Electronic Installation Guide{1000} Caterpillar

Engine:

C18 (S/N: CYN1-UP)

C9 (S/N: C9A1-UP)

Introduction

This document should be used with the electrical schematic and the troubleshooting manual for the installation. The document provides information for wiring the engine electronics and programming the engine electronics. The installation guide should be fully read before you start the installation. This will help you understand the requirements in order to complete the installation.

The troubleshooting manual will have following information:

• System overview

• Electronic Service Tool

• Sensors and electrical connectors

Reference: Electrical Schematic, RENR7937, "C18 Marine Engine Electrical System "

Reference: Electrical Schematic, RENR8119, "C9 Marine Engine Electrical System"

Reference: Troubleshooting, RENR5032, "C9 Marine Auxiliary Engine"

Reference: Troubleshooting, RENR5013, "C18 Marine Engine"

Reference: Special Instruction, REHS2566, "Programming ECM Governor Gain Parameters"

Reference: Operation and Maintenance Manual, SEBU7912, "C9 Marine Auxiliary and Generator Set Engines"

Reference: Operation and Maintenance Manual, SEBU7917, "C18 Marine Auxiliary Engine "

Reference: Service Manual, SENR5002, "Installation Guide for Marine Engine Electronic Displays"

Reference: Service Manual, RENR7651, "Marine Multi-Station Control System"

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 the operation, maintenance and repair information. Do not operate or perform any maintenance or repair on this product, until you understand 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. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Caterpillar dealers will have the most current information.

Show/hide table

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.

Required Tools

Table 1

Required Service Tools
Part Number	Description
1U-7563	Hex Key Wrench
1U-5804	Crimp Tool (12 to 18 AWG)
7X-1710	Multimeter Probes
9U-7330 or 146-4080	Digital Multimeter Digital Multimeter Gp (RS232)
147-6456 (1)	Wedge Removal Tool (DT Connector)
1U-5805	Wire Removal Tool
151-6320 (1) (2)	Wire Removal Tool
175-3700	Connector Repair Kit (Deutsch DT)
190-8900	Connector Repair Kit (Deutsch)
140-9944	Terminal Repair Kit
9U-6070 (3)	Heat Gun Gp (120 VOLT, 50/60-HZ)
JERD2124	"Electronic Technician Program" (Caterpillar Electronic Technician (ET))
JERD2129	"Data Subscription for All Engines and Machines"
171-4400 (4)	Communication Adapter Gp (Cat ET to ECM Interface)
237-7547 (5)	Adapter Cable As

( 1 )	Included in 175-3700 Connector Repair Kit (Deutsch DT)
( 2 )	Included in 190-8900 Connector Repair Kit (Deutsch)
( 3 )	Use for the heat shrink tube
( 4 )	7X-1700 Communication Adapter Gp may also be used.
( 5 )	The 237-7547 Adapter Cable As is required to connect to the USB port on computers that are not equipped with a RS232 serial port.

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.

There are other tools that are required to troubleshoot the engine electronics. Refer to the appropriate Troubleshooting Guide for your engine for more information.

System Configuration Parameters

System configuration parameters are parameters that affect emissions and power of the engine applications. 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. System configuration parameters consist of the following values.

• "Selected Engine Rating Parameters"

• "ECM Identification Parameters"

• "Engine/Gear Parameters"

• "Maintenance Parameters"

• "Security Access Parameters"

The ECM Identification Parameters must be programmed if the ECM is replaced and/or you reprogram the engine rating. If a new personality module is flashed, it is not necessary to reprogram the "ECM Identification Parameters". Proper values for these parameters are available on the Cat ET. Certain configuration parameters are also stamped on the engine information plate.

Note: If the parameters that are protected with the factory passwords are changed, the Caterpillar warranty may be voided.

Rating Configuration

The Rating Configuration is defined by the performance maps in the software.

Rated Real Genset Power

The output power of the engine in kilowatts

Rated Apparent Power

The kVA rating of the engine

Rated Frequency

The line frequency of the generator

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.

Rated Engine Speed

The Rated Engine Speed is the optimum speed of the engine.

Engine Serial Number

The 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.

Coolant Level Sensor

The coolant level sensor may be installed or not installed.

Equipment ID

Equipment ID allows the customer to enter a description into the ECM in order to identify 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.

Personality Module Description

The Personality Module Description describes the engine model and the fuel system of the engine.

Personality Module Part Number

The Personality Module Part Number is the part number in the Caterpillar system that indicates the software version that currently resides in the engine ECM.

Personality Module Release Date

The Personality Module Release Date is the date of release for the software in the personality module.

ECM Serial Number

The ECM Serial Number is stored in the memory of the ECM. The "ECM Serial Number" can be accessed by the use of the service tool.

Total Tattletale

The Total Tattletale parameter counts the number of changes to system parameters.

Low Idle Speed

Low Idle Speed is the minimum allowable operating speed for the engine.

Engine Acceleration Rate

The Engine Acceleration Rate is the maximum ramp rate in order to reach desired engine speed.

Engine Speed Droop

The Engine Speed Droop determines the change in the reduction of engine speed at full load from the engine speed at no load. Droop can be adjusted for stability of engines with different rates of speed changes. Engine Speed Droop allows the operator to equalize the load between engines that are operating in parallel.

Droop Mode Selection

Droop Mode Selection allows the customer to select either droop or isochronous mode.

Governor Gain Factor

The Governor Gain Factor is a parameter that is used in determining the engine's rate of response to an engine load.

Governor Minimum Stability Factor

Governor Minimum Stability Factor functions in order to eliminate steady state speed error. The parameter is used by the ECM when the steady state speed error is less than 20 rpm.

Governor Maximum Stability Factor

Governor Maximum Stability Factor functions in order to eliminate steady state speed error. The parameter is used by the ECM when the steady state speed error is greater than 20 rpm.

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.

