SENR1064-07 January 2005

Jack/Plug J1/P1 J2/P2 J3/P3 J114/P114 J109/P109 J20/P20 J21/P21 J22/P22 J23/P23 P26 J27/P27 J34/P34 J35/P35 J42 J43/P43 J44/P44 J45/P45 J46/P46
Injection Actuation Pressure Sensor
Electronics Ground Stud Electronic Control Module ECM Connector J2/P2

Electrical Connectors and Functions

Functional Description Electronic Control Module (ECM) Connector (key C) Electronic Control Module (ECM) Connector (key D) Customer Connector (40-Pin) Auxiliary Temperature Sensor Connector (3-Pin) Auxiliary Pressure Sensor Connector (3-Pin) Primary Speed/Timing Sensor Connector (3-Pin) Coolant Temperature Sensor Connector (3-Pin) Oil Pressure Sensor Connector (3-Pin) Turbocharger Compressor Outlet Pressure Sensor Connector (3-Pin) Timing Calibration Connector (2-Pin) Atmospheric Pressure Sensor Connector (3-Pin) Coolant Level Sensor Connector (3-Pin) Throttle Position Sensor Connector (3-Pin) Customer Installed Service Tool Connector Fuel Temperature Sensor Connector (3-Pin) Secondary Speed/Timing Sensor Connector (3-Pin) Injection Actuation Pressure Sensor Connector (3-Pin) Injection Actuation Pressure Control Valve Sensor Connector(2-Pin) Fuel Pressure Sensor Connector (3-Pin) Engine Oil Temperature Sensor Connector (3-Pin) #1, #3 Hydraulic Electronic Unit Injector Connector (4-Pin) #5, #7 Hydraulic Electronic Unit Injector Connector (4-Pin) #9, #11 Hydraulic Electronic Unit Injector Connector (4-Pin) #2, #4 Hydraulic Electronic Unit Injector Connector (4-Pin) #6, #8 Hydraulic Electronic Unit Injector Connector (4-Pin) #12, #10 Hydraulic Electronic Unit Injector Connector (4-Pin) Service Tool Connector (9-Pin) Inlet Air Temperature Sensor Connector (3-Pin)

TOP VIEW
Fuel Pressure Sensor Connector P49 Caterpillar Supplied Engine Service Tool Connector J60 Inlet Air Temperature Sensor P89 (Specific Arrangements Only)

Customer Connector J3

Injectors 10 & 12 P58

Timing Calibration (TC) Probe Connector J26/P26 Injectors 9 & 11 P54 Injectors 5&7 P53

Injectors 6&8 P57 Timing Calibration (TC) Probe Connector J26/P26 ECM Connector J2/P2 ECM Connector J1/P1

ECM Connector J1/P1

Fuel Pressure Sensor Connector P49

Customer Connector J3

Caterpillar Supplied Engine Service Tool Connector J60 Electronics Ground Stud

3412E Industrial Engine Electrical System

Z2D1-UP 4CR1-UP BDT1-UP BFT1-UP

J49/P49 J51/P51 J52/P52 J53/P53 J54/P54 J56/P56 J57/P57 J58/P58 J60 J89/P89

Electronic Control Module

Injection Actuation Pressure Control Valve Connector J46/P46 Injectors 1&3 P52

Primary Engine Speed/Timing Sensor Connector J20/P20 Injectors 2&4 P56

Atmospheric Pressure Sensor

Engine Coolant Temperature Sensor

Injection Actuation Pressure Sensor Connector J45/P45

Atmospheric Pressure Sensor Connector J27/P27

Intake Manifold (Boost) (Turbo Outlet) Pressure Sensor Connector J23/P23

J2
Fuel Temperature Sensor Injection Actuation Pressure Control Valve Engine Oil Pressure Sensor

J1

Engine Oil Temperature Sensor

Atmospheric Pressure Sensor

Electronic Control Module

2005 Caterpillar All Rights Reserved

Printed in U.S.A.

