ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

S
A
E
J
1
5
8
7
D
a
t
a
L
i
n
k

3 Retarder
Solenoids

Electronic
Control
Module

SAE J1922 Data Link

SAE J1939 Data Link

6 Electronic Unit
Injectors

BATT
ERIE
S

Cruise Control On/Off &

Set/Resume Switches
Engine Retarder Level Switches
Crankshaft Position
Sensor
Camshaft Position
Sensor

Atmospheric Pressure
Sensor

Oil Pressure Sensor

Accelerator Pedal
Position Sensor

Caterpillar

Installed

Installed

OEM

Clutch and Service Brake Switches

Check Engine & Warning Lamps
Coolant Level Sensor

/h

RPM X 100

30

Speedometer & Tachometer

15

25

Cooling Fan
1.5 A

Vehicle Speed Sensor

A/C High
Pressure
Switch

Boost Pressure
Sensor

Coolant
Temperature
Sensor

Remote Accelerator
Position Sensor

Fuel Temperature Sensor

2, 0.3A Outputs
Ignition Key Switch
7 Switch
Inputs

Intake Manifold Air Temperature Sensor

3, 1.0A Outputs
2 Passive Temperature
Sensor Inputs
3,
1.5A
Outpu
ts

Figure 3 - C-10, C-12, C-15 and C-16 Component

Diagram

Caterpillar Pub# LEBT9010-02 ___ C-10, C-12, C-15 & C16 Truck Engines
8

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

2.0 Engine Component Overview

Electronic Unit
Injector Connector

Boost
Pressure
Sensor

Intake Manifold Air

Temperature Sensor

Engine
Ground
Stud

Camshaft
Position
Sensor

Engine
Control
Module
(ECM)
OEM
Vehicle
Harness
Connector
J1/P1

Engine
Harness
Connector
J2/P2
Crankshaft
Position
Sensor
Atmospheric
Pressure
Sensor

Engine
Ground
Stud

Oil
Pressure
Sensor

Left Side View

Figure 4 - C-15 and C-16 Left Side View

Coolant
Temperature
Sensor
Intake
Manifold Air
Temperature
Sensor

Fuel
Temperature
Sensor

Top View

Figure 5 - C-15 and C-16 Right Side and Front View

C-10, C-12, C-15 & C-16 Truck Engines ___ Caterpillar Pub# LEBT9010-02

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

Oil
Pressure
Sensor

Fuel
Temperature
Sensor

Electronic Unit
Injector Connector

Atmospheric
Pressure
Sensor

Engine
Ground
Stud

Electronic
Control
Module
(ECM)

Camshaft
Position
Sensor

OEM
Vehicle
Harness
Connector
J1/P1

Crankshaft
Position
Sensor

Engine
Harness
Connector
J2/P2
Left Side View

Engine
Ground
Stud

Figure 6 - C-10 and C-12 Left Side View

Coolant
Temperature
Sensor

Intake Manifold
Air Temperature
Sensor

Boost
Pressure
Sensor

Atmospheric
Front Right Side View

Front Top View

Figure 7 - C-10 and C-12 Right Side and Top View

Pressure

Sensor

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

3.0 Power and Grounding Requirements and Considerations

The ECM requires unswitched power and ground connections. An Ignition Key Switch input is used to turn the
ECM ON, allowing the engine to start and run.
3.1 Grounding
Proper grounding for vehicle and engine electrical systems is necessary for proper performance and reliability.
Improper grounding results in unreliable electrical circuit paths. Stray electrical currents can damage main
bearings, crankshaft journal surfaces, and aluminum components. They can also cause electrical noise
degrading control system, vehicle, speedometer, and radio performance. These problems are often very difficult
to diagnose and repair.
All ground paths must be capable of carrying any conceivable fault currents. An AWG #4 or larger cable is
recommended between the engine ground stud and the frame or starter negative post to handle alternator currents.
A maximum of three ring terminals are to be connected to the engine ground stud to insure ground connection
integrity. More than three terminals can cause the stud to loosen too easily. Caterpillar recommends splicing like size
wires together as a method of reducing ring terminal congestion at the ground stud.

CIRCUITS WITHIN THIS

AREA ARE RECOMMENDATIONS
OFF
ON
ST.

BAT. MTR.
ALTERNATOR

STARTER
MOTOR
(12V)

GND.

