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
This document is intended to provide information
for wiring the engine electronics and
programming the engine electronics.
Important Safety Information
Most accidents that involve product operation,
maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An
accident can often be avoided by recognizing
potentially hazardous situations before an
accident occurs. A person must be alert to
potential hazards. This person should also have
the necessary training, skills, and tools to
perform these functions properly.
Improper operation, lubrication, maintenance
or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication,
maintenance, or repair on this product until
you have read and understood the operation,
lubrication, maintenance, and repair
information.
Safety precautions and warnings are provided in
this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death
could occur to you or to other persons.
The hazards are identified by the “Safety Alert
Symbol” and followed by a “Signal Word” such
as “DANGER,” “WARNING,” or “CAUTION.”
The Safety Alert “WARNING” label is shown
below.
WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.
The message that appears under the warning
explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are
identified by “NOTICE” labels on the product
and in this publication.
Caterpillar cannot anticipate every possible
circumstance that might involve a potential
hazard. The warnings in this publication and
on the product are, therefore, not all-inclusive.
If a tool, procedure, work method, or
operating technique that is not specifically
recommended by Caterpillar is used, you must
satisfy yourself that it is safe for you and for
others. You should also ensure that the
product will not be damaged or be made
unsafe by the operation, lubrication,
maintenance, or repair procedures that you
choose.
The information, specifications, and illustrations
in this publication are on the basis of information
that was available at the time that the publication
was written. The specifications, torques,
pressures, measurements, adjustments,
illustrations, and other items can change at any
time. These changes can affect the service that is
given to the product. Obtain the complete and
most current information before you start any
job. Caterpillar® dealers have the most current
information available.
WARNING
When replacement parts are required for this
product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength,
and material.
Any OEM supplied component must be
approved to be installed in a hazardous
location.
Failure to heed this warning can lead to
premature failures, product damage, personal
injury, or death.
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
Attach a “Do Not Operate” warning tag or a
similar warning tag to the start switch or to the
controls before the engine is serviced or before
the engine is repaired. These warning tags
(Special Instruction, SEHS7332) are available
from your Caterpillar dealer. Attach the warning
tags to the engine and to each operator control
station. When it is appropriate, disconnect the
starting controls.
Do not allow unauthorized personnel on the
engine or around the engine when the engine is
being serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always
start the engine and operate the engine in a well
ventilated area. If the engine is in an enclosed
area, vent the engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized
fluids, hold a rag over the part that is being
removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing
the last two bolts or nuts, pry the cover loose in
order to relieve any spring pressure or other
pressure.
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• When work is performed around an engine that
is operating, wear protective devices for ears in
order to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers
are secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided,
perform the maintenance under the following
conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
Electrostatic Phenomena
The operator, the installer, and other personnel
should be aware of excessive polishing or buffing
of plastic parts which could result in an energy
potential that could cause a spark that could
possibly ignite an explosive atmosphere.
7
 This petroleum engine is for use in a Zone 2
Hazardous environment. The OEM must ensure
that Non Static belts are used. Failure to use Non
Static belts could result in an energy potential
that could cause a spark that could possibly ignite
an explosive atmosphere.
Pressure Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could
result in personal injury.
When pressure air and/or pressure water is used
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
Always use a board or cardboard when you
check for a leak. Leaking fluid that is under
pressure can penetrate body tissue. Fluid
penetration can cause serious injury and possible
death. A pin hole leak can cause severe injury. If
fluid is injected into your skin, you must get
treatment immediately. Seek treatment from a
doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before any compartment is opened or
before the disassembly of any component
containing fluids.
8
Refer to Special Publication, NENG2500, “Tools
and Shop Products Guide” for the following
items:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of
liquids.
Asbestos Information
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
contain asbestos fibers. Inhaling this dust can be
hazardous to your health. The components that
may contain asbestos fibers are brake pads, brake
bands, lining material, clutch plates, and some
gaskets. The asbestos that is used in these
components is usually bound in a resin or sealed
in some way. Normal handling is not hazardous
unless airborne dust that contains asbestos is
generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also
be used.
• Use exhaust ventilation on permanent
machining jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA
requirements can be found in “29 CFR
1910.1001.”
• Obey environmental regulations for the disposal
of asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
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.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters
or to the engine contain hot coolant.
Any contact with hot coolant or with steam can
cause severe burns. Allow cooling system
components to cool before the cooling system
is drained.
Check the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing
the filler cap. The filler cap must be cool enough
to touch with a bare hand. Remove the filler cap
slowly in order to relieve pressure.
Cooling system conditioner contains alkali.
Alkali can cause personal injury. Do not allow
alkali to contact the skin, the eyes, or the mouth.
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
protective glasses for servicing batteries. Wash
hands after touching the batteries and connectors.
Use of gloves is recommended.
9
 Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 7405
All fuels, most lubricants, and some coolant
mixtures are flammable.
Flammable fluids that are leaking or spilled onto
hot surfaces or onto electrical components can
cause a fire. Fire may cause personal injury and
property damage.
A flash fire may result if the covers for the
engine crankcase are removed within fifteen
minutes after an emergency shutdown.
Determine whether the engine will be operated in
an environment that allows combustible gases to
be drawn into the air inlet system. These gases
could cause the engine to overspeed. Personal
injury, property damage, or engine damage
could result.
If the application involves the presence of
combustible gases, consult your Caterpillar
dealer for additional information about suitable
protection devices.
Remove all flammable materials such as fuel, oil,
and debris from the engine. Do not allow any
flammable materials to accumulate on the engine.
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
Non Static belts must be used. Failure to use Non
Static belts could result in an energy potential
that could create a spark which could ignite an
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.
Wiring must be kept in good condition. All
electrical wires must be properly routed and
securely attached. Check all electrical wires
daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that
are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent
arcing or sparking.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be properly
installed. The filter housings must be tightened to
the proper torque.

