C7-C9 Electrical Electronic Guide

C7 & C9 Truck Engines EPA 2004 Electrical and Electronic Application and Installation Guide

Serial Number Prefixes FMM FML KAL YPG 9DG CKP

LEBT2835-02

November 2008

ELECTRICAL & ELECTRONIC APPLICATION AND INSTALLATION GUIDE

INTRODUCTION AND PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Engine Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Power and Grounding Requirements and Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Connectors and Wiring Harness Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Accelerator Pedal Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Vehicle Speed Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ECM Speedometer and Tachometer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Lamp Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 OEM Installed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Inlet Air Heater, Lamp and Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Hard-wired Switch Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Idle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 J1939 Based Switch Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Dedicated PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Programmable Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Governor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Data Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Customer Specified Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 Diagnostics, Service Tools and Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____

3


INTRODUCTION AND PURPOSE This document is intended to provide necessary information for correct electrical & electronic application and installation of a C7 or C9 truck engine into an on-highway truck, bus, motor coach or vocational chassis. Caterpillar expects there will be some additions and modifications to this document as the engine program development continues, and as OEM requests for information not currently addressed are added. The information contained in this version of the document reflects the Caterpillar design for production C7 and C9 engines built with March 2004 software.

The information herein is the property of Caterpillar Inc. and/or its subsidiaries. Without written permission, any copying, transmittal to others, and any use except that for which it is loaned is prohibited. General Electronic Engine Operation 1.0 Engine Functions 1.1 Electronic Governing Two engine speed range electronic governors are available for use. These electronic governors are selectable through a programmable parameter. 1.2 Fuel/Air Ratio Control The control system has full authority over engine fuel delivery. The mechanical fuel/air ratio control is eliminated. Electronic control of the fuel/air ratio provides optimum performance with reduced emissions. 1.3 Injection Timing Control Injection timing is varied as a function of engine operating conditions to optimize engine performance for emissions, noise, fuel consumption, and drivability. 1.4 Torque Rise Shaping Electronic controls provide increased flexibility to tailor the torque curve over a wide speed range. 1.5 Cold Mode Operation When the engine is started with cold coolant, the engine will operate in “Cold Mode”. The engine will operate with reduced performance until the coolant temperature has warmed. The Caterpillar electronic service tool software will indicate when the engine is operating in Cold Mode. The C7 engine will operate in Cold Mode below 64 Deg C and the C9 engine will operate in Cold Mode below 40 Deg C.

4



2.0 Engine Component Overview 2.1 Engine Control Module (ECM) The ECM is located on the left rear side of the engine. The ECM has two connectors, one for the Caterpillar Engine Harness, the other for the Vehicle OEM Harness. 2.2 Boost Pressure Sensor The Boost Pressure Sensor is an absolute pressure sensor measuring inlet manifold pressure. Boost pressure displayed by service tools and communicated over the data link is referenced to the Atmospheric Pressure Sensor reading. The Boost Pressure Sensor measures gauge pressure from 0 psi (0 kPa) to 49 psi (340 kPa). The ECM supplies the sensor with a regulated 5 Volts DC. 2.3 Atmospheric Pressure Sensor The Atmospheric Pressure Sensor is an absolute pressure sensor. The Atmospheric Pressure Sensor measures pressure to 16.8 psiA (116 kPaA). The ECM supplies the sensor with a regulated 5 Volts DC. 2.4 Oil Pressure Sensor An optional Oil Pressure Sensor is available for use in applications where an actual oil pressure indication is desired. Typical applications include vehicles with a vehicle data link capable Instrument Cluster that can display engine information. C7 or C9 engines do not require Engine Lube Oil Pressure monitoring because the HEUI (Hydraulically actuated Electronically controlled Unit Injector) fuel system requires oil pressure for the engine to operate. Without sufficient oil pressure, the fuel system cannot supply fuel to the engine. The Oil Pressure Sensor measures gauge pressure from 0 psi (0 kPa) to 165 psi (1135 kPa). Oil Pressure as displayed by service tools and communicated over the data link is referenced to the Atmospheric Pressure Sensor reading. The ECM supplies this sensor with the necessary voltage. 2.5 Coolant Temperature Sensor The thermistor based Coolant Temperature Sensor is used to monitor engine coolant temperature. Output from this sensor is used for several engine functions including Inlet Air Heater Operation, Cold Mode Operation, Cold Elevated Idle and the Engine Monitoring System. 2.6 Inlet Manifold Air Temperature Sensor The Inlet Manifold Air Temperature Sensor is used to measure the inlet air temperature and is thermistor based like the Coolant Temperature Sensor. This sensor output is used in controlling the Inlet Air Heater, Cold Elevated Idle, Cooling Fan Output, and for Engine Monitoring. 2.7 Engine Speed/Timing Sensors The engine speed/timing sensors are used to determine both engine speed and fuel injection timing. The sensors detect this information from a wheel on the camshaft. 2.8 Coolant Level Sensor The coolant level sensor is an option device used to monitor the engine’s coolant level. This sensor is usually mounted in the cooling system’s surge tank. There are three types of sensors that may be used. 2.9 Injection Actuation Pressure (IAP) Sensor The Injection Actuation Pressure Sensor measures the pressure in the high-pressure oil manifold. This oil is used to feed the hydraulically actuated electronically controlled unit injectors. The ECM supplies the sensor with the necessary voltage. 2.10 Injection Actuation Pressure Control Valve (IAPCV) This valve controls the output injection actuation pressure of the high-pressure oil pump. The ECM uses the output of the Injection Actuation Pressure Sensor to determine the required output to this valve.


5


2.11 Inlet Air Heater and Relay The Inlet Air Heater is an engine mounted, Caterpillar supplied and installed heater grid used for warming the inlet air to aid in starting during cold ambient temperatures. Operation is based on elevation (above sea level) and the sum of the Coolant and Inlet Manifold Air temperatures. The ECM controls the normally open relay to provide battery power to the grid. 2.12 Fuel Pressure Sensor A Fuel Pressure sensor is included in the engine pressure sensor package. This sensor monitors the fuel supply pressure to the engine. 2.13 Oil Level Switch (GMT560 Trucks Only) An Oil Level Switch is available only on General Motors engines. This switch is mounted in the oil pan and wired to the Engine Connector (J2) of the ECM. This switch monitors the oil level in the oil pan and is checked at initial engine power up. Proper Oil level in the engine will keep a normally open switch closed. Oil level that is too low will allow the switch to open. If the ECM senses an open switch upon three sequential engine starts, low oil level is indicated.

ECM Oil Level Switch (Shown With Oil Level Normal)

B428-OR

33

G829-GN

3

Oil Level Sensor Common

P2 J2

Figure 1

6



ADEM 2000 Engine Control Module

6 HEUI Injectors

SAE J1939/13 OFF-BOARD DIAGNOTSIC CONNECTOR

ñ 12V + BATTERIES

Cruise Control On/Off & Set/Resume Switches

Throttle Position Sensor

Injection Actuation Pressure Control Valve

Ignition Key Switch

Top Camshaft Position Sensor

Caterpillar Installed

Bottom Camshaft Position Sensor Injection Actuation Pressure Sensor Fuel Pressure Sensor Boost Pressure Sensor

Atmospheric Pressure Sensor

OEM Installed

Clutch and Service Brake Switches

Coolant Level Sensor Check Engine & Warning Lamps Speedometer & Tachometer 15

45 35

20

55

25

10

65

75

15

25

5

5 0

MPH

85

RPM X 100

30

Cooling Fan

Turbo Wastegate Control Valve

Vehicle Speed Sensor

(Not All Ratings)

Engine Oil Pressure Sensor (Optional) PTO Throttle Position Sensor Oil Level Switch (GMT560 Trucks Only)

2, 0.3A Lamp Outputs 2 +Battery & 9 Ground Switch Inputs

Coolant Temperature Sensor

3, 1.0A Outputs

Intake Manifold Air Temperature Sensor

Intake Air Heater Relay

3, 1.5A Outputs

Intake Air Heater Lamp Intake Air Heater 109-3000 12 V

AIR FLOW

Figure 2


7


Injection Pressure Sensor

Inlet Air Heater Relay

Inlet Air Temperature Sensor Boost Pressure Sensor

Injection Actuation Control Valve

OEM Connector J1/P1

ECM

Engine Speed/Timing Sensors


Engine Connector J2/P2

Engine Oil Pressure Sensor (Optional)

Figure 3 - C7 Sensor Locations

Boost Pressure Sensor Injection Actuation Pressure Control Valve

Inlet Air Temperature Sensor Atmospheric Pressure Sensor


Inlet Air Heater Relay

Injection Actuation Pressure Sensor

OEM Harness Connector J1/P1

Speed/Timing Sensors

Oil Pressure Sensor (Optional)

Engine Harness Connector J2/P2

ECM

Figure 4 - C9 Sensor Locations

8



NOTE A

INJECTOR CYLINDER NO.3

J303 P303 B A

A B

C B A

TO ENGINE CYLINDER HEAD

G833-PK

995-BU

C967-BU G833-PK

G826-BR

C991-PK G827-BU

J103 P103

1 2

J100 P100

1 2

G826-BR

G827-BU

994-GY

A747-GY G829-GN G828-WH

G849-BR G829-GN G828-WH

P205 J205

GN YL 0R

TO INTAKE AIR HEATER CIRCUIT PROTECTION (BATTERY +)

ENGINE FUEL PRESSURE SENSOR COMMON SENSOR +5V

ENGINE INTAKE MANIFOLD AIR TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

ENGINE COOLANT TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

OIL Level -

OIL Level -

C B A

ENGINE OIL PRESSURE ENGINE OIL PRESSURE SENSOR COMMON ENGINE OIL PRESSURE SENSOR +5V

P203

P201

C B A

C B A

P200

A746-PK G829-GN G828-WH

A703-BR


J304 P304 B A

L984-OR

P204 J204

GN YL 0R

C B A

ENGINE ATMOSPHERIC PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

ENGINE INJECTION ACTUATION PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

ENGINE BOOST PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

A702-PU

L983-WH

NOTE A: INDICATES AN OPTIONAL COMPONENT NOT INSTALLED ON ALL ENGINES

FUEL TRANSFER PUMP PRESSURE

TEMPERATURE SENSOR

MANIFOLD AIR

ENGINE INTAKE

ENGINE COOLANT TEMPERATURE SENSOR

ENGINE OIL LEVEL SWITCH (GMT560 Only)

ENGINE OIL PRESSURE SENSOR

ENGINE ATMOSPHERIC PRESSURE SENSOR NOTE A

ENGINE INJECTION ACTUATION PRESSURE SENSOR

ENGINE BOOST PRESSURE SENSOR



A701-GY

J302 P302 B A

J301 P301 B A

L983-WH

K995-OR

INTAKE AIR HEATER

A704-GN


J305 P305 B A

L984-OR

TO CONNECTOR J648 (OEM HARNESS)

BOTTOM CAMSHAFT POSITION BOTTOM CAMSHAFT POSITION +

B A

C987-RD

G850-BU

P648

J501 P501 1 C987-RD G850-BU 2

INJECTION ACTUATION

P300 J300

6 5 4 3 2 1 A701-GY

A704-GN A703-BR A702-PU

L985-YL A706-GY A705-BU

L983-WH L984-OR

A B

J402 P402

A B

J401 P401

1 2

J500 P500

1 2

C991-PK

G850-BU

E965-BU E966-YL

E963-BK E964-WH

G833-PK

995-BU C967-BU

C211-BK

M 795-WH

994-GY G827-BU G826-BR

ECM GROUND STRAP

TO ECM MOUNTING BOLT

INTAKE AIR HEATER RELAY

ENGINE TIMING CALIBRATION PROBE+ ENGINE TIMING CALIBRATION PROBE-

BOTTOM CAMSHAFT POSITION BOTTOM CAMSHAFT POSITION +

TOP CAMSHAFT POSITION TOP CAMSHAFT POSITION +

ENGINE TEMPERATURE SENSOR COMMON

ENGINE COOLANT TEMPERATURE ENGINE INTAKE MANIFOLD AIR TEMP.

TURBO WASTEGATE SOL POSITIVE TURBO WASTEGATE SOL NEGATIVE

ENGINE OIL PRESSURE ENGINE OIL PRESSURE SENSOR COMMON ENGINE OIL PRESSURE SENSOR +5V

FUEL PRESSURE

OIL LEVEL SWITCH ENGINE ATMOSPHERIC PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

ENGINE BOOST PRESSURE ENGINE INJECTION ACTUATION PRESSURE

IAP CONTROL VALVE IAP CONTROL VALVE COMMON

INJECTOR COMMON CYLINDERS 1 & 2 INJECTOR COMMON CYLINDERS 3 & 4 INJECTOR COMMON CYLINDERS 5 & 6 INJECTOR CYLINDER 6 INJECTOR CYLINDER 5 INJECTOR CYLINDER 4 INJECTOR CYLINDER 3 INJECTOR CYLINDER 2 INJECTOR CYLINDER 1

VEHICLE HARNESS CONNECTOR

P1 J1

44 45 46 55 54 39 38 37 36 47 67 68 1 52 53 4 5 61 62 70 40 25 6 33 14 3 2 15 16 17 24 42 41 27 50 63 64 66 9 32 35 7 34 26 18 10 11 12 49 48 13 19 20 21 28 29 30 59 58 31 43 51 22 23 56 57 65 60 69 8

P2 J2

ENGINE HARNESS CONNECTOR

G829-GN G828-WH

A747-GY

G458-GY

A746-PK G849-BR

G855-PU

G854-PK

PRESSURE CONTROL VALVE

TOP CAMSHAFT POSITION TOP CAMSHAFT POSITION +

BOTTOM CAMSHAFT POSITION SENSOR

N/O RELAY

A706-GY

L985-YL

TURBO WASTEGATE SOLENOID *** Not On All Ratings ***


J306 P306 B A

TOP CAMSHAFT POSITION SENSOR

A705-BU

L985-YL

12 11 10 9 8 7


Figure 5 - C7 Engine Wiring Diagram

9

A B

J500 P500


Figure 6 - C9 Engine Wiring Diagram

10


BATTERY 2

BATTERY 3

NOTE A

H795-PK C977-BU

H795-PK

E971-GN

A/C HIGH PRESSURE SWITCH

(N/C - PEDAL RELEASED POSITION)

Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____ NOTE A

NOTE A

10A

H795-PK

BK RD WH

C978-BR C979-OR

CRUISE CONTROL SET/RESUME SWITCH

H795-PK

BATTERY +

C992-PU

H795-PK

H795-PK C985-BU C986-BR

J403 P403

B A C

451-BR

450-YL

C973-GN

C974-PU

L902-GN

409-OR

NOTE A

COOLING FAN SOLENOID

PASSIVE MAGNETIC VEHICLE SPEED SENSOR

(N/O - TRANSMISSION IN GEAR)

G808-BU G809-GN

NOTE A

1 2

NOTE A

FLYBACK RESISTOR

TRANSMISSION NEUTRAL SWITCH

G882-WH

NOTE A

14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL

NOTE A

SERVICE BRAKE PEDAL POSITION SWITCH #2

H795-PK

FAST IDLE ENABLE SWITCH

(N/O - PEDAL RELEASED POSITION)

NOTE A

SIGNAL-

SIGNAL+

INTAKE AIR HEATER LAMP

C987-RD

EXHAUST BRAKE ON/OFF SWITCH H795-PK

FLYBACK DIODE

NOTE A

N/O MOMENTARY SWITCH

NOTE A

10A

NOTE A

TACHOMETER

SIGNAL-

NOTE A: INDICATES AN OPTIONAL FEATURE NOT INSTALLED ON ALL CHASSIS

BATTERY +

G844-PK

DIAGNOSTIC ENABLE SWITCH N/O MOMENTARY SWITCH

NOTE A

10A

B A J H G F E D C

EXHAUST BRAKE SOLENOID

10A

J1587 DATA LINK NEGATIVE J1587 DATA LINK POSITIVE J1939 DATA LINK SHIELD J1939 DATA LINK NEGATIVE J1939 DATA LINK POSITIVE

BATTERY + BATTERY -

NOTE A

SIGNAL+

TO INTAKE AIR HEATER RELAY (CONTACT SIDE)

SPEEDOMETER

NOTE A

NOTE A

G880-PK

659-PK

L994-YL

SAEJ1939/13 OFF-BOARD DIAGNOSTIC CONNECTOR

FAST IDLE LAMP OR WAIT TO START LAMP

WARNING LAMP

SERVICE BRAKE PEDAL POSITION SWITCH

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED / OEM INSTALLED

ACCELERATOR PEDAL POSITION SENSOR

K995-OR

(N/C - PEDAL RELEASED POSITION)

C975-WH

CLUTCH PEDAL POSITION SWITCH

H795-PK

C987-RD

TO ALLISON AT/MT/HT TRANSMISSION SHIFT MODULATOR (AUTOMATIC TRANSMISSIONS)

BATTERY 1

- 12V+

CRUISE CONTROL ON/OFF SWITCH

- 12V+

- 12V+

STARTER MOTOR (12V)

ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION

ENGINE BLOCK

GROUND

ALTERNATOR

KEY SWITCH

OFF ON START

N/O RELAY

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

CHECK ENGINE LAMP

100A WITH 130A PEAK AT 11V J648

B A

P1 J1

28 29 31 30 36 37 27 26 3 17 38 39 57 43 9 8 42 34 50 70 48 52 53 55 63 65 67 69 20 10 12 13 15 19 25 16 61 51 35 44 56 58 40 21 59 60 7 45 1 47 64 6 18 22 23 2 46 49 54 62 24 41 14 32 33 68 5 4 66 11

VEHICLE SPEED IN POSITIVE VEHICLE SPEED IN NEGATIVE INPUT #8 (REMOTE PTO ACCELERATOR) AP SENSOR/SWITCH SENSOR COMMON +8V ACCELERATOR PEDAL POSITION OUTPUT #5

INPUT #11

INPUT #5 INPUT #13 INPUT #6 INPUT SENSOR COMMON #1 CLUTCH PEDAL POSITION SWITCH INPUT #19 +5V INPUT #7 ENGINE COOLANT LEVEL NORMAL ENGINE COOLANT LEVEL LOW INPUT #12

SET RESUME INPUT #1 (PTO ON/OFF SWITCH) INPUT #2 INPUT #18 OUTPUT #8 CRUISE CONTROL ON/OFF SWITCH INPUT #3 INPUT #4 SERVICE BRAKE PEDAL POSITION SWITCH

EXHAUST BRAKE ON/OFF SWITCH

OUTPUT #6

J1587 DATA LINK NEGATIVE J1587 DATA LINK POSITIVE J1939 DATA LINK SHIELD J1939 DATA LINK NEGATIVE J1939 DATA LINK POSITIVE IGNITION KEY SWITCH UNSWITCHED +BATTERY UNSWITCHED +BATTERY UNSWITCHED +BATTERY UNSWITCHED +BATTERY -BATTERY -BATTERY -BATTERY -BATTERY OUTPUT #7 OUTPUT #2 OUTPUT #3 OUTPUT #4

INPUT SENSOR COMMON #2 INPUT #14 TACHOMETER POSITIVE TACHOMETER NEGATIVE

CHECK ENGINE LAMP WARNING LAMP OUTPUT #9 OUTPUT #1 SPEEDOMETER POSITIVE SPEEDOMETER NEGATIVE

VEHICLE HARNESS CONNECTOR

G808-BU G809-GN G845-PU H795-PK C985-BU C986-BR G837-YL

E971-GN

G844-PK C983-WH C984-YL 409-OR

G879-OR

G842-GY G882-WH G843-OR L901-GY C977-BU

C978-BR C979-OR K999-GN K980-PK L902-GN G840-PU C975-WH K982-YL G841-GN C992-PU

C981-GY

G838-BR

E718-PK E991-GY G836-WH

G839-BU

229-BK 229-BK 229-BK

101-RD 101-RD 229-BK

E793-BU E794-YL A249-BK K990-GN K900-YL J906-BR 101-RD 101-RD

993-BR F713-OR 450-YL 451-BR

L994-YL 659-PK G880-PK K998-BU C974-PU C973-GN

P2 J2

ENGINE HARNESS CONNECTOR

TO CONNECTOR P648 (ENGINE HARNESS)


Figure 7 - C7 & C9 OEM Diagram

11


3.0 Engine Monitoring The Engine Monitoring system monitors engine coolant temperature, engine oil pressure (optional), coolant level (optional) and Inlet manifold air temperature. C7 and C9 engines are shipped with the Caterpillar coolant temperature sensor and Inlet manifold air temperature sensor. Optional sensors include an engine oil pressure sensor and an OEM supplied coolant level sensor. If a monitored engine parameter exceeds normal conditions, one or more lamps will be turned on and one or more diagnostic codes will be logged. There are three Customer Programmable Levels for the Engine Monitoring Mode parameter. 1) Warning. 2) Derate. 3) Shutdown. 3.1. Engine Monitoring Lamp Options The Check Engine Lamp is a requirement but a Programmable Customer Parameter, Engine Monitoring Lamps, is available to determine what additional lamps are to be turned On if normal engine operating conditions are exceeded. The default option for Engine Monitoring Lamps is Warning Lamp. This default option provides for one lamp output designated as the Warning Lamp and is used for all monitored engine condition warnings. When the Engine Warning Lamps parameter is programmed to Option 1, the lamp outputs are re-designated as follows: J1/P1: 29 (normally used as the Warning Lamp) is used as a Low Oil Pressure Lamp. J1/P1: 30 (normally used as a PTO Enabled Lamp) is used as a Low Coolant Lamp. J1/P1: 31 is used as a High Coolant Temperature lamp. The Check Engine Lamp (J1/P1: 28) is unaffected. NOTE: The Engine Monitoring Lamps parameter is not available for GM trucks. 3.2. Engine Monitoring and OEM Requirements The OEM is responsible for providing and installing lamps and the optional Coolant Level Sensor. The coolant level sensor is programmed through the Customer Programmable Parameter, Coolant Level Sensor. This parameter has a default factory setting of NO. OEM provided and installed components required: 1) Lamp connected to J1/P1: 28 (Check Engine Lamp). 2) Lamp connected to J1/P1: 29 (Warning Lamp or Low Oil Pressure – Warning Lamp programmed to Option1). 3) Lamp connected to J1/P1: 30 (Low Coolant Level – Warning Lamp programmed to Option 1). 4) Lamp connected to J1/P1: 31 (High Coolant Temp – Warning Lamp programmed to Option 1). 5) Coolant Level sensor – 4 Pin, 2 Wire Float Sensor or 2 Pin Switch (GM only). Customer Parameter programming required: 1) Coolant Level Sensor programmed to “4-pin” or “2 Wire Float Sensor”. 2) Engine Monitoring programmed to “Warning”, “Derate”, or “Shutdown”. 3) Warning Lamps programmed to “Warning” or “Option 1”.

12



3.3. Engine Monitoring – Engine Sensors The Engine Monitoring System Engine uses the engine’s sensors to monitor the engine’s operating condition. Limits have been established for each of the engine conditions monitored by these sensors.

3.3.1. Engine Monitoring – Intake Air Temperature Sensor Intake Manifold Air Temperature is monitored to warn the operator of excessive intake manifold air temperature. Excessive intake manifold air temperatures will not cause the ECM to derate or shutdown the engine when Engine Monitoring is programmed to Derate or Shutdown. Intake Manifold Air Temperature must exceed the triggering temperatures for 30 seconds after engine start up before a Diagnostic Code is generated and logged. A High Intake Manifold Air Temperature Warning diagnostic code is triggered at 194°F (90°C), and a Very High Intake Manifold Air Temperature at 230°F (110°C). In addition to the Check Engine Lamp, the Warning Lamp is also turned ON if Engine Monitoring is programmed to Warning, Derate, or Shutdown.

3.3.2. Engine Monitoring – Oil Pressure Sensor The Engine Oil Pressure Sensor is an optional sensor and can be used to automatically protect the engine from operating without sufficient oil pressure. With Engine Monitoring programmed to Warning, the Check Engine Lamp will turn On at the Low Oil Pressure trip point. At the Very Low Oil Pressure trip point the Warning Lamp will be turned On in addition to the Check Engine Lamp. When programmed to Derate the Check Engine Lamp will turn On at the Low Oil Pressure trip point. At the Very Low Oil Pressure trip point the Warning Lamp will flash and the engine will be derated. When programmed to Shut Down the Check Engine Lamp will turn On at the Low Oil Pressure trip point. At the Very Low Oil Pressure trip point the Warning Lamp will flash during engine derate and then the engine will shut down after 30 seconds. The ECM will indicate a Very Low Oil Pressure fault when the Engine Oil Pressure falls below 4 psi (29 kPa) at 750 RPM or below 6 psi (43 kPa) at 800 RPM and higher.

3.3.3. Engine Monitoring – Coolant Temperature Sensor C7 and C9 engines include a Coolant Temperature Sensor as standard equipment. Engine coolant temperature trip points have been established for High and Very High Coolant Temperatures. These trip points are illustrated in the charts on the following pages and are used for logging fault codes. With the Engine Monitoring System programmed to Warning the Check Engine Lamp will turn On at the High Coolant Temperature trip point (110-00). At the Very High Coolant Temperature trip point (110-11) the Warning Lamp will turn On in addition to the Check Engine Lamp. When programmed to Derate, the Check Engine Lamp will turn On at the High Coolant Temperature trip point. The Warning Lamp will flash at the Very High Coolant temperature trip point and the engine will be derated. When programmed to Shutdown, the Check Engine Lamp will turn On at the High Coolant Temperature trip point. The Warning Lamp will flash at the Very High Coolant temperature trip point and the engine will be derated. After 20 seconds the engine will be shut down. The ECM derates available power and limits vehicle speed in steps as temperature increases. Each step represents a reduction in available power and limits vehicle speed as follows: HP REDUCTION = 25% X (rated HP – 120 hp [90 kW]) VSL REDUCTION = 25% X (VSL – 45 mph [72.5 km/h])


13


Available Power, Vehicle Speed

The actual rate of change of HP or VSL reduction is limited to 10% per second maximum.

Rated Power, Full Vehicle Speed Range 110-00 Triggered

120 hp, 45 mph Maximums (90 kW, 72.5 km/h) 110-11 Triggered

107

108

109

110

111

112

Coolant Temperature (C°)


Figure 8 - C7 Truck Trip Points

Rated Power, Full Vehicle Speed Range 110-00 Triggered

120 hp, 45 mph Maximums (90 kW, 72.5 km/h) 110-11 Triggered

112

113

114

115

116

117


Figure 9 - C7 Emergency and C9 Truck Trip Points

14



Coolant Temperature Engine Monitoring Operation – Emergency Vehicle Applications


For C9 emergency vehicle ratings with automatic transmissions, the High and Very High Coolant Temperature trip points are adjusted as indicated below.

Rated Power, Full Vehicle Speed Range

110-00 Triggered

120 hp, 45 mph Maximums (90 kW, 72.5 km/h)

110-11 Triggered

117

118

119

120

121

122


Figure 10 - C9 Emergency Trip Points C9 Coolant Temperature Graph for Emergency Vehicles with automatic transmissions 3.3.4. Engine Monitoring – Coolant Level Sensor The coolant level will be monitored if an optional Coolant Level Sensor is installed and the Customer Parameter, Coolant Level Sensor, is programmed to one of the available options. The OEM is responsible for providing, installing, and programming the ECM to monitor the optional coolant level sensor. Trip points, times or values, have been established for Low and Very Low coolant levels. When programmed to Warning, the Check Engine Lamp will be turned on at the Low Coolant Level trip point and the Warning Lamp will be turned on at the Very Low Coolant Level trip point. When programmed to Derate, the Check Engine Lamp will be turned on at the Low Coolant Level trip point. At the Very Low Coolant level trip point the Warning Lamp will flash and the engine will be derated. When programmed to Shutdown, the Check Engine Lamp will be turned on at the Low Coolant Level trip point. At the Very Low Coolant Level trip point the Warning Lamp will flash and the engine will be derated. After 30 seconds the engine will shut down. 3.3.5. Low Coolant Level During an Engine’s First 6 Hours of Operation If a low coolant level condition is detected during the first six hours of engine operation, an OEM clearable fault (111-14) will be recorded. This delay in logging of low coolant level events will allow OEMs to purge air trapped in the engine’s cooling system during the assembly process. After the engine has logged 6 hours of engine running time, the diagnostic faults and events for Low (111-01) and Very Low Coolant Levels (111-11) will be logged into the ECM’s nonvolatile memory. Service technicians are required to contact Caterpillar for permissions to clear Low (111-01) and Very Low (111-11) Coolant Level events from the ECM’s nonvolatile memory.


15


3.4. Engine Monitoring Programmed to “Warning” Warning is the default setting of the Engine Monitoring System. The ECM monitors Coolant Temperature, Inlet Manifold Air Temperature and the optional Coolant Level or Engine Oil Pressure (if installed). The following table indicates the diagnostic codes available. There is no effect on engine performance when active. The Check Engine Lamp will flash and the Warning Lamp will come ON as indicated in the table when the diagnostic code is active.

16

PIDFMI

Code Description

Trip Point Emergency Vehicle Ratings

Trip Point

Warning Lamp

Derate

100-11

Very Low Oil Pressure 750 RPM 800 RPM and up

4 psi (29 kPa) 6psi (43 kPa)


SOLID

NONE

105-00

High Inlet Manifold Air Temp. Warning

90°C (194°F)

90°C (194°F)

SOLID

NONE

105-11

Very High Inlet Manifold Air Temp.

110°C (230°F)

110°C (230°F)

SOLID

NONE

110-00

High Coolant Temp. Warning

C9 – 113°C (235°F) C7 – 108°C (226°F)

C9 – 118°C (244°F) C7 – 113°C (235°F)

SOLID

NONE

110-11

Very High Coolant Temperature

C9 – 116°C (241°F) C7 – 111°C (232°F)

C9 – 121°C (250°F) C7 – 116°C (241°F)

SOLID

NONE

111-01

Low Coolant Level Warning

SOLID

NONE

111-11

Very Low Coolant Level

SOLID

NONE

111-14

Low Coolant Level Warning (less than 6 Hours)

SOLID

NONE



3.5. Engine Monitoring Programmed to Derate When the Engine Monitoring System is programmed to Derate, the ECM will alter engine performance when operating parameters are exceeded. Whenever the engine is derated, the Check Engine Lamp (due to active diagnostic) and the Engine Warning Lamp will flash. For the DERATE column in the following table, mph indicates vehicle speed is limited (maximum speed is 45 mph [72.5 km/h]), “pwr” indicates engine power is limited (maximum derate is 120 hp [90 kW]), and rpm indicates engine speed is limited (maximum derate is 1350 rpm). For operating conditions causing these codes see the appropriate section for the sensor under consideration. PIDFMI

Code Description

Trip Point

Trip Point Emergency Vehicle Ratings

Warning Lamp

Derate

100-11




FLASH

NONE

105-00


90°C (194°F)

90°C (194°F)

SOLID

NONE

105-11


110°C (230°F)

110°C (230°F)

SOLID

NONE

110-00


C9 – 113°C (235°F) C7 – 108°C (226°F)

C9 – 118°C (244°F) C7 – 113°C (235°F)

FLASH

NONE

110-11


C9 – 116°C (241°F) C7 – 111°C (232°F)

C9 – 121°C (250°F) C7 – 116°C (241°F)

FLASH

NONE

111-01


SOLID

NONE

111-11


FLASH

NONE

111-14

Low Coolant Level Warning (less than 6 Hours)

FLASH

NONE


17


3.6. Engine Monitoring Programmed to Shutdown The following table indicates the active diagnostic codes capable of shutting down the engine when the ECM is programmed to Shutdown. The “Time to Shutdown, Engine running > 30 Sec” column indicates the minimum time before the engine will shutdown if the engine has already been running for at least 30 seconds. The “Time to Shutdown, Fault Code at Start/Restart” column is running time if the code is active when the engine starts, or following an Engine Monitoring caused shutdown. “NO” indicates the code will not shutdown the engine. Note: These times assume the condition causing the code exists continuously and is not intermittent.

18

PID-FMI

Code Description

Time To Shutdown Engine running > 30 Sec

Time to Shutdown Fault Code at Start/Restart

100-11


30 Sec

18 SEC

105-00


NO

NO

105-11


NO

NO

110-00


NO

NO

110-11


30 Sec

60 Sec

111-01


NO

NO

111-11


30 Sec

60 Sec

111-14

Low Coolant Level Warning less than 6 Hours)

30 Sec

60 Sec



OEM INSTALLED COMPONENT REQUIREMENTS and FEATURES All of the functions described in the following text are available or enhanced if the vehicle OEM provides and installs the appropriate components. The components required for each feature are listed with the particular feature description. It is assumed the associated wire harness necessary for component connection is part of the component.

4.0 Power and Grounding Requirements and Considerations The ECM requires unswitched power and ground connections. An Ignition Key Switch input is used to turn the ECM ON, allowing the engine to start and run.

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS OFF ON ST.

BAT. MTR. ALTERNATOR

STARTER MOTOR (12V)

GND.

ADEM 3 ECM

10 A

- 12V +

- 12V +

ENGINE BLOCK

- 12V +

J906-BR

70

101-RD 101-RD 101-RD 101-RD 229-BK 229-BK 14 AWG 229-BK 229-BK

48 52 53 55 63 65 67 69

14 AWG

IGNITION KEY SWITCH UNSWITCHED +BATTERY UNSWITCHED +BATTERY UNSWITCHED +BATTERY UNSWITCHED +BATTERY -BATTERY -BATTERY -BATTERY -BATTERY

P1 J1

Wiring Diagram 1 - Preferred Wiring Medium Duty ACERT Engine Battery Wiring For C7 & C9


19


4.1 Grounding Proper grounding for vehicle and engine electrical systems is necessary for proper performance and reliability. Improper grounding results in unreliable electrical circuit paths. Stray electrical currents can damage main bearings, crankshaft journal surfaces, and aluminum components. They can also cause electrical noise degrading control system, vehicle, speedometer, and radio performance. These problems are often very difficult to diagnose and repair. All ground paths must be capable of carrying any conceivable fault currents. An AWG # 4 or larger cable is recommended between the engine ground stud and the frame or starter negative post to handle alternator currents. A maximum of three ring terminals are to be connected to the engine ground stud to insure ground connection integrity. More than three terminals can cause the stud to loosen too easily. Caterpillar recommends splicing like size wires together as a method of reducing ring terminal congestion at the ground stud.

Optional Engine Ground Stud Location

Engine Ground Stud

Engine Ground Wire

Chassis Frame Rail

Starter

+

Battery

Figure 11 - Ground Stud to Frame Rail

20



Optional Engine Engine Ground Ground Stud Stud Location

Engine Ground Wire

Chassis Frame Rail

+

Battery

Starter

Figure 12 - Ground Stud to Starter Ground Points for C9 Engines

Figure 13 Note: C9 Ground Points are different from C7. Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____

21


4.2 Engine Connection To Vehicle Battery Ground To insure proper functioning of the vehicle and engine electrical systems, there must be a direct wire path from the engine ground stud to the battery negative post. Caterpillar prefers this connection route through the starter negative post. In Figure 13 and Figure 14 an additional ground stud location is identified, either location can be used. A connection routed to a main frame ground, can also be made if the following guidelines are followed: 1) Connections to the frame must not be made with star washers. Star washers should not be counted on to remove paint from painted surfaces. Use flat washers for this connection, with the paint completely removed in this area. 2) Any paint must be completely removed from the frame rail at the point where the connection is made. Failure to do so reduces the effectiveness of the connection. 3) The ground path is not made through frame cross members. Bolted connections of frame cross members may not always provide required continuity for this critical connection. 4) Conductive grease or other methods used to reduce/eliminate the affect of corrosion on the frame rail connection. 5) Caterpillar does not recommend a connection from the engine ground stud to the main frame rail at a connection point different than where the battery ground connection is made. A two-point frame rail connection method depends on frame rail connections. Manufacturing process control of frame rail connections is difficult to control. This multiple frame rail connection scheme is also more difficult to troubleshoot. 4.3 ECM Negative Battery Connections Caterpillar requires the OEM to install the ECM “-Battery” wires into their harness connector. These connections should be #14 AWG GXL wire.

4.3.1 Engine Ground Stud C7 and C9 engines use a M8 X 1.25 Thread stud with a 20 mm stud length located on the cylinder head. The stud has two washers and properly sized nut supplied for attaching all OEM supplied ground terminals. 4.4 Electric Starting Motors The truck engine starting system must be able to crank the engine at sufficient speed for fuel combustion to begin normal firing and keep the engine running. This requires adequate battery capacity, a starting motor, and cables to connect the battery to the starter. The following must be observed in order to obtain a satisfactory installation: Electric starting motors must be 12 or 24 volt DC and use a positive engagement pinion drive which engages with the flywheel ring gear before the motor begins to turn. Air or hydraulic starters may also be used. 4.5 Sensor Common Connections Only those components interfacing directly to the ECM should be connected to the ECM Sensor Common connections. ECM Connector P1 terminal-5 should be used to connect the ground side of the following engine control connected items: cruise control switches, clutch pedal position switch, fast idle enable switch, 1 service brake pedal position switch #1, A/C High Pressure switch, and the accelerator pedal position sensor. These components must not be connected to any vehicle ground. Additional Sensor Common connections are also available. ECM terminal-18 (Input Sensor Common #1) and terminal-3 (Input Sensor Common #2) can be used if required by the harness design, for example, to splice all cab components together at terminal-5, and engine compartment components at terminal-18 or terminal-3. Caterpillar recommends that Input Sensor Common #2 remain open for Aftermarket/Body Builder connections. If additional Sensor Common connections are required, please contact Caterpillar. All switches connected to the control system must be externally grounded, two-wire design. Internally grounded or case grounded switches must not be used.

22



OEM installed components used as inputs to the ECM must not be connected to the vehicle or cab ground, and must not be case grounded. OEM installed switches must be grounded to an ECM Sensor Common via a dedicated return line to the ECM. Terminal Description

ECM Terminal Assignment

AP Sensor/Switch Sensor Common

J1/P1: 5

Input Sensor Common #1

J1/P1: 18


J1/P1: 3

4.6 Suppression Of Voltage Transients and Electrical Noise Caterpillar recommends transient suppression be installed at the source of the transient in addition to the suppression in the ECM. Caterpillar controls are designed to comply with SAE J1455. The use of inductive devices such as relays and solenoids can result in the generation of voltage transients on the battery lines. Unsuppressed voltage transients can exceed SAE J1455 specifications and degrade control system performance. Some specific devices that should use transient suppression are fan clutch solenoids, A/C clutch solenoids, and all relays. This is not an all-inclusive list. The OEM should specify relays and solenoids with built-in voltage transient suppression on the vehicle where possible. The following illustration provides several possible suppression techniques to minimize the generation of voltage transients from relays and solenoids without built-in voltage transient suppression. These 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 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.

Power

Power Power

Power

Figure 14 - Examples of Voltage Transient Suppression


23


4.6.1 EMI/RFI Testing Caterpillar EMI/RFI testing on C7 and C9 engines is performed at both the component and system level. Component level testing is performed in a TEM cell and screen room. This radiated susceptibility testing is performed using the substitution method. In-vehicle radiated susceptibility testing is also performed. 4.7 ECM Positive Battery Connections The positive battery connection to the C7 or C9 ECM must be made through a dedicated and unswitched circuit of 4 individual #14 AWG wires capable of a continuous duty load of 30 Amperes at 9 volts DC. Recommended fusing is 10 Amperes for each wire for a total of 40 amperes. The four required unswitched positive battery connections are terminals 48, 52, 53 and 55. Caterpillar prefers the circuit protection be located in the cab if possible. On vehicle documentation for the circuit protection should be provided for none cab locations. In the event of a charging system failure, the engine will operate with a supplied voltage of 9 Volts DC. At this voltage level the engine will draw up to 30 amperes. Fusing the unswitched battery wiring with less than the stated fusing recommendation of 40 Amperes can result in blown fuses and an unexpected engine shutdown due to a failed vehicle charging system. In addition to suppressing inductive loads, powering the ECM on a dedicated fused circuit will reduce the possibility of degraded control system performance due to voltage transients. No additional loads should be connected between the ECM and ECM circuit protection. The ECM monitors the battery supply voltage and will trigger a diagnostic code if this voltage drops below and then returns above 6 Volts DC. 4.8 Voltage Requirements and Considerations The control system has been designed to operate on 12 Volt or 24 Volt electrical systems. The control system is protected against jump start conditions and short circuits to positive battery and negative battery. Minimum voltage requirements and maximum current draw for the C7 and C9 control system are as follows: Condition

Minimum Voltage

Maximum Current Draw

Normal Operation

11.0 VDC

22.0 Amperes

Engine Cranking

6.0 VDC

16 Amperes

Ignition Key On, Engine Off **

9.0 VDC

20 Amperes

Electrical Charging System Failure

9.0 VDC

30 Amperes

**This condition includes the Inlet Air Heater Relay and HEUI injector solenoid cycling during cold weather conditions. Minimum voltages are specified at the OEM connector (P1 – terminals 48, 52, 53, 55 referenced to P1 – terminals 63, 65, 67, 69). 4.9 ECM Current Draw with Ignition Key Off The ECM draws less than 20 mA while the Ignition Key Switch is in the OFF position. 4.10 Welding on a Vehicle Equipped with a C7 or C9 Engine Before welding on a vehicle equipped with an electronic engine, the following precautions should be observed. 1. Turn the engine OFF. Place the ignition key switch in the OFF position. 2. Disconnect the negative battery cable from the battery. If the vehicle is equipped with a battery disconnect switch, open the switch.

24



3. Clamp the ground cable of the welder to the component that will be welded. Place the clamp as close as possible to the weld. 4. Protect any wiring harnesses from welding debris and spatter. Use proper welding procedures in order to weld the materials. NOTICE DO NOT use electrical components in order to ground the welder. Do not use the ECM or sensors or any other electronic component in order to ground the welder. Clamp the ground cable for the welder to the component that will be welded. Place that clamp as close as possible to the weld. This will reduce the possibility of damage to the bearings of the drive train, hydraulic components, ground straps, and other components of the vehicle.

1

31

1

32

41

13

42

93 74

23 04

75

84 85

07

2

3

4

5

6

8

> PEI<

14

23 31

24 35

36

40

47

48

57

58 59 60 61 62 63

ECM Side

9 10 11 12 13

65 66 67 68 69 70

Harness Side

Front of Engine

OEM Connector J1

Engine Connector J2

Figure 15 - ADEM 2000TM ECM and Wiring Harness Connectors


25


5.0 Connectors and Wiring Harness Requirements 5.1 ECM Connector Caterpillar does not recommend the use of “non-conductive grease” with the ECM connector.

5.1.1 70 Terminal ECM Connector Part Numbers The ECM uses an integral rectangular 70 Terminal AMP connector to interface to the OEM vehicle wiring harness (AMP part number 776241-1, Caterpillar part number 160-7689). The ECM also uses a 70 Terminal AMP connector to interface to the engine electronics (AMP part number 776241-2, Caterpillar part number 160-7690).

5.1.2 ECM 70 Terminal Connector Allen Screw Torque ECM Connector Screw torque should be 6 N•m ±1 N•m (4.4 lb.- ft. ± 0.7 lb.- ft., 53 lb. - in. ± 8.9 lb. - in.). 5.2 ECM Connector Wire Gauge Size The battery positive and negative connections must be made with #14 AWG SAE J1128 type GXL wire for the AMP 776093-1 stamped and formed terminal or the Deutsch 0462-209-1631 solid terminal. All other connections may be #16 SAE J1128 type SXL or GXL or #18 AWG SAE J1128 type SXL (or equivalent wire).

5.2.1 ECM 70 Terminal Connector Wire Insulation and Size Range Insulation material is cross – linked polyethylene. Outside diameter insulation range is 2.26 to 3.33 mm (0.089 to 0.131 in.). The following table provides insulation diameter range for each gauge and wire type. ECM Connector Wire Insulation and Gauge Size Wire Type

GXL

SXL

Wire Gauge

Insulation Diameter

14

0.114 - 0.125

16

0.098 - 0.112

18

0.089 - 0.098

16

0.116 - 0.131

18

0.103 - 0.118

5.3 ECM Connector Terminals and Sealing Plugs The OEM connector socket terminals must be compatible with the wire size used. All unused connector socket slots must be filled with plugs to insure connector sealing. Note: Do not use “non-conductive” grease to seal unused terminal cavities.

26



5.3.1 ECM 70 Terminal Connector Terminals The following table provides terminal and plug part numbers. All terminals used in the ECM connectors must be gold or selective gold flash terminals. Required ECM 70 Terminal Connector Parts Description

Usage

Vendor – Part Numbers

Caterpillar Part Numbers

70 Terminal Plug, Keyed

OEM Vehicle Harness

AMP – 776241-1

160-7689

AMP Gold Socket Contact (stamped & formed)

#16 & #18 AWG SXL and #14, #16 & #18 AWG GXL wire

AMP – 638090-1

126-1766

Deutsch Gold Socket Contact (machined-for field service)

#14 AWG SXL and #14 AWG GXL wire

Deutsch – 0462-209-1631

126-1768

Deutsch Gold Socket Contact (machined-for field service)

#16 & #18 AWG SXL and #16 & #18 AWG GXL wire

Deutsch – 0462-201-1631

9X-3402

Sealing Plug #14 – 18 AWG

Unused Connector Cavities

PEI Genesis – 225-0093-000

9G-3695

Sealing Plug #14 – 18 AWG

Unused Connector Cavities

Deutsch – 114017

8T-8737

5.3.2 ECM Connector Terminal Installation Guidelines Two options are available for AMP terminals. It is critical the harness supplier use the correct crimp tools and tool calibration/setup procedures, when selecting AMP and Deutsch connector terminals. The following tables indicate proper crimp tooling, go-no-go criteria, and crimp dimensions for each contact- wire combination. *AMP 776093-1 Stamped & Formed Socket with #16 and #18 AWG SXL Wire or with #14, #16 or #18 AWG GXL Wire (Caterpillar P/N 126-1766) Wire Type

Wire Gauge

Crimp Height (+/- 0.002 In)

Crimp Width (in)

GXL

14

0.064

0.100

16

0.059

0.100

18

0.054

0.100

16

0.054

0.100

18

0.059

0.100

SXL

*Insulation barrel crimp height for AMP 776093-1 stamped and formed sockets must be set according to the insulation diameter. Crimp width for all insulations is 0.145 inches maximum.


