c7-c9 electrical electronic guide

C7 & C9 Truck EnginesEPA 2004

Electrical and ElectronicApplication and Installation Guide

Serial Number PrefixesFMMFMLKALYPG9DGCKP

LEBT2835-02 November 2008

INTRODUCTION AND PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Engine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Engine Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Power and Grounding Requirements and Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Connectors and Wiring Harness Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Accelerator Pedal Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Vehicle Speed Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38ECM Speedometer and Tachometer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Lamp Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45OEM Installed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Inlet Air Heater, Lamp and Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Hard-wired Switch Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Idle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70J1939 Based Switch Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72Dedicated PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Programmable Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100Governor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113Data Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114Customer Specified Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144Diagnostics, Service Tools and Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ 3

INTRODUCTION AND PURPOSE

This document is intended to provide necessary information for correct electrical & electronic application andinstallation of a C7 or C9 truck engine into an on-highway truck, bus, motor coach or vocational chassis.Caterpillar expects there will be some additions and modifications to this document as the engine programdevelopment continues, and as OEM requests for information not currently addressed are added. The informationcontained in this version of the document reflects the Caterpillar design for production C7 and C9 engines builtwith March 2004 software.

General Electronic Engine Operation

1.0 Engine Functions1.1 Electronic Governing

Two engine speed range electronic governors are available for use. These electronic governors are selectablethrough a programmable parameter.

1.2 Fuel/Air Ratio ControlThe control system has full authority over engine fuel delivery. The mechanical fuel/air ratio control is eliminated.Electronic control of the fuel/air ratio provides optimum performance with reduced emissions.

1.3 Injection Timing ControlInjection timing is varied as a function of engine operating conditions to optimize engine performance for emissions,noise, fuel consumption, and drivability.

1.4 Torque Rise ShapingElectronic controls provide increased flexibility to tailor the torque curve over a wide speed range.

1.5 Cold Mode OperationWhen the engine is started with cold coolant, the engine will operate in Cold Mode. The engine will operate withreduced performance until the coolant temperature has warmed. The Caterpillar electronic service tool software willindicate when the engine is operating in Cold Mode. The C7 engine will operate in Cold Mode below 64 Deg C andthe C9 engine will operate in Cold Mode below 40 Deg C.


4 Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____

The information herein is the property of Caterpillar Inc. and/or its subsidiaries. Withoutwritten permission, any copying, transmittal to others, and any use except that forwhich it is loaned is prohibited.

2.0 Engine Component Overview2.1 Engine Control Module (ECM)

The ECM is located on the left rear side of the engine. The ECM has two connectors, one for the Caterpillar EngineHarness, the other for the Vehicle OEM Harness.

2.2 Boost Pressure SensorThe Boost Pressure Sensor is an absolute pressure sensor measuring inlet manifold pressure. Boost pressuredisplayed by service tools and communicated over the data link is referenced to the Atmospheric Pressure Sensorreading. The Boost Pressure Sensor measures gauge pressure from 0 psi (0 kPa) to 49 psi (340 kPa). The ECMsupplies the sensor with a regulated 5 Volts DC.

2.3 Atmospheric Pressure SensorThe Atmospheric Pressure Sensor is an absolute pressure sensor. The Atmospheric Pressure Sensor measurespressure to 16.8 psiA (116 kPaA). The ECM supplies the sensor with a regulated 5 Volts DC.

2.4 Oil Pressure SensorAn optional Oil Pressure Sensor is available for use in applications where an actual oil pressure indication isdesired. Typical applications include vehicles with a vehicle data link capable Instrument Cluster that can displayengine information. C7 or C9 engines do not require Engine Lube Oil Pressure monitoring because the HEUI(Hydraulically actuated Electronically controlled Unit Injector) fuel system requires oil pressure for the engineto operate. Without sufficient oil pressure, the fuel system cannot supply fuel to the engine.The Oil Pressure Sensor measures gauge pressure from 0 psi (0 kPa) to 165 psi (1135 kPa). Oil Pressure asdisplayed by service tools and communicated over the data link is referenced to the Atmospheric Pressure Sensorreading. The ECM supplies this sensor with the necessary voltage.

2.5 Coolant Temperature SensorThe thermistor based Coolant Temperature Sensor is used to monitor engine coolant temperature. Output fromthis sensor is used for several engine functions including Inlet Air Heater Operation, Cold Mode Operation,Cold Elevated Idle and the Engine Monitoring System.

2.6 Inlet Manifold Air Temperature SensorThe Inlet Manifold Air Temperature Sensor is used to measure the inlet air temperature and is thermistor based likethe Coolant Temperature Sensor. This sensor output is used in controlling the Inlet Air Heater, Cold Elevated Idle,Cooling Fan Output, and for Engine Monitoring.

2.7 Engine Speed/Timing SensorsThe engine speed/timing sensors are used to determine both engine speed and fuel injection timing. The sensorsdetect this information from a wheel on the camshaft.

2.8 Coolant Level SensorThe coolant level sensor is an option device used to monitor the engines coolant level. This sensor is usuallymounted in the cooling systems surge tank. There are three types of sensors that may be used.

2.9 Injection Actuation Pressure (IAP) SensorThe Injection Actuation Pressure Sensor measures the pressure in the high-pressure oil manifold. This oil is usedto feed the hydraulically actuated electronically controlled unit injectors. The ECM supplies the sensor with thenecessary voltage.

2.10 Injection Actuation Pressure Control Valve (IAPCV)This valve controls the output injection actuation pressure of the high-pressure oil pump. The ECM uses the outputof the Injection Actuation Pressure Sensor to determine the required output to this valve.





2.11 Inlet Air Heater and RelayThe Inlet Air Heater is an engine mounted, Caterpillar supplied and installed heater grid used for warming the inletair to aid in starting during cold ambient temperatures. Operation is based on elevation (above sea level) and thesum of the Coolant and Inlet Manifold Air temperatures. The ECM controls the normally open relay to providebattery power to the grid.

2.12 Fuel Pressure SensorA Fuel Pressure sensor is included in the engine pressure sensor package. This sensor monitors the fuel supplypressure to the engine.

2.13 Oil Level Switch (GMT560 Trucks Only)An Oil Level Switch is available only on General Motors engines. This switch is mounted in the oil pan and wiredto the Engine Connector (J2) of the ECM. This switch monitors the oil level in the oil pan and is checked at initialengine power up. Proper Oil level in the engine will keep a normally open switch closed. Oil level that is too lowwill allow the switch to open. If the ECM senses an open switch upon three sequential engine starts, low oil levelis indicated.

Figure 1

33

3

P2 J2

Sensor Common

Oil Level

ECMOil Level Switch(Shown With Oil Level Normal) B428-OR

G829-GN



Figure 2

Boost Pressure Sensor

Top Camshaft Position Sensor

Bottom Camshaft Position Sensor

12V +

BATTERIES

6 HEUI Injectors

Injection Actuation Pressure Control Valve

Injection Actuation Pressure Sensor

Atmospheric Pressure Sensor

Coolant Level Sensor

Coolant Temperature Sensor

Intake Manifold Air Temperature Sensor

109-300012 V AIR FLOW

Intake Air Heater

Intake Air Heater Relay

Intake Air Heater Lamp

Vehicle Speed Sensor

Cooling Fan

SAE J1939/13 OFF-BOARDDIAGNOTSIC CONNECTOR

Ignition Key Switch

2 +Battery & 9 Ground Switch Inputs

3, 1.5A Outputs

3, 1.0A Outputs

2, 0.3A Lamp Outputs

Clutch and Service Brake Switches

Check Engine & Warning Lamps

MPH

15

50

25

4535 55

65

75

85 RPM X 100

5

10

1520

25

30

Speedometer & Tachometer

Throttle Position Sensor

PTO Throttle Position Sensor

OEM

Inst

alled

CaterpillarInstalled

Cruise Control On/Off& Set/Resume Switches

ADEM 2000EngineControl Module

Engine Oil Pressure Sensor (Optional)

Oil Level Switch (GMT560 Trucks Only)

Turbo Wastegate Control Valve(Not All Ratings)

Fuel Pressure Sensor



Engine Oil PressureSensor(Optional)

