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2002 Caterpillar

All Rights Reserved


Printed in U.S.A.
RENR4930
December 2002
3500B Engi ne f or Pow er Modul es
El ec t r i c al Syst em
Engine:
1FZ1-UP
Power Module:
BLM1-UP
1GZ1-UP
1HZ1-UP
BNR1-UP
BPD1-UP
Related Electrical Service Manuals
Form Number
Alternator: 5N-5692 SENR4978
Electric Starting Motor: 8N-3896 SENR3860
Electric Starting Motor: 7C-0527 SENR3581
Title
Resistor and Solenoid Specifications
Part No. Component Description Resistance (Ohms)
134-2540 Resistor: Smartlink Connector 120
189-5746 Resistor: LH Mag Pick Up 142
189-5746 Resistor: Timing Calibration Connector 142
9X-5484 Resistor: Diode/Resistor 20 0.2
8C-6099 Solenoids: Ether #1 and #2 3.33 - 4.07
At roomtemperature unless otherwise noted.
Off Machine Switch Specification
Part No. Function Actuate Deactuate Contact Position
3N-1400 Prelube Pressure
9 to 2 kPa
(1.3 to .29 psi.)
7 kPa
(1 psi.)
Normally Open
T
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
Normally open switch that is closed due to an applied condition, and will open again with a
specific decrease in that condition.
Normally closed switch that will open with an increase of a specific condition.
Normally closed switch that is open due to an applied condition, and will close again
with a specific decrease in that condition.
The circle indicates that the component has screwterminals and a wire can be disconnected
fromit.
No circle indicates that the wire cannot be disconnected fromthe component.
This indicates that the component has a wire connected to it that is connected to ground.
This indicates that the component does not have a wire connected to ground. It is grounded
by being fastened to the machine.
Electrical Schematic Symbols And Definitions
Pressure
Symbol
Temperature
Symbol
Level
Symbol
Flow
Symbol
A AA
2
A AA
1
2
325-PK-14
C A
325-PK-14
200-BK-14
T
FUSE - A component in an electrical circuit that will open the circuit if too much current flows
through it.
REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the
contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
SENDER - A component that is used with a temperature or pressure gauge. The sender
measures the temperature or pressure. Its resistance changes to give an indication to the
gauge of the temperature or pressure.
RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity.
It has a coil that makes an electromagnet when current flows through it. The electromagnet
can open or close the switch part of the relay.
CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too
much current flows through it. This does not destroy the circuit breaker and it can be reset to
become part of the circuit again.
SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil
that makes an electromagnet when current flows through it. The electromagnet can open or
close a valve or move a piece of metal that can do work.
Harness And Wire Electrical Schematic Symbols
Socket Pin
Pin or Socket
Number Wire, Cable, or Harness
Assembly Identification
Single Wire
Connector
Circuit Number
Identification
Wire
Gauge
Wire
Color
Plug Receptacle
9X-1123
Component
Part Number
Electrical Schematic Symbols And Definitions
1
1 1
2 2
Typical representation of a
Sure-Seal connector. The
plugand receptacle contain
both pins and sockets.
Typical representation of a
Deutsch connector. The
plug contains all sockets
and the receptacle contains
all pins.
MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is
activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch)
that make electromagnet when current flows through them. It also has an internal switch that places
the latch coil circuit open at the time the coil latches.