27


Deutsch 0462-209-1631 Solid Socket with #14 AWG Wire (Caterpillar P/N 126-1768) Crimp Tool Options

DIE

Locator

GO

No – GO

Deutsch Hand Tool HDT-48-00

N/A

N/A

0.045

0.057

Pico Model 400

4301-16

414DA- 16N

0.043

0.50

Deutsch 0462-209-1631 Solid Socket with #16 and #18 AWG Wire (Caterpillar P/N 9X3402) Crimp Tool Options

DIE

Locator

GO

No – GO

Deutsch Hand Tool HDT-48-00

N/A

N/A

0.045

0.050

Pico Model 400

414DA- 16N

4301-16

0.043

0.50

5.3.3 ECM 70 Terminal Connector Sealing Plugs Two options are available for plugging unused connector cavities. Either the Deutsch 114017 (Caterpillar part number 8T-8737) or PEI Genesis 225-0093-000 (Caterpillar part number 9G-3695) sealing plugs can be used. Correct installation of either of these cavity plugs is critical to maintain connector socket seal integrity. The plug cap is designed to rest against the seal, not inserted in the hole in the seal. Note: Do not use “non-conductive” grease to seal unused cavities.

Correct

AVOID

Figure 16

28



5.3.4 Connector Interface Seal The ECM Connector Interface seal is serviceable using Caterpillar part number 159-9322.

Connector Interface Seal

1

31 32

41

13

42

93

23

74

04

75

84

07

85

Figure 17 - ECM 70 Terminal Interface Seal 5.4 Sealing Splices and Ring Terminals Caterpillar requires all ring terminals and splices connected to the Engine ECM be sealed using Raychem ES2000 or equivalent. This reduces moisture invasion under wire insulation.


29


5.5 OEM Harness Routing Routing of the harness should insure connector seals are not stressed because the harness curvature is too close to the connector. This applies to routing of OEM lines on or near the engine harness as well as the OEM ECM Connector. The following graphic 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 before curving as necessary for routing. The harness bundle should have a bend radius greater than twice the harness diameter. This routing practice will also ensure the harness is not pulled too tightly resulting in intermittent connections or broken harness wires. Caterpillar recommends the OEM harness supplier perform the harness to provide the correct bend radius, assuring connector sealing and preventing harness abrasion.

AVOID Correct

Figure 18

End Bell

Engine Connector

OEM Connector

Figure 19 - 70 Terminal ECM Connector with Endbell

30



5.5.1 ECM Connector Endbell An AMP 638092-1 (Caterpillar part number 126-1774) Connector Endbell is available to provide additional protection and controlled wire routing for the harness at the ECM.

5.5.2 Twisted Pair Wiring Twisted pair wiring must be used for the SAE J1587 Data Link, and input or output with a differential signal such as the vehicle speed signal wires. There should be a minimum of one twist per inch within the harness. All twisted pair wires should not be twisted within an inch of the connector to avoid seal stress. The speedometer and tachometer outputs, and any other differential input or output circuit, should also use twisted pair wiring. SAE J1939 Data Link wiring should comply with SAE J1939/11 specifications.


31


6.0 Accelerator Pedal Position Sensors The accelerator pedal position sensor converts the mechanical accelerator pedal position into an electrical signal for the ECM. Caterpillar requires one of the sensors described in this document for use with an accelerator pedal.

Figure 20 - 204-7949 or 204-7950 Accelerator Pedal Position Sensor with Deutsch DT Connector

Figure 21 - 204-7951 Accelerator Pedal Position Sensor with Packard Connector The accelerator pedal position sensor is designed to comply with FMVSS124 (Federal Motor Vehicle Safety Standard 124). The sensor also meets the SAE J1843 Recommended Practice. 204-7949, 204-7950, and the 204-7951sensors mount directly to the accelerator pedal. This eliminates the need for accelerator pedal linkages and OEM adjustments. These sensors are designed to operate from the ECM + 8V supply. The 204-7949 (32 inch [81 cm] harness with Deutsch connector), 204-7950 (6 inch [15 cm] harness with Deutsch connector), and the 204-7951 (6 inch [15 cm] harness with Packard connector) use the same sensor but have different connectors or pigtail lengths as described.

32



6.1 Accelerator Pedal Position Sensor Electrical Specifications The sensor output is a constant frequency signal whose pulse width (duty cycle) varies with accelerator pedal position. The Pulse Width Modulated (PWM) signal is expressed as a percentage (percent duty cycle) as shown in Figure 21.

25% Duty Cycle

75% Duty Cycle Figure 22 - Example PWM Signals 6.2 Accelerator Pedal Position Sensor Duty Cycle The Accelerator Pedal Position Sensor (APP Sensor) mounts directly to the pedal and should not be adjusted by the OEM. The OEM must insure that pedals supplied by the pedal manufacturer meet the following specification for sensor output duty cycle. Accelerator pedal position

Duty Cycle

Low Idle

10% - 20%

High Idle

75% - 90%

The pedal assembly should also conform to SAE J1843. NOTE: The ECM automatically calibrates (auto-cal) new duty cycle values for the Low Idle and High Idle throttle positions each time the ECM is powered. The ECM initially assumes 22 percent duty cycle is low idle and 75 percent duty cycle is high idle. As a result, the Throttle Position Status may reach 100 percent well before the accelerator pedal is fully depressed. This is normal operation and will continue until the ECM learns the limits of the low and high idle stops. Following some cycling of the accelerator pedal from the low to the high idle positions, the ECM will adjust its calibration automatically, provided the high idle stop position is within the 75 to 90 percent duty cycle range, and the low idle is in the 10 to 22 percent duty cycle range. During normal operation it may initially require more accelerator pedal movement for the Throttle Position Status to increase above 3 percent (low idle) and the Throttle Position Status may reach the 100 percent (high idle) value prior to the limit of the high idle position. This is done to ensure the throttle reaches these two critical points for engine operation. As the ECM learns the physical limits, the range is expanded as long as it is within the values specified above. If the Duty Cycle value goes outside of the expected range, a diagnostic code will be activated.


33


NOTE: There is no direct correlation between the Sensor Duty Cycle value and a Desired Engine RPM. For example, it is not possible to input a 50% duty cycle value and expect the engine to operate at 1800 rpm. This is due to the Auto-Cal function which constantly calibrates for the low and high idle stop positions. 6.3 ECM +8V Cab Accelerator Pedal Position Sensor Supply This sensor supply is designed to provide power for connection to OEM installed Cab Accelerator Pedal Position Sensor (+8V). No other vehicle components may be connected to this supply. 6.4 Accelerator Pedal Position Sensor Connections The 204-7949 accelerator pedal position sensor is designed to operate on 8 Volts DC supplied by the ECM. The ECM supplied +8V, AP Sensor/Switch Sensor Common, and Accelerator Pedal Position wiring must be connected to the control system through an OEM harness. Current draw for the sensor is less than 40 mA. AP Sensor/Switch Sensor Common must not be connected to the vehicle cab ground. Connecting AP Sensor/ Switch Sensor Common to the vehicle cab ground can degrade control system performance. AP Sensor/Switch Sensor Common must be connected to the ECM at the OEM connector (P1 terminal-5) via a dedicated return line. Connector terminal assignments are as follows: Sensor Terminal Assignment


Terminal Description

Terminal A

J1/P1: 4

+ 8 VDC

Terminal B

J1/P1: 5

AP Sensor Common

Terminal C

J1/P1: 66

Accelerator Pedal Position

6.5 Accelerator Pedal Position Sensor Connectors

6.5.1 Three Terminal Deutsch Mating Connector The 204-7949 (32 inch [81 cm] harness) and 204-7950 (6 inch [15 cm] harness) Accelerator Pedal Position Sensors require a Deutsch DT06-3S-EP04 (Caterpillar part number 3E-3367) mating connector plug with a Deutsch W3S (Caterpillar part number 3E-3368) connector plug wedge.

Figure 23 - Three Terminal Accelerator Pedal Position Sensor Deutsch DT Connector 34



6.5.2 Deutsch Connector Wire Gauge Size The connections may be made with #16 or #18 AWG SAE J1128 type SXL (or GXL) or equivalent wire.

6.5.3 Deutsch Connector Wire Insulation Size Range Outside diameter insulation range is 2.24 mm to 3.81 mm (0.09 to 0.15 in.)

6.5.4 Three Terminal Packard Electric Mating Connector The 204-7951 Accelerator Pedal Position Sensor (6 inch [15 cm] harness) requires a Packard Electric Division 12110293 (Caterpillar part number 124-5641) mating connector.

Figure 24 - Three Terminal Accelerator Pedal Position Sensor Packard Electric Connector 6.5.5 Packard Electric Connector Wire Gauge Size The connections may be made to 204-7951 with #18 AWG SAE J1128 type SXL (or GXL) or equivalent wire.

6.5.6 Packard Electric Connector Wire Insulation Size Range Outside diameter insulation should be 2.80 mm (0.11 in.).

6.5.7 Accelerator Pedal Position Sensor Three Terminal Connector Terminals The following table provides terminal part numbers. Required Connector Parts Description

Usage

Part Numbers

Caterpillar Part Numbers

3 Terminal Plug and Seal

APP Sensor Connector

Deutsch DT06-3S-EP04

3E-3367

3 Terminal Plug Wedge

APP Sensor Connector

Deutsch W3S

3E-3368

Socket Contact (machined)

#16 OR #18 AWG Wires

Deutsch 0462-201-16141

8T-8730

Socket Contact (stamped & formed)

#18 AWG Wires

Deutsch 1062-16-0122

115-1051

3 Terminal Plugs

APP Sensor Connectors

Packard 12110293

124-5641

Socket Terminal

#18/#20 AWG Wires

Packard 12048074

124-5640


35


6.6 Accelerator Pedal Position Sensor for Remote PTO Applications Caterpillar recommends the 161-8906 accelerator pedal position sensor for remote PTO applications. The sensor provides the same type of signal as the 204-7949, 204-7950, and the 204-7951 sensors, but requires battery voltage (12 or 24 volt systems) to operate. This Sensor must NOT be connected to the +8V supply intended for the Cab Sensor, nor can the Cab Sensor be connected to a +12 Volt supply.

Figure 25 - 161-8906 Accelerator Position Sensor with Deutsch HD Connector 6.6.1 PTO Accelerator Position Sensor Connector The 161-8906 is supplied with a 3-terminal Deutsch HD plug connector (HD16-3-96S, Caterpillar P/N 8T-8731). The connecting harness will require a Deutsch HD receptacle connector (HD14-3-96P, Caterpillar P/N 8T-8732).

6.6.2 Mounting the Remote Accelerator Position Sensor The 161-8906 Accelerator Pedal Position Sensor can be attached to either an accelerator pedal assembly (contact the vehicle OEM for parts) or a Caterpillar 107-2281 PTO Accelerator Assembly. The PTO Accelerator Assembly does not include a handle. It may be used in applications where a mechanical linkage is required. The accelerator position sensor mounts directly to the PTO Accelerator Assembly and does not require additional sensor calibration.

(Sensor Not Included)

(Handle Not Included)

Figure 26 6.6.3 Remote Accelerator Position Sensor Assemblies Two Remote Accelerator Pedal Position Sensor Assembly packages are available from Caterpillar that include the 161-8906 sensor and mounting hardware. The 134-0597 assembly provides the 161-8906 sensor mounted to a control arm lever. The 134-0670 assembly provides the 161-8906 sensor mounted to an adjustable dial mechanism, which can be automatically reset to the low idle position or locked into place at a specific position. NOTE: The Remote Throttle PTO Configuration requires the Remote Throttle to be returned to the Low Idle position upon engine start up, in order for Remote Throttle control to be provided. If the engine is started with the PTO Switch ON and the Remote Throttle at a position above Low Idle, the engine will be limited to Low Idle until the Throttle is cycled to the low idle position.

36



134-0597 Remote Accelerator Assembly

134-0670 Remote Accelerator Assembly

Figure 27 6.6.4 Remote Accelerator Position Sensor PWM Input Input #8 (terminal-68) is available for use as a Remote Accelerator Input for Remote Throttle PTO applications. OEM provided and installed components required: 1) Throttle Sensor 2) Accelerator pedal or other mechanical linkage. Customer Parameter programming required: 3) PTO Configuration programmed to Remote Throttle. 4) PTO On/Off circuit

6.6.5 Remote Accelerator Pedal Sensor Input Electrical Specifications All signal requirements are identical to those outlined for 204-7949 except the 161-8906 sensor requires connection to battery voltage (12 VDC or 24 VDC) instead of the ECM supplied 8 VDC. 6.6.6 Remote Accelerator Pedal Sensor Common Connections Three different Sensor Common terminals can be used (J1/P1: 3, 5 or 18) to ground the Remote Accelerator Pedal Position Sensor to the ECM. However, Caterpillar recommends that Input J1/P1: 3 remain open for aftermarket/body builder installation.


37


7.0 Vehicle Speed Input Circuit Vehicle speed information is a requirement for many features. These would include: a) Cruise Control b) PTO Control with Vehicle Speed Limit kickout c) Idle Control with Vehicle Speed Limit kickout d) Vehicle Speed Limiting e) Vehicle Speed Limit Protection f) Upshift Engine Speed Control g) Progressive Shifting h) Idle Shutdown Timer i) Inlet Air Heater j) ECM Controlled Speedometer k) Trip Recorder Functions l) Secure Idle – Theft Deterrent If the application does not require any vehicle speed related features, the vehicle speed circuit may not be required. If the Vehicle Speed Input is not used, the VSL Protection Parameter should be programmed to 2640 rpm to prevent any Vehicle Speed Faults from occurring during engine operation. 7.1 General Vehicle Speed Source Requirements for Passive Speed Sensor Input Caterpillar recommends using single coil passive magnetic speed sensors for the vehicle speed sensor detecting speed via a transmission chopper wheel. The sensor should connect directly to the ECM using twisted pair wiring. The vehicle speed sensor must detect vehicle speed directly from the transmission output shaft. The source should be a rigid chopper wheel immune to noise inducing vibration. Caterpillar does not recommend use of less rigid tone wheel rings using magnetic disks to provide the change in magnetic flux for the vehicle speed source. This arrangement is prone to vibration induced electrical noise. The sensor must not be detecting vehicle speed through a system that uses a cable linkage such as a mechanical speedometer drive to the transmission output shaft. The cable will tend to wind up, causing opposing ends to deviate erratically from each other. This twisting results in erratic fluctuations in the vehicle speed signal, causing cruise control/PTO and Vehicle Speed Limit malfunctions. Caterpillar will accept a vehicle speed from the SAE J1939 Data Link. Caterpillar will not accept vehicle speed from the SAE J1587 Data Link for control system purposes. Because vehicle speed is critical to cruise control operation, any unnecessary and erratic signal delays are unacceptable, as well as the reduced accuracy associated with SAE J1587 vehicle speed sources. The signal frequency from the vehicle speed source should be between 0 and 5.3 kHz. OEM provided and installed components required: 1) Passive Vehicle Speed Sensor, or Electronic Speed Source. Customer Parameter programming required: 1) Vehicle Speed Calibration parameter must be programmed to correct Pulses Per Mile setting. 2) Vehicle Speed Input parameter must be programmed to J1/P1: 32 & 33 (Default) hardwired sensor option.

38



7.2 Passive Magnetic Vehicle Speed Sensor Electrical Requirements The passive vehicle speed sensor must be a magnetic sensor with the sensor output signal resulting from variation in magnetic flux. Output voltage from the sensor at the ECM (at connector P1 terminals 32 and 33) should not be less than 0.70 Volts peak to peak (referenced to the ECM connector battery terminals) when vehicle speed is greater than 2 mph. The ECM Vehicle Speed Input can withstand up to a 100 Volt peak-to-peak input signal. Twisted pair wiring should be used to connect the vehicle speed sensor to the ECM. Caterpillar recommends a minimum of one twist per inch. 7.3 Passive Magnetic Vehicle Speed Circuit Options

Option 1 – One Single Coil Speed Sensor One single coil speed sensor with the ECM Speedometer output supplying the speedometer input signal.

SIGNAL+ SPEEDOMETER SIGNAL-

ECM

VEHICLE SPEED SENSOR VEHICLE SPEED + VEHICLE SPEED -

1 2

C974-PU C973-GN G808-BU G809-GN

36 37 32 33

SPEEDOMETER + SPEEDOMETER VEHICLE SPEED IN + VEHICLE SPEED IN -

P1 J1

Wiring Diagram 2 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed Sensor and ECM Speedometer Output for Speedometer Option 2 – One Single Coil Speed Sensor One single coil speed sensor, with the ECM J1587 Data Link output supplying the speedometer input signal.

SPEEDOMETER

J1587 DL+ J1587 DL-

ECM


1 2

E794-YL E793-BU G808-BU G809-GN

8 9 32 33

J1587 DATA LINK + J1587 DATA LINK VEHICLE SPEED IN + VEHICLE SPEED IN -

P1 J1

Wiring Diagram 3 - Vehicle Speed Circuit Using One Single Coil Vehicle Speed Sensor and Data Link for Speedometer Option 3 – Separate Single Coil Speed Sensors Using two speed sensors, one for the speedometer and one for the ECM, completely isolates the two circuits.


39


SIGNAL+

VEHICLE SPEED + VEHICLE SPEED -

SIGNAL-


1 2

SPEEDOMETER ECM 36 37 32 33

C974-PU C973-GN G808-BU G809-GN


P1 J1

Wiring Diagram 4 - Vehicle Speed Circuit Using Two Single Coil Vehicle Speed Sensors 7.4 Dual Coil Speed Sensor Dual coil magnetic speed sensors are not recommended because of the increased risk of electrical noise coupling into the engine control vehicle speed circuit. Ground noise from the circuit connected to the speedometer ground will be coupled into the vehicle speed circuit of the engine control degrading system performance. 7.5 Automatic Transmissions with Electronic Vehicle Speed Source Some electronically controlled transmissions do not have a passive magnetic vehicle speed signal available. For these transmissions follow guidelines indicated below. When a single ended signal is used, a signal with amplitude greater than 4.0 volts is required for the ECM vehicle speed input. NOTE: Proper grounding is required to ensure the ECM Vehicle Speed Input Signal is of the same ground potential as the ECM ground reference. Improper grounding may result in lost or intermittent vehicle speed signals.

SIGNAL+ SPEEDOMETER

SIGNAL-

ELECTRONIC VEHICLE SPEED SOURCE VEHICLE SPEED

ECM C974-PU C973-GN G808-BU G809-GN

36 37 32 33


P1 J1

Wiring Diagram 5 - Vehicle Speed Circuit with Allison Electronic Transmission 7.5.1 Allison Electronic Transmissions Connect the single ended vehicle speed signal line to the ECM “Vehicle Speed In +” (P1 terminal-32). Leave ECM “Vehicle Speed In -” (P1 terminal-33) unconnected (DO NOT Connect to Ground). No other devices should be receiving vehicle speed from the Allison Vehicle Speed line providing vehicle speed to the Caterpillar ECM. Caterpillar recommends using the Caterpillar ECM Speedometer Driver for the speedometer signal or the SAE J1587 Data Link.

40



7.6 J1939 Transmission Output Shaft Speed Based Vehicle Speed Source The ECM can be configured to receive Vehicle Speed Information from an Electronic Transmission Control Unit via the J1939 data link. The Transmission must be capable of supporting the J1939 ETC1 Broadcast Message (PGN 61,442 Bytes 2&3), which provides transmission output shaft speed. The OEM is responsible for determining if the transmission is capable of supporting the required message protocol. This feature also requires the necessary J1939 data link hardware to be installed in chassis. When configured for the J1939 option, the ECM Vehicle Speed Input Circuit (terminals 32 & 33) will be ignored. The ECM uses the Vehicle Speed Cal (J1939-Trans) parameter value to calculate vehicle speed, based on the programmed value and the output shaft speed (received over the J1939 data link). The Vehicle Speed Cal (J1939-Trans) setting is based on Output Shaft revolutions per mile. The OEM is responsible for determining the specific value for any given chassis. There are several methods to arrive at this value: Vehicle Speed Cal (J1939-Trans) = Transmission Output Shaft revolutions per mile Transmission Speed Sensor pulse per mile Vehicle Speed Cal (J1939-Trans) = Number of Teeth on Output Shaft Chopper Wheel Vehicle Speed Cal (J1939-Trans) = (Tire revolutions per mile) x (Axle Ratio) OEM provided and installed components required: 1) Transmission ECU capable of supporting required J1939 message protocol. 2) J1939 Vehicle Data link. Customer Parameter programming required: 1) Vehicle Speed Cal (J1939-Trans) parameter must be programmed for correct Trans Output Shaft revs per mile. 2) Vehicle Speed Input parameter must be programmed to J1939-Trans option. 7.7 J1939 ABS Wheel Speed Based Vehicle Speed Source The ECM can be configured to receive Vehicle Speed Information from an Antilock Brake System (ABS) via the J1939 data link. The ABS must be capable of supporting the J1939 High Resolution Wheel Speed Broadcast Message (PGN 65,134 Byte 5-8), which provides wheel speed from the two rear wheels. The OEM is responsible for determining if the ABS is capable of supporting the required message protocol. This feature also requires the necessary J1939 data link hardware to be installed in the chassis. The ABS will broadcast the ASSUMED tire revolutions per mile. If this value is the ACTUAL tire revolution per mile, the calibration value will be one (1.0) If the ASSUMED tire revolutions per mile is not the same as the ACTUAL tire revolutions per mile, then the cal factor can be calculated in the following manner. ABS Assumed tire revolutions per mile = 500 Actual Tire revolutions per mile = 400 Vehicle Speed Cal = 400/500 = 0.800 OEM provided and installed components required: 1) ABS capable of supporting required J1939 message protocol. 2) J1939 Vehicle Data link. Customer Parameter programming required: 1) Vehicle Speed Cal (J1939-ABS) parameter must be programmed for correct Tire revs per mile. 2) Vehicle Speed Input parameter must be programmed to the J1939-ABS option.


41


8.0 ECM Speedometer and Tachometer Outputs 8.1 Speedometer And Tachometer The ECM provides complementary ±9 V speedometer and tachometer signals. The Tachometer Output can be customer programmed to provide an output between 12.0 to 500.0 pulses per revolution. The Speedometer Output provides a fixed 30,000 pulse per mile signal when the Truck Manufacturer parameter is programmed to “Other”, and a fixed 4,000 pulse per mile signal when programmed to the “GM” setting. The ECM receives the vehicle speed signal from an OEM installed sensor or electronic vehicle speed source, and scales the signal for the speedometer output. The ECM can also receive information over the J1939 data link from a transmission ECU broadcast, in order to calculate vehicle speed for the speedometer output. A speedometer may also be driven from the SAE J1587 Data Link message broadcast by the ECM, if the speedometer is capable of processing the information. The tachometer does not require an external sensor. The ECM determines engine speed from the Speed/Timing Sensor signals. A tachometer may also be driven from the SAE J1587 Data Link if the gauge is capable. OEM provided and installed components required: 1) Vehicle speed source (for speedometer output only). Customer Parameter programming required: 1) Vehicle Speed Calibration (for speedometer output only). 2) Tachometer Calibration (default is 134.0). SPEEDOMETER SIGNAL + SIGNAL -

ECM

TACHOMETER SIGNAL +

C974-PU C973-GN 45 0- YL 4 51- B R

SIGNAL -

36 37 38 39

SPEEDOMETER + SPEEDOMETER TACHOMETER + TACHOMETER -

P 1 J1

Wiring Diagram 6 - Speedometer and Tachometer Circuits Terminal Description


Voltage

Speedometer +

J1/P1: 36

± 9V

Speedometer -

J1/P1: 37

± 9V

Tachometer +

J1/P1: 38

± 9V

Tachometer -

J1/P1: 39

± 9V

The optional speedometer driver provides a signal from the ECM (OEM Connector P1, terminals 36 and 37), as does the tachometer driver (Connector P1 terminals 38 and 39). The signals are zero-crossing square waves with an amplitude (unloaded) of ±9 Volts. The amplitude of the signals will be ±5 Volts or greater when the speedometer load current is less than 4 mA. The output at terminal 36 (Terminal 38 for the tachometer) is the complement of terminal-37 (Terminal-39 for the tachometer) for those speedometers or tachometers requiring two signal lines. Connect either one of the two output lines from the ECM for speedometers or tachometers with a single input terminal. Leave the remaining line unconnected. When the control senses zero vehicle or engine speed, the driver signals will provide the following output voltages (unloaded). 42



NOTE: Do not connect the negative terminal of the ECM Speedometer or Tachometer Output to Sensor Common or any vehicle ground. 10

Voltage (Volts)

5

0

-5

- 10

Figure 28 - Unloaded Speedometer/Tachometer Signal 10

Voltage (Volts)

5

0

-5

- 10 0

5000

10000

15000

20000

Load In Ohms Figure 29 - Speedometer/Tachometer Signal vs. Load


43


The output signal for the speedometer is 30,000 pulses per mile, and for the tachometer the signal is programmable from 2.0 – 500.0 ppr (pulses per revolution, selectable in 0.1 increments through a Customer Parameter). Note that Caterpillar still provides a threaded hole in the flywheel housing for a magnetic engine speed sensor. Caterpillar requires twisted pair wiring if both signal connections from the ECM to the speedometer or tachometer are made. This is to prevent radiated electrical noise problems. Cab grounding of the speedometer is acceptable. 8.2 Connection Of Devices Other Than A Speedometer/Tachometer Do not connect these drivers to more than a single speedometer and tachometer. For questions regarding simultaneous connection, or connection of additional devices to these drivers contact Caterpillar. Caterpillar requests device specifications, a sample of the intended additional device, a connection diagram for vehicle installation, and sufficient lead time to evaluate this request. 8.3 Speedometer and Tachometer Output Accuracy

8.3.1 Speedometer Signal Accuracy The engine control processes the vehicle speed input signal using the pulses per mile as determined by the customer programmable Vehicle Speed Calibration parameter. It is then scaled for the speedometer driver at 30,000 pulses per mile. The most likely source of error for the output signal is incorrectly programming the ECM or speedometer pulses per mile, and driveline variations such as tire wear. There are five sources of signal processing error of the vehicle speed by the ECM: 1) ECM input resolution is ± 2 µsec. 2) Vehicle Speeds less than 1.5 miles per hour are ignored. 3) Rounding error due to division (scaling from pulses-in to pulses-out per mile). 4) ECM output resolution is ± 2 µsec. 5) ECM sampling of the vehicle speed occurs every 30 mS.

8.3.2 Tachometer Signal Accuracy The tachometer driver accuracy is ± 5 rpm.

44



9.0 Lamp Outputs The ECM provides four lamp outputs that can be used in a variety of ways depending upon Customer Parameter programming. The Check Engine Lamp is the only required lamp. The Check Engine Lamp is a yellow lamp that indicates an active diagnostic code or alerts the driver to impending idle/PTO shutdown. An optional Warning Lamp is required for the Engine Monitoring feature. The Warning Lamp indicates an active problem with one of the monitored conditions such as high coolant temperature. A flashing Warning Lamp indicates the engine is derating power. For “Other” truck Manufacturers Engine Monitoring Lamps parameter provides the option of using a single Warning Lamp for all monitored conditions, or discrete lamps for each monitored condition. If the Engine Monitoring Lamps parameter is programmed to Warning Lamp, then J1/P1 terminal-29 is used for connection of a single Warning Lamp. If the Engine Monitoring Lamps parameter is programmed to Option 1, then J1/P1 terminal-29 is used to connect a Low Oil Pressure Warning Lamp and J1/P1 terminal-31 is used to connect a High Coolant Temperature Lamp. If an optional Coolant Level Sensor is also installed (Coolant Level Sensor parameter programmed to 4-Pin or 2-Wire Float Sensor) then J1/P1 terminal-30 is used to connect a Low Coolant Level Lamp. For GM trucks, the Engine Monitoring Lamps parameter is limited to a High Coolant Temp option. Choosing this option changes J1/P1: 29 to a High Coolant Temperature Lamp. The other lamp drivers are not affected by choosing this option. If a Coolant Level Sensor is not installed (Coolant Level Sensor parameter programmed to No) then J1/P1 terminal-30 will be available for other functions including PTO Switch On Lamp or Change Oil Lamp. 9.1 Electrical Specifications Electrical characteristics of the Lamp Driver ECM outputs are as follows: Maximum Current: 0.30 Amperes Maximum Leakage Current in OFF State: 1mA These circuits are low side drivers—the ECM provides a path to ground to activate the load. Caterpillar does not request dedicated circuit protection for this circuit. The engine control has not implemented diagnostic codes for these circuits. ECM Lamp Output Terminal Description


Check Engine Lamp

J1/P1: 28

Warning Lamp, Low Oil Pressure, High Coolant Temp

J1/P1: 29 (Parameter programming Dependent)

PTO Switch On Lamp, Change Oil Lamp, Low Coolant Level Lamp


High Coolant Temperature Lamp, Wait To Start Lamp, Fast Idle Enabled Lamp



45


- 12V +

CHECK ENGINE LAMP ECM WARNING LAMP or Low Oil Pressure Lamp

L994-YL 659-PK K998-BU G880-PK

PTO Switch ON Lamp, Change Oil Lamp or Low Coolant Level Lamp

28 29 30 31

CHECK ENGINE LAMP WARNING LAMP OUTPUT #1 OUTPUT #9

P1 J1 Fast Idle Lamp, Wait to Start Lamp or High Coolant Temp Lamp

Wiring Diagram 7 - Lamp Driver Output Wiring Diagram 9.2 Lamp Test On power up (key ON, engine OFF), the Check Engine Lamp will come ON for five seconds and turn off indicating the lamp circuit is functional. When the engine is first started, the Check Engine Lamp (terminal 28) and the Warning Lamp (terminal 29) will be turned On for 2 seconds indicating that both lamp circuits are functional. 9.3 Check Engine Lamp Operation An OEM installed Check Engine Lamp (hardwired, Not J1939 driven) is required to indicate a control system malfunction (diagnostic condition) to the driver, for diagnosing control system component failures, and for indicating that the Idle Shutdown Timer is in the Driver Alert phase, indicating a pending engine shutdown when the timer expires. When a diagnostic code alert is active the Check Engine Lamp will flash ON and OFF. On power up (key ON, engine OFF), the Check Engine Lamp will come ON for five seconds and turn off indicating the lamp circuit is functional. Any time there is an Active diagnostic code the lamp will flash ON five seconds, blink off, flash ON five seconds, blink off, etc.

9.3.1 Viewing Diagnostic Flash Codes Caterpillar’s proprietary two-digit diagnostic flash codes can be prompted from the Check Engine Lamp. Active or logged codes (occurring since ECM power up) may be determined from the Check Engine Lamp as follows: 1

CRUISE ON

SET

3 CHECK ENGINE

CRUISE OFF

RESUME

Make sure Cruise Control On/Off switch is OFF.

2

CRUISE ON

SET CHECK ENGINE

CRUISE OFF

RESUME

CH ECK ENGIN E

CHEC K EN GINE

ON

OFF

CH ECK ENGIN E

CHEC K EN GINE

CH ECK ENGIN E

CH ECK ENGINE

CH ECK ENGIN E

CH ECK ENGINE

CHEC K ENGIN E

C HECK ENGIN E

CHEC K EN GINE

C HECK ENGIN E

CH ECK EN GINE

CHEC K EN GI NE

CHEC K EN GINE

C HECK ENGIN E

CH ECK EN GINE

CHEC K EN GI NE

Pause CHEC K ENGIN E

C HECK ENGIN E

Count the flashes as shown. In this example a code 55 is flashed = No Active or Logged codes. 4 If more than one code is active or has been logged, the Check Engine Lamp will continue to flash as indicated in 3, above. If any codes are missed, repeat steps 1 and 2.

Hold the Set/Resume switch in the SET position. Release when Check Engine Lamp begins to Flash.

OR CRUISE ON

SET CHECK ENGINE

CRUISE OFF

RESUME

Hold the Set/Resume switch in the RESUME position. Release when Check Engine Lamp begins to Flash.

Figure 30 - Viewing Diagnostic Flash Codes 46



Note: It is suggested the Diagnostic Flash Codes only be used to indicate the nature of a diagnostic code occurrence, not to perform detailed troubleshooting. Troubleshooting should be performed using SAE J1587 PID/FMI Diagnostic Codes obtained via an electronic service tool or digital dash display.

9.3.2 Viewing Diagnostic Flash Codes using Diagnostic Enable Input The diagnostic flash codes can be prompted using the Diagnostic Enable input. To initiate the flash codes, depress the momentary Diagnostic Enable switch until the Check Engine Lamp begins to flash. The codes should flash out as indicated above. 9.4 Warning Lamp Operation Engine Monitoring requires additional OEM installed warning lamp or lamps to alert the driver to an engine problem detected by the ECM. The Warning Lamp also alerts the driver to the level of action the ECM is taking to respond to the condition. The lamp is ON continuously while the engine is in the warning mode. Warning mode indicates the ECM has detected a problem, but the ECM is not altering engine performance to force driver action. The Warning Lamp flashes when in the derate mode, indicating the ECM has begun to force driver action and is reducing available horsepower and the maximum vehicle speed. During warning and derate the Check Engine Lamp will flash because of the active diagnostic code. The Warning Lamp will come on for two seconds following engine start-up to check the lamp and circuit function.

9.4.1 Warning Lamp Output used for High Coolant Temperature Shutdown Signal For GM 530/540 engines, the Warning Lamp output can be used as a dedicated High Coolant Lamp. The Engine Monitoring Lamps parameter may be programmed to Warning Lamp or to High Coolant Warning Lamp. When programmed to Warning Lamp, the output operates as already described. When programmed to High Coolant temperature Warning Lamp, the output at J1/P1: 29 will be turned On in conjunction when the upper coolant temperature limit is exceeded. This feature option allows for the engine coolant temperature diagnostic to be tied into the chassis system for an engine protection shutdown. Customer Parameter programming required: 1) Engine Monitoring Lamps parameter programmed to High Coolant Warning Lamp. 9.5 Low Oil Pressure Lamp This lamp will be available if the Engine Warning Lamps parameter is programmed to Option 1. A lamp connected to J1/P1:29 will turn On when the diagnostic code for Low Oil Pressure or Very Low Oil Pressure is active. This feature is not available for GM trucks. OEM provided and installed components required: 1) Low Oil Pressure Lamp. Customer Parameter programming required: 1) Engine Monitoring Lamps parameter programmed to Option 1. 9.6 Low Coolant Level Lamp With the Coolant Level Parameter programmed to other than No, a coolant level sensor installed and the Engine Monitoring Lamps parameter programmed to Option 1, J1/P1:30 is available for a Low Coolant Level Lamp. This lamp will turn on when the active diagnostic codes for Low or Very Low Coolant Level are active. This feature is not available for GM trucks. OEM provided and installed components required: 1) Low Coolant Level Lamp. 2) Coolant Level Sensor


47


Customer Parameter programming required: 1) Engine Monitoring Lamps parameter programmed to Option 1. 2) Coolant Level Sensor programmed to 4-Pin or 2-Wire Float 9.7 PTO Switch ON Lamp If the PTO Switch On Lamp parameter is programmed to J1/P1: 30 (default), the ECM will turn Output #1 ON when the PTO On/Off Switch circuit (Input #1) is ON. Customer Parameter programming required: 1) PTO Configuration programmed to Cab Switches, Remote Switches or Remote Throttle. 2) PTO Switch On Lamp programmed to J1/P1: 30 NOTE: This parameter is unavailable if Change Oil Lamp is programmed to this terminal. This feature will not be available if the Engine Monitoring Lamps parameter is programmed to Option 1 and the Coolant Level Sensor is programmed to other than No. 9.8 Change Oil Lamp If the Change Oil Lamp parameter is programmed to J1/P1: 30, the ECM will turn Output #1 ON when the oil change interval exceeds the interval set in the PM1 parameter. Customer Parameter programming required: 1) Maintenance parameters; Maintenance Indicator Mode, PM1 Interval and Engine Oil Capacity 2) Change Oil Lamp programmed to J1/P1:30 NOTE: This parameter is unavailable if PTO Switch On Lamp is programmed to this terminal. This feature will not be available if the Engine Monitoring Lamps parameter is programmed to Option 1 and the Coolant Level Sensor is programmed to other than No. 9.9 Fast Idle Enabled Lamp The Fast Idle Enabled Lamp parameter may be programmed to J1/P1:31 (Default), J1/P1:21 or None. When programmed to J1/P1:31 the ECM will turn 99Output #9 (Terminal 31) ON when Fast Idle is active. OEM provided and installed components required: 1) Fast Idle Lamp. Customer Parameter programming required: 1) Fast Idle Enabled Lamp parameter is programmed to J1/P1:31(default) or J1/P1:21. 2) Engine Monitoring Lamps programmed to Warning NOTE: The Fast Idle Enabled Lamp is not available for some GM configurations. This feature is not available if the Engine Monitoring Lamps parameter is programmed to Option 1. 9.10 Wait To Start Lamp The Wait To Start Lamp parameter may be programmed to J1/P1: 31, J1939 or None (default). The ECM will enable J1/P1: 31 (or J1939 message) when the Inlet Air Heater is operating and the engine is not running. This function is different from the engine harness connection for the Inlet Air Heater Lamp that will turn On whenever the Inlet Air Heater is operating. The Wait to Start Lamp is not available for all GM configurations. The hardwired connection (J1/P1: 31) is not available if the Engine Monitoring Lamps parameter is programmed to Option 1. The J1939 option for the Wait to Start Lamp is available regardless of the Warning Lamp programming for Non-GM trucks. OEM provided and installed components required: 1) Lamp or J1939 data link device

48



Customer Parameter programming required: 1) Wait to Start Lamp is programmed to J1/P1: 31 if Engine Monitoring Lamps programmed to Warning Or, 2) Wait To Start Lamp programmed to J1939 9.11 J1939 Data Link Driven Lamps The ECM will broadcast the SAE J1939 DM1 message ($FECA [65,226]) for engine diagnostic codes and will include the information necessary to illuminate an OEM provided Check Engine, Engine Protect and the Engine Stop lamps.

9.11.1 Amber Check Engine Lamp With the ECM Engine Monitor programmed to Warning, Derate or Shutdown, the ECM will broadcast the message on J1939 to illuminate an amber Check Engine Lamp during those conditions that illuminate the hardwired Check Engine Lamp (during Active Diagnostic Codes). This message will not support the “FLASH CODES” generated during trouble shooting of the ECM.

9.11.2 Protect Lamp With the ECM Engine Monitor programmed to Warning, Derate or Shutdown, the ECM will broadcast the message on J1939 to illuminate the Protect Engine Lamp during those conditions that illuminate the hardwired “Warning Lamp” (Red). The DM1 protocol will be followed and up to 10 active fault codes will be transmitted (highest priority first).

9.11.3 Stop Lamp With the ECM Engine Monitor programmed to Warning, Derate or Shutdown, the ECM will broadcast the message on J1939 to illuminate the RED STOP Lamp during those conditions that cause the hardwired “Warning Lamp” (Red) to flash.

9.11.4 Wait to Start Lamp The Wait To Start Lamp status is available to be broadcast over J1939. The message is PGN $FEE4 (65252) Byte 4, bits 2,1. This message will indicate that the inlet Air Heater is enabled and the operator should wait until the lamp goes Off before attempting to start the engine.


49


10.0 OEM Installed Sensors 10.1 Coolant Level Sensors The OEM is responsible for providing and installing the Coolant Level Sensor and a Warning Lamp. It is programmed through the Customer Programmable Parameter, Coolant Level Sensor. The default factory setting is No. OEM provided and installed components required: 1) Warning Lamp. 2) Coolant Level Sensor. Customer Parameter programming required: 1) Coolant Level Sensor parameter must be programmed to 4-pin, 2-Pin Switch (GM Only), or 2-Wire Float Sensor. 2) Engine Monitoring must be programmed to Warning, Derate, or Shutdown. 10.2 Selecting a Sensor Three types of coolant level sensors are supported. These include a four pin coolant level sensor, 2 Wire Float Sensor (a resistive ladder type sensor), or the 2- wire switch (used ONLY in General Motors (C7) applications). Each sensor operates as a coolant loss sensor. If a sensor is installed the Coolant Level Sensor parameter must be programmed to 4-Pin, 2-Wire Float Sensor or 2-Pin Switch. 10.3 Coolant Level Sensor Environmental Compatibility The OEM should determine worst case coolant type, mechanical, electrical, and electromagnetic field environments for the coolant level sensor and verify the coolant level sensor will function properly and reliably under those worst case conditions. Specifically, the OEM must verify that the sensor is compatible with “Extended Life Coolants”. NOTE: If the Coolant Level Sensing is disabled through the Customer Programmable option, it is not necessary to jumper any connector terminals on the OEM connector. The ECM will ignore the coolant level inputs. The vehicle harness for the Coolant Level Sensor should not be connected to the ECM when a sensor is not installed. 10.4 Coolant Level Sensor Mounting Guidelines (4-Pin) To insure proper operation of the 4 pin coolant level sensor, the following mounting guidelines should be followed: A. The sensor is supplied with thread sealant applied to the threads. No other tape or sealant should be applied when mounting. B. For the liquid present signal, the sensor must be mounted in a position completely immersing the sensing tube and mounting thread. C. For the liquid absent signal, the sensor must be mounted in a position with no fluid contacting the entire sensing tube and mounting thread. D. The output signal is indeterminate when only a portion of the sensing tube is immersed in fluid. E. The sensor should be mounted low enough in the tank to operate correctly under all slosh, tilt, and roll conditions. F. Preferred sensor mounting is horizontal.

50



Figure 31 - Cooper Standard Coolant Level Sensor Installation in Top Tank 10.5 Four Pin Coolant Level Sensor Electrical Specifications The four pin coolant level sensor specifications are shown in the following table.

10.5.1 Coolant Level Sensor Connections

ECM +5V COOLANT LEVEL NORMAL COOLANT LEVEL LOW AP SENSOR/SWITCH SENSOR COMMON

G 8 79 -O R C98 3- WH C9 84 -Y L H 79 5-P K

C D A B

2 49 54 5

+5V COOLANT LEVEL NORMAL COOLANT LEVEL LOW AP SENSOR/SWITCH SENSOR COMMON

P1 J1

Figure 32 Sensor Terminal Assignment



Terminal A

J1/P1: 54

Coolant Level Low

Terminal B

J1/P1: 5


Terminal C

J1/P1: 2

+5V

Terminal D

J1/P1: 49

Coolant Level Normal

10.5.2 Coolant Level Sensor Power Supply The sensor must operate off the ECM regulated power supply of 5.0 ± 0.25 Vdc. Total current draw by the sensor at the +5V terminal must not exceed 20 mA under any conditions.


51


10.5.3 Coolant Level Sensor Outputs (All voltages are DC and referenced to AP Sensor/Switch Sensor Common at the ECM Connector J1/P1). I. Coolant Level Low (J1/P1:54) A. Fluid Present: Output voltage = 0.5V MAXIMUM when sinking 10 mA or less. B. Fluid Absent: Output voltage = 4.1V MINIMUM when sourcing 1 mA or less. (The outputs must be able to tolerate a 20 kΩ or greater resistance pulled up to 13V). II. Coolant Level Normal (J1/P1:49) A. Fluid Present: Output voltage = 4.1V MINIMUM when sourcing 1 mA or less. (The outputs must be able to tolerate a 20 kW or greater resistance pulled up to 13V). B. Fluid Absent: Output voltage = 0.5V MAXIMUM when sinking 10 mA or less.

10.5.4 Coolant Level Sensor Response Time Sensor outputs must change states in less than 2 seconds when subjected to an immersion-removal transition. Cool Level Low must change states within ±1.0 millisecond of a Cool Level Normal state change.

10.5.5 Coolant Level Sensor Diagnostic Coolant level faults, 111-01 for Low & 111-11 for Very Low will cause the Check Engine Lamp to illuminate. Active faults will be broadcast over the J1587 and the J1939 data links. The J1939 message will indicate that the coolant level is at 50% for Low and 0% for Very Low. If the ECM Coolant Level Circuit indicates the sensor outputs are at the same voltage for at least two seconds, a diagnostic code is triggered. OEM provided and installed components required: 1) Coolant Level sensor meeting this specification. 2) Engine Monitoring Warning Lamp installed. Customer Parameter programming required: 1) Coolant Level Sensor Customer Parameter programmed to 4 Pin. 10.6 2-Wire Float Coolant Level Sensor The 2-Wire Coolant Level Float Sensor option allows the OEM to install a resistor ladder float switch sensor to indicate coolant level. This sensor is powered with a 5-volt supply internal to the ECM. The expected voltage for a Normal coolant level is between 0.75 and 1.75 volts. The expected voltage for a Low coolant level is between 2.0 and 3.0 volts. The expected voltage for a Very Low or Critical level is between is between 3.25 and 4.25 volts. Hysteresis voltage ranges are included to allow for some slosh in the tank. Voltages levels changing from a defined range into a hysteresis zone will be considered to be in the previous range until the voltage level changes to outside of the hysteresis zone.