CoolantTemperatureSensor

EngineSpeed/TimingSensors

Injection ActuationControl Valve

Injection PressureSensor

Boost PressureSensor

Inlet AirTemperatureSensor

Inlet AirHeaterRelay

OEM ConnectorJ1/P1

ECM

EngineConnectorJ2/P2

ECM

Inlet AirHeater Relay

Atmospheric Pressure Sensor

Inlet AirTemperatureSensor

Boost PressureSensor

Injection Actuation PressureControl Valve

Coolant Temperature Sensor

Injection Actuation Pressure Sensor

Speed/TimingSensors

Oil PressureSensor(Optional)

OEM HarnessConnectorJ1/P1

EngineHarnessConnectorJ2/P2

Figure 3 - C7 Sensor Locations

Figure 4 - C9 Sensor Locations



Figure 5 - C7 Engine Wiring Diagram

1 2

INJE

CTIO

N A

CTUA

TIO

NPR

ESSU

RE CO

NTRO

L VA

LVE

J500

P5

00

E963

-BK

E964

-W

H

E965

-BU

E966

-YL

49 48 13 19 20 21 28 29 30 59 58 31 43 51 22 23 56 57 65 60 69 8

A B

TOP

CAM

SHAF

T PO

SITI

ON

SE

NSO

R TOP

CAM

SHAF

T PO

SITI

ON

-

TOP

CAM

SHAF

T PO

SITI

ON

+

J401

P4

01

J402

P4

02

BA

BOTT

OM

CAM

SHAF

T PO

SITI

ON

-BO

TTO

M C

AMSH

AFT

POSI

TIO

N +

BOTT

OM

CA

MSH

AFT

POSI

TIO

N SE

NSO

R

995-

BUC9

67-BU

G83

3-PK

C B A

G84

9-BR

G82

9-G

NG

828-

WH

A746

-PK

G84

9-BR

A747

-G

YG

829-

GN

G82

8-W

H

P204

J20

4

ENG

INE

ATM

OSP

HERI

C PR

ESSU

RE

ENG

INE

PRES

SURE

SEN

SOR

CO

MM

ON

ENG

INE

PRES

SUR

E SE

NSO

R +

5V

ENG

INE

ATM

OSP

HERI

CPR

ESSU

RE

NO

TE A

ENG

INE

INJE

CTIO

N

ACTU

ATIO

NPR

ESSU

RE

ENG

INE

INJE

CTIO

N AC

TUAT

ION

PR

ESSU

RE

ENG

INE

PRES

SURE

SEN

SOR

COM

MO

NEN

GIN

E PR

ESSU

RE S

ENSO

R +5

V

P203

A747

-G

YG

829-

GN

G82

8-W

HABC

P200

A746

-PK

G82

9-G

NG

828-

WH

SENS

OR

ENG

INE

BOO

STPR

ESSU

RE

ENG

INE

BOO

ST PR

ESSU

REEN

GIN

E PR

ESSU

RE S

ENSO

R CO

MM

ON

ENG

INE

PRES

SURE

SEN

SOR

+

5V

GN

YL 0R

INTA

KE A

IR H

EATE

R R

ELAY

ENG

INE

COO

LAN

T TE

MPE

RAT

URE

ENG

INE

INTA

KE M

ANIF

OLD

AIR

TEM

P. EN

GIN

E TE

MPE

RAT

URE

SENS

OR

CO

MM

ON

ENG

INE

ATM

OSP

HERI

C PR

ESSU

REEN

GIN

E PR

ESSU

RE S

ENSO

R CO

MM

ON

ENG

INE

PRES

SURE

SEN

SOR

+5V

IAP

CONT

ROL

VALV

EIA

P CO

NTRO

L VA

LVE

COM

MO

N EN

GIN

E BO

OST

PR

ESSU

REEN

GIN

E IN

JECT

ION

ACT

UATI

ON

PR

ESSU

RE

P1 J

1

ECM

GRO

UND

STR

AP

G85

4-PK

G85

5-PU

TO EC

MM

OUN

TIN

GBO

LTEN

GIN

E H

ARN

ESS

CON

NEC

TOR

VEH

ICLE

HAR

NES

S CO

NNEC

TOR

C987

-R

DG

850-

BU

P648

TO CO

NN

ECTO

R J

648

(OEM

HAR

NES

S)AB

K995

-O

R

G85

0-BU

C987

-R

D

1 2

ENG

INE

TIM

ING

CA

LIBR

ATIO

N P

RO

BE+

ENG

INE

TIM

ING

CA

LIBR

ATIO

N P

RO

BE-

TO IN

TAKE

AIR

HEA

TER

CIRC

UIT

PRO

TECT

ION

(BAT

TERY

+

)

TO EN

GIN

E CY

LIND

ER H

EAD

INTA

KE AI

RH

EATE

R

G85

0-BU

P2 J

2

J501

P5

01

N/O

REL

AY

32 35 7 34 26 18 10 11 1215 16 17 24 274142 5052 53 66 940 25 6 33 14 3 2

B A INJE

CTO

RCY

LIN

DER

NO

.5 1 63 64

4

5 61 62 70

INJE

CTO

RCY

LIN

DER

NO

.6

B AJ306

P3

06J3

05 P3

05J3

04 P3

04J3

03 P3

03J3

02 P3

02

L984

-O

R

B A INJE

CTO

RCY

LIN

DER

NO

.4

J301

P3

01

INJE

CTO

RCY

LIN

DER

NO

.1

A704

-G

N

B A

A705

-BU

A703

-BR

A702

-PU

A701

-G

Y

L985

-YL

L984

-O

R

A706

-GY

L985

-YL

L983

-W

HL9

83-W

H

INJE

CTO

RCY

LIN

DER

NO

.3

B AB A IN

JECT

OR

CYLI

NDER

NO

.2P3

00 J3

00

L983

-W

HL9

84-O

RL9

85-YL

A706

-GY

A705

-BU

A704

-GN

A703

-BR

A702

-PU

A701

-GY

INJE

CTO

R CO

MM

ON

CYLI

NDER

S 1

& 2

INJE

CTO

R CO

MM

ON

CYLI

NDER

S 3

& 4

INJE

CTO

R CO

MM

ON

CYLI

NDER

S 5

& 6

INJE

CTO

R CY

LIN

DER

6IN

JECT

OR

CY

LIN

DER

5IN

JECT

OR

CY

LIN

DER

4IN

JECT

OR

CY

LIN

DER

3IN

JECT

OR

CY

LIN

DER

2IN

JECT

OR

CY

LIN

DER

1

44 45 46 55 54 39 38 37 36 47 67 68

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

SENS

OR

1 2EN

GIN

E CO

OLA

NT

TEM

PER

ATUR

E99

5-BU

G83

3-PK

J100

P1

00

ENG

INE

COO

LANT

TE

MPE

RAT

URE

ENG

INE

TEM

PER

ATUR

E SE

NSO

R CO

MM

ON

ENG

INE

INTA

KE M

ANIF

OLD

AIR

TEM

PER

ATUR

EEN

GIN

E TE

MPE

RAT

URE

SENS

OR

CO

MM

ON

J103

P1

03

C967

-BU

G83

3-PK

ENG

INE

INTA

KEM

ANIF

OLD

AIR

TEM

PER

ATUR

E

1 2

SEN

SOR

SENS

OR

SENS

OR NO

TE A

: IN

DIC

ATES

AN

O

PTIO

NAL

COM

PONE

NT

N

OT

INST

ALLE

D O

N AL

L EN

GIN

ES

ENG

INE

OIL

PR

ESSU

REEN

GIN

E O

IL PR

ESSU

RE S

ENSO

R CO

MM

ON

ENG

INE

OIL

PR

ESSU

RE SE

NSO

R +5

V

P201

994-

GY

G82

7-BU

G82

6-BR

994-

GY

G82

7-BU

G82

6-BR

ENG

INE

OIL

PRES

SURE

NO

TE A

SENS

OR

ENG

INE

OIL

PR

ESSU

REEN

GIN

E O

IL PR

ESSU

RE SE

NSO

R CO

MM

ON

ENG

INE

OIL

PR

ESSU

RE SE

NSO

R +5

V

TOP

CAM

SHAF

T PO

SITI

ON

-TO

P CA

MSH

AFT

POSI

TIO

N +

BOTT

OM

CA

MSH

AFT

POSI

TIO

N -

BOTT

OM

CA

MSH

AFT

POSI

TIO

N +

ABCABC

ENG

INE

OIL

LEVE

L SW

ITCH

(GM

T560

On

ly)

