Professional Documents
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C7-C9 Electrical Electronic Guide PDF
C7-C9 Electrical Electronic Guide PDF
EPA 2004
This document is intended to provide necessary information for correct electrical & electronic application and
installation of a C7 or C9 truck engine into an on-highway truck, bus, motor coach or vocational chassis.
Caterpillar expects there will be some additions and modifications to this document as the engine program
development continues, and as OEM requests for information not currently addressed are added. The information
contained in this version of the document reflects the Caterpillar design for production C7 and C9 engines built
with March 2004 software.
The information herein is the property of Caterpillar Inc. and/or its subsidiaries. Without
written permission, any copying, transmittal to others, and any use except that for
which it is loaned is prohibited.
ECM
Oil Level Switch
(Shown With Oil Level Normal) B428-OR 33 Oil Level
P2 J2
Figure 1
ñ 12V +
BATTERIES
Cruise Control On/Off
& Set/Resume Switches
25 65 10
15 75 5 25
5
0 MPH 85 RPM X 100 30
Turbo Wastegate
Control Valve
(Not All Ratings) Vehicle Speed Sensor
3, 1.0A Outputs
Intake Manifold Air Temperature Sensor
Figure 2
Inlet Air
Inlet Air Temperature
Injection Pressure Heater Sensor
Sensor Relay
Boost Pressure
Injection Actuation Sensor
Control Valve
OEM
Connector
J1/P1
ECM
Engine
Engine Coolant
Engine Connector
Speed/Timing Temperature
Oil J2/P2
Sensors Sensor
Pressure
Sensor
(Optional)
Coolant
Temperature
Sensor Inlet Air
Heater Relay
Injection
Actuation
Pressure
Sensor
OEM Harness
Speed/Timing Connector
Sensors J1/P1
Engine
Oil ECM
Harness
Pressure
Connector
Sensor
J2/P2
(Optional)
N/O
TO ENGINE CYLINDER HEAD RELAY
INTAKE AIR
HEATER
P648 VEHICLE HARNESS CONNECTOR
NOTE A: INDICATES AN OPTIONAL COMPONENT NOT INSTALLED ON ALL ENGINES TO CONNECTOR J648 B G850-BU
(OEM HARNESS) A C987-RD
9
ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
J500 P500
A
B
N/O NOTE A
RELAY WARNING LAMP
659-PK P2 J2
K995-OR
C987-RD
FAST IDLE LAMP NOTE A
L994-YL 28 CHECK ENGINE LAMP
OR G880-PK
WAIT TO START LAMP 659-PK 29 WARNING LAMP
OFF G880-PK 31 OUTPUT #9
ON
SPEEDOMETER C974-PU K998-BU 30 OUTPUT #1
START SIGNAL+ C974-PU 36 SPEEDOMETER POSITIVE
NOTE A C973-GN C973-GN 37
SIGNAL- SPEEDOMETER NEGATIVE
27
SAEJ1939/13 OFF-BOARD 26
DIAGNOSTIC CONNECTOR 993-BR 3 INPUT SENSOR COMMON #2
KEY SWITCH
TACHOMETER 450-YL F713-OR 17 INPUT #14
B SIGNAL+
BATTERY + 450-YL 38 TACHOMETER POSITIVE
BATTERY - A NOTE A 451-BR 451-BR 39 TACHOMETER NEGATIVE
SIGNAL-
J 57
NOTE A
ALTERNATOR STARTER H 43
MOTOR J1587 DATA LINK NEGATIVE G E793-BU 9 J1587 DATA LINK NEGATIVE
GROUND (12V) J1587 DATA LINK POSITIVE F E794-YL 8 J1587 DATA LINK POSITIVE
J1939 DATA LINK SHIELD E A249-BK 42 J1939 DATA LINK SHIELD
J1939 DATA LINK NEGATIVE D K990-GN 34 J1939 DATA LINK NEGATIVE
J1939 DATA LINK POSITIVE C K900-YL 50 J1939 DATA LINK POSITIVE
J906-BR 70 IGNITION KEY SWITCH
10A 14 AWG GXL 101-RD 48 UNSWITCHED +BATTERY
10A 14 AWG GXL 101-RD 52 UNSWITCHED +BATTERY
10A 14 AWG GXL
101-RD 53 UNSWITCHED +BATTERY
14 AWG GXL
101-RD 55 UNSWITCHED +BATTERY
14 AWG GXL
- 12V+ - 12V+ - 12V+ 10A 229-BK 63 -BATTERY
14 AWG GXL
229-BK 65 -BATTERY
14 AWG GXL
229-BK 67 -BATTERY
BATTERY 3 BATTERY 2 BATTERY 1 14 AWG GXL
229-BK 69 -BATTERY
G839-BU 20 OUTPUT #7
TO ALLISON AT/MT/HT TRANSMISSION
SHIFT MODULATOR (AUTOMATIC TRANSMISSIONS) NOTE A E718-PK 10 OUTPUT #2
E991-GY 12 OUTPUT #3
EXHAUST BRAKE
SOLENOID FLYBACK G836-WH 13 OUTPUT #4
NOTE A
DIODE 15
G838-BR 19 OUTPUT #6
EXHAUST BRAKE ON/OFF SWITCH
ENGINE 25
NOTE A
H795-PK C981-GY 16 EXHAUST BRAKE ON/OFF SWITCH
BLOCK
61
CRUISE CONTROL SET/RESUME SWITCH
51
C978-BR C978-BR 35 SET
H795-PK NOTE A
C979-OR C979-OR 44 RESUME
FAST IDLE ENABLE SWITCH K999-GN 56 INPUT #1 (PTO ON/OFF SWITCH)
N/O MOMENTARY SWITCH NOTE A K980-PK 58 INPUT #2
H795-PK L902-GN L902-GN 40 INPUT #18
CRUISE CONTROL ON/OFF SWITCH G840-PU 21 OUTPUT #8
NOTE A
H795-PK C975-WH C975-WH 59 CRUISE CONTROL ON/OFF SWITCH
11
ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
The actual rate of change of HP or VSL reduction is limited to 10% per second maximum.
Rated Power,
Full Vehicle Speed Range
Available Power, Vehicle Speed
110-00 Triggered
110-11 Triggered
Rated Power,
Full Vehicle Speed Range
Available Power, Vehicle Speed
110-00 Triggered
110-11 Triggered
Rated Power,
Full Vehicle Speed Range
Available Power, Vehicle Speed
110-00 Triggered
110-11 Triggered
100-11 Very Low Oil Pressure 4 psi (29 kPa) 4 psi (29 kPa) SOLID NONE
750 RPM 6psi (43 kPa) 6psi (43 kPa)
800 RPM and up
105-00 High Inlet Manifold 90°C 90°C SOLID NONE
Air Temp. Warning (194°F) (194°F)
105-11 Very High Inlet Manifold 110°C 110°C SOLID NONE
Air Temp. (230°F) (230°F)
110-00 High Coolant Temp. C9 – 113°C C9 – 118°C SOLID NONE
Warning (235°F) (244°F)
C7 – 108°C C7 – 113°C
(226°F) (235°F)
110-11 Very High Coolant C9 – 116°C C9 – 121°C SOLID NONE
Temperature (241°F) (250°F)
C7 – 111°C C7 – 116°C
(232°F) (241°F)
111-01 Low Coolant Level SOLID NONE
Warning
111-11 Very Low Coolant Level SOLID NONE
111-14 Low Coolant Level Warning SOLID NONE
(less than 6 Hours)
100-11 Very Low Oil Pressure 4 psi (29 kPa) 4 psi (29 kPa)
750 RPM 6psi (43 kPa) 6psi (43 kPa) FLASH NONE
800 RPM and up
105-00 High Inlet Manifold 90°C 90°C SOLID NONE
Air Temp. Warning (194°F) (194°F)
105-11 Very High Inlet Manifold 110°C 110°C SOLID NONE
Air Temp. (230°F) (230°F)
110-00 High Coolant Temp. C9 – 113°C C9 – 118°C FLASH NONE
Warning (235°F) (244°F)
C7 – 108°C C7 – 113°C
(226°F) (235°F)
110-11 Very High Coolant C9 – 116°C C9 – 121°C FLASH NONE
Temperature (241°F) (250°F)
C7 – 111°C C7 – 116°C
(232°F) (241°F)
111-01 Low Coolant Level Warning SOLID NONE
111-11 Very Low Coolant Level FLASH NONE
111-14 Low Coolant Level Warning FLASH NONE
(less than 6 Hours)
OFF
ON
ST.
BAT. MTR.
ALTERNATOR
STARTER
MOTOR ADEM 3 ECM
GND.
(12V)
J906-BR 70 IGNITION KEY SWITCH
10 A
14 AWG
101-RD 48 UNSWITCHED +BATTERY
101-RD 52 UNSWITCHED +BATTERY
101-RD 53 UNSWITCHED +BATTERY
- 12V + - 12V + - 12V + 101-RD 55 UNSWITCHED +BATTERY
229-BK 63 -BATTERY
229-BK 65 -BATTERY
14 AWG 229-BK
67 -BATTERY
229-BK 69 -BATTERY
ENGINE BLOCK
P1 J1
Wiring Diagram 1 - Preferred Wiring Medium Duty ACERT Engine Battery Wiring For C7 & C9
4.1 Grounding
Proper grounding for vehicle and engine electrical systems is necessary for proper performance and reliability.
Improper grounding results in unreliable electrical circuit paths. Stray electrical currents can damage main bearings,
crankshaft journal surfaces, and aluminum components. They can also cause electrical noise degrading control
system, vehicle, speedometer, and radio performance. These problems are often very difficult to diagnose and repair.
All ground paths must be capable of carrying any conceivable fault currents. An AWG # 4 or larger cable is
recommended between the engine ground stud and the frame or starter negative post to handle alternator currents.
A maximum of three ring terminals are to be connected to the engine ground stud to insure ground connection
integrity. More than three terminals can cause the stud to loosen too easily. Caterpillar recommends splicing like
size wires together as a method of reducing ring terminal congestion at the ground stud.
- +
- +
Figure 13
Note: C9 Ground Points are different from C7.
OEM installed components used as inputs to the ECM must not be connected to the vehicle or cab ground,
and must not be case grounded. OEM installed switches must be grounded to an ECM Sensor Common via a
dedicated return line to the ECM.
3. Clamp the ground cable of the welder to the component that will be welded. Place the clamp as close as
possible to the weld.
4. Protect any wiring harnesses from welding debris and spatter. Use proper welding procedures in order to weld
the materials.
NOTICE
DO NOT use electrical components in order to ground the welder. Do not use the ECM or sensors or any
other electronic component in order to ground the welder. Clamp the ground cable for the welder to the
component that will be welded.
Place that clamp as close as possible to the weld. This will reduce the possibility of damage to the
bearings of the drive train, hydraulic components, ground straps, and other components of the vehicle.
1 2 3 4 5 6 8 9 10 11 12 13
31 1
32 41 14 > PEI< 23
13 42 24 31
93 23 35 36
74 04
40 47
75 84 48 57
07 85
58 59 60 61 62 63 65 66 67 68 69 70
Front of Engine
OEM
Engine Connector J1
Connector J2
*Insulation barrel crimp height for AMP 776093-1 stamped and formed sockets must be set according to the
insulation diameter. Crimp width for all insulations is 0.145 inches maximum.
Deutsch 0462-209-1631 Solid Socket with #14 AWG Wire (Caterpillar P/N 126-1768)
Deutsch 0462-209-1631 Solid Socket with #16 and #18 AWG Wire (Caterpillar P/N 9X3402)
Correct
AVOID
Figure 16
31 1
32 41
13 42
93 23
74 04
75 84
07 85
AVOID
Correct
Figure 18
End Bell
Engine
Connector OEM
Connector
Figure 20 - 204-7949 or 204-7950 Accelerator Pedal Position Sensor with Deutsch DT Connector
NOTE: There is no direct correlation between the Sensor Duty Cycle value and a Desired Engine RPM. For
example, it is not possible to input a 50% duty cycle value and expect the engine to operate at 1800 rpm.
