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APPLICATION AND INSTALLATION GUIDE

DIESEL ENGINE
CONTROL SYSTEMS
Contents

Diesel Engine Control Systems ................................................ 1


Engine Protection & Monitoring System Parameters ............... 2
Engine Lubrication System .............................................. 2
Lube Oil Pressure ....................................................... 2
Lube Oil Temperature ................................................. 2
Oil Level Alarm .......................................................... 3
Lubricating Oil Filter Differential Pressure ...................... 3
Crankcase Pressure .................................................... 3
Oil Mist Detector Shutdown ........................................ 3
Metal Particle Detection .............................................. 3
Oil Scavenge Pump Outlet Pressure.............................. 3
Engine Cooling System ................................................... 4
Jacket Water Temperature .......................................... 4
Jacket Water Pressure ................................................ 4
Aftercooler Water Temperature.................................... 4
Aftercooler Water Pressure ......................................... 4
Expansion Tank Level Alarm........................................ 4
Cooling Water Loss-of-Flow Alarm ............................... 4
Sea Water Pressure .................................................... 5
Engine Fuel System ........................................................ 5
Fuel Pressure ............................................................. 5
Fuel Temperature ....................................................... 5
Fuel Filter Differential Pressure .................................... 5
Engine Starting Air System.............................................. 5
Starting Air Pressure................................................... 5
Engine Combustion Air System........................................ 5
Inlet Manifold Air Temperature .................................... 5
Inlet Manifold Air Pressure .......................................... 5
Air Cleaner Differential Pressure................................... 5
Engine Exhaust System................................................... 6
Exhaust Stack Temperature......................................... 6
Individual Cylinder Exhaust Temperature....................... 6
Exhaust Temperature Deviation Alarm .......................... 6
Miscellaneous Engine Parameters..................................... 6
Engine Speed............................................................. 6
Clock Hour Meter ....................................................... 6
Voltmeter .................................................................. 6
Off-Engine Parameters .................................................... 7
Marine Transmission Oil Pressure ................................. 7
Marine Transmission Oil Temperature ........................... 7
Generator Stator (Winding) Temperature....................... 7
Generator Bearing Temperature ................................... 7
Recommended Alarms and Shutdowns ......................... 7
Engine Control, Protection and Monitoring Systems for
Electronic Unit Injection (EUI) Engines .................................. 9
Electronic Control Module (ECM) and Control Software ...... 9
Electronic Control Module ........................................... 9
Electronic Unit Injection (EUI) ........................................ 10
Mechanically Actuated Electronic Unit Injectors
(MEUI) .................................................................... 10
Hydraulically Actuated Electronic Unit Injectors
(HEUI) ..................................................................... 10
Engine Instrument Panel................................................ 11
ADEM II Control System ............................................... 11
ADEM A3 Control System Specifics ............................... 11
ADEM A4 Control System Specifics ............................... 12
Engine Control, Protection and Monitoring Systems
for Mechanical Unit Injection (MUI) Engines ........................ 17
3600 Series Engines..................................................... 18
Marine Monitoring System (MMS) .............................. 18
Generator Monitoring System (GMS) .......................... 19
Engine Control Panel (ECP) - Relay Based Protection
System ................................................................... 19
Alarm Panels ........................................................... 19
3500 Series & Smaller MUI Engines ............................... 20
Instrumentation Options............................................ 20
Protection System Options ........................................ 20
Electronic Modular Control Panels (EMCP) .......................... 21
EMCP II+ Control Panel................................................ 21
EMCP 3.x Control Panel................................................ 22
Alarm Modules............................................................. 22
EMCP II Alarm Modules ............................................ 23
EMCP 3 Alarm Annunciator ....................................... 23
Other Alarm Modules & Panels .................................. 23
Customer Interface Module (CIM) .................................. 23
Customer Supplied Shutoffs .............................................. 24
Engine Communication Methods ........................................ 25
Customer Communication Module (CCM) ....................... 25
Programmable Relay Control Module (PRCM) .................. 25
Relay Driver Module (RDM) ........................................... 25
Caterpillar PL1000 Series Communication Modules.......... 26
PL1000T Communication Module .............................. 26
PL1000E Communication Module .............................. 27
Wiring Methods and Considerations ................................... 29
Wire Size and Type ...................................................... 29
Wire Insulation............................................................. 29
Support & Protection of Harnesses ................................ 29
Connectors.................................................................. 29
Routing Considerations ................................................. 30
Reference Material ........................................................... 30
Media List ................................................................... 30
Foreword
This section of the Application and Installation Guide generally describes
Diesel Engine Control Systems for Caterpillar® engines listed on the cover
of this section. Additional engine systems, components and dynamics are
addressed in other sections of this Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references.
Systems and components described in this guide may not be available
or applicable for every engine.

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.

©2008 Caterpillar®
All rights reserved.
Application and Installation Guide Diesel Engine Control Systems

Diesel Engine Control Systems


This section on Diesel Engine Control Systems covers multiple inter-related
topics dealing with all aspects of diesel engine control, protection and
monitoring systems. We begin with a brief discussion of the various diesel
engine protection and monitoring system parameters and outlining the
purpose of each parameter in order to help determine the appropriate level
required for a particular application. This is followed by a discussion of the
control system that is currently in use on Caterpillar diesel engines utilizing
Electronic Unit Injection (EUI). Finally, we cover the control systems used on
Caterpillar diesel engines utilizing Mechanical Unit injection (MUI).

SECTION CONTENTS
Engine Protection & Monitoring Electronic Modular Control
System Parameters.............. 2 Panels (EMCP 3) ................ 21
• Lubrication System • EMCP II
• Cooling System • EMCP 3.x
• Fuel System • Alarm Modules
• Air Starting • Customer Interface Module
• Combustion Air (CIM)
• Miscellaneous Customer Supplied Shutoffs 25
• Off-Engine Parameters
Engine Communication
Engine Control, Protection and
Methods ........................... 25
Monitoring Systems for
• Customer Communication
Electronic Unit Injection (EUI)
Module
Engines.............................. 9
• ECM and Control Software • Programmable Relay Control
Module
• Electronic Unit Injection
(EUI) • Relay Driver Module
• Engine Instrument Panel • PL 1000 Series
(EIP) Communication Modules
• ADEMTM II Wiring Methods &
Considerations................... 29
• ADEM A3
• Wire Size & Type
• ADEM A4
• Wire Insulation
Engine Control, Protection and
• Support & Protection of
Monitoring Systems for
Harnesses
Mechanical Unit Injection (MUI)
Engines.............................17 • Connectors
• 3600 Series Engines • Routing Considerations
• 3500 Series & Smaller MUI Reference Material ............. 30
Engines • Media Numbers