G45

8-G

YO

IL LE

VEL

SWIT

CH

1 2M

79

5-W

HC2

11-BK

TUR

BO W

ASTE

GAT

E SO

L N

EGAT

IVE

TUR

BO W

ASTE

GAT

E SO

L PO

SITI

VETU

RBO

WAS

TEG

ATE

SOLE

NOID

*** N

ot O

n Al

l Rat

ings

***

OIL

Le

vel -

OIL

Le

vel -

A B

C B A

C991

-PK

G82

7-BU

G82

6-BR

P205

J2

05

ENG

INE

FUEL

PR

ESSU

RESE

NSO

R CO

MM

ON

SENS

OR

+5V

GN

YL 0R

C991

-PK

FUEL

PR

ESSU

RE

FUEL

TR

ANSF

ERPU

MP

PRES

SURE



A B J500

P5

00

Figure 6 - C9 Engine Wiring Diagram



NO

TE A

TO AL

LISO

N AT

/MT/

HT

TRAN

SMIS

SIO

N

SHIF

T M

ODU

LATO

R (A

UTO

MAT

IC TR

ANSM

ISSI

ONS

)

COO

LIN

G F

AN

SOLE

NO

ID

NO

TE A

INTA

KE A

IRHE

ATER

LAM

PTO

CO

NNEC

TOR

P648

(ENG

INE

HARN

ESS)

J648

100A

W

ITH

130

A PE

AK AT

11

V

C987

-RD

TO IN

TAKE

AIR

HEA

TER

REL

AY

(C

ONT

ACT

SIDE

)

ACCE

LER

ATO

R P

EDAL

POSI

TIO

N SE

NSO

R

BK RD

WH

J403

P4

03

ACCE

LER

ATO

R PE

DAL

SE

NSO

R/SW

ITCH

SEN

SOR

COM

MO

N+

8 V

ACCE

LER

ATO

R P

EDAL

PO

SITI

ON

B A C

L901

-G

YC9

77-BU

G87

9-O

R

H795

-PK

H79

5-PK

A/C

HIG

H PR

ESSU

RE SW

ITCH

E971

-G

N

INPU

T SE

NSO

R C

OM

MO

N #

1 CL

UTCH

PE

DAL

PO

SITI

ON

SWIT

CH +

5V INPU

T #1

2 IN

PUT

#11

INPU

T #7

ENG

INE

COO

LAN

T LE

VEL

NO

RM

AL

ENG

INE

COO

LAN

T LE

VEL

LOW

VEH

ICLE

SPE

ED IN

PO

SITI

VE

VEH

ICLE

SPE

ED IN

N

EGAT

IVE

INPU

T #8

(R

EMOT

E PT

O A

CCEL

ERAT

OR

)AP

SE

NSO

R/SW

ITCH

SEN

SOR

COM

MO

N

+8V AC

CELE

RAT

OR

PE

DAL

PO

SITI

ON

OUT

PUT

#5

18 22 23 2 46 49 54

PASS

IVE

MAG

NETI

CVE

HIC

LE SP

EED

SENS

OR

G80

8-BU

G80

9-G

N

H79

5-PK

H795

-PK

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PUT

#6

52 53 65 67 19

101-

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101-

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14 AW

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14 AW

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BATT

ERY

UNSW

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BATT

ERY

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TTER

Y

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Y

10A

10A

10A

10A

Figure 7 - C7 & C9 OEM Diagram

3.0 Engine MonitoringThe Engine Monitoring system monitors engine coolant temperature, engine oil pressure (optional), coolantlevel (optional) and Inlet manifold air temperature. C7 and C9 engines are shipped with the Caterpillar coolanttemperature sensor and Inlet manifold air temperature sensor. Optional sensors include an engine oil pressuresensor and an OEM supplied coolant level sensor. If a monitored engine parameter exceeds normal conditions,one or more lamps will be turned on and one or more diagnostic codes will be logged. There are three CustomerProgrammable Levels for the Engine Monitoring Mode parameter.1) Warning.2) Derate.3) Shutdown.

3.1. Engine Monitoring Lamp OptionsThe Check Engine Lamp is a requirement but a Programmable Customer Parameter, Engine Monitoring Lamps,is available to determine what additional lamps are to be turned On if normal engine operating conditions areexceeded. The default option for Engine Monitoring Lamps is Warning Lamp. This default option provides for onelamp output designated as the Warning Lamp and is used for all monitored engine condition warnings. When theEngine Warning Lamps parameter is programmed to Option 1, the lamp outputs are re-designated as follows:J1/P1: 29 (normally used as the Warning Lamp) is used as a Low Oil Pressure Lamp.J1/P1: 30 (normally used as a PTO Enabled Lamp) is used as a Low Coolant Lamp.J1/P1: 31 is used as a High Coolant Temperature lamp.The Check Engine Lamp (J1/P1: 28) is unaffected.NOTE: The Engine Monitoring Lamps parameter is not available for GM trucks.

3.2. Engine Monitoring and OEM RequirementsThe OEM is responsible for providing and installing lamps and the optional Coolant Level Sensor. The coolant levelsensor is programmed through the Customer Programmable Parameter, Coolant Level Sensor. This parameter hasa default factory setting of NO.OEM provided and installed components required:

1) Lamp connected to J1/P1: 28 (Check Engine Lamp).2) Lamp connected to J1/P1: 29 (Warning Lamp or Low Oil Pressure Warning Lamp programmed to Option1).3) Lamp connected to J1/P1: 30 (Low Coolant Level Warning Lamp programmed to Option 1).4) Lamp connected to J1/P1: 31 (High Coolant Temp Warning Lamp programmed to Option 1).5) Coolant Level sensor 4 Pin, 2 Wire Float Sensor or 2 Pin Switch (GM only).Customer Parameter programming required:

1) Coolant Level Sensor programmed to 4-pin or 2 Wire Float Sensor.2) Engine Monitoring programmed to Warning, Derate, or Shutdown.3) Warning Lamps programmed to Warning or Option 1.



3.3. Engine Monitoring Engine SensorsThe Engine Monitoring System Engine uses the engines sensors to monitor the engines operating condition.Limits have been established for each of the engine conditions monitored by these sensors.

3.3.1. Engine Monitoring Intake Air Temperature SensorIntake Manifold Air Temperature is monitored to warn the operator of excessive intake manifold air temperature.Excessive intake manifold air temperatures will not cause the ECM to derate or shutdown the engine when EngineMonitoring is programmed to Derate or Shutdown.Intake Manifold Air Temperature must exceed the triggering temperatures for 30 seconds after engine start upbefore a Diagnostic Code is generated and logged. A High Intake Manifold Air Temperature Warning diagnosticcode is triggered at 194F (90C), and a Very High Intake Manifold Air Temperature at 230F (110C).In addition to the Check Engine Lamp, the Warning Lamp is also turned ON if Engine Monitoring is programmedto Warning, Derate, or Shutdown.

3.3.2. Engine Monitoring Oil Pressure SensorThe Engine Oil Pressure Sensor is an optional sensor and can be used to automatically protect the engine fromoperating without sufficient oil pressure.With Engine Monitoring programmed to Warning, the Check Engine Lamp will turn On at the Low Oil Pressuretrip point. At the Very Low Oil Pressure trip point the Warning Lamp will be turned On in addition to theCheck Engine Lamp.When programmed to Derate the Check Engine Lamp will turn On at the Low Oil Pressure trip point. At theVery Low Oil Pressure trip point the Warning Lamp will flash and the engine will be derated.When programmed to Shut Down the Check Engine Lamp will turn On at the Low Oil Pressure trip point. At theVery Low Oil Pressure trip point the Warning Lamp will flash during engine derate and then the engine will shutdown after 30 seconds.The ECM will indicate a Very Low Oil Pressure fault when the Engine Oil Pressure falls below 4 psi (29 kPa)at 750 RPM or below 6 psi (43 kPa) at 800 RPM and higher.

3.3.3. Engine Monitoring Coolant Temperature SensorC7 and C9 engines include a Coolant Temperature Sensor as standard equipment. Engine coolant temperaturetrip points have been established for High and Very High Coolant Temperatures. These trip points are illustratedin the charts on the following pages and are used for logging fault codes.With the Engine Monitoring System programmed to Warning the Check Engine Lamp will turn On at the HighCoolant Temperature trip point (110-00). At the Very High Coolant Temperature trip point (110-11) the WarningLamp will turn On in addition to the Check Engine Lamp.When programmed to Derate, the Check Engine 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.When programmed to Shutdown, the Check Engine 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 20 seconds the engine will be shut down.The ECM derates available power and limits vehicle speed in steps as temperature increases. Each steprepresents a reduction in available power and limits vehicle speed as follows:HP REDUCTION = 25% X (rated HP 120 hp [90 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.