AI R CLEANER
UNFI LTERED OI L PRESSURE
FRONT VI EW
TURBO OUTLET
PRESSURE
ATMOS PRESSURE
ENGI NE OI L
PRESSURE
AI R SHUT- OFF
ELECTRI C STARTER
AI R CLEANER
STARTI NG AI D
UNFI LTERED FUEL PRESSURE
FI LTERED FUEL PRESSURE
FI LTERED OI L PRESSURE
LEFT SI DE VI EW
AFTERCOOLER
TEMP ELECTRI C STARTER
ENGI NE SPEED
TI MI NG
LEFT HAND
TURBO EXHAUST
UNFI LTERED OI L
PRESSURE
ATMOS PRESSURE
ENGI NE COOLANT
TEMP
RI GHT HAND
TURBO PRESSURE
LEFT HAND
TURBO I NLET PRESSURE
AI R CLEANER
TI MMI NG
CALI BRATI ON
REAR VI EW
ALTERNATOR
AI R SHUT- OFF
AI R CLEANER
AI R START SOLENOI D
RI GHT SI DE VI EW
TURBO EXHAUST
TEMP
CRANK CASE
PRESSURE
RI GHT AI R SHUTOFF 23
28
31
32
24
06
07
08
09
10
11
12
04
05
37
39
40
01
02
O3
13
14
33
34
15
27
16
18
19
21
22
25
26
29
30
17
20
35
36
38
852- TN- 14
852- TN- 14
382- PK- 14
926- RD
F701- BR
F720- GN
844- TN- 18
845- TN- 18
846- TN- 18
101- TN- 14
101- TN- 14
102- GN/YL
102- GN/YL- 14
102- GN/YL- 14
838- SHLD- 18
838- RD- 18
838- BK- 18
998- BR
F701- BR
F716- WH- 18
113- OR- 18
F715- PU- 18
F702- GN- 18
F722- OR- 18
E798- PK- 18
E797- WH- 18
F710- BR- 18
F707- WH- 18
M754- RD- 16
M753- BK- 18
M756- YL- 19
M755- GN- 19
M757- CU- 19
846- TN- 18
845- TN- 18
844- TN- 18
709- OR- 18
A235- BK- 18
G429- GN- 18
709- OR- 18
G429- GN- 18
A235- BK- 18
102- GN/YL- 14
102- GN/YL- 14
102- GN/YL
RD- 6
F701- BR
LEFT AI R SHUTOFF
ETHER SOLENOI DS
ETHER SOLENOI DS
STARTER MOTOR MAGC SW.
ENGI NE OI L TEMP. SENSOR ( VS)
ENGI NE OI L TEMP. SENSOR ( SI G)
ENGI NE OI L TEMP. SENSOR ( GND)
ETHER AUTO/MANUAL
COOLANT LEVEL SENSOR ( A)
COOLANT LEVEL SENSOR ( B)
COOLANT LEVEL SENSOR ( C)
POWER ( +)
POWER ( +)
POWER ( - ) /LO
POWER ( - )
POWER ( - )
LG MAGC PU ( SHLD)
LH MAGC PU ( 2)
LG MAGC PU ( 1)
PRI MARY CAT DATA LI NK ( +)
PRI MARY CAT DATA LI NK ( - )
SECONDARY CAT DATA LI NK ( - )
SECONDARY CAT DATA LI NK ( +)
DI GI TAL SENSOR RETURN
CRANK SI GNAL
START/STOP/RUN 1
ECM PWR. SWI TCHED ( ON/OFF)
ENGI NE SHUTDOWN SI GNAL
RATED SPEED
DROOP SPEED
SHUTDOWN NOTI FY PWR.
SHUTDOWN NOTI FY RET.