Electronic Control Module (ECM)

Timing Calibration (TC) Probe

4-Pin DT Connector
J60 Caterpillar Supplied Engine Service Tool Connector Electronics Ground Stud P26/J26
3E-3376 Receptacle As. 102-8804 Receptacle Kit 3E-3377 Wedge 102-8814 Seal

12 HEUI Injectors

3E-3374 Wedge 102-8809 Plug Kit

3E-3373 Plug As.

Wire Gauge
14 16 - 18

Pin #
9W-0852 8T-8729

Socket #
9W-0844 8T-8730

J3 P3

Customer Connector Battery Disconnect Switch

40-Pin Deutsch Connector

110-6844 Seal

Battery 24VDC

9-Pin HD10 Receptacle

D C A F J B

Primary Speed/Timing Sensor

SMMS P20/J20
Primary Engine Speed/Timing Sensor

Keyswitch P44/J44 15 Amp Breaker 15 Amp Breaker

110-6845 Plug As. or 110-6846 Plug As. (Service Replacement) 110-6846 Plug As.

8T-8736 Receptacle

Fuel System Block Diagram

To Lubrication System

12 Hydraulic Electronic Unit Injectors

Wire Gauge
14 16 - 18

Pin #
9W-0852 8T-8729

Socket #
9W-0844 8T-8730

Wire Gauge
14 16 - 18

Pin #
9W-0852 8T-8729

Socket #
9W-0844 8T-8730

J46/P46
Injection Actuation Pressure Control Valve (IAPCV) Injection Actuation Pressure Sensor

P45/J45

Engine Oil Temperature Sensor

P27/P27
Oil Pressure Sensor

Atmospheric Pressure Sensor Engine Oil Pressure Sensor

High Pressure Oil Manifold

P22/J22

Intake Manifold (Boost) (Turbo Outlet) Pressure Sensor

Cold Start Oil Reservoir Cooldown Circuit

J23/P23
Intake Manifold Pressure Sensor

OEM Installed Switches: PTO Enable PTO Ramp Up/Down PTO Interrupt Remote Shutdown Starting Aid Override Overspeed Verify Intermediate Engine Speed Maintenance Due Reset Torque Limit J35/P35
3E-3307 Receptacle As.

3-Pin DT Connector
102-8813 Seal

3E-3371 Wedge

3E-3368 Wedge 104-2921 Plug As. 102-8808 Plug Kit

High Pressure Oil Pump

Fuel Temperature Sensor High Pressure Oil Manifold

Injection Actuation Pressure Sensor

P21/J21
Engine Coolant Temperature Sensor

Throttle Position Sensor P34/J34 Coolant Level Sensor P109/J109 Auxiliary Pressure Sensor P114/J114 Auxiliary Temperature Sensor

102-8803 Receptacle Kit

P43/J43
Fuel Temperature Sensor

Wire Gauge
14 16 - 18

Pin #
9W-0852 8T-8729

Socket #
9W-0844 8T-8730

Oil Filter Injection Actuation Pressure Control Valve Oil Cooler Fuel Transfer Pump Hydraulic Electronic Unit Injectors (HEUI) Lubrication Oil Pump Primary Fuel Filter Water Separator Secondary Fuel Filter Pressure Regulating Valve

P51/J51

ECM

Engine Oil Temperature Sensor

J89/P89
Intake Manifold Air Temperature Sensor

40-Pin DRC Connector

40 40 10 10 20 30 40 39

P49/J49
Fuel Pressure Sensor
3E-8557 Bolt
38

36

16

26

Warning Lamp Diagnostic Lamp NOTE: Components within this area are recommendations Maintenance Due Lamp Customer Installed J42 Service Tool Connector

15

25

35

31

Ether Solenoid & Relay Engine Monitoring System (EMS) Display Modules

11

21

10

15

8T-9834 Connector As.