Figure 8 - C7 Truck Trip Points

Figure 9 - C7 Emergency and C9 Truck Trip Points

112 113 114 115 116 117Coolant Temperature (C)

Avai

labl

ePo

wer

,Ve

hicl

eSp

eed

Rated Power,Full Vehicle Speed Range

120 hp, 45 mph Maximums(90 kW, 72.5 km/h)

110-00 Triggered

110-11 Triggered


Avai

labl

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110-00 Triggered

110-11 Triggered



Coolant Temperature Engine Monitoring Operation Emergency Vehicle ApplicationsFor C9 emergency vehicle ratings with automatic transmissions, the High and Very High Coolant Temperaturetrip points are adjusted as indicated below.

Figure 10 - C9 Emergency Trip PointsC9 Coolant Temperature Graph for Emergency Vehicles with automatic transmissions

3.3.4. Engine Monitoring Coolant Level SensorThe 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.When programmed to Warning, the Check Engine Lamp will be turned on at the Low Coolant Level trip point andthe Warning Lamp will be turned on at the Very Low Coolant Level trip point.When programmed to Derate, the Check Engine Lamp will be turned on at the Low Coolant Level trip point. At theVery Low Coolant level trip point the Warning Lamp will flash and the engine will be derated.When programmed to Shutdown, the Check Engine 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 shut down.

3.3.5. Low Coolant Level During an Engines First 6 Hours of OperationIf 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 inthe engines cooling system during the assembly process. After the engine has logged 6 hours of engine runningtime, the diagnostic faults and events for Low (111-01) and Very Low Coolant Levels (111-11) will be logged intothe ECMs nonvolatile memory. Service technicians are required to contact Caterpillar for permissions to clearLow (111-01) and Very Low (111-11) Coolant Level events from the ECMs nonvolatile memory.


Avai

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110-00 Triggered

110-11 Triggered



3.4. Engine Monitoring Programmed to WarningWarning is the default setting of the Engine Monitoring System. The ECM monitors Coolant Temperature, InletManifold Air Temperature and the optional Coolant Level or Engine Oil Pressure (if installed). The following tableindicates the diagnostic codes available. There is no effect on engine performance when active. The Check EngineLamp will flash and the Warning Lamp will come ON as indicated in the table when the diagnostic code is active.



PID- Code Description Trip Point Trip Point Warning DerateFMI Emergency Lamp

Vehicle Ratings

100-11 Very Low Oil Pressure 4 psi (29 kPa) 4 psi (29 kPa) SOLID NONE750 RPM 6psi (43 kPa) 6psi (43 kPa)

800 RPM and up105-00 High Inlet Manifold 90C 90C SOLID NONE

Air Temp. Warning (194F) (194F)105-11 Very High Inlet Manifold 110C 110C SOLID NONE

Air Temp. (230F) (230F)110-00 High Coolant Temp. C9 113C C9 118C SOLID NONE

Warning (235F) (244F)C7 108C C7 113C

(226F) (235F)110-11 Very High Coolant C9 116C C9 121C SOLID NONE

Temperature (241F) (250F)C7 111C C7 116C

(232F) (241F)111-01 Low Coolant Level SOLID NONE

Warning111-11 Very Low Coolant Level SOLID NONE111-14 Low Coolant Level Warning SOLID NONE

(less than 6 Hours)

3.5.Engine Monitoring Programmed to DerateWhen the Engine Monitoring System is programmed to Derate, the ECM will alter engine performance whenoperating parameters are exceeded. Whenever the engine is derated, the Check Engine Lamp (due to activediagnostic) and the Engine Warning Lamp will flash. For the DERATE column in the following table, mph indicatesvehicle speed is limited (maximum speed is 45 mph [72.5 km/h]), pwr indicates engine power is limited (maximumderate is 120 hp [90 kW]), and rpm indicates engine speed is limited (maximum derate is 1350 rpm). For operatingconditions causing these codes see the appropriate section for the sensor under consideration.



PID- Code Description Trip Point Trip Point Warning DerateFMI Emergency Lamp

Vehicle Ratings

100-11 Very Low Oil Pressure 4 psi (29 kPa) 4 psi (29 kPa)750 RPM 6psi (43 kPa) 6psi (43 kPa) FLASH NONE

800 RPM and up105-00 High Inlet Manifold 90C 90C SOLID NONE

Air Temp. Warning (194F) (194F)105-11 Very High Inlet Manifold 110C 110C SOLID NONE

Air Temp. (230F) (230F)110-00 High Coolant Temp. C9 113C C9 118C FLASH NONE

Warning (235F) (244F)C7 108C C7 113C

(226F) (235F)110-11 Very High Coolant C9 116C C9 121C FLASH NONE

Temperature (241F) (250F)C7 111C C7 116C

(232F) (241F)111-01 Low Coolant Level Warning SOLID NONE111-11 Very Low Coolant Level FLASH NONE111-14 Low Coolant Level Warning FLASH NONE

(less than 6 Hours)

3.6.Engine Monitoring Programmed to ShutdownThe following table indicates the active diagnostic codes capable of shutting down the engine when the ECM isprogrammed to Shutdown. The Time to Shutdown, Engine running > 30 Sec column indicates the minimum timebefore the engine will shutdown if the engine has already been running for at least 30 seconds. The Time toShutdown, Fault Code at Start/Restart column is running time if the code is active when the engine starts, orfollowing an Engine Monitoring caused shutdown. NO indicates the code will not shutdown the engine.Note: These times assume the condition causing the code exists continuously and is not intermittent.



PID-FMI Code Description Time To Shutdown Time to ShutdownEngine running > 30 Sec Fault Code at

Start/Restart

100-11 Very Low Oil Pressure 30 Sec 18 SEC750 RPM

800 RPM and up105-00 High Inlet Manifold Air Temp. Warning NO NO105-11 Very High Inlet Manifold Air Temp. NO NO110-00 High Coolant Temp. Warning NO NO110-11 Very High Coolant Temperature 30 Sec 60 Sec111-01 Low Coolant Level Warning NO NO111-11 Very Low Coolant Level 30 Sec 60 Sec111-14 Low Coolant Level Warning 30 Sec 60 Sec

less than 6 Hours)

OEM INSTALLED COMPONENT REQUIREMENTS and FEATURESAll of the functions described in the following text are available or enhanced if the vehicle OEM provides andinstalls the appropriate components. The components required for each feature are listed with the particular featuredescription. It is assumed the associated wire harness necessary for component connection is part of the component.

4.0 Power and Grounding Requirements and ConsiderationsThe ECM requires unswitched power and ground connections. An Ignition Key Switch input is used to turn the ECMON, allowing the engine to start and run.



IGNITION KEY SWITCH

UNSWITCHED +BATTERY

-BATTERY-BATTERY

ALTERNATOR

GND.

J906-BR

101-RD

65

70

67

53

P1 J1

10 A

+12V- +12V- +12V-

OFFON

ST.

ENGINE BLOCK

STARTERMOTOR

(12V)

BAT. MTR.

ADEM 3 ECM

CIRCUITS WITHIN THISAREA ARE RECOMMENDATIONS

14 AWG

229-BK14 AWG 229-BK

101-RD55

69

-BATTERY-BATTERY

229-BK

101-RD63

229-BK

UNSWITCHED +BATTERY

UNSWITCHED +BATTERYUNSWITCHED +BATTERY

5248101-RD

Wiring Diagram 1 - Preferred Wiring Medium Duty ACERT Engine Battery Wiring For C7 & C9

4.1 GroundingProper grounding for vehicle and engine electrical systems is necessary for proper performance and reliability.Improper grounding results in unreliable electrical circuit paths. Stray electrical currents can damage main bearings,crankshaft journal surfaces, and aluminum components. They can also cause electrical noise degrading controlsystem, vehicle, speedometer, and radio performance. These problems are often very difficult to diagnose and repair.All ground paths must be capable of carrying any conceivable fault currents. An AWG # 4 or larger cable isrecommended between the engine ground stud and the frame or starter negative post to handle alternator currents.A maximum of three ring terminals are to be connected to the engine ground stud to insure ground connectionintegrity. More than three terminals can cause the stud to loosen too easily. Caterpillar recommends splicing likesize wires together as a method of reducing ring terminal congestion at the ground stud.



