Electronic Installation Guide{1900} Caterpillar


Electronic Installation Guide{1900}

Usage:

3412E 9KS
Marine Engines:
3412E (S/N: 9KS1-UP; 9PW1-UP)
C30 (S/N: CLX1-UP)
C32 (S/N: RXB1-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.

------ WARNING! ------

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 1g00879646

Component Locations




Illustration 2g00879645

Sensor locations (top view)




Illustration 3g00881458

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

Table 1
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.

Table 2
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

Table 3
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

Table 4
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

Table 5
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.

Table 6
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 4g00647144

(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.

  1. Turn the keyswitch to the OFF/RESET position. If the keyswitch is not placed in the OFF/RESET position, the engine may start.

  1. Connect cable (2) between the "COMPUTER" end of communication adapter (3) and the RS232 serial port of PC (1) .

  1. Connect cable (4) between the "DATA LINK" end of communication adapter (3) and the service tool connector.

  1. 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.

Table 7
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 5g00763648

Voltage measurement

Measuring Current in Switch Circuits




Illustration 6g00763649

Current measurement

Measuring Resistance in Switch Circuits




Illustration 7g00763650

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

Table 8
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.

Table 9
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 8g01042483

3E-87663E-8768 Switches

(R) ON (top or left)

(S) NONE (center)

(T) OFF (bottom or right)

(1) Tabs for the actuator




Illustration 9g01042484

Schematic of 3E-87663E-8768 Switches

The backlight that is connected to switch terminals (A) and (B) turns on when contacts (2) and (3) are closed.




Illustration 10g01042486

3E-8772 Rocker Switch

(R) ON (top or left)

(S) OFF (center)

(T) ON (bottom or right)

(1) Tabs for the actuator




Illustration 11g01042488

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 12g00816724

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 13g00690571

Installation of seal plugs




Illustration 14g00738352

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 15g01043375

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 16g00675955

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 17g01043380

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.

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 18g00816778

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.


Table 11
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 19g01042518

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.


  1. Stop the engine. Turn the switched power (keyswitch) to the OFF position.

  1. Disconnect the negative battery cable from the battery. If a battery disconnect switch is installed, open the switch.



    Illustration 20g00818551

    In Illustration 20, the current flow from the welder to the welder ground will not cause damage to any of the associated components.

  1. 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.

  1. Protect the wiring harness from welding debris and spatter.

  1. Use standard welding methods to weld the materials.

Switched Positive Battery and Unswitched Positive Battery




Illustration 21g01043419

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 22g00737516

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.

Table 12
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 23g00751431

Duty Cycle




Illustration 24g00751478

Definition of PWM




Illustration 25g00766798

Percent of Throttle Position versus PWM Input

Table 13
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 26g00762874

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.

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 27g01043044

Connections for the throttle position sensor for a single engine installation

Synchronization for Two Engines




Illustration 28g01043046

Connections for the throttle position sensor for a twin engine installation

Synchronization for Three Engines




Illustration 29g01043047

Connections for the throttle position sensor for three engine installation

Synchronization for Four Engines




Illustration 30g01043048

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.

  1. Turn the ignition switch to the OFF position.

  1. Connect Cat ET to the service tool connector.

  1. Turn the ignition switch to the ON position. Do not start the engine.

  1. Observe the indication for the duty cycle on the "Monitor Throttle Position Sensor Signal" screen of the electronic service tool.

  1. 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.

  1. 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 31g01043441

Connection for remote shutdown switch

Table 15
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.

Table 16
Minimum Engine Speed     Maximum Engine Speed     Default Engine Speed    
900 rpm     1200 rpm     900 rpm    

Table 17
Required Parts    
Part Number     Description     Qty    
186-3736     Connector Socket     1    
N/A     16 AWG Wire      (1)    
( 1 ) Fabricated to length



Illustration 32g01043054

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.

Table 18
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 33g01043059

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.

Table 19
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 34g01043063

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.

Table 20
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 35g01043069

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 36g01043072

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 37g01043078

Schematic for warning lamps and alarms

Table 21
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 38g01043081

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.

Table 22
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 39g01043082

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.

Table 23
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 40g01043545

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).

Table 24
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 41g01043084

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.

Table 25
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

Table 26
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.

Table 27
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 42g01043548

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:




    Illustration 43g00783780



    Illustration 44g00779822

  1. Run the CAN data link from the P61customer connector to a module.

      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).

    1. Run 153-2707 Cable (Shielded Twisted Pair) from the P3 customer connector to the location of the first module. Cut the cable to length.

    1. Remove 25 mm (1.0 inch) of insulation from both ends of the cable.

    1. Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.

    1. Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .

    1. Crimp a 133-0969 Connector Socket (Extended) on each end of the shield with a 1U-5804 Crimp Tool .

    1. 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.

    1. 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.

    1. Insert the wires from one end of the data link into the P3 customer connector. See Table 28.

      Table 28
      Terminal Locations in P3 Customer Connector    
      Wire Color     Location in P3    
      Shield     16    
      Yellow     17    
      Green     18    

    1. 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.

    1. 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.

      Table 29
      Terminal Locations in the Plug    
      Wire Color     Location in the Plug    
      Shield     C    
      Yellow     A    
      Green     B    

    1. 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.

    1. Plug the end of the data link into the single end of a 133-0970 Receptacle As (Tee).



    Illustration 45g00746640

  1. Run the data link from the tee to another tee for an additional module.

    Note: For single module installations, proceed to Step 3.

      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).

    1. Run 153-2707 Cable (Shielded Twisted Pair) from the tee to the location of the next module. Cut the cable to length.

    1. Remove 25 mm (1.0 inch) of insulation from both ends of the cable.

    1. Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.

    1. Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .

    1. Crimp a 133-0969 Connector Socket (Extended) on each end of the shield with a 1U-5804 Crimp Tool .

    1. 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.

    1. 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.

    1. 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.

      Table 30
      Terminal Locations in the Plug    
      Wire Color     Location in Plug    
      Shield     C    
      Yellow     A    
      Green     B    

    1. 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.

    1. 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.

    1. If you are installing additional modules, repeat Step 2 for each module.



    Illustration 46g00746601

  1. Connect a receiving module to the tee.

    1. Plug a 165-0200 Cable As into the 133-0970 Receptacle As (Tee) .

    1. 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.

      Note: Do not connect the shield to the receiving module.

    1. 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.

    1. 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.

    1. Repeat Step 3 for each module.

  1. Connect the service tool connector.

    1. 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).

    1. Remove 25 mm (1.0 inch) of insulation from both ends of the cable.

    1. Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.

    1. Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .

    1. Crimp a 133-0969 Connector Socket (Extended) on each end of the shield with a 1U-5804 Crimp Tool .

    1. 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.

    1. 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.

    1. Insert the wires from one end of the data link into the J42 service tool connector.

      Table 31
      Terminal Locations in the J42 Service Tool Connector    
      Wire Color     Location in J42    
      Shield     C    
      Yellow     G    
      Green     F    

    1. 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.

    1. 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.

      Table 32
      Terminal Locations in the Plug    
      Wire Color     Location in Plug    
      Shield     C    
      Yellow     A    
      Green     B    

    1. 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.

    1. Plug the 174-0503 Plug Kit into the double end of a 133-0970 Receptacle As (Tee) .

  1. Connect a termination resistor to the tee at the end of the data link.

    1. Connect a 174-3016 Receptacle As (Termination Resistor) to the 133-0970 Receptacle As (Tee).

      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    

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 47g01043554

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)"

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