- Marine Engines:
- 3412E (S/N: 9KS1-UP; 9PW1-UP)
- C30 (S/N: CLX1-UP)
- C32 (S/N: RXB1-UP)
- C30 (S/N: CLX1-UP)
Introduction
This document is intended to provide information for wiring the engine electronics and programming the engine electronics.
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by 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 specifically 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. You must also be sure that the product will not be made unsafe by the procedures that are used.
The information in this publication was based upon current information at the time of publication. Check for the most current information before you start any job. Caterpillar dealers will have the most current information.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. |
System Overview
These engines were designed for electronic control. The injection pump, the fuel lines, and the nozzles that are used in mechanical engines have been replaced with a unit injector in each cylinder. A solenoid on each injector controls the amount of fuel that is delivered by the injector. An electronic control module (ECM) sends a signal to each injector solenoid in order to provide complete control of the engine.
Electronic Controls
The electronic system consists of the following components: electronic control module (ECM), unit injectors, wiring harness, switches and sensors. The ECM is the computer. The personality module (flash file) is the software for the computer. The personality module (flash file) contains the operating maps. The operating maps define the following characteristics of the engine:
- Horsepower
- Torque curves
The ECM determines the timing and the amount of fuel that is delivered to the cylinders. These decisions are based on the actual conditions and the desired conditions at any given time.
The ECM compares the desired engine speed to the actual engine speed. The actual engine speed is determined through the engine speed/timing sensor. The desired engine speed is determined by monitoring the following inputs to the ECM:
- Sensors (throttle position, etc)
- Diagnostic codes
- Event codes (derates)
If the desired engine speed is greater than the actual engine speed, the ECM will signal the injectors to inject more fuel. This will increase the actual engine speed.
System Component Diagram
Illustration 1 | g00879646 |
Component Locations
Illustration 2 | g00879645 |
Sensor locations (top view) |
Illustration 3 | g00881458 |
Sensor locations (details) |
System Configuration Parameters
System configuration parameters are parameters that affect emissions, power of the engine, and features that are specific to the application. Default values for the parameters are programmed at the factory. Some parameters may be changed by the customer in order to suit the needs of the specific application. You must reprogram the system configuration parameters if the ECM is replaced. You do not need to reprogram the system configuration parameters if you replace the personality module. Proper values for these parameters are available on the Caterpillar Electronic Technician (Cat ET). Certain configuration parameters are also stamped on the engine information plate.
Note: If the parameters that are protected with factory passwords are changed, the Caterpillar warranty may be voided.
Parameter Descriptions
"Rating Number"
The "Rating Number" corresponds to the selected set of performance maps for the application. This selected set of performance maps comes out of several unique sets of maps that may be resident in the flash file. The dealer and/or the OEM will need to select the appropriate rating tier, if more than one rating tier is present. The rating tier is A through E.
"Equipment ID"
"Equipment ID" allows the customer to enter a description into the ECM in order to identify the engine and/or the vessel. A maximum of 17 characters may be entered in the field. This parameter is only for reference by the customer. This parameter is not required.
"Engine Serial Number"
"Engine Serial Number" should be programmed to match the engine serial number that is stamped on the engine information plate. If the ECM is replaced, the engine serial number from the engine information plate should be programmed into the new ECM.
Note: When you are requesting factory passwords, always use the engine serial number that is resident in the ECM.
"Engine Location"
"Engine Location" is used to identify the location (center, port, or starboard) of each engine.
"Fuel to Air Ratio Mode"
The ECM controls the delivery of fuel to the engine. The electronic controls eliminate the mechanical fuel air ratio control. The electronic control of the fuel air mixture provides the optimum performance of the engine.
There are three different settings for the "Fuel to Air Ratio Mode". The setting depends on the characteristic of operation that is desired by the customer. The default setting provides a balance between the emissions and the performance of the engine. The "Fuel to Air Ratio Mode" can be set to the following settings.
- Level 1 (Leanest mixture)
- Level 2 (Default)
- Level 3 (Richest mixture)
"Low Idle Speed"
"Low Idle Speed" is the minimum allowable operating speed for the engine with the throttle at the low idle position.
"Maximum Trolling Engine Speed"
The "Maximum Trolling Engine Speed" sets the high idle limit to the programmed value when the vessel is in trolling mode. The value must be higher than the programmed "Low Idle Speed" and the "Slow Vessel Speed".
"Transmission Oil Temperature High Set Point"
The "Transmission Oil Temperature High Set Point" can be programmed to any value in the available range. The event code for the transmission oil temperature will be active when the transmission oil temperature exceeds the set point.
"Transmission Oil Pressure High Set Point"
The "Transmission Oil Pressure High Set Point" can be programmed to any value in the available range. The event code for transmission oil pressure becomes active when the transmission oil pressure exceeds the set point.
"Transmission Oil Temperature Sensor"
The "Transmission Oil Temperature Sensor" parameter can be set to either "Installed" or "Not Installed".
"Transmission Oil Pressure Sensor"
The "Transmission Oil Pressure Sensor" parameter can be set to either "Installed" or "Not Installed".
"Fuel Correction Factor"
The "Fuel Correction Factor" is available to fine tune all fuel data that will be stored in the future by the ECM. Caterpillar recommends changing this factor only after a significant operating interval that includes a comparison of actual tank fuel economy to the fuel economy that is recorded in the ECM. The operating interval should also reflect normal engine operation. The "Fuel Correction Factor" is a percentage that is programmable in 0.5 percent increments.
"FLS" (Full Load Setting)
"FLS" is a number that represents the adjustment to the fuel system that was made at the factory in order to fine tune the fuel system. The correct value for this parameter is stamped on the engine information plate. Factory passwords are required in order to change "FLS".
"FTS" (Full Torque Setting)
"FTS" is similar to "FLS". Factory passwords are required in order to change "FTS".
"Engine Monitoring Mode"
The "Engine Monitoring Mode" determines the level of action that is taken by the ECM. If the "Engine Monitoring Mode" is programmed to "Warning", the operator will be warned of a potential problem. If the "Engine Monitoring Mode" is programmed to "Derate", the ECM will derate engine power in order to prevent engine damage.
"Coolant Level Sensor"
The "Coolant Level Sensor" parameter can be set to either "Installed" or "Not Installed".
"Maintenance Indicator Mode"
The ECM records data that is related to equipment maintenance. The ECM will activate the maintenance indicator lamp when scheduled maintenance is due. The maintenance indicator lamp can be reset by actuating the "Maintenance Due Reset Switch". The maintenance interval may be based on operating hours or fuel consumption. The ECM provides information that pertains to maintenance intervals and the last maintenance that was performed.
"PM1 Interval"
"PM1 Interval" allows the customer to define the maintenance interval if "Maintenance Indicator Mode" is programmed to one of the manual options. Refer to the Operation and Maintenance Manual for more information.
"Engine Oil Capacity"
This parameter should be programmed to the capacity of engine oil.
"Customer Password #1"
This parameter allows the customer to lock out certain parameters by entering a password. Customer passwords must be used to unlock any parameters that are protected by customer passwords before the parameter can be changed. Factory passwords are required if this password is lost.
"Customer Password #2"
This parameter allows the customer to lock out certain parameters by entering a password. Customer passwords must be used to unlock any parameters that are protected by customer passwords before the parameter can be changed. Factory passwords are required if this password is lost.
"6 Cylinder Cutout"
This parameter becomes active when coolant temperature is less than 60 °C (140 °F) and runs for 14 minutes in order to help reduce white smoke.