- +

Chassis Frame Rail Starter Battery

EngineGroundWire

EngineGroundStud

Optional Engine Ground StudLocation

Figure 11 - Ground Stud to Frame Rail



Chassis Frame Rail BatteryStarter

EngineGroundStud

- +

EngineGroundWire

Optional Engine Ground StudLocation

Figure 12 - Ground Stud to Starter

Ground Points for C9 Engines

Figure 13Note: C9 Ground Points are different from C7.

4.2 Engine Connection To Vehicle Battery GroundTo insure proper functioning of the vehicle and engine electrical systems, there must be a direct wire path from theengine ground stud to the battery negative post. Caterpillar prefers this connection route through the starter negativepost. In Figure 13 and Figure 14 an additional ground stud location is identified, either location can be used.A connection routed to a main frame ground, can also be made if the following guidelines are followed:1) Connections to the frame must not be made with star washers. Star washers should not be counted on to

remove paint from painted surfaces. Use flat washers for this connection, with the paint completely removedin this area.

2) Any paint must be completely removed from the frame rail at the point where the connection is made.Failure to do so reduces the effectiveness of the connection.

3) The ground path is not made through frame cross members. Bolted connections of frame cross membersmay not always provide required continuity for this critical connection.

4) Conductive grease or other methods used to reduce/eliminate the affect of corrosion on the frame railconnection.

5) Caterpillar does not recommend a connection from the engine ground stud to the main frame rail at a connectionpoint different than where the battery ground connection is made. A two-point frame rail connection methoddepends on frame rail connections. Manufacturing process control of frame rail connections is difficult to control.This multiple frame rail connection scheme is also more difficult to troubleshoot.

4.3 ECM Negative Battery ConnectionsCaterpillar requires the OEM to install the ECM -Battery wires into their harness connector. These connectionsshould be #14 AWG GXL wire.

4.3.1 Engine Ground StudC7 and C9 engines use a M8 X 1.25 Thread stud with a 20 mm stud length located on the cylinder head. The studhas two washers and properly sized nut supplied for attaching all OEM supplied ground terminals.

4.4 Electric Starting MotorsThe truck engine starting system must be able to crank the engine at sufficient speed for fuel combustion to beginnormal firing and keep the engine running. This requires adequate battery capacity, a starting motor, and cablesto connect the battery to the starter. The following must be observed in order to obtain a satisfactory installation:Electric starting motors must be 12 or 24 volt DC and use a positive engagement pinion drive which engages withthe flywheel ring gear before the motor begins to turn. Air or hydraulic starters may also be used.

4.5 Sensor Common ConnectionsOnly those components interfacing directly to the ECM should be connected to the ECM Sensor Commonconnections. ECM Connector P1 terminal-5 should be used to connect the ground side of the followingengine control connected items: cruise control switches, clutch pedal position switch, fast idle enable switch,1 service brake pedal position switch #1, A/C High Pressure switch, and the accelerator pedal position sensor.These components must not be connected to any vehicle ground.Additional Sensor Common connections are also available. ECM terminal-18 (Input Sensor Common #1) andterminal-3 (Input Sensor Common #2) can be used if required by the harness design, for example, to splice allcab components together at terminal-5, and engine compartment components at terminal-18 or terminal-3.Caterpillar recommends that Input Sensor Common #2 remain open for Aftermarket/Body Builder connections.If additional Sensor Common connections are required, please contact Caterpillar.All switches connected to the control system must be externally grounded, two-wire design. Internally groundedor case grounded switches must not be used.



OEM installed components used as inputs to the ECM must not be connected to the vehicle or cab ground,and must not be case grounded. OEM installed switches must be grounded to an ECM Sensor Common via adedicated return line to the ECM.

4.6 Suppression Of Voltage Transients and Electrical NoiseCaterpillar recommends transient suppression be installed at the source of the transient in addition to thesuppression in the ECM. Caterpillar controls are designed to comply with SAE J1455.The use of inductive devices such as relays and solenoids can result in the generation of voltage transients on thebattery lines. Unsuppressed voltage transients can exceed SAE J1455 specifications and degrade control systemperformance. Some specific devices that should use transient suppression are fan clutch solenoids, A/C clutchsolenoids, and all relays. This is not an all-inclusive list. The OEM should specify relays and solenoids with built-involtage transient suppression on the vehicle where possible.The following illustration provides several possible suppression techniques to minimize the generation of voltagetransients from relays and solenoids without built-in voltage transient suppression. These include, but are not limitedto, installing a properly sized diode or resistor in parallel with solenoid and relay coils.Inductive devices should be located to maximize the distance from control system components. OEM installedwiring harnesses should be routed to maximize the distance from the control system wiring harness to avoidinductive coupling of noise transients.



PowerPower Power Power

Figure 14 - Examples of Voltage Transient Suppression

Terminal Description ECM Terminal AssignmentAP Sensor/Switch Sensor Common J1/P1: 5Input Sensor Common #1 J1/P1: 18Input Sensor Common #2 J1/P1: 3

4.6.1 EMI/RFI TestingCaterpillar EMI/RFI testing on C7 and C9 engines is performed at both the component and system level.Component level testing is performed in a TEM cell and screen room. This radiated susceptibility testingis performed using the substitution method. In-vehicle radiated susceptibility testing is also performed.

4.7 ECM Positive Battery ConnectionsThe positive battery connection to the C7 or C9 ECM must be made through a dedicated and unswitched circuit of4 individual #14 AWG wires capable of a continuous duty load of 30 Amperes at 9 volts DC. Recommended fusingis 10 Amperes for each wire for a total of 40 amperes. The four required unswitched positive battery connectionsare terminals 48, 52, 53 and 55.Caterpillar prefers the circuit protection be located in the cab if possible. On vehicle documentation for the circuitprotection should be provided for none cab locations.In the event of a charging system failure, the engine will operate with a supplied voltage of 9 Volts DC. At thisvoltage level the engine will draw up to 30 amperes. Fusing the unswitched battery wiring with less than the statedfusing recommendation of 40 Amperes can result in blown fuses and an unexpected engine shutdown due to afailed vehicle charging system.In addition to suppressing inductive loads, powering the ECM on a dedicated fused circuit will reduce the possibilityof degraded control system performance due to voltage transients. No additional loads should be connectedbetween the ECM and ECM circuit protection.The ECM monitors the battery supply voltage and will trigger a diagnostic code if this voltage drops below and thenreturns above 6 Volts DC.

4.8 Voltage Requirements and ConsiderationsThe control system has been designed to operate on 12 Volt or 24 Volt electrical systems. The control system isprotected against jump start conditions and short circuits to positive battery and negative battery.Minimum voltage requirements and maximum current draw for the C7 and C9 control system are as follows:

**This condition includes the Inlet Air Heater Relay and HEUI injector solenoid cycling during cold weather conditions.Minimum voltages are specified at the OEM connector (P1 terminals 48, 52, 53, 55 referenced to P1 terminals 63, 65, 67, 69).

4.9 ECM Current Draw with Ignition Key OffThe ECM draws less than 20 mA while the Ignition Key Switch is in the OFF position.

4.10 Welding on a Vehicle Equipped with a C7 or C9 EngineBefore 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.



Condition Minimum Voltage Maximum Current DrawNormal Operation 11.0 VDC 22.0 AmperesEngine Cranking 6.0 VDC 16 AmperesIgnition Key On, Engine Off ** 9.0 VDC 20 AmperesElectrical Charging 9.0 VDC 30 AmperesSystem Failure

3. Clamp the ground cable of the welder to the component that will be welded. Place the clamp as close aspossible to the weld.

4. Protect any wiring harnesses from welding debris and spatter. Use proper welding procedures in order to weldthe materials.

NOTICEDO NOT use electrical components in order to ground the welder. Do not use the ECM or sensors or anyother electronic component in order to ground the welder. Clamp the ground cable for the welder to thecomponent that will be welded.Place that clamp as close as possible to the weld.This will reduce the possibility of damage to thebearings of the drive train, hydraulic components, ground straps, and other components of the vehicle.



