Installation Procedure for the Workover Rig Instrument Panel Kits for C9, C11, C13, and C15 Engines with TH31 / TH35 and CX31 / CX35 Transmissions in 12 Volt and 24 Volt Applications{7451} Caterpillar

Petroleum Power Train Package:

CX31-P600-C11I (S/N: PDY1-UP)

CX31-P600-C13I (S/N: PDN1-UP)

CX31-P600-C15I (S/N: PDM1-UP)

CX31-P600-C9I (S/N: PDZ1-UP)

TH31-C9I (S/N: PAZ1-UP)

TH31-C9P (S/N: PFZ1-UP)

TH35-C11I (S/N: PBZ1-UP)

TH35-C13I (S/N: PBY1-UP)

TH35-C15I (S/N: PBN1-UP)

Introduction

The purpose of this special instruction letter is to provide dealers and customers with information regarding the control panel kits available for the various work over applications. The panel kits are for the 12-volt and 24-volt applications.

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. Incorrect wiring 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. Incorrect wiring 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.

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, procedure, work method, or an operating technique that is not recommended by Caterpillar is used, make sure that it is safe for you and for other people. It is important to be sure that the product will not be damaged. Ensure that the product will not be made unsafe by the procedures that are used.

Installation Procedure for Control Panel Kits

Illustration 1	g02726243
(1) Starter motor (2) To start relay (3) Battery (4) Battery disconnect switch (5) Chassis (6) Control panel

Illustration 2	g02726417
Workover Rig engine and transmission wiring and control panel - Block diagram (1) Ignition switch (2) Tach (3) Engine oil pressure (4) Engine coolant temperature (5) Messenger (6) Primary shifter (7) Shifter selector with mode lamps (8) Engine warning (9) Transmission warning (10) Check transmission warning (11) Service brake pressure switch (12) Parking brake pressure switch (13) Engine ECM (14) Junction box (15) Cab harness (16) ECM shutdown relay (17) Fuse box 10 ckt (18) Starter relay (19) Backup alarm relay (20) 9 pin diagnostic connector (21) Air throttle pressure (22) Starter and starter wire (23) Battery and battery wire (24) ECM to pig tails (25) Air shutdown (26) Low coolant switch input (27) Engine ECM "J1" harness (28) Transmission OEM harness (29) Transmission PEM connector (30) Sand drum emergency stop (31) < 10 m (33 ft) (32) < 0.7 m (2.3 ft) (33) Backup alarm (34) Backup alarm harness (35) Backup alarm (36) Platform harness (37) Platform panel (38) Engine warning (39) Transmission warning (40) Check transmission warning (41) Lockup clutch lamp (42) Emergency stop (43) Secondary shifter

Installation Procedure for 12-Volt Kits

Note: The panel kit is packaged with all necessary parts for operation on a work over unit.

12 Volt Panel Kit for TH Transmissions

Note: Refer to 359-1918 Schematic

The 359-4130 Instrument Panel Gp TH is connected to the engine ECM, transmission ECM, and cab mounted components. The connection is through "J1939" harnesses and displays vital engine information such as engine speed, oil pressure, and coolant temperature.

Illustration 3	g02727560
359-1917 Electronic Panel Gp

The 359-1917 Electronic Panel Gp 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.

Illustration 4	g02732997
332-7684 Instrument Panel Gp (1) Emergency shutdown switch (2) Converter (3) Engine warning light (4) Transmission warning light (5) Shift pad (6) Instrument panel

Work platform 332-7684 Instrument Panel Gp is connected to the junction panel group through a "J1939" harness. This panel contains the 298-3860 Transmission Control Gp shift pad. Also contained on this panel are the engine emergency shutdown switch, engine warning light, transmission warning light, and converter.

Refer to ""Procedure for Harness Installations" " for information pertaining to harness installations.

12 Volt Panel Kit for CX Transmissions

Note: Refer to 359-1918 Schematic

The 359-4132 Instrument Panel Gp CX is connected to the engine ECM, transmission ECM, and cab components. The connection is through "J1939" harnesses and displays vital engine information such as engine speed, oil pressure, and coolant temperature.