Parameters Table
Parameters     | |||||
---|---|---|---|---|---|
Parameter     | Available Range or Options     | Default     | Required Password     | ||
Selected Engine Rating     | |||||
"Rating Number"     | Software Dependent     | None     | |||
"Rated Power"     | Software Dependent     | Read Only (1)     | |||
"Rated Peak Torque"     | Software Dependent     | Read Only (1)     | |||
"Top Engine Speed Range"     | Software Dependent     | Read Only (1)     | |||
"Test Spec"     | Software Dependent     | Read Only (1)     | |||
ECM Identification Parameters     | |||||
"Equipment ID"     | 17 alphanumeric characters     | Blank     | None     | ||
"Engine Serial Number"     | 0XX00000 or XXX00000     |
Blank     | None     | ||
"ECM Serial Number"     | Hardware Dependent     | Read Only (1)     | |||
"Personality Module Part Number"     | Software Dependent     | Read Only (1)     | |||
"Personality Module Release Date"     | Software Dependent     | Read Only (1)     | |||
"Personality Module Description"     | Software Dependent     | Read Only (1)     | |||
Security Access Parameters     | |||||
"Total Tattletale"     | 0 to 65535     | 0     | Read Only (1)     | ||
Engine/Gear Parameters     | |||||
"Engine Location"     | "Port" "Center" "Starboard"     |
"Center"     | None     | ||
"Fuel To Air Ratio Mode"     | "Level 1" "Level 2" "Level 3"     |
"Level 2"     | Customer     | ||
"Low Idle Speed"     | 600 to 750 rpm     | 700 rpm     | None     | ||
"Maximum Trolling Engine Speed"     | 900 to 1200 rpm     | 900 rpm     | Customer     | ||
"Transmission Oil Temperature High Set Point"     | 50 °C (122 °F) to 120 °C (248 °F)     |
95 °C (203 °F)     |
Customer     | ||
"Transmission Oil Pressure High Set Point"     | 700 kPa (100 psi) to 3000 kPa (435 psi)     |
2398 kPa (350 psi)     |
Customer     | ||
"Transmission Oil Temperature Sensor"     | "Installed" "Not Installed"     |
"Not Installed"     | Customer     | ||
"Transmission Oil Pressure Sensor"     | "Installed" "Not Installed"     |
"Not Installed"     | Customer     | ||
"Fuel Correction Factor"     | -63.5% to 63.5%     | 0%     | None     | ||
"FLS" (Full Load Setting)     | Programmed at the Factory     | Factory     | |||
"FTS" (Full Torque Setting)     | Programmed at the Factory     | Factory     | |||
Engine Monitoring Parameters     | |||||
"Engine Monitoring Mode"     | "Warning" "Derate"     |
"Warning"     | None     | ||
"Coolant Level Sensor"     | "Installed" "Not Installed"     |
"Installed"     | None     | ||
Maintenance Parameters     | |||||
"Maintenance Indicator Mode"     | "OFF" "Auto Fuel" "Auto Hour" "Man Fuel" "Man Hour"     |
"OFF"     | None     | ||
"PM1 Interval"     | "Man Hour" 100 to 750 "Man Fuel" 3785 L (1000 US gal) to 28390 L (7500 US gal)     |
"Man Hour" 250 "Man Fuel" 9463 L (2500 US gal)     |
Customer     | ||
Engine Oil Capacity     | 20 L (21 qt) to 250 L (264 qt)     |
85 L (90 qt)     |
Customer     | ||
Passwords     | |||||
"Customer Password #1"     | 8 alphanumeric characters     | Blank     | Customer     | ||
"Customer Password #2"     | 8 alphanumeric characters     | Blank     | Customer     | ||
"6 Cylinder Cutout"     | "On" "Off"     |
"On"     | None     |
( 1 ) | The parameter can be viewed only. No changes are allowed. |
Parameter Worksheet
Record the following information before you change any programmable parameter.
Parameter Worksheet     | |
"Rating Number"     |     |
"Rated Power"     |     |
"Rated Peak Torque"     |     |
"Top Engine Speed Range"     |     |
"Test Spec"     |     |
"Equipment ID"     |     |
"Engine Serial Number"     |     |
"ECM Serial Number"     |     |
"Personality Module Part Number"     |     |
"Personality Module Release Date"     |     |
"Personality Module Description"     |     |
"Total Tattletale"     |     |
"Engine Location"     |     |
"Fuel To Air Ratio Mode"     |     |
"Low Idle Speed"     |     |
"Maximum Trolling Engine Speed"     |     |
"Transmission Oil Temperature High Set Point"     |     |
"Transmission Oil Pressure High Set Point"     |     |
"Transmission Oil Temperature Sensor"     |     |
"Transmission Oil Pressure Sensor"     |     |
"Fuel Correction Factor"     |     |
"FLS" (Full Load Setting)     |     |
"FTS" (Full Torque Setting)     |     |
"Engine Monitoring Mode"     |     |
"Coolant Level Sensor"     |     |
"Maintenance Indicator Mode"     |     |
"PM1 Interval"     |     |
Engine Oil Capacity     |     |
"Customer Password #1"     |     |
"Customer Password #2"     |     |
"6 Cylinder Cutout"     |     |
Information from Engine Information Plate     | |
"Engine Serial Number"     |     |
"FLS"     |     |
"FTS"     |     |
Note: Compare the FLS and the FTS from the ECM with the values that are listed on the Engine Information Plate. The FLS and the FTS should only be changed because of a mechanical change in the engine. The use of the wrong parameters could cause damage to the engine.
Monitoring System
The Monitoring System determines the level of action that is taken by the ECM in response to a condition that can damage the engine. These conditions are identified by the ECM from the signals that are produced from the following sensors.
- Coolant level sensor
- Engine coolant temperature sensor
- Engine oil pressure sensor
- Engine speed/timing sensors
- 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"
Note: "WARNING" is the factory default setting.
The ECM Engine Monitoring is 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
The engine will not do a derate when the "WARNING" parameter is selected.
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 for warning or the warning lamp will flash for a derate.
Table 3 provides the following information.
- The diagnostic event code (EID)
- The description of the event code
- The status of the warning lamp with an active diagnostic code
- The effect of derate
Monitoring of the Engine that is Programmed to "WARNING"     | |||
EID     | Description of the Code     | Warning Lamp     | Derate     |
E015     | High Engine Coolant Temperature Derate     | ON     | None     |
E017     | High Engine Coolant Temperature Warning     | ON     | None     |
E025     | High Inlet Air Temperature Derate     | ON     | None     |
E027     | High Inlet Air Temperature Warning     | ON     | None     |
E030     | High Transmission Oil Temperature Warning     | ON     | None     |
E039     | Low Engine Oil Pressure Derate     | ON     | None     |
E057     | Low Engine Coolant Level Derate     | ON     | None     |
E059     | Low Engine Coolant Level Warning     | ON     | None     |
E100     | Low Engine Oil Pressure Warning     | ON     | None     |
E113     | High Transmission Oil Pressure     | ON     | None     |
E164     | High Injector Actuation Pressure     | ON     | None     |
E268     | Unexpected Engine Shutdown     | ON     | Shutdown     |
Monitoring of the Engine that is 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 a 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 process of derate.
- 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
- Engine coolant temperature
- Engine oil pressure
- Inlet air temperature
When the engine is derated, the power is derated.
Table 4 provides the following information.
