Professional Documents
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C11-C13-C15 Electrical Guide PDF
C11-C13-C15 Electrical Guide PDF
EPA 2004
LEBT3886-03 2008
ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
Electronic engine controls have been developed for heavy duty diesel truck engines to improve performance and
fuel consumption. Caterpillar developed an electronic control system and fuel system with electronically controlled
unit injectors for the C11, C13 and C15 truck engines.
This document is intended to provide necessary information for correct electrical & electronic application and
installation of the C11, C13 and C15 truck engines 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 engines meeting EPA 2004
Emissions Regulations.
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.
3 Retarder Solenoids
BATTERIES
Cruise Control On/Off & Set/Resume Switches
Crankshaft Position
Sensor 5 25
Camshaft MPH
km/h RPM X 100 30
Position Sensor
Cooling Fan
Atmospheric
Pressure Sensor 1.5 A
V V A Oil Pressure
Sensor
A/C High Pressure Switch
Coolant Temperature
Sensor
V V A Oil
3, 1.0A Outputs
Valve
Passive Temperature
Sensor Input
3, 1.5A Outputs
Coolant Diverter
Valve
VVA Oil
VVA Oil Temperature
Pressure Sensor
Sensor
Intake Air
Fuel Manifold
Temperature Pressure Sensor
Sensor
Atmospheric
Pressure
Sensor
Intake Air
Manifold
Temperature
Secondary Sensor
Speed Timing
Sensor
Primary
Speed Timing
Sensor
ECM
Engine Oil
Pressure
Sensor
Coolant
Temperature
Sensor
Primary
Speed/Timing
Sensor
TO VEHICLE
COMPONENTS CHECK ENGINE LAMP P2 J2
L994-YL
0.3A CURRENT LIMIT
OFF C WARNING LAMP L994-YL 28 CHECK ENGINE LAMP
B ON 659-PK 659-PK 29 WARNING LAMP
S 0.3A CURRENT LIMIT K998-BU 30 OUTPUT #1
START G880-PK 31 OUTPUT #9
R J906-BR 70 IGNITION KEY SWITCH
NOTE B G881-BU 62 INPUT #12
KEY SWITCH G882-WH 64 INPUT #13
SPEEDOMETER C974-PU 61
S G SIGNAL+
C974-PU 36 SPEEDOMETER POSITIVE
NOTE E
SIGNAL- C973-GN C973-GN 37 SPEEDOMETER NEGATIVE
BAT MTR NOTE H
E718-PK 10 OUTPUT #2
ALTERNATOR STARTER E991-GY 12 OUTPUT #3
MOTOR G836-WH 13 OUTPUT #4
NOTE B
GROUND (12V) 15
450-YL 16
TACHOMETER SIGNAL+
450-YL 38 TACHOMETER POSITIVE
SAE J1939/13 OFF-BOARD NOTE E
SIGNAL- 451-BR 451-BR 39 TACHOMETER NEGATIVE
DIAGNOSTIC CONNECTOR NOTE H
NOTE D L901-GY 18 INPUT SENSOR COMMON #1
NOTE D G842-GY 47 INPUT #5 (NOTE L)
+BATTERY B G843-OR 6 INPUT #6 (NOTE L)
-BATTERY A G844-PK 46 INPUT #7 (NOTE L)
- 12V+ - 12V+ - 12V+ J 57
H G933-YL 27 INPUT #9
100mA
J1587 DATA LINK NEGATIVE G E793-BU E793-BU 9 J1587 DATA LINK NEGATIVE
BATTERY 3 BATTERY 2 BATTERY 1 100mA
J1587 DATA LINK POSITIVE F E794-YL E794-YL 8 J1587 DATA LINK POSITIVE
J1939 DATA LINK Shield E A249-BK A249-BK 42 J1939 DATA LINK SHIELD (NOTE K & NOTE M)
J1939 DATA LINK Negative D K990-GN K990-GN 34 J1939 DATA LINK NEGATIVE (NOTE K & NOTE M)
NOTE J J1939 DATA LINK Positive C K900-YL K900-YL J1939 DATA LINK POSITIVE (NOTE K & NOTE M)
50
1
TO CHASSIS J1939 DATA LINK 14
ENGINE 10A 26 INPUT #10
BLOCK 101-RD 48 UNSWITCHED +BATTERY (NOTE D)
10A 14 AWG GXL 101-RD 52 UNSWITCHED +BATTERY (NOTE D)
10A 14 AWG GXL 101-RD 53 UNSWITCHED +BATTERY (NOTE D)
14 AWG GXL 229-BK 63 -BATTERY
14 AWG GXL 229-BK 65 -BATTERY
14 AWG GXL
229-BK 67 -BATTERY
14 AWG GXL INPUT SENSOR COMMON #2
SET/RESUME 3
F713-OR 17 INPUT #14
C978-BR 6.5mA C978-BR C453-YL
H795-PK 35 SET
C979-OR 6.5mA C979-OR 44 RESUME 993-BR
CRUISE CONTROL ON/OFF K999-GN 56 INPUT #1 (NOTE L)
K980-PK 58 INPUT #2 (NOTE L)
H795-PK C975-WH 6.5mA C975-WH 59 CRUISE CONTROL ON/OFF SWITCH
K982-YL 60 INPUT #3 (NOTE L)
SERVICE BRAKE PEDAL POSITION N/C G841-GN INPUT #4 (NOTE L)
7
H795-PK C992-PU 6.5mA C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) G837-YL 11 OUTPUT #5
G838-BR 19 OUTPUT #6
COOLING FAN SOLENOID
CLUTCH PEDAL POSITION N/C G839-BU 20 OUTPUT #7
G840-PU 21 OUTPUT #8
45.5mA MAX
H795-PK C977-BU 6.5mA C977-BU 22 CLUTCH PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) RETARDER SOLENOID ON/OFF SWITCH 43
LO
E716-GY E716-GY 23 RETARDER SOLENOID LOW/HI SWITCH
13mA NOTE H MED
H795-PK G879-OR 2 +5V
HI ENGINE RETARDER C983-WH 49 ENGINE COOLANT LEVEL NORMAL (NOTE G)
LO SOLENOID SELECTOR SWITCH C984-YL 54 ENGINE COOLANT LEVEL LOW (NOTE G)
MED
E717-GN E717-GN 40 RETARDER SOLENOID MED/HI SWITCH
HI
A/C HIGH PRESS. SWITCH N/C 51
55
6.5mA NOTE H H795-PK E971-GN E971-GN 41 INPUT #11 (NOTE L)
G834-PU 24 INPUT #15 POSITIVE
PASSIVE G835-OR 25 INPUT #15 NEGATIVE
NOTE C MAGNETIC G808-BU 1 G808-BU 32 VEHICLE SPEED IN POSITIVE (NOTE F)
NOTE F VEHICLE SPEED G809-GN 2 G809-GN 33 VEHICLE SPEED IN NEGATIVE
SENSOR 69
G845-PU 68 INPUT #8 (NOTE L)
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON BK B H795-PK H795-PK 5 ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON
+8 V RD A C985-BU 40mA C985-BU 4 +8V
ACCELERATOR PEDAL POSITION WH C C986-BR 5mA C986-BR 66 ACCELERATOR PEDAL POSITION
J403 P403
ACCELERATOR PEDAL P1 J1
POSITION SENSOR
NOTE B: FOR SPEEDOMETERS OR TACHOMETERS WITH A SINGLE SIGNAL INPUT NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE
TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO
THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED, SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED
DO NOT CONNECT TO GROUND THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS
ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
T858-GY 8
T958-YL 5
T957-PU 4
T859-WH 7
T959-BR 6
K737-BR 1
K738-GN 2 ENGINE HARNESS CONNECTOR
K739-BU 3
X987-BR 11 P2 J2
ENGINE X989-OR
RETARDER 14 T858-GY 36 INJECTOR High Side CYLINDERS 1 & 2
X986-YL 13
SOLENOID T958-YL 45 INJECTOR # 2RETURN
X985-OR 10
1&2 T957-PU 44 INJECTOR # 1 RETURN
INJECTOR INJECTOR X983-BU 9 INJECTOR High Side CYLINDERS 3 & 4
T859-WH 37
CYLINDER CYLINDER INJECTOR T853-OR 18 46 INJECTOR Low Side CYLINDER 3
T959-BR
NO.1 NO.2 CYLINDER G827-BU 16 K737-BR 10 RETARDER SOLENOID MED/HI
NO.3 G826-BR 17 11
K738-GN RETARDER SOLENOID LOW/HI
15 K739-BU 9 RETARDER SOLENOID COMMON
V V A OIL PRESSURE K739-BU 12
SENSOR X987-BR 39 V V A 1 & 2 High Side
VVA1 VVA2 VVA3 X989-OR 54 V V A 3 & 4 High Side
224-4535
X986-YL 65 V V A # 3 RETURN
P205 J205 X985-OR 21 V V A # 2 RETURN
V V A Oil Pressure 3&4 X983-BU 20 V V A # 1 RETURN
GN C T853-OR
T853-OR 25 V V A Oil Pressure
ENGINE PRESSURE SENSOR COMMON YL B G827-BU ENGINE G827-BU 42 Under Cover Sensor Return
ENGINE PRESSURE SENSOR +5V OR A G826-BR RETARDER G826-BR 41 Under Cover Sensor +5V
SOLENOIDS 34
5&6 REAR VALVE COVER 63
CONNECTOR 64
43
K737-BR 1 15
K739-BU 2 69
T859-WH 6 13
T860-OR 7 T860-OR 38 INJECTOR High Side CYLINDERS 5 & 6
T962-WH 5 T962-WH 67 INJECTOR # 6 RETURN
X988-PU 8 X988-PU 55 V V A 5 & 6 High Side
VVA5 X989-OR 12 17
VVA6 VVA4 X984-BR 9 X984-BR 66 V V A # 4 RETURN
T857-GN 11 T857-GN 29 V V A # 6 RETURN
T856-WH 10 T856-WH 28 V V A # 5 RETURN
T961-GN 4 T961-GN 68 INJECTOR # 5 RETURN
T960-BU 3 T960-BU 47 INJECTOR # 4 RETURN
27
INJECTOR INJECTOR INJECTOR 26
CYLINDER CYLINDER CYLINDER ENGINE BOOST PRESSURE C R746-PK 33
ENGINE BOOST ENGINE PRESSURE SENSOR COMMON G829-GN
NO.4 NO.5 NO.6 B 62
PRESSURE SENSOR A R746-PK 40 ENGINE BOOST PRESSURE
ENGINE PRESSURE SENSOR +5V G828-WH
PN 161-1704 G829-GN
P200 3 ENGINE PRESSURE SENSOR COMMON
G828-WH 2 ENGINE PRESSURE SENSOR +5V
R747-GY 14 ENGINE ATM PRESSURE
ENGINE ATMOSPHERIC PRESSURE C A747-GY 994-GY 24 ENGINE OIL PRESSURE
ENGINE ATMOSPHERIC ENGINE PRESSURE SENSOR COMMON B G829-GN 12
PRESSURE SENSOR ENGINE PRESSURE SENSOR +5V A G828-WH 1 T852-GY 31 V V A OIL VALVE
V V A Oil Valve
P203 2 H807-YL 53 V V A & CDV VALVE COMMON
57
J701 P701 51
ENGINE OIL ENGINE OIL PRESSURE C 994-GY 70
PRESSURE SENSOR ENGINE PRESSURE SENSOR COMMON B G829-GN 7
ENGINE PRESSURE SENSOR +5V A G828-WH 56
1
P201 2 19
1 T855-BU 8 COOLANT DIVERTER VALVE
16
J702 P702 30
Coolant Diverter Valve 61
60
G833-PK 18 ENGINE TEMPERATURE SENSOR COMMON
ENGINE COOLANT TEMPERATURE 1 995-BU 995-BU 32 ENGINE COOLANT TEMPERATURE
ENGINE COOLANT ENGINE TEMPERATURE SENSOR COMMON 2 G833-PK C967-BU 35 ENGINE INTAKE MANIFOLD AIR TEPERATURE
TEMPERATURE SENSOR A751-YL 33 ENGINE FUEL TEMPERATURE
J100 P100
6
ENGINE INTAKE MANIFOLD AIR TEMPERATURE 1 C967-BU 4
J402 P402
(-) CAMSHAFT
2 P1 J1 TO ECM
POSITION SENSOR
11
12
FRONT VALVE COVER
CONNECTOR
T957-PU 1
T858-GY 5
T958-YL 2
T959-BR 3
T859-WH 6
T960-BU 4
K737-BR 10 ENGINE HARNESS CONNECTOR
K739-BU 12
K738-GN P2 J2
11
X987-BR 9 T957-PU 44 INJECTOR # 1
X985-OR 8 T858-GY INJECTOR 1 & 2 COMMON
36
X983-BU 7 T958-YL
1&2 3&4 45 INJECTOR # 2
INJECTOR INJECTOR VVA 1 T959-BR 46 INJECTOR # 3
CYLINDER INJECTOR INJECTOR ENGINE VVA 2
CYLINDER T859-WH 37 INJECTOR 3 & 4 COMMON
NO.1 NO.2 CYLINDER CYLINDER RETARDER
SOLENOIDS T960-BU 47 INJECTOR # 4
NO.3 NO.4 K737-BR 10 RETARDER SOL 1 & 2
REAR VALVE COVER K739-BU 9 RETARDER SOLENOID COMMON
CONNECTOR K738-GN 11 RETARDER SOL 3 & 4
X987-BR 39 VVA 1 & 2 COMMON
T961-GN 3 X985-OR 21 VVA # 2
T860-OR 5 X983-BU 20 VVA # 1
T962-WH 4 T961-GN 68 INJECTOR # 5
K737-BR 1 T860-OR 38 INJECTOR 5 & 6 COMMON
K739-BU 2 T962-WH 67 INJECTOR # 6
X989-OR 10 X989-OR 54 VVA 3 & 4 COMMON
X984-BR 7 X984-BR 66 VVA # 4
X986-YL 6 X986-YL 65 VVA # 3
5&6 X988-PU X988-PU 55 VVA 5 & 6 COMMON
ENGINE VVA 4 11
VVA 3 T857-GN T857-GN 29 VVA # 6
9
RETARDER T856-WH T856-WH 28 VVA # 5
SOLENOID 8
VVA 5 VVA 6 12 13
69
INJECTOR INJECTOR 6
CYLINDER CYLINDER 43
NO.5 NO.6
63
P205 J205 17
VVA OIL PRESSURE 64
VVA Oil Pressure C T853-OR T853-OR VVA Oil Pressure
SENSOR GN 25
ENGINE PRESSURE SENSOR COMMON YL B G827-BU G827-BU 42 VVA Oil Pressure Sensor Common