©2008 Caterpillar®
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Diesel Engine Control Systems Application and Installation Guide

Engine Protection & Monitoring System Parameters


Engine protection and monitoring Minimum engine protection
systems supplied by Caterpillar are typically includes automatic
strongly recommended. Installations shutdowns for overspeed, low
not using systems supplied by lubricating oil pressure at both low
Caterpillar must obtain factory and high engine speeds and high
approval. coolant temperature. Additional
A wide variety of preset contactors shutdowns are available for coolant
(switches), transducers and sensors loss, high lubricating oil temperature,
are available to activate a specified high crankcase pressure and oil mist
alarm, light or engine shutdown. Any detection. Refer to the Price List for
equipment operating function can be engine model specific availability.
monitored depending on individual
Engine Lubrication System
installation requirements. Control
system parameters on electronic Lube Oil Pressure
engines allow the engines to “warn”, Oil pressure loss while operating at
“derate” or “shutdown” the engine, full power is likely to result in severe
when values are not within a engine damage. Reduction of engine
specified range. This allows the speed and load, or stopping the
operator to establish the required engine can minimize damage. Engine
engine protection, for parameters oil pressure must be monitored. Two
such as water temperature and oil operating conditions require alarms
pressure, determined by the and shutdowns.
application. Emergency applications • Low oil pressure at low engine
such as emergency generators and speed (idle conditions)
fire pumps may warrant disabling
• Low oil pressure at high
this feature.
engine speed and/or load.
The following section outlines the
A safe oil pressure while operating
various diesel engine systems
at very low loads and/or speeds is
operating parameters available for
too low at full load/speed conditions.
protection and monitoring purposes;
The system includes two pressure-
however, the extent of the
sensitive contactors for alarm, two
instrumentation required will vary
for shutdown and one speed (rpm)
with the specific engine model and
switch to decide which pressure
application. All engines will include
switch has the authority to initiate
the minimum standard protection
the alarm or shutdown for the
and monitoring offered by
engine.
Caterpillar, but the level of
protection and monitoring will Lube Oil Temperature
increase, commensurate with the Much like all modern diesel
level of investment. engines, Caterpillar engines rely on
piston cooling with lubricating oil. Oil

©2008 Caterpillar®
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Application and Installation Guide Diesel Engine Control Systems

temperature is a good indicator of Crankcase Pressure


cooling system operation as well as Changing trends in crankcase
oil cooler condition. Oil temperature pressure will normally detect
measured near the supply to the impending problems. Continued
engine oil manifolds and piston operation of an engine with severe
cooling jets indicates the lube oil problems can result in significant
cooling system's condition. Higher damage to the engine. A gradual
than normal oil temperatures can increase in crankcase pressure can
result in bearing and/or piston indicate crankcase breather
problems. malfunctions or problems in the
piston and piston ring belt areas.
Oil Level Alarm
A sudden spike indicates piston
Oil pressure and temperature is
failure. In these rare instances, the
not the only indicator of lubricating
damage occurs much too rapidly to
oil system condition. Low oil levels,
detect by normal gauge observation.
sometimes caused by an external
Automatic engine shutdown for high
leak or insufficient oil filling, can
crankcase pressure is essential.
cause engine damage. An alarm to
Crankcase explosion relief valves,
signal low oil level in the sump is
standard on some engines and
recommended to reduce the
optional on others, can help to
possibility of oil starvation.
minimize the engine damage.
Engine tilt, inherent in many marine
applications, may cause false low oil Oil Mist Detector Shutdown
level alarms. This can be avoided by An oil mist detector is required by
measuring the oil level at two marine societies on engines with a
locations using two level switches. rating of 2250 bkW and higher, or
One switch should be located at the 300 mm bore or larger. An
transverse center of the sump at the impending main or connecting rod
front or rear, and the other at the bearing failure can be inferred by
longitudinal center on either side. measuring oil mist particle size. A
A true low level can be detected smaller particle occurs when bearing
when both switches show low level temperature exceeds normal limits.
at the same time. Oil mist sensors operate based on
this principle. If an oil mist sensor
Lubricating Oil Filter Differential alarm occurs, the engine should be
Pressure shutdown. It must also be inspected,
Lubricating oil filter condition once it has been allowed to cool.
can be accurately monitored with
the differential pressure gauge. Metal Particle Detection
Differential pressure determines the Metal particles in the lubricating oil
service period of the lubricating oil can indicate a serious condition that
filter. Filter service should be requires immediate attention.
signaled with a differential pressure Oil Scavenge Pump Outlet Pressure
alarm to prevent low lubricating oil Large engines can be applied in
pressure delivery to the engine. installations requiring very large

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Diesel Engine Control Systems Application and Installation Guide

external oil sumps in addition to the inlet regulator can be detected with
engine lubricating oil pan (dry sump a gradual rise in water temperature.
configuration). In those instances Aftercooler Water Pressure
the lubricating oil pressure measured Aftercooler water pressure loss
at the scavenge pump outlet can will result in high inlet manifold air
detect lubricating oil system temperature and lubricating oil
problems prior to low pressure temperature, which can quickly
detection in the main engine cause engine damage. An electric
lubricating oil supply. emergency aftercooler water pump
Engine Cooling System can be installed to automatically
start upon loss of engine driven
Jacket Water Temperature pump pressure; this is sometimes
Jacket water temperature increase required by marine classification
is almost as serious as loss of societies. A low aftercooler water
lubricating oil pressure but is more pressure alarm can warn of
likely to occur. Similar reduction of impending problems with an engine
engine speed and load, or stopping mounted aftercooler water pump.
the engine can minimize engine
damage. Set the high coolant Expansion Tank Level Alarm
temperature contactors to activate While coolant temperatures and
within 2.8°C (5°F) of the highest pressures are important indicators
normal engine temperature at the of cooling system operation, an
time of installation. expansion tank level alarm can
indicate low coolant level or loss of
Jacket Water Pressure system coolant. A low coolant level
It is important to maintain jacket can activate an alarm or shutdown
water pressure to the engine to to prevent engine overheating.
prevent overheating. Single engine In a variable speed application,
applications can use an electric observance of expansion tank level
emergency jacket water pump to reduction proportional to engine
automatically start upon loss of speed increase is an indicator of
engine driven pump pressure; this is air trapped in the coolant system
sometimes required by marine piping.
classification societies. A low jacket
water pressure alarm can warn of Cooling Water Loss-of-Flow Alarm
impending problems with an engine Warning of coolant loss can allow
mounted jacket water pump. the operator to save an engine
which would otherwise be lost to
Aftercooler Water Temperature overheat failure. If the high water
It is also beneficial to monitor temperature sensors discussed
aftercooler water temperature to below are not immersed in water
help determine operating efficiencies they will not activate. This coolant
of the coolers in the aftercooler detection switch is installed on 3600
circuit. Impending problems with the series engines at the highest location
in the jacket water system.