- The diagnostic event code (EID)
- The description of the event code
- The status of the warning lamp with an active diagnostic code
- The effect of derate
Monitoring of the Engine that is Programmed to "DERATE"     | |||
EID     | Description of the Code     | Warning Lamp     | Derate     |
E015     | High Engine Coolant Temperature Derate     | Flashing     | Power     |
E017     | High Engine Coolant Temperature Warning     | ON     | None     |
E025     | High Inlet Air Temperature Derate     | Flashing     | Power     |
E027     | High Inlet Air Temperature Warning     | ON     | None     |
E030     | High Transmission Oil Temperature Warning     | ON     | None     |
E039     | Low Engine Oil Pressure Derate     | Flashing     | Power     |
E057     | Low Engine Coolant Level Derate     | Flashing     | Power     |
E059     | Low Engine Coolant Level Warning     | ON     | None     |
E100     | Low Engine Oil Pressure Warning     | ON     | None     |
E113     | High Transmission Oil Pressure     | ON     | None     |
E164     | High Injector Actuation Pressure     | ON     | None     |
E268     | Unexpected Engine Shutdown     | ON     | Shutdown     |
Required Tools
Required Service Tools     | |
---|---|
Part Number     | Description     |
N/A     | 4 mm Allen Wrench     |
6V-2197     | Magnetic Transducer (Timing Calibration Probe)     |
6V-3093     | Transducer Adapter (Timing Calibration Probe)     |
7X-1695     | Cable (Timing Calibration)     |
9U-7330 or 146-4080     |
Digital Multimeter Digital Multimeter (RS-232)     |
7X-1710     | Multimeter Probes     |
7X-1715 and 134-5195     |
Adapter Cable (40 Pin Breakout T) Adapter Cable (40 Pin)     |
7X-6370     | Adapter Cable (3 Pin DT Breakout)     |
1U-5804     | Crimp Tool (12-18 AWG)     |
175-3700     | Connector Repair Kit     |
Two short jumper wires are needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector. A long extension wire may also be needed to check the continuity of some wiring harness circuits.
Caterpillar Electronic Technician (Cat ET)
Cat ET can display the following information:
- Parameters
- Event codes
- Diagnostic codes
- Engine configuration
Cat 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 Cat ET to service the engine.
Required Electronic Service Tools for the Use of Cat ET     | |
---|---|
Part Number     | Description     |
JERD2124     | "Electronic Technician Program" (ET)     |
JERD2129     | "Data Subscription for All Engines and Machines"     |
171-4400 (1)     | Communication Adapter II Gp     |
( 1 ) | The 7X-1700 Communication Adapter Gp may also be used. |
Note: For more information regarding the use of Cat ET and the PC requirements for Cat ET, refer to the documentation that accompanies your Cat ET software.
Connecting Cat ET and the Communication Adapter II
Illustration 4 | g00647144 |
(1) Personal computer (PC) (2) 160-0141 Adapter Cable (PC Serial) (3) 171-4401 Communication Adapter II (4) 207-6845 Adapter Cable (Data Link) |
Note: Items (2), (3), and (4) are part of the 171-4400 Communication Adapter II Gp .
Use the following procedure to connect Cat ET and the Communication Adapter II.
- Turn the keyswitch to the OFF/RESET position. If the keyswitch is not placed in the OFF/RESET position, the engine may start.
- Connect cable (2) between the "COMPUTER" end of communication adapter (3) and the RS232 serial port of PC (1) .
- Connect cable (4) between the "DATA LINK" end of communication adapter (3) and the service tool connector.
- Turn the keyswitch to the ON position. If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate With ECM".
Optional Service Tools
The following table contains service tools that may be helpful to service the engine, but these tools are not required.
Optional Service Tools     | |
---|---|
Part Number     | Description     |
1U-5470 or 198-4240     |
Engine Pressure Gp Digital Pressure Indicator     |
4C-4075     | Crimp Tool (4-10 AWG)     |
4C-4911 (1)     | Battery Load Tester     |
5P-7277     | Voltage Tester     |
6V-9130 (2)     | Temperature Adapter Gp     |
8T-5319     | Connector Tool Gp     |
9S-9082     | Engine Turning Tool     |
( 1 ) | Refer to Special Instructions, SEHS9249, "Use of the 4C-4911 Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteries" and Special Instructions, SEHS7633, "Battery Test Procedure". |
( 2 ) | Refer to Special Instructions, SEHS8382, "Use of the 6V-9130 Temperature Adapter Group". |
Switches
Measuring Voltage in Switch Circuits
Illustration 5 | g00763648 |
Voltage measurement |
Measuring Current in Switch Circuits
Illustration 6 | g00763649 |
Current measurement |
Measuring Resistance in Switch Circuits
Illustration 7 | g00763650 |
Resistance measurement |
Switch Specifications
All switches that are provided by the OEM and connected to the Electronic Control Module (ECM) must be of a two wire design. These switches must be externally connected to the negative battery bus bar. Switches which are grounded internally to the case must not be used.
Supplied voltage from the ECM to the switches will not normally exceed 24 VDC. Normal current through the switches will not exceed 5.0 mA.
Momentary opening or closing of the switches and contact chatter should not exceed 100 milliseconds in duration. Vibration or shock that is normally found in the application should not cause opening or closing of the switches.
The plating on the contacts should not be susceptible to corrosion or oxidation. 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. Closing an OEM installed switch must short circuit the switch input to the negative battery bus bar. Refer to the ""Battery Circuit Requirements" " section of this publication.
All switches are supplied by the OEM. If a problem occurs with an undetermined cause, connect Cat ET and observe the status of the switch. Refer to the appropriate Troubleshooting Module for your engine.
Voltage Thresholds 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: OEM installed switches must be connected to the negative battery bus bar.
The Customer Installed Switches
The Customer Installed Switches     | ||
Switch     | Actuator     | Type     |
3E-8766     | 155-2706     | SPST     |
3E-8768     | 155-2706     | SPST Momentary     |
3E-8772     | 155-2705     | DPDT Center Off     |
Note: The switches in Table 8 require 5P-4571 Blade Terminal for installation.
Pin Connections for Customer Connectors for Switches     | |
Description of the Pin     | Pin Assignment on Customer Connector     |
Trip Clear Switch     | Pin 19     |
Synchronization Input 1     | Pin 34     |
Synchronization Input 2     | Pin 35     |
Remote Shutdown Switch     | Pin 36     |
Trolling Mode Input     | Pin 37     |
Slow Vessel Mode Switch     | Pin 38     |
Maintenance Clear Switch     | Pin 39     |
Illustration 8 | g01042483 |
(R) ON (top or left) (S) NONE (center) (T) OFF (bottom or right) (1) Tabs for the actuator |
Illustration 9 | g01042484 |
The backlight that is connected to switch terminals (A) and (B) turns on when contacts (2) and (3) are closed.
Illustration 10 | g01042486 |
3E-8772 Rocker Switch (R) ON (top or left) (S) OFF (center) (T) ON (bottom or right) (1) Tabs for the actuator |
Illustration 11 | g01042488 |
Schematic of 3E-8772 Rocker Switch |
The backlight that is connected to switch terminals (A) and (B) turns on when contacts (1) and (2) are closed.
The backlight that is connected to switch terminals (C) and (D) turns on when contacts (5) and (6) are closed.
Connectors
Illustration 12 | g00816724 |
Pull Test
The pull test is used to verify that the wire is properly crimped in the terminal and the terminal is properly inserted in the connector.
Perform the pull test on each wire. Each terminal (socket or pin) and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body.
Installation of Terminals and Seal Plugs
Illustration 13 | g00690571 |
Installation of seal plugs |
Illustration 14 | g00738352 |
Terminal connections |
The following requirements ensure the correct installation of terminals in the connectors:
- Do not solder the sockets and pins to the wires.
