Cat C11-C13-C15-C18 MANUAL DE CALIBRACIONES

Download as pdf or txt
Download as pdf or txt
You are on page 1of 27

345C Excavator TAJ00001-UP (MACHINE) POWERED BY C13 Engine(SEBP4347 - 12) - Estructura del documento

Cerrar SIS

Pantalla anterior

Producto: EXCAVATOR
Modelo: 345C EXCAVATOR TAJ
Configuración: 345C Excavator TAJ00001-UP (MACHINE) POWERED
BY C13 Engine

Pruebas y Ajustes
C11 and C13 Engines for Caterpillar Built Machines
Número de medio -SENR9888-05 Fecha de publicación -01/10/2006 Fecha de actualización -27/10/2006

i02793330

Engine Valve Lash - Inspect/Adjust


SMCS - 1102-025

To prevent possible injury, do not use the starter to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the engine to
cool before measuring valve clearance.
----------------------

This engine uses high voltage to control the fuel injectors.

Disconnect electronic fuel injector enable circuit connector to prevent personal


injury.

Do not come in contact with the fuel injector terminals while the engine is
running.
----------------------
Note: Valve lash is measured between the rocker arm and the bridge for the inlet valves. Valve lash is measured between
the rocker arm and the valve stem for the exhaust valve. All of the clearance measurements and the adjustments must be
made with the engine stopped. The valves must be fully closed.

Valve Lash Check


Table 1

Inlet Valves Exhaust Valves

0.38 ± 0.08 mm (0.0150 ± 0.0031


Valve Lash Check (Stopped Engine) 0.64 ± 0.08 mm (0.0252 ± 0.0031
inch) inch)

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_p...&calledpage=/sisweb/sisweb/techdoc/techdoc_print_page.jsp (1 de 5)21/10/2007 9:38:40


345C Excavator TAJ00001-UP (MACHINE) POWERED BY C13 Engine(SEBP4347 - 12) - Estructura del documento

TC Compression Stroke 1-2-4 1-3-5

TC Exhaust Stroke (1) 3-5-6 2-4-6

Firing Order 1-5-3-6-2-4 (2)


(1) 360° from TC compression stroke
(2) The No. 1 cylinder is at the front of the engine.

An adjustment is not necessary if the measurement of the valve lash is in the acceptable range. Adjust the valve lash while
the engine is stopped. The range is specified in Table 2.

If the measurement is not within this range adjustment is necessary. See Testing And Adjusting, "Valve Lash And Valve
Bridge Adjustment".

Illustration 1 g01193938
Cylinder and Valve location

(A) Exhaust valves

(B) Inlet valves

Valve Lash and Valve Bridge Adjustment

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_p...&calledpage=/sisweb/sisweb/techdoc/techdoc_print_page.jsp (2 de 5)21/10/2007 9:38:40


345C Excavator TAJ00001-UP (MACHINE) POWERED BY C13 Engine(SEBP4347 - 12) - Estructura del documento

Illustration 2 g01229786
(1) Exhaust rocker arm

(2) Inlet valve bridge

(3) Rocker arm adjustment screw locknut for the exhaust rocker arm

(4) Rocker arm adjustment screw for the exhaust rocker arm

Table 2

Valve Lash

Valves Dimension of Gauge

Inlet 0.38 ± 0.08 mm (0.0150 ± 0.0031 inch)

Exhaust 0.64 ± 0.08 mm (0.0252 ± 0.0031 inch)

Adjust the valve lash while the engine is stopped. Use the following procedure to adjust the valves:

1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and Adjusting, "Finding
Top Center Position for No. 1 Piston".

Table 3

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_p...&calledpage=/sisweb/sisweb/techdoc/techdoc_print_page.jsp (3 de 5)21/10/2007 9:38:40


345C Excavator TAJ00001-UP (MACHINE) POWERED BY C13 Engine(SEBP4347 - 12) - Estructura del documento

TC Compression Stroke Inlet Valves Exhaust Valves

Valve Lash 0.38 ± 0.08 mm (0.0150 ± 0.0031


0.64 ± 0.08 mm (0.0252 ± 0.0031 inch)
inch)

Cylinders 1-2-4 1-3-5

2. Adjust the valve lash according to Table 4.

a. Lightly tap the rocker arm at the top of the adjustment screw with a soft mallet. This will ensure that the lifter
roller seats against the camshaft's base circle.

b. Loosen the adjustment locknut.

c. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the adjustment screw
in a clockwise direction. Slide the feeler gauge between the rocker arm and the valve bridge. Continue
turning the adjustment screw until a slight drag is felt on the feeler gauge. Remove the feeler gauge.

d. Tighten the adjustment locknut to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow the adjustment screw to
turn while you are tightening the adjustment locknut. Recheck the valve lash after tightening the adjustment
locknut.

3. Remove the timing bolt and turn the flywheel by 360 degrees in the direction of engine rotation. This will put the
No. 6 piston at the top center position on the compression stroke. Install the timing bolt in the flywheel.

Table 4

TC Exhaust Stroke (3) Inlet Valves Exhaust Valves

Valve Lash 0.38 ± 0.08 mm (0.0150 ± 0.0031 inch)


0.64 ± 0.08 mm (0.0252 ± 0.0031 inch)

Cylinders 3-5-6 2-4-6


(3) Position for No. 1 cylinder

4. Adjust the valve lash according to Table 5.

a. Lightly tap the rocker arm at the top of the adjustment screw with a soft mallet. This will ensure that the lifter
roller seats against the camshaft's base circle.

b. Loosen the adjustment locknut.

c. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the adjustment screw
in a clockwise direction. Slide the feeler gauge between the rocker arm and the valve bridge. Continue
turning the adjustment screw until a slight drag is felt on the feeler gauge. Remove the feeler gauge.

d. Tighten the adjustment locknut to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow the adjustment screw to
turn while you are tightening the adjustment locknut. Recheck the valve lash after tightening the adjustment
locknut.

5. Remove the timing bolt from the flywheel after all adjustments to the valve lash have been made. Reinstall the
timing cover.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_p...&calledpage=/sisweb/sisweb/techdoc/techdoc_print_page.jsp (4 de 5)21/10/2007 9:38:40


345C Excavator TAJ00001-UP (MACHINE) POWERED BY C13 Engine(SEBP4347 - 12) - Estructura del documento

Cerrar SIS

Pantalla anterior

Producto: EXCAVATOR
Modelo: 345C EXCAVATOR TAJ
Configuración: 345C Excavator TAJ00001-UP (MACHINE) POWERED
BY C13 Engine

Pruebas y Ajustes
C11 and C13 Engines for Caterpillar Built Machines
Número de medio -SENR9888-05 Fecha de publicación -01/10/2006 Fecha de actualización -27/10/2006

i02738289

Electronic Unit Injector - Adjust


SMCS - 1290-025

Illustration 1 g01126970

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_p...&calledpage=/sisweb/sisweb/techdoc/techdoc_print_page.jsp (1 de 2)21/10/2007 9:30:16


345C Excavator TAJ00001-UP (MACHINE) POWERED BY C13 Engine(SEBP4347 - 12) - Estructura del documento

Injector Mechanism

(1) Rocker arm

(2) Adjustment screw

(3) Locknut

Follow the procedure in order to adjust your electronic unit injectors:

1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Systems Operation/Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".

a. Cylinder 3, 5, and 6 can be adjusted with cylinder 1 at TC compression stroke.

b. Loosen the locknut.

c. Turn the adjustment screw until the screw makes contact with the electronic unit injector.

d. Tighten the adjustment screw to an additional 2 turns.

e. Turn the adjustment screw counterclockwise for 2.5 turns.

f. Turn the adjustment screw until the screw makes contact with the electronic unit injector.

g. Turn the adjustment screw through 180 degrees in a clockwise direction.

h. Tighten the locknut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

2. Rotate the engine in the normal operating direction by 360 degrees. Cylinder 1 will now be on TC exhaust stroke.

a. Cylinder 1, 2, and 4 can be adjusted with cylinder 1 at TC exhaust stroke.

b. Loosen the locknut.

c. Turn the adjustment screw until the screw makes contact with the electronic unit injector.

d. Turn the adjustment screw to an additional two turns.

e. Turn the adjustment screw counterclockwise for 2.5 turns.

f. Turn the adjustment screw until the screw makes contact with the electronic unit injector.

g. Turn the adjustment screw through 180 degrees in a clockwise direction.

h. Tighten the locknut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Copyright 1993 - 2007 Caterpillar Inc. Sun Oct 21 09:30:04 EST 2007
Todos los derechos reservados.
Red privada para licenciados del SIS.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_p...&calledpage=/sisweb/sisweb/techdoc/techdoc_print_page.jsp (2 de 2)21/10/2007 9:30:16


345C Excavator TAJ00001-UP (MACHINE) POWERED BY C13 Engine(SEBP4347 - 12) - Estructura del documento

Cerrar SIS

Pantalla anterior

Producto: EXCAVATOR
Modelo: 345C EXCAVATOR TAJ
Configuración: 345C Excavator TAJ00001-UP (MACHINE) POWERED
BY C13 Engine

Pruebas y Ajustes
C11 and C13 Engines for Caterpillar Built Machines
Número de medio -SENR9888-05 Fecha de publicación -01/10/2006 Fecha de actualización -27/10/2006

i02232306

Electronic Unit Injector - Test


SMCS - 1290-081

This procedure assists in identifying the cause for an injector misfiring. Perform this procedure only after performing the
Cylinder Cutout Test. Refer to Troubleshooting for more information.

