Installation Manual

Electrical & Electronic Application And Installation Manual
Production Release Version 1.0
Page 3
4.9.1 Actuator Driver Return ......................................................................................................... 46
4.9.2 Analogue Sensor Return ........................................................................................................ 46
4.9.3 Switch Return ........................................................................................................................ 47
4.9.4 Digital Return ........................................................................................................................ 47
5.0 CONNECTORS & WIRING HARNESS REQUIREMENTS ..................... 48
5.1 E NGINE ECM J1 C ONNECTOR ....................................................................................................... 48
5.1.1 J1 Connector Layout ............................................................................................................. 48
5.1.2 Tightening The OEM Connector ........................................................................................... 49
5.1.3 ECM Connector Wire Gauge Sealing Capability .................................................................. 49
5.1.4 Hand Crimping For Prototype machines and Low Volume Production: .............................. 49
5.1