Installation Procedure for the Mud Pump Control Panel Kits for C27 and C32 Engines with TH48 Transmissions in 24-Volt Applications{7451} Caterpillar

Petroleum Power Train Package:

TH48-E70-C27I (S/N: PKZ1-UP)

TH48-E70-C32I (S/N: PKY1-UP)

TH48-E70-C32P (S/N: PKG1-UP)

Introduction

The purpose of this special instruction letter is to provide dealers and customers with information regarding the new control panel kit available for mud pumping applications. The panel kit contains two panels as well as "J1939" harnesses to connect the two panels to the engine and transmission.

Illustration 1	g02722147
Mud pump engine and transmission wiring and control panel (1) Engine ECM (2) Air shutdown relay output (3) Transmission OEM connector (4) Engine instrument panel (5) Platform panel (6) Low coolant switch input (7) Transmission ECM harness - 3 m (10 ft) (8) Engine ECM "J1" harness - 3 m (10 ft) (9) Ignition switch (10) Tack (11) Engine oil pressure (12) < 10 m (33 ft) (13) Platform harness - 20 m (66 ft) (14) < 0.7 m (2.3 ft) (15) Not used in pump application (16) Engine coolant temperature (17) Engine warning (18) Transmission warning (19) nine pin diagnostic connector (20) ECM shutdown relay (21) Starter relay (22) Starter with external starter wire (23) Battery with external battery wire (24) Messenger (25) Engine warning (26) Transmission warning (27) Lockup clutch lamp (28) Quick to neutral switch (29) Emergency stop (30) Shifter control (31) Throttle

Safety Section

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

Most accidents that involve product operation, maintenance, and repair are caused by the failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Improper operation, maintenance, or repair of this product may be dangerous. Improper operation, maintenance, or repair of this product may result in injury or death.

Do not operate or perform any maintenance or repair on this product until you have read and understood the operation, maintenance, and repair information.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used, you must be sure that it is safe for you and for other people. You must also be sure that the product will not be damaged. Ensure that the product will not be made unsafe by the procedures that are used.

Required Parts

Installation Procedure

Installation Procedure for 335-4026 Instrument Panel Gp

Illustration 2	g02717537
Control panel wiring diagram (1) Starter motor (2) To start relay (3) Battery (4) Battery disconnect switch (5) To chassis (6) Control panel

Note: Power for the panel group must come directly from the battery.

Note: Do NOT connect the positive (+) wire of the panel group to the starter terminal. Connecting the positive (+) wire to the starter terminal may cause the panel group to malfunction. Connecting the positive (+) wire to the starter terminal could also damage the components inside the panel. Connect the positive (+) wire directly to the battery.

Note: Do NOT connect the negative (-) wire on the panel group to the starter, the chassis, or the engine ground. Connecting the negative (-) wire to the panel may also cause the panel group to malfunction. The negative (-) wire on the panel group must be connected to the battery through the battery disconnect switch.

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Illustration 3	g02718057
(7) Engine coolant temperature (8) Engine warning (9) Transmission warning (10) Engine speed (11) Engine oil pressure (12) Keyswitch (13) Service tool connector

1. The panel kit is packaged with all necessary parts for operation on a mud pump unit. The 335-4026 Instrument Panel Gp is connected to the engine ECM and transmission ECM through the J1939 harnesses. The panel group displays vital engine information such as engine speed, engine oil pressure, and engine coolant temperature. This panel also has an engine warning light and a transmission warning light as well as an engine ignition switch. This panel should NOT be mounted directly to the engine due to vibration. This panel should be mounted to the chassis or skid with a frame or bracket.

   Note: Install the harness so the harness does not bind or get pinched when panel door is opened and closed.

   Note: Refer to ""Monitoring System" " for information pertaining to the configuration of the panel kit with Electronic Technician.

Installation Procedure for 335-4027 Instrument Panel Gp

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Illustration 4	g02718152
335-4027 Instrument Panel Gp (14) Messenger display module (15) Engine warning light (16) Transmission warning light (17) Quick to neutral switch (18) Converter lockup indicator (19) Electronic control throttle (20) Emergency stop (21) Shifter control

1. The 335-4027 Instrument Panel Gp is connected to the engine panel group through a J1939 harness. This panel contains the shifter control as well as the messenger display module. On this panel are the engine electronic throttle control, emergency stop, quick to neutral switch, engine warning light, transmission warning light, and converter lockup indicator. The following list describes the functionality of the panel components.

   ReferenceRefer to Special Instruction, "Electrical Application and Installation Guide for Petroleum Transmissions and Petroleum Power Train Packages"

   • Messenger display module - Machine diagnostic codes may be displayed for the operator. The messenger display will automatically display potentially serious machine problems. When one of these codes is detected, a warning will appear on the screen. Message can include diagnostic data, configuration of language and units and Engine parameters

   • Quick to neutral switch - When the switch is activated, the transmission quickly downshifts to the NEUTRAL position. When the quick to neutral switch is deactivated, the transmission will remain in the NEUTRAL position until the transmission shift control is placed in the NEUTRAL position. Once the shift controller has been placed in the NEUTRAL position, the transmission can be shifted to the desired gear.