1. Check for air in the fuel, if this procedure has not already been performed. Refer to Testing and Adjusting, "Air in
Fuel - Test".

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.

2. Remove the valve cover and look for broken parts. Repair any broken parts or replace any broken parts that are
found. Inspect all wiring to the solenoids. Look for loose connections. Also look for frayed wires or broken wires.
Ensure that the connector for the unit injector solenoid is properly connected. Perform a pull test on each of the
wires. Refer to Troubleshooting, "Electrical Connectors - Inspect". Inspect the posts of the solenoid for arcing. If
arcing or evidence of arcing is found, remove the cap assembly. Refer to Disassembly and Assembly Manual,
"Electronic Unit Injector - Remove". Clean the connecting posts. Reinstall the cap assembly and tighten the solenoid
nuts to a torque of 2.5 ± 0.25 N·m (22 ± 2 lb in).

3. Check the valve lash setting for the cylinder of the suspect unit injector. Refer to Testing and Adjusting, "Engine
Valve Lash - Inspect/Adjust".

4. Ensure that the bolt that holds the unit injector is tightened to the proper torque. If necessary, loosen the bolt that
holds the unit injector and tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

5. Remove the suspect unit injector and check the unit injector for signs of exposure to coolant. Refer to Disassembly
and Assembly Manual, "Electronic Unit Injector - Remove". Exposure to coolant will cause rust to form on the
injector. If the unit injector shows signs of exposure to coolant, remove the injector sleeve and inspect the injector
sleeve. Refer to Disassembly and Assembly Manual, "Electronic Unit Injector Sleeve - Remove". Replace the
injector sleeve if the injector sleeve is damaged. Check the unit injector for an excessive brown discoloration that
extends beyond the injector tip. If excessive discoloration is found, check the quality of the fuel. Refer to Testing
and Adjusting, "Fuel Quality - Test". Replace the seals on the injector and reinstall the injector. Refer to
Disassembly and Assembly Manual, "Electronic Unit Injector - Install". Also refer to Disassembly and Assembly
Manual, "Electronic Unit Injector Sleeve - Install".

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_p...&calledpage=/sisweb/sisweb/techdoc/techdoc_print_page.jsp (1 de 2)21/10/2007 9:12:16


C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 1 of 5

Shutdown SIS

Previous Screen

Product: TRUCK ENGINE


Model: C15 TRUCK ENGINE BXS
Configuration: C15 On-highway Engine BXS00001-UP

Testing and Adjusting


C15 On-highway Engine
Media Number -SENR9692-07 Publication Date -01/08/2008 Date Updated -15/08/2008

i02230869

Engine Valve Lash - Inspect/Adjust


SMCS - 1102-025

To prevent possible injury, do not use the starter to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve clearance.

This engine uses high voltage to control the fuel injectors.

Disconnect electronic fuel injector enable circuit connector to prevent


personal injury.

Do not come in contact with the fuel injector terminals while the engine
is running.

Note: Valve lash is measured between the rocker arm and the valve bridge. All measurements and
adjustments must be made with the engine stopped and the valves fully closed.

https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 12/25/2010
C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 2 of 5

Valve Lash Check


An adjustment is NOT NECESSARY if the measurement of the valve lash is in the acceptable range.
Check the valve lash while the engine is stopped. The range is specified in Table 1.

Table 1
Valve Lash
Valves Acceptable Range for Valve Lash

Inlet
0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust
0.76 ± .08 mm (0.030 ± 0.003 inch)

If the measurement is not within this range adjustment is necessary. Refer to Testing And Adjusting,
"Valve Lash Adjustment".

Valve Lash Adjustment

Illustration 1 g01125936

(A) Inlet valves

(B) Exhaust valves

(C) Left side of the engine

(D) Cylinder number

https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 12/25/2010
C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 3 of 5

(E) Front of the engine

(F) Flywheel end of the engine

(G) Right side of the engine

Illustration 2 g01023432

(1) Valve adjustment locknut

(2) Exhaust adjustment screw

(3) Valve adjustment locknut

(4) Inlet adjustment screw

(5) Place for feeler gauge

Table 2
Valve Lash
Valves Lash Setting

Inlet
0.38 mm (0.015 inch)

Exhaust
0.76 mm (0.030 inch)

Adjust the valve lash while the engine is stopped. Use the following procedure in order to adjust the
valves:

https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 12/25/2010
C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 4 of 5

1. Determine the style of variable valve actuator that is installed on the engine.

a. For the BXS engines, remove the variable valve actuators.

b. For the, MXS engines, it is not necessary to remove the variable valve actuators.

2. Put the No. 1 piston at the top center position. See Testing and Adjusting, "Finding Top Center
Position for No. 1 Piston" for further details.

Note: If the engine is equipped with an engine compression brake, loosen the adjustment screw
for the lash on the slave piston for the compression brake prior to adjusting the engine valve
lash. Refer to the Testing and Adjusting, "Slave Piston Lash - Adjust" topic in order to adjust
the slave piston lash.

3. With No. 1 piston at the top center position of the compression stroke, an adjustment can be
made to the valves.

Before any adjustments are made, lightly tap each rocker arm at the top of the adjustment
screw. Use a soft mallet to ensure that the lifter roller seats against the camshaft's base circle.

4. Make an adjustment to the valve lash on the inlet valves for cylinders 1, 2, and 4.

a. Loosen valve adjustment locknut (3) .

b. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve
bridge. Turn inlet adjustment screw (4) while valve adjustment locknut (3) is being held
from turning. Adjust the valve lash until the correct specification is achieved. Refer to
Table 2.

c. After each adjustment, tighten valve adjustment locknut (3) while valve adjustment screw
(4) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.

5. Make an adjustment to the valve lash on the exhaust valves for cylinders 1, 3, and 5.

a. Loosen valve adjustment locknut (1) .

b. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust
valve bridge. Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is
being held from turning. Adjust the valve lash until the correct specification is achieved.
Refer to Table 2.

c. After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw
(2) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.

6. Remove the timing bolt, and turn the flywheel by 360 degrees in the direction of engine
rotation. This will position the No. 6 piston at the top center on the compression stroke. Install
the timing bolt in the flywheel.

7. Make an adjustment to the valve lash on the inlet valves 3, 5, and 6.

a. Loosen valve adjustment locknut (3) .

https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 12/25/2010
C15 On-highway Engine BXS00001-UP(SEBP3722 - 36) - Document Structure Page 5 of 5

b. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve
bridge. Turn inlet adjustment screw (4) while valve adjustment locknut (3) is being held
from turning. Adjust the valve lash until the correct specification is achieved. Refer to
Table 2.

c. After each adjustment, tighten valve adjustment locknut (3) while valve adjustment screw
(4) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.

8. Make an adjustment to the valve lash on the exhaust valves 2, 4, and 6.

a. Loosen valve adjustment locknut (1) .

b. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust
valve bridge. Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is
being held from turning. Adjust the valve lash until the correct specification is achieved.
Refer to Table 2.

c. After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw
(2) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck
each adjustment.

9. Remove the timing bolt from the flywheel after all valve lash adjustments have been made.

Refer to the Testing and Adjusting, "Slave Piston Lash - Adjust" topic for information on
adjusting the slave piston lash.

Note: The engine valve lash must be adjusted before you adjust the compression brake.

The lash must also be adjusted on the electronic unit injector. Refer to Testing and Adjusting,
"Electronic Unit Injector - Adjust" for more information.

Copyright 1993 - 2010 Caterpillar Inc. Sat Dec 25 15:59:11 PST 2010
All Rights Reserved.
Private Network For SIS Licensees.

https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 12/25/2010
Page 1 of 8

Testing and Adjusting


C-15, C-16 and C-18 Engines

Slave Piston Lash - Adjust

To prevent possible injury, do not use the starter to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring valve clearance.

This engine uses high voltage to control the fuel injectors.

Disconnect electronic fuel injector enable circuit connector to prevent


personal injury.

Do not come in contact with the fuel injector terminals while the engine
is running.

NOTICE

Failure to follow the recommended procedure or the specified tooling


that is required for the procedure could result in damage to
components.
Page 2 of 8

To avoid component damage, follow the recommended procedure


using the recommended tools.

The engine valve lash and the injector lash must be within specifications prior to adjusting the
compression brake slave piston lash. Refer to Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust" for the correct procedure for inspection of the engine valve lash. Refer to Testing
and Adjusting, "Electronic Unit Injector - Adjust" for the proper procedure for inspection of the
injector lash adjustment.

Note: The slave piston lash adjustment must be performed while the engine is cold. If the
engine is warm, allow the engine to cool prior to performing the following adjustments.

Use the following procedure to adjust the slave piston lash on cylinders 1, 3, and 5:

Put the No. 1 piston at the top center position on the compression stroke. See Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston" for further details.

Jake Brake Compression Brake Adjustment

Illustration 1 g00596577

Typical configuration for Jake Brake engine compression brake

(1) Adjustment screw for the slave piston

(2) Slave piston

(3) Rocker arm

NOTICE

Prior to adjusting the lash setting for the engine compression brake,
check the identification plate that is on the compression brake casting
in order to determine the model that is installed on your engine. You
Page 3 of 8

must have this model number and the engine serial number prefixin
order to determine the lash setting for your engine.

