- Engine:
- 3508B (S/N: 5PS)
- 3512B (S/N: 3ZW)
- 3516B (S/N: 6HZ)
- 3512B (S/N: 3ZW)
Introduction
The 151-9216 Harness is used to connect the remote mounted junction box to the engine harness. The 155-2579 Wiring Harness is used to connect the instrument panel to the junction box. Assemble both of the harnesses at the site since the harness length will differ for each installation. The methods of routing the harnesses will also differ for each installation. This Special Instruction describes the correct procedure for assembling the wiring harnesses. Do not perform any procedure in this Special Instruction until you have read this information and you have understood this information.
Wire Recommendation
- Insulation: EXANE
- Voltage Rating: 2000 Volts (or as per local requirements)
- Operating Temperature Range: - 65 °C (- 85 °F) to 125 °C (257 °F)
| Insulation Diameter | ||
|---|---|---|
| AWG | Maximum | Minimum |
| 8 to 10 | 6.22 mm (0.25 inch) |
3.85 mm (0.15 inch) |
| 12 to 14 | 4.57 mm (0.18 inch) |
2.72 mm (0.11 inch) |
| 16 to 18 | 3.43 mm (0.14 inch) |
1.99 mm (0.08 inch) |
| Necessary Parts | ||
|---|---|---|
| 4C-3406 | Connector Repair Kit | 01 |
| 16 Gauge Wire | ||
| 14 Gauge Wire | ||
| 12 Gauge Wire | ||
| 10 Gauge Wire | ||
Assembly Procedure
Refer to table 3 through table 7 for the correct gauge of wire for each circuit. With the proper gauge of wire, determine the appropriate length and cut the wire.
Note: The following CAN (control area network) DATA LINK circuit requires a shielded cable:
- (Reference Delta Suprenant DAC 02A AHD) 151-9216 Harness - Connectors B and D, Pins 6, 15, and 23
Use 10 gauge wire for the positive connection and the negative connection to the Isolated Power at the customer connector. Use 12 gauge wire for the positive connection and the negative connection of the Isolated Power in the following components: 151-9216 Harness and the 155-2579 Wiring Harness .
The following circuits must be twisted together:
- 1 Twist per 25 mm (1 inch) ( 143-5018 Electrical Cable )
- 151-9216 Harness - Connectors C and D, Pins 2 and 3, and Pins 5 and 6
- 155-2579 Wiring Harness - Connectors A and B, Pins 5 and 6
Note: Replace the twisted pairs that are listed above with a shielded cable of low capacitance, if a data link boosting device such as the Customer Communication Module (CCM) is used. Caterpillar recommends the use of 123-2376 Electrical Cable .
This task will help to avoid electronic noise and this task will also reduce the signal distortion.
Contact Crimping And Insertion
Follow the instructions in the 4C-3406 Connector Repair Kit for crimping and for the procedures for insertion.
Note: If a contact is inserted into the wrong receptacle, follow the instructions in the 4C-3406 Connector Repair Kit for removal of the contact. A removal tool for 14 gauge wire may work well in order to remove the 16 gauge wires (2000 Volt) from the CE connectors.
| 151-9216 Harness (Connector A) | ||||||
|---|---|---|---|---|---|---|
| Engine Connection A | Gauge | Function | Circuit Identification | Twisted Pair | Shielded Cable | Junction Box Connection A |
| 2 | 16 | Secondary CAT Data Link (-) | J982 | A (1) | 2 | |
| 3 | 16 | Secondary CAT Data Link (+) | J981 | A (1) | 3 | |
| 5 | 16 | CAT Data Link (-) | 892 | A (1) | 5 | |
| 6 | 16 | CAT Data Link (+) | 893 | A (1) | 6 | |
| 4 | 16 | Shut Down Notify | E798 | 4 | ||
| 7 | 12 | (+) Battery | 150 | 7 | ||
| 9 | 12 | (+) Battery | 150 | 9 | ||
| 10 | 16 | Crank Relay Power | F701 | 10 | ||
| 11 | 12 | (-) Battery | 229 | 11 | ||
| 12 | 16 | General Alarm Relay | F700 | 12 | ||
| 13 | 12 | (-) Battery | 229 | 13 | ||
| 14 | 16 | Rated Speed Signal | F702 | 14 | ||
| 15 | 16 | Load Feed Back | J782 | 15 | ||
| 21 | 16 | Engine Shutdown D | F719 | 21 | ||
| 23 | 16 | Engine Shutdown C | F715 | 23 | ||
| 25 | 16 | Digital Return | 998 | 25 | ||
| ( 1 ) | A = Circuits must be twisted together: One twist per 25 mm (1 inch): Circuits J982 and J981. One twist per 25 mm (1 inch): Circuits 892 and 893 |
| 151-9216 Harness (Connector B) | ||||||
|---|---|---|---|---|---|---|
| Engine Connection B | Gauge | Function | Circuit Identification | Twisted Pair | Shielded Cable | Junction Box Connection B |
| 2 | 16 | Start/Run/Stop 1 | F716 | 2 | ||
| 3 | 16 | Start/Run/Stop 2 | F717 | 3 | ||