ENGINE PRESSURE SENSOR +5V OR A G826-BR G826-BR 41 VVA Oil Pressure Sensor +5V
15
27
26
ENGINE BOOST PRESSURE C R746-PK 33
ENGINE BOOST ENGINE PRESSURE SENSOR COMMON B G829-GN 62
PRESSURE SENSOR A R746-PK 40 ENGINE BOOST PRESSURE
ENGINE PRESSURE SENSOR +5V G828-WH
P200 G829-GN 3 ENGINE PRESSURE SENSOR COMMON
G828-WH 2 ENGINE PRESSURE SENSOR +5V
R747-GY 14 ENGINE ATM PRESSURE
ENGINE ATMOSPHERIC PRESSURE C A747-GY 994-GY 24 ENGINE OIL PRESSURE
ENGINE ATMOSPHERIC ENGINE PRESSURE SENSOR COMMON B G829-GN 12
PRESSURE SENSOR ENGINE PRESSURE SENSOR +5V A G828-WH 1 T852-GY 31 VVA OIL VALVE
P203 2 H807-YL 53 VVA & CDV VALVE COMMON
57
J701 P701 51
ENGINE OIL PRESSURE C 994-GY V V A Oil Valve 70
ENGINE OIL
PRESSURE SENSOR ENGINE PRESSURE SENSOR COMMON B G829-GN 7
ENGINE PRESSURE SENSOR +5V A G828-WH 56
1
P201 2 19
1 T855-BU 8 COOLANT DIVERTER VALVE
16
J702 P702 30
Coolant Diverter Valve 61
60
J100 P100
When programmed to Derate, the Check Engine Lamp and the Warning Lamp will turn On at the High Coolant
Temperature trip point. The Warning Lamp will flash at the Very High Coolant temperature trip point and the engine
power will be derated 25%. The engine will be derated an additional 25% for each Degree C above the initial
diagnostic code trip level. Refer to “Figure 10 - Coolant Temperature Graph (Engine Monitoring programmed to
Derate)” on page 18 for the levels. At 100% derate, the engine is derated to 160 horsepower and 45 mph in vehicle
speed.
When programmed to Shutdown, the Check Engine Lamp and the Warning Lamp will turn On at the High Coolant
Temperature trip point. The Warning Lamp will flash at the Very High Coolant temperature trip point and the engine
will be derated. After approximately 25 seconds the engine will be shutdown. Refer to Figure 11 - “Minimum Time To
Shutdown For Excessive Coolant Temperature Graphs” on page 19.
NOTE: When programmed to Shutdown, the engine will shutdown approximately 25 seconds after the engine has
exceeded the diagnostic trip point for Very High Coolant Temperature. Total engine power derate may not occur
before shutdown.
3.3.5 Engine Monitoring - Coolant Level Sensor
The coolant level will be monitored if an optional Coolant Level Sensor is installed and the Customer Parameter,
Coolant Level Sensor, is programmed to one of the available options.The OEM is responsible for providing, installing,
and programming the ECM to monitor the optional coolant level sensor. Trip points, times or values, have been
established for Low and Very Low coolant levels. Refer to Figure 12 - “Low and Very Low Coolant Level Graph” on
page 19.
When programmed to Warning, the Check Engine Lamp and the Warning Lamp will be turned On at the Low
Coolant Level trip point and the Warning Lamp will turn On at the Very Low Coolant Level trip point.
When programmed to Derate, the Check Engine Lamp and the Warning Lamp will be turned On at the Low Coolant
Level trip point. At the Very Low Coolant level trip point the Warning Lamp will flash and the engine will be derated.
When programmed to Shutdown, the Check Engine Lamp and the Warning Lamp will be turned on at the Low
Coolant Level trip point. At the Very Low Coolant level trip point the Warning Lamp will flash and the engine will be
derated. After 30 seconds the engine will shutdown. Refer to “Figure 12 - Low and Very Low Coolant Level Graph”
on page 19 for additional information on time to shutdown.
3.3.6 Low Coolant Level During an Engine’s First 6 Hours of Operation
If a low coolant level condition is detected during the first six hours of engine operation, an OEM clearable fault
(111-14) will be recorded. This delay in logging of low coolant level events will allow OEMs to purge air trapped in
the engine’s cooling system during the assembly process. After the engine has logged 6 hours of engine running
time, the diagnostic faults and events for Low (111-01) and Very Low Coolant Levels (111-11) will be logged into the
ECM’s nonvolatile memory. Service technicians are required to contact Caterpillar for permission to clear Low (111-01)
and Very Low (111-11) Coolant Level events from the ECM’s memory.
15.0 25.0
Very Low Oil Pressure
20.0
10.0 15.0
Very Low Oil Pressure
10.0
5.0
5.0
0.0 0.0
580 600 800 1400 2100 500 700 1200 1600 2100
Engine rpm Engine rpm
C11 and C13 Engine Monitoring Oil Pressure Graph C15 Engine Monitoring Oil Pressure Graph
Rated Power,
Full Vehicle Speed Range
Available Power
The ECM derates available power and limits vehicle speed in steps as temperature increases. Each step
represents a reduction in available power and limits vehicle speed as follows:
HP REDUCTION = 25% X (rated HP - 160 hp [119 kW])
VSL REDUCTION = 25% X (VSL - 45 mph [72.5 km/h])
The actual rate of change of HP or VSL reduction is limited to 10% per second maximum.
(25% Reduction in HP and Vehicle Speed) 110-11 Very High Coolant Temperature
100% 100%
Diagnostic Code Triggered
HP and Vehicle Speed
Reduced by 25%
75% 75%
Available Power
Available Power
Vehicle Speed
Vehicle Speed
50% Shutdown 50%
Shutdown
25% 25%
0 10 20 30 40 0 20 40 60 80
Time (seconds) Time (seconds)
Initial Shutdown for Excessive Coolant Temperature Start/Restart Shutdown For Excessive Coolant Temperature
Start/Restart
Warning Tripped
Derate
Maximum rate will not
exceed 10% per second
30 Second
Debounce
Shutdown
0 10 20 30 40 50 60
Time (seconds)
For more information on coolant level sensor types and their operation, refer to ‘10.0 Coolant Level Sensor’ on page 50.
OFF
ON
Required Wiring for
ST.
ACERT Engines
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 + 55
229-BK 63 -BATTERY
229-BK 65 -BATTERY
229-BK 67 -BATTERY
14 AWG 69
ENGINE BLOCK
P1 J1
OEM
Ground
Stud
Frame Rail
- +
Frame Rail Stud
Optional
Ground Stud
Location
Figure 13 - Ground Stud To Frame Rail and Ground Stud to Starter Connections
Inductive devices should be located to maximize the distance from control system components. OEM installed
wiring harnesses should be routed to maximize the distance from the control system wiring harness to avoid
inductive coupling of noise transients.
Minimum voltages are specified at the OEM connector (P1 - terminals 52, 53 and P1 - terminals 65, 67).
4.8.1 Operation in 24 Volt Systems
The C11, C13 and C15 can operate in 24 volt electrical systems. Circuit protection is 30 amps (same as 12 volt
systems). The Output Drivers are current limited and will supply the same amount of current regardless of system
operating voltage.
4.8.2 Other Battery Connections
The pedal mounted accelerator pedal position sensor does not require separate circuit protection because it is
powered from the ECM provided +8V. Installation of a remotely mounted accelerator pedal position sensor still
requires separate +Battery circuit protection for this circuit. Integration of a Caterpillar factory installed engine
retarder eliminates separate circuit protection for the retarder solenoid circuit.
4.8.3 ECM Supplied +5V and +8V
These supplies are designed to provide power for connection to the OEM provided and installed 4-Pin Coolant
Level Sensor (+5V), and Caterpillar provides OEM installed Accelerator Pedal Position Sensor (+8V). No other
vehicle components can be connected to these supplies.
4.9 Ignition Key Off Current
The ECM draws less than 20 mA while the Ignition Key Switch is OFF.
4.10 Welding on a Vehicle Equipped with a C11, C13 or C15 Engine
Before welding on a vehicle equipped with an electronic engine, the following precautions should be observed.
1. Turn the engine OFF. Place the ignition key switch in the OFF position.
2. Disconnect the negative battery cable from the battery. If the vehicle is equipped with a battery disconnect
switch, open the switch.
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.
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.
1 2 3 4 5 6 8 9 10 11 12 13
13 1
23 14 14 >PEI< 23
31 24 24 31
39 32 35 36
47 40 40 47
57 48 48 57
70 58
58 59 60 61 62 63 65 66 67 68 69 70
Front of Engine
Engine Harness
Connector J2/P2
OEM Vehicle
Harness
Connector J1/P1
*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 0462-201-1631 Solid Socket with #16 and #18 AWG Wire (Caterpillar P/N 9X3402)
Correct
AVOID
13 1
23 14
31 24
39 32
47 40
57 48
70 58
AVOID
Correct
Figure 20 - 204-7949 or 204-7950 Accelerator Pedal Position Sensor with Deutsch DT Connector
25 % Duty Cycle
75 % Duty Cycle
Figure 22 - Example PWM Signals
NOTE: When the ECM is first powered, it automatically calibrates (auto-cal) new values for the low idle and high
idle throttle positions. It assumes 22 percent is low idle and 75 percent is high idle. As a result, the Throttle Position
status may initially reach 100 percent well before the accelerator pedal is fully depressed, this is normal. Following
some cycling of the accelerator pedal between the low and high idle positions, the ECM will adjust its calibration
automatically, provided the high idle stop position is within the 75 to 90 percent duty cycle range, and the low idle is
in the 10 to 22 percent duty cycle range. During initial operation it may require more accelerator pedal movement
for the Throttle Position status to increase above 3 percent Throttle Position, and the status may reach 100 percent
Throttle Position prior to the mechanical limit of the high idle position. This is done to ensure the throttle can reach
these two critical points during engine operation.