Use caution when you are refueling an engine.
Do not smoke while you are refueling an engine.
Do not refuel an engine near open flames or
sparks. Always stop the engine before refueling.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery.
Do not smoke in battery charging areas.
Never check the battery charge by placing a
metal object across the terminal posts. Use a
voltmeter or a hydrometer.
Do not connect or disconnect the battery cables
in an explosive atmosphere. This could cause a
spark that could ignite the explosive atmosphere.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
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.
Lines, Tubes, and Hoses
Do not bend high pressure lines. Do not strike
high pressure lines. Do not install any lines that
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.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat
shields are installed correctly. During engine
operation, this will help to prevent vibration,
rubbing against other parts, and excessive heat.
11
 Crushing Prevention and Cutting
Prevention
SMCS Code: 1000; 7405
Support the component properly when work
beneath the component is performed.
Unless other maintenance instructions are
provided, never attempt adjustments while the
engine is running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until
maintenance is performed. After the maintenance
is performed, reinstall the guards.
Keep objects away from moving fan blades. The
fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses
in order to avoid injury to the eyes.
Chips or other debris may fly off objects when
objects are struck. Before objects are struck,
ensure that no one will be injured by flying
debris.
Mounting and Dismounting
SMCS Code: 1000; 7405
Inspect the steps, the handholds, and the work
area before mounting the engine. Keep these
items clean and keep these items in good repair.
Mount the engine and dismount the engine only
at locations that have steps and/or handholds. Do
not climb on the engine, and do not jump off the
engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point
contact with the steps and handholds. Use two
feet and one hand or use one foot and two hands.
Do not use any controls as handholds.
Do not stand on components which cannot
support your weight. Use an adequate ladder or
use a work platform. Secure the climbing
equipment so that the equipment will not move.
Do not carry tools or supplies when you mount
the engine or when you dismount the engine. Use
a hand line to raise and lower tools or supplies.
12
Before Starting Engine
SMCS Code: 1000
NOTICE: For initial start-up of a new or
rebuilt engine, and for start-up of an engine
that has been serviced, make provision to shut
the engine off should an overspeed occur. This
may be accomplished by shutting off the air
and/or fuel supply to the engine.
Overspeed shutdown should occur automatically.
If automatic shutdown does not occur, press the
emergency stop button in order to cut the fuel
and/or air to the engine.
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is
on, underneath, or close to the engine. Ensure
that the area is free of personnel.
If equipped, ensure that the lighting system for
the engine is suitable for the conditions. Ensure
that all lights work properly, if equipped.
All protective guards and all protective covers
must be installed if the engine must be started in
order to perform service procedures. To help
prevent an accident that is caused by parts in
rotation, work around the parts carefully.
Do not bypass the automatic shutoff circuits. Do
not disable the automatic shutoff circuits. The
circuits are provided in order to help prevent
personal injury. The circuits are also provided in
order to help prevent engine damage.
See the Service Manual for repairs and for
adjustments.
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start
switch or to the controls, DO NOT start the
engine or move the controls. Consult with the
person that attached the warning tag before the
engine is started.
All protective guards and all protective covers
must be installed if the engine must be started in
order to perform service procedures. To help
prevent an accident that is caused by parts in
rotation, work around the parts carefully.
Start the engine from the operator’s compartment
or from the engine start switch.
Always start the engine according to the
procedure that is described in the Operation and
Maintenance Manual, “Engine Starting” topic in
the Operation Section. Knowing the correct
procedure will help to prevent major damage to
the engine components. Knowing the procedure
will also help to prevent personal injury.
To ensure that the jacket water heater (if
equipped) and/or the lube oil heater (if equipped)
is working properly, check the water temperature
and the oil temperature during heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always
start the engine and operate the engine in a well
ventilated area. If the engine is started in an
enclosed area, vent the engine exhaust to the
outside.
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in the
Operation and Maintenance Manual, “Engine
Stopping” topic in the Operation Section in order
to avoid overheating of the engine and
accelerated wear of the engine components.
Use the Emergency Stop Button (if equipped)
ONLY in an emergency situation. Do not use the
Emergency Stop Button for normal engine
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.
Electrical System
SMCS Code: 1000; 1400
WARNING
The connection of battery cables to a battery
and the disconnection of battery cables from a
battery may cause an explosion which may
result in injury or death. The connection and
the disconnection of other electrical equipment
may also cause an explosion which may result
in injury or death. The procedures for the
connection and the disconnection of battery
cables and other electrical equipment should
only be performed in a nonexplosive
atmosphere.
Never disconnect any charging unit circuit or
battery circuit cable from the battery when the
charging unit is operating. A spark can cause the
combustible gases that are produced by some
batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “-” jump start cable should be connected
last from the external power source to the engine
block or to the frame.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for
specific starting instructions.
13
 Grounding Practices
Typical example of Alternate Grounding Stud
To Battery Ground
Proper grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in
unreliable electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Engines that are installed without engine-to-
frame ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine
electrical systems function properly, an engine-
to-frame ground strap with a direct path to the
battery must be used. This path may be provided
by way of a direct engine ground to the frame.
All grounds should be tight and free of corrosion.
The engine alternator must be grounded to the
negative “-” battery terminal with a wire that is
adequate to handle the full charging current of
the alternator.
14
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
monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes
have the ability to limit engine speed and/or the
engine power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine
monitoring functions. The following parameters
can be monitored as a part of the Programmable
Monitoring System:
• Operating Altitude
• Engine Coolant Level
• Engine Coolant Temperature
• Engine Oil Pressure
• Engine Speed
• Fuel Temperature
• Intake Manifold Air Temperature
• System Voltage
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
Required Service Manuals
(Caterpillar Service Manual
SENR9950 contains all of the
required media numbers and
may be obtained from the local
Caterpillar dealer.)
Part Number
Enclosure Protection
Ambient Temperature
Relative Humidity
ECM Operating Voltage
Operating Pressures
Operating Temperatures
16
Zone 2, Group II, Category 3G, Gas Group IIB, Temperature Class T3
LEGW3354 Installation Guide
RENR8042 Schematic
SEBU7895 Operation and Maintenance Manual
SENR9953 Systems Operation Testing and Adjusting Manual
RENR5061 Troubleshooting Guide
SENR2995 Product Safety
SENR3190 Specifications – Torque Specifications
RENR8626 Disassembly and Assembly
SENR9952 Specifications – C-15 Petroleum Engines
SEBP4170 Parts Manual
ECM 191-5208, 210-0849
Engine Arrangement 245-3904
Electronics Group 192-0883
Wiring Group 237-7594, 237-7561
210-0849 – ECM, wiring harness and sensors – IP 56
243-3820 – Messenger Display – IP 68
134-0670 – Throttle Position Sensor – IP 56
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)
0 to 100%
12 VDC or 24 VDC
SENR9952 Specifications – C-15 Petroleum Engines
SENR9952 Specifications – C-15 Petroleum Engines
SENR9952 Specifications – C-15 Petroleum Engines
System Overview
The C-15 Petroleum engine was designed for
electronic control. The injection pump, the fuel
lines, and the nozzles that are used in mechanical
engines have been replaced with a unit injector in
each cylinder. A solenoid on each injector
controls the amount of fuel that is delivered by
the injector. An electronic control module (ECM)
sends a signal to each injector solenoid in order
to provide complete control of the engine.
Electronic Controls
The electronic system consists of the following
components: electronic control module (ECM),
unit injectors, wiring harness, switches, and
sensors. The ECM is the computer. The
personality module (flash file) is the software for
the computer. The personality module (flash file)
contains the operating maps. The operating maps
define the following characteristics of the engine:
• Horsepower
• Torque curves
The ECM determines the timing and the amount
of fuel that is delivered to the cylinders. These
decisions are based on the actual conditions and
the desired conditions at any given time. The
ECM compares the desired engine speed to the
actual engine speed. The actual engine speed is
determined through the engine speed/timing
sensor. The desired engine speed is determined
by monitoring the following inputs to the ECM:
• Sensors (throttle position, etc.)
• Diagnostic codes
• Event codes (derates)
If the desired engine speed is greater than the
actual engine speed, the ECM will signal the
injectors to inject more fuel. This will increase
the actual engine speed.
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
System configuration parameters are parameters
that affect the emissions, the power of the engine,
and features of the engine. Default values for the
parameters are programmed at the factory. The
customer may change some parameters in order
to suit the needs of the specific application.
These parameters can be changed with the
Caterpillar Electronic Technician (ET), which is
an electronic service tool. System configuration
parameters consist of ECM Identification
Parameters and Selected Engine Rating
Parameters. You must reprogram the ECM
Identification Parameters if the ECM is replaced
and/or you reprogram the engine rating. You do
not need to reprogram the ECM Identification
Parameters if you reflash the ECM. Proper values
for these parameters are available on Cat ET.
Certain configuration parameters are also
stamped on the engine information plate.
Note: If the parameters that are protected with
the factory passwords are changed, the
Caterpillar warranty may be voided.
Customer Passwords
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
Parameter Lockout
Parameter Lockout is available to restrict access
to changing some of the available parameters.
Locking out a parameter requires customer
passwords (if used). Once a parameter is locked
out, factory passwords are required to unlock the
parameter. If a lockable parameter is not locked
out, factory passwords are not required. A locked
out parameter restricts the parameter from being
changed directly by the customer or unauthorized
personnel. This helps engine owners that are
encountering problems with operators that are
obtaining customer passwords and altering
parameters.
The following parameters can be locked out:
• Engine Power Trim
• High Idle Speed
• Monitoring System Configuration Access
• Rating Number
• Top Engine Limit
When an attempt to change a locked out
parameter occurs, the factory password screen
will come up. If changing the parameter is
required, follow the instructions on Cat ET.
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