Illustration 5	g02733416
359-1917 Electronic Panel Gp

The 359-1917 Electronic Panel Gp 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.

Illustration 6	g02733440
359-1909 Instrument Panel Gp (1) Emergency shutdown switch (2) Transmission warning light (3) Converter (4) Engine warning light (5) Transmission oil temperature (6) Shift pad (7) Instrument panel

Refer to ""Procedure for Harness Installations" " for information pertaining to harness installations.

12 Volt Panel Kit with Hazardous Shifter

Note: Refer to 359-1920 Schematic

The 368-6869 Instrument Panel Gp is connected to the engine ECM, transmission ECM, and cab components. The connection is through "J1939" harnesses and displays vital engine information such as engine speed, oil pressure, and coolant temperature.

Illustration 7	g02733416
359-1917 Electronic Panel Gp

The 359-1917 Electronic Panel Gp 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.

Illustration 8	g02733614
373-2771 Display Module Gp

Hazardous shifter or otherwise known as the 373-2771 Display Module Gp is connected to the engine panel group through a "J1939" harness.

Refer to ""Procedure for Harness Installations" " for information pertaining to harness installations.

Installation Procedure for 24-Volt Kits

Note: The panel kit is packaged with all necessary parts for operation on a work over unit.

24 Volt Panel Kit for TH Transmissions

Note: Refer to 359-1918 Schematic

The 359-4131 Instrument Panel Gp TH is connected to the engine ECM, transmission ECM, and cab mounted components. The connection is through "J1939" harnesses and displays vital engine information such as engine speed, oil pressure, and coolant temperature.

Illustration 9	g02733650
361-1985 Electronic Panel Gp

The 361-1985 Electronic Panel Gp 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.

Illustration 10	g02733651
332-7684 Instrument Panel Gp (1) Emergency shutdown switch (2) Converter (3) Engine warning light (4) Transmission warning light (5) Shift pad (6) Instrument panel

Refer to ""Procedure for Harness Installations" " for information pertaining to harness installations.

24 Volt Panel Kit for CX Transmissions

Note: Refer to 359-1918 Schematic

The panel kit is packaged with all necessary parts for operation on a work over unit. The 359-4133 Instrument panel gp , is connected to the engine ECM, transmission ECM, and cab components. The connection is through "J1939" harnesses and displays vital engine information such as engine speed, oil pressure, and coolant temperature.

Illustration 11	g02727560
361-1985 Electronic Panel Gp

The 361-1985 Electronic Panel Gp 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.

Illustration 12	g02733440
359-1909 Instrument panel gp (1) Emergency shutdown switch (2) Transmission warning light (3) Converter (4) Engine warning light (5) Transmission oil temperature (6) Shift pad (7) Instrument panel

The 359-1909 Instrument panel gp is connected to the engine panel group through a "J1939" harness. This panel contains the 298-3860 Transmission Control Gp shift pad. Also contained on this panel are the emergency shutdown switch, transmission warning light, engine warning light, transmission oil temperature warning light, and converter.

Refer to ""Procedure for Harness Installations" " for information pertaining to harness installations.

Messenger Display Module

Illustration 13	g02734226
Messenger display

The messenger display module will provide machine diagnostic codes that are 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.

The type of information that will be displayed by the module is :

• Diagnostic data

• Configuration of language and units

• Engine parameters such as engine speed, boost pressure, and gear position

ReferenceRefer to Electrical Application and Installation Guide for Petroleum Transmissions and Petroleum Power Train Packages, REHS2888

Keypad Shifter

Illustration 14	g02734436
Keypad shifter

The keypad shifter is 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.

Advisor Hazardous Shifter

Illustration 15	g02734748

The Advisor is an information display providing real time operating information on parameters such as engine speed, ground speed, and fuel consumption, and is targeted for use on heavy-duty engines and machines operating in adverse conditions. The displayed data can be obtained off an existing data link that connects engines, transmissions, and hydraulic systems. This product can also be used as an input device to the machine electronic system using the integral buttons or an external keypad to modify parameters such as engine idle speed, idle shutdown time, hydraulic kick-outs, and other customer modifiable parameters.

