BAIC Truck Engine Electrical System Service Manual PDF (EN)

Diagnostic Code Listing RENR7869 May 2005 Connector Tables for Harness 246-4947 P2 1 GROMMET 231-6517 2 STRAP 3S-2093 P100 QTY PART NAME P/N 1 PLUG_AS. 155-2269 1 WEDGE 155-2261 P300 160-7690 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG_AS. 155-2269 1 WEDGE 155-2261 P401 CLR-GA WIRE NAME POS TERM/PLUG BK-18 E963-E39 A 111-1567 WH-18 E964-E38 B 111-1567 ACCESSORY TABLE QTY PART NAME P/N 1 RECEPTACLE_AS. 100-3320 P200 CLR-GA WIRE NAME POS TERM/PLUG WH-18 G828-E3 A 180-9340 GN-18 G829-E7 B 180-9340 PK-18 A746-E25 C 180-9340 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG_AS.

155-2267 1 WEDGE 155-2276 P402 CLR-GA WIRE NAME POS TERM/PLUG BU-18 E965-E37 A 111-1567 YL-18 E966-E36 B 111-1567 ACCESSORY TABLE QTY PART NAME P/N 1 RECEPTACLE_AS. 111-2416 246-4475 P201 CLR-GA WIRE NAME POS TERM/PLUG BR-18 G826-E26 A 180-9340 P500 CLR-GA WIRE NAME POS TERM/PLUG PK-18 G854-E45 1 180-9340 PU-18 G855-E46 2 180-9340 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG_AS. 155-2269 1 WEDGE 155-2261 A B J K I L C7 Truck Engine Electrical System 1 PLUG_AS. 155-2269 1 WEDGE 155-2261 C D G N H P203 CLR-GA WIRE NAME POS TERM/PLUG 1 PLUG_AS.

155-2267 1 WEDGE 155-2276 E F M 246-4476 I J K A B L H N C FML1-UP FMM1-UP G E F M D P648 P209 Harness identification code This example indicates wire 135 in harness "AG".

Harness And Wire Symbols 116-6158 237-0227 100-3320 Connector Reference Designator B A A B 1 2 3 GRAY P274 1117898 J274 3E5179 P174 1306795 J174 1306795 Part Number For Connector Assembly 325-AG135 PK-14 Receptacle Plug 1 325-A135 PK-14 3E-3370 155-2267 111-2416 Pin Socket Fuse Wire Color Wire Gauge 2 Connector Tables for Harness 246-4948 B A B A B A Single Wire Ground Connection Connector Pin or Socket Number J300 CLR-GA WIRE NAME POS TERM/PLUG GY-16 A701-A1 A - P301 NOTE X CLR-GA WIRE NAME POS TERM/PLUG GY-16 A701-A1 A 154-2389 P303 NOTE X CLR-GA WIRE NAME POS TERM/PLUG BR-16 A703-A5 A 154-2389 P305 NOTE X CLR-GA WIRE NAME POS TERM/PLUG BU-16 A705-A9 A 154-2389 C C Circuit Number Identification 200-L32 BK-14 105-9344 153-9693 NOTE X 155-2269 3E-3364 Component Part Number P302 NOTE X CLR-GA WIRE NAME POS TERM/PLUG PU-16 A702-A3 A 154-2389 P304 NOTE X CLR-GA WIRE NAME POS TERM/PLUG GN-16 A704-A7 A 154-2389 P306 NOTE X CLR-GA WIRE NAME POS TERM/PLUG GY-16 A706-A11 A 154-2389 B B 2 1 2 1 A 2005 Caterpillar All Rights Reserved Printed in U.S.A.