This is due to the Auto-Cal function which constantly calibrates for the low and high idle stop positions.
6.3 ECM +8V Cab Accelerator Pedal Position Sensor Supply
This sensor supply is designed to provide power for connection to OEM installed Cab Accelerator Pedal Position
Sensor (+8V). No other vehicle components may be connected to this supply.
6.4 Accelerator Pedal Position Sensor Connections
The 204-7949 accelerator pedal position sensor is designed to operate on 8 Volts DC supplied by the ECM. The
ECM supplied +8V, AP Sensor/Switch Sensor Common, and Accelerator Pedal Position wiring must be connected
to the control system through an OEM harness. Current draw for the sensor is less than 40 mA.
AP Sensor/Switch Sensor Common must not be connected to the vehicle cab ground. Connecting AP Sensor/
Switch Sensor Common to the vehicle cab ground can degrade control system performance. AP Sensor/Switch
Sensor Common must be connected to the ECM at the OEM connector (P1 terminal-5) via a dedicated return line.
Connector terminal assignments are as follows:
Figure 24 - Three Terminal Accelerator Pedal Position Sensor Packard Electric Connector
6.5.5 Packard Electric Connector Wire Gauge Size
The connections may be made to 204-7951 with #18 AWG SAE J1128 type SXL (or GXL) or equivalent wire.
6.5.6 Packard Electric Connector Wire Insulation Size Range
Outside diameter insulation should be 2.80 mm (0.11 in.).
6.5.7 Accelerator Pedal Position Sensor Three Terminal Connector Terminals
The following table provides terminal part numbers.
Required Connector Parts
Figure 26
6.6.3 Remote Accelerator Position Sensor Assemblies
Two Remote Accelerator Pedal Position Sensor Assembly packages are available from Caterpillar that include the
161-8906 sensor and mounting hardware. The 134-0597 assembly provides the 161-8906 sensor mounted to a
control arm lever. The 134-0670 assembly provides the 161-8906 sensor mounted to an adjustable dial mechanism,
which can be automatically reset to the low idle position or locked into place at a specific position.
NOTE: The Remote Throttle PTO Configuration requires the Remote Throttle to be returned to the Low Idle position
upon engine start up, in order for Remote Throttle control to be provided. If the engine is started with the PTO
Switch ON and the Remote Throttle at a position above Low Idle, the engine will be limited to Low Idle until the
Throttle is cycled to the low idle position.
SIGNAL+
SPEEDOMETER
SIGNAL-
ECM
Wiring Diagram 2 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed Sensor
and ECM Speedometer Output for Speedometer
Option 2 – One Single Coil Speed Sensor
One single coil speed sensor, with the ECM J1587 Data Link output supplying the speedometer input signal.
J1587 DL+
SPEEDOMETER
J1587 DL-
ECM
Wiring Diagram 3 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed
Sensor and Data Link for Speedometer
Option 3 – Separate Single Coil Speed Sensors
Using two speed sensors, one for the speedometer and one for the ECM, completely isolates the two circuits.
Wiring Diagram 4 - Vehicle Speed Circuit Using Two Single Coil Vehicle Speed Sensors
7.4 Dual Coil Speed Sensor
Dual coil magnetic speed sensors are not recommended because of the increased risk of electrical noise coupling
into the engine control vehicle speed circuit. Ground noise from the circuit connected to the speedometer ground
will be coupled into the vehicle speed circuit of the engine control degrading system performance.
7.5 Automatic Transmissions with Electronic Vehicle Speed Source
Some electronically controlled transmissions do not have a passive magnetic vehicle speed signal available. For
these transmissions follow guidelines indicated below. When a single ended signal is used, a signal with amplitude
greater than 4.0 volts is required for the ECM vehicle speed input.
NOTE: Proper grounding is required to ensure the ECM Vehicle Speed Input Signal is of the same ground potential
as the ECM ground reference. Improper grounding may result in lost or intermittent vehicle speed signals.
SIGNAL+
SPEEDOMETER
SIGNAL-
ECM
ELECTRONIC VEHICLE
SPEED SOURCE C974-PU 36 SPEEDOMETER +
C973-GN 37 SPEEDOMETER -
VEHICLE SPEED G808-BU 32 VEHICLE SPEED IN +
G809-GN 33 VEHICLE SPEED IN -
P1 J1
7.6 J1939 Transmission Output Shaft Speed Based Vehicle Speed Source
The ECM can be configured to receive Vehicle Speed Information from an Electronic Transmission Control Unit
via the J1939 data link. The Transmission must be capable of supporting the J1939 ETC1 Broadcast Message
(PGN 61,442 Bytes 2&3), which provides transmission output shaft speed. The OEM is responsible for determining
if the transmission is capable of supporting the required message protocol. This feature also requires the necessary
J1939 data link hardware to be installed in chassis.
When configured for the J1939 option, the ECM Vehicle Speed Input Circuit (terminals 32 & 33) will be ignored.
The ECM uses the Vehicle Speed Cal (J1939-Trans) parameter value to calculate vehicle speed, based on
the programmed value and the output shaft speed (received over the J1939 data link). The Vehicle Speed Cal
(J1939-Trans) setting is based on Output Shaft revolutions per mile. The OEM is responsible for determining
the specific value for any given chassis. There are several methods to arrive at this value:
Vehicle Speed Cal (J1939-Trans) = Transmission Output Shaft revolutions per mile
Vehicle Speed Cal (J1939-Trans) = (Tire revolutions per mile) x (Axle Ratio)
OEM provided and installed components required:
1) Transmission ECU capable of supporting required J1939 message protocol.
2) J1939 Vehicle Data link.
Customer Parameter programming required:
1) Vehicle Speed Cal (J1939-Trans) parameter must be programmed for correct Trans Output Shaft revs per mile.
2) Vehicle Speed Input parameter must be programmed to J1939-Trans option.
7.7 J1939 ABS Wheel Speed Based Vehicle Speed Source
The ECM can be configured to receive Vehicle Speed Information from an Antilock Brake System (ABS) via the
J1939 data link. The ABS must be capable of supporting the J1939 High Resolution Wheel Speed Broadcast
Message (PGN 65,134 Byte 5-8), which provides wheel speed from the two rear wheels. The OEM is responsible
for determining if the ABS is capable of supporting the required message protocol. This feature also requires the
necessary J1939 data link hardware to be installed in the chassis.
The ABS will broadcast the ASSUMED tire revolutions per mile. If this value is the ACTUAL tire revolution per mile,
the calibration value will be one (1.0) If the ASSUMED tire revolutions per mile is not the same as the ACTUAL tire
revolutions per mile, then the cal factor can be calculated in the following manner.
ABS Assumed tire revolutions per mile = 500
Actual Tire revolutions per mile = 400
Vehicle Speed Cal = 400/500 = 0.800
OEM provided and installed components required:
1) ABS capable of supporting required J1939 message protocol.
2) J1939 Vehicle Data link.
Customer Parameter programming required:
1) Vehicle Speed Cal (J1939-ABS) parameter must be programmed for correct Tire revs per mile.
2) Vehicle Speed Input parameter must be programmed to the J1939-ABS option.
SPEEDOMETER
SIGNAL +
SIGNAL -
ECM
The optional speedometer driver provides a signal from the ECM (OEM Connector P1, terminals 36 and 37),
as does the tachometer driver (Connector P1 terminals 38 and 39). The signals are zero-crossing square
waves with an amplitude (unloaded) of ±9 Volts. The amplitude of the signals will be ±5 Volts or greater when
the speedometer load current is less than 4 mA.
The output at terminal 36 (Terminal 38 for the tachometer) is the complement of terminal-37 (Terminal-39 for
the tachometer) for those speedometers or tachometers requiring two signal lines. Connect either one of the
two output lines from the ECM for speedometers or tachometers with a single input terminal. Leave the remaining
line unconnected. When the control senses zero vehicle or engine speed, the driver signals will provide the
following output voltages (unloaded).
NOTE: Do not connect the negative terminal of the ECM Speedometer or Tachometer Output to Sensor Common
or any vehicle ground.
10
5
Voltage (Volts)
-5
- 10
10
5
Voltage (Volts)
-5
- 10
0 5000 10000 15000 20000
Load In Ohms
The output signal for the speedometer is 30,000 pulses per mile, and for the tachometer the signal is
programmable from 2.0 – 500.0 ppr (pulses per revolution, selectable in 0.1 increments through a Customer
Parameter). Note that Caterpillar still provides a threaded hole in the flywheel housing for a magnetic engine
speed sensor. Caterpillar requires twisted pair wiring if both signal connections from the ECM to the speedometer
or tachometer are made. This is to prevent radiated electrical noise problems. Cab grounding of the speedometer
is acceptable.
8.2 Connection Of Devices Other Than A Speedometer/Tachometer
Do not connect these drivers to more than a single speedometer and tachometer. For questions regarding
simultaneous connection, or connection of additional devices to these drivers contact Caterpillar. Caterpillar
requests device specifications, a sample of the intended additional device, a connection diagram for vehicle
installation, and sufficient lead time to evaluate this request.
8.3 Speedometer and Tachometer Output Accuracy
8.3.1 Speedometer Signal Accuracy
The engine control processes the vehicle speed input signal using the pulses per mile as determined by the
customer programmable Vehicle Speed Calibration parameter. It is then scaled for the speedometer driver
at 30,000 pulses per mile. The most likely source of error for the output signal is incorrectly programming
the ECM or speedometer pulses per mile, and driveline variations such as tire wear.
There are five sources of signal processing error of the vehicle speed by the ECM:
1) ECM input resolution is ± 2 µsec.
2) Vehicle Speeds less than 1.5 miles per hour are ignored.
3) Rounding error due to division (scaling from pulses-in to pulses-out per mile).
4) ECM output resolution is ± 2 µsec.
5) ECM sampling of the vehicle speed occurs every 30 mS.
8.3.2 Tachometer Signal Accuracy
The tachometer driver accuracy is ± 5 rpm.
- 12V +
1 CRUISE ON SET 3 CH ECK CHEC K CH ECK CH ECK CHEC K C HECK CHEC K C HECK CH ECK CHEC K
ENGIN E EN GINE ENGIN E ENGINE ENGIN E ENGIN E EN GINE ENGIN E EN GINE EN GI NE
CHECK ON OFF
ENGINE Pause
CRUISE OFF RESUME CH ECK CHEC K CH ECK CH ECK CHEC K C HECK CHEC K C HECK CH ECK CHEC K
ENGIN E EN GINE ENGIN E ENGINE ENGIN E ENGIN E EN GINE ENGIN E EN GINE EN GI NE
2 CRUISE ON SET 4 If more than one code is active or has been logged,
CHECK the Check Engine Lamp will continue to flash as
ENGINE indicated in 3, above. If any codes are missed,
CRUISE OFF RESUME repeat steps 1 and 2.
Note: It is suggested the Diagnostic Flash Codes only be used to indicate the nature of a diagnostic code
occurrence, not to perform detailed troubleshooting. Troubleshooting should be performed using SAE J1587
PID/FMI Diagnostic Codes obtained via an electronic service tool or digital dash display.
9.3.2 Viewing Diagnostic Flash Codes using Diagnostic Enable Input
The diagnostic flash codes can be prompted using the Diagnostic Enable input. To initiate the flash codes, depress
the momentary Diagnostic Enable switch until the Check Engine Lamp begins to flash. The codes should flash out
as indicated above.
9.4 Warning Lamp Operation
Engine Monitoring requires additional OEM installed warning lamp or lamps to alert the driver to an engine problem
detected by the ECM. The Warning Lamp also alerts the driver to the level of action the ECM is taking to respond
to the condition. The lamp is ON continuously while the engine is in the warning mode. Warning mode indicates the
ECM has detected a problem, but the ECM is not altering engine performance to force driver action. The Warning
Lamp flashes when in the derate mode, indicating the ECM has begun to force driver action and is reducing available
horsepower and the maximum vehicle speed. During warning and derate the Check Engine Lamp will flash
because of the active diagnostic code.
The Warning Lamp will come on for two seconds following engine start-up to check the lamp and circuit function.
