3412E & C30 MARINE ENGINE Caterpillar

This document provides necessary information for the correct electrical/electronic installation and application of these engines.

Engine Functions

Electronic Governing

An electronic governor with a full speed range is used. The electronic governor is isochronous at Low Idle through High Idle or the programmed top engine limit.

Fuel to Air Ratio Control (FARC)

The electronic control system has full control of the fuel delivery to the engine. The mechanical Fuel Ratio Control is eliminated. Electronic control of the fuel to air ratio provides optimum performance while limiting emissions.

Fuel Injection Timing

Fuel injection timing varies as a function of engine operating conditions to optimize the engine performance. Engine performance is determined by the following conditions:

* Cylinder pressure

* Emissions

* Exhaust temperature

* Fuel consumption

Shaping of Torque Rise

Electronic controls provide increased flexibility to customize the torque curve over a wide range of engine speeds.

Engine Monitoring Feature

The engine monitoring mode determines the level of action that is taken by the Electronic Control Module (ECM) in response to a condition that can damage the engine. These conditions are identified by the ECM from the signals that are produced by the following sensors:

* Coolant level sensor

* Engine coolant temperature sensor

* Engine oil pressure sensor

* Inlet air temperature sensor

* Transmission pressure sensor

* Transmission temperature sensor

Engine Monitoring Mode

The engine monitoring mode can be programmed to the following settings:

* WARNING

* DERATE

WARNING is the factor default setting.

ECM Engine Monitoring Programmed to WARNING

When the engine monitoring is programmed to WARNING, the following parameters are monitored:

* Engine coolant level (if enabled)

* Engine coolant temperature

* Engine oil pressure

* Inlet air temperature

* Transmission oil pressure

* Transmission oil temperature

When WARNING is selected, the engine will not derate.

When an event code is active, the following lamps will be activated:

* The diagnostic lamp will flash the flash code.

* The alarm for the sensor will come on (if equipped).

* The warning lamp will turn on (warning) or flash (derate).

Table 1 provides the following information:

* The diagnostic event code (EID)

* The description of the event code

* The status of warning lamp when the diagnostic code is active

* The effect of derate

Table 1: Engine Monitoring Programmed to WARNING

ECM Engine Monitoring Programmed to DERATE

If the normal operating conditions are exceeded and the engine monitoring is programmed to DERATE, the ECM will alter the engine performance in steps. The process that reduces the performance of the engine is called "derate."

When the engine is derated, the ECM reduces the engine performance in steps until the excessive operating condition is returned to the normal range. The following parameters control the derate process:

* The coolant temperature is excessive.

* The oil pressure is too low.

When the engine monitoring is programmed to DERATE, the following parameters will derate the engine:

* Engine coolant level (if enabled)

* Engine coolant temperature

* Engine oil pressure

* Inlet air temperature

When the engine is derated, power is derated.

Table 2 provides the following information:

* the diagnostic event code (EID)

* the description of the event code

* the condition of the warning lamp when the diagnostic code is active

* the effect of derate on the engine

Table 2: Engine Monitoring Programmed to DERATE

Required Tools

Installation Tools

Basic electrical installation tools required are listed below. Additional sensors, lamps, connectors, etc, may be required.

Table 3: Basic Electrical Installation Tools

Caterpillar Electronic Technician (Cat ET) Electronic Service Tool

Cat ET can display the following information:

* Parameters

* Logged event codes

* Active diagnostic codes and logged diagnostic codes

* Engine configuration

* Current totals

* Job history

Cat ET can be used by the technician to perform the following functions:

* Diagnostic tests

* Calibrate the engine speed/timing sensors

* Flash programming

* Select and/or program parameters

* Data logging

* Customize the Programmable Monitoring System

* Customize the maintenance schedule

* Establish the security of parameters

Table 4: Required Tools for Cat ET

Connecting Cat ET and the Communication Adapter

Figure 1 - Connecting Cat ET

Use the following procedure to connect Cat ET and the Communication Adapter to the engine.

1. Turn off all switched power to the ECM. If the switched power is not shut off, the engine may start.

2. Connect the 160-0141 Adapter Cable between the communication adapter and the PC.

3. Connect the 207-6845 Adapter Cable between the communication adapter and the service tool connector.

4. Turn on the switched power to the ECM. The ECM must be powered in order for Cat ET to operate. Cat ET will operate while the engine is running or stopped.

