C-15 Petroleum Engines

C-15
PETROLEUM ENGINES
INSTALLATION GUIDE
C-15
PETROLEUM ENGINES
INSTALLATION GUIDE
Introduction .................................................................................. 5
Safety Section.................................................................................6
Welding on Engines with Electronic Controls .............................15
Technical Data ............................................................................ 16
System Overview ....................................................................... 17
System Configuration Parameters .............................................. 20
Parameters Worksheet ................................................................ 22
Parameter Descriptions ............................................................... 23
Monitoring System ..................................................................... 27
Monitoring System Parameters .................................................. 27
Required Service Tools ............................................................... 28
Connecting Cat® ET and the Communication Adapter .............. 30
Switches ...................................................................................... 31
Connectors ................................................................................. 32
Installation of Terminals and Seal Plugs .................................... 33
Wiring Considerations ................................................................ 35
Requirements for the Battery Circuit .......................................... 37
Customer Installed Components ................................................. 40
Air Shutoff System...................................................................... 42
J66 Customer Supplied Service Tool Connector ........................ 43
J1939 Data Link .......................................................................... 50
Indicator Lamps........................................................................... 54
Switch Inputs............................................................................... 57
Interconnect Harness ................................................................... 60
Messenger Installation................................................................. 61
Abbreviations and Definitions..................................................... 65
Introduction Operations that may cause product damage are
identified by “NOTICE” labels on the product
This document is intended to provide information and in this publication.
for wiring the engine electronics and
Caterpillar cannot anticipate every possible
programming the engine electronics.
circumstance that might involve a potential
Important Safety Information hazard. The warnings in this publication and
on the product are, therefore, not all-inclusive.
Most accidents that involve product operation, If a tool, procedure, work method, or
maintenance, and repair are caused by failure to operating technique that is not specifically
observe basic safety rules or precautions. An recommended by Caterpillar is used, you must
accident can often be avoided by recognizing satisfy yourself that it is safe for you and for
potentially hazardous situations before an others. You should also ensure that the
accident occurs. A person must be alert to product will not be damaged or be made
potential hazards. This person should also have unsafe by the operation, lubrication,
the necessary training, skills, and tools to maintenance, or repair procedures that you
perform these functions properly. choose.
Improper operation, lubrication, maintenance The information, specifications, and illustrations
or repair of this product can be dangerous and in this publication are on the basis of information
could result in injury or death. that was available at the time that the publication
was written. The specifications, torques,
Do not operate or perform any lubrication,
pressures, measurements, adjustments,
maintenance, or repair on this product until
illustrations, and other items can change at any
you have read and understood the operation,
time. These changes can affect the service that is
lubrication, maintenance, and repair
given to the product. Obtain the complete and
information.
most current information before you start any
Safety precautions and warnings are provided in job. Caterpillar® dealers have the most current
this manual and on the product. If these hazard information available.
warnings are not heeded, bodily injury or death
could occur to you or to other persons.
WARNING
The hazards are identified by the “Safety Alert
Symbol” and followed by a “Signal Word” such When replacement parts are required for this
as “DANGER,” “WARNING,” or “CAUTION.” product Caterpillar recommends using
The Safety Alert “WARNING” label is shown Caterpillar replacement parts or parts with
below. equivalent specifications including, but not
limited to, physical dimensions, type, strength,
and material.
WARNING
Any OEM supplied component must be
The meaning of this safety alert symbol is as approved to be installed in a hazardous
follows: location.
Attention! Become Alert! Your Safety is Failure to heed this warning can lead to
Involved. premature failures, product damage, personal
injury, or death.
The message that appears under the warning
explains the hazard and can be either written or
pictorially presented.
5
Safety Section or missing warning signs. If a warning sign is
attached to a part of the engine that is replaced,
Installation Environment install a new warning sign on the replacement
part. Any Caterpillar dealer can provide new
SMCS Code: 1000 warning signs. The warning labels that may be
found on the engine are illustrated and described
This engine is for use in UL Zone II and ATEX
in this section.
Directive (94/9/EC) Group II, 3G environments
with Gas Group IIB, Temperature Class T3
(200 Deg. C maximum surface temperature).
This environmental classification is described as Universal Warning
an area that is not likely to experience an
explosive atmosphere. Gases, which could make
the atmosphere explosive, are confined in a
closed system. Only with the occurrence of
unexpected and abnormal conditions can the gas
escape and make the atmosphere explosive.
The following literature explains the potential
hazards that are associated with this engine used
in these environments. This literature should all
be read and understood.
• Operation and Maintenance Manual,
SEBU7895 The universal warning label is located on each
side of the valve cover base.
• Installation Guide, LEGW3354
• Specifications Manual, SENR9952
Safety Messages
SMCS Code: 1000; 7405
There may be several specific warning signs on
an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs. Ensure that all of the warning signs are
legible. Clean the warning signs or replace the WARNING
warning signs if the words cannot be read or if
the pictures are not visible. When the warning Do not operate or work on this engine unless
signs are cleaned, use a cloth, water, and soap. you have read and understand the instructions
Do not use solvent, gasoline, or other harsh and warnings in the Operation and
chemicals to clean the warning signs. Solvents, Maintenance Manual. Failure to follow the
gasoline, or harsh chemicals could loosen the instructions or heed the warnings could result
adhesive that secures the warning signs. The in injury or death. Contact any Caterpillar
warning signs that are loosened could drop off of dealer for replacement manuals. Proper care
the engine. Replace any damaged warning signs is your responsibility.
6
General Hazard Information
SMCS Code: 1000; 7405
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
• When work is performed around an engine that
Attach a “Do Not Operate” warning tag or a is operating, wear protective devices for ears in
similar warning tag to the start switch or to the order to help prevent damage to hearing.
controls before the engine is serviced or before
the engine is repaired. These warning tags • Do not wear loose clothing or jewelry that can
(Special Instruction, SEHS7332) are available snag on controls or on other parts of the engine.
from your Caterpillar dealer. Attach the warning
• Ensure that all protective guards and all covers
tags to the engine and to each operator control
are secured in place on the engine.
station. When it is appropriate, disconnect the
starting controls. • Never put maintenance fluids into glass
containers. Glass containers can break.
Do not allow unauthorized personnel on the
engine or around the engine when the engine is • Use all cleaning solutions with care.
being serviced.
• Report all necessary repairs.
Engine exhaust contains products of combustion
which may be harmful to your health. Always Unless other instructions are provided,
start the engine and operate the engine in a well perform the maintenance under the following
ventilated area. If the engine is in an enclosed conditions:
area, vent the engine exhaust to the outside. • The engine is stopped. Ensure that the engine
Cautiously remove the following parts. To help cannot be started.
prevent spraying or splashing of pressurized • Disconnect the batteries when maintenance is
fluids, hold a rag over the part that is being performed or when the electrical system is
removed. serviced. Disconnect the battery ground leads.
• Filler caps Tape the leads in order to help prevent sparks.
• Grease fittings • Do not attempt any repairs that are not

understood. Use the proper tools. Replace any
• Pressure taps equipment that is damaged or repair the
equipment.
• Breathers
• Drain plugs Electrostatic Phenomena
The operator, the installer, and other personnel
Use caution when cover plates are removed. should be aware of excessive polishing or buffing
Gradually loosen, but do not remove the last two of plastic parts which could result in an energy
bolts or nuts that are located at opposite ends of potential that could cause a spark that could
the cover plate or the device. Before removing possibly ignite an explosive atmosphere.
the last two bolts or nuts, pry the cover loose in
order to relieve any spring pressure or other
pressure.
7
This petroleum engine is for use in a Zone 2 Refer to Special Publication, NENG2500, “Tools
Hazardous environment. The OEM must ensure and Shop Products Guide” for the following
that Non Static belts are used. Failure to use Non items:
Static belts could result in an energy potential
that could cause a spark that could possibly ignite • Tools that are suitable for collecting fluids and
an explosive atmosphere. equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
Pressure Air and Water
equipment that is suitable for containing fluids
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could Obey all local regulations for the disposal of
result in personal injury. liquids.
When pressure air and/or pressure water is used Asbestos Information

for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection
includes goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be
below 275 kPa (40 psi).
Fluid Penetration
Caterpillar equipment and replacement parts that

are shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only
Caterpillar replacement parts. Use the following
guidelines when you handle any replacement
parts that contain asbestos or when you handle
asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that
Always use a board or cardboard when you contain asbestos fibers. Inhaling this dust can be
check for a leak. Leaking fluid that is under hazardous to your health. The components that
pressure can penetrate body tissue. Fluid may contain asbestos fibers are brake pads, brake
penetration can cause serious injury and possible bands, lining material, clutch plates, and some
death. A pin hole leak can cause severe injury. If gaskets. The asbestos that is used in these
fluid is injected into your skin, you must get components is usually bound in a resin or sealed
treatment immediately. Seek treatment from a in some way. Normal handling is not hazardous
doctor that is familiar with this type of injury. unless airborne dust that contains asbestos is
Containing Fluid Spillage generated.
Care must be taken in order to ensure that fluids If dust that may contain asbestos is present, there
are contained during performance of inspection, are several guidelines that should be followed:
maintenance, testing, adjusting and repair of the
• Never use compressed air for cleaning.
engine. Prepare to collect the fluid with suitable
containers before any compartment is opened or • Avoid brushing materials that contain asbestos.
before the disassembly of any component
containing fluids. • Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
8
• A vacuum cleaner that is equipped with a high Coolant
efficiency particulate air filter (HEPA) can also When the engine is at operating temperature, the
be used. engine coolant is hot. The coolant is also under
• Use exhaust ventilation on permanent pressure. The radiator and all lines to the heaters
machining jobs. or to the engine contain hot coolant.
• Wear an approved respirator if there is no other Any contact with hot coolant or with steam can
way to control the dust. cause severe burns. Allow cooling system
components to cool before the cooling system
• Comply with applicable rules and regulations is drained.
for the work place. In the United States, use
Occupational Safety and Health Administration Check the coolant level after the engine has
(OSHA) requirements. These OSHA stopped and the engine has been allowed to cool.
requirements can be found in “29 CFR Ensure that the filler cap is cool before removing
1910.1001.” the filler cap. The filler cap must be cool enough
• Obey environmental regulations for the disposal to touch with a bare hand. Remove the filler cap
of asbestos. slowly in order to relieve pressure.
• Stay away from areas that might have asbestos Cooling system conditioner contains alkali.
particles in the air. Alkali can cause personal injury. Do not allow
alkali to contact the skin, the eyes, or the mouth.
Dispose of Waste Properly
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact
the skin. Also, do not allow hot components to
contact the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause
personal injury. Do not allow electrolyte to
contact the skin or the eyes. Always wear
Improperly disposing of waste can threaten the protective glasses for servicing batteries. Wash
environment. Potentially harmful fluids should be hands after touching the batteries and connectors.
disposed of according to local regulations. Use of gloves is recommended.
Always use leakproof containers when you drain