9X-3132 Seals

20

Engine Coolant Temperature Sensor

25

Wire Gauge
14 16 - 18

Pin #
9W-0852 8T-8729

Socket #
9W-0844 8T-8730

Oil Sump

Fuel Tank

31

3E-4367 Ring

35

Inlet Air Shutoff Solenoid & Relay

36

9X-1343 Receptacle As.

16 Page, RED

Secondary Engine Speed/Timing Sensor

SENR1064-07

Secondary Speed/Timing Sensor

Breaker

110-6845 Plug As. or

37 36 DEUTSCH IPD DRC16-40S 35 34 33 32 31

MAIN UNIT (NOTE E) TACHOMETER (NOTE E) 15 20 25

OPTIONAL EMS DISPLAY MODULES

QUAD GAGE (NOTE E)

10 5

1 2 5 14 15 25 34 35 20 23 13 7 4 33 3 6 8 9 10 11 12 16 17 18 19 21 22 24 26 27 28 29 30 31 32 36 37 38 39 40

0 RPM X100 30
1 2 3 4 5 6

OPTIONAL REMOTE TACHOMETER OR QUAD GAGE (NOTES E & J)

1 2 3 4 5 6

(NOTE D)

+24V -BAT. US/METRIC SCROLL FORWARD CAT DATA LINK CAT DATA LINK + UNUSED WARNING LAMP WARNING BACKLIGHT LAMP PWR SCROLL BACKWARD

1 2 3 4 5 6 7 8 9 10 11 12
(NOTE J)

(NOTE F)

INJECTORS #1 #3

INJECTORS #5 #7 #9

INJECTORS #11

INJECTORS #10 #12

INJECTORS #6 #8

INJECTORS #2 #4

GY-16 WH-16

OR-16 PU-16

GY-16 WH-16

OR-16 PU-16

GY-16 WH-16

OR-16 PU-16

GY-16 WH-16

OR-16 PU-16

GY-16 WH-16

OR-16 PU-16

GY-16 WH-16

1 2 3 4

1 2 3 4

1 2 3 4

1 2 3 4

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

J2/P2 16 40 26 34 32 28 38 22 37 18 31 12 5 11 17 21 27 33

A701/GY A702/PU A703/BR A704/GN A705/BU A706/GY A707/PU A708/BR A709/OR A710/GY A711/PU A712/BR F726/YL F727/BU F728/BR F729/GN F730/GY F731/OR

A701/GY A703/BR F726/YL A705/BU A707/PU F728/BR F709/OR A711/PU F730/GY F731/OR A712/BR A710/GY F729/GN A708/BR A706/GY F727/BU A704/GN A702/PU

A705/BU F728/BR A707/PU F728/BR

F709/OR F730/GY A711/PU F730/GY

A710/GY F731/OR A712/BR F731/OR

A706/GY F729/GN A708/BR F729/GN

A702/PU F727/BU A704/GN F727/BU

P52

P53

P54

P58

1 2 3 4

P57

1 2 3 4

OR-16 PU-16

P56

1 2 3 4 5 6 7 8

START RELAY

C OFF ON S ST R

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

B AIR SHUTOFF SOLENOID

(NOTE J)