52



A/D Input (Max 5V)

5.00 v

Open Sensor 4.50 v

Hysteresis zone

4.25 v

Critical Level

Critical Level

3.25 v

Hysteresis zone

3.00 v

Low Level

Low Level

2.00 v

Hysteresis zone

1.75 v

Normal Level

Normal Level

0.75 v

Hysteresis zone

0.50 v

Short to ground

Figure 33 The 2-Wire Float Sensor is connected to J1/P1: 26 and J1/P1: 5. Pin J1/P1: 23 provides 5 volt excitation through a 499 Ohm pull up resistor. Resistor ladder values must be selected to produce the voltage levels for Normal, Low and Very low (critical) coolant levels. Caterpillar does not recommend any specific supplier or circuit. The following diagram is for reference. Coolant Level Normal = R1 + R2 + R3 Coolant Level Low = R2 + R3 Coolant Level Very Low = R3

5 Volts

499 Ohms

R1

R2

R3

E452-WH

26

H795-PK

5

P1

J1

Sensor Common

ECM

2-Wire Float Coolant Level Sensor Typical Circuitry OEM Supplied Wiring Diagram 8 Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____

53


10.7 2-Wire Float Sensor Diagnostics Ignition Key On and the engine Not running: If the Coolant Level Sensor voltage is in the Normal range or either of the hysteresis zones bordering Normal Coolant Level range, the coolant level State will be Normal. A coolant level fault (111-01 for Low, 111-11 for Very Low, 111-03 for Open & 111-04 for Shorted) will occur if the voltage is not between 0.5 and 2.0 volts for at least 10 seconds. The Check Engine Lamp will illuminate and an active fault will be broadcast over the J1587 and the J1939 data links if there is a fault condition present. The J1939 message will indicate that the coolant level is at 50% for Low and 0% for Very Low. For Low and Very Low coolant levels, an Event will be logged in the ECM. The logged Event will stay in the ECM nonvolatile memory and will be erased after 100 hours of engine operation if there are no other occurrences. Engine has been running for more than 4 seconds but less than 30 seconds: (Allows for initialization of the Coolant level) 1) If the Coolant Level Sensor voltage is in the Normal range or either of the hysteresis zones bordering Normal Coolant Level range, the coolant level State will be Normal. 2) If the Coolant Level Sensor voltage is in the Low range or in the hysteresis zone between Low and Very Low, the Coolant Level State will be Low (111-01). 3) If the Coolant Level Sensor voltage is in Very Low range or the Hysteresis Zone between Very Low and Sensor Open, the Coolant Level Sate will be Very Low (111-11). 4) If the sensor is shorted (111-04) or open (111-03), a fault code will be active. 5) A fault condition will cause the Check Engine Lamp will illuminate and an active fault will be broadcast over the J1587 and the J1939 data links. The J1939 message will indicate that the coolant level is at 50% for Low and 0% for Very Low. Engine has been running for 30 seconds: (Allows for coolant levels to stabilize) 1) If the Coolant Level state was Normal and the voltage level is in the Normal Coolant Level range or either of the hysteresis zones bordering Normal Coolant Level range, the coolant level will be considered Normal. 2) If the Coolant Level State was Low and the voltage is in the Low Coolant Level range or either of the hysteresis zones around the Low range, the Coolant level will be considered Low (111-01). 3) If the Coolant Level State was Very Low and the voltage is in the Very Low Coolant Level range or either of the hysteresis zones around the Very Low Coolant range the Coolant Level State will be Very Low (111-11). 4) If the sensor is shorted (111-04) or open (111-03), a fault code will be active. 5) A fault condition will cause the Check Engine Lamp to illuminate and an active fault will be broadcast over the J1587 and the J1939 data links. The J1939 message will indicate that the coolant level is at 50% for Low and 0% for Very Low. OEM provided and installed components required: 1) Coolant Level sensor meeting this specification. 2) Engine Monitoring Warning Lamp installed. Customer Parameter programming required: 1) Coolant Level Sensor Customer Parameter programmed to 2-Wire Float Sensor. 10.8 2-Pin Switch Coolant Level Sensor (GMT 560 only) The 2-Pin Switch sensor used on GMT 560 trucks provides closed contacts when coolant is present and open contacts when coolant is Low. The sensor is connected between J1/P1:49 and J1/P1:3

54



OEM provided and installed components required: 1) Coolant Level sensor meeting this specification. 2) Engine Monitoring Warning Lamp installed. Customer Parameter programming required: 1) Coolant Level Sensor Customer Parameter programmed to 2-Pin Switch. 10.9 Fuel Tank Level Sensing (GMT560 trucks only) Two passive inputs may be used for connecting a resistive fuel tank level sensor. These inputs are supplied with 5 volts through an internal 500-Ohm pull-up resistor. This feature may be available upon a joint effort between Caterpillar and interested OEMs. Primary Tank Fuel Level Sensor

ECM 15

Primary Tank Fuel Level (INPUT #2)

3

Sensor Common

26

Secondary Tank Fuel Level

P1 J1

Secondary Tank Fuel Level Sensor Wiring Diagram 9 OEM provided and installed components required: 1) A Fuel Level sensor meeting GM’s specification. Customer Parameter programming required: 1) Primary or Secondary Fuel Tank Capacity programmed to 50, 35, or 25 gal


55


11.0 Inlet Air Heater, Lamp and Relay Operation The Inlet Air Heater (IAH) is used to improve cold start capability of the engine and to reduce white smoke. The ECM controls the Inlet Air Heater Grid and Inlet Air Heater Lamp through the Inlet Air Heater Relay. The heater and relay are installed on the engine at Caterpillar. The Inlet Air Heater operation is determined at three different times: Power Up/Preheat, Engine Cranking and Engine Running. This operation is based on measured engine temperatures and affected by operational conditions including vehicle speed and service brake pedal position. The Inlet Air Heater will be disabled (engine running or not) whenever the Service Brake is depressed and the vehicle speed is equal to or more than 5 mph (8 KPH). If there is an active vehicle speed sensor fault the ECM will assume that the vehicle speed is above 5 mph and will disable the Intake air Heater when the Service Brake is applied. 11.1 Inlet Air Heater Relay Electrical Specifications The OEM is responsible for connecting the contact side of the Inlet air heater relay to battery voltage. Recommended circuit protection for this connection is 130 Amps with a circuit load of 100 Amps continuous. The Inlet Air Heater Relay has a maximum ‘On’ time of 7 minutes. Minimum required wire size is 4 AWG. 11.2 Inlet Air Heater Relay Connections The battery supply wire must be secured and not attached to a fuel line. Secure the wire with the clip before applying the proper torque of 9.0 Newton-Meters (NM) +/- 1.0 NM to the wire terminal at the terminal stud. Wire terminal nuts and locking washers are supplied with the relay. Caterpillar recommends the use of a breaking torque wrench such as the Mountz TLS-1360. CAUTION: Not meeting the specified torque limit may cause electrical arcing due to a mechanical failure of the relay stud or a loose connection.

Battery Cable

Air Inlet Heater

Figure 34 - Inlet Air Heater Relay

56



A boot must be installed on the Battery connection to the Inlet Air Heater Relay to help prevent electrical arcing. This boot must be made of heat resistant material that can meet the UL94V0 rating for flammability. Choose terminals made of tin plated brass with a hole that size is closest to the diameter of the stud (5/16 inch). The terminal hole should provide enough clearance to make assembly easy while maintaining contact. Caution must be taken to prevent the terminal from causing a short to chassis ground. Caterpillar recommends that the terminal ring connection to the battery supply wire should be made with a bare terminal and then insulated using a sealed heat shrink. 11.3 Inlet Air Heater Lamp An Inlet Air Heater Lamp may be installed to indicate when the Inlet Air Heater is operating. This lamp will normally be installed at the operator station. The Inlet Air Heater Lamp can be connected in parallel with the Caterpillar installed Inlet Air Heater Relay. The engine wiring harness provides a 116-6158 two terminal Packard (12052641) Metri-pack 150 Series Plug (P648) to connect the Inlet Air Heater Lamp. The mating half of the P648 plug is a Packard (12162000) Metri-pack 150 Series Receptacle (J648). A connector cap is installed on the plug to seal the connection until the Inlet Air Heater Lamp is connected. The ECM Inlet Air Heater driver provides a ground path when the heater should be ON (low side driver sinking 1.5 A maximum). OEM INSTALLED COMPONENTS INLET AIR HEATER LAMP - 12V +

100 Amp with 130 A Peak @ 11 V B A

INLET AIR HEATER

ENGINE GROUND

INLET AIR HEATER RELAY

J501 P501 1 2

J648 P648

ECM 850-BU

8 P2 J2

INLET AIR HEATER

Wiring Diagram 10 - Inlet Air Heater Wiring Diagram


57


Ignition Switch On

Is the SUM of Coolant Temp1 +Inlet Manifold Air Temp2 less than 136°F (40°C) when operating below 5500 Ft (1678 M) Or 3less than 159°F (53°C) when operating above 5500 Ft (1678 M)

No

No

Yes Is Starting Aid Temp <= 0C? **

Yes

Automatic

Starting Aid Mode Off Turn Heater On and Start 30 Sec Timer (PreHeat)

No

Timer Expired?

Engine started?

Yes

No Engine Cranking?

Yes

Yes No

Heater On

Wait 5 Seconds after Ether injection is finished

No

Turn Heater Off

Engine started? Yes Is the SUM of Coolant Temp1 +Inlet Manifold Air Temp2 less than 136°F (40°C) when operating below 5500 Ft (1678 M) Or 3 less than 159°F (53°C) when operating above 5500 Ft (1678 M)

No

Yes Turn Heater On and Start 7 minute Timer (first time thru) Timer Expired?

No

Yes Is the SUM of Coolant Temp1 +Inlet Manifold Air Temp2 less than 136°F (40°C) when operating below 5500 Ft (1678 M) Or 3 less than 159°F (53°C) when operating above 5500 Ft (1678 M) Yes Start 13 minute Timer (first time thru) Cycle Heater On and Off every 10 seconds No

Timer Expired?

Yes

1

If a coolant temperature sensor open circuit or short circuit diagnostic code is active, the heater will come on if inlet manifold temperature < 50°F (10°C) If an inlet manifold air temp sensor open circuit or short circuit diagnostic code is active, the heater will come on if coolant temperature < 104°F (40°C) 3 With APR99 and newer Personality Modules, the Boost Pressure reading is used to determine Atmospheric Pressure. This indicates if the engine is operating above 5500 Ft (1678 M). If so, the temperature calculations used to determine inlet air heater operation are adjusted to compensate for the extreme altitude operation. NOTE: If the Service brake switch is open and Vehicle Speed is greater than or equal to 5 mph (or a vehicle speed diagnostic is present) the heater will be turned OFF. If the brake switch closes or speed drops below 5 mph, the heater will resume operation. 2

Figure 35

58



11.4 ECM Power Up and Preheat Cycle If the SUM of the Coolant Temperature and Inlet Manifold Air Temperature is less than 136°F or 40°C and the engine is being operated below 5500 feet (1678 meters) of elevation, the ECM will turn the Inlet Air Heater relay output ON for 30 seconds as a preheat cycle. If the engine is being operated at elevations higher than 5500 feet (1678 meters) the sum of the Coolant Temperature and Inlet Manifold Air Temperature must only be less than 160°F or 53°C in order to compensate for the extreme altitude operation. NOTE: DO NOT convert the sum of the temperatures!!! The temperatures MUST be converted before summing! The ECM adds Coolant Temperature and Inlet Manifold Air Temperature as measured in centigrade. In order to get the correct conversion of the summed value in Fahrenheit, each temperature must first be converted to Fahrenheit and then added together as follows: ([Coolant Temperature °C] X 1.8 +32) + ([Inlet Manifold Air Temperature °C] X 1.8 +32) = sum in Fahrenheit. The Heater and Heater Lamp will turn ON, and then turn OFF when the cycle is complete. If the operator attempts to start the engine before the 30 second preheat cycle ends, the ECM will continue to control the Heater during engine cranking. 11.5 Engine Cranking Cycle When the engine is cranking, the Heater will turn ON if the SUM of the Coolant Temperature and Inlet Manifold Air Temperature is less than 136°F or 40°C at elevations below 5500 feet (1678 meters), and stay ON while cranking. If the engine fails to start the Heater will activate for 30 seconds (preheat cycle is restarted). At elevations above 5500 feet (1678 meters) the SUM of the Coolant Temperature and Inlet Manifold Air Temperature must only be less than 160°F or 53°C in order to compensate for the extreme altitude operation. 11.6 Engine Running Cycle After the engine has started, the Inlet Air Heater operation is determined by the same combination of both the Inlet Manifold Air Temperature and Coolant Temperature. The Engine Running Cycle has two segments, a continuous mode followed by an On/Off cycling mode. The Continuous ON mode lasts for a maximum of seven minutes. The On/Off cycle mode can last for a maximum of 13 minutes. During the On/Off cycle mode, the Heater is cycled ON and OFF for ten seconds. The Inlet Air Heater will turn OFF anytime the SUM of the Inlet Manifold Air Temperature and Coolant Temperature exceeds 126°F or 40°C if the engine is being operated below 5500 feet (1678 meters) of elevation. If the engine is being operated at elevations higher than 5500 feet (1678 meters), the Heater will turn OFF anytime the SUM of the Inlet Manifold Air Temperature and Coolant Temperature exceeds 178°F or 63°C. 11.7 IAH and Active Engine Diagnostics Whenever there is an Active Open or Short Circuit Diagnostic Code for the Coolant Temperature Sensor, the Heater will activate if the Inlet Manifold Air Temperature is less than 50°F (10°C). For an Active Inlet Manifold Air Temperature Sensor Diagnostic, the Heater will activate if Coolant Temperature is less than 104°F (40°C). 2.8 IAH and Starting Aid Interaction At key switch On, the Inlet Air Heater will not be activated if the Starting Aid Output is programmed to Automatic and the inlet air temperature is below 0 Deg C. The Inlet Air Heater will not be activated if the Starting Aid circuit is activated. When the Starting Aid Output is programmed to Automatic, the Inlet Air Heater will not be activated until the engine is running and the starting Aid output has been turned off for 5 seconds.


59


12.0 Hard-wired Switch Inputs The ECM has 18 switch inputs available for feature interaction. There are 15 Switch To Input Sensor Common inputs and three Switch To Battery Positive inputs. 12.1 Switch to Sensor Common Electrical Specifications Applied voltage to switches by the control will normally not exceed 11.5 Volts DC. Contact plating should not corrode or oxidize. Gold plated or silver alloy contacts are recommended. Normal current draw through the switches by the control will not exceed 6.5 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 internal pull-ups force the respective input to 11.5 Volts DC when a switch contact is opened or the harness is open circuited. Closure of an OEM installed switch must short circuit the input to a dedicated Sensor Common connection of the ECM (J1/P1 terminal-5, terminal-3 or terminal-18). Voltage thresholds measured at ECM: Voltage-In-Low < 0.9 Volts DC – 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 Volts DC between the respective control inputs and Sensor Common terminal. Voltage-In-High > 4.0 Volts DC – With the switch contacts open, ground potential differences, switch voltage drops, and wiring harness voltage drops must be such that a switch opening results in greater than 4.0 Volts DC between the control input and Sensor Common terminal. 12.2 Sensor Common Connections Three Sensor Common terminals are available to “ground” inputs connected to the ECM. All of the Switch To Sensor Common inputs must use one of the three terminals (J1/P1: 3, 5, or 18). Switch inputs must not use chassis ground. Switches must not be Case grounded.

60




J1/P1: 5


J1/P1: 18


J1/P1: 3



12.3 Switch to Sensor Common Inputs Switch function

Default Connection

Optional Connection(s)

Cruise Control On/Off

J1/P1: 59

J1939

Cruise Control Set

J1/P1: 35

J1939

Cruise Control Resume

J1/P1: 44

J1939

Clutch Pedal Position Switch

J1/P1: 22

J1939

Service Brake Position Switch #1

J1/P1: 45

J1939

Torque Limit Switch

None

J1/P1: 7, 23

Ignore Brake/Clutch Switch

None

J1/P1: 47

Two Speed Axle

None

J1/P1: 6

Diagnostic Enable

None

J1/P1: 46, J1939

PTO On/Off

J1/P1: 56

J1939

PTO Set

J1/P1: 58

J1939

PTO Resume

J1/P1: 60

J1939

PTO Engine RPM Set Speed Input A

None

J1/P1: 46, J1939

PTO Engine RPM Set Speed Input B

None

J1/P1: 7, 23

PTO Engine Shutdown

None

J1/P1: 7, 23

Fast Idle

J1/P1: 40

None

A/C High Pressure

J1/P1: 41

None

A/C Fan Request (GMT560 Only)

Sw to + Batt

J1/P1: 41

Shutdown Override

J1/P1: 40

None

Note: For switches with J1939 options, refer to the “J1939 Based Switched Messages” section for additional details.

12.3.1 Service Brake Pedal Position Switches/Function The Service Brake Position Switch #1 is required for ALL applications. This is a normally closed switch and must be an open circuit when the service brake pedal is depressed. An Open circuit will deactivate or will not activate Cruise Control, Fast Idle (1 or 2), Extended Idle, or Cab Switches PTO. A change in state (depressing a released pedal, or releasing a depressed pedal) of the Service Brake, during Driver Alert, while the Idle Shutdown Timer is counting also overrides the Idle Shutdown Timer if the Customer Parameter Allow Idle Shutdown Override” is programmed to Yes (default). Service Brake Position Switch #2 (switch to Battery Plus) may be required if needed to support the transmission style.

12.3.2 Clutch Pedal Position Switch Function The clutch pedal position switch must be an open circuit when the clutch pedal is depressed. This switch is required on any application that uses a clutch and the Transmission Style must be programmed to Manual Option 1 or 2. An Open circuit will deactivate or will not activate Cruise Control, Fast Idle (1 or 2), Extended Idle, or Cab Switches PTO. Adjustment of the Clutch Pedal Position Switch is critical to proper system performance. A change in state (depressing a released pedal, or releasing a depressed pedal) of the Clutch, during Driver Alert, also overrides the Idle Shutdown Timer, if the ECM is programmed to allow Idle Shutdown Override.


61


12.3.2.1 Clutch Pedal Position Switch with Automatic Transmissions The Clutch Pedal Position switch is required if the parameter Transmission Style is programmed to Manual Option 1, Manual Option 2 or Universal. If the transmission Style parameter is not programmed to one of these options, the clutch switch circuitry may be omitted. A jumper circuit from this input to Sensor Common is not required.

12.3.3 Diagnostic Enable A Diagnostic Enable input is available to prompt the ECM for flashing Diagnostic Flash Codes via the hardwired Check Engine Lamp. The Diagnostic Enable parameter must be programmed to J1/P1: 46 for this feature to function. A momentary normally open switch is required. The ECM will begin flashing and continue to flash out codes while this switch is closed.

DIAGNOSTIC ENABLE

ECM G844-PK H795-PK

46 INPUT #7 5 AP SENSOR/SWITCH SENSOR COMMON P1 J1

Wiring Diagram 11 - Diagnostic Enable Circuit OEM provided and installed components required: 1) Normally open momentary switch. 2) Hardwired Check Engine Lamp Customer Parameter programming required: 1) Diagnostic Enable programmed to J1/P1:46

12.3.4 Two Speed Axle Switch Two Speed Axle Switch may be programmed to None (Default) or J1/P1: 6. When a two-speed axle is used Two Speed Axle Switch must be programmed to J1/P1: 6 (Input #6). A normally open switch is required. When a twospeed axle is used, the change in gear ratios from the high-speed range to the low speed range alters the calibration of the vehicle speed signal. With this system, the ECM will automatically adjust the vehicle speed calibration when the switch is ON. This will ensure an ECM driven speedometer and ECM stored information correctly reflect the actual vehicle speed. The Low Speed Range Axle Ratio and High Speed Range Axle Ratio must be programmed as well. When the switch is closed between the ECM terminals 16 and 5, the ECM will use the following equation to calculate the actual vehicle speed: High Speed Range Axle X calculated vehicle speed = actual vehicle speed Low Speed Range Axle Ratio Note: GM trucks use a normally closed switch for this input. Where the calculated vehicle speed is the vehicle speed calculated using the programmed vehicle speed calibration (pulse per mile). This adjusted vehicle speed will be used to determine idle, PTO, and Fast Idle “Kickout” speeds as programmed. The vehicle speed broadcast over the data links and the ECM speedometer output vehicle speed will reflect the adjustment. If Two Speed Axle Switch is not programmed to J1/P1: 6, the ECM does not use either axle ratio to determine the actual speed. OEM provided and installed components required: 1) Switch to close when low speed axle ratio is used (switch to OPEN if GM truck). Customer Parameter programming required: 1) Two Speed Axle Switch programmed to J1/P1:6 when a two-speed axle is used (default is NONE). 2) High Speed Range Axle Ratio and Low Speed Range Axle Ratio must be programmed or the feature is disabled. 62



Two-Speed Axle On/Off Switch

ECM

G843-OR H795-PK Switch Shown in High Speed Range

6 INPUT #6 5 AP SENSOR/SWITCH SENSOR COMMON P1 J1

Wiring Diagram 12 12.3.5 PTO Switches Several options are available to control engine rpm while in PTO. In order to operate in PTO Mode, a dedicated PTO ON/OFF switch is required. Three PTO modes are available. The Cruise Control Set/Resume switches can be used or dedicated PTO switch inputs can be programmed and installed to give a variety of controlled engine speeds. OEM provided and installed switches (required and/or optional): 1) PTO On/Off switch 2) Optional Switches 3) Transmission Neutral switch 4) Cruise Control Set/Resume 5) PTO Set/Resume 6) PTO Set Speed A 7) PTO Set Speed B 8) Torque Limit 9) Clutch Pedal Position Switch (for manual transmissions). 10) Service Brake Pedal Position 11) Ignore Brake/Clutch Customer Parameter programming required: 1) PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle. 2) Individual switch inputs as necessary.

12.3.6 Fast Idle Switch A momentary Fast Idle switch can be used to elevate and maintain up to two programmed engine rpm settings. Pressing and releasing the switch once will cause the engine to ramp from Low idle to the programmed Fast Idle RPM #1 (1000 rpm default). Pressing and releasing the switch while at Fast Idle #1 will cause the engine to ramp to the programmed Fast Idle #2 at the programmed “Idle/PTO Engine Speed Ramp Rate.” If Fast Idle #2 is not programmed, the engine will return to low idle. Fast Idle will be deactivated (kicked out) if the Service Brake or Clutch is depressed. The transmission Neutral switch, when in Gear, will also cause the Fast Idle to deactivate.


63


FAST IDLE ENABLE

- 12V +

L902-GN H795-PK G880-PK G880-PK

P1 J1 40 5 31 21

ECM INPUT #18 AP SENSOR/SWITCH SENSOR COMMON OUTPUT #9 OUTPUT #8

FAST IDLE ENABLED LAMP Optional Fast Idle Enabled Lamp Circuit

Wiring Diagram 13 - Fast Idle Enable Switch and Fast Idle Enable Lamp Circuits OEM provided and installed components required: 1) Fast Idle Enable Momentary Switch (N/O). 2) Fast Idle Enabled Lamp (optional) Customer Parameter programming required: 1) Fast Idle Lamp parameter programmed to J1/P1: 31(default) or J1/P1:21. (optional) 2) Fast Idle RPM #1. 3) Fast Idle RPM #2 (optional).

12.3.7 Ignore Brake/Clutch Switch The Ignore Brake/Clutch Switch is used to allow use of an engine set speed in mobile vehicle operations. When the Ignore Brake/Clutch parameter is programmed to J1/P1: 47 and the switch is closed, PTO, Extended Idle and Fast Idle features will ignore service brake and clutch switch inputs. If this switch is in the closed position when the ECM is powered up, this switch function is ignored until the switch is cycled Off and ON.

12.3.8 Shutdown Override Switch (Mass Transit only) The transit industry calls for an engine shut down override switch to allow the operator to override a critical engine diagnostic induced engine shutdown. The purpose of the Shutdown Override Switch is to allow an operator to override the impending engine shutdown to allow the operator to move the vehicle to a more safe location. This feature is only available on C9 Mass Transit ratings. Shutdown Override Operation The Engine Monitoring System can be used to cause the engine to shut down when the engine has an active diagnostic code for Very Low Engine Oil Pressure, Very low Coolant Level or Very High Engine Coolant Temperature. When one of these Diagnostics is active, the Warning Lamp, or the dedicated lamps defined by the Warning Lamp option of “Option 1”, will start to flash. The flashing lamp indicates that the engine power is being derated and engine shutdown will occur within a few seconds. If the Shutdown Override Switch has been closed before the Shutdown sequence has ended, a Shutdown Timer will start to countdown from 30 seconds. If the Shutdown Override Switch is opened and closed again before the engine has turned the fuel injectors Off, the timer will reset for another 30 seconds. Once the timer has counted down to zero and the fuel injectors have been disabled, the engine will shut down regardless of the position of the Shutdown Override Switch. Initiating the Shutdown Override Timer will result in a Diagnostic Code being generated and logged into memory. A Diagnostic Snapshot will also be generated. The logged diagnostic code will require Caterpillar Factory Passwords to clear from the ECM’s memory.

64



ECM

40

Shutdown Override Switch

3

Switch Common

P1/J1

Wiring Diagram 14 12.3.9 A/C High Pressure Switch The A/C High Pressure switch is used in conjunction with the ECM controlled Cooling Fan. This is a normally closed switch and when opened, causes the ECM to engage the cooling fan.

12.3.10 Exhaust Brake Switch The Exhaust Brake switch is used to allow the operator to enable or disable the engine’s exhaust retarder. OEM provided and installed components required: 1) Exhaust Brake Switch Customer Parameter programming required: 2) Exhaust Brake Switch programmed to J1/P1: 16 12.4 Switch-to-Battery Electrical Specifications Contact plating should not corrode or oxidize. Gold plated or silver alloy contacts are recommended. Normal current draw through the Input #12 and Input #13 by the control is 6.0 mA at 12 Volts DC. Normal current draw through the Ignition Key Switch by the control is 1.2 mA at 12 Volts DC. 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. Each of these ECM inputs is pulled to ground eliminating the need for external termination. Closure of an OEM installed switch must short circuit the input to the vehicle positive battery connection.

12.4.1 Voltage thresholds measured at ECM: Switch Open < 0.9 Volts DC – With the switch contacts open, ground potential differences, switch voltage drops, and wiring harness voltage drops, the ECM must detect less than 0.9 Volts DC between the control input and the ECM negative battery connection. Switch Closed > 9.0 Volts DC – With the switch contacts closed, ground potential differences, switch voltage drops, and wiring harness voltage drops, the ECM must detect a switch closure resulting in greater than 9.0 Volts DC between the control input and the ECM negative battery connection.


65


12.4.2 Switch-to-Battery Circuit Protection These circuits do not require dedicated circuit protection. Switch function

Default Connection

Optional Connection(s)

Ignition Key Switch

J1/P1: 70

None

Transmission Neutral

J1/P1: 62

J1939

Service Brake #2

J1/P1: 64

None


J1/P1: 62

None

12.4.3 Ignition Key Switch to Positive Battery The Ignition Key Switch input is J1/P1: 70 and is not changeable. When the ECM detects the input is switched to vehicle battery (Ignition Key Switch ON), the ECM will be powered. The ECM will then control the injectors allowing the engine to start. OEM provided and installed components required: 1) Switch to close when the ignition is ON.

12.4.4 Service Brake Pedal Position Switch #2 Function Service Brake Pedal Position Switch #2 is required if the Transmission Style is programmed to Manual Option 2, Universal, AT/MT/HT Option 2, AT/MT/HT Option 3, Automatic Option 2, or Automatic Option 3. Input #13 is used as the Service Brake Position Switch #2 input. The Service Brake Pedal Position Switch #1 (switch to ground) must also be used. This switch must be a short circuit to +Battery when the service brake pedal is depressed. The control will deactivate Cruise Control, Cab Switches PTO, Fast Idle, or Extended Idle when the Service Brake Pedal Position Switch #2 is ON. The Brake and Clutch Pedal Position Switches do not affect remote PTO. A change in state (depressing a released pedal, or releasing a depressed pedal) of the Service Brake, during Driver Alert, while the Idle Shutdown Timer is counting can also override the Idle Shutdown Timer, if the ECM is programmed to allow Idle Shutdown Override. SERVICE BRAKE #2 PEDAL POSITION (PEDAL RELEASED POSITION) - 12V +

ECM L900-PU

64 P1 J1

INPUT #13

Wiring Diagram 15 OEM provided and installed components required: 1) Switch to close when service brakes are applied. Customer Parameter programming required: 1) Customer Parameter Transmission Style programmed to Manual Option 2, AT/MT/HT Option 2, AT/MT/HT Option 3, Automatic Option 2, or Automatic Option 3.

12.4.5 Transmission Neutral Switch The ECM can be configured to monitor the transmission’s Neutral Switch. This switch is used to indicate when an automatic transmission is in neutral. The neutral condition allows features such as Cab Switches PTO, Fast Idle, and Extended Idle to be used. The switch is required if the Transmission Style Parameter is programmed to AT/MT/HT Option 3, AT/MT/HT Option 4, Automatic Option 3, or Automatic Option 4.

66



TRANSMISSION NEUTRAL SWITCH (IN GEAR POSITION) - 12V +

ECM 409-OR

62 P1 J1

INPUT #12

Wiring Diagram 16 OEM provided and installed components required: 1) Switch to close when the transmission is in neutral. Customer Parameter programming required: 1) Customer Parameter Transmission Style programmed to AT/MT/HT Option 3, AT/MT/HT Option 4, Automatic Option 3, or Automatic Option 4. 2) Transmission Neutral Switch parameter programmed to J1/P1: 62.

12.4.5.1 Transmission Neutral Switch Status via J1939 Data Link The ECM has the ability to receive Neutral Switch status information from a Transmission ECU capable of broadcasting the status via the J1939 data link. The J1939 option can be used to replace the hardwired switch input to the ECM. This option can only be used if the Transmission is capable of supporting the required J1939 message protocol, such as an Allison 2000 Series Transmission. The OEM is responsible for making this determination. The Transmission must support the J1939 PGN $F005 (ETC2 – Byte 1 – Selected Gear, Byte 4 – Current Gear or Byte 7 – Current Range) message to be compatible. If the message is not received, the ECM will assume the transmission to be In gear. OEM provided and installed components required: 1) Electronically Controlled Transmission capable or supporting required J1939 message protocol. Customer Parameter programming required: 1) Customer Parameter Transmission Style programmed to either AT/MT/HT Option 3, AT/MT/HT Option 4, Automatic Option 3, or Automatic Option 4. 1) Transmission Neutral Switch parameter programmed to J1939 option.

12.4.5.2 Ignoring the Transmission Neutral Switch input. The neutral switch is not normally used with manual transmissions. The ECM can also be configured to ignore the neutral switch if an automatic transmission is used. Customer Parameter programming required: 1) Transmission Style parameter programmed to Manual Option 1 or 2, AT/MT/HT Option 1, AT/MT/HT Option 2, Automatic Option 1, or Automatic Option 2. 2) Transmission Neutral Switch parameter programmed to J1/P1:62 (default) hardwired option or None. NOTE: Programming the Neutral Switch to “None” and the Transmission Style to “Automatic option 3” (or 4) or “AT/ MT/HT Option 3” (or 4) will cause the ECM to assume that the transmission is IN GEAR.


67


13.0 Cruise Control Cruise control operation is a standard feature and requires the following OEM installed switches: Cruise Control ON/OFF, Set/Resume, and Service Brake Pedal Position Switch #1. Depending on Transmission Style programming, additional switches may be required. These would include the Clutch Pedal Position, Service Brake Pedal Position Switch #2 and Neutral switches. SET/RESUME (SET OFF POSITION) (RESUME OFF POSITION) CRUISE CONTROL ON/OFF (CRUISE OFF POSITION) SERVICE BRAKE PEDAL POSITION (PEDAL RELEASED POSITION)

ECM C978-BR C979-OR C975-WH C992-PU C977-BU H795-PK

35 44 59 45 22 5

SET RESUME CRUISE CONTROL ON/OFF SWITCH SERVICE BRAKE PEDAL POSITION SWITCH CLUTCH PEDAL POSITION SWITCH AP SENSOR/SWITCH SENSOR COMMON

P1 J1

CLUTCH PEDAL POSITION (PEDAL RELEASED POSITION)

Wiring Diagram 17 - Typical Cruise Control Wiring Diagram OEM provided and installed components required: 1) Cruise Control On/Off switch. 2) Vehicle speed source. 3) Service Brake Pedal Position Switch. 4) Set /Resume switch. Optional Switch Inputs 1) Clutch Pedal Position Switch (Transmission Style programming dependent) 2) Transmission Neutral switch (Transmission Style programming dependent) 3) Service Brake Pedal Position Switch #2 (Transmission Style programming dependent) 4) Cruise Pause Switch (J1939 Only) Customer Parameter programming required: 1) Vehicle Speed Calibration. 2) Low Cruise Control Speed Set Limit. 3) High Cruise Control Speed Set Limit. 4) Transmission Style. 13.1 Cruise Control Switches and Operation Cruise Control will operate the same for either hard-wired switch inputs or J1939 based switch inputs.

13.1.1 Cruise Control On/Off Switch When the On/Off switch input is toggled to the ON position (switch contacts closed) Cruise Control or Extended Idle function is enabled.

68



13.1.2 Set/Resume Switch The Set/Resume switch is normally a three-position switch biased to the Off position. The ECM inputs are Customer programmable determining the Accel/Decel function of the Set and the Resume input. The factory default is Set/Accel and Resume/Decel. The Set/Resume switch is normally a three-position switch biased to the off (center) position. The Customer Programmable parameter “Cruise/Idle/PTO Switch Configuration” is used to determine which switch contact is associated with accelerate and decelerate functions. The default is Set/Accelerate and Resume/Decelerate.

13.1.3 Switch Function/Interaction for Cruise Control Cruise Control requires that the vehicle speed be within the programmed Low and High Cruise Set Speed Limits. The Cruise Control “Set” speed may only be established between these limits. The “set” speed is the vehicle speed that the engine will attempt to maintain while normal cruise control conditions are met. The switches used with the Service Brake, Clutch, Pause and transmission neutral can deactivate (kick out) Cruise Control. With the Cruise Control On/Off switch on, toggling (turning the switch On for less than 0ne second) the Set Switch or the Resume Switch will cause the Cruise Control Vehicle Set Speed to be equal to the present vehicle speed. This “set” speed will remain as the Cruise Control Vehicle Speed until a new “set speed” is established or the ignition switch is turned off. With a “set” speed established, the vehicle “set” speed may be “bumped” (increased or decreased) by toggling the Set or the Resume switches. A “Bump” means that the Set or Resume switch is closed for less than one second. The increase or decrease of the vehicle “set” speed will be one mph for every “bump”. With a “set” speed established, the vehicle speed may be “ramped” (increased or decreased) by holding either the Set or Resume switch closed for more than 1.5 seconds. The vehicle “set” speed will change by one mph/sec while the switch is closed. When the switch is released, the actual vehicle speed will become the new vehicle “set” speed. With a “set” speed established and Cruise Control actively maintaining vehicle speed, the cab throttle may be used to increase vehicle speed. To make this vehicle speed the new “set” speed, the Set switch must be closed for at least two and one half seconds to establish a new “set” speed. With a “set” speed established but Cruise Control has been disabled or “kicked out” the Resume Switch can be toggled to reactivate Cruise Control. This includes the Cruise On/Off switch as a reason for the “kick out”. Once reactivated, the existing “set” speed will be “resumed” and the engine will recover to the “set” speed. With a “set” speed established but Cruise Control has been disabled or “kicked out” the Set Switch can be toggled to increase (or decrease depending on the configuration of the Set/Accel Resume/Decel parameter) the current Cruise Control set speed. The speed that the vehicle is currently traveling will not be established as a new “set” speed until the Set Switch is held down for more than two and one half seconds.


69


14.0 Idle Functions 14.1 Smart Idle The “Battery Monitor and Engine Control Voltage” parameter is used to determine when the Battery Monitor and Engine Speed Control System will automatically elevate engine idle to the engine RPM specified in the “Battery Monitor & Low Idle Engine Speed” parameter in order to maintain ideal battery system voltage. This feature is used to promote additional battery life. The engine idle will only be increased if the vehicle is stopped, the transmission is out of gear and neither the clutch nor the brake pedal are depressed. If these conditions are not met, the engine idle will not be adjusted. This feature will not function when the engine is operating in dedicated PTO mode (PTO On/Off switch in the ON position). The recommended setting is 12.2 Volts for a 12 Volt system, and 24.5 Volts for a 24 Volt system. The engine will stay at this idle speed for 5 minutes (unless interrupted). At the end of 5 minutes the engine will return to low idle or a previously established elevated idle speed. If the battery voltage is still below the programmed trip point the engine will return to the programmed Smart Idle speed for another 5 minutes. NOTE: This feature requires the installation of a Neutral Switch (J1/P1: 62 or the SAE J1939 based input message) if the Transmission Style parameter is programmed to AT/MT/HT Option 3, or AT/MT/HT Option 4. 14.2 Extended Idle Cruise Control switch inputs can be used to control the engine idle speed in Extended Idle mode. Extended Idle is available if the engine is not in Cold Mode, Smart Idle (battery voltage induced) is not engaged, Fast Idle is not enabled, the PTO ON/OFF Switch is not ON, Service Brake or Clutch is not depressed, transmission is not in gear, Cruise Pause Switch is not On and the vehicle speed is not equal to or exceeding the programmable Idle Vehicle Speed Limit. Note: Some switch inputs are programming dependent. With conditions met for Extended idle, and the Cruise Control On/Off switch is in the ON position, the engine rpm may be bumped or ramped by using the Cruise Control Set/Resume switch inputs. The amount of engine rpm change for a “bump” is determined by the Idle/PTO RPM Bump Rate parameter. The Idle/PTO Bump RPM Rate is programmable from 5 to 1000 RPM (default is 20 RPM). The engine rpm “ramp” value is determined by the Idle/PTO Engine Speed Ramp Rate parameter. The Idle/PTO Engine Speed Ramp Rate parameter is programmable from 5 to 1000 RPM/sec (default is 50 RPM/sec). When the engine speed is “bumped” the engine will ramp to the new rpm at the programmed “ramp rate”. The Cruise/Idle/PTO Switch Configuration parameter programming will determine the direction of the engine rpm bump or ramp. When programmed to Set/Accel – Resume /Decel, the engine rpm will increase with the Set switch and Decrease with the Resume Switch. When programmed to Set/Decel – Resume /Accel, the engine rpm will decrease with the Set switch and increase with the Resume Switch. Pressing and then releasing the Set Switch or the Resume Switch will establish the current engine rpm as the idle “set” speed. The “set” rpm may be established at any engine speed from the programmed Low Idle to the programmed Idle RPM Limit. Once an idle speed has been “set”, the engine speed may be bumped or ramped using the Set/Resume switches. Pressing and holding the Set or Resume switch will establish the engine’s current rpm as the “set” rpm and then after 1 second the engine will ramp at the programmed rate in the direction of the programmed setting for Cruise/Idle/PTO Switch Configuration. The last idle “set” rpm will stay in the ECM’s memory until the key switch has been turned Off. With a “set” idle rpm, pressing an holding the (Set or Resume) /Accel Switch for less than one second will cause the engine rpm to “bump” or increase by the programmed Idle/PTO Bump RPM value. This “bump” process can be repeated until the engine reaches the programmed Idle RPM Limit. With a “set” idle rpm, pressing an holding the (Set or Resume) /Decel Switch for less than one second will cause the engine rpm to “bump” or decrease by the programmed Idle/PTO Bump RPM value. This “bump” process can be repeated until the engine reaches the programmed Low Idle. With a “set” idle rpm, pressing and holding the Set or Resume switch for more than one second will cause the engine to ramp at the programmed rate in the direction of the programmed setting for Cruise/Idle/PTO Switch Configuration. The engine rpm will ramp as long as the switch is held or until the engine reaches the programmed

70



Idle RPM Limit or the programmed Low Idle. Releasing the Set or Resume switch while the engine rpm is ramping will establish the current engine rpm as the new “set” rpm. If the Extended Idle has been disabled or “kicked out”, the “set” rpm is still in memory. Once the condition for Kickout no longer exists, pressing and releasing the Resume Switch will cause the engine rpm to ramp to the “set” rpm.

14.2.1 Extended Idle kick outs Extended Idle may be deactivated or “kicked out” by a variety of switch inputs and by exceeding the programmable vehicle speed limit. When Kicked Out, the “set” rpm remains in memory but the engine will return to the programmed low idle rpm. Pressing on the Service Brake or Clutch, shifting the transmission into gear, turning the PTO Switch On or by turning the Pause Switch On, can “kick out” Extended Idle. If the vehicle operation requires that the Service Brake and Clutch switches be used while the engine is in Elevated Idle mode, the Ignore Brake/Clutch switch input can be used. With this switch enabled, the Service Brake and Clutch may be used to control the vehicle speed while the Extended Idle is Active. In the following table, an “L” means the input can return the engine to low idle from a set speed, a “A“ means the input can adjust engine rpm, and “P” means the input function is programmable to a limit. ECM Input

Result

Cruise On/Off

L

Cruise Set

A

Cruise Resume

A

Cruise Pause

L

Service Break

L

Clutch

L

Neutral

L

Fast Idle

A

Idle Vehicle Speed Limit

L

Throttle

A

OEM provided and installed components required: 1) Cruise Control Switches 2) Service Brake Switch #1 3) Clutch, Service Brake #2 and Neutral switches are transmission style dependent Customer Parameter programming required: 1) Idle Vehicle Speed Limit (1 – 15 mph) 2) Idle RPM Limit (700 – 2640 RPM) 3) Idle PTO Ramp Rate (5 – 1000 RPM/s) 4) Idle Bump Rate (5 – 1000 RPM)


71


15.0 J1939 Based Switch Messages The Powertrain Data Link parameter must be programmed to J1939 before the ECM will respond to messages received from the J1939 data link. Individual switch input parameters must be programmed to receive messages from either the Cab Controller (source address 49, $31), the Body Controller (source address 33, $21) or the Instrument Cluster (source address 23, $17). All programmed switch inputs require that the status of the switch be broadcast as On or Off when the key switch is On. Not broadcasting a switch status message will result in a diagnostic code to be active and the Check Engine lamp will be enabled. 15.1 Cruise Switch Inputs

15.1.1 Cruise Control On/Off Switch Cruise Switch (PGN 65265 ($FEF1) Byte 4, bits 4,3 is set to 01) The Cruise switch will allow enabling cruise control, if turned on and will deactivate (kickout) cruise control if switched off. The switch must be in the On position to activate cruise control.

15.1.2 Cruise Control Set Switch Set Switch (PGN 65265 ($FEF1) Byte 5, bits 2,1 set to 01) As long as the Cruise switch is Off the Set switch has no functionality for the cruise feature. If the Cruise On/Off switch is on and all other conditions are met (Veh spd, Clutch, Brake, Neutral, Cruise Pause) an On/Off transition of the Set switch will activate cruise and set the cruise target speed to the actual vehicle speed. As long as Cruise stays active, any other On/Off, Off/On or hold transition of the Set switch will be ignored. The Set switch is only used to activate Cruise, set the current veh spd = cruise target speed and enable the Accel and Decel switch.

15.1.3 Cruise Control Resume Switch Resume switch (PGN 65265 ($FEF1) Byte 5, bits 6,5 set to 01) As long as the Cruise switch is Off the Resume switch has no functionality for the cruise feature. If the Cruise On/Off switch is on and all other conditions are met (Veh spd, Clutch, Brake, Neutral, Cruise Pause) an On/Off transition of the Resume switch will activate cruise. If, since the last ECM power up, cruise control was never active and the Resume switch goes from On/Off, the cruise target speed will be set to the actual veh spd. But if Cruise was active before, the Cruise Target Speed will be set to the last Cruise Set Speed, which will be lost during an ECM power cycle. As long as Cruise stays active, any other On/Off, Off/On or hold transition of the resume switch will be ignored. The Resume switch is only used to activate Cruise, set the old set speed = cruise target speed, if not 0, and enable the Accel and Decel switch.

15.1.4 Cruise Control Accel Switch Accel switch (PGN 65265 ($FEF1) Byte 5, bits 8,7 set to 01) As long as the Cruise switch is Off and cruise is not active (by Set or Resume), the Accel switch has no functionality for the cruise feature. If cruise is active (Cruise on, Set or Resume On/Off transition, all other conditions are met – Veh spd, Clutch, Brake, Neutral, Cruise Pause), an Off/On transition of the Accel switch, which lasts longer (ON) than 1.26 seconds (Hold), will cause the cruise target speed to ramp UP, by a fixed ramp rate. When the Accel switch is released (On/Off) the cruise target speed will be set to the current veh spd. If the holding time after the Off/On transition is shorter than 1.26 seconds (Bump), then the cruise target speed will be INCREASED by 1 mph (1.6 km/h). The Resume or Set switch must be On to enable the Accel or Decel switch function. NOTE: The Accel switch is not dependent on the Cruise/Idle/PTO switch configuration parameter.

72



15.1.5 Cruise Control Decel Switch Decel switch (PGN 65265 ($FEF1) Byte 5, bits 4,3 set to 01) As long as the Cruise switch is Off and cruise is not active (by Set or Resume), the Decel switch has no functionality for the cruise feature. If Cruise is active (Cruise on, Set or Resume On/Off transition, all other conditions are met – Veh spd, Clutch, Brake, Neutral, Cruise Pause), an Off/On transition of the Decel switch, which lasts longer (ON) than 1.26 seconds (Hold) will cause the cruise target speed to ramp DOWN, by a fixed ramp rate. When the Decel switch is released (On/Off) the cruise target speed will be set to the current veh spd. If the holding time after the Off/On transition is shorter than 1 second (Bump), then the cruise target speed will be DECREASED by 1 mph (1.6 km/h). The Resume or Set switch must be On to enable the Accel or Decel switch function. NOTE: The Decel switch is not dependent on the Cruise/Idle/PTO switch configuration parameter. Priority Set has a higher priority than Resume if both switch inputs are received at the same time. Accel has a higher priority than Decel if both switch inputs are received at the same time. 15.1.6 Cruise Pause Switch PGN (65265 ($FEF1) Byte 1, bits 6,5 set to 01) (J1939 input only) The Cruise Pause switch will disable (kick out) cruise control (if active) and will prevent Cruise from being engaged if the switch is turned. The switch is independent from the Ignore Brake/Clutch switch status and it will not affect any timer functionality (Idle Shutdown and PTO Shutdown). This switch will act like the service brake or clutch switches can cause PTO or Extended Idle to kick out. If in the ON position, this switch will prevent the engine from entering into PTO mode or Extended Idle. 15.2 Service Brake Switch (PGN 65265 ($FEF1) Byte 4 Bits 6,5) The Service Brake Switch input will respond to an Off to On transition and the ECM will respond the same as to hardwired switch inputs. This includes all features that respond to the Service Brake Switch #1 input (Cruise Control, Extended Idle, PTO, exhaust brake, etc.). 15.3 Clutch Switch (PGN 65265 ($FEF1) Byte 4 Bits 8,7) The Clutch switch input will respond to an OFF to ON transition and the ECM will respond the same as to hardwired switch inputs. This includes all functions that respond to the Clutch Switch input (Cruise Control, Extended Idle, PTO, exhaust brake, etc.). 15.4 Fan Override Switch (PGN 65213 ($E000) Byte 1 Bits 8-1) The Fan Override Switch may be programmed to None (Default), J1939 Cab Controller, J1939 Body Controller or J1939 Instrument Cluster. When the received message => 95.2% (switch ON), the ECM will turn J1/P1: 11 OFF which will turn the fan ON. When the received message <= 94.8%, the ECM will control the fan according to engine conditions. The ECM will also support the Fan Override Switch message when broadcast from the transmission. The transmission may require that the fan be engaged to cool the transmission fluid during vehicle operating conditions that result in high transmission loads. 15.5 Exhaust Brake Switch (PGN 61441 ($F001) Byte 5 Bits 8-1) Exhaust Brake Switch may be programmed to None (Default), J1/P1: 16, J1939 Cab Controller, J1939 Body Controller or J1939 Instrument Cluster. When programmed to one of the J1939 inputs the received message must be => 95.2%, before the Engine Exhaust Brake can be enabled. Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____

73


15.6 Engine Diagnostic Switch (PGN 65265 ($FEF1) Byte 8 Bits 6,5) Engine Diagnostic Switch may be programmed to None (Default), J1/P1: 46, J1939 Cab Controller, J1939 Body Controller or J1939 Instrument Cluster. When programmed to one of the J1939 inputs and the ECM receives an On/ Off message transition, the ECM will enter into Diagnostic Mode and will cause the hardwired Check Engine Lamp to flash active Error codes. 15.7 Transmission Neutral Switch The Transmission must support the J1939 PGN $F005 (ETC2 – Byte 1 – Selected Gear, Byte 4 – Current Gear or Byte 7 – Current Range) message to be compatible. Selected gear and Actual Gear must be 0 when the transmission is in Neutral. If the message is not received, the ECM will assume the transmission to be in gear.