© RENR7869-00 8 Page PID-FMI Flash Description PID-FMI Flash Description N/A 001-11 Code 55 72 No Diagnostic Code Detected Cylinder #1 Injector current fault 105-00 105-03 Code 64 38 High Intake Manifold Air Temperature Warning Intake Manifold Air Temperature voltage high 002-11 003-11 72 73 Cylinder #2 Injector current fault Cylinder #3 Injector current fault 105-04 105-11 38 64 Intake Manifold Air Temperature voltage low Very High Intake Manifold Air Temperature 004-11 005-11 006-11 73 74 74 Cylinder #4 Injector current fault Cylinder #5 Injector current fault Cylinder #6 Injector current fault 108-03 108-04 110-00 26 26 61 Barometric Pressure voltage high Barometric Pressure voltage low High Coolant Temperature Warning 022-11 022-13 42 42 Primary to Secondary Engine Speed Signal Calibration Engine Speed Signal Calibration Not Performed 110-03 110-04 27 27 Coolant Temperature voltage high Coolant Temperature voltage low 030-08 29 PTO Throttle signal invalid 110-11 61 Very High Coolant Temperature 030-13 29 PTO Throttle out of calibration 111-01 62 Low Coolant Level Warning 032-05 33 Turbo Wastegate Solenoid current low 111-02 12 Coolant Level signal invalid 032-06 032-11 041-03 041-04 042-11 043-02 33 33 21 21 18 71 Turbo Wastegate Solenoid current high Turbo Wastegate Solenoid current mismatch 8 Volt Supply voltage high 8 Volt Supply voltage low Injection Actuation Pressure output fault Key Switch Fault 111-03 111-04 111-11 164-00 164-02 164-03 12 12 62 17 15 15 Coolant Level voltage high Coolant Level voltage low Very Low Coolant Level Excessive Injection Actuation Pressure Injection Actuation Pressure Signal Erratic Injection Actuation Pressure Voltage High 064-02 064-08 064-11 070-05 070-06 071-00 071-01 34 34 34 49 49 01 47 Secondary Engine Speed loss of signal Secondary Engine Speed loss of signal Secondary Engine Speed no pattern Inlet Air Heater current low Inlet Air Heater current high Idle Shutdown Override Idle Shutdown 164-04 164-11 168-00 168-01 168-02 173-00 173-11 15 39 17 51 51 16 16 Injection Actuation Pressure Voltage Low Injection Actuation Pressure system fault Excessive ECM Battery Power Low ECM Battery Power ECM Battery Power Intermittent High Exhaust Gas Temperature Derate Very High Exhaust Gas Temperature Derate 071-14 084-00 47 41 PTO Shutdown Vehicle Overspeed Warning 186-04 186-14 00 47 PTO Engine Shutdown Switch Voltage Low PTO Engine Shutdown Switch Occurrence 084-01 31 Vehicle Speed loss of signal 190-00 35 Engine Overspeed Warning 084-02 084-08 36 36 Vehicle Speed signal invalid Vehicle Speed signal out of range 190-02 190-08 34 34 Primary Engine Speed loss of signal Primary Engine Speed loss of signal 084-10 084-14 091-08 36 00 32 Vehicle Speed signal rate of change Quick Stop Occurrence Throttle Position Invalid 190-11 224-11 224-14 34 00 00 Primary Engine Speed no pattern Theft Deterrent Active Theft Deterrent Active with Engine Cranking 091-13 100-01 100-03 28 46 24 Throttle Position out of Calibration Low Oil Pressure Warning Oil Pressure voltage high 231-02 231-12 231-14 58 58 57 J1939 Data Incorrect J1939 Data Link Not Responding Transmission Data Link Derate 100-04 24 Oil Pressure voltage low 232-03 21 5 Volt Supply voltage high 100-11 46 Very Low Oil Pressure 232-04 21 5 Volt Supply voltage low 102-01 102-02 25 25 Low Boost Pressure Boost Pressure signal erratic 246-11 247-11 00 00 Brake Pedal Switch #1 Fault Brake Pedal Switch #2 Fault 102-03 25 Boost Pressure voltage high 252-11 59 Engine Software Incorrect 102-04 25 Boost Pressure voltage low 253-02 56 Check Customer or System Parameters 102-07 25 Boost Pressure not responding 253-14 56 Truck Manufacturer Parameter Not Programmed CLR-GA WIRE NAME POS 1 TERM/PLUG 8T-8737 WH-18 GN-18 G828-E1 G829-E5 2 3 180-9340 180-9340 4 5 6 7 8T-8737 8T-8737 8T-8737 8T-8737 BU-18 G850-E9 8 9 10 11 180-9340 8T-8737 8T-8737 8T-8737 GY-18 A747-E10 12 13 14 8T-8737 8T-8737 180-9340 15 8T-8737 16 8T-8737 PK-18 C991-E51 17 180-9340 PK-18 G833-E11 18 19 180-9340 8T-8737 GY-18 BR-18 994-E16 G849-E17 20 21 22 23 24 25 26 27 28 8T-8737 8T-8737 8T-8737 8T-8737 180-9340 180-9340 8T-8737 8T-8737 8T-8737 BU-18 GN-18 BU-18 GY-18 PU-18 BR-18 995-E18 Y772-E19 C967-E20 A701-E21 A702-E22 A703-E23 29 30 31 32 33 34 35 36 37 38 8T-8737 8T-8737 8T-8737 180-9340 8T-8737 180-9340 180-9340 180-9340 180-9340 180-9340 GN-18 PK-18 BR-18 BU-18 A704-E24 A746-E25 G826-E15 G827-E48 39 40 41 42 180-9340 180-9340 180-9340 180-9340 43 8T-8737 WH-18 OR-18 YL-18 L983-E27 L984-E32 L985-E33 44 45 46 180-9340 180-9340 180-9340 WH-18 BK-18 E964-E38 E963-E39 47 48 49 8T-8737 180-9340 180-9340 50 51 8T-8737 8T-8737 BU-18 GY-18 A705-E40 A706-E41 52 53 54 55 8T-8737 8T-8737 180-9340 180-9340 56 57 8T-8737 8T-8737 YL-18 BU-18 E966-E36 E965-E37 58 59 180-9340 180-9340 PK-18 PU-18 G854-E45 G855-E46 60 61 62 8T-8737 180-9340 180-9340 WH-18 M795-E99 63 180-9340 BK-18 C211-E98 64 65 180-9340 8T-8737 66 8T-8737 67 8T-8737 68 8T-8737 69 70 8T-8737 8T-8737 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG AS.