FTS (Full Torque Setting)

FTS is similar to "FLS". Factory passwords are required.

Control Ether Starting Aid (C18)

The control has the following features:

• Pulse operated

• Able to disable the control in Cat ET

• The control has automatic controls and manual controls.

• This tracks the amount of ether used and able to reset the tracking.

Parameter Tables

Table 2

C9 Parameters
System Configuration Parameters
Parameter	Available Range or Options	Default	Required Password
Selected Engine Ratings
Rating Number	Software Dependent		None
Rated Frequency	Software Dependent		Read Only (1)
Rated Engine Speed	Software Dependent		Read Only (1)
Rated Real Genset Power	kVA (if applicable)	Rated power	Read Only (1)
Rated Apparent Genset Power	Kilowatts (if applicable)	Rated power	Read Only (1)
Rating Configuration	Low Emissions or Low "Brake Specific Fuel Consumption (BSFC)"	Rated power	Read Only (1)
Rated Standby Genset Power	Software Dependent		Read Only (1)
ECM Identification Parameters
Equipment ID	17 alphanumeric characters	Blank	Customer
Engine Serial Number	0XX00000 or XXX00000	Blank	Factory
ECM Serial Number	Hardware Dependent	Blank	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 Acceleration Rate	5 - 2000 rpm/sec	500	Customer
Low Idle Speed	600 to 1200 rpm	1200	Customer
Engine Speed Droop	0.0 - 8.0 %	0.0 %	Customer
Droop mode switch	Installed or not installed	Not installed	Customer
I/O Configuration Parameters
Fuel Temperature Sensor	Installed or Not installed	Not installed	Customer
Coolant Level Sensor	Installed or not installed	Not installed	Customer
Droop/Isochronous Switch Enable	Enabled or Disabled	Enabled	Customer
Desired Speed Input Configuration	PWM or CAN	PWM	Customer
Secondary Desired Speed Input Configuration	Not Installed or PWM	PWM	Customer
Fuel Enable Input Configuration	Switch to Ground or CAN input	Switch	Customer
Secondary Fuel Enable Input Enable Status	Enable or Disable	Disable	Customer
System Parameters
FLS	Programmed at the Factory		Factory
FTS	Programmed at the Factory		Factory
Governor Gain Factor	0 - 65,535	47186	Customer
Governor Minimum Stability Factor	0 - 65,535	2818	Customer
Governor Maximum Stability Factor	0 - 65,535	7864	Customer
Maintenance hours	0 - 65535 hours	0	Customer

( 1 )

This parameter can be viewed only. No changes are allowed.

Table 3

C18 Parameters
System Configuration Parameters
Parameter	Available Range or Options	Default	Required Password
Selected Engine Ratings
Rating Number	Software Dependent		None
Rated Frequency	Software Dependent		Read Only (1)
Rated Engine Speed	Software Dependent		Read Only (1)
Rated Real Genset Power	Kilowatts (if applicable)	Rated Power	Read Only (1)
Rated Apparent Genset Power	kVA (if applicable)	Rated Power	Read Only (1)
Rating Configuration	Low Emissions or Low Brake Specific Fuel Consumption (BSFC)	Rated Power	Read Only (1)
ECM Identification Parameters
Equipment ID	17 alphanumeric characters	Blank	Customer
Engine Serial Number	0XX00000 or XXX00000	Blank	Factory
ECM Serial Number	Hardware Dependent	Blank	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 Acceleration Rate	5 - 2000 rpm/sec	500	Customer
Low Idle Speed (optional)	600 to 1200 rpm	1200	Customer
Engine Speed Droop	0.0 - 8.0 %	"3 %"	Customer
Droop/Isochronous Switch Enable (optional)	"Enabled" or "Disabled"	"Enabled"	Customer
Droop Mode Selection	"Droop" or "Isochronous"	"Droop"	Customer
I/O Configuration Parameters
Ether	Installed or not installed	Not installed	Customer
Exhaust Temperature Sensor Installation Status	Installed or not installed	Not installed	Customer
Engine Oil Temperature Sensor Installation Status	Installed or not installed	Not installed	Customer
Desired Speed Input Configuration	PWM or CAN	PWM	Customer
Secondary Desired Speed Input Configuration	Not Installed or PWM	PWM	Customer
Fuel Enable Input Configuration	Switch to Ground or CAN input	Switch	Customer
Secondary Fuel Enable Input Enable Status	Enable or Disable	Disable	Customer
Coolant Level Sensor	Installed or not installed	Not installed	Customer
Passwords
Customer Password #1	8 alphanumeric characters	Blank	Customer
Customer Password #2	8 alphanumeric characters	Blank	Customer
System Parameters
FLS	Programmed at the Factory		Factory
FTS	Programmed at the Factory		Factory
Governor Gain Factor	0 - 65,535	Software dependent	Customer
Governor minimum Stability Factor	0 - 65,535	Software dependent	Customer
Governor Maximum Stability Factor	0 - 65,535	Enabled	Customer
Maintenance Hours	0 - 65535 hours	0	Customer

( 1 )

This parameter can be viewed only. No changes are allowed.

Parameter Worksheets

Note: Providing the customer with a printed copy of the "Configuration" and the "Monitoring System" screens from the Cat ET is good practice. You may also copy the following table with this information for the customer.

Table 4

C9 Parameter Worksheet
Description	Value
Personality Module Description
Rating Number
Rated Power
Rated Peak Torque
Top Engine Speed Range
Test Specification
Personality Module Part Number
Personality Module Release Date
Equipment ID
Engine Serial Number
ECM Serial Number
Total Tattletale
FLS
FTS
Low Idle Speed
Fuel Temperature Sensor
Coolant Level Sensor
Droop/Isochronous Switch Enable
Desired Speed Input Configuration
Secondary Desired Speed Input Configuration
Fuel Enable Input Configuration
Secondary Fuel Enable Input Enable Status
Governor Gain Factor
Governor minimum Stability Factor
Governor Maximum Stability Factor
Injector Codes
Injector Code (1)
Injector Code (2)
Injector Code (3)
Injector Code (4)
Injector Code (5)
Injector Code (6)

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. Incorrectly changing the "FLS" and/or the "FTS" may result in engine damage. Incorrectly changing the "FLS" and/or the "FTS" may also void the Caterpillar warranty.