ETHER PULL- I N
ETHER HOLD- I N
DEVI CENET V+
DEVI CENET V-
DEVI CENET CAN_H
DEVI CENET CAN_L
DEVI CENET DRAI N
J981- WH
J982- OR
892- BR
893- GN
101-TN-14
101-TN-14
101- TN- 14
101- TN- 14
M757- CU- 19
M755- GN- 19
M756- YL- 19
M753- BK- 16
M754- RD- 16
NOTES BLOCK
L1
L2
L3
L4
L5
L6
L7
L8
L9
L10
L11
L12
L13
L14
L15
L16
L17
L18 EMCP POWER ( +)
BATTERY POWER ( - )
ECM POWER
ETHER PULL- I N / HOLD- I N
PRELUBE PRESSURE SWI TCH
AI R SHUTOFFS
ENGI NE SPEED TI MI NG
ANALOG SENSOR POWER
OI L TEMPERATURE SENSOR
CAT DATALI NK
ECM ON/OFF \ START/STOP
ETHER SOLENOI DS
SENSOR I NPUTS
SENSOR I NPUTS
COOLANT LEVEL SENSOR
SHUTDOWN NOTI FY
DI GI TAL SENSOR POWER
CYLI NDER I NJECTORS
L19 TI MI NG CALI BRATI ON
LH MAG PI CK UP L20
L21 DROOP/RATED SPEED
L22 SMARTLI NK
155- 2269 PLUG ASSEMBLY
155- 2261 WEDGE ASSEMBLY
155- 2276 WEDGE ASSEMBLY
169- 8670 PLUG ASSEMBLY
134- 2540 RESI STOR RECEPTACLE
177- 0071
6V- 5049
9X3271
( SMARTLI NK USE)
J982- OR
J981- WH
J981- WH
J982- GR
CONNECTOR
133- 0970
GENERATOR
8T9834
L22
L22
L15
L4
L21
L10
L11
L20
L17
L18
L5
L12
L9
L13
L21
L21
L14
L18
L17
L13
L11
L12
L20
L10
L15
L14
L4
L4
L10
AND HARNESS
TO THERMOCOUPLE
SMARTLI NK ADAPTER
1
2
B
A
C
EMCP CB
30A
1 2
E797-WH
E798-PK
L4
SMARTLI NK
C
B
A
CONNECTORS
838- SHLD- 18
2
1
838- RD- 18
838- BK- 18 BK- 18
WH- 18 LH
MAGC
PU
189- 5746
L11
892- BR
893- GN
H
J
229-BK-14
229-BK-14
L16
150- RD- 14
150- RD- 14
BK- 6 BK- 6
RD- 6
B
C
A
WH- 18
BK- 18
OR- 18
ANALOG RET
SI GNAL
+V ANALOG ENGI NE OI L
TEMP. SENSOR
102- 0050
( EMCP I I USE)
998- BR- 18
F718- BU- 18
F705- PK
200- BK 104- RD- 10
104- RD- 10
C465- OR- 10
2 1
PRELUBE
PRESSURE
SWI TCH
3N- 1400
NOTE A
7
A
4
PPR- M
B
2 1
PPR- S
3 4
PRELUBE CONTROL
( 148- 8026)
200- BK- 6
200- BK- 10
314- PU- 10
200- BK- 10
109- RD- 6
109- RD- 6
200- BK- 6
+ R
ALT
45A
POWER DI STRI BUTI ON BOX
2
1
1
MAG RELAY
2 1
CI RCUI T BREAKER
40A
1
60A
ALT CB
2
ECM CB
15A
2
30A
PRELUBE CB
STARTER
SMMS2
1
3 4
2
MAG SWI TCH
MAG SWI TCH
STARTER
3 4
1 2
SMMS1
( 147- 3347/147- 3346)
WH-18
BK-18
ADEM I I - J2 ADEM I I - J1
F722- OR
L2
L19
I NJECTOR GP ( 16)
998- BR
A713-GN
SHUTDOWN NOTIFY RET.
FUEL PRESSURE SNSR - UNFILTERED
F737-YL
ENGINE SHUTDOWN SIGNAL 'D' SW6
DIG SNSR RETURN
ANA SNSR PWR (5V)
362704 39 33 21 17 11 05 10 06 30 12 31 18 37 22 38 28 1534 26 40 16 35 29 01 25 2409D- KEY
PLUG AS.