Equipment ID
Equipment ID allows the customer to enter a
description into the ECM in order to identify the
machine. A maximum of 17 characters may be
entered in the field. This parameter is only for
reference by the customer. This parameter is not
required.
Engine Serial Number should be programmed to
match the engine serial number that is stamped
on the engine information plate. If the ECM is
replaced, the engine serial number from the
Engine Information Plate should be programmed
into the new ECM.
Note: When you are requesting factory passwords,
always use the engine serial number that is
resident in the ECM.

23
 Rating Number
The Rating Number corresponds to the selected
set of performance maps for the application. This
selected set of performance maps comes out of
several unique sets of maps that may be resident
in the flash file. The dealer and/or the OEM will
need to select the appropriate rating tier, if more
than one rating tier is present. The rating tier is A
through E.
Top Engine Limit
Engine Speed Limits
Engine Power
Engine Accel. Rate
Engine Accel. Rate determines the rate of change
of the engine speed (acceleration or deceleration)
during PTO operation. This rate of change is also
used to achieve intermediate engine speed.
Low Idle Speed
Low Idle Speed is the minimum allowable
operating speed for the engine. This parameter
can be programmed between 600 and 1400 rpm.
PTO Mode
PTO Mode allows the ECM to be programmed to
either one of the two PTO configurations that are