ECM
20 A

J906-BR
14 AWG 101-RD
101-RD

229-BK
14 AWG 229-BK
- 12V

12V

- 12V

70 IGNITION KEY SWITCH

52 UNSWITCHED +BATTERY
53 UNSWITCHED +BATTERY

65 -BATTERY
67 -BATTERY
P1 J1

ENGINE BLOCK

Wiring Diagram 1 - ECM and Engine Stud Battery Connections

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

5.5.1 ECM Connector Endbell

An AMP 638092-1 (Caterpillar part number 126-1774) Connector Endbell is available to provide additional
protection and controlled wire routing for the harness at the ECM.
5.5.2 Twisted Pair Wiring

Twisted pair wiring must be used for the SAE J1587 Data Link, SAE J1922 Data Link, and the vehicle speed
signal wires. There should be a minimum of one twist per inch within the harness. All twisted pair wires should not
be twisted within an inch of the connector to avoid seal stress. The speedometer and tachometer outputs should
also use twisted pair wiring. SAE J1939 Data Link wiring should comply with SAE J1939/11 specifications.
5.6 Accelerator Pedal Position Sensor Connector
5.6.1 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.

Three Terminal Deutsch DT Plug Connector

Wedge

Figure 20 - Three Terminal Accelerator Pedal Position Sensor Deutsch DT Connector

5.6.2 Accelerator Pedal Position Sensor (176-1602 and 176-1604) with Deutsch Three Terminal Connector
Wire Gauge Size

The connections may be made with #16 or #18 AWG SAE J1128 type SXL, GXL or equivalent wire.
5.6.3 Accelerator Pedal Position Sensor (176-1602 and 176-1604) with Deutsch Three Terminal Connector
Wire Insulation Size Range

Outside diameter insulation range is 2.24 mm to 3.81 mm (0.09 to 0.15 in).

5.6.4 Accelerator Pedal Position Sensor with Three Terminal Packard Electric Connector

The 176-1605 Accelerator Pedal Position Sensor (6 inch [15 cm] harness) requires a Packard Electric Division
12110293 (Caterpillar part number 124-5641) mating connector.

Figure 21 - Three Terminal Accelerator Pedal Position Sensor Packard Electric Connector

26

Caterpillar Pub# LEBT9010-02 ___ C-10, C-12, C-15 & C-16 Truck Engines

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

5.6.5 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.
5.6.6 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.).

5.6.7 Accelerator Pedal Position Sensor Three Terminal Connector Terminals

The following table provides terminal part numbers

Required Deutsch Parts
Description

Usage

Part Number

Caterpillar Part Number

3 Terminal Plug w/Cap

APP Sensor Connector

Deutsch DT06-3S-EP04

3E-3367

3 Terminal Plug Wedge

APP Sensor Connector

Deutsch W3S

3E-3368

Socket Contact (machined)

#16 & #18 AWG Wire

Deutsch 0462-201-16141

8T-8730

Socket Contact (stamped & formed)

#18 AWG Wire

Deutsch 1062-16-0122

115-1051

3 Terminal Plug

APP Sensor Connector

Packard 12110293

124-5641

Socket Terminal

#18 / #20 AWG Wire

Packard 12048074

124-5640

6.0 Accelerator Pedal Position Sensors

The accelerator pedal position sensor converts the mechanical accelerator pedal position into an electrical signal for
the ECM. Caterpillar requires one of the sensors described in this document for use with an accelerator pedal.

Figure 22 - 176-1602 or 176-1604 Accelerator Pedal Position Sensor with Deutsch DT Connector

Figure 23 - 176-1605 Accelerator Pedal Position Sensor with Packard Connector

The accelerator pedal position sensor and ECM are designed to comply with FMVSS124 (Federal Motor
Vehicle Safety Standard 124). The sensor also meets the SAE J1843 Recommended Practice.
176-1602, 176-1604, and the 176-1605 sensors mount directly to the accelerator pedal. This eliminates the need
for accelerator pedal linkages and OEM adjustments. These sensors are designed to operate from the ECM + 8V
supply. The 176-1602 (32 inch [81 cm] harness with Deutsch connector), 176-1604 (6 inch [15 cm] harness with
Deutsch connector), and the 176-1605 (6 inch [15 cm] harness with Packard connector) use the same sensor but
have different connectors or pigtail lengths as described.
C-10, C-12, C-15 & C-16 Truck Engines ___ Caterpillar Pub# LEBT9010-02

27

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

6.1 Accelerator Pedal Position Sensor Electrical Specifications
The sensor output is a constant frequency signal whose pulse width (duty cycle) varies with accelerator pedal
position. The Pulse Width Modulated (PWM) signal is expressed as a percentage (percent duty cycle) as shown
in Figure 24 Example PWM Signals.