Front of Engine

Engine Connector J2

OEM Connector J1

Figure 15 - ADEM 2000TM ECM and Wiring Harness Connectors

1142432404858

13233139475770

1 2 3 4 5 6 8 9 10 11 12 13

14

24

40

48

58 59 60 61 62 63 65 66 67 68 69 70

23

31

47

57

35 36

> PEI 4.0 Volts DC With the switch contacts open, ground potential differences, switch voltage drops,and wiring harness voltage drops must be such that a switch opening results in greater than 4.0 Volts DC betweenthe control input and Sensor Common terminal.

12.2 Sensor Common ConnectionsThree Sensor Common terminals are available to ground inputs connected to the ECM. All of the Switch To SensorCommon inputs must use one of the three terminals (J1/P1: 3, 5, or 18). Switch inputs must not use chassisground. Switches must not be Case grounded.



Terminal Description ECM Terminal AssignmentAP Sensor/Switch Sensor Common J1/P1: 5Input Sensor Common #1 J1/P1: 18Input Sensor Common #2 J1/P1: 3

12.3 Switch to Sensor Common Inputs

Note: For switches with J1939 options, refer to the J1939 Based Switched Messages section for additional details.12.3.1 Service Brake Pedal Position Switches/Function

The Service Brake Position Switch #1 is required for ALL applications. This is a normally closed switch and must bean open circuit when the service brake pedal is depressed. An Open circuit will deactivate or will not activate CruiseControl, Fast Idle (1 or 2), Extended Idle, or Cab Switches PTO. A change in state (depressing a released pedal, orreleasing a depressed pedal) of the Service Brake, during Driver Alert, while the Idle Shutdown Timer is countingalso overrides the Idle Shutdown Timer if the Customer Parameter Allow Idle Shutdown Override is programmedto Yes (default). Service Brake Position Switch #2 (switch to Battery Plus) may be required if needed to support thetransmission style.

12.3.2 Clutch Pedal Position Switch FunctionThe clutch pedal position switch must be an open circuit when the clutch pedal is depressed. This switch is requiredon any application that uses a clutch and the Transmission Style must be programmed to Manual Option 1 or 2.An Open circuit will deactivate or will not activate Cruise Control, Fast Idle (1 or 2), Extended Idle, or Cab SwitchesPTO. Adjustment of the Clutch Pedal Position Switch is critical to proper system performance. A change in state(depressing a released pedal, or releasing a depressed pedal) of the Clutch, during Driver Alert, also overridesthe Idle Shutdown Timer, if the ECM is programmed to allow Idle Shutdown Override.



Switch function Default Optional Connection Connection(s)

Cruise Control On/Off J1/P1: 59 J1939Cruise Control Set J1/P1: 35 J1939Cruise Control Resume J1/P1: 44 J1939Clutch Pedal Position Switch J1/P1: 22 J1939Service Brake Position Switch #1 J1/P1: 45 J1939Torque Limit Switch None J1/P1: 7, 23Ignore Brake/Clutch Switch None J1/P1: 47Two Speed Axle None J1/P1: 6Diagnostic Enable None J1/P1: 46,

J1939PTO On/Off J1/P1: 56 J1939PTO Set J1/P1: 58 J1939PTO Resume J1/P1: 60 J1939PTO Engine RPM Set Speed Input A None J1/P1: 46,

J1939PTO Engine RPM Set Speed Input B None J1/P1: 7, 23PTO Engine Shutdown None J1/P1: 7, 23Fast Idle J1/P1: 40 NoneA/C High Pressure J1/P1: 41 NoneA/C Fan Request (GMT560 Only) Sw to + Batt J1/P1: 41Shutdown Override J1/P1: 40 None

12.3.2.1 Clutch Pedal Position Switch with Automatic TransmissionsThe Clutch Pedal Position switch is required if the parameter Transmission Style is programmed to Manual Option1, Manual Option 2 or Universal. If the transmission Style parameter is not programmed to one of these options, theclutch switch circuitry may be omitted. A jumper circuit from this input to Sensor Common is not required.

12.3.3 Diagnostic EnableA Diagnostic Enable input is available to prompt the ECM for flashing Diagnostic Flash Codes via the hardwiredCheck Engine Lamp. The Diagnostic Enable parameter must be programmed to J1/P1: 46 for this feature tofunction. A momentary normally open switch is required. The ECM will begin flashing and continue to flash outcodes while this switch is closed.

Wiring Diagram 11 - Diagnostic Enable CircuitOEM provided and installed components required:

1) Normally open momentary switch.2) Hardwired Check Engine LampCustomer Parameter programming required:

1) Diagnostic Enable programmed to J1/P1:4612.3.4 Two Speed Axle Switch

Two Speed Axle Switch may be programmed to None (Default) or J1/P1: 6. When a two-speed axle is used TwoSpeed Axle Switch must be programmed to J1/P1: 6 (Input #6). A normally open switch is required. When a two-speed axle is used, the change in gear ratios from the high-speed range to the low speed range alters thecalibration of the vehicle speed signal. With this system, the ECM will automatically adjust the vehicle speedcalibration when the switch is ON. This will ensure an ECM driven speedometer and ECM stored informationcorrectly reflect the actual vehicle speed. The Low Speed Range Axle Ratio and High Speed Range Axle Ratiomust be programmed as well. When the switch is closed between the ECM terminals 16 and 5, the ECM will usethe following equation to calculate the actual vehicle speed:

High Speed Range AxleLow Speed Range Axle Ratio X calculated vehicle speed = actual vehicle speed

Note: GM trucks use a normally closed switch for this input.Where the calculated vehicle speed is the vehicle speed calculated using the programmed vehicle speedcalibration (pulse per mile). This adjusted vehicle speed will be used to determine idle, PTO, and Fast Idle Kickoutspeeds as programmed. The vehicle speed broadcast over the data links and the ECM speedometer output vehiclespeed will reflect the adjustment. If Two Speed Axle Switch is not programmed to J1/P1: 6, the ECM does not useeither axle ratio to determine the actual speed.OEM provided and installed components required:

1) Switch to close when low speed axle ratio is used (switch to OPEN if GM truck).Customer Parameter programming required:

1) Two Speed Axle Switch programmed to J1/P1:6 when a two-speed axle is used (default is NONE).2) High Speed Range Axle Ratio and Low Speed Range Axle Ratio must be programmed or the feature is disabled.

G844-PKH795-PK

465

P1 J1

INPUT #7AP SENSOR/SWITCH SENSOR COMMON

DIAGNOSTIC ENABLE ECM



Wiring Diagram 1212.3.5 PTO Switches

Several options are available to control engine rpm while in PTO. In order to operate in PTO Mode, a dedicatedPTO ON/OFF switch is required. Three PTO modes are available. The Cruise Control Set/Resume switches can beused or dedicated PTO switch inputs can be programmed and installed to give a variety of controlled engine speeds.OEM provided and installed switches (required and/or optional):1) PTO On/Off switch2) Optional Switches3) Transmission Neutral switch4) Cruise Control Set/Resume5) PTO Set/Resume6) PTO Set Speed A7) PTO Set Speed B8) Torque Limit9) Clutch Pedal Position Switch (for manual transmissions).

10) Service Brake Pedal Position11) Ignore Brake/ClutchCustomer Parameter programming required:

1) PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle.2) Individual switch inputs as necessary.

12.3.6 Fast Idle SwitchA momentary Fast Idle switch can be used to elevate and maintain up to two programmed engine rpm settings.Pressing and releasing the switch once will cause the engine to ramp from Low idle to the programmed Fast IdleRPM #1 (1000 rpm default). Pressing and releasing the switch while at Fast Idle #1 will cause the engine to rampto the programmed Fast Idle #2 at the programmed Idle/PTO Engine Speed Ramp Rate. If Fast Idle #2 is notprogrammed, the engine will return to low idle. Fast Idle will be deactivated (kicked out) if the Service Brake orClutch is depressed. The transmission Neutral switch, when in Gear, will also cause the Fast Idle to deactivate.

G843-ORH795-PK

65

P1 J1

INPUT #6AP SENSOR/SWITCH SENSOR COMMON

Two-Speed Axle On/Off Switch

Switch Shown in High Speed Range

ECM



Wiring Diagram 13 - Fast Idle Enable Switch and Fast Idle Enable Lamp CircuitsOEM provided and installed components required:

1) Fast Idle Enable Momentary Switch (N/O).2) Fast Idle Enabled Lamp (optional)Customer Parameter programming required:

1) Fast Idle Lamp parameter programmed to J1/P1: 31(default) or J1/P1:21. (optional)2) Fast Idle RPM #1.3) Fast Idle RPM #2 (optional).