160-7690 CLR-GA BU-18 WIRE NAME 995-E18 POS 1 TERM/PLUG 180-9340 PK-18 G833-E12 2 180-9340 ACCESSORY TABLE CLR-GA GY-18 WIRE NAME A701-E21 POS A TERM/PLUG - PU-18 BR-18 A702-E22 A703-E23 B C - - GN-18 BU-18 GY-18 YL-18 A704-E24 A705-E40 A706-E41 L985-E35 D E F G - - - - YL-18 OR-18 OR-18 WH-18 L985-E34 L984-E30 L984-E31 L985-E29 H I J K - - - - WH-18 L985-E28 L M N - - - ACCESSORY TABLE QTY PART NAME P/N 1 PLUG AS. 246-4475 J102 CLR-GA WIRE NAME POS TERM/PLUG GN-18 Y772-E19 1 180-9339 PK-18 G833-E14 2 180-9339 ACCESSORY TABLE QTY PART NAME P/N 1 RECEPTACLE_AS.

3E-3364 1 WEDGE 3E-3365 P103 CLR-GA BU-18 PK-18 WIRE NAME C967-E20 G833-E13 POS 1 2 TERM/PLUG 180-9340 180-9340 BU-18 G827-E47 B 180-9340 GY-18 994-E16 C 180-9340 ACCESSORY TABLE QTY PART NAME P/N 1 1 PLUG_AS. WEDGE 155-2267 155-2276 CLR-GA RD-18 BU-18 WIRE NAME C987-E44 G850-E43 POS 1 2 TERM/PLUG 180-9340 180-9340 ACCESSORY TABLE QTY PART NAME P/N WH-18 GN-18 G828-E2 G829-E8 A B 180-9340 180-9340 GY-18 A747-E10 C 180-9340 ACCESSORY TABLE QTY PART NAME P/N P511 CLR-GA WIRE NAME POS TERM/PLUG WH-18 M795-E99 1 180-9340 BK-18 C211-E98 2 180-9340 ACCESSORY TABLE QTY PART NAME P/N 1 1 PLUG_AS.