Table 5

C18 Parameter Worksheet
Description	Value
Personality Module Description
Rating Number
Rated Power
Rated Peak Torque
Top Engine Speed Range
Test Specification
Personality Module Part Number
Personality Module Release Date
Equipment ID
Engine Serial Number
ECM Serial Number
Total Tattletale
FLS
FTS
Low Idle Speed
Engine Location
Number of Synchronized Engines Configuration
Cold Cylinder Cutout engine
Ether
Exhaust Temperature Sensor Installation Status
Engine Oil Temperature Sensor Installation Status
Desired Speed Input Configuration
Secondary Desired Speed Input Configuration
Fuel Enable Input Configuration
Secondary Fuel Enable Input Enable Status
Coolant Level Sensor
Governor Maximum Stability Factor
Information from Engine Information Plate
Engine Serial Number
FTS
FLS
Injector Codes
Injector Code (1)
Injector Code (2)
Injector Code (3)
Injector Code (4)
Injector Code (5)
Injector Code (6)

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. Incorrectly changing the "FLS" and/or the "FTS" may result in engine damage. Incorrectly changing the "FLS" and/or the "FTS" may also void the Caterpillar warranty.

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. When any of these conditions occur, the appropriate Event code will trip. The following tables represent the conditions that are monitored and the programmable trip points for each of the conditions:

Table 6

C9 Monitoring System Parameters
Parameter	Action	Delay Time in Seconds			Trip Point			"Disable"
		Min	Max	Default	Min	Max	Default
Low Engine Oil Pressure	Warning	N/A	N/A	8	N/A	N/A	(1)	YES
	Derate	N/A	N/A	4	N/A	N/A	(1)	YES
	Engine Shutdown	N/A	N/A	2	N/A	N/A	(1)	YES
High Engine Coolant Temperature	Warning	N/A	N/A	10	N/A	N/A	112 °C (235 °F)	YES
	Derate	N/A	N/A	10	N/A	N/A	116 °C (241 °F)	YES
	Engine Shutdown	N/A	N/A	10	N/A	N/A	119 °C (246 °F)	YES
Engine Overspeed 50 Hz	Warning	N/A	N/A	0	N/A	N/A	1700 rpm	NO
	Engine Shutdown	N/A	N/A	0	N/A	N/A	1800 rpm	YES
Engine Overspeed 60 Hz	Warning	N/A	N/A	0	N/A	N/A	2060 rpm	NO
	Engine Shutdown	N/A	N/A	0	N/A	N/A	2160 rpm	YES
High Engine Inlet Air Temperature	Warning	N/A	N/A	8	60 °C (140 °F)	75 °C (167 °F)	75 °C (167 °F)	YES
	Derate	N/A	N/A	8	66 °C (150 °F)	79 °C (174.2 °F)	79 °C (174.2 °F)	YES
Low Coolant Level	Warning	4	60	30	N/A	N/A	N/A	YES
	Derate	4	60	30	N/A	N/A	N/A	YES
High Fuel Temperature	Warning	N/A	N/A	30	N/A	N/A	N/A	YES
	Derate	N/A	N/A	30	N/A	N/A	N/A	YES
Low Fuel Pressure	Warning	1	30	10	N/A	N/A	(1)	YES
High Fuel Pressure	Warning	1	30	8	N/A	N/A	(1)	YES

( 1 )

Map Dependent

Table 7

C18 Monitoring System Parameters
Parameter	Action	Delay Time in Seconds			Trip Point			"Disable"
		Min	Max	Default	Min	Max	Default
Low Engine Oil Pressure	Warning	N/A	N/A	30	N/A	N/A	(1)	YES
	Shutdown	0	30	2	N/A	N/A	(1)	YES
High Engine Coolant Temperature	Warning	N/A	N/A	5	90 °C (194 °F )	103 °C (217 °F)	103 °C (217 °F)	YES
	Derate	N/A	N/A	5	90 °C (194 °F )	107 °C (2256 °F)	105 °C (221 °F)	YES
	shutdown	N/A	N/A	20	90 °C (194 °F )	107 °C (224 °F)	106 °C (223 °F)	YES
Low Engine Coolant Temperature	Warning	N/A	N/A	5	17 °C (62 °F)	29 °C (84 °F)	-4 °C (24 °F)	YES
Engine Overspeed	Warning	N/A	N/A	0	N/A	N/A	2200 rpm	YES
	Derate	N/A	N/A	N/A	N/A	N/A	2300 rpm	YES
High Exhaust Temperature (Optional)	Warning	1	30	10	600 °C (1112 °F)	900 °C (1652 °F)	800 °C (1472 °F)	YES
High Engine Oil Temperature (Optional)	Warning	1	60	10	85 °C (185 °F)	120 °C (248 °F)	110 °C (230 °F)	YES
	Derate	1	60	10	85 °C (185 °F)	120 °C (248 °F)	115 °C (239 °F)	YES
High Engine Inlet Air Temperature	Warning	1	30	10	N/A	N/A	75.5 °C (168 °F)	YES
High Fuel Temperature	Warning	1	30	30	65 °C (149 °F)	85 °C (185 °F)	80 °C (176 °F)	YES
Low atmospheric pressure	Derate	N/A	N/A	0	55 kPa (8 psi)	98 kPa (14.2139 psi)	92.5 kPa (13.41 psi)	YES
High Fuel Pressure	Warning	1	30	2	N/A	N/A	(1)	YES
Low Fuel Pressure	Warning	1	30	2	N/A	N/A	(1)	YES
Low Coolant Level (Optional)	Warning	4	60	30	N/A	N/A	N/A	YES
	Derate	4	60	30	N/A	N/A	N/A	YES

( 1 )

Map Dependent

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 J61/P61 customer connector should be sealed with Raychem ES2000 adhesive lined heat shrink tubing. An equivalent substitute may be used. Refer to Table 8.