101- 0205
32
TI MI NG
CALI BRATI ON
CONNECTOR
189- 5746
COOLANT TEMP SNSR
995-BU
1 2
F723-PK
F724-PU
L19
XXX-XX
XXX-XX
F701-BR
04062319 051112183339 4028 27 213529363026 2202081434 2425 13030907 38323137101516 17 01
L16
L19
START/RUN/STOP1 SW3
L15
A714-PK
A715-GY
A716-PU
20
G769-PU
ANA SNSR RETURN
SW7 (UNUSED)
G770-WH
BATTERY(+)
BATTERY(+)
BATTERY(-)
BATTERY(-)
START/RUN/STOP2 SW4
ETHER HOLD-IN
D-OUT 3 - HIGH SIDE (UNUSED)
TIMING CAL-FAN SPD(-)
TIMING CAL-FAN SPD(+)
D-OUT 2 - HIGH SIDE (UNUSED)
PRELUBE PUMP
DIG SNSR PWR (8V)
SECONDARY CAT DATA LINK (+)
SW9 (UNUSED)
ENGINE SHUTDOWN SIGNAL 'C' SW2
OIL PRESSURE SNSR - UNFILTERED
CAN DATA LINK (-) (UNUSED)
HSDL SHIELD GROUND (UNUSED)
CAN DATA LINK (+) (UNUSED)
FUEL PRESSURE SNSR - FILTERED
150-RD-14
150-RD-14
F718-BU
F716-WH
F717-YL
F707-WH
XXX-XX
893-GN
J982-OR
XXX-XX
F705-PK
A700-OR
J981-WH
F715-PU
XXX-XX
E796-GN
XXX-XX
XXX-XX
XXX-XX
F725-WH
F704-OR
A700-OR
998-BR
A B C
YL
GN-18
+V DIGTAL
SIGNAL
DIGITAL RET
TURBO
EXHAUST
TEMP RH
163- 7882
TURBO
EXHAUST
TEMP LH
163- 7882
DIGITAL RET
SIGNAL
+V DIGITAL
YL-18
YL
YL
CBA
998-BR
A700-OR
F703-GY
L3 L3
L6
998-BR
997-OR
993-BR
ECM ON/OFF - KEYSWITCH INPUT
F724- PU
F723- PK
998- BR
A700- OR
L7
SPD PWM 1B+ (UNUSED)
SPD PWM 1B- (UNUSED)
ETHER PULL-IN
PRELUBE PRESSURE SWITCH
D-OUT 5 - LOW SIDE (UNUSED)
DROOP SPD SIG (TERM D) SW10
CAT DATA LINK (-)
CAT DATA LINK (+)
SECONDARY CAT DATA LINK (-)
ENG SPEED/TIMING SIG
+V SPEED/TIMING
CRANKCASE PRESSURE SENSOR
CRANK SIGNAL
POUT 1 (UNUSED)
TURBO INLET RH PRESSURE SNSR
1907 23 201408020313
POUT 1 & 2 RETURN (UNUSED)
TURBO OUTLET PRESSURE SNSR
ATMOS PRES SNSR
TURBO INLET LH PRESSURE SNSR
OIL PRESSURE SNSR - FILTERED
A751-YL
AFTERCOOLER TEMPERATURE SNSR
RATED SPEED (TERM S)
TURBO IN EXH LH TEMP SNSR
TURBO IN EXH RH TEMP SNSR
SHUTDOWN NOTIFY PWR.
F702-GN
F703-GY
F704-OR
F714-PK
994-GY
F713-OR
A747-GY
A746-PK
( +)
113-OR
229-BK-14
229-BK-14
F724-PU
F723-PK
XXX-XX
XXX-XX
F710-BR
C- KEY
PLUG AS.
101- 0204
F719-BR
F720-GN
F722-OR
892-BR
999-WH
996-GN
E795-YL
ETHER AUTO/MANUAL SW8
L3 L2
L2
L8
L21
L11
L1
SOLENOID 1 POWER
SOLENOID 2 POWER
SOLENOID 3 POWER
SOLENOID 4 POWER
SOLENOID 5 POWER
SOLENOID 6 POWER
SOLENOID 7 POWER
SOLENOID 8 POWER
SOLENOID 9 POWER
SOLENOID 10 POWER
SOLENOID 11 POWER
SOLENOID 12 POWER
SOLENOID 13 POWER
SOLENOID 14 POWER
SOLENOID 15 POWER
SOLENOID 16 POWER
SOL 1&3 RETURN
SOL 2&4 RETURN
SOL 5&7 RETURN
SOL 6&8 RETURN
SOL 9&11 RETURN
SOL 10&12 RETURN
SOL 13&15 RETURN
SOL 14&16 RETURN
A701-GY
A702-PU
A703-BR
A704-GN
A705-YL
A706-GY
A707-PU
A708-BR
A709-OR
A710-GY
A711-PU
A712-BR
F726-YL
F727-GN
F728-BR
F729-GN
F730-GY
F731-OR
C
ENGI NE
SPEED/
TI MI NG
SENSOR