9.4.1 Warning Lamp Output used for High Coolant Temperature Shutdown Signal
For GM 530/540 engines, the Warning Lamp output can be used as a dedicated High Coolant Lamp. The Engine
Monitoring Lamps parameter may be programmed to Warning Lamp or to High Coolant Warning Lamp. When
programmed to Warning Lamp, the output operates as already described. When programmed to High Coolant
temperature Warning Lamp, the output at J1/P1: 29 will be turned On in conjunction when the upper coolant
temperature limit is exceeded. This feature option allows for the engine coolant temperature diagnostic to be
tied into the chassis system for an engine protection shutdown.
Customer Parameter programming required:
1) Engine Monitoring Lamps parameter programmed to High Coolant Warning Lamp.
9.5 Low Oil Pressure Lamp
This lamp will be available if the Engine Warning Lamps parameter is programmed to Option 1. A lamp connected
to J1/P1:29 will turn On when the diagnostic code for Low Oil Pressure or Very Low Oil Pressure is active. This
feature is not available for GM trucks.
OEM provided and installed components required:
1) Low Oil Pressure Lamp.
Customer Parameter programming required:
1) Engine Monitoring Lamps parameter programmed to Option 1.
9.6 Low Coolant Level Lamp
With the Coolant Level Parameter programmed to other than No, a coolant level sensor installed and the Engine
Monitoring Lamps parameter programmed to Option 1, J1/P1:30 is available for a Low Coolant Level Lamp.
This lamp will turn on when the active diagnostic codes for Low or Very Low Coolant Level are active. This feature
is not available for GM trucks.
OEM provided and installed components required:
1) Low Coolant Level Lamp.
2) Coolant Level Sensor
ECM
+5V C G 8 79 -O R 2 +5V
COOLANT LEVEL NORMAL D C98 3- WH 49 COOLANT LEVEL NORMAL
COOLANT LEVEL LOW A C9 84 -Y L 54 COOLANT LEVEL LOW
AP SENSOR/SWITCH SENSOR COMMON B H 79 5-P K 5 AP SENSOR/SWITCH SENSOR COMMON
P1 J1
Figure 32
A/D Input
(Max 5V)
5.00 v
Open Sensor
4.50 v
Hysteresis zone
4.25 v
Critical Level
Critical Level
3.25 v
Hysteresis zone
3.00 v
2.00 v
Hysteresis zone
1.75 v
Normal Level
Normal Level
0.75 v
Hysteresis zone
0.50 v
Short to ground
Figure 33
The 2-Wire Float Sensor is connected to J1/P1: 26 and J1/P1: 5. Pin J1/P1: 23 provides 5 volt excitation through
a 499 Ohm pull up resistor. Resistor ladder values must be selected to produce the voltage levels for Normal,
Low and Very low (critical) coolant levels. Caterpillar does not recommend any specific supplier or circuit.
The following diagram is for reference.
R1 499 Ohms
E452-WH 26
R2
R3
H795-PK 5 Sensor Common
P1 J1 ECM
Wiring Diagram 8
ECM
3 Sensor Common
Wiring Diagram 9
OEM provided and installed components required:
1) A Fuel Level sensor meeting GM’s specification.
Customer Parameter programming required:
1) Primary or Secondary Fuel Tank Capacity programmed to 50, 35, or 25 gal
Battery Cable
Air Inlet
Heater
A boot must be installed on the Battery connection to the Inlet Air Heater Relay to help prevent electrical
arcing. This boot must be made of heat resistant material that can meet the UL94V0 rating for flammability.
Choose terminals made of tin plated brass with a hole that size is closest to the diameter of the stud (5/16 inch).
The terminal hole should provide enough clearance to make assembly easy while maintaining contact. Caution
must be taken to prevent the terminal from causing a short to chassis ground. Caterpillar recommends that the
terminal ring connection to the battery supply wire should be made with a bare terminal and then insulated using
a sealed heat shrink.
11.3 Inlet Air Heater Lamp
An Inlet Air Heater Lamp may be installed to indicate when the Inlet Air Heater is operating. This lamp will normally
be installed at the operator station. The Inlet Air Heater Lamp can be connected in parallel with the Caterpillar
installed Inlet Air Heater Relay. The engine wiring harness provides a 116-6158 two terminal Packard (12052641)
Metri-pack 150 Series Plug (P648) to connect the Inlet Air Heater Lamp. The mating half of the P648 plug is a
Packard (12162000) Metri-pack 150 Series Receptacle (J648). A connector cap is installed on the plug to seal the
connection until the Inlet Air Heater Lamp is connected. The ECM Inlet Air Heater driver provides a ground path
when the heater should be ON (low side driver sinking 1.5 A maximum).
J648
INLET AIR INLET AIR P648
HEATER HEATER RELAY
Ignition Switch On
Yes
Is Starting Aid
Yes Automatic Starting Aid Mode
Temp <= 0C? **
Off
Timer Yes
Expired?
Engine
started? No
Engine
Cranking?
Yes Yes
No
Heater On No
Turn
Wait 5 Seconds after Ether
Engine Heater
injection is finished
started? Off
Yes
Timer
No
Expired?
Yes
Yes
No Timer Yes
Expired?
1
If a coolant temperature sensor open circuit or short circuit diagnostic code is active, the heater will come on if inlet manifold temperature < 50°F (10°C)
2
If an inlet manifold air temp sensor open circuit or short circuit diagnostic code is active, the heater will come on if coolant temperature < 104°F (40°C)
3
With APR99 and newer Personality Modules, the Boost Pressure reading is used to determine Atmospheric Pressure. This indicates if the engine is
operating above 5500 Ft (1678 M). If so, the temperature calculations used to determine inlet air heater operation are adjusted to compensate for the
extreme altitude operation.
NOTE: If the Service brake switch is open and Vehicle Speed is greater than or equal to 5 mph (or a vehicle speed diagnostic is present) the heater will
be turned OFF. If the brake switch closes or speed drops below 5 mph, the heater will resume operation.
Figure 35
Note: For switches with J1939 options, refer to the “J1939 Based Switched Messages” section for additional details.
12.3.1 Service Brake Pedal Position Switches/Function
The Service Brake Position Switch #1 is required for ALL applications. This is a normally closed switch and must be
an open circuit when the service brake pedal is depressed. An Open circuit will deactivate or will not activate Cruise
Control, Fast Idle (1 or 2), Extended Idle, or Cab Switches PTO. A change in state (depressing a released pedal, or
releasing a depressed pedal) of the Service Brake, during Driver Alert, while the Idle Shutdown Timer is counting
also overrides the Idle Shutdown Timer if the Customer Parameter Allow Idle Shutdown Override” is programmed
to Yes (default). Service Brake Position Switch #2 (switch to Battery Plus) may be required if needed to support the
transmission style.
12.3.2 Clutch Pedal Position Switch Function
The clutch pedal position switch must be an open circuit when the clutch pedal is depressed. This switch is required
on any application that uses a clutch and the Transmission Style must be programmed to Manual Option 1 or 2.
An Open circuit will deactivate or will not activate Cruise Control, Fast Idle (1 or 2), Extended Idle, or Cab Switches
PTO. Adjustment of the Clutch Pedal Position Switch is critical to proper system performance. A change in state
(depressing a released pedal, or releasing a depressed pedal) of the Clutch, during Driver Alert, also overrides
the Idle Shutdown Timer, if the ECM is programmed to allow Idle Shutdown Override.
DIAGNOSTIC ENABLE
ECM
G844-PK 46 INPUT #7
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
P1 J1
Wiring Diagram 11 - Diagnostic Enable Circuit
OEM provided and installed components required:
1) Normally open momentary switch.
2) Hardwired Check Engine Lamp
Customer Parameter programming required:
1) Diagnostic Enable programmed to J1/P1:46
12.3.4 Two Speed Axle Switch
Two Speed Axle Switch may be programmed to None (Default) or J1/P1: 6. When a two-speed axle is used Two
Speed Axle Switch must be programmed to J1/P1: 6 (Input #6). A normally open switch is required. When a two-
speed axle is used, the change in gear ratios from the high-speed range to the low speed range alters the
calibration of the vehicle speed signal. With this system, the ECM will automatically adjust the vehicle speed
calibration when the switch is ON. This will ensure an ECM driven speedometer and ECM stored information
correctly reflect the actual vehicle speed. The Low Speed Range Axle Ratio and High Speed Range Axle Ratio
must be programmed as well. When the switch is closed between the ECM terminals 16 and 5, the ECM will use
the following equation to calculate the actual vehicle speed:
High Speed Range Axle
X calculated vehicle speed = actual vehicle speed
Low Speed Range Axle Ratio
Note: GM trucks use a normally closed switch for this input.
Where the calculated vehicle speed is the vehicle speed calculated using the programmed vehicle speed
calibration (pulse per mile). This adjusted vehicle speed will be used to determine idle, PTO, and Fast Idle “Kickout”
speeds as programmed. The vehicle speed broadcast over the data links and the ECM speedometer output vehicle
speed will reflect the adjustment. If Two Speed Axle Switch is not programmed to J1/P1: 6, the ECM does not use
either axle ratio to determine the actual speed.
OEM provided and installed components required:
1) Switch to close when low speed axle ratio is used (switch to OPEN if GM truck).
Customer Parameter programming required:
1) Two Speed Axle Switch programmed to J1/P1:6 when a two-speed axle is used (default is NONE).
2) High Speed Range Axle Ratio and Low Speed Range Axle Ratio must be programmed or the feature is disabled.
G843-OR 6 INPUT #6
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
Switch Shown in High Speed Range P1 J1
Wiring Diagram 12
12.3.5 PTO Switches
Several options are available to control engine rpm while in PTO. In order to operate in PTO Mode, a dedicated
PTO ON/OFF switch is required. Three PTO modes are available. The Cruise Control Set/Resume switches can be
used or dedicated PTO switch inputs can be programmed and installed to give a variety of controlled engine speeds.
OEM provided and installed switches (required and/or optional):
1) PTO On/Off switch
2) Optional Switches
3) Transmission Neutral switch
4) Cruise Control Set/Resume
5) PTO Set/Resume
6) PTO Set Speed A
7) PTO Set Speed B
8) Torque Limit
9) Clutch Pedal Position Switch (for manual transmissions).
10) Service Brake Pedal Position
11) Ignore Brake/Clutch
Customer Parameter programming required:
1) PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle.
2) Individual switch inputs as necessary.
12.3.6 Fast Idle Switch
A momentary Fast Idle switch can be used to elevate and maintain up to two programmed engine rpm settings.
Pressing and releasing the switch once will cause the engine to ramp from Low idle to the programmed Fast Idle
RPM #1 (1000 rpm default). Pressing and releasing the switch while at Fast Idle #1 will cause the engine to ramp
to the programmed Fast Idle #2 at the programmed “Idle/PTO Engine Speed Ramp Rate.” If Fast Idle #2 is not
programmed, the engine will return to low idle. Fast Idle will be deactivated (kicked out) if the Service Brake or
Clutch is depressed. The transmission Neutral switch, when in Gear, will also cause the Fast Idle to deactivate.
Wiring Diagram 13 - Fast Idle Enable Switch and Fast Idle Enable Lamp Circuits
OEM provided and installed components required:
1) Fast Idle Enable Momentary Switch (N/O).
2) Fast Idle Enabled Lamp (optional)
Customer Parameter programming required:
1) Fast Idle Lamp parameter programmed to J1/P1: 31(default) or J1/P1:21. (optional)
2) Fast Idle RPM #1.
3) Fast Idle RPM #2 (optional).
12.3.7 Ignore Brake/Clutch Switch
The Ignore Brake/Clutch Switch is used to allow use of an engine set speed in mobile vehicle operations.
When the Ignore Brake/Clutch parameter is programmed to J1/P1: 47 and the switch is closed, PTO, Extended Idle
and Fast Idle features will ignore service brake and clutch switch inputs. If this switch is in the closed position when
the ECM is powered up, this switch function is ignored until the switch is cycled Off and ON.