74



16.0 Dedicated PTO Operation PTO operation is very flexible and can be programmed to take advantage of a variety of switch and throttle input options. Engine speed can be controlled to maintain a Set Speed from Low to High Idle. There are programmable set points and limits for engine RPM. There are programmable Kickout limits that can be set to return the engine to Low idle when those limits are exceeded. There are also outputs that can be used to enhance PTO operation. There are four programmable PTO Configurations available: 1) Off 2) Cab Switches 3) Remote Switches 4) Remote Throttle The PTO features are designed to provide functional capability to cover most typical applications: Bulk Hauler, Cement Mixers, Fire Truck, Refuse Packers, Bucker Trucks, etc. A variety of inputs allow the OEM or body-builder to add the necessary switches and/or accelerator pedal sensor, which will reduce the amount of splicing and disturbance of the cab wiring. Caterpillar recommends the OEM provide an access connector in an easily accessible location to aid the body builder in installation of these features. 16.1 Input Electrical Specifications Caterpillar requires all switches, and all components used in these circuits to meet the specifications as outlined in this document. Electrical specifications for the remote accelerator pedal position sensor are described in Section 6 of this document. 16.2 Sensor Common for PTO Applications ECM Vehicle Harness Connector J1/P1: 3 (Input Sensor Common #2) is designated as the Sensor Common connection for PTO additions. Caterpillar recommends this connection be reserved for components connected to the engine to control engine speed for PTO applications only. In the event that additional sensor or switch returns are required, the PTO components can also be connected to J1/P1: 18 (Input Sensor Common #1) or J1/P1: 5 (AP Sensor/Switch Sensor Common) if desired. Devices that do not interface with the ECM Must Not be connected to these common connections. 16.3 PTO On/Off Switch Operation Whenever this switch is cycled to the ON position, PTO operation is assumed. If the engine is started with this switch closed, the engine will be in PTO mode, but not active until the operator toggles a PTO related switch. The PTO On/Off switch is connected to J1/P1: 56. 16.4 PTO Switch On Lamp The ECM provides a lamp driver output on J1/P1: 30. When the Customer Parameter PTO Switch On Lamp is programmed to J12/P1: 30 (default is None) and the PTO Switch is closed, the lamp will turn On. J1/P1: 30 is a low side driver. This lamp should be located where the operator will see it. For remote PTO applications, a cab and remote lamp should be installed This lamp will flash when the PTO Timer is within the 90 seconds of shutting the engine down. If another feature is using this output (Change Oil Lamp or Warning Lamp Option 1) then a lamp can be wired to a multiple pole PTO ON/OFF switch.


75


ECM 993-BR

3

INPUT SENSOR COMMON #2

PTO ON/OFF (PTO OFF POSITION) K999-GN PTO INTERLOCK

56 INPUT #1 P1 J1

- 12V +

Wiring Diagram 18 - Optional PTO On Lamp circuit 16.5 PTO Active Output The PTO Active Output parameter is available for controlling an output when the engine is actively in PTO Mode. Active means that PTO is enabled and is actively controlling engine speed. This battery voltage output is available at J1/P1: 19 when PTO Active Output is programmed to J1/P1: 19 (default is None). This High Side Driver has a current capability of up to 1.0 Amperes.

ECM

G838-BR

19 P1 J1

OUTPUT #6

OEM Supplied Relay/Solenoid Wiring Diagram 19 - PTO Active Output Circuit 16.6 PTO Engine Shutdown Switch A PTO Engine Shutdown Switch input is available for shutting down the engine while in PTO Mode. Several conditions must be met before the engine will shut down. 1) The customer parameter “PTO configuration” has been programmed to either Cab Switches, Remote Switches or Remote Throttle, and 2) If: PTO Engine Shutdown Switch has been programmed to either J1 PIN 7 or PIN 23, and 3) If: PTO Switch is in the ON (input grounded) position and PTO is active, and 4) If: PTO Engine Shutdown Switch is in the ON (input floating) position for 120 milliseconds, and 5) If: PTO Engine Shutdown Short Circuit (186-04) is not active, and 6) If: Vehicle Speed = zero and vehicle speed fault is not active If the vehicle speed is not equal to zero or if there is an active vehicle speed fault, the engine will go to Low Idle. The engine will not shut down when the vehicle speed returns to zero. The ECM will log an Emergency PTO Shutdown Event when the PTO Engine Shutdown Switch is pressed.

76



- 12V+

ECM PTO ON/OFF (PTO OFF POSITION)

K998-BU

30 OUTPUT #1

E489-PK K999-GN 993-BR

23 INPUT#19 56 INPUT #1 3 INPUT SENSOR COMMON #2

PTO Engine Shutdown Switch

PTO Engine Interlock

P1 J1 Wiring Diagram 20 - PTO Engine Shutdown Circuit OEM provided and installed components required: 1) Two Pole switch used for a PTO mode ON Switch 2) Mushroom type “Emergency” Shutdown Switch. This switch must be a “non-spring returned, Push to Trip” type of switch requiring the mushroom button to be pulled or twisted in order to be reset. Customer Parameter programming required: 1) None 16.7 Maximum PTO Enable Speed The Maximum PTO Enable Speed parameter may be programmed to prevent the engine from entering PTO mode when the engine RPM is too high. The engine will not be in PTO mode, the PTO Active Output will remain OFF and the PTO On Lamp will FLASH until the engine RPM is at or below the programmed limit. With the PTO mode On Switch in the ON position, once the engine drops below this limit the engine will enter PTO mode. Once in PTO mode all the applicable PTO settings and features will apply. 16.8 PTO Kickout Vehicle Speed Limit The PTO Kickout Vehicle Speed Limit parameter may be used to cause the ECM to kickout of PTO mode when this vehicle speed limit is exceeded. Kicking out of PTO mode will return the engine to normal cab controls. 16.9 Maximum Vehicle Speed in PTO Mode The Maximum Vehicle Speed in PTO Mode parameter may be programmed to limit the vehicle speed while in PTO mode. Increasing vehicle speed past this limit will result in the engine speed being reduced in order to maintain the programmed PTO mode vehicle speed limit. 16.10 PTO Activates Cooling Fan PTO Activates Cooling Fan is a parameter that is programmable to Normal (default) or Continuous. This parameter requires use of the ECM cooling fan circuit. The ECM will signal the cooling fan to continuous operation when the PTO On/Off circuit is ON to reduce changes in load while being used for dedicated PTO applications. Setting this parameter to Normal (default) indicates the fan will operate the same (dependent upon coolant temperature, etc.) with the PTO On/Off circuit ON or OFF. PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle before this parameter can be programmed. The Fan Control Type parameter must not be programmed “None”.


77


16.11 PTO Output Activation Speed PTO Output Activation Speed allows the customer/operator the ability to engage PTO, using the PTO Active Output, at a desired engine speed. The engine will ramp to the desired programmed speed before the PTO Active Output is turned ON. Once engine speed has reached the programmed value – 100 rpm, the PTO Active Output will be turned ON. This feature allows easier engine operation for applications where PTO load dump is high. This feature is designed to work in conjunction with PTO Applications utilizing the PTO Active Output feature of the engine. PTO Active Output is covered in section 16.5 of this chapter. This feature is only available on Emergency Vehicle Horsepower ratings. 16.12 PTO Interlocks The switches labeled PTO Interlock in the wiring diagrams are redundant switches and should be added to insure the engine is put in PTO mode only when the vehicle is ready and prepared for PTO operation. It is the responsibility of the OEM (or Body Builder) to determine which interlocks are required for their particular application. 16.13 PTO Customer Access Connector Caterpillar recommends that the OEM provide an access connector for those chassis’ frequently used in vocational applications. This connector should provide wiring from the ECM to a connector that is easily located and identified on the vehicle. Caterpillar recommends the circuits listed in the following table be provided at this connector. PTO Access Connector Recommendations Terminal Description


PTO On/Off

J1/P1: 56

PTO Set

J1/P1: 58

PTO Resume

J1/P1: 60

PTO Shutdown

J1/P1: 7

PTO Throttle Signal

J1/P1: 68


J1/P1: 46


J1/P1: 23

Switch/Sensor Common #2

J1/P1: 3

PTO On Lamp

J1/P1: 30

PTO Active Output

J1/P1: 19

Additional circuits such as positive and negative battery connections should also be considered but these circuits must be separate from the ECM battery circuits.

78



16.14 PTO Configurations The following table outlines the operating differences for each of the PTO Configurations. The table shows each inputs affect on the engine rpm when the PTO On/Off switch is ON for each configuration. For the following table, an “L” means the input can return the engine to low idle from a set speed, a “A“ means the input can adjust engine rpm. Limits can be established for elevated idle speeds. Note: The Service Brake includes Switch #1 and Switch #2 (Switch #2 is transmission style dependent) PTO Configuration Input

Cab Switches

Remote Switches

Remote Throttle

Cruise Set

A

N/A

N/A

Cruise Resume

A

N/A

N/A

Cruise Pause

L

L

L

Cab Throttle

A

N/A

N/A

N/A

A

A

Service Brake

L

N/A

N/A

Clutch

L

N/A

N/A

Neutral

L

N/A

N/A

PTO Set

N/A

A

A

PTO Resume

N/A

A

A

PTO Engine RPM Set Speed A

A

A

A

PTO Engine RPM Set Speed B

A

A

A

Remote Throttle


79


16.14.1 PTO Configuration – Cab Switches The Cab Switches Configuration utilizes a dedicated PTO On/Off circuit (J1/P1: 56), the Cruise Control Set/Resume switch inputs and the Cab throttle. This configuration interacts with the Service Brake, Clutch, Cruise Pause and the transmission’s Neutral Switch. The Cruise Control Set/Resume switches can be used to Bump and Ramp engine speed if PTO Engine RPM Set Speed is not programmed. - 12V +

PTO SWITCH ON LAMP

SET/RESUME (SET OFF POSITION) (RESUME OFF POSITION) SERVICE BRAKE PEDAL POSITION (PEDAL RELEASED POSITION)

CLUTCH PEDAL POSITION (PEDAL RELEASED POSITION)

PTO ON/OFF

PTO INTERLOCK

ECM K998-BU C978-BR C979-OR C992-PU C977-BU H795-PK K999-GN 993-BR G842-GY L901-GY G841-GN

30 35 44 45 22 5 56 3 47 18 7 P1 J1

OUTPUT #1 SET RESUME SERVICE BRAKE PEDAL POSITION SWITCH CLUTCH PEDAL POSITION SWITCH AP SENSOR/SWITCH SENSOR COMMON INPUT #1 INPUT SENSOR COMMON #2 INPUT #5 INPUT SENSOR COMMON #1 INPUT #4

(PTO OFF POSITION) IGNORE BRAKE/CLUTCH SWITCH (MONITOR BRAKE/CLUTCH POSITION) TORQUE LIMIT SWITCH (TORQUE LIMIT OFF POSITION)

Wiring Diagram 21 - Typical Cab Switches wiring Diagrams - 12V +

PTO SWITCH ON LAMP

CRUISE CONTROL SET/RESUME SWITCH ECM PTO ENGINE RPM SET SPEED A SWITCH

PTO ENGINE RPM SET SPEED B SWITCH

K998-BU C978-BR C979-OR G844-PK M990-OR H795-PK 993-BR K999-GN

30 35 44 46 23 5 3 56

OUTPUT #1 SET RESUME INPUT #7 INPUT #19 * AP SENSOR / SWITCH SENSOR COMMON INPUT SENSOR COMMON #2 INPUT #1

P1 J1 * Input is selectable through Customer Parameter Programming PTO INTERLOCK

PTO ON/OFF SWITCH

NOTE: INPUT SENSOR COMMON #1 (TERMINAL-18) MAY BE USED IN PLACE OF INPUT SENSOR COMMON #2 (TERMINAL-3)

Wiring Diagram 22 - Typical Cab Switches wiring Diagrams

80



Parameter PTO Configuration

Setting Cab Switches

PTO Top Engine Limit PTO Engine RPM Set Speed

1200 RPM 1000 RPM


1200 RPM


1000 RPM

PTO To Set Speed

Yes

PTO Kickout Vehicle Speed Limit PTO Cab Throttle Limit Torque Limit

2 mph

PTO Shutdown Time

3 minutes

PTO Activates Cooling Fan Max PTO Vehicle Speed

Yes

Maximum PTO Enable Speed Ignore Brake, Clutch, Transmission Switch Input PTO Switch On lamp PTO Active Output Configuration

1000 RPM

Low Idle 200 NM

20 mph

J1/P1: 47

J1/P1: 30 J1/P1: 19

Result Engine responds to the Cab Throttle, Cruise Control Set/Resume, Cruise Pause, service brake, clutch and Neutral Switches Limits engine to 1200 RPM while in PTO mode If Go To Set Speed is programmed to Yes, engine will ramp to 1000 RPM when the PTO switch is closed. If Go To Set Speed is programmed to No, Toggling the Set/Accelerate Switch will cause the engine to ramp to 1000 RPM. Toggling the Set/Accelerate switch a second time will cause the engine to go to PTO TEL. Toggling the Resume/Decelerate Switch from PTO TEL will cause the engine to drop to 1000 RPM Toggling the Resume/Decelerate switch a second time will cause the engine to go to Low Idle. Engine ramps to 1200 RPM when switch is closed. Overrides Set Speed B. Overrides cab throttle/set speed Engine ramps to 1000 RPM when switch is closed and Switch For Set Speed A is open. Overrides Cab Throttle/set speed Enables the engine to go to the programmed Set Speed with PTO Switch On. Vehicle speed where vehicle speed kicks out PTO, returning the engine to low idle and control to cab throttle. Cab throttle is limited to Low Idle When the Torque Limit Switch is closed, the engine torque will be limited to 200 NM. The engine shuts down after PTO Mode has been active for 3 minutes. When the PTO switch is On, the ECM controlled cooling fan will be On. When PTO is Active, exceeding this vehicle speed will cause the engine RPM to lower in an attempt to maintain 20 mph. Engine will not enter into PTO mode until engine RPM drops to or is less than 1000 RPM. With switch closed, the engine will NOT Kickout of a “Set Speed” when one of the switches is activated. Output will turn On when the PTO Switch is On Output will turn On when PTO is On and Active.


81


16.14.2 Cab Switches Programmable Options The following list includes all of the programmable options available for the PTO Configuration Cab Switches: 1) Cruise/Idle/PTO Switch Configuration – determines the function of the Set and Resume inputs when held in position or toggled. The two options are Set-Accel, Resume – Decel or Set -Decel, Resume-Accel. This applies to cruise control, idle, and PTO modes of operation. If any PTO Engine RPM Set Speeds are programmed, the Set switch is an RPM increase switch and Resume is an RPM decrease switch for PTO. 2) Cruise Control Pause Switch Configuration – If programmed to J1939 Body Controller, Instrument Cluster or Cab Controller this switch will act like the service brake or clutch switches for causing the PTO Mode to kickout. If in the ON position, this switch will prevent the engine from entering into PTO mode. There is no programmable parameter for ignoring this switch. 3) PTO Kickout Vehicle Speed Limit – determines the vehicle speed operating range of the PTO inputs. If vehicle speed exceeds this limit the engine will either not allow an engine speed to be set, or disengage a set PTO speed. The PTO On/Off circuit has priority over Cruise Control On/Off and Fast Idle. A Vehicle Speed Input must be installed for this feature to function properly. 4) Ignore Brake/Clutch/Neutral Switch – allows the PTO mode to ignore the brake, clutch and neutral switch inputs and not kickout of PTO mode if any of the switches are activated. The Ignore Brake/Clutch/Neutral Switch input must be programmed to and installed at J1/P1: 47. 5) Maximum Vehicle Speed in PTO Mode – may be programmed to limit the vehicle speed while in PTO mode. Increasing vehicle speed past this limit will result in the engine being derated to maintain the programmed PTO mode vehicle speed limit. A Vehicle Speed Input must be installed for this feature to function properly. 6) Idle/PTO RPM Ramp Rate – determines the rate of engine speed acceleration/deceleration for the Resume, Accel, and Decel operation. Applies to both PTO and Idle engine speed control. 7) Idle/PTO Bump RPM – determines the amount of rpm increase/decrease when the Set/Resume switch is toggled in the Accel/Decel position. If a PTO Engine RPM Set Speed has been programmed this parameter applies to Idle only, where engine speed is set using the cruise control On/Off circuit. If PTO Engine RPM Set Speed has not been programmed this parameter applies to engine speed control using the cruise control On/Off and PTO On/Off circuit. 8) PTO Top Engine Limit – Top RPM Limit of the engine when the PTO On/Off circuit is ON. For applications requiring one PTO engine speed above low idle this parameter should be programmed to the same value as the PTO Engine RPM Set Speed parameter. For operation limiting PTO engine speed to two engine speeds above low idle with a toggle adjustment switch this parameter can be programmed to the top or second engine speed. 9) PTO Engine RPM Set Speed – program this parameter only if one or two specific engine speed points above low idle are desired. The programmed low idle and PTO Top Engine Limit bound this parameter. Program this parameter above low idle but less than the PTO Top Engine limit to get three discrete engine speeds. With the PTO circuit ON, toggling the Set switch once advances engine speed to this programmed value. Toggle the Set switch again and the engine speed proceeds to the PTO Top Engine Limit. Toggle the Resume switch and the engine speed is reduced to the programmed Set Speed. Toggle the Resume switch again to return the engine to Low Idle. Program this parameter to the same RPM as the PTO Top Engine Limit if only two discrete engine speeds are desired. 10) PTO to Set Speed – program this parameter only if the application requires the engine speed to ramp up to the PTO Engine RPM Set Speed whenever the PTO On/Off circuit is turned ON. 11) PTO Cab Throttle RPM Limit – program this parameter if the operation requires limiting engine speed to protect equipment. If programmed to Low Idle, this parameter has the affect of ignoring/disabling the accelerator pedal position sensor when the PTO On/Off circuit is ON.

82



If programmed to PTO TEL the accelerator pedal position sensor can be used to control the engine speed up to the programmed PTO TEL when the PTO On/Off circuit is ON. 12) Torque Limit – program this parameter to a value established by the system limits for operation when a lower than rated torque limit is desired to protect equipment used for PTO operation. This limit applies whenever the Torque Limit switch is ON. 13) Torque Limit Switch – must be programmed to J1/P1: 7 or J1/P1:23 and a switch must be installed corresponding to the programmed ECM terminal input for the Torque Limit option to work. 14) PTO Engine RPM Set Speed Input A – This parameter can be programmed to a desired set speed that can be attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input A must be programmed to J1/P1:46 (Input #7) and an additional switch installed for this feature to function. 15) PTO Engine RPM Set Speed B – This parameter can be programmed to a desired set speed that can be attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input B must be programmed to J1/P1:7 or J1/ P1:23 (Input #4 or Input #19) and an additional switch installed for this feature to function. 16) PTO Shutdown Time – This parameter is programmable between 3 to 1440 minutes (a value of 0 turns this feature Off). This parameter sets the duration of time (in minutes) that engine will operate, with the PTO On/Off circuit ON and no vehicle speed present, before shutting down. 17) PTO Activates Cooling Fan – This parameter determines if the engine cooling fan is on normally or Continuous while in PTO Mode. The Fan Control Type parameter must be programmed to other than None. 18) Transmission Neutral Switch – This parameter must be programmed to J1/P1:62 or J1939 if the Transmission Style parameter is programmed to Automatic Option 3, Automatic Option 4, AT/MT/HT Option 3 or AT/MT/HT Option 4.

16.14.3 Remote Switches The Remote Switches Configuration utilizes a dedicated PTO On/Off circuit (J1/P1: 56) and dedicated PTO Set (J1/P1: 58) and PTO Resume (J1/P1: 60) switch inputs. Two PTO Switch On Lamps are recommended. One in the operator station and one at the Remote PTO control location. The ECM will ignore the Cab controls (Cruise Switches, service brake, etc.) when PTO is On. The PTO Set/Resume switches can be used to Bump and Ramp engine speed if the PTO Engine Set Speed is not programmed.

- 12V +

CAB PTO SWITCH ON LAMP

REMOTE PTO SWITCH ON LAMP

PTO SET/RESUME (SET OFF POSITION) (RESUME OFF POSITION)

PTO ON/OFF

PTO INTERLOCK

ECM K998-BU K980-PK K982-YL 993-BR K999-GN

(PTO OFF POSITION)

30 58 60 3 56

OUTPUT #1 INPUT #2 INPUT #3 INPUT SENSOR COMMON #2 INPUT #1

P1 J1

NOTE: INPUT SENSOR COMMON #1 (TERMINAL-18) MAY BE USED IN PLACE OF INPUT SENSOR COMMON #2 (TERMINAL-3)

Wiring Diagram 23


83



Setting Remote Switches

PTO Top Engine Limit PTO Engine RPM Set Speed

1200 RPM 1000 RPM


1200 RPM


1000 RPM

PTO To Set Speed

Yes

PTO Kickout Vehicle Speed Limit PTO Cab Throttle Limit Torque Limit

2 mph Unavailable 200 NM

PTO Shutdown Time

3 minutes


Yes


1000 RPM

84

Unavailable

Result Engine ignores the Cab Throttle, Cruise Control Set/Resume, Cruise Pause, service brake, clutch and Neutral Switches. Limits engine to 1200 RPM while in PTO mode If Go To Set Speed is programmed to Yes, engine will ramp to 1000 RPM when the PTO switch is closed. If Go To Set Speed is programmed to No, Toggling the PTO Set Switch will cause the engine to ramp to 1000 RPM. Toggling the PTO Set switch a second time with the engine at 1000 RPM will cause the engine to go to PTO TEL. Toggling the PTO Resume Switch at PTO TEL will cause the engine to drop to 1000 RPM Toggling the PTO Resume switch a second time will cause the engine to go to Low Idle. Engine ramps to 1200 RPM when switch is closed. Overrides Set Speed B. Overrides existing Set Speed Engine ramps to 1000 RPM when switch is closed and Switch For Set Speed A is open. Overrides existing Set Speed Enables the engine to go to the programmed Set Speed with PTO Switch On. Vehicle speed where vehicle speed kicks out PTO, returning the engine to low idle. Ignored When the Torque Limit Switch is closed, the engine torque will be limited to 200 NM The engine shuts down after PTO Mode has been active for 3 minutes. When the PTO switch is On, the ECM controlled cooling fan will be On. When PTO is Active, exceeding this vehicle speed will cause the engine RPM to lower in an attempt to maintain 20 mph. Engine will not enter into PTO mode until engine RPM drops to or is less than 1000 RPM. Unavailable

J1/P1: 30 J1/P1: 19

Output will turn On when the PTO Switch is On Output will turn On when PTO is On and Active.

20 mph



16.14.4 Remote Switches Programmable Options The following list includes all of the programmable options available for the PTO Configuration Remote Switches. The options listed below are nearly identical to those for the Cab Switches Configuration. Differences include: the disabling of ECM response to all cab inputs (Cruise Control On/Off, Set/Resume, accelerator pedal position sensor, service brake pedal position, transmission neutral, and clutch pedal position switches) when the PTO On/ Off circuit is ON. 1) Cruise/Idle/PTO Switch Configuration – only affects Remote Switches if a Remote Set and Remote Resume are installed, and PTO Set Speeds are not programmed. If PTO Set Speeds are programmed, the PTO Set is always RPM increases, the PTO Resume is always a RPM decrease. 2) PTO Kickout Vehicle Speed Limit – determines the vehicle speed operating range of the PTO inputs. If vehicle speed exceeds this limit the engine will either not allow an engine speed to be set, or disengage a set PTO speed. The PTO On/Off circuit has priority over Fast Idle and Cruise Control On/Off circuits. The PTO Switch On Lamp will reflect this. 3) Maximum Vehicle Speed In PTO Mode – determines the vehicle speed limit IN PTO mode. The existing “Vehicle Speed Limit” parameter will have overriding authority over the “Maximum PTO Vehicle Speed”, should the Maximum PTO Vehicle Speed be programmed to a value higher than the Vehicle Speed Limit. A Vehicle Speed Input must be installed for this feature to function properly. NOTE: This feature differs from the existing “PTO Vehicle Speed Limit”, in that it does not cause a PTO Kickout when the limit is reached. Instead, it allows the engine to remain in PTO Mode, but limits engine speed to provide vehicle speed limiting. If the PTO Vehicle Speed Limit is programmed to a lower value than the Maximum PTO Vehicle Speed, the existing kickout functionality will be used. 4) Idle/PTO RPM Ramp Rate – determines the rate of engine speed acceleration/deceleration for the PTO and Idle engine speed control. 5) Idle/PTO Bump RPM – determines the amount of rpm increase/decrease if a PTO Set/Resume switch is toggled in the Accel/ Decel position. If a PTO Engine RPM Set Speed has been programmed this parameter does not apply to PTO. 6) PTO Top Engine Limit – Top RPM Limit of the engine when the PTO On/Off circuit is ON. 7) PTO Engine RPM Set Speed – program this parameter only if one or two specific engine speed points above low idle are desired. The programmed low idle and PTO Top Engine Limit bound this parameter. Program this parameter above low idle but less than the PTO Top Engine limit to get two discrete engine speeds above idle. With the PTO circuit ON, toggling the Set switch once advances engine speed to this programmed value. Toggle the Set switch again and the engine speed proceeds to the PTO Top Engine Limit. Toggle the Resume switch and the engine speed is reduced to the next lower operating speed. Program this parameter to the same RPM as the PTO Top Engine Limit if only one engine speed above idle is desired. 8) PTO to Set Speed – program this parameter only if the application wants the engine speed to ramp up to the PTO Engine RPM Set Speed whenever the PTO On/Off circuit is turned ON. 9) PTO Cab Throttle RPM Limit – this parameter has no affect on operation for the PTO Configuration Remote Switches- the Cab Throttle RPM Limit is always low idle when the PTO On/Off circuit is ON. 10) Torque Limit – program this parameter to a value established by the system limits for operation when a lower than rated torque limit is desired to protect equipment used for PTO operation. This limit applies whenever the Torque Limit Switch is ON. 11) Torque Limit Switch – must be programmed to J1/P1:7 or J1/P1:23 and a switch must be installed corresponding to the programmed ECM terminal input for the Torque Limit option to work. 12) PTO Engine RPM Set Speed A – This parameter can be programmed to a desired set speed that can be attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input A must be programmed to J1/P1:46 (Input #7) and an additional switch installed for this feature to function.


85


13) PTO Engine RPM Set Speed B – This parameter can be programmed to a desired set speed that can be attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input B must be programmed to J1/P1:7 or J1/ P1:23 (Input #4 or Input #19) and an additional switch installed for this feature to function. 14) PTO Shutdown Time – This parameter is programmable between 3 to 1440 minutes (a value of 0 turns off this feature). This parameter sets the duration of time (in minutes) that engine will operate, with the PTO On/Off circuit ON and no vehicle speed present, before shutting down. 15) PTO Activates Cooling Fan – This parameter determines if the engine cooling fan is on normally or Continuous while in PTO Mode. The Fan Control Type parameter must be programmed to other than None.

16.14.5 Remote Throttle The Remote Throttle Configuration utilizes the dedicated PTO On/Off circuit (J1/P1: 56), and requires a dedicated PTO throttle. This throttle MUST be connected at all times. Disconnecting this throttle will result in diagnostics codes and the Check Engine Lamp will be On. The Remote PTO Set/Resume switches are not required for this configuration. A pair of “PTO Switch On Lamps” (one in cab and the other at the remote location) is recommended. The Engine will respond to the Remote Throttle position but the throttle must be at minimum or returned to minimum before engine will respond. The PTO Set and Resume switches can be used to Bump and Ramp engine speed. The remote throttle can raise engine speed above a “Set Speed”.

- 12V +

CAB PTO SWITCH ON LAMP PTO SET/RESUME (SET OFF POSITION) (RESUME OFF POSITION) PTO ON/OFF

PTO INTERLOCK

(PTO OFF POSITION) ACCELERATOR POSITION SENSOR +BATTERY INPUT SENSOR COMMON #2 ACCELERATOR POSITION

REMOTE PTO SWITCH ON LAMP

ECM K998-BU K980-PK K982-YL K999-GN 993-BR G845-PU

30 58 60 56 3 68

OUTPUT #1 INPUT #2 INPUT #3 INPUT #1 INPUT SENSOR COMMON #2 INPUT #8

P1 J1 OR BK WH

A B C

Wiring Diagram 24

86




Setting Remote Throttle

PTO Top Engine Limit PTO Engine RPM Set Speed PTO Engine RPM Set Speed A

1200 RPM Unavailable

Result Engine ignores the Cab Throttle, Cruise Control Set/Resume, Cruise Pause, service brake, clutch and Neutral Switches. Limits engine to 1200 RPM while in PTO mode N/A

1200 RPM

Engine ramps to 1200 RPM when switch is closed.

Unavailable

Overrides Set Speed B. Overrides existing Set Speed Overrides Throttle. Engine ramps to 1000 RPM when switch is closed and Switch For Set Speed A is open. Overrides existing Set Speed Overrides Throttle. N/A Vehicle speed where vehicle speed kicks out PTO, returning the engine to low idle. Ignored When the Torque Limit Switch is closed, the engine torque will be limited to 200 NM. The engine shuts down after PTO Mode has been active for 3 minutes. When the PTO switch is On, the ECM controlled cooling fan will be On. When PTO is Active, exceeding this vehicle speed will cause the engine RPM to lower in an attempt to maintain 20 mph. Engine will not enter into PTO mode until engine RPM drops to or is less than 1000 RPM. Unavailable

J1/P1: 30 J1/P1: 19

Output will turn On when the PTO Switch is On Output will turn On when PTO is On and Active.


1000 RPM

PTO To Set Speed PTO Kickout Vehicle Speed Limit PTO Cab Throttle Limit Torque Limit

Unavailable 2 mph Unavailable 200 NM

PTO Shutdown Time

3 minutes


Yes


1000 RPM

20 mph

16.14.6 Remote Throttle Programmable Options The following list includes all of the programmable options available for the PTO Configuration Remote Throttle. The disabling of ECM response to cab inputs Cruise Control On/Off, Set/Resume, service brake pedal position and clutch pedal position switches, cab accelerator pedal sensor) occurs when the PTO On/Off circuit is ON. 1) Cruise/Idle/PTO Switch Configuration – determines the function of the Set and Resume inputs when held in position or toggled. The two options are Set-Accel, Resume – Decel or Set -Decel, Resume Accel. This applies to cruise control, PTO, and idle modes of operation.


87


2) PTO Vehicle Speed Limit – determines the vehicle speed operating range of the PTO inputs. If vehicle speed exceeds this limit the engine will either not allow an engine speed to be set, or disengage a set PTO speed. This parameter also applies to the Idle circuit if using the Cruise Control On/Off switch instead of the PTO On/Off circuit. The PTO On/Off circuit has priority over Fast Idle and Cruise Control On/Off. 3) Maximum Vehicle Speed in PTO Mode – may be programmed to limit the vehicle speed while in PTO mode. Increasing vehicle speed past this limit will result in the engine being derated to maintain the programmed PTO mode vehicle speed limit. 4) Idle/PTO RPM Ramp Rate – determines the rate of engine speed acceleration/deceleration for the resume, accel, and decel operation. Applies to both PTO and Idle engine speed control. 5) Idle/PTO Bump RPM – determines the amount of rpm increase/decrease when the Set/Resume switch is toggled in the Accel/Decel position. For the Remote Throttle configuration this parameter applies to engine speed control using the cruise control On/Off and PTO On/Off circuit. 6) PTO Top Engine Limit – Top RPM Limit of the engine when the PTO On/Off circuit is ON. 7) PTO Engine RPM Set Speed – this parameter is not available if the PTO Configuration is Remote Throttle. 8) PTO to Set Speed – this parameter is not available if the PTO Configuration is Remote Throttle. 9) PTO Cab Throttle RPM Limit – programming this parameter has no affect for the PTO Configuration Remote Throttle. 10) Torque Limit – program this parameter if a lower than rated torque limit is desired for equipment used for PTO operation, whenever the Torque Limit switch is ON. 11) PTO Engine RPM Set Speed A – This parameter can be programmed to a desired set speed that can be attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input A must be programmed to J1/P1: 46 and an additional switch installed for this feature to function. 12) PTO Engine RPM Set Speed B – This parameter can be programmed to a desired set speed that can be attained by turning on a dedicated switch during PTO operation. PTO Engine RPM Set Speed Input B must be programmed to J1/P1:7 or J1/ P1:23 and an additional switch installed for this feature to function. 13) PTO Shutdown Time – This parameter is programmable between 3 to 1440 minutes (a value of 0 turns off this feature). This parameter sets the duration of time (in minutes) that engine will operate, with the PTO On/Off circuit ON and no vehicle speed present, before shutting down. 14) PTO Activates Cooling Fan – This parameter determines if the engine cooling fan is on normally or Continuous while in PTO Mode. The Fan Control Type parameter must be programmed to other than None.

88



16.15 Programming examples: PTO Configuration set to Cab Switches or Remote Switches. For set engine speeds above Low Idle

Parameter PTO TEL ** PTO To Set Speed PTO Set Speed

Parameter setting 1500 rpm ** YES

Parameter setting 1500 rpm ** NO

1200 rpm

1200 rpm

Switch Input

Engine speed reaction


PTO Enable *Set/Accel

** Engine goes to 1200 rpm If at 1200 rpm, toggle once to go to 1500 rpm. N/A at 1500 rpm.

*Resume/Decel

N/A if at Low Idle. If at 1500 rpm Toggle once to go to 1200 rpm. Toggle again to go to low idle.

** Engine Stays at Low Idle If at Low Idle, Toggle once to go to 1200 rpm. Toggle again to go to 1500 rpm. N/A at 1500 rpm. N/A if at Low Idle. If at 1500 rpm Toggle once to go to 1200 rpm. Toggle again to go to low idle.

Notes: ** Notice difference in function with different “PTO To Set Speed” parameter settings. * With “PTO Set Speed” parameter programmed to an engine rpm, the “Cruise/Idle/PTO Switch Configuration” parameter setting has no effect on the cab cruise ‘Set’ and ‘Resume’ switches. For One desired speed above low idle, set the “PTO Set Speed” and the “PTO TEL” to the same rpm value. Throttle can override ‘PTO Set Speed’ rpm up to PTO TEL. The ‘Set’ switch will not set ‘PTO Set Speed’ to the throttle controlled engine speed.


89


Programming examples continued: PTO engine rpm control with Set Speed A and B PTO Configuration set to Cab Switches, Remote Switches or Remote Throttle

Parameter PTO TEL Set Speed A Set Speed B PTO to Set Speed

Parameter setting 1500 rpm 1000 rpm 1200 rpm No (N/A for Remote throttle)

Switch Input


PTO Enable Set Speed A Set Speed B

Engine Stays at Low Idle Engine speed ramps to 1000 rpm If Set Speed A is Off, Engine speed ramps to 1200 rpm.

Notes: Set Speed A and B switch inputs must be programmed. Set Speed A overrides Set Speed B, Cruise Accel, Cruise Decel, PTO set Speed and Throttle. Set Speed B Overrides Cruise Accel, Cruise Decel, PTO Set Speed and Throttle. If PTO To Set Speed is programmed to NO, switching A or B off returns the PTO Set Speed to Low Idle. If PTO To Set Speed is programmed to YES, switching A or B off returns to the programmed PTO Engine RPM Set Speed to Low Idle.

90



Programming examples continued: PTO Configuration set to Cab Switches, Remote Switches or Remote Throttle. To get variable engine speeds above low idle:

Parameter PTO TEL PTO To Set Speed PTO Set Speed Idle/PTO Ramp Rate Idle/PTO Bump Rate

Parameter setting 1500 rpm No (N/A for Remote throttle) 0 (N/A for Remote throttle) 50 rpm/sec 20 rpm

Switch Input

Engine Speed Reaction

PTO Enable *Set/Accel

Engine Stays at Low Idle Toggle once to set “PTO Set Speed” at current engine speed. Toggle to ‘Bump’ 20 rpm (up to 1500 rpm). Hold to ‘Ramp’ up @ 50 rpm/sec (up to 1500 rpm). N/A at 1500 rpm. N/A if PTO Set Speed not set. N/A if at Low Idle. Toggle to ‘Bump’ down 20 RPM (to Low Idle). Hold to ‘Ramp’ down @ 50 rpm/sec (to Low Idle).

*Resume/Decel

Notes: * The “Cruise/Idle/PTO Switch Configuration” parameter setting Does affect the Remote PTO Set and Resume switches. Throttle can override ‘PTO Set Speed’ rpm up to PTO TEL. The ‘Set’ switch will set ‘PTO Set Speed’ to the throttle controlled engine speed. Remote PTO Set and Resume switch inputs must be programmed for Remote Switches and Remote.


91


Programming examples continued: J1939 Based Cruise Switch Input Messages PTO Configuration set to Cab Switches. For set engine speeds above Low Idle

Parameter PTO TEL **PTO To Set Speed PTO Set Speed

Parameter setting 1500 rpm **YES

Parameter setting 1500 rpm **NO

1200 rpm

1200 rpm

Switch Input



PTO Enable

**Engine goes to 1200 rpm (“PTO Set Speed” has been set) N/A (“PTO Set Speed” has been set)

**Engine Stays at Low Idle

J1939 Set Message

J1939 Resume Message J1939 Cruise Accel Message

J1939 Decel Message

N/A If at Low Idle, Toggle once to go to 1200 rpm. Toggle again to go to 1500 rpm. N/A at PTO TEL (1500 rpm)

N/A if at Low Idle. If at 1500 rpm Toggle once to go to 1200 rpm. Toggle again to go to low idle.

Toggle once to raise RPM to 1200 rpm. (“PTO Set Speed” has been set) N/A Once a “PTO Set Speed” has been established. N/A After a “PTO Set Speed” has been established. If at Low Idle, Toggle once to go to 1200 rpm. Toggle again to go to 1500 rpm. N/A at PTO TEL (1500 rpm) N/A if at Low Idle. If at 1500 rpm Toggle once to go to 1200 rpm. Toggle again to go to low idle.

Notes: ** Notice difference in function with different “PTO To Set Speed” parameter settings. For One desired speed above low idle, set the “PTO Set Speed” and the “PTO TEL” to the same rpm value Throttle can override ‘PTO Set Speed’ rpm up to PTO TEL.

92



Programming examples continued: J1939 Based Switch Remote PTO Set & Resume Message Inputs PTO Configuration set to Remote Switches. For set engine speeds above low idle:

Parameter PTO TEL PTO To Set Speed PTO Set Speed Idle/PTO Ramp Rate Idle/PTO Bump Rate

1500 rpm Yes 1200 50 rpm/sec

Parameter setting 1500 rpm No 1200 50 rpm/sec

20 rpm

20 rpm

Switch Input



PTO Enable J1939 Remote PTO Set Message

** Engine goes to 1200 rpm Toggle and Engine goes to 1500 RPM

J1939 Remote PTO Resume Message

N/A @ Low Idle @ 1500 RPM, Toggle to reduce RPM to 1200 RPM. @1200 RPM, Toggle to reduce RPM to Low Idle NOT SUPPORTED

Engine Stays at Low Idle Toggle to increase rpm to 1200 RPM Toggle and Engine goes to 1500 RPM N/A @ Low Idle @ 1500 RPM, Toggle to reduce RPM to 1200 RPM. @1200 RPM, Toggle to reduce RPM to Low Idle NOT SUPPORTED

NOT SUPPORTED

NOT SUPPORTED

J1939 Remote PTO Accel Message J1939 Remote PTO Decel Message Notes:

The ECM will respond to the J1939 message (PGN 65,264 ($FEF) Byte 6 Bits 4-3 “Remote PTO preprogrammed speed control switch”) in the same manner as the PTO Engine Rpm Set Speed A hardwired switch input.


93


17.0 Programmable Outputs J1/P1: 10 (Output #2) can be used for a Starting Aid Output J1/P1: 12 Output #3 can be used for an Engine Exhaust Brake J1/P1: 13 (Output #4) can be used for an Engine Running Output 17.1 Programmable Output Electrical Specifications Electrical characteristics of the high side drivers are as follows: Minimum “On” Output Voltage

Maximum “On” Output Voltage

Maximum Current Draw

Off State

2.0 Volts DC

Battery voltage

1.5 Amps

High Impedance

This output can be connected to the coil side of a relay or directly to a solenoid (1.5 Amps maximum). If connected to a relay, the contact side of the relay should be connected to “+Battery” and the appropriate solenoid. Regardless if the output is used to connect to a solenoid or relay coil, Caterpillar recommends transient suppression be used on the inductive load in addition to the ECM internal protection. Circuit protection for the contact side of the relay and its grounding (when powering a relay) is left to the OEM’s discretion. Do not ground the relay or solenoid to the ECM Sensor Common connections. 17.2 Starting Aid Output A Starting Aid Output parameter is available to connect to a relay and/or solenoid to control a Continuous Flow Starting Aid System. The Starting Aid Output parameter can be programmed to use J1/P1: 10 (Output #2) by programming the Starting Aid Output parameter to “Automatic”. The Coolant Temperature reading is used to determine if conditions require use of the Starting Aid. If a fault condition exists with the Intake Manifold Air Temperature sensor circuit, the Intake Manifold Air Temperature Sensor reading will be used. If the temperature reading is below 0°C (32°F) and an attempt is made to start the engine, the Starting Aid Output will be enabled for up to 30 seconds while the engine is cranking. If the engine starts or a condition occurs that prevents fuel from being injected, the Staring Aid Output will be disabled.

E718 - PK

10

Output #2

Wiring Diagram 25

94



17.3 Engine Exhaust Brake The ECM can drive an OEM installed exhaust type engine brake solenoid directly or through an OEM installed relay. The Engine Exhaust Brake output will be enabled based upon Customer Parameter programming, engine speed, accelerator pedal position, clutch and brake engagement, and the cruise control ON/OFF switch setting. The exhaust brake output will be turned Off while the fuel injectors are delivering fuel to the engine. Connections for the exhaust brake: Description


Exhaust Brake Output

J1/P1: 12

Exhaust Brake Switch

J1/P1: 16

Sensor Common

J1/P1: 5 (3 or 18)

OEM provided and installed components required: 1) Exhaust Brake On/Off switch if transmission communicates over J1939. 2) OEM Installed Exhaust Brake. Customer Parameter programming required: 1) The Exhaust Brake Switch parameter must be programmed to J1/P1: 16 (Optional J1939 source).

EXHAUST BRAKE ON/OFF SWITCH (BRAKE OFF POSITION)


ECM C981-GY H795-PK E991-GY

16 5 12

EXHAUST BRAKE ON/OFF SWITCH AP SENSOR/SWITCH SENSOR COMMON OUTPUT #3

P1 J1

Wiring Diagram 26 - Exhaust Brake with Exhaust Brake Switch Programmed to Installed


95


If the On/Off Switch is installed in the Output Driver Circuit (terminal-12), the Exhaust Brake Switch parameter must be programmed to None (this setting MUST not be used if the transmission communicates over J1939).

EXHAUST BRAKE ON/OFF SWITCH

ECM

(BRAKE OFF POSITION)

E991-GY


12 OUTPUT #3 P1 J1

EXHAUST BRAKE SWITCH Programmed to NONE Wiring Diagram 27


EXHAUST BRAKE RELAY

+BATTERY

ECM E991-GY EXHAUST BRAKE ON/OFF SWITCH

12

OUTPUT #3

P1 J1

Wiring Diagram 28 - Exhaust Brake with Relay 17.3.1 Operation with the Cruise Control On/Off Switch in the OFF position The exhaust brake output is enabled under the following conditions: 1) Engine rpm is greater than 1000 rpm. 2) Driver’s foot is off the accelerator pedal (accelerator pedal position < 7%) and clutch pedal. 3) Dedicated PTO is not ON (PTO On/Off Switch OFF) 4) ECM Exhaust Brake Switch Input is ON (Exhaust Brake Switch parameter must be set to Installed) 5) Torque Converter Locked with vehicle speed 6) ABS is not requesting the Exhaust Brake to be OFF NOTE: If an Exhaust Brake On/Off Switch is installed in the Exhaust Brake OUTPUT circuit (Output #3), the Exhaust Brake will not function unless the On/Off switch is in the ON position (closed circuit).

17.3.2 Exhaust Brake Operation While In Cruise When the Exhaust Brake Mode parameter is programmed to “COAST” the exhaust brake will operate only with the service brakes applied, allowing the engine to coast with no braking after they are released. Programming the Exhaust Brake Mode parameter to “LATCH” allows braking with the service brakes applied and keeps the exhaust brake ON after the service brakes are released (until rpm drops below 900 rpm or the driver presses the accelerator or clutch pedal). Programming the Exhaust Brake Mode parameter to “MANUAL” provides identical operation whether the cruise On/Off switch is ON or OFF (but not while in cruise control).

