3406E Left Side View RENR2237-04

November 2003 C-15 and C-16 Left Side View

C-10 and C-12 Left Side View
Electronic Electronic Inlet
Boost Unit Inlet Engine
Air Unit Air
Pressure Injector Ground Injector Temperature Engine
Electronic Temperature Stud
Sensor Connector Connector Sensor Ground
Fuel Unit Atmospheric Sensor Boost Stud
Temperature Injector Pressure Pressure
Sensor Connector Sensor Sensor

Oil Engine Engine

Pressure Ground Camshaft Control Camshaft
Sensor Stud Position Module Position
Sensor (ECM) Sensor
Engine
Control
Module
Engine OEM (ECM)
Camshaft Control Vehicle
Position Module Harness OEM
Sensor (ECM) Fuel Connector Vehicle
Temperature J1/P1 Harness
Sensor Connector
J1/P1
OEM
Vehicle
Harness
Connector
J1/P1

Engine Atmospheric
Crankshaft Harness Pressure
Position Connector Sensor
Sensor J2/P2

Engine
Ground
Stud
C-10, C-12, 3406E, C-15, and C-16 Engine
Harness
Connector
Crankshaft J2/P2
Position
Sensor Engine
Harness
Truck Engine Crankshaft
Position
Connector
J2/P2 Electrical System Sensor Atmospheric
Pressure
Sensor
Oil
Pressure
Sensor

Inlet
Air Boost Coolant
Coolant Air Inlet Temperature Pressure Temperature
Temperature
Sensor
Air Inlet
Shutoff
Shutoff Sensor Sensor Sensor CPD1-UP
Relay Oil
Solenoid (Optional) Pressure EGH1-UP
(Optional) Sensor Coolant
1MM1-UP Temperature
Sensor
2KS1-UP
2WS1-UP Inlet
3CS1-UP Air
Temperature
6NZ1-UP Sensor

7CZ1-UP

Fuel
Atmospheric Temperature
C-10 and C-12 Front Right Side View C-10 and C-12 Front Top View Pressure 3406E Right Side View 3406E Front View
Sensor
Sensor
2003 Caterpillar Printed in U.S.A.
All Rights Reserved C-15 and C-16 Front Top View