WEDGE 155-2269 155-2261 CLR-GA WH-18 WIRE NAME G828-E4 POS A TERM/PLUG 180-9339 GN-18 BR-18 G829-E6 G849-E17 B C 180-9339 180-9339 ACCESSORY TABLE QTY PART NAME P/N 1 1 RECEPTACLE_AS. WEDGE 3E-3370 3E-3371 CLR-GA RD-18 WIRE NAME C987-E44 POS A TERM/PLUG 116-6159 BU-18 G850-E42 B 116-6159 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG AS. 116-6158 2 _ SEAL 100-6674 1 RETAINER 111-2422 CLR-GA WIRE NAME POS TERM/PLUG BR-18 G826-E50 A 180-9340 BU-18 G827-E49 B 180-9340 PK-18 C991-E51 C 180-9340 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG_AS.

237-0227 PU-16 BR-16 GN-16 BU-16 A702-A3 A703-A5 A704-A7 A705-A9 B C D E - - - - GY-16 A706-A11 F - YL-16 L985-A10 G - YL-16 OR-16 OR-16 WH-16 L985-A12 L984-A6 L984-A8 L983-A2 H I J K - - - - WH-16 L983-A4 L - M N ACCESSORY TABLE QTY PART NAME P/N 1 RECEPTACLE AS.

246-4476 WH-16 L983-A2 B 154-2389 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG 153-9693 1 SEAL 154-0877 1 CLIP 154-3769 OR-16 L984-A6 B 154-2389 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG 153-9693 1 SEAL 154-0877 1 CLIP 154-3769 YL-16 L985-A10 B 154-2389 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG 153-9693 1 SEAL 154-0877 1 CLIP 154-3769 WH-16 L983-A4 B 154-2389 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG 153-9693 1 SEAL 154-0877 1 CLIP 154-3769 OR-16 L984-A8 B 154-2389 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG 153-9693 1 SEAL 154-0877 1 CLIP 154-3769 YL-16 L985-A12 B 154-2389 ACCESSORY TABLE QTY PART NAME P/N 1 PLUG 153-9693 1 SEAL 154-0877 1 CLIP 154-3769