Table 8

Adhesive Lined Heat Shrink Tubing
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)

Requirements for the Wire Sizes

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. Observe the requirements in Table 9.

Note: All wires should be at least 16 AWG. Any exceptions to the wire size must be specified.

Table 9

Requirements for Wire Sizes
Circuit	Location	Size	Part Number
- Battery	Negative Battery Bus Bar	4 AWG	-
- Battery	J61:2 J61:3 J61:9	14 AWG	-
+ Battery (Switched)	J61:30	14 AWG	-
+ Battery (Unswitched)	J61:1 J61:5 J61:8	14 AWG	-
Cat Data link +	J61:7	18 AWG	143-5018 (1)
Cat Data link -	J61:6	18 AWG
J1939 (CAN) Data Link +	J61:17	19 AWG	153-2707 (2)
J1939 (CAN) Data Link -	J61:18	19 AWG
J1939 (CAN) Data Link Shield	J61:16	19 AWG
All Other Applications	-	16 AWG	-

( 1 )	143-5018 Electrical Cable
( 2 )	153-2707 Electrical Cable

Table 10

Metric Equivalents for AWG Numbers
AWG	20	19	18	16	14	12	4
Diameter in mm	0.5	0.65	0.8	1	2	3	19

Harness Routing

Illustration 1	g00878503
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

Show/hide table

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 return paths to the negative battery must be capable of carrying any likely fault currents.

The starter should be connected directly to the negative battery post. The alternator must be connected to the negative battery, bus bar, or negative side of the starter motor.

Welding on a Vessel that is Equipped with an Electronic Controlled Engine

Refer to the appropriate Troubleshooting Guide for more information about welding on a vessel that is equipped with an electronic controlled engine. Also refer to the appropriate Operation and Maintenance Manual for more information about welding.

Switched Positive Battery and Unswitched Positive Battery

Illustration 2	g00854176

Note: All battery connections to the ECM must be utilized in order to prolong the service life of the ECM.

The electronic control system can operate on either a 12 V electrical system or a 24 V electrical system. The switched positive battery and the unswitched positive battery connections to the ECM are made at the P61 Customer connector.

The ECM receives electrical power through the input for the switched positive battery. Protection for this circuit must be rated at 15 Amp (12 V or 24 V system).

The input for the unswitched positive battery is used to power the ECM memory that contains maintenance information and certain logged diagnostics. Protection for the unswitched positive battery circuit is specified as 20 Amp.

Powering the electronic control system through dedicated circuits with circuit breakers reduces the possibility of performance problems of the electronic control system. 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 devices for 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 Transient Voltage

The installation of transient suppression at the source of the transient is recommended. Refer to Illustration 4. 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 transient voltage in electrical circuits. Transient voltage that is not suppressed can exceed SAE specifications and lead to the degradation of the performance of the electronic control system.

Illustration 3	g00875659
Use of a diode in a relay as a transient voltage suppressor

The OEM should specify relays and solenoids with built-in voltage transient suppression. Refer to Illustration 3 for ways to minimize transient voltage 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.

Examples of devices that require suppression of transient voltages include any device that switches inductive loads on and off. The following list provides examples of such devices:

• Solenoids (trim tab solenoids, etc)

• DC electric motors

• Relays that use the same power and ground as the sensor

The following list provides other examples of situations that may cause transient voltages:

• Improperly grounded electronic components

• Improperly grounded cable shields

• Improperly grounded antennas

• Signal wires that are installed too closely to power wires

All of the components that are connected to the ECM must have return wires (ground) that are connected to the engine's - Battery. The return wires (ground) should be connected as close to the battery as possible. Caterpillar recommends the use of a separate return wire for each component. Each return wire (ground) should be attached to the engine's - Battery bus bar.

Caterpillar recommends the use of a 218-4935 Arc Suppressor on all inductive devices such as relays and solenoids. The 218-4935 Arc Suppressor is not polarized. This arc suppressor can be wired into the circuit without any concern for the direction of current flow.

Table 11

Required Parts
Part Number	Description	Quantity
218-4935	Arc Suppressor	1
155-2270	Connecting Plug Kit	1
186-3736	Connector Socket	2
130-5300 (1)	Clip	1
130-5301 (1)	Clip	1

( 1 )

Optional mounting clips

Illustration 4	g01093137
Typical wiring for 218-4935 Arc Suppressor

Connectors

Illustration 5	g01127475
(1) 102-8803 Receptacle Kit (1A) Receptacle wedge (2) 155-2260 Connecting Plug Kit (2A) Receptacle wedge (3) 102-8805 Receptacle Kit (3A) Receptacle wedge (4) 155-2274 Connecting Plug Kit (4A) Receptacle wedge (5) 102-8806 Receptacle Kit (5A) Receptacle wedge (6) 155-2265 Connecting Plug Kit (6A) Receptacle wedge (7) 133-0970 Receptacle As (8) 155-2270 Connecting Plug Kit (8A) Receptacle wedge (9) 8T-8732 Receptacle (10) 174-0503 Connecting Plug Kit (10A) Receptacle wedge (11) 8T-8736 Connector Receptacle (12) 8T-8731 Connector Plug (13) 9W-1951 Receptacle (14) 8T-9834 Connector Plug As (15) 8T-8737 Seal Plug (16) 9X-4391 Connector Plug As (17) 186-3736 Connector Socket (16-18 AWG) (18) 9W-0844 Connector Socket (14 AWG) (19) 133-0969 Socket Connector (20) 186-3735 Connector Pin (16-18 AWG) (21) 9W-0852 Connector Pin (14 AWG)

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 6	g00878501
Installation of seal plugs

Illustration 7	g00738352
Terminal connections

Adherence to the following requirements will 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. Never crimp multiple wires in any connector pin, or any connector socket.