96



17.3.3 Exhaust Brake Operation and Auto Retarder in Cruise When the Auto Retarder In Cruise parameter is programmed between “3 – 10” mph and Cruise Control is active, the exhaust brake will engage to help maintain the Cruise Control Set Speed. The Exhaust Brake in Cruise parameter value is the desired vehicle speed above the Cruise Control “Set Speed” to engage the exhaust brake. The exhaust brake will remain engaged until the vehicle speed has dropped below this value. The Exhaust Brake in Cruise option requires the optional Exhaust Brake Switch to be in the ON position. When the Auto Retarder In Cruise parameter is programmed to “0”, the feature is disabled. Some automatic transmissions will down shift when the engine retarder engages. Caterpillar recommends that the Auto Retarder In Cruise parameter value be set to a minimum of “5 mph” reduce transmission down shifting with the Auto retarder in Cruise feature. NOTE: If Soft Cruise is enabled, the programmable speed range over the Cruise Control Set Speed is 5 – 10 mph. OEM provided and installed components required: 1) Exhaust Brake On/Off switch (optional). 2) Service Brake Switch #1 (Service Brake Switch #2 as well if required for transmission style) Clutch Switch (transmission style dependent) 1) OEM Installed Exhaust Brake.

17.3.4 Exhaust Brake Operation as a Warm Up Device The Exhaust Brake may be used as an engine warm up device to add parasitic load to the engine to aid in attaining and maintaining normal engine operating temperatures. When programmed to Warm Up Only or Exhaust Brake & Warm Up, and the Exhaust Brake Switch is in the ON position (Exhaust Brake Switch Input is programmed to J1/P1:16 or a J1939 Data Link based source), the engine will ramp to the programmed Warm Up Mode Idle Speed and engage the Exhaust Brake. Warm Up Mode will kick-out once the engine is warmed up or if one of the following conditions are met: 1) The Service Brake is depressed 2) Clutch pedal is depressed (transmission style dependent) 3) Exhaust Retarder Switch OFF (Optional) 4) Vehicle in Gear (Optional neutral switch) 5) Throttle is depressed 6) Vehicle speed is more than 1 mph 7) ECM detects excessive engine load 8) Engine rpm is less than 500 or more than 1450 rpm OEM provided and installed components required: 1) Exhaust Brake On/Off switch. 2) Service Brake Switch #1 (Service Brake Switch #2 – transmission style dependent) 3) Clutch Switch (transmission style dependent) 4) OEM Installed Exhaust Brake. Customer Parameter programming required: 1) The Exhaust Brake Switch parameter must be programmed to J1/P1: 16, Cab Controller, Body Controller or Instrument Cluster. 2) Exhaust Brake/Warm Up Enable configuration programmed to Warm Up Only or Exhaust Brake & Warm Up 3) Warm Up Mode Idle Speed is programmed between 700 and 1400 rpm. Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____

97


17.3.5 Engine Exhaust Brake and Automatic Transmissions Automatic transmissions will utilize the exhaust brake status during a downshift when the exhaust brake is engaged. This exhaust brake status may come from the engine J1939 broadcast, or from a signal provided from the retarder circuit by chassis wiring. Consequently the integration of the engine, transmission, and chassis wiring must be taken into account when configuring the transmission and engine. Below are tables, which illustrate the required engine programming, based on the chassis and transmission configuration. 1) Chassis: Exhaust Brake Not Installed Transmission-to-retarder integration: Any ECM Programming Parameter

Setting

Exhaust Brake

None


None

2) Chassis: Exhaust Brake Installed Transmission-to-retarder integration: Transmission controller has input signal from engine ECM via chassis wiring ECM Programming Parameter

Setting

Exhaust Brake

Exhaust Brake Only, or Exhaust Brake + Warm Up


J1/P1:16, J1939 Cab Controller, J1939 Instrument Cluster or J1939 Body Controller

3) Chassis: Exhaust Brake Installed Transmission-to-retarder integration: Transmission uses J1939 ERC #1 message from the engine (not from the engine ECM retarder circuit). ECM Programming Parameter

Setting

Exhaust Brake

Exhaust Brake Only, or Exhaust Brake + Warm Up


J1/P1:16, J1939 Cab Controller, J1939 Instrument Cluster or J1939 Body Controller

17.4 Engine Running Output (Starter Lockout) The engine is running Output is available on J1/P1: 13. This output is capable of 1.5 Amps and can drive a relay or solenoid. This output can be used to disable the starter or other devices when the engine is running. A normally closed relay is recommended so that cranking can be achieved immediately at power up. During cranking, the ECM will energize the relay once the engine speed reaches 50 rpm below low idle (700-800 rpm). A normally closed relay is recommended because the ECM could see insufficient battery voltage during cranking, preventing the ECM from providing sufficient battery voltage to energize the relay. OEM provided and installed components required: 1) Engine Running Output Solenoid or Relay. Customer Parameter programming required: 2) None.

98



Connections for the engine running output:

ENGINE RUNNING OUTPUT RELAY (N/C)

TO VEHICLE + BATTERY

TO STARTER ECM

G836-WH

13 P1 J1

OUTPUT #4

Wiring Diagram 29 17.4.1 Optional Engine Running Output (GMT560 trucks only) Engine Running Output may be programmed to J1/P1: 31(Default) or None. When programmed to J1/P1: 31 the ECM will enable a low power circuit (300 milli-Amps) until the engine is within 50 RPM of the low idle limit. This output can be connected to the coil side of a relay (if the maximum current draw for the solenoid is less than 0.3 amps). The contact side of the relay should be connected to “+Battery” and the appropriate solenoid. Caterpillar recommends transient suppression be used on the inductive load in addition to the ECM internal protection. Circuit protection for the contact side of the relay and its grounding (when powering a relay) is left to the OEM’s discretion. Do not ground the relay or solenoid to the ECM Sensor Common connections.

Starter Enable Relay

ECM

G880 - PK

31

OUTPUT #9

- 12V + P1 J1

Wiring Diagram 30


99


18.0 Transmissions Caterpillar C7 and C9 engines can be connected to a variety of transmissions. The following table lists the available transmission style options and the required switch inputs for each option. Correct programming and switch wiring is required to provide proper cruise control, PTO, and Fast Idle operation. Transmission Style Parameter Setting

Switch Usage Service Brake #1 J1/P1: 45 *

Service Brake # 2 J1/P1: 64

Clutch J1/P1: 22*

Transmission Neutral J1/P1: 62**

Manual Option 1

X

–

X

–

Manual Option 2

X

X

X

–

Universal

X

X

X

X

Automatic Option 1

X

–

–

–

Automatic Option 2

X

X

–

–

Automatic Option 3

X

X

–

X

Automatic Option 4

X

–

–

X

AT/MT/HT Option 1

X

–

–

–

AT/MT/HT Option 2

X

–

–

–

AT/MT/HT Option 3

X

–

–

X

AT/MT/HT Option 4

X

–

–

X

*This switch input can be a J1939 message from the J1939 Instrument Cluster, J1939 Cab Controller, or J1939 Body Controller. **This switch input can be a J1939 message from the transmission. 18.1 Transmissions Equipped with J1939 Communication The C7 and C9 engines can communicate with transmissions over the SAE J1939 data link. The engine will respond to transmission requests for speed and torque limiting. Transmissions can request that the engine engage the auxiliary brake to assist in shifting or prevent shift cycling. The transmission may request that the engine’s auxiliary brake be disengaged to prevent damage to torque converter. 18.2 Recommendations for the Exhaust Brake The transmission torque converter cannot tolerate engine auxiliary brake operation if the torque converter clutch is not engaged. If the engine is equipped with an Exhaust Brake the Engine Exhaust Brake Switch parameter must be programmed to J1/P1:16 or one of the J1939 sourced inputs. A physical switch does not have to be installed as an open circuit is the same as an open switch. 18.3 Recommendations for Cooling Fan The cooling fan causes engine loading that may interfere with transmission shifting. The J1939 broadcast for engine load is adjusted to compensate for cooling fan loading. Caterpillar recommends the following: 1) ECM controlled cooling fan 2) Air Conditioning input for fan control 3) If used, the manual fan override switch must be an input to the ECM

100



18.4 Allison WT Series The Allison WT requires connection to the SAE J1587/J1708 or SAE J1939 data link to communicate to the C7 or C9 ECM. OEM provided and installed components required: 1) SAE J1587 or SAE J1939 Data link connection to the Allison transmission control. 2) If the Transmission Style parameter is programmed to Automatic Option 2 or Automatic Option 3, connect Input #13 to Brake Switch #2. 3) If the Transmission Style parameter is programmed to Automatic Option 3, Automatic Option 4 or Universal, connect the Neutral switch to Input #12 or the SAE J1939 data link. Customer Parameter programming required: 1) Transmission Style parameter programmed to Automatic Option 1, Automatic Option 2, Automatic Option 3, or Automatic Option 4. 2) Driveline Data Link parameter programmed to J1939 3) Transmission Neutral Switch parameter programmed to J1/P1:62 or J1939 (Transmission Style dependent) 18.5 Allison 1000 & 2000 Series The Allison 1000 and 2000 Series transmissions REQUIRE connection to the J1939 data link to communicate to the C7 or C9 ECM. OEM provided and installed components required: 1) SAE J1587 or SAE J1939 Data link connection to the Allison transmission control. 2) If the Transmission Style parameter is programmed to Automatic Option 2 or Automatic Option 3, connect Input #13 to Brake Switch #2. 3) If the Transmission Style parameter is programmed to Automatic Option 3 or Automatic Option 4, connect the Neutral switch to Input #12 or the SAE J1939 data link. Customer Parameter programming required: 1) Transmission Style parameter programmed to Automatic Option 1, Automatic Option 2, Automatic Option 3, or Automatic Option 4. 2) Driveline Data Link parameter programmed to J1939 3) Transmission Neutral Switch parameter programmed to J1/P1:62 or J1939 18.6 Allison AT/MT/HT Transmissions The Allison AT/MT/HT (non-electronic) transmissions require an input from the ECM to regulate transmission shifting. The ECM does not control the transmission shift schedule. The ECM monitors accelerator pedal position, engine speed, load, and cruise control status to determine if the transmission should use “closed throttle” or “full throttle” shift modulation. Programming the Transmission Style parameter to AT/MT/HT Option 1, AT/MT/HT Option 2, AT/MT/HT Option 3, or AT/MT/HT Option 4 activates 7J1/P1: 20 to control a shift interface relay connected to the transmission. This output does not control an Allison AT/MT/HT transmission with an ATEC control. The Shift Modulation setting is selectable by programming the AT/MT/HT Part Throttle Shift Speed parameter. Three different modulation settings are available: Low (80% ON/65% OFF), Medium (70% ON/55% OFF), and High (60% ON/45% OFF). The High setting is the default setting, which will cause the transmission to remain in a lower gear longer (higher engine speed before shift occurs). The Medium setting is a compromise between the Default and the High setting. NOTE: Contact Allison Transmissions regarding recommended settings of this parameter for your application.


101


OEM provided and installed components required: 1) Shift Interface Relay. 2) J1/P1: 20 connected to the Shift Interface Relay. 3) Allison AT/MT/HT mechanical transmission with shift modulator. If the Transmission Style parameter is programmed to AT/MT/HT Option 2 or AT/MT/HT Option 3, connect J1/P1: 64 to Service Brake Pedal Position Switch #2. If the Transmission Style parameter is programmed to AT/MT/HT Option 3 or AT/MT/HT Option 4, connect J1/P1: 62 to the Transmission Neutral Switch. Customer Parameter programming required: 1) Transmission Style programmed to AT/MT/HT Option 1, AT/MT/HT Option 2, AT/MT/HT Option 3, or AT/MT/HT Option 4. 2) AT/MT/HT Part Throttle Shift Speed programmed to desired setting – Low, Medium or High. 18.7 Allison AT/MT/HT Shift Interface Relay Operation The AT/MT/HT Relay Circuit is provided by the ECM to indicate when the transmission should utilize closed throttle modulation or full throttle modulation. This allows the transmission to select Economy Mode or Performance mode. Operation of the relay is different depending upon whether cruise control is active or inactive. NOTE: Minimum ON and OFF time of the driver is based on vehicle speed changes.

C ALLISON ELECTRIC M MODULATOR

ALLISON AT/MT RELAY

+IGNITION

ECM G839-BU

20

OUTPUT #7

J1 P1

Wiring Diagram 31 18.7.1 Shift Relay Operation with Cruise Control or Vehicle Speed Limiting Not Active If enabled, the AT/MT/HT Relay is disabled under any of the following conditions: 1) Engine is not running. 2) Accelerator Pedal Position less than he AT/MT/HT Part Throttle Shift Speed setting: Low = 65%, Medium = 55%, or High = 45% (default). If disabled, the AT/MT/HT Relay is enabled when all of the following conditions are met: 1) Engine is running. 2) Accelerator Pedal Position greater than the AT/MT/HT Part Throttle Shift Speed setting: Low = 80%, Medium = 70%, or High = 60% (default).

102



18.7.2 Shift Relay Operation with Cruise Control or Vehicle Speed Limiting Active If enabled, the AT/MT/HT Relay is disabled when all of the following conditions are met: 1) Vehicle speed is greater than or within 2 mph (3.2 km/h) of the Cruise Set Speed or the Vehicle Speed Limit. 2) Unfiltered Load factor is < 75%. 3) Engine Speed > 2000 rpm. If disabled, the AT/MT/HT Relay is enabled when the following conditions are met: 1) Filtered Load factor is > 98% 2) Vehicle Speed is more than 4 mph below the Cruise set speed.


103


19.0 Governor Type The ECM has the capability of being programmed to one of two governor types. These governor types are Full Range and Min/Max. 19.1 Full Range Governor The Full Range governor is an engine speed governor that works on the principle that the engine will try to maintain an engine speed for a given throttle position. This governor type is recommended for all manual transmissions. Customer Parameter programming required: Governor Type programmed to Full Range. 19.2 Min/Max Governor The purpose of this feature is to provide an alternative type of engine speed governor commonly referred to as “Min/Max Governor.” This governor essentially only “governs” engine speed when at the minimum or maximum allowed engine speed. When in between these limits, the throttle -position will cause the engine to produce power proportional to its value. The benefit of this type of governor is smoother shifting for engines with automatic/ automated transmissions. Includes: Eaton Autoshift, Merritor Freedom, SureShift, All Allison and ZF Customer Parameter programming required: Governor Type programmed to Min/Max.

Power

% 80

% 50

% 20

80%

100% Throttle Lug Curve, both governors

Full Range Throttle Position

ax M i n t tl e M ro i on T h osi t P

50%

20%

ENGINE SPEED – > Figure 36

104



19.3 Min/Max Governor with Speed Control The Min/Max Governor with Speed Control feature allows the engine to switch to the Full Range Governor response characteristics when the Vehicle speed is less than 1 mph or when the transmission neutral switch (required) indicates that the transmission is in neutral. When the engine senses that the vehicle is in gear or is moving one mph or faster, the Min/Max Governor will take over. Note: When the transmission style programming expects a neutral switch input, programming the Neutral Switch Input to “None” causes the ECM to assume that the transmission is in gear at all times. OEM provided and installed components required: 1) Vehicle Speed Input 2) Neutral switch (hardwired switch input or J1939 message) Customer Parameter programming required: 1) Governor Type programmed to Min/Max with Speed Control 2) Transmission Neutral Switch programmed to J1/P1: 62 or J1939 3) Vehicle Speed Input programmed to J1/P1: 32 & 33, J1939 trans or J1939 ABSs


105


20.0 Cooling Fan The ECM provides a programmable parameter, Fan Control Type, and an output terminal, J1/P1: 11, for optional cooling fan control. The Fan Control Type parameter two options for types of cooling fan control systems. The Fan Control Type parameter also includes optional output signal types for design flexibility. 20.1 Fan Control basics The fan control output available at J1/P1: 11 provides a “High” for fan Off and “Low” for fan On. Because an electrical open circuit is the most likely failure mode, Caterpillar recommends a normally open circuit(s). The fan control is based on engine coolant temperature, engine retarder operation, intake manifold temperature and engine speed. Optional inputs can include an A/C compressor pressure switch, operator controlled Fan Override Switch and PTO programming. The Electronic Technician service tool can also cause the fan to turn on with special tests. During engine cranking, the ECM turns the output(s) OFF (fan ON) to prevent unnecessary cycling due to reduced voltage levels. The ECM controlled Cooling Fan may be turned ON with a J1939 based Fan Override Switch message. This allows the operator to turn the fan ON whenever the switch is closed for additional engine retarding and/or cooling. The J1939 Fan Override message may also be based from the transmission. When vehicle operating conditions cause elevated transmission oil temperatures, the transmission can broadcast the J1939 based Fan Override message to turn the fan ON for the required cooling. 20.2 Fan Control Options The Fan Control Type parameter determines what kind of fan the ECM is to control and the type of output signal. The Fan Control Type programmable options are On-Off PWM, On-Off DC, Variable Speed Option S and NONE (default). Program this parameter to NONE if the ECM is not connected to the Cooling Fan circuit. The DC and PWM options describe the output signal types available at J1:P1: 11. Fan Control Programming

Output at J1/P1:11 With Fan Off

Output at J1/P1: 11 With Fan On

Current Capability

On/Off PWM

225 Hz Square Wave, 0 Volts to Battery Voltage, @ 90% Duty Cycle

0 Volts

1.5 Amperes

On/Off DC

Battery Voltage

0 Volts

1.0 Amperes

Variable Speed Option S

80 HZ Square Wave, 0 to Battery voltage @~ 80 % Duty Cycle

225 HZ Square Wave, 0 to Battery voltage @~ 20 % Duty Cycle

This output can be connected to the coil side of a relay or directly to a solenoid (if the maximum current draw for the solenoid is less than 1.5 amps). If connected to a relay, the contact side of the relay should be connected to “+Battery” and the appropriate solenoid. Regardless if the output is used to connect to a solenoid or relay coil, Caterpillar recommends transient suppression be used on the inductive load in addition to the ECM internal protection. Circuit protection for the contact side of the relay and its grounding (when powering a relay) is left to the OEM’s discretion.

106



ECM

G837-YL

11

OUTPUT #5

P1 J1

Wiring Diagram 32 20.3 Cooling Fan Output Operation (On/Off) If the Fan Control Type parameter is programmed to ON/OFF the ECM provides control of an ON-OFF fan clutch. The Cooling Fan circuit sends out a high signal to turn the fan OFF. The fan comes ON in the event of an output circuit failure such as an open circuit. This requires a relay with normally open contacts (if powering the coil side of a relay), or a solenoid valve that deactivates the fan when it receives the disable (high) signal. Additional switching devices in the circuit should cause an open circuit to turn the fan ON. This circuit is designed to withstand a short circuit to “+Battery” voltage and will not be adversely affected if other devices are connected to this line when directly driving a solenoid. When driving a relay, connection of other devices to the Cooling Fan Output should not be necessary. To prevent unnecessary cooling fan cycling due to reduced voltage levels during engine cranking, the ECM turns the output OFF (fan ON). Because an electrical open circuit is the most likely failure mode, Caterpillar recommends a normally open circuit. The ECM will turn the cooling fan ON under any of the following conditions if engine rpm is less than 2750 rpm. 1) Engine Not Running. 2) During Engine Cranking. 3) Coolant Sensor Temperature > 207°F (97°C). 4) Active Coolant Temperature Sensor Diagnostic. 5) Inlet Manifold Air Temperature > 190°F (88°C). 6) Inlet Manifold Air Temperature > 163°F (73°C) with Boost Pressure > 10 psi (70 kPa). 7) Exhaust Brake ON > 2 seconds, when Fan With Engine Brake ON parameter is programmed to YES 8) A/C High Pressure Switch Input is Open or ECM is Counting. 9) PTO On/Off Switch in the ON position (PTO Activates Cooling Fan parameter is programmed to Continuous). 10) J1939 Fan Override Switch Message is =>95.2% (ON). Item 7, 8, and 9 are dependent upon Customer Parameters as shown in the following table ECM Input

Customer Parameter

Exhaust Brake On > 2 Seconds

Fan On with Engine Brake On

J1/P1: 41 (A/C High Pressure Switch)

A/C Switch Fan On-Time

J1/P1: 56

PTO Activates Cooling Fan

J1/P1: 41

A/C High Pressure Switch

J1/P1: 62


J1939 Data link

Fan Override Switch Message


107


NOTICE Caterpillar requires the OEM to install a warning sticker near the fan indicating the fan is automatically controlled and may come ON at any time. ECM will keep the fan ON for 2 seconds after the engine has reached the programmed low idle (700 – 750 rpm). This is done because unstable vehicle battery voltage during cranking may cause the fan to cycle. The fan will be turned OFF by the control (after being turned ON) if engine rpm exceeds 2800 rpm or when all the following circumstances are met. 1) Coolant Sensor Temperature < 196°F (91°C) and Inlet Manifold Air Temperature < 151°F (66°C). 2) The fan has been ON for at least 30 seconds or the programmed A/C Pressure Switch Fan On Time. 3) Exhaust Brake ON Strategy is not Active, when Fan With Engine Brake ON parameter is programmed to YES 4) A/C High Pressure Switch is not Active. 5) The PTO On/Off Switch in the OFF position, when PTO Activates Cooling Fan parameter is programmed to Continuous. 6) J1939 Fan Override Switch message is <=94.8% (OFF). OEM provided and installed components required: 1) Solenoid or Solenoid and Relay. 2) J1939 Data Link 3) Fan Override Switch Customer Parameter programming required: 1) Cooling Fan Type programmed to On-Off Fan 2) A/C High Pressure Switch programmed to J1/P1: 41 3) A/C Fan Request programmed to J1/P1: 41 or J1/P1:62 (GMT-560 Only) 4) Fan Override Switch programmed to other than “None”. 5) Powertrain Data Link programmed to J1939. 20.4 Cooling Fan Output Operation (Variable Speed Fan Option S) The variable speed fan control is based on a fan system manufactured by Sauer-Danfoss. When the Fan Control Type parameter is programmed to Variable Speed Option S, the Engine Control Module provides a pulse width modulated (PWM) signal for open loop control. This output to the Fan Drive Controller (FDC) will vary fan speed in proportion to cooling demand. Any system non-linearity is compensated for by the FDC. The fan control will turn the fan FULL On (100%) during those conditions that require the fan to be On. These conditions include but are not restricted to: fan ON during PTO mode and fan ON with the exhaust brake engaged. Note: The Fan Override Switch message over J1939 will not vary the fan speed. The fan will be turned ON (100%) when the Switch Message value is =>95.2%.

108



ECM Fan Drive

G837-YL

Controller

11

Output #5

J1 P1 Wiring Diagram 33 ECM Request for ECM Request for 0% Cooling 100% Cooling 93 Deg C 101 Deg C 100

PWM Fault Detection 0% Cooling

PWM % Duty Cycle

50

100% Cooling PWM Fault Detection

0 50

60

70

80

90

100

110

Coolant Temperature (Deg C)

Figure 37 The ECM will turn the cooling fan ON for a minimum of 30 seconds under any of the following conditions if engine rpm is less than 2750 rpm. 1) Engine Running less than 2 seconds (100%). 2) Coolant Sensor Temperature > 199°F (93°C). 3) Active Coolant Temperature Sensor Diagnostic (100%). 4) Inlet Manifold Air Temperature > 189°F (87°C) (100%). 5) Inlet Manifold Air Temperature > 162°F (72°C) with Boost Pressure > 10 psi (70 kPa) (100%). 6) Exhaust Brake ON > 2 seconds, when Fan With Engine Brake ON parameter is programmed to YES 7) (100%) 8) A/C High Pressure Switch Input is Open or A/C Switch On Time Counter is Counting (50%).


109


9) PTO On/Off Switch is in the ON position (PTO Activates Cooling Fan parameter is programmed to Continuous – 100%) 10) J1939 Fan Override Switch message received as =>95.2%. Item 6, 7, and 8 are dependent upon Customer Parameters as shown in the following table ECM Input

Customer Parameter

Exhaust Brake ON > 2 seconds

Fan with Engine Brake On

J1/P1: 41 (A/C High Pressure Switch)

A/C High Pressure Switch

J1/P1: 56 (PTO On/Off Switch)


J1939 Data Link

Fan Override Switch A/C Switch Fan On Time

The fan will be turned OFF (0%) by the control (after being turned ON) if engine rpm exceeds 2800 rpm or when all the following circumstances are met. 1) Coolant Sensor Temperature < 198°F (92°C). 2) The fan has been ON for at least 30 seconds or the programmed A/C Pressure Switch Fan On Time is finished counting. 3) Inlet Manifold Air Temperature < 151°F (66°C). 4) Exhaust Brake ON Strategy is not Active, when Fan With Engine Brake ON parameter is programmed to YES. 5) A/C High Pressure Switch is not open. 6) PTO On/Off Switch is in the OFF position. (PTO Activates Cooling Fan parameter is programmed to Continuous) 7) J1939 Fan Override Switch message <=94.8% (fan OFF). EM provided and installed components required: 1) Fan Drive Controller. 2) Variable Speed Fan 3) Fan Override Switch 4) J1939 Data Link Customer Parameter programming required: 1) Cooling Fan Type programmed to Variable Speed Fan Option S. 2) Fan Override Switch programmed to other than “None”. 3) Powertrain Data Link programmed to J1939 20.5 Cooling Fan Control with the Ignition Key Off The Cooling fan output will remain powered (On/Off Fan disengaged) for up to 10 seconds after the ignition key has been turned off. This allows enough time for the engine to stop rotating before the fan solenoid is engaged. This helps to limit fan belt damage due to fan inertia.

110



20.6 Air Conditioning High Pressure Switch Programming the A/C High Pressure Switch parameter to J1/P1:41 (default is None) allows the ECM to respond to a normally closed high pressure A/C switch. This switch opens when the refrigerant pressure exceeds the desired level. The ECM has a timer available to prevent excessive cycling of the cooling fan clutch due to successive cycling of the A/C switch input. The timer is programmable from 0 to 600 seconds, with 0 seconds indicating the feature is OFF (the default). Typical programming is 30 seconds, with 1 second recommended for systems connecting this input to other controls with their own built in timers. OEM provided and installed components required: 1) Normally closed high pressure A/C switch. 2) Cooling fan connection to Terminal 11(Output #5). Customer Parameter programming required: 1) Fan Control Type programmed to On-Off or Variable Speed Fan Option S. 2) A/C Switch Fan On-Time programmed in the 1 – 600 second range (0 = disabled).

High Press. Refrigerant Pressure

Low Press.

A/C Pressure Switch Circuit

Switch Open Switch Closed

Cooling Fan

Fan On Fan Off

A/C Fan Switch On Time

Output #5

Output #5 On Output #5 Off

Figure 38 Caterpillar Pub # LEBT2835-02________C7 & C9 ACERT Truck Engines________EPA 2004_____

111


ECM A/C HIGH PRESSURE SWITCH (FAN ON POSITION)

G837-YL E971-GN H795-PK

11 41 5 P1 J1

OUTPUT #5 INPUT #11 AP SENSOR/SWITCH SENSOR COMMON

Wiring DIagram 34 20.7 A/C Fan request Switch (GMT560 Only) Programming the A/C Fan Request parameter may be used to activate the Cooling Fan when programmed to J1/P1 41 or J1/P1: 62 (Default is None) whenever the air conditioning compressor clutch is engaged. The fan control will follow previously described functionality when activated by this switch input. Note: J1/P1: 41 is a switch to ground input and J1/P1: 62 is a switch to battery input.

+

12V

ECM

-

Vehicle A/C Control Circuit

41 5 P1 J1

Input #11 AP Sensor/Switch Sensor Common

Program A/C Fan Request Switch parameter to J1/P1:41

A/C Compressor Clutch

Wiring DIagram 35

+

12V

ECM

Vehicle A/C Control Circuit

62

Input #12

P1 J1

Program A/C Fan Request Switch parameter to J1/P1:62

A/C Compressor Clutch

Wiring DIagram 36

112



21.0 Idle Shutdown Timer To conserve fuel, the control system can be programmed to shut down the engine. The engine will shut down if it operates under reduced load with the vehicle stationary for a customer-defined period of time. This feature does not shut off vehicle electrical power. The Idle Shutdown Timer can be programmed between 1 and 1,440 minutes. The check engine lamp will begin to flash when the Idle Shutdown Timer enters the Driver Alert phase of the Idle Shutdown sequence. The Driver Alert phase is determined by the number of minutes programmed for the Idle Shutdown Timer, during this phase the check engine lamp will flash, warning the driver of an impending engine shutdown. When the Idle Shutdown Timer is programmed to one minute, the check engine lamp will begin to flash thirty seconds before the programmed time expires. If the Idle Shutdown Timer is programmed to two minutes or more, the check engine lamp will begin to flash ninety seconds before the programmed time expires. The operator can move the clutch or service brake during Driver Alert to override the timer. When the timer is overridden a diagnostic event is logged. The timer will remain in Override until the ECM has detected that the vehicle has moved. The status of the Shutdown Timer will be broadcast as part of the J1939 Data Link SHUTDOWN message $FEE4 (65,252). Note: If the transmission neutral switch is programmed and installed, the idle shutdown timer will not start counting if the transmission indicates that the transmission is in gear. OEM provided and installed components required: 1) Vehicle speed source. 2) Check Engine Lamp. 3) Service Brake Pedal Position Switch #1. (Service Brake Switch #2 if required by transmission style). 4) Clutch Pedal Position Switch. (If Transmission Style is programmed to Manual Option 1 or 2, Universal). 5) Transmission Neutral Switch (If Transmission style parameter is programmed to Automatic Option 3, Automatic option 4, AT/MT/HT Option 3, or AT/MT/HT Option 4). Customer Parameter programming required: 1) Idle Shutdown Time programmed in the 1 – 1440 minutes range. 2) Vehicle Speed Calibration. 21.1 Cold Mode Idle Shutdown Timer Enable The Idle Shutdown Timer is disabled if Engine Coolant Temperature is less than 38 DEG C (100 DEG F) and the engine is running less than 15 minutes. After 15 minutes, the Idle Shutdown Timer is enabled regardless of engine coolant temperature. The default is set to Disabled. When programmed to Enabled, the Idle Shutdown Timer will begin counting down immediately once the engine reaches low idle. Regardless of Engine Coolant Temperature or how long the engine has been running.


113


22.0 Data Links An OEM installed wiring harness to a cab mounted diagnostic connector is necessary to allow for accessing the data link with a service tool. There is not a diagnostic connector supplied in the engine harness. Caterpillar requests the vehicle OEM install a diagnostic connector in the engine compartment for those applications where the cab diagnostic connector is too far away for practical service of the engine. For an engine compartment mounted diagnostic connector, Caterpillar recommends grounding the engine data link connector directly to the engine ground stud through a splice into either “-Battery” wire (Connector P1, terminal 65 or 67). It must not be grounded to ECM Sensor Common connections. An example application for an engine compartment installed diagnostic connector would be found on a bus or RV with a rear-mounted engine. 22.1 SAE J1587/J1708 Data Link The ECM has a standard data link available for communicating with electronic service tools, dash displays, and certain transmissions. The ATA (American Trucking Association), SAE J1587/SAE J1708 Data Link is standard on all Caterpillar Truck Engines. The ATA data link can reduce duplication of engine and vehicle sensors by allowing other control systems to share sensor information. The ATA data link is used to communicate with Caterpillar Pocket Technician and Caterpillar Electronic Technician service tools. The ATA data link does not require a Customer Parameter to activate. The data link follows SAE recommended practice J1708 for hardware and SAE recommended practice J1587 for the communication protocol. The following diagrams represent the ATA data link installed into a 6-terminal or 9-terminal dash connectors. +BATTERY C -BATTERY E D F J1587 DL- B J1587 DL+ A

ECM

9 8 P1 J1

E793-BU E794-YL

J1587 DATA LINK NEGATIVE J1587 DATA LINK POSITIVE

Wiring DIagram 37 +BATTERY B -BATTERY A J1587 DLJ1587 DL+ J1939 DATA LINK SHIELD J1939 DATA LINK J1939 DATA LINK +

G F E D C

ECM E793-BU E794-YL A249-BK K990-GN K900-YL

9 8 42 34 50

J1587 DATA LINK NEGATIVE J1587 DATA LINK POSITIVE J1939 DATA LINK SHIELD J1939 DATA LINK J1939 DATA LINK +

P1 J1

Wiring DIagram 38 Note: The above connector is black in color with a “Keyed center pin”. This connector requires Caterpillar # 157-4829 Adapter Harness for connection to the Caterpillar # 139-4166 Service Tool Cable.

114



- BATTERY + BATTERY

B A

J1587 DLJ1587 DL+ J1939 DATA LINK SHIELD J1939 DATA LINK J1939 DATA LINK +

H J C F G

ECM E793-BU E794-YL A249-BK K990-GN K900-YL

9 8 42 34 50

J1587 DATA LINK NEGATIVE J1587 DATA LINK POSITIVE J1939 DATA LINK SHIELD J1939 DATA LINK J1939 DATA LINK +

P1 J1

Wiring DIagram 39 Note: The above connector is gray in color and connects directly to the Caterpillar # 139-4166 Service Tool Cable.

22.1.1 SAE J1587 Data Link Broadcast Parameters SAE J1708/J1587 data link parameters, parameter identifiers (PID’s), size, scaling, and broadcast period for C7 and C9 engines are as follows: Message Identifier (MID) – 128 [engine control MID] Broadcast Period

Parameter Name

PID

Size

Scaling per Bit

0.1 sec

Road Speed

84

1

0.5 mph

Cruise Control Set Speed

86

1

0.5

Percent Accelerator Pedal Position

91

1

0.4

Percent Engine Load

92

1

0.5

Power Take Off Set Speed

187

2

0.25

Engine Speed

190

2

0.25

Engine Status

2

1

Bit Code

Cruise Control Status

85

1

Bit Code

Engine Retarder Switches Status

40

1

Bit Code

Engine Retarder Status

121

1

Bit Code

Fuel Rate

183

2

4.34 10-6 gal

Instantaneous Fuel Economy

184

2

1/256 mpg

Parking Brake Status

70

1

Bit Code

Idle Shutdown Status

71

1

Bit Code

Road Speed Limit Status

83

1

Bit Code

Power Take Off Status

89

1

Bit Code

Engine Oil Pressure

100

1

0.125 PSI

Boost Pressure

102

1

0.125 PSI

Inlet Manifold Pressure

105

1

1 DEG F

Coolant Temperature

110

1

1 DEG F

Injection Actuation Pressure

164

2

1/256 Mpa

ECM Battery Voltage

168

2

0.05

Engine Diagnostic

194

Variable

PID/SID & FMI

0.2 sec

1.0 sec


115


Broadcast Period

Parameter Name

PID

Size

Scaling per Bit

10.0 sec

Cruise Control Set Speed

86

1

0.5 mph

Atmospheric Pressure

108

1

0.0625 PSI

Average Fuel Economy

185

2

1/256 mpg

Power Take Off Set Speed

187

2

0.25 rpm

Total Miles

245

4

0.1 miles

Retarder Inhibit Status

62

1

Bit Code

Road Speed Limit

74

1

0.5 mph

High Cruise Control Speed Set Limit

87

1

0.5 mph

Low Cruise Control Speed Set Limit

88

1

0.5 mph

Rated Horse Power

166

2

1.0 BHP

Engine Idle RPM Speed

188

2

0.25 rpm

Engine Rated RPM Speed

189

2

0.25 rpm

Software Identification (Cat P/N)

234

10

ASCII Char.

Total Idle Hours

235

4

0.05 hours

Total Idle Fuel Consumption

236

4

0.05 hours

Vehicle Identification

237

17

ASCII Char.

Total Engine Hours

247

4

0.05 hours

Total Engine PTO Hours

248

4

0.05 hours

Clock

251

3

Char 1 = 0.25 sec/bit Char 2 = 1 min/bit Char 3 = 1 hr/bit

Date

252

3

Char 1 = 0.25 day/bit Char 2 = 1 month/bit Char 3 = 1 year/bit

Total Fuel Consumption

250

4

0.125 gal

On Request

116



Broadcast Period

Parameter Name

PID

Size

Scaling per Bit

On Request (Sent as a multipacket message)

Component Identification Message #1 Byte 1- MID = 128

243

21

ASCII Char.

Byte 2- PID for multi-packet message = 192 Byte 3- number of characters following = 16 Byte 4- Requested PID 243 = 243 Byte 5- Last and current section number = 16 Byte 6- Byte count of total data portion = 21 Byte 7-19 – PID 243 data portion = 128, ASCII Characters = CTRPL*C7 or CTRPL*C9 Byte 29 – Checksum Message #2 Byte 1- MID = 128 Byte 2- PID for multi-packet message = 192 Byte 3- number of characters following = 11 Byte 4- Requested PID 243 = 243 Byte 5- Last and current section number = 17 Byte 6- Byte count of total data portion = 8 Byte 7-14 – PID 243 data portion = 128, ASCII Characters = C7 or C9 Byte 15- Checksum

22.1.2 Bit Code Definition Status Definition:

Parameter Name

Indication

Indication

Bit 7

undefined

0 = not active

1 = active

Bit 6

Powertrain Data Link

0 = not active

1 = active

Bit 5

undefined

0 = not active

1 = active

Bit 4

undefined

0 = not active

1 = active

Bit 3

Cold Mode

0 = not active

1 = active

Bit 2

Road Speed Limit

0 = not active

1 = active

Bit 1

Top Engine Limit

0 = not active

1 = active

Bit 0

Engine Shutdown

0 = not active

1 = active

Engine Status Code Definitions (PID 2):


117


Bit code definitions for Cruise Control Status (PID 85), Exhaust Brake Status (PID 121), Parking Brake Switch (PID 70), Idle Shutdown Status (PID 71), Road Speed Limit Status (PID 83), and Power Take Off Status (PID 89) are as per SAE J1587 definitions. NOTE: The Caterpillar service tools follow the SAE/ATA J1587 and J1708 standards in all communications. Service tool interfacing is done using the escape provision defined in SAE J1587. The escape information is considered proprietary and is, therefore, not described here. 22.2 SAE J1939 Data Link The SAE J1939 data link is supported on all Caterpillar On-Highway Truck Engines and must be enabled through Customer Programmable Parameter programming. This data link can be used for communications with the transmission, anti-lock brake systems (ABS), traction control (TC) systems, instrument clusters and other devices that use that use SAE J1939 communications protocol. Contact Caterpillar for new application assistance. ECM TO J1939 DATA LINK CONNECTOR TO J1939 DATA LINK CONNECTOR TO J1939 DATA LINK CONNECTOR

42 34 50

A249-BK K990-GN K900-YL

J1939 DATA LINK SHIELD J1939 DATA LINK J1939 DATA LINK +

P1 J1

Wiring DIagram 40 OEM provided and installed components required: 1) Data link connection to power train components. Customer Parameter programming required: 1) Powertrain Data Link parameter programmed to J1939. The Powertrain Data Link parameter should be programmed to match the configuration of the vehicle. If no J1939 support is required, Program the Power Train Datalink parameter to NONE. Caterpillar electronic service tools have the capability to temporarily disable the Powertrain Data Link for dynamometer or other diagnostic testing purposes. Caterpillar recommends that J1939 wiring be added to the engine diagnostic connector. This will allow for service tool support. J1939 DATA LINK D

D E

J1939 DATA LINK -

C A

F

E

J1939 DATA LINK SHIELD

B

A

F

J1939 DATA LINK SHIELD

J1939 DATA LINK +

C

B J

J G

G H

+BATTERY

H

-BATTERY

J1587 DATA LINK +

J1939 DATA LINK + J1587 DATA LINK + +BATTERY

J1587 DATA LINK -

J1587 DATA LINK -

DEUTSCH 9-TERMINAL CAB CONNECTOR Does not require an Adapter Harness for connection to the 139-4166 Service Tool Cable

-BATTERY

DEUTSCH J1939 CAB CONNECTOR Requires 157-4829 Adapter Harness for connection to the 139-4166 Service Tool Cable

Figure 39

118



22.2.1 SAE J1939 Data Link Broadcast Messages The following tables list J1939 broadcast messages currently supported by the ECM. The Powertrain Datalink parameter must be programmed to J1939 (Default = None) to enable communications. Broadcast messages will default to a priority of 6 unless the SAE specification specifies a higher priority (EEC#1 has a priority of 3). Messages that are broadcast as a result of a request will have a priority of 2. Medium Duty Engine J1939 Broadcast Messages

PGN $E000 (57,344) CM #1 Source Address: $0 Priority: 6 Repetition rate: 1s Data length: 8 Bytes Data Page: 0 On request service: N/A SAE section: SAE – J1939-71 Notes: Source can be the transmission or if Fan Override Switch is programmed to J1939_Cab_Controller, J1939_Body_Controller or J1939_Instrument_Cluster. Switch on >= 95.2 %. Byte

Bits

Parameter

1

8–1

Requested Percent Fan speed (SPN 986) Resolution: 0.4 %/bit gain, 0 % offset Data range: 0 – 100 % 0 – 94.8% = OFF (00 – ED) 95.2 – 100% = Fan On (EE – FA) 100.4 – 101.6% = DIAG/OFF (FB – FE) $FF Not unused

2–8

8–1

Not Supported

PGN $F000 (61,440) Electronic Retarder Controller #1 : ERC#1 Source Address: $29 (41) Priority: 6 Repetition rate: 100 ms Data length: 8 Bytes Data Page: 0 On request service: Yes SAE section: SAE – J1939-71 Notes: Only the Retarder enable-brake assist switch information is used, if the exhaust brake switch is installed and programmed. If the Exhaust Brake/Warm up feature is programmed to None, all message fields will be set to $FF. Byte

Bits

Parameter

1

8–7

Retarder enable-shift assist switch (SPN 572) Not Supported

6–5

Retarder enable-brake assist switch (SPN 571) 00 Retarder – brake assist disabled 01 Retarder – brake assist enabled 11 not used

4–1

Engine/Retarder torque mode (SPN 900) 0000 Low idle governor/no request 0001 Accelerator pedal/operator selection 0010 – 1111 Not Supported

2

8–1

Actual Retarder – Percent torque (SPN 520) Resolution: 1%/bit gain, -125% Offset Data Range: -125% – 125% $FE Error Indicator $FF Not used

3-8

8–1

Not Supported


119


Medium Duty Engines J1939 Broadcast Messages (continued)

PGN $F003 (61,443) Electronic Engine Controller #2 : EEC#2 Source Address: $0 (0) Priority: 3 Repetition rate: 50 ms Data length: 8 Bytes Data Page: 0 On request service: Yes SAE section: 5.3.6 (SAE – J1939-71) Notes: Percent load at current speed is heavily filtered and includes hysteresis, IF the transmission style is programmed to any automatic option.

120

Byte

Bits

Parameter

1

8–7

Not defined

6–5

Road speed limit status (SPN 1437) 00 active 01 not active

4–1

Not Supported

2

8–1

Accelerator pedal (AP) position (SPN 91) Resolution: 0.4%/Bit gain, 0% Offset Data range: 0 – 100% $FF Not used

3

8–1

Percent load at current speed (SP 92) Resolution: 1%/Bit gain, 0% Offset Data Range: 0 – 125% $FF Not used

4–8

8–1

Not Supported




PGN $F004 (61,444) Electronic Engine Controller #1 : EEC#1 Source Address: $0 (0) Repetition rate: 15 ms Data Page: 0 SAE section: SAE – J1939-71

Priority: 3 Data length: 8 Bytes On request service: Yes

Byte

Bits

Parameter

1

8–5

Not defined

4–1

Engine/Retarder torque mode (SPN 899) 0000 Low idle governor/no request 0001 Accelerator pedal/operator selection 0010 Cruise control 0011 PTO governor 0100 Road speed governor 0101 ASR control 0110 Transmission control 0111 ABS control 1000 Torque limiting 1001 High speed governor 1010 – 1111 Not Supported

2

8–1

Driver’s demand engine – percent torque (SPN 512) Only if Governor Programmed to Min/Max governor Resolution: 1%/Bit gain, -125% Offset Data Range: -125 – 125% $FF Not used

3

8–1

Actual engine – percent torque (SPN 513) Resolution: 1%/Bit gain, -125% Offset Data Range: -125 – 125% $FF Not used

4–5

8–1

Engine speed (SPN 190) Resolution: 0.125 rpm/Bit gain, 0 rpm offset Data range: 0 – 8031.875 rpm $FFFF Not used

6–7

8–1

Not Supported

8

8–1

Engine demand – percent torque (SPN 899) Use of the Engine Torque Mode is discouraged for critical subsystem performance purposes. Resolution: 1%/Bit gain, -125% Offset Data Range: -125 – 125% $FF Not used


121



PGN $FEBE (65,214) EEC#4 Source Address: $0 (0) Repetition rate: On Request Data Page: 0 SAE section: SAE – J1939-71


Byte

Bits

Parameter

1–2

8–1

Rated Engine Power (SPN 166)

3–4

8–1

Rated Engine Speed (SPN 189)

5–8

8 –1

Not Defined

PGN $FEC0 (65,216) Service Source Address: $0 (0) Priority: 6 Repetition rate: 5000ms Data length: 8 Bytes Data Page: 0 On request service: Yes SAE section: SAE – J1939-71 Notes: The Repetition rate is not j1939 spec compliant. This message is connected to the Maintenance Indicator Mode configuration. If it is programmed to off, the service distance and the service operational hours are set to some default values. 4000 h and 16125 km. The service component ID supports engine oil only. (ID 32)

122

Byte

Bits

Parameter

1

8–1

Service component identification (SPN 911) Resolution: 1 Component ID/bit gain, 0 offset Data range: 0 – 250 $FF Not used

2–3

8–1

Service distance (SPN 914) Resolution: 5 km/bit gain, -160635 km offset Data range: -160636 – 160640 km $FFFF Not used

4–5

8–1

Not Supported

6

8–1

Service component identification (SPN 912) Resolution: 1 Component ID/bit gain, 0 offset Data range: 0 – 250 $FF Not used

7–8

8–1

Service delay/operational time based (SPN 916) Resolution: 1h/bit gain, -32127 h offset Data range: -32127 – 32128 h $FFFF Not used




PGN $FECA (65,226) DM1 Source Address: $0 (0) Priority: 6 Repetition rate: 1000ms Data length: variable Data Page: 0 On request service: Yes SAE section: SAE – J1939-73 Notes: Broadcast every second, not on fault status change. The maximum supported fault code number is limited to 10 and will be prioritized equal to the service tool priority for ATA fault codes. If no fault is active this message will not be broadcast. Only Public fault codes will be transmitted. Byte

Bits

Parameter

1

8–7

Not Supported

6–5

Red Stop Lamp Status 00 Off 01 On 11 Not used

4–3

Amber Warning lamp Status 00 Off 01 On 11 Not used

2–1

Protect Lamp Status 00 Off 01 On 11 Not used

2

8–1

Reserved $FF Not used (default)

3

8–1

SPN, 8 least significant bits of SPN $FF Not used

4

8–1

SPN, second byte of SPN $FF Not used

5

8–6

SPN, 3 most significant bits of SPN

5–1

FMI $FF Not used

8

SPN Conversion

7–1

Occurrence Count $FF Not used

6

PGN $FEDB (65,243) Engine Fluid Level/Pressure #2 Source Address: $0 (0) Repetition rate: 500 ms Data Page: 0 SAE section: SAE – J1939-71 Notes:


Byte

Bits

Parameter

1–2

8–1

Injection control pressure (SPN 164) Resolution: 1/256 MPa/Bit gain, 0 MPa Offset Data range: 0 – 252 MPa $FFFF Not used

3–8

8–1

Not Supported


123



PGN $FEDF (65,247) Electronic Engine Controller #3 : EEC#3 Source Address: $0 (0) Repetition rate: 250 ms Data Page: 0 SAE section: SAE – J1939-71


Byte

Bits

Parameter

1

8–1

Nominal friction – percent torque (SPN 514) Resolution: 1%/Bit gain, -125% Offset Data Range: -125 – 125% $FF Not used

2–3

8–1

Engine’s desired operating speed (SPN 515) Resolution: 0.125 rpm/Bit gain, 0 rpm offset Data range: 0 – 8031.875 rpm $FFFF Not used Caterpillar truck engines, which use the full range engine speed governing option, will have comprehensive support of this byte. Caterpillar truck engines which are configured to use the available MinMax governor, will support this parameter are relevant to engine operation.