129- 6628
OR-18
BK-18
WH-18
+V SPD/TIM
SIGNAL
DIGITAL RET
BA
999- WH
996- GN
999-WH
998-BR
996-GN
XXX-XX
( - )
150- RD
RECEPT AS. ( 16)
9X- 0352
YLYL
2
2
1
1122 1
A702-PU
F727-GN
A701- GY
F727-GN
122 1
A704-GN
F726- YL
A706-GY
F729-GN
F729-GN
A708-BR
I NJECTOR GP ( 16)
A703- BR
A714- PK
RD- 00
FOR 3512B/3516B ONLY
39
229- BK
A B CA B CCBA
27
BK- 00
A
POS NEG
MOTOR
BAT MTR
S G
ENGI NE COOLANT
LEVEL SENSOR
165- 6634
L5
RES2
GND
VS
ALARM
RD- 18
BK- 18
GN- 18 C
B
A
BK- 00
17
304- WH- 18
200- BK- 18
05
1
RD- 00
2
926- RD
200- BK- 14
382- PK- 14
B
A
BK- 00
C
AI R STARTER
SOLENOI D
5N- 8980
1/2 MOTOR GP.
8N- 3896 ( 3512/6)
7C- 0527 ( 3508)
1/2 MOTOR GP.
8N- 3896 ( 3512/6)
7C- 0527 ( 3508)
RD- 00
304- WH- 10
CUSTOMER
SUPPLI ED
RD- 16
RD- 16
2
1
RESI STOR
9X- 9584
RESI STOR
9X- 9584
+
AI R SHUT- OFF
SOLENOI D LH
8C- 6099
PRELUBE
MOTOR AS.
3T- 7583
ETHER SOL #1
9X- 7137
DI ODE AS.
1W- 9070
G S
MTR BAT
MOTOR
L9
852- TN- 14
200- BK- 14
ATTACHMENTS
B
200- BK- 14
852- TN- 14
382- PK- 14
200- BK- 14
926- RD
BK
1
2
DI ODE AS.
1W- 9070
382- PK BU
200- BK
MOTOR
AI R SHUT- OFF
SOLENOI D RH
8C- 6099
CCBAA B C CB
1
2
RD- 16
RD- 16
AA B
RES1
DI SCONNECT
SWI TCH
7N- 0718
BU
2
1
BK ETHER SOL #2
9X- 7137 200- BK
382- PK
C
NEG
C
POS
BA
998- BR
36
HARNESS AS.
119- 8959
RD-00
BK- 00
BK-00
30
L6
31 38 32
ENGI NE
OI L
PRESSURE
SENSOR
FI LTD
194- 6725
ANALOG RET
SIGNAL
+V ANALOG
GN-18
YL-18
OR-18
993-BR
997-OR
994-GY
E795-YL
997-OR
993-BR
OR-18
WH-18
OR-18
+V ANALOG
SIGNAL
DIGITAL RET
CRANK
CASE
PRESSURE
SENSOR
161- 9926
FUEL
FI LTER
PRESSURE
SENSOR
UNFI LTD
194- 6725
26
AFTER
COOLER
TEMP
SENSOR
102- 2240
A751- YL
ANALOG RET
SIGNAL
+V ANALOG
GN-18
YL-18
OR-18
993-BR
997-OR
F737-YL
993- BR
997- OR
995- BU
E796- GN
F714- PK
F713- OR
A746- PK
994- GY
E795- YL
F737- YL
997-OR
993-BR
A751-YL
OR-18
BK-18
WH-18
+V ANALOG
SIGNAL
ANALOG RET
L7
L8 L8
F725-WH
997-OR
993-BR
OR-18
YL-18
GN-18
+V ANALOG
SIGNAL
ANALOG RET
FUEL
FI LTER
PRESSURE
SENSOR
FI LTD
194- 6725
F725- WH
L6
A747-GY
997-OR
993-BR
ATMOS
PRESSURE
SENSOR
161- 9926
ANALOG RET
SIGNAL
+V ANALOG
GN-18
YL-18
OR-18
A747- GY
OR-18
YL-18
GN-18
+V ANALOG
SIGNAL
ANALOG RET
ENGI NE
COOLANT
TEMP
SENSOR
102- 2240
ENGI NE
OI L
PRESSURE
SENSOR
UNFI LTD
194- 6725
RI GHT
TURBO
I NLET
PRESSURE
SENSOR
161- 9926
LEFT
TURBO
I NLET
PRESSURE
SENSOR
161- 9926
TURBO
OUTLET
PRESSURE
SENSOR
194- 6724
ANALOG RET
SIGNAL
+V ANALOG
GN-18
YL-18
OR-18
OR-18
YL-18
GN-18
+V ANALOG
SIGNAL
ANALOG RET
ANALOG RET
SIGNAL
+V ANALOG
YL
BK-18
YL
ANALOG RET
SIGNAL
+V ANALOG
GN-18
YL-18
OR-18
CBA CBA
995-BU
993-BR
997-OR
997-OR
993-BR
993-BR
997-OR
993-BR
997-OR
993-BR
997-OR
E796-GN
F714-OR
F713-PK
A746-PK
16D- KEY
PLUG AS.