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 6 for correct installation of plugs.

J61/P61 Customer Connector

Illustration 8	g00735800
Customer connector (40 pin)

Tighten the allen head screw into the customer connector to a torque of 2.25 ± 0.25 N·m (20 ± 2 lb in). All unused cavities for the sockets and the pins must be filled with 8T-8737 Seal Plugs in order to ensure that the connector is sealed.

The acceptable diameter of the insulation for a wire that is connected to the customer connector is 2.54 to 3.43 mm (0.100 to 0.135 inch).

Deutsch DT Connectors

A Deutsch DT connector has a wedge that acts as a lock for the connector pins and the connector sockets. 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, an audible click should be heard as the two halves lock together. After the DT connector has locked, you should not be able to pull apart the connector.

The acceptable range for the diameter of the insulation on the wire that is used with the DT connectors is 2.54 to 3.43 mm (0.100 to 0.135 inch).

Inspect the plug and the receptacle in order to ensure that the following conditions are met:

• The connector seals are properly seated.

• The pins and sockets are not damaged.

• The pins and the sockets are securely installed in the connector.

• Both halves of the connector have an equal number of pins and sockets.

• The pins are aligned correctly with the sockets.

• The connector's locking tabs are not damaged.

• The connector's wedges are not damaged.

Deutsch HD Connectors

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 collar of 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 3.43 mm (0.100 to 0.135 inch).

Switches

Switch Specifications

All switches that are provided by the OEM and connected to the ECM must provide a two wire electrical connection. 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 12 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 12 VDC. Closing an OEM installed switch must short circuit the switch input to the negative battery bus bar. Refer to the section on ""Battery Circuit Requirements" " in 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 Guide for your engine.

Mounting Dimensions for Switches

Illustration 9	g00766635
Toggle switch

Illustration 10	g00766842
Rocker switch

Voltage Specifications 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 input for the negative battery at 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 input for the negative battery at the ECM should not be less than 5000 Ohms. Potential paths for leakage may exist within the following components:

• Connectors

• Harnesses

• Switches

Note: Switches that are installed by the OEM must be connected to the negative battery bus bar.

Measuring the Voltage in Switch Circuits

Illustration 11	g00878488
Voltage measurement

Measuring the Current in Switch Circuits

Illustration 12	g00878489
Current measurement

Measuring the Resistance in Switch Circuits

Illustration 13	g00878490
Resistance measurement

Customer Installed Components

Note: Refer to the appropriate Parts Manual for your engine for further details on parts information.

P61 Customer Connector

Table 12

Pin-Outs for Customer Connections
J61/P61	Circuit Function	J61/P61	Circuit Function
1	+ Battery (Unswitched)	21	N/C (1)
2	- Battery	22	Maintenance Indicator Lamp
3	- Battery	23	N/C (1)
4	N/C (1)	24	Diagnostic Lamp
5	+ Battery (Unswitched)	25	Warning Lamp
6	Cat Datalink -	26	N/C (1)
7	Cat Datalink +	27	N/C (1)
8	+ Battery (Unswitched)	28	N/C (1)
9	- Battery	29	Remote Start
10	Primary Throttle Position	30	Keyswitch
11	N/C (1)	31	N/C (1)
12	Hour Meter +	32	N/C (1)
13	Hour Meter -	33	N/C (1)
14	N/C (1)	34	Droop or Isochronous switch
15	N/C (1)	35	Low Idle switch
16	J1939 Shield	36	Maintenance clear switch
17	J1939 Data +	37	Reset switch
18	J1939 Data -	38	N/C (1)
19	Run/stop switch	39	Remote engine shutdown switch
20	N/C (1)	40	N/C (1)

( 1 )

This terminal is for future expansion. Install an 8T-8737 Seal Plug .

The P61 customer connector utilizes a 8T-9834 Connector Plug As . All circuits that are connected to the P61 customer connector require a 186-3736 Connector Socket . Any unused cavities in the connector must be filled with 8T-8737 Seal Plugs . The torque for the allen head screw is 2.25 ± 0.25 N·m (20 ± 2 lb in).

Note: Earlier engines were equipped with a 40-pin customer connector. Newer engines are equipped with a 70-pin customer connector.

Sensor Return Connections

Certain components that interface directly with the ECM are connected to the dedicated sensor returns at the P61 customer connector. Separate sensor returns are provided for analog signal and digital signals. Refer to the Electrical System Schematic.

Note: Do not connect negative power or positive power for the throttle position sensor to the J61/P61 customer connector.

Connecting switches and/or the throttle position sensor to the sensor returns at the P61 customer connector can degrade the performance of the electronic control system. These components must be connected to the negative battery bus bar. These components must be connected to the negative terminal of the battery. For more detail, refer to the Electrical System Schematic for your application.

J42 Customer Supplied Service Tool Connector

An additional service tool connector is recommended in applications that have limited accessibility to the J60 engine service tool connector. Proper wiring of the J42 customer supplied service tool connector is essential for reliable communication of data. Use 143-5018 Electrical Cable and dedicated terminal strips for all data connections. Mount the terminal strips in a central location in order to minimize the overall length of the data link cable. The total length of the data link cable should not exceed 30 m (100 ft).

Illustration 14	g01142986
Schematic for the J42 service tool connector

Note: Refer to ""J1939CAN Data Link" " for more information on the installation of the J1939 Data Link.