   • Shifter control - Used to control the operation of the transmission. The transmission will operate as a power shift transmission. The transmission will shift according to the operator input by using the up arrow and down arrow.

   • Electronic control throttle - The engine electronic control throttle control is located on the work platform control panel. This allows the operator to control the engine speed without having to leave the work platform control panel.

   • Emergency stop - When the emergency stop is pressed, the engine quickly shuts down. The switch is located on the work platform control panel for easy access by the machine operator in an emergency situation. When the emergency shutdown switch is engaged, the shutdown relay is de-energized which stops the supply of battery power to the engine ECM.

   Note: Refer to ""Monitoring System" " for information pertaining to the configuration of the panel kit with Electronic Technician.

Installation of Harness Assemblies

Installation of 373-4891 Engine Harness As

Illustration 5	g02718246
(A) Endbell orientation (B) Diode pin location detail - Place the diode at the position shown. Solder the leads of anode and cathode to wires G971-C35 and G971-C5 respectively. Cover the soldered portion with heat shrink tube covering at a length of 25 ± 5 mm (1 ± 0.2 inch) for both leads and the diode and wire. (C) 2788 mm (110 inch) (D) 333 mm (13 inch) (E) 204 mm (8 inch) (F) 209 mm (8 inch) (1) Connector "C-C1" for the engine panel (2) YL-Braid (3) Place the diode at the position shown. Refer to (B). (4) Connector "C-C4" for the low coolant sensor (5) Connector "C-C3" for the air shutoff solenoid relay (6) Connector "C-C2" for the engine ECM (7) Pin 1 location (8) Pin 70 location (9) Two key slots positioned as shown in Illustration 5. (10) G971-C35 (11) Heat shrink tube - Place the diode at the position shown. Refer to (B). (12) "C_B7 Bare" 25 mm (1 inch) (13) "C_B9 Bare" 24 mm (0.9 inch) (14) 25 mm (1 inch)

1. Connect "C-C1" (1) to the engine panel connector.

2. Connect "C-C4" (4) to the sensor.

3. Connect "C-C2" (6) to the engine ECM.

Installation of 328-2150 Platform Harness As

Illustration 6	g02719921
(A) 10000 mm (394 inch) (B) 19309 mm (760.2 inch) (C) 147 mm (6 inch) (D) 200 mm (8 inch) (E) 9956 mm (392 inch) (1) Connector "N-C1" for the engine / JCT panel (2) YL-Braid-HI Temp (3) Connector "N-C5" for the emergency stop jumper (4) Connector "N-C4" for the emergency stop (5) Connector "N-C2 " for the remote panel

1. Connect "N-C1" (1) to the panel connector.

2. Connect "N-C5" (3) to the emergency stop jumper connector of the panel.

3. Connect "N-C2" (5) to the remote panel connector.

Installation of 353-0223 Transmission Harness As

Illustration 7	g02719991
(A) 2999 mm (118.1 inch) (B) 164 mm (7 inch) (1) Connector "K-C1" for the engine / JCT (2) YL-Braid-HI Temp (3) Connector "K-C3 " for the mate to CAN terminal resistor (4) Resistance plug (5) Connector "K-C2"for the transmission

1. Connect "K-C1" (1) to the connector on the panel for the transmission.

2. Connect the "K-C2 " (5) to the transmission connector on the transmission.

3. Connect resistance plug (4) to the appropriate connection.

Monitoring System

Service Tool: Electronic Technician

ET can display the following information:

• Parameters

• Event codes

• Diagnostic codes

• Engine configuration

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

• Diagnostic tests

• Sensor calibrations

• Flash programming

• Set parameters

The following components are required to use ET to service the transmission:

Connecting ET and the Communication Adapter

Illustration 8	g01216138
Communication Adapter II (1) Personal computer (PC) (2) 160-0141 Adapter Cable Assembly (PC Serial) (3) 171-4401 Communication Adapter Assembly (Communication Adapter II) (4) 160-0133 Data Link Cable As (Data Link)

Note: Items (2), (3), and (4) are part of the 171-4400 Communication Adapter Group (Communication Adapter II Group).

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

1. Turn off all switched power to the ECM.

2. Connect cable (2) between the computer (service tool) port of communication adapter (3) and the RS232 serial port of PC (1) .

3. Connect cable (4) between the Data Link (control) end of communication adapter (3) and the service tool connector.

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

ET Support

For authorization and ordering information, contact Caterpillar Media and Product Information Logistics. You can call between 7:00 AM and 5:00 PM Central Standard Time.

E-mail: media_logistics@cat.com

If you are having problems with the software, you can contact the SIS Help Desk. You can call between 6:00 AM and 9:00 PM Central Standard Time.

E-mail: sishelp@cat.com