6.2 ECM +8V Cab Accelerator Pedal Position Sensor Supply
This sensor supply is designed to provide power for connection to Caterpillar provided, OEM installed Cab
Accelerator Pedal Position Sensor (+8V). No other vehicle components can be connected to this supply.
6.3 Accelerator Pedal Position Sensor Connector
6.3.1 Accelerator Pedal Position Sensor with Three Terminal Deutsch Connector
The 176-1602 (32 inch [81 cm] harness) and 176-1604 (6 inch [15 cm] harness) Accelerator Pedal Position Sensors
require a Deutsch DT06-3S-EP04 (Caterpillar part number 3E-3367) mating connector with a Deutsch W3S
(Caterpillar part number 3E3368) connector plug wedge.
Wedge
Figure 24 - Three Terminal Accelerator Pedal Position Sensor Packard Electric Connector
6.3.5 Accelerator Pedal Position Sensor (176-1605) with Packard Electric Three Terminal Connector
Wire Gauge Size
The connections may be made with #18 AWG SAE J1128 type SXL (or GXL) or equivalent wire.
6.3.6 Accelerator Pedal Position Sensor (176-1605) with Packard Electric Three Terminal Connector
Wire Insulation Size Range
Outside diameter insulation should be 2.80 mm (0.11 in).
SIGNAL+
SPEEDOMETER
SIGNAL-
ECM
Wiring Diagram 2 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed Sensor and
ECM Speedometer Output for Speedometer
J1587 DL+
SPEEDOMETER
J1587 DL-
ECM
Wiring Diagram 3 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed Sensor
and Data Link for Speedometer
Wiring Diagram 4 - Vehicle Speed Circuit Using Two Single Coil Vehicle Speed Sensors
7.3.1 Option 1 - One Single Coil Speed Sensor
Use one single coil speed sensor, with the ECM Speedometer output supplying the speedometer input signal.
Refer to “Wiring Diagram 2 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed Sensor and ECM
Speedometer Output for Speedometer” on page 40.
7.3.2 Option 2 - One Single Coil Speed Sensor
Use one single coil speed sensor, with the ECM J1587 Data Link output supplying the speedometer input signal.
Refer to “Wiring Diagram 3 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed Sensor and Data Link for
Speedometer” on page 40.
7.3.3 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.
Refer to “Wiring Diagram 4 - Vehicle Speed Circuit Using Two Single Coil Vehicle Speed Sensors” shown above.
7.3.4 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.
7.4 Vehicle Speed Connections To 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
an 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
Wiring Diagram 5 - Vehicle Speed Circuit with Electronic Vehicle Speed Source
Connect the single vehicle speed signal line to the ECM “Vehicle Speed In +” (P1 terminal-32). Leave ECM “Vehicle
Speed In -” (P1 terminal-33) unconnected, without a harness connection to this terminal.
NOTE: Do NOT connect terminal-33 to ground when using an electronic vehicle speed source.
No other devices should be receiving vehicle speed from the Vehicle Speed line providing vehicle speed to the
Caterpillar ECM. Caterpillar recommends using the Caterpillar ECM Speedometer Driver for the speedometer
signal or the SAE J1587 Data Link.
7.5 General Requirements for 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 datalink. 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 datalink hardware to be installed in chassis. Refer to 27.0 “SAE J1939 Received Messages” on page 154.
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 datalink). 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
or
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 Datalink.
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.
7.6 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 datalink. 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 datalink hardware to be installed in the chassis. Refer to 27.0 “SAE J1939 Received Messages”
on page 154.
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
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 load current
is less than 4 mA. Refer to “Figure 28 - Unloaded Speedometer/Tachometer Signal” shown below for a wave form
example, and refer to “Figure 29 - Speedometer/Tachometer Signal vs. Load” on page 46 for the effect of load on
the output signal. 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 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 Vehicle Ground.
10
5
Voltage (Volts)
-5
- 10
10
5
Voltage (Volts)
-5
- 10
0 5000 10000 15000 20000
Load In Ohms
Figure 29 - Speedometer/Tachometer Signal vs. Load
The output signal for the speedometer is 30,000 pulses per mile, and for the tachometer the signal is programmable
from 12.0 - 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.
8.3 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.
8.4 Speedometer and Tachometer Output Accuracy
8.4.1 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 drive line 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.
8.4.2 Tachometer Signal Accuracy
The tachometer driver accuracy is ± 5 rpm.
*If the Coolant Level Sensor parameter is programmed to “4-Pin” or “2-Wire Float Sensor” and the Engine
Monitoring Lamps parameter is programmed to “Option 1”, then J1/P1 terminal 30 is used for a Low Coolant
Level Lamp. Otherwise, it can be used as a PTO Switch On Lamp.
+ 12V -
ECM
*WARNING LAMP or
LOW OIL PRESSURE LAMP L994-YL 28 CHECK ENGINE LAMP
659-PK 29 WARNING LAMP
*PTO SWITCH ON LAMP or K998-BU 30 OUTPUT #1
LOW COOLANT LEVEL LAMP G880-PK 31 OUTPUT #9
P1 J1
*HIGH COOLANT TEMP LAMP
1 CRUISE ON SET
3 CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK
ENGINE
CHECK ON OFF
ENGINE Pause
CRUISE OFF RESUME CHECK CHECK CHECK CHECK CHECK CHECK CHECK CHECK CHECK CHECK
ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE
Make sure Cruise Control On/Off switch is OFF. Count the flashes as shown. In this example
a code 55 is flashed= No Active or Logged codes.
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.
9.4.1 Viewing Diagnostic Flash Codes using the Diagnostic Enable Input
Diagnostic flash codes can also be prompted using a Diagnostic Enable switch. The Diagnostic Enable parameter
must be programmed to J1/P1:46, J1939 Cab Controller, J1939 Body Controller or J1939 Instrument Cluster.
Refer to “12.5 Diagnostic Enable” on page 61 for details.
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.
9.5 Warning Lamp Operation
A Warning Lamp can be connected to J1/P1: 29 when the Engine Monitoring Lamps parameter is programmed to
Warning Lamp. The red warning lamp is used to alert the driver to a potentially damaging engine condition 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 but the engine performance is not
being altered to force driver action. The Warning Lamp will flash when the engine is in the derate mode, indicating
the ECM has begun to force driver action and is reducing available horsepower and the maximum vehicle speed.
If the Engine Monitoring Mode parameter is programmed to Shutdown, the Warning Lamp will flash during engine
derate and will continue to flash after the engine has shutdown. The Warning Lamp will come on for two seconds
following engine start-up to check the lamp and circuit function. Refer to “9.0 Lamp Outputs” on page 47 for
additional information on the warning lamp options.
9.6 Low Oil Pressure Lamp Operation
When the Engine Monitoring Lamps parameter is programmed to the “Option 1” option, J1/P1:29 can be used as a
Low Oil Pressure Lamp. If low oil pressure is detected, the ECM will turn this lamp On as described in “3.0 Engine
Monitoring” on page 13. This lamp will flash during engine derate caused by low oil pressure.
9.7 PTO Switch On Lamp Operation
When the Engine Monitoring Lamps parameter is programmed to the “Warning Lamp” option, and the PTO
configuration is not programmed to Off, J1/P1:30 (Output #1) can be used as a PTO Switch On Lamp. This lamp
will turn On when the PTO mode is active. This lamp will flash when the PTO Shutdown Time is within 90 seconds
of shutting the engine down.
9.8 Low Coolant Level Lamp Operation
When the Engine Monitoring Lamps parameter is programmed to the “Option 1” option and the Coolant Level
Sensor parameter is not programmed to No, J1/P1:30 (Output #1) can be used as a Low Coolant Level Lamp.
If the Engine Monitoring Mode parameter is programmed to Warning, Derate, or Shutdown and a loss of coolant
is detected, the ECM will turn this lamp On as described in “3.0 Engine Monitoring” on page 13. This lamp will flash
during engine derate caused by low coolant level.
9.9 High Coolant Temperature Lamp Operation
When the Engine Monitoring Lamps parameter is programmed to the “Option 1” option J1/P1:31 (Output #9) is
used as a High Coolant Temperature Lamp. The ECM will turn the High Coolant Temp Warning Lamp On if a high
coolant temperature is detected as described in “3.1 Engine Monitoring Lamp Options” on page 13. This lamp will
flash during engine derate caused by a high coolant temperature. If the Engine Monitoring Lamps parameter is
programmed to the “Warning Lamp” option, Output #9 is not used.
Cooper-Standard Sensor
Coolant
Coolant Top Tank
ECM
A/D Input
(Max 5V)
5.0 v
Open Sensor
4.50 v
Hysteresis Zone
4.25 v
3.25 v
Hysteresis Zone
3.00 v
R1 499 Ohms
E452-WH 26
R2
R3
H795-PK 5 Sensor Common
P1 J1 ECM
Idle Shutdown
Timer Reset
Engine
RPM Programmed
Idle Shutdown Timer
Maximum RPM
Idle Shutdown
Timer Counting
ECM
AMBIENT AIR TEMPERATURE 1 C453-YL 26 AMBIENT AIR TEMPERATURE
INPUT SENSOR COMMON 2 L901-GY 18 INPUT SENSOR COMMON #1
P1 J1
NOTE: INPUT SENSOR COMMON #2 (TERMINAL-3) MAY BE USED IN PLACE OF
INPUT SENSOR COMMON #1 (TERMINAL-18).
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
9) Clutch Pedal Switch programmed to J1/P1: 22 or one of the J1939 Based sources (transmission Style
programming dependent).
10) Transmission Neutral Switch programmed to J1/P1: 62 or J1939 trans.
12.4.1 Cruise Control On/Off Switch
The On/Off input enables the cruise control or extended idle function. When the On/Off switch input is toggled to the
ON position, circuit closed, the cruise control or extended idle function is enabled.
12.4.2 Set/Resume Switch
The Set/Resume switch is a three position switch biased to the Off position. Programmable Customer programming
is available to determine the Accelerate (Accel) or Decelerate (Decel) function of the Set and the Resume switch
inputs. The factory default is Set/Accel and Resume/Decel.
If the Set/Resume switch is toggled to the Set position the control will enter the current vehicle or engine speed into
memory for use in control of vehicle speed in the cruise control mode or engine speed in the idle mode. While in
cruise control, momentary toggling the Set/Resume switch to the Accel position will increase or ‘bump’ vehicle
speed by 1 MPH. While in ‘Extended Idle’ mode, momentary toggling the Set/Resume switch to the Accel position
will increase or ‘bump’ the engine RPM by the “Idle/PTO Idle Bump RPM” programmed value. Holding the Set/Resume
switch in the Accel position for more than one second will cause the vehicle speed to ramp up while in cruise
control mode. Holding the Set/Resume switch in the Accel position for more than one second will cause the engine
RPM to ramp up at the “Idle/PTO RPM Ramp Rate” programmed value. Note that the High Cruise Control Speed
Set Limit and Idle RPM Limit will not be exceeded using the switches as outlined above.
While in cruise control, momentarily toggling the Set/Resume switch to the Decel position will decrease vehicle
speed by 1 MPH. While in ‘Extended Idle’ mode, momentary toggling the Set/Resume switch to the Decel position
will decrease or ‘bump’ the engine RPM by the “Idle/PTO Idle Bump RPM” programmed value. Holding the Set/Resume
switch in the Decel position for more than one second will cause the vehicle speed to ramp down while in cruise
control mode. Holding the Set/Resume switch in the Decel position for more than one second will cause the engine
RPM to ramp Down at the “Idle/PTO RPM Ramp Rate” programmed value.
If the Cruise Control On/Off Switch is in the ON position, but cruise control is not active (i.e., the brake or clutch has
been depressed to disengage a Cruise Control set speed), toggling the Set/Resume switch to the Resume position
the control will return the vehicle speed to the previous set point. If the Cruise Control On/Off Switch is in the ON
position, but Extended Idle is not active (i.e., the brake or clutch has been depressed to disengage an engine set
RPM), toggling the Set/Resume switch to the Resume position the control will return the Engine RPM to the
previous set point.
The Cruise Control set speed must be set following power up of the control. Turning the Ignition Key Switch OFF
(connector P1, Terminal 70) loses the previously set Cruise Control speed, whereas turning the Cruise Control
On/Off switch OFF does not lose a previously set speed. If the operator has not set the Cruise Control Set speed
since the engine control power up, and he attempts to Resume to a speed that has not been previously set (cruise
control switch in the ON position), the engine control will use the vehicle speed at the time the Resume switch is
pressed as the Cruise Control Set speed.
