CAT C-10, C-12, C-15, C-16 Schematics

INTAKE MANIFOLD

j

j

j

AIR TEMPERATURE
P103

TURBO OUTLET
(INTAKE MANIFOLD AIR)
PRESSURE
P200

SPLICE
G828

ENGINE COOLANT
TEMPERATURE
P100

SPLICE
G829

SPLICE
G833

FUEL
TEMPERATURE
P105

ATMOSPHERIC
PRESSURE
P203

FUEL
PRESSURE
J209

ELECTRONIC
CONTROL MODULE
P2

ENGINE COOLANT
TEMPERATURE
P100

SECONDARY ENGINE
SPEED/TIMING
(CAMSHAFT)
P402

ENGINE OIL
PRESSURE
J201

P300
UNIT INJECTOR
HARNESS CONNECTOR

ATMOSPHERIC
PRESSURE
J203

TURBO OUTLET
(INTAKE MANIFOLD AIR)
PRESSURE
J200

INTAKE MANIFOLD
AIR TEMPERATURE
P103

FUEL
TEMPERATURE
P105

FUEL
PRESSURE
J209

TIMING CALIBRATION(TC)
PROBE CONNECTOR
P400

SENR9575-05

November 2007

Pressure

Symbol

Harness And Wire Electrical Schematic Symbols

Symbols

T

Temperature

Symbol

Level

Symbol

Flow

Symbol

Symbols and Definitions

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.
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
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.

Circuit Breaker

Symbol

INTAKE MANIFOLD
AIR TEMPERATURE
P103

TURBO OUTLET
(INTAKE MANIFOLD AIR)
PRESSURE
J200

SECONDARY ENGINE
SPEED/TIMING
(CAMSHAFT)
P402

SPLICE
997

PRIMARY ENGINE
SPEED/TIMING
(CRANKSHAFT)
P401

SPLICE
993

SPLICE
R993

ENGINE OIL
PRESSURE
P201

ATMOSPHERIC
PRESSURE
J203

P300
UNIT INJECTOR
HARNESS CONNECTOR

CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES
226-5758 AND 243-6620 (C-10/C-12)
INTEGRAL SENSORS

FUEL
TEMPERATURE
P105

FUEL
PRESSURE
J209

TIMING CALIBRATION(TC)
PROBE CONNECTOR
P400

ELECTRONIC
CONTROL MODULE
P2

SPLICE
R993

SPLICE
993

SPLICE
997

PRIMARY ENGINE
SPEED/TIMING
(CRANKSHAFT)
P401

CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES
191-5204, 238-1773, AND 237-7595 (C-15/C-16)

INJECTOR HARNESS

CONNECTOR

J300

ELECTRONIC
CONTROL MODULE
P2

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

Electrical System

Z2B1-UP
Z2C1-UP
BDL1-UP
BEM1-UP
BFM1-UP
BCX1-UP

T

Deutsch connector: Typical representation

1

of a Deutsch connector. The plug contains all

2

sockets and the receptacle contains all pins.

Wire, Cable, or Harness Assembly Identification:
Includes Harness Identification Letters and Harness
Connector Serialization Codes

C-C4

130-6795

Pin

Single Wire
Connector

©

2007 Caterpillar

AG-C3

130-6795

Harness identification code:
This example indicates wire
135 in harness "AG".

All Rights Reserved

Sender: A component that is used with a temperature or pressure gauge. The sender
measures the temperature or pressure. Its resistance changes to give an indication to
the gauge of the temperature or pressure.

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

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

Sure-Seal connector: Typical representation

1

of a Sure-Seal connector. The plug and receptacle

2

contain both pins and sockets.

Harness Identification Letter(s):
(A, B, C, ..., AA, AB, AC, ...)

Harness Connector Serialization Code: The "C" stands
for "Connector" and the number indicates which

connector in the harness. (C1, C2, C3, .....)

Part Number For
Connector Recepticle

Fuse

9X-1123

(5 Amps)

Component
Part Number

200-L32 BK-14

Wire Color

Wire Gauge

325-AG135 PK-14

Socket

Part Number for
Connector Plug

AG-C4

111-7898

Receptacle

Plug

Ground
Connection

L-C12

3E-5179

1

2

Circuit Identification
Number

Pin or Socket
Number

5A

Printed in U.S.A.

ENGINE COOLANT
TEMPERATURE
P100

SECONDARY ENGINE
SPEED/TIMING
(CAMSHAFT)
P402

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 189-6594 (C-10/C-12)
PIGTAIL SENSORS

PRIMARY ENGINE
SPEED/TIMING
(CRANKSHAFT)
P401

ENGINE OIL
PRESSURE
J201

P300
UNIT INJECTOR
HARNESS CONNECTOR

INJECTOR
#6

6

D791

D788

A706

SPLICE
D791

A705

D786

INJECTOR
#5

5

D791

INJECTOR
#4

4

D790

D788

A704

SPLICE
D788

A703

D787

INJECTOR
#3

3

D790

SPLICE
D786

SPLICE
D790

INJECTOR
#2

SPLICE
D789

2

D789

D788

A702

D786

A701

1

INJECTOR
#1

D789

174-0502

AB

C

155-2269

1

2

3E-3370

160-7689

160-7690

A

B

SPLICE
120

SPLICE
892

SPLICE
893

CATERPILLAR SUPPLIED
ENGINE SERVICE
TOOL CONNECTOR
J63

CUSTOMER
CONNECTOR
J61

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 122-1486 (C-15/C-16)