fluids. Do not pour waste onto the ground, down
a drain, or into any source of water.
Burn Prevention
SMCS Code: 1000; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings, or
related items are disconnected.
9
Fire Prevention and Explosion Non Static belts must be used. Failure to use Non
Static belts could result in an energy potential
Prevention
that could create a spark which could ignite an
SMCS Code: 1000; 7405 explosive atmosphere.
Excessive polishing or buffing of plastic parts can
result in an energy potential that could create a
spark which could ignite an explosive
atmosphere.
Do not weld on lines or tanks that contain
flammable fluids. Do not flame cut lines or tanks
that contain flammable fluid. Clean any such
lines or tanks thoroughly with a nonflammable
solvent prior to welding or flame cutting.
All fuels, most lubricants, and some coolant Wiring must be kept in good condition. All
mixtures are flammable. electrical wires must be properly routed and
Flammable fluids that are leaking or spilled onto securely attached. Check all electrical wires
hot surfaces or onto electrical components can daily. Repair any wires that are loose or frayed
cause a fire. Fire may cause personal injury and before you operate the engine. Clean all electrical
property damage. connections and tighten all electrical connections.
A flash fire may result if the covers for the Eliminate all wiring that is unattached or
engine crankcase are removed within fifteen unnecessary. Do not use any wires or cables that
minutes after an emergency shutdown. are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Determine whether the engine will be operated in
an environment that allows combustible gases to Arcing or sparking could cause a fire. Secure
be drawn into the air inlet system. These gases connections, recommended wiring, and properly
could cause the engine to overspeed. Personal maintained battery cables will help to prevent
injury, property damage, or engine damage arcing or sparking.
could result. Inspect all lines and hoses for wear or for
If the application involves the presence of deterioration. The hoses must be properly routed.
combustible gases, consult your Caterpillar The lines and hoses must have adequate support
dealer for additional information about suitable and secure clamps. Tighten all connections to the
protection devices. recommended torque. Leaks can cause fires.
Remove all flammable materials such as fuel, oil, Oil filters and fuel filters must be properly
and debris from the engine. Do not allow any installed. The filter housings must be tightened to
flammable materials to accumulate on the engine. the proper torque.
Store fuels and lubricants in properly marked

containers away from unauthorized persons.
Store oily rags and any flammable materials in
protective containers. Do not smoke in areas that
are used for storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a
line, a tube, or a seal failure. Exhaust shields
must be installed correctly.
10
Do not charge a frozen battery. This may cause
an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery
box covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire
extinguisher. Inspect the fire extinguisher and
service the fire extinguisher regularly. Obey the
recommendations on the instruction plate.
Use caution when you are refueling an engine. Lines, Tubes, and Hoses
Do not smoke while you are refueling an engine. Do not bend high pressure lines. Do not strike
Do not refuel an engine near open flames or high pressure lines. Do not install any lines that
sparks. Always stop the engine before refueling. are bent or damaged.
Repair any lines that are loose or damaged.
Leaks can cause fires. Consult your Caterpillar
dealer for repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not
use your bare hand to check for leaks. Use a
board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Replace the parts if any of the following
conditions are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. • Outer coverings are ballooning.
Do not smoke in battery charging areas.
• Flexible part of the hoses are kinked.
Never check the battery charge by placing a
metal object across the terminal posts. Use a • Outer covers have embedded armoring.
voltmeter or a hydrometer. • End fittings are displaced.
Do not connect or disconnect the battery cables Make sure that all clamps, guards, and heat
in an explosive atmosphere. This could cause a shields are installed correctly. During engine
spark that could ignite the explosive atmosphere. operation, this will help to prevent vibration,
Improper jumper cable connections can cause an rubbing against other parts, and excessive heat.
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
11
Crushing Prevention and Cutting Before Starting Engine
Prevention SMCS Code: 1000
SMCS Code: 1000; 7405 NOTICE: For initial start-up of a new or
Support the component properly when work rebuilt engine, and for start-up of an engine
beneath the component is performed. that has been serviced, make provision to shut
the engine off should an overspeed occur. This
Unless other maintenance instructions are may be accomplished by shutting off the air
provided, never attempt adjustments while the and/or fuel supply to the engine.
engine is running.
Overspeed shutdown should occur automatically.
Stay clear of all rotating parts and of all moving If automatic shutdown does not occur, press the
parts. Leave the guards in place until emergency stop button in order to cut the fuel
maintenance is performed. After the maintenance and/or air to the engine.
is performed, reinstall the guards.
Inspect the engine for potential hazards.
Keep objects away from moving fan blades. The
fan blades will throw objects or cut objects. Before starting the engine, ensure that no one is
on, underneath, or close to the engine. Ensure
When objects are struck, wear protective glasses that the area is free of personnel.
in order to avoid injury to the eyes.
If equipped, ensure that the lighting system for
Chips or other debris may fly off objects when the engine is suitable for the conditions. Ensure
objects are struck. Before objects are struck, that all lights work properly, if equipped.
ensure that no one will be injured by flying
debris. All protective guards and all protective covers
must be installed if the engine must be started in
Mounting and Dismounting order to perform service procedures. To help
prevent an accident that is caused by parts in
SMCS Code: 1000; 7405 rotation, work around the parts carefully.
Inspect the steps, the handholds, and the work Do not bypass the automatic shutoff circuits. Do
area before mounting the engine. Keep these not disable the automatic shutoff circuits. The
items clean and keep these items in good repair. circuits are provided in order to help prevent
Mount the engine and dismount the engine only personal injury. The circuits are also provided in
at locations that have steps and/or handholds. Do order to help prevent engine damage.
not climb on the engine, and do not jump off the See the Service Manual for repairs and for
engine. adjustments.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point
Engine Starting
contact with the steps and handholds. Use two SMCS Code: 1000
feet and one hand or use one foot and two hands.
Do not use any controls as handholds. If a warning tag is attached to the engine start
switch or to the controls, DO NOT start the
Do not stand on components which cannot engine or move the controls. Consult with the
support your weight. Use an adequate ladder or person that attached the warning tag before the
use a work platform. Secure the climbing engine is started.
equipment so that the equipment will not move.
All protective guards and all protective covers
Do not carry tools or supplies when you mount must be installed if the engine must be started in
the engine or when you dismount the engine. Use order to perform service procedures. To help
a hand line to raise and lower tools or supplies. prevent an accident that is caused by parts in
rotation, work around the parts carefully.
12
Start the engine from the operator’s compartment Electrical System
or from the engine start switch.
SMCS Code: 1000; 1400
Always start the engine according to the
procedure that is described in the Operation and WARNING
Maintenance Manual, “Engine Starting” topic in The connection of battery cables to a battery
the Operation Section. Knowing the correct and the disconnection of battery cables from a
procedure will help to prevent major damage to battery may cause an explosion which may
the engine components. Knowing the procedure result in injury or death. The connection and
will also help to prevent personal injury. the disconnection of other electrical equipment
To ensure that the jacket water heater (if may also cause an explosion which may result
equipped) and/or the lube oil heater (if equipped) in injury or death. The procedures for the
is working properly, check the water temperature connection and the disconnection of battery
and the oil temperature during heater operation. cables and other electrical equipment should
only be performed in a nonexplosive
Engine exhaust contains products of combustion atmosphere.
which can be harmful to your health. Always
start the engine and operate the engine in a well Never disconnect any charging unit circuit or
ventilated area. If the engine is started in an battery circuit cable from the battery when the
enclosed area, vent the engine exhaust to the charging unit is operating. A spark can cause the
outside. combustible gases that are produced by some
batteries to ignite.
Engine Stopping
To help prevent sparks from igniting combustible
SMCS Code: 1000 gases that are produced by some batteries, the
negative “-” jump start cable should be connected
Stop the engine according to the procedure in the last from the external power source to the engine
Operation and Maintenance Manual, “Engine block or to the frame.
Stopping” topic in the Operation Section in order
to avoid overheating of the engine and Check the electrical wires daily for wires that are
accelerated wear of the engine components. loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
Use the Emergency Stop Button (if equipped) electrical wires before the engine is started. See
ONLY in an emergency situation. Do not use the the Operation and Maintenance Manual for
Emergency Stop Button for normal engine specific starting instructions.
stopping. After an emergency stop, DO NOT start
the engine until the problem that caused the
emergency stop has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to
the engine and/or shutting off the air supply to
the engine.
Removing the power to the ECM will shut off the
fuel supply to the engine.
13
Grounding Practices Engine Electronics
SMCS Code: 1000; 1400; 1900
WARNING
Tampering with the electronic system
installation or the OEM wiring installation
can be dangerous and could result in personal
injury or death and/or engine damage.
This engine has a comprehensive Programmable
Monitoring System (PMS). The Engine Control
Module (ECM) has the ability to monitor the
engine operating conditions. If any of the engine
parameters extend outside an allowable range, the
ECM will initiate an immediate action.
The following actions are available for engine
Typical example of Alternate Grounding Stud
monitoring control: WARNING, DERATE, and
To Battery Ground
SHUTDOWN. These engine monitoring modes
Proper grounding for the engine electrical system have the ability to limit engine speed and/or the
is necessary for optimum engine performance engine power.
and reliability. Improper grounding will result in
Many of the parameters that are monitored by the
uncontrolled electrical circuit paths and in
ECM can be programmed for the engine
unreliable electrical circuit paths.
monitoring functions. The following parameters
Uncontrolled electrical circuit paths can result in can be monitored as a part of the Programmable
damage to main bearings, to crankshaft bearing Monitoring System:
journal surfaces, and to aluminum components.
• Operating Altitude
Engines that are installed without engine-to-
frame ground straps can be damaged by electrical • Engine Coolant Level
discharge.
• Engine Coolant Temperature
To ensure that the engine and the engine
electrical systems function properly, an engine- • Engine Oil Pressure
to-frame ground strap with a direct path to the • Engine Speed
battery must be used. This path may be provided
by way of a direct engine ground to the frame. • Fuel Temperature
All grounds should be tight and free of corrosion. • Intake Manifold Air Temperature
The engine alternator must be grounded to the
• System Voltage
negative “-” battery terminal with a wire that is
adequate to handle the full charging current of
the alternator.
14
Product Information Section—
General Information
Welding on Engines with Electronic
Controls
SMCS Code: 1000
NOTICE: Because the strength of the frame
may decrease, some manufacturers do not
recommend welding onto a chassis frame or
rail. Consult the OEM of the equipment or
your Caterpillar dealer regarding welding on
a chassis frame or rail. Use the example above. The current flow from
the welder to the ground clamp of the welder will
Proper welding procedures are necessary in order not cause damage to any associated components.
to avoid damage to the engine’s ECM, sensors,
and associated components. When possible, (1) Engine
remove the component from the unit and then
weld the component. If removal of the (2) Welding rod
component is not possible, the following (3) Keyswitch in the OFF position
procedure must be followed when you weld on a
unit that is equipped with a Caterpillar Electronic (4) Battery disconnect switch in the open position
Engine. The following procedure is considered to
(5) Disconnected battery cables
be the safest procedure to weld on a component.
This procedure should provide a minimum risk of (6) Battery
damage to electronic components.
(7) Electrical/Electronic component
NOTICE: Do not ground the welder to
electrical components such as the ECM or (8) Maximum distance between the component
sensors. Improper grounding can cause that is being welded and any
damage to the drive train bearings, hydraulic electrical/electronic component
components, electrical components, and other (9) The component that is being welded
components.
(10) Current path of the welder
Clamp the ground cable from the welder to
the component that will be welded. Place the (11) Ground clamp for the welder
clamp as close as possible to the weld. This
5. Connect the welding ground cable directly to
will help reduce the possibility of damage.
the part that will be welded. Place the ground
1. Stop the engine. Turn the switched power to cable as close as possible to the weld in order to
the OFF position. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
2. Perform the welding in areas that are free from components, and ground straps.
explosive hazards.
Note: If electrical/electronic components are
3. Disconnect the negative battery cable from the used as a ground for the welder, or electrical/
battery. If a battery disconnect switch is electronic components are located between the
provided, open the switch. welder ground and the weld, current flow from
4. Disconnect the J1/P1 and J2/P2 connectors the welder could severely damage the component.
from the ECM. Move the harness to a position 6. Protect the wiring harness from welding debris
that will not allow the harness to accidentally and spatter.
move back and make contact with any of the
ECM pins. 7. Use standard welding practices to weld the
materials.
15
Technical Data
The following information covers all relevant points listed in clause 1.0.6 of the EHSR’s of the
ATEX Directive.
Explosion Protection Zone 2, Group II, Category 3G, Gas Group IIB, Temperature Class T3
Required Service Manuals LEGW3354 Installation Guide
(Caterpillar Service Manual RENR8042 Schematic
SENR9950 contains all of the SEBU7895 Operation and Maintenance Manual
required media numbers and SENR9953 Systems Operation Testing and Adjusting Manual
may be obtained from the local RENR5061 Troubleshooting Guide
Caterpillar dealer.) SENR2995 Product Safety
SENR3190 Specifications – Torque Specifications
RENR8626 Disassembly and Assembly
SENR9952 Specifications – C-15 Petroleum Engines
SEBP4170 Parts Manual
Part Number ECM 191-5208, 210-0849
Engine Arrangement 245-3904
Electronics Group 192-0883
Wiring Group 237-7594, 237-7561
Enclosure Protection 210-0849 – ECM, wiring harness and sensors – IP 56
243-3820 – Messenger Display – IP 68
134-0670 – Throttle Position Sensor – IP 56
Ambient Temperature 210-0849 – wiring harness and sensors – -40°C to 85°C (-40°F to 185°F)
– ECM Air Cooled -40°C to 85°C (-40°F to 185°F)
– Fuel Cooled -40°C to 102°C (-40°F to 248°F)
– Fuel Temp 80°C Max
– Fuel Rate 10 L/min Max
243-3820 – Messenger Display – -40°C to 85°C (-40°F to 185°F)
134-0670 – Throttle Position Sensor – -40°C to 85°C (-40°F to 185°F)
Relative Humidity 0 to 100%
ECM Operating Voltage 12 VDC or 24 VDC
SENR9952 Specifications – C-15 Petroleum Engines
Operating Pressures SENR9952 Specifications – C-15 Petroleum Engines
Operating Temperatures SENR9952 Specifications – C-15 Petroleum Engines
16
System Overview The ECM determines the timing and the amount
of fuel that is delivered to the cylinders. These
The C-15 Petroleum engine was designed for decisions are based on the actual conditions and
electronic control. The injection pump, the fuel the desired conditions at any given time. The
lines, and the nozzles that are used in mechanical ECM compares the desired engine speed to the
engines have been replaced with a unit injector in actual engine speed. The actual engine speed is
each cylinder. A solenoid on each injector determined through the engine speed/timing
controls the amount of fuel that is delivered by sensor. The desired engine speed is determined
the injector. An electronic control module (ECM) by monitoring the following inputs to the ECM:
sends a signal to each injector solenoid in order
• Sensors (throttle position, etc.)
to provide complete control of the engine.
• Diagnostic codes
• Event codes (derates)
Electronic Controls
If the desired engine speed is greater than the
The electronic system consists of the following actual engine speed, the ECM will signal the
components: electronic control module (ECM), injectors to inject more fuel. This will increase
unit injectors, wiring harness, switches, and the actual engine speed.
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
17
C-15 Engine
Electronic Control Module (ECM)