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

High Idle
Low Idle Range TEL Range
Maximum Rated
Engine Speed
Engine Speed (rpm)
High Idle Speed is the maximum no-load engine
speed when the throttle or the PTO switch is in
the maximum position.
Note: High Idle Speed cannot be programmed
lower than TEL.
Intermediate Engine Speed
Intermediate Engine Speed defines the speed for
the engine when the intermediate engine speed
switch is activated. This parameter can be
programmed to any engine speed between Low
Idle Speed and TEL. Engine speed will increase
or engine speed will decrease at the rate that is
defined by the programmed value for Engine
Accel. Rate.
Engine Power Trim
Engine Power Trim allows small adjustments to
be made to engine power within a selected rating.
This parameter is expressed as a percentage. This
parameter will allow the lug curve to be adjusted
by the programmed value.
Maximum Rated
Engine Speed (rpm) Engine Speed
High Idle
Engine Torque Limit can be used to limit torque
output to the programmed value when the torque
limit switch is activated.
FLS (Full Load Setting)
FLS is a number that represents the adjustment to
the fuel system that was made at the factory in
order to fine-tune the fuel system. The correct
value for this parameter is stamped on the engine
information plate. Factory passwords are required.
FTS (Full Torque Setting)
FTS is similar to FLS. Factory passwords are
required.
Ether Control
Ether Control should be programmed to Enabled
if an ether injection system is installed on the
engine. This allows the ECM to control ether
injection.
Air Shutoff
Air Shutoff allows the ECM to be programmed
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
The ECM records data that is related to
equipment maintenance. The ECM will activate
the maintenance indicator lamp when scheduled
maintenance is due. The maintenance indicator
lamp can be reset by actuating the maintenance
due reset switch. The maintenance interval may
be based on operating hours or fuel consumption.
The ECM provides information that pertains to
maintenance intervals and the last maintenance
that was performed.
PM1 Interval
PM1 Interval allows the customer to define the
maintenance interval if Maintenance Indicator
Mode is programmed to one of the manual
options. Refer to the Operation and Maintenance
Manual for more information.
Throttle Position Sensor
The Throttle Position Sensor should be
programmed to “Installed” if a throttle position
sensor is used for desired speed control.
Coolant Level Sensor
The Coolant Level Sensor parameter should be
programmed to “Installed” if a coolant level
sensor is installed on the engine.
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
Engine Oil Weight (C-15 Engine)
The Engine Oil Viscosity selection on the
electronic service tool screen should not be used
to select the oil viscosity. The correct oil grade
plug should be used to select the oil viscosity.
Note: Refer to Operation and Maintenance
Manual, “Engine Oil and Filter – Change” for
more information.
Aux Press Sensor Installation Status
Aux Press Enable should be programmed to
“Installed” if an auxiliary pressure sensor is
installed.
Aux Temp Sensor Installation Status
Aux Temp Enable should be programmed to
“Installed” if an auxiliary temperature sensor is
installed.
Desired Speed Input Configuration
The Desired Speed Input Configuration
parameter should be programmed to match the
type on input signal for desired engine speed.
The ECM can be programmed to “CAN Input” if
a J1939 throttle message is transmitted over the
J1939 data link. The ECM should be
programmed to “PWM” if a throttle position
sensor or direct fuel control is used.
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
Shutdown Off 0 to 54 3 90°C (195°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
Shutdown Off 0 to 54 4 107°C (224°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
Communication Adapter
Communication Adapter II
(1) Personal computer (PC)
(2) 196-0055 Adapter Cable (PC Serial)
(3) 171-4401 Communication Adapter II
(4) 207-6845 Adapter Cable (Data Link)
Note: The ET Service Tool and Communications
Adapter must only be used in Non-Hazardous
(safe) areas.
30
Note: Items (2), (3), and (4) are part of the
171-4400 Communication Adapter II Gp.
Use the following procedure to connect Cat ET
and the Communication Adapter II.
1. Turn 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
Fax: (309) 494-1345, (309) 494-1348
E-mail: media_logistics@cat.com
Hours: 7:30 a.m. to 4:30 p.m. (CST)
Contact the Caterpillar SIS Help Desk if
problems with the software are encountered.
Phone: (800) 765-0999, (309) 675-4000
Fax: (309) 675-4001
E-mail: dcsghlp@cat.com
Hours: 6:00 a.m. to 6:00 p.m. (CST)
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
Incorrect Installation
Seal
Sealing
Plug
The following requirements ensure the correct
installation of terminals in the connectors:
• Do not solder the sockets and pins to the wires.
• Never crimp more than one wire into a socket
or a pin. The 186-3735 Connector Pin and the
186-3736 Connector Socket are designed to
accept only one 16 or 18 AWG wire. The
9W-0844 Connector Socket and the 9W-0852
Connector Pin are designed to accept only one
14 AWG wire. Do NOT insert multiple wires of
a smaller gauge.
Installation of Seal Plugs
Correct Incorrect
• All sockets and pins should be crimped on the
wires. Use the 1U-5804 Crimp Tool for 12 to
26 AWG wire.
• All unused cavities for sockets and pins must be
filled with 8T-8737 Seal Plugs in order to ensure
that the connector is sealed. The seal plugs must
be installed from the wire insertion side of the
plug or receptacle. The seal plugs must seal
correctly. The head of the seal plug should rest
against the seal. Do not insert the head of the
seal plug into the seal. Refer to the illustration
above for correct installation of plugs.
33
 J61/P61 Customer Connector
Ensure that the allen head screw in the customer
connector is tightened to a torque of 2.25 ± 0.25
N•m (20 ± 2 lb in). All unused cavities for
sockets and for pins must be filled with 8T-8737