If the High Cruise Control Speed Set Limit is programmed to a value greater than the Vehicle Speed Limit, the
Cruise Switches can be used to exceed the programmed Vehicle Speed Limit. If the set speed is then terminated
using the brake or clutch, the vehicle can be returned to the set speed by toggling the Resume switch.
12.4.3 Cruise Control Pause Switch
The Cruise Control Pause switch is not a “switch to sensor common input” but a J1939 sourced switch message
that is used for kicking out of Cruise Control mode and functions much like the service brake switch(es). Cruise
Control will function normally when the switch is in the OFF position. When the Pause switch is in the ON position,
Cruise will be kicked out of speed control mode. If the Pause switch is in the ON position, Cruise Control will be
prevented from engaging. This switch input is independent from the Service Brake and Clutch switches. The Cruise
Pause switch is part of the J1939 PGN 65265 ($FEF1), Byte 1, bits 6 & 5.
DIAGNOSTIC ENABLE
ECM
G844-PK 46 INPUT #7
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
P1 J1
G843-OR 6 INPUT #6
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
Switch Shown in High Speed Range P1 J1
Refer to Wiring Diagram 1 - “ECM and Engine Stud Battery Connections” on page 20 for a wiring diagram of the
Ignition Key Switch circuit.
OEM provided and installed components required:
1) Switch to close when the ignition is ON.
12.11 Service Brake Pedal Position Switch #2
The ECM terminal J1/P1: 64 (Input #13) is used as the Service Brake Switch #2 input. Service Brake Pedal Position
Switch #2 is required if the Transmission Style is programmed to Automatic Option 2 or Automatic Option 3. Refer to
“Transmission Style Parameter Switch Input Table” on page 118.
This switch is normally Open and must be a short circuit to + Battery when the service brake pedal is depressed.
This switch is used as a redundant switch for the Service Brake and is in addition to the Service Brake Switch #1
connected to J1/P1: 45. Both switches must change state at the same time to prevent diagnostic codes. When the
switch closes to + Battery, features that are sensitive to the Service Brake Switch status will react. For instance,
cruise control, Cab Switches PTO Configuration, or Extended Idle will deactivate when the Service Brake Pedal
Position Switch #2 is a short circuit.
There is no J1939 support for this switch.
Cruise Pause
Speed Limit
PTO On/Off
Idle Vehicle
Cruise Set
Neutral
Clutch
L L A A L A L L L L-P L-P
G838-BR 19 OUTPUT #6
Remote Throttle
Cruise Resume
Service Brake
Cruise On/Off
Cruise Pause
PTO Resume
Cruise Set
PTO Set
Neutral
Clutch
PTO Configuration
Off A A L A L L L
Cab Switches L A A L AP L L L A A
Remote Switches A A A A
Remote Throttle AP A A A A
Refer to“15.10.2 Multiple PTO Engine Speed Operation - Example #1” on page 90, through “15.10.8 Multiple PTO
engine speed Example #7” on page 96 for additional information on how PTO switch inputs can control engine
speed.
15.7.1 PTO Configuration - Cab Switches, Remote Switches, or Remote Throttle Operation
When the PTO On/Off switch is turned to the ON position and vehicle speed and engine RPM are within
programmed limits:
1) A PTO Switch On Lamp Comes On.
2) The PTO Top Engine Limit is activated.
3) The engine will proceed directly to the PTO Engine RPM Set Speed if programmed.
4) The engine will proceed directly to PTO Engine RPM Set Speed A if switch A is ON and a valid RPM is programmed.
5) The engine will proceed directly to PTO Engine RPM Set Speed B if switch B is ON, PTO Engine RPM Set
Speed A switch is OFF, and a valid RPM is programmed.
6) The Engine Retarder is disabled.
7) The PTO Active Output is activated (if programmed).
15.7.2 PTO Configuration - Cab Switches Operation Differences
1) The cruise control Set/Resume switch and cab throttle can be used to adjust engine speed.
2) Optional Set Speed A and/or B switch inputs are available to adjust engine speed.
3) The Cruise Control Pause Switch (if equipped) will cause PTO to kickout if turned ON.
4) The cab throttle can be limited to Low Idle, Top Engine Limit, or the PTO Top Engine Limit.
5) Brake and Clutch switch inputs can cause PTO to kickout.
6) Ignore Brake/Clutch switch input available for allowing mobile operation of vehicle.
Customer PTO Configuration PTO Cab Throttle PTO TEL PTO Engine PTO to Set
Parameter RPM Limit RPM Set Speed Speed
Parameter Cab Switches Desired Limit Desired RPM Desired RPM Yes
Setting
Input/Output Input #1 Output #1 Cab Throttle
Connection PTO On/Off Circuit PTO Switch On Lamp J1/P1:66
- 12V +
ECM
SERVICE BRAKE PEDAL POSITION
(PEDAL RELEASED POSITION) K998-BU 30 OUTPUT #1
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
P1 J1
PTO ON/OFF PTO INTERLOCK
Wiring Diagram 16 - PTO Configuration Cab Switches with One Speed Above Idle Circuit
15.7.6 One Speed Above Low Idle after PTO Switched On, Using Cruise Set /Resume
These diagrams provide cab accelerator pedal limiting before the rpm ramps up, and allows one speed above idle
to be controlled from the Cruise Set/Resume switches. Wiring Diagram 17 - “PTO Configuration Cab Switches with
One Speed Above Idle Circuit” shown below is for applications requiring only one rpm above low idle. If the PTO to
Set Speed parameter is programmed to NO, the ECM will not go to the programmed PTO Engine rpm Set Speed
until the Set (rpm increase) switch is toggled. When the PTO Top Engine Limit is set to the same value as the PTO
Engine rpm Set Speed, the engine will not exceed this rpm. Toggling the Set/Resume Switch in the Decel direction
will cause the engine to ramp down from PTO Top Engine Limit to Low Idle. The Throttle can be used to control
engine rpm if the engine is at Low Idle.
The Cruise Set/Resume, Service Brake, and Clutch circuits are included because they will interrupt a set rpm using
the Cab Switches configuration. The cab accelerator pedal position sensor can be limited to low idle, PTO Top
Engine Limit, or Top Engine Limit using the PTO Cab Throttle RPM Limit parameter.
NOTE: If the PTO Engine RPM Set Speed is programmed to 0 rpm, the Set/Resume switch can be used to bump
(increment) engine speed up and down by the Idle/PTO Bump RPM parameter. Engine speed may be ramped as
well according to the programmed value of the Idle/PTO Ramp Rate parameter.
Parameter settings for PTO Configuration Cab Switches with One Speed Above Idle Circuit
Customer PTO Configuration PTO Cab Throttle PTO TEL PTO Engine PTO to Set
Parameter RPM Limit RPM Set Speed Speed
Parameter Cab Switches Desired Limit Desired RPM Desired RPM No
Setting
Input/Output Input #1 Output #1 Cruise Set Cruise Resume
Connection PTO On/Off Circuit PTO Switch on Lamp J1/P1:35 J1/P1:44
- 12V +
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
P1 J1
PTO ON/OFF PTO INTERLOCK
Wiring Diagram 17 - PTO Configuration Cab Switches with One Speed Above Idle Circuit
- 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
G841-GN 7 INPUT #4
PTO ON/OFF PTO INTERLOCK P1 J1
- 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-GN 47 INPUT #5
PTO ON/OFF PTO INTERLOCK P1 J1
18) Ignore Brake/Clutch Switch - This switch input allows PTO to disregard the status of the Service brake and
Clutch switch settings.
19) Torque Limit Switch - Program this switch input to J1/P1:7 in order to enable the programmed Torque Limit.
20) PTO Active Output - This output will turn “ON” when PTO is enabled and will remain active until PTO is turned
Off or Kicked Out.
15.8 PTO Configuration - Remote Switches
The Remote Switches Configuration utilizes the PTO On/Off switch, Remote PTO Set and Resume switches and
up to two Set Speed Switches. Each switch input may be hardwired directly to the ECM or switch input messages,
except for the Set Speed B switch input, may be received over the J1939 Data Link. An optional pair of PTO Switch
On Lamps connected to terminal-30 (one in cab, the other out of the cab at the remote location - programming
dependent) may be used.
15.8.1 One Speed Above Low Idle with PTO Switched On
Wiring Diagram 20 - “PTO Configuration Remote Switches with One Speed Above Idle Circuit” shown below is for
applications requiring only one rpm above low idle. Program the PTO Top Engine Limit and the PTO Engine RPM
Set Speed to the same value. Program the PTO to Set Speed parameter to Yes. The ECM will ramp up to the pre-
programmed PTO Engine RPM Set Speed when the PTO On/Off switch is turned ON. When the PTO Top Engine
Limit is set to the same value as the PTO Engine RPM Set Speed, the engine will not exceed this rpm. The Service
Brake Pedal Position switch, Clutch Pedal Position switch, and cab accelerator pedal position sensor circuits are
ignored whenever the PTO On/Off switch is ON.
Parameter settings for PTO Configuration Remote Switches with One Speed Above Idle Circuit
Parameter PTO Configuration PTO Cab Throttle PTO TEL PTO Engine PTO to
RPM Limit RPM Set Speed Set Speed
Setting Remote Switches Not Used 700 - TEL Desired RPM Yes
Input/Output Input #1 Output #1
Connection PTO On/Off Circuit PTO Switch On Lamp
- 12V +
REMOTE PTO
CAB PTO SWITCH SWITCH ON LAMP
ON LAMP ECM
PTO ON/OFF PTO INTERLOCK K998-BU 30 OUTPUT #1
K999-GN 56 INPUT #1
993-BR 3 INPUT SENSOR COMMON #2
(PTO OFF POSITION)
P1 J1
Wiring Diagram 20 - PTO Configuration Remote Switches with One Speed Above Idle Circuit
If the preset speed must not come ON until after the PTO On/Off switch is ON and the activating switch is a
Set/Resume type toggle switch, refer to “15.8.2 One Speed Above Low Idle after PTO Switched On, Using PTO
Set /Resume” on page 82.
15.8.2 One Speed Above Low Idle after PTO Switched On, Using PTO Set/Resume
Wiring Diagram 21 - “PTO Configuration Remote Switches with One Speed Above Idle Circuit” shown below is for
applications requiring only one rpm above low idle. Program the PTO to Set Speed parameter NO. Program the
PTO Top Engine Limit to the same value as the PTO Set Speed. The ECM will not go to the programmed PTO
Engine rpm Set Speed until the Set (rpm increase) switch is toggled. If the PTO Top Engine Limit is set to the same
value as the PTO Engine rpm Set Speed, the engine will not exceed this rpm.
The service brake pedal position and clutch pedal position switches, and the cab accelerator pedal position sensor
circuits are ignored whenever the PTO On/Off switch is ON.
Parameter settings for PTO Configuration Remote Switches with One Speed Above Idle Circuit
Customer PTO Cab Throttle PTO PTO TEL PTO Engine PTO to Set
Parameter RPM Limit Configuration RPM Set Speed Speed
Parameter Not Used Remote Switches 700 - TEL Desired RPM No
Setting
Input/Output Output #1 Input #1 Input #2 Input #3
Connection PTO Switch PTO On/Off PTO Set PTO Resume
On Lamp Circuit Switch Switch
- 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 21 - PTO Configuration Remote Switches with One Speed Above Idle Circuit
- 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) G841-GN 7 INPUT #4
TORQUE LIMIT SWITCH P1 J1
NOTE: INPUT SENSOR COMMON #1 (TERMINAL-18) MAY BE
(TORQUE LIMIT OFF POSITION) USED IN PLACE OF INPUT SENSOR COMMON #2 (TERMINAL-3)
Customer PTO PTO to Set Speed PTO Cab Throttle PTO TEL PTO Engine
Parameter Configuration RPM Limit RPM Set Speed
Parameter Remote Throttle Not Available Not Available 700 - TEL Not Available
Setting
Input/Output Input #1 Input #8 Output #1
Connection PTO On/Off Remote Accelerator PTO Switch
Circuit Position Sensor On Lamp
- 12V +
REMOTE PTO
CAB PTO SWITCH SWITCH ON LAMP
ON LAMP ECM
PTO ON/OFF PTO INTERLOCK
K998-BU 30 OUTPUT #1
K999-BR 56 INPUT #1
(PTO OFF POSITION) 993-BR 3 INPUT SENSOR COMMON #2
G845-PU 68 INPUT #8
ACCELERATOR POSITION SENSOR P1 J1
+BATTERY RD A
INPUT SENSOR COMMON #2 BK B
ACCELERATOR POSITION WH C
Parameter settings for PTO Configurations using PTO Engine Set Speed A and B
Customer PTO Configuration PTO Engine PTO Engine RPM PTO Engine PTO Engine RPM
Parameter RPM Set Set Speed A RPM Set Set Speed B
Speed Input A Speed Input B
Parameter Cab Switches, J1/P1:58 Desired RPM J1/P1:60 Desired RPM
Setting Remote Switches
or
Remote Throttle
Input/Output Input #1 Input #2 Input #3 Output #1
Connection PTO On/Off Circuit Set Speed A Set Speed B PTO Switch
Switch Circuit Switch Circuit on Lamp
PTO SWITCH
- 12V +
ON LAMP
ECM
PTO
PTO ON/OFF SWITCH
INTERLOCK
Wiring Diagram 25 - PTO Configuration with PTO Engine RPM Set Speed A and B
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 Throttle.