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Application and Installation Guide Diesel Engine Control Systems

Sea Water Pressure differential pressure gauge.


When using an engine driven Differential pressure determines
seawater pump, it is particularly the service period of the filter.
important to insure that sufficient Filter service should be signaled
seawater pressure is delivered to the with a differential pressure alarm
engine cooler. Engine overheating to prevent low fuel pressure delivery
can result from loss of seawater to the engine.
pressure. Unusually low seawater
pump discharge pressure is often Engine Starting Air System
used to detect the need to service Starting Air Pressure
the seawater pump strainer. In Low air tank pressure can prevent
many single engine applications, an engine starting until tank pressure is
electric emergency seawater pump raised to the required level. A low
will be used to automatically start starting air pressure alarm is a time
upon loss of engine driven pump saving feature to alert the operator
pressure; this is sometimes required of impending starting problems prior
by marine classification societies. to attempting to start the engine.
A low seawater pressure alarm can
warn of impending problems with Engine Combustion Air System
an engine mounted seawater pump. Inlet Manifold Air Temperature
Engine Fuel System High technology diesel engines
rely on efficient turbocharger and
Fuel Pressure aftercooler operation to produce the
Low fuel pressure in the fuel required output within safe operating
manifold supplying the unit injectors limits. Air manifold temperature is a
can result in poor performance, good indication of the turbocharger
reduced power, poor starting and air inlet system operation.
characteristics and misfire. Excessive air manifold temperature
Fuel Temperature indicates problems in the turbo/
The temperature of the fuel aftercooler/air intake system.
delivered to the engine can be useful Inlet Manifold Air Pressure
for determining the fuel viscosity Air manifold pressure measurement
and power limitations of the engine. is also helpful in determining the
Fuel at higher temperatures causes condition of the turbocharger,
a reduction in maximum available aftercooler and air inlet system, as
engine power and lower fuel well as being an indicator of engine
viscosity which can lead to seized load.
injectors. High fuel temperature can
present poor performance, power Air Cleaner Differential Pressure
loss and injector durability problems. Air cleaner condition can be
accurately monitored with the
Fuel Filter Differential Pressure differential pressure gauge.
Fuel filter condition can be Differential pressure determines
accurately monitored with the the service period of the air cleaner.

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Diesel Engine Control Systems Application and Installation Guide

Air cleaner service should be shutdown for an overspeed fault is


signaled with a differential pressure not possible as an engine will
alarm to prevent low inlet manifold overspeed too quickly for operator
air pressure. reaction. Overspeed faults occur
when some part of the engine fails,
Engine Exhaust System causing the fuel control mechanism
Exhaust Stack Temperature to lock in a high fuel flow condition.
Changes from normal exhaust When the engine load goes to a low
stack temperatures give useful level, the engine will continue to
information concerning air filter receive a high fuel flow. Without the
restriction, aftercooler restriction, load, the engine speed increases
valve problems, turbocharger fouling rapidly to a dangerously high level.
and engine speed and load. Generally, the engine's air and fuel
Excessive temperatures indicate a supply must both be cut off to stop
variety of impending engine the engine. If air operated, the inlet
problems. air shutoff requires a minimum air
supply pressure for activation force,
Individual Cylinder Exhaust or 24 VDC for electrically operated
Temperature air shut-off valves. Overspeed
While these instruments will give contactors are typically set 13 to
warning of individual injector failure, 25% nominally over rated engine
the inevitable wide tolerance on the speed to avoid nuisance engine
standard temperature, ± 42°C shutdowns during sudden reductions
(75°F), often causes undue operator in engine load.
concern. Advantages gained can be
overshadowed by cost, such as the Clock Hour Meter
annual replacement of Operating hours are essential for
thermocouples, and need for special determining required maintenance
operator training. These are available intervals.
on large engines only. Voltmeter
Exhaust Temperature Deviation Voltage of the starter/alternator
Alarm circuit gives useful information
An individual injector failure may regarding battery condition,
be detected with an exhaust port alternator condition, state of charge
temperature deviation alarm. of the batteries and condition of
battery cables. A voltmeter is highly
Miscellaneous Engine recommended on electronically
Parameters controlled engines because voltage
drops below 9/18 volts will cause
Engine Speed
the engine to shutdown.
Observing the relationship between
engine speed, in rpm, and governor
(or rack) can allow the operator to
make engine operation and
maintenance judgments. Manual

©2008 Caterpillar®
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Application and Installation Guide Diesel Engine Control Systems

Off-Engine Parameters Devices (RTD’s) or type J Iron-


Constantan thermocouples for
Marine Transmission Oil Pressure
monitoring winding temperature.
Transmission oil pressure Insufficient generator air flow,
measurement shows when the excessive current output and high
transmission clutches have engaged
ambient temperature cause high
and provides useful information
winding temperature.
concerning the condition of the
pump, filters, or clutches. Excessive Generator Bearing Temperature
pressure can damage components Many large generators include
in the hydraulic circuit. Low oil 100 Ohm platinum RTD's for
pressure will allow the clutches to monitoring bearing condition.
slip, causing damage to the clutch Recommended Alarms and
discs. Shutdowns
Marine Transmission Oil The engine protection and
Temperature monitoring system parameters
Many transmission problems, such discussed above are the standard
as clutch slippage, insufficient clutch systems. Customers routinely add
pressure, bearing wear, cooler alarms and shutdowns to meet the
blockage, or loss of cooling water needs of the application. Table 1
flow will be manifested as an suggests various alarms and
increase in transmission oil shutdowns to be considered and
temperature. how they might be applied. This
chart is frequently modified to fit the
Generator Stator (Winding) site, application and maintenance
Temperature
personnel preferences.
Many generators include 100 Ohm
platinum Resistive Temperature

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Diesel Engine Control Systems Application and Installation Guide