Service Tool
Connector
6 Electronic
J2 J1
Unit Injectors J1939 Terminating
Resistor
J300/P300
Electronics Ground
Stud
OEM Supplied Components

J61
These components must be
P61
approved for installation in a
hazardous location.
Timing Calibration P400
Probe Connector
Primary Engine
Speed Timing J401/P401
Sensor (Crankshaft)
Secondary Engine J402/P402

Speed Timing
Sensor (Camshaft)
Fuel Pressure J209/P209

Sensor
Atmospheric J203/P203
Pressure Sensor
Engine Oil
Pressure Sensor P201/J201
Turbo Outlet (Intake

Manifold Air) P200/J200
Pressure Sensor
Engine Coolant
J100/P100
Temperature
Sensor
Fuel Temperature
Sensor J105/P105
Intake Manifold Air

Temperature P103/J103
Sensor
18
C-15 Engine (Sensor Locations)
LEFT SIDE VIEW

Turbo Outlet (Intake Fuel Temperature
J61 Customer Electronics Fuel Pressure
Manifold Air) Pressure Caterpillar Supplied Sensor
Connector Ground Stud Sensor
Sensor Engine Service
Intake Manifold
Air Temperature
Secondary Speed Sensor
Timing Sensor
Timing
Calibration
Probe
Connector
P400
Primary Engine Atmospheric Engine Oil ECM Connector ECM ECM

Speed Timing Sensor Pressure Sensor Pressure Sensor J2/P2 Connector
J1/P1
FRONT VIEW
Engine Coolant
Temperature Sensor
19
System Configuration Parameters Parameter Lockout
System configuration parameters are parameters Parameter Lockout is available to restrict access
that affect the emissions, the power of the engine, to changing some of the available parameters.
and features of the engine. Default values for the Locking out a parameter requires customer
parameters are programmed at the factory. The passwords (if used). Once a parameter is locked
customer may change some parameters in order out, factory passwords are required to unlock the
to suit the needs of the specific application. parameter. If a lockable parameter is not locked
These parameters can be changed with the out, factory passwords are not required. A locked
Caterpillar Electronic Technician (ET), which is out parameter restricts the parameter from being
an electronic service tool. System configuration changed directly by the customer or unauthorized
parameters consist of ECM Identification personnel. This helps engine owners that are
Parameters and Selected Engine Rating encountering problems with operators that are
Parameters. You must reprogram the ECM obtaining customer passwords and altering
Identification Parameters if the ECM is replaced parameters.
and/or you reprogram the engine rating. You do The following parameters can be locked out:
not need to reprogram the ECM Identification
• Engine Power Trim
Parameters if you reflash the ECM. Proper values
for these parameters are available on Cat ET. • High Idle Speed
Certain configuration parameters are also • Monitoring System Configuration Access
stamped on the engine information plate. • Rating Number
Note: If the parameters that are protected with • Top Engine Limit
the factory passwords are changed, the When an attempt to change a locked out
Caterpillar warranty may be voided. parameter occurs, the factory password screen
will come up. If changing the parameter is
Customer Passwords required, follow the instructions on Cat ET.
Customer passwords may be programmed in
order to limit access to certain parameters. A
maximum of eight alphanumeric characters may
be entered for each of the two available customer
passwords. These passwords are case sensitive.
Both customer passwords do not need to be
programmed in order to provide protection.
20
System Configuration Parameters
Parameter Available Range or Options Default Required Password
ECM Identification Parameters

Equipment ID 17 alphanumeric characters blank none
Engine Serial Number XXX00000 0XX00000 none
Personality Module Read Only
Part Number
Software Gp Release Date Software Dependent Read Only
Selected Engine Rating

Rating Number Software Dependent Customer
Rated Power Software Dependent Read Only
Rated Peak Torque Software Dependent Read Only
Top Engine Speed Range Software Dependent Read Only
Test Spec Software Dependent Read Only
Top Engine Limit Software Dependent Customer
Engine Accel Rate 50 to 1000 500 None
Low Idle Speed 600 to 1400 700 None
PTO Mode Ramp Up/Ramp Down Ramp Up/ None
Set/Resume Ramp
High Idle Speed Software Dependent Customer
Intermediate Engine Programmed “Low Idle” Programmed None
Speed to TEL “Low Idle”
Engine Power Trim -3.0 to 3.0 1.2 Customer
Maximum Engine Software Dependent None
Torque Limit
Customer Password #1 8 alphanumeric characters blank Customer
Customer Password #2 8 alphanumeric characters blank Customer
FLS Factory Programmed Factory
FTS Factory Programmed Factory
Ether Control Enabled Disabled None
Disabled
Air Shutoff Enabled Disabled None
Disabled
Maintenance OFF OFF None
Indicator Mode Auto Fuel
Auto Hour
Man Fuel
Man Hour
PM1 Interval 100 to 750 Hours 250 Hours None
1000 to 7500 US Gallons 2500 US Gal.
Throttle Position Sensor Installed Not Installed None
Not Installed
21
System Configuration Parameters
Parameter Available Range or Options Default Required Password
Coolant Level On Installed Not Installed None
Not Installed
Direct Fuel Enabled Disabled Factory
Control Mode Disabled
Engine Oil Weight
Last Tool to change Read Only
Customer Parameters
Last Tool to change Read Only
System Parameters
Aux Temp Sensor Installed Not Installed None
Installation Status Not Installed
Aux Pressure Sensor Installed Not Installed None
Installation Status Not Installed
Desired Speed Input CAN Input PWM Customer
Configuration PWM
Total Tattletale Read Only
Parameters Worksheet
Note: Providing the customer with a printed copy of the “Configuration” and the “Monitoring System”
screens from Cat ET is good practice. You may also copy the following table with this information for
the customer.
Parameters
Equipment ID
Engine Serial Number
Personality Module Part Number
Software Gp Release Date
Rating Number
Rated Power
Rated Peak Torque
Top Engine Speed Range
Test Spec
Top Engine Limit
Engine Accel Rate
Low Idle Speed
PTO Mode
22
Parameters
High Idle Speed
Intermediate Engine Speed
Engine Power Trim
Maximum Engine Torque Limit
Customer Password #1
Customer Password #2
FLS
FTS
Ether Control
Air Shutoff
Maintenance Indicator Mode
PM1 Interval
Throttle Position Sensor
Coolant Level Sensor
Direct Fuel Control Mode
Engine Oil Weight
Last Tool to change Customer Parameters
Last Tool to change System Parameters
Aux Press Sensor Installation Status
Aux Temp Sensor Installation Status
Desired Speed Input Configuration
Total Tattletale
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. 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.
Parameter Descriptions Engine Serial Number

Engine Serial Number should be programmed to
Equipment ID
match the engine serial number that is stamped
Equipment ID allows the customer to enter a on the engine information plate. If the ECM is
description into the ECM in order to identify the replaced, the engine serial number from the
machine. A maximum of 17 characters may be Engine Information Plate should be programmed
entered in the field. This parameter is only for into the new ECM.
reference by the customer. This parameter is not
required. Note: When you are requesting factory passwords,
always use the engine serial number that is
resident in the ECM.
23
Rating Number Engine Accel. Rate
The Rating Number corresponds to the selected Engine Accel. Rate determines the rate of change
set of performance maps for the application. This of the engine speed (acceleration or deceleration)
selected set of performance maps comes out of during PTO operation. This rate of change is also
several unique sets of maps that may be resident used to achieve intermediate engine speed.
in the flash file. The dealer and/or the OEM will
need to select the appropriate rating tier, if more Low Idle Speed
than one rating tier is present. The rating tier is A Low Idle Speed is the minimum allowable
through E. operating speed for the engine. This parameter
can be programmed between 600 and 1400 rpm.
Top Engine Limit
Engine Speed Limits
PTO Mode
PTO Mode allows the ECM to be programmed to
either one of the two PTO configurations that are
Engine Power
available.
Ramp Up/Ramp Down – When PTO Mode is
programmed to Ramp Up/Ramp Down, the ECM
allows PTO operation with traditional features.
Refer to PTO Switches for more details.
Set/Resume – When PTO Mode is programmed
High Idle
Low Idle Range TEL Range to Set/Resume, the ECM allows PTO operation
Maximum Rated with enhanced features. Refer to PTO Switches
Engine Speed for more details.
Engine Speed (rpm)
Engine Overspeed
TEL is a customer programmable parameter that “Engine Overspeed” is a feature provided in
defines the maximum allowable engine speed for order to help prevent damage to the engine or
maximum power. TEL can be programmed up to driven equipment in the event of an overspeed
the maximum rated engine speed. TEL is defined condition. The Monitoring System must have the
along the engine’s lug curve. “Engine Overspeed” parameter set to the ON
position in order to enable this feature. When the
overspeed verify switch is activated, the engine
will shut down when engine speed reaches 75
percent of the overspeed setpoint. The ECM
shuts down the engine by disabling fuel injection
and activating the relay for the air shutoff
solenoid.
Refer to Monitoring System parameter table on
page 27.
24
High Idle Speed Maximum Engine Torque Limit
Engine Speed Limits Engine Torque Limit

