T957-A16 PU-16 1 T957-J1 PU-16 T302
1552269 T958-A17 YL-16 2 T958-J2 YL-16 J-S2
Solenoid INTAKE VALVE ACTUATION T959-A18 BR-16 3 T959-J3 BR-16 T859-J6 WH-16 T859-J15 WH-16 7E6513
Front RD-16 1 T852-A32 GY-18 4 1
INJECTOR 2
PRESSURE SOLENOID VALVE T960-A19 BU-16 T960-J4 BU-16 T859-J16 WH-16 T958-J2 YL-16
P540 Valve Cover RD-16 2 H807-A53 YL-18 T858-A23 GY-16 5 T858-J5 GY-16 T858-J14 GY-16 2 239-4909
A-S5 231-3269(12V)
T859-A24 WH-16 6 T859-J6 WH-16 X983-J7 BU-16 X983-J7 BU-16
Connector A-S6 X983-A7 BU-16 7 X983-J7 BU-16 X985-J8 OR-16 X985-J8 OR-16 0668391 P542
P681 INTAKE VALVE ACTUATION X985-A14 OR-16 8 X985-J8 OR-16 J-S3 J-T1
GN-16 1 9 1&2 RETARDER 1539693
PRESSURE SOLENOID VALVE X987-A37 BR-16 X987-J9 BR-16 X987-J9 BR-16 X987-J19 BR-16 K737-J10 BR-16
GN-16 2 K737-A54 BR-16 10 K737-J10 BR-16 X987-J20 BR-16 K739-J17 BU-16 SOLENOID X985-J8 OR-16 A INTAKE VALVE ACTUATOR 2
236-9837(24V) 11 B
K738-A5 GN-16 K738-J11 GN-16 J-T2 163-1533 X987-J19 BR-16 221-9895
K739-A56 BU-16 12 K739-J12 BU-16 0668391
K737-J10 BR-16 K737-J10 BR-16 T303
FRONT VALVE COVER K738-J11 GN-16 K738-J11 GN-16
CONNECTOR J-S4 7E6513
1
P531 K739-J12 BU-16 K739-J18 BU-16 0668391 T959-J3 BR-16 INJECTOR 3
1552269 K739-J17 BU-16 J-T3 T859-J16 WH-16 2 239-4909
ENGINE COOLANT DIVERTER K738-J11 GN-16 3&4 RETARDER
SOLENOID VALVE RD-16 1 T855-A34 BU-18 K739-J18 BU-16 SOLENOID
Intake Valve RD-16 2 H807-A35 YL-18 T304
Fuel 176-6480(12V) J-T4 163-1533 7E6513
Actuation Pressure 0668391 1
Temperature T960-J4 BU-16 INJECTOR 4
Sensor Sensor ENGINE COOLANT DIVERTER T859-J15 WH-16 2 239-4909
SOLENOID VALVE GN-16 1
J227 P105 GN-16 2 0668391
213-8760(24V) E-T1
Engine Coolant P682 J682 K737-E1 BR-16 K737-E1 BR-16 5&6 RETARDER
Temperature 1552252 3E8969 K739-E2 BU-16 K739-E2 BU-16 SOLENOID
P543
E-T2 163-1533
Sensor Intake Manifold Rear K737-A55 BR-16 1 K737-E1 BR-16 0668391 1539693
Valve Cover K739-A57 BU-16 2 K739-E2 BU-16 T961-E3 GN-16 T961-E3 GN-16 X986-E6 YL-16 A INTAKE VALVE ACTUATOR 3
P100 Air Temperature T961-A28 GN-16 3 T961-E3 GN-16 T962-E4 WH-16 T962-E4 WH-16 X989-E13 OR-16 B 221-9895
Sensor Connector T962-A29 WH-16 4 T962-E4 WH-16 E-S1
Secondary P100 T860-A25 OR-16 5 T860-E5 OR-16 T860-E5 OR-16 T860-E16 OR-16
P103 P682 1552269 X986-A22 YL-16 6 X986-E6 YL-16 T860-E17 OR-16 P544
Engine X984-A30 BR-16 7 X984-E7 BR-16 1539693
ENGINE COOLANT
Speed/Timing TEMPERATURE SENSOR SIGNAL 1 995-A12 BU-18 T856-A31 WH-16 8 T856-E8 WH-16 X986-E6 YL-16 X986-E6 YL-16 X984-E7 BR-16 A INTAKE VALVE ACTUATOR 4
GROUND 2 G833-A44 PK-18 T857-A36 GN-16 9 T857-E9 GN-16 X984-E7 BR-16 X984-E7 BR-16 X989-E12 OR-16 B 221-9895
(Camshaft) Sensor 130-9811 X989-A51 OR-16 10 X989-E10 OR-16 T856-E8 WH-16 T856-E8 WH-16
P402 X988-A52 PU-16 11 X988-E11 PU-16 T857-E9 GN-16 T857-E9 GN-16
12 E-S2 T305
X989-E10 OR-16 X989-E12 OR-16 7E6513
A-S2 A-S3 REAR VALVE COVER 1
INJECTOR 5
X989-E13 OR-16 T961-E3 GN-16
CONNECTOR E-S3 T860-E17 OR-16 239-4909
P103 X988-E11 PU-16 X988-E14 PU-16
2