Diesel Engine Controls and Safety Devices


Malfunction Unattended Attended
Low Oil Pressure S S
High Oil Temperature A A
Low Oil Level A A
High Oil Filter Differential Pressure A A
Crankcase Pressure S S
Oil Mist Detection A A
Metal Particle Detection A A
High Jacket Water Temperature S S
Low Jacket Water Pressure A A
High Aftercooler Water Temperature A A
Low Aftercooler Water Pressure A A
Low Water Level A A
Cooling Water Loss-of-Flow (3600 Only) S S
Low Sea Water Pressure A A
Low Fuel Pressure A A
High Fuel Temperature A A
High Fuel Filter Differential Pressure A A
Low Starting Air Pressure A A
High Intake Manifold Air Temperature A A
High Exhaust Stack Temperature A A
High Exhaust Temperature Deviation A A
Engine Overspeed S S
S – Engine Shutdown A – Alarm only
Table 1

©2008 Caterpillar®
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Application and Installation Guide Diesel Engine Control Systems

Engine Control, Protection and Monitoring Systems


for Electronic Unit Injection (EUI) Engines
The Caterpillar ADEMTM system is controlled Unit
specifically designed to control and Injectors (HEUI)
interface with Electronic Unit • Injection Actuation Pressure
Injector (EUI) equipped diesel Control Valve (IAPCV) on
engines. The ADEM electronic HEUI engines only
controls integrate start/stop
• Wiring Harness
controls, speed governing, engine
sensing/monitoring and fuel injection • Engine switches and sensors
control into one comprehensive Electronic Control Module
engine control system for optimum The Electronic Control Module
performance and reliability. (ECM) controls most of the functions
There are three versions of this of the engine. The module is an
control system in use on current environmentally sealed unit installed
Caterpillar engines. in an engine-mounted junction box.
• ADEM II The ECM monitors various inputs
from sensors in order to activate
• ADEM A3
relays, solenoids and other devices
• ADEM A4 at the appropriate levels. The ECM
Refer to Table 2 and the Price List supports the following primary
for a specific engine's control functions:
system. • Start/stop control
The basic ADEM control system is • Engine speed governing
generally the same for all three
• Engine monitoring and
systems. Common system features
protection
will be outlined first and descriptions
of the individual control system The ECM control parameters are all
versions will follow. preset at the factory with any site
specific reprogramming performed
Electronic Control Module by Caterpillar service personnel
(ECM) and Control Software during the commissioning process.
• Electronic Unit Injectors (EUI): The Caterpillar Electronic Service
Technician (Cat ET) service tool is
o Mechanically actuated
used for any needed reprogramming.
and Electronically
controlled Unit The ECM control parameters
Injectors (MEUI) include start/stop control, engine
speed governing and engine
or
monitoring and protection.
o Hydraulically actuated
and Electronically

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Diesel Engine Control Systems Application and Installation Guide

Start/Stop Control
Electronic Unit Injection (EUI)
The ECM contains the logic and
The ECM controls the timing,
outputs for control of engine starting
duration and pressure of the fuel by
and shutdown, including
varying the signals to the injectors.
prelubrication and postlubrication,
The timing and duration of the
when available. The customer
injection is controlled through the
programmable logic responds to
injector solenoid valves, common to
signals from the engine control
all electronic unit injectors. The fuel
switch, emergency stop switch,
pressure is controlled by two
remote start switch, data link and
different means of injector actuation,
other inputs, and the ECM controls
either mechanical or hydraulic.
the prelube pump (when available),
the starting motor, and the Mechanically Actuated Electronic
electronic fuel injector solenoid Unit Injectors (MEUI)
valves at the appropriate times. Mechanically Actuated Electronic
Unit Injectors (MEUI) use the engine
Engine Speed Governing
camshaft and push rods to generate
The ECM governs the engine speed
fuel injection pressure, while the
by controlling the amount of fuel
ECM controls the amount of fuel
that is delivered by the injectors.
injected.
The ECM compares the desired
engine speed to the actual engine Hydraulically Actuated Electronic
speed and adjusts the amount of Unit Injectors (HEUI)
fuel injected until the actual engine Hydraulically Actuated Electronic
speed matches the desired engine Unit Injectors (HEUI) use a hydraulic
speed. Desired speed is based on pump and engine oil to generate fuel
throttle switch position and actual injection pressure. On the HEUI
speed is based on engine system, the ECM modulates the
speed/timing sensor signals. injection pressure by varying the
signal to the Injection Actuation
Engine Monitoring and Protection Pressure Control Valve (IAPCV). The
The ECM monitors engine IAPCV controls the pressure of the
operation and the electronic system. high-pressure oil which pressurizes
Any problems with the engine the fuel that is in the injectors.
operation will cause the ECM to
generate an event code that can
issue a warning or cause a
shutdown. The severity of the
condition determines whether a
warning is issued or the engine is
shutdown. Problems with the
electronic system produce a
diagnostic code that can be
addressed using the Cat ET.

©2008 Caterpillar®
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Application and Installation Guide Diesel Engine Control Systems

o RS-232 Data Link


Engine Instrument Panel
The Engine Instrument Panel (EIP) • Sensor Power Supplies
is part of the standard scope of o Analog Sensor Supply
supply for some engines and (5V)
optional for others. Refer to the o Digital Sensor Supply
Price List for a specific engine's (8V)
scope of supply.
o Speed/Timing Sensor
For Caterpillar packaged generator Supply (12V)
sets, Electronic Modular Control
Panels (EMCP II or EMCP 3.X) are ADEM A3 Control System
used to consolidate engine and Specifics
generator control, monitoring and The following is a list of features
protection functions. These panels and details specific to the ADEM A3
are discussed in more detail in the control system. Refer to Figure 2 for
service literature for each engine. a typical ADEM A3 control system
schematic.
ADEM II Control System
The following is a list of features • 2 x 70-Pin Input/Output
and details specific to the ADEM II Connectors
control system. Refer to Figure 1 • The ECM is fuel cooled to
for a typical ADEM II control system maintain operational
schematic. temperatures.
Although fuel cooling is standard • Communication
for the ADEM II, air-cooling is an o J1939 (CAN) Data
option. Note that the ECM has a Link
maximum operating temperature of
85°C (185°F) o ATA (J1587) Data
Link
Features for the ADEM II include:
o High Speed
• 2 x 40-Pin Input/Output Proprietary Data Link
Connectors
• Sensor Power Supplies
• Fuel cooling of the ECM is
required in some cases o Analog Sensor Supply
(5V, 400mA)
• Actuators for starter motor
control, integrated prelube o Digital Sensor Supply
control and air shut-off control (8V, 400mA)
are optional o Speed Sensor Supply
• Communication (13V, 60mA)

o Cat Data Link


o CAN 2.0 Data
Link/24V ATA Data
Link

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Diesel Engine Control Systems Application and Installation Guide