Seal Plugs in order to ensure that the connector
is sealed. The acceptable diameter of the
insulation for a wire that is connected to the
customer connector is 2.54 to 3.43 mm (0.100 to
0.135 inch).
Refer to page 40 for pin outs of the J61/P61
Customer Connector.
Deutsch DT Connectors
A DT connector has a wedge that locks the pins
and the sockets in place. The wedge can be
removed and replaced without cutting the wires.
The 147-6456 Wedge Removal Tool (DT
Connector) aids in the removal of the wedges.
When the receptacle is inserted into the plug, a
click should be heard as the two halves lock
together. The connector should not be able to be
pulled apart.
34
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.
• The wedges are not damaged.
Deutsch HD Connectors
Ensure that the wires in the plug align with the
corresponding wires in the receptacle. Ensure that
the index markings on the plug and the receptacle
are aligned. Rotate the plug until the plug slips
into the receptacle. Rotate the coupling by
approximately 90 degrees until a click is heard.
Ensure that the plug and the receptacle cannot be
pulled apart.
The acceptable range for the diameter of the
insulation of the wire that is used with the
connectors is 2.54 to 3.43 mm (0.100 to
0.135 inch).
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
Circuit
Grounding
NOTICE: Improper grounding can cause
uncontrolled or unreliable circuit paths and
electrical noise. This can result in damage to
the engine bearings, and other engine
components.
Proper grounding of the unit and the engine
electrical systems is necessary for proper
performance and reliability.
Negative Battery Connection
NOTICE: The customer must provide a
4 AWG or larger ground cable from the
electronics ground stud on the engine to
negative battery. All ground paths must be
capable of carrying any likely fault currents.
The electronics ground stud is located on the
bracket for the J61/P61 customer connector.
The alternator should be grounded at the bus bar
on the negative battery or grounded directly to
the negative battery post.
Note: Grounding through frame members is not
recommended.
A maximum of three ring terminals should be
connected to the electronics ground stud in order
to ensure integrity of the ground connection. The
use of more than three terminals at the
electronics ground stud can cause the connection
to become loose.
WARNING
The connection of battery cables to a battery
and the disconnection of battery cables from a
battery may cause an explosion which may
result in injury or death. The connection and
the disconnection of other electrical equipment
may also cause an explosion which may result
in injury or death. The procedures for the
connection and the disconnection of battery
cables and other electrical equipment should
only be performed in a nonexplosive
atmosphere.
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
source of the transient is recommended.
Caterpillar follows a stringent electrical
environment standard that is similar to SAE
recommended practices. The use of inductive
devices such as relays and solenoids can result in
Positive
Relay with low side
driver or switch
Using a diode in a relay in order to suppress voltage transients.
The OEM should specify relays and solenoids
that are approved for hazardous locations. These
relays and solenoids should have built-in voltage
transient suppression. Refer to the illustration
above for ways to minimize voltage transients
from relays and solenoids without built-in
voltage transient suppression. Techniques include
the installation of a diode or resistor of the
proper size in parallel with the solenoid or the
relay coil. Other techniques may also be used.
the generation of voltage transients in electrical
circuits. Voltage transients that are not suppressed
can exceed SAE specifications and lead to the
degradation of the performance of the electronic
control system.
Positive
Relay with high side
driver or switch
Inductive devices such as relays or solenoids
should be located as far as possible from the
components of the electronic control system.
Wiring harnesses that are installed by the OEM
should be routed as far as possible from the
wiring harness of the electronic control system in
order to avoid problems that are associated with
electrical noise.
39
 Customer Installed Components
Note: Refer to the appropriate Parts Manual for
your engine for further details on parts
information.
P61 Customer Connector
The P61 Customer Connector utilizes an 8T-9834
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 ECM are connected to the dedicated sensor
returns at the P61 Customer Connector. Separate
sensor returns are provided for analog signal and
digital signals. Refer to the Electrical System
Schematic.
Note: Do not connect negative power or positive
power for the TPS to the J61/P61 Customer
Connector. Connecting switches and/or the
throttle position sensor to the sensor returns at
the P61 customer connector can degrade the
performance of the electronic control system.
These components must be connected to the
negative terminal of the battery. Any relays or
solenoids that are driven by the ECM must not be
connected to the sensor returns at the P61
customer connector. These components must be
connected to the negative terminal of the battery.
Refer to the Electrical System Schematic for
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
Part Number Description Qty
(1)
Air Shutoff System 1
155-2270 Connecting Plug Kit 1
186-3736 Connector Socket 4
(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
recommended in applications that have limited
accessibility to the J63 engine service tool
connector. Proper wiring of the J66 customer
supplied service tool connector is essential for
reliable communication of data. Use 143-5018
Cable (Twisted Pair) and dedicated terminal
strips for all data connections. Mount the
terminal strips in a central location in order to
minimize the overall length of the data link cable.
The total length of the data link cable should not
exceed 30 m (100 ft).