INTAKE MANIFOLD AIR 1552269 X988-E15 PU-16

SIGNAL 1 C967-A15 BU-18 P545
TEMPERATURE SENSOR GROUND 2 1539693
G833-A45 PK-18
A-S1 130-9811 T856-E8 WH-16 A INTAKE VALVE ACTUATOR 5
X988-E15 PU-16 B 221-9895

T306
7E6513
P105 1
T962-E4 WH-16 INJECTOR 6
Timing FUEL 1552269 T860-E16 OR-16 239-4909
1 2
Engine Oil SIGNAL A751-A13 YL-18
Engine Coolant Calibration TEMPERATURE SENSOR GROUND 2 G833-A46 PK-18
130-9811 P546
Diverter Solenoid Atmospheric Pressure (TC) Probe 1539693
P531 Boost Pressure Sensor Connector P2 T857-E9 GN-16 A INTAKE VALVE ACTUATOR 6
Pressure J201 1607690 X988-E14 PU-16 B 221-9895
Sensor P400 A-S5 1
Sensor J203 K737-A54 BR-16 K737-A4 BR-16 G828-A1 WH-18 2 PRESSURE SENSOR SUPPLY +5V
K737-A55 BR-16 G829-A2 GN-18 3 PRESSURE SENSOR RETURN
P200 4
A-S6 5
K739-A56 BU-16 K739-A3 BU-16 6
K739-A57 BU-16 7
T855-A34 BU-18 8 COOLANT DIVERTER SOLENOID VALVE
K739-A3 BU-16 9 RETARDER COMMON
K738-A5 GN-16 K737-A4 BR-16 10 RETARDER SOLENOID MED/HI
Primary T856-A31 WH-16 K738-A5 GN-16 11 RETARDER SOLENOID LOW/HI
Engine Control T857-A36 GN-16 12
Engine Speed/Timing Module Connector T858-A23 GY-16 13
T860-A25 OR-16 R747-A6 GY-18 14 ATMOSPHERIC PRESSURE
(Crankshaft) Sensor P2 T957-A16 PU-16 15
P401 T958-A17 YL-16 16
T959-A18 BR-16 17
P402 TWISTED PAIRS T960-A19 BU-16 G833-A47 PK-18 18 TEMPERATURE SENSOR COMMON
1552269 T961-A28 GN-16 19
SECONDARY T962-A29 WH-16 X983-A7 BU-16 20 INTAKE VALVE ACTUATOR 1 RETURN
ENGINE SPEED/TIMING SENSOR SIGNAL- BK-18 1 E965-A48 BU-18 X983-A7 BU-16 X985-A14 OR-16 21 INTAKE VALVE ACTUATOR 2 RETURN
(CAMSHAFT) SIGNAL+ WH-18 2 E966-A49 YL-18 X984-A30 BR-16 G856-A8 WH-18 22 TIMING CALIBRATION PROBE(+)
201-6617 X985-A14 OR-16 G857-A9 YL-18 23 TIMING CALIBRATION PROBE(-)
X986-A22 YL-16 994-A10 GY-18 24 ENGINE OIL PRESSURE SENSOR
X987-A37 BR-16 T853-A11 OR-18 25 INTAKE VALVE ACTUATION OIL PRESSURE
P401 X988-A52 PU-16 26
T859-A24 WH-16 27
PRIMARY 1552269 X989-A51 OR-16 T856-A31 WH-16 28 INTAKE VALVE ACTUATOR 5 RETURN
ENGINE SPEED/TIMING SENSOR SIGNAL- 1 E963-A27 BK-18 T857-A36 GN-16 29 INTAKE VALVE ACTUATOR 6 RETURN