INJECTOR HARNESS

CONNECTOR

J300

SPLICE
D788

SPLICE
D786

C

9X-1343

155-2267

B

A

C

169-8670

B

A

C

21

31

25

26

35

36

10651

20161511

30

40

8T-8736

8T-8736

E

E

F

F

G

G

D

D

C

C

AB

AB

J

J

H

H

SENR9575-05

30 Page, (Dimensions: 39 inches x 28 inches)

155-2252

12 11

948

10

7

GROUND

229

GROUND

229

SPLICE
A234
K990
K900

TERMINATION
RESISTOR
P154

CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES
189-6596, 191-1531, 238-1774, 242-7248, AND 243-6618 (ALL)

ELECTRONIC
CONTROL
MODULE
P1

D786

D788

D791

6

INJECTOR
#6

A706

A705

SPLICE
D791

D791

5

INJECTOR
#5

D787

D788

D790

4

INJECTOR
#4

A704

A703

SPLICE
D790

D790

3

INJECTOR
#3

D786

D788

D789

2

INJECTOR
#2

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 4P-9537 (C-10/C-12)

A702

A701

SPLICE
D789

D789

1

INJECTOR
#1

Related Electrical Service Manuals

Title

Installation Guide C-10,C-12 REHS0871
System Operation

Test and Ad
Troubleshooting C-10,C-12 SENR9576

Installation Guide C-15,C-16 REHS0871
System Operation

Test and Ad
Troubleshooting C-15,C-16 SENR9576
System Operation

Test and Ad
Troubleshooting C-10(Z2B),C-15(Z2C) RENR5061

ust

ust

ust

Industrial

Engine

C-10,C-12 SENR9573

C-15,C-16 RENR2347

C-10(Z2B),C-15(Z2C) SENR9953

Form Number

216

5

3

3E-7990

3E-8969

948

1211

10

7

5

216

3

5

216

3

948

12 11

10

7

C-10 and C-12 Engine
and Injector Harness
(Pigtail Sensors)

ECM
GROUND
STRAP

ELECTRONIC CONTROL
MODULE (ECM)

ANALOG SENSOR POWER (+5V)

ANALOG SENS0R COMMON

ATMOSPHERIC PRESSURE

FUEL PRESSURE

PASSIVE SENSOR RETURN

TIMING CALIBRATION PROBE +
TIMING CALIBRATION PROBE -

ENGINE OIL PRESSURE

ENGINE COOLANT TEMPERATURE

INTAKE MANIF. AIR TEMPERATURE

SENR9575-05

FUEL TEMPERATURE

INJECTOR 1
INJECTOR 2
INJECTOR 3

TURBO OUTLET PRESSURE

INJECTOR COMMON 1 & 2
INJECTOR COMMON 3 & 4
INJECTOR COMMON 5 & 6

PRIMARY SPEED/TIMING +
PRIMARY SPEED/TIMING -

SECONDARY SPEED/TIMING +
SECONDARY SPEED/TIMING -

INLET AIR SHUTOFF SOLENOID RELAY

INTERMEDIATE ENGINE SPEED SWITCH

RETARDER SOLENOID MED/LO/HI (NOTE M)

ELECTRONIC CONTROL MODULE (ECM)

INJECTOR 4

INJECTOR 5
INJECTOR 6

ANALOG SENSOR POWER (+5V)

DIGITAL SENSOR POWER (+8V)

AUXILIARY PRESSURE SENSOR

STARTING AID OVERRIDE SWITCH
MAINTENANCE DUE RESET SWITCH

REMOTE SHUTDOWN SWITCH

RETARDER SOLENOID HI (NOTE M)

RETARDER SOLENOID MED (NOTE M)

75% OVERSPEED VERIFY SWITCH

PTO RAMP UP/SET SWITCH

PTO RAMP DOWN / RESUME SWITCH

THROTTLE POSITION SENSOR

AUXILIARY TEMPERATURE SENSOR

ECM
MOUNTING
BOLT

P2

1607690
1
2

997/OR

3

993/BR
4
5
6
7
8
9

10
11
12
13
14

A747/GY

15
16

413/BR

17
18

R993/BR

19
20
21
22

G811/YL

23

G810/PU

24

994/GY

25
26
27
28
29
30
31
32

995/BU

33

F421/YL

34
35

C967/BU

36

A701/GY

37

A702/PU

38

A703/BR

39

A704/GN

40

A746/PK

41
42
43
44

L983/WH

45

L984/OR

46

L985/YL

47
48

F732/PK

49

P920/BR

50
51
52
53
54

A705/BU

55

A706/GY

56
57
58

999/WH

59

998/BR

60
61
62
63
64
65
66
67
68
69
70

ANALOG SENSOR RETURN

DIGITAL SENSOR RETURN

CAT DATA LINK (+)
CATDATALINK(-)