RENR2237-04
8 Page, JVD
 ELECTRONIC CONTROL MODULE (ECM)
ENGINE HARNESS CONNECTOR
P2 J2
J300 P300
L983-WH 12 L983-WH 44 INJECTOR COMMON CYLINDERS 1 & 2
L984-OR 10 L984-OR 45 INJECTOR COMMON CYLINDERS 3 & 4
L985-YL 8 L985-YL 46 INJECTOR COMMON CYLINDERS 5 & 6
A706-GY 6 A706-GY 55 INJECTOR CYLINDER 6
A705-BU 5 A705-BU 54 INJECTOR CYLINDER 5
A704-GN 4 A704-GN 39 INJECTOR CYLINDER 4
A703-BR 3 A703-BR 38 INJECTOR CYLINDER 3
A702-PU 2 A702-PU 37 INJECTOR CYLINDER 2
A701-GY 1 A701-GY 36 INJECTOR CYLINDER 1
J700-BR 11 J700-BR 10 RETARDER SOLENOID MED/HI
J701-GN 9 J701-GN 11 RETARDER SOLENOID LOW/HI
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR J702-BK 7 J702-BK 9 RETARDER SOLENOID COMMON
CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER 1
NO.1 NO.2 NO.3 NO.4 NO.5 NO.6 4
6
7
NOTE N 8
12
16
17
ENGINE RETARDER ENGINE RETARDER ENGINE RETARDER 19
SOLENOID CYLINDERS SOLENOID CYLINDERS SOLENOID CYLINDERS 20
1 & 2 NOTE H 5 & 6 NOTE H 3 & 4 NOTE H 21
25
26
G884-YL 15 INPUT #17
ENGINE
ENGINE BOOST PRESSURE GN C A746-PK A746-PK 40 ENGINE BOOST PRESSURE
BOOST
(+) BATTERY SUPPLY WIRES
ENGINE PRESSURE SENSOR COMMON YL B G829-GN A747-GY 14 ENGINE ATM PRESSURE
PRESSURE ENGINE PRESSURE SENSOR +5V OR A G828-WH 994-GY 24 ENGINE OIL PRESSURE
SENSOR 27
INPUT SIGNAL WIRES TO ECM P200 J200
28
G829-GN 3 ENGINE PRESSURE SENSOR COMMON
OUTPUT SIGNAL WIRES FROM ECM G828-WH 2 ENGINE PRESSURE SENSOR +5V
NOTE A
ENGINE ENGINE ATMOSPHERIC PRESSURE A747-GY
C AIR INLET 29
SENSOR SUPPLY VOLTAGE ATMOSPHERIC ENGINE PRESSURE SENSOR COMMON B G829-GN 30
PRESSURE SHUTOFF
ENGINE PRESSURE SENSOR +5V A G828-WH 31
SIGNAL PLUS SENSOR RELAY N/O (NOTE N)
J203 P203 34
TO +BATTERY TO AIR INLET 41
SIGNAL MINUS
SHUTOFF VALVE 43
ENGINE J201 P201 47
(-) BATTERY / SENSOR RETURN J502 P502
ENGINE OIL PRESSURE C 994-GY 50
OIL P700 J700
ENGINE PRESSURE SENSOR COMMON B G829-GN 1 J702-BK 51
PRESSURE ENGINE PRESSURE SENSOR +5V G828-WH 2 2 386-PK 13 AIR INLET SHUTOFF VALVE (NOTE N)
A
SENSOR NOTE A 1 386-PK NOTE N 52
NOTE N 386-PK 53
MOMENTARY 56
PUSHBUTTON CRANKSHAFT CRANK SPEED/TIMING- 1 E963-BK E963-BK 49 CRANK SPEED/TIMING NEGATIVE
POSITION SENSOR CRANK SPEED/TIMING+ 2 E964-WH E964-WH 48 CRANK SPEED/TIMING POSITIVE
TO +BATTERY 57
J401 P401 61
MANUAL AIR INLET
62
SHUTOFF SWITCH 63
CAMSHAFT CAM SPEED/TIMING- 1 E965-BU E965-BU 59 CAM SPEED/TIMING NEGATIVE
CIRCUITS WITHIN THIS AREA POSITION SENSOR CAM SPEED/TIMING+ 2 E966-YL E966-YL 58 CAM SPEED/TIMING POSITIVE
ARE RECOMMENDATIONS 64
J402 P402 65
ENGINE COOLANT ENGINE COOLANT TEMPERATURE 1 995-BU 995-BU 32 ENGINE COOLANT TEMPERATURE
TEMPERATURE SENSOR ENGINE TEMPERATURE SENSOR COMMON 2 G833-PK C967-BU 35 INLET AIR TEMPERATURE
A751-YL 33 ENGINE FUEL TEMPERATURE
J100 P100 66
G833-PK 18 ENGINE TEMPERATURE SENSOR COMMON
G832-OR 5 INPUT SENSOR COMMON #4
INLET AIR INLET AIR TEMPERATURE 1 C967-BU G827-BU 42 INPUT SENSOR COMMON #3
TEMPERATURE SENSOR ENGINE TEMPERATURE SENSOR COMMON 2 G833-PK 67
J103 P103 68
ENGINE TIMING CALIBRATION PROBE POSITIVE 1 G856-WH 22 ENGINE TIMING CALIBRATION PROBE POSITIVE
ENGINE TIMING CALIBRATION PROBE NEGATIVE 2 G857-YL 23 ENGINE TIMING CALIBRATION PROBE NEGATIVE
J400 P400 69
ENGINE FUEL ENGINE FUEL TEMPERATURE 1 A751-YL 70
TEMPERATURE SENSOR ENGINE TEMPERATURE SENSOR COMMON 2 G833-PK G883-GN 60 INPUT #16
J105 P105