4–8

8–1

Not Supported

PGN $FEE0 (65,248) Vehicle Distance (VD) Source Address: $31, 28, $21, $17, or $3 Repetition rate: 100 ms Data Page: 0 SAE section: SAE- J1939-71

124

Priority: 6 Data Length: 8 bytes On request service: Yes

Byte

Bits

Parameter

1–4

8–1

Not supported

5–8

8–1

Total Vehicle Distance (SPN 245) Resolution: 0.125 km/bit, 0 offset Data Range:0 to 526,385,151.9 km



PGN $FEE1 (65,249) Retarder Configuration Source Address: $0 (0) Priority: 6 Repetition rate: 5000 ms Data length: 19 Bytes Data Page: 0 On request service: Yes SAE section: SAE – J1939-71 Notes: If the Exhaust Brake/Warm up feature is programmed to None, this message will not be available. Byte

Bits

Parameter

1

8–5

Retarder location (SPN 902) 0000 Not Supported 0001 Engine exhaust brake 0010 – 111 Not Supported

4–1

Retarder Type (SPN 901) 0000 – 0011 Not Supported 0100 Exhaust 0101 – 1111 Not Supported

2

8–1

Retarder control method (SPN 557) Resolution: 1 step/bit gain, 0 step offset Data range: 0 = continuous control 1 = On/off control 2 – 250 = Not Supported $FF Not used

3 – 16

8–1

Not Supported

17 – 18

8–1

Reference Retarder Torque (5.2.1.49) Resolution: 1 Nm/bit gain, 0 Nm offset Data range: 0 – 64255 Nm $FFFF Not used

19

8–1

Not Supported


125



PGN $FEE3 (65,251) Engine Configuration Source Address: $0 (0) Repetition rate: 5000 ms Data Page: 0 SAE section: SAE – J1939-71

126


Byte

Bits

Parameter

1–2

8–1

Engine speed at idle, point 1 (SPN 188) Resolution: 0.125 rpm/Bit gain, 0 rpm offset Data range: 0 – 8031.875 rpm $FFFF Not used

3

8–1

Percent Torque at idle, point 1 (SPN 539) Resolution: 1%/Bit gain, -125% Offset Data Range: -125 – 125% $FF Not used

4–5

8–1

Engine speed at point 2 (SPN 528) Resolution: 0.125 rpm/Bit gain, 0 rpm offset Data range: 0 – 8031.875 rpm $FFFF Not used

6

8–1

Percent Torque at point 2 (SPN 540) Resolution: 1%/Bit gain, -125% Offset Data Range: -125 – 125% $FF Not used

7–8

8–1


9

8–1


10 – 11

8–1


12

8–1


13 – 14

8–1


15

8–1


16 – 17

8–1

Engine speed at high idle, point 6 (SPN 532) Resolution: 0.125 rpm/Bit gain, 0 rpm offset Data range: 0 – 8031.875 rpm $FFFF Not used




PGN $FEE3 (65,251) Engine Configuration (continued) Source Address: $0 (0) Repetition rate: 5000 ms Data Page: 0 SAE section: SAE – J1939-71


Byte

Bits

Parameter

18 – 19

8–1

Not Supported

20 – 21

8–1

Reference engine torque (SPN 544) Resolution1 Nm/bit gain, 0 Nm offset Data range: 0 – 64255 Nm $FFFF Not used

22 – 23

8–1

Maximum momentary engine override speed, point 7 (SPN 533) Resolution: 0.125 rpm/Bit gain, 0 rpm offset Data range: 0 – 8031.875 rpm $FFFF Not used

24

8–1

Maximum momentary engine override time limit (SPN 534) Resolution: 0.1 s/bit gain, 0 s offset Data range: 0 – 25 s $FF Not used

25 – 30

8–1

Not Supported

31 – 32

8–1

Engine inertia Resolution: 0.004 kgm2/Bit gain, 0 kgm2 offset Data range: 0 – 257.02 kgm2 $FFFF Not used

33 – 35

8–1

Default Engine Torque


127


Medium Duty J1939 Broadcast Messages (continued)

PGN $FEE4 (65,252) Shutdown Source Address: $0 (0) Priority: 6 Repetition rate: 1 s Data length: 8 Bytes Data Page: 0 On request service: Yes SAE section: SAE – J1939-71 Notes: Only byte 2 bits 8-7 will be supported when no shutdown timer is configured. Both Idle Shutdown timer and PTO Idle shutdown timer will be supported by this message. Byte

Bits

Parameter

1

8–7

Idle Shutdown Timer State (SPN 590) 00 Off 01 On 11 Not used

6–5

Idle Shutdown Timer Override (SPN 592) 00 Off 01 On 11 Not used

4–3

Idle Shutdown Driver Alert Mode (SPN 594) 00 Off 01 On 11 Not used

2–1

Idle Shutdown has shutdown Engine (SPN 593) 00 Off 01 On 11 Not used

8–7

Idle Shutdown Timer function (SPN 591) 00 Off 01 On 11 Not used

6–1

Not Supported

3

8–1

Not Supported

4

8–3

Not Supported

2–1

Wait to Start Lamp

8–1

Not Supported

2

5–8

128




PGN $FEE5 (65,253) Engine Hours/Revolutions Source Address: $0 (0) Repetition rate: on request only Data Page: 0 SAE section: SAE – J1939-71 Notes:


Byte

Bits

Parameter

1–4

8–1

Total Engine Hours (SPN 247) Resolution: 0.05 h/bit gain, 0 h offset Data range: 0 to 210554060.75 h $FFFFFFFF Not used

5–8

8–1

Total Engine revolutions (SPN 249) Resolution: 1000 r/bit gain, 0 r offset Data range: 0 to 4211081215000 r $FFFFFFFF Not used

PGN $FEE7 (65,255) Vehicle Hours Source Address: $0 (0) Repetition rate: on request only Data Page: 0 SAE section: SAE – J1939-71 Notes:


Byte

Bits

Parameter

1–4

8–1

Not Supported

5–8

8–1

Total PTO hours (SPN 248) Resolution: 0.05 h/bit gain, 0 h offset Data range: 0 to 210554060.75 h $FFFFFFFF Not used

PGN $FEE9 (65,257) Fuel Consumption (Liquid) (LFC) Source Address: $31, $21, $28, $19, $17, $3 Repetition rate: On Request Only Data Page: 0 SAE section: SAE – J1939-71


Byte

Bits

Parameter

1–4

8–1

Not supported

5–8

8–1

Total Fuel Used (SPN 250) Resolution: 0.5 L/bit, 0 offset Data Range: 0 to 2,105,540,607.5 L


129



PGN $FEEB (65,259) Component ID Source Address: $0 (0) Repetition rate: on request only Data Page: 0 SAE section: SAE – J1939-71 Notes:


Field

* Delimited Information

A

Make (SPN 586)

B

Model (SPN 587)

C

Serial Number (SPN 588)

D

Unit Number (SPN 233)

Field

C7

C9

C10

C12

C15

C16

A

CTRPL

CTRPL

CTRPL

CTRPL

CTRPL

CTRPL

B

C7

C-9

C-10

C-12

C-15

C-16

C

Note – 1

Note – 1

Note – 1

Note – 1

Note – 1

Note – 1

D

Note – 2

Note – 2

Note – 2

Note – 2

Note – 2

Note – 2

Fields with less than 5 characters are filled with a space ($20) Note – 1 = Engine Serial Number Note – 2 = Vehicle ID

PGN $FEEC (65,260) Vehicle Identification Source Address: $0 (0) Priority: 6 Repetition rate: on request only Data length: 17 Bytes Data Page: 0 On request service: Yes SAE section: SAE – J1939-71 Notes: The ASCII character “*” is reserved as a delimiter.

130

Byte

Bits

Parameter

1 – 17

8–1

Vehicle identification Number (SPN 237) Resolution: ASCII Data range: ASCII $FFFF Not used




PGN $FEED (65,261) Cruise control/Vehicle speed setup Source Address: $0 (0) Repetition rate: on request only Data Page: 0 SAE section: 5.3.27 (SAE – J1939-71)


Byte

Bits

Parameter

1

8–1

Maximum vehicle speed limit (SPN 74) Resolution: 1 km/h/bit gain, 0 km/h offset Data range: 0 – 250 km/h $FF Not used

2

8–1

Cruise control high set limit speed (SPN 87) Resolution: 1 km/h/bit gain, 0 km/h offset Data range: 0 – 250 km/h $FF Not used

3

8–1

Cruise control low set limit speed (SPN 88) Resolution: 1 km/h/bit gain, 0 km/h offset Data range: 0 – 250 km/h $FF Not used

4–8

8–1

Not defined

PGN $FEEE (65,262) Engine Temperature Source Address: $0 (0) Repetition rate: 1000ms Data Page: 0 SAE section: 5.3.28 (SAE – J1939-71)


Byte

Bits

Parameter

1

8–1

Engine coolant Temperature (SPN 110) Resolution: 1 °C/bit gain, -40 °C offset Data range: -40 – 210 °C $FF Not used

2–8

8–1

Not Supported


131



PGN $FEEF (65,263) Engine Fluid Level/Pressure Source Address: $0 (0) Priority: 6 Repetition rate: 500ms Data length: 8 Bytes Data Page: 0 On request service: Yes SAE section: SAE – J1939-71 Notes: This message will only be active, if the engine oil pressure sensor is installed or a coolant level sensor is programmed. The coolant level message will reflect the diagnostic status for the coolant level. 100% for coolant level OK, 50% for coolant level Low and 0% for coolant level Very Low. Byte

Bits

Parameter

1–3

8–1

Not Supported

4

8–1

Engine oil pressure (SPN 100) Resolution: 4 kPa/bit gain, 0 kPa offset Data range: 0 – 1000 kPa $FF Not used

5–7

8–1

Not Supported

8

8–1

Coolant Level (SPN 111) Resolution: 0.4%/bit gain, 0% offset Data range: 0 – 100% $FF Not used

PGN $FEF0 (65,264) Power Takeoff Information Source Address: $0 Repetition rate: 100ms Data Page: 0 SAE section: SAE – J1939-71 Byte

Bits

Parameter

1–5

8–1

Not Supported

6

8–5

Not Supported

4–3

PTO Set Speed Input A

2–1

PTO enable switch (SPN 980) 00 Off 01 On 11 Not used

8–7

Not Supported

6–5

PTO resume switch (SPN 982) 00 Off 01 On 11 Not used

4–3

Not Supported

2–1

PTO set switch (SPN 984) 00 Off 01 On 11 Not used

8–1

Not Supported

7

8

132

Priority: 6 Data length: 8 Bytes On request service: N/A




PGN $FEF1 (65,265) Cruise Control/Vehicle Speed Source Address: $0 (0) Priority: 6 Repetition rate: 100ms Data length: 8 Bytes Data Page: 0 On request service: Yes SAE section: SAE – J1939-71 Notes: To get the engine Test mode switch & Cruise Pause switch information, the I/O has to be programmed to one of the J1939 options. It is only supported over J1939. The Cruise Accelerate and Coast switch functionality is depending on its configuration too. (J1939 or hard wired) Byte

Bits

Parameter

1

8–7

Not defined

6–5

Cruise Pause switch (SPN 1633) 00 Cruise Pause switch not set 01 Cruise Pause switch set

4–1

Not Supported

2–3

8–1

Wheel base vehicle speed (SPN 84) Resolution: 1/256 km/h/bit gain, 0 km/h offset Data range: 0 –250.996 km/h $FFFF Not unused

4

8–7

Clutch switch (SPN 598) 00 Clutch pedal released 01 Clutch pedal depressed 11 Not used

6–5

Brake switch (SPN 597) 00 Brake pedal released 01 Brake pedal depressed 11 Not used

4–3

Cruise control enable switch (SPN 596) 00 Cruise control disabled 01 Cruise control enabled 11 Not used

2–1

Cruise control active (SPN 595) 00 Cruise control switch off 01 Cruise control switch on 11 Not used


133



PGN $FEF1 (65,265) Cruise Control/Vehicle Speed (continued) Source Address: $0 (0) Repetition rate: 100ms Data Page: 0 SAE section: SAE – J1939-71 Byte

Bits

Parameter

5

8–7

Cruise control accelerate switch (SPN 602) 00 Cruise accelerate switch off 01 Cruise accelerate switch on

6–5

Cruise control resume switch (SPN 601) 00 Cruise resume switch off 01 Cruise resume switch on

4–3

Cruise control coast switch (SPN 600) 00 Cruise coast switch off 01 Cruise coast switch on

2–1

Cruise control set switch (SPN 599) 00 Cruise set switch off 01 Cruise set switch on

6

8–1

Cruise control set speed (SPN 86) Resolution: 1 km/h/bit gain, 0 km/h offset Data range: 0 – 250 km/h $FF Not used

7

8–6

Cruise control state (SPN 527) 000 Off/Disabled 001 Hold 010 Accelerate 011 Decelerate/Coast 100 Resume 101 Set 110 Accelerator override 111 Not Used

5–1

111 Not Supported

8–7

Not Supported

6–5

Engine test mode switch (SPN 966) 00 Off 01 On

4–1

Not Supported

8

134





PGN $FEF2 (65,266) Fuel Economy Source Address: $0 (0) Repetition rate: 100ms Data Page: 0 SAE section: 5.3.32 (SAE – J1939-71) Notes:


Byte

Bits

Parameter

1–2

8–1

Fuel rate (SPN 183) Resolution: 0.05 l/h/bit gain, 0 l/h offset Data range: 0 – 3212.75 l $FFFF Not used

3–4

8–1

Instantaneous Fuel economy (SPN 184) Resolution: 1/512 km/l/bit gain. 0 km/l offset Data range: 0 – 125.5 km/l $FFFF Not used

5–6

8–1

Average Fuel economy (SPN 185) Resolution: 1/512 km/l/bit gain. 0 km/l offset Data range: 0 – 125.5 km/l $FFFF Not used

7–8

8–1

Not Supported


135



PGN $FEF6 (65,270) Inlet/Exhaust Conditions Source Address: $0 (0) Repetition rate: 500ms Data Page: 0 SAE section: SAE – J1939-71 Notes:


Byte

Bits

Parameter

1

8–1

Not Supported

2

8–1

Boost pressure (SPN 102) Resolution: 2 kPa/bit gain, 0 kPa offset Data range: 0 – 500 kPa $FF Not used

3

8–1

Intake manifold 1 temperature (SPN 105) Resolution: 1° C/bit gain, -40° C offset Data range: -40 – 210° C $FF Not used

4–8

8–1

Not Supported

PGN $FEF7 (65,271) Vehicle Electrical Power Source Address: $0 (0) Repetition rate: 1000ms Data Page: 0 SAE section: SAE – J1939-71 Notes:

136


Byte

Bits

Parameter

1–4

8–1

Not Supported

5–6

8–1

Electrical potential (SPN 168) Resolution: 0.05V/bit gain, 0V offset Data range: 0 – 3212.75 V $FFFF Not used

7–8

8–1

Not Supported



22.2.2 SAE J1939 Data Link Received Messages The following tables list all J1939 messages currently received by the ECM. The Powertrain Datalink parameter must be programmed to the J1939 option to enable communications. Medium Duty Engine J1939 Received Messages

PGN $0000 (0) Torque/Speed Control #1: TSC1 Transmission to Engine Source Address: Transmission Repetition rate: 10 ms Data Page: 0 SAE section: SAE – J1939-71 Notes: Speed override commands are followed for

Priority: 3 Data length: 8 Bytes On request service: N/A 25 seconds

Byte

Bits

Parameter

1

8–7

Control bits Not defined

6–5

Override control mode priority (SPN 897) 00 Highest priority 01 High priority 10 Medium priority 11 Low priority Not Supported

4–3 2–1

Override control modes (SPN 695) 00 Override disabled 01 Speed control 10 Torque control 11 Speed limit/Torque limit control

2–3

8–1

Requested speed/Speed limit (SPN 898) Resolution: 0.125 rpm/bit gain, 0 rpm offset Data range: 0 – 8031.875 rpm $FFFF Not used

4

8–1

Requested torque/Torque limit (SPN 518) Resolution: 1%/bit gain, -125% offset Data range: 0 – 125 % $FF Not used

5–8

8–1

Not defined


137


Medium Duty J1939 Received Messages (continued)

PGN $0000 (0) Torque/Speed Control #1: TSC1 Transmission or ABS to Retarder Source Address: $3, $B Destination: Retarder ($ 0F) Repetition rate: 50 ms Data Page: 0 SAE section: SAE – J1939-71 Notes:

138


Byte

Bits

Parameter

1

8–7

Not Supported

6–5

Override control mode priority (SPN 897) 00 Highest priority 01 High priority 10 Medium priority 11 Low priority

4–3

Not Supported

2–1

Override control modes (SPN 695) 00 – 10 Not Supported 11 Speed limit/Torque limit control

2–3

8–1

Not Supported

4

8–1

Requested torque/Torque limit (SPN 518) Resolution: 1%/bit gain, -125% offset Data range: 0 – 125% $FF Not used

5–8

8–1

Not defined




PGN $0000 (0) Torque/Speed Control #1: TSC1 ABS to Engine Source Address: ABS Repetition rate: 50 ms Data Page: 0 SAE section: SAE – J1939-71 Notes: Engine responds to torque limit commands

Priority: 3 Data length: 8 Bytes On request service: N/A only

Byte

Bits

Parameter

1

8–7

Control bits Not defined

6–5

Override control mode priority (SPN 897) 00 Highest priority 01 High priority 10 Medium priority 11 Low priority

4–3

Not Supported

2–1

Override control modes (SPN 695) 00 Override disabled 01 Speed control – Not Supported 10 Torque control – Not Supported 11 Speed limit/Torque limit control

2–3

8–1

Not Supported

4

8–1

Requested torque/Torque limit (SPN 518) Resolution: 1%/bit gain, -125% offset Data range: 0 – 125% $FF Not used

5–8

8–1

Not defined

PGN $E000 (65,213) CM #1 Source Address: $3, $31, $21 or $17 Priority: 6 Repetition rate: 1s Data length: 8 Bytes Data Page: 0 On request service: N/A SAE section: SAE – J1939-71 Notes: Source can be the transmission, J1939_Cab_Controller, J1939_Body_Controller or J1939_Instrument_Cluster. Switch on >= 95.2 %. Byte

Bits

Parameter

1

8–1

Requested Percent Fan speed (SPN 986) Resolution: 0.4 %/bit gain, 0% offset Data range: 0 – 100% 0 – 94.8% = OFF (00 – ED) 95.2 – 100% = Fan On (EE – FA) 100.4 – 101.6% = DIAG/OFF (FB – FE) $FF Not unused

2–8

8–1

Not defined


139



PGN $F001 (61,441) Electronic Brake Controller #1: EBC1 Source Address: Brakes Repetition rate: Depends on sender Data Page: 0 SAE section:SAE – J1939-71 Notes: Exhaust Retarder Switch on >= 95.2 %.


Byte

Bits

Parameter

1–4

8–1

Not Supported

5

8–1

Engine Retarder Selection (SPN 973) Resolution: 0.4%/bit gain, 0% Offset Data Range: 0-100% $FF Not Used

6–8

8–1

Not Supported

PGN $F002 (61,442) Electronic Transmission Controller #1: ETC1 Source Address: Transmission Priority: 3 Repetition rate: Depends on sender Data length: 8 Bytes Data Page: 0 On request service: N/A SAE section: SAE – J1939-71 Notes: Shift-In-Progress message is used to enhance cruise control. The engine Retarder will be disabled if the status of the Torque converter lockup is disengaged. The output shaft speed is only used, if the vehicle speed input is set to J1939_Transmission and the vehicle speed calibration parameter is programmed. Byte

Bits

Parameter

1

8–7

Not Supported

6–5

Shift In Progress (SPN 574) 00 Shift Not in Progress 01 Shift in Progress

4–3

Torque Converter Lockup Engaged (SPN 573) 00 Torque converter lockup disengaged 01 Torque converter lockup engaged

2–1

Not Supported

2–3

8–1

Output Shaft Speed (SPN 191) Resolution: 0.125 rpm/bit gain, 0 rpm offset Data Range: 0 – 8031.875 rpm

4

8–1

Not supported

5

8–3

Not Supported

2–1

Momentary engine over speed enable (SPN 606) 00 Momentary engine over speed disable 01 momentary engine over speed enable 11 Not Used

8–1

Not Supported

6–8

140




PGN $F005 (61,445) Electronic Transmission Controller #2: ETC2 Source Address: Transmission Priority: 6 Repetition rate: Depends on sender Data length: 8 Bytes Data Page: 0 On request service: N/A SAE section: 5.3.8 (SAE – J1939-71) Notes: For Neutral, Bytes 1 and 4 must be ZERO Byte

Bits

Parameter

1

8–1

Selected Gear (SPN 524) Resolution: 1 gear value/bit, -125 offset Data range: -125 – +125 $FF Not used

2–3

8–1

Not Supported

4

8–1

Current Gear (SPN 523) Resolution: 1 gear value/bit, -125 offset Data range: -125 – +125 $FF Not used

6–8

8–1

Not Supported

PGN $FE4A (65,098) Electronic Transmission Controller #7: (ETC7) Source Address: $3 Repetition rate: 100 ms Data Page: 0 SAE section: 5.3.6 (SAE – J1939-71) Notes:


Byte

Bits

Parameter

1

8–1

Not Supported

2

8–7

Not Supported

6–5

Transmission Engine Crank Enable (SPN 2900) 00 – Cranking disabled; engine cranking is prohibited by the transmission 01 – Cranking enabled; engine cranking is allowed by the transmission 10 – Error 11 – Not available

4–1

Not Supported

8-1

Not Supported

3-8


141



PGN $FE6E (65,134) High Resolution Wheel Speed Source Address: ABS ($0b) Priority: 2 Repetition rate: 20 ms Data length: 8 Bytes Data Page: 0 On request service: N/A SAE section: SAE – J1939-71 Notes: Vehicle Speed Input must to be programmed to J1939_ABS. Byte

Bits

Parameter

1–4

8–1

Not Supported

5–6

8–1

Rear Axle, left wheel speed (SPN 1594) Resolution: 1/256 km/h/bit, 0 km/h offset Data range: 0 – 250.996 km/h $FFFF Not used

7–8

8–1

Rear Axle, right wheel speed (SPN 1595) Resolution: 1/256 km/h/bit, 0 km/h offset Data range: 0 – 250.996 km/h $FFFF Not used

PGN $FEF0 (65,264) Power Takeoff Information Source Address: $31, $21, $17 Repetition rate: 100ms Data Page: 0 SAE section: SAE – J1939-71 Byte

Bits

Parameter

1–5

8–1

Not Supported

6

8–5

Not Supported

4–3

PTO Set Speed Input A 00 Off 01 On 11 Not used

2–1

PTO enable switch (SPN 980) 00 Off 01 On 11 Not used

8–7

Not Supported

6–5

PTO resume switch (SPN 982) 00 Off 01 On 11 Not used

4–3

Not Supported

2–1

PTO set switch (SPN 984) 00 Off 01 On 11 Not used

8–1

Not Supported

7

8

142





PGN $FEF1 (65,265) Cruise Control/Vehicle Speed Source Address: $31, $21, $17 Repetition rate: Depends on sender Data Page: 0 SAE section: 5.3.31 (SAE – J1939-71) Notes:


Byte

Bits

Parameter

1

8–5

Not Supported

6–5

Cruise Pause switch (SPN 1633) 00 Cruise Pause switch not set 01 Cruise Pause switch set 11 Not used

4–1

Not Supported

2–3

8–1

Not Supported

4

8–7

Clutch switch (SPN 598) 00 Clutch pedal released 01 Clutch pedal depressed 11 Not used

6–5

Brake switch (SPN 597) 00 Brake pedal released 01 Brake pedal depressed 11 Not used

4–3

Cruise control enable switch (SPN 596) 00 Cruise control disabled 01 Cruise control enabled 11 Not used

2–1

Not Supported

8–7

Cruise control accelerate switch (SPN 602) 00 Cruise accelerate switch off 01 Cruise accelerate switch on 11 Not used

6–5

Cruise control resume switch (SPN 601) 00 Cruise resume switch off 01 Cruise resume switch on 11 Not used

4–3

Cruise control coast switch (SPN 600) 00 Cruise coast switch off 01 Cruise coast switch on 11 Not used

2–1

Cruise control set switch (SPN 599) 00 Cruise set switch off 01 Cruise set switch on 11 Not used

6

8–1

Not Supported

7

8–1

Not Supported

8

8–7

Not Supported

6–5

Engine test mode switch (SPN 966) 00 Off 01 On

4–1

Not Supported

5


143


23.0 Customer Specified Parameters Customer Specified Parameters allow the truck owner to influence how a driver operates the vehicle. Some parameters may affect engine operation in ways an inadequately trained driver does not expect. These parameters may lead to power or performance complaints, even when the engine is performing to specification. Customer parameters may be changed repeatedly as a customer changes his operation or as new drivers are assigned to a truck. Customer Passwords (once programmed) are required to change these parameters. The following is a brief description of the Customer Specified Parameters. Along with each are the available values for the parameter and the default value. The parameter value shown in bold is the programmed setting that will disable a feature. The tables show values in U.S. (or English) units (miles, mph, quarts), followed by an approximate range for its metric (kilometers, km/h, liters) units counterpart. The exact range of the parameter in metric units depends upon the Service Tool used because each Tool may use slightly different conversion factors. 23.1 Customer Parameter Lockout This feature is available to restrict access to changing some available parameters. Locking out a parameter requires Customer Passwords if they have been previously programmed. Once a parameter is locked out, Factory Passwords are required to change the parameter or 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. This helps vehicle owners encountering problems with operators obtaining Customer Passwords and tampering with the parameter configuration. The following Customer Parameters are available for lockout using an Electronic Service Tool or VEPS: • A/C Switch Fan On-Time

• Transmission Style

• Battery Monitor & Engine Control Voltage

• Two Speed Axle Switch

• Battery Monitor & Low Idle Engine Speed

• Vehicle ID

• High Cruise Control Speed Set Limit

• Vehicle Speed Cal (J1939-ABS)

• High Speed Range Axle Ratio

• Vehicle Speed Cal (J1939-TRANS)

• Low Speed Range Axle Ratio

• Vehicle Speed Calibration

• Max PTO Vehicle Speed

• Vehicle Speed Limit

• Soft Vehicle Speed Limit

• Vehicle Speed Limit Protection

• Top Engine Limit Factory Passwords are also required to change a parameter from “locked” to “unlocked”. If all of the parameters are locked out, and each one needs to be unlocked, only one Factory Password is required when the Parameter Lockout screen is accessed on the Electronic Service Tool.

144



23.2 Selected Engine Rating

23.2.1 Rating Number Rating number within a power family. The C7 an C9 do not support multiple ratings.

23.2.2 Vehicle ID Identification of the vehicle assigned by the customer and used only for customer reference. The ECM does not require this parameter. Up to seventeen alpha-numeric characters can be entered. Alternative

Default

VEPS PID

17 Digits (A-B, 0-9)

Not Programmed

60

23.3 Truck Manufacturer Parameters

23.3.1 Truck Manufacturer This parameter is not available for C9 engines. The C9 engine does not support GM designated parameters. This parameter is used to configure the correct set of parameter options/ranges and defaults for the vehicle application. The Truck Manufacturer parameter is Factory Programmed at Caterpillar to provide the same functionality with one ECM and one set of Personality Module software. Factory Passwords are required to change the parameter setting once it has been programmed. The following list of customer parameters identifies the different options and/or defaults provided for both configurations listed below. Truck Mfg

Default

VEPS PID

GM, Other

Not Programmed

N/A (Factory Programmed)

23.4 Vehicle Speed Parameters

23.4.1 Vehicle Speed Calibration This calibration is used when the ECM is configured for use with a hardwired Vehicle Speed Sensor connected to ECM Vehicle Harness Connector J1/P1 terminal 32 & 33. The ECM uses this value to scale the vehicle speed signal into miles per hour. It is programmed in pulses per mile (PPM), which represents the number of pulses produced per mile in the vehicle speed sensor by the teeth of the chopper wheel mounted on the transmission output shaft. When the hardwired Vehicle Speed Input option is used (Vehicle Speed Input parameter programmed to J1/P1:32 & 33), this parameter must be programmed or a Diagnostic Code 253-02 Check Customer Or System Parameters (56) will occur. This parameter affects cruise control, the ECM speedometer signal, Trip Totals, PTO operation, etc. Truck Mfg

Minimum

Maximum

Default

Other (2485 ppkm)

4000 PPM (238080 ppkm)

383000 PPM

Not Programmed

GM

4000 PPM (2485 ppkm)

383000 PPM (238080 ppkm)

32000 (19884)

VEPS PID

FC5F


145


23.4.2 Vehicle Speed Cal (J1939-Trans) This calibration is used when the ECM is configured to calculate Vehicle Speed based on Transmission Output Shaft Speed information received via the J1939 datalink (Vehicle Speed Input parameter programmed to J1939-Trans). This value represents the Transmission Output Shaft revolutions per mile. The ECM uses this value, and the information received from the Transmission ECU via J1939 datalink (output shaft speed) to calculate actual vehicle speed. When the J1939 Vehicle Speed option is used (Vehicle Speed Input parameter programmed to J1939-Trans), this parameter must be programmed or a Diagnostic Code 253-02 Check Customer Or System Parameters (flash code 56) will occur. This parameter affects cruise control, the ECM speedometer signal, Trip Totals, PTO operation, etc. Minimum

Maximum

Default

VEPS PID

0 PPM (0 rev/km)

65000 PPM (43000 rev/km)

Not Programmed

FCEC

23.4.3 Vehicle Speed Cal (J1939 ABS) This calibration is used when the ECM is configured to calculate Vehicle Speed based on ABS wheel speed information received via the J1939 datalink (Vehicle Speed Input parameter programmed to J1939-ABS). The ABS manufacturer should be contacted to verify this message is supported. This value represents the ratio to ASSUMED ABS tire revolutions per mile divided by the ACTUAL tire revolutions per mile. If the assumed tire size matches the actual tire size, the Vehicle Speed Cal will be equal to 1. If the ABS assumed tire revolution per mile is not correct, the vehicle speed cal is equal to the ACTUAL Tire Revolutions per mile/ABS ASSUMED Tire revolutions per mile. ABS Assumed tire revolutions per mile = 500 Actual Tire revolutions per mile = 400 Vehicle Speed Cal = 400/500 = 0.800 Note: If the Vehicle Speed Input parameter is programmed to J1939-ABS, the Vehicle Speed Cal parameter must be programmed or a Diagnostic Code 253-02 “Check Customer Or System Parameters” (56) will occur. This parameter affects cruise control, the ECM speedometer signal, Trip Totals, PTO operation, etc. Minimum

Maximum

Default

VEPS PID

0

6.550

Not Programmed

FCED

23.4.4 Vehicle Speed Limit Top vehicle speed the ECM will permit. The ECM will shut off fuel above this speed. An inexperienced driver may think something is wrong with the engine, because the engine will not fuel above this vehicle speed limit. Vehicle speed limiting allows implementation of a gear fast/run slow truck specification to further improve fuel economy while limiting top vehicle speed.

146

Truck Mfg

Minimum

Maximum

Default

VEPS PID

GM

30 MPH (48 km/h)

75 MPH (121 km/h)

75 MPH (121 km/h)

61

Other

30 MPH (48 km/h)

127 MPH (204 km/h)

127 MPH (204 km/h)



23.4.5 VSL Protection Maximum engine rpm when there is an ECM detected vehicle speed signal problem. The ECM limits to this engine rpm when it senses no vehicle speed signal, and the engine is loaded. This is a feature to deter tampering by running without a Vehicle Speed input to the ECM. Truck Mfg

Minimum

Maximum

Default

VEPS PID

All

1700 rpm

TEL rpm

TEL rpm

66

NOTE: When this parameter is programmed to TEL rpm, diagnostic codes 84-01 Loss Of Vehicle Speed Signal (31) and 84-10 Vehicle Speed Rate of Change (36) are disabled. When programmed this way, the VSL Protection can be exceeded by disconnecting the Vehicle Speed Sensor. 23.4.6 Tachometer Calibration The ECM uses this value to scale the engine speed signal into revolutions per minute for a tachometer. It is programmed in pulses per revolution (ppr). Programmable range is from 2.0 to 500.0 in 0.1 ppr increments. Truck Mfg

Minimum

Maximum

Default

VEPS PID

Other

2.0 PPR

500.0 PPR

134.0 PPR

C7

GM 530/540

2.0 PPR

500.0 PPR

17.5 PPR

GMT560

2.0 PPR

500.0 PPR

2.0 PPR

23.4.7 Soft Vehicle Speed Limit This limit operates in conjunction with the Vehicle Speed Limit. It limits the vehicle speed from 2.5 mph (4 km/h) below the programmed Vehicle Speed Limit at full load, to 2.5 mph (4 km/h) above the selected Vehicle Speed Limit at no load. Minimum

Maximum

Default

VEPS PID

0.00

19.99

0.00

FC5E

23.4.8 High Speed Range Axle Ratio This parameter must be programmed when the Two Speed Axle Switch parameter is programmed to other than none. When a two-speed axle is used, the change in gear ratios from the main drive axle ratio to the low-speed axle ratio alters the calibration of the vehicle speed input. This requires a calibration adjustment to ensure the ECM driven speedometer and stored ECM information correctly reflect the actual vehicle speed. This parameter should be programmed to the main drive axle ratio. If a two-speed axle is not used then this parameter does not require programming. Minimum

Maximum

Default

VEPS PID

0.00

19.99

0.00

FC5D


147


23.5 Cruise Control Parameters

23.5.1 Low Cruise Control Speed Set Limit The lowest vehicle speed at which cruise control can be used. Programming this parameter to the maximum value disables cruise control. Truck Mfg

Minimum

Maximum

Default

VEPS PID

Other

15 mph (24 km/h)

127 mph (204 km/h)

127 PPR (204 km/h)

63

GM

25 mph (40 km/h)

75 mph (121 km/h)

25 mph (40 km/h)

23.5.2 High Cruise Control Speed Set Limit The highest vehicle speed at which Cruise Control can be set. Attempts to set a vehicle speed higher than this value will result in the Cruise Set speed be equal to the High Cruise Control Speed Set Limit. Truck Mfg

Minimum

Maximum

Default

VEPS PID

Other

20 mph (32 km/h)

127 mph (204 km/h)

127 PPR (204 km/h)

62

GM

30 mph (48 km/h)

75 mph (121 km/h)

75 mph (121 km/h)

23.5.3 Exhaust Brake Mode Determines operation of the Exhaust Brake while the cruise control On/Off switch is in the ON position, but the engine is not in cruise control. This does not determine, or allow exhaust brake operation while the engine is in cruise control.

APPLIED SERVICE BRAKE

RELEASED ON

ENGINE RETARDER

OFF

"COAST" ENGINE BRAKE OPERATION APPLIED SERVICE BRAKE

RELEASED ON

ENGINE RETARDER "LATCH" ENGINE BRAKE OPERATION Figure 40 148



Allowable options are COAST, LATCH or MANUAL. When programmed to COAST, the exhaust brake is enabled only while the service brakes are being applied. When programmed to LATCH, the exhaust brake stays enabled after the service brakes are released. A direct, immediate pressure on the brake pedal latches the exhaust brake ON. If programmed to MANUAL, the exhaust brake operates the same with the cruise control switch ON (but not in Cruise) as when it is OFF. Alternative

Default

VEPS PID

Coast, Latch

Manual

A1

23.5.4 Auto Retarder In Cruise This is the vehicle speed above the Cruise Control Set Speed to engage the engine exhaust brake. This feature is used to help maintain the Cruise Control Set Speed. NOTE: The minimum value is 5 mph (8 km/h) if Soft Cruise is programmed to Yes. NOTE: This feature is disabled if the Exhaust Brake/Warmup Device is programmed to None. Minimum

Maximum

Default

VEPS PID

3 mph (5 km/h)

10 mph (16 km/h)

0 mph (0 km/h)

FC00

23.5.5 Cruise/Idle/PTO Switch Configuration The configuration defines the function of Set/Resume for ACCEL and DECEL modes. This parameter applies to cruise control, idle, and PTO modes. Truck Mfg

Alternatives

Default

Other

Set/Decel – Res/Accel Set/Accel – Res/Decel

GM

Set/Accel – Res/Decel Set/Decel – Res/Accel

VEPS PID 62


149


23.5.6 SoftCruise Control SoftCruise Control provides a 5 mph (8 km/h) operating range around the cruise control set speed to provide a smoother cruise control.

5 MPH 100%

Off

Available HP On

0 Vehicle Speed

Cruise Set Speed Or VSL

Figure 41 It controls the cruise speed from 2.5 mph (4 km/h) below the set vehicle speed at full load to 2.5 mph (4 km/h) above the set vehicle speed at no load.

150

Truck Mfg

Alternatives

Default

VEPS PID

Other

No

Yes

C5

GM

Yes

No



23.6 Idle Parameters

23.6.1 Idle Vehicle Speed Limit This is the Maximum vehicle speed for setting or maintaining a set engine rpm in idle mode. Idle mode is entered if the engine rpm is set using the cruise control On/Off switch along with Set/Resume. If the vehicle speed signal exceeds this value, the engine will not maintain the set engine rpm. Minimum

Maximum

Default

VEPS PID

1 mph (2 km/h)

15 mph (24 km/h)

1 mph (2 km/h)

64

23.6.2 Idle RPM Limit This is the Maximum engine rpm while operating in idle mode. Idle mode occurs if the engine rpm is set using the cruise control On/Off switch and the Set/Resume switch. Minimum

Maximum

Default

VEPS PID

5 rpm/sec

1000 rpm/sec

50 rpm/sec

C4

23.6.3 Idle/PTO Bump RPM Determines the rpm increment/decrement when the Accel/Decel switches are briefly toggled. It also applies to both dedicated PTO and idle. If a PTO Engine RPM Set Speed has been programmed the Idle/PTO Bump RPM applies only to engine rpm control initiated using the Cruise Control On/Off circuit not the PTO On/Off circuit. Minimum

Maximum

Default

VEPS PID

5 rpm

500 rpm

20 rpm

F1

23.6.4 Fast Idle RPM #1 Fast Idle RPM #1 determines the preset Fast Idle engine rpm as controlled using the Fast Idle Enable Switch. The operator can override this rpm. To override, depress the accelerator pedal until the desired rpm is reached, and then depress the Fast Idle Enable Switch. This rpm will be the Fast Idle RPM #1 as long as the ECM is powered up. This feature requires Input #18 connected to a Fast Idle Enable Switch and Output #9 programmed for and connected to a Fast Idle Enabled Lamp. Minimum

Maximum

Default

VEPS PID

700 rpm

TEL rpm

1000 rpm

C6


151


23.6.5 Fast Idle RPM #2 Fast Idle RPM #2 determines a second preset Fast Idle engine rpm as controlled using the Fast Idle Enable Switch. This rpm cannot be overridden within its programmable range by the operator. The ECM will increase from the programmed Low Idle to Fast Idle RPM #1 the first time the Fast Idle Enable switch is depressed and released, and then increase rpm to Fast Idle RPM #2 after the Fast Idle Enable switch is depressed and released the second time. If the Fast Idle Enable switch is depressed and released a third time, the ECM returns to low idle, disabling the Fast Idle. The default of 0 rpm disables this feature. This feature requires Input #18 connected to a Fast Idle Enable Switch and Output #9 programmed for and connected to a Fast Idle Enabled Lamp. Minimum

Maximum

Default

VEPS PID

700 rpm

TEL rpm

0 rpm

FC42

23.6.6 Warm Up Mode Idle Speed Determines the engine rpm while in warm up mode. The Warm Up Mode Idle Speed can be programmed between 700 and 1400 RPM. The Warm Up Mode Idle Speed is activated if the sum of Coolant and Inlet Manifold Air Temperature is less than 86°F (30°C). The warm Up Mode Idle Speed can be disabled by depressing the service brake, clutch or by placing the transmission in gear from neutral (transmission style and Neutral switch programming dependent). The engine Cold Elevated Idle can slowly ramp and return to the programmed Warm Up Mode Idle Speed after being disabled. Minimum

Maximum

Default

VEPS PID

700 rpm

1400 rpm

1000 rpm

FE08

23.7 Dedicated PTO Parameters

23.7.1 PTO Configuration Determines the features available and inputs used for Dedicated PTO applications. OFF (default) indicates the application does not use PTO. The remaining PTO programmable options require a PTO On/Off circuit connected to ECM Input #1. Output #1 (ECM Connector J1/P1, terminal 30) can also be used as a PTO Switch On Lamp. If programmed to Cab Switches the ECM will use the Cruise Control SET (J1/P1, terminal-35) and RESUME. (J1/P1, terminal-44) switch inputs for PTO control and Cruise Control. If programmed to Remote Switches the ECM will monitor the programmed inputs and ignore the cab controls when the PTO On/Off circuit is ON. If programmed to Remote Throttle, the ECM will monitor Input #8 (J1/P1 terminal-68) for the remote accelerator pedal. The ECM will monitor the programmed inputs and ignore the cab controls when the PTO On/Off circuit is ON.

152

Alternatives

Default

VEPS PID

Cab Switches, Remote Switches, Remote Throttle

Off

F3



23.7.2 PTO Top Engine Limit The maximum engine RPM while in PTO. Top Engine Limit (TEL) limits this parameter. The PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle before this parameter can be programmed. Minimum

Maximum

Default

VEPS PID

Programmed Low Idle rpm

TEL rpm

0 rpm

F0

23.7.3 PTO Engine RPM Set Speed The desired engine RPM between Low Idle and PTO Top Engine Limit. The engine will operate at this rpm either when the engine to operate when PTO mode is enabled (PTO To Set Speed programmed to “Yes”) or after the “Set Switch” is toggled one time. Minimum

Maximum

Default

VEPS PID


PTO TEL rpm

0 rpm

F2

23.7.4 PTO Engine RPM Set Speed A The engine rpm the ECM will control the engine to when the PTO On/Off circuit is ON and the PTO Engine RPM Set Speed Input A switch is ON. The RPM can be programmed to operate from Low Idle up to the PTO Top Engine Limit RPM. While operating at this set speed, all other speed control inputs are ignored (Cab and Remote Throttle, and the Set/Accel and Resume/Decel switches). This feature can also be used in conjunction with (and will override) the PTO to Set Speed and PTO Engine RPM Set Speed B features for multiple speed PTO operation. Any time the PTO On/Off circuit is ON and the PTO Engine RPM Set Speed Input A switch is ON, the engine will only operate at this programmed speed, unless a condition is present to kickout PTO operation (brake or clutch pedal depressed, PTO Vehicle Speed Limit exceeded, etc.). In the event that the PTO operation is kicked out, the engine will return to low idle. NOTE: The PTO Configuration parameter must be programmed to Cab Switches, Remote Switches or Remote Throttle and the PTO Engine RPM Set Speed Input A parameter must be programmed to J1/P1: 46 for this feature to function. Minimum

Maximum

Default

VEPS PID


PTO TEL rpm

0 rpm

FC8B

23.7.5 PTO Engine RPM Set Speed B The engine rpm the ECM will control the engine to when the PTO On/Off circuit is ON, the PTO Engine RPM Set Speed Input B switch is ON and the PTO Engine RPM Set Speed Input A switch if OFF. The RPM can be programmed to operate from Low Idle up to the PTO Top Engine Limit RPM. While operating at this set speed, all other speed control inputs are ignored (Cab and Remote Throttle, and the Set/Accel and Resume/Decel switches) except PTO Engine RPM Set Speed Input A. This feature can also be used in conjunction with (and will override) the PTO to Set Speed feature for multiple speed PTO operation. Any time the PTO On/Off circuit is ON, the PTO Engine RPM Set Speed Input B switch is ON and the PTO Engine RPM Set Speed Input A switch if OFF, the engine will only operate at this programmed speed, unless a condition is present to kickout PTO operation (brake or clutch pedal depressed, PTO Vehicle Speed Limit exceeded, etc.). In the event that the PTO operation is kicked out, the engine will return to low idle.


153


NOTE: The PTO Configuration parameter must be programmed to Cab Switches, Remote Switches or Remote Throttle and the PTO Engine RPM Set Speed Input B parameter must be programmed to J1/P1:7 or J1/P1:23 for this feature to function. Minimum

Maximum

Default

VEPS PID


PTO TEL rpm

0 rpm

FC8C

23.7.6 PTO to Set Speed The PTO Configuration must be programmed to Cab Switches or Remote Switches before this parameter can be programmed. Programming this parameter to “Yes” will cause the engine to “ramp” at the programmed ramp rate to the programmed “PTO Set Speed” when PTO is enabled. PTO Engine RPM Set Speed A or B will override this feature. Programming this parameter to ‘No’ (default) will prevent automatic engine RPM ramping when PTO is enabled. NOTE: This parameter is not available for the PTO configuration- Remote Throttle. Alternatives

Default

VEPS PID

Yes

No

F6

23.7.7 Maximum PTO Enable Speed Maximum allowed engine speed that PTO mode will engage. PTO mode will engage when the engine rpm is at or below this programmed value. Alternatives

Default

VEPS PID

700 to TEL (rpm)

TEL

FCF6

23.7.8 PTO Cab Throttle RPM Limit Determines the engine rpm limit of the Cab Accelerator Pedal Position Sensor when PTO Configuration is programmed to Cab Switches and the PTO On/Off circuit is ON. This parameter is intended to prevent engine overspeed while using dedicated PTO. It can be programmed to allow the Cab Throttle to exceed the programmed PTO TEL during PTO operation, by programming it to TEL. If programmed to Low Idle, the Cab Accelerator Pedal Position Sensor is ignored. If programmed to TEL, the engine will operate to the programmed Top Engine Limit. If programmed to PTO TEL, the engine will operate to the programmed PTO Top Engine Limit. NOTE: PTO Configuration must be programmed to Cab Switches for this parameter to take effect. If PTO Configuration is programmed to Remote Switches or Remote Throttle, the ECM will always ignore the Cab Accelerator Pedal Position Sensor when the PTO On/Off circuit is ON.