12.3.8 Shutdown Override Switch (Mass Transit only)
The transit industry calls for an engine shut down override switch to allow the operator to override a critical engine
diagnostic induced engine shutdown. The purpose of the Shutdown Override Switch is to allow an operator to
override the impending engine shutdown to allow the operator to move the vehicle to a more safe location. This
feature is only available on C9 Mass Transit ratings.
Shutdown Override Operation
The Engine Monitoring System can be used to cause the engine to shut down when the engine has an active
diagnostic code for Very Low Engine Oil Pressure, Very low Coolant Level or Very High Engine Coolant
Temperature. When one of these Diagnostics is active, the Warning Lamp, or the dedicated lamps defined by
the Warning Lamp option of “Option 1”, will start to flash. The flashing lamp indicates that the engine power is
being derated and engine shutdown will occur within a few seconds.
If the Shutdown Override Switch has been closed before the Shutdown sequence has ended, a Shutdown Timer
will start to countdown from 30 seconds. If the Shutdown Override Switch is opened and closed again before the
engine has turned the fuel injectors Off, the timer will reset for another 30 seconds. Once the timer has counted
down to zero and the fuel injectors have been disabled, the engine will shut down regardless of the position of
the Shutdown Override Switch.
Initiating the Shutdown Override Timer will result in a Diagnostic Code being generated and logged into memory.
A Diagnostic Snapshot will also be generated. The logged diagnostic code will require Caterpillar Factory
Passwords to clear from the ECM’s memory.
ECM
P1/J1
Wiring Diagram 14
12.3.9 A/C High Pressure Switch
The A/C High Pressure switch is used in conjunction with the ECM controlled Cooling Fan. This is a normally
closed switch and when opened, causes the ECM to engage the cooling fan.
12.3.10 Exhaust Brake Switch
The Exhaust Brake switch is used to allow the operator to enable or disable the engine’s exhaust retarder.
OEM provided and installed components required:
1) Exhaust Brake Switch
Customer Parameter programming required:
2) Exhaust Brake Switch programmed to J1/P1: 16
12.4 Switch-to-Battery Electrical Specifications
Contact plating should not corrode or oxidize. Gold plated or silver alloy contacts are recommended. Normal current
draw through the Input #12 and Input #13 by the control is 6.0 mA at 12 Volts DC. Normal current draw through the
Ignition Key Switch by the control is 1.2 mA at 12 Volts DC.
Contact chatter and momentary opening or closing should not exceed 100 milliseconds in duration. The switches
should not open or close due to vibration or shock normally found in the application.
Each of these ECM inputs is pulled to ground eliminating the need for external termination. Closure of an OEM
installed switch must short circuit the input to the vehicle positive battery connection.
12.4.1 Voltage thresholds measured at ECM:
Switch Open < 0.9 Volts DC – With the switch contacts open, ground potential differences, switch voltage drops,
and wiring harness voltage drops, the ECM must detect less than 0.9 Volts DC between the control input and the
ECM negative battery connection.
Switch Closed > 9.0 Volts DC – With the switch contacts closed, ground potential differences, switch voltage drops,
and wiring harness voltage drops, the ECM must detect a switch closure resulting in greater than 9.0 Volts DC
between the control input and the ECM negative battery connection.
Wiring Diagram 15
OEM provided and installed components required:
1) Switch to close when service brakes are applied.
Customer Parameter programming required:
1) Customer Parameter Transmission Style programmed to Manual Option 2, AT/MT/HT Option 2,
AT/MT/HT Option 3, Automatic Option 2, or Automatic Option 3.
12.4.5 Transmission Neutral Switch
The ECM can be configured to monitor the transmission’s Neutral Switch. This switch is used to indicate when
an automatic transmission is in neutral. The neutral condition allows features such as Cab Switches PTO, Fast Idle,
and Extended Idle to be used. The switch is required if the Transmission Style Parameter is programmed to
AT/MT/HT Option 3, AT/MT/HT Option 4, Automatic Option 3, or Automatic Option 4.
Wiring Diagram 16
OEM provided and installed components required:
1) Switch to close when the transmission is in neutral.
Customer Parameter programming required:
1) Customer Parameter Transmission Style programmed to AT/MT/HT Option 3, AT/MT/HT Option 4,
Automatic Option 3, or Automatic Option 4.
2) Transmission Neutral Switch parameter programmed to J1/P1: 62.
12.4.5.1 Transmission Neutral Switch Status via J1939 Data Link
The ECM has the ability to receive Neutral Switch status information from a Transmission ECU capable of
broadcasting the status via the J1939 data link. The J1939 option can be used to replace the hardwired switch input
to the ECM. This option can only be used if the Transmission is capable of supporting the required J1939 message
protocol, such as an Allison 2000 Series Transmission. The OEM is responsible for making this determination.
The Transmission must support the J1939 PGN $F005 (ETC2 – Byte 1 – Selected Gear, Byte 4 – Current Gear or
Byte 7 – Current Range) message to be compatible. If the message is not received, the ECM will assume the
transmission to be In gear.
OEM provided and installed components required:
1) Electronically Controlled Transmission capable or supporting required J1939 message protocol.
Customer Parameter programming required:
1) Customer Parameter Transmission Style programmed to either AT/MT/HT Option 3, AT/MT/HT Option 4,
Automatic Option 3, or Automatic Option 4.
1) Transmission Neutral Switch parameter programmed to J1939 option.
12.4.5.2 Ignoring the Transmission Neutral Switch input.
The neutral switch is not normally used with manual transmissions. The ECM can also be configured to ignore the
neutral switch if an automatic transmission is used.
Customer Parameter programming required:
1) Transmission Style parameter programmed to Manual Option 1 or 2, AT/MT/HT Option 1, AT/MT/HT Option 2,
Automatic Option 1, or Automatic Option 2.
2) Transmission Neutral Switch parameter programmed to J1/P1:62 (default) hardwired option or None.
NOTE: Programming the Neutral Switch to “None” and the Transmission Style to “Automatic option 3” (or 4) or “AT/
MT/HT Option 3” (or 4) will cause the ECM to assume that the transmission is IN GEAR.
SET/RESUME
(SET OFF POSITION)
(RESUME OFF POSITION)
ECM
CRUISE CONTROL ON/OFF C978-BR 35 SET
(CRUISE OFF POSITION) C979-OR 44 RESUME
C975-WH 59 CRUISE CONTROL ON/OFF SWITCH
SERVICE BRAKE PEDAL POSITION C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH
C977-BU 22 CLUTCH PEDAL POSITION SWITCH
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
(PEDAL RELEASED POSITION)
P1 J1
CLUTCH PEDAL POSITION
Idle RPM Limit or the programmed Low Idle. Releasing the Set or Resume switch while the engine rpm is ramping
will establish the current engine rpm as the new “set” rpm.
If the Extended Idle has been disabled or “kicked out”, the “set” rpm is still in memory. Once the condition for
Kickout no longer exists, pressing and releasing the Resume Switch will cause the engine rpm to ramp to the
“set” rpm.
14.2.1 Extended Idle kick outs
Extended Idle may be deactivated or “kicked out” by a variety of switch inputs and by exceeding the programmable
vehicle speed limit. When Kicked Out, the “set” rpm remains in memory but the engine will return to the programmed
low idle rpm. Pressing on the Service Brake or Clutch, shifting the transmission into gear, turning the PTO Switch
On or by turning the Pause Switch On, can “kick out” Extended Idle.
If the vehicle operation requires that the Service Brake and Clutch switches be used while the engine is in Elevated
Idle mode, the Ignore Brake/Clutch switch input can be used. With this switch enabled, the Service Brake and
Clutch may be used to control the vehicle speed while the Extended Idle is Active.
In the following table, an “L” means the input can return the engine to low idle from a set speed, a “A“ means the
input can adjust engine rpm, and “P” means the input function is programmable to a limit.
ECM
993-BR 3 INPUT SENSOR COMMON #2
PTO ON/OFF
(PTO OFF POSITION)
K999-GN 56 INPUT #1
PTO INTERLOCK P1 J1
- 12V +
ECM
G838-BR 19 OUTPUT #6
P1 J1
- 12V+
ECM
PTO ON/OFF K998-BU 30 OUTPUT #1
(PTO OFF POSITION) PTO Engine Shutdown Switch
E489-PK 23 INPUT#19
K999-GN 56 INPUT #1
PTO Engine Interlock 993-BR 3 INPUT SENSOR COMMON #2
P1 J1
Additional circuits such as positive and negative battery connections should also be considered but these circuits
must be separate from the ECM battery circuits.
PTO Configuration
Input Cab Switches Remote Switches Remote Throttle
Cruise Set A N/A N/A
Cruise Resume A N/A N/A
Cruise Pause L L L
Cab Throttle A N/A N/A
Remote Throttle N/A A A
Service Brake L N/A N/A
Clutch L N/A N/A
Neutral L N/A N/A
PTO Set N/A A A
PTO Resume N/A A A
PTO Engine RPM Set Speed A A A A
PTO Engine RPM Set Speed B A A A
- 12V +
PTO SWITCH ON LAMP
SET/RESUME
(SET OFF POSITION)
(RESUME OFF POSITION) ECM
K998-BU 30 OUTPUT #1
SERVICE BRAKE PEDAL POSITION C978-BR 35 SET
(PEDAL RELEASED POSITION) C979-OR 44 RESUME
C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH
C977-BU 22 CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
(PEDAL RELEASED POSITION) K999-GN 56 INPUT #1
993-BR 3 INPUT SENSOR COMMON #2
G842-GY 47 INPUT #5
PTO ON/OFF PTO INTERLOCK L901-GY 18 INPUT SENSOR COMMON #1
G841-GN 7 INPUT #4
P1 J1
(PTO OFF POSITION)
CRUISE CONTROL
SET/RESUME SWITCH
ECM
K998-BU 30 OUTPUT #1
PTO ENGINE RPM
SET SPEED A SWITCH C978-BR 35 SET
C979-OR 44 RESUME
G844-PK 46 INPUT #7
M990-OR 23 INPUT #19 *
PTO ENGINE RPM H795-PK 5 AP SENSOR / SWITCH SENSOR COMMON
SET SPEED B SWITCH 993-BR 3 INPUT SENSOR COMMON #2
K999-GN 56 INPUT #1
P1 J1
* Input is selectable through Customer Parameter Programming
PTO
INTERLOCK PTO ON/OFF SWITCH
If programmed to PTO TEL the accelerator pedal position sensor can be used to control the engine speed up to the
programmed PTO TEL when the PTO On/Off circuit is ON.
12) Torque Limit – program this parameter to a value established by the system limits for operation when a lower
than rated torque limit is desired to protect equipment used for PTO operation. This limit applies whenever the
Torque Limit switch is ON.
13) Torque Limit Switch – must be programmed to J1/P1: 7 or J1/P1:23 and a switch must be installed
corresponding to the programmed ECM terminal input for the Torque Limit option to work.
14) PTO Engine RPM Set Speed Input A – This parameter can be programmed to a desired set speed that can
be attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input A must
be programmed to J1/P1:46 (Input #7) and an additional switch installed for this feature to function.
15) PTO Engine RPM Set Speed B – This parameter can be programmed to a desired set speed that can be
attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input B must
be programmed to J1/P1:7 or J1/ P1:23 (Input #4 or Input #19) and an additional switch installed for this
feature to function.
16) PTO Shutdown Time – This parameter is programmable between 3 to 1440 minutes (a value of 0 turns this
feature Off). This parameter sets the duration of time (in minutes) that engine will operate, with the PTO On/Off
circuit ON and no vehicle speed present, before shutting down.
17) PTO Activates Cooling Fan – This parameter determines if the engine cooling fan is on normally or Continuous
while in PTO Mode. The Fan Control Type parameter must be programmed to other than None.
18) Transmission Neutral Switch – This parameter must be programmed to J1/P1:62 or J1939 if the Transmission
Style parameter is programmed to Automatic Option 3, Automatic Option 4, AT/MT/HT Option 3 or AT/MT/HT
Option 4.