Table 13

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	2
8C-6354	Receptacle Cap	1
186-3735	Connector Pin	4
8T-8737	Seal Plug	2
8T-8736 or 9W-1951 (flanged mounting)	Connector Receptacle Receptacle	1
143-5018	Electrical Cable	(1)
N/A	16 AWG Wire (Power)	(1)

( 1 )

Fabricated to length

Coolant Level Sensor

Illustration 15	g01153511
Schematic for the coolant level sensor

PWM throttle

Illustration 16	g01153512
Schematic for the 134-0670 Engine Speed Control Gp

Fuel Temperature Sensor (C9)

Illustration 17	g01153513
Schematic for the 130-9811 Temperature Sensor Gp

Oil Temperature Sensor (C18)

Note: This is a customer installed part.

Illustration 18	g01153514
Schematic for the 130-9811 Temperature Sensor Gp

Exhaust Temperature Sensor (C18)

Note: This is a customer installed part.

Illustration 19	g01153516
Schematic for the 109-4367 Exhaust Temperature Sensor Gp

The transducer will require the correct 1/4 NPT boss fitting for your application. The wire between the buffer and the transducer should be clamped. Also, the wire between the buffer and the connector should be clamped in order to prevent abrasion from rough surfaces.

Desired Speed Input

Note: In order to avoid problems with the throttle position sensor circuit that are associated with transient voltages, refer to ""Suppression of Transient Voltage" ".

Care should be taken when you consider the mounting location of the throttle position sensor. The sensor must be located as close to the control as possible. Avoid any linkage and/or cable lengths that are excessively long. These excessive lengths will generally require more frequent adjustment.

When you wire the throttle position sensor, avoid running the wires along other power wires. Run a dedicated return circuit (ground) back to the - Battery bus bar that is connected to the engine's batteries. In addition, the power to the throttle position sensor must come from the same power source (engine's batteries) as the rest of the electronic control system.

The Throttle Position Sensor (TPS) eliminates the mechanical throttle and governor linkages. The TPS interprets the position of the throttle lever into an electrical signal that is sent to the ECM. The throttle position signal and the engine speed/timing signal are processed by the ECM in order to precisely control engine speed.

PWM throttle for desired Engine Speed

The control system accepts a 500 Hz PWM frequency signal input in order to determine the desired engine speed. This input must be activated using the primary/secondary throttle configuration parameter. The input will be translated to a desired engine speed.

PWM Input Requirements

Open collector sinking PWM output with a pull up resistor

Sensor stops

Low sensor stop ... 7.5 ± 2.5%

High sensor stop ... 92.5 ± 2.5%

Output frequency

Minimum ... 300 Hz

Nominal ... 500 Hz

Maximum ... 700 Hz

Output voltage high

Minimum ... 4.0 VDC

Nominal ... 5.0 VDC

Output voltage low

1.0 mA sink current

Nominal ... 0.23 VDC

Maximum ... 0.25 VDC

10.0 mA sink current

Nominal ... 0.65 VDC

Maximum ... 0.7 VDC

Output linearity

Duty cycle versus throttle lever position ... ± 2.5%

Illustration 20	g00766342
PWM input requirements

Note: An active diagnostic code will be active when the desired engine speed is set to low idle.

Table 14

PWM Throttle Sensor Input
Percent Duty Cycle	Percent Throttle (± 2.0 percent)	50 Hz RPM (1500 rpm)	60 Hz RPM (1800 rpm)
0.0 to 2.5	0	Low Idle	Low Idle
2.6 – 9.9	0	1141	1369
10.0 – 90.0	0 – 100	1141 to 1621	1369 to 1945
90.1 to 95.0	100	1621	1945
95.1 to 100.0	0	Low Idle	Low Idle

Primary/Secondary Desired Engine Speed Configuration

This feature allows the user to select a primary and secondary desired engine speed input to the control system by using configuration parameters in Cat ET. The primary input will be used only if the primary input is available. The control system will use the secondary input, if the primary input fails and the secondary input is configured.

Desired Engine Speed using J1939 CAN Data link

The control system will accept a desired engine speed by using J1939 CAN data link.

Starter Interlock

The starter interlock output is shorted to ground when the starter interlock is active. This will be active when the engine speed is equal to zero. The starter interlock will remain active until the engine speed is greater than 500 rpm. If the output is inactive the output will remain inactive until the engine speed is equal to zero.

Overspeed Verify

The command for the overspeed verify will force the overspeed shutdown speed threshold to be reduced to 75% of the programmed value for the duration of the test. The command for the overspeed verify can be sent from the diagnostic test menu in Cat ET.

Reset Switch

The input for the reset switch can be used to clear latched shutdown events. In order to reset an event the engine speed must be equal to zero. Also, the condition that created the event must no longer be present.

The Droop Set Point for the Desired Engine Speed Using Cat Data link

The speed droop adjustment is the percentage of reduction in engine speed at full load from a reduction at no load. This function is important because the speed droop determines the distribution of the load among several engines. Droop can be adjusted, as needed, for stability of engines with different rates of engine speed changes. Droop function allows for load division between two or more engines connected for operation in parallel.

Lamps and Switches (C9)

Installation of both a warning alarm 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 powered up in order to indicate that the lamp circuit is functional.

Illustration 21	g01142991
Schematic for the warning lamps and the warning alarm (C9)

Table 15

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	2
2N-2371	Indicator Lamp	2
7N-5876	Lamp	2
9G-9813 or 123-9694	Alarm Gp Horn	1 1
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

Electrical Specifications for the Lamp Circuit

Electrical specifications for the 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 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.

Diagnostic Lamp Operation

Installation of a diagnostic lamp is recommended. The diagnostic lamp is used to alert the operator of a malfunction of the electronic control system (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. Refer to Troubleshooting, "Flash Codes" for more information about flash codes.

Warning Lamp or Alarm Operation

Installation of a warning lamp is recommended. The warning lamp is used to alert the operator of an engine operating condition (event code) which has the potential to cause engine damage.