12.3.7 Ignore Brake/Clutch SwitchThe Ignore Brake/Clutch Switch is used to allow use of an engine set speed in mobile vehicle operations.When the Ignore Brake/Clutch parameter is programmed to J1/P1: 47 and the switch is closed, PTO, Extended Idleand Fast Idle features will ignore service brake and clutch switch inputs. If this switch is in the closed position whenthe ECM is powered up, this switch function is ignored until the switch is cycled Off and ON.

12.3.8 Shutdown Override Switch (Mass Transit only)The transit industry calls for an engine shut down override switch to allow the operator to override a critical enginediagnostic induced engine shutdown. The purpose of the Shutdown Override Switch is to allow an operator tooverride the impending engine shutdown to allow the operator to move the vehicle to a more safe location. Thisfeature is only available on C9 Mass Transit ratings.Shutdown Override Operation

The Engine Monitoring System can be used to cause the engine to shut down when the engine has an activediagnostic code for Very Low Engine Oil Pressure, Very low Coolant Level or Very High Engine CoolantTemperature. When one of these Diagnostics is active, the Warning Lamp, or the dedicated lamps defined bythe Warning Lamp option of Option 1, will start to flash. The flashing lamp indicates that the engine power isbeing derated and engine shutdown will occur within a few seconds.If the Shutdown Override Switch has been closed before the Shutdown sequence has ended, a Shutdown Timerwill start to countdown from 30 seconds. If the Shutdown Override Switch is opened and closed again before theengine has turned the fuel injectors Off, the timer will reset for another 30 seconds. Once the timer has counteddown to zero and the fuel injectors have been disabled, the engine will shut down regardless of the position ofthe Shutdown Override Switch.Initiating the Shutdown Override Timer will result in a Diagnostic Code being generated and logged into memory.A Diagnostic Snapshot will also be generated. The logged diagnostic code will require Caterpillar FactoryPasswords to clear from the ECMs memory.

L902-GNH795-PKG880-PK

405

31

P1 J1INPUT #18AP SENSOR/SWITCH SENSOR COMMONOUTPUT #9

FAST IDLE ENABLE

FAST IDLE ENABLED LAMP

+12V- ECM

G880-PK 21 OUTPUT #8

Optional Fast Idle Enabled Lamp Circuit



Wiring Diagram 1412.3.9 A/C High Pressure Switch

The A/C High Pressure switch is used in conjunction with the ECM controlled Cooling Fan. This is a normallyclosed switch and when opened, causes the ECM to engage the cooling fan.

12.3.10 Exhaust Brake SwitchThe Exhaust Brake switch is used to allow the operator to enable or disable the engines exhaust retarder.OEM provided and installed components required:

1) Exhaust Brake SwitchCustomer Parameter programming required:

2) Exhaust Brake Switch programmed to J1/P1: 1612.4 Switch-to-Battery Electrical Specifications

Contact plating should not corrode or oxidize. Gold plated or silver alloy contacts are recommended. Normal currentdraw through the Input #12 and Input #13 by the control is 6.0 mA at 12 Volts DC. Normal current draw through theIgnition Key Switch by the control is 1.2 mA at 12 Volts DC.Contact chatter and momentary opening or closing should not exceed 100 milliseconds in duration. The switchesshould not open or close due to vibration or shock normally found in the application.Each of these ECM inputs is pulled to ground eliminating the need for external termination. Closure of an OEMinstalled switch must short circuit the input to the vehicle positive battery connection.

12.4.1 Voltage thresholds measured at ECM:Switch Open < 0.9 Volts DC With the switch contacts open, ground potential differences, switch voltage drops,and wiring harness voltage drops, the ECM must detect less than 0.9 Volts DC between the control input and theECM negative battery connection.Switch Closed > 9.0 Volts DC With the switch contacts closed, ground potential differences, switch voltage drops,and wiring harness voltage drops, the ECM must detect a switch closure resulting in greater than 9.0 Volts DCbetween the control input and the ECM negative battery connection.

Shutdown Override SwitchSwitch Common

403

ECM

P1/J1



12.4.2 Switch-to-Battery Circuit ProtectionThese circuits do not require dedicated circuit protection.

12.4.3 Ignition Key Switch to Positive BatteryThe Ignition Key Switch input is J1/P1: 70 and is not changeable. When the ECM detects the input is switched tovehicle battery (Ignition Key Switch ON), the ECM will be powered. The ECM will then control the injectors allowingthe engine to start.OEM provided and installed components required:

1) Switch to close when the ignition is ON.12.4.4 Service Brake Pedal Position Switch #2 Function

Service Brake Pedal Position Switch #2 is required if the Transmission Style is programmed to Manual Option 2,Universal, AT/MT/HT Option 2, AT/MT/HT Option 3, Automatic Option 2, or Automatic Option 3. Input #13 is usedas the Service Brake Position Switch #2 input. The Service Brake Pedal Position Switch #1 (switch to ground) mustalso be used.This switch must be a short circuit to +Battery when the service brake pedal is depressed. The control willdeactivate Cruise Control, Cab Switches PTO, Fast Idle, or Extended Idle when the Service Brake Pedal PositionSwitch #2 is ON. The Brake and Clutch Pedal Position Switches do not affect remote PTO. A change in state(depressing a released pedal, or releasing a depressed pedal) of the Service Brake, during Driver Alert, while theIdle Shutdown Timer is counting can also override the Idle Shutdown Timer, if the ECM is programmed to allow IdleShutdown Override.

Wiring Diagram 15OEM provided and installed components required:

1) Switch to close when service brakes are applied.Customer Parameter programming required:

1) Customer Parameter Transmission Style programmed to Manual Option 2, AT/MT/HT Option 2,AT/MT/HT Option 3, Automatic Option 2, or Automatic Option 3.

12.4.5 Transmission Neutral SwitchThe ECM can be configured to monitor the transmissions Neutral Switch. This switch is used to indicate whenan automatic transmission is in neutral. The neutral condition allows features such as Cab Switches PTO, Fast Idle,and Extended Idle to be used. The switch is required if the Transmission Style Parameter is programmed toAT/MT/HT Option 3, AT/MT/HT Option 4, Automatic Option 3, or Automatic Option 4.

L900-PU 64P1 J1

INPUT #13

SERVICE BRAKE #2 PEDAL POSITION

+12V-

ECM(PEDAL RELEASED POSITION)



Switch function Default Optional Connection Connection(s)

Ignition Key Switch J1/P1: 70 NoneTransmission Neutral J1/P1: 62 J1939Service Brake #2 J1/P1: 64 NoneA/C Fan Request (GMT560 Only) J1/P1: 62 None

Wiring Diagram 16OEM provided and installed components required:

1) Switch to close when the transmission is in neutral.Customer Parameter programming required:

1) Customer Parameter Transmission Style programmed to AT/MT/HT Option 3, AT/MT/HT Option 4,Automatic Option 3, or Automatic Option 4.

2) Transmission Neutral Switch parameter programmed to J1/P1: 62.12.4.5.1 Transmission Neutral Switch Status via J1939 Data Link

The ECM has the ability to receive Neutral Switch status information from a Transmission ECU capable ofbroadcasting the status via the J1939 data link. The J1939 option can be used to replace the hardwired switch inputto the ECM. This option can only be used if the Transmission is capable of supporting the required J1939 messageprotocol, such as an Allison 2000 Series Transmission. The OEM is responsible for making this determination.The Transmission must support the J1939 PGN $F005 (ETC2 Byte 1 Selected Gear, Byte 4 Current Gear orByte 7 Current Range) message to be compatible. If the message is not received, the ECM will assume thetransmission to be In gear.OEM provided and installed components required:

1) Electronically Controlled Transmission capable or supporting required J1939 message protocol.Customer Parameter programming required:

1) Customer Parameter Transmission Style programmed to either AT/MT/HT Option 3, AT/MT/HT Option 4,Automatic Option 3, or Automatic Option 4.

1) Transmission Neutral Switch parameter programmed to J1939 option.12.4.5.2 Ignoring the Transmission Neutral Switch input.