RETARDER LAMP

ETHER START VALVE

NOT USED

DIAGNOSTIC LAMP

WARNING LAMP

MAINTENANCE DUE LAMP

J1939 DATA (-)

TACHOMETER +
TACHOMETER -

TORQUE LIMIT SWITCH

PTO INTERRUPT SWITCH

J1939 SHIELD

(NOT USED)NOTE Z

COOLANT LEVEL SENSOR

+BATTERY (UNSWITCHED)

J1939 DATA (+)

+BATTERY (UNSWITCHED)
+BATTERY (UNSWITCHED)

PTO ENABLE SWITCH

BATTERY (-)

BATTERY (-)

BATTERY (-)

SOLENOID COMMON

+BATTERY (SWITCHED)

30 Page, Color 2, (Dimensions: 39 inches x 28 inches)

P1
1607689

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

A701/GY
A702/PU
A703/BR
A704/GN
A705/BU
A706/GY

L985/YL

L984/OR

L983/WH

G811/YL
G810/PU

P920/BR
F732/PK

998/BR
999/WH

995/BU

R993/BR

997/OR
993/BR

A746/PK

A747/GY

F421/YL

413/BR

C967/BU

125/OR

T993/BR
167/OR
A274/BK

893/PK
892/WH
T936/GN
G971/BR

G469/BU

382/PK
M910/OR
F426/BU

J983/YL
F404/RD
F420/GN
F424/YL

K990/GN

450/YL
451/BR
M909/GN
M904/OR
A234/BK
E798/PK
F716/WH
G968/WH
E452/WH
H405/BU
150/OR(48)
H406/GY
K900/YL

150/OR(52)
150/OR(53)
387/PK

381/PU

G955/GN
H407/YL
G967/WH
229/BK(61)

229/BK(63)

229/BK(65)
A307/GY
G969/YL
G488/GN

120/YL

994/GY

INJECTOR
HARNESS
CONNECTOR

P300

1552252

NOT
USED

NOT
USED

A705 BU-16

NO.6
CYLINDER
INJECTOR

D791 YL-16

P920/BR
F732/PK

998/BR
999/WH

995/BU

R993/BR

3E3370
997/OR
993/BR

A746/PK

3E3370
997/OR
993/BR

A747/GY

3E3370
997/OR
993/BR
994/GY

R993/BR

P209
1698670

A
B
C

ELECTRONICS
GROUND STUD
NOTE A

A745/WH

Extension harness used for
specific fuel filter arrangements.
Not present on all engines.

C967/BU
R993/BR

120/YL A
229/BK

A234/BK

893/PK

892/WH

K990/GN

K900/YL

120/YL

A234/BK

K990/GN

K900/YL

892/WH
893/PK

J300
3E7990

1

A701 GY-16

2

A702 PU-16

3

A703 BR-16

4

A704 GN-16

5

A705 BU-16

6

A706 GY-16

7

D788 BK-16

8

D791 YL-16

9

D787 GN-16

10

D790 OR-16

11

D786 BR-16

12

D789 WH-16

TERMINATION
RESISTOR
(134-2540)
(NOTE B&C)

229/BK(63)
229/BK(61)
229/BK(65)

120/YL

A234/BK

K990/GN

K900/YL

892/WH
893/PK

P400

1552269

3E3364

TIMING CALIBRATION

1

(TC) PROBE CONNECTOR

2

120

CBA

P154
1740502

E798/PK(H406/GY)NOTE Z

NOT
USED

A706 GY-16

D791 YL-16

3E3370
997/OR
993/BR
413/BR

M909/GN

T936/GN
G971/BR
G969/YL

167/OR
A274/BK
A307/GY
G488/GN
F426/BU
F424/YL
125/OR
T993/BR
M904/OR
382/PK
F404/RD
F420/GN
F716/WH
G968/WH
381/PU
G955/GN

G469/BU
H407/YL

E452/WH
H405/BU
M910/OR
G967/WH
387/PK
150/OR(48)
150/OR(52)
150/OR(53)
450/YL
451/BR
J983/YL

J209

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

Customer Harness

A704 GN-16

NO.5
CYLINDER
INJECTOR

P401

1552269

P402

1552269

J200

B
C

J203

B
C

J201

B
C

997/OR
993/BR

J63
ENGINE SERVICE
TOOL CONNECTOR

8T8736

B
C
D
E
F
G
H
J

NOTE Z

A703 BR-16

NO.4
CYLINDER
INJECTOR

D790 OR-16

D790 OR-16

1

BK-18
WH-18

2

1

SIGNAL(-)
SIGNAL(+)

2

P100

1552269

OR-18
YL-18
GN-18

OR-18
YL-18
GN-18

OR-18
YL-18
GN-18

P105

1552269

J209A

3E3370

1552269

(+)BATTERY
(-)BATTERY
J1939 SHIELD
CAT DATA LINK(+)
CAT DATA LINK(-)
J1939(-)
J1939(+)