The warning lamp will come on for five seconds when the ECM is first powered in order to indicate that the lamp circuit is functional.

Maintenance Lamp and Maintenance Clear Switch

The maintenance lamp illuminates in order to alert the operator when scheduled maintenance is due. The accumulated values for the maintenance interval in the ECM are reset to zero when the maintenance clear switch is activated.

Note: For more information on the maintenance interval, refer to the Parameters Table for your engine.

The maintenance indicator lamp will turn on when the programmed maintenance interval has passed. When the ECM is powered, the maintenance indicator lamp will turn on for five seconds.

The maintenance clear switch is used to reset the maintenance interval after maintenance on the engine is performed.

Illustration 22	g01143004
Schematic for the maintenance indicator lamp and the maintenance clear switch

Table 16

Required Parts
Part Number	Description	Qty
2N-2371	Indicator Lamp	1
3E-8768	Switch (1)	1
7N-5876	Lamp	1
186-3736	Connector Socket	2
155-2706	Rocker Actuator	1
5P-4571	Blade Terminal	2
6V-2689	Heat Shrink Tube	(2)
N/A	16 AWG Wire	(2)

( 1 )	SPST Momentary
( 2 )	Fabricated to length

Droop / Isochronous Mode Control Switch

A switch can be used to override the governing mode when the ECM is properly configured.

Rated Speed Switch

Note: The rated speed switch will override any throttle input. This is either the PWM or the J1939.

The rated speed switch will allow the engine to run at the exact rated speed. The Ground position is the rated speed. The Open position is the normal speed or the selected data link mode.

Low Idle Control Switch

The low idle control switch will allow the engine to run at the programmed low idle speed. The Ground position is the low idle speed. The Open position is the rated speed. The rated speed is either the data link mode or PWM.

Emergency Shutdown Switch

The control system will activate the emergency stop event based on the status of the emergency switch input. If the input is active, no event will be active. If the input is not active, an emergency stop event will be activated. The engine will stop when the emergency shutdown switch is moved to the OPENED position. The remote shutdown switch must be moved to the CLOSED position in order to restart the engine. The ECM must be powered down or the reset switch toggled in order to restart the engine.

Illustration 23	g01143033
Schematic for the emergency shutdown switch

Table 17

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	1
109-6507	Push Button Switch	1
111-1325	Contact Block	1
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

Run/Stop Switch

The control system will enable and disable fuel based on the Run/Stop input. If the Run/Stop input is active, fuel will be enabled. If the input is not active, fuel will be disabled. If the Run/Stop switch is set to switch input, the logic below will be used. If set to CAN input, the Defuel J1939 message will be use

Table 18

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	1
109-6507	Push Button Switch	1
111-1325	Contact Block	1
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

Remote Start Switch

The remote start switch is used for starting the engine. Circuit protection is required for this circuit.

Illustration 24	g00876074
Schematic for the remote start switch

Table 19

Required Parts
Part Number	Description	Qty
9W-1077	Start Switch Gp	1
8J-4785	Instruction Plate	1
N/A	Circuit Protection (1)	1
N/A	Wire (1)	(2)

( 1 )	The wire size is dependent on the requirements of the circuit.
( 2 )	Fabricated to length

Air Inlet Heater (C9)

Illustration 25	g01142714
Schematic for the air inlet heater (C9)

Table 20

Required Parts
Part Number	Description	Qty
N/A	Circuit Protection (1)	1
N/A	4 AWG Wire (1)	(2)

( 1 )	The wire size is dependent on the requirements of the circuit.
( 2 )	Fabricated to length

Engine Hour Meter (C9)

The ECM begins to count the operation time of the engine once the engine speed is greater than 500 rpm. This signal is the actual engine operational hours.

Illustration 26	g00854169
Schematic for the hour meter

Table 21

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	2
9W-1494	Service Meter Kit	1
6V-2689	Heat Shrink Tube	(1)
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

J1939 CAN Data Link

Note: If the vessel is equipped with a Multi-Station Control System (MSCS), refer to Service Manual, RENR7651, "Marine Multi-Station Control System" for more information.

The SAE J1939 CAN data link is used to communicate engine information to a J1939 display.

Parameters for the CAN Data Link Broadcast

Table 22

Parameters for CAN Data Link Broadcast
Parameter	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
Engine Oil Pressure	65263
Engine Oil Temperature (1)	65262
Transmission Oil Pressure	65272
Transmission Oil Temperature	65272

( 1 )

The parameter is only available for C9 engines.

The engines will accept two CAN Datalink request parameters on J1939:

• Defuel actuator is PGN 65223

• Engine Speed Request is PGN 0

Connecting the J1939 CAN Data Link

Table 23

Required Parts Installation of a Single Module
Part Number	Description	Qty
5P-6001	Tube (1)	6 cm (2.4 inch)
125-7876	Heat Shrink Tube	15 cm (6 inch)
133-0970	Receptacle As	1
133-0969	Socket Connector	2
134-2540	Receptacle As	1
153-2707	Electrical Cable	(2)
165-0200	Cable As	2
8T-8736 or 9W-1951 (3)	Connector Receptacle  (4) or Receptacle	1
174-0503	Connecting Plug Kit  (5)	1
186-3736	Connector Socket	4

( 1 )	Heat shrink tube
( 2 )	Fabricated to length
( 3 )	The 9W-1951 Receptacle has a flanged mounting.
( 4 )	The customer supplied service tool connector should only be used if one was not previously installed.
( 5 )	Use the blue wedge.

Table 24

Required Parts Installation of Each Additional Module
Part Number	Description	Qty
5P-6001	Tube (1)	6 cm (2.4 inch)
125-7876	Heat shrink tube	15 cm (6 inch)
133-0969	Connector Socket	2
133-0970	Receptacle As	1
153-2707	Electrical Cable	(2)
165-0200	Cable As	1
174-0503	Connecting Plug Kit  (3)	2
186-3736	Connector Socket	4

( 1 )	Heat shrink tube
( 2 )	Fabricated to length
( 3 )	Use the blue wedge.