Monochrome graphical information display capable of displaying critical operator information off a standard "J1939", or Cat data link in a multi-lingual text or graphical format.

Cab Components

The cab components consist of the following items :

• Ignition switch

• Tachometer gauge

• Engine oil pressure gauge

• Engine coolant temperature gauge

• Messenger unit

• Primary shifter

• Shifter selector with mode lamps

• Engine warning light

• Transmission warning light

• Check transmission light

• Service brake pressure switch

• Parking brake pressure switch

Shifter Selector

The ECM will use the state of the selector switch to determine which shifter is active and will ignore the other shifter. The ECM will also run a different shift schedule based on the active shifter. The shifter in the cab must be configured by location code wiring to be the primary shifter. For the shifter in the cab, the ECM will automatically shift the transmission up and down based on transmission output speed. The shifter on the deck must be configured by location code wiring to be the secondary shifter. For the shifter on the deck, the ECM will function in a manual shift mode, shifting into whatever gear is selected on the keypad. The transmission will not shift unless the engine speed is below 850 rpm in "deck mode". The shifter will display two alphanumeric codes. The display on the left is desired gear and the display on the right is actual gear. Both shifters will display the information for the shifter that is active. For example if the vehicle is in "road mode", the deck shifter will display the information about the cab shifter.

In order to switch between "road mode" and "deck mode", both shifters must be in neutral. Then toggling the selector switch will signal the ECM to switch from one shifter to the other shifter.

Backup Alarm

The backup alarm is used in order to alert personnel that the machine is backing up. When this function is enabled, the ECU causes the backup alarm to "SOUND". When the operator selects REVERSE the ECU activates the relay for the backup alarm, which activates the backup alarm.

Note: The backup alarm will only be active when the transmission is in "road mode".

The function is enabled when the transmission is in REVERSE. This feature is standard in this software. Not all vehicles may connect up an audible backup alarm. Diagnostics are not performed on the driver for the backup alarm. If the alarm is hooked up to the output driver, the device may be different from one vehicle to the next (relay or direct alarm connection).

The function is enabled when the operator selects REVERSE at the shift lever. The shift lever tells the ECU that the shift lever is in REVERSE.

Note: The backup alarm output has the ability to drive up to 2 amperes.

Air Throttle

The air throttle sensor is located in the junction control panel.

Emergency Shutdown Switch

When the emergency shutdown switch 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: The emergency shutdown switch will also engage the air shutoff valve if the unit is equipped with this feature.

Procedure for Harness Installations

Installation Procedure for the 328-2149 Transmission Harness As

Illustration 16	g02738477
328-2149 Transmission Harness As (A) 2999 mm (118.1 inch) (B) 199 mm (8 inch) (1) "K-C1" - Transmission panel connector (2) Yellow high temperature braid - total wire required 3198 mm (126 inch) (3) "K-C2" - Transmission connector (4) "K-C3" - Terminal Resistor

1. Connect transmission panel connector (1) to corresponding connection on the 359-4130 Instrument Panel Gp .

2. Connect transmission connector (3) to the transmission connection.

3. Connect terminal resistor (3) connector to the terminal resistor connecion.

Installation Procedure for the 328-2150 Transmission Harness As

Illustration 17	g02739337
328-2150 Platform Harness As (A) 10000 mm (393.7 inch) (B) 200 mm (8 inch) (C) 9956 mm (392 inch) (D) 147 mm (6 inch) (E) 9389 mm (370 inch) (1) "N-C1" - Engine / JCT (2) Yellow high temperature braid - total required 29692 mm (1169 inch) (3) "N-C5" - Emergency stop jumper (4) "N-C4" - Emergency stop (5) "N-C2" - Remote panel (6) "N-C3" - Backup alarm

