INTERACTIVE SCHEMATIC

Bookmarks X
*This document is best viewed at a
Options
screen resolution of 1024 X 768.
Features
Cover Page
To set your screen resolution do the following:
Tables RIGHT CLICK on the DESKTOP.
Component Select PROPERTIES.
Connector
CLICK the SETTINGS TAB.
Schematic
Machine Views
MOVE THE SLIDER under SCREEN RESOLUTION
Chassis View until it shows 1024 X 768.
Cab View CLICK OK to apply the resolution.
Engine View
*Due to different monitor sizes and PDF reader preferences
The Bookmarks panel will allow you to there may be some variance in linked schematic locations
quickly navigate to points of interest.

Click here to save a copy of

EC-C2 E-C60 this interactive schematic
EC-C3
to your desktop
E-C61

VIEW ALL CALLOUTS

EC-C1
Click on any text that is BLUE and
underlined. These are hyperlinks
that can be used to navigate the
schematic and machine views.
When only one callout is showing on a
machine view, clicking on this button will
make all of the callouts visible. This
button is located in the top right corner
of every machine view page.

ELECTRICAL SYMBOLS BASIC HYDRAULIC

HOTKEYS (Keyboard Shortcuts) COMPONENT SYMBOLS
T

Pressure Temperature Level Flow

Pump

FUNCTION KEYS
Switch Switch Switch Switch Circuit Breaker
or Motor Variability

Click here to view the

Zoom In “CTRL” / “+” Schematic Symbols
Fluid
Conditioner
Spring
(Adjustable)

Zoom Out “CTRL” / “-” and Definitions page

Fit to Page “CTRL” / “0” (zero)

Hand Tool “SPACEBAR” (hold down)
Find “CTRL” / “F”
Search “CTRL” / “SHIFT” / “F”
 RENR9964-03
September 2016

C4.4 Industrial Engine and

C4.4 Engine for Genset
Electrical System
Industrial: Genset:
4441-UP D4B1-UP

© 2016 Caterpillar CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade dress as well as
All Rights Reserved corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
SCHEMATIC SYMBOLS AND DEFINITIONS

VALVES INTERNAL PASSAGEWAYS PUMPS BASIC HYDRAULIC

ENVELOPES FLOW IN ONE
DIRECTION
FLOW ALLOWED IN
EITHER DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FIXED DISPLACEMENT
COMPONENT SYMBOLS

One Position Two Position Three Position Unidirectional Bidirectional Pump

Infinite Two Three Variability
Positioning Position Position or Motor
PORTS VARIABLE DISPLACEMENT
NON- COMPENSATED

CYLINDERS Fluid Spring

(Adjustable)
Two-way Three-Way Four-Way Conditioner
Unidirectional Bidirectional
CONTROL
AB AB
Single Acting Double Acting
MOTORS Pressure
FIXED DISPLACEMENT Spring
P T P T Compensation
Normal Position Shifted Position Infinite Position

CHECK
Control
ACCUMULATORS Unidirectional Bidirectional
Valves
Line Restriction
(Variable)
VARIABLE DISPLACEMENT
Basic Spring Shuttle NON- COMPENSATED
Pilot
Symbol Loaded Line Restriction
Controlled Spring Loaded Gas Charged Restriction
(Fixed)

Unidirectional Bidirectional

MAIN AUX.
Line Restriction
PILOT CONTROL 2-Section
RELEASED PRESSURE ROTATING SHAFTS Variable and Pressure
Compensated
Pump

Unidirectional Bidirectional
External Return Internal Return
Attachment Pump: Variable and
REMOTE SUPPLY PRESSURE Pressure Compensated

Internal Hydraulic Pneumatic

Simplified Complete Supply Pressure Energy Triangles

COMBINATION CONTROLS
LINES MEASUREMENT

Solenoid Solenoid Solenoid Solenoid and Servo Thermal Detent Crossing Joining
or Manual and Pilot Pilot or Manual Pressure Temperature Flow