154

Alternatives

Default

VEPS PID

Low Idle, PTO TEL

TEL

F4



23.7.9 PTO Kickout Vehicle Speed Limit Maximum vehicle speed for setting or maintaining a set engine rpm in PTO mode. PTO mode is entered if the PTO On/Off switch is ON (uses Input #1). If the vehicle speed signal exceeds this value, the engine will not maintain the set engine rpm. Minimum

Maximum

Default

VEPS PID

1 mph (2 km/h)

127 mph (204 km/h)

1 mph (2 km/h)

FC17

23.7.10 Maximum PTO Vehicle Speed Maximum vehicle speed while in PTO mode. Engine will be derated to maintain this vehicle speed while in PTO mode. Minimum

Maximum

Default

VEPS PID

15 mph (24 km/h)

127 mph (204 km/h)

1 mph (2 km/h)

FC17

23.7.11 Torque Limit This is the maximum torque the engine is allowed to produce when the accompanying switch is closed. PTO Configuration can be Cab Switches, Remote Switches, or Remote Throttle. This feature should only be used for temporary protection of equipment. The dashed line in the following diagram indicates the programmed torque limit.

Torque

Programmed Torque Limit

Engine Speed (rpm) Figure 42 Minimum

Maximum

Default

VEPS PID

100 lb ft (135 NM)

2000 lb ft (2712 NM)

2000 lb ft (2700 NM)

F7


155


23.7.12 PTO Shutdown Time Time (in minutes) that engine will operate with the PTO On/Off circuit ON and no vehicle speed before shutting down. Engine will only count this timer with no vehicle speed and the PTO On/Off circuit ON. The PTO Shutdown Timer will not begin counting if the engine is in Cold Mode. This parameter requires PTO Configuration programmed to Cab Switches, Remote Switches, or Remote Throttle for the timer to function. NOTE: This feature does not remove vehicle power, and the ECM will remain powered. Minimum

Maximum

Default

VEPS PID

3 minutes

1440 minutes

0 minutes

FC14

23.7.13 PTO Activates Cooling Fan Requires use of the ECM cooling fan circuit. The ECM will signal the cooling fan to continuous operation when the PTO On/Off circuit is ON to reduce changes in load while being used for dedicated PTO applications. Setting this parameter to Normal (default) indicates the fan will operate the same (dependent upon coolant temperature, etc.) with the PTO On/Off circuit ON or OFF. PTO Configuration must be programmed to Cab Switches, Remote Switches, or Remote Throttle before this parameter can be programmed. Fan Control Type must also be programmed to On-Off or Variable speed Option S. Alternatives

Default

VEPS PID

Continuous

Normal

F5

23.7.14 PTO Output Activation Speed Determines actual engine speed (-100 rpm) the PTO Active Output will be turned On. This feature is available on Emergency Vehicle Horsepower ratings only. Minimum

Maximum

Default

VEPS PID

700 rpm

2640 rpm

700 rpm

FED8

23.8 Exhaust Brake Options

23.8.1 Exhaust Brake Configuration Determines if the exhaust brake will act as a warm up device, exhaust brake retarder, warm up device and exhaust brake retarder, or not operate at all. NOTE: Programming this parameter to None will disable the output to the engine exhaust brake. Truck Mfg

Alternatives

Default

VEPS PID

Other & GM 530/540

None, Warm Up Only, Exhaust Brake & Warm Up

Exhaust Brake Only

FE07

GMT560

Warm Up Only, Exhaust Brake & Warm Up, Exhaust Brake Only

None

23.9 Engine/Gear Parameters To promote progressive shifting and obtain the best fuel economy, the control system can be programmed to limit engine speed for certain vehicle speed ranges. Each gear Engine RPM and Vehicle Speed parameter set should be matched for the specific drive train for best performance.

156



23.9.1 Lower Gears Engine RPM Limit Engine rpm limited below “Lower Gears Engine RPM Limit (Low Gear #1 Turn Off Speed)”. The engine will accelerate at a slower rate when this limit is exceeded under normal driving conditions. This is to encourage the driver to shift to the next highest gear. Minimum

Maximum

Default

VEPS PID

1500 rpm

TEL

TEL

6C

23.9.2 Lower Gears Turn Off Speed This is the Vehicle Speed where “Lower Gears Engine RPM Limit (Low Gears #1 RPM Limit)” is shut off. This must be matched with “Low Gear #1 RPM Limit” to the specific drive train for best performance. Minimum

Maximum

Default

VEPS PID

1 mph (2 km/h)

15 mph (24 km/h)

1 mph (2 km/h)

69

23.9.3 Intermediate Gears Engine RPM Limit This is similar to “Lower Gears Engine RPM Limit (Low Gears #1 RPM Limit)” in that the engine will accelerate at a slower rate when this RPM is exceeded under normal driving conditions. Typically programmed to slightly higher rpm than the Low Gears #1 RPM Limit parameter. Minimum

Maximum

Default

VEPS PID

1500 rpm

TEL

TEL

6D

23.9.4 Intermediate Gears Turn Off Speed This is similar to “Lower Gears Turn Off Speed (Low Gears #1 Turn Off Speed)”. Typically programmed to a slightly higher vehicle speed than the Low Gears #1 Turn Off Speed parameter. Minimum

Maximum

Default

VEPS PID

10 mph (16 km/h)

50 mph (80 km/h)

10 mph (16 km/h)

6A

23.9.5 Gear Down Protection RPM Limit Engine RPM Limit when vehicle speed is above “Gear Down Protection Turn On Speed (High Gear Turn On Speed)”. This is a “hard” limit. The ECM will not allow fuel to the engine above this limit. This is to encourage the driver to shift into overdrive or top gear. Minimum

Maximum

Default

VEPS PID

1700 rpm

TEL

TEL

6E


157


23.9.6 Gear Down Protection Turn On Speed Vehicle Speed where “Gear Down Protection RPM Limit (High Gear RPM Limit)” is ON. This must be matched to the specific drive train for best performance. Above this vehicle speed limit the engine rpm will be limited by the Gear Down Protection RPM Limit. Truck Mfg

Minimum

Maximum

Default

VEPS PID

Other

30 mph (48 km/h)

127 mph (204/h)

127 mph (204 km/h)

6B

GM

30 mph (48 km/h)

75 mph (121 km/h)

75 mph (121 km/h)

23.9.7 Top Engine Limit (TEL) Maximum engine rpm when the engine is under load. The engine will still achieve Rated RPM under no load conditions. This parameter is not programmable.

23.9.8 Low Idle Engine RPM Minimum engine idle rpm. Minimum

Maximum

Default

VEPS PID

700 rpm

800

700

6F

23.9.9 Transmission Style Indicates to the ECM the type of transmission installed in the vehicle. It is also used by the ECM to determine whether or not to read inputs (brake switch #2, clutch, and neutral switches) and whether the Allison AT/MT/HT transmission driver is used. The Manual Option 1 & 2 selections require a clutch pedal position switch connected to ECM Connector J1/P1, terminal-24 or a clutch switch message from one of the supported J1939 sources. The transmission selections with a neutral switch require a transmission neutral switch connected to ECM Connector J1/P1, terminal-62 (Input #12) or available from the J1939 data link. The transmission selections with two brake switches require a second brake switch connected to ECM Connector J1/P1 terminal-64 (Input #13). If an Allison Automatic Transmission is installed, this parameter must be programmed to AT/MT/HT Option 1, AT/MT/HT Option 2, AT/MT/HT Option 3, or AT/MT/HT Option 4. If any other automatic transmission is installed, this parameter should be programmed to Automatic Option 1, Automatic Option 2, Automatic Option 3, or Automatic Option 4.

158



The Universal option for GM configurations controls all inputs/outputs as described above and requires the appropriate jumper wires to be installed in the chassis wiring based on the type of transmission used in the vehicle. Truck Mfg

Alternatives

Default

VEPS PID

Other

Automatic Option 1, Automatic Option 2, Automatic Option 3, Automatic Option 4, AT/MT/HT Option 1, AT/MT/HT Option 2, AT/MT/HT Option 3, AT/MT/HT Option 4

Manual Option 1

7B

GM 530/540

Automatic Option 1, Automatic Option 2, Automatic Option 3, Automatic Option 4, AT/MT/HT Option 1, AT/MT/HT Option 2, AT/MT/HT Option 3, AT/MT/HT Option 4 Manual Option 1, Manual Option 2

Universal

GMT560

Automatic Option 1, Automatic Option 2, Automatic Option 3, Automatic Option 4, AT/MT/HT Option 1, AT/MT/HT Option 2, AT/MT/HT Option 3, AT/MT/HT Option 4 Manual Option 1, Manual Option 2

Manual Option 2

23.9.10 AT/MT/HT Part Throttle Shift Speed The Allison AT/MT/HT (non-electronic) transmissions require an input from the ECM to regulate transmission shifting. The ECM monitors accelerator pedal position, engine speed, vehicle speed, load, and cruise control status to determine if the transmission should use “closed throttle” or “full throttle” shift modulation. Programming the Transmission Style parameter to AT/MT/HT Option 1, AT/MT/HT Option 2, AT/MT/HT Option 3, or AT/MT/HT Option 4 activates ECM 7 Output #7 to control a shift interface relay connected to the Allison Electric Modulator. This output does not control an Allison AT/MT/HT transmission with the ATEC control. The Shift Modulation setting is selectable by programming the AT/MT/HT Part Throttle Shift Speed parameter. Three different modulation settings are available: Low (80% Enable/65% Disable), Medium (70% Enable/55% Disable), and High (60% Enable/45% Disable). The settings are based on the % Throttle required to either enable or disable the relay output. The High setting will cause the transmission to remain in a lower gear longer (higher engine speed before shift occurs). The Medium setting is a compromise between the Low and the High setting. Contact Allison Transmissions regarding recommended settings of this parameter for your application. Alternatives

Default

VEPS PID

Low (80% Enable/65% Disable), Medium (70% Enable/55% Disable)

High (60% Enable/45% Disable)

FCA5


159


23.9.11 Starting Aid Output This parameter is used to allow the engine to automatically control a starting aid (ether) system. Alternatives

Default

VEPS PID

Automatic

Off

FCDA

23.9.12 Governor Type Indicates to the ECM the type of Governor that controls the engine. Select Full Range for manual transmissions and electronically shifted manual transmission. Select Min/Max With Speed Control (recommended) or Min/Max for automatic transmissions. Alternatives

Default

VEPS PID

Min/Max With Speed Control, Min/Max

Full Range

FE06

23.10 Transmission Neutral Start Interlock

23.10.1 Programmable Parameters Transmission Neutral Start Interlock allow the engine ECM to monitor the J1939 ETC#7 message from the transmission to either enable or disable the engine from cranking. The Engine Running Output must be programmed to J1/P1:31 and the Power Train Data Link must be programmed to J1939 for this feature to function. When programmed to Enabled, the ECM will listen to the ETC #7 message from the transmission. If the ECM sees a Crank Enable (01) message from the transmission, the Engine Running Output will be turned on and allow the engine to crank. If the ECM sees a Crank Disable (00), Error (10), Not Available (11), or the message is not received, the Engine Running Output will remain OFF, and the engine will not be allowed to crank. A Diagnostic code of 226-14 will be active if the Neutral Start Interlock is programmed to Enabled and no ETC #7 message is received from the transmission. Programming the Neutral Start Interlock when the ETC #7 message is not broadcast or failure of the J1939 Data Link occurs, the engine will not start under any conditions. This feature is only available for Truck Manufacturer of GM, and Truck Model Type of GM560. Alternatives

Default

VEPS PID

Enabled

Disabled

FF36

23.11 Timer Parameters

23.11.1 Idle Shutdown Time Time (in minutes) that engine will idle before shutting down. Engine will only shut down if ECM senses low engine load and no vehicle speed. The Idle Shutdown Timer will not begin counting if the engine is in Cold Mode. If this parameter is programmed to zero, this feature is disabled and the engine will idle until the ignition key switch is in the OFF position. NOTE: This feature does not shut down vehicle power. The ECM and vehicle will remain powered.

160

Minimum

Maximum

Default

VEPS PID

1 minute

1440 minutes

0 minutes

FC13



23.11.2 Cold Mode Idle Shutdown Timer Enable Determines if the Idle Shutdown System will operate if Engine Coolant Temperature is less than 38 DEG C (100 DEG F) and the engine has been running less than 15 minutes. When set to Disabled (default) the Idle Shutdown Timer will not operate if Engine Coolant Temperature is less than 38 Deg C (100 Deg F) and the engine has been running for less than 15 minutes. If the engine has been running (between low idle and top engine limit) for 15 minutes, the Idle Shutdown Timer is enabled regardless of engine coolant temperature. When set to Enabled, the Idle Shutdown Timer will operate regardless of engine coolant temperature and engine run time. Alternatives

Default

VEPS PID

Enabled

Disabled

FEF7

23.11.3 Allow Idle Shutdown Override Determines if the clutch or service brake can be used to override the idle shutdown timer during the driver alert (in the last 90 seconds when the Check Engine Lamp begins flashing). Requires Idle Shutdown Time to be programmed in the 1 to 1440 minute range to function (0=OFF). Alternatives

Default

VEPS PID

No

Yes

4F

23.11.4 A/C Switch Fan On-Time The ECM has a timer built in to prevent excessive cycling of the cooling fan clutch due to successive cycling of the A/C switch input. Programming this parameter to 0 disables the function. Programming depends upon refrigerant and A/C system design as well use of the input. Program the timer to 1 second for connection of this input to another system also providing a time delay. This feature requires Fan Control Type programmed to either On-Off or Variable Speed Fan Option S and the A/C High Pressure Switch parameter programmed to J1/P1: 41. Minimum

Maximum

Default

VEPS PID

0 seconds

600 seconds

0 seconds

C0

23.11.5 Fan with Engine Brake On Fan with Engine Brake On determines if the Cooling Fan will come ON when the Exhaust Brake has been active for at least two seconds. This feature requires the Fan Control Type programmed to On-Off or Variable Speed Fan Option S. The fan will be FULL on when programmed to Variable Speed Fan Option S. Alternatives

Default

VEPS PID

Yes

No

4E


161


23.12 Smart Idle Parameters

23.12.1 Battery Monitor & Engine Control Voltage This parameter is used to determine the voltage trip point below which the Battery Monitor and Engine Speed Control System will automatically elevate engine idle to the engine RPM specified in the “Battery Monitor & Low Idle Engine Speed” parameter. NOTE: This feature requires the installation of a Neutral Switch (J1/P1 terminal-62 (Input #12) or a SAE J1939 based message) if the Transmission Style parameter is programmed to AT/MT/HT Option 3, or AT/MT/HT Option 4. Minimum

Maximum

Default

VEPS PID

0 seconds

25.5 Volts

0

FCD8

23.12.2 Battery Monitor Low Idle Engine Speed This parameter is used to determine what speed the engine will increase to if the battery voltage is below the Battery Voltage & Engine Control Voltage trip point. Minimum

Maximum

Default

VEPS PID

700 seconds

TEL

1000

FCFF

23.13 Engine Monitoring Parameters

23.13.1 Engine Monitoring Mode Determines the level of action taken by the ECM in response to a potential engine damaging condition. The ECM reads the Caterpillar Coolant Temperature Sensor, and the OEM installed Coolant Level Sensor (if programmed). Truck Mfg

Alternatives

Default

VEPS PID

Other

Derate, Shutdown

Warning

7F

GM 530/540

Warning, Shutdown

Warning

GMT560

Derate, Shutdown

Derate

23.13.2 Engine Monitoring Lamps This parameter determines the lamp requirements for the Engine Monitoring System. If programmed to the Warning Lamp option, J1/P1 terminal-29 is available for connection of a red Warning Lamp. The Warning Lamp is used to alert the operator that an engine problem is occurring, and indicate when the engine is being derated or shutdown is impending. For non-GM trucks, this parameter may be programmed to Option 1. This option allows up to three discrete lamp outputs to be used for indicating specific engine problems. Option 1 configures J1/P1 terminal-29 for connection of a Low Oil Pressure Warning Lamp, J1/P1 terminal-31 for connection of a High Coolant Temperature Warning Lamp and J1/P1 terminal-30 for connection of a Low Coolant Level Warning Lamp. If the Coolant Level Sensor parameter is programmed to No, then J1/P1 terminal-30 can be used to connect a PTO Switch On Lamp.

162



For GMT530 trucks, this parameter may be programmed to High Coolant Temp Warning Lamp. The optional setting configures the ECM to provide an indication when engine coolant temperature is abnormally high. This circuit is used to interface the GM Vehicle Shutdown System. When programmed to the High Coolant Temp Warning Lamp setting, J1/P1:29 is not available for use as a Warning Lamp for the Caterpillar Engine Monitoring System. Truck Mfg

Alternatives

Default

VEPS PID

Other

Option 1

Warning Lamps

FCD2

GMT560

N/A

N/A

GM 530/540

High Coolant Temp Warning Lamp

Warning Lamp

23.13.3 Coolant Level Sensor Determines if the ECM is to monitor a Coolant Level Sensor. Truck Mfg

Alternatives

Default

VEPS PID

Other

4-Pin, 2 Wire Float

None

7E

GM 530/540

4-Pin

None

GMT560

4-Pin, None

2-Pin Switch

23.13.4 Engine Oil Pressure Sensor Determines if the engine ECM is to monitor an Oil Pressure Sensor. The Engine Oil Pressure Sensor is an optional factory-installed option. C7 or C9 engines do not require this sensor because without sufficient oil pressure, the engine will not run. The ECM will indicate a Very Low Oil Pressure condition if oil pressure drops below 4 psi. Truck Mfg

Alternatives

Default

VEPS PID

Other

Installed

None

7E

GM 530/540

None

None

GMT560

None

Installed

23.13.5 Oil Level Switch Installation Status (GMT560 only) Tells the engine ECM to monitor the Oil Level Switch input. Alternatives

Default

VEPS PID

Not Installed

Installed

FCE2

23.13.6 Primary Fuel Tank Capacity (GMT560 only) Determines the capacity of the primary fuel tank in gallons. Alternatives

Default

VEPS PID

25, 35, None

50

FCF1


163


23.13.7 Secondary Fuel Tank Size (GMT560 only) Determines the capacity of the secondary fuel tank in gallons Alternatives

Default

VEPS PID

25, 35, 50

None

FCF2

23.14 Maintenance Parameters When programming with VEPS, the C8 parameter must be set to a 1 before programming C9, CA and CB.

23.14.1 Maintenance Indicator Mode The ECM records data related to vehicle maintenance. If Distance is selected (Manual – Distance or Automatic – Distance), then all maintenance indications (PM1, PM2, Coolant Flush/Fill) on the service tool will be displayed in Distance. If Hours is selected (Manual – Hours or Automatic – Hours), then all maintenance indications (PM1, PM2, Coolant Flush/Fill) on the service tool will be in Hours. The ECM provides PM1 maintenance interval and last maintenance information. Truck Mfg

Alternatives

Default

VEPS PID

Other

Manual – Distance, Manual – Hours, Automatic – Distance, Automatic – Hours

Off

C9

GM 530/540


Off

GMT560


Auto Distance

23.14.2 PM1 Interval (for Manual Maintenance Indicator Mode) PM1 Interval allows a user-specified PM1 maintenance interval. This parameter (PM1 Interval) must be programmed only if Maintenance Indicator Mode is programmed to Manual – Distance or Manual – Hours. Manual Distance Minimum

Maximum

Default

VEPS PID

5000 miles (8047 km)

35000 miles (56327 km)

15000 miles (21140 km)

CA

Manual Hours

164

Minimum

Maximum

Default

VEPS PID

100

750

250

CB



23.14.3 PM1 Engine Oil Capacity (for Automatic Maintenance Indicator Mode) The ECM can calculate the PM1 Interval based on fuel usage. This parameter must be programmed only if Maintenance Indicator Mode is programmed to Automatic – Distance or Automatic – Hours. The Sump Capacity influences the Maintenance Interval. Truck Mfg

Minimum

Maximum

Default

VEPS PID

Other

20 qts (19L)

60 qts (57 L)

33 qts (31 L)

CC

GM

20 qts (19L)

60 qts (57 L)

22 qts (21 L)

Example VEPS parameter file syntax: P,C8,B,1,Maintenance Indicator Set P,C9,B,man-distance, Maintenance Indicator Mode P,CA,B,5000, Maintenance Indicator Manual Miles – min P,CB,B,750, Maintenance Indicator Manual Hours – max 23.15 Trip Parameters

23.15.1 Dash – PM1 Reset This parameter determines if the Caterpillar Messenger display system can be used to reset the PM1 Maintenance Interval. A CAT Messenger display system is required and the Maintenance Indicator parameter must be programmed to one of the Manual or Automatic modes. Alternatives

Default

VEPS PID

VEPS value

Yes

No

E0

P

23.15.2 Dash – Customer Parameters This parameter determines if the Caterpillar Driver Information Display (CAT ID) can be used to reset the following Customer Parameters: Soft Cruise, Fast Idle RPM #1, Fast Idle RPM #2, and Low Idle. Alternatives

Default

VEPS PID

VEPS Value

Yes

No

E0

A

23.15.3 Theft Deterrent System Control When used with a Theft Deterrent Password, this feature prevents the engine from starting unless the password has been entered via the Caterpillar Driver Information Display (CAT ID). If programmed to YES, the operator must first enter the password before the engine is shut down in order to enable the Theft Deterrent system, preventing the engine from starting until the password is re-entered. If programmed to Auto-Enable, the Theft Deterrent system is automatically enabled each time the engine is shut down, preventing the engine from starting until the password is entered. The engine can also be operated in Secure Idle mode by entering the Theft Deterrent password with the engine operating at an idle condition, preventing the engine from accelerating above low idle until the password is re-entered Alternatives

Default

VEPS PID

Yes, Auto-Enable

None

FC08


165


23.15.4 Theft Deterrent Password This password is required to start the engine or move the vehicle if the Theft Deterrent feature has been enabled. Four characters are available for the password (Upper Case A-Z & 0-9). If the Theft Deterrent password is lost or forgotten, a service tool and factory passwords are required to start the engine. Range

Default

VEPS PID

Four Characters (A-Z, 0-9)

0000

FC09

23.15.5 Quick Stop Rate Determines the rate of vehicle speed change the ECM uses to record a Quick Stop Event Code and Quick Stop Snapshot. Each Quick Stop Snapshot contains 60 frames of information with frame 45 being the Quick Stop occurrence. There are 44 frames before the Quick Stop Event and 15 frames following the Quick Stop Event. Each frame is separated by 1.0 second. ECM Snapshot Frame Data Engine RPM

Vehicle Speed

Throttle Position

Cruise Status

Clutch Switch

Brake Switch

The most recent Quick Stop Snapshot is stored in the ECM memory. Each time another Quick Stop occurs the ECM replaces the old Snapshot with the new one. The ECM also logs a diagnostic event code (maximum of 255 occurrences stored) for each Quick Stop Occurrence. Minimum

Maximum

Default

VEPS PID

0 mph/second

128 MPH/second (205 kmh/second)

O mph/second

FC0C

NOTE: The allowable range is from 0 -15 mph/s (0 – 24 km/h/s) (0 = OFF) but the recommended range is from 3-15 mph/s (5 – 24 km/h/s). Programming the Quick Stop Rate too low will cause an excessive number of Quick Stop Event Codes. If too many Quick Stop Event Codes are being logged, the Quick Stop Rate should be increased to better detect the exceptions when they occur. 23.16 Input Selections

23.16.1 Fan Override Switch This parameter denotes which J1939 source will broadcast a switch position for overriding the normal fan control. When this override switch message is received (J1939 PGN 65,213, Byte 1, Bits 8-1), the ECM will disregard all normal fan control parameters and will turn the fan On if programmed to ON/OFF or 100% Cooling if programmed to Variable Speed Fan Option S. If not programmed to NONE, the Fan Override message from the transmission is also supported.

166

Alternatives

Default

VEPS PID

J1939 Cab Controller, J1939 Body Controller, J1939 Instrument Cluster

None

FD01



23.16.2 Transmission Neutral Switch This parameter determines how the ECM will receive Neutral Switch status information. The Powertrain Data Link parameter must be programmed to J1939 if this parameter is programmed to J1939. Alternatives

Default

VEPS PID

J1939, None

J1/P1: 62

FD4B

23.16.3 Exhaust Brake Switch The Exhaust Brake can be controlled by an On/Off Switch installed in the ECM Exhaust Brake Output circuit, or by a switch circuit connected to the ECM Switch Input. If a switch is installed in the output circuit (switch used to disable brake by opening output circuit), this parameter must be programmed to Not Installed. If a switch to sensor common circuit is connected to the dedicated ECM Exhaust Brake Switch Input, this parameter must be programmed to Installed. Alternatives

Default

VEPS PID

J1/P1:16, J1939 Body Controller, J1939 Cab Controller, J1939 Instrument Cluster

None

FD2B

23.16.4 Ignore Brake/Clutch Switch An Ignore Brake/Clutch Switch input is available for applications requiring mobile use of the vehicle with a set engine rpm that does NOT require the Brake or Clutch to disengage the engine rpm set speed. The parameter must be programmed to J1/P1: 47 to enable this feature. Alternatives

Default

VEPS PID

J1/P1: 47

None

FD05

23.16.5 Two Speed Axle Switch A Two Speed Axle Switch input is available for vehicles with two speed axles. When a two speed axle is used, the change in gear ratios from the main drive axle ratio to the two speed axle ratio alters the calibration of the vehicle speed signal. When the parameter is programmed to J1/P1:6 and the switch is in the ON position the ECM will automatically adjust the vehicle speed calibration. This will ensure the ECM driven speedometer and ECM stored information correctly reflect the actual vehicle speed. Alternatives

Default

VEPS PID

J1/P1: 6

None

FD23


167


23.16.6 Vehicle Speed Input The ECM has an input circuit that can be used to connect a hardwired vehicle speed sensor (mag pick-up) producing a differential input signal, or a single ended signal from an electronic control. To utilize this option, the Vehicle Speed Input parameter must be programmed to the J1/P1:32 & 33 (default) option. When programmed to J1939-Trans, the ECM will be configured to receive Vehicle Speed information from an Electronic Transmission Control Unit via the J1939 datalink, if the Transmission is capable of supporting the J1939 ETC1 Broadcast Message (PGN 61,442 Bytes 2&3). When programmed to J1939-ABS the ECM will respond to the Anti-Lock Braking System and the J1939 High Resolution Wheel Speed Broadcast Message (PGN 65,134). Alternatives

Default

VEPS PID

J1939 – Trans, J1939 – ABS

None

FD76

23.16.7 PTO Engine Shutdown Switch The PTO Engine Shutdown Switch is used to shut down the engine while the engine is PTO mode and there is no vehicle speed present. This parameter selects the input connection. Alternatives

Default

VEPS PID

J1P1: 23 J1/P1: 7

None

FD71

23.16.8 Torque limit Switch The Torque Limit Switch parameter selects the input for enabling the programmed Torque Limit. This feature should only be used for temporary protection of equipment. Alternatives

Default

VEPS PID

J1P1: 23 J1/P1: 7

None

FD09

23.16.9 PTO Engine RPM Set Speed Input A The PTO Engine RPM Set Speed Input A switch is used to control engine speed during PTO operation. The PTO Configuration parameter must be programmed to Cab Switches, Remote Switches or Remote Throttle and the PTO Engine RPM Set Speed A parameter must be programmed to a valid speed. Alternatives

Default

VEPS PID

J1P1: 46 J1939 Cab Controller, J1939 Body Controller, J1939 Instrument Cluster

None

FD13

23.16.10 PTO Engine RPM Set Speed Input B The PTO Engine RPM Set Speed Input B switch is used to control engine speed during PTO operation. The PTO Configuration parameter must be programmed to Cab Switches, Remote Switches or Remote Throttle and the PTO Engine RPM Set Speed B parameter must be programmed to a valid speed.

168

Alternatives

Default

VEPS PID

J1P1: 7, J1/P1: 23

None

FD13



23.16.11 Diagnostic Enable The Diagnostic Enable Switch input is used to cause the Check Engine Lamp to flash out the Flash Codes of logged Diagnostic Codes. Alternatives

Default

VEPS PID

J1P1: 46, J1939 Cab Controller, J1939 Body Controller, J1939 Instrument Cluster

None

FD0B

23.16.12 PTO On/Off Switch The PTO On/Off Switch is used when the PTO Configuration is programmed to Cab Switches, Remote Switches or Remote Throttle. Note: Programming this parameter to a Non-existent J1939 source, even though the PTO Configuration parameter is programmed to “Off”, will cause a 231-12 Diagnostic Code. Alternatives

Default

VEPS PID


J1/P1: 56

FD0D

23.16.13 Remote PTO Set Switch The Remote PTO Set Switch is used when the PTO Configuration is programmed to Remote Switches or Remote Throttle. Note: Programming this parameter to a Non-existent J1939 source, even though the PTO Configuration parameter is programmed to “Off”, will cause a 231-12 Diagnostic Code. Alternatives

Default

VEPS PID

None, J1939 Cab Controller, J1939 Body Controller, J1939 Instrument Cluster

J1/P1: 58

FD0F

23.16.14 Remote PTO Resume Switch The Remote PTO Resume Switch is used when the PTO Configuration is programmed to Remote Switches or Remote Throttle. Note: Programming this parameter to a Non-existent J1939 source, even though the PTO Configuration parameter is programmed to “Off”, will cause a 231-12 Diagnostic Code. Alternatives

Default

VEPS PID

None, J1939 Cab Controller, J1939 Body Controller, J1939 Instrument Cluster

J1/P1: 60

FD11


169


23.16.15 PTO Engine RPM Set Speed Input A The switch is used to control engine speed during PTO operation. The PTO Configuration parameter must be programmed to Cab Switches, Remote Switches or Remote Throttle and the PTO Engine RPM Set Speed A parameter must be programmed to a valid speed. Note: Programming this parameter to a Non-existent J1939 source, even though the PTO Configuration parameter is programmed to “Off”, will cause a 231-12 Diagnostic Code. Alternatives

Default

VEPS PID

J1/P1:46, J1939 Cab Controller, J1939 Body Controller, J1939 Instrument Cluster

None

FD13

23.16.16 Cruise Control On/Off Switch The Cruise Control On/Off Switch parameter allows this input to be received either by a hardwired switch input or over the J1939 network (J1939 PGN 65,265, Byte 4, Bits 4-3). Alternatives

Default

VEPS PID


J1/P1: 59

FD25

23.16.17 Cruise Control Set/Resume Switch The Cruise Control Set/Resume Switch parameter is available to allow this input to be received either by a hardwired switch inputs or over the J1939 network (J1939 PGN 65,265, Byte 5 Bits 8-1). Alternatives

Default

VEPS PID


J1/P1: 35 & 33

FD27

23.16.18 Cruise Control Pause Switch The Cruise Pause Switch is only available from the J1939 Datalink (J1939 PGN 65,265, Byte 1, Bits 6-5). Alternatives

Default

VEPS PID


None

FD7F

23.16.19 A/C High Pressure Switch This parameter enables an air conditioning system high-pressure switch to be used as an input for cooling fan control. The A/C High Pressure Switch input is used to start the A/C Fan On Time timer.

170

Alternatives

Default

VEPS PID

None

J1/P1: 41

FD7F



23.16.20 Service Brake Pedal Position Switch #1 This required switch input can be programmed to either a hard wired terminal or J1939 Message (J1939 PGN 65,265, Byte 4, Bits 6-5). Alternatives

Default

VEPS PID


J1/P1: 45

FD2D

23.16.21 Clutch Pedal Position Switch This required switch input can be programmed to either a hard wired terminal or J1939 Message (J1939 PGN 65,265, Byte 4, Bits 8-7). Alternatives

Default

VEPS PID


J1/P1: 22

FD29

23.16.22 A/C Fan Request Switch (GMT560 Only) The fan ON condition is requested when the air conditioning compressor clutch is engaged. Alternatives

Default

VEPS PID

J1/P1: 41

J1/P1: 62

FD75

23.17 Output Selections

23.17.1 Fan Control Type This parameter is used to determine what type of fan (if any) the ECM is expected to control. This parameter should be programmed to ‘None’ if the ECM is not controlling the cooling fan. Alternatives

Default

VEPS PID

On/Off PWM, On/Off DC, Variable Speed Option S

None

FC18

23.17.2 Fast Idle Enabled Lamp A Fast Idle Enabled Lamp parameter is available to turn ON outputs J1/P1: 31(default) or J1/P1: 21 when Fast Idle #1 or #2 operation is active. This requires a momentary Fast Idle switch installed on Input #18 (J1/P1: 40) and the Fast Idle RPM #1 to be programmed to a valid speed above low idle. J1/P1: 31 may not be used if the Engine Monitoring Lamps is programmed to Option 1. Alternatives

Default

VEPS PID

J1/P1: 21, None

J1/P1: 31

FD49


171


23.17.3 Wait To Start Lamp The Wait to Start Lamp parameter is used to turn a lamp ON when the Inlet Air Heater is ON and the engine is not running. J1/P1: 31 may not be used if the Engine Monitoring Lamps is programmed to Option 1. Alternatives

Default

VEPS PID

J1/P1: 31, J1939

None

FD7b

23.17.4 PTO Active Output Configuration This output is turned On while the engine is actively in PTO mode. Alternatives

Default

VEPS PID

None

J1/P1: 19

FD6D

23.17.5 PTO Switch On Lamp The PTO Switch On Lamp parameter is used to enable a lamp output (J1/P1: 30) whenever the PTO switch is closed. This parameter is not available when the Warning Lamp parameter is programmed to Option 1. Alternatives

Default

VEPS PID

None

J1/P1: 30

FD3B

23.17.6 Change Oil Lamp The Change Oil Lamp parameter is used to dedicate an output for indicating when the engine is in need of an oil change. The change oil interval is determined by the Maintenance parameter values. Alternatives

Default

VEPS PID

J1/P1: 30

None

FD7D

23.17.7 Engine Running Output (GMT560 Only) This parameter is used to allow the ECM to drive a solenoid or relay to prevent the starter from being engaged after the engine is running.

172

Alternatives

Default

VEPS PID

J1/P1: 31

None

FD37



23.18 Passwords

23.18.1 Customer Password #1 and Customer Password #2 Customer Passwords can be programmed to protect against unauthorized parameter changes. Either one or two passwords (eight alphanumeric characters each) can be used. When programmed, the ECM will require the password(s) to be entered before a parameter can be changed. After entering the configuration screen, the password(s) must only be entered one time in order to change one or several parameters. If the passwords are lost or forgotten, obtaining Factory Passwords from an Authorized dealer can allow them to be viewed. Password #1 Alternatives

Default

VEPS PID

8 Alphanumeric Characters Available

Not Programmed

45

Password #2 Alternatives

Default

VEPS PID

8 Alphanumeric Characters Available

Not Programmed

46

23.19 Data Link Parameters

23.19.1 Powertrain Data link This parameter enables the ECM to communicate over the SAE J1939 data link. If the vehicle is not using the data link for communication between the engine and another chassis system, this parameter should be programmed to NONE. NOTE: For GM trucks, a diagnostic code for a J1939 Data Link Fault (231-11 [58]) will occur if the Powertrain Data Link parameter is set to J1939 without a SAE J1939 powertrain component ECM on the vehicle to communicate with the engine ECM. With the GM configuration, the 231-11 fault will be disabled after five hours if a J1939 Powertrain component is not connected to the ECM. Truck Mfg

Alternatives

Default

VEPS PID

Other

J1939

None

FC0D

GM

None

J1939


173


C7 & C9 MEDIUM DUTY ENGINES SYSTEM and CUSTOMER PROGRAMMABLE PARAMETERS VEPS PID

Parameter

Available Range/Options

VEPS Range/Options

Default

As displayed on Caterpillar ET Selected Engine Rating 56

Rating Number

Engine Power Dependent


Factory Programmed

5A

Rating Type

Read Only

Read Only

Factory Programmed

N/A

Advertised Power

Read Only

Not Applicable to VEPS Programming

Factory Programmed

N/A

Governed Speed

Read Only


Factory Programmed

N/A

Rated Peak Torque

Read Only


Factory Programmed

N/A

Top Engine Speed Range

Read Only


Factory Programmed

N/A

Test Spec

Read Only


Factory Programmed

N/A

Test Spec with BrakeSaver

Read Only


Factory Programmed

ECM Identification Parameters

174

60

Vehicle ID

17 Characters Available


0000000000000 0000

51

Engine Serial Number

Read Only

Read Only

Factory Programmed

0F

ECM Serial Number

Read Only

Read Only

Factory Programmed

11

Personality Module Part Number

Read Only

Read Only

Factory Programmed

0A

Personality Module Release Date

Read Only

Read Only

Factory Programmed




Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET Security Access Parameters N/A

Total Tattletale

Read Only


Not Programmed

57

Last Tool to Change Customer Parameters

Read Only

Read Only

Not Programmed

58

Last Tool to Change System Parameters

Read Only

Read Only

Not Programmed

Truck Manufacturer Parameters N/A

Truck Manufacturer C7 Only

Other GM

Programmed at Caterpillar prior to Engine Delivery. This parameter determines the available parameter range/options as specified.

Factory Programmed

FCF4

Truck Model Type C7 Only (“GM” Truck Manufacturer Only)

GMT 530/540 GMT-560

GM 530/540,GM530/540, GM_530_540, GM530, GM 530, GM 530 540 GM 560, GM560, GM_560

GMT 530/540

Vehicle Speed Parameters FC5F

*Vehicle Speed Calibration

4000 to 384000 (pulses per mile)

4000 to 384000 (pulses per mile)

Other: Not Programmed GM: 32000

FCEC

*Vehicle Speed Cal (J1939-Trans)

0 to 65000 (output shaft revs per mile)

0 to 65000 (output shaft revs per mile)

Not Programmed

FCED

*Vehicle Speed Cal (J1939-ABS)

0 to 6.550

0 to 6.550

Not Programmed

61

*Vehicle Speed Limit

GM Trucks: 30 to 75 Other: 30 to 127 (mph)

GM Trucks: 30 to 75 (mph) Other Trucks: 30 to 127 (mph)

GM Trucks: 75 Other Trucks: 127

66

*VSL Protection

1700 to TEL (rpm)

1700 to TEL (rpm)

Other: TEL GM: 1700

C7

Tachometer Calibration

2.0 to 500.0 (pulse per revolution)

2.0 to 500.0 (pulse per revolution)

Other: 134.0 GMT 530/540: 17.5 GMT-560: 2.0


175



Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET C2 FC5E FC5D

*Soft Vehicle Speed Limit

No Yes

No – Off, Disable Yes – On, Enable

All: No

*Low Speed Range Axle Ratio

0.00 to 19.99

0.00 to 19.99

All: 0.00

*High Speed Range Axle Ratio

0.00 to 9.99

0.00 to 9.99

All: 0.00

Cruise Control Parameters 63

Low Cruise Control Speed Set Limit

Other: 15 to 127 (mph) GM: 25 to 75 (mph)


Other: 127 GM: 25

62

*High Cruise Control Speed Set Limit



Other: 127 GM: 75

A1

Exhaust Brake Mode

Coast Latch Manual

Coast – C Latch – L Manual – M

All: Manual

Auto Retarder in Cruise

3 – 10 (mph) * 5-10 if SCC = yes

3-10 (mph)

Other & GMT530: 0 GMT560: 3

3C

Cruise/Idle/PTO Switch Configuration

Set/Accel – Res/Decel Set/Decel – Res/Accel

Set/Accel, Accel/Set, Accel, Acc, A, Set_Accel Set/Decel, Decel/Set, Decel, Dec, D, Set_Decel

Other: Set/Accel GM: Set/Decel

C5

Soft Cruise Control (SCC)

No Yes


Other: Yes GM: No

FC00

Idle Parameters 64

Idle Vehicle Speed Limit

1 to 15 (mph)

1 to 15 (mph)

All: 1

65

Idle RPM Limit

700 to TEL (rpm)

700 to TEL (rpm)

All: TEL

C4

Idle/PTO RPM Ramp Rate

5 to 1000 5 to 1000 (rpm change per second) (rpm change per second)

All: 50

F1

Idle/PTO Bump RPM

5 to 500 (rpm)

All: 20 rpm

5 to 500 (rpm)

* SCC = Soft Cruise Control

176




Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET C6

Fast Idle RPM #1

700 to TEL (rpm)

700 to TEL (rpm)

All: 1000 rpm

FC42

Fast Idle RPM #2

700 to TEL (rpm)

700 to TEL (rpm)

All: 0

FE08

Warm Up Mode Idle Speed

700-1400 (RPM)

700 – 1400 (RPM)

All: 1000

Dedicated PTO Parameters F3

PTO Configuration

Off Cab Switches Remote Switches Remote Throttle

Off – None, O, N, Cab Switches – Cab, C, Cab_Switches Remote Switches – Remote, R, Remote_Switches Remote Throttle – Throttle, T, Remote_Throttle

All: Off

F0

PTO Top Engine Limit

700 to TEL (rpm)

700 to TEL (rpm)

All: TEL GMT560:1500

F2

PTO Engine RPM Set Speed

Low Idle to PTO TEL (rpm)


All: 0 RPM

FC8B




All: 0 RPM

FC8C




All: 0 RPM

F6

PTO to Set Speed

No Yes


All: No

700 to TEL (rpm)

700 to TEL (rpm)

All: TEL

PTO Cab Throttle RPM Limit

TEL Low Idle PTO TEL

TEL – T Low Idle – L, Low, Low_Idle PTO TEL – P, PTO, PTO_TEL

Other and GMT530: TEL GMT560: PTO TEL

FC17

PTO Kickout Vehicle Speed Limit

1 to 127 (mph)

1 to 127 (mph)

All: 1

FE05

* Max PTO Vehicle Speed

3 to 127 (mph)

3 to 127 (mph)

All: 127

F7

Torque Limit

100 – Rated Torque (lb-ft)

100 – Rated Torque (lb-ft)

All: 2000

PTO Shutdown Time

3 to 1440 (minutes)

3 to 1440 (minutes)

All: 0


Normal Continuous

Normal – N, A Continuous – C, B

All: Normal

PTO Output Activation Speed

700 – 2640 (rpm)

700 – 2640 (rpm)

All: 700 rpm

FCF6 F4

FC14 F5 FED8

Maximum PTO Enable Speed


177



Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET Exhaust Brake options FE07

Exhaust Brake/ Warm Up Enable

None Warm Up Only Exhaust Brake Only Exhaust Brake & Warm Up

None, Disabled Exhaust Brake Only, Brake, Exhaust_Brake_Only Exh Brake/Warm Up Device, Brake/WarmUp Warm Up Device Only, Warm_Up_Device_Only

Other: Exhaust Brake Only GM530/540: Exhaust Brake Only GMT 560: None

Engine/Gear Parameters

178

6C

Lower Gears Engine RPM Limit

1500 to TEL (rpm)

1500 to TEL (rpm)

All: TEL

69

Lower Gears Turn Off Speed

1 to 15 (mph)

1 to 15 (mph)

All: 1

6D

Intermediate Gears Engine RPM Limit

1500 to TEL (rpm)

1500 to TEL (rpm)

All: TEL

6A

Intermediate Gears Turn Off Speed

10 to 50 (mph)

10 to 50 (mph)

All: 10

6E

Gear Down Protection RPM Limit

1700 to TEL (rpm)

1700 to TEL (rpm)

All: TEL

6B

Gear Down Protection Turn On Speed

Other Trucks: 30 to 127 (mph) GM Trucks: 30 to 75 (mph)

Other Trucks: 30 to 127 (mph) GM Trucks: 30 to 75 (mph)

Other: 127 GM: 75

67

*Top Engine Limit (fixed value)

Engine and Rating Dependent


N/A

6F

Low Idle Engine RPM

700 to 800 (rpm)

700 to 800 (rpm)

All: 700




Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET 7B

*Transmission Style

Universal (GM Trucks Only) Manual Option 1 Manual Option 2 (GM Trucks Only) Automatic Option 1 Automatic Option 2 Automatic Option 3 Automatic Option 4 AT/MT/HT Option 1 AT/MT/HT Option 2 AT/MT/HT Option 3 AT/MT/HT Option 4

Universal – U Manual Option 1, Manual, A Manual Option 2, Manual_Option_2 Auto Option 1, Auto_Option_1 Auto Option 2, Auto_Option_2 Auto Option 3, Auto_Option_3 Auto Option 4, Auto_Option_4 AT/MT/HT Option 1, AT/MT/HT_Option_1 AT/MT/HT Option 2, AT/MT/HT_Option_2 AT/MT/HT Option 3, AT/MT/HT_Option_3 AT/MT/HT Option 4, AT/MT/HT_Option_4

Other: Manual Option 1 GM 530/540: Universal GMT-560: Manual Option 2

FCA5

AT/MT/HT Part Throttle Shift Speed

Low (80% Enable/ 65% Disable) Medium (70% Enable/ 55% Disable) High (60% Enable/ 45% Disable)

Default – A Medium – B High – C

All: High

FCDA

Starting Aid Output Mode

Off Automatic

Off, No, Disable Automatic, On, Yes, Enable

All: Off

FE06

Governor Type

Full Range Min/Max Min/Max With Speed Control

Full Range Min/Max, Min_Max Min/Max/SC, Min_Max_w_SC, Min_Max_SC

All: Full Range

FF36

Transmission Neutral Start Interlock

Disabled Enabled

Disabled, Off, No Enabled, On, Yes

Disabled

Smart Idle Parameters FCD8

*Battery Monitor & Engine Control Voltage

0 – 25.5 (volts)