SIGNAL

1

COMMON

2

SIGNAL

1F421/YL

COMMON

2

B
C

P103

SIGNAL

1

COMMON

2

150/OR(48)
M909/GN
T936/GN
G971/BR
G969/YL

892/WH

893/PK

167/OR
A274/BK
A307/GY
G488/GN
F426/BU
F424/YL

125/OR

T993/BR

A234/BK
K900/YL
K990/GN

M904/OR

450/YL

451/BR

382/PK
J983/YL
F404/RD
F420/GN

120/YL
F716/WH
G968/WH

381/PU
G955/GN

150/OR(52)

150/OR(53)
G469/BU
H407/YL

E798/PK(H406/GY)

E452/WH
H405/BU
M910/OR
G967/WH

387/PK

NO.3
CYLINDER
INJECTOR

D789 WH-16

+5VA
RETURN
SIGNAL

A701 GY-16

NO.2
CYLINDER
INJECTOR

D789 WH-16

(CRANKSHAFT POSITION)
PRIMARY ENGINE SPEED/TIMING SENSOR
188-7511

ENGINE COOLANT
TEMPERATURE SENSOR
130-9811

TURBO OUTLET
PRESSURE SENSOR
(INTAKE MANIFOLD AIR)
194-6724

ATMOSPHERIC PRESSURE
SENSOR
194-6722

ENGINE OIL PRESSURE
SENSOR
194-6725

FUEL TEMPERATURE
SENSOR
130-9811

INTAKE MANIFOLD AIR
TEMPERATURE SENSOR
130-9811

A702 PU-16

SIGNAL(-)
SIGNAL(+)

(CAMSHAFT POSITION)
SECONDARY ENGINE SPEED/TIMING SENSOR
189-9801

+5VA
RETURN
SIGNAL

+5VA
RETURN
SIGNAL

+5VA
RETURN
SIGNAL

OR-18
YL-18
GN-18

BATTERY

1297163

1

G

S

MTR BAT.

STARTING

MOTOR

+BAT. (UNSWITCHED)
TORQUE LIMIT SW
RETARDER LAMP(NOTE M)
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

ETHER START VALVE

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 MED/LO/HI SW(NOTE M)
RETARDER MED SW(NOTE M)
COOLANT LEVEL SNSR
RETARDER HI SW(NOTE M)
STARTING AID OVERRIDE SW
PTO RAMP DOWN/RESUME SW
75% OVERSPEED VERIFY SW

J61

9X1343

CUSTOMER

CONNECTOR

1297164

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

P61

NO.1
CYLINDER
INJECTOR

FUEL PRESSURE SENSOR
194-6725

BATTERY
DISCONNECT
SWITCH

1297164

1297163

1

1

NOTE D

START RELAY

ALTERNATOR

BATTERY

OPTIONAL

WIRING

(SMMS)

11

BK-18
BK-18

C-10 and C-12 Engine
and Injector Harness
(Integral Sensors)

ECM
GROUND
STRAP

ELECTRONIC CONTROL
MODULE (ECM)

ANALOG SENSOR POWER (+5V)

ANALOG SENS0R COMMON

ATMOSPHERIC PRESSURE

FUEL PRESSURE

PASSIVE SENSOR RETURN

TIMING CALIBRATION PROBE +
TIMING CALIBRATION PROBE -

ENGINE OIL PRESSURE

ENGINE COOLANT TEMPERATURE

INTAKE MANIF. AIR TEMPERATURE

NOTE D

P515
1552269

1

2

+BAT. (UNSWITCHED)
+BAT. (UNSWITCHED)
+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

PTO RAMP UP/SET SW
PTO RAMP DOWN/RESUME SW
MAINTENANCE DUE LAMP
DIAGNOSTIC LAMP
WARNING LAMP
RETARDER LAMP(NOTE M)
+BAT. (SWITCHED)
CAT DATA LINK ­CAT DATA LINK +

J1939 SHIELD
J1939 DATA +
J1939 DATA -

(153-2707)
(NOTES B & E)

RETARDER MED/LO/HI SW

NOTE M

RETARDER MED SW

NOTE M

RETARDER HI SW

FUEL TEMPERATURE

INJECTOR 1
INJECTOR 2
INJECTOR 3

ST

14 AWG
14 AWG
14 AWG

14 AWG

INJECTOR 4

INJECTOR 5
INJECTOR 6

NOTE D

B

ON

S

C

OFF

R

MED/LO/HI
RETARD SWITCH

MED
RETARD SWITCH

HI
RETARD SWITCH

TURBO OUTLET PRESSURE

INJECTOR COMMON 1 & 2
INJECTOR COMMON 3 & 4
INJECTOR COMMON 5 & 6

PRIMARY SPEED/TIMING +
PRIMARY SPEED/TIMING -

SECONDARY SPEED/TIMING +
SECONDARY SPEED/TIMING -

KEYSTART
SWITCH

NOT USED
NOT USED
NOT USED

ECM
MOUNTING
BOLT

P2

1607690
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

G828/WH
G829/GN

J702/BK
J700/BR
J701/GN

A747/GY

413/BR

R833/BR

994/GY

995/BU
A751/YL

C967/BU
A701/GY
A702/PU
A703/BR
A704/GN
A746/PK

L983/WH
L984/OR
L985/YL

E964/WH
E963/BK

A705/BU
A706/GY

E966/YL
E965/BU

-BAT.