Table 1
Slave Piston Lash Setting
Jake Brake Compression Brakes

Serial Number Prefixand Model Slave Piston Lash Setting


Horsepower Rating
Number (1)

0.94 ± 0.08 mm (0.037 ±


410 hp or less
0.003 inch)
2WS1-UP
Jake Brake 340B
435-550 hp 0.84 ± 0.08 mm (0.033 ±
0.003 inch)

410 hp or less 0.94 ± 0.08 mm (0.037 ±


2WS1-UP 0.003 inch)
Jake Brake 340C
435-550 hp 0.84 ± 0.08 mm (0.033 ±
0.003 inch)

410 hp or less 0.94 ± 0.08 mm (0.037 ±


0.003 inch)

6NZ1-UP
435 hp or more 0.84 ± 0.08 mm (0.033 ±
Jake Brake 340C
0.003 inch)

375/435 hp Multitorque
0.84 ± 0.08 mm (0.033 ±
rating
0.003 inch)
1MM1-UP
7CZ1-UP
All ratings 0.94 ± 0.08 mm (0.037 ±
5DS1-UP
0.003 inch)
Jake Brake 340C

410 hp or less 0.84 ± 0.08 mm (0.033 ±


1LW1-UP 0.003 inch)
Jake Brake 340C
435 hp or more 0.68 ± 0.08 mm (0.027 ±
0.003 inch)
5EK1-UP (2)
6TS1-UP 410 hp or less 0.68 ± 0.08 mm (0.027 ±
Jake Brake 340A 0.003 inch)
Page 4 of 8

435 hp or more 0.76 ± 0.08 mm (0.030 ±


0.003 inch)

5EK1-UP (2)
435 hp or more 0.68 ± 0.08 mm (0.027 ±
Jake Brake 340
0.003 inch)
1LW1-UP
6NZ1-UP
All ratings 0.64 ± 0.08 mm (0.025 ±
7CZ1-UP
0.003 inch)
Jake Brake 340D
CJP1-UP
MDP1-UP
MEP1-UP All ratings 1.02 ± 0.08 mm (0.040 ±
W1A1-UP 0.003 inch)
Jake Brake 340C

MBN1-UP
Jake Brake 340D All ratings 0.76 ± 0.08 mm (0.030 ±
0.003 inch)

BXS1-UP
All ratings 0.89 ± 0.08 mm (0.035 ±
Jake Brake 340C 0.003 inch)

BXS1-UP
All ratings 0.84 ± 0.08 mm (0.033 ±
Jake Brake 340E
0.003 inch)
(1)
Check the identification plate that is on the compression brake casting in order to determine the model that is
installed on your engine.
(2)
Some of the early 3406E Engines , 5EK1-01820 were built with either the 340 or the 340A compression brakes.

Note: The slave piston lash settings are specific to the model number of the compression brake
and to the serial number prefix of the engine. Use these settings only for the compression brakes
and serial number prefixes that are specified in the table.

340D Compression Brakes


1. Loosen adjustment locknut (1) and back out the adjustment screw until the slave piston is
not in contact with the exhaust valve rocker arm.

2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 1 for the correct slave piston lash setting.

3. Turn the adjustment screw for the slave piston in a clockwise direction until the slave piston
tightens against the feeler gauge. A slight drag should be felt on the feeler gauge.

4. Tighten the adjustment locknut (1) to a torque of 34 ± 5 N·m (25 ± 4 lb ft). Recheck the
adjustment after you tighten the locknut. If necessary, repeat this procedure.

340, 340A, 340B, 340C, and 340E Compression Brakes


Page 5 of 8

1. Loosen adjustment locknut (1) and back out the adjustment screw until the slave piston is
not in contact with the exhaust valve rocker arm.

2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 1 for the correct slave piston lash setting.

3. Turn the adjustment screw for the slave piston in a clockwise direction until the slave piston
tightens against the feeler gauge. Tighten the adjustment screw for one additional turn in the
clockwise direction. The valve spring should start to compress. Allow the oil to be purged
from the autolash assembly of the compression brake for 30 seconds.

Note: All of the oil must be allowed to drain from the autolash assembly of the compression
brake. If the temperature of the oil is below 16 °C (60 °F), allow the oil to be purged for an
additional 2 minutes. Serious engine damage may occur if the oil is not properly purged
from the autolash assembly.

4. Slowly turn the adjustment screw counterclockwise until the slave piston begins to loosen
against the feeler gauge. A slight drag should be felt on the feeler gauge when the
adjustment is correct.

Note: Do not overshoot the setting of the slave piston during adjustment. If you
overshoot the setting, this procedure must be repeated.

5. Tighten the adjustment locknut (1) to a torque of 34 ± 5 N·m (25 ± 4 lb ft). Recheck the
adjustment after tightening the locknut. If necessary, repeat the procedure.

Adjust the slave piston lash settings for cylinders 3 and 5 prior to rotating the engine.

After you adjust cylinders 1, 3, and 5, reset the timing pin and turn the flywheel for 360 degrees in
the direction of engine rotation. This will position the No. 6 piston at the top center on the
compression stroke. Ensure that the timing pin has located the timing hole that is in the flywheel.

Continue to perform the adjustment procedure for the slave piston lash settings on cylinders 2, 4,
and 6.

Remove the timing pin from the flywheel after all adjustments have been performed. Reinstall the
timing cover.

Pacbrake Compression Brake Adjustment


Page 6 of 8

Illustration 2 g00975814

Typical configuration for Pacbrake's engine compression brake

(1) Adjustment screw for the slave piston

(2) Slave piston

(3) Rocker arm

Table 2
Slave Piston Lash Setting
Pacbrake Compression Brakes
Serial Number Prefix and Model Horsepower
Slave Piston Lash Setting
Designation Rating

410 or less 0.685 ± 0.076 mm (0.027 ±


5EK1-UP 0.003 inch)
6TS1-UP
Pacbrake P-39A
435 or higher 0.762 ± 0.076 mm (0.030 ±
0.003 inch)

1LW1-UP
5DS1-UP All ratings 0.762 ± 0.076 mm (0.030 ±
Pacbrake P-39A 0.003 inch)

410 or less 1.066 ± 0.076 mm (0.042 ±


2WS1-UP 0.003 inch)
1MM1-UP
Pacbrake P-39A
435 or higher 0.762 ± 0.076 mm (0.030 ±
0.003 inch)
6NZ1-UP
7CZ1-UP All ratings 0.762 ± 0.076 mm (0.030 ±
Pacbrake P-39A 0.003 inch)

5EK1-UP
6TS1-UP
1LW1-UP
5DS1-UP
2WS1-UP All ratings 0.838 ± 0.076 mm (0.033 ±
1MM1-UP 0.003 inch)
6NZ1-UP
7CZ1-UP
Pacbrake P-39B

6NZ1-UP
7CZ1-UP N/A Product Campaign (1)
Pacbrake P-39C
Page 7 of 8

MBN1-UP
All ratings 0.97 ± 0.08 mm (0.038 ± 0.003
Pacbrake P-39D
inch)

BXS1-UP
All ratings 0.71 ± 0.08 mm (0.028 ± 0.003
Pacbrake P-39E (1)
inch)
(1)
Contact Pacbrake for information that relates to the product campaign.
(1)
C15 Engines only

Note: The slave piston lash settings are specific to the serial number of the engine. Ensure
that the slave piston lash setting that is being used is correct for the serial number of your
engine.

P39A Compression Brakes


1. Loosen adjustment locknut (1) and back out the adjustment screw until the slave piston is
not in contact with the exhaust valve rocker arm.

2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 2 for the correct slave piston lash settings.

3. Turn the adjustment screw for the slave piston in a clockwise direction. Tighten the
adjustment screw for the slave piston beyond the point of contact with the exhaust valve
rocker arm. This will allow the oil to be purged from the slave piston. Once the oil has been
purged from the piston, turn the adjustment screw for the slave piston in a counterclockwise
direction until the feeler gauge is loose between the adjustment screw and the rocker arm.

4. Again, turn the adjustment screw for the slave piston in a clockwise direction until a slight
drag is felt on the feeler gauge.

5. Tighten the adjustment locknut (1) to a torque of 34 ± 5 N·m (25 ± 4 lb ft).

Adjust the slave piston lash settings for cylinders 3 and 5 prior to rotating the engine.

P39B, P39D, and P39E Compression Brakes


1. Loosen adjustment locknut (1) and back out the adjustment screw until the slave piston is
not in contact with the exhaust valve rocker arm.

2. Insert the appropriate feeler gauge between the foot of the slave piston (2) and the rocker
arm (3) . Refer to Table 2 for the correct slave piston lash settings.

3. Turn the adjustment screw for the slave piston in a clockwise direction until the slave piston
tightens against the feeler gauge. Tighten the adjustment screw for one additional turn in the
clockwise direction. The valve spring should start to compress. Allow the oil to be purged
from the components of the compression brake for 1 minute.

4. Slowly turn the adjustment screw counterclockwise until a slight drag is felt on the feeler
gauge.

Note: Do not overshoot the setting of the slave piston during this adjustment. If you
overshoot the setting, this procedure must be repeat.
Page 8 of 8

5. While you hold the screw of the adjuster, tighten the adjustment locknut (1) to a torque of
34 ± 5 N·m (25 ± 4 lb ft).

Note: Do not place excessive torque on the locknut that is on the adjustment screw. If
excessive torque is placed on the adjustment screw, damage to the components of the
compression brake may result.

6. Recheck the adjustment after tightening the locknut. If a slight drag is not felt on the feeler
gauge, repeat the adjustment procedure.