- Never crimp more than one wire into a socket or a pin. The 186-3735 Connector Pin and the 186-3736 Connector Socket are designed to accept only one 16 or 18 AWG wire. The 9W-0844 Connector Socket and the 9W-0852 Connector Pin are designed to accept only one 14 AWG wire. Do NOT insert multiple wires of a smaller gauge.
- All sockets and pins should be crimped on the wires. Use the 1U-5804 Crimp Tool for 12 to 26 AWG wire.
- All unused cavities for sockets and pins must be filled with 8T-8737 Seal Plugs in order to ensure that the connector is sealed. The seal plugs must be installed from the wire insertion side of the plug or receptacle. The seal plugs must seal correctly. The head of the seal plug should rest against the seal. Do not insert the head of the seal plug into the seal. Refer to Illustration 13 for correct installation of plugs.
Customer Connector
Illustration 15 | g01043375 |
Wiring harness and connectors for ECM and customer connector |
Ensure that the allen head screw in the customer connector is tightened to a torque of 2.25 ± 0.25 N·m (20 ± 2 lb in). All unused cavities for sockets and for pins must be filled with 8T-8737 Seal Plugs in order to ensure that the connector is sealed.
Deutsch DT Connectors
Illustration 16 | g00675955 |
A DT connector has a wedge that locks the pins and the sockets in place. The wedge can be removed and replaced without cutting the wires. The 147-6456 Wedge Removal Tool (DT Connector) aids in the removal of the wedges. When the receptacle is inserted into the plug, a click should be heard as the two halves lock together. The connector should not be able to 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 inch).
Inspect the plug and the receptacle in order to ensure that the following conditions are met:
- 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.
Deutsch HD Connectors
Illustration 17 | g01043380 |
Ensure that the wires in the plug align with the corresponding 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 by approximately 90 degrees until a click 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).
Wiring Considerations
The Caterpillar supplied engine wiring harness must not be modified in any way that may affect the engine operation.
All of the terminals and the splices on the customer connector should be sealed with Raychem ES2000 adhesive lined heat shrink tubing. An equivalent substitute may be used. Refer to Table 10.
Heat Shrink Tube     | ||
---|---|---|
Part Number     | I.D. Before Shrink     | I.D. After Shrink     |
8T-6342     | 3.20 mm (0.126 inch)     |
1.58 mm (0.062 inch)     |
3E-9553     | 4.70 mm (0.185 inch)     |
1.78 mm (0.070 inch)     |
125-7874     | 5.72 mm (0.225 inch)     |
1.27 mm (0.050 inch)     |
9X-2109     | 6.40 mm (0.252 inch)     |
3.20 mm (0.126 inch)     |
125-7875     | 7.44 mm (0.293 inch)     |
1.65 mm (0.065 inch)     |
119-3662     | 10.85 mm (0.427 inch)     |
2.41 mm (0.095 inch)     |
125-7876     | 17.78 mm (0.700 inch)     |
4.45 mm (0.175 inch)     |
8C-3423     | 68.00 mm (2.678 inch)     |
22.00 mm (0.866 inch)     |
Wire Size Requirements
The size of the wire that is used to connect all electrical components must be of adequate size for the maximum current in the circuit.
Note: All wire should be at least 16 AWG. Any exceptions to the wire size must be specified.
Harness Routing
Illustration 18 | g00816778 |
Harness Routing |
The routing of the OEM wiring harness should be designed so that the radius of any bend is greater than two times the diameter of the wiring harness. Curvatures should be avoided within 25 mm (1.0 inch) of any connector in order to avoid seal distortion (moisture entry path).
Requirements for the Battery Circuit
Grounding
NOTICE |
---|
Improper grounding can cause uncontrolled or unreliable circuit paths and electrical noise. This can result in damage to the engine bearings, and other engine components. |
Proper grounding of the unit and the engine electrical systems is necessary for proper performance and reliability.
Negative Battery Connection
All ground paths must be capable of carrying any likely fault currents.
The alternator should be grounded at the bus bar on the negative battery or grounded directly to the negative battery post.
Note: Grounding through frame members is not recommended.
Power Supply Connections to the Starting System
NOTICE |
---|
Improper grounding can cause uncontrolled or unreliable circuit paths and electrical noise. This can result in damage to the engine bearings, and other engine components. |
Wire Length to Connect the Starting Motor to the Battery     | |
Size of Wire     | Maximum Allowable Distance     |
0 AWG     | 2.5 m (8.20 ft)     |
00 AWG     | 3.25 m (10.66 ft)     |
000 AWG     | 4.0 m (13.12 ft)     |
0000 AWG     | 5.0 m (16.40 ft)     |
Table 11 gives the size of wire and the maximum allowable length of the wire that is recommended in order to connect the battery to the starting motor.
The size of wire to the positive battery which supplies the power to electrical components and electronic components must be of adequate size in order to carry the maximum current of the circuit.
The size of the wire that connects the electrical components and the electronic components to the negative battery bus bar must be of adequate size in order to carry the maximum current of the circuit.
The causes of intermittent shorts or power interruptions is often difficult to identify. Proper wire connections for all electrical systems and the connection to a common negative bus bar on the vessel are necessary for the correct performance and reliability of the engine.
The alternator, the starting motor, and all of the electrical systems must have a common ground with the negative battery terminal. The alternator and the starting motor must conform to the requirements of electrical isolation for marine applications.
If the alternator is grounded to an engine component, a ground strap must connect that component to the negative battery terminal. Also, that component must be electrically isolated from the engine.
Illustration 19 | g01042518 |
Battery Connections of Operator Stations for a Twin Engine Arrangement |
All negative battery connections on the components should be directly wired to the Negative Battery Bus Bar. Wire that is a minimum size of 12 AWG should be used to connect the operator stations to the Negative Battery Bus Bar that is located in the engine room.
Negative battery connections that conform to Illustration 19 ensure that all components in the electrical system have the Negative Battery Bus Bar in the engine room as a common reference point. Reliable operation of the electrical system requires that all of the components in the system are correctly connected.
All wires for the positive battery and the negative battery bus bar to the customer connector should have a wire size of 14 AWG.
Welding Guidelines for Engines with Electronic Controls
Proper welding procedures are necessary in order to avoid damage to the engine ECM, sensors, and associated components. A component should be removed from the engine prior to welding. If removal of the component is not possible, the following procedure must be followed on Caterpillar Electronic Engines. This procedure should provide the minimum risk of electronic component damage.
NOTICE |
---|
Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage. |
- Stop the engine. Turn the switched power (keyswitch) to the OFF position.
- Disconnect the negative battery cable from the battery. If a battery disconnect switch is installed, open the switch.
- Connect the welding ground cable as close as possible to the area that will be welded. Components which may be damaged by welding include bearings, hydraulic components, and electrical/electronic components.
Illustration 20 | g00818551 |
In Illustration 20, the current flow from the welder to the welder ground will not cause damage to any of the associated components. |
- Protect the wiring harness from welding debris and spatter.
- Use standard welding methods to weld the materials.
Switched Positive Battery and Unswitched Positive Battery
Illustration 21 | g01043419 |
Unswitched positive battery connections |
Note: All battery connections to the ECM must be utilized in order to prolong the service life of the ECM.
The switched positive battery and the unswitched positive battery connections to the ECM are made at the customer connector.
The ECM receives electrical power through the input for the switched positive battery.
The input for the unswitched positive battery is used to power ECM memory that contains maintenance information and certain logged diagnostics.
Powering the electronic control system through dedicated circuits with circuit breakers reduces the possibility of degradation of electronic control system performance. This also minimizes the chance of an engine shutdown due to a short in the electrical system. Additional loads should not be connected between the ECM and the circuit protection for the ECM.