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.
The “Cruise/Idle/PTO Switch Configuration” parameter setting does affect the J1939 Remote PTO Set
and Resume switch messages.
Notes:
The ECM will respond to the J1939 message (PGN 65,264 [$FEF] Byte 6 Bits 4-3 “Remote PTO preprogrammed
speed control switch”) in the same manner as the PTO Engine RPM Set Speed A Hardwired Switch Input.
The “Cruise/Idle/PTO Switch Configuration” parameter setting does affect the J1939 Remote PTO Set
and Resume switch messages.
Notes:
The ECM will respond to the J1939 message (PGN 65,264 [$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.
The “Cruise/Idle/PTO Switch Configuration” parameter setting does affect the J1939 Remote PTO Set
and Resume switch messages.
ENGINE RETARDER
SOLENOID SELECTOR SWITCH
OEM RESPONSIBILITY
APPLIED
APPLIED
ON
ENGINE RETARDER
“LATCH” ENGINE BRAKE OPERATION
Figure 36 - Coast and Latch Engine Retarder Mode
Additional operating requirements must be met if the Cruise Control On/Off Switch is in the ON position, or the
engine is in Cruise Control, or when the vehicle is moving due to Customer Specified Parameters - Engine
Retarder, Auto Retarder in Cruise, Engine Retarder Minimum VSL Type, Engine Retarder Minimum Vehicle Speed,
and Engine Retarder Delay.
The engine retarder is disabled if the vehicle speed is above 0 mph (0 km/h) but less than the programmed Engine
Retarder Minimum Vehicle Speed (program this parameter to 0 mph (0 km/h) to disable vehicle speed regulation of
the retarder). The engine retarder is also disabled whenever the PTO On/Off switch is ON if the customer
parameter PTO Configuration is programmed to Cab Switches, Remote Switches, or Remote Throttle.
16.2.3 Engine Retarder Minimum Vehicle Speed
The Customer Programmable Parameter Engine Retarder Vehicle Speed determines the minimum vehicle speed
that the engine retarder will be enabled. A typical application for this feature is to prevent the engine retarder from
engaging while operating in a noise restricted area while the vehicle is operating at slower than highway speeds.
16.2.4 Engine Retarder Minimum VSL Type
The Customer Programmable Parameter Engine Retarder Minimum VSL Type is used to allow the engine retarder
to stay engaged below the programmed “Minimum Vehicle Speed” programming. When programmed to “Soft Limit”
and the engine retarder has been engaged, the engine retarder will continue to stay engaged until the engine
reaches a minimum RPM, the clutch is engaged or the operator depresses the throttle. When programmed to
“Hard Limit” the engine retarder will disengage at the programmed Engine Retarder Minimum Vehicle Speed.
The parameter has no effect on when the engine retarder is engaged.
16.2.5 Auto Retarder in Cruise
The Auto Retarder in Cruise option allows the engine retarder to come on while the engine is active in cruise
control in order to attempt to maintain the cruise control set speed. The Auto Retarder in Cruise option still requires
the engine retarder switches to be in the ON position, and will only activate the retarder to the level at which the
switches indicate operation should occur. The Auto Retarder in Cruise parameter programs a vehicle speed above
the cruise control set speed at which the retarder will begin engaging the engine retarder. At this vehicle speed the
engine retarder will come on at the “low” level.
ENGINE RETARDER
ACTIVE LAMP ECM
E991-GY 12 OUTPUT #3
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
E716-GY 23 RETARDER SOLENOID LOW/HI SWITCH
E717-GN 40 RETARDER SOLENOID MED/HI SWITCH
ENGINE RETARDER P1 J1
SOLENOID ON/OFF SWITCH LO
MED
HI
LO
MED
ENGINE RETARDER HI
SOLENOID SELECTOR SWITCH
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These outputs 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. Do not ground the relay or solenoid to the ECM Sensor Common connections.
Connections for Output #2, #3, #4, #5, #6 and #7:
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TO STARTER
ECM
E718-PK 10 OUTPUT #2
E991-GY 12 OUTPUT #3
G836-WH 13 OUTPUT #4
P1 J1
IGNITION
OFF
KEY SWITCH
ON
START
TO STARTER
ENGINE
SHUTDOWN
RELAY (N/O)
TO VEHICLE TO VEHICLE
ELECTRICAL +BATTERY
SYSTEMS
ECM
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** NOTE: OUTPUT #2, #3, OR #4 MAY BE USED. THE STARTING AID OUTPUT PARAMETER
MUST BE PROGRAMMED TO THE DESIRED OUTPUT SELECTION.
* NOTE: INPUT #4, #5, #6 OR #7 MAY BE USED. THE STARTING AID ON/OFF SWITCH PARAMETER
MUST BE PROGRAMMED TO THE DESIRED INPUT SELECTION.
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BRAKESAVER
AUTO/MANUAL BRAKESAVER TO VEHICLE
SWITCH (IN MANUAL) RELAY N/O +BATTERY
ECM
BRAKESAVER E991-GY 12 OUTPUT #3
SOLENOID
P1 J1
AUXILIARY BRAKE
AUXILIARY BRAKE AUTO/MANUAL AUXILIARY BRAKE TO VEHICLE
SELECTOR SWITCH SWITCH (IN MANUAL) RELAY N/O +BATTERY
LO
MED
ECM
HI
LO E991-GY 12 OUTPUT #3
MED
HI
P1 J1
AUXILIARY BRAKE
SOLENOIDS
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ABS BRAKE
RELAY N/C ECM
C977-BU 22 CLUTCH PEDAL POSITION SWITCH
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
P1 J1
TO ABS
CONTROL
Wiring Diagram 33 - ABS Connection for Engine Retarder or Auxiliary Brake without SAE J1939 Communications
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Power
%
20
%
%
50%
i n t tl e
T h osit
/M
P
ax
20%
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For the Three Speed Fan option, an additional fan control output is provided at J1/P1: 13. This output is a high side
driver (Battery voltage - DC) and is not a PWM signal. Current capability is 1.5 Amps.
Caterpillar recommends transient suppression be used on the inductive load in addition to the ECM’s internal
protection. Some solenoids produce less RFI when suppressed with resistive loads.
Connections for the Fan Control outputs
ECM
G837-YL 11 OUTPUT #5
COOLING FAN SOLENOID P1 J1
SLIP MODE
SOLENOID
G837-YL 11 OUTPUT #5
G836-WH 13 OUTPUT #4
P1 J1
BRAKE MODE
SOLENOID
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.
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The ECM will turn the cooling fan ON under any of the following conditions if engine rpm is less than 2250 rpm:
• Engine Not Running
• During Engine Cranking
• Coolant Sensor Temperature > 216 DEG F (102 DEG C)
• Active Coolant Temperature Sensor Diagnostic
• Intake Manifold Air Temperature > 189 DEG F (87 DEG C)
• Intake Manifold Air Temperature > 162 DEG F (72 DEG C) with Boost Pressure > 10 psi (70 kPa)
• *Engine Retarder ON in high mode > 2 seconds, when Fan With Engine Retarder in High Mode is programmed to YES
• *A/C High Pressure Switch Input is Open or ECM is Counting
• *PTO On/Off Switch in ON position, when PTO Activates Cooling Fan parameter is programmed to Continuous
• *Manual Fan Override Switch is ON, when the Fan Override Switch parameter is programmed to a selected input.
*These items are dependent upon programming of Customer Parameters.
NOTE: The ECM will turn the cooling fan OFF for 10 seconds during an engine shutdown.
The fan will remain on for a minimum of 30 seconds following ECM initiated activation except following engine start
up, or if the A/C Pressure Switch Fan On Time is programmed less than 30 seconds. During engine start up, the
ECM will keep the fan ON for 2 seconds after the engine has reached the programmed low idle (600 - 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 2300 rpm or when all the
following circumstances are met.
• Coolant Sensor Temperature < 208 DEG F (98 DEG C)
• The fan has been ON for at least 30 seconds
• Intake Manifold Air Temperature < 151 DEG F (66 DEG C)
• Engine Retarder ON Strategy is not Active
• A/C High Pressure Switch not Active
• PTO On/Off Switch in OFF position
• Manual Fan Override Switch in OFF position
• Key Switch turned OFF with Engine Speed Present
NOTE: The ECM will turn the cooling fan OFF for 10 seconds during an engine shutdown.
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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.
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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
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Wiring Diagram 36 - Cooling Fan and A/C High Pressure Switch Circuit for On-Off Fan Type
Wiring Diagram 37 - Cooling Fan and A/C High Pressure Switch Circuit for Three Speed Fan Type
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ECM
G841-GN 7 INPUT #4
FAN OVERRIDE SWITCH G842-GY 47 INPUT #5
(SHOWN IN OFF POSITION) G843-OR 6 INPUT #6
G844-PK 46 INPUT #7
H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
P1 J1
NOTE: INPUT #4, #5, #6 OR #7 MAY BE USED. THE FAN OVERRIDE SWITCH
PARAMETER MUST BE PROGRAMMED TO THE INPUT SELECTION.
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MOMEMTARY
MANUAL AIR INLET
SHUTOFF SWITCH
N/O
P2/J2
Switch Closed
TO +BATTERY Enabled Position
P1/J1
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22.0 Transmissions
Caterpillar C11, C13 and C15 engines can be connected to a variety of transmissions. The type or “Style” of
transmission determines what switch inputs and datalinks are required for proper engine/transmission operation.
Caterpillar provides the Customer Parameter “Transmission Style” that has the options of Manual, Automatic Option 1,
Automatic Option 2, Automatic Option 3, Automatic Option 4 and Eaton Top 2. This selection should be based on
the type of transmission and whether a neutral switch or a second separate service brake pedal position switch is
used. Correct programming is required to provide proper cruise control, PTO, and Extended Idle operation. Refer to
Chapters 12 and 14 for information about hardwired and J1939 switch inputs.
Transmission Style Parameter Switch Input Table
J1/P1: 64
Automatic Option 4 ✓ ✓ J1/P1: 62
or
J1939 Neutral
Switch Message
Eaton Top 2 ✓ ✓ J1/P1: 22
or
J1939 Clutch
Switch Message
NOTE: All options require a Service Brake Pedal Position Switch circuit connected to the ECM Connector J1/P1: 45
or a J1939 Service Brake message.
22.1 Transmissions and Datalinks
Transmissions may or may not use a datalink to communicate with the engine. The following table contains a
representative listing of transmissions, acceptable “Transmission Style” programming and the typical data link used.
Transmissions that use the J1587 Data Link do not require that the “Powertrain Datalink” parameter to be
programmed. Transmissions that use the J1939 Data Link require the “Powertrain Datalink” parameter be
programmed to J1939. “Transmission Style” programming is independent of the Power Train Datalink programming.
For specific switch inputs required for each “Transmission Style” option, refer to “Transmission Style Parameter
Switch Input Table” shown above.