Adjust the slave piston lash settings for cylinders 3 and 5 prior to rotating the engine.

After you adjust cylinders 1, 3, and 5, reset the timing pin and turn the flywheel for 360 degrees in
the direction of engine rotation. This will position the No. 6 piston at the top center on the
compression stroke. Ensure that the timing pin has located the timing hole that is in the flywheel.

Continue to perform the adjustment procedure for the slave piston lash settings on cylinders 2, 4,
and 6.

Remove the timing pin from the flywheel after all adjustments have been performed. Reinstall the
timing cover.
C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 1 of 2

Shutdown SIS

Previous Screen

Product: TRUCK ENGINE


Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP

Testing and Adjusting


C15 On-highway Engines
Media Number -SENR9692-06 Publication Date -01/06/2006 Date Updated -14/06/2006

i02230867

Electronic Unit Injector - Adjust


SMCS - 1290-025

Table 1

Required Tools
Part Number Part Name Quantity
9U-7227 Injector Height Gauge 1

Note: Determine the style of variable valve actuator that is installed on the engine. For the BXS engines,
remove the variable valve actuators. For the MXS engines, it is not necessary to remove the variable valve
actuators.

Illustration 1 g01023138

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 1/18/2012
C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 2 of 2

Injector Mechanism

(1) Rocker arm

(2) Adjustment screw

(3) Locknut

(4) 9U-7227 Injector Height Gauge

To make an adjustment to the unit injectors on cylinders 3, 5, and 6 use the following procedure:

1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".

2. Injector height gauge (4) is used in order to obtain a dimension of 78.0 ± 0.2 mm (3.07 ± 0.01 inch).
The dimension is measured from the top of the unit injector to the machined ledge of the fuel injector
body.

3. Turn unit injector adjustment screw (2) clockwise until the correct height is obtained.

4. Hold the adjustment screw in this position and tighten locknut (3) to a torque of 100 ± 10 N·m (74 ± 7
lb ft).

5. To make an adjustment to the unit injectors on cylinders 1, 2, and 4, remove the timing bolt. Turn the
flywheel by 360 degrees in the direction of engine rotation. The direction of engine rotation is
counterclockwise, as the engine is viewed from the flywheel end. This will put the number 1 piston at
the top center position on the exhaust stroke.

6. Repeat Steps 3 through 4.

7. Remove the timing bolt from the flywheel after all the unit injector adjustments have been made.
Reinstall the valve mechanism cover.

Copyright 1993 - 2012 Caterpillar Inc. Wed Jan 18 18:48:58 UTC-0400 2012
All Rights Reserved.
Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 1/18/2012
C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 1 of 3

Shutdown SIS

Previous Screen

Product: TRUCK ENGINE


Model: C15 TRUCK ENGINE MXS
Configuration: C15 On-highway Truck MXS00001-UP

Testing and Adjusting


C15 On-highway Engines
Media Number -SENR9692-06 Publication Date -01/06/2006 Date Updated -14/06/2006

i02283578

Variable Valve Actuators - Inspect/Adjust


SMCS - 1105-025; 1105-040

S/N - MXS1-UP

S/N - NXS1-UP

NOTICE
Do not disassemble the Variable Valve Actuator. There are no
components of the Variable Valve Actuator that are serviceable. If the
Variable Valve Actuator is disassembled, the warranty will be void.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 1/18/2012
C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 2 of 3

Illustration 1 g01102463
(1) Adjustment screw

(2) Adjustment screw locknut

(3) Intake rocker arm

(4) Actuator rod

1. Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".

2. Loosen adjustment screw locknut (2) and back out adjustment screw (1) until actuator rod (4) is not in
contact with intake rocker arm (3) .

Note: During this procedure, ensure that the intake rocker arm is in full contact with the valve
bridge.

3. Place the appropriate feeler gauge between the actuator rod and the intake rocker arm. Turn the
adjustment screw in a clockwise direction. Slide the feeler gauge between the actuator rod and the
intake rocker arm. Continue turning the adjustment screw until a slight drag is felt on the feeler gauge.
Remove the feeler gauge. Refer to Specifications, "Variable Valve Actuators" for the proper lash
setting.

4. Tighten the adjustment screw locknut. Refer to Specifications, "Variable Valve Actuators" for the

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 1/18/2012
C15 On-highway Truck MXS00001-UP(SEBP4186 - 31) - Document Structure Page 3 of 3

proper torque for the adjustment screw locknut.

5. Recheck the lash setting after the adjustment screw locknut has been torqued.

6. Make the lash setting on the following cylinders: 1, 2 and 4.

7. Remove the timing bolt from the flywheel. Turn the crankshaft clockwise by 360 degrees. This will
position the No. 6 piston at the top center on the compression stroke. Install the timing bolt in the
flywheel.

8. Repeat Step 6 for the following cylinders: 3, 5 and 6.

9. Remove the timing bolt from the flywheel.

Copyright 1993 - 2012 Caterpillar Inc. Wed Jan 18 18:55:27 UTC-0400 2012
All Rights Reserved.
Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 1/18/2012
SENR9575-05 Harness And Wire Electrical Schematic Symbols
November 2007
P300
Symbols
UNIT INJECTOR
HARNESS CONNECTOR

FUEL Pressure Temperature Level Flow Circuit Breaker


ENGINE COOLANT TEMPERATURE Symbol Symbol Symbol Symbol Symbol
TEMPERATURE P105 FUEL
P100 PRESSURE
INTAKE MANIFOLD J209
AIR TEMPERATURE
P103
Symbols and Definitions
SPLICE ATMOSPHERIC Fuse - A component in an electrical circuit that will open the circuit if too much current flows
G828 PRESSURE ENGINE OIL
through it.
P203 PRESSURE ATMOSPHERIC Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
SPLICE J201 PRESSURE
G829 circle indicates that the component has screw terminals and a wire can be disconnected from it.
J203

INTAKE MANIFOLD Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
FUEL AIR TEMPERATURE No circle indicates that the wire cannot be disconnected from the component.
TEMPERATURE P103
SPLICE P105 FUEL
G833 PRESSURE ELECTRONIC
CONTROL MODULE Ground (Wired): This indicates that the component is connected to a grounded wire. The
J209 P2 grounded wire is fastened to the machine.

ENGINE COOLANT SECONDARY ENGINE


TEMPERATURE SPEED/TIMING TIMING CALIBRATION(TC) Ground (Case): This indicates that the component does not have a wire connected to ground.
TURBO OUTLET P100 (CAMSHAFT)
(INTAKE MANIFOLD AIR) P402 TURBO OUTLET PROBE CONNECTOR It is grounded by being fastened to the machine.
PRESSURE (INTAKE MANIFOLD AIR) P400
P200 PRESSURE
J200
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.

P300
UNIT INJECTOR
SPLICE
993
C-10, C-12, C-15 and C-16 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

Industrial Engine
SECONDARY ENGINE
SPEED/TIMING HARNESS CONNECTOR T
the gauge of the temperature or pressure.
(CAMSHAFT)
P402
SPLICE

Electrical System
SPLICE Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.
R993 997
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.
ELECTRONIC
CONTROL MODULE
P2 Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
PRIMARY ENGINE ENGINE OIL PRIMARY ENGINE
SPEED/TIMING PRESSURE SPEED/TIMING coil that makes an electromagnet when current flows through it. The electromagnet
(CRANKSHAFT) P201 (CRANKSHAFT) can open or close a valve or move a piece of metal that can do work.
P401 P401
CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES Z2B1-UP
226-5758 AND 243-6620 (C-10/C-12) Z2C1-UP
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)
INTEGRAL SENSORS CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES that make electromagnet when current flows through them. It also has an internal switch that places
BDL1-UP the latch coil circuit open at the time the coil latches.
191-5204, 238-1773, AND 237-7595 (C-15/C-16)
BEM1-UP
Harness and Wire Symbols
BFM1-UP
BCX1-UP 1 Deutsch connector: Typical representation
of a Deutsch connector. The plug contains all
1 Sure-Seal connector: Typical representation
of a Sure-Seal connector. The plug and receptacle
2 sockets and the receptacle contains all pins. 2 contain both pins and sockets.

Harness Identification Letter(s):


Wire, Cable, or Harness Assembly Identification: (A, B, C, ..., AA, AB, AC, ...)
Includes Harness Identification Letters and Harness
Connector Serialization Codes Harness Connector Serialization Code: The "C" stands
for "Connector" and the number indicates which
connector in the harness. (C1, C2, C3, .....)
Part Number for
C-C4 AG-C3 Connector Plug AG-C4 L-C12 Part Number For
130-6795 130-6795 111-7898 3E-5179 Connector Recepticle

325-AG135 PK-14 1 5A
Pin Socket Fuse
Receptacle
Pin or Socket (5 Amps)
Single Wire
Number
9X-1123
Connector
Component
INTAKE MANIFOLD Plug
Part Number
AIR TEMPERATURE
P103 Harness identification code: 2 200-L32 BK-14
This example indicates wire
135 in harness "AG".
Ground Circuit Identification Wire Gauge
Connection Number Wire Color
SPLICE
997

SPLICE © 2007 Caterpillar Printed in U.S.A.