KEYSWITCH IAPCV RETURN IAPCV ENGINE COOLANT TEMPERATURE FUEL TEMPERATURE ATMOSPHERIC PRESSURE INTAKE MANIFOLD PRESSURE ENGINE OIL PRESSURE INLET AIR TEMPERATURE FUEL PRESSURE SOLENOID RETURN AIR SHUTOFF SOLENOID NOT USED THROTTLE POSITION SENSOR AUXILIARY TEMPERATURE SENSOR MAINTENANCE CLEAR SWITCH SPARE 35 29 9 15 20 23 8 14 2 7 13 19 24 25 1 3 4 6 10 30 36 39 J1/P1 29 36 30 26 31 32 37 38 39 33 2 8 15 16 10 13 23 14 20 19 17 22 27 25 34 35 4 21 24 28 40 18 12 6 1 7 3 9 5 11 E797/WH E798/PK 995/BU A751/YL A747/GY A746/PK 994/GY F713/OR F714/PK E799/BR F701/BR F700/BU F702/GN G468/GN F426/BU F737/YL E797/WH E798/PK 995/BU A751/YL A747/GY A746/PK 994/GY F713/OR F714/PK E797/WH E798/PK 412/BU 998/BR 997/OR 993/BR E796/GN 996/GN 998/BR 999/WH 996/GN 996/GN 998/BR 998/BR 998/BR 997/OR 997/OR 997/OR 997/OR 997/OR 997/OR 997/OR 997/OR 997/OR 993/BR 993/BR 993/BR 993/BR 993/BR 993/BR 993/BR 993/BR 993/BR 996/GN 998/BR F732/PK 997/OR 993/BR 995/BU 997/OR 993/BR A746/PK 997/OR 993/BR A747/GY 997/OR 993/BR 994/GY 997/OR 993/BR E795/YL 997/OR 993/BR A751/YL 1 NOT USED 2 J45 A B C J20 A B C J44 A B C P21 A B C J23 A B C J27 A B C J22 A B C P51 A B C P43 A B C 1 2 P46 INJECTION ACTUATION PRESSURE CONTROL VALVE +
G MTR S BAT

CB 15A

997/OR F714/PK 993/BR

(P49) A C B (P114) A C B (P34) A C B (P19B) A C B (P35) C A B

+5V SIGNAL RETURN (NOTE K) +8V SIGNAL RETURN

FUEL PRESSURE SENSOR

15A

ALTERNATOR GND

CB (NOTE B) 15A

AUXILIARY TEMPERATURE SENSOR (131-0427)

+5V RETURN SIGNAL +12V RETURN SIGNAL +12V GND SIGNAL +5V GND SIGNAL +5V GND SIGNAL +5V GND SIGNAL +5V GND SIGNAL +5V GND SIGNAL +5V GND SIGNAL

INJECTION ACTUATION PRESSURE SENSOR

CB (NOTE C)

412/BU E795/YL E796/GN 999/WH F732/PK 993/BR 997/OR 998/BR F714/PK F714/PK F714/PK E799/BR F701/BR F700/BU F702/GN G468/GN F426/BU F737/YL 996/GN 998/BR 998/BR

PRIMARY SPEED/TIMING SENSOR BATTERY DISCONNECT SWITCH (NOTE B) + ENGINE COOLANT TEMPERATURE SENSOR -

STARTING MOTOR

+8V SIGNAL RETURN

COOLANT LEVEL SENSOR (111-3794)

CB (NOTE B)

SECONDARY SPEED/TIMING SENSOR

+5V SIGNAL RETURN SIG + BAT. - BAT.

AUXILIARY PRESSURE SENSOR (161-9932)

DIGITAL SENSOR RETURN ANALOG SENSOR POWER (+5V) ANALOG SENSOR RETURN NOT USED ENGINE OIL TEMPERATURE SPEED/TIMING SENSOR POWER INJECTION ACTUATION PRESSURE PRIMARY SPEED/TIMING SECONDARY SPEED/TIMING REMOTE SHUTDOWN SWITCH (NO) INTERMEDIATE SPEED SWITCH J1939 SHIELD J1939 DATA + J1939 DATA OVERSPEED VERIFY SWITCH KEYSWITCH PTO ENABLE SWITCH PTO RAMP UP SWITCH PTO RAMP DOWN SWITCH AUXILIARY PRESSURE SENSOR DIAGNOSTIC LAMP WARNING LAMP STARTING AID SWITCH ETHER START VALVE RELAY DIGITAL SENSOR POWER (+8V) +BATTERY (UNSWITCHED)(NOTE B) MAINTENANCE OVERDUE LAMP COOLANT LEVEL SENSOR PTO INTERUPT SWITCH TORQUE LIMIT SWITCH TIMING CALIBRATION (TC) PROBE + TIMING CALIBRATION (TC) PROBE +BATTERY (UNSWITCHED) ATA DATA LINK ATA DATA LINK + CAT DATA LINK CAT DATA LINK + -BATTERY -BATTERY