The neutral switch is not normally used with manual transmissions. The ECM can also be configured to ignore theneutral switch if an automatic transmission is used.Customer Parameter programming required:

1) Transmission Style parameter programmed to Manual Option 1 or 2, AT/MT/HT Option 1, AT/MT/HT Option 2,Automatic Option 1, or Automatic Option 2.

2) Transmission Neutral Switch parameter programmed to J1/P1:62 (default) hardwired option or None.NOTE: Programming the Neutral Switch to None and the Transmission Style to Automatic option 3 (or 4) or AT/MT/HT Option 3 (or 4) will cause the ECM to assume that the transmission is IN GEAR.

409-OR 62P1 J1

INPUT #12

TRANSMISSION NEUTRAL SWITCH

+12V-

ECM(IN GEAR POSITION)



13.0 Cruise ControlCruise control operation is a standard feature and requires the following OEM installed switches: Cruise ControlON/OFF, Set/Resume, and Service Brake Pedal Position Switch #1. Depending on Transmission Style programming,additional switches may be required. These would include the Clutch Pedal Position, Service Brake Pedal PositionSwitch #2 and Neutral switches.

Wiring Diagram 17 - Typical Cruise Control Wiring DiagramOEM provided and installed components required:

1) Cruise Control On/Off switch.2) Vehicle speed source.3) Service Brake Pedal Position Switch.4) Set /Resume switch.Optional Switch Inputs

1) Clutch Pedal Position Switch (Transmission Style programming dependent)2) Transmission Neutral switch (Transmission Style programming dependent)3) Service Brake Pedal Position Switch #2 (Transmission Style programming dependent)4) Cruise Pause Switch (J1939 Only)Customer Parameter programming required:

1) Vehicle Speed Calibration.2) Low Cruise Control Speed Set Limit.3) High Cruise Control Speed Set Limit.4) Transmission Style.

13.1 Cruise Control Switches and OperationCruise Control will operate the same for either hard-wired switch inputs or J1939 based switch inputs.

13.1.1 Cruise Control On/Off SwitchWhen the On/Off switch input is toggled to the ON position (switch contacts closed) Cruise Control or Extended Idlefunction is enabled.

C978-BRC979-ORC975-WHC992-PUC977-BUH795-PK

35445945225

P1 J1

SETRESUMECRUISE CONTROL ON/OFF SWITCHSERVICE BRAKE PEDAL POSITION SWITCHCLUTCH PEDAL POSITION SWITCHAP SENSOR/SWITCH SENSOR COMMON

SET/RESUME

CRUISE CONTROL ON/OFF

SERVICE BRAKE PEDAL POSITION

CLUTCH PEDAL POSITION

ECM

(CRUISE OFF POSITION)

(SET OFF POSITION)(RESUME OFF POSITION)

(PEDAL RELEASED POSITION)

(PEDAL RELEASED POSITION)



13.1.2 Set/Resume SwitchThe Set/Resume switch is normally a three-position switch biased to the Off position. The ECM inputs areCustomer programmable determining the Accel/Decel function of the Set and the Resume input. The factory defaultis Set/Accel and Resume/Decel.The Set/Resume switch is normally a three-position switch biased to the off (center) position. The CustomerProgrammable parameter Cruise/Idle/PTO Switch Configuration is used to determine which switch contact isassociated with accelerate and decelerate functions. The default is Set/Accelerate and Resume/Decelerate.

13.1.3 Switch Function/Interaction for Cruise ControlCruise Control requires that the vehicle speed be within the programmed Low and High Cruise Set Speed Limits.The Cruise Control Set speed may only be established between these limits. The set speed is the vehicle speedthat the engine will attempt to maintain while normal cruise control conditions are met. The switches used with theService Brake, Clutch, Pause and transmission neutral can deactivate (kick out) Cruise Control.With the Cruise Control On/Off switch on, toggling (turning the switch On for less than 0ne second) the Set Switchor the Resume Switch will cause the Cruise Control Vehicle Set Speed to be equal to the present vehicle speed.This set speed will remain as the Cruise Control Vehicle Speed until a new set speed is established or theignition switch is turned off.With a set speed established, the vehicle set speed may be bumped (increased or decreased) by toggling theSet or the Resume switches. A Bump means that the Set or Resume switch is closed for less than one second.The increase or decrease of the vehicle set speed will be one mph for every bump.With a set speed established, the vehicle speed may be ramped (increased or decreased) by holding either theSet or Resume switch closed for more than 1.5 seconds. The vehicle set speed will change by one mph/sec whilethe switch is closed. When the switch is released, the actual vehicle speed will become the new vehicle set speed.With a set speed established and Cruise Control actively maintaining vehicle speed, the cab throttle may be usedto increase vehicle speed. To make this vehicle speed the new set speed, the Set switch must be closed for atleast two and one half seconds to establish a new set speed.With a set speed established but Cruise Control has been disabled or kicked out the Resume Switch can betoggled to reactivate Cruise Control. This includes the Cruise On/Off switch as a reason for the kick out. Oncereactivated, the existing set speed will be resumed and the engine will recover to the set speed.With a set speed established but Cruise Control has been disabled or kicked out the Set Switch can be toggledto increase (or decrease depending on the configuration of the Set/Accel Resume/Decel parameter) the currentCruise Control set speed. The speed that the vehicle is currently traveling will not be established as a new setspeed until the Set Switch is held down for more than two and one half seconds.



14.0 Idle Functions14.1 Smart Idle

The Battery Monitor and Engine Control Voltage parameter is used to determine when the Battery Monitor andEngine Speed Control System will automatically elevate engine idle to the engine RPM specified in the BatteryMonitor & Low Idle Engine Speed parameter in order to maintain ideal battery system voltage. This feature is usedto promote additional battery life. The engine idle will only be increased if the vehicle is stopped, the transmissionis out of gear and neither the clutch nor the brake pedal are depressed. If these conditions are not met, the engineidle will not be adjusted. This feature will not function when the engine is operating in dedicated PTO mode(PTO On/Off switch in the ON position). The recommended setting is 12.2 Volts for a 12 Volt system, and 24.5 Voltsfor a 24 Volt system. The engine will stay at this idle speed for 5 minutes (unless interrupted). At the end of 5 minutesthe engine will return to low idle or a previously established elevated idle speed. If the battery voltage is still belowthe programmed trip point the engine will return to the programmed Smart Idle speed for another 5 minutes.NOTE: This feature requires the installation of a Neutral Switch (J1/P1: 62 or the SAE J1939 based input message)if the Transmission Style parameter is programmed to AT/MT/HT Option 3, or AT/MT/HT Option 4.

14.2 Extended IdleCruise Control switch inputs can be used to control the engine idle speed in Extended Idle mode. Extended Idleis available if the engine is not in Cold Mode, Smart Idle (battery voltage induced) is not engaged, Fast Idle is notenabled, the PTO ON/OFF Switch is not ON, Service Brake or Clutch is not depressed, transmission is not in gear,Cruise Pause Switch is not On and the vehicle speed is not equal to or exceeding the programmable Idle VehicleSpeed Limit.Note: Some switch inputs are programming dependent.With conditions met for Extended idle, and the Cruise Control On/Off switch is in the ON position, the engine rpmmay be bumped or ramped by using the Cruise Control Set/Resume switch inputs. The amount of engine rpmchange for a bump is determined by the Idle/PTO RPM Bump Rate parameter. The Idle/PTO Bump RPM Rateis programmable from 5 to 1000 RPM (default is 20 RPM). The engine rpm ramp value is determined by theIdle/PTO Engine Speed Ramp Rate parameter. The Idle/PTO Engine Speed Ramp Rate parameter is programmablefrom 5 to 1000 RPM/sec (default is 50 RPM/sec). When the engine speed is bumped the engine will ramp to thenew rpm at the programmed ramp rate.The Cruise/Idle/PTO Switch Configuration parameter programming will determine the direction of the engine rpmbump or ramp. When programmed to Set/Accel Resume /Decel, the engine rpm will increase with the Set switchand Decrease with the Resume Switch. When programmed to Set/Decel Resume /Accel, the engine rpm willdecrease with the Set switch and increase with the Resume Switch.Pressing and then releasing the Set Switch or the Resume Switch will establish the current engine rpm as the idleset speed. The set rpm may be established at any engine speed from the programm

c7-c9 electrical electronic guide

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