Note: DO NOT use in-line fuses for circuit protection. Caterpillar recommends the use of circuit breakers for circuit protection. Circuit breakers should be located with other circuit protection in a centrally located, dedicated panel. If circuit breakers that automatically reset are used, consideration of the environment of the location of the breaker is critical and the effect on the trip point is critical. The trip point of some circuit breakers can be significantly reduced below the rated trip point if the circuit breaker is exposed to high temperatures. This can cause intermittent shutdowns that result with needless replacement of electronic components.
Suppression of Voltage Transients
The installation of transient suppression at the source of the transient is recommended. Caterpillar follows a stringent electrical environment standard that is similar to SAE recommended practices.
The use of inductive devices such as relays and solenoids can result in the generation of voltage transients in electrical circuits. Voltage transients that are not suppressed can exceed SAE specifications and lead to the degradation of the performance of the electronic control system.
Illustration 22 | g00737516 |
Using a diode in a relay in order to suppress voltage transients |
The OEM should specify relays and solenoids with built-in voltage transient suppression. Refer to Illustration 22 for ways to minimize voltage transients from relays and solenoids without built-in voltage transient suppression. Techniques include the installation of a diode or resistor of the proper size in parallel with the solenoid or the relay coil. Other techniques may also be used.
Inductive devices such as relays or solenoids should be located as far as possible from the components of the electronic control system. Wiring harnesses that are installed by the OEM should be routed as far as possible from the wiring harness of the electronic control system in order to avoid problems that are associated with electrical noise.
Customer Installed Components
Note: Refer to the appropriate Parts Manual for your engine for further details on parts information.
Throttle Position Sensor
The Throttle Position Sensor (TPS) eliminates the mechanical throttle and governor linkages. The TPS utilizes the lever movement by the operator to send an electrical signal to the ECM for the engine. The signal from the TPS and the signal from the speed/timing sensors are processed by the ECM in order to control the engine speed.
Pin Assignment on the Sensor     | Connection     |
Pin A     | Switched Positive Battery     |
Pin B     | Negative Battery Bus Bar     |
Pin C     | Throttle Position Signal     |
The output of the sensor is a constant frequency signal with a pulse width that varies with the throttle position. The Pulse Width Modulated signal (PWM) is expressed as a percentage of the duty cycle. This percentage is between 0 and 100 percent. The TPS will produce a minimum duty cycle when the throttle is released. The TPS will produce a maximum duty cycle when the throttle is fully actuated.
Illustration 23 | g00751431 |
Duty Cycle |
Illustration 24 | g00751478 |
Definition of PWM |
Illustration 25 | g00766798 |
Percent of Throttle Position versus PWM Input |
Throttle Position     | Duty Cycle     | Nominal Duty Cycle     |
Low idle     | 5-10%     | 8%     |
High idle     | 90-95%     | 92%     |
PWM Input Requirements
The following criteria are required for the correct operations of a throttle position sensor that is not Caterpillar:
"Active pull up/pull down with output protection"
"Sensor stop"
- Low stop 7.5% ± 2.5%
- High stop 92.5% ± 2.5%
"Output frequency"
- Minimum of 300 Hz
- Nominal of 500 Hz
- Maximum of 700 Hz
"High output voltage"
- Minimum of 4.5 VDC
- Maximum of 32 VDC
"Low output voltage"
- Minimum of -0.3 VDC
- Maximum of 0.5 VDC
"Sink current"
- -1.5 mA
"Source current"
- -2.0 mA
Note: The sourcing driver must be capable of sinking 1.5 mA if the output voltage of the output driver is less than 13.0 VDC.
"Output linearity"
- ± 2.5 % duty cycle versus throttle lever position
Illustration 26 | g00762874 |
Simulated Load for the ECM |
Throttle Synchronization Switch
The purpose of the synchronization switch is connecting multiple electronic control modules to a single throttle on the vessel. The single throttle controls the engine speed for all the engines. This feature improves the control of the vessel and this feature adds operator convenience.
A single throttle control for vessels that have multiple engines is standard practice which allows the transfer of throttle control to any other throttle.
The function of the synchronization can only be activated or deactivated when the desired engine speed of all engines are within 50 rpm of each other. Refer to Table 14.
Code for Synchronization of Throttle Controls     | ||
Synchronization for Input 1 Circuit     | Synchronization for Input 2 Circuit     | Throttle     |
Negative Battery     | Open     | Primary     |
Open     | Negative Battery     | Secondary     |
Open     | Open     | Primary     |
Multiple Installations of the Synchronization Switch
These engines support synchronization of the throttle for a single station. The synchronization is accomplished by the use of two switch inputs on each ECM in order to determine the synchronization of the throttle. The engine ECM is not designed to support synchronization switches from multiple stations.
Multiple stations complicate the wiring and multiple stations typically require some method of transferring control from one station to another station. The transfer of control may be accomplished by several methods. The manufacturer of the boat or the installer of the boat is responsible for determining the method and ensuring proper operation of synchronization.
If multiple switches for synchronization of the station are installed, care must be taken in order to prevent both of the inputs for the synchronization from being connected to the negative battery bus bar. If both inputs for synchronization are low, the ECM will only monitor the primary throttle and the inputs for synchronization will be ignored.
Throttle Control for Single Engine Installation
Illustration 27 | g01043044 |
Connections for the throttle position sensor for a single engine installation |
Synchronization for Two Engines
Illustration 28 | g01043046 |
Connections for the throttle position sensor for a twin engine installation |
Synchronization for Three Engines
Illustration 29 | g01043047 |
Connections for the throttle position sensor for three engine installation |
Synchronization for Four Engines
Illustration 30 | g01043048 |
Connections for the throttle position sensor for four engine installation |
Calibration of Throttle Position Sensor
Calibration of the throttle position sensor requires Cat ET.
Refer to Troubleshooting, SENR5015 for additional information on calibrating the throttle position sensor.
Throttle Linkage
Inspect the throttle linkage for components that are in the following conditions.
- Loose
- Bent
- Broken
- Missing
- Worn
The throttle linkage should operate without binding or excessive drag. The throttle linkage should automatically return to the position of low idle in less than one second.
Perform the following steps in order to adjust the throttle linkage.
- Turn the ignition switch to the OFF position.
- Connect Cat ET to the service tool connector.
- Turn the ignition switch to the ON position. Do not start the engine.
- Observe the indication for the duty cycle on the "Monitor Throttle Position Sensor Signal" screen of the electronic service tool.
- Place the throttle lever in the position for low idle. Adjust the throttle linkage.
When the engine is in low idle, the duty cycle should indicate between 5 and 10 percent. The duty cycle should increase when the throttle lever is moved inward from the position of the low idle.
- Place the throttle lever in the position of high idle. Adjust the throttle linkage.
When the engine is in high idle, the duty cycle should indicate between 90 and 95 percent. When the adjustment of high idle is made on some types of linkage, that adjustment may change the low idle position. Repeat the adjustment for low idle in order to verify that the low idle is correctly adjusted.
Remote Shutdown Switch
The ECM disables fuel injection in order to stop the engine when the remote shutdown switch is activated closed. The remote shutdown switch must be deactivated opened in order to restart the engine and the keyswitch must be cycled.