101- 0205
37
SOLENOID 1 POWER
SOLENOID 2 POWER
SOLENOID 3 POWER
SOLENOID 4 POWER
CYLI NDER
HEAD
SOL 2
SOLENOID 5 POWER
SOLENOID 6 POWER
SOLENOID 7 POWER
SOLENOID 8 POWER
SOL 1&3 RETURN
SOL 2&4 RETURN
SOL 5&7 RETURN
SOL 6&8 RETURN
A701-GY
A702-PU
F729-GN
CYLI NDER
HEAD
SOL 4
CYLI NDER
HEAD
SOL 6
CYLI NDER
HEAD
SOL 8
CYLI NDER
HEAD
SOL 10
CYLI NDER
HEAD
SOL 12
CYLI NDER
HEAD
SOL 1
L1
CYLI NDER
HEAD
SOL 3
CYLI NDER
HEAD
SOL 5
CYLI NDER
HEAD
SOL 7
CYLI NDER
HEAD
SOL 9
F728-BR
CYLI NDER
HEAD
SOL 11
A710-GY
F731-OR
F731-OR
A712-BR
A711-PU
F730-GY
F730-GY
A709-OR
A707-PU
F728-BR
F728-BR
A705-YL
A703-BR
F726-YL
F726-YL
A701-GY
F727-GN
F726-YL
A708-BR
A707-PU
A705- YL
F728- BR
A707- PU
A709- OR
F730- GY
A711- PU
A712- BR
F731- OR
A710- GY
A708- BR
F729- GN
A706- GY
A704- GN
F727- GN
A702- PU
G770- WH
A716- PU
A706-GY
A705-YL
A704-GN
A703-BR
YL
A715- GY
G769- PU
A713- GN
FOR 3508B ONLY
L1
YL
G769-PU
A713-GN
CYLI NDER
HEAD
SOL 13
CYLI NDER
HEAD
SOL 15
A715-GY
G769-PU
A714-PK
G770-WH
CYLI NDER
HEAD
SOL 14
CYLI NDER
HEAD
SOL 16
G770-WH
A716-PU
122 1122 1
122 1
122 1
12
12
8C- 6354
COVER 8T- 8736
CONNECTOR
SERVI CE
A
B
C
D
E
F
G
YL
YL YLYLYL
YL YLYLYL
YL YLYLYL
YL YLYLYL
YL YLYLYL
YL YL
L7
893- GN
892- BR
WH-18
BK-18
OR-18
OR-18
BK-18
WH-18
XXX-XX
F703- GY
F704- OR
109- RD- 6
5N- 5692
THI S WI RI NG DI AGRAM ( 193- 3042- 01) , I S FOR THE
3500B ENGI NE, USED I N POWER MODULES
AI R SHUTOFF
SWI TCH ( RH)
227- 7483
AI R SHUTOFF
SWI TCH ( LH)
227- 7483
F715- PU- 18
F715-PU-18
F715-PU-18