MARINE ENGINE ELECTRONIC DISPLAY CMS, EMS, GPS AND EN Caterpillar

This document provides the necessary information for correct electrical/electronic installation and application of Caterpillar Electronic Marine Display Systems.

Battery Circuit Requirements And Considerations

Grounding (Minus Battery Bus Bar Connections)

Proper grounding for vessel and engine electrical systems is necessary for engine/vessel performance and reliability. Problems with intermittent or improper power or ground connections are often very difficult to diagnose and repair. All negative battery connections MUST have a common ground that terminates at a negative battery bus bar. Refer to Figure 1.

The alternator, starting motor, and all electrical systems MUST be grounded to -Battery. The alternator and starting motor must also meet marine isolation requirements. For engines which have an alternator grounded to an engine component, a ground strap MUST connect that component to -Battery and the component MUST be electrically isolated from the engine.

A -Battery Bus Bar with a direct connection to the Minus Battery Terminal is recommended for all engine common ground connections.

Operator Station Grounding

Caterpillar recommends a separate Engine Room Minus Battery Bus Bar for all engine ECM connected electronics. This ensures that the ECM and all associated components, including switches, sensors and electronic display modules, have a common reference point. All -Battery connections should begin at the -Battery connection of the component being wired and terminate at the -Battery Bus Bar.

The connection from the Engine Room -Battery Bus Bar to the bridge display Station -Battery Bus Bar should be made with a minimum of 12 AWG wire. Each Station -Battery Bus Bar is for the display modules only and should not have any other electrical components connected to it.

NOTE: -Battery Bus Bar connections made in manner shown in Figure 1 ensures that all components in the system have the -Battery Bus Bar as a common reference point at the engine room. Properly grounded systems are a MUST for reliable operation.

Figure 1 - Operator Station Grounding Connections

+Battery For ECM Power

Powering the electronic control system on dedicated fused circuits reduces the possibility of degraded electronic control system performance due to voltage transients. Additional loads should not be connected between the ECM and ECM circuit protection. The ECM and display MUST be powered from the same switch (source).

The ECM battery connections are made at the ECM Customer Connector using 14 AWG wire. Refer to the Engine Schematic and Engine Installation Guide for information on required connections and circuit protection ratings.

NOTE: Caterpillar recommends using circuit breakers for circuit protection. Circuit breakers should be placed with other vessel circuit protection devices in a centrally located, dedicated panel.

If automatically resetting circuit breakers are used, consideration of the breaker location environment and its effect on the trip point is critical. The trip point of some circuit breakers can be significantly reduced below the rated trip point if exposed to high temperatures. This can cause intermittent shutdowns and result in incorrectly replaced engine electronic components.

The ECM monitors battery voltage and triggers a diagnostic code if the voltage to the ECM drops below 83% of system voltage.

Vessels may be equipped with an engine protection shutdown system (external to ECM) that interrupts electrical power to the ECM. These systems may not supply power to the ECM until the engine is cranked, until oil pressure achieves minimum acceptable limits, or until engine shutdown verify override button is depressed. These devices must not interrupt the Unswitched +Battery line.

Suppression Of Voltage Transients

Caterpillar recommends transient suppression be installed at the source of the transient as well as at the ECM. Caterpillar follows a proprietary stringent electrical environmental standard similar to SAE J1455.

The use of inductive devices such as relays and solenoids can result in the generation of voltage transients on the battery lines. Voltage transients that are not suppressed can exceed SAE J1455 specifications and degrade electronic control system performance.

The OEM should specify relays and solenoids with built-in voltage transient suppression on the vessel where possible.

Figure 2 - Examples of Voltage Transient Suppression

Refer to Figure 2: Examples of Voltage Transient Suppression for suppression techniques used to minimize the generation of voltage transients from relays and solenoids without built-in voltage transient suppression. Techniques include but are not limited to installing a properly sized diode or resistor in parallel with solenoid and relay coils.

Inductive devices should be located to maximize the distance from electronic control system components. OEM installed wiring harnesses should be routed to maximize the distance from the control system wiring harness to avoid inductive coupling of noise transients.

Data Connections

Communication Data Link

The ECM provides output pins that are dedicated to the communication data link. The data link is available to share data between the ECM, electronic display modules, electronic service tools, and other modules.

SAE J1587/J1708 (ATA) Data Link

The electronic control system has a standard data link available. The ATA (American Trucking Association), SAE J1587/SAE J1708 Data Link is standard. The J1587/ATA Data Link communicates with Caterpillar Electronic Service Tools. Use 143-5018 Data Link Cable for all ATA Data Link connections.

Optional Electronic Service Tool Connection

The optional electronic service tool connection is NOT recommended for the 3400 High Performance Marine Engines.

CAT Data Link

The CAT Data Link is a proprietary communication medium available on all Marine Engines. The CAT Data Link is for communication between the engine and other Caterpillar microprocessor based electronic display modules.