993 FUEL All Rights Reserved
TEMPERATURE
P105
TIMING CALIBRATION(TC)
PROBE CONNECTOR INJECTOR HARNESS
SPLICE P400 CONNECTOR
TURBO OUTLET R993 FUEL ELECTRONIC
(INTAKE MANIFOLD AIR) ATMOSPHERIC PRESSURE CONTROL MODULE J300
PRESSURE PRESSURE J209 P2
J200 J203

ENGINE COOLANT
TEMPERATURE
P100

174-0502 160-7689

P300 A B
UNIT INJECTOR D788 D786 D788 D787 D788 D786
SECONDARY ENGINE HARNESS CONNECTOR
SPEED/TIMING
(CAMSHAFT) SPLICE
P402 D786 C
ENGINE OIL
PRESSURE INJECTOR
#5 INJECTOR INJECTOR INJECTOR
J201 INJECTOR INJECTOR
#3 #2 #1
#6 #4

(Dimensions: 39 inches x 28 inches)


155-2269

A701
PRIMARY ENGINE SPLICE A702

3
5

1
6

4
A704 A703
SPEED/TIMING A706 A705 D790
(CRANKSHAFT) D790 D789 160-7690
P401 D791 D790 D789
D791 2 1

SENR9575-05
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 189-6594 (C-10/C-12)
PIGTAIL SENSORS

3E-3370

SPLICE SPLICE
SPLICE
D791 D789
D788
B A

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 122-1486 (C-15/C-16) 9X-1343

1 5 6 10
155-2267 11 15 16 20

21 25 26 30
31 35 36 40

A B
CATERPILLAR SUPPLIED
ENGINE SERVICE
TOOL CONNECTOR C
J63
8T-8736

CUSTOMER 169-8670
CONNECTOR D

30 Page,
J61 E C
F A B
A B
INJECTOR HARNESS J
CONNECTOR G
J300
C H
SPLICE
120

SPLICE
892 SPLICE
893

SPLICE 155-2252
SPLICE
D788
D786

12 11 10 9 8 7

GROUND
229 1 2 3 4 5 6

D786 D786 SPLICE


SPLICE D787
D789
D791
GROUND
229
SPLICE
D790

SPLICE
A234 D788 D788 D788
K990
K900

TERMINATION
RESISTOR D791 D791 D789 D789 3E-7990
P154
A705
5

A706
1
6

A702 A701
1 2 3 4 5 6

CONNECTOR AND SPLICE LOCATIONS FOR HARNESSES Related Electrical Service Manuals
D790 D790
INJECTOR INJECTOR INJECTOR INJECTOR
189-6596, 191-1531, 238-1774, 242-7248, AND 243-6618 (ALL) #6 #5 #2 #1 Title
Industrial
Form Number
ELECTRONIC Engine
3
4

A704 A703 12 11 10 9 8 7
CONTROL
Installation Guide C-10,C-12 REHS0871
MODULE
P1 System Operation
C-10,C-12 SENR9573
INJECTOR INJECTOR Test and Adjust
#4 #3 Troubleshooting C-10,C-12 SENR9576
Installation Guide C-15,C-16 REHS0871
3E-8969
System Operation
C-15,C-16 RENR2347
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 4P-9537 (C-10/C-12) Test and Adjust
Troubleshooting C-15,C-16 SENR9576
7 8 9 10 11 12
System Operation
C-10(Z2B),C-15(Z2C) SENR9953
Test and Adjust
Troubleshooting C-10(Z2B),C-15(Z2C) RENR5061
6 5 4 3 2 1
NOT NOT

C-10 and C-12 Engine USED


C-10 and C-12 Engine USED
C-15 and C-16 Engine RETARDER MED/HI
A701 GY-16 A701 GY-16 (SPECIFIC ARRANGEMENTS)
and Injector Harness NOT
USED A703 BR-16
A702 PU-16 and Injector Harness NOT
USED A703 BR-16
A702 PU-16
and Injector Harness A701 GY-16
(Integral Sensors)
RETARDER MED/HI
(Pigtail Sensors) INJECTOR
HARNESS
CONNECTOR
A704 GN-16
A705 BU-16
INJECTOR
HARNESS
CONNECTOR
A705 BU-16
A704 GN-16
ECM
(SPECIFIC ARRANGEMENTS)
A703 BR-16
A702 PU-16