16.14.3 Remote Switches
The Remote Switches Configuration utilizes a dedicated PTO On/Off circuit (J1/P1: 56) and dedicated PTO Set
(J1/P1: 58) and PTO Resume (J1/P1: 60) switch inputs. Two PTO Switch On Lamps are recommended. One in
the operator station and one at the Remote PTO control location. The ECM will ignore the Cab controls (Cruise
Switches, service brake, etc.) when PTO is On. The PTO Set/Resume switches can be used to Bump and Ramp
engine speed if the PTO Engine Set Speed is not programmed.
- 12V +
CAB PTO SWITCH REMOTE PTO
ON LAMP SWITCH ON LAMP
PTO SET/RESUME
(SET OFF POSITION)
(RESUME OFF POSITION) ECM
K998-BU 30 OUTPUT #1
K980-PK 58 INPUT #2
PTO ON/OFF PTO INTERLOCK K982-YL 60 INPUT #3
993-BR 3 INPUT SENSOR COMMON #2
K999-GN 56 INPUT #1
(PTO OFF POSITION) P1 J1
Wiring Diagram 23
13) PTO Engine RPM Set Speed B – This parameter can be programmed to a desired set speed that can be
attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input B must be
programmed to J1/P1:7 or J1/ P1:23 (Input #4 or Input #19) and an additional switch installed for this feature
to function.
14) PTO Shutdown Time – This parameter is programmable between 3 to 1440 minutes (a value of 0 turns off this
feature). This parameter sets the duration of time (in minutes) that engine will operate, with the PTO On/Off
circuit ON and no vehicle speed present, before shutting down.
15) PTO Activates Cooling Fan – This parameter determines if the engine cooling fan is on normally or Continuous
while in PTO Mode. The Fan Control Type parameter must be programmed to other than None.
16.14.5 Remote Throttle
The Remote Throttle Configuration utilizes the dedicated PTO On/Off circuit (J1/P1: 56), and requires a dedicated
PTO throttle. This throttle MUST be connected at all times. Disconnecting this throttle will result in diagnostics
codes and the Check Engine Lamp will be On. The Remote PTO Set/Resume switches are not required for this
configuration. A pair of “PTO Switch On Lamps” (one in cab and the other at the remote location) is recommended.
The Engine will respond to the Remote Throttle position but the throttle must be at minimum or returned to
minimum before engine will respond. The PTO Set and Resume switches can be used to Bump and Ramp engine
speed. The remote throttle can raise engine speed above a “Set Speed”.
Wiring Diagram 24
2) PTO Vehicle Speed Limit – determines the vehicle speed operating range of the PTO inputs. If vehicle speed
exceeds this limit the engine will either not allow an engine speed to be set, or disengage a set PTO speed.
This parameter also applies to the Idle circuit if using the Cruise Control On/Off switch instead of the PTO
On/Off circuit. The PTO On/Off circuit has priority over Fast Idle and Cruise Control On/Off.
3) Maximum Vehicle Speed in PTO Mode – may be programmed to limit the vehicle speed while in PTO mode.
Increasing vehicle speed past this limit will result in the engine being derated to maintain the programmed
PTO mode vehicle speed limit.
4) Idle/PTO RPM Ramp Rate – determines the rate of engine speed acceleration/deceleration for the resume,
accel, and decel operation. Applies to both PTO and Idle engine speed control.
5) Idle/PTO Bump RPM – determines the amount of rpm increase/decrease when the Set/Resume switch is
toggled in the Accel/Decel position. For the Remote Throttle configuration this parameter applies to engine
speed control using the cruise control On/Off and PTO On/Off circuit.
6) PTO Top Engine Limit – Top RPM Limit of the engine when the PTO On/Off circuit is ON.
7) PTO Engine RPM Set Speed – this parameter is not available if the PTO Configuration is Remote Throttle.
8) PTO to Set Speed – this parameter is not available if the PTO Configuration is Remote Throttle.
9) PTO Cab Throttle RPM Limit – programming this parameter has no affect for the PTO Configuration
Remote Throttle.
10) Torque Limit – program this parameter if a lower than rated torque limit is desired for equipment used for
PTO operation, whenever the Torque Limit switch is ON.
11) PTO Engine RPM Set Speed A – This parameter can be programmed to a desired set speed that can be
attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input A must
be programmed to J1/P1: 46 and an additional switch installed for this feature to function.
12) PTO Engine RPM Set Speed B – This parameter can be programmed to a desired set speed that can be
attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input B must
be programmed to J1/P1:7 or J1/ P1:23 and an additional switch installed for this feature to function.
13) PTO Shutdown Time – This parameter is programmable between 3 to 1440 minutes (a value of 0 turns off
this feature). This parameter sets the duration of time (in minutes) that engine will operate, with the PTO
On/Off circuit ON and no vehicle speed present, before shutting down.
14) PTO Activates Cooling Fan – This parameter determines if the engine cooling fan is on normally or
Continuous while in PTO Mode. The Fan Control Type parameter must be programmed to other than None.
Notes:
** Notice difference in function with different “PTO To Set Speed” parameter settings.
* With “PTO Set Speed” parameter programmed to an engine rpm, the “Cruise/Idle/PTO Switch
Configuration” parameter setting has no effect on the cab cruise ‘Set’ and ‘Resume’ switches.
For One desired speed above low idle, set the “PTO Set Speed” and the “PTO TEL” to the same rpm value.
Throttle can override ‘PTO Set Speed’ rpm up to PTO TEL.
The ‘Set’ switch will not set ‘PTO Set Speed’ to the throttle controlled engine speed.
Notes:
Set Speed A and B switch inputs must be programmed.
Set Speed A overrides Set Speed B, Cruise Accel, Cruise Decel, PTO set Speed and Throttle.
Set Speed B Overrides Cruise Accel, Cruise Decel, PTO Set Speed and Throttle.
If PTO To Set Speed is programmed to NO, switching A or B off returns the PTO Set Speed to Low Idle.
If PTO To Set Speed is programmed to YES, switching A or B off returns to the programmed PTO Engine
RPM Set Speed to Low Idle.
Notes:
* The “Cruise/Idle/PTO Switch Configuration” parameter setting Does affect the Remote PTO Set and
Resume switches.
Throttle can override ‘PTO Set Speed’ rpm up to PTO TEL.
The ‘Set’ switch will set ‘PTO Set Speed’ to the throttle controlled engine speed.
Remote PTO Set and Resume switch inputs must be programmed for Remote Switches and Remote.
Notes:
** Notice difference in function with different “PTO To Set Speed” parameter settings.
For One desired speed above low idle, set the “PTO Set Speed” and the “PTO TEL” to the same rpm value
Throttle can override ‘PTO Set Speed’ rpm up to PTO TEL.
Notes:
The ECM will respond to the J1939 message (PGN 65,264 ($FEF) Byte 6 Bits 4-3 “Remote PTO
preprogrammed speed control switch”) in the same manner as the PTO Engine Rpm Set Speed A hardwired
switch input.
This output can be connected to the coil side of a relay or directly to a solenoid (1.5 Amps maximum). If connected
to a relay, the contact side of the relay should be connected to “+Battery” and the appropriate solenoid. Regardless
if the output is used to connect to a solenoid or relay coil, Caterpillar recommends transient suppression be used
on the inductive load in addition to the ECM internal protection. Circuit protection for the contact side of the relay
and its grounding (when powering a relay) is left to the OEM’s discretion. Do not ground the relay or solenoid to
the ECM Sensor Common connections.
17.2 Starting Aid Output
A Starting Aid Output parameter is available to connect to a relay and/or solenoid to control a Continuous Flow
Starting Aid System. The Starting Aid Output parameter can be programmed to use J1/P1: 10 (Output #2) by
programming the Starting Aid Output parameter to “Automatic”.
The Coolant Temperature reading is used to determine if conditions require use of the Starting Aid. If a fault
condition exists with the Intake Manifold Air Temperature sensor circuit, the Intake Manifold Air Temperature Sensor
reading will be used. If the temperature reading is below 0°C (32°F) and an attempt is made to start the engine,
the Starting Aid Output will be enabled for up to 30 seconds while the engine is cranking. If the engine starts
or a condition occurs that prevents fuel from being injected, the Staring Aid Output will be disabled.
E718 - PK 10 Output #2
Wiring Diagram 25
EXHAUST BRAKE
ON/OFF SWITCH ECM
(BRAKE OFF POSITION)
C981-GY 16 EXHAUST BRAKE ON/OFF SWITCH
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
E991-GY 12 OUTPUT #3
P1 J1
EXHAUST BRAKE
SOLENOID
Wiring Diagram 26 - Exhaust Brake with Exhaust Brake Switch Programmed to Installed
If the On/Off Switch is installed in the Output Driver Circuit (terminal-12), the Exhaust Brake Switch parameter must
be programmed to None (this setting MUST not be used if the transmission communicates over J1939).
EXHAUST BRAKE
ON/OFF SWITCH ECM
(BRAKE OFF POSITION)
E991-GY 12 OUTPUT #3
P1 J1
EXHAUST BRAKE
SOLENOID
Wiring Diagram 27
EXHAUST BRAKE
EXHAUST BRAKE RELAY +BATTERY
SOLENOID
ECM
E991-GY 12 OUTPUT #3
EXHAUST BRAKE P1 J1
ON/OFF SWITCH
ECM Programming
Parameter Setting
Exhaust Brake None
Exhaust Brake Switch None
ECM Programming
Parameter Setting
Exhaust Brake Exhaust Brake Only, or Exhaust Brake + Warm Up
Exhaust Brake Switch J1/P1:16, J1939 Cab Controller, J1939 Instrument
Cluster or J1939 Body Controller
ECM Programming
Parameter Setting
Exhaust Brake Exhaust Brake Only, or Exhaust Brake + Warm Up
Exhaust Brake Switch J1/P1:16, J1939 Cab Controller, J1939 Instrument
Cluster or J1939 Body Controller
TO STARTER
ECM
G836-WH 13 OUTPUT #4
P1 J1
Wiring Diagram 29
17.4.1 Optional Engine Running Output (GMT560 trucks only)
Engine Running Output may be programmed to J1/P1: 31(Default) or None. When programmed to J1/P1: 31
the ECM will enable a low power circuit (300 milli-Amps) until the engine is within 50 RPM of the low idle limit.
This output can be connected to the coil side of a relay (if the maximum current draw for the solenoid is less
than 0.3 amps). The contact side of the relay should be connected to “+Battery” and the appropriate solenoid.
Caterpillar recommends transient suppression be used on the inductive load in addition to the ECM internal
protection. Circuit protection for the contact side of the relay and its grounding (when powering a relay) is left
to the OEM’s discretion. Do not ground the relay or solenoid to the ECM Sensor Common connections.
G880 - PK 31 OUTPUT #9
- 12V +
P1 J1
Wiring Diagram 30
18.0 Transmissions
Caterpillar C7 and C9 engines can be connected to a variety of transmissions. The following table lists the available
transmission style options and the required switch inputs for each option. Correct programming and switch wiring is
required to provide proper cruise control, PTO, and Fast Idle operation.
+IGNITION
ALLISON AT/MT
C
ALLISON ELECTRIC RELAY
M
MODULATOR
ECM
G839-BU 20 OUTPUT #7
J1 P1
Wiring Diagram 31
18.7.1 Shift Relay Operation with Cruise Control or Vehicle Speed Limiting Not Active
If enabled, the AT/MT/HT Relay is disabled under any of the following conditions:
1) Engine is not running.
2) Accelerator Pedal Position less than he AT/MT/HT Part Throttle Shift Speed setting: Low = 65%, Medium = 55%,
or High = 45% (default).
If disabled, the AT/MT/HT Relay is enabled when all of the following conditions are met:
1) Engine is running.
2) Accelerator Pedal Position greater than the AT/MT/HT Part Throttle Shift Speed setting: Low = 80%,
Medium = 70%, or High = 60% (default).
18.7.2 Shift Relay Operation with Cruise Control or Vehicle Speed Limiting Active
If enabled, the AT/MT/HT Relay is disabled when all of the following conditions are met:
1) Vehicle speed is greater than or within 2 mph (3.2 km/h) of the Cruise Set Speed or the Vehicle Speed Limit.