Engine Power
Engine Torque
Allowable Range
of Torque Limit
Maximum Rated
High Idle Engine Speed (rpm) Engine Speed
Low Idle Range TEL Range
Maximum Rated High Idle
Engine Speed
Engine Speed (rpm)
Engine Torque Limit can be used to limit torque
output to the programmed value when the torque
High Idle Speed is the maximum no-load engine
limit switch is activated.
speed when the throttle or the PTO switch is in
the maximum position.
FLS (Full Load Setting)
Note: High Idle Speed cannot be programmed FLS is a number that represents the adjustment to
lower than TEL. the fuel system that was made at the factory in
order to fine-tune the fuel system. The correct
Intermediate Engine Speed value for this parameter is stamped on the engine
Intermediate Engine Speed defines the speed for information plate. Factory passwords are required.
the engine when the intermediate engine speed
switch is activated. This parameter can be FTS (Full Torque Setting)
programmed to any engine speed between Low FTS is similar to FLS. Factory passwords are
Idle Speed and TEL. Engine speed will increase required.
or engine speed will decrease at the rate that is
defined by the programmed value for Engine Ether Control
Accel. Rate.
Ether Control should be programmed to Enabled
if an ether injection system is installed on the
Engine Power Trim
engine. This allows the ECM to control ether
Engine Power Trim allows small adjustments to injection.
be made to engine power within a selected rating.
This parameter is expressed as a percentage. This Air Shutoff
parameter will allow the lug curve to be adjusted
Air Shutoff allows the ECM to be programmed
by the programmed value.
for operation of an air shutoff system. If this
parameter is programmed to “Installed,” the
ECM will activate the air shutoff solenoid in the
event of an engine overspeed condition.
Note: If an engine overspeed condition occurs
and Air Shutoff is programmed to “Enabled,” the
switched power to the ECM must be cycled and
the air shutoff solenoid must be manually reset
before the engine will restart.
25
Maintenance Indicator Mode Engine Oil Weight (C-15 Engine)
The ECM records data that is related to The Engine Oil Viscosity selection on the
equipment maintenance. The ECM will activate electronic service tool screen should not be used
the maintenance indicator lamp when scheduled to select the oil viscosity. The correct oil grade
maintenance is due. The maintenance indicator plug should be used to select the oil viscosity.
lamp can be reset by actuating the maintenance
due reset switch. The maintenance interval may Note: Refer to Operation and Maintenance
be based on operating hours or fuel consumption. Manual, “Engine Oil and Filter – Change” for
The ECM provides information that pertains to more information.
maintenance intervals and the last maintenance
that was performed. Aux Press Sensor Installation Status
Aux Press Enable should be programmed to
PM1 Interval “Installed” if an auxiliary pressure sensor is
PM1 Interval allows the customer to define the installed.
maintenance interval if Maintenance Indicator
Mode is programmed to one of the manual Aux Temp Sensor Installation Status
options. Refer to the Operation and Maintenance Aux Temp Enable should be programmed to
Manual for more information. “Installed” if an auxiliary temperature sensor is
installed.
The Throttle Position Sensor should be Desired Speed Input Configuration
programmed to “Installed” if a throttle position The Desired Speed Input Configuration
sensor is used for desired speed control. parameter should be programmed to match the
type on input signal for desired engine speed.
Coolant Level Sensor The ECM can be programmed to “CAN Input” if
The Coolant Level Sensor parameter should be a J1939 throttle message is transmitted over the
programmed to “Installed” if a coolant level J1939 data link. The ECM should be
sensor is installed on the engine. programmed to “PWM” if a throttle position
sensor or direct fuel control is used.
Direct Fuel Control Mode
The Direct Fuel Control Mode parameter should
be “Enabled” if an external governor is used.
Once this parameter is enabled, the governing
system in the ECM is disabled.
26
Monitoring System
The Monitoring System determines the level of • Engine coolant temperature sensor
action that is taken by the ECM in response to a • Engine oil pressure sensor
condition that can damage the engine. These • Engine speed/timing sensors
conditions are identified by the ECM from the
• Fuel pressure sensor
signals that are produced from the following sensors.
• Fuel temperature sensor
• Auxiliary pressure sensor
• Inlet air temperature sensor
• Auxiliary temperature sensor
• Coolant level sensor
Monitoring System Parameters

Time Delay
Default Set Points
Parameter Action in Seconds Disable
Value
Range Default Range Default
Low Engine Warning On 2 YES
Oil Pressure Derate On None 2 Maps are not programmable YES
Shutdown Off 10 YES
High Engine 85°C (185°F) to
Warning On None 4 105°C (221°F) YES
Coolant 105°C (221°F)
Temperature 86°C (187°F) to
Derate On 0 to 54 4 106°C (223°F) YES
106°C (223°F)
87°C (189°F) to
Shutdown Off 0 to 54 4 107°C (224°F) YES
107°C (224°F)
Engine Warning On 0 to 1 1 YES
1800 to 2500 2500
Overspeed Shutdown On None 1.0 YES
High Engine Warning On None 4 75°C (167°F) YES
Air Inlet None
Temperature Derate On 0 to 54 4 79°C (174°F) YES
Low Coolant Warning On 0 to 20 10 YES
Level Derate On 0 to 54 10 N/A YES
Shutdown Off 0 to 54 10 YES
High Fuel 70°C (158°F) to
Warning On 0 to 54 4 91°C (196°F) YES
Temperature 80°C (176°F)
Derate On 0 to 54 3 81°C (178°F) to 91°C (196°F) YES
High Fuel
Warning On None 2 Maps are not programmable YES
Pressure
High Fuel Warning On None 10 YES
Filter Pressure Derate Off None 10 Maps are not programmable YES
Restriction Shutdown Off None 10 YES
High Warning On 0 to 54 4 105°C (221°F) YES
Auxiliary 0°C (0°F) to
Temperature Derate Off 0 to 54 4 120°C (248°F) 106°C (223°F) YES
High Warning On 0 to 54 4 0 kPa (0 psi) to YES
1500 kPa
Auxiliary Derate On 0 to 54 3 3150 kPa YES
(218 psi)
Pressure Shutdown On 0 to 54 3 (457 psi) YES
27
Required Service Tools
Part Number Description
N/A Hex Key Wrench
7X-1710 Multimeter Probes
9U-7330 Digital Multimeter
9U-6070 (1)
Heat Gun Gp (115 VAC)(2)
9U-6072(1) Heat Gun Gp (220 VAC)(2)
1U-5804 Crimp Tool (12-26 AWG)
1U-5805 Wire Removal Tool (14 AWG)
140-9944 Terminal Repair Kit
175-3700 Connector Repair Kit (Deutsch DT)
190-8900 Connector Repair Kit (Deutsch HD)
(1)
Use for the heat shrink tubing
(2)
Not ATEX approved
Note: Tools are not approved for use in a hazardous environment and
all work should be performed in a non-hazardous (safe) area.
There are other tools that are required to troubleshoot the engine
electronics. Refer to the appropriate troubleshooting module for your
engine for more information.
Caterpillar Electronic Technician (ET)

Cat ET can display the following information: Cat ET can be used by the technician to perform
• Parameters the following functions:
• Logged event codes • Diagnostic tests
• Active diagnostic codes and logged diagnostic • Calibrate the engine speed-timing sensors.
codes • Flash programming
• Engine configuration • Select the parameters and/or program the
• Current totals parameters.
• Job history • Data logging
• Customize the Programmable Monitoring
System (PMS).
• Customize the maintenance schedule.
• Establish the security of the parameters.
28
Required Electronic Service Tools for the Use of Cat ET
Part Number Description
N/A Required
IBM Compatible PC with a minimum of 266 MHz Pentium processor
64 MB of RAM
400 MB of available hard drive space
CD-ROM drive
3.5" 1.44 MB floppy disk drive
Windows NT, 4.0, 95
RS232 port with 16550AF UART
VGA monitor or display (800 x 600)
N/A Recommended
IBM compatible PC with
450 MHz Pentium processor
128 MB of RAM
1 GB of available hard drive space
40X speed CD=ROM drive or (8X speed)
DVD drive
3.5" 1.44 MB floppy disk drive
Windows NT, 4.0, 98
RS232 port with 16550AF UART
Super VGA monitor or display (800 x 600)
JERD2124 Electronic Technician Program (ET)
JERD2129 Data Subscription for All Engines and Machines
171-4400 Communications Adapter II Gp
29
Connecting Cat ET and the Note: Items (2), (3), and (4) are part of the
171-4400 Communication Adapter II Gp.
Communication Adapter
Use the following procedure to connect Cat ET
and the Communication Adapter II.
1. Turn off all switched power to the ECM.
2. Connect cable (2) between the COMPUTER
or Service Tool port of communication adapter
(3) and the RS232 serial port of PC (1).
3. Connect cable (4) between the DATA LINK or
Control end of communication adapter (3) and
the service tool connector.
4. Turn on the switched power to the ECM. The
ECM must be powered in order for Cat ET to
operate. Cat ET will operate while the engine
is running or stopped.
Support for Cat ET