MANUAL CONTROL FLUID STORAGE RESERVOIRS

Push-pull Lever Manual Shutoff General Manual Push Button Pedal Spring Vented Pressurized Return Above Fluid Level Return Below Fluid Level

HYDRAULIC SYMBOLS - ELECTRICAL ELECTRICAL SYMBOLS

G
M T

Pressure Temperature Level Flow

Transducer Transducer Generator Electric Pressure Pressure Switch Temperature Electrical
Switch Switch Switch Switch Circuit Breaker
(Fluid) (Gas / Air) Motor Switch (Adjustable) Switch Wire

BASIC ELECTRICAL COMPONENT SYMBOLS HARNESS AND WIRE SYMBOLS

Wire, Cable, or Harness Assembly Identification:
Fuse: A component in an electrical circuit that will open the circuit if too much current flows through it. Includes Harness Identification Letters and Harness
Connector Serialization Codes (see sample).
Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The circle indicates
that the component has screw terminals and a wire can be disconnected from it.
AG-C4 L-C12
Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.). 111-7898 3E-5179
No circle indicates that the wire cannot be disconnected from the component. Part Number: for 1
Connector Plug
Ground (Wired): This indicates that the component is connected to a grounded wire. 2
The grounded wire is fastened to the machine.
Plug Receptacle
Pin or Socket Number
Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine. Harness Identification Letter(s): (A, B, C, AA, AB, AC, ...)

Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the contacts of Harness Connector Serialization Code: The "C" stands for
"Connector" and the number indicates which connector in the
a normally open reed switch; it opens the contacts of a normally closed reed switch.
harness (C1, C2, C3, ...)
L-C12
Sender: A component that is used with a temperature or pressure gauge. 3E-5179
The sender measures the temperature or pressure.
T Its resistance changes to give an indication to the gauge of the temperature or pressure. 5A
Component
Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity. Fuse (5 Amps) 9X-1123 Part Number
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. 325-AG135 PK-14
Harness identification code:
This example indicates wire group 325, Wire Gauge
Solenoid: A solenoid is an electrical component that is activated by electricity. wire 135 in harness "AG". Wire Color
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. 1 Deutsch connector: Typical representation
of a Deutsch connector. The plug contains all
2 sockets and the receptacle contains all pins.
Magnetic Latch Solenoid: An electrical component that is activated by electricity and held latched by a
permanent magnet. It has two coils (latch and unlatch) that make electromagnet 1 Sure-Seal connector: Typical representation
when current flows through them. It also has an internal switch that places of a Sure-Seal connector. The plug and receptacle
2 contain both pins and sockets.
the latch coil circuit open at the time the coil latches.
CID / MID / FMI

Component Identifiers (CID¹) Failure Mode Identifiers (FMI)¹

FMI No. Failure Description
0 Data valid but above normal operational range (most severe).
Engine Control Module 1 Data valid but below normal operational range (most severe).
CID Component 2 Data Erratic, intermittent, or incorrect.
0001 Cylinder #1 Injector 3 Voltage above normal or shorted high.
0002 Cylinder #2 Injector 4 Voltage below normal or shorted low.
0003 Cylinder #3 Injector 5 Current below normal or open circuit.
0004 Cylinder #4 Injector 6 Current above normal or grounded circuit.
0041 ECM (Engine Control Module) 8 Volt DC Supply 7 Mechanical system not responding properly.
0091 Throttle Position Sensor 8 Abnormal frequency, pulse width, or period.
0100 Engine Oil Pressure Sensor 9 Abnormal update rate.
0110 Engine Coolant Temperature Sensor 10 Abnormal rate of change.
0168 Electrical System Voltage 11 Failure mode not identifiable.
0172 Intake Manifold Air Temperature Sensor 12 Bad device or component.
0190 Engine speed Sensor 13 Out of calibration.
0247 SAE J.1939 Data Link 14 Special instruction.
0253 Personality Module 15 Data valid but above normal operational range (least severity).
0261 Engine Timing 16 Data valid but above normal operational range (moderate severity).
0262 5 Volt Sensor DC Power Supply 17 Data valid but below normal operational range (least severity).
0268 Programmed Parameter Fault 18 Data valid but below normal operational range (moderate severity).
0342 Secondary Engine Speed Sensor
0526 Turbo Wastegate Drive ¹The FMI is a diagnostic code that indicates
0774 Secondary Throttle Position Sensor what type of failure has occurred.
1639 Machine Security System Module
1743 Engine Operation Mode Selection Switch
1779 Fuel Rail #1Pressure Valve Solenoid
1785 Intake Manifold Pressure Sensor
1797 Fuel Rail Pressure Sensor
1834 Ignition Key Switch
2246 Glow Plug Start Aid Relay