NOT NOT GROUND INJECTOR A704 GN-16


P300 J300 USED P300 J300 USED STRAP HARNESS A705 BU-16
ECM NO.5 NO.4 NO.3 NO.2 NO.1 ECM NO.5 NO.4 NO.3 NO.2 NO.1 ECM CONNECTOR
1552252 3E7990 1552252 3E7990 RETARDER LO/HI
GROUND ECM GROUND ECM MOUNTING
CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER (SPECIFIC ARRANGEMENTS)
STRAP MOUNTING A701/GY 1 A701 GY-16 NO.6 STRAP MOUNTING A701/GY 1 A701 GY-16 NO.6 BOLT P300 J300
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR BOLT INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR 1552252 NO.5 NO.4 NO.3 NO.2 NO.1
BOLT A702/PU 2 A702 PU-16 CYLINDER A702/PU 2 A702 PU-16 CYLINDER 3E8969
CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER
ELECTRONIC CONTROL A703/BR 3 A703 BR-16 INJECTOR ELECTRONIC CONTROL A703/BR 3 A703 BR-16 INJECTOR ELECTRONIC CONTROL A701/GY 1 A701 GY-16 NO.6 INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR
MODULE (ECM) P2 A704/GN 4 A704 GN-16 MODULE (ECM) P2 A704/GN 4 A704 GN-16 MODULE (ECM) P2 A702/PU 2 A702 PU-16 CYLINDER
1607690 A705/BU 5 A705 BU-16 1607690 A705/BU 5 A705 BU-16 1607690 A703/BR 3 A703 BR-16 INJECTOR
D790 OR-16 D789 WH-16
1 A706/GY 6 A706 GY-16 A706 GY-16 1 A706/GY 6 A706 GY-16 A706 GY-16 1 A704/GN 4 A704 GN-16
ANALOG SENSOR POWER (+5V) 2 997/OR 7 D788 BK-16 D791 YL-16 D790 OR-16 D789 WH-16 ANALOG SENSOR POWER (+5V) 2 G828/WH J702/BK 7 D788 BK-16 D791 YL-16 ANALOG SENSOR POWER (+5V) 2 997/OR A705/BU 5 A705 BU-16
ANALOG SENS0R COMMON D790 OR-16 D789 WH-16
ANALOG SENS0R COMMON 3 993/BR L985/YL 8 D791 YL-16 D791 YL-16 ANALOG SENS0R COMMON 3 G829/GN L985/YL 8 D791 YL-16 D791 YL-16 3 993/BR A706/GY 6 A706 GY-16 A706 GY-16
4 9 D787 GN-16 4 J701/GN 9 D787 GN-16 4 J702/BK 7 D788 BK-16 D791 YL-16
5 L984/OR 10 D790 OR-16 D790 OR-16 5 L984/OR 10 D790 OR-16 D790 OR-16 5 L985/YL 8 D791 YL-16 D791 YL-16
6 11 D786 BR-16 6 J700/BR 11 D786 BR-16 6 J701/GN 9 D787 GN-16
7 L983/WH 12 D789 WH-16 D789 WH-16 7 L983/WH 12 D789 WH-16 D789 WH-16 7 L984/OR 10 D790 OR-16 D790 OR-16
8 8 8 J700/BR 11 D786 BR-16
9 NOT USED 9 J702/BK RETARDER COMMON (NOTE Y) 9 J702/BK L983/WH 12 D789 WH-16 D789 WH-16
10 NOT USED 10 J700/BR P401 RETARDER MED/HI (NOTE Y) 10 J700/BR
11 P400 NOT USED 11 J701/GN 1552269 RETARDER LOW/HI (NOTE Y) 11 P400
J701/GN
1552269 3E3364 1552269 3E3364
12 12 E963/BK E963/BK 1 BK-18 SIGNAL(-) (CRANKSHAFT POSITION) 12
13 G811/YL 1 TIMING CALIBRATION 13 E964/WH E964/WH WH-18 SIGNAL(+) PRIMARY ENGINE SPEED/TIMING SENSOR 13 G811/YL 1 TIMING CALIBRATION P401
2
G810/PU 2 (TC) PROBE CONNECTOR P401 188-7511 G810/PU 2 (TC) PROBE CONNECTOR 1552269
ATMOSPHERIC PRESSURE 14 A747/GY ATMOSPHERIC PRESSURE 14 A747/GY E965/BU ATMOSPHERIC PRESSURE 14 A747/GY
15 1552269 15 E966/YL P402 15 P920/BR P920/BR 1 SIGNAL(-) (CRANKSHAFT POSITION)
PRIMARY ENGINE SPEED/TIMING SENSOR
FUEL PRESSURE 16 413/BR P920/BR P920/BR 1 BK-18 SIGNAL(-) (CRANKSHAFT POSITION) FUEL PRESSURE 16 413/BR 995/BU 1552269 FUEL PRESSURE 16 413/BR F732/PK F732/PK 2 SIGNAL(+) 189-9266
17 F732/PK F732/PK 2 WH-18 SIGNAL(+) PRIMARY ENGINE SPEED/TIMING SENSOR 17 R833/BR E965/BU 1 SIGNAL(-) (CAMSHAFT POSITION) 17 998/BR
188-7511 SECONDARY ENGINE SPEED/TIMING SENSOR P402
PASSIVE SENSOR RETURN 18 R993/BR 998/BR PASSIVE SENSOR RETURN 18 R833/BR G828/WH E966/YL 2 SIGNAL(+) 189-9801 PASSIVE SENSOR RETURN 18 R993/BR 999/WH
19 999/WH P402 19 G829/GN 19 995/LTBU 1552269
20 995/BU 1552269 20 A746/PK P100 20 R993/BR 998/BR 1 BK-18 SIGNAL(-) (CAMSHAFT POSITION)
(CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR
21 R993/BR 998/BR 1 SIGNAL(-) 21 A747/GY 1552269 21 997/OR 999/WH 2 WH-18 SIGNAL(+) 188-7513
TIMING CALIBRATION PROBE +
TIMING CALIBRATION PROBE -
22
23
G811/YL
G810/PU
997/OR
993/BR
999/WH 2 SIGNAL(+)
SECONDARY ENGINE SPEED/TIMING SENSOR
189-9801 TIMING CALIBRATION PROBE +
TIMING CALIBRATION PROBE -
22
23
994/GY
A751/YL
995/BU
R833/BR
1
2
SIGNAL
COMMON
ENGINE COOLANT
TEMPERATURE SENSOR
TIMING CALIBRATION PROBE +
TIMING CALIBRATION PROBE -
22
23
G811/YL
G810/PU
993/BR
A746/PK P100
C-10 and C-12 Engines
ENGINE OIL PRESSURE 24 994/GY P100 ENGINE OIL PRESSURE 24 994/GY 413/BR 130-9811 ENGINE OIL PRESSURE 24 994/GY A747/GY 1552269
A746/PK
25 A747/GY 1552269 25 C967/BU 25 994/GY 995/LTBU 1 SIGNAL ENGINE COOLANT
26 994/GY 995/BU 1 SIGNAL ENGINE COOLANT 26 P200 26 F421/YL R993/BR 2 COMMON TEMPERATURE SENSOR Intake Manifold Turbo Outlet
27 F421/YL R993/BR 2 COMMON TEMPERATURE SENSOR 27 27 413/BR 130-9811
1552267 EARLY J200
28 413/BR J200
130-9811 28 1698670 LATE 28 C967/LTBU 3E3370
Air Temperature Pressure
29 C967/BU 29 G828/WH A +5V TURBO OUTLET 29 997/OR A OR-18 +5V TURBO OUTLET
3E3370
TURBO OUTLET PRESSURE SENSOR PRESSURE SENSOR Sensor Sensor
30 997/OR A OR-18 +5V 30 G829/GN B RETURN 30 993/BR B YL-18 RETURN
31 PRESSURE SENSOR 31 (INTAKE MANIFOLD AIR) (INTAKE MANIFOLD AIR) P103
993/BR B YL-18 RETURN A746/PK C SIGNAL 31 A746/PK C GN-18 SIGNAL
ENGINE COOLANT TEMPERATURE 32 995/BU A746/PK C GN-18 SIGNAL
(INTAKE MANIFOLD AIR)
ENGINE COOLANT TEMPERATURE 32 995/BU
161-1704
ENGINE COOLANT TEMPERATURE 32 995/LTBU
194-6724 (Intake Manifold Air)
194-6724
FUEL TEMPERATURE 33 F421/YL FUEL TEMPERATURE 33 A751/YL P203 FUEL TEMPERATURE 33 F421/YL J203 P200(J200)
34 J203 34 1698670 34 3E3370
35 C967/BU 35 C967/BU G828/WH A +5V ATMOSPHERIC PRESSURE 35 C967/LTBU 997/OR A OR-18 +5V ATMOSPHERIC PRESSURE
INTAKE MANIF. AIR TEMPERATURE 3E3370 INTAKE MANIF. AIR TEMPERATURE INTAKE MANIF. AIR TEMPERATURE
36 A701/GY 997/OR A OR-18 +5V ATMOSPHERIC PRESSURE 36 A701/GY G829/GN B RETURN SENSOR 36 A701/GY 993/BR B YL-18 RETURN SENSOR
INJECTOR 1 INJECTOR 1 INJECTOR 1
INJECTOR 2 37 A702/PU 993/BR B YL-18 RETURN SENSOR INJECTOR 2 37 A702/PU A747/GY C SIGNAL 161-1703 INJECTOR 2 37 A702/PU A747/GY C GN-18 SIGNAL 194-6722
INJECTOR 3 38 A703/BR A747/GY C GN-18 SIGNAL 194-6722 INJECTOR 3 38 A703/BR INJECTOR 3 38 A703/BR
INJECTOR 4 39 A704/GN INJECTOR 4 39 A704/GN P201 INJECTOR 4 39 A704/GN J201
TURBO OUTLET PRESSURE 40 A746/PK J201 TURBO OUTLET PRESSURE 40 A746/PK 1698670 TURBO OUTLET PRESSURE 40 A746/PK 3E3370
41 3E3370 41 G828/WH A +5V ENGINE OIL PRESSURE 41 997/OR A OR-18 +5V ENGINE OIL PRESSURE
42 997/OR A OR-18 +5V ENGINE OIL PRESSURE 42 G829/GN B RETURN SENSOR 42 993/BR B YL-18 RETURN SENSOR
43 993/BR B YL-18 RETURN SENSOR 43 994/GY C SIGNAL 161-1705 43 994/GY C GN-18 SIGNAL 194-6725
INJECTOR COMMON 1 & 2 44 L983/WH 994/GY C GN-18 SIGNAL 194-6725 INJECTOR COMMON 1 & 2 44 L983/WH INJECTOR COMMON 1 & 2 44 L983/WH
INJECTOR COMMON 3 & 4 45 L984/OR INJECTOR COMMON 3 & 4 45 L984/OR INJECTOR COMMON 3 & 4 45 L984/OR P105
INJECTOR COMMON 5 & 6 46 L985/YL INJECTOR COMMON 5 & 6 46 L985/YL P105 INJECTOR COMMON 5 & 6 46 L985/YL 1552269
47 P105 47 1552269 47 F421/YL 1 SIGNAL FUEL TEMPERATURE
48 1552269 FUEL TEMPERATURE F732/PK SENSOR
PRIMARY SPEED/TIMING + F732/PK PRIMARY SPEED/TIMING + 48 E964/WH A751/YL 1 SIGNAL PRIMARY SPEED/TIMING + 48 R993/BR 2 COMMON
FUEL TEMPERATURE SENSOR 130-9811
PRIMARY SPEED/TIMING - 49 P920/BR F421/YL 1 SIGNAL PRIMARY SPEED/TIMING - 49 E963/BK R833/BR 2 COMMON PRIMARY SPEED/TIMING - 49 P920/BR
SENSOR 130-9811 J209
50 R993/BR 2 COMMON 50 50
130-9811 3E3370
51 51 51
52 52 J209 P209 52 997/OR A OR-18 +5V
J209A FUEL PRESSURE SENSOR
53 J209 P209 53 3E3370 1698670 3E3370 53 993/BR B YL-18 RETURN
J209A 194-6725
54 A705/BU 3E3370 1698670 3E3370 54 A705/BU G828/WH A 997/OR OR-18
A +5V 54 A705/BU 413/BR C GN-18 SIGNAL
INJECTOR 5 INJECTOR 5 INJECTOR 5
FUEL PRESSURE SENSOR
INJECTOR 6 55 A706/GY 997/OR A 997/OR OR-18
A +5V INJECTOR 6 55 A706/GY G829/GN B 993/BR YL-18
B RETURN INJECTOR 6 55 A706/GY P103
FUEL PRESSURE SENSOR 194-6725
56 993/BR B 993/BR YL-18
B RETURN 56 413/BR C A745/WH GN-18
C SIGNAL 56 1552269
194-6725 INTAKE MANIFOLD AIR
57 413/BR C A745/WH GN-18
C SIGNAL 57 Extension harness used for 57 C967/LTBU 1 SIGNAL
SECONDARY SPEED/TIMING + 58 999/WH SECONDARY SPEED/TIMING + 58 E966/YL specific fuel filter arrangements. SECONDARY SPEED/TIMING + 58 999/WH TEMPERATURE SENSOR
Extension harness used for R993/BR 2 COMMON
SECONDARY SPEED/TIMING - 59 998/BR SECONDARY SPEED/TIMING - 59 E965/BU Not present on all engines. SECONDARY SPEED/TIMING - 59 998/BR 130-9811
specific fuel filter arrangements.
60 Not present on all engines. 60 60
61
62
61
62 P103
61
62 TOP VIEW
63 P103 63 1552269 63
64 64 INTAKE MANIFOLD AIR 64
1552269 C967/BU 1 SIGNAL
65 INTAKE MANIFOLD AIR 65 TEMPERATURE SENSOR 65
C967/BU 1 SIGNAL R833/BR 2 COMMON
66 TEMPERATURE SENSOR 66 130-9811 66
R993/BR 2 COMMON
67 130-9811 67 67
68 68 68
69 69 69
70 70 70