Illustration 31 | g01043441 |
Connection for remote shutdown switch |
Required Parts     | ||
---|---|---|
Part Number     | Description     | Qty     |
186-3736     | Connector Socket     | 1     |
3E-8768     | Switch     | 1     |
155-2705     | Rocker Actuator     | 1     |
5P-4571     | Blade Terminal     | 2     |
N/A     | 16 AWG Wire     | (1)     |
( 1 ) | Fabricated to length |
Input for the Trolling Mode
When the trolling mode is in operation, the full travel of the throttle lever causes the engine speed to change from low idle to the maximum programmed trolling speed. The trolling mode only engages if the engine speed is within 30 rpm of low idle. Trolling mode can also be activated when the engine is shut down.
When the transmission is in trolling mode, the switch input for the trolling mode is connected to the negative battery bus bar. The activation of the valve for trolling must automatically connect the switch input of the trolling mode to the negative battery bus bar. Table 17 shows the required parts for installation of the actuation of the trolling mode.
Minimum Engine Speed     | Maximum Engine Speed     | Default Engine Speed     |
900 rpm     | 1200 rpm     | 900 rpm     |
Required Parts     | ||
Part Number     | Description     | Qty     |
186-3736     | Connector Socket     | 1     |
N/A     | 16 AWG Wire     | (1)     |
( 1 ) | Fabricated to length |
Illustration 32 | g01043054 |
Connection for actuation of the trolling mode |
Note: A physical switch does not exist for actuation of the valve for trolling. When the valve for trolling is activated, the circuit is automatically completed.
Slow Vessel Mode Switch
When the slow vessel mode switch closes, the ECM reduces the programmed low idle to 550 rpm. This feature improves the maneuverability of the vessel in docking and "no wake" zones. Table 18 shows the required parts for installation of the slow vessel mode switch.
Required Parts     | ||
Part Number     | Description     | Qty     |
186-3736     | Connector Socket     | 1     |
3E-8766     | Switch     | 1     |
155-2706     | Rocker Actuator     | 1     |
5P-4571     | Blade Terminal     | 2     |
N/A     | 16 AWG Wire     | (1)     |
( 1 ) | Fabricated to length |
Illustration 33 | g01043059 |
Connection for the slow vessel mode switch |
Trip Clear Switch
When the trip clear switch is activated, the ECM clears the trip data. Then, the ECM starts a new log for the trip. This action clears the trip histograms and the trip total. The lifetime totals are not cleared. Table 19 shows the required parts for installation of the trip clear switch.
Required Parts     | ||
Part Number     | Description     | Qty     |
186-3736     | Connector Socket     | 1     |
3E-8768     | Switch     | 1     |
155-2706     | Rocker Actuator     | 1     |
5P-4571     | Blade Terminal     | 2     |
N/A     | 16 AWG Wire     | (1)     |
( 1 ) | Fabricated to length |
Illustration 34 | g01043063 |
Connection for trip clear switch |
Indicator Lamps
Installation of both a warning lamp and a diagnostic lamp is strongly recommended in order to alert the operator of problems that may be detected by the ECM. The warning lamp will come ON for five seconds when the ECM is first turned ON in order to indicate that the lamp circuit is functional.
Required Parts     | ||
---|---|---|
Part Number     | Description     | Qty     |
186-3736     | Connector Socket     | 2     |
    | Lamp     | 2     |
    | Circuit Protection (1 Amp)     | 1     |
N/A     | 16 AWG Wire     | (1)     |
( 1 ) | Fabricated to length |
Lamp Driver Electrical Specifications
Electrical specifications for the ECM low side drivers that are used for the diagnostic lamp and the warning lamp allow a maximum current load of 0.30 Amp (300 mA). The ECM does not provide diagnostic codes for either lamp circuit.
Low side ECM drivers provide a path to the negative battery terminal in order to activate the device (lamp, etc) that is connected to the circuit. While circuit protection is recommended for the lamp driver circuits, Caterpillar does not require dedicated circuit protection.
Illustration 35 | g01043069 |
Low side driver |
High side ECM drivers provide a path to the positive battery terminal in order to activate the device (lamp, etc) that is connected to the circuit. While circuit protection is recommended for the lamp driver circuits, Caterpillar does not require dedicated circuit protection.
Illustration 36 | g01043072 |
High side driver |
Diagnostic Lamp Operation
Installation of a diagnostic lamp is strongly recommended. The diagnostic lamp is used to alert the operator of an electronic control system malfunction (active diagnostic code).
Caterpillar's proprietary two digit flash codes can be viewed from the diagnostic lamp. A sequence of flashes represents the system diagnostic message (flash code). The first sequence of flashes represents the first digit of the flash code. After a two second pause, a second sequence of flashes which represent the second digit of the flash code will occur. Any additional flash codes will follow after a pause. These flash codes will be displayed in the same manner.
Note: Flash codes should only be used to indicate the nature of a diagnostic condition. Do not use flash codes to perform detailed troubleshooting.
Warning Lamp Operation
Installation of a warning lamp is strongly recommended. The warning lamp is used to alert the operator of an engine operating condition which has the potential to cause engine damage (event code).
The warning lamp will come ON for five seconds when the ECM is first turned ON in order to indicate that the lamp circuit is functional.
Warning Indicator Lamp or Alarm
The lamp or the alarm alerts the operator that a fault condition has occurred. If the following events occur, the warning lamp is activated:
- An active event code
- Derate mode for the engine
When the ECM is energized, the warning lamp will turn on for five seconds. The lamp will turn off, unless the ECM detects an active event code.
Low Oil Pressure Lamp
The low oil pressure lamp indicates the occurrence of low oil pressure. This condition is determined by the ECM which is based on the relationship between the engine speed and the actual oil pressure.
When the ECM is energized, the low oil pressure lamp will turn on for five seconds. Then, the lamp will turn off unless the ECM detects a low oil pressure condition.
High Coolant Temperature Lamp
The high coolant temperature lamp indicates the occurrence of high coolant temperature.
When the ECM is energized, the high coolant temperature lamp will turn on for five seconds. Then, the lamp will turn off unless the ECM detects a high coolant temperature condition.
Light for Low Coolant Level
The low coolant level lamp indicates the occurrence of low coolant level.
When the ECM is energized, the low coolant level lamp will turn on for five seconds. Then, the lamp will turn off unless the ECM detects a low coolant level.
Installation of Warning Lamp
Illustration 37 | g01043078 |
Schematic for warning lamps and alarms |
Required Parts     | ||
Part Number     | Description     | Qty     |
186-3736     | Connector Socket     | 6     |
2N-2371     | Indicator Lamp     | 6     |
7N-5876     | Lamp     | 6     |
9G-9813     | Alarm Gp     | 1     |
OR     | ||
123-9694     | Horn     | 1     |
Warning Alarms that Require More Than 300 mA
Illustration 38 | g01043081 |
Schematic for warning lamps and alarms that require more than 300 mA |
Optional Hour Meter
The ECM provides a signal for the hour meter. When the ECM reads an engine speed that is greater than 500 rpm, the ECM turns on the hour meter. This signal is actual engine hours.
Required Parts     | ||
---|---|---|
Part Number     | Description     | Qty     |
186-3736     | Connector Socket     | 2     |
9W-1494     | Service Meter Kit     | 1     |
N/A     | 16 AWG Wire     | (1)     |
( 1 ) | Fabricated to length |
Illustration 39 | g01043082 |
Connections for hour meter |
Maintenance Indicator Lamp
When the preventive maintenance interval occurs, such as PM Level 1, the maintenance indicator lamp turns on.
When the ECM runs against the map for air/fuel ratio control, the lamp turns on for 90 seconds.
When the ECM is energized, the maintenance indicator lamp will turn on for five seconds. The lamp will turn off unless the ECM detects a maintenance interval.