• System does not support


ADEM A4 Control System
EMS, it is replaced with
Specifics Caterpillar Messenger
The following is a list of features
and details specific to the ADEM A4 • System interfaces with some
control system. Refer to Figure 3 for electronic transmissions
a typical ADEM A3 control system • Communication
schematic. o J1939 (CAN) Data
• 1 x 70-Pin Input Connector Link
and 1 x 120-Pin Output • Sensor Power Supplies
Connector
o Sensor Supply (5V,
• The ECM is fuel cooled to 450mAdc)
maintain operational
o Sensor Supply (5V,
temperatures; however,
80mAdc OEM)
customers can select an
optional air-cooled o Sensor Supply (8V,
arrangement if adequate 150mAdc)
airflow and maximum ambient o Speed/Timing Sensor
temperature requirements can Supply (13V,
be documented. The ECM has 30mAdc)
a maximum operating
temperature of 85°C (185°F).

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Application and Installation Guide Diesel Engine Control Systems

Typical ADEM II Control System

Figure 1

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Diesel Engine Control Systems Application and Installation Guide

Typical ADEM A3 Control System

Figure 2

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Application and Installation Guide Diesel Engine Control Systems

Typical ADEM A4 Control System

Figure 3

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Diesel Engine Control Systems Application and Installation Guide

Caterpillar ADEM System Matrix


Engine Model ADEM II ADEM A3 ADEM A4
3126B X
3400E X
3500B X X
3500C X
C7 Models without ACERTTM Models with ACERT
C9 Models without ACERT Models with ACERT
C10 Models without ACERT Models with ACERT
C12 Models without ACERT Models with ACERT
C13 Models without ACERT Models with ACERT
C15 Models without ACERT Models with ACERT
C16 Models without ACERT Models with ACERT
C18 Models without ACERT Models with ACERT
C27 Models without ACERT Models with ACERT
C30 Models without ACERT Models with ACERT
C32 Models without ACERT Models with ACERT
C175 X

Table 2

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Application and Installation Guide Diesel Engine Control Systems

Engine Control, Protection and Monitoring Systems


for Mechanical Unit Injection (MUI) Engines
Control, protection and monitoring offerings will be expanded upon in
systems are a basic requirement of the following sections.
all engine installations, and provide When designing an installation,
protection to the engine as well as consider if the engines will be
to the facility and operating attended or unattended when
personnel. All Caterpillar MUI selecting protection and monitoring
engines are controlled using separate equipment. When attended, alarms
engine speed governing systems. can be provided to warn of
These systems are discussed in the approaching shutdown limits in each
Governors – Gas & Diesel monitored system before an actual
Application & Installation Guide. This engine shutdown occurs. This allows
section provides basic information the attendant to decide the urgency
about the Caterpillar MUI Engine of the fault and schedule repairs
protection and monitoring systems. before a shutdown. Protection
While engine protection and equipment for unattended
monitoring are appropriate and applications can be tailored to the
useful for diesel engine systems in specific requirements.
general, they are essential for the Although most Caterpillar diesel
lubrication and cooling systems. engines are equipped with a
The lubrication system must standard set of shutoffs, some
maintain the oil pressure within a engines are configured with
certain range; oil temperature is additional shutoffs and alarms. They
internally controlled via a coolant may also use different strategies for
thermostat for most arrangements. shutdowns, annunciation and other
The cooling system must maintain features. Refer to the diesel engine
the cooling water below a certain schematics for each engine to
temperature. Overspeed protection connect to a specific engine's safety
is also very important. These three system.
parameters form the basis for the
Diesel generator set engines are
standard protection system common
offered with Energize-To-Run (ETR)
to all diesel engines.
and Energize-To-Shutoff (ETS) fuel
• Low Oil Pressure shut-off systems, which are
• High Water Temperature discussed in more detail in the
• Overspeed Governors – Gas & Diesel
Application & Installation Guide.
A listing of standard and optional
instrumentation and protection
systems can be found with each
engine pricing arrangement in the
price list. The details of these

©2008 Caterpillar®
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Diesel Engine Control Systems Application and Installation Guide

The monitoring features allow the


3600 Series Engines
operator to view current operating
Caterpillar offers three types of
conditions of various engine
engine protection and monitoring
parameters. A ten inch color display
systems for the 3600 engine family.
touch screen provides the
They are the Marine Monitoring
information and shows when a
System (MMS), the Generator
parameter is in alarm condition.
Monitoring System (GMS) and the
Engine Control Panel (ECP) - Relay The MMS utilizes all engine-
Based Monitoring System. mounted sensors, so there are no
customer pressure connections or
Marine Monitoring System (MMS) temperature capillary connections.
The Caterpillar MMS is All sensors are wired to an engine
microprocessor based engine mounted terminal box, and the entire
control, protection and monitoring system is enclosed in a single panel
system designed specifically for for ease of installation. The MMS
marine applications. MMS is also can also communicate with other
available for petroleum and industrial shipboard alarm systems via an
applications that do not involve industry standard data link
generators. connection. The system has been
The control features of the system designed to meet most marine
enable the operator to start and stop classification society's requirements
the engine locally from the MMS for unmanned engine room
panel or remotely. The minimum operation. The MMS is flexible and
protection features enable the allows customers to add additional
system to shut down the engine if monitoring and alarm parameters.
overspeed, low oil pressure, high These can include bilge level alarms,
water temperature, high crankcase marine reduction gear oil
pressure or oil mist detector temperature and pressure and
parameters exceed the set points others. See Figure 4 for a typical
MMS system diagram.