1. Connect engine / jct (1) to the connector to the engine / jct panel connector.

2. Connect the emergency stop jumper (3) to the emergency stop connector.

3. Connect the remote panel connector (5) to the remote panel.

Installation Procedure for the 359-1919 Panel Harness As

Illustration 18	g02740156
359-1919 Panel Harness As (A) 8013 mm (316 inch) (B) 531 mm (20.8 inch) (C) 530 mm (20.9 inch) (D) 532 mm (21 inch) (E) 534 mm (21.02 inch) (F) 76 mm (3 inch) (G) 532 mm (21 inch) (H) 532 mm (21 inch) (J) 533 mm (21.9 inch) (K) 533 mm (21.9 inch) (M) 533 mm (21.9 inch) (N) 532 mm (21 inch) (P) 533 mm (21.9 inch) (R) 532 mm (21 inch) (S) 533 mm (21.9 inch) (T) 500 mm (19.7 inch) (U) 498 mm (19.6 inch) (1) "G-C7" - Junction box (2) Yellow high temperature braid - total required 7912 mm (312 inch) (3) "G-C14" - Transmission warning lamp (4) "G-C13" - Engine warning lamp (5) "G-C17" - Transmission check lamp (6) "G-C21" - Emergency stop jumper (7) "G-C3" - Shifter (8) "G-T2" - K808-YL (9) "G-T1" - J765-BU (10) "G-C11" - Gauge control (11) "G-C12" - Gauge control (12) "G-C6" - Road work mode switch (13) "G-C1" - Key start switch (14) "G-C4" - Service brake pressure switch (15) "G-C5" - Parking brake pressure switch (16) "G-C2" - Messenger (17) Power wires (18) "G-C15" - Can resistor (19) "G-C9" - Tachometer (20) "G-C10" - Engine oil pressure gauge (21) "G-C8" - Engine coolant temperature gauge

Installation Procedure for the 361-1984 Panel Harness As

Illustration 19	g02744359
361-1984 Panel Harness As (A) 2801 mm (110.3 inch) (B) 570 mm (22.44 inch) (C) 329 mm (13 inch) (D) 209 mm (8.2 inch) (E) 204 mm (8 inch) (1) "C-C1" - Engine panel (2) Yellow high temperature braid (3) "C-C5" - Instrument panel (4) "C-C4" - Low coolant sensor (5) "C-C2" - Engine ECM (6) "C-C3" - Air shutoff solenoid relay

1. Connect the engine panel connection (1) to the engine panel connector.

2. Connect the Instrument panel connector (3) to the instrument panel connection.

3. Connect the low coolant sensor connector (4) to the low coolant sensor connection.

4. Connect the engine ECM connector (5) to the engine ECM connection.

5. Connect the air shutoff solenoid relay connector (6) to the air shutoff solenoid relay connection.

Installation Procedure for the 344-3958 Panel Harness As

Illustration 20	g02779378
(A) 3008 mm (118.4inch) (B) 196 mm (8 inch) (1) "KK-C2" - Transmission (2) Yellow high temperature braid (3) "KK-C1" - Transmission panel (4) "KK-C3" - Terminal resistor - Remove resistor for Workover Rig application.

1. Connect the transmission connector (1) to the transmission connection.

2. Connect the transmission panel connector (2) to the transmission panel connection.

Installation Procedure for the 350-3507 Alarm Harness As

Illustration 21	g02779556
(A) 5060 mm (199 inch) (1) "JA-C2" - Alarm connection (2) Yellow high temperature braid (3) "JA-C1" - Alarm horn

1. Connect the alarm connector (1) to the alarm connection.

2. Connect the alarm horn (2) to the alarm horn connection.

Installation Procedure for the 359-4124 Alarm Harness As

Illustration 22	g02779696
(A) 19871 mm (782.32inch) (B) 174 mm (7 inch) (C) 148 mm (6 inch) (1) "N-C2" - Remote panel (2) Yellow high temperature braid (3) "N-C1" - Engine / JCT panel (4) "N-C4" - "CAN" resistor (5) "N-C3" - Backup alarm

1. Connect the remote panel (1) connector to the remote panel connection.

2. Connect the "CAN" resistor connector to the "CAN" resistor connection.

3. Connect the backup alarm (5) connector to the backup alarm connection.

4. Connect the engine/JCT panel (3) connector to the engine/JCT panel connection.