For authorization and local ordering information,
contact Caterpillar Media and Product
Information Logistics.
To find local dealer: www.cat.com
Phone: (800) 566-7782, (309) 266-0942
Communication Adapter II Fax: (309) 494-1345, (309) 494-1348
(1) Personal computer (PC) E-mail: [email protected]
(2) 196-0055 Adapter Cable (PC Serial) Hours: 7:30 a.m. to 4:30 p.m. (CST)
(3) 171-4401 Communication Adapter II
Contact the Caterpillar SIS Help Desk if
(4) 207-6845 Adapter Cable (Data Link)
problems with the software are encountered.
Note: The ET Service Tool and Communications Phone: (800) 765-0999, (309) 675-4000
Adapter must only be used in Non-Hazardous Fax: (309) 675-4001
(safe) areas.
E-mail: [email protected]
Hours: 6:00 a.m. to 6:00 p.m. (CST)
30
Switches Voltage Thresholds at the ECM
When any of the switch contacts are closed, the
Switch Specifications
voltage drop through the switch circuit must be
All switches that are provided by the OEM and less than 0.9 VDC. This measurement should be
connected to the Electronic Control Module taken at the respective control input and the
(ECM) must be of a two-wire design. These negative battery input to the ECM. This
switches must be externally connected to the measurement includes the following values:
negative battery ground stud that is located near
• Ground potential differences
the J61/P61 Customer Connector. Switches
which are grounded internally to the case must • Voltage drop across the switch
not be used. Supplied voltage from the ECM to • Voltage drop across the wiring harness
the switches will not normally exceed 12 VDC.
When any of the switch contacts are open, the
Normal current through the switches will not
resistance between the respective control input
exceed 5.0 mA.
and the negative battery input to the ECM
Momentary opening or closing of the switches should not be less than 5,000 Ohms. Potential
and contact chatter should not exceed 100 paths for leakage may exist within the
milliseconds in duration. Vibration or shock that following components:
is normally found in the application should not • Connectors
cause opening or closing of the switches. The • Harnesses
plating on the contacts should not be susceptible
to corrosion or oxidation. Gold plated switch • Switches
contacts are recommended. Note: OEM installed switches must be connected
When a switch contact is opened or the wiring to the electronics ground stud that is located near
harness has an open circuit, the internal pull up the J61/P61 Customer Connector.
voltages of the ECM force the respective input to
12 VDC. Closing an OEM installed switch must
short circuit the switch input to the electronics
ground stud that is located near the J61/P61
Customer Connector. 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.
31
Connectors
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.
32
Installation of Terminals and Seal Plugs
Deutsch Sealing Plug Insertion
Correct Installation
Seal
Sealing Plug
Installation of Seal Plugs
Correct Incorrect
Incorrect Installation
Seal
Sealing
Plug
The following requirements ensure the correct • All sockets and pins should be crimped on the
installation of terminals in the connectors: wires. Use the 1U-5804 Crimp Tool for 12 to
26 AWG wire.
• Do not solder the sockets and pins to the wires.
• All unused cavities for sockets and pins must be
• Never crimp more than one wire into a socket filled with 8T-8737 Seal Plugs in order to ensure
or a pin. The 186-3735 Connector Pin and the that the connector is sealed. The seal plugs must
186-3736 Connector Socket are designed to be installed from the wire insertion side of the
accept only one 16 or 18 AWG wire. The plug or receptacle. The seal plugs must seal
9W-0844 Connector Socket and the 9W-0852 correctly. The head of the seal plug should rest
Connector Pin are designed to accept only one against the seal. Do not insert the head of the
14 AWG wire. Do NOT insert multiple wires of seal plug into the seal. Refer to the illustration
a smaller gauge. above for correct installation of plugs.
33
J61/P61 Customer 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 seated.
• The pins and sockets are not damaged.
• The pins and the sockets are securely installed
on the wires. Perform the 10 pound 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.
Ensure that the allen head screw in the customer • The wedges are not damaged.
connector is tightened to a torque of 2.25 ± 0.25
N•m (20 ± 2 lb in). All unused cavities for
Deutsch HD Connectors
sockets and for pins must be filled with 8T-8737
Seal Plugs in order to ensure that the connector Ensure that the wires in the plug align with the
is sealed. The acceptable diameter of the corresponding wires in the receptacle. Ensure that
insulation for a wire that is connected to the the index markings on the plug and the receptacle
customer connector is 2.54 to 3.43 mm (0.100 to are aligned. Rotate the plug until the plug slips
0.135 inch). into the receptacle. Rotate the coupling by
approximately 90 degrees until a click is heard.
Refer to page 40 for pin outs of the J61/P61
Customer Connector. Ensure that the plug and the receptacle cannot be
pulled apart.
Deutsch DT Connectors The acceptable range for the diameter of the
A DT connector has a wedge that locks the pins insulation of the wire that is used with the
and the sockets in place. The wedge can be connectors is 2.54 to 3.43 mm (0.100 to
removed and replaced without cutting the wires. 0.135 inch).
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.
34
Wiring Considerations
The Caterpillar supplied engine wiring harness splices on the J61/P61 customer connector should
must not be modified in any way that may affect be sealed with Raychem ES2000 adhesive lined
the engine operation. All of the terminals and the heat shrink tubing. An equivalent substitute may
be used. Refer to the following table.
Heat Shrink Tubing
Part Number I.D. Before Shrink I.D. After Shrink
3.20 mm 1.58 mm
8T-6342
(0.126 inch) (0.062 inch)
4.70 mm 1.78 mm
3E-9553
(0.185 inch) (0.070 inch)
5.72 mm 1.27 mm
125-7874
(0.225 inch) (0.050 inch)
6.40 mm 3.20 mm
9X-2109
(0.252 inch) (0.126 inch)
7.44 mm 1.65 mm
125-7875
(0.293 inch) (0.065 inch)
10.85 mm 2.41 mm
119-3662
(0.427 inch) (0.095 inch)
17.78 mm 4.45 mm
125-7876
(0.700 inch) (0.175 inch)
68.00 mm 22.00 mm
8C-3423
(2.678 inch) (0.866 inch)
Wire Size Requirement

The size of the wire that is used to connect all Note: All wire should be at least 16 AWG. Any
electrical components must be of adequate size exceptions to the wire size must be specified.
for the maximum current in the circuit. Observe
the requirements in the following chart.
Requirements for Wire Size
Circuit Location Size(1) Part Number
Negative Battery Electronics Ground Stud 4 AWG
Switched Positive Battery J61-1 14 AWG
Unswitched Positive Battery J61-48
J61-52
J61-53 14 AWG
CAT Data Link + J61-7 18 AWG
CAT Data Link – J61-6 18 AWG
J1939 Data Link + J61-16 19 AWG
J1939 Data Link – J61-17 19 AWG
J1939 Data Link Shield J61-18 19 AWG
All Other Applications — 16 AWG
Metric Equivalent for AWG Wire Numbers

(1)
AWG 20 19 18 16 14 12 4
Diameter (mm2) 0.5 0.65 0.8 1 2 3 19
35
Harness Routing
The routing of the OEM wiring harness should harness. Curvatures should be avoided within
be designed so that the radius of any bend is 25 mm (1.0 inch) of any connector in order to
greater than two times the diameter of the wiring avoid seal distortion (moisture entry path).
Harness Routing at ECM Connector
Correct Installation
Wire Exiting Straight Out

Harness Correctly Routed of Connector Correctly
Incorrect Installation
Harness Pulled
Harness Pulled
Wire Exiting Pulled Toward Center
Up Too Close
Up On Connector Too Close to
to Connector
Incorrectly Connector
36
Requirements for the Battery Note: Grounding through frame members is not
recommended.
Circuit
A maximum of three ring terminals should be
Grounding
connected to the electronics ground stud in order
NOTICE: Improper grounding can cause to ensure integrity of the ground connection. The
uncontrolled or unreliable circuit paths and use of more than three terminals at the
electrical noise. This can result in damage to electronics ground stud can cause the connection
the engine bearings, and other engine to become loose.
components.
Proper grounding of the unit and the engine WARNING
electrical systems is necessary for proper
performance and reliability. The connection of battery cables to a battery
and the disconnection of battery cables from a
Negative Battery Connection battery may cause an explosion which may
NOTICE: The customer must provide a result in injury or death. The connection and
4 AWG or larger ground cable from the the disconnection of other electrical equipment
electronics ground stud on the engine to may also cause an explosion which may result
negative battery. All ground paths must be in injury or death. The procedures for the
capable of carrying any likely fault currents. connection and the disconnection of battery
The electronics ground stud is located on the cables and other electrical equipment should
bracket for the J61/P61 customer connector. only be performed in a nonexplosive
atmosphere.
The alternator should be grounded at the bus bar
on the negative battery or grounded directly to
the negative battery post.
37
(Pins 1, 26, 31, 32) Switched Positive Battery and Unswitched Positive Battery
Customer Connector
P61/J61
Unswitched 31
Positive Battery 15A
32
Switched
15A 26
Positive Battery
Note: Use 14AWG wire for all positive battery

(switched/unswitched) circuits to the Customer Connector.
Note: All battery connections to the ECM must control system performance. This also minimizes
be utilized in order to prolong the service life of the chance of an engine shutdown due to a short
the ECM. in the electrical system. Additional loads should
not be connected between the ECM and the
The electronic control system can operate on circuit protection for the ECM.
either a 12V electrical system or a 24V electrical
system. The switched positive battery and the Note: DO NOT use in-line fuses for circuit
unswitched positive battery connections to the protection. Caterpillar recommends the use of
ECM are made at the P61 customer connector. circuit breakers that are approved for hazardous
The ECM receives electrical power through the locations. Circuit breakers should be located
input for the switched positive battery. Protection with other circuit protection in a centrally
for this circuit must be rated at 15 Amp (12V or located, dedicated panel. If circuit breakers that
24V system). automatically reset are used, consideration of the
environment of the location of the breaker is
The input for the unswitched positive battery is critical and the effect on the trip point is critical.
used to power ECM memory that contains The trip point of some circuit breakers can be
maintenance information and certain logged significantly reduced below the rated trip point if
diagnostics. Protection for the unswitched the circuit breaker is exposed to high
positive battery circuit is specified as 15 Amp. temperatures. This can cause intermittent
Powering the electronic control system through shutdowns that result in needless replacement of
dedicated circuits with circuit breakers reduces electronic components.
the possibility of degradation of electronic
ADEM-III Current Requirements
Parameter ADEM-III Units
12V
Sleep Mode Current 6.7 mA
Power On with no I/O 550 mA
Inrush Amplitude – Switched + ON 35 A
Inrush Amplitude – Unswitched + ON 4.4 A
Inrush Duration – Switched + ON 8 ms
Inrush Duration – Unswitched + ON 8 ms
Normal Operating Current – Peak 20 A
Normal Operating Current – RMS 7.1 A
24V
Sleep Mode Current 7.5 mA
Power On with no I/O 450 mA
Inrush Amplitude – Switched + ON 50 A
Inrush Amplitude – Unswitched + ON 3.5 A
Inrush Duration – Switched + ON 5.5 ms
Inrush Duration – Unswitched + ON 5.5 ms
Normal Operating Current – Peak 16 A
Normal Operating Current – RMS 2.2 A
38
Suppression of Voltage Transients
The installation of transient suppression at the the generation of voltage transients in electrical
source of the transient is recommended. circuits. Voltage transients that are not suppressed
Caterpillar follows a stringent electrical can exceed SAE specifications and lead to the
environment standard that is similar to SAE degradation of the performance of the electronic
recommended practices. The use of inductive control system.
devices such as relays and solenoids can result in
Positive Positive
Relay with low side Relay with high side

driver or switch driver or switch
Using a diode in a relay in order to suppress voltage transients.
The OEM should specify relays and solenoids Inductive devices such as relays or solenoids
that are approved for hazardous locations. These should be located as far as possible from the
relays and solenoids should have built-in voltage components of the electronic control system.
transient suppression. Refer to the illustration Wiring harnesses that are installed by the OEM
above for ways to minimize voltage transients should be routed as far as possible from the
from relays and solenoids without built-in wiring harness of the electronic control system in
voltage transient suppression. Techniques include order to avoid problems that are associated with
the installation of a diode or resistor of the electrical noise.
proper size in parallel with the solenoid or the
relay coil. Other techniques may also be used.
39
Customer Installed Components
Note: Refer to the appropriate Parts Manual for P61 Customer Connector
your engine for further details on parts The P61 Customer Connector utilizes an 8T-9834
information. Connector Plug. 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).
Pin-outs for Customer Connections

