Caterpillar C7 / C9 Engines Electrical and Electronic Application and Installation Guide

C7 & C9 Truck Engines EPA 2004 Electrical and Electronic Application and Installation Guide Serial Number Prefixes FMM FML KAL YPG 9DG CKP LEBT2835-02 November 2008

INTRODUCTION AND PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Engine Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Power and Grounding Requirements and Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Connectors and Wiring Harness Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Accelerator Pedal Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Vehicle Speed Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ECM Speedometer and Tachometer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Lamp Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 OEM Installed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Inlet Air Heater, Lamp and Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Hard-wired Switch Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Idle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 J1939 Based Switch Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Dedicated PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Programmable Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Governor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Data Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Customer Specified Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 Diagnostics, Service Tools and Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ 3

INTR ODUCTION AND PURPOSE This document is intended to provide necessary information for correct electrical & electronic application and installation of a C7 or C9 truck engine into an on-highway truck, bus, motor coach or vocational chassis. Caterpillar expects there will be some additions and modifications to this document as the engine program development continues, and as OEM requests for information not currently addressed are added.The information contained in this version of the document reflects the Caterpillar design for production C7 and C9 engines built with March 2004 software. General Electronic Engine Operation 1.0 Engine Functions 1.1 Electronic Governing Two engine speed range electronic governors are available for use.These electronic governors are selectable through a programmable parameter. 1.2 Fuel/Air Ratio Control The 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 Control Injection 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 Shaping Electronic controls provide increased flexibility to tailor the torque curve over a wide speed range. 1.5 Cold Mode Operation When the engine is started with cold coolant, the engine will operate in “Cold Mode”. The engine will operate with reduced performance until the coolant temperature has warmed. The Caterpillar electronic service tool software will indicate when the engine is operating in Cold Mode. The C7 engine will operate in Cold Mode below 64 Deg C and the C9 engine will operate in Cold Mode below 40 Deg C. ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE 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. Without written permission, any copying, transmittal to others, and any use except that for which it is loaned is prohibited.

2.0 Engine Component Overview 2.1 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 Engine Harness, the other for the Vehicle OEM Harness. 2.2 Boost Pressure Sensor The Boost Pressure Sensor is an absolute pressure sensor measuring inlet manifold pressure. Boost pressure displayed by service tools and communicated over the data link is referenced to the Atmospheric Pressure Sensor reading. The Boost Pressure Sensor measures gauge pressure from 0 psi (0 kPa) to 49 psi (340 kPa). The ECM supplies the sensor with a regulated 5 Volts DC. 2.3 Atmospheric Pressure Sensor The Atmospheric Pressure Sensor is an absolute pressure sensor. The Atmospheric Pressure Sensor measures pressure to 16.8 psiA (116 kPaA).The ECM supplies the sensor with a regulated 5 Volts DC. 2.4 Oil Pressure Sensor An optional Oil Pressure Sensor is available for use in applications where an actual oil pressure indication is desired.Typical applications include vehicles with a vehicle data link capable Instrument Cluster that can display engine 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 engine to 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 as displayed by service tools and communicated over the data link is referenced to the Atmospheric Pressure Sensor reading. The ECM supplies this sensor with the necessary voltage. 2.5 Coolant Temperature Sensor The thermistor based Coolant Temperature Sensor is used to monitor engine coolant temperature. Output from this 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 Sensor The Inlet Manifold Air Temperature Sensor is used to measure the inlet air temperature and is thermistor based like the 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 Sensors The engine speed/timing sensors are used to determine both engine speed and fuel injection timing. The sensors detect this information from a wheel on the camshaft. 2.8 Coolant Level Sensor The coolant level sensor is an option device used to monitor the engine’s coolant level.This sensor is usually mounted in the cooling system’s surge tank. There are three types of sensors that may be used. 2.9 Injection Actuation Pressure (IAP) Sensor The Injection Actuation Pressure Sensor measures the pressure in the high-pressure oil manifold. This oil is used to feed the hydraulically actuated electronically controlled unit injectors. The ECM supplies the sensor with the necessary 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 output of the Injection Actuation Pressure Sensor to determine the required output to this valve. ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ 5