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
Part Number Description Qty
8T-8736 or 9W-1951 Connector Receptacle 1
186-3736 Connector Socket 2
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)
OEM Supplied – component must be approved to be installed in a hazardous location.

43
 (Pins 8, 9 & 11) Auxiliary
Temperature Sensor
An additional temperature sensor input is
provided in order to allow an auxiliary
temperature to be displayed. The auxiliary
temperature may be displayed on the Cat ET
screen, the PMS display module, and the J1939
(CAN) display module.
To utilize this feature, the Caterpillar supplied
temperature sensor must be used and the
parameter Aux Temp Sensor Installation Status
must be programmed to “Installed.” This
temperature sensor is a digital PWM sensor with
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
Part Number Description Qty
131-0427 Temperature Sensor (Auxiliary) 1
155-2260 Connecting Plug Kit 1
186-3736 Connector socket 6
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

44
(Pins 8, 15 & 36) Coolant Level Sensor
An optional coolant level sensor allows the ECM
to monitor the coolant level in order to have the
ability to warn the operator of a low coolant
level. The Coolant Level Sensor parameter
should be programmed to “Installed.” The sensor
output voltage is approximately 0 VDC (negative
battery) when coolant is present. The sensor
output voltage is approximately 5 VDC when
coolant is not present. The ECM supplies the
sensor with 8 VDC.
Note: The sensor must be mounted in a position
that keeps the sensing element immersed under
all operating conditions. The sensor is normally
installed in the radiator top tank. The sensor is
supplied with thread sealant on the threads, so it
is not necessary to apply thread sealant on a new
sensor. Apply 5P-3413 Pipe Sealant to the
threads of the sensor before the reinstallation, if
the sensor has been removed.

Customer Connector
P61/J61
Coolant Level Sensor J800/P800

+8 VDC A 8

Return B 15
Signal
C 36

Required Parts
Part Number Description Qty
165-6634 Coolant Level Sensor 1
155-2260 Connecting Plug Kit 1
186-3736 Connector socket 6
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

45
 (Pin 10) Throttle Position Sensor
The throttle position sensor (TPS) eliminates the
mechanical throttle and governor linkages. The
TPS interprets the position of the throttle lever
into an electrical signal that is sent to the ECM.
The ECM processes the throttle position signal
and the engine speed/timing signal in order to
precisely control engine speed.
• The “Desired Speed Input Configuration”
parameter should be programmed to “PWM.”
• The “Throttle Position Sensor” parameter
should be programmed to “Installed.”
• The “Direct Fuel Control Mode” parameter
should be programmed to “Disabled.”

Throttle Position
Switched Positive
Sensor
Battery
+Battery A
– Battery B Negative Battery
Signal
C
Customer Connector

10

Required Parts
Part Number Description Qty
134-0597 Throttle Position Sensor 1
8T-8732 Connector Receptacle 1
186-3735 Connector Pin 3
186-3736 Connector Socket 1
(2)
16 AWG (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

46
Throttle Position Sensor

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
Part Number Description Qty
(2)
Toggle Switch (SPST Momentary) 1
186-3736 Connector Socket 2
(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
order to allow an auxiliary pressure to be
displayed on Cat ET, PMS display modules, and
J1939 (CAN) display modules. To utilize this
feature, the Caterpillar supplied pressure sensor
must be used and the parameter “Aux Press
Sensor Installation Status” must be programmed
to “Installed.” This pressure sensor is an analog
sensor with an operating range of 0 to 3150 kPa
(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
Part Number Description Qty
161-9932 Pressure Sensor (Auxiliary) 1
155-2260 Connecting Plug Kit 1
186-3736 Connector socket 6
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

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

Part Number Description Qty
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
186-3736 Connector Socket 4
(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
to the CAN data link:
1. Run the CAN data link from the P61 customer
connector to a module.
Note: The end of the data link must be within
approximately 150 mm (6 inch) of the module.
The total length of the data link run must not
exceed 40 m (130 ft).
a. Run 153-2707 Cable (Shielded Twisted Pair)
from the P61 customer connector to the
location of the first module. Cut the cable to
length.
b. Remove 25 mm (1.0 inch) of insulation from
both ends of the cable.
c. Remove 7 mm (0.28 inch) of insulation from
each end of the green wire and the yellow
wire.
d. Crimp a 186-3736 Connector Socket on each
end of the green wire and the yellow wire
with a 1U-5804 Crimp Tool.
e. Crimp a 133-0969 Connector Socket
(Extended) on each end of the shield with a
1U-5804 Crimp Tool.
f. Cut two 30 mm (1.2 inch) pieces of 5P-6001
Heat Shrink Tubing. Slide a piece of the heat
shrink tubing over the shield at each end of
the cable. Position the heat shrink tubing so
that 1 cm (0.4 inch) of the socket is covered
and the remaining tubing is covering the
shield. Apply heat until a complete seal is
52
formed around the shield and the socket. Be
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
tubing is over the cable. Apply heat until a
complete seal is formed. Be careful to avoid
skin contact with any hot glue that may seep
from the heat shrink tubing.
j. Insert the sockets at the opposite end of the
CAN data link into a 174-0503 Connecting
Plug Kit. See table below. Insert the blue
wedge into the connector in order to secure
the terminals in place.
Terminal Locations in the Plug
Wire Color Location in the Plug
Shield C
Yellow A
Green B
k. Position the 125-7876 Heat Shrink Tubing
so that 10 mm (0.4 inch) of the plug is
covered and the rest of the heat shrink tubing
is over the cable. Apply heat until a complete
seal is formed around both the plug and the
cable. Be careful to avoid skin contact with
any hot glue that may seep from the heat
shrink tubing.
l. Plug the end of the data link into the single
end of a 133-0970 Receptacle As (Tee).