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A703-A5 BR-16 A702-A3 PU-16 A701-A1 GY-16 ENGINE HARNESS WIRING DIAGRAM A704-A7 GN-16 A705-A9 BU-16 INJECTOR HARNESS CONNECTOR CYLINDER INJECTOR #2 CYLINDER INJECTOR #3 CYLINDER INJECTOR #4 CYLINDER INJECTOR #5 CYLINDER INJECTOR #6 CYLINDER INJECTOR #1 P300 J300 2464475 P2 1607690 ENGINE CONTROL MODULE A B NOTE X A B NOTE X A B NOTE X A B NOTE X A B NOTE X A B NOTE X A706-A11 GY-16 A705-A9 BU-16 A704-A7 GN-16 A703-A5 BR-16 A702-A3 PU-16 A701-A1 GY-16 2464476 A B A701-E21 GY-18 A702-E22 PU-18 A703-E23 BR-18 A704-E24 GN-18 A705-E40 BU-18 A706-E41 GY-18 A702-E22 PU-18 A701-E21 GY-18 G828-E1 WH-18 G829-E5 GN-18 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 PRESSURE SENSOR +5V PRESSURE SENSOR RETURN P301 1539693 P302 1539693 P303 1539693 P304 1539693 P305 1539693 P306 1539693 A706-A11 GY-16 C D E F G H I J K L M N A704-E24 GN-18 A705-E40 BU-18 A703-E23 BR-18 A706-E41 GY-18 L985-A10 YL-16 L985-A10 YL-16 L985-A12 YL-16 L984-A6 OR-16 L984-A8 OR-16 L983-A2 WH-16 L983-A4 WH-16 L983-A2 WH-16 L983-A4 WH-16 L984-A6 OR-16 L985-A12 YL-16 L983-E28 WH-18 L983-E29 WH-18 L984-E31 OR-18 L984-E30 OR-18 L985-E34 YL-18 L985-E35 YL-18 L983-E29 WH-18 L983-E28 WH-18 G850-E9 BU-18 INLET AIR HEATER RELAY L984-A8 OR-16 L984-E30 OR-18 L983-E27 WH-18 A747-E10 GY-18 ATMOSPHERIC PRESSURE P401 1003320 L984-E31 OR-18 L984-E32 OR-18 1 C991-E51 PK-18 TEMPERATURE SENSOR RETURN FUEL PRESSURE PRIMARY(TOP) A B E963-E39 BK-18 E964-E38 WH-18 L985-E35 YL-18 L985-E34 YL-18 L985-E33 YL-18 G833-E11 PK-18 ENGINE SPEED/TIMING SENSORS 236-6221 SECONDARY(BOTTOM) A B P402 1112416 E965-E37 BU-18 E963-E39 BK-18 994-E16 GY-18 ENGINE OIL PRESSURE INJECTION ACT.

PRESSURE TIMING CALIBRATION(-) TIMING CALIBRATION(+) P500 1552269 INJECTION ACTUATION PRESSURE CONTROL VALVE G855-E46 PU-18 G854-E45 PK-18 G855-E46 PU-18 G854-E45 PK-18 E966-E36 YL-18 E964-E38 WH-18 E965-E37 BU-18 E966-E36 YL-18 G849-E17 BR-18 (+) BATTERY SWITCHED (+) BATTERY 1 2 (-) BATTERY / SENSOR RETURN STARTING CIRCUIT +5V RETURN SIGNAL OR-18 YL-18 GN-18 A B C J204 3E3370 G828-E4 WH-18 G829-E6 GN-18 Y772-E19 GN-18 A746-E25 PK-18 A747-E10 GY-18 C967-E20 BU -18 995-E18 BU-18 Y772-E19 GN-18 INTAKE MANIFOLD AIR TEMP.