NOTE A: CONNECTOR GENDER MAY BE REVERSED ON SOME VEHICLES. NOTE J: ENGINE BLOCK MUST HAVE A DIRECT WIRE CONNECTION
NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED. TO BATTERY(-). THIS CONNECTION CAN BE MADE AT THE ECM GND STRAP
NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE STARTER(-) TERMINAL OR MAINFRAME GROUND LUG
VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER
SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. NOTE L: SENSOR COMMON CONNECTION FOR INPUTS #1 THROUGH #8
THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS AND #11 MAY BE MADE TO EITHER J1-5 OR J1-18 TO ECM
OF EACH OTHER. FOR SPEEDOMETERS WITH A SINGLE SIGNAL INPUT J1-18 IS FOR BODY BUILDER/AFTERMARKET INSTALLATIONS MOUNTING
TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM BOLT
THE ECM MAY BE USED. NOTE M: J1922 AND J1939 DATA LINKS MUST BE PROGRAMMED FOR ECM TO ALL SWITCHES ARE SHOWN IN THE OFF POSITION
INTERACT ON DATA LINK, J1939 MUST NOT BE PROGRAMMED UNLESS USED UNLESS OTHERWISE SPECIFIED:
NOTE F: AN ELECTRONIC SIGNAL MAY BE PROVIDED IN PLACE OF A PASSIVE
IF PROGRAMMED WITHOUT PROPER CONNECTION A DIAGNOSTIC ALL WIRES TO BE 18 AWG OR LARGER SAE J1128 TYPE SXL
MAGNETIC SENSOR, THE ELECTRONIC SIGNAL INPUT WILL BE
CODE WILL RESULT OR EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708
CONNECTED TO THE +SIGNAL PIN.
NOTE H: A DASHED LINE INDICATES AN OPTIONAL FEATURE NOT AVAILABLE NOTE N: OPTION ONLY AVAILABLE ON C-10 AND C-12 ENGINES.
ON ALL SYSTEMS.

TYPICAL VEHICLE HARNESS WIRING DIAGRAM

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS
TO +BATTERY
N/O
RELAY
TO VEHICLE
COMPONENTS CHECK ENGINE LAMP L994-YL
OFF C L994-YL 28 CHECK ENGINE LAMP
B ON WARNING LAMP 659-PK 29 WARNING LAMP
S 659-PK
K998-BU 30 OUTPUT #1
START G880-PK 31 OUTPUT #9
R J906-BR 70 IGNITION KEY SWITCH
409-OR 62 PARK / NEUTRAL INTERLOCK
KEY SWITCH G882-WH 64 INPUT #13
G C974-PU 15
S PARK/NEUTRAL SPEEDOMETER SIGNAL+ C974-PU 36 SPEEDOMETER POSITIVE
INTERLOCK SWITCH NOTE E C973-GN 37
BAT MTR SIGNAL- C973-GN SPEEDOMETER NEGATIVE
TO +BATTERY NOTE H E718-PK 10 OUTPUT #2
ALTERNATOR E991-GY 12 OUTPUT #3
GROUND STARTER OFF POSITION G836-WH 13 OUTPUT #4
MOTOR 16
(12V) 43
TACHOMETER SIGNAL+ 450-YL
NOTE E 450-YL 38 TACHOMETER POSITIVE
NOTE H SIGNAL- 451-BR 451-BR 39 TACHOMETER NEGATIVE
CAB DIAGNOSTIC TOOL CONNECTOR G837-YL 11 OUTPUT #5
+BAT. C G838-BR 19 OUTPUT #6
COOLING FAN SOLENOID
-BAT. E G839-BU 20 OUTPUT #7
D G840-PU 21 OUTPUT #8
- 12V+ - 12V+ - 12V+ F 48
J1587 DL NEGATIVE B E793-BU E793-BU 9 J1587 DATA LINK NEGATIVE
J1587 DL POSITIVE A E794-YL E794-YL 8 J1587 DATA LINK POSITIVE
BATTERY 3 BATTERY 2 BATTERY 1 A249-BK 42 J1939 DATA LINK SHIELD (NOTE K & NOTE M)
TO J1939 DATA LINK CONNECTOR NOTE H K990-GN
TO J1939 DATA LINK CONNECTOR 34 J1939 DATA LINK NEGATIVE (NOTE K & NOTE M)
TO J1939 DATA LINK CONNECTOR K900-YL 50 J1939 DATA LINK POSITIVE (NOTE K & NOTE M)
NOTE J NOTE H E721-WH 1 J1922 DATA LINK POSITIVE (NOTE M)
TO J1922 DATA LINK CONNECTOR
TO J1922 DATA LINK CONNECTOR E720-PK 14 J1922 DATA LINK NEGATIVE (NOTE M)
51
ENGINE 55
BLOCK 14 AWG GXL 101-RD 52 UNSWITCHED +BATTERY (NOTE D)
14 AWG GXL 101-RD 53
20A UNSWITCHED +BATTERY (NOTE D)
14 AWG GXL 229-BK 65 -BATTERY
14 AWG GXL 229-BK 67 -BATTERY
G933-YL 27 INPUT #9
C453-YL 26 INPUT #10
SET/RESUME SWITCH 993-BR 3 INPUT SENSOR COMMON #2
F713-OR 17 INPUT #14
C978-BR C978-BR 35 SET
H795-PK C979-OR 44 RESUME
C979-OR
CRUISE CONTROL ON/OFF SWITCH K999-GN 56 INPUT #1 (NOTE L)
K980-PK 58 INPUT #2 (NOTE L)
H795-PK C975-WH C975-WH 59 CRUISE CONTROL ON/OFF SWITCH
K982-YL 60 INPUT #3 (NOTE L)
SERVICE BRAKE PEDAL POSITION SWITCH N/C G841-GN 7 INPUT #4 (NOTE L)
45.5mA MAX