Connector and Splice Locations for Harness 229-7365 -03 (CRANKSHAFT) SIGNAL+ 2
191-8303
E964-A26 WH-18
T852-A32 GY-18
995-A12 BU-18
30
31
32
INTAKE VALVE ACTUATOR OIL VALVE
ENGINE COOLANT TEMPERATURE
(+) BATTERY SUPPLY WIRES

INPUT SIGNAL WIRES TO ECM

A751-A13 YL-18 33 FUEL TEMPERATURE
34
P400 INTAKE MANIFOLD AIR TEMPERATURE OUTPUT SIGNAL WIRES FROM ECM
C967-A15 BU-18 35
1552269 T858-A23 GY-16 36 INJECTOR 1&2
Front Valve Cover TIMING CALIBRATION(TC) 1 G856-A8 WH-18 T859-A24 WH-16 37 INJECTOR 3&4 SENSOR SUPPLY VOLTAGE
PROBE CONNECTOR 2 G857-A9 YL-18 T860-A25 OR-16 38 INJECTOR 5&6
Connector X987-A37 BR-16 39 INTAKE VALVE ACTUATOR 1&2 SIGNAL PLUS
J681 R746-A20 PK-18 40 BOOST PRESSURE SENSOR
T853-A11 OR-18 G826-A21 BR-18 41 IVA OIL PRESSURE SENSOR +5V SIGNAL MINUS
G826-A21 BR-18 G827-A50 BU-18 42 IVA OIL SENSOR COMMON
G827-A50 BU-18 43 (-) BATTERY / SENSOR RETURN
Retarder Solenoid 995-A12 BU-18 T957-A16 PU-16 44 INJECTOR 1 RETURN
A751-A13 YL-18 T958-A17 YL-16 45 INJECTOR 2 RETURN
Cylinder 1 and 2 (J-T1) C967-A15 BU-18 T959-A18 BR-16 46 INJECTOR 3 RETURN
T852-A32 GY-18 T960-A19 BU-16 47 INJECTOR 4 RETURN
T855-A34 BU-18 E964-A26 WH-18 48 PRIMARY ENGINE SPEED/TIMING+
E963-A27 BK-18 49 PRIMARY ENGINE SPEED/TIMING-
P200 50
A-S4
1552267 H807-A35 YL-18 H807-A33 YL-18 51
Retarder Solenoid BOOST +5 VOLTS OR-18 A G828-A39 WH-18 H807-A53 YL-18 52
Cylinder 3 and 4 (J-T4) PRESSURE SENSOR GROUND YL-18 B G829-A41 GN-18 H807-A33 YL-18 53 CDV & IVA OIL VALVE RETURN
239-3478 SIGNAL GN-18 C R746-A20 PK-18 A-S3 X989-A51 OR-16 54 INTAKE VALVE ACTUATOR 3&4
G833-A44 PK-18 G833-A47 PK-18 X988-A52 PU-16 55 INTAKE VALVE ACTUATOR 5&6
G833-A46 PK-18 56
G833-A45 PK-18 57
Injector E966-A49 YL-18 58 SECONDARY ENGINE SPEED/TIMING+
J203 E965-A48 BU-18 59 SECONDARY ENGINE SPEED/TIMING-
Cylinder 1 Intake Valve 3E3370 A-S2 60
ATMOSPHERIC +5 VOLTS OR-18 A G828-A40 WH-18 G829-A42 GN-18 G829-A2 GN-18 61
T301 Actuator PRESSURE SENSOR GROUND YL-18 B G829-A42 GN-18 G829-A41 GN-18 62 THIS SCHEMATIC IS FOR THE C15 ON-HIGHWAY ENGINE (S/N: BXS)