Optional Maintenance Clear Switch
The maintenance clear switch is required to reset the PM Level 1 for the maintenance indicator after maintenance on the engine is performed. The maintenance clear switch is standard equipment on the engine mounted control panel. The installation of the switch is optional.
Required Parts     | ||
---|---|---|
Part Number     | Description     | Qty     |
2N-2371     | Indicator Lamp     | 1     |
3E-8768     | Switch     | 1     |
7N-5876     | Lamp     | 1     |
186-3736     | Connector Socket     | 2     |
155-2706     | Rocker Actuator     | 1     |
5P-4571     | Blade Terminal     | 2     |
N/A     | 16 AWG Wire     | (1)     |
( 1 ) | Fabricated to length |
Illustration 40 | g01043545 |
Connection for maintenance clear switch |
Communication Data Links
The ECM provides output pins that are dedicated to the communication data links. The data links are available to share data between the ECM, the electronic service tools, and the electronic display modules.
The engine is equipped with a service tool connector. An additional customer supplied service tool connector may be installed for improved accessibility.
Optional Remote Electronic Service Tool
The optional electronic service tool is installed by the customer or the Original Equipment Manufacturer (OEM).
Required Parts     | ||
Part Number     | Description     | Qty     |
8T-9834     | Connector Plug (1)     | 1     |
9W-1951     | Receptacle As     | 1     |
8C-6354     | Receptacle Cap     | 1     |
186-3736     | Connector Socket     | 4     |
186-3735     | Connector Pin     | 6     |
8T-8737     | Seal Plug     | 3     |
143-5018     | Wire     | (2)     |
( 1 ) | This component is supplied by Caterpillar. |
( 2 ) | Fabricated to length |
The electronic service tool will operate when the engine is running. The electronic service tool will also operate when the engine is not running and the ignition switch turned to the ON position.
Illustration 41 | g01043084 |
Schematic of data link connections for the remote service tool |
The negative battery bus bar on the remote electronic service tool connector (pin B) must be connected directly to the negative battery bus bar. This circuit must not be connected to the negative battery terminal through any other path.
The wires for CDL and the ATA data links should be the 143-5018 Wire . The pair of wires should have a minimum of one twist per 25.4 mm (1.00 inch). The length of the wire between the remote electronic service tool and the customer connector should not exceed 30 m (98.4 ft).
ATA Data Link
A standard data link is available for the electronic control system. This data link is supported by the American Trucking Association (ATA). The ATA data link conforms to SAE J1587 and SAE J1708.
Parameters for SAE J1587 Data Link Broadcast     | |||||
---|---|---|---|---|---|
Parameter     | CID     | Bytes     | Resolution (Offset)     |
Byte Order in Message     | Transmission Rate     |
Engine Speed     | 190     | 2     | 0.25 rpm/bit     | 1     | 100 ms     |
Throttle Position     | 91     | 1     | 0.40%/bit     | 1     | 100 ms     |
Percent Engine Load     | 92     | 2     | 0.50%/bit     | 1     | 100 ms     |
Fuel Rate     | 183     | 2     | 0.00000434 gal/sec/bit     | 2     | 200 ms     |
Boost Pressure     | 102     | 1     | 0.86 kPa/bit     | 3     | 1.0 s     |
Coolant Temperature     | 110     | 1     | 0.55 °C/bit     | 3     | 1.0 s     |
Oil Pressure     | 100     | 1     | 3.45 kPa/bit     | 3     | 1.0 s     |
Fuel Pressure     | 94     | 1     | 3.45 kPa/bit     | 3     | 1.0 s     |
Inlet Air Temperature     | 105     | 2     | 0.55 °C/bit     | 3     | 1.0 s     |
Atmospheric Pressure     | 108     | 1     | 0.431 kPa/bit     | 4     | 10.0 s     |
Engine Diagnostic     | 196     | Variable     | CID and FMI     | 5     | 1.0 s     |
J1939 Data Link
The SAE J1939 CAN data link is used in order to communicate the engine information to a J1939 receiving device. The CAN data link is limited to broadcast messages only.
Connecting Modules to the CAN Data Link
Required Parts Installation of a Single Module     |
||
---|---|---|
Part Number     | Description     | Qty     |
5P-6001     | Heat Shrink Tube     | 6 cm (2.4 inch)     |
125-7876     | Heat Shrink Tube     | 15 cm (6 inch)     |
133-0969     | Connector Socket (Extended)     | 2     |
133-0970     | Receptacle As (Tee)     | 1     |
174-3016     | Receptacle As (Termination Resistor)     | 1     |
153-2707     | Cable (Shielded Twisted Pair)     | (1)     |
165-0200     | Cable As     | 1     |
174-0503     | Connecting Plug Kit (2)     | 1     |
186-3736     | Connector Socket     | 4     |
( 1 ) | Fabricated to length |
( 2 ) | Use the blue wedge. |
Required Parts Installation of Each Additional Module     |
||
---|---|---|
Part Number     | Description     | Qty     |
5P-6001     | Heat Shrink Tube     | 6 cm (2.4 inch)     |
125-7876     | Heat Shrink Tube     | 15 cm (6 inch)     |
133-0969     | Connector Socket (Extended)     | 2     |
133-0970     | Receptacle As (Tee)     | 1     |
153-2707     | Cable (Shielded Twisted Pair)     | (1)     |
165-0200     | Cable As     | 1     |
174-0503     | Connecting Plug Kit (2)     | 2     |
186-3736     | Connector Socket     | 4     |
( 1 ) | Fabricated to length |
( 2 ) | Use the blue wedge. |
Illustration 42 | g01043548 |
Schematic for the modules of the CAN data link |
Illustration 42 shows the connection of modules to the CAN data link. The following requirements must be met for installation of modules on the CAN data link:
- 153-2707 Cable (Shielded Twisted Pair) must be used for all CAN data link runs.
- The total length of the data link run must not exceed 40 m (130 ft).
- All splices into the data link require a 133-0970 Receptacle As (Tee) .
- A 174-3016 Receptacle As (Termination Resistor) must be installed at the end of the data link in order to ensure proper operation.
Note: A termination resistor for the CAN data link is included in the Caterpillar supplied wiring harness to the J61 customer connector. Only one additional termination resistor needs to be installed at the end of the data link run. Older engines do not have a factory installed termination resistor in the wiring harness. A termination resistor must be installed on both ends of the data link in order to ensure proper operation.
Use the following procedure to connect modules to the CAN data link:
- Run the CAN data link from the P61customer connector to a module.
- Run 153-2707 Cable (Shielded Twisted Pair) from the P3 customer connector to the location of the first module. Cut the cable to length.
Note: Older engines do not have a factory installed termination resistor in the wiring harness. A termination resistor must be installed on both ends of the data link in order to ensure proper operation.
Note: The end of the data link must be within approximately 150 mm (6 inch) of the module. The total length of the data link run must not exceed 40 m (130 ft).
- Remove 25 mm (1.0 inch) of insulation from both ends of the cable.
- Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.
- Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .
- Cut two 30 mm (1.2 inch) pieces of 5P-6001 Heat Shrink Tube . Slide a piece of the heat shrink tube over the shield at each end of the cable. Position the heat shrink tube so that 1 cm (0.4 inch) of the socket is covered and the remaining tubing is covering the shield. Apply heat until a complete seal is formed around the shield and the socket. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Cut two 50 mm (2 inch) pieces of 125-7876 Heat Shrink Tube . Slide a piece of the heat shrink tube over each end of the cable.
- Insert the wires from one end of the data link into the P3 customer connector. See Table 28.