J61/P61 Circuit Function J61/P61 Circuit Function
1 +Bat. (Unswitched) 21 N/C
2 Torque Limit 22 Ether Start Valve Relay
3 N/C 23 N/C
4 Relay for Air Inlet Shutoff Solenoid 24 Diagnostic Lamp
5 Solenoid Common 25 Warning Lamp
6 Cat Data Link – 26 + Bat (Switched)
7 Cat Data Link + 27 Remote Shutdown Switch
8 Digital Sensor Power (+8V) 28 Intermediate Engine Speed Switch
9 Digital Sensor Return 29 PTO Enable Switch
10 Throttle Signal 30 PTO Ramp Up/Set Switch
11 Auxiliary Temperature Sensor 31 +Bat (Unswitched)
12 Maintenance Due Reset Lamp 32 +Bat (Unswitched)
13 Maintenance Due Lamp 33 Auxiliary Pressure Sensor
14 Analog Sensor Power (+5V) 34 N/C
15 Analog Sensor Return 35 N/C
16 J1939 Shield 36 Coolant Level Sensor
17 J1939 Data + 37 N/C
18 J1939 Data – 38 Starting Aid Override Switch
19 PTO Interrupt Switch 39 PTO Ramp Down/Resume Switch
20 N/C 40 75% Overspeed Verify Switch
Sensor Return Connections

Certain components that interface directly with the P61 customer connector can degrade the
the ECM are connected to the dedicated sensor performance of the electronic control system.
returns at the P61 Customer Connector. Separate These components must be connected to the
sensor returns are provided for analog signal and negative terminal of the battery. Any relays or
digital signals. Refer to the Electrical System solenoids that are driven by the ECM must not be
Schematic. connected to the sensor returns at the P61
customer connector. These components must be
Note: Do not connect negative power or positive connected to the negative terminal of the battery.
power for the TPS to the J61/P61 Customer
Connector. Connecting switches and/or the Refer to the Electrical System Schematic for
throttle position sensor to the sensor returns at details.
40
(Pin 2) Torque Limit Switch
Torque output is limited to the programmed
value for Engine Torque Limit when the torque
limit switch is activated.
Engine Torque Limit
Allowable Range of Torque Limit

Engine Torque
TEL
Engine Speed (rpm) Maximum rated

engine speed
High Idle
Customer Connector
Torque Limit Switch P61/J61
Negative Battery
Required Parts
Part Number Description Qty
(2)
Toggle Switch (SPST, Momentary)
Toggle Switch (SPST) 1
186-3736 Connector Socket 2
(2)
Terminal 2
(2)
16 AWG Wire (1)
Fabricate to length
(1)
OEM Supplied – component must be approved to be installed in a

(2)
hazardous location.
41
(Pins 4 & 5) Air Shutoff System
The engine may be equipped with an air shutoff Note: If an event for engine overspeed occurs
system. The parameter for Air Shutoff must be and Air Shutoff is programmed to “Enabled,”
programmed to “Enabled” for the ECM to switched power to the ECM must be cycled and
operate this feature in the event of an engine the air shutoff solenoid must be manually reset
overspeed condition. before the engine will start.
The ECM shuts down the engine by disabling
fuel injection activating the relay for the air
shutoff solenoid.
Required Parts
(1)
Air Shutoff System 1
155-2270 Connecting Plug Kit 1
(2)
Terminal (Relay) 1
(2)
Terminal (Solenoid) 1
(2)
10 AWG Wire (+Battery) (3)
(2)
16 AWG Wire (ECM) (3)
(1)
Refer to Parts Manual
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.
(3)
Fabricate to Length
Positive Battery
Air Air
Shutoff Shutoff 15A
Customer
Connector
10 AWG 10 AWG
Air Shutoff Solenoid
4
16 AWG
Solenoid Common
5
16 AWG
Negative Battery
Air Shutoff Valve Installation
1/4-20-2A THD
ø 8.2-A 31 Deep
3/8-16-2B THD
23 Deep
2 places
42
(Pins 6 & 7) J66 Customer Supplied
Service Tool Connector
An additional service tool connector is Cable (Twisted Pair) and dedicated terminal
recommended in applications that have limited strips for all data connections. Mount the
accessibility to the J63 engine service tool terminal strips in a central location in order to
connector. Proper wiring of the J66 customer minimize the overall length of the data link cable.
supplied service tool connector is essential for The total length of the data link cable should not
reliable communication of data. Use 143-5018 exceed 30 m (100 ft).
Negative
Switched Battery
Positive Battery
16 16
AWG AWG
J66
A
Customer Connector
B P61/J61
C 7 CAT Data Link +
D 6 CAT Data Link –

143-5018
Required Parts
8T-8736 or 9W-1951 Connector Receptacle 1
8C-6354 Receptacle Cap 1
186-3735 Connector Pin 4
8T-8737 Seal Plug 5
(2)
Cable (Twisted Pair) (1)
(2)
16 AWG Wire (1)
(1)
Fabricate to Length
(2)
43
(Pins 8, 9 & 11) Auxiliary
Temperature Sensor
An additional temperature sensor input is To utilize this feature, the Caterpillar supplied
provided in order to allow an auxiliary temperature sensor must be used and the
temperature to be displayed. The auxiliary parameter Aux Temp Sensor Installation Status
temperature may be displayed on the Cat ET must be programmed to “Installed.” This
screen, the PMS display module, and the J1939 temperature sensor is a digital PWM sensor with
(CAN) display module. an operating range of 0°C to 120°C (0°F to
216°F).
Customer Connector
Auxiliary Temperature P61/J61
Sensor J142/P142
+8 VDC A 8
Return B 9
Signal
C 11
Required Parts
131-0427 Temperature Sensor (Auxiliary) 1
186-3736 Connector socket 6
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
44
(Pins 8, 15 & 36) Coolant Level Sensor
An optional coolant level sensor allows the ECM Note: The sensor must be mounted in a position
to monitor the coolant level in order to have the that keeps the sensing element immersed under
ability to warn the operator of a low coolant all operating conditions. The sensor is normally
level. The Coolant Level Sensor parameter installed in the radiator top tank. The sensor is
should be programmed to “Installed.” The sensor supplied with thread sealant on the threads, so it
output voltage is approximately 0 VDC (negative is not necessary to apply thread sealant on a new
battery) when coolant is present. The sensor sensor. Apply 5P-3413 Pipe Sealant to the
output voltage is approximately 5 VDC when threads of the sensor before the reinstallation, if
coolant is not present. The ECM supplies the the sensor has been removed.
sensor with 8 VDC.
Customer Connector
P61/J61
Coolant Level Sensor J800/P800
+8 VDC A 8
Return B 15
Signal
C 36
Required Parts
165-6634 Coolant Level Sensor 1
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
45
(Pin 10) Throttle Position Sensor
The throttle position sensor (TPS) eliminates the • The “Desired Speed Input Configuration”
mechanical throttle and governor linkages. The parameter should be programmed to “PWM.”
TPS interprets the position of the throttle lever • The “Throttle Position Sensor” parameter
into an electrical signal that is sent to the ECM. should be programmed to “Installed.”
The ECM processes the throttle position signal
• The “Direct Fuel Control Mode” parameter
and the engine speed/timing signal in order to
should be programmed to “Disabled.”
precisely control engine speed.
Throttle Position
Switched Positive
Sensor
Battery
+Battery A
– Battery B Negative Battery
Signal
C
Customer Connector
10
Required Parts
134-0597 Throttle Position Sensor 1
8T-8732 Connector Receptacle 1
186-3735 Connector Pin 3
(2)
16 AWG (1)
(1)
Fabricate to length
(2)
46
Hole Diameter 20.0 mm

(.79 inch)
Mounting Hole Dimensions
86.0 mm Mounting
(3.39 inch) Surface 19.8 mm
(0.781 inch dia)
78.0 mm
(3.07 inch) 17.8 mm
(0.7 inch)
77.0 mm
(3.03 inch)
67.0 mm
(2.64 inch)
Throttle Position vs. PWM Input

Programmed
High Idle 100%
PWM Input Requirements
• Open collector sinking PWM output with a pull
Throttle Position %
up resistor
• Sensor stops Programmed
Low sensor stop............................ 7.5 ± 2.5% Low Idle 0%
High sensor stop ......................... 92.5 ± 2.5% 0 5 10 90 95 100
• Output frequency
Minimum ............................................ 300 Hz
Nominal .............................................. 500 Hz 5% “Deadband” ensures engine will reach low idle
Maximum ........................................... 700 Hz 5% “Deadband” ensures engine will reach high idle
• Output voltage high Engine drops to low idle and a fault is logged
Minimum.......................................... 4.0 VDC
Nominal............................................ 5.0 VDC
• Output voltage low
PWM Input Requirements
1.0 mA sink current
Nominal.......................................... 0.23 VDC PWM Generator ECM
Maximum....................................... 0.25 VDC Throttle Position
Sensor
10.0 mA sink current
Nominal.......................................... 0.65 VDC +VDC Sensor +VDC Control
Maximum......................................... 0.7 VDC
• Output linearity
Duty cycle versus throttle lever PWM Signal
position ............................................... ± 2.5%
47
(Pins 12 & 13) Maintenance Lamp and
Maintenance Due Reset Switch
The maintenance lamp illuminates in order to alert reset the maintenance interval values in the ECM
the operator when scheduled maintenance is due. to zero.
Press the maintenance due reset switch in order to
Maintenance Due
Positive Battery Lamp
1A 13
12
Maintenance Due
Reset Switch
Negative Battery
Required Parts
(2)
Toggle Switch (SPST Momentary) 1
(2)
Terminal 2
(2)
Lamp 1
(2)
Circuit Protection (1 Amp) 1
(2)
16 AWG Wire (1)
Fabricate to Length
(1)
OEM Supplied – component must be approved to be installed in a

(2)
hazardous location.
48
(Pins 14, 15 & 33) Auxiliary
Pressure Sensor
An additional pressure sensor input is provided in must be used and the parameter “Aux Press
order to allow an auxiliary pressure to be Sensor Installation Status” must be programmed
displayed on Cat ET, PMS display modules, and to “Installed.” This pressure sensor is an analog
J1939 (CAN) display modules. To utilize this sensor with an operating range of 0 to 3150 kPa
feature, the Caterpillar supplied pressure sensor (0 to 457 psi).
Customer Connector
J220/P220 P61/J61
Auxiliary Pressure Sensor
+8 VDC A 14
Return B 15
Signal C 33
Required Parts
161-9932 Pressure Sensor (Auxiliary) 1
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
49
(Pins 16, 17 & 18) J1939 Data Link
The SAE J1939 CAN data link is used in order to receiving device. The CAN data link is limited to
communicate the engine information to a J1939 broadcasting only.
Parameters for Data Link Broadcast

Parameter PGN Bytes Resolution Byte Order Transmission
(Offset) in Message Rate
Percent Load 61443 1 1%/bit 3 50 ms
(0%)
Oil Pressure 65263 1 4 kPa/bit 4 500 ms
(0 kPa)
Battery Voltage 65271 2 0.05 V/bit 5,6 1.0 s
(0 V)
Boost Pressure 65270 1 2 kPa/bit 2 500 ms
(0 kPa)
Coolant Temperature 65262 1 1°C/bit 1 1.0 s
(-40°C)
Fuel Pressure 65263 1 4 kPa/bit 1 500 ms
(0 kPa)
Fuel Temperature 65262 1 1°C/bit 2 1.0 s
(-40°C)
Fuel Rate 65266 2 0.05 L/hr/bit 1,2 100 ms
(0 Lhr)
Engine Speed 61444 2 0.125 rpm/bit 4,5 15 ms
(0 rpm)
Inlet Manifold Temperature 65270 1 1°C/bit 3 500 ms
(-40°C)
Auxiliary Temperature 65164 1 1°C/bit 1 1.0 s
(-40°C)
Auxiliary Pressure 65164 1 16 kPa/bit 3 1.0 s
(0 kPa)
Engine Hours 65253 4 0.05 hr/bit 1,2,3,4 50 ms
(0 hr)
50
Connecting Modules to the CAN Data Link
Required Parts – Installation of a Single Module