Proper wiring of the CAT Data Link (CDL) system is essential for proper display operation. Use 143-5018 Data Link Cable and dedicated terminal strips for ALL CDL connections. Locate terminal strips to minimize the overall CDL cable length. The total length of data link wires should NOT exceed 30 m (100 ft).

Figure 3 - Engine Room CAT Data Link Connections

There should be only one CDL Data Cable that runs from the engine room up to the electronic displays. If a second station is to have a Caterpillar electronic display, then data link cable should be run from the engine room terminal strip to the first station, then from the first station to the second station. Refer to Connecting Multiple Engine Vision Displays and Connecting Multiple EMS Displays in this guide for details.

Improper wiring of the CAT Data Link System will result in a Data Loop that can cause electronic systems to function improperly.

Switch, Connector, And Harness Requirements And Considerations

Switch Electrical Specifications

Applied voltage to switches by the electronic control will normally not exceed 24 VDC. Contact plating should not corrode or oxidize. Gold plated contacts are recommended. Normal current draw through the switches by the control will not exceed 5.0 mA.

Contact chatter and momentary opening or closing should not exceed 100 milliseconds in duration. The switches should not open or close due to vibration or shock normally found in the application.

ECM and display module internal pull up resistors force the respective input to +Battery when a switch contact is opened or the harness has an open circuit. Closure of OEM installed switches must short circuit the switch input to -Battery of the Customer Connector.

Voltage thresholds measured at ECM:

Voltage In Low < 0.9 VDC - With any switch contacts closed, ground potential differences, switch voltage drops, and wiring harness voltage drops must be such that a switch closure results in less than 0.9 VDC between the respective control inputs and -Battery.

Voltage In High > 3.5 VDC - With any switch contacts open, pin-to-pin leakage paths in connectors, harnesses, and switches must not result in an effective resistance of less than 5k Ohms from the respective control inputs to -Battery.

NOTE: OEM installed switches must be grounded to the -Battery Bus Bar connection.

Electrical Connectors

Many of the procedures in this guide will direct you to a specific electrical connector. The connectors have a locking mechanism to hold the pins and sockets and are repairable without cutting the wires. Connector pins and sockets are crimped onto the wires using a 1U5804 Crimp Tool.

HD-10 Connector- Ensure the plug and receptacle are aligned using the index markings. Rotate the plug until it slips into the receptacle, rotate the coupling approximately one-quarter turn, until a click is heard. Ensure the two halves cannot be pulled apart. The acceptable range for the wire installation outside diameter is 2.4 to 3.68 mm (.09 to .14 in).

DT Connector- The DT connectors use an orange wedge to lock the pins in place. Check to ensure all seals are present and properly seated. Check pins and sockets before joining connectors. Verify proper alignment and locations of pins and sockets in each connector. Check DT connector locking tab for damage. Replace the connector if tab is damaged. Ensure that the connector is properly locked together (you will hear an audible click) and that the two mating halves can not be pulled apart. The acceptable range for the wire installation outside diameter is 2.4 to 3.68 mm (.09 to .14 in).

Figure 1.4 Electrical Connectors

Figure 1.5 Plug Insertion In Unused Pins

NOTE: Do not solder sockets/pins and wires. Sockets/pins should always be crimped onto the wires using the 1U5804 Deutsch Crimp Tool. All unused connector socket slots must be filled with plugs to insure connector sealing. Proper insertion of connector plugs, used to fill unused pins and socket cavities of connectors, is also critical. The illustration above demonstrates the correct insertion of the plug. The plug cap is designed to rest against the seal, not inserted in the hole in the seal.

ECM And Customer Connectors

Ensure the ECM and Customer Connector Allen head bolts are properly tightened. DO NOT exceed 2.25 N·m (20 lb in) of torque on the Allen head connector bolt when connecting the connector halves.

Perform 45 N (10 lb) pull test on each socket/pin and wire. Each socket/pin and wire should easily withstand the pull test value and remain in the connector body. This test ensures the wire was properly crimped in the socket/pin, and the socket/pin properly inserted in the connector.

The acceptable range for the wire insulation outside diameter is 2.54 to 3.43 mm (0.100 to 0.135 in) for the ECM and Customer Connectors.

Figure 1.6 Customer Connectors

Wiring Harnesses Requirements

As stated previously, all unused ECM connector and Customer Connector socket slots MUST be sealed with plugs to ensure connector sealing.

Wire Size Requirements

The wire size to all Caterpillar components must be of adequate size to handle the maximum current of the circuit. All +Battery and -Battery connections to the ECM Customer connector should be made with 14 AWG wire. The connections from the -Battery Bus Bar to the bridge displays should be made with a minimum of 12 AWG wire. All other connection should be made with 16 AWG wire minimum.

All Data Link connection (Cat Data Link and ATA) should be made with the 143-5018 Data Link Cable.

NOTE: No other components are allowed to be connected to the Caterpillar -Battery wire to the bridge displays.

Figure 7 - Engine Room Battery And Ground Wiring

NOTE: some ECM's do not require an unswitched +Battery connection. Refer to the Engine Electronic Installation Guide for details.