| 5 | 16 | Overspeed Verify | F706 | 5 | ||
| 8 | 16 | Torque Limit | G746 | 8 | ||
| 13 | 16 | ECM On/Off | 113 | 13 | ||
| 14 | 16 | ECS in Auto | G721 | 14 | ||
| 31 | 16 | Ether Switch | F720 | 31 | ||
| 32 | 16 | Ether Relay | F710 | 32 | ||
| 35 | 16 | Prelube Pump Drive Return | A268 | 35 | ||
| 36 | 16 | Prelube Pump Drive | F705 | 36 | ||
| 37 | 16 | Prelube Pressure Switch | F718 | 37 | ||
| 6 | 18 | Magnetic Pickup 1 | SPD1 | B1 (1) | 6 | |
| 15 | 18 | Magnetic Pickup 2 | SPD2 | B1 (1) | 15 | |
| 23 | 18 | Magnetic Pickup Shield | SPDS | B1 (1) | 23 | |
| 16 | 16 | CAN Data Link (+) | F711 | B2 (2) | 16 | |
| 17 | 16 | CAN Data Link (-) | F712 | B2 (2) | 17 | |
| 25 | 18 | HSDL Shield Ground | A249 | B2 (2) | 25 | |
| ( 1 ) | This circuit must be wired with shielded cable. |
| ( 2 ) | This circuit must be wired with shielded cable. |
| Instrument Panel Connections | ||||||
|---|---|---|---|---|---|---|
| Junction Box Connection J | Gauge | Function | Circuit Identification | Twisted Pair | Shielded Cable | Instrument Panel Connection |
| 1 | Isolated Power (+) | 150 | 1 | |||
| 2 | Isolated Power (-) | 200 | 2 | |||
| 5 | CAT Data Link (-) | 892 | A (1) | 5 | ||
| 6 | CAT Data Link (+) | 893 | A (1) | 6 | ||
| 7 | Oil Temperature Signal | D839 | 7 | |||
| 8 | Inlet Temperature Signal | B472 | 8 | |||
| 19 | Inlet Temperature Return | 200 | 19 | |||
| 20 | Oil Temperature Return | 200 | 20 | |||
| ( 1 ) | A = Circuits must be twisted together: One twist per 25 mm (1 inch): Circuits 892 and 893 |
| Power Connections | |||||
|---|---|---|---|---|---|
| Power Connection F | Gauge | Function | Circuit Identification | Twisted Pair | Shielded Cable |
| 2 | 10 | Power Minus | * (1) | ||
| 3 | 14 | Battery (+) | * (1) | ||
| 5 | 14 | Battery (-) | * (1) | ||
| 6 | 10 | Power Plus | * (1) | ||
| ( 1 ) | Circuit Identification is left to the customer. |
| Customer Connections | |||||
|---|---|---|---|---|---|
| Junction Box Connection G | Gauge | Function | Circuit Identification | Twisted Pair | Shielded Cable |
| 1 | 16 | Crank Enable (NO) | * (1) | ||
| 2 | 16 | Crank Enable | * (1) | ||
| 3 | 16 | Emergency Shutdown C | * (1) | ||
| 4 | 16 | Shutdown 1 | * (1) | ||
| 5 | 16 | Crank Enable (NC) | * (1) | ||
| 6 | 16 | Shutdown 2 | * (1) | ||
| 7 | 16 | Emergency Shutdown D | * (1) | ||
| 8 | 16 | General Alarm (NO) | * (1) | ||
| 9 | 16 | Global CAT Link (+) (Not Used) | * (1) | A2 (5) | |
| 10 | 18 | HSDL Shield Ground | * (1) | B1 (2) | |
| 11 | 16 | CAN Data Link (-) (Not Used) | * (1) | B1 (2) | |
| 12 | 16 | CAN Data Link (+) (Not Used) | * (1) | B1 (2) | |
| 13 | 16 | General Alarm (NC) | * (1) | ||
| 15 | 16 | Shutdown Notify (COM) | * (1) | ||
| 16 | 16 | Shutdown Notify (NC) | * (1) | ||
| 17 | 16 | Shutdown Notify (NO) | * (1) | ||
| 18 | 16 | General Alarm (COM) | * (1) | ||
| 19 | 16 | Load Feedback | * (1) | ||
| 24 | 16 | Torque Limit | * (1) | ||
| 25 | 16 | Global CAT Link (-) (Not Used) | * (1) | A2 (5) | |
| 14 | 16 | CAT Data Link (-) | * (1) | A1 (3) | |
| 27 | 16 | CAT Data Link (+) | * (1) | A1 (3) | |
| 29 | 16 | Throttle | * (1) | ||
| 30 | 18 | Magnetic Pickup (+) | * (1) | B2 (4) | |
| 31 | 18 | Magnetic Pickup (-) | * (1) | B2 (4) | |
| 32 | 18 | Magnetic Pickup Shield | * (1) | B2 (4) | |
| 37 | 16 | Digital Reference | * (1) | ||
| ( 1 ) | Circuit Identification is left to the customer. |
| ( 5 ) | Circuits must be twisted together. |
| ( 2 ) | This circuit must be wired with a shielded cable. |
| ( 3 ) | Circuits must be twisted together. |
| ( 4 ) | This circuit must be wired with shielded cable. |
 | |
| Illustration 1 | g00580078 |
This is an Illustration of a 155-2579 Wiring Harness . (1) 8N-1525 Connector Plug (2) 8N-1535 End Bell Assembly (3) 9X-6772 Cable Strap (4) 3T-0203 Connector Plug (5) 113-7027 Shrinkable Tube (6) 9X-6857 Connection Socket (7) 9X-6856 Connector Pin (8) 7G-7917 Seal Plug | |
 | |
| Illustration 2 | g00580160 |
This is an Illustration of the 151-9216 Harness . (1) 3T-3044 Connector Plug (2) 8N-1521 End Bell Assembly (3) 9X-6772 Cable Strap (4) 3T-3043 Receptacle (5) 113-7027 Shrinkable Tube (6) 3T-3412 Connector Plug (7) 3T-3410 Receptacle (8) 7G-7919 Seal Plug (9) 7G-7920 Seal Plug (10) 7G-7917 Seal Plug (11) 9X-6856 Connector Pin (12) 8N-1540 Connector Pin (13) 9X-6857 Connection Socket (14) 8N-1541 Connection Socket | |