©2008 Caterpillar®
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Application and Installation Guide Diesel Engine Control Systems

Marine Propulsion Engine Control and Monitoring System Block Diagram

Figure 4

Generator Monitoring System (GMS) and separate contactor panel


The Caterpillar GMS, used in provides the required switches for
power generation applications, is alarm and shutdown parameters.
identical to the MMS, but with six Flexible hoses must be used to
additional sensor inputs for connect the pressure switches from
generator bearing and stator the contactor panel to the engine;
temperatures. The optional PM3000 temperature switch capillaries must
module allows basic electrical also be connected to the engine.
parameters to be included on the A separate relay based alarm
color display. annunciation panel is also available
with this system.
Engine Control Panel (ECP) - Relay
Based Protection System Alarm Panels
Caterpillar also offers an ECP relay If the optional alarm annunciation
based protection system that uses panel is not used, Caterpillar
separate panels for control, recommends the following minimum
protection and monitoring. A alarm panel features.
start/stop control panel provides • Fault light lock-in circuitry
these functions for the engine. keeps the fault light on when
A customer-mounted junction box intermittent faults occur.
contains the relay protection logic

©2008 Caterpillar®
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Diesel Engine Control Systems Application and Installation Guide

• Lockout of additional alarm level; these instrumentation options


lights prevents subsequent are included in each model specific
alarm lights from going on price list.
after the activated engine Each model specific price list
shut-off stops the engine. includes other instrumentation
This aids in troubleshooting. options that may be available for
• Alarm silence allows the that model, including mechanical
operator to acknowledge the and digital tachometers, pyrometers,
alarm without the need to thermocouples, marine pilot house
continually listen to the alarm and reduction gear panels.
horn. The alarm light is left on Protection System Options
until the fault is corrected. The standard engine protection
• If more than one engine is system provided on MUI engines
connected to an alarm panel, typically includes Energized to
a fault in a second engine Shutdown (ETS) fuel shutoff
should activate the alarm even protection for low oil pressure, high
though the alarm horn may water temperature and overspeed.
have been silenced after a However, there are numerous
fault on another engine. protection system options available
• Circuit test provides for for MUI engines. Refer to the price
periodic checking of alarm list for model specific protection
panel functions. system option availability.

3500 Series & Smaller MUI


Engines
Caterpillar 3500 series and
smaller diesel engines offer several
instrumentation and protection
system options. In the price list,
the desired instrumentation and
protection systems are selected
from lists of available options. Not
all options are available for every
engine; consult the use codes for
compatibility.
Instrumentation Options
An engine-mounted instrument
panel is standard on most 3500
series and smaller MUI engines.
For many applications, this panel
may provide a sufficient level of
instrumentation, but some
applications will require a higher

©2008 Caterpillar®
Page 20 All rights reserved.
Application and Installation Guide Diesel Engine Control Systems

Electronic Modular Control Panels (EMCP)


An all-inclusive protection and Engine and generator controls,
monitoring system, available on diagnostics and operating
generator sets, is the Electronic information is available via the
Modular Control Panel (EMCP). control panel, shown in Figure 5,
This Caterpillar family of control or a remote personal computer.
panels, including EMCP II and EMCP Safety and shutdown set points
3, provides basic to complete are programmed using a keypad
generator set monitoring. The on the GSC.
EMCP's also contain generator set Additional modules add to the
controls (GSC) and several flexibility of the EMCP II+. These
instrument panel switches plus include:
optional alarm modules and
• Alarm modules NFPA 99/110
customer interface module.
• Customer Interface Module
The GSC provides the following.
• Manual Synchronizing Module
• Controls starting and stopping
of the engine • Customer Communication /
PL1000x module
• Displays engine condition and
generator output • Relay Driver Module
• Displays engine faults and These modules, discussed later in
codes this section, provide operation and
maintenance flexibility to the
• Displays GSC programming
application.
information
EMCP II+ requires isolation from
The safeties and shutdowns are
engine vibration. Maximum vibration
all contained in the EMCP. Set
of the panel is 2.0 g’s @ 18 to
points are programmed into the
500 Hz. Input power requirement
EMCP using a keypad on the GSC.
of 10 watts (24 VDC) on generator
Safeties and shutdowns are standby with no alarms.
contained in the EMCP. Their set
points are programmable.

EMCP II+ Control Panel


The Caterpillar Electronic Modular
Control Panel (EMCP II+) provides
full-featured power metering,
protective relays, simultaneous
display of engine and generator
parameters, and expanded AC
metering.

©2008 Caterpillar®
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Diesel Engine Control Systems Application and Installation Guide

The safety and shutdown setpoints


EMCP II+ Instrument Panel can be programmed using the
onboard keypad and display or via
the Caterpillar Service Tool.
Complete application and
installation requirements for the
EMCP 3.x can be found in the EMCP
3 Application & Installation Guide,
Media Number LEBE5255.

Figure 5 EMCP 3 Instrument Panel

1. Generator Set Control+ (GSC+)


2. Engine Control Switch (ECS)
3. Start Aid Switch (SAS)
4. Panel Lights (PL)
5. Alarm Module (ALM) (Optional)
6. Synchronizing Lights Module (Optional) or Custom
Alarm Module (CAM) (Optional)
7. Speed Potentiometer (SP) (Optional) or Governor
Switch (Optional)
Figure 6
8. Voltage Adjust Rheostat (VAR)
9. Emergency Stop Push Button (ESPB) 1. Electronic Control Module (ECM) for the Generator
10. Panel Light Switch (PLS) Set
2. Annunciator Module (ALM)
EMCP 3.x Control Panel 3. Panel Light Switch (PLS)
The EMCP 3.x is a new generation 4. Ether Start Aid Switch (SAS) (optional)
of control panels that provides 5. Speed Potentiometer (SP) (optional)
Modbus and J1939 communication 6. Emergency Stop Push Button (ESPB)
protocols. An example of the
7. Lamp Test Switch
instrument panel is shown in
8. Alarm Acknowledge/Silence Switch
Figure 6.
9. Alarm Horn
Similar to the EMCPII+, the 10. Panel Lights
EMCP 3.x allows for relay control
(dry contacts), automatic starts,
cool-down timers and complete Alarm Modules
annunciation of generator Alarm modules, both local and
parameters. In addition, the 32-bit remote, are optional equipment,
processor of the EMCP 3.x allows available as an attachment to the
for 5 levels of password protection EMCP. These provide red and amber
and eliminates the need for many of LED's plus an audible indicator.
the gauges, meters, and switches
required in the past.