998/BR 997/OR 993/BR 998/BR 997/OR 993/BR 412/BU E795/YL 996/GN E796/GN 999/WH F732/PK F715/PU F716/WH A234/BK K900/YL K990/GN F722/OR 113/OR F717/YL F718/BU F721/GY G469/BU F707/WH F706/PU F720/GN F709/BU A700/OR 150/OR F424/YL F719/BR F708/YL F710/BR F723/PK F724/PU 150/OR E793/BU E794/YL 892/BR 893/GN 229/BK 229/BK

THROTTLE POSITION SENSOR (161-8906)

BATTERY J3/P3 1 2 4 5 11 36 8 9 20 19 33 10 14 15 22 38 12 21 27 28 40 23 29 3 30 39 13 24 25 37 26 6 7 31 32 16 17 18 34 35

997/OR 997/OR

INTAKE MANIFOLD PRESSURE (BOOST) (TURBO OUTLET) SENSOR ATMOSPHERIC PRESSURE SENSOR

Note: Early engines may have pin 10 connected to K900/YL & pin 16 connected to K990/GN.

150(6)/OR 150(4)/OR F701/BR E799/BR G468/GN F719/BR A700/OR 998/BR F714/PK G469/BU F702/GN 997/OR 993/BR F709/BU F720/GN F426/BU F710/BR F715/PU F716/WH F722/OR F708/YL F717/YL F700/BU F718/BU F721/GY F424/YL F707/WH F706/PU F737/YL 113/OR 892/BR 893/GN E794/YL E793/BU A234/BK K900/YL K990/GN F723/PK F724/PU 1 2 P26 J26 F723/PK F724/PU

+BAT. (UNSWITCHED) +BAT. (UNSWITCHED) AIR SHUTOFF SOLENOID SOLENOID COMMON AUXILIARY TEMP SENSOR COOLANT LEVEL SENSOR DIGITAL SNSR PWR (+8V) DIGITAL SNSR RETURN FUEL PRESSURE SENSOR AUXILIARY PRESS. SENSOR THROTTLE POSITION SENSOR ANLG SNSR PWR (+5V) ANLG SNSR RETURN ETHER START VALVE RELAY STARTING AID SW MAINTENANCE CLEAR SW TORQUE LIMIT SW REMOTE SHUTDOWN SW INTERMEDIATE SPEED SW OVERSPEED VERIFY SW PTO INTERRUPT SW PTO ENABLE SW NOT USED PTO RAMP UP SW PTO RAMP DOWN SW MAINTENANCE OVERDUE LAMP DIAGNOSTIC LAMP WARNING LAMP SPARE KEYSWITCH INPUT CAT DATA LINK CAT DATA LINK + ATA DATA LINK + ATA DATA LINK BARE YL GN REMOTE TC PROBE + REMOTE TC PROBE CABLE 153-2707 MAX LENGTH 40 METERS A B C

ETHER VALVE

STARTING AID SW MAINTENANCE CLEAR SW TORQUE LIMIT SW (NOTE H) REMOTE SHUTDOWN SW INTERMEDIATE SPEED SW OVERSPEED VERIFY SW PTO INTERUPT SW PTO ENABLE SW

993/BR 993/BR

ENGINE OIL PRESSURE SENSOR

SENR1064-07

ENGINE OIL TEMPERATURE SENSOR

16 Page, Color 2, RED

FUEL TEMPERATURE SENSOR

150(4)/OR

997/OR 993/BR F713/OR

150(6)/OR

P89

A B C

+5V RETURN SIGNAL

NOTE K

PTO RAMP UP/DOWN SWITCH

INLET AIR TEMPERATURE SENSOR

997/OR 993/BR F714/PK

J49 A B C

MAINTENANCE OVERDUE LAMP DIAGNOSTIC LAMP WARNING LAMP A B C E D F G J H + BAT. - BAT. CAT DATA LINK CAT DATA LINK J1939 DATA J1939 DATA + ATA DATA LINK ATA DATA LINK + + -