AMBIENT AIR TEMPERATURE ENGINE COOLANT TEMPERATURE SENSOR / ACTUATOR SUPPLY SIGNAL PLUS TO ECM INJECTION ACTUATION PRESSURE SENSOR 224-4536 G849-E17 BR-18 G828-E1 WH-18 G828-E2 WH-18 A702-E22 PU-18 A701-E21 GY-18 A703-E23 BR-18 INJECTOR CYL 1 INJECTOR CYL 3 INJECTOR CYL 2 SIGNAL MINUS TO ECM CONTROL PLUS FROM ECM CONTROL MINUS FROM ECM +5V RETURN SIGNAL A B C P201 1552267 G826-E26 BR-18 G828-E3 WH-18 G828-E4 WH-18 A704-E24 GN-18 G827-E48 BU-18 G826-E15 BR-18 A746-E25 PK-18 BOOST PRESSURE ENGINE OIL PRESSURE (+5V) ENGINE OIL PRESSURE RETURN INJECTOR CYL 4 DATA LINK PLUS DATA LINK MINUS ENGINE OIL PRESSURE SENSOR 161-1705 G827-E47 BU-18 994-E16 GY-18 G826-E26 BR -18 G826-E50 BR -18 G826-E15 BR -18 L983-E27 WH-18 L984-E32 OR-18 INJECTOR COMMON CYL 3&4 INJECTOR COMMON CYL 5&6 INJECTOR COMMON CYL 1&2 FUEL PRESSURE SENSOR 248-2167 +5V RETURN SIGNAL 1 2 3 P209 2370227 G826-E50 BR-18 G827-E49 BU-18 G829-E5 GN-18 1 L985-E33 YL-18 E963-E39 BK-18 E964-E38 WH-18 SPEED/TIMING TOP(+) SPEED/TIMING TOP(-) 1552267 P203 C991-E51 PK-18 G829-E7 GN-18 G829-E8 GN-18 G829-E6 GN-18 ATMOSPHERIC PRESSURE SENSOR 161-1703 +5V RETURN SIGNAL A B C A747-E10 GY-18 G829-E8 GN-18 G828-E2 WH-18 G827-E47 BU -18 G827-E49 BU -18 G827-E48 BU -18 1 A705-E40 BU-18 A706-E41 GY-18 INJECTOR CYL 6 INJECTOR CYL 5 3E3364 J102 G833-E11 PK-18 E965-E37 BU-18 E966-E36 YL-18 SPEED/TIMING BOTTOM(+) SPEED/TIMING BOTTOM(-) AMBIENT AIR TEMPERATURE SENSOR 191-6587 BK-18 BK-18 +5V RETURN 1 2 P200 1552267 Y772-E19 GN-18 G833-E14 PK-18 G833-E13 PK-18 G833-E14 PK-18 G833-E12 PK-18 1 G855-E46 PU-18 C211-E98 BK-18 M795-E99 WH-18 G854-E45 PK-18 IAP CONTROL VALVE(+) IAP CONTROL VALVE(-) TURBO WASTEGATE(+) TURBO WASTEGATE(-) K995-OR BOOST PRESSURE SENSOR 161-1704 +5V RETURN SIGNAL A B C G829-E7 GN-18 G828-E3 WH-18 C991-E51 PK-18 C967-E20 BU-18 INLET AIR HEATER RELAY 175-2300 209-5581 P501 1552269 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 130-9811 P103 1552269 A746-E25 PK-18 G849-E17 BR-18 995-E18 BU -18 994-E16 GY -18 ECM GND STRAP SIGNAL RETURN 1 2 P100 1552269 P648 1166158 C987-E44 RD-18 G850-E43 BU-18 G850-E9 BU-18 1 2 C967-E20 BU-18 G833-E13 PK-18 G850-E9 BU-18 INLET AIR HEATER A B G850-E42 BU-18 C987-E44 RD-18 ENGINE COOLANT TEMPERATURE SENSOR 130-9811 SIGNAL RETURN 1 2 995-E18 BU -18 G833-E12 PK-18 M795-E99 WH-18 C211-E98 BK-18 TO ECM MOUNTING BOLT INLET AIR HEATER GROUND STRAP P511 1552269 G850-E9 BU-18 TURBO WASTEGATE SOLENOID 230-9944 C211-E98 BK-18 M795-E99 WH-18 STAINLESS STEEL BRAIDING RUNS THROUGHOUT THE ENTIRE 246-4947 HARNESS.

THE STAINLESS STEEL BRAIDING IS GROUNDED AT THE BACK OF THE TURBO WASTEGATE SOLENOID CONNECTOR P511.

INLET AIR HEATER LAMP J648 B A C987-RD TYPICAL VEHICLE HARNESS WIRING DIAGRAM CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS N/O RELAY K995-OR C987-RD CHECK ENGINE LAMP L994-YL P1 1607689 ENGINE CONTROL MODULE KEY SWITCH 659-PK START ON OFF FAST IDLE ENABLED LAMP OR WAIT TO START LAMP WARNING LAMP 659-PK L994-YL 29 28 WARNING LAMP CHECK ENGINE LAMP G880-PK G880-PK K998-BU 30 31 14 61 10 12 13 15 16 1 OUTPUT #1 OUTPUT #9 FLYBACK DIODE EXHAUST BRAKE SOLENOID EXHAUST BRAKE ON/OFF SWITCH E718-PK E991-GY G836-WH OUTPUT #2 OUTPUT #3 OUTPUT #4 C973-GN SIGNAL+ C974-PU C974-PU C981-GY 36 37 27 26 3 17 SPEEDOMETER POSITIVE EXHAUST BRAKE ON/OFF SWITCH ALTERNATOR GROUND STARTER MOTOR 9 PIN CAB CONNECTOR NOTE Z SPEEDOMETER SIGNAL- C973-GN SPEEDOMETER NEGATIVE +BAT.