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Minimum “ON” Output Maximum “ON” Output Maximum Current OFF State
Voltage Voltage Draw
Battery - 2.0 Volts DC Battery 1.0 A High Impedance
These drivers are intended for connection to a solenoid. Caterpillar recommends transient suppression be used on
the inductive load in addition to the ECM’s internal protection. Circuit protection is left to the OEM’s discretion.
Connection for this output:
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ECM
A G838-BR 19 OUTPUT #6
C G839-BU 20 OUTPUT #7
EATON EATON B P1 J1
TOP 2 TOP 2
LOCKOUT SHIFT
SOLENOID SOLENOID
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Chart displays the number of gears captured by the selected switch-over ratio for 10 speed transmissions.
10-speed transmissions have top three gear ratios of 0.73, 1.00, 1.38.
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+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 42 - J1587 Data Link Circuit with 6-Terminal Diagnostic Connector
+BATTERY B
-BATTERY A
ECM
Wiring Diagram 43 - J1587 Data Link Circuit with 9-Terminal J1939/13 Off-Board Diagnostic Connector
NOTE: The J1939/13 connector is black in color and requires a Caterpillar # 157-4829 Service Tool Adapter Cable.
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+BATTERY B
-BATTERY A
ECM
Wiring Diagram 44 - 1587 Data Link Circuit with Deutsch 9-Terminal Cab Diagnostic Connector
NOTE: This connector is gray in color and connects directly to the Caterpillar # 139-4166 Service Tool Cable.
24.2 Service Tools and Diagnostics
The control system has built-in diagnostics to verify system components are operating properly. In the event of a
component failure, the driver is alerted to the condition via an OEM installed “Check Engine” or diagnostic lamp, or
from a message transmitted over the SAE J1587 or J1939 data links. Intermittent faults are logged and stored in
the memory of the ECM and can be retrieved using an Electronic Service Tool.
The required electronic service tool for the C11, C13 and C15 engine is Caterpillar Electronic Technician (ET). ET is
a software based service tool used to diagnose and repair Caterpillar products. It is designed to run on a personal
computer using the Windows® 95 or newer operating systems. The C11, C13 and C15 engines are not compatible
with the MPSI Pro-Link service tool.
OEM provided and installed components required:
1) Data link connector, following The Maintenance Council RP1202.
2) Check Engine Lamp.
Customer Parameter programming required:
1) Availability of some diagnostic codes is influenced by parameter programming, such as Engine Monitoring.
The Caterpillar service tool connector uses a 9-terminal Deutsch HD series connector to connect to the vehicle.
Caterpillar offers a variety of adapter cables to connect various cab/engine datalink connectors to the standard
9-pin connector found on the 139-4166 or 160-0141 Service Tool cable. The following list identifies some of those
adapter cables commonly used on various applications.
• 7X-1686 - Connects 9-terminal Service Tool Cable (139-4166 or 160-0141) to GM ALDL Cab Connector
• 7X-1714 - Connects 9-terminal Service Tool Cable (139-4166 or 160-0141) to a 6-terminal Cab Connector
• 157-4829 - Connects 9-terminal Service Tool Cable (139-4166 or 160-0141) to a 9-terminal J1939/13 Off-Board
Diagnostic Connector
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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 +
Average Load Factor is calculated using actual fuel used, maximum fuel possible, and idle fuel:
Average Load Factor = [(actual fuel - idle fuel)/(maximum fuel-idle fuel)]
All data is stored in metric form except distance (miles) and vehicle speed (mph). Conversions to other formats are
performed by the Electronic Service Tool.
24.6 Trip Data
Included under the heading of Trip Segment is a Fleet Trip Segment and Driver Trip Segment. These two data
segments are independent — resetting one does not affect the other. The fleet trip segment also includes a
3-dimensional histogram (engine rpm, vehicle speed, and engine hours), two 2-dimensional histogram (one for
engine rpm — hours, the other for vehicle speed — hours), and five sets of Fleet Segment Custom Data.
The 2-dimensional histograms are a subset of the 3-dimensional histogram.
A segment is defined as the difference from the current instantaneous Engine Totals data and the Engine Totals
stored at the previous reset of the data. When a reset occurs, the ECM stores the current ECM Engine Totals value
in place of the old value for the respective Trip Data information. The ECM maintains only the data reset values for
the Fleet Trip Data or Driver Trip Data segments, and Maintenance Indicator segment. The ECM does not calculate
actual trip data for these trip segments. It does however, calculate the data for the Fleet Trip Data Histograms and
Fleet Segment Custom data. The Fleet Trip Segment can be further divided into two driver trip segments tagged by
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the Driver ID, and also into state segments. Driver ID and State crossing data requires a Caterpillar Messenger
display or Caterpillar Pocket Tec to enter Driver ID’s and State crossings.
24.6.1 Fleet Trip Segment
The Fleet Trip Segment maintains the following Engine Totals information, recorded at the time of reset:
Fleet Trip Segment Data
Variable xxxx Range xxxx Variables yyyy & zzzz Range yyyy & zzzz
Engine Hours 131,000 Engine Speed 0 - 3000
Distance Traveled 1,677,720 Vehicle Speed 0 - 127.5
Fuel Burned 8,192 Fuel Rate 0 - 40
Occurrences 4,294,967,296 Load Factor 0 - 100
Coolant Temperature 0 - 248 (°F)
Oil Pressure 0 - 100 (psi)
Fuel Temperature 0 - 248 (°F)
Intake Manifold Air Temp 0 - 248 (°F)
Cruise ON or OFF
PTO ON or OFF
Engine Retarder Active or Not Active
Throttle Position 0 - 100 Percent
Brake ON or OFF
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Broadcast Period Parameter Name PID Size (bytes) Scaling per bit
0.1 sec Road Speed 84 1 0.5 mph
* Cruise Control Set Speed 86 1 0.5 mph
Percent Accelerator Pedal Position 91 1 0.4 percent
Percent Engine Load 92 1 0.5 percent
* Power Take Off Set Speed 187 2 0.25 rpm
Engine Speed 190 2 0.25 rpm
0.2 sec Engine Status 2 1 Bit Code
Cruise Control Status 85 1 Bit Code
Engine Retarder Status** 121 1 Bit Code
Fuel Rate 183 2 4.34x10-6 gal/s
Instantaneous Fuel Economy 184 2 1/256 mpg
1.0 sec Idle Shutdown Status 71 1 Bit Code
Road Speed Limit Status 83 1 Bit Code
Power Take Off Status 89 1 Bit Code
Engine Oil Pressure 100 1 0.5 PSI
Boost Pressure 102 1 0.125 PSI
Boost Pressure (extended range) 439 2 0.125 PSI
Intake Manifold Temperature 105 1 1°F
Coolant Temperature 110 1 1°F
ECM Battery Voltage 168 2 0.05 V
(Optional) Ambient Air Temperature 171 2 0.25°F
Fuel Temperature 174 2 0.25°F
(Inferred) Engine Oil Temperature 175 2 0.25°F
(Active only) Engine Diagnostic 194 Variable PID/SID & FMI
*Cruise and PTO set speeds are sent at 0.1 second intervals only when they are changing.
**Engine Retarder status is for ECM Solenoid Retarder, controlled via OEM installed switches. This may differ from
the Auxiliary Brake, which the ECM operates without OEM switch inputs.
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Broadcast Period Parameter Name PID Size (bytes) Scaling per bit
10.0 sec Cruise Control Set Speed 86 1 0.5 mph
(Not all ratings) Atmospheric Pressure 108 1 0.0625 PSI
Average Fuel Economy 185 2 1/256 mpg
Power Take Off Set Speed 187 2 0.25 rpm
Total Miles 245 4 0.1 miles
On Request Road Speed Limit 74 1 0.5 mph
High Cruise Control Speed Set Limit 87 1 0.5 mph
Low Cruise Control Speed Set Limit 88 1 0.5 mph
Rated Horsepower 166 2 1.0 BHP
Engine Idle RPM Speed 188 2 0.25 rpm
Engine Rated RPM Speed 189 2 0.25 rpm
Software Identification (Caterpillar P/N) 234 16 ASCII Char.
Total Idle Hours 235 4 0.05 hours
Total Idle Fuel Consumption 236 4 0.125 gal
Vehicle Identification 237 17 ASCII Char.
Total Miles 245 4 0.1 miles
Total Engine Hours 247 4 0.05 hours
Total Engine PTO Hours 248 4 0.05 hours
Total Fuel Consumption 250 4 0.125 gal
Real Time Clock - Time 251 3 Char 1: 0.25 sec
Char 2: 1.0 min
Char 3: 1.0 hour
Real Time Clock - Date 252 3 Char 1: 0.25 day
Char 2: 1.0 month
Char 3: 1.0 year
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Broadcast Period Parameter Name PID Size (bytes) Scaling per bit
On Request Component Identification 243 21 ASCII Char.
(Sent as multi- Message #1
packet message) Byte 1 - MID = 128
Byte 2 - PID for multi-packet message = 192
Byte 3 - Number of characters following = 16
Byte 4 - Requested PID 243 = 243
Byte 5 - Last and current section number = 16
Byte 6 - Byte count of total data portion = 21
Byte 7 -19 - PID 243 data portion = 128,
ASCII Characters = CTRPL*C11,
CTRPL*C13 or CTRPL*C15
Byte 29 - Checksum
Message #2
Byte 1 - MID = 128
Byte 2 - PID for multi-packet message = 192
Byte 3 - Number of characters following = 11
Byte 4 - Requested PID 243 = 243
Byte 5 - Last and current section number = 17
Byte 6 - Byte count of total data portion = 8
Byte 7 -14 - PID 243 data portion = 128
Byte 15 - Checksum
On Request Clock 251 3 Character 1 =
0.25 sec/bit
Character 2 =
1 min/bit
Character 3 =
1 hr/bit
Date 252 3 Character 1 =
0.25 day/bit
Character 2 =
1 month/bit
Character 3 =
1 year/bit
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Bit code definitions for Cruise Control Status (PID 85), Engine 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.
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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
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Factory Passwords are required to change a parameter from “locked” to “unlocked”. Only one set of Factory
Passwords is required to unlock one or all locked parameters. If the Parameter Lockout screen is exited before
unlocking all parameters, a second set of Factory Passwords will be required to unlock the remaining parameters.
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Multi-Torque Ratio
The Multi-Torque Ratio is available on selected ratings only. This parameter is used to select the desired Multi-
Torque trip point. Multi-Torque ratings allow the engine to provide additional torque or additional horsepower and
torque when the transmission is operating in higher gears. The additional torque allows the truck to crest a hill
without downshifting, increases fuel economy, and reduce wear. The trip point is determined by a ratio of engine
speed versus vehicle speed. The three programmable options represent the different trip point values listed below:
MT-C ...turn on ratio is 38 rpm/mph & below (Top 4 Gears)
MT-B ...turn on ratio is 33 rpm/mph & below (Top 2 Gears)
MT-A ...turn on ratio is 27.9 rpm/mph & below (Top 1 Gear)
NOTE: Oil Well Service Ratings.
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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 12.0 to 500.0 in 0.1 ppr increments.
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APPLIED
APPLIED
ON
ENGINE RETARDER
“LATCH” ENGINE BRAKE OPERATION
Figure 41 - Coast and Latch Engine Retarder Mode
If programmed to Manual, the retarder operates the same with the cruise control switch ON (but Cruise is not
active) as when it is OFF.
Refer to “16.1 Engine Retarder Control” on page 97 for more information on Engine Retarder operation.
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Retarder
Vehicle Speed
Minimum
60 Vehicle
MPH Speed
30
0
ON
Eng Retarder
OFF
(Hard Limit)
ON
Eng Retarder
(Soft Limit) OFF
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5 MPH
100% Off
Available
HP
On
0 Cruise Set
Speed
Vehicle Speed Or VSL
Idle Parameters
Idle Vehicle Speed Limit
Maximum vehicle speed for setting or maintaining a set engine rpm in idle mode. Idle mode is entered if the engine
rpm is set using the cruise control On/Off switch along with Set/Resume. If the vehicle speed signal exceeds this
value, the engine will not maintain the set engine rpm.
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When programmed to Remote Throttle, the ECM will monitor J1/P1, terminal-68 for the remote accelerator pedal.
The ECM will monitor the Remote Set and Remote Resume inputs and ignore all cab controls when the PTO
On/Off circuit is ON.