2. Connect a receiving module to the tee.
a. Plug a 165-0200 Cable As into the 133-0970
Receptacle As (Tee).
b. Cut a 50 mm (2 inch) piece of 125-7876
Heat Shrink Tubing. Slide the heat shrink
tubing over the module end of the cable
assembly.
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
seal can be obtained. Apply heat until a
complete seal is formed. Be careful to avoid
skin contact with any hot glue that may seep
from the heat shrink tubing.
e. Repeat Step 2 for each module.
3. Connect a termination resistor to the tee at the
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
diagnostic lamp is strongly recommended in
order to alert the operator of problems that may
be detected by the ECM. The warning lamp will
Positive Battery Diagnostic Lamp
1A
Warning Lamp
Required Parts
Part Number Description
186-3736 Connector Socket
(2)
Lamp
(2)
Circuit Protection (1 Amp)
N/A 16 AWG Wire
(1)
Fabricate to Length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.
Lamp Driver Electrical Specifications
Electrical specifications for the ECM low side
drivers that are used for the diagnostic lamp and
the warning lamp allow a maximum current load
of 0.30 Amp (300 mA). The ECM does not
provide diagnostic codes for either lamp circuit.
Low side ECM drivers provide a path to the
negative battery terminal in order to activate the
device (lamp, etc) that is connected to the circuit.
While circuit protection is recommended for the
lamp driver circuits, Caterpillar does not require
dedicated circuit protection.
Diagnostic Lamp Operation
Installation of a diagnostic lamp is strongly
recommended. The diagnostic lamp is used to
alert the operator of an electronic control system
malfunction (active diagnostic code). Caterpillar’s
proprietary two-digit flash codes can be viewed
from the diagnostic lamp. A sequence of flashes
represents the system diagnostic message (flash
code). The first sequence of flashes represents the
54
come ON for five seconds when the ECM is first
turned ON in order to indicate that the lamp
circuit is functional.
Customer Connector
P61/J61
24
25
Qty
2
2
1
(1)
first digit of the flash code. After a two-second
pause, a second sequence of flashes which
represent the second digit of the flash code will
occur. Any additional flash codes will follow
after a pause. These flash codes will be displayed
in the same manner.
Note: Flash codes should only be used to
indicate the nature of a diagnostic condition.
Do not use flash codes to perform detailed
troubleshooting.
Warning Lamp Operation
Installation of a warning lamp is strongly
recommended. The warning lamp is used to alert
the operator of an engine operating condition
that has the potential to cause engine damage
(event code).
The warning lamp will come ON for five seconds
when the ECM is first turned ON in order to
indicate that the lamp circuit is functional.
(Pin 27) Remote Shutdown Switch
The ECM disables fuel injection in order to stop
the engine when the remote shutdown switch is
activated closed. The remote shutdown switch
must be deactivated, opened, in order to restart
the engine.
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
Part Number Description Qty
(2)
Toggle Switch (SPST) 2
186-3736 Connector Socket 1
(2)
Terminal 2
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

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
Part Number Description Qty
(2)
Toggle Switch (SPST) 1
186-3736 Connector Socket 1
(2)
Terminal 2
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

56
(Pins 19, 29, 30 & 39) PTO Switches
The ECM can be programmed to operate in
either one of the two PTO configurations that are
available. When PTO Mode is programmed to
“Ramp Up/Ramp Down,” the ECM allows PTO
operation with traditional features. When PTO
Ramp Up/Ramp Down Mode
Mode is programmed to “Set/Resume,” the ECM
allows PTO operation with enhanced features.
Note: If the PTO is the only means of controlling
engine speed, the PTO enable circuit may be
wired directly to the negative battery.

PTO Enable
Customer Connector
P61/J61

PTO Ramp 29
Up/Down
30
Ramp Up
39
Ramp Down

Negative Battery

Required Parts
Part Number Description Qty
(2)
Toggle Switch (SPST) 1
(2)
Toggle Switch (SPDT, Momentary) 1
186-3736 Connector Socket 1
(2)
Terminal 2
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

Switch Inputs input and the Ramp Down input cannot be

• PTO Enable
• Ramp Up
• Ramp Down
PTO Enable Switch
The PTO enable switch is used to determine
whether the ECM should acknowledge the PTO
ramp up/down switch.
PTO Ramp Up/Down Switch
When the PTO Enable Switch is in the ON
position, the throttle position sensor is disabled
and the desired engine speed is controlled by the
PTO Ramp Up/Down Switch. The Ramp Up
connected to the negative battery at the same
time. If this occurs, the ECM will generate a
diagnostic code and the ECM will make no
adjustments to the desired engine speed when the
unit is in the PTO mode.
Note: The ECM will use the selected speed that
is higher when the ECM chooses between the
throttle input and the PTO input. When the switch
is toggled, the engine will respond according to
the programmed value for Engine Accel. Rate.
The engine will maintain the current desired
engine rpm when the switch is open in the center
position. “Opened” in this case means that the
switch is in the center position.