Fuel
Customer Fuel Pressure Atmospheric
Engine Coolant
Connector Temperature Sensor Pressure
Temperature Service Tool
J61 Sensor J209 Sensor
Sensor Connector Electronics
P105 P203(J203)
P100 J63 Ground
Engine Control Module
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS Stud
(NOTE B) Primary Engine
CID Component Speed/Timing
1
2 INLET AIR SHUTOFF 0001 Injector #1
SOLENOID RELAY Sensor
INLET AIR SHUTOFF (NOTE V) 0002 Injector #2
SOLENOID (NOTE V) (Crankshaft)
0003 Injector #3
P401
0004 Injector #4
P142/J142 0005 Injector #5
AUXILIARY
A +8V
TEMPERATURE
B RETURN 0006 Injector #6
SENSOR
C SIGNAL
0022 Timing Sensor
P800/J800
BATTERY A +8V COOLANT LEVEL 0041 8 Volt DC Supply
B RETURN SENSOR
BATTERY OFF ENGINE 0091 Throttle Position
DISCONNECT C SIGNAL
SWITCH
0094 Fuel Pressure Secondary Engine
TERMINATION
RESISTOR
120
P220/J220 0100 Engine Oil Pressure Speed/Timing
J63 AUXILIARY
(134-2540)
ENGINE SERVICE
A +5V
PRESSURE
0110 Engine Coolant Temperature Sensor
(NOTE B&C) OPTIONAL B RETURN
TOOL CONNECTOR
BATTERY WIRING C SIGNAL SENSOR 0168 System Voltage (Camshaft) ECM
A B C 8T8736
P154 120/YL A (+)BATTERY 0172 Intake Manifold Air Temp P402 Ground
1740502
1297163

229/BK B (-)BATTERY J403/P403 Strap


A234/BK C J1939 SHIELD 1297163 1297164 DESIRED 0174 Fuel Temperature
A + BATTERY
893/PK D CAT DATA LINK(+) 1
B - BATTERY SPEED 0247 Data Link Communications
892/WH E CAT DATA LINK(-) NOTE D CONTROL
C SIGNAL
1

K990/GN F J1939(-) (NOTE W) 0253 Personality Module


1297164

K900/YL G J1939(+) BATTERY(-)


H
J
G S
ETHER START VALVE
0254
0261
Electronic Control Module
Engine Timing
FRONT VIEW
P1 MTR BAT.
1607689 0262 5 Volt Sensor DC Power Supply
ETHER START
1 B
STARTING ST VALVE RELAY ETHER
ANALOG SENSOR POWER (+5V) 2 125/OR 229/BK(63)
MOTOR
ON S (NOTE V)
0263 Digital Sensor Supply
NOTE D NOTE D 1 START
ANALOG SENSOR RETURN 3 T993/BR 229/BK(61) C
OFF 2 VALVE 0268 Check Programmable Parameters
DIGITAL SENSOR POWER (+8V) 4 167/OR 229/BK(65)
(NOTE V)
DIGITAL SENSOR RETURN 5 A274/BK R 0273 Turbo Outlet Pressure
6 ELECTRONICS START RELAY
GROUND STUD (SMMS)
7 KEYSTART 0274 Atmospheric Pressure
CAT DATA LINK (+) 893/PK NOTE A SWITCH
Electronic
8 1 1

0320 Speed / Timing Sensor Event Codes For ADEM III ECM
CAT DATA LINK (-) 892/WH 120/YL 120/YL Control
(Dimensions: 39 inches x 28 inches)

9 P515
RETARDER LAMP 10 T936/GN ALTERNATOR 1552269 Event Code Condition
BK-18 0342 Loss of Secondary Engine Speed Module
INLET AIR SHUTOFF SOLENOID RELAY 11 G971/BR 1
12 A234/BK A234/BK BK-18 2 STARTING AID OVERRIDE SW 0545 Ether Start Relay E004 Engine Overspeed Shutdown
13
(ECM)
14 K990/GN K990/GN 1835 Auxiliary Pressure Sensor E005 Fuel Filter Restriction Derate Timing Calibration
AUXILIARY PRESSURE SENSOR 15 G469/BU
(TC) Probe Connector
16 K900/YL K900/YL MAINTENANCE DUE RESET SW
1836 Auxiliary Temperature Sensor E006 Fuel Filter Restriction Shutdown
ECM
17
18
¹ The CID is a diagnostic code that indicates which component is faulty. E015 High Engine Coolant Temperature Derate P400 Connector ECM
19 892/WH 892/WH ² The MID is a diagnostic code that indicates which electronic control module Engine Oil Connector
20 893/PK 893/PK J61 +BAT. (UNSWITCHED) 14 AWG E016 High Engine Coolant Temperature Shutdown P2/J2
TORQUE LIMIT SW Pressure
ETHER START VALVE
STARTING AID OVERRIDE SWITCH
21
22
382/PK
M910/OR M909/GN
9X1343
150/OR(48) 1
P61
+BAT. (UNSWITCHED)
+BAT. (UNSWITCHED)
+BAT. (UNSWITCHED)
14 AWG
14 AWG
diagnosed the fault.
E017 High Engine Coolant Temperature Warning Sensor
LEFT SIDE VIEW P1/J1
MAINTENANCE DUE RESET SWITCH 23 F426/BU T936/GN M909/GN 2 TORQUE LIMIT SW INLET AIR SHUTOFF SOLENOID RELAY
24 G971/BR T936/GN 3 RETARDER LAMP(NOTE M) SOLENOID COMMON REMOTE SHUTDOWN SW (NOTE K) Failure Mode Identifiers (FMI)¹ E025 High Inlet Air Temperature Derate P201(J201)
25 G969/YL G971/BR 4 INLET AIR SHUTOFF SOLENOID RELAY AUXILIARY TEMP SNSR
SENR9575-05

26 167/OR G969/YL 5 SOLENOID COMMON COOLANT LEVEL SNSR FMI No. Failure Description E027 High Inlet Air Temperature Warning
NOT USED 27 J983/YL A274/BK 892/WH 6 CAT DATA LINK - DIG SNSR PWR (+8V)
0 Data valid but above normal operational range. E039 Low Engine Oil Pressure Derate
DIAGNOSTIC LAMP 28 F404/RD A307/GY 893/PK 7 CAT DATA LINK + DIG SNSR RETURN INTERMEDIATE ENGINE SPEED SW
WARNING LAMP 29 F420/GN G488/GN 167/OR 8 DIG SNSR PWR (+8V) AUXILIARY PRESS. SNSR 1 Data valid but below normal operational range.
A274/BK 9 DIG SNSR RETURN THROTTLE POSITION SNSR
E040 Low Engine Oil Pressure Shutdown
MAINTENANCE DUE LAMP 30 F424/YL F426/BU
31 F424/YL A307/GY 10 THROTTLE POSITION SNSR ANLG SNSR PWR (+5V) 2 Data erratic, intermittent, or incorrect.
G488/GN 11 AUXILIARY TEMP SNSR ANLG SNSR RETURN
E054 High Fuel Temperature Derate
32 125/OR OVERSPEED VERIFY SW 3 Voltage above normal or shorted high.
33 T993/BR F426/BU 12 MAINTENANCE DUE RESET SW ETHER START VALVE NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST
F424/YL 13
E055 High Fuel Temperature Shutdown
M904/OR MAINTENANCE DUE LAMP STARTING AID OVERRIDE SW 4 Voltage below normal or shorted low.
J1939 DATA (-) 34 K990/GN HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS
382/PK 125/OR 14 ANLG SNSR PWR (+5V) MAINTENANCE DUE RESET SW (+) BATTERY
35
T993/BR 15 ANLG SNSR RETURN TORQUE LIMIT SW 5 Current below normal or open circuit. E056 High Fuel Temperature Warning CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL
36 F404/RD PTO INTERRUPT SW
37 F420/GN A234/BK 16 J1939 SHIELD REMOTE SHUTDOWN SW E057 Low Engine Coolant Level Derate
F716/WH K900/YL 17 J1939 DATA + INTERMEDIATE ENGINE SPEED SW
6 Current above normal or grounded circuit. (+) BATTERY SWITCHED NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL
TACHOMETER + 38 450/YL
451/BR G968/WH K990/GN 18 J1939 DATA - 75% OVERSPEED VERIFY SW 7 Mechanical system not responding properly. E058 Low Engine Coolant Level Shutdown INSTALLATION DETAILS
TACHOMETER - 39
TORQUE LIMIT SWITCH 40 M909/GN 381/PU M904/OR 19 PTO INTERRUPT SW PTO INTERRUPT SW PTO ENABLE SW
STARTING CIRCUIT
PTO INTERRUPT SWITCH 41 M904/OR G955/GN 450/YL 20 PTO ENABLE SW 8 Abnormal frequency, pulse width, or period. E059 Low Engine Coolant Level Warning NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR
J1939 SHIELD 42 A234/BK G469/BU 451/BR 21
9 Abnormal update. (-) BATTERY / SENSOR RETURN TO TERMINATION RESISTOR) IS 40 METERS
(NOT USED)NOTE Z 43 E798/PK H407/YL 382/PK 22 ETHER START VALVE PTO RAMP UP/SET SW E095 Fuel Filter Restriction Warning
E798/PK(H406/GY)NOTE Z J983/YL 23 PTO RAMP DOWN/RESUME SW 10 Abnormal rate of change. NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION
REMOTE SHUTDOWN SWITCH 44 F716/WH
INTERMEDIATE ENGINE SPEED SWITCH 45 G968/WH E452/WH F404/RD 24 DIAGNOSTIC LAMP MAINTENANCE DUE LAMP E096 High Fuel Pressure SENSOR / ACTUATOR SUPPLY NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939
COOLANT LEVEL SENSOR 46 E452/WH H405/BU F420/GN 25 WARNING LAMP DIAGNOSTIC LAMP 11 Failure mode not identifiable. SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS
RETARDER SOLENOID HI (NOTE M) 47 H405/BU M910/OR 120/YL 26 +BAT. (SWITCHED) WARNING LAMP E100 Low Engine Oil Pressure Warning SIGNAL PLUS TO ECM
F716/WH 27 REMOTE SHUTDOWN SW RETARDER LAMP(NOTE M) PTO RAMP
12 Bad device or component. NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR
+BATTERY (UNSWITCHED) 48 150/OR(48) G967/WH SIGNAL MINUS TO ECM
387/PK G968/WH 28 INTERMEDIATE ENGINE SPEED SW +BAT. (SWITCHED) 14 AWG UP/DOWN SWITCH E190 Engine Overspeed Warning MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION
RETARDER SOLENOID MED (NOTE M) 49 H406/GY 13 Out of calibration.
J1939 DATA (+) 50 K900/YL 150/OR(48) 381/PU 29 PTO ENABLE SW CAT DATA LINK -
51 150/OR(52) G955/GN 30 PTO RAMP UP/SET SW CAT DATA LINK + 14 Parameter failures. E443 High Auxiliary Pressure CONTROL PLUS FROM ECM NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING
+BATTERY (UNSWITCHED) 52 150/OR(52) 150/OR(53) 150/OR(52) 31 +BAT. (UNSWITCHED) MAINTENANCE CONTROL MINUS FROM ECM STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE
450/YL 150/OR(53) 32 +BAT. (UNSWITCHED)
CB DUE LAMP 15 Parameter failures. E445 High Auxiliary Temperature OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO
+BATTERY (UNSWITCHED) 53 150/OR(53)
75% OVERSPEED VERIFY SWITCH 54 387/PK 451/BR G469/BU 33 AUXILIARY PRESS. SNSR
MAX LENGTH 40 METERS 1A 16 Parameter not available. CAT DATA LINK A MAIN EMS MODULE
55 J983/YL H407/YL 34 RETARDER MED/LO/HI SW(NOTE M) J1939 SHIELD
NOTE Z E798/PK(H406/GY) 35 RETARDER MED SW(NOTE M) J1939 DATA + 17 Module not responding. J1939 DATA LINK NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS.
PTO ENABLE SWITCH 56 381/PU
57 E452/WH 36 COOLANT LEVEL SNSR J1939 DATA - DIAGNOSTIC LAMP
IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED.
H405/BU 37 RETARDER HI SW(NOTE M) (153-2707)
CB 18 Sensor supply fault. IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO
PTO RAMP UP/SET SWITCH 58 G955/GN
M910/OR 38 STARTING AID OVERRIDE SW (NOTES B & E) 1A 19 Condition not met. BATTERY (-) IS REQUIRED
30 Page, Color 2,