997/OR 993/BR A745/WH NOTE W

A B C

+5V RETURN SIGNAL

FUEL PRESSURE SENSOR

ELECTRONIC CONTROL MODULE

to P2, pin 4 TERMINATION RESISTOR 174-3016 120 ohms A B C P154 ELECTRONICS GROUND STUD (NOTE A) 150/OR 229/BK A234/BK 893/GN 892/BR K990/GN K900/YL E793/BU E794/YL 150(4)/OR SERVICE TOOL CONNECTOR J60 A B C D E F G H J +BAT. -BAT. J1939 SHIELD CAT DATA LINK CAT DATA LINK J1939 DATA J1939 DATA + ATA DATA LINK ATA DATA LINK

A B C CABLE AS 165-0200 MAX LENGTH 30 METERS MAX LENGTH 1 METER MAX LENGTH 40 METERS A B C CABLE TEE 133-0970 120 ohms TERMINATION RESISTOR 174-3016

TIMING CALIBRATION TC PROBE CONNECTOR

+ +

150(6)/OR to J60, pin A

(J42) CUST. SUPPLIED ENG SERVICE TOOL CONN

Early engines were wired as shown above

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL. NOTE B: TO AVOID LOSS OF JOB DATA STORED BY THE ECM, DISCONNECT SWITCHES SHOULD NOT INTERRUPT EITHER THE ECM BATTERY (-) OR UNSWITCHED BATTERY (+) LINES. NOTE C: PLACE APPROPRIATE CIRCUIT PROTECTION. NOTE D: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION.

NOTE E: ONE MAIN EMS MODULE IS MONITORING STATION. THE GAGE UNITA ARE OPTIONAL WITHOUT CONNECTION TO A

REQUIRED FOR EACH DESIRED TACHOMETER AND/OR QUAD AND WILL NOT OPERATE MAIN EMS MODULE.

NOTE F: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS. IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED. IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO BATTERY (-) IS REQUIRED. NOTE G: 16 AWG WIRE

NOTE H: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-) THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS. NOTE J: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL INSTALLATION DETAILS. NOTE K: THIS OPTIONAL FEATURE NOT AVAILABLE ON ALL SYSTEMS. NOTE W: FUEL PRESSURE EXTENSION USED FOR RIGHT-HAND ENGINES.

(+) BATTERY (+) BATTERY SWITCHED

NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES WITHOUT CATERPILLAR ENGINEERING APPROVAL UNLESS OTHERWISE SPECIFIED: ALL WIRES TO BE 18 AWG OR LARGER SAE J1128 TYPE SEE SAE J1708 ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN CONSIDERING COMPONENT REMOVAL COMPONENTS ARE SHOWN WITH THE KEY OFF

STARTING CIRCUIT (-) BATTERY / SENSOR RETURN SENSOR / ACTUATOR SUPPLY SIGNAL PLUS TO ECM SIGNAL MINUS TO ECM CONTROL PLUS FROM ECM CONTROL MINUS FROM ECM DATA LINK PLUS DATA LINK MINUS

= Circuit Connection = Circuit Connection (Harness Splice) THIS SCHEMATIC IS FOR THE 3412E INDUSTRIAL ENGINE (S/N: 4CR, BDT, & BFT) HARNESS 230-4490 179-7087 132-3144 CHG 01 (ENGINE/CUSTOMER) 00 (INJECTOR HARNESS) 00 (FUEL PRESSURE EXTENSION: NOTE W)

ABBREVIATION
IAPCV INJECTION ACTUATION PRESSURE CONTROL VALVE