5P-6001 Heat Shrink Tubing 6 cm (2.4 inch)
125-7876 Heat Shrink Tubing 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
(1)
Fabricated to length
(2)
Use the blue wedge.
This illustration 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 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 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.
51
Use the following procedure to connect modules formed around the shield and the socket. Be
to the CAN data link: careful to avoid skin contact with any hot glue
that may seep from the heat shrink tubing.
g. Cut two 50 mm (2 inch) pieces of 125-7876
Heat Shrink Tubing. Slide a piece of the heat
shrink tubing over each end of the cable.
h. Insert the wires from one end of the data link
into the P61 customer connector. See table
below.
Terminal Locations in P61 Customer Connector

Wire Color Location in P61
Shield 16
Yellow 17
Green 18
i. Position the 125-7876 Heat Shrink Tubing so

that 20 mm (0.8 inch) of the exposed wires
are covered and the rest of the heat shrink
1. Run the CAN data link from the P61 customer tubing is over the cable. Apply heat until a
connector to a module. complete seal is formed. Be careful to avoid
Note: The end of the data link must be within skin contact with any hot glue that may seep
approximately 150 mm (6 inch) of the module. from the heat shrink tubing.
The total length of the data link run must not j. Insert the sockets at the opposite end of the
exceed 40 m (130 ft). CAN data link into a 174-0503 Connecting
a. Run 153-2707 Cable (Shielded Twisted Pair) Plug Kit. See table below. Insert the blue
from the P61 customer connector to the wedge into the connector in order to secure
location of the first module. Cut the cable to the terminals in place.
length.
b. Remove 25 mm (1.0 inch) of insulation from Terminal Locations in the Plug
both ends of the cable.
Wire Color Location in the Plug
c. Remove 7 mm (0.28 inch) of insulation from
Shield C
each end of the green wire and the yellow
wire. Yellow A
d. Crimp a 186-3736 Connector Socket on each Green B
end of the green wire and the yellow wire
with a 1U-5804 Crimp Tool. k. Position the 125-7876 Heat Shrink Tubing
e. Crimp a 133-0969 Connector Socket so that 10 mm (0.4 inch) of the plug is
(Extended) on each end of the shield with a covered and the rest of the heat shrink tubing
1U-5804 Crimp Tool. is over the cable. Apply heat until a complete
f. Cut two 30 mm (1.2 inch) pieces of 5P-6001 seal is formed around both the plug and the
Heat Shrink Tubing. Slide a piece of the heat cable. Be careful to avoid skin contact with
shrink tubing over the shield at each end of any hot glue that may seep from the heat
the cable. Position the heat shrink tubing so shrink tubing.
that 1 cm (0.4 inch) of the socket is covered l. Plug the end of the data link into the single
and the remaining tubing is covering the end of a 133-0970 Receptacle As (Tee).
shield. Apply heat until a complete seal is
52
Note: Do not connect the shield to the receiving
module.
c. 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.
d. Trim the shield back to the existing heat
shrink tubing on the cable assembly. Position
the 125-7876 Heat Shrink Tubing so that the
shield is completely insulated and a proper
2. Connect a receiving module to the tee. seal can be obtained. Apply heat until a
a. Plug a 165-0200 Cable As into the 133-0970 complete seal is formed. Be careful to avoid
Receptacle As (Tee). skin contact with any hot glue that may seep
b. Cut a 50 mm (2 inch) piece of 125-7876 from the heat shrink tubing.
Heat Shrink Tubing. Slide the heat shrink e. Repeat Step 2 for each module.
tubing over the module end of the cable 3. Connect a termination resistor to the tee at the
assembly. end of the data link.
a. Connect a 174-3016 Receptacle As
(Termination Resistor) to the 133-0970
Receptacle As (Tee).
53
(Pins 24 & 25) Indicator Lamps
Installation of both a warning lamp and a come ON for five seconds when the ECM is first
diagnostic lamp is strongly recommended in turned ON in order to indicate that the lamp
order to alert the operator of problems that may circuit is functional.
be detected by the ECM. The warning lamp will
Customer Connector
Positive Battery Diagnostic Lamp P61/J61
1A 24
Warning Lamp 25
Required Parts
(2)
Lamp 2
(2)
Circuit Protection (1 Amp) 1
N/A 16 AWG Wire (1)
(1)
Fabricate to Length
(2)
Lamp Driver Electrical Specifications first digit of the flash code. After a two-second
Electrical specifications for the ECM low side pause, a second sequence of flashes which
drivers that are used for the diagnostic lamp and represent the second digit of the flash code will
the warning lamp allow a maximum current load occur. Any additional flash codes will follow
of 0.30 Amp (300 mA). The ECM does not after a pause. These flash codes will be displayed
provide diagnostic codes for either lamp circuit. in the same manner.
Low side ECM drivers provide a path to the Note: Flash codes should only be used to
negative battery terminal in order to activate the indicate the nature of a diagnostic condition.
device (lamp, etc) that is connected to the circuit. Do not use flash codes to perform detailed
While circuit protection is recommended for the troubleshooting.
lamp driver circuits, Caterpillar does not require
dedicated circuit protection. Warning Lamp Operation
Installation of a warning lamp is strongly
Diagnostic Lamp Operation
recommended. The warning lamp is used to alert
Installation of a diagnostic lamp is strongly the operator of an engine operating condition
recommended. The diagnostic lamp is used to that has the potential to cause engine damage
alert the operator of an electronic control system (event code).
malfunction (active diagnostic code). Caterpillar’s
proprietary two-digit flash codes can be viewed The warning lamp will come ON for five seconds
from the diagnostic lamp. A sequence of flashes when the ECM is first turned ON in order to
represents the system diagnostic message (flash indicate that the lamp circuit is functional.
code). The first sequence of flashes represents the
54
(Pin 27) Remote Shutdown Switch
The ECM disables fuel injection in order to stop must be deactivated, opened, in order to restart
the engine when the remote shutdown switch is the engine.
activated closed. The remote shutdown switch
Note: The air shutoff solenoid is not activated
and the ECM remains energized.
Customer Connector
Remote Shutdown
P61/J61
Switch
27
Negative Battery
Required Parts
(2)
(2)
Terminal 2
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
55
(Pin 28) Intermediate Engine
Speed Switch
The intermediate engine speed switch allows the speed will increase or engine speed will decrease
operator to change the desired engine speed from at the rate that is defined by the programmed
the current engine speed to the programmed value for “Engine Accel. Rate.”
value for Intermediate Engine Speed. Engine
Customer Connector
Intermediate Engine P61/J61
Speed Switch
28
Negative Battery
Required Parts
(2)
(2)
Terminal 2
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
56
(Pins 19, 29, 30 & 39) PTO Switches
The ECM can be programmed to operate in Mode is programmed to “Set/Resume,” the ECM
either one of the two PTO configurations that are allows PTO operation with enhanced features.
available. When PTO Mode is programmed to
“Ramp Up/Ramp Down,” the ECM allows PTO Note: If the PTO is the only means of controlling
operation with traditional features. When PTO engine speed, the PTO enable circuit may be
wired directly to the negative battery.
Ramp Up/Ramp Down Mode
PTO Enable
Customer Connector
P61/J61
PTO Ramp 29
Up/Down
30
Ramp Up
39
Ramp Down
Negative Battery
Required Parts
(2)
(2)
Toggle Switch (SPDT, Momentary) 1
(2)
Terminal 2
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
Switch Inputs input and the Ramp Down input cannot be

• PTO Enable connected to the negative battery at the same
• Ramp Up time. If this occurs, the ECM will generate a
• Ramp Down diagnostic code and the ECM will make no
adjustments to the desired engine speed when the
PTO Enable Switch unit is in the PTO mode.
The PTO enable switch is used to determine Note: The ECM will use the selected speed that
whether the ECM should acknowledge the PTO is higher when the ECM chooses between the
ramp up/down switch. throttle input and the PTO input. When the switch
is toggled, the engine will respond according to
PTO Ramp Up/Down Switch the programmed value for Engine Accel. Rate.
The engine will maintain the current desired
When the PTO Enable Switch is in the ON
engine rpm when the switch is open in the center
position, the throttle position sensor is disabled
position. “Opened” in this case means that the
and the desired engine speed is controlled by the
switch is in the center position.
PTO Ramp Up/Down Switch. The Ramp Up
57
PTO Enable
N.O. Customer Connector
P61/J61
PTO Ramp 29
Up/Down Ramp Up
30
Ramp Down
39
PTO Interrupt
19
N.C.
Negative Battery
Note: If the PTO is the only means of controlling engine speed, the PTO enable circuit
may be wired directly to the negative battery.
Required Parts
(2)
(2)
Toggle Switch (SPDT, Momentary) 1
(2)
Terminal 2
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
PTO Enable Switch • If this input is connected to the negative battery

The PTO enable switch is used to determine and held in that position, the desired engine
whether the ECM should acknowledge the PTO speed will decrease at the rate that is
Ramp Up/Down Switch. programmed for Engine Accel. Rate.
• After the desired engine speed is set,
Set Switch (Ramp Up) momentarily connecting this input to the
• If the input is momentarily connected to the negative battery will decrease the engine speed
negative battery, the desired engine speed will in increments of 20 rpm.
be set to the current engine speed.
PTO Interrupt Switch
• If the input is connected to the negative battery
and held in that position, the desired engine When this input is open, the ECM uses the
speed will increase according to the throttle position sensor as the source for
programmed value for Engine Accel. Rate. determining the desired engine speed. When this
input is connected to the negative battery, the
• After the desired engine speed is set,
ECM returns control of the desired engine speed
momentarily connecting this input to the
to the PTO. When control of the desired engine
negative battery will increase the engine speed
speed is transferred from the throttle position
in increments of 20 rpm.
sensor to the PTO, engine speed will change at
the rate that is programmed for Engine Accel.
Resume Switch (Ramp Down)
Rate. The PTO set speed will be lost whenever
• If this input is momentarily connected to the the keyswitch is turned OFF.
negative battery, the desired engine speed will
be set to the last known value that was used
58
during PTO operation.
(Pin 40) Overspeed Verify Switch
NOTICE: Activating the overspeed verify overspeed protection system is operating correctly.
switch will result in an engine shutdown when When the overspeed verify switch is activated, the
engine speed reaches 75 percent of the engine will shut down when engine speed reaches
overspeed set point. 75 percent of the overspeed set point. The ECM
shuts down the engine by disabling fuel injection
An overspeed shutdown feature is provided in and activating the relay for the air shutoff
order to help prevent damage to the engine or solenoid.
driven equipment in the event of an overspeed
condition. The monitoring system must have the Note: The air shutoff solenoid must be manually
Engine Overspeed parameter set to the ON reset in order to restart the engine. The power to
position in order to enable this feature. The the ECM must be cycled in order to restart the
overspeed verify switch allows the operator or a engine.
service technician to quickly verify that the
Customer Connector
Overspeed Verify Switch P61/J61
40
Negative Battery
Required Parts
(2)
Toggle Switch (SPST, Momentary) 1
(2)
Terminal 2
(2)
16 AWG Wire (1)
(1)
Fabricate to length
(2)
59
Interconnect Harness
The Interconnect Harness utilizes an 8T-9834 connector must be filled with 8T-8737 Seal
Connector Plug. All circuits that are connected to Plugs. The torque for the allen head screw is
the Interconnect Harness require a 186-3736 2.25 ± 0.25 N•m (20 ± 2 lb in).
Connector Socket. Any unused cavities in the
Pin-outs for Interconnect Harness