CAT DATA LINK -

CAT DATA LINK +

+BAT. (SWITCHED)

INJECTOR
HARNESS
CONNECTOR

J300

P300

1552252

A701/GY
A702/PU
A703/BR
A704/GN
A705/BU
A706/GY
J702/BK
L985/YL
J701/GN
L984/OR
J700/BR
L983/WH

E963/BK
E964/WH

E965/BU
E966/YL

995/BU

R833/BR

G828/WH

G829/GN

A746/PK
A747/GY

994/GY

A751/YL

413/BR

C967/BU

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

MAX LENGTH 40 METERS

3E7990

1

A701 GY-16

2

A702 PU-16

3

A703 BR-16

4

A704 GN-16

5

A705 BU-16

6

A706 GY-16

7

D788 BK-16

8

D791 YL-16

9

D787 GN-16

10

D790 OR-16

11

D786 BR-16

12

D789 WH-16

ABC

120

TERMINATION
RESISTOR
(174-3016)
(NOTE B & C)

(NOTE B)

BABC

DEVICE

NOT
USED

NOT
USED

NOT
USED

G828/WH
G829/GN

413/BR

CA

(165-0200)
MAX LENGTH 1 METER
(NOTE B)

A706 GY-16

E963/BK
E964/WH

E965/BU
E966/YL

995/BU

R833/BR

P200
1552267 EARLY
1698670 LATE

G828/WH
G829/GN

A746/PK

G828/WH
G829/GN

A747/GY

G828/WH
G829/GN

994/GY

R833/BR

P209

J209

1698670

3E3370

A
B
C

Extension harness used for
specific fuel filter arrangements.
Not present on all engines.

C967/BU
R833/BR

BATTERY(-)

ETHER START VALVE

ETHER START
VALVE RELAY
(NOTE V)

STARTING AID OVERRIDE SW

MAINTENANCE DUE RESET SW

TORQUE LIMIT SW

REMOTE SHUTDOWN SW (NOTE K)

INTERMEDIATE ENGINE SPEED SW

OVERSPEED VERIFY SW

PTO INTERRUPT SW

PTO ENABLE SW

MAX LENGTH 30 METERS

A
B
C

P203
1698670

B
C

P201

1698670

B
C

997/OR
993/BR

A745/WH

INLET AIR SHUTOFF
SOLENOID (NOTE V)

P142/J142

A
B
C

P800/J800

A
B
C

P220/J220

A
B
C

J403/P403

A
B
C

D791 YL-16

P401

1552269

P402

1552269

1552269

+5V
RETURN
SIGNAL

+5VA
RETURN
SIGNAL

+5VA
RETURN
SIGNAL

1552269

1552269

1
2

+8V
RETURN
SIGNAL

+8V
RETURN
SIGNAL

+5V
RETURN
SIGNAL

+ BATTERY

- BATTERY
SIGNAL

CB

1A

CB

1A

CB

1A

CB

1A

A705 BU-16

1
2

1
2

P100

P105

J209A

3E3370

P103

NO.6
CYLINDER
INJECTOR

D791 YL-16

BK-18
WH-18

SIGNAL(-)
SIGNAL(+)

SIGNAL

1

COMMON

2

SIGNAL

1A751/YL

COMMON

2

OR-18
YL-18

B

GN-18

C

1

SIGNAL

2

COMMON

1
2

CUSTOMER INSTALLED

SERVICE TOOL CONN

A704 GN-16

NO.5
CYLINDER
INJECTOR

D790 OR-16

SIGNAL(-)
SIGNAL(+)

(CAMSHAFT POSITION)
SECONDARY ENGINE SPEED/TIMING SENSOR
189-9801

TURBO OUTLET
PRESSURE SENSOR
(INTAKE MANIFOLD AIR)
161-1704

ATMOSPHERIC PRESSURE
SENSOR
161-1703

ENGINE OIL PRESSURE
SENSOR
161-1705

+5VA
RETURN
SIGNAL

INLET AIR SHUTOFF
SOLENOID RELAY
(NOTE V)

AUXILIARY
TEMPERATURE
SENSOR

COOLANT LEVEL
SENSOR
OFF ENGINE

AUXILIARY
PRESSURE
SENSOR

DESIRED
SPEED
CONTROL
(NOTE W)

ETHER
START
VALVE
(NOTE V)

PTO RAMP

UP/DOWN SWITCH

MAINTENANCE
DUE LAMP

DIAGNOSTIC LAMP

WARNING LAMP

RETARDER LAMP
NOTE M

A + BAT.