2) Unfiltered Load factor is < 75%.
3) Engine Speed > 2000 rpm.
If disabled, the AT/MT/HT Relay is enabled when the following conditions are met:
1) Filtered Load factor is > 98%
2) Vehicle Speed is more than 4 mph below the Cruise set speed.
Power
%
20
%
%
50%
i n t tl e
T h osi t
M
P
ax
20%
This output can be connected to the coil side of a relay or directly to a solenoid (if the maximum current draw for
the solenoid is less than 1.5 amps). If connected to a relay, the contact side of the relay should be connected to
“+Battery” and the appropriate solenoid. Regardless if the output is used to connect to a solenoid or relay coil,
Caterpillar recommends transient suppression be used on the inductive load in addition to the ECM internal
protection. Circuit protection for the contact side of the relay and its grounding (when powering a relay) is left to
the OEM’s discretion.
ECM
G837-YL 11 OUTPUT #5
P1 J1
Wiring Diagram 32
20.3 Cooling Fan Output Operation (On/Off)
If the Fan Control Type parameter is programmed to ON/OFF the ECM provides control of an ON-OFF fan clutch.
The Cooling Fan circuit sends out a high signal to turn the fan OFF. The fan comes ON in the event of an output
circuit failure such as an open circuit. This requires a relay with normally open contacts (if powering the coil side of
a relay), or a solenoid valve that deactivates the fan when it receives the disable (high) signal. Additional switching
devices in the circuit should cause an open circuit to turn the fan ON. This circuit is designed to withstand a short
circuit to “+Battery” voltage and will not be adversely affected if other devices are connected to this line when
directly driving a solenoid. When driving a relay, connection of other devices to the Cooling Fan Output should
not be necessary.
To prevent unnecessary cooling fan cycling due to reduced voltage levels during engine cranking, the ECM turns
the output OFF (fan ON). Because an electrical open circuit is the most likely failure mode, Caterpillar recommends
a normally open circuit.
The ECM will turn the cooling fan ON under any of the following conditions if engine rpm is less than 2750 rpm.
1) Engine Not Running.
2) During Engine Cranking.
3) Coolant Sensor Temperature > 207°F (97°C).
4) Active Coolant Temperature Sensor Diagnostic.
5) Inlet Manifold Air Temperature > 190°F (88°C).
6) Inlet Manifold Air Temperature > 163°F (73°C) with Boost Pressure > 10 psi (70 kPa).
7) Exhaust Brake ON > 2 seconds, when Fan With Engine Brake ON parameter is programmed to YES
8) A/C High Pressure Switch Input is Open or ECM is Counting.
9) PTO On/Off Switch in the ON position (PTO Activates Cooling Fan parameter is programmed to Continuous).
10) J1939 Fan Override Switch Message is =>95.2% (ON).
Item 7, 8, and 9 are dependent upon Customer Parameters as shown in the following table
NOTICE
Caterpillar requires the OEM to install a warning sticker near the fan indicating
the fan is automatically controlled and may come ON at any time.
ECM will keep the fan ON for 2 seconds after the engine has reached the programmed low idle (700 – 750 rpm).
This is done because unstable vehicle battery voltage during cranking may cause the fan to cycle.
The fan will be turned OFF by the control (after being turned ON) if engine rpm exceeds 2800 rpm or when all
the following circumstances are met.
1) Coolant Sensor Temperature < 196°F (91°C) and Inlet Manifold Air Temperature < 151°F (66°C).
2) The fan has been ON for at least 30 seconds or the programmed A/C Pressure Switch Fan On Time.
3) Exhaust Brake ON Strategy is not Active, when Fan With Engine Brake ON parameter is programmed to YES
4) A/C High Pressure Switch is not Active.
5) The PTO On/Off Switch in the OFF position, when PTO Activates Cooling Fan parameter is programmed
to Continuous.
6) J1939 Fan Override Switch message is <=94.8% (OFF).
OEM provided and installed components required:
1) Solenoid or Solenoid and Relay.
2) J1939 Data Link
3) Fan Override Switch
Customer Parameter programming required:
1) Cooling Fan Type programmed to On-Off Fan
2) A/C High Pressure Switch programmed to J1/P1: 41
3) A/C Fan Request programmed to J1/P1: 41 or J1/P1:62 (GMT-560 Only)
4) Fan Override Switch programmed to other than “None”.
5) Powertrain Data Link programmed to J1939.
20.4 Cooling Fan Output Operation (Variable Speed Fan Option S)
The variable speed fan control is based on a fan system manufactured by Sauer-Danfoss. When the Fan Control
Type parameter is programmed to Variable Speed Option S, the Engine Control Module provides a pulse width
modulated (PWM) signal for open loop control. This output to the Fan Drive Controller (FDC) will vary fan speed in
proportion to cooling demand. Any system non-linearity is compensated for by the FDC. The fan control will turn the
fan FULL On (100%) during those conditions that require the fan to be On. These conditions include but are not
restricted to: fan ON during PTO mode and fan ON with the exhaust brake engaged.
Note: The Fan Override Switch message over J1939 will not vary the fan speed. The fan will be turned ON (100%)
when the Switch Message value is =>95.2%.
ECM
Fan Drive
J1 P1
Wiring Diagram 33
100
PWM Fault Detection
0% Cooling
PWM %
Duty Cycle
50
100% Cooling
50 60 70 80 90 100 110
Coolant Temperature (Deg C)
Figure 37
The ECM will turn the cooling fan ON for a minimum of 30 seconds under any of the following conditions if engine
rpm is less than 2750 rpm.
1) Engine Running less than 2 seconds (100%).
2) Coolant Sensor Temperature > 199°F (93°C).
3) Active Coolant Temperature Sensor Diagnostic (100%).
4) Inlet Manifold Air Temperature > 189°F (87°C) (100%).
5) Inlet Manifold Air Temperature > 162°F (72°C) with Boost Pressure > 10 psi (70 kPa) (100%).
6) Exhaust Brake ON > 2 seconds, when Fan With Engine Brake ON parameter is programmed to YES
7) (100%)
8) A/C High Pressure Switch Input is Open or A/C Switch On Time Counter is Counting (50%).
9) PTO On/Off Switch is in the ON position (PTO Activates Cooling Fan parameter is programmed
to Continuous – 100%)
10) J1939 Fan Override Switch message received as =>95.2%.
Item 6, 7, and 8 are dependent upon Customer Parameters as shown in the following table
The fan will be turned OFF (0%) by the control (after being turned ON) if engine rpm exceeds 2800 rpm or when
all the following circumstances are met.
1) Coolant Sensor Temperature < 198°F (92°C).
2) The fan has been ON for at least 30 seconds or the programmed A/C Pressure Switch Fan On Time
is finished counting.
3) Inlet Manifold Air Temperature < 151°F (66°C).
4) Exhaust Brake ON Strategy is not Active, when Fan With Engine Brake ON parameter is programmed to YES.
5) A/C High Pressure Switch is not open.
6) PTO On/Off Switch is in the OFF position. (PTO Activates Cooling Fan parameter is programmed to Continuous)
7) J1939 Fan Override Switch message <=94.8% (fan OFF).
EM provided and installed components required:
1) Fan Drive Controller.
2) Variable Speed Fan
3) Fan Override Switch
4) J1939 Data Link
Customer Parameter programming required:
1) Cooling Fan Type programmed to Variable Speed Fan Option S.
2) Fan Override Switch programmed to other than “None”.
3) Powertrain Data Link programmed to J1939
20.5 Cooling Fan Control with the Ignition Key Off
The Cooling fan output will remain powered (On/Off Fan disengaged) for up to 10 seconds after the ignition key
has been turned off. This allows enough time for the engine to stop rotating before the fan solenoid is engaged.
This helps to limit fan belt damage due to fan inertia.
High Press.
Refrigerant
Low Press. Pressure
A/C Pressure
Switch Circuit
Switch Open
Switch Closed
Cooling Fan
Fan On
A/C Fan
Fan Off Switch On Time
Output #5
Output #5 On
Output #5 Off
Figure 38
ECM
A/C HIGH PRESSURE SWITCH
(FAN ON POSITION) G837-YL 11 OUTPUT #5
E971-GN 41 INPUT #11
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
P1 J1
Wiring DIagram 34
20.7 A/C Fan request Switch (GMT560 Only)
Programming the A/C Fan Request parameter may be used to activate the Cooling Fan when programmed
to J1/P1 41 or J1/P1: 62 (Default is None) whenever the air conditioning compressor clutch is engaged.
The fan control will follow previously described functionality when activated by this switch input.
Note: J1/P1: 41 is a switch to ground input and J1/P1: 62 is a switch to battery input.
- 12V +
ECM
Vehicle
A/C Control 41 Input #11
Circuit
5 AP Sensor/Switch Sensor Common
P1 J1
A/C
Compressor
Clutch
Wiring DIagram 35
- +
12V
ECM
Vehicle
A/C Control 62 Input #12
Circuit
P1 J1
A/C
Compressor
Clutch
Wiring DIagram 36
+BATTERY C
-BATTERY E
D ECM
F
J1587 DL- B E793-BU 9 J1587 DATA LINK NEGATIVE
J1587 DL+ A E794-YL 8 J1587 DATA LINK POSITIVE
P1 J1
Wiring DIagram 37
+BATTERY B
-BATTERY A
ECM
Wiring DIagram 38
Note: The above connector is black in color with a “Keyed center pin”. This connector requires Caterpillar
# 157-4829 Adapter Harness for connection to the Caterpillar # 139-4166 Service Tool Cable.
- BATTERY B
+ BATTERY A
ECM
Wiring DIagram 39
Note: The above connector is gray in color and connects directly to the Caterpillar # 139-4166 Service Tool Cable.
22.1.1 SAE J1587 Data Link Broadcast Parameters
SAE J1708/J1587 data link parameters, parameter identifiers (PID’s), size, scaling, and broadcast period for C7
and C9 engines are as follows:
Message Identifier (MID) – 128 [engine control MID]
Bit code definitions for Cruise Control Status (PID 85), Exhaust Brake Status (PID 121), Parking Brake Switch
(PID 70), Idle Shutdown Status (PID 71), Road Speed Limit Status (PID 83), and Power Take Off Status (PID 89)
are as per SAE J1587 definitions.
NOTE: The Caterpillar service tools follow the SAE/ATA J1587 and J1708 standards in all communications. Service
tool interfacing is done using the escape provision defined in SAE J1587. The escape information is considered
proprietary and is, therefore, not described here.
22.2 SAE J1939 Data Link
The SAE J1939 data link is supported on all Caterpillar On-Highway Truck Engines and must be enabled through
Customer Programmable Parameter programming. This data link can be used for communications with the
transmission, anti-lock brake systems (ABS), traction control (TC) systems, instrument clusters and other devices
that use that use SAE J1939 communications protocol. Contact Caterpillar for new application assistance.
ECM
TO J1939 DATA LINK CONNECTOR A249-BK 42 J1939 DATA LINK SHIELD
TO J1939 DATA LINK CONNECTOR K990-GN 34 J1939 DATA LINK -
TO J1939 DATA LINK CONNECTOR K900-YL 50 J1939 DATA LINK +
P1 J1
Wiring DIagram 40
OEM provided and installed components required:
1) Data link connection to power train components.
Customer Parameter programming required:
1) Powertrain Data Link parameter programmed to J1939.
The Powertrain Data Link parameter should be programmed to match the configuration of the vehicle.
If no J1939 support is required, Program the Power Train Datalink parameter to NONE.
Caterpillar electronic service tools have the capability to temporarily disable the Powertrain Data Link for
dynamometer or other diagnostic testing purposes.
Caterpillar recommends that J1939 wiring be added to the engine diagnostic connector. This will allow for
service tool support.