-BAT.

A B TACHOMETER SIGNAL+ SIGNAL- 450-YL 451-BR 993-BR F713-OR 450-YL 451-BR TACHOMETER POSITIVE TACHOMETER NEGATIVE 38 39 57 43 INPUT SENSOR COMMON #2 INPUT #14 J1587 - J1587 + J H G F E D C E793-BU E794-YL E793-BU E794-YL A249-BK K990-GN K900-YL 9 8 42 34 50 J1587 DATA LINK NEGATIVE J1587 DATA LINK POSITIVE J1939 DATA LINK SHIELD J1939 DATA LINK NEGATIVE J1939 DATA LINK POSITIVE IGNITION KEY SWITCH BATTERY 3 BATTERY 1 - 12V + - 12V + + 12V - BATTERY 2 J1939 - J1939 SHIELD J1939 + A249-BK K990-GN K900-YL J906-BR 10A 10A 10A 10A 14 AWG GXL 14 AWG GXL 101-RD 101-RD 14 AWG GXL 14 AWG GXL UNSWITCHED +BATTERY UNSWITCHED +BATTERY 52 48 70 UNSWITCHED +BATTERY UNSWITCHED +BATTERY TO ALLISON AT/MT/HT SHIFT MODULATOR FOR AUTOMATIC TRANSMISSIONS 14 AWG GXL 14 AWG GXL 14 AWG GXL -BATTERY 229-BK 101-RD 101-RD 229-BK 53 55 63 65 67 69 20 19 ENGINE BLOCK 229-BK 14 AWG GXL -BATTERY 229-BK G838-BR G839-BU -BATTERY -BATTERY OUTPUT #6 OUTPUT #7 H795-PK C978-BR C979-OR C978-BR C979-OR K999-GN K980-PK L902-GN G840-PU 35 44 56 58 40 21 SET RESUME INPUT #1 (PTO ON/OFF SWITCH) INPUT #2 INPUT #18 OUTPUT #8 SET/RESUME SWITCH H795-PK FAST IDLE ENABLE SWITCH L902-GN N/O MOMENTARY SWITCH CRUISE CONTROL ON/OFF SWITCH H795-PK C975-WH SERVICE BRAKE PEDAL POSITION SWITCH N/C C975-WH K982-YL G841-GN 59 60 7 CRUISE CONTROL ON/OFF SWITCH INPUT #3 INPUT #4 (PEDAL RELEASED POSITION) H795-PK C992-PU +BAT.

SERVICE BRAKE PEDAL POSITION SWITCH #2 N/O G882-WH C992-PU G842-GY G882-WH G843-OR 45 25 47 64 6 SERVICE BRAKE PEDAL POSITION SWITCH INPUT #5 INPUT #13 INPUT #6 (PEDAL RELEASED POSITION) CLUTCH PEDAL POSITION SWITCH N/C H795-PK C977-BU (PEDAL RELEASED POSITION) L901-GY C977-BU 18 22 23 2 46 49 54 INPUT SENSOR COMMON #1 CLUTCH PEDAL POSITION SWITCH DIAGNOSTIC ENABLE SWITCH H795-PK G844-PK G844-PK INPUT #19 M990-OR C983-WH C984-YL G879-OR +5V INPUT #7 ENGINE COOLANT LEVEL NORMAL ENGINE COOLANT LEVEL LOW RENR7869-00 8 Page, Color 2 A/C HIGH PRESSURE SWITCH N/C N/O MOMENTARY SWITCH +BAT.