- BAT.B
C
D

CAT DATA LINK +
CAT DATA LINK -

E
F
G
H
J

(J66)

A703 BR-16

NO.4
CYLINDER
INJECTOR

D790 OR-16

(CRANKSHAFT POSITION)
PRIMARY ENGINE SPEED/TIMING SENSOR
188-7511

ENGINE COOLANT
TEMPERATURE SENSOR
130-9811

FUEL TEMPERATURE
SENSOR
130-9811

FUEL PRESSURE SENSOR
194-6725

INTAKE MANIFOLD AIR
TEMPERATURE SENSOR
130-9811

A702 PU-16

NO.3
CYLINDER
INJECTOR

D789 WH-16

A701 GY-16

C-15 and C-16 Engine
and Injector Harness

ECM
GROUND

NO.2
CYLINDER
INJECTOR

D789 WH-16

NO.1
CYLINDER
INJECTOR

ELECTRONIC CONTROL
MODULE (ECM)

INTAKE MANIF. AIR TEMPERATURE

Engine Control Module

CID Component

0001 Injector #1
0002 Injector #2
0003 Injector #3
0004 Injector #4
0005 Injector #5
0006 Injector #6
0022 Timing Sensor
0041 8 Volt DC Supply
0091 Throttle Position
0094 Fuel Pressure
0100 Engine Oil Pressure
0110 Engine Coolant Temperature
0168 System Voltage
0172 Intake Manifold Air Temp
0174 Fuel Temperature
0247 Data Link Communications
0253 Personality Module
0254 Electronic Control Module
0261 Engine Timing
0262 5 Volt Sensor DC Power Supply
0263 Digital Sensor Supply
0268 Check Programmable Parameters
0273 Turbo Outlet Pressure
0274 Atmospheric Pressure
0320 Speed / Timing Sensor
0342 Loss of Secondary Engine Speed
0545 Ether Start Relay
1835 Auxiliary Pressure Sensor

1836 Auxiliary Temperature Sensor
¹ The CID is a diagnostic code that indicates which component is faulty.
² The MID is a diagnostic code that indicates which electronic control module

diagnosed the fault.

Failure Mode Identifiers (FMI)¹

FMI No. Failure Description

0 Data valid but above normal operational range.
1 Data valid but below normal operational range.
2 Data erratic, intermittent, or incorrect.
3 Voltage above normal or shorted high.
4 Voltage below normal or shorted low.
5 Current below normal or open circuit.
6 Current above normal or grounded circuit.
7 Mechanical system not responding properly.
8 Abnormal frequency, pulse width, or period.

9 Abnormal update.
10 Abnormal rate of change.
11 Failure mode not identifiable.
12 Bad device or component.
13 Out of calibration.
14 Parameter failures.
15 Parameter failures.
16 Parameter not available.
17 Module not responding.
18 Sensor supply fault.
19 Condition not met.
20 Parameter failures.

¹The FMI is a diagnostic code that indicates what type of failure has occurred.

Turbo Outlet
Pressure
Sensor
(Intake
Manifold Air)
J200

STRAP

ANALOG SENSOR POWER (+5V)

ANALOG SENS0R COMMON

RETARDER COMMON (NOTE Y)
RETARDER MED/HI (NOTE Y)
RETARDER LOW/HI (NOTE Y)

ATMOSPHERIC PRESSURE

PASSIVE SENSOR RETURN

TIMING CALIBRATION PROBE +
TIMING CALIBRATION PROBE -

ENGINE OIL PRESSURE

ENGINE COOLANT TEMPERATURE

TURBO OUTLET PRESSURE

INJECTOR COMMON 1 & 2
INJECTOR COMMON 3 & 4
INJECTOR COMMON 5 & 6

PRIMARY SPEED/TIMING +
PRIMARY SPEED/TIMING -

SECONDARY SPEED/TIMING +
SECONDARY SPEED/TIMING -

FUEL PRESSURE

FUEL TEMPERATURE

INJECTOR 1
INJECTOR 2
INJECTOR 3
INJECTOR 4

INJECTOR 5
INJECTOR 6

ECM
MOUNTING
BOLT

P2

1607690
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

Customer

Connector

J61

997/OR
993/BR

J702/BK
J700/BR
J701/GN

A747/GY

413/BR

R993/BR

G811/YL
G810/PU
994/GY

995/LTBU
F421/YL

C967/LTBU

A701/GY
A702/PU
A703/BR
A704/GN

A746/PK

L983/WH
L984/OR
L985/YL

F732/PK
P920/BR

A705/BU
A706/GY

999/WH
998/BR

INJECTOR
HARNESS
CONNECTOR

J300

P300

A701/GY
A702/PU
A703/BR
A704/GN
A705/BU
A706/GY
J702/BK
L985/YL
J701/GN
L984/OR
J700/BR
L983/WH

G811/YL
G810/PU

P920/BR
F732/PK

998/BR

999/WH
995/LTBU
R993/BR

997/OR

993/BR

A746/PK

A747/GY
994/GY
F421/YL
413/BR

C967/LTBU

1552252

1
2
3
4
5
6
7
8

9
10
11
12

3E8969

A701 GY-16
A702 PU-16
A703 BR-16
A704 GN-16
A705 BU-16
A706 GY-16
D788 BK-16
D791 YL-16
D787 GN-16
D790 OR-16
D786 BR-16
D789 WH-16