0 – 25.5 (volts)

Other: 0 GMT530/540: 0 GMT560: 11.5

FCFF

*Battery Monitor Low Idle Engine Speed

700 to TEL (rpm)

700 to TEL (rpm)

All: 1000


179



Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET Timer Parameters FC13

Idle Shutdown Time

1 to 1440 minutes

1 to 1440 minutes

All: 0

FEF7

Cold Mode Idle Shutdown Timer Enable

Disabled Enabled

Disabled, Disable, D Enabled, Enable, E

Disabled

4F

Allow Idle Shutdown Override

Yes No

Yes – On, Enable, C No – Off, Disable, A

All: Yes

C0

*A/C Switch Fan On-Time

0 to 600 (seconds)

0 to 600 (seconds)

All: 0

4E

Fan with Exhaust Brake On

No Yes


All: No

Engine Monitoring Mode

Warning Derate Shutdown (Other & GMT-560 Only)

Warning – W Derate – D Shutdown – S

Other: Warning GM 530/540: Warning GMT-560: Derate

* Engine Monitoring Lamps (Other & GM 530/ 540 Only)

Warning Lamp (Other & GMT560 Only) High Coolant Temp Warning Lamp (GM 530/540 ONLY) Option 1 (Other Only) — NEW —

Warning Lamp – Warning_Lamp, WL, A High Coolant Temp Warning Lamp, CTWL, Coolant_Temp_Warning_Lamp, HCTWL, B Option 1, Option_1, Option1, C

All: Warning Lamp

Coolant Level Sensor

No 4-Pin 2-Pin Switch (GMT 560 Only) 2-wire Float Sensor (Other Only)

No – Off, Disable, None 4-Pin – 4_Pin, 4 Pin, 4Pin 2-Pin Switch – 2Switch 2-wire Float Sensor – 2Float

Other: No GM 530/540: No GMT-560: 2-Pin Switch

FC61

Engine Oil Pressure Sensor

Installed Not Installed

Installed – Yes, On, Enable Not Installed – No, Off, Disable

Other: Not Installed GM 530/540 : Not Installed GMT-560: Installed

FCE2

Oil Level Switch (GMT-560 Only)

Installed Not Installed

Installed, On, Enabled, Yes Not Installed, Off, Disable, No

GMT-560: Installed

Engine Monitoring Parameters 7F

FCD2

7E

180




Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET Maintenance Parameters C8 C9

Maintenance Indicator Mode (Refer to VEPS *.DEF and example .PAR files for specific programming information)

CA CB

CC

Off Man – Distance Man – Hour Auto – Distance Auto – Hour

Off – Reset Mode, O, Reset_Mode, Disable_Mode Man-Distance, MD Man-Hours, MH Auto-Distance, AD Auto-Hours, AH

Other: Off GM 530/540: Off GMT-560: Auto-Distance

PM1 Interval: 5000 to 35000 (miles) (Manual Maintenance 100 to 750 (hours) Indicator) Manual Distance Manual Hours

5000 to 35000 (miles) 100 to 750 (hours)

All: 15000 All: 250 GM: 12000

Engine Oil Capacity

20 to 60 (quarts)

20 to 60 (quarts)

Other: 33 GMT530/540: 22 GMT-560: 30

Trip Parameters E0

Dash – PM1 Reset

No Yes

D P

Other: No GM 530/540: No GMT-560: Yes

E0

Dash – Customer Parameters

No Yes

D A

All: No

FC08

Theft Deterrent System Control

Yes No Auto-Enable

Yes – On, Enable No – Off, Disable Auto-Enable, AutoEnable, AE

All: No

FC09

Theft Deterrent Password

Four Characters

Four Characters

All: 0000

FC0C

Quick Stop Rate

0 to 127 (mph/second)

0 to 127 (mph/second)

All: 0


181



Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET Input Selections

182

FD01

Fan Override Switch Configuration

None J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

None J1939 Body Controller – J1939_Body J1939 Cab Controller – J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: None

FD4B

Transmission Neutral Switch

J1/P1: 62 J1939

J1/P1:62 J1939

Other: J1/P1: 62 GM530/540: J1/P1: 62 GMT-560: J1939

FD2B


None J1/P1:16 J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

None J1/P1: 16 J1939 Body Controller – J1939_Body J1939 Cab Controller – J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: None

FD05

Ignore Brake/ Clutch Switch

None J1/P1: 47

None J1/P1: 47

All: None

FD23

*Two Speed Axle Switch

None J1/P1:6

None J1/P1: 6

All: None

FD76

*Vehicle Speed Input

J1/P1:32&33 J1939 Trans J1939 ABS

J1/P1: 32&33 – A J1939 Trans – J1939Trans, B, JTSS J1939 ABS – J1939_ABS, C, ABS_Axle_Speed

All: J1/P1: 32&33




Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET Input Selections (Continued) FD71

PTO Engine Shutdown Switch

None J1/P1: 7 J1/P1: 23

None J1/P1: 7 J1/P1: 23

All: None

FD09

Torque Limit Switch

None J1/P1: 7 J1/P1: 23

None J1/P1: 7 J1/P1: 23

All: None

FD0D

PTO On/Off Switch

J1/P1: 56 J1939 Cab Controller J1939 Body Controller J1939 Instrument Cluster

J1/P1:56 J1939 Body Controller, J1939_Body J1939 Cab Controller, J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

J1/P1: 56

FD13


None J1/P1: 46 J1939 Cab Controller J1939 Body Controller J1939 Instrument Cluster

None J1/P1: 46 J1939 Body Controller, J1939_Body J1939 Cab Controller, J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: None

FD15


None J1/P1: 7 J1/P1: 23

None J1/P1: 7 J1/P1: 23

All: None

FD0F

Remote PTO Set Switch



J1/P1: 58

FD11

Remote PTO Resume Switch



J1/P1: 60

FD0B

Diagnostic Enable Switch

None J1/P1: 46 J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

None J1/P1: 46 J1939 Body Controller , J1939_Body J1939 Cab Controller, J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: None


183



Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET Input Selections (Continued)

184

FD25

Cruise Control On/Off Switch

J1/P1: 59 J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

J1/P1: 59 J1939 Body Controller , J1939_Body J1939 Cab Controller, J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: J1/P1: 59

FD27

Cruise Control Set/ Resume/Accel/ Decl Switch

J1/P1: 35&44 J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

J1/P1: 35&44 J1939 Body Controller – J1939_Body J1939 Cab Controller – J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: J1/P1: 35&44

FD7F

Cruise Control Pause Switch

None J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

None J1939 Body Controller – J1939_Body J1939 Cab Controller – J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: None

FD29


J1/P1:22 J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

J1/P1:22 J1939 Body Controller , J1939_Body J1939 Cab Controller, J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: J1/P1: 22




Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET FD2D

Service Brake Pedal Position Switch #1

J1/P1:45 J1939 Body Controller J1939 Cab Controller J1939 Instrument Cluster

J1/P1: 45 J1939 Body Controller – J1939_Body J1939 Cab Controller – J1939_Cab J1939 Instrument Cluster, J1939_Instrument_Cluster, J1939_Inst_Cluster

All: J1/P1: 45

FD35

Accelerator Pedal Position

J1/P1:66

J1/P1: 66

All: J1/P1: 66

FD31

A/C High Pressure Switch (Other & GM 530/540 Only)

None J1/P1: 41

None J1/P1: 41

Other: J1/P1: 41 GM 530/540: J1/P1: 41

FD75

A/C Fan Request (GMT-560 Only)

None J1/P1: 41 J1/P1: 62

None J1/P1: 41 J1/P1: 62

GMT-560: J1/P1: 62

Output Selections: FC18

*Fan Control Type NEW PWM and DC Options

None On/Off PWM On/Off DC Variable Speed Fan Option S

None – A On/Off PWM – On/Off, Simple On/Off, Simple_On/Off, On/off_pwm On/Off DC, On_Off_dc Variable Speed Option S, VSOSS

All: None

FD6D

PTO Active Output CONFIG

None J1/P1:19

None J1/P1:19

All: J1/P1: 19

FD3B

PTO Switch On Lamp None J1/P1:30

None J1/P1:30

All: J1/P1: 30

FD49

Fast Idle Enabled Lamp (Other & GMT-560 Only)

None J1/P1:31 J1/P1:21

None J1/P1:31 J1/P1:21

Other: J1/P1: 31 GMT-560: J1/P1: 21

FD7B

Wait To Start Lamp (Other Only)

None J1/P1:31 J1939

None J1/P1:31 J1939

Other: None


185



Parameter


VEPS Range/Options

Default

As displayed on Caterpillar ET FD37

Engine Running Output (GMT-560 Only)

None J1/P1: 31

None J1/P1: 31

GMT-560: J1/P1: 31

FD7D

Change oil Lamp

None J1/P1: 30

None J1/P1:30

All: None

FCF1

Primary Fuel Level Tank Capacity GMT-560 Only

None 25 (gal) 35 (gal) 50 (gal)

None 25 Gal, 25Gal 35 Gal, 35Gal 50 Gal, 50Gal

GMT 560: 50

FCF2

Secondary Fuel Level None Tank Capacity 25 Gal GMT-560 Only 35 Gal 50 Gal

None 25 Gal, 25Gal 35 Gal, 35Gal 50 Gal, 50Gal

GMT 560: None

Passwords 45

Customer Password #1



Not Programmed

46

Customer Password #2



Not Programmed

None J1939

None, Off, A J1939, B

Other: None GM (ALL): J1939

Data Link Parameters FC0D

Powertrain Data Link

System Parameters 5B

Personality Module Code


Read Only

Factory Programmed

N/A

FLS

Read Only


Factory Programmed

N/A

FTS

Read Only


Factory Programmed

**Denotes Parameters available for Lockout using an Electronic Service Tool or VEPS. Factory Passwords are required to unlock a locked parameter. **In some instances, the parameter option (as displayed on ET) cannot be used with VEPS programming due to Character Length limitations. In these instances, one of the VEPS alternative options must be used. Otherwise, the exact option (as displayed on ET) is recommended (but not required) for the VEPS .PAR file.

186



24.0 Diagnostics, Service Tools and Service Information The control system has built-in diagnostics to verify system components are operating properly. In the event of a component failure, the driver is alerted to the condition via an OEM installed “Check Engine” or diagnostic lamp, or from a message transmitted over the SAE J1587 and/or J1939 data links. Intermittent faults are logged and stored in the memory of the ECM and can be retrieved using an Electronic Service Tool. The recommended electronic service tool for C7 and C9 engines is Caterpillar Electronic Technician (ET). ET is a software based service tool used to diagnose and repair Caterpillar products. It is designed to run on a personal computer using the Windows® 95, 98, 2000, or Windows® NT operating system. A new product from Caterpillar, Pocket Technician® is software for the Palm Operating System (Palm OS®) that allows a user to run diagnostics on CAT On-Highway Electronic Truck engines. Contact your local Caterpillar Dealer for more details. Older service tools will not recognize the C7 or C9 engine. These tools include the Electronic Control Analyzer and Programmer (ECAP) and the MPSI Pro-Link service tool with existing Caterpillar Cartridge. The Caterpillar Communication Adapter (PC to engine ECM) connector uses a 9-terminal Deutsch HD series connector to connect to the vehicle. Caterpillar offers a variety of adapter cables to connect various cab/engine datalink connectors to the standard 9-pin connector found on the 139-4166 or 207-6845 Service Tool cable. The following list identifies some of those adapter cables commonly used on various applications. X-1714- Connects 9-terminal Service Tool Cable (139-4166 or 207-6845) to GM ALDL Connector 7X-1686- Connects 9-terminal Service Tool Cable (139-4166 or 207-6845) to a 6-terminal Diagnostic Connector 157-4829 – Connects 9-terminal Service Tool Cable (139-4166 or 207-6845) to a 9-terminal J1939/13 Off-Board Diagnostic Connector


187


PID/SID – FMI

188

Diagnostic Code Description

Flash Code

0-00

No Faults Active or Logged

55

1-11

Cylinder #1 Fault

72

2-11

Cylinder #2 Fault

72

3-11

Cylinder #3 Fault

73

4-11

Cylinder #4 Fault

73

5-11

Cylinder #5 Fault

74

6-11

Cylinder #6 Fault

74

22-11

Primary to Secondary Engine Speed Signal Calibration

42

22-13

Check Timing Sensor Calibration

42

30-08

Invalid PTO Throttle Signal

29

30-13

PTO Throttle Sensor Calibration

29

32-05

Turbo Wastegate Solenoid Open Circuit

33

32-06

Turbo Wastegate Solenoid Short Circuit

33

32-11

Turbo Wastegate Solenoid SHort to + Battery

33

41-03

8 Volt Supply Above Normal

21

41-04

8 Volt Supply Below Normal

21

42-11

Injection Actuation Pressure Driver Fault

18

43-02

Ignition Key Switch Fault

71

64-02

Loss of Engine RPM Signal on (Bottom) Sensor #2

34

64-11

No Pattern on (Bottom) Engine Speed Sensor #2

34

70-05

Intake Air Heater Open Circuit

49

70-06

Intake Air Heater Short Circuit

49

71-00

Idle Shutdown Override

01

71-01

Idle Shutdown Occurrence

47

71-11

Engine Shutdown Override Switch Occurrence

00

71-14

PTO Shutdown Occurrence

47

84-00

Vehicle Overspeed Warning

41

84-01

Loss of Vehicle Speed Signal

31

84-02

Invalid Vehicle Speed Signal

36

84-08

Vehicle Speed Out of Range

36

84-10

Vehicle Speed Rate of Change

36

84-14

Quick Stop Occurrence

00

91-08

Invalid Throttle Pedal Position Signal

32

91-13

Throttle Pedal Position Sensor Calibration

28

94-01

Fuel Pressure Low – Engine Cranking

37

94-03

Fuel Pressure Voltage High

37

94-04

Fuel Pressure Voltage Low

37

94-11

Fuel Pressure Low – Engine Running

96-03

Primary Fuel Level Sensor Open Circuit

00



PID/SID – FMI


Flash Code

96-04

Primary Fuel Level Sensor Short Circuit

00

100-01

Low Oil Pressure Warning

46

100-03

Oil Pressure Sensor Open Circuit

24

100-04

Oil Pressure Sensor Short Circuit

24

100-11

Very Low Oil Pressure

46

102-01

Boost Pressure Reading Stuck Low

25

102-02

Erratic Boost Pressure

25

102-03

Boost Pressure Sensor Open Circuit

25

102-04

Boost Pressure Sensor Short Circuit

25

102-07

Excessive Boost Pressure

25

105-00

High Inlet Manifold Temperature Warning

64

105-03

Intake Manifold Air Temperature Sensor Open Circuit

38

105-04

Intake Manifold Air Temperature Sensor Short Circuit

38

105-11

Very High Intake Manifold Air Temperature Warning

64

108-03

Atmospheric Pressure Sensor Open Circuit

26

108-04

Atmospheric Pressure Sensor Short Circuit

26

110-00

High Coolant Temperature Warning

61

110-03

Coolant Temperature Sensor Open Circuit

27

110-04

Coolant Temperature Sensor Short Circuit

27

110-11


61

111-01


62

111-02

Coolant Level Sensor Fault

12

111-03

Coolant Level Open Circuit

12

111-04

Coolant Level Sensor Short Circuit

12

111-11


62

111-14

Low Coolant Level Warning (Less than 6 engine hours)

62

128-03

Secondary Fuel Level Sensor Open Circuit

44

128-04

Secondary Fuel Level Sensor Short Circuit

44

164-00

Injection Actuation Pressure Out of Range

17

164-02

Injection Actuation Pressure Sensor Erratic

15

164-03

Injection Actuation Pressure Open Circuit

15

164-04

Injection Actuation Pressure Short Circuit

15

164-11

Injection Actuation Pressure System

39

168-00

Excessive Battery Power to ECM

51

168-01

Low Battery Power to the ECM

51

168-02

Intermittent Battery Power to the ECM

51

173-00

High Exhaust Temperature Derate

16

173-11

Very High Exhaust Temperature

16

186-04

PTO Shutdown Switch Short Circuit

00


189


PID/SID – FMI


Flash Code

186-14

PTO Shutdown Switch Occurrence

47

190-00

Engine Overspeed Warning

35

190-02

Loss of Engine RPM Signal on (Top) Sensor #1

34

190-11

No Pattern on (Top) Speed Sensor #1

34

224-11

Theft Deterrent Enabled

00

224-14

Engine Cranking with Theft Deterrent Enabled

00

231-02

J1939 Device Sending Incorrect Data

58

231-11

J1939 Data Link Fault

58

231-12

J1939 Device Not Responding

00

231-14

Transmission Datalink Engine Derate

57

232-03

5 Volt Supply Above Normal

21

232-04

5 Volt Supply Below Normal

21

246-11

Service Brake Switch #1 Fault

00

247-11

Service Brake Switch #2 Fault

00

252-11

Incorrect Engine Software

59

253-02

Check Customer or System Parameters

56

253-14

Truck Manufacturer Parameter Not Programmed

56

24.1 ECM Software Changes ECM software changes (uprates, updates) require a personal computer, a Caterpillar approved communication adapter, and Caterpillar Electronic Technician (ET) Win-Flash. 24.2 Engine Totals The ECM maintains current totals for the following information ECM Maintained Total Data 1) Total Time 2) Total Distance 3) Total Idle Fuel 4) Total PTO Time 5) Total Fuel 6) Total Idle Time 7) Total PTO Fuel All data is stored in metric form except distance (miles), and vehicle speed (mph). Conversion to other formats are performed by the Electronic Service Tool. 24.3 Trip Data Included under the heading of Trip Segment is a Fleet Trip Segment. A segment is defined as the difference from the current instantaneous Engine Totals data and the Engine Totals stored at the previous reset of the data. When a reset occurs, the ECM stores the current ECM Engine Totals value in place of the old value for the respective Trip Data information. The ECM maintains only the data reset values for the Fleet Trip Data segment. The Trip Histograms include a 3-dimensional histogram (engine rpm, vehicle speed, and engine hours), two 2-dimensional histogram (one for engine rpm – hours, the other for vehicle speed – hours), and five sets of Fleet Segment Custom Data. The 2-dimensional histograms are a subset of the 3-dimensional histogram.

190



24.3.1 Fleet Trip Segment The Fleet Trip Segment maintains the following Engine Totals information, recorded at the time of reset: Time (Engine Hours)

Idle Fuel

Average Driving Speed

Driving Time

Percent Idle Time

Max Vehicle Speed

Distance

PTO Time

Max Engine Speed

Fuel

PTO Fuel

Start Time

Overall Fuel Economy

Percent PTO Time

End Time

Driving Fuel Economy

Average Load Factor

Start Odometer

Idle Time

Average Vehicle Speed

End Odometer

24.3.2 Trip Histograms The ECM maintains the histograms tracking Engine Hours at specific Engine Speed and Vehicle Speed ranges. The RPM data points and vehicle speed ranges are broken down into various ranges such as 0-4, 5-9, 10-14 mph or 0-599, 600-699, 700-799 rpm. A reset occurs via a data link message only. 24.4 Engine Snapshot Recorder The ECM stores engine operating parameters when diagnostic codes occur. An Electronic Service Tool or the Cruise Set/Resume switch can also be used to manually trigger a snapshot. The Set/Resume switch must be toggled to the Set then the Resume position within one second to trigger the snapshot recorder. The ECM can store up to two Diagnostic Code Triggered snapshots, two Externally triggered snapshots, and one Quick Stop Snapshot. Each type is stored in a “circular buffer”. When a new snapshot is taken, the oldest one in the buffer will be replaced. 24.5 Engine Snapshot Recorder Records Each diagnostic record contains 27 frames of information; frame 20 is the diagnostic code occurrence, 19 frames before, 7 frames following the code. Each frame is separated by 0.48 seconds. Each switch activated record contains 54 frames; frame 40 is the switch activation trigger, 39 frames before, 14 frames after the switch trigger. Time between frame is 0.24 seconds for the switch activated record. 24.6 Quick Stop Recorder A snapshot can also be stored for a Quick Stop occurrence if the Customer Parameter is programmed. The ECM stores the number of occurrences of the Quick Stop Events, as well as a snapshot of the latest occurrence. Each Quick Stop record contains 60 frames of information; frame 45 is the Quick Stop occurrence, 44 frames before, 15 frames following the code. Each frame is separated by 1.0 second. 24.6.1 Data Stored In Quick Stop Recorder Frames Each frame of the Quick Stop snapshot record stores the following data; ECM Snapshot Frame Data Engine rpm

Vehicle Speed

Throttle Position

Cruise Status

Clutch Switch

Brake Switch #1


191


24.7 ECM Date/Time Clock The ECM date & time can be programmed using an Electronic Service Tool or VEPS. The Electronic Service Tool will display the programmed Date in Month/Day/Year format and the programmed Time in Hour:Minute:Second format. The Electronic Service Tool has the option to program any date/time or automatically select the date/time stored in the PC real time clock. The date and time will remain in the ECM and will not reset even if the Unswitched Battery connections are removed. The ECM real time clock is accurate to within four minutes per month worst case. Typically the accuracy is similar to a personal computer real time clock. Date

Time

VEPS PID

Month Day Year

hour:minute:second

FC1D

24.8 ECM Diagnostic Clock The Diagnostic Clock should not be confused with the ECM Date/Time clock. The Diagnostic Clock records actual hours that the ECM has been powered (ignition key switch ON). The diagnostic clock information is used to log diagnostic code and event code occurrences. Logged diagnostic codes and event codes display the diagnostic clock hour of the first and last occurrence and the total number of occurrences. The Diagnostic Clock does not represent actual Engine Hours, it increments any time the ECM is powered regardless of whether the engine is running or not. Actual Engine Running hours (Total Time) can be obtained from the Current Totals menu of ET (Electronic Technician).

192



24.9 C7 and C9 ECM Vehicle Harness Connector Terminal Assignments and Loads Terminal

Wire ID

Wire

Signal

1

Assignment

Voltage

Current

Not Used

2

G897-OR

18 AWG

Supply

+5V

3

993-BR

18 AWG

Common


5 Volts DC

40 mA

4

C985-BU

18 AWG

Supply

+8V Cab Throttle Sensor Supply

5

H795-PK

18 AWG

Common


8 Volts DC

40 mA

6

G843-OR

18 AWG

Switch to Sensor Common

2 SPD Axle Switch

13 Volts DC

6.5 mA

7

G841-GN

18 AWG


Torque Limit Switch PTO Engine RPM Set Speed B PTO Engine Shutdown Switch

13 Volts DC

6.5 mA

8

E794-YL

18 AWG

Data Link

J1587 Data Link Positive

5 Volts DC

100 mA

9

E793-BU

18 AWG

Data Link

J1587Data Link Negative

5 Volts DC

100 mA

10

E718-PK

18 AWG

High Side

Starting Aid

battery

1.5 A

11

G837-YL

18 AWG

High Side PWM

Fan Control

battery

1.0 A PWM

12

E991-GY

18 AWG

High Side

Exhaust Brake

battery

1.5 A

13

G836-WH

18 AWG

High Side

Engine Running Output

battery

1.5 A

13 Volts DC

6.5 mA

14

Not Used

15

* Primary Fuel Tank Level

16

C981-GY

18 AWG


17

Exhaust Brake Switch Not Used

18

L901-GY

18 AWG

Common


19

G838-BR

18 AWG

High Side

PTO Active Output

battery

1.0 A

20

G839-BU

18 AWG

High Side

Transmission shift Output

battery

1.0 A

21

G880-PK

18 AWG

High Side

Fast Idle Lamp

battery

1.0 A

22

C977-BU

18 AWG



13 Volts DC

6.5 mA

23

M990-OR

18 AWG


Torque Limit Switch PTO Engine RPM Set SPD B PTO Engine Shutdown Switch

13 Volts DC

6.5 mA

24

Not Used

25

Not Used

26

2 Wire Float Coolant Level Sensor *Secondary Fuel Tank Level

27

Not Used (Transit Rating Only)

28

L994-YL

18 AWG

Low Side Driver

Check Engine Lamp

battery

0.3 A

29

659-PK

18 AWG

Low Side Driver

Warning Lamp Low Oil Pressure Lamp

battery

0.3 A

30

K998-BU

18 AWG

Low Side Driver

PTO Switch On Lamp Change Oil Lamp Low Coolant Level

battery

0.3 A


193


Terminal

Wire ID

Wire

Signal

Assignment

31

G880-PK

18 AWG

Low Side Driver

Fast Idle Lamp Wait To Start Lamp High Coolant Temp * Engine Running Output

32

G808-BU

18 AWG

Differential Input

Vehicle Speed In +

Voltage battery

Current 0.3 A

33

G809-GN

18 AWG

Differential Input

Vehicle Speed In -

34

K990-GN

18 AWG

Data Link

J1939 Data Link Negative

per J1939

35

C978-BR

18 AWG


Cruise Control Set

13 Volts DC

6.5 mA

36

C974-PU

18 AWG

Complementary

Speedometer+

10 Volts

4 mA

37

C973-GN

18 AWG

Complementary

Speedometer-

10 Volts

4 mA

38

450-YL

18 AWG

Complementary

Tachometer +

10 Volts

4 mA

39

451-BR

18 AWG

Complementary

Tachometer -

10 Volts

4 mA

40

L902-GN

18 AWG


Input #18 (Fast Idle)

13 Volts DC

6.5 mA

41

E971-GN

18 AWG


A/C High Press. Sw * A/C Fan Request Switch

13 Volts DC

6.5 mA

42

A249-BK

18 AWG

Data Link

J1939 Data Link Shield

per J1939

43

Not Used

44

C979-OR

18 AWG


Cruise Control Resume

13 Volts DC

6.5 mA

45

C992-PU

18 AWG


Service Brake Pedal Pos. Sw.#1

13 Volts DC

6.5 mA

46

G844-PK

18 AWG


Diagnostic Enable PTO Engine RPM Set Speed A

13 Volts DC

6.5 mA

47

G842-GY

18 AWG


Ignore Brake/Clutch

13 Volts DC

6.5 mA

48

101-RD

14 AWG

Supply

Unswitched +Battery

battery

10 Amps

49

C983-WH

18 AWG

Input

Coolant Level Normal

13 VDC

0.6 mA

50

K900-YL

18 AWG

Data Link

J1939 Data Link Positive

per J1939

51

Not Used

52

101-RD

14 AWG

Supply

Unswitched +Battery

battery

10 Amps

53

101-RD

14 AWG

Supply

Unswitched +Battery

battery

10 Amps

54

C984-YL

18 AWG

Input

Coolant Level Low

13 Volts DC

0.6 mA

55

101-RD

14 AWG

Supply

Unswitched +Battery

battery

10 Amps

56

K999-GN

18 AWG


PTO On/Off Switch

13 Volts DC

6.5 mA

58

K980-PK

18 AWG


Remote PTO Set Switch

13 Volts DC

6.5 mA

59

C975-WH

18 AWG


Cruise Control On/Off Switch

13 Volts DC

6.5 mA

60

K982-YL

18 AWG


Remote PTO Resume Switch

13 Volts DC

6.5 mA

57

Not Used

61

Not Used

62

409-OR

18 AWG

Switch to Bat.

Neutral Switch *A/C Fan Request Switch

battery

6.0 mA

63

229-BK

14 AWG

Supply

- Battery

battery

10 Amps

194



Terminal

Wire ID

Wire

Signal

Assignment

Voltage

Current

64

L900-PU

18 AWG

Switch to Bat.

Service Brake Switch #2

battery

6.0 mA

65

229-BK

14 AWG

Supply

- Battery

battery

10 Amps

66

C986-BR

18 AWG

Accelerator Input

Cab Throttle Position

5 Volts DC

40 mA

67

229-BK

14 AWG

Supply

-Battery

battery

10 Amps

68

G845-PU

18 AWG

Accelerator Input

Remote Throttle

5 Volts DC

40 mA

69

229-BK

14 AWG

Supply

- Battery

battery

10 Amps

70

J906

18 AWG

Switch to Bat.

Ignition Key Switch

battery

1.2 mA

*Parameter is restricted to GMT560 trucks.


195


INDEX 2-Pin Switch Coolant Level Sensor (GMT 560 only) ..........................................54

Automatic Transmissions with Electronic Vehicle Speed Source................................40

2-Wire Float Coolant Level Sensor ............52

B

2-Wire Float Sensor Diagnostics ..............54

Battery Monitor & Engine Control Voltage ........................................162

70 Terminal ECM Connector Part Numbers ............................................26 A A/C Fan request Switch (GMT560 Only) ........................................112 A/C Fan Request Switch (GMT560 Only) ........................................171 A/C High Pressure Switch........................170 A/C High Pressure Switch..........................65 A/C Switch Fan On-Time ........................161 Accelerator Pedal Position Sensor Connections ..............................................34 Accelerator Pedal Position Sensor Connectors ................................................34 Accelerator Pedal Position Sensor Duty Cycle..................................................33 Accelerator Pedal Position Sensor Electrical Specifications ............................33 Accelerator Pedal Position Sensor for Remote PTO Applications ....................36 Accelerator Pedal Position Sensor Three Terminal Connector Terminals ........35 Accelerator Pedal Position Sensors ..........32

Battery Monitor Low Idle Engine Speed ..........................................162 Bit Code Definition ..................................117 Boost Pressure Sensor ................................5 C C7 and C9 ECM Vehicle Harness Connector Terminal Assignments and Loads ..........................193 Cab Switches Programmable Options ......82 Change Oil Lamp ....................................172 Change Oil Lamp ......................................48 Check Engine Lamp Operation ..................46 Clutch Pedal Position Switch Function ......61 Clutch Pedal Position Switch with Automatic Transmissions ....................62 Clutch Pedal Position Switch....................171 Clutch Switch ............................................73 Cold Mode Idle Shutdown Timer Enable ..113 Cold Mode Idle Shutdown Timer Enable..161 Cold Mode Operation ..................................4

Air Conditioning High Pressure Switch ....111

Connection Of Devices Other Than A Speedometer/Tachometer ......................44

Allison 1000 & 2000 Series ......................101

Connector Interface Seal ..........................29

Allison AT/MT/HT Shift Interface Relay Operation ......................................102

Connectors and Wiring Harness Requirements ............................................26

Allison AT/MT/HT Transmissions..............101

Coolant Level Sensor Connections ............51

Allison Electronic Transmissions ................40

Coolant Level Sensor Diagnostic ..............52

Allison WT Series ....................................101

Coolant Level Sensor Environmental Compatibility ..............................................50

Allow Idle Shutdown Override ..................161 Amber Check Engine Lamp ......................49 AT/MT/HT Part Throttle Shift Speed ........159 Atmospheric Pressure Sensor ....................5 Auto Retarder In Cruise ..........................149

196

Coolant Level Sensor Mounting Guidelines (4-Pin) ......................................50 Coolant Level Sensor Outputs ..................52 Coolant Level Sensor Power Supply ..........51 Coolant Level Sensor Response Time ......52



INDEX Coolant Level Sensor ..............................163

Dedicated PTO Operation ..........................75

Coolant Level Sensor ..................................5

Dedicated PTO Parameters ....................152

Coolant Level Sensors ..............................50

Deutsch Connector Wire Gauge Size ........35

Coolant Temperature Sensor ......................5

Deutsch Connector Wire Insulation Size Range ................................................35

Cooling Fan Control with the Ignition Key Off ..................................110 Cooling Fan Output Operation (On/Off) ....................................................107 Cooling Fan Output Operation (Variable Speed Fan Option S) ................108 Cooling Fan ..............................................106 Cruise Control Accel Switch ......................72 Cruise Control Decel Switch ......................73 Cruise Control On/Off Switch ..................170 Cruise Control On/Off Switch ....................68 Cruise Control On/Off Switch ....................72 Cruise Control Parameters ......................148 Cruise Control Pause Switch ..................170

Diagnostic Enable ....................................169 Diagnostic Enable ......................................62 Diagnostics, Service Tools and Service Information ..................................187 Dual Coil Speed Sensor ............................40 E ECM +8V Cab Accelerator Pedal Position Sensor Supply ..............................34 ECM 70 Terminal Connector Allen Screw Torque ............................................26 ECM 70 Terminal Connector Sealing Plugs ............................................28 ECM 70 Terminal Connector Terminals......27

Cruise Control Resume Switch ..................72

ECM 70 Terminal Connector Wire Insulation and Size Range ........................26

Cruise Control Set Switch ..........................72

ECM Connector Endbell ............................31

Cruise Control Set/Resume Switch..........170

ECM Connector Terminal Installation Guidelines ................................27

Cruise Control Switches and Operation ....68 Cruise Control ............................................68 Cruise Pause Switch ..................................73 Cruise Switch Inputs ..................................72 Cruise/Idle/PTO Switch Configuration......149 Customer Parameter Lockout ..................144 Customer Password #1 and Customer Password #2 ............................173 Customer Specified Parameters ..............144 D Dash - Customer Parameters ..................165 Dash - PM1 Reset....................................165 Data Link Parameters ..............................173 Data Links ................................................114 Data Stored In Quick Stop Recorder Frames ....................................191

ECM Connector Terminals and Sealing Plugs ............................................26 ECM Connector Wire Gauge Size ............26 ECM Connector ........................................26 ECM Current Draw with Ignition Key Off ..........................................24 ECM Date/Time Clock..............................192 ECM Diagnostic Clock ............................192 ECM Negative Battery Connections ..........22 ECM Positive Battery Connections ............24 ECM Power Up and Preheat Cycle ............59 ECM Software Changes ..........................190 ECM Speedometer and Tachometer Outputs ..................................42 Electric Starting Motors..............................22 Electrical Specifications ............................45


197


INDEX Electronic Governing....................................4 EMI/RFI Testing..........................................24 Engine Component Overview ......................5 Engine Connection To Vehicle Battery Ground ..........................................22

Engine Running Output (Starter Lockout) ........................................98 Engine Snapshot Recorder Records ......191 Engine Snapshot Recorder ......................191 Engine Speed/Timing Sensors ....................5

Engine Control Module (ECM) ....................5

Engine Totals............................................190

Engine Cranking Cycle ..............................59

Engine/Gear Parameters ........................156

Engine Diagnostic Switch ..........................74

Exhaust Brake Configuration ..................156

Engine Exhaust Brake and Automatic Transmissions............................98

Exhaust Brake Mode................................148

Engine Exhaust Brake................................95 Engine Functions ........................................4 Engine Ground Stud ..................................22 Engine Monitoring Coolant Level Sensor ................................15 Engine Monitoring Coolant Temperature Sensor ....................13

Exhaust Brake Operation and Auto Retarder in Cruise..............................97 Exhaust Brake Operation as a Warm Up Device ................................97 Exhaust Brake Operation While In Cruise ..........................................96 Exhaust Brake Options ............................156 Exhaust Brake Switch ..............................167

Engine Monitoring - Engine Sensors ........13

Exhaust Brake Switch ................................65

Engine Monitoring - Intake Air Temperature Sensor ..................................13

Exhaust Brake Switch ................................73

Engine Monitoring Oil Pressure Sensor ..................................13 Engine Monitoring and OEM Requirements ..................................12

Extended Idle kick outs ..............................71 Extended Idle ............................................70 F Fan Control basics ..................................106

Engine Monitoring Lamp Options ..............12

Fan Control Options ................................106

Engine Monitoring Lamps ........................162

Fan Control Type ......................................171

Engine Monitoring Mode ..........................162

Fan Override Switch ................................166

Engine Monitoring Parameters ................162

Fan Override Switch ..................................73

Engine Monitoring Programmed to “Warning” ..............................................16

Fan with Engine Brake On ......................161

Engine Monitoring Programmed to Derate ....................................................17 Engine Monitoring Programmed to Shutdown ..............................................18

Fast Idle Enabled Lamp ..........................171 Fast Idle Enabled Lamp ............................48 Fast Idle RPM #1 ....................................151 Fast Idle RPM #2 ....................................152

Engine Monitoring ......................................12

Fast Idle Switch ..........................................63

Engine Oil Pressure Sensor ....................163

Fleet Trip Segment ..................................191

Engine Running Cycle ..............................59

Four Pin Coolant Level Sensor Electrical Specifications ............................51

Engine Running Output (GMT560 Only) ........................................172

198

Fuel Pressure Sensor ..................................6



INDEX Fuel Tank Level Sensing (GMT560 trucks only) ................................55 Fuel/Air Ratio Control ..................................4 Full Range Governor................................104 G Gear Down Protection RPM Limit ............157 Gear Down Protection Turn On Speed ....158 General Vehicle Speed Source Requirements for Passive Speed Sensor Input ..............................................38 Governor Type..........................................104 Governor Type..........................................160 Grounding ..................................................20 H

Inlet Air Heater and Relay ............................6 Inlet Air Heater Lamp ................................57 Inlet Air Heater Relay Connections ............56 Inlet Air Heater Relay Electrical Specifications ............................................56 Inlet Air Heater, Lamp and Relay Operation ........................................56 Inlet Manifold Air Temperature Sensor ........5 Input Electrical Specifications ....................75 Input Selections ......................................166 Intermediate Gears Engine RPM Limit ....157 Intermediate Gears Turn Off Speed ........157 J

Hard-wired Switch Inputs ..........................60

J1939 ABS Wheel Speed Based Vehicle Speed Source................................41

High Cruise Control Speed Set Limit ......148

J1939 Based Switch Messages ................72

High Speed Range Axle Ratio ................147

J1939 Data Link Driven Lamps ..................49

I

J1939 Transmission Output Shaft Speed Based Vehicle Speed Source ........41

IAH and Active Engine Diagnostics............59 IAH and Starting Aid Interaction ................59 Idle Functions ............................................70 Idle Parameters ........................................151 Idle RPM Limit..........................................151 Idle Shutdown Time..................................160 Idle Shutdown Timer ................................113 Idle Vehicle Speed Limit ..........................151 Idle/PTO Bump RPM................................151 Ignition Key Switch to Positive Battery ......66 Ignore Brake/Clutch Switch......................167 Ignore Brake/Clutch Switch........................64 Ignoring the Transmission Neutral Switch input. ..............................................67 Injection Actuation Pressure (IAP) Sensor ................................................5 Injection Actuation Pressure Control Valve (IAPCV) ..................................5 Injection Timing Control ..............................4

L Lamp Outputs ............................................45 Lamp Test ..................................................46 Low Coolant Level During an Engine’s First 6 Hours of Operation..........................15 Low Coolant Level Lamp............................47 Low Cruise Control Speed Set Limit ........148 Low Idle Engine RPM ..............................158 Low Oil Pressure Lamp..............................47 Lower Gears Engine RPM Limit ..............157 Lower Gears Turn Off Speed ..................157 M Maintenance Indicator Mode....................164 Maintenance Parameters ........................164 Maximum PTO Enable Speed..................154 Maximum PTO Enable Speed....................77 Maximum PTO Vehicle Speed..................155 Maximum Vehicle Speed in PTO Mode......77


199


INDEX Medium Duty Engine J1939 Broadcast Messages ..............................119 Min/Max Governor with Speed Control ....105 Min/Max Governor....................................104 Mounting the Remote Accelerator Position Sensor ..........................................36

Powertrain Data link ................................173 Primary Fuel Tank Capacity (GMT560 only) ........................................163 Programmable Output Electrical Specifications ............................................94 Programmable Outputs ..............................94

O

Programmable Parameters ......................160

OEM Harness Routing ..............................30

Programming examples ............................89

OEM Installed Sensors ..............................50

Protect Lamp..............................................49

Oil Level Switch (GMT560 Trucks Only) ......6

PTO Accelerator Position Sensor Connector ......................................36

Oil Level Switch Installation Status (GMT560 only) ........................................163

PTO Activates Cooling Fan ......................156

Oil Pressure Sensor ....................................5

PTO Activates Cooling Fan ........................77

Operation with the Cruise Control On/Off Switch in the OFF position ............96

PTO Active Output Configuration ............172

Option 1 - One Single Coil Speed Sensor ............................................39 Option 2 - One Single Coil Speed Sensor ............................................39 Option 3 - Separate Single Coil Speed Sensors ..........................................39 Optional Engine Running Output (GMT560 trucks only) ................................99 Output Selections ....................................171

PTO Active Output ....................................76 PTO Cab Throttle RPM Limit....................154 PTO Configuration - Cab Switches ............80 PTO Configuration ..................................152 PTO Configurations....................................79 PTO Customer Access Connector ............78 PTO Engine RPM Set Speed A ..............153 PTO Engine RPM Set Speed B ..............153 PTO Engine RPM Set Speed Input A ......168

P Packard Electric Connector Wire Gauge Size ................................................35 Packard Electric Connector Wire Insulation Size Range ................................35 Passive Magnetic Vehicle Speed Circuit Options ..........................................39 Passive Magnetic Vehicle Speed Sensor Electrical Requirements ................39

PTO Engine RPM Set Speed Input A ......170 PTO Engine RPM Set Speed Input B ......168 PTO Engine RPM Set Speed ..................152 PTO Engine Shutdown Switch ................168 PTO Engine Shutdown Switch ..................76 PTO Interlocks ..........................................78 PTO Kickout Vehicle Speed Limit ............155

Passwords................................................173

PTO Kickout Vehicle Speed Limit ..............77

PM1 Engine Oil Capacity (for Automatic Maintenance Indicator Mode) ........................................165

PTO On/Off Switch Operation ....................75

PM1 Interval (for Manual Maintenance Indicator Mode) ........................................164 Power and Grounding Requirements and Considerations ....................................19 200

PTO On/Off Switch ..................................169 PTO Output Activation Speed ..................156 PTO Shutdown Time ................................156 PTO Switch On Lamp ..............................172



INDEX PTO Switch ON Lamp ................................48 PTO Switch On Lamp ................................75 PTO Switches ............................................63 PTO to Set Speed ....................................154 PTO Top Engine Limit ..............................153 Q Quick Stop Rate ......................................166 Quick Stop Recorder................................191 R Rating Number ........................................145 Recommendations for Cooling Fan..........100 Recommendations for the Exhaust Brake....................................100 Remote Accelerator Pedal Sensor Common Connections ..................37 Remote Accelerator Pedal Sensor Input Electrical Specifications ....................37 Remote Accelerator Position Sensor Assemblies ....................................36 Remote Accelerator Position Sensor PWM Input ....................................37 Remote PTO Resume Switch ..................169 Remote PTO Set Switch ..........................169 Remote Switches Programmable Options ......................................................85

Secondary Fuel Tank Size (GMT560 only) ........................................164 Selected Engine Rating ..........................145 Selecting a Sensor ....................................50 Sensor Common Connections ..................22 Sensor Common Connections ..................60 Sensor Common for PTO Applications ......75 Service Brake Pedal Position Switch #1 ................................................171 Service Brake Pedal Position Switch #2 Function ....................................66 Service Brake Pedal Position Switches/Function ......................................61 Service Brake Switch ................................73 Set/Resume Switch....................................68 Set/Resume Switch....................................69 Shift Relay Operation with Cruise Control or Vehicle Speed Limiting Not Active ..................................102 Shift Relay Operation with Cruise Control or Vehicle Speed Limiting Active ..........................................103 Shutdown Override Switch (Mass Transit only) ....................................64 Smart Idle Parameters ............................162 Smart Idle ..................................................70

Remote Switches ......................................83

Soft Vehicle Speed Limit ..........................147

Remote Throttle Programmable Options....87

SoftCruise Control....................................150

Remote Throttle ........................................86

Speedometer and Tachometer Output Accuracy ........................................44

S SAE J1587 Data Link Broadcast Parameters ............................115

Speedometer And Tachometer ..................42 Speedometer Signal Accuracy ..................44

SAE J1587/J1708 Data Link ....................114

Starting Aid Output ..................................160

SAE J1939 Data Link Broadcast Messages ..............................119

Stop Lamp..................................................49

SAE J1939 Data Link Received Messages ................................136 SAE J1939 Data Link ..............................118 Sealing Splices and Ring Terminals ..........29

Suppression Of Voltage Transients and Electrical Noise ..................................23 Switch Function/Interaction for Cruise Control ......................................69 Switch to Sensor Common Electrical Specifications ............................60


201


INDEX Switch to Sensor Common Inputs..............61

Two Speed Axle Switch............................167

Switch-to-Battery Circuit Protection ..........66

Two Speed Axle Switch..............................62

Switch-to-Battery Electrical Specifications ............................65

V

T

Vehicle ID ................................................145 Vehicle Speed Cal (J1939 ABS) ..............146

Tachometer Calibration ............................147 Tachometer Signal Accuracy......................44 Theft Deterrent Password ........................166 Theft Deterrent System Control ..............165 Three Terminal Deutsch Mating Connector ......................................34 Three Terminal Packard Electric Mating Connector ..........................35 Timer Parameters ....................................160 Top Engine Limit (TEL) ............................158 Torque limit Switch ..................................168 Torque Limit..............................................155 Torque Rise Shaping....................................4 Transmission Neutral Start Interlock ........160 Transmission Neutral Switch Status via J1939 Data Link ........................67 Transmission Neutral Switch ....................167 Transmission Neutral Switch ......................66 Transmission Neutral Switch ......................74 Transmission Style ..................................158 Transmissions Equipped with J1939 Communication ......................100 Transmissions ..........................................100 Trip Data ..................................................190

Vehicle Speed Cal (J1939-Trans) ............146 Vehicle Speed Calibration ........................145 Vehicle Speed Input Circuit ........................38 Vehicle Speed Input ................................168 Vehicle Speed Limit..................................146 Vehicle Speed Parameters ......................145 Viewing Diagnostic Flash Codes using Diagnostic Enable Input....................47 Viewing Diagnostic Flash Codes................46 Voltage Requirements and Considerations ....................................24 Voltage thresholds measured at ECM........65 VSL Protection ........................................147 W Wait To Start Lamp ..................................172 Wait To Start Lamp ....................................48 Wait to Start Lamp ....................................49 Warm Up Mode Idle Speed......................152 Warning Lamp Operation ..........................47 Warning Lamp Output used for High Coolant Temperature Shutdown Signal ........................................47 Welding on a Vehicle Equipped with a C7 or C9 Engine ..............................24

Trip Histograms ........................................191 Trip Parameters ........................................165 Truck Manufacturer Parameters ..............145 Truck Manufacturer ..................................145 Twisted Pair Wiring ....................................31

202


Information contained in this publication may be considered confidential. Discretion is recommended when distributing. Materials and specifications are subject to change without notice. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

LEBT2835-02

©2008 Caterpillar

Printed in U.S.A. All rights reserved.

C7-C9 Electrical Electronic Guide

Recommend Documents