RETARDER SOLENOID MED/LO/HI (NOTE M) 59 H407/YL


PTO RAMP DOWN / RESUME SWITCH 60 G967/WH G967/WH 39 PTO RAMP DOWN/RESUME SW
BATTERY (-) 61 229/BK(61) 387/PK 40 75% OVERSPEED VERIFY SW 20 Parameter failures. NOTE K: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-)
62 CUSTOMER RETARDER MED/LO/HI SW
CB WARNING LAMP THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS
BATTERY (-) 63 229/BK(63) CONNECTOR MED/LO/HI ¹The FMI is a diagnostic code that indicates what type of failure has occurred. ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING
64
NOTE M
RETARD SWITCH 1A THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS
BATTERY (-)
THROTTLE POSITION SENSOR
SOLENOID COMMON
65
66
67
229/BK(65)
A307/GY
G969/YL C-10, C-12, C-15, and C-16 RETARDER MED SW C B A RETARDER LAMP
C-15 and C-16 Engines NOTE L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER
FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS
CB
AUXILIARY TEMPERATURE SENSOR 68 G488/GN MED NOTE M SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS
+BATTERY (SWITCHED)
69
70 120/YL
Customer Harness NOTE M RETARD SWITCH 1A 1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR
Fuel Fuel NOTE M: THE RETARDER FEATURE IS ONLY AVAILABLE ON SPECIFIC MODELS
ELECTRONIC CONTROL MODULE (ECM)
RETARDER HI SW Customer Service Tool Electronics
A + BAT. Pressure Temperature NOTE V: ARC SUPPRESSION DIODES ARE REQUIRED
HI B - BAT. Connector Connector Ground ON RELAY COILS AND SOLENOID COILS.
RETARD SWITCH
C B A B A C C Turbo Outlet Sensor Sensor
MAX LENGTH 30 METERS
D CAT DATA LINK + J61 J63 Stud NOTE W: WIRING FOR DESIRED SPEED CONTROL DETERMINED BY APPLICATION.
E CAT DATA LINK - Pressure J209 P105 FOR DESIRED SPEED CONTROL OPTIONS, REFER TO THE ELECTRONIC
F INSTALLATION GUIDE.
Sensor
-BAT.
+BAT. (SWITCHED)
CAT DATA LINK +
CAT DATA LINK -

120 G Intake Manifold NOTE Y: HARNESSES 237-7595 -00 AND 238-1773 -00 HAVE WIRES J700/BR, J701/GN,
H
TERMINATION
(165-0200)
J
(Intake Air Temperature AND J702/BK INSTALLED. ALL OTHER C-15/C-16 ENGINE HARNESSES DO NOT INCLUDE
MAX LENGTH 1 METER
RESISTOR
(NOTE B) Manifold Air) THESE WIRES.
(174-3016)
DEVICE
(J66) Sensor NOTE Z: HARNESS 242-7248 -00 HAS WIRE H406/GY INSTALLED. ALL OTHER CUSTOMER
(NOTE B & C) CUSTOMER INSTALLED
SERVICE TOOL CONN
J200 P103 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

Secondary Engine
MAIN EMS MODULE
OPTIONAL EMS DISPLAY MODULES
Speed/Timing ABBREVIATION
(NOTE G)
Sensor ALT ALTERNATOR
ATA AMERICAN TRUCKING ASSOCIATION
TACHOMETER MODULE QUAD GAUGE MODULE
Engine Coolant (Camshaft) Timing Calibration CB CIRCUIT BREAKER
CAT DATA LINK +
CAT DATA LINK -

SCROLL BACKWARD

(NOTE G) (NOTE G)
SCROLL FORWARD

P402 CIS CUSTOMER IGNITION SWITCH


AUXILIARY CKT

Temperature (TC) Probe Connector


MODULE CLOCK

WARNING LAMP

DIG DIGITAL
MODULE LOAD

MODULE DATA
CAT DATA LINK +
CAT DATA LINK -
-BAT.
+BAT. (SWITCHED)

P400 ECM ELECTRONIC CONTROL MODULE


+V MODULE

US/METRIC

10
15
20 Sensor
WARNING

OPTIONAL REMOTE N/C NO CONNECTION


5 25 TACHOMETER MODULE OR P100 PWM PULSE WIDTH MODULATION
+24V
-BAT

-BAT

QUAD GAUGE MODULE SM STARTING MOTOR


RPM X100
0 30 (NOTES G & B) SMMS START MOTOR MAG SWITCH
Atmospheric
14
15
25
34
35
20
23
13

33

10
11
12
16
17
18
19
21
22
24
26
27
28
29
30
31
32
36
37
38
39
40
1
2
5

7
4

3
6
8
9

1
2
3
4
5
6

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

Pressure
Sensor THIS SCHEMATIC IS FOR THE C-10, C-12, C-15, and C-16 INDUSTRIAL ENGINES
J203 WIRING DIAGRAMS- 201-0649 CHG04 AND 238-1775 CHG01
(NOTE F)

MODULE DATA Electronic HARNESS TABLE


+V MODULE
MODULE CLOCK Control PART NO. CHG. NAME
MODULE LOAD
-BAT
Primary Engine Module 189-6594 05 J2/ENGINE(C-10/C-12 Pigtail Sensors)
BACKLIGHT LAMP PWR Speed/Timing (ECM) 226-5758 03 J2/ENGINE(C-10/C-12 Integral Sensors)
Sensor 243-6620 00 J2/ENGINE(C-10/C-12 Specific Arrangements)
+24V 1 (Crankshaft) ECM 191-5204 02 J2/ENGINE(C-15/C-16)
- BAT. 2 Engine Oil
US/METRIC 3 P401 Ground 238-1773 00 J2/ENGINE(C-15/C-16 Retarder)
SCROLL FORWARD 4 (NOTE H) Pressure ECM 237-7595 01 J2/ENGINE(C-15/C-16 Specific Arrangements)
ECM
CAT DATA LINK -
CAT DATA LINK +
5
6 -V OUT +V OUT FRONT VIEW Sensor Strap Connector
Connector 189-6596 04 J1/CUSTOMER(C-10/C-12)
UNUSED
WARNING LAMP
7
8 DC/DC CONVERTER J201 P2/J2
WARNING 9 (127-8853) P1/J1 243-6618 00 J1/CUSTOMER(C-10/C-12 Specific Arrangements)
BACKLIGHT LAMP PWR 10 (NOTES B & L)
SCROLL BACKWARD 11
-V IN +V IN
191-1531 04 J1/CUSTOMER(C-15/C-16)
12
238-1774 00 J1/CUSTOMER(C-15/C-16 Retarder)
(NOTE B)
LEFT SIDE VIEW 242-7248 00 J1/CUSTOMER(C-15/C-16 Specific Arrangements)

4P-9537 07 INJECTOR(C-10/C-12)
CAT DATA LINK +
CAT DATA LINK - 122-1486 10 INJECTOR(C-15/C-16)
-BAT.
(NOTES B & L) 132-3144 00 FUEL PRESSURE EXTENSION(C-10/C-12)
+BAT. (SWITCHED)

You might also like