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Table 28 Terminal Locations in P3 Customer Connector     Wire Color     Location in P3     Shield     16     Yellow     17     Green     18    
- Position the 125-7876 Heat Shrink Tube so that 20 mm (0.8 inch) of the exposed wires are covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Insert the sockets at the opposite end of the CAN data link into a 174-0503 Connecting Plug Kit . See Table 29. Insert the blue wedge into the connector in order to secure the terminals in place.
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Table 29 Terminal Locations in the Plug     Wire Color     Location in the Plug     Shield     C     Yellow     A     Green     B    
- Position the 125-7876 Heat Shrink Tube so that 10 mm (0.4 inch) of the plug is covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed around both the plug and the cable. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Plug the end of the data link into the single end of a 133-0970 Receptacle As (Tee).
Illustration 43 | g00783780 |
Illustration 44 | g00779822 |
- Run the data link from the tee to another tee for an additional module.
Note: For single module installations, proceed to Step 3.
- Run 153-2707 Cable (Shielded Twisted Pair) from the tee to the location of the next module. Cut the cable to length.
Note: The end of the data link must be within approximately 150 mm (6 inch) of the module. The total length of the data link run must not exceed 40 m (130 ft).
- Remove 25 mm (1.0 inch) of insulation from both ends of the cable.
- Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.
- Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .
- Cut two 30 mm (1.2 inch) pieces of 5P-6001 Heat Shrink Tube . Slide a piece of the heat shrink tube over the shield at each end of the cable. Position the heat shrink tube so that 10 mm (0.4 inch) of the socket is covered and the remaining tubing is covering the shield. Apply heat until a complete seal is formed around the shield and the socket. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Cut two 50 mm (2 inch) pieces of 125-7876 Heat Shrink Tube . Slide a piece of the heat shrink tube over each end of the cable.
- Install a 174-0503 Connecting Plug Kit on each end of the cable. See Table 30. Insert the blue wedge into the connector in order to secure the terminals in place.
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Table 30 Terminal Locations in the Plug     Wire Color     Location in Plug     Shield     C     Yellow     A     Green     B    
- Position the 125-7876 Heat Shrink Tube so that 10 mm (0.4 inch) of the plug is covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed around both the plug and the cable. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube. Perform this process on both ends of the cable.
- Plug one end of the new cable into one of the openings in the existing tee. Plug the other end of the new cable into the single end of a 133-0970 Receptacle As (Tee) for the additional module.
- If you are installing additional modules, repeat Step 2 for each module.
Illustration 45 | g00746640 |
- Connect a receiving module to the tee.
- Cut a 50 mm (2 inch) piece of 125-7876 Heat Shrink Tube . Slide the heat shrink tube over the module end of the cable assembly.
- Connect the green wire J1939 Data- and the yellow wire J1939 Data+ of the cable assembly to the correct terminals of the plug for the module.
Note: Do not connect the shield to the receiving module.
- Trim the shield back to the existing heat shrink tube on the cable assembly. Position the 125-7876 Heat Shrink Tube so that the shield is completely insulated and a proper seal can be obtained. Apply heat until a complete seal is formed. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Repeat Step 3 for each module.
Illustration 46 | g00746601 |
- Connect the service tool connector.
- Run 153-2707 Cable (Shielded Twisted Pair) from the last 133-0970 Receptacle As (Tee) to the J42 service tool connector. Cut the cable to length.
Note: The total length from the 133-0970 Receptacle As (Tee) to the communications adapter should be no more than 1.00 m (3.28 ft).
- Remove 25 mm (1.0 inch) of insulation from both ends of the cable.
- Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.
- Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .
- Cut two 30 mm (1.2 inch) pieces of 5P-6001 Heat Shrink Tube . Slide a piece of the heat shrink tube over the shield at each end of the cable. Position the heat shrink tube so that 10 mm (0.4 inch) of the socket is covered and the remaining tubing is covering the shield. Apply heat until a complete seal is formed around the shield and the socket. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Cut two 50 mm (2 inch) pieces of 125-7876 Heat Shrink Tube . Slide a piece of the heat shrink tube over each end of the cable.
- Insert the wires from one end of the data link into the J42 service tool connector.
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Table 31 Terminal Locations in the J42 Service Tool Connector     Wire Color     Location in J42     Shield     C     Yellow     G     Green     F    
- Position the 125-7876 Heat Shrink Tube so that 20 mm (0.8 inch) of the exposed wires are covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Insert the sockets at the opposite end of the CAN data link into a 174-0503 Plug Kit . Insert the blue wedge into the connector in order to secure the terminals in place.
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Table 32 Terminal Locations in the Plug     Wire Color     Location in Plug     Shield     C     Yellow     A     Green     B    
- Position the 125-7876 Heat Shrink Tube so that 10 mm (0.4 inch) of the plug is covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed around both the plug and the cable. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.
- Run 153-2707 Cable (Shielded Twisted Pair) from the last 133-0970 Receptacle As (Tee) to the J42 service tool connector. Cut the cable to length.
- Connect a termination resistor to the tee at the end of the data link.
- Connect a 174-3016 Receptacle As (Termination Resistor) to the 133-0970 Receptacle As (Tee).
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Table 33 Parameters for the CAN Data Link     Status Parameters     PGN     Percent Load     61443     Battery Voltage     65271     Boost Pressure     65270     Coolant Temperature     65262     Engine Hours     65253     Engine Speed     61444     Fuel Pressure     65263     Fuel Temperature     65262     Fuel Rate     65266     Intake Manifold Temperature     65270     Oil Pressure     65263     Oil Temperature     65262     Transmission Pressure     65272     Transmission Temperature     65272    
- Connect a 174-3016 Receptacle As (Termination Resistor) to the 133-0970 Receptacle As (Tee).
CAT Data Link
The CAT data link is a proprietary communication medium. The CAT data link is for communication with other Caterpillar microprocessor based devices such as the Electronic Control Module (ECM), Engine Monitoring System (EMS), Global Positioning System (GPS), Engine Vision Interface Module (EVIM), Cat ET, etc.
Data Loops
A device that is incorrectly wired or incorrectly connected to the CAT data link will result in a data loop that will cause the CAT data link to work improperly.
The following precautions will help prevent data loops and the following precautions will help improve reliability of the system:
- Use the 143-5018 Wire (Twisted Pair) for connecting components to the data link.
- Use a dedicated terminal strip for data link connections.
- Terminate all the wires at the terminal strips.
- Locate the terminal strip so that the length of the wire between data link connections is minimized.
- The combined length of data link wires should not exceed 30 m (98.4 ft).
- Only one set of twisted pair of data wires should be installed to the bridge displays.
- The data link wires should be installed from the terminal strip in the engine room to the first station. Only one set of twisted pair of data wires should be run to the bridge displays.
- If a second station utilizes a Caterpillar display, the data link wires should be installed from the terminal strip in the engine room to the first station and continued from the first station to the second station.
- Do not splice wires.
- Do not solder wires.
Illustration 47 | g01043554 |
Reference Materials
For additional information, use the following publications:
- Electrical Schematic, SENR5030, "3412E Marine Engine"
- Electrical Schematic, SENR9657, "C30 Marine Engine"
- Electrical Schematic, RENR8038, "C32 Marine Engine"
- Operation and Maintenance Manual, SEBU7178, "3412E and C30 Marine Engines"
- Operation and Maintenance Manual, SEBU7908, "C32 Marine Engine"
- Troubleshooting, SENR5015, "3412E, C30 and C32 Marine Engines"
- Pocket Guide, SEBD0402, "Guidelines for Routing and Installing Wire Harness Assemblies"
- Special Publication, NEHS0685, "Caterpillar Electronic Technician (Cat ET)"