Illustration 27	g00889188
Schematic for the J1939 Data Link

Illustration 27 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 Electrical Cable (shielded twisted pair cable) must be used for all CAN data link wiring. If the Caterpillar recommended cable is not used, the cable must meet J1939 standards.

Table 25

J1939 Specifications for Conductors
	Minimum	Nominal	Maximum
Impedance (ohm)	108	120	132
Capacitance between conductors (pF/m)	0	40	75
Capacitance between the conductors and the shield (pF/m)	0	70	110

Note: The total length of the data link must not exceed 40 m (130 ft). All splices into the data link require a 133-0970 Receptacle As . A 134-2540 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 may be included in the Caterpillar supplied wiring harness to the customer connector. One additional termination resistor must be installed at the end of the data link.

Use the following procedure to connect modules to the CAN data link:

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Illustration 28	g00889189
Connecting the customer connector to a tee

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Illustration 29	g00779822
Connector sockets

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

   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 must not exceed 40 m (130 ft).

   1. Run 153-2707 Electrical Cable (shielded twisted pair cable) from the customer connector to the location of the first module. Cut the cable to length.

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

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

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

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

   6. Cut two 30 mm (1.2 inch) pieces of 5P-6001 Tube (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.

   7. 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.

   8. Insert the wires from one end of the data link into the customer connector. See Table 26.
      Show/hide table

      Table 26

      Terminal Locations in the Customer Connector
      Wire Color	Location
      Shield	16
      Yellow	17
      Green	18

   9. 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.

   10. Insert the sockets at the opposite end of the CAN data link into a 174-0503 Connecting Plug Kit . See Table 27. Insert the blue wedge into the connector in order to secure the terminals in place.
       Show/hide table

       Table 27

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

   11. 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.

   12. Plug the end of the data link into the single end of a 133-0970 Receptacle As .

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Illustration 30	g00746640
Connecting from one tee to another tee

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

   Note: For installations of a single module, 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 not exceed 40 m (130 ft).

   1. Run 153-2707 Electrical Cable (shielded twisted pair cable) from the tee to the location of the next module. Cut the cable to length.

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

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

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

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

   6. Cut two 30 mm (1.2 inch) pieces of 5P-6001 Tube (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.

   7. 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.

   8. Install a 174-0503 Connecting Plug Kit on each end of the cable. See Table 28. Insert the blue wedge into the connector in order to secure the terminals in place.
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      Table 28

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

   9. 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.

   10. 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 for the additional module.

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

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Illustration 31	g00935709

3. Connect a receiving module to the tee.

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

   2. Cut a 50 mm (2 inch) piece of 125-7876 Heat Shrink Tube . Slide the heat shrink tube over the display connector of the cable assembly.

   3. Connect the three wires from the end of the cable assembly to the appropriate terminals on the plug for the module.

   4. Repeat Step 3 for each module.

4. Connect the service tool connector.

   Note: If a customer supplied service tool connector is already installed, connect the J1939 data link to the existing connector.

   1. Run the 153-2707 Electrical Cable (shielded twisted pair cable) from the last 133-0970 Receptacle As to the service tool connector. Cut the cable to length.

      Note: The total length from the 133-0970 Receptacle As to the communications adapter should be no more than 1.00 m (3.250 ft).

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

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

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

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

   6. 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.

   7. 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.

   8. Insert the wires from one end of the data link into the service tool connector. See Table 29.
      Show/hide table

      Table 29

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

   9. 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.

   10. Insert the sockets at the opposite end of the CAN data link into a 174-0503 Connecting Plug Kit . See Table 30. Insert the green wedge into the connector in order to secure the terminals in place.
       Show/hide table

       Table 30

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

   11. 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.

   12. Plug the 174-0503 Connecting Plug Kit into the double end of a 133-0970 Receptacle As .

5. 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 .

      Note: Refer to ""J42 Customer Supplied Service Tool Connector" " for additional details on wiring the customer supplied service tool connector.

Cat Data Link

Avoid splicing or soldering wire connections. All connections should be terminated at the terminal strips. Terminal strip connections will help to ensure the reliability of the engine. These connections will also help to ensure the reliability of the communications.

Table 31

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	4
143-5018	Wire (1)	(2)

( 1 )	Twisted pair wiring
( 2 )	Fabricated to length

Connections in the Engine Room

The terminal strip for the data link in the engine room should be located as close as possible to the customer connector. This will help minimize the length of the data link cable.

Note: Ensure that there is a terminal strip for the data link in the engine room. A terminal strip should be located at the operator station on the bridge. For multiple operator stations, route the data link cable from the bridge to the second operator station.

1. Connect the wires for the STBD CDL and the wires for the PORT CDL to the terminal strip in the engine room. Use 143-5018 Wire (twisted pair wiring) to make this connection.

Illustration 32	g00941316
Connections for the engine room

Connections from the Engine Room to the Bridge

1. Connect the CDL from the terminal strip in the engine room to the terminal strip on the bridge. Use 143-5018 Wire (twisted pair wiring) to make this connection.

Illustration 33	g00783003
Connections from the engine room to the bridge

Correct wiring of the CDL is essential for proper display operation. The CDL requires the use of the 143-5018 Wire (twisted pair wiring). The installation is required to have a terminal strip that is dedicated to the connections for the CDL. This terminal strip must be placed at a location that will minimize the length of the wire that is required for the CDL. Only one set of twisted wire shall run to the displays on the bridge. If a second operator station requires a display, perform the following procedure:

1. Begin the data wires at the terminal strip in the engine room.

2. Continue the wires to the first station.

3. Wiring will then continue from the first station to the second station.