OEM Harness Routing/Design

Figure 8 - Improper Harness Routing At ECM and Customer Connectors

Routing of harnesses should ensure connector seals are not stressed because the harness wiring curvature is too close to a connector. The previous diagram illustrates the problem if the harness curvature is too close to the connector. When this occurs the connector seal is stretched away from the wire, providing an opening for moisture entry. The wire should exit perpendicular to the connector with 25 mm (1.0 inch) of straight length before curving as necessary for routing. The harness bundle should have a bend radius greater than twice the harness diameter. All Twisted pair wires should not be twisted within an inch of the connector to avoid seal stress.

Figure 9 - Harness Routing At ECM and Customer Connectors

Caterpillar requires all ring terminals and splices connected to the Customer Connector be sealed using Raychem ES2000 adhesive lined heat shrink sleeve (Caterpillar 1E2358 Specification) or equivalent.

Warning Alarm And Diagnostic Lamps

The electronic control system provides drivers capable of sinking or sourcing 300 mA, which can be used to drive a relay or audible/visual alarms to indicate various diagnostic conditions.

Driver Specifications

Electrical specifications for the ECM low and high side drivers used for the Diagnostic Lamp and Warning/Alarm Lamps allow a maximum load current of 0.30 amperes (300 mAmps). The ECM does not provide diagnostic codes associated with either lamp circuit.

Figure 10 - Low Side Driver (Sinking Driver)

Low side ECM drivers provide a path to the -Battery Bus Bar to activate a lamp or other device connected to it. Caterpillar does not require dedicated circuit protection for these circuits.

Figure 11 - High Side Driver (Sourcing Driver)

High side ECM drivers provides a path to +Battery to activate a lamp or other device connected to it. Caterpillar does not require dedicated circuit protection for these circuits.

Diagnostic Lamp Operation

An OEM installed Diagnostic Lamp indicates an electronic control system malfunction (diagnostic condition) by alerting the operator of Active diagnostic codes.

Viewing Diagnostic Flash Codes

Caterpillar's proprietary two-digit diagnostic flash codes can be viewed from the Check Engine/Diagnostic Lamp. A sequence of flashes represents the system diagnostic message. The first sequence of flashes represents the first digit of a diagnostic code. After a two second pause, a second sequence of flashes will occur which represent the second digit of the diagnostic code. Any additional diagnostic flash codes will follow after a pause and will be displayed in the same manner.

NOTE: It is suggested the Diagnostic Flash Codes be used only to indicate the nature of a diagnostic code occurrence, not to perform detailed troubleshooting.

3408C & 3412C Engines

The 3400C Engine ECM provides six diagnostic outputs to warn the operator of potential engine or marine gear problem. These warnings are:

- High Coolant Temperature

- Low Coolant Level

- Low Boost Pressure

- Low Engine Oil Pressure

- Transmission Warning (High Oil Pressure or High Oil Temperature)

- Optional Diagnostic Lamp

These outputs can be used to drive a warning lamp and/or warning alarm. The Diagnostic driver outputs are capable of sinking 300 mAmps, and the diagnostic driver output pin-12 is capable of sourcing 300 mAmps. The alarm requirements MUST not exceed 300 mAmps.

On system power up, the ECM will turn on the Diagnostic outputs for five seconds, then turn them off. If a diagnostic condition exists, the ECM will turn the driver on and it will stay on until the fault is corrected.

3176B Engine

The 3176B Engine ECM provides six warning outputs to warn the operator of a potential engine or marine gear problem. These warnings are:

- High Coolant Temperature

- Low Coolant Level

- Low Engine Oil Pressure

- Transmission Status (High Oil Pressure and/or High Oil Temperature)

- Optional Diagnostic Lamp

- Maintenance Indicator Lamp

These outputs can be used to drive a warning lamp or a warning alarm. The Diagnostic driver outputs pin-21, pin-22 and pin-27 are capable of sinking 300 mAmps, and the diagnostic driver output pin-34 and pin-40 are capable of sourcing 300 mAmps. The alarm requirements MUST NOT exceed 300 mAmps.

3176C, 3196 & 3406E Engines

The 3176C, 3196 & 3406E Engine ECM provides six warning outputs to warn the operator of a potential engine or marine gear problem. These warnings are:

- High Coolant Temperature

- Low Coolant Level

- Low Engine Oil Pressure

- Warning Alarm

- Diagnostic Lamp

- Maintenance Indicator Lamp

These outputs can be used to drive a warning lamp or a warning alarm. The Diagnostic driver outputs pin-20, pin-21 and pin-23 are capable of sinking 300 mAmps, and the diagnostic driver output pin-22, pin-24 and pin-25 are capable of sourcing 300 mAmps. The alarm requirements MUST NOT exceed 300 mAmps.

NOTE: The Warning Alarm will activate during an engine event such as Low Oil Pressure or High Transmission Temperature. It will NOT activate for sensor open or short circuit diagnostic codes.