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Torque Limit
Torque limit of the engine applies when the Torque Limit Switch circuit is ON, and the vehicle speed is less than the
programmed Idle/PTO Kickout vehicle speed limit. PTO mode does not have to be active for this feature to function.
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PTO Shutdown
Timer Reset
Engine
RPM Programmed
PTO Shutdown Timer
Maximum RPM
PTO Shutdown
Timer Counting
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Transmission Style
Indicates to the ECM the type of transmission configuration installed in the vehicle. It is used by the ECM to
determine how to read inputs (brake switch #2, clutch, and neutral switches).
If an automatic transmission is installed, this parameter should be programmed to Automatic Option 1, Automatic
Option 2, Automatic Option 3, or Automatic Option 4.
The Manual selection requires a clutch pedal position switch connected to ECM Connector J1/P1, terminal 22.
The transmission selections with a neutral switch require a transmission neutral switch connected to ECM
Connector J1/P1, terminal-62 (Input #12). The transmission selections with two brake switches require a second
brake switch connected to ECM Connector J1/P1 terminal-64 (Input #13). Refer to “Transmission Style Parameter
Switch Input Table” on page 118 for additional information.
The Eaton Top 2 transmission is a manual transmission and requires a clutch switch. The ECM operates two
outputs to control shifting between the top two gears of an Eaton Top 2 transmission. A total of four parameters
must be programmed for the system to operate correctly.
NOTE: For GFRS ratings, the default is locked to Eaton Top 2 and may not be changed.
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NOTE: XX appearing in Transmission Model number refers to (x) 100 = Nominal Torque Capacity. For example,
RTLO-14613A has a Nominal Torque Capacity of 14 (x) 100 or 1400 lb ft.
Transmission model designation and other transmission identification information are stamped on the transmission
tag. The tag is located on the lower left side near the front of the transmission.
Governor Type
Indicates to the ECM the type of Governor that controls the engine. Select Full Range (Default) for manual
transmissions and electronically shifted manual transmission. Select either the Min/Max governor or Min/Max with
Speed Control for automatic transmissions. Refer to “18.0 Governor Type” on page 106 for additional information.
Timer Parameters
Idle Shutdown Time
Time (in minutes) that engine will idle before shutting down. Engine will only shutdown if the ECM senses low
engine load and no vehicle speed. The Idle Shutdown Timer will not begin counting if the engine is in Cold Mode.
If this parameter is programmed to zero, this feature is disabled.
NOTE: This feature does not shutdown vehicle power. The ECM and vehicle remain powered.
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Outside Temperature
Idle Shutdown Override Allowed
Maximum Idle Shutdown
Outside Temperature
Idle Shutdown Override Not Allowed
Minimum Idle Shutdown
Outside Temperature
Idle Shutdown Override Allowed
0 90
Time (seconds)
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Maintenance Parameters
When programming with VEPS, the C8 parameter must be set to a 1 before programming C9, CA and CB.
Maintenance Indicator Mode
The ECM records data related to vehicle maintenance. If Distance is selected (Manual - Distance or Automatic -
Distance), then all maintenance indications (PM1, PM2, Coolant Flush/Fill) on the service tool will be displayed
in Distance.
If Hours is selected (Manual - Hours or Automatic - Hours), then all maintenance indications (PM1, PM2, Coolant
Flush/Fill) on the service tool will be in Hours. The ECM provides PM1 maintenance interval and last maintenance
information.
Manual - Distance
Minimum Maximum Default VEPS PID
8050 km 56325 km 24140 km CA
(5000 miles) (35000 miles) (15000 miles)
Manual - Hours
Minimum Maximum Default VEPS PID
100 750 300 CB
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Trip Parameters
Fuel Correction Factor
The fuel correction factor is available to fine tune all fuel data stored in the future by the ECM. Caterpillar recommends
this factor be changed only after a significant operating interval with a comparison of actual tank fuel economy compared
to ECM recorded fuel economy. The operating interval should also reflect a typical route. The Factor is a percentage,
programmable in 0.5 percent increments.
error = (ECMTANK
- TANK
)
new fcf = ((100 + old fcf) error) + old fcf
Where OLD FCF is the Fuel Correction Factor currently in ECM, TANK is the actual fuel economy, and ECM is the
fuel economy indicated in the ECM Trip Data.
Example
The Actual TANK fuel economy is determined to be 7.1 mpg, but the ECM Trip Data economy is 7.0 mpg over the
same distance with an OLD FCF of -2.5.
The following parameters (Change Fuel Correction Factor, PM1 Reset, and Fleet Trip Reset) establish security
access for the Caterpillar Messenger display. These parameters require a Caterpillar Messenger display
for access.
Dash - Change Fuel Correction Factor
Allows the driver to adjust the Fuel Correction Factor. An owner-operator would want driver access to this
information, but a fleet operation might not.
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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 - 24 km/h/s (0 -15 mph/s) (0 = OFF) but the recommended range is from
5 - 24 km/h/s (3-15 mph/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.
Vehicle Overspeed Threshold
The Vehicle Overspeed Threshold may be programmed to generate a Vehicle Overspeed Warning event (84-00)
when the vehicle speed exceeds this value. Caterpillar recommends that this value be set above the Vehicle Speed
Limit (VSL) including the 2.5 mph above VSL, when the Soft Vehicle Speed Limit parameter is programmed to “Yes”
and any Driver Reward values. This parameter may be “Locked”.
Driver Reward
Driver Reward Enable
Driver Reward is a feature that allows a truck owner to place weighting factors on desired operating habits. If the
vehicle is operated in a manner that exceeds the owner’s specifications, the maximum vehicle speed limit can be
automatically increased to a specified value as a reward to the driver. The Driver Reward Enable parameter
provides a means to Disable and Lockout the Driver Reward feature using an Electronic Service Tool, for those
areas with regulations that require a fixed maximum Vehicle Speed Limit.
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Input Selections
Fan Override Switch
The Fan Override Switch parameter can be programmed to one of the Hard Wired options or to one of the SAE
J1939 sourced inputs. This switch allows the operator to turn ON the cooling fan at any time for improved engine
retarding/braking and engine cooling.
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Output Selections
Engine Running Output
The Engine Running Output feature is used to prevent starter engagement while the engine is running. The Engine
Running Output comes ON when the engine is running and turns OFF when the engine rpm = 0. The relay is
normally closed so cranking can be achieved immediately at power up. During cranking, the ECM energizes the
Engine Running Output once engine low idle rpm has been achieved. The relay is de-energized if engine speed
falls 100 RPM below the programmed low idle (600-750 rpm is low idle range).
Auxiliary Brake
The Auxiliary Brake Output is for use with a BrakeSaver or other Aftermarket braking devices. Operation of the
auxiliary brake and relay is inhibited during undesirable engine operating conditions (such as while the engine
injectors are being fueled).
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Passwords
Customer Password #1
The Customer Password #1 parameter can be used to limit access to parameters. When a password is programmed,
this password must be entered before any parameter can be changed. This password does not allow “Locked
Parameters” to be changed. This parameter may be programmed with or without programming Password #2.
If both Password #1 and #2 are programmed, both passwords must be entered before a parameter may be changed.
Factory Passwords and the Electronic Technician service tool are required to read a programmed password.
Customer Password #2
The Customer Password #2 parameter can be used to limit access to parameters. When a password is programmed,
this password must be entered before any parameter can be changed. This password does not allow “Locked
Parameters” to be changed. This parameter may be programmed with or without programming Password #1.
If both Password #1 and #2 are programmed, both passwords must be entered before a parameter may be changed.
Factory Passwords and the Electronic Technician service tool are required to read a programmed password.
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ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
An * 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 as specified in
the VEPS documentation. Contact Caterpillar Inc. for information on VEPS programming options.
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ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
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INDEX
161-8906 Accelerator Position Accelerator Pedal Position Sensor
Sensor Connector ......................................36 Duty Cycle..................................................35
2-Wire Float Sensor ..................................52 Accelerator Pedal Position Sensor
Electrical Specifications ............................32
2-Wire Float Sensor Diagnostics ..............54
Accelerator Pedal Position Sensor for
4-Pin Coolant Level Sensor Diagnostic......52
Remote PTO Applications ..........................36
4-Pin Coolant Level Sensor Electrical
Accelerator Pedal Position Sensor
Specifications ............................................51
Three Terminal Connector Terminals ........35
4-Pin Coolant Level Sensor Mounting
Accelerator Pedal Position Sensor with
Guidelines ..................................................50
Three Terminal Deutsch Connector ..........33
4-Pin Coolant Level Sensor Outputs ..........51
Accelerator Pedal Position Sensor
4-Pin Coolant Level Sensor with Three Terminal Packard Electric
Power Supply ............................................51 Connector ..................................................34
4-Pin Coolant Level Sensor Accelerator Pedal Position Sensors ..........32
Response Time ..........................................52
Adaptive Cruise Control ..........................116
70 Terminal ECM Connector Part
Additional Switch to Sensor
Numbers ....................................................26
Common Inputs..........................................62
A
Advantages of PTO Configurations............70
A/C High Pressure Switch Operation ......113
Air Conditioning High Pressure Switch ....113
ABS and Traction Control ........................124
Air Starter Equipped Vehicles ....................22
ABS Auxiliary Brake Specification............105
Allison ATEC Series ................................119
ABS Engine Retarder Relay
Allison WTEC Series................................119
Specification ............................................100
Ambient Air Temperature Sensor ..............57
Accelerator Pedal Position Sensor
(176-1602 and 176-1604) with Ambient Air Temperature Sensor
Deutsch Three Terminal Connector Connections ..............................................57
Wire Insulation Size Range........................34
Atmospheric Pressure Sensor ....................5
Accelerator Pedal Position Sensor
Auto Retarder in Cruise..............................98
(176-1602 and 176-1604) with
Deutsch Three Terminal Connector Auto Retarder in Cruise Increment ..........100
Wire Gauge Size ........................................34
Auxiliary Brake ........................................103
Accelerator Pedal Position Sensor
B
(176-1605) with Packard Electric
Three Terminal Connector Wire Bit Code Definitions ................................134
Insulation Size Range ................................34
Boost Pressure Sensor ................................5
Accelerator Pedal Position Sensor
C
(176-1605) with Packard Electric
Three Terminal Connector Wire C11 and C13 Ground Stud ........................22
Gauge Size ................................................34
C15 Ground Stud ......................................22
Accelerator Pedal Position Sensor
Caterpillar BrakeSaver Installation ..........104
Connection ................................................35
Check Engine Lamp Operation ..................48
Accelerator Pedal Position Sensor
Connector ..................................................33 Clock Accuracy ........................................214
222 Caterpillar Pub # LEBT3886-03________C11, C13 & C15 Truck Engines________EPA 2004_____
ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
INDEX
Clutch Pedal Position Switch Function ......61 D
Clutch Pedal Position Switch with Data Links ................................................125
Automatic Transmissions............................61
Data Stored In Engine Snapshot
Clutch Switch ............................................68 Recorder Frames ....................................130
Cold Mode Idle Shutdown Timer Enable ..183 Data Stored In Quick Stop Recorder
Frames ....................................................130
Cold Mode Operation ..................................4
Dedicated PTO Operation ..........................70
Connection Of Devices Other Than
A Speedometer/Tachometer ......................46 Diagnostic Code Quick Reference: ..........219
Connectors and Wiring Harness Diagnostic Enable ......................................61
Requirements ............................................26
Driver Reward ..........................................129
Coolant Diverter Valve..................................6
Driver Trip Segment Data ........................129
Coolant Level Sensor ................................50
Dual Coil Speed Sensor ............................41
Coolant Level Sensor Connections ............51
E
Coolant Level Sensor Environmental
Eaton Autoshift ........................................120
Compatibility ..............................................50
Eaton CEEMAT ........................................119
Coolant Temperature Sensor ......................5
Eaton Top 2 Installation Requirements ....121
Cooling Fan ..............................................108
Eaton Top 2 Transmissions ......................120
Cooling Fan Control With Ignition
Key Off ....................................................115 ECM +8V Cab Accelerator Pedal
Position Sensor Supply ..............................33
Cooling Fan Output Operation
(On-Off Fan) ............................................109 ECM 70 Terminal Connector Allen
Screw Torque ............................................26
Cooling Fan Output Operation
(Three Speed Fan) ..................................111 ECM 70 Terminal Connector Interface
Seal ............................................................29
Cruise Control ............................................59
ECM 70 Terminal Connector Sealing
Cruise Control Accel Switch ......................67
Plugs ..........................................................29
Cruise Control Decel Switch ......................68
ECM 70 Terminal Connector Terminals......27
Cruise Control On/Off Switch ....................60
ECM 70 Terminal Connector Wire
Cruise Control On/Off Switch ....................67 Insulation and Size Range ........................27
Cruise Control Pause Switch ....................60 ECM Connector ........................................26