25 % Duty Cycle

75 % Duty Cycle

Figure 24 - 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.
6.2.1 Accelerator Pedal Position Sensor Connection

The 176-1602 accelerator pedal position sensor is designed to operate on 8 Volts DC supplied by the ECM. The
ECM supplied +8V, AP Sensor/Switch Sensor Common, and Accelerator Pedal Position wiring must be
connected to the control system through an OEM harness. Current draw for the sensor is less than 40 mA.
AP Sensor/Switch Sensor Common must not be connected to the vehicle cab ground. Connecting AP Sensor/ Switch
Sensor Common to the vehicle cab ground can degrade control system performance. AP Sensor/Switch Sensor
Common must be connected to the ECM at the OEM connector (P1 terminal-5) via a dedicated return line.

Refer to 5.6 Accelerator Pedal Position Sensor Connector on page 26 for OEM harness connector
requirements. Connector terminal assignments are as follows:

28

Sensor Terminal Assignment

ECM Terminal Assignment

Terminal Description

Terminal A

Terminal 4

+ 8V

Terminal B

Terminal 5

AP Sensor/Switch Sensor Common

Terminal C

Terminal 66

Accelerator Pedal Position

Caterpillar Pub# LEBT9010-02 ___ C-10, C-12, C-15 & C-16 Truck Engines

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

6.2.2 Accelerator Pedal Position Sensor Duty Cycle

The Accelerator Pedal Position Sensor (APP Sensor) mounts directly to the pedal and should not be adjusted by
the OEM. The OEM must insure that pedals supplied by the pedal manufacturer meet the following specification
for sensor output duty cycle:
Accelerator Pedal Position

Duty Cycle

Low Idle

10% - 22%

High Idle

75% - 90%

The pedal assembly should also conform to SAE J1843.

NOTE: The ECM automatically calibrates (auto-cal) new duty cycle values for the Low Idle and High Idle throttle
positions each time the ECM is powered. The ECM initially assumes 22 percent duty cycle is low idle and 75
percent duty cycle is high idle. As a result, the Throttle Position Status may reaches 100 percent well before the
accelerator pedal is fully depressed. This is normal operation and will continue until the ECM learns the limits of
the low and high idle stops. Following some cycling of the accelerator pedal from the low to the 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 normal operation it may initially require more accelerator pedal movement for the Throttle Position Status to
increase above 3 percent (low idle) and the Throttle Position Status may reach the 100 percent (high idle) value prior to
the limit of the high idle position. This is done to ensure the throttle reaches these two critical points for engine
operation. As the ECM learns the physical limits, the range is expanded as long as it is within the values specified
above. If the Duty Cycle value goes outside of the expected range, a diagnostic code will be activated.

NOTE: There is no direct correlation between the Sensor Duty Cycle value and a Desired Engine RPM. For
example, it is not possible to input a 50% duty cycle value and expect the engine to operate at 1800 rpm. This is
due to the Auto-Cal function which constantly calibrates for the low and high idle stop positions.
6.3 Accelerator Pedal Position Sensor for Remote PTO Applications
Caterpillar provides several dedicated PTO features that can be used by programming specific Customer
Programmable Parameters. For applications also requiring variable engine speed control from outside of the cab during
PTO Operation, a second accelerator pedal sensor input is provided on the ECM. This input is provided for the
connection of ONE +12V Accelerator Position Sensor than can be used when the engine is operating in Dedicated PTO
Mode. This requires a PTO On/Off Switch Circuit to be installed. Refer to 14.0 Dedicated PTO Operation on page 53
for details. When this input is in use, the Cab Accelerator Pedal Position Sensor is ignored.

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

Figure 25 - 161-8906 Accelerator Position Sensor with Deutsch HD Connector

Caterpillar recommends the 161-8906 accelerator pedal position sensor for remote PTO applications. The sensor
provides the same signal as the 176-1602, 176-1604, and the 176-1605 sensors, but requires battery voltage (12
or 24 volt systems) to operate. This Sensor must NOT be connected to the +8V supply intended for the Cab
Sensor, nor can the Cab Sensor be connected to a +12 Volt supply.
6.3.1 161-8906 Accelerator Position Sensor Connector

The 161-8906 is supplied with a 3-terminal Deutsch HD plug connector (HD16-3-96S, Caterpillar P/N 8T-8731).
The connecting harness will require a Deutsch HD receptacle connector (HD14-3-96P, Caterpillar P/N 8T-8732).
6.3.2 Mounting the Remote Accelerator Position Sensor

The 161-8906 Accelerator Pedal Position Sensor can be attached to either an accelerator pedal assembly (contact the
vehicle OEM for parts) or a Caterpillar 107-2281 PTO Accelerator Assembly. The PTO Accelerator Assembly does not
include a handle. It may be used in applications where a mechanical linkage is required. The accelerator position
sensor mounts directly to the PTO Accelerator Assembly and does not require additional sensor calibration.

(Sensor Not Included)

(Handle Not Included)

PTO Accelerator Assembly

Figure 26 - 107-2281 Remote Accelerator Pedal Assembly