TWISTED PAIRS
Cylinder 2 194-6722 SIGNAL GN-18 C R747-A6 GY-18 G829-A43 GN-18 63
A-S1 64
P542 G828-A39 WH-18 G828-A1 WH-18 X986-A22 YL-16 65 INTAKE VALVE ACTUATOR 3 RETURN IDENT HARNESS CHG
G828-A40 WH-18 X984-A30 BR-16 66 INTAKE VALVE ACTUATOR 4 RETURN
G828-A38 WH-18 T962-A29 WH-16 67 INJECTOR 6 RETURN A 241-3150 01 (J2 / ENGINE)
J-S1 J201 994-A10 GY-18 T961-A28 GN-16 68 INJECTOR 5 RETURN
Injector 3E3370 E963-A27 BK-18 69
E 229-7366 02 (AFT - IVA/INJECTOR/RETARDER)
Cylinder 2 ENGINE OIL +5 VOLTS OR-18 A
Injector PRESSURE SENSOR GROUND YL-18 B
G828-A38 WH-18
G829-A43 GN-18
E964-A26 WH-18
E965-A48 BU-18
70
J 229-7365 03 (FORE - IVA/INJECTOR/RETARDER)
T302 Cylinder 4 194-6725 SIGNAL GN-18 C 994-A10 GY-18 E966-A49 YL-18
R746-A20 PK-18
T304 R747-A6 GY-18
ENGINE CONTROL MODULE(ECM)
J-S2

J-S3 J-S4

Intake Valve
Actuator
Cylinder 1
P541

Injector
Connector and Splice Locations for Harness 229-7366 -02
Cylinder 3
T303 Rear Valve Cover TYPICAL VEHICLE HARNESS WIRING DIAGRAM
Connector CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS TO +BATTERY
J682 CHECK ENGINE LAMP ENGINE CONTROL MODULE
N/O L994-YL
Intake Valve RELAY
Retarder Solenoid P1
Actuator TO VEHICLE 1607689
Cylinder 1 and 2 (J-T2) Retarder Solenoid Cylinder 6 COMPONENTS WARNING LAMP
Cylinder 3 and 4 (J-T3) P546 KEY SWITCH
659-PK L994-YL 28 CHECK ENGINE LAMP
659-PK 29 WARNING LAMP
OFF K998-BU 30 OUTPUT #1
ON
G880-PK 31 OUTPUT #9
START
14
61
SENR9697-01

E718-PK 10 OUTPUT #2
E991-GY 12 OUTPUT #3
G836-WH 13 OUTPUT #4
9 PIN CAB 15
CONNECTOR
NOTE B 16
+BATTERY B 1
NOTE Z
-BATTERY A C974-PU C974-PU 36 SPEEDOMETER POSITIVE
SIGNAL+
J 37 SPEEDOMETER NEGATIVE
ALTERNATOR SPEEDOMETER C973-GN
STARTER H G933-YL 27 INPUT #19
SIGNAL- C973-GN
Injector MOTOR J1587 - G E793-BU
NOTE B 26 INPUT #10
16 Page, Color 2