©2008 Caterpillar®
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Application and Installation Guide Diesel Engine Control Systems

EMCP II Alarm Modules • Fault light lock-in circuitry -


Two standard versions of the keeps fault light on when
alarm module are available for intermittent faults occur.
use with EMCP II. • Lockout of additional alarm
• NFPA 99 alarm module lights - prevents subsequent
• NFPA 110 alarm module alarm lights from going on
after the activated engine
The NFPA 99 provides alarms
shutoff stops the engine.
for low oil pressure, low coolant
This aids in troubleshooting.
temperature and high coolant
temperature. The NFPA 110 • Alarm silence - allows engine
provides alarms for low oil pressure, operator to acknowledge the
low coolant temperature and high alarm without having to
coolant temperature, low battery continually listen to the alarm
voltage, battery charge malfunction horn. Alarm light is left on.
and system not in auto. • If more than one engine is
Alarm modules used with EMCP II connected to an alarm panel,
connect to the GSC via a serial data a fault in a second engine
link and must be located within should activate the alarm,
305 m (1000 feet). even though the alarm horn
may have been silenced after
EMCP 3 Alarm Annunciator a fault on another engine.
The optional EMCP 3 Alarm
Annunciator is configurable to the • Circuit Test - provides for
standards of NFPA 99/110 for local periodic checking of alarm
and remote annunciation. It can panel functions
annunciate alarm conditions received Customer Interface Module
from any module on the J1939 data
link, including the EMCP 3, engine
(CIM)
The Customer Interface Module
ECM, RTD module, DIO module, and
(CIM) provides an interface (separate
Thermocouple module. The
relay contacts) between the GSC for
Annunciator can be mounted locally,
on the package generator set, or EMCP II and the switchgear. The
two major components of the CIM
remotely (up to 800 feet) on the
are the relay board and the
Accessory J1939 Data Link.
electronic control. The electronic
A maximum of 8 alarm modules control connects to the serial data
may be connected to EMCP 3 on link and decodes the information into
one CAN data link. discrete outputs. The output drives
Other Alarm Modules & Panels relays to sound a horn, flash a lamp,
When using alarm modules and or trigger some other action.
panels not supplied by Caterpillar, Information available from the serial
the following features are data link includes the following.
recommended.

©2008 Caterpillar®
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Diesel Engine Control Systems Application and Installation Guide

• High coolant temperature • Overcrank


alarm • Overspeed
• High coolant temperature • Engine control switch not in
shutdown auto
• Low coolant temperature • Diagnostic failure
alarm
The CIM is normally shipped loose
• Low coolant temperature for installation in a convenient
shutdown location, such as the switch gear.
• Low oil pressure alarm The CIM must be located within
• Low oil pressure shutdown 305 m (1000 ft) of the GSC.

Customer Supplied Shutoffs


Customer supplied shutoffs must Maintenance Manuals for each
meet all Caterpillar and other local engine model. For a typical 3500
requirements. Caterpillar requires at series engine, the Caterpillar system
a minimum a duplication of the provides the following features.
safeties and shutdowns that would • Emergency stop button
have been provided by Caterpillar for
• Energized to shutoff solenoid
the particular engine. These safeties
valves
and their limiting values are shown
for each engine in the product • Power, warning, and
description section of the price list shutdown lights
and in the Operation and • Start, stop, run switch

©2008 Caterpillar®
Page 24 All rights reserved.
Application and Installation Guide Diesel Engine Control Systems

Engine Communication Methods


Customer Communication Customer Communication Module
Module (CCM)
The Customer Communication
Module (CCM) provides a
communication link between the
electronic control system of an
engine and a host device. An
example of this module is shown in
Figure 7. The communication link is
established with the CAT Data Link
and the industry standard RS-232C
port. The host device can be one of
the following items.
• Personal Computer (PC)
Figure 7
• Programmable Logic Controller
(PLC)
Programmable Relay Control
• Any other device with an
Module (PRCM)
RS-232C port
The Programmable Relay Control
The host device can be connected Module (PRCM) provides the control
directly to the CCM or can be used of seven relays, six alarms and two
with a modem. LED displays. In addition, the PRCM
If the host device is a PC, software can be programmed to control up to
that is compatible with the CCM is two Relay Driver Modules (RDM),
available from Caterpillar. each of which provide an additional
The host device will usually be a nine relay outputs, for a total of
PLC, and the CCM can be used with 25 relays. The PRCM receives
a customized PLC software. Refer information via the CAT data link
to the Operation and Maintenance from the Engine Control Module
Manuals for each engine model for (ECM), utilizing information from the
further information on this subject. eight switched inputs on the PRCM
to control the output. Control of
each relay is programmable through
the keypad and displayed on the
PRCM.

Relay Driver Module (RDM)


The Relay Driver Module (RDM)
expands the number of available
relay outputs on the PRCM, each
RDM providing nine additional relay

©2008 Caterpillar®
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Diesel Engine Control Systems Application and Installation Guide

outputs. The outputs of the RDM are


individually controlled via a serial PL1000 Communications Module
data link from the PRCM, and may
drive the optional relay board, or can
be directly connected to horns,
lamps or other devices. The relay
board contains nine relays, each
with a set of normally open (NO) and
normally closed (NC) contacts. The
maximum length of wire between
the RDM and PRCM is 305 m
Figure 8
(1000 feet).

Caterpillar PL1000 Series


Communication Modules PL1000T Communication Module
The Caterpillar PL1000 This module will specifically
Communication Modules are ECM's replace the Caterpillar Customer
that provide the customer with the Communications Module (CCM),
processing power, memory, Caterpillar Engine Vision Interface
numerous communications Module (EVIM) and Caterpillar GPS
interfaces and software to integrate Interface Module (GPSIM). The
Caterpillar engines into many mobile following list describes the module's
and industrial applications. The features and benefits.
modules' flexible communications • EVIM Replacement - enables
architecture can potentially replace the Engine Vision Display
many of today's purpose built System to access Caterpillar
applications and provide almost proprietary engine parameter
limitless possibilities for future data.
applications. An example of the PL • GPSIM Replacement - relays
1000 Series communication module GPS location and heading
is shown in Figure 8. information using the NMEA-
A software tool, Caterpillar 183 protocol from a GPS
Communications Toolkit, media receiver to a monitoring
number EERP1000 is available to system or display through a
facilitate installation, programming CDL or J1939 network. The
and troubleshooting to PL1000 GPSIM replacement
modules. application provides
translation of water
temperature and depth
information gathered using
sonar technology.
• CDL Boost - enables a
customer to extend lengths