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE 6 Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ 2.11 Inlet Air Heater and Relay The Inlet Air Heater is an engine mounted, Caterpillar supplied and installed heater grid used for warming the inlet air to aid in starting during cold ambient temperatures. Operation is based on elevation (above sea level) and the sum of the Coolant and Inlet Manifold Air temperatures. The ECM controls the normally open relay to provide battery power to the grid. 2.12 Fuel Pressure Sensor A Fuel Pressure sensor is included in the engine pressure sensor package. This sensor monitors the fuel supply pressure 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 wired to the Engine Connector (J2) of the ECM.This switch monitors the oil level in the oil pan and is checked at initial engine power up. Proper Oil level in the engine will keep a normally open switch closed. Oil level that is too low will allow the switch to open. If the ECM senses an open switch upon three sequential engine starts, low oil level is indicated. Figure 1 33 3 P2 J2 Sensor Common Oil Level ECM Oil Level Switch (Shown With Oil Level Normal) B428-OR G829-GN

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ 7 Figure 2 Boost Pressure Sensor Top Camshaft Position Sensor Bottom Camshaft Position Sensor 12V ñ + 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 109-3000 12 V AIR FLOW Intake Air Heater Intake Air Heater Relay Intake Air Heater Lamp Vehicle Speed Sensor Cooling Fan SAE J1939/13 OFF-BOARD DIAGNOTSIC 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 5 0 25 45 35 55 65 75 85 RPM X 100 5 10 15 20 25 30 Speedometer & Tachometer Throttle Position Sensor PTO Throttle Position Sensor OEM Installed Caterpillar Installed Cruise Control On/Off & Set/Resume Switches ADEM 2000 Engine Control Module Engine Oil Pressure Sensor (Optional) Oil Level Switch (GMT560 Trucks Only) Turbo Wastegate Control Valve (Not All Ratings) Fuel Pressure Sensor

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE 8 Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ Engine Oil Pressure Sensor (Optional) Coolant Temperature Sensor Engine Speed/Timing Sensors Injection Actuation Control Valve Injection Pressure Sensor Boost Pressure Sensor Inlet Air Temperature Sensor Inlet Air Heater Relay OEM Connector J1/P1 ECM Engine Connector J2/P2 ECM Inlet Air Heater Relay Atmospheric Pressure Sensor Inlet Air Temperature Sensor Boost Pressure Sensor Injection Actuation Pressure Control Valve Coolant Temperature Sensor Injection Actuation Pressure Sensor Speed/Timing Sensors Oil Pressure Sensor (Optional) OEM Harness Connector J1/P1 Engine Harness Connector J2/P2 Figure 3 - C7 Sensor Locations Figure 4 - C9 Sensor Locations