Sensors and Electrical Connectors

Component Diagram

Figure 2 - 12 Cylinder Marine Engine Components

Sensor and Wiring Harness Connector Locations

Figure 3 - Sensor Locations and Wiring Harness Connectors on Top of the Engine

Component and Wiring Harness Connector Locations

Figure 4 - Component and Wiring Harness Connector Locations

Right and Left Hand Service Options

Figure 5 - Right and Left Hand Service Options

Switch Requirements and Considerations

Switch Specifications

All OEM provided switches connected to the electronic control system must be a two wire design and externally connected to the Negative Battery Bus Bar. Internally grounded or case grounded switches must not be used.

Voltages supplied to switches by the electronic control system will normally not exceed 24 VDC. Normal current through the switches will not exceed 5.0 milliampere.

Contact chatter and momentary opening or closing of the switches should not exceed 100 milliseconds in duration. The switches should not open or close due to vibration or shock normally found in the application.

Contact plating should not corrode or oxidize. Gold plated switch contacts are recommended.

When a switch contact is opened or the wiring harness has an open circuit, the internal pull up voltages of the ECM force the respective input to the positive battery. The closure of a switch that is installed by the OEM must short circuit the switch input to the Negative Battery Bus Bar connection of the ECM connector P1.

All switches are supplied by the OEM. If a problem occurs that has an undertermined cause, install an Electronic Service Tool. Observe the display status screen of the Electronic Service Tool to determine the status of the switch.

Voltage Thresholds Measured At The ECM

When any of the switch contacts are closed, the voltage drop through the switch circuit must be less than 0.9 VDC. This measurement should be taken at the respective control input and the negative battery input to the ECM. This measurement includes the following values:

* Ground potential differences

* Voltage drop across the switch

* Voltage drop across the wiring harness

When any of the switch contacts are open, the resistance between the respective control input and the negative battery input to the ECM should not be less than 5,000 Ohms. Potential paths for leakage may exist within the following components:

* Connectors

* Harnesses

* Switches

NOTE: Switches that are installed by the OEM must be connected to the negative battery bus bar.

Customer Installed Switches

Table 5: Customer Installed Switches

NOTE: These switches require 5P-4571 Terminals (Blade) for installation.

Table 6: Customer Connector Pin Connections for Switches

Figure 6 - 3E-8766 and 3E-8768 Switches

(R) ON (top or left)

(S) NONE (center)

(T) OFF (bottom or right)

(1) Actuator orientation tabs

Figure 7 - Schematic of 3E-8766 and 3E-8768 Switches

When the switch contacts 2 and 3 are closed, the backlight connected to switch terminals A and B turns on.

Figure 8 - 3E-8772 Switch

(R) ON (top or left)

(S) OFF (center)

(T) ON (bottom or right)

(1) Actuator orientation tabs

Figure 9 - Schematic of 3E-8772 Switch

When the contacts 1 and 2 of the switch are closed, the backlight connected to switch terminals A and B turns on.

When the contacts 5 and 6 of the switch are closed, the backlight connected to switch terminals C and D turns on.

Wire Size Requirements

The size of the wire that is used to connect all electrical components must be adequate size for the maximum current in the circuit. All positive battery connections and all negative battery connections to the Customer Connector for the ECM should use 14 AWG wire.

The circuit from the Negative Battery Bus Bar to the bridge displays should be made with a minimum of 12 AWG wire. The circuit from the Negative Battery Bus Bar to the bridge displays must be a dedicated circuit that has no other connected components.

The CAT Data Link and the ATA Data Link should be wired with 143-5018 Cable (Twisted Pair). The J1939 (CAN) data link should be wired with 153-2707 Cable (Shielded Twisted Pair). All other electronic system circuits should use 16 AWG wire.

OEM Wiring Harness

Figure 10 - Correct Wiring Harness Routing at the Connector

(A) 25mm (1 inch) perpendicular length of wire

(1) No gap between wire and seal

The routing of the OEM wiring harness should be designed so that the curvature of the wire from the connector meets the standards that are shown in Figure 10 - "Correct Wiring Harness Routing at the Connector".

Special attention should be given to the routing of wiring that is near the following components:

* Valve corner

* Wiring harness connector

* Components mounted on the engine

* Customer Connector

* Display connectors

Figure 11 - Incorrect Wiring Harness Routing at the Connector

(2) Gap between the wire and the seal

Figure 11 - "Incorrect Wiring Harness Routing at the Connector" shows the incorrect routing of the wiring harness. When the curvature of the wire is too close to the connector, the seal is stretched away from the wire within the connector. This stretching of the seal provides an opening of the entry of moisture.

The wire should exit from the connector perpendicular to the connector. The perpendicular length of the wire should be 25 mm (1 inch) before any curvature exists in the wire.

The radius of a bend in the bundle of wires of the wiring harness should be greater than twice the diameter of the bundle of wires.