GROUND J1587 + F
E-S1 Cylinder 6
E794-YL 993-BR 3 INPUT SENSOR COMMON #2
J1939 SHIELD E A249-BK 450-YL F713-OR 17 INPUT #14
SIGNAL+
T306 J1939 - D K990-GN
TACHOMETER 450-YL 38 TACHOMETER POSITIVE
J1939 + C
Intake Valve NOTE D K900-YL SIGNAL- 451-BR 451-BR 39 TACHOMETER NEGATIVE
NOTE D 57
Actuator 43
Cylinder 4 E793-BU 9 J1587 DATA LINK NEGATIVE
- 12V + - 12V + - 12V +
P544 E794-YL 8 J1587 DATA LINK POSITIVE
A249-BK 42 J1939 DATA LINK SHIELD
TO CHASSIS
J1939 DATALINK K990-GN 34 J1939 DATA LINK NEGATIVE
BATTERY 3 BATTERY 2 BATTERY 1
K900-YL 50 J1939 DATA LINK POSITIVE
J906-BR 70 IGNITION KEY SWITCH
14 AWG GXL
10A 101-RD 48 UNSWITCHED +BATTERY
14 AWG GXL
10A 101-RD 52 UNSWITCHED +BATTERY
E-S2 10A
14 AWG GXL
101-RD 53 UNSWITCHED +BATTERY
Retarder Solenoid 14 AWG GXL
55
229-BK 63 -BATTERY
Cylinder 5 and 6 (E-T2) 14 AWG GXL
229-BK 65 -BATTERY
ENGINE 14 AWG GXL
229-BK 67 -BATTERY
BLOCK
69
G839-BU 20 OUTPUT #7
G838-BR 19 OUTPUT #6
C978-BR C978-BR 35 SET
H795-PK
C979-OR C979-OR 44 RESUME
K999-GN 56 INPUT #1
SET/RESUME SWITCH SERVICE BRAKE PEDAL POSITION SWITCH N/C
K980-PK 58 INPUT #2
H795-PK C992-PU C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) G840-PU 21 OUTPUT #8
E-S3
H795-PK C975-WH C975-WH 59 CRUISE CONTROL ON/OFF SWITCH
K982-YL 60 INPUT #3
CRUISE CONTROL ON/OFF SWITCH
G841-GN 7 INPUT #4
LO RETARDER SOLENOID LOW/HI SWITCH
E716-GY 23
MED
H795-PK G835-OR 25 INPUT #15 NEGATIVE
HI
G842-GY 47 INPUT #5
Intake Valve RETARDER SOLENOID ON/OFF SWITCH LO
G882-WH 64 INPUT #13
Actuator CLUTCH PEDAL POSITION SWITCH N/C
MED
E717-GN 40 RETARDER SOLENOID MED/HI SWITCH
HI
L901-GY 18
Cylinder 3 H795-PK C977-BU
INPUT SENSOR COMMON #1
C977-BU 22 CLUTCH PEDAL POSITION SWITCH
P543 (PEDAL RELEASED POSITION) G843-OR 6 INPUT #6
G879-OR 2 +5V
G844-PK 46 INPUT #7
C983-WH 49 ENGINE COOLANT LEVEL NORMAL
C984-YL 54 ENGINE COOLANT LEVEL LOW
Retarder Solenoid A/C HIGH PRESSURE SWITCH N/C G881-BU 62 INPUT #12
Cylinder 5 and 6 (E-T1) G834-PU 24 INPUT #15 POSITIVE
H795-PK E971-GN E971-GN 41 INPUT #11
51
PASSIVE MAGNETIC
NOTE C G808-BU 1 G808-BU 32 VEHICLE SPEED IN POSITIVE(NOTE F)
VEHICLE SPEED
NOTE F G809-GN 2 G809-GN 33 VEHICLE SPEED IN NEGATIVE
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED/OEM INSTALLED SENSOR
G845-PU 68 INPUT #8
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON BK B H795-PK H795-PK 5 AP SENSOR/SWITCH COMMON
+8 V RD A C985-BU C985-BU 4 +8V
ACCELERATOR PEDAL POSITION WH C C986-BR C986-BR 66 ACCELERATOR PEDAL POSITION
COOLING FAN SOLENOID G837-YL 11 OUTPUT #5
ACCELERATOR PEDAL POSITION SENSOR J403 P403
ARC
SUPPRESSOR

NOTE B: FOR SPEEDOMETERS OR TACHOMETERS WITH A SINGLE SIGNAL INPUT NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE NOTE Z: THE CONNECTOR ON THIS SCHEMATIC IS BLACK
TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER AND CONNECTS DIRECTLY TO SERVICE TOOL CABLE 157-4829.
THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED, SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. THE DIAGNOSTIC CONNECTOR NOT SHOWN HAS +BATTERY ON PIN (A) AND -BATTERY
DO NOT CONNECT TO GROUND THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS ON PIN (B). THIS CONNECTOR IS GRAY AND CONNECTS TO SERVICE TOOL
OF EACH OTHER. MAXIMUM SIGNAL AMPLITUDE OF J1-36, J1-37, CABLE 139-4166.
Intake Valve J1-38, AND J1-39 IS +/- 10 VOLTS. AMPLITUDE WILL BE +/- 5 VOLTS
Actuator OR GREATER IF LOAD CURRENT IS LESS THAN 4mA.
Cylinder 5
NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED
P545 NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE
Injector MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO
THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED
Cylinder 5 OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS
NOTE D: THESE CONNECTIONS ARE UNSWITCHED, DIRECT CONNECTION
T305 TO THE BATTERY IS NOT REQUIRED.