8T-9834 Circuit Function Wire/Color Gauge
1 Unswitched Batt + 101/RED 14
2 Torque Limit Switch M872/PINK 18
3 N/C
4 Air Shutoff Solenoid M972/YELLOW 18
5 Solenoid Common C212/BLACK 18
6 N/C
7 N/C
8 N/C
9 N/C
10 Throttle Position Signal F427/PINK 18
11 N/C
12 N/C
13 N/C
14 Analog Sensor Power +5 VDC F429/BLUE 18
15 Analog Sensor Return M971/BROWN 18
16 J1939 Shield BARE 18
17 J1939 Data + K900/YELLOW 18
18 J1939 Data - K990/GREEN 18
19 N/C
20 N/C
21 N/C
22 N/C
23 N/C
24 Diagnostic Lamp F400/GRAY 18
25 Warning Lamp F473/YELLOW 18
26 Switched Batt + H419/BLACK 14
27 Remote Shutdown Switch F425/VIOLET 18
28 N/C
29 PTO Enable F426/BLUE 18
30 PTO Rampup Set Switch 450/YELLOW 18
33 Auxiliary Pressure Sensor F424/YELLOW 18
34 N/C
35 N/C
36 N/C
37 N/C
38 N/C
39 PTO Rampdown Resume Switch 451/BROWN 18
40 N/C
Harness Requirements
The diameter of the cable is approximately 29.2 mm -20°C to +105°C and have a voltage rating of
(1.15 in.) and the bend radius is 76.2 mm (6.0 in.). 600V. Conductors shall meet SAE J378 and
Harness shall withstand temperatures from SAE J1128 105°C 600V rating.
60
Messenger Installation
Overview of the Messenger Display
1
2
3
(1) Messenger display
(2) Mounting bracket
(3) Mounting screws
(4) Keypad
This display allows the operator to monitor the automatically display diagnostic codes when the
engine information while the engine is being diagnostic code becomes active. This allows the
operated. The Messenger Display can provide operator to take appropriate action when a
information on various engine operating diagnostic code becomes active.
parameters.
The Messenger Display provides information to
Engine diagnostic codes can also be displayed on the operator from the engine Electronic Control
the Messenger Display. Messenger will Module (ECM) through the J1939 data link.
61
Mounting the Messenger Display into a Console
Tools that are required
Part Number Description WARNING

Drill
Improper tool usage can cause an explosion
Digital Multimeter
hazard which may result in Personal Injury or
3S-2093 Tie Strap Death. Tools should be approved for use in a
6V-6193 Diagonal cutting pliers hazardous environment or all work should be
1U-7264 Standard Screwdriver performed in a non-hazardous (non-explosive)
environment.
1U-7267 Phillips screwdriver
6V-6194 Needle nose pliers
1U-7319 Flashlight
140-9944 Terminal kit
Mounting Considerations
90 mm
26 mm (3.5 inch)
(1.0 inch)
61 mm
(2.4 inch)
48 mm
(1.9 inch) 120 mm
58 mm (4.7 inch)
(2.3 inch)
Cutout
Determine and mark the location for the 112.75 mm
Messenger Display. (4.439 inch)
Note: If the dash is more than 6 mm (0.3 inch)

thick, the brackets may be carefully trimmed. Clearance Cutout
61.00 mm 54.00 mm
(2.4 inch) (2.125 inch)
Clearance
120.00 mm
(4.7 inch)
Dimensions for the cutout that is necessary

for installing the Messenger Display
62
Wiring the Messenger Display
1. Disconnect the batteries.
2. Connect the wiring to the Messenger display.
a. Connect the 3-pin connector of the 165-0200
Cable to a 133-0970 Receptacle As (Tee).
Note: Refer to the section Specifications, Wiring Messenger Pinout Specification
(J1939 Data Link), for more information on the Terminal Function
wiring of the J1939 data link.
1 +Battery
b. Cut a 50 mm (2 inch) piece of 125-7876 Heat 2 -Battery
Shrink Tube. Slide the heat shrink tube over 3 Keyswitch
the 165-0200 Cable.
7 J1939+
c. Connect the remaining end of the 165-0200
8 J1939 –
Cable to the display connector. Part number
155-2265 Connector Kit.
Note: The total length between the 133-0970
Receptacle As (Tee) and the display should not
exceed 1 m (3.3 ft). Total length from engine not to
exceed 40 meters.
Switched
+Battery -Battery +Battery
Messenger
1 +Battery
2 - Battery
3 Keyswitch
A 7 J1939+
Tee 8 J1939 -
133-0970 B
C
165-0200
J1939
Shield
(Refer to note i.)
d. Connect the yellow wire (J1939+) to pin 7 i. Trim the shield (bare wire) flush to outer
on the connector for the display. sheath to prevent accidental contact.
e. Connect the green wire (J1939-) to pin 8 Position the 125-7876 Heat Shrink Tube so
on the connector for the display. that the shield is completely insulated and a
proper seal can be obtained. Apply heat until
f. Connect pin 1 on the connector for the
a complete seal is formed. Be careful to
display to an unswitched +Battery source.
avoid skin contact with any hot glue that
g. Connect pin 2 on the connector for the may seep from the heat shrink tube. Shield
display to a +Battery source. should terminate only at the ECM (J1/P1
h. Connect pin 3 on the connector for the Connector) through the J61/P61 Connector.
display to a switched +Battery source.
3. Reconnect the batteries.
63
4. Verify the supply voltage at the display unit. Install the Messenger Display into the
a. Use a multimeter to measure the voltage. Console
Measure the voltage between the +Battery 1. Place the gasket around the cutout on the front
(pin 1) and the +Battery (pin 2) with the of the console.
keyswitch in the ON position. The voltage
should be 11 to 13.5 VDC for 12 volt 2. Mount the Messenger Display into the console.
systems, and 23 to 27 VDC for 24 volt a. Insert the display into the cutout from the
systems. front of the console.
Note: The supply voltage to the Messenger b. Install the rear brackets and loosely tighten
Display may be from 9 to 32 VDC. the four pan head screws that hold the
b. Use a multimeter to measure the voltage. brackets in place.
Measure the voltage between the switched c. Ensure that the face of the Messenger
+Battery (pin 3) and the +Battery (pin 2) display is straight and positioned correctly
with the keyswitch in the ON position. The in the opening.
voltage should be 11 to 13.5 VDC for 12 d. Fully tighten the four screws that hold the
volt systems, and 23 to 27 VDC for 24 volt brackets in place.
systems.
c. Turn the keyswitch to the OFF position. 3. Connect the 8-pin connector to the back of the
Measure the voltage between the +Battery display.
(pin 1) and the +Battery (pin 2). The 4. Secure the Messenger Display wiring with tie
voltage should be 11 to 13.5 VDC for 12 straps in order to avoid wiring abrasion and
volt systems, and 23 to 27 VDC for 24 volt interference with the operator.
systems when the keyswitch is in the OFF
position.
d. Turn the keyswitch to the OFF position.
Measure the voltage between the switched
+Battery (pin 3) and the Battery (pin 2).
The voltage should be 0 VDC when the
keyswitch is in the OFF position.
64
Abbreviations
Cat ET Caterpillar Electronic Technician
ECM Electronic Control Module
ECS Engine Control Switch
EHSR Essential Health & Safety Requirements
FLS Full Load Setting
FTS Full Torque Setting
NC Normally Closed
NO Normally Open
OEM Original Equipment Manufacturer
OMM Operation & Maintenance Manual
PGN Program Group Number
PMS Programmable Monitoring System
PTO Power Take Off
PWM Pulse Width Modulation
TEL Top Engine Limit
TPS Throttle Position Sensor
Definitions
Cat ET Electronic service tool
ECM An Electronic Control Module (ECM) sends a signal to each injector solenoid in order to
provide complete control of the engine. The ECM has the ability to monitor the engine
operating conditions.
FLS 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.
FTS FTS is similar to FLS.
OMM The OMM contains safety, operation instructions, lubrication and maintenance information.
PMS The PMS display is used to display various engine parameters.
PTO The desired engine speed is controlled by the PTO ramp up/down switch when the throttle
position sensor is disabled.
TEL TEL is a customer programmable parameter that defines the maximum allowable engine speed
for maximum power.
TPS The TPS interprets the position of the throttle lever into an electrical signal that is sent
to the ECM.
65
LEGW3354-00 (06-04) ©2004 Caterpillar
All Rights Reserved.

C-15 Petroleum Engines

Uploaded by

Copyright:

Available Formats

C-15 Petroleum Engines

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

C-15 Petroleum Engines

Uploaded by

Copyright:

Available Formats

What is the document about?

What is the document about?

What are some important safety considerations mentioned?

What are some important safety considerations mentioned?

C-15

• Wear a hard hat, protective glasses, and other

• Grease fittings • Do not attempt any repairs that are not

When pressure air and/or pressure water is used Asbestos Information

Caterpillar equipment and replacement parts that

Always use leakproof containers when you drain

Store fuels and lubricants in properly marked

Electronic Control Module (ECM)

OEM Supplied Components

Secondary Engine J402/P402

Fuel Pressure J209/P209

Turbo Outlet (Intake

Intake Manifold Air

LEFT SIDE VIEW

Primary Engine Atmospheric Engine Oil ECM Connector ECM ECM

ECM Identification Parameters

Selected Engine Rating

Parameter Descriptions Engine Serial Number

Engine Speed Limits Engine Torque Limit

Monitoring System Parameters

Caterpillar Electronic Technician (ET)

JERD2124 Electronic Technician Program (ET)

JERD2129 Data Subscription for All Engines and Machines

171-4400 Communications Adapter II Gp

Support for Cat ET

Wire Size Requirement

Metric Equivalent for AWG Wire Numbers

Harness Routing at ECM Connector

Wire Exiting Straight Out

Note: Use 14AWG wire for all positive battery

Relay with low side Relay with high side

Using a diode in a relay in order to suppress voltage transients.

Pin-outs for Customer Connections

Sensor Return Connections

Engine Torque Limit

Allowable Range of Torque Limit

Engine Speed (rpm) Maximum rated

OEM Supplied – component must be approved to be installed in a

Air Shutoff Valve Installation

C 7 CAT Data Link +

D 6 CAT Data Link –

Hole Diameter 20.0 mm

Throttle Position vs. PWM Input

position ............................................... ± 2.5%

OEM Supplied – component must be approved to be installed in a

Parameters for Data Link Broadcast

Required Parts – Installation of a Single Module

This illustration shows the connection of

Terminal Locations in P61 Customer Connector

i. Position the 125-7876 Heat Shrink Tubing so

Switch Inputs input and the Ramp Down input cannot be

PTO Enable Switch • If this input is connected to the negative battery

Pin-outs for Interconnect Harness

Part Number Description WARNING

Note: If the dash is more than 6 mm (0.3 inch)

Dimensions for the cutout that is necessary