(TRANSMISSION IN GEAR) TRANSMISSION NEUTRAL SWITCH N/O 409-OR 62 24 409-OR INPUT #12 H795-PK E971-GN PASSIVE MAGNETIC VEHICLE SPEED SENSOR G808-BU G809-GN 1 2 E971-GN 41 51 32 33 68 H795-PK C985-BU C986-BR G837-YL G808-BU G809-GN INPUT #11 VEHICLE SPEED IN POSITIVE VEHICLE SPEED IN NEGATIVE INPUT #8 (REMOTE PTO ACCELERATOR) COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED/OEM INSTALLED ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION BK RD WH B A C H795-PK C985-BU C986-BR G845-PU 5 4 66 11 AP SENSOR/SWITCH COMMON +8V ACCELERATOR PEDAL POSITION OUTPUT #5 ACCELERATOR PEDAL POSITION SENSOR J403 P403 COOLING FAN SOLENOID ARC SUPPRESSOR Injection Actuation Pressure Sensor J204 Injector Harness Connector P300/J300 (Behind Intake Manifold) Intake Manifold Air Temperature Sensor P103 Atmospheric Pressure Sensor P203 Boost Pressure Sensor P200 Ambient Air Temperature Sensor J102 (Behind Plate not shown) Inlet Air Heater Lamp Connector P648 Inlet Air Heater Relay P501 Injection Actuation Pressure Control Valve P500 Fuel Pressure Sensor P209 (not shown) Turbo Wastegate Solenoid P511 Primary Engine Speed / Timing Sensor (Top) P401 Secondary Engine Speed / Timing Sensor (Bottom) P402 Engine Coolant Temperature Sensor P100 Engine Oil Pressure Sensor P201 P2/J2 Engine Control Module J1 Turbo Wastegate Solenoid P511 Injector Harness Connector P300 Connector and Splice Locations for Harness 246-4947 Injection Actuation Pressure Sensor J204 Injection Actuation Pressure Control Valve P500 Inlet Air Heater Relay P501 Engine Coolant Temperature Sensor P100 Engine Oil Pressure Sensor P201 Boost Pressure Sensor P200 STAINLESS STEEL BRAIDING RUNS THROUGHOUT THE ENTIRE 246-4947 HARNESS.

THE STAINLESS STEEL BRAIDING IS GROUNDED AT THE BACK OF THE TURBO WASTEGATE SOLENOID CONNECTOR P511. G829-GN Splice G828-WH Splice G833-PK Splice L985-YL Splice G850-BU Splice L984-OR Splice L983-WH Splice G826-BR Splice Engine Control Module P2 G827-BU Splice Intake Manifold Air Temperature Sensor P103 Ambient Air Temperature Sensor J102 Inlet Air Heater Lamp Connector P648 Secondary Engine Speed / Timing Sensor (Bottom) P402 Primary Engine Speed / Timing Sensor (Top) P401 Atmospheric Pressure Sensor P203 Fuel Pressure Sensor P209 THIS SCHEMATIC IS FOR THE C7 TRUCK ENGINE (S/N: FML & FMM) IDENT HARNESS CHG E 246-4947 04 (J2 / ENGINE) A 246-4948 01 (INJECTOR) NOTE X:

USE KIT 156-7106 WHEN REPLACING CONNECTOR 153-9693. REFER TO REHS1809 FOR REPAIR AND INSTALLATION DETAILS. NOTE Z: THE CONNECTOR ON THIS SCHEMATIC IS BLACK AND CONNECTS DIRECTLY TO SERVICE TOOL CABLE 157-4829. THE DIAGNOSTIC CONNECTOR NOT SHOWN HAS +BATTERY ON PIN (A) AND -BATTERY ON PIN (B). THIS CONNECTOR IS GRAY AND CONNECTS TO SERVICE TOOL CABLE 139-4166. 1 2 Related Electrical Service Manuals Title Form Number al Troubleshooting Guide SENR9808 s Operation / Testing and Adjusting SENR9812

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