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
Part Number Description Qty
(2)
Toggle Switch (SPST) 2
(2)
Toggle Switch (SPDT, Momentary) 1
186-3736 Connector Socket 1
(2)
Terminal 2
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

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

The PTO enable switch is used to determine
whether the ECM should acknowledge the PTO
Ramp Up/Down Switch.
Set Switch (Ramp Up)
• If the input is momentarily connected to the
negative battery, the desired engine speed will
be set to the current engine speed.
• If the input is connected to the negative battery
and held in that position, the desired engine
speed will increase according to the
programmed value for Engine Accel. Rate.
• After the desired engine speed is set,
momentarily connecting this input to the
negative battery will increase the engine speed
in increments of 20 rpm.
Resume Switch (Ramp Down)
• If this input is momentarily connected to the
negative battery, the desired engine speed will
be set to the last known value that was used
58
during PTO operation.
and held in that position, the desired engine
speed will decrease at the rate that is
programmed for Engine Accel. Rate.
• After the desired engine speed is set,
momentarily connecting this input to the
negative battery will decrease the engine speed
in increments of 20 rpm.
PTO Interrupt Switch
When this input is open, the ECM uses the
throttle position sensor as the source for
determining the desired engine speed. When this
input is connected to the negative battery, the
ECM returns control of the desired engine speed
to the PTO. When control of the desired engine
speed is transferred from the throttle position
sensor to the PTO, engine speed will change at
the rate that is programmed for Engine Accel.
Rate. The PTO set speed will be lost whenever
the keyswitch is turned OFF.
(Pin 40) Overspeed Verify Switch
NOTICE: Activating the overspeed verify
switch will result in an engine shutdown when
engine speed reaches 75 percent of the
overspeed set point.
An overspeed shutdown feature is provided in
order to help prevent damage to the engine or
driven equipment in the event of an overspeed
condition. The monitoring system must have the
Engine Overspeed parameter set to the ON
position in order to enable this feature. The
overspeed verify switch allows the operator or a
service technician to quickly verify that the
overspeed protection system is operating correctly.
When the overspeed verify switch is activated, the
engine will shut down when engine speed reaches
75 percent of the overspeed set point. The ECM
shuts down the engine by disabling fuel injection
and activating the relay for the air shutoff
solenoid.
Note: The air shutoff solenoid must be manually
reset in order to restart the engine. The power to
the ECM must be cycled in order to restart the
engine.

Customer Connector
Overspeed Verify Switch P61/J61

40

Negative Battery

Required Parts
Part Number Description Qty
(2)
Toggle Switch (SPST, Momentary) 1
186-3736 Connector Socket 1
(2)
Terminal 2
(2)
16 AWG Wire (1)

(1)
Fabricate to length
(2)
OEM Supplied – component must be approved to be installed in a hazardous location.

59
 Interconnect Harness
The Interconnect Harness utilizes an 8T-9834
Connector Plug. All circuits that are connected to
the Interconnect Harness 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 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
31 Unswitched Batt + 101/RED 14
32 Unswitched Batt + 101/RED 14
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
This display allows the operator to monitor the
engine information while the engine is being
operated. The Messenger Display can provide
information on various engine operating
parameters.
Engine diagnostic codes can also be displayed on
the Messenger Display. Messenger will
3
(1) Messenger display
(2) Mounting bracket
(3) Mounting screws
(4) Keypad
automatically display diagnostic codes when the
diagnostic code becomes active. This allows the
operator to take appropriate action when a
diagnostic code becomes active.
The Messenger Display provides information to
the operator from the engine Electronic Control
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
on the connector for the display.
e. Connect the green wire (J1939-) to pin 8
on the connector for the display.
f. Connect pin 1 on the connector for the
display to an unswitched +Battery source.
g. Connect pin 2 on the connector for the
display to a +Battery source.
h. Connect pin 3 on the connector for the
display to a switched +Battery source.
3. Reconnect the batteries.
i. Trim the shield (bare wire) flush to outer
sheath to prevent accidental contact.
Position the 125-7876 Heat Shrink Tube so
that the shield is completely insulated and a
proper seal can be obtained. Apply heat until
a complete seal is formed. Be careful to
avoid skin contact with any hot glue that
may seep from the heat shrink tube. Shield
should terminate only at the ECM (J1/P1
Connector) through the J61/P61 Connector.

63
 4. Verify the supply voltage at the display unit.
a. Use a multimeter to measure the voltage.
Measure the voltage between the +Battery
(pin 1) and the +Battery (pin 2) with the
keyswitch in the ON position. The voltage
should be 11 to 13.5 VDC for 12 volt
systems, and 23 to 27 VDC for 24 volt
systems.
Note: The supply voltage to the Messenger
Display may be from 9 to 32 VDC.
b. Use a multimeter to measure the voltage.
Measure the voltage between the switched
+Battery (pin 3) and the +Battery (pin 2)
with the keyswitch in the ON position. The
voltage should be 11 to 13.5 VDC for 12
volt systems, and 23 to 27 VDC for 24 volt
systems.
c. Turn the keyswitch to the OFF position.
Measure the voltage between the +Battery
(pin 1) and the +Battery (pin 2). The
voltage should be 11 to 13.5 VDC for 12
volt systems, and 23 to 27 VDC for 24 volt
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
Install the Messenger Display into the
Console
1. Place the gasket around the cutout on the front
of the console.
2. Mount the Messenger Display into the console.
a. Insert the display into the cutout from the
front of the console.
b. Install the rear brackets and loosely tighten
the four pan head screws that hold the
brackets in place.
c. Ensure that the face of the Messenger
display is straight and positioned correctly
in the opening.
d. Fully tighten the four screws that hold the
brackets in place.
3. Connect the 8-pin connector to the back of the
display.
4. Secure the Messenger Display wiring with tie
straps in order to avoid wiring abrasion and
interference with the operator.
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.