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ 9 Figure 5 - C7 Engine Wiring Diagram 1 2 INJECTION ACTUATION PRESSURE CONTROL VALVE J500 P500 E963-BK E964-WH 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 CAMSHAFT POSITION SENSOR TOP CAMSHAFT POSITION - TOP CAMSHAFT POSITION + J401 P401 J402 P402 B A BOTTOM CAMSHAFT POSITION - BOTTOM CAMSHAFT POSITION + BOTTOM CAMSHAFT POSITION SENSOR 995-BU C967-BU G833-PK C B A G849-BR G829-GN G828-WH A746-PK G849-BR A747-GY G829-GN G828-WH P204 J204 ENGINE ATMOSPHERIC PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V ENGINE ATMOSPHERIC PRESSURE NOTE A ENGINE INJECTION ACTUATION PRESSURE ENGINE INJECTION ACTUATION PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V P203 A747-GY G829-GN G828-WH A B C P200 A746-PK G829-GN G828-WH SENSOR ENGINE BOOST PRESSURE ENGINE BOOST PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V GN YL 0R INTAKE AIR HEATER RELAY ENGINE COOLANT TEMPERATURE ENGINE INTAKE MANIFOLD AIR TEMP. ENGINE TEMPERATURE SENSOR COMMON ENGINE ATMOSPHERIC PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V IAP CONTROL VALVE IAP CONTROL VALVE COMMON ENGINE BOOST PRESSURE ENGINE INJECTION ACTUATION PRESSURE P1 J1 ECM GROUND STRAP G854-PK G855-PU TO ECM MOUNTING BOLT ENGINE HARNESS CONNECTOR VEHICLE HARNESS CONNECTOR C987-RD G850-BU P648 TO CONNECTOR J648 (OEM HARNESS) A B K995-OR G850-BU C987-RD 1 2 ENGINE TIMING CALIBRATION PROBE+ ENGINE TIMING CALIBRATION PROBE- TO INTAKE AIR HEATER CIRCUIT PROTECTION (BATTERY +) TO ENGINE CYLINDER HEAD INTAKE AIR HEATER G850-BU P2 J2 J501 P501 N/O RELAY 32 35 7 34 26 18 10 11 12 15 16 17 24 27 41 42 50 52 53 66 9 40 25 6 33 14 3 2 B A INJECTOR CYLINDER NO.5 1 63 64 4 5 61 62 70 INJECTOR CYLINDER NO.6 B A J306 P306 J305 P305 J304 P304 J303 P303 J302 P302 L984-OR B A INJECTOR CYLINDER NO.4 J301 P301 INJECTOR CYLINDER NO.1 A704-GN B A A705-BU A703-BR A702-PU A701-GY L985-YL L984-OR A706-GY L985-YL L983-WH L983-WH INJECTOR CYLINDER NO.3 B A B A INJECTOR CYLINDER NO.2 P300 J300 L983-WH L984-OR L985-YL A706-GY A705-BU A704-GN A703-BR A702-PU A701-GY INJECTOR COMMON CYLINDERS 1 & 2 INJECTOR COMMON CYLINDERS 3 & 4 INJECTOR COMMON CYLINDERS 5 & 6 INJECTOR CYLINDER 6 INJECTOR CYLINDER 5 INJECTOR CYLINDER 4 INJECTOR CYLINDER 3 INJECTOR CYLINDER 2 INJECTOR CYLINDER 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 SENSOR 1 2 ENGINE COOLANT TEMPERATURE 995-BU G833-PK J100 P100 ENGINE COOLANT TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON ENGINE INTAKE MANIFOLD AIR TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON J103 P103 C967-BU G833-PK ENGINE INTAKE MANIFOLD AIR TEMPERATURE 1 2 SENSOR SENSOR SENSOR NOTE A: INDICATES AN OPTIONAL COMPONENT NOT INSTALLED ON ALL ENGINES ENGINE OIL PRESSURE ENGINE OIL PRESSURE SENSOR COMMON ENGINE OIL PRESSURE SENSOR +5V P201 994-GY G827-BU G826-BR 994-GY G827-BU G826-BR ENGINE OIL PRESSURE NOTE A SENSOR ENGINE OIL PRESSURE ENGINE OIL PRESSURE SENSOR COMMON ENGINE OIL PRESSURE SENSOR +5V TOP CAMSHAFT POSITION - TOP CAMSHAFT POSITION + BOTTOM CAMSHAFT POSITION - BOTTOM CAMSHAFT POSITION + A B C A B C ENGINE OIL LEVEL SWITCH (GMT560 Only) G458-GY OIL LEVEL SWITCH 1 2 M 795-WH C211-BK TURBO WASTEGATE SOL NEGATIVE TURBO WASTEGATE SOL POSITIVE TURBO WASTEGATE SOLENOID *** Not On All Ratings *** OIL Level - OIL Level - A B C B A C991-PK G827-BU G826-BR P205 J205 ENGINE FUEL PRESSURE SENSOR COMMON SENSOR +5V GN YL 0R C991-PK FUEL PRESSURE FUEL TRANSFER PUMP PRESSURE

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE 10 Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ A B J500 P500 Figure 6 - C9 Engine Wiring Diagram

Caterpillar C7 / C9 Engines Electrical and Electronic Application and Installation Guide

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