H795-PK C992-PU C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH

(PEDAL RELEASED POSITION) L901-GY 18 INPUT SENSOR COMMON #1
G842-GY 47 INPUT #5 (NOTE L)
CLUTCH PEDAL POSITION SWITCH N/C G843-OR 6 INPUT #6 (NOTE L)
G844-PK 46 INPUT #7 (NOTE L)
H795-PK C977-BU C977-BU 22 CLUTCH PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) 57
LO
NOTE H E716-GY E716-GY 23 RETARDER SOLENOID LOW/HI SWITCH
MED
H795-PK ENGINE RETARDER G879-OR 2 +5V
HI
SOLENOID SELECTOR SWITCH C983-WH 49 ENGINE COOLANT LEVEL NORMAL (NOTE G)
ENGINE RETARDER LO
C984-YL 54 ENGINE COOLANT LEVEL LOW (NOTE G)
SOLENOID MED
E717-GN E717-GN 40 RETARDER SOLENOID MED/HI SWITCH
A/C HIGH PRESSURE SWITCH ON/OFF SWITCH HI
N/C 61
NOTE H 63
H795-PK E971-GN E971-GN 41 INPUT #11 (NOTE L)
G834-PU 24 INPUT #15 POSITIVE
PASSIVE G835-OR 25 INPUT #15 NEGATIVE
RENR2237-04

NOTE C MAGNETIC G808-BU 1 G808-BU 32 VEHICLE SPEED IN POSITIVE (NOTE F)

NOTE F VEHICLE SPEED G809-GN 2 G809-GN 33 VEHICLE SPEED IN NEGATIVE
SENSOR 69
G845-PU 68 INPUT #8 (NOTE L)
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON BK B H795-PK H795-PK 5 ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON
+8 V RD A C985-BU C985-BU 4 +8V
ACCELERATOR PEDAL POSITION WH C C986-BR C986-BR 66 ACCELERATOR PEDAL POSITION
8 Page, Color 2, JVD

SENSOR ACCELERATOR J403 P403 P1 J1

PEDAL POSITION
ELECTRONIC CONTROL MODULE (ECM)
VEHICLE HARNESS CONNECTOR
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED

Speed/Timing Sensor Connectors ECM AMP Connectors

IAPCV Connector

ECM Side ECM Connector P1 Harness Side

150 Series Plug

150 Series Receptacle

ECM Side Harness Side

ECM Connector P2

DT Connector Receptacle DT Connector Plug

Receptacle Wedge
Plug Wedge

Receptacle Wedge
Plug Wedge

Receptacle Wedge

Plug Wedge

HD Connector Receptacle HD Connector Plug

Pin Contact Socket Contact Sealing Plug

Diagnostic Code Listing

Flash Flash
PID-FMI Description PID-FMI Description
Codes Codes
0-00 No Detected Faults 55 105-03 Inlet Air Temp Sensor Open Circuit 38
1-11 Cylinder 1 Fault 72 105-04 Inlet Air Temp Sensor Short Circuit 38
2-11 Cylinder 2 Fault 72 105-11 Very High Intake Manifold Temp Warning 64
3-11 Cylinder 3 Fault 73 108-03 Atmospheric Pressure Sensor Open Circuit 26
4-11 Cylinder 4 Fault 73 108-04 Atmospheric Pressure Sensor Short Circuit 26
5-11 Cylinder 5 Fault 74 110-00 High Coolant Temp Warning 61
6-11 Cylinder 6 Fault 74 110-03 Coolant Temp Sensor Open Circuit 27
22-11 Cam Sensor to Crank Sensor Calibration 42 110-04 Coolant Temp Sensor Short Circuit 27
22-13 Check Timing Sensor Calibration 42 110-11 Very High Coolant Temp Warning 61
30-08 Invalid PTO Throttle Signal 29 111-01 Low Coolant Level Warning 62
30-13 PTO Throttle Sensor Calibration 29 111-02 Coolant Level Sensor Fault 12
41-03 8 Volt Supply Above Normal 21 111-11 Very Low Coolant Level 62
41-04 8 Volt Supply Below Normal 21 121-05 Retarder Solenoid Lo/Hi Open Circuit 14
43-02 Ignition Key Switch Fault 71 121-06 Retarder Solenoid Lo/Hi Short Circuit 14
52-11 Air Inlet Shutoff Shutdown 00 122-05 Retarder Solenoid Med/Hi Open Circuit 14
54-05 Multi-Function Output #6 Open Circuit 66 122-06 Retarder Solenoid Med/Hi Short Circuit 14
54-06 Multi-Function Output #6 Short Circuit 66 168-02 Low or Intermittent Battery Power to ECM 51
55-05 Multi-Function Output #7 Open Circuit 67 171-03 Outside Air Temp Sensor Open Circuit 00
55-06 Multi-Function Output #7 Short Circuit 67 171-04 Outside Air Temp Sensor Short Circuit 00
64-12 Loss of Engine Cam Sensor RPM Signal 34 171-11 No Ambient Air Temp Data 00
71-00 Idle Shutdown Override 01 174-00 High Fuel Temp Warning 65
71-01 Idle Shutdown Occurrence 47 174-03 Fuel Temp Sensor Open Circuit 13
71-14 PTO Shutdown Occurrence 47 174-04 Fuel Temp Sensor Short Circuit 13
84-00 Vehicle Overspeed Warning 41 190-00 Engine Overspeed Warning 35
84-01 Loss of Vehicle Speed Signal 31 190-12 Loss of Engine Crank Sensor RPM Signal 34
84-02 Invalid Vehicle Speed Signal 36 191-07 Transmission Not Responding 68
84-08 Vehicle Speed Out of Range 36 224-11 Theft Deterrent Enabled 00
84-10 Vehicle Speed Rate of Change 36 224-14 Emergency Cranking With Theft Deterrent Enabled 00
84-14 Quick Stop Occurrence 00 231-02 J1939 Required Data Not Received 58
91-08 Invalid Throttle Signal 32 231-12 J1939 Device Not Responding 58
91-13 Throttle Sensor Calibration 28 232-03 5 Volt Supply Above Normal 21
100-01 Low Oil Pressure Warning 46 232-04 5 Volt Supply Below Normal 21
100-03 Oil Pressure Sensor Open Circuit 24 246-11 Brake Switch #1 Fault 00
100-04 Oil Pressure Sensor Short Circuit 24 247-11 Brake Switch #2 Fault 00
100-11 Very Low Oil Pressure 46 249-11 J1922 Data Link Fault 58
102-00 Boost Pressure Sensor Stuck High 25 252-11 Incorrect Engine Software 59
102-03 Boost Pressure Sensor Open Circuit 25 253-02 Check Customer or System Parameters 56
102-04 Boost Pressure Sensor Short Circuit 25 253-11 Check Transmission Customer Parameters 56
105-00 High Inlet Air Temp Warning 64