©2008 Caterpillar®
Page 26 All rights reserved.
Application and Installation Guide Diesel Engine Control Systems

of CDL harnessing to a PL1000E Communication Module


maximum distance of 305 m This module will specifically
(1000 feet) while maintaining provide a user configurable
data integrity. parameter translation from
• Embedded Communications Caterpillar proprietary Cat Data Link
Adapter - provides an onboard to a Modbus interface, or from an
CDL and J1939 connection industry standard J1939 data link
interface between the (including Caterpillar proprietary
PL1000T ECM and a laptop messaging) to a Modbus interface.
or PC for the Caterpillar The following describes the
Electronic Service Tool. This module's features and benefits:
connection requires no other • Cat Data Link to Modbus
equipment than a serial Translation - provides
connection from the harness translation of parameter data
or an extension cable. from the proprietary CDL
• J1939 to J1939 Bridge - protocol to the industry
enables extended lengths of standard Modbus interface.
J1939 harnessing to a This capability replaces the
maximum of 80 m (260 feet), use of multiple conversion
doubling the J1939 standard tools with a direct conversion
harness specifications. from CDL data to the Modbus
protocol.
• J1939 to RS-485 to CAN
Extension Bridge - enables • J1939 to Modbus Translation
long distance relay of J1939 - provides translation of
information via an RS-485 parameter data from the
twisted pair for a maximum proprietary CDL protocol to
length of 305 m (1000 feet). an industry standard Modbus-
Note: This distance enabled interface. This
specification is directly capability replaces the use of
affected by the customer multiple conversion tools with
selected communications a direct conversion from
rates. J1939 data to the Modbus
protocol.
• CDL Tunneling through J1939
- enables CDL messages to be • User Configurable Parameter
received through the physical Translation - provides the user
CAN/J1939 data link. This is or system integrator the
only used with Caterpillar opportunity to customize the
engine configurations that data translated by the
require a secondary CAT data PL1000E Communication
link, but must utilize a Module by selecting CAT
physical CAN port. Electronic Technician
supported parameters to
translate as well as specifying

©2008 Caterpillar®
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Diesel Engine Control Systems Application and Installation Guide

the source and destination • CDL Boost - enables a


of the translated data. customer to extend lengths of
• Web Server - The PL1000 E CDL harnessing to a maximum
Communication Module distance of 305 m (1000 feet)
provides the capability to view while maintaining data
web pages stored on the integrity.
ECM. The Status and • Embedded Communications
Configuration Pages are part Adapter - provides an onboard
of the software initially CDL and J1939 connection
configured on the PL1000E interface between the
Communication Module. PL1000E ECM and a laptop
These pages are accessible or PC for the Caterpillar
to the user via most standard Electronic Service Tool. This
web browsers and provide connection requires no other
the same PL1000E equipment than a serial
information as the Caterpillar connection from the harness
Electronic Technician Status or an extension cable.
and Configuration screens.

©2008 Caterpillar®
Page 28 All rights reserved.
Application and Installation Guide Diesel Engine Control Systems

Wiring Methods and Considerations


Wire Size and Type conductor can carry without
It is imperative to size the wire exceeding its temperature limits.
according to the maximum amperage
Support & Protection of
the wire will carry. Improper sizing
can result in excessive voltage drop Harnesses
of the signal or supply and heat Harnesses should be installed and
dissipation in the wire. Wire size routed to prevent accidental contact
needs to be considered from battery by personnel or components that
or power supply to low voltage may wear into the conductors.
signal wiring. Refer to the NFPA, Unavoidable contact with vibrating
National Electric Code or similar for components requires protection to
wire sizing tables. prevent wear into the harness.
Generally, use shielded wire for Depending on method of
magnetic pickups as well as wiring harnessing, either bundled wires in a
for the electronic governor actuator. flexible sleeve or in rigid conduit, the
The shield should be grounded on harnesses should be supported as
one end only to prevent current flow needed to prevent sagging or strain
from creating a potential noise on the conductors. Provide support
source in the shield. Shield between 150 to 300 mm (6 to
breakouts should not exceed 51 mm 12 in) on either side of the
(2 in) in length. connectors. This support distance
prevents vibrations from being
Factory supplied RTD's are
induced into the connector and
commonly 100 Ohm Platinum or
prevents undue strain of the
10 Ohm Copper. Factory supplied
connector's weight on the
thermocouples are commonly type K
conductors.
Chromel-Alumel or type J Iron-
Constantan. Care must be taken Connectors
when attaching additional wiring at It is imperative that connectors be
the job site. The wrong material, applied that are acceptable to the
incorrect fastening or different specific application. Sealing and
lengths can result in erroneous vibration capabilities need to be
temperature readings. considered for reliability. A minimum
sealing capability of 35 kPa (5 psi)
Wire Insulation and vibration capability of 30 G's
Consideration of wire insulation
rms (100 to 2000 Hz) should be
will allow proper usage to protect
considered in engine applications.
the current conductors from
environmental conditions and Moisture ingression, of the
abrasion. It will also contribute to connector, will allow the formation
the ampacity of the wire. Ampacity of corrosion and create a conductive
is a measured amount of amperage a path between conductors. Excessive
vibration will allow the wearing

©2008 Caterpillar®
All rights reserved. Page 29
Diesel Engine Control Systems Application and Installation Guide

away of the metal at the contact Metal conduit will help reduce
points of the connector, also called electrical noise, therefore, it's
pin fretting. Corrosion and pin preferred to plastic conduit.
fretting may cause intermittent or Avoid coiling extra wire length as
complete failure of the connector. it can create an electromagnetic
compatibility (EMC) issue. Extra wire
Routing Considerations
length should be cut off.
Wiring for DC circuits, magnetic
pickups, thermocouples and RTD's Ground loops should be avoided.
can be routed in common conduits. Ground points should not be painted.
However, they must not be in the Electrical codes and service
same conduit with AC circuits. In publications or instructions may
addition, AC circuits greater than provide additional requirements.
600 volts should be separated from IEEE Standard 142 (Recommended
AC circuits less than 600 volts. Practice for Grounding of Industrial
Route harnesses and wires away and Commercial Power Systems),
from hot exhaust manifolds and IEEE Standard 1100 (Recommended
turbochargers, unless special Practice for Powering and Grounding
insulation is provided. Route so Sensitive Electronic Equipment) may
wiring is protected from abrasive also provide additional assistance.
wear (such as grommets). Avoid To avoid potential noise, signal
sharp harness radii to reduce wiring should not exceed 30 m
unnecessary wire connection strain. (98 ft) in length.
Route harnesses such that someone Installations with severe
standing on equipment does not electromagnetic interference (EMI)
strain wiring. may require shielded wire run in
conduit, double shielded wire, or
other precautions.

Reference Material
REHS1187: Electronic Installation
Media List
Guide for 3126B, C7, C9, C12,
The following information is
C15, C18, and C32 Marine
provided as an additional reference
Engines
to subjects discussed in this manual.
EERP1000: Caterpillar
Communications Toolkit
LEBE5255: EMCP 3 Application &
Installation Guide

©2008 Caterpillar®
Page 30 All rights reserved.
LEBW4981-01 ©2008 Caterpillar Printed in U.S.A.
All rights reserved.