Cruise Control Resume Switch ..................67 ECM Connector Endbell ............................31
Cruise Control Set Switch ..........................67 ECM Connector Terminal Installation
Guidelines ..................................................28
Cruise Control Set/Resume Switch............71
ECM Connector Terminals and Sealing
Cruise Pause Switch ..................................68
Plugs ..........................................................27
Customer Parameter Cross Check ..........129
ECM Connector Wire Gauge Size ............26
Customer Parameter Worksheet ..............210
ECM Date/Time Clock..............................214
Customer Specified Parameter Table ......199
ECM Diagnostic Clock ............................215
Customer Specified Parameters ..............164
ECM Negative Battery Connections ..........22
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ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
INDEX
ECM Positive Battery Connections ............24 Engine Monitoring Time to Shutdown ........17
ECM Software Changes ..........................127 Engine Retarder ........................................97
ECM Speedometer and Tachometer Engine Retarder Control ............................97
Outputs ......................................................44
Engine Retarder Delay ............................100
ECM Supplied +5V and +8V ......................25
Engine Retarder Level ..............................97
ECM Vehicle Harness Connector
Engine Retarder Minimum
Terminal Assignments and Loads ............216
Vehicle Speed ............................................99
ECM Wireless Communication Enable ....129
Engine Retarder Minimum VSL Type ........99
Economy Model ......................................129
Engine Retarder Mode ..............................98
Electrical Specifications ............................47
Engine Retarder Operation ........................97
Electronic Governing....................................4
Engine Running Output............................101
Electronic Transmission Controller
Engine Shutdown Output ........................102
#1: ETC1 ..................................................154
Engine Snapshot Recorder ......................130
EMI/RFI Testing..........................................24
Engine Speed/Timing Sensors ....................5
Engine Component Overview ......................5
Engine Totals............................................127
Engine Connection To Vehicle Battery
Ground ......................................................22 Extended Idle ............................................65
Engine Control Module (ECM) ....................5 F
Engine Diagnostic Switch ..........................69 Fan Control Basics ..................................108
Engine Functions ........................................4 Fan Control Options ................................108
Engine Monitoring ......................................13 Fan Control Output Electrical
Specifications ..........................................108
Engine Monitoring - Coolant Level
Sensor........................................................15 Fan Override Switch ..................................68
Engine Monitoring - Coolant Fan Override Switch ................................115
Temperature Sensor ..................................14
Fleet Segment Custom Data....................128
Engine Monitoring - Fuel
Fleet Trip Histograms ..............................128
Temperature Sensor ..................................14
Fleet Trip Segment ..................................128
Engine Monitoring - Intake Manifold
Air Temperature Sensor ............................14 Fuel Temperature Sensor ............................5
Engine Monitoring - Oil Pressure Fuel/Air Ratio Control ..................................4
Sensor........................................................14
Full Range Governor................................106
Engine Monitoring and OEM
G
Requirements ............................................13
Gear Fast/Run Slow ................................121
Engine Monitoring Lamp Options ..............13
General Requirements for J1939
Engine Monitoring Programmed to
Transmission Output Shaft Speed
"Derate" or "Shutdown" ..............................16
Based Vehicle Speed Source ....................42
Engine Monitoring Programmed to
General Vehicle Speed Source
"Warning" ..................................................16
Requirements ............................................39
Engine Monitoring -Sensors ......................14
Governor Type..........................................106
224 Caterpillar Pub # LEBT3886-03________C11, C13 & C15 Truck Engines________EPA 2004_____
ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
INDEX
Grounding ..................................................20 M
H Maintenance Indicator Data ....................129
High Coolant Temperature Lamp Maximum PTO Enable Speed....................73
Operation ..................................................49
Min/Max Governor....................................106
I
Min/Max Governor with Speed Control ....107
Idle Shutdown and Ambient Air
Mounting the Remote Accelerator
Temperature Sensor Installation ................55
Position Sensor ..........................................36
Idle Shutdown Timer ..................................55
Multiple PTO Engine Speed Operation -
Ignition Key Off Current..............................25 Example #2 ................................................91
Ignition Key Switch to Positive Battery ......63 Multiple PTO Engine Speed Operation -
Example #3 ................................................92
Ignore Brake and Clutch ............................73
Multiple PTO Engine Speed Operation -
Information Available Via SAE
Example #4 ................................................93
J1587/J1708 Using SAE J1587
Escape Parameter ..................................127 Multiple PTO Engine Speed Operation -
Example #5 ................................................94
Injection Timing Control ..............................4
Multiple PTO Engine Speed Operation -
Inlet Air Shut Off ......................................117
Example #6 ................................................95
Inlet Manifold Air Temperature Sensor ........5
Multiple PTO Engine Speed Operation -
Input Electrical Specifications ....................70 Example #7 ................................................96
Installing an Engine Retarder Multiple Speed PTO Operation ..................88
Active Lamp ............................................100
Multiple Speed PTO Operation using
J PTO Engine RPM Set Speed A and B ......88
J1939 ABS Wheel Speed Based Multi-Torque Ratio ....................................121
Vehicle Speed Source................................42
O
J1939 Based Switch Messages ................67
OEM Harness Routing ..............................30
J1939 Cruise Switch Inputs ......................67
OEM Installed Auxiliary Brake..................104
L
OEM Installed Switch Inputs ......................58
Lamp Outputs ............................................47
Oil Pressure Sensor ....................................5
Lamp Test ..................................................48
One Speed Above Low Idle after
Lockout Solenoid Operation ....................121 PTO Switched On, Using Cruise
Set /Resume ..............................................77
Low Coolant Level During an
Engine's First 6 Hours of Operation ..........15 One Speed Above Low Idle after
PTO Switched On, Using PTO
Low Coolant Level Lamp Operation ..........49
Set/Resume ..............................................82
Low Oil Pressure Lamp Operation ............49
One Speed Above Low Idle with
PTO Switched On ......................................76
One Speed Above Low Idle with
PTO Switched On ......................................81
Operation in 24 Volt Systems ....................25
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INDEX
Option 1 - One Single Coil PTO Configuration - Remote Switches
Speed Sensor ............................................41 Programmable Options ..............................84
Option 2 - One Single Coil PTO Configuration - Remote Switches
Speed Sensor ............................................41 with Torque Limiting....................................83
Option 3 - Separate Single Coil PTO Configuration - Remote Throttle ........85
Speed Sensors ..........................................41
PTO Configuration - Remote Throttle
Other Battery Connections ........................25 Operation Differences ................................76
Output #2, Output #3, Output #4, PTO Configuration - Remote Throttle
Output #6 and Output #7 Electrical Programmable Options ..............................87
Specifications ..........................................101
PTO Configurations....................................75
Output #5 Electrical Specifications ..........101
PTO Customer Access Connector ............74
Output #6 and Output #7 Electrical
PTO Enable Switch ....................................69
Specifications ..........................................120
PTO Engine RPM Set Speed ....................72
P
PTO Engine RPM Set Speed A ................72
Parking Brake Switch ........................61, 196
PTO Engine RPM Set Speed B ................72
Passive Magnetic Vehicle Speed
Circuit Options ..........................................40 PTO Engine RPM Set Speed Input A ........69
Passive Magnetic Vehicle Speed PTO Engine RPM Set Speed Input A ........72
Sensor Electrical Requirements ................40
PTO Engine RPM Set Speed Input B ........72
PM1 Maintenance ....................................130
PTO Inputs ................................................70
Power and Grounding Requirements
PTO Interlocks ..........................................74
and Considerations ....................................20
PTO Kickout Vehicle Speed Limit ..............73
Preset Switch to Sensor Common
Inputs ........................................................58 PTO On/Off Switch ....................................71
Programmable Outputs ............................101 PTO On/Off Switch ....................................72
PTO Activates Cooling Fan ........................73 PTO Parameter and Switch Function ........71
PTO Active Output ....................................74 PTO Set Speed ..........................................71
PTO Cab Controls RPM Limit ....................73 PTO Shutdown Time ..................................73
PTO Configuration - Cab Switches PTO Shutdown Timer Maximum RPM ......73
Operation Differences ................................75
PTO Switch On Lamp ................................72
PTO Configuration - Cab Switches
PTO Switch On Lamp Operation................49
Programmable Options ..............................80
PTO Switches ............................................62
PTO Configuration - Cab Switches
with Torque Limiting....................................78 PTO to Set Speed ......................................72
PTO Configuration - Cab Switches, PTO Top Engine Limit ................................72
Remote Switches, or Remote Throttle
Q
Operation ..................................................75
Quick Stop Recorder................................130
PTO Configuration - Remote Switches ......81
Quick Stop Recorder Records ................130
PTO Configuration - Remote Switches
Operation Differences ................................76
226 Caterpillar Pub # LEBT3886-03________C11, C13 & C15 Truck Engines________EPA 2004_____
ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE
INDEX
R Speedometer and Tachometer
Output Accuracy ........................................46
Remote Accelerator Pedal Sensor
Common Connections ..............................38 Speedometer and Tachometer
Output Electrical Specifications
Remote Accelerator Pedal Sensor
and Connections ........................................44
Input Electrical Specifications ....................38
Speedometer Signal Accuracy ..................46
Remote Accelerator Pedal Sensor
without Set and Resume ............................85 Spicer Automate-2 10 Speed
Electronically Automated Transmission ....119
Remote Accelerator Position Sensor
Assemblies ................................................37 Starting Aid Output ..................................103
Remote Accelerator Position Sensor Suppression of Voltage Transients ............23
PWM Input ................................................38
Switch to Sensor Common Electrical
Remote PTO Resume Switch ....................69 Specifications ............................................58
Remote PTO Resume Switch ....................72 Switch-to-Battery Circuit Protection ..........63
Remote PTO Set Switch ............................69 Switch-to-Battery Electrical
Specifications ............................................63
Remote PTO Set Switch ............................72
T
Remote Throttle Sensor with Set
and Resume ..............................................86 Tachometer Signal Accuracy......................46
Retarder Off/Low/Med/High Switch............69 Torque Limit................................................73
S Torque Limit Switch ....................................73
SAE J1587 Data Link Broadcast Torque Rise Shaping....................................4
Parameters ..............................................131
Torque/Speed Control #1 from
SAE J1587/J1708 Data Link ....................125 Transmission Control to Retarder ............154
SAE J1939 Broadcast Messages ............136 Transmission Neutral Switch ......................64
SAE J1939 Data Link ..............................135 Transmission Neutral Switch ......................69
SAE J1939 Received Messages..............154 Transmission Neutral Switch Status
via J1939 Datalink......................................64
Sealing Splices and Ring Terminals ..........30
Transmissions ..........................................118
Sensor Common Connections ..................23
Transmissions and Datalinks....................118
Sensor Common Connections ..................58
Trip Data ..................................................127
Sensor Common for PTO Applications ......71
Twisted Pair Wiring ....................................31
Service Brake Pedal Position Switch
#1 Function ................................................61 Two-Speed Axle On/Off Switch ..................62
Service Brake Pedal Position Switch #2 ....63 V
Service Brake Switch ................................68 V V A Oil System Control Valve....................6
Service Tools and Diagnostics ................126 Vehicle Speed Circuit ................................39
Set/Resume Switch....................................60 Vehicle Speed Connections To
Automatic Transmissions with
Shift Solenoid Operation ..........................121
Electronic Vehicle Speed Source ..............41
Speedometer and Tachometer ..................44
Viewing Diagnostic Flash Codes................48
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INDEX
Viewing Diagnostic Flash Codes
using the Diagnostic Enable Input..............49
Voltage Requirements and
Considerations ..........................................25
W
Warning Lamp Operation ..........................49
Welding on a Vehicle Equipped with
a C11, C13 or C15 Engine ........................25
228 Caterpillar Pub # LEBT3886-03________C11, C13 & C15 Truck Engines________EPA 2004_____
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Discretion is recommended when distributing.
Materials and specifications are subject to change without notice.
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corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.