P400

1552269

3E3364

TIMING CALIBRATION

1

(TC) PROBE CONNECTOR

2

Primary Engine
Speed/Timing
Sensor
(Crankshaft)
P401

FRONT VIEW

Event Codes For ADEM III ECM

Event Code Condition

E004 Engine Overspeed Shutdown
E005 Fuel Filter Restriction Derate
E006 Fuel Filter Restriction Shutdown
E015 High Engine Coolant Temperature Derate
E016 High Engine Coolant Temperature Shutdown
E017 High Engine Coolant Temperature Warning
E025 High Inlet Air Temperature Derate
E027 High Inlet Air Temperature Warning
E039 Low Engine Oil Pressure Derate
E040 Low Engine Oil Pressure Shutdown
E054 High Fuel Temperature Derate
E055 High Fuel Temperature Shutdown
E056 High Fuel Temperature Warning
E057 Low Engine Coolant Level Derate
E058 Low Engine Coolant Level Shutdown
E059 Low Engine Coolant Level Warning
E095 Fuel Filter Restriction Warning
E096 High Fuel Pressure
E100 Low Engine Oil Pressure Warning
E190 Engine Overspeed Warning
E443 High Auxiliary Pressure
E445 High Auxiliary Temperature

C-15 and C-16 Engines

Service Tool
Connector
J63

Electronics
Ground
Stud

RETARDER MED/HI
(SPECIFIC ARRANGEMENTS)

RETARDER MED/HI
(SPECIFIC ARRANGEMENTS)

RETARDER LO/HI
(SPECIFIC ARRANGEMENTS)

P920/BR
F732/PK

998/BR
999/WH

995/LTBU
R993/BR

997/OR
993/BR

A746/PK

997/OR
993/BR

A747/GY

997/OR
993/BR
994/GY

R993/BR

997/OR
993/BR
413/BR

C967/LTBU

R993/BR

Fuel
Pressure
Sensor
J209

A706 GY-16

D791 YL-16

P401

1552269

P402

1552269

J200

3E3370

A
B
C

J203

3E3370

B
C

J201

3E3370

B
C

J209

3E3370

B
C

A705 BU-16

NO.6
CYLINDER
INJECTOR

D791 YL-16

1
2

1
2

1552269

1552269

SIGNAL(-)
SIGNAL(+)

P100

OR-18
YL-18
GN-18

OR-18
YL-18
GN-18

OR-18
YL-18
GN-18

P105

OR-18
YL-18
GN-18

1552269

(CRANKSHAFT POSITION)
PRIMARY ENGINE SPEED/TIMING SENSOR
189-9266

SIGNAL(-)

BK-18

SIGNAL(+)

WH-18

SIGNAL

1

COMMON

2

+5V
RETURN
SIGNAL

+5VA
RETURN
SIGNAL

+5VA
RETURN
SIGNAL

1F421/YL

SIGNAL

2

COMMON

+5VA
RETURN
SIGNAL

P103

SIGNAL

1

COMMON

2

Secondary Engine
Speed/Timing
Sensor
(Camshaft)
P402

Fuel
Temperature
Sensor
P105

A704 GN-16

NO.5
CYLINDER
INJECTOR

D790 OR-16

(CAMSHAFT POSITION)
SECONDARY ENGINE SPEED/TIMING SENSOR
188-7513

ENGINE COOLANT
TEMPERATURE SENSOR
130-9811

TURBO OUTLET
PRESSURE SENSOR
(INTAKE MANIFOLD AIR)
194-6724

ATMOSPHERIC PRESSURE
SENSOR
194-6722

ENGINE OIL PRESSURE
SENSOR
194-6725

FUEL TEMPERATURE
SENSOR
130-9811

FUEL PRESSURE SENSOR
194-6725

INTAKE MANIFOLD AIR
TEMPERATURE SENSOR
130-9811

Engine Coolant
Temperature
Sensor
P100

A703 BR-16

NO.4
CYLINDER
INJECTOR

D790 OR-16

A702 PU-16

NO.3
CYLINDER
INJECTOR

Customer
Connector
J61

Timing Calibration
(TC) Probe Connector
P400

(+) BATTERY
(+) BATTERY SWITCHED
STARTING CIRCUIT
(-) BATTERY / SENSOR RETURN
SENSOR / ACTUATOR SUPPLY
SIGNAL PLUS TO ECM

SIGNAL MINUS TO ECM
CONTROL PLUS FROM ECM

CONTROL MINUS FROM ECM
CAT DATA LINK

J1939 DATA LINK

Intake Manifold
Air Temperature
Sensor
P103

A701 GY-16

NO.2
CYLINDER
INJECTOR

D789 WH-16

D789 WH-16

Service Tool
Connector
J63

NO.1
CYLINDER
INJECTOR

C-10 and C-12 Engines

Intake Manifold
Air Temperature
Sensor
P103

Turbo Outlet
Pressure
Sensor
(Intake Manifold Air)
P200(J200)

TOP VIEW

Fuel
Temperature

Electronics
Ground

Sensor
P105

Stud

ECM

Engine Oil
Pressure

Connector
P2/J2

Sensor
P201(J201)

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST

HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS
CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL

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 F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR

MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION

NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING

STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE
OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO
A MAIN EMS MODULE

NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS.

IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED.
IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO
BATTERY (-) IS REQUIRED

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 L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER

FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS
SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS
1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR

NOTE M: THE RETARDER FEATURE IS ONLY AVAILABLE ON SPECIFIC MODELS

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 Y: HARNESSES 237-7595 -00 AND 238-1773 -00 HAVE WIRES J700/BR, J701/GN,
AND J702/BK INSTALLED. ALL OTHER C-15/C-16 ENGINE HARNESSES DO NOT INCLUDE
THESE WIRES.
NOTE Z: HARNESS 242-7248 -00 HAS WIRE H406/GY INSTALLED. ALL OTHER CUSTOMER
HARNESSES HAVE WIRE E798/PK INSTALLED. H406/GY TERMINATES AT P1/49 AND J61/35.
E798/PK TERMINATES AT P1/43 AND J61/35.

NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES
WITHOUT CATERPILLAR ENGINEERING APPROVAL

UNLESS OTHERWISE SPECIFIED:
ALL WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR
EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708

ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN
ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN
CONSIDERING COMPONENT REMOVAL

Fuel
Pressure
Sensor
J209

LEFT SIDE VIEW

Atmospheric
Pressure
Sensor
P203(J203)

ECM
Ground
Strap

Electronic
Control
Module
(ECM)

ECM
Connector
P1/J1

-BAT.

CAT DATA LINK -

CAT DATA LINK +

+BAT. (SWITCHED)

+24V

MODULE LOAD

-BAT

CAT DATA LINK +

CAT DATA LINK -

14

521

MODULE DATA

+V MODULE

MODULE CLOCK

US/METRIC

SCROLL FORWARD

AUXILIARY CKT

WARNING LAMP

WARNING

SCROLL BACKWARD

13232035342515

33

4

7

3

MAIN EMS MODULE

(NOTE G)

10

986

BACKLIGHT LAMP PWR

-BAT

+24V

- BAT.

US/METRIC

SCROLL FORWARD
CAT DATA LINK ­CAT DATA LINK +

UNUSED

WARNING LAMP

WARNING

SCROLL BACKWARD

(NOTE F)

(NOTE B)

1
2
3
4
5
6
7
8
9
10
11
12

CAT DATA LINK +
CAT DATA LINK -

-BAT.
+BAT. (SWITCHED)

403938373632313029282726242221191817161211

(NOTE H)

TACHOMETER MODULE

(NOTE G)

15

20

10

RPM X100

25

30

65432

5

0

1

-V OUT

DC/DC CONVERTER

(127-8853)

(NOTES B & L)

-V IN

(NOTES B & L)

OPTIONAL EMS DISPLAY MODULES

OPTIONAL REMOTE

TACHOMETER MODULE OR

QUAD GAUGE MODULE

(NOTES G & B)

687

54321

MODULE DATA
+V MODULE
MODULE CLOCK
MODULE LOAD

-BAT
BACKLIGHT LAMP PWR

+V OUT

+V IN

QUAD GAUGE MODULE

(NOTE G)

687

54321

Engine Coolant
Temperature
Sensor
P100

FRONT VIEW

Secondary Engine
Speed/Timing
Sensor
(Camshaft)
P402

Atmospheric
Pressure
Sensor
J203

Primary Engine
Speed/Timing
Sensor
(Crankshaft)
P401

Engine Oil
Pressure
Sensor
J201

LEFT SIDE VIEW

ECM
Ground
Strap

ECM
Connector
P2/J2

Timing Calibration
(TC) Probe Connector
P400

Electronic
Control
Module
(ECM)

ECM
Connector
P1/J1

ABBREVIATION

ALT ALTERNATOR
ATA AMERICAN TRUCKING ASSOCIATION
CB CIRCUIT BREAKER
CIS CUSTOMER IGNITION SWITCH
DIG DIGITAL
ECM ELECTRONIC CONTROL MODULE
N/C NO CONNECTION
PWM PULSE WIDTH MODULATION
SM STARTING MOTOR
SMMS START MOTOR MAG SWITCH

THIS SCHEMATIC IS FOR THE C-10, C-12, C-15, and C-16 INDUSTRIAL ENGINES
WIRING DIAGRAMS- 201-0649 CHG04 AND 238-1775 CHG01

HARNESS TABLE

PART NO. NAME

189-6594

CHG.

J2/ENGINE(C-10/C-12 Pigtail Sensors)

05
226-5758 J2/ENGINE(C-10/C-12 Integral Sensors)03
243-6620 J2/ENGINE(C-10/C-12 Specific Arrangements)00

191-5204 J2/ENGINE(C-15/C-16)02
238-1773 J2/ENGINE(C-15/C-16 Retarder)00
237-7595 J2/ENGINE(C-15/C-16 Specific Arrangements)01

189-6596 J1/CUSTOMER(C-10/C-12)

04
243-6618 00 J1/CUSTOMER(C-10/C-12 Specific Arrangements)

191-1531

J1/CUSTOMER(C-15/C-16)04
238-1774 J1/CUSTOMER(C-15/C-16 Retarder)00
242-7248 00 J1/CUSTOMER(C-15/C-16 Specific Arrangements)

4P-9537 07 INJECTOR(C-10/C-12)
122-1486 10 INJECTOR(C-15/C-16)
132-3144 FUEL PRESSURE EXTENSION(C-10/C-12)

00