¹ The CID is a diagnostic code that indicates

which circuit is faulty.

Event Codes
Machine Control
Event Code Condition
E172 High Air Filter Restriction
E194 High Exhaust Temperature
E232 High Fuel / Water Separator Water Level
E360 Low Engine Oil Pressure
E361 High Engine Coolant Temperature
E362 Engine Overspeed
E396 High Fuel Rail Pressure
E398 Low Fuel Rail Pressure
E539 High Intake Manifold Air Temperature
E2143 Low Engine Coolant Temperature
RELATED ELECTRICAL SERVICE MANUALS

Related Electrical Service Manuals

Title Form Number
Troubleshooting: C4.4 and C6.6 Industrial Engines SENR9969
 7 6 5 4 3 2 1
ELECTRONIC CONTROL MODULE (ECM) HARNESS SIDE P2 ECM
P511 J511 ECM SIDE P2
1 25 25 1
65 C211-E44 BK-18 1 WASTEGATE J1
Y951-E26 PU-18 M795-E17 WH-18 2 REGULATOR
INJECTOR 3 HIGH SIDE DRIVE 64 X922-E64 WH-18
Y950-E25 YL-18
INJECTOR 2 HIGH SIDE DRIVE 63 X921-E63 PK-18
62 P532
M795-E17 WH-18
61 Y950-E25 YL-18 1 FUEL RAIL PUMP J2
60 C211-E44 BK-18 SOLENOID
Y951-E26 PU-18 2 8 32 32 8
59
INJECTOR 4 HIGH SIDE DRIVE 58 X923-E58 OR-18
INJECTOR 1 HIGH SIDE DRIVE 57 X920-E57 PK-18
OIL PRESSURE SIGNAL 56
F INTAKE MANIFOLD PRESSURE SIGNAL 55
994-E56 GY-18
X731-E55 BU-18 F
54 1 25
SECONDARY SPEED/TIMING SIGNAL 53 P920-E53 BR-18 P201 33 57 57 33
PRIMARY SPEED/TIMING SIGNAL 52 E965-E52 BU-18 L730-E47 OR-18 1 8 32
FUEL RAIL PRESSURE SIGNAL 51 Y946-E51 BU-18 T993-E38 BR-18 Y947-E39 BU-18 2
OIL PRESSURE
50 SENSOR
X731-E55 BU-18 994-E56 GY-18 3
57
49 33
P228
FUEL RAIL PRESSURE POWER SUPPLY 48 R997 E48 OR-18 R997 E48 OR-18
R997-E48 OR-18 1 64
OIL PRESSURE POWER SUPPLY 47 L730-E47 OR-18 FUEL RAIL 40 64 40
Y946-E51 BU-18 Y948-E40 BR-18 2
64
INTAKE MANIFOLD AIR PRESS PWR SUPPLY 46 T997-E46 OR-18 PRESSURE SENSOR 40
45 229-BK Y946-E51 BU-18 3
DIAGNOSTIC CONNECTOR B 994-E56 GY-18
44 P200
COOLANT TEMPERATURE SIGNAL 43 995-E43 BU-18 Y948-E40 BR-18 T997-E46 OR-18 1
T993-E38 BR-18 2
INTAKE MANIFOLD
INTAKE MANIFOLD AIR TEMPERATURE SIGNAL 42 C967-E42 BU-18 Y947-E39 BR-18
X731-E55 BU-18 PRESSURE SENSOR
41 3
FUEL RAIL PRESSURE GROUND 40 Y948-E40 BR-18 L730-E47 OR-18
OIL PRESSURE GROUND 39 Y947-E39 BR-18 T997-E46 OR-18
INTAKE MANIFOLD AIR PRESSURE GROUND 38 T993-E38 BR-18
COMMON SENSOR GROUND 37 L731-E37 BR-18
36 L731-E66 BR-18
INJECTOR 1 DRIVE RETURN 35 X926-E35 GY-18 P103 J1 PIN LOCATION INDUSTRIAL ENGINE
L731-E37 BR-18
INJECTOR 4 DRIVE RETURN 34 X929-E34 BU-18
33 C967-E42 BU-18 1 INTAKE MANIFOLD PIN PIN
L731-E68 BR-18 NUMBER DESCRIPTION FUNCTION DESCRIPTION FUNCTION
L731-E68 BR-18 2 TEMPERATURE SENSOR NUMBER
32 995-E43 BU-18
31 1 BATTERY (-) BATTERY –VE 33 VS RET SENSOR 0V RETURN
30 995-E43 BU-18 1 COOLANT TEMPERATURE
C967-E42 BU-18 2 BATTERY (-) BATTERY –VE 34 VS RET SENSOR 0V RETURN
L731-E66 BR-18 2 SENSOR
29 3 BATTERY (-) BATTERY –VE 35 SWG RET SWITCH RETURN
28 P100
E 27
995-E43 BU-18
L731-E37 BR-18
TWISTED PAIR
4
5
N/A
N/A
N/A 36
37
SWB 2
SWB 1
MAINTENANCE RESET
N/A
E
FUEL PUMP SOLENOID RETURN 26 Y951-E26 PU-18 N/A
FUEL PUMP SOLENOID SIGNAL 25 Y950-E25 YL-18 C967-E42 BU-18 6 N/A N/A 38 SWG 11 AIR FILTER RESTRICTION SWITCH
DIAGNOSTIC CONNECTOR G 24 Y792-PK P920-E53 BR-18 7 BATTERY (+) BATTERY +VE 39 SWG 10 MODE SWITCH 1
DIAGNOSTIC CONNECTOR F 23 Y793-YL 996-E10 GN-18 BATTERY (+) BATTERY +VE 40 SWK 0
8 IGNITION SWITCH INPUT
22 E965-E52 BU-18 BATTERY (-) 41 VS 5 200MA
P402 9 BATTERY -VE SENSOR 5V SUPPLY
DIAGNOSTIC CONNECTOR D 21 944-OR
10 BATTERY (-) BATTERY -VE 42 VS 5 200MA SENSOR 5V SUPPLY
DIAGNOSTIC CONNECTOR E 20 945-BR P920-E53 BR-18 996-E70 BU-18 1 SECONDARY
19 P920-E53 BR-18 2 11 DF PWM 2 SHIELD N/A 43 VS 8 100MA PWM THROTTLE SENSOR 8V SUPPLY
WASTEGATE GROUND M795-E17 WH-18 X920-E57 BR-18 SPEED/TIMING SENSOR
18 101-RD E965-E52 BU-18 12 DF PWM 2- N/A 44 SWG 9 THROTTLE 2 IVS
DIAGNOSTIC CONNECTOR A
WASTEGATE PWM SIGNAL 17 C211-E44 BK-18 X926-E35 GY-18 996-E70 BU-18 996-E69 BU-18 1 PRIMARY 13 DF PWM 2+ N/A 45 SWG 8 THROTTLE 1 IVS
E965-E52 GN-18 2 SPEED/TIMING SENSOR
16 996-E10 GN-18 14 N/A N/A 46 SWG 7 MODE SWITCH 2
X921-E63 PK-18
15
996-E69 BU-18 P401 THROTTLE SELECT SWITCH OR
14 15 BATTERY (+) BATTERY +VE 47 SWG 6
X927-E7 YL-18 COOLANT LEVEL SWITCH
13
16 BATTERY (+) BATTERY +VE 48 SWG 5 REMOTE SHUTDOWN SWITCH (NO)
12
11 17 N/A N/A 49 SWG 4 PTO MODE DISENGAGE (NC)
T301
SPEED SENSOR SUPPLY 10 996-E10 GN-18 18 N/A N/A 50 SWG 3 PTO MODE RAISE/RESUME
P691 J691
9 INJECTOR 1 19 N/A 51 SWG 2 PTO MODE SET/LOWER
X920-E57 BR-18 4 T951-H1 BK-16 N/A
INJECTOR 3 DRIVE RETURN 8 X928-E8 GN-18 20 CAN (+) 52 SWG 1 PTO MODE ON/OFF
X922-E64 WH-18 X926-E35 GY-18 3 T957-H2 BK-16 J1939 CAN DL +
INJECTOR 2 DRIVE RETURN 7 X927-E7 YL-18 CAN (-)
21 J1939 CAN DL - 53 AIN ACT/PWM I 1 PWM THROTTLE INPUT
6 X928-E8 GN-18 X921-E63 PK-18 2 T952-H3 BK-16
T302 22 CAN A SHIELD CAN SHIELD 54 AIN ACT 7 THROTTLE 1 ANALOGUE INPUT
5 X927-E7 YL-18 1 T958-H4 BK-16
X923-E58 OR-18 CDL (+) 55 THROTTLE 2 ANALOGUE INPUT
4 23 CDL (+) AIN ACT 5
INJECTOR 2 56
3 X929-E34 BL-18 24 CDL (-) CDL (-) AIN ACT 4 N/A
2 57
D D
25 DOUT PWM RET PWM RETURN DOUT 1A 1 START AID CONTROL
1 26 DOUT PWM RET PWM RETURN 58 MAINTENANCE DUE LAMP
DOUT 0.3A 10
27 N/A N/A 59 DOUT 0.3A 9 WARNING LAMP
101-RD
28 N/A N/A 60 DOUT 0.3A 8 SHUTDOWN LAMP
229-BK
29 N/A N/A 61 DOUT 0.3A 4 PTO MODE LAMP
944-OR T303
30 N/A N/A 62 DOUT 0.3A 3 LOW OIL PRESSURE LAMP
945-BR P692 J692
INJECTOR 3 PWM 2A RETURN 1 N/A
4 T953-G1 BK-16 31 63 DOUT 0.3A 2 COLD START LAMP
Y793-YL X922-E64 WH-18
3 T959-G2 BK-16 32 PWM 2A DRIVER 1 N/A 64 DOUT 0.3A 1 N/A
Y792-PK X928-E8 GN-18
X923-E58 OR-18 2 T954-G3 BK-16
BATTERY X929-E34 BU-18 1 T960-G4 BK-16 T304

-
STARTING AND CHARGING INJECTOR 4
245-1043

J23

+
101-RD A
229-BK B
RELAY FUSE C
944-OR D
945-BR E DIAGNOSTIC CONNECTOR
30
50 Y793-YL F 113-4630 230-4013 230-4011

G
C G
Y792-PK
C
H
RED
J
RESISTORS 3 2 1

STARTING MOTOR OPTIONAL

300 OHMS (24V)
155-2271 238-8247 P532

100 OHMS (12V)

B+ KEYSWITCH T301 T302 T303 T304
ALTERNATOR D+
W IGNITION WARNING
LIGHT
237-0227 238-8245
SYSTEM OVERVIEW
J691
J692
P691 P692
GRAY
P691 3 2 1

P692
J691 J692
P511

T301 T302 T303 T304

P103
B P100 B
PART NUMBER PLUG OR JACK CONNECTOR
J511
P532
P228 230-4011 P103 INTAKE MANIFOLD TEMPERATURE CONNECTOR
SYMBOL DESCRIPTION 230-4011 P100 COOLANT TEMPERATURE CONNECTOR
ABBREV COLOR
P402
P200 RD RED
230-4013 P201 OIL PRESSURE CONNECTOR
CIRCUIT CONNECTED 237-0227 P200 INTAKE MANIFOLD PRESSURE CONNECTOR
WH WHITE 230-4013 P228 FUEL RAIL PRESSURE CONNECTOR
CIRCUIT NOT CONNECTED
PART OF WIRING HARNESS P532 SOLENOID CONNECTOR FOR FUEL RAIL PUMP
NO1 NO2 NO3 NO4 OR ORANGE
ELECTRICAL CONNECTION TO
238-8247 P401 PRIMARY SPEED/TIMING CONNECTOR
MACHINE STRUCTURE
YL YELLOW
INTERNAL ELECTRICAL CONNECTION 238-8247 P402 SECONDARY SPEED/TIMING CONNECTOR
TO SURFACE OF COMPONENT PK PINK 113-4630 J691 INTERNAL CONNECTOR FOR THE INJECTORS 1 AND 2
P401 CONNECTOR BK BLACK 113-4630 J692 INTERNAL CONNECTOR FOR THE INJECTORS 3 AND 4
155-2271 P691 EXTERNAL CONNECTOR FOR THE INJECTORS 1 AND 2
H# GY GRAY

J23 P511 CIRCUIT GROUPING DESIGNATION

PU PURPLE
155-2271
238-8245
P692
P511
EXTERNAL CONNECTOR FOR THE INJECTORS 3 AND 4
CONNECTION TO WASTEGATE
J1 ATCH WIRE, CABLE, COMPONENT
BR BROWN 8T-8736 J23 DIAGNOSTIC CONNECTOR

P200
P2 SPLICE
GN GREEN NOTE: 1 THE OIL PRESSURE SENSOR CAN BE
BLADE, SPADE, RING OR SCREW
BU BLUE
INSTALL IN ONE OF TWO DIFFERENT POSITION.
TERMINAL

J2
P228

P2 Do not operate or work on this product unless you have

(+) BATTERY
read and understood the instruction and warnings in the
P201 relevant Operation and Maintenance Manuals and
(+) BATTERY SWITCHED
A STARTING CIRCUIT
relevant service literature. Failure to follow the instruc-
tions or heed the warnings could result in injury or
A
(-) BATTERY / SENSOR RETURN
death. Proper care is your responsibility.
P103
P402
SENSOR / ACTUATOR SUPPLY

P532 SIGNAL TO ECM THIS SCHEMATIC IS FOR THE C4.4 INDUSTRIAL ENGINE AND
CONTROL (POSITIVE) FROM ECM
P100 CONTROL (RETURN) FROM ECM C4.4 ENGINE FOR GENSET ELECTRICAL SYSTEM
CAT DATA LINK
MEDIA NUMBER: RENR9964-03
J1939 DATA LINK
Components are shown installed on a fully operable engine in a non powered state.
HIGHWAYS
P401 Refer to the appropriate service manual for troubleshooting, specifications and systems operations.
P201
Refer to the parts manual using a specific serial number prefix in sis before ordering parts from this schematic.

7 6 5 4 3 2 1
LEFT SIDE VIEW
T303
T304 FUEL RAIL PUMP VIEW ALL CALLOUTS

T302 SOLENOID P532

J692
T301
P692
SECONDARY
J691 SPEED/TIMING
SENSOR P402

P691 PRIMARY SPEED/TIMING

P103 SENSOR P401

P100 P228

P200 P511

P532 P2 FUEL RAIL PRESSURE

INTAKE MANIFOLD
PRESSURE SENSOR P228
COOLANT SENSOR P200
P402 TEMPERATURE
SENSOR P100 OIL PRESSURE
SENSOR P201
P201 P401 (SEE NOTE 1)