Twisted pair wiring should be used for the ATA Data Link and the CAT Data Link. Twisted pair wiring should have a minimum of one twist per 25 mm (1 inch) of the wiring harness. The twisted pair wires should not be twisted closer than 25 mm (1 inch) from the connector to avoid stress on the seal.

The acceptable diameter of the insulation for a wire that is connected to the 40 pin customer Connector is 2.54 to 3.43 mm (0.100 to 0.135 inch). The acceptable diameter of the insulation for a wire that is connected to an HD-10 connector is 2.54 to 3.81 mm (0.100 to 0.150 inch). The acceptable diameter of the insulation for a wire that is connected to a DT connector is 2.40 to 3.68 mm (0.095 to 0.145 inch).

Caterpillar recommends that all ring terminals and splices to be sealed using Raychem ES2000 adhesive lined heat shrink tubing or equivalent.

Table 7 - Heat Shrink Tubing

Installation of Pins, Sockets, and Connector Sealing Plugs

Figure 12 - Insertion of Plug in Unused Slot

The following procedures should be performed to ensure the correct installation of pins and sockets in connectors:

* Do not solder the sockets and pins to the wires.

* All sockets and pins should be crimped on the wires. Use the 1U-5804 Crimping Tool for 12-18 gauge wire.

* All unused slots for sockets and pins must be filled with sealing plugs to ensure that the connector is sealed.

* The sealing plugs are installed from the wire entry end of the plug or receptacle.

* The sealing plugs that are installed in unused slots must seal correctly. Refer to Figure 12 - "Insertion of Plug in Unused Slot" for correct installation of plugs. The plug rests against the seal. The plug does not insert into the seal.

Caterpillar Wiring Harness

Do not modify the Caterpillar wiring harness.

Integral 40 pin Deutsch connectors on the ECM and the Customer Connector are used to interface the engine electronics with the wiring harness provided by the customer.

The 40 pin Deutsch connectors are J1/P1 and J2/P2. The Customer Connector is J3/P3.

The electronic control system is designed to operate with a 24 VDC electrical system. The control system is protected against jump start conditions and short circuits to the battery.

The 40 pin Deutsch connectors and the Customer Connector must have sealing plugs inserted in all of the unused sockets to ensure proper sealing.

ECM and Customer Connectors

Ensure that the Allen head bolt in the ECM Connectors J1 and J2 and the Customer Connector P3 are tightened to a maximum torque of 2.25 Nm (20 lb in). ECM Connectors J1 and J2 are located on the ECM. The Allen bolts for J1 and J2 are on the ECM and are not shown on Figure 13 - "Wiring Harness and Connectors for ECM and Customer Connector".

The Customer Connector P3 is shipped with the engine. Perform the pull test on each wire and the respective pin or socket from the wire entry end of each connector. The force for the pull test is 45 N (10 lb).

When the pull test is performed, the wire and the socket or pin should remain in the connector. The pull test ensures that the wire was correctly crimped in the socket or pin. Also, the pull test ensures the socket or pin was correctly inserted through the wire entry end of the connector.

Figure 13 - Wiring Harness and Connectors for ECM and Customer Connector

HD-10 Connector

Figure 14 - HD-10 Plugs and Receptacles

Ensure that the wires in the plug align with the matching wires in the receptacle. Ensure that the index markings on the plug and the receptacle are aligned.

Rotate the plug until the plug slips into the receptacle. Rotate the coupling approximately 90 degrees until a click sound is heard. Ensure that the plug and the receptacle cannot be pulled apart.

The acceptable range for the diameter of the insulation of the wire that is used with the connectors is 2.54 to 3.81 mm (0.100 to 0.150 inch).

DT Connector

Figure 15 - Deutsch DT Connector

A DT connector has a wedge that locks the pins and sockets in place. The wedge can be removed and replaced without cutting the wires. When the two halves properly lock together, a click sound should be heard when the receptacle is inserted in the plug. The two mating halves can not be pulled apart.

The acceptable range for the diameter of the insulation on the wire that is used with the DT connectors is 2.24 to 3.68 mm (0.088 to 0.145 in).

Inspect the plug and the receptacle to ensure that the following components are correctly installed:

* The connector seals are seated.

* The pins and sockets are not damaged.

* The pins and the sockets are securely installed on the wires. Perform the Pull Test.

* The correct number of pins and sockets exist on both halves of the connector.

* The pins align correctly with the sockets.

* The locking tabs are not damaged. Replace the connector if the tab is damaged.

* The wedges are not damaged. The 147-6456 DT wedge removal tool aids in the removal of the wedges.