F A B F A B
J1939 DATA LINK SHIELD
J J
G G
H -BATTERY H +BATTERY
J1939 DATA LINK + J1587 DATA LINK +
J1587 DATA LINK +
+BATTERY J1587 DATA LINK - J1587 DATA LINK - -BATTERY
Figure 39
Fields with less than 5 characters are filled with a space ($20)
Note – 1 = Engine Serial Number
Note – 2 = Vehicle ID
Factory Passwords are also required to change a parameter from “locked” to “unlocked”. If all of the parameters are
locked out, and each one needs to be unlocked, only one Factory Password is required when the Parameter
Lockout screen is accessed on the Electronic Service Tool.
NOTE: When this parameter is programmed to TEL rpm, diagnostic codes 84-01 Loss Of Vehicle Speed Signal (31)
and 84-10 Vehicle Speed Rate of Change (36) are disabled. When programmed this way, the VSL Protection can be
exceeded by disconnecting the Vehicle Speed Sensor.
23.4.6 Tachometer Calibration
The ECM uses this value to scale the engine speed signal into revolutions per minute for a tachometer. It is
programmed in pulses per revolution (ppr). Programmable range is from 2.0 to 500.0 in 0.1 ppr increments.
APPLIED
APPLIED
ON
ENGINE RETARDER
"LATCH" ENGINE BRAKE OPERATION
Figure 40
Allowable options are COAST, LATCH or MANUAL. When programmed to COAST, the exhaust brake is enabled
only while the service brakes are being applied. When programmed to LATCH, the exhaust brake stays enabled
after the service brakes are released. A direct, immediate pressure on the brake pedal latches the exhaust brake
ON. If programmed to MANUAL, the exhaust brake operates the same with the cruise control switch ON (but not
in Cruise) as when it is OFF.
5 MPH
100% Off
Available
HP
On
0 Cruise Set
Speed
Vehicle Speed Or VSL
Figure 41
It controls the cruise speed from 2.5 mph (4 km/h) below the set vehicle speed at full load to 2.5 mph (4 km/h)
above the set vehicle speed at no load.
NOTE: The PTO Configuration parameter must be programmed to Cab Switches, Remote Switches or Remote
Throttle and the PTO Engine RPM Set Speed Input B parameter must be programmed to J1/P1:7 or J1/P1:23
for this feature to function.
The Universal option for GM configurations controls all inputs/outputs as described above and requires the
appropriate jumper wires to be installed in the chassis wiring based on the type of transmission used in the vehicle.
For GMT530 trucks, this parameter may be programmed to High Coolant Temp Warning Lamp. The optional setting
configures the ECM to provide an indication when engine coolant temperature is abnormally high. This circuit is
used to interface the GM Vehicle Shutdown System. When programmed to the High Coolant Temp Warning Lamp
setting, J1/P1:29 is not available for use as a Warning Lamp for the Caterpillar Engine Monitoring System.
Manual Distance
Minimum Maximum Default VEPS PID
5000 miles 35000 miles 15000 miles CA
(8047 km) (56327 km) (21140 km)
Manual Hours
Minimum Maximum Default VEPS PID
100 750 250 CB
23.14.3 PM1 Engine Oil Capacity (for Automatic Maintenance Indicator Mode)
The ECM can calculate the PM1 Interval based on fuel usage. This parameter must be programmed only if
Maintenance Indicator Mode is programmed to Automatic – Distance or Automatic – Hours. The Sump Capacity
influences the Maintenance Interval.
The most recent Quick Stop Snapshot is stored in the ECM memory. Each time another Quick Stop occurs the
ECM replaces the old Snapshot with the new one. The ECM also logs a diagnostic event code (maximum of
255 occurrences stored) for each Quick Stop Occurrence.
NOTE: The allowable range is from 0 -15 mph/s (0 – 24 km/h/s) (0 = OFF) but the recommended range is
from 3-15 mph/s (5 – 24 km/h/s). Programming the Quick Stop Rate too low will cause an excessive number
of Quick Stop Event Codes. If too many Quick Stop Event Codes are being logged, the Quick Stop Rate should
be increased to better detect the exceptions when they occur.
23.16 Input Selections
23.16.1 Fan Override Switch
This parameter denotes which J1939 source will broadcast a switch position for overriding the normal fan control.
When this override switch message is received (J1939 PGN 65,213, Byte 1, Bits 8-1), the ECM will disregard all
normal fan control parameters and will turn the fan On if programmed to ON/OFF or 100% Cooling if programmed
to Variable Speed Fan Option S. If not programmed to NONE, the Fan Override message from the transmission
is also supported.
23.18 Passwords
23.18.1 Customer Password #1 and Customer Password #2
Customer Passwords can be programmed to protect against unauthorized parameter changes. Either one or
two passwords (eight alphanumeric characters each) can be used. When programmed, the ECM will require
the password(s) to be entered before a parameter can be changed. After entering the configuration screen,
the password(s) must only be entered one time in order to change one or several parameters. If the passwords
are lost or forgotten, obtaining Factory Passwords from an Authorized dealer can allow them to be viewed.
Password #1
Alternatives Default VEPS PID
8 Alphanumeric Not Programmed 45
Characters Available
Password #2
Alternatives Default VEPS PID
8 Alphanumeric Not Programmed 46
Characters Available
**Denotes Parameters available for Lockout using an Electronic Service Tool or VEPS. Factory Passwords are
required to unlock a locked parameter.
**In some instances, the parameter option (as displayed on ET) cannot be used with VEPS programming due
to Character Length limitations. In these instances, one of the VEPS alternative options must be used.
Otherwise, the exact option (as displayed on ET) is recommended (but not required) for the VEPS .PAR file.
24.9 C7 and C9 ECM Vehicle Harness Connector Terminal Assignments and Loads
INDEX
2-Pin Switch Coolant Level Sensor Automatic Transmissions with Electronic
(GMT 560 only) ..........................................54 Vehicle Speed Source................................40
2-Wire Float Coolant Level Sensor ............52 B
2-Wire Float Sensor Diagnostics ..............54 Battery Monitor & Engine
Control Voltage ........................................162
70 Terminal ECM Connector
Part Numbers ............................................26 Battery Monitor Low Idle
Engine Speed ..........................................162
A
Bit Code Definition ..................................117
A/C Fan request Switch
(GMT560 Only) ........................................112 Boost Pressure Sensor ................................5
A/C Fan Request Switch C
(GMT560 Only) ........................................171
C7 and C9 ECM Vehicle
A/C High Pressure Switch........................170 Harness Connector Terminal
Assignments and Loads ..........................193
A/C High Pressure Switch..........................65
Cab Switches Programmable Options ......82
A/C Switch Fan On-Time ........................161
Change Oil Lamp ....................................172
Accelerator Pedal Position Sensor
Connections ..............................................34 Change Oil Lamp ......................................48
Accelerator Pedal Position Sensor Check Engine Lamp Operation ..................46
Connectors ................................................34
Clutch Pedal Position Switch Function ......61
Accelerator Pedal Position Sensor
Clutch Pedal Position Switch
Duty Cycle..................................................33
with Automatic Transmissions ....................62
Accelerator Pedal Position Sensor
Clutch Pedal Position Switch....................171
Electrical Specifications ............................33
Clutch Switch ............................................73
Accelerator Pedal Position Sensor
for Remote PTO Applications ....................36 Cold Mode Idle Shutdown Timer Enable ..113
Accelerator Pedal Position Sensor Cold Mode Idle Shutdown Timer Enable..161
Three Terminal Connector Terminals ........35
Cold Mode Operation ..................................4
Accelerator Pedal Position Sensors ..........32
Connection Of Devices Other Than
Air Conditioning High Pressure Switch ....111 A Speedometer/Tachometer ......................44
Allison 1000 & 2000 Series ......................101 Connector Interface Seal ..........................29
Allison AT/MT/HT Shift Interface Connectors and Wiring Harness
Relay Operation ......................................102 Requirements ............................................26
Allison AT/MT/HT Transmissions..............101 Coolant Level Sensor Connections ............51
Allison Electronic Transmissions ................40 Coolant Level Sensor Diagnostic ..............52
Allison WT Series ....................................101 Coolant Level Sensor Environmental
Compatibility ..............................................50
Allow Idle Shutdown Override ..................161
Coolant Level Sensor Mounting
Amber Check Engine Lamp ......................49
Guidelines (4-Pin) ......................................50
AT/MT/HT Part Throttle Shift Speed ........159
Coolant Level Sensor Outputs ..................52
Atmospheric Pressure Sensor ....................5
Coolant Level Sensor Power Supply ..........51
Auto Retarder In Cruise ..........................149
Coolant Level Sensor Response Time ......52
INDEX
Coolant Level Sensor ..............................163 Dedicated PTO Operation ..........................75
Coolant Level Sensor ..................................5 Dedicated PTO Parameters ....................152
Coolant Level Sensors ..............................50 Deutsch Connector Wire Gauge Size ........35
Coolant Temperature Sensor ......................5 Deutsch Connector Wire Insulation
Size Range ................................................35
Cooling Fan Control with
the Ignition Key Off ..................................110 Diagnostic Enable ....................................169
Cooling Fan Output Operation Diagnostic Enable ......................................62
(On/Off) ....................................................107
Diagnostics, Service Tools and
Cooling Fan Output Operation Service Information ..................................187
(Variable Speed Fan Option S) ................108
Dual Coil Speed Sensor ............................40
Cooling Fan ..............................................106
E
Cruise Control Accel Switch ......................72
ECM +8V Cab Accelerator Pedal
Cruise Control Decel Switch ......................73 Position Sensor Supply ..............................34
Cruise Control On/Off Switch ..................170 ECM 70 Terminal Connector Allen
Screw Torque ............................................26
Cruise Control On/Off Switch ....................68
ECM 70 Terminal Connector
Cruise Control On/Off Switch ....................72
Sealing Plugs ............................................28
Cruise Control Parameters ......................148
ECM 70 Terminal Connector Terminals......27
Cruise Control Pause Switch ..................170
ECM 70 Terminal Connector Wire
Cruise Control Resume Switch ..................72 Insulation and Size Range ........................26
Cruise Control Set Switch ..........................72 ECM Connector Endbell ............................31
Cruise Control Set/Resume Switch..........170 ECM Connector Terminal
Installation Guidelines ................................27
Cruise Control Switches and Operation ....68
ECM Connector Terminals and
Cruise Control ............................................68
Sealing Plugs ............................................26
Cruise Pause Switch ..................................73
ECM Connector Wire Gauge Size ............26
Cruise Switch Inputs ..................................72
ECM Connector ........................................26
Cruise/Idle/PTO Switch Configuration......149
ECM Current Draw with
Customer Parameter Lockout ..................144 Ignition Key Off ..........................................24
Customer Password #1 and ECM Date/Time Clock..............................192
Customer Password #2 ............................173
ECM Diagnostic Clock ............................192
Customer Specified Parameters ..............144
ECM Negative Battery Connections ..........22
D
ECM Positive Battery Connections ............24
Dash - Customer Parameters ..................165
ECM Power Up and Preheat Cycle ............59
Dash - PM1 Reset....................................165
ECM Software Changes ..........................190
Data Link Parameters ..............................173
ECM Speedometer and
Data Links ................................................114 Tachometer Outputs ..................................42
Data Stored In Quick Stop Electric Starting Motors..............................22
Recorder Frames ....................................191
Electrical Specifications ............................45
INDEX
Electronic Governing....................................4 Engine Running Output
(Starter Lockout) ........................................98
EMI/RFI Testing..........................................24
Engine Snapshot Recorder Records ......191
Engine Component Overview ......................5
Engine Snapshot Recorder ......................191
Engine Connection To Vehicle
Battery Ground ..........................................22 Engine Speed/Timing Sensors ....................5
Engine Control Module (ECM) ....................5 Engine Totals............................................190
Engine Cranking Cycle ..............................59 Engine/Gear Parameters ........................156
Engine Diagnostic Switch ..........................74 Exhaust Brake Configuration ..................156
Engine Exhaust Brake and Exhaust Brake Mode................................148
Automatic Transmissions............................98
Exhaust Brake Operation and
Engine Exhaust Brake................................95 Auto Retarder in Cruise..............................97
Engine Functions ........................................4 Exhaust Brake Operation
as a Warm Up Device ................................97
Engine Ground Stud ..................................22
Exhaust Brake Operation
Engine Monitoring -
While In Cruise ..........................................96
Coolant Level Sensor ................................15
Exhaust Brake Options ............................156
Engine Monitoring -
Coolant Temperature Sensor ....................13 Exhaust Brake Switch ..............................167
Engine Monitoring - Engine Sensors ........13 Exhaust Brake Switch ................................65
Engine Monitoring - Intake Air Exhaust Brake Switch ................................73
Temperature Sensor ..................................13
Extended Idle kick outs ..............................71
Engine Monitoring -
Extended Idle ............................................70
Oil Pressure Sensor ..................................13
F
Engine Monitoring and
OEM Requirements ..................................12 Fan Control basics ..................................106
Engine Monitoring Lamp Options ..............12 Fan Control Options ................................106
Engine Monitoring Lamps ........................162 Fan Control Type ......................................171
Engine Monitoring Mode ..........................162 Fan Override Switch ................................166
Engine Monitoring Parameters ................162 Fan Override Switch ..................................73
Engine Monitoring Programmed Fan with Engine Brake On ......................161
to “Warning” ..............................................16
Fast Idle Enabled Lamp ..........................171
Engine Monitoring Programmed
Fast Idle Enabled Lamp ............................48
to Derate ....................................................17
Fast Idle RPM #1 ....................................151
Engine Monitoring Programmed
to Shutdown ..............................................18 Fast Idle RPM #2 ....................................152
Engine Monitoring ......................................12 Fast Idle Switch ..........................................63
Engine Oil Pressure Sensor ....................163 Fleet Trip Segment ..................................191
Engine Running Cycle ..............................59 Four Pin Coolant Level Sensor
Electrical Specifications ............................51
Engine Running Output
(GMT560 Only) ........................................172 Fuel Pressure Sensor ..................................6
INDEX
Fuel Tank Level Sensing Inlet Air Heater and Relay ............................6
(GMT560 trucks only) ................................55
Inlet Air Heater Lamp ................................57
Fuel/Air Ratio Control ..................................4
Inlet Air Heater Relay Connections ............56
Full Range Governor................................104
Inlet Air Heater Relay Electrical
G Specifications ............................................56
Gear Down Protection RPM Limit ............157 Inlet Air Heater, Lamp and
Relay Operation ........................................56
Gear Down Protection Turn On Speed ....158
Inlet Manifold Air Temperature Sensor ........5
General Vehicle Speed Source
Requirements for Passive Speed Input Electrical Specifications ....................75
Sensor Input ..............................................38
Input Selections ......................................166
Governor Type..........................................104
Intermediate Gears Engine RPM Limit ....157
Governor Type..........................................160
Intermediate Gears Turn Off Speed ........157
Grounding ..................................................20
J
H
J1939 ABS Wheel Speed Based
Hard-wired Switch Inputs ..........................60 Vehicle Speed Source................................41
High Cruise Control Speed Set Limit ......148 J1939 Based Switch Messages ................72
High Speed Range Axle Ratio ................147 J1939 Data Link Driven Lamps ..................49
I J1939 Transmission Output Shaft
Speed Based Vehicle Speed Source ........41
IAH and Active Engine Diagnostics............59
L
IAH and Starting Aid Interaction ................59
Lamp Outputs ............................................45
Idle Functions ............................................70
Lamp Test ..................................................46
Idle Parameters ........................................151
Low Coolant Level During an Engine’s
Idle RPM Limit..........................................151
First 6 Hours of Operation..........................15
Idle Shutdown Time..................................160
Low Coolant Level Lamp............................47
Idle Shutdown Timer ................................113
Low Cruise Control Speed Set Limit ........148
Idle Vehicle Speed Limit ..........................151
Low Idle Engine RPM ..............................158
Idle/PTO Bump RPM................................151
Low Oil Pressure Lamp..............................47
Ignition Key Switch to Positive Battery ......66
Lower Gears Engine RPM Limit ..............157
Ignore Brake/Clutch Switch......................167
Lower Gears Turn Off Speed ..................157
Ignore Brake/Clutch Switch........................64
M
Ignoring the Transmission Neutral
Maintenance Indicator Mode....................164
Switch input. ..............................................67
Maintenance Parameters ........................164
Injection Actuation Pressure
(IAP) Sensor ................................................5 Maximum PTO Enable Speed..................154
Injection Actuation Pressure Maximum PTO Enable Speed....................77
Control Valve (IAPCV) ..................................5
Maximum PTO Vehicle Speed..................155
Injection Timing Control ..............................4
Maximum Vehicle Speed in PTO Mode......77
INDEX
Medium Duty Engine J1939 Powertrain Data link ................................173
Broadcast Messages ..............................119
Primary Fuel Tank Capacity
Min/Max Governor with Speed Control ....105 (GMT560 only) ........................................163
Min/Max Governor....................................104 Programmable Output Electrical
Specifications ............................................94
Mounting the Remote Accelerator
Position Sensor ..........................................36 Programmable Outputs ..............................94
O Programmable Parameters ......................160
OEM Harness Routing ..............................30 Programming examples ............................89
OEM Installed Sensors ..............................50 Protect Lamp..............................................49
Oil Level Switch (GMT560 Trucks Only) ......6 PTO Accelerator Position
Sensor Connector ......................................36
Oil Level Switch Installation Status
(GMT560 only) ........................................163 PTO Activates Cooling Fan ......................156
Oil Pressure Sensor ....................................5 PTO Activates Cooling Fan ........................77
Operation with the Cruise Control PTO Active Output Configuration ............172
On/Off Switch in the OFF position ............96
PTO Active Output ....................................76
Option 1 - One Single Coil
PTO Cab Throttle RPM Limit....................154
Speed Sensor ............................................39
PTO Configuration - Cab Switches ............80
Option 2 - One Single Coil
Speed Sensor ............................................39 PTO Configuration ..................................152
Option 3 - Separate Single Coil PTO Configurations....................................79
Speed Sensors ..........................................39
PTO Customer Access Connector ............78
Optional Engine Running Output
PTO Engine RPM Set Speed A ..............153
(GMT560 trucks only) ................................99
PTO Engine RPM Set Speed B ..............153
Output Selections ....................................171
PTO Engine RPM Set Speed Input A ......168
P
PTO Engine RPM Set Speed Input A ......170
Packard Electric Connector Wire
Gauge Size ................................................35 PTO Engine RPM Set Speed Input B ......168
Packard Electric Connector Wire PTO Engine RPM Set Speed ..................152
Insulation Size Range ................................35
PTO Engine Shutdown Switch ................168
Passive Magnetic Vehicle Speed
PTO Engine Shutdown Switch ..................76
Circuit Options ..........................................39
PTO Interlocks ..........................................78
Passive Magnetic Vehicle Speed
Sensor Electrical Requirements ................39 PTO Kickout Vehicle Speed Limit ............155
Passwords................................................173 PTO Kickout Vehicle Speed Limit ..............77
PM1 Engine Oil Capacity PTO On/Off Switch Operation ....................75
(for Automatic Maintenance
PTO On/Off Switch ..................................169
Indicator Mode) ........................................165
PTO Output Activation Speed ..................156
PM1 Interval (for Manual Maintenance
Indicator Mode) ........................................164 PTO Shutdown Time ................................156
Power and Grounding Requirements PTO Switch On Lamp ..............................172
and Considerations ....................................19
INDEX
PTO Switch ON Lamp ................................48 Secondary Fuel Tank Size
(GMT560 only) ........................................164
PTO Switch On Lamp ................................75
Selected Engine Rating ..........................145
PTO Switches ............................................63
Selecting a Sensor ....................................50
PTO to Set Speed ....................................154
Sensor Common Connections ..................22
PTO Top Engine Limit ..............................153
Sensor Common Connections ..................60
Q
Sensor Common for PTO Applications ......75
Quick Stop Rate ......................................166
Service Brake Pedal Position
Quick Stop Recorder................................191
Switch #1 ................................................171
R
Service Brake Pedal Position
Rating Number ........................................145 Switch #2 Function ....................................66
Recommendations for Cooling Fan..........100 Service Brake Pedal Position
Switches/Function ......................................61
Recommendations for
the Exhaust Brake....................................100 Service Brake Switch ................................73
Remote Accelerator Pedal Set/Resume Switch....................................68
Sensor Common Connections ..................37
Set/Resume Switch....................................69
Remote Accelerator Pedal Sensor
Shift Relay Operation with
Input Electrical Specifications ....................37
Cruise Control or Vehicle Speed
Remote Accelerator Position Limiting Not Active ..................................102
Sensor Assemblies ....................................36
Shift Relay Operation with
Remote Accelerator Position Cruise Control or Vehicle Speed
Sensor PWM Input ....................................37 Limiting Active ..........................................103
Remote PTO Resume Switch ..................169 Shutdown Override Switch
(Mass Transit only) ....................................64
Remote PTO Set Switch ..........................169
Smart Idle Parameters ............................162
Remote Switches Programmable
Options ......................................................85 Smart Idle ..................................................70
Remote Switches ......................................83 Soft Vehicle Speed Limit ..........................147
Remote Throttle Programmable Options....87 SoftCruise Control....................................150
Remote Throttle ........................................86 Speedometer and Tachometer
Output Accuracy ........................................44
S
Speedometer And Tachometer ..................42
SAE J1587 Data Link
Broadcast Parameters ............................115 Speedometer Signal Accuracy ..................44
SAE J1587/J1708 Data Link ....................114 Starting Aid Output ..................................160
SAE J1939 Data Link Stop Lamp..................................................49
Broadcast Messages ..............................119
Suppression Of Voltage Transients
SAE J1939 Data Link and Electrical Noise ..................................23
Received Messages ................................136
Switch Function/Interaction
SAE J1939 Data Link ..............................118 for Cruise Control ......................................69
Sealing Splices and Ring Terminals ..........29 Switch to Sensor Common
Electrical Specifications ............................60
INDEX
Switch to Sensor Common Inputs..............61 Two Speed Axle Switch............................167
Switch-to-Battery Circuit Protection ..........66 Two Speed Axle Switch..............................62
Switch-to-Battery V
Electrical Specifications ............................65
Vehicle ID ................................................145
T
Vehicle Speed Cal (J1939 ABS) ..............146
Tachometer Calibration ............................147
Vehicle Speed Cal (J1939-Trans) ............146
Tachometer Signal Accuracy......................44
Vehicle Speed Calibration ........................145
Theft Deterrent Password ........................166
Vehicle Speed Input Circuit ........................38
Theft Deterrent System Control ..............165
Vehicle Speed Input ................................168
Three Terminal Deutsch
Vehicle Speed Limit..................................146
Mating Connector ......................................34
Vehicle Speed Parameters ......................145
Three Terminal Packard
Electric Mating Connector ..........................35 Viewing Diagnostic Flash Codes
using Diagnostic Enable Input....................47
Timer Parameters ....................................160
Viewing Diagnostic Flash Codes................46
Top Engine Limit (TEL) ............................158
Voltage Requirements
Torque limit Switch ..................................168
and Considerations ....................................24
Torque Limit..............................................155
Voltage thresholds measured at ECM........65
Torque Rise Shaping....................................4
VSL Protection ........................................147
Transmission Neutral Start Interlock ........160
W
Transmission Neutral Switch
Wait To Start Lamp ..................................172
Status via J1939 Data Link ........................67
Wait To Start Lamp ....................................48
Transmission Neutral Switch ....................167
Wait to Start Lamp ....................................49
Transmission Neutral Switch ......................66
Warm Up Mode Idle Speed......................152
Transmission Neutral Switch ......................74
Warning Lamp Operation ..........................47
Transmission Style ..................................158
Warning Lamp Output used
Transmissions Equipped
for High Coolant Temperature
with J1939 Communication ......................100
Shutdown Signal ........................................47
Transmissions ..........................................100
Welding on a Vehicle Equipped
Trip Data ..................................................190 with a C7 or C9 Engine ..............................24
Trip Histograms ........................................191
Trip Parameters ........................................165
Truck Manufacturer Parameters ..............145
Truck Manufacturer ..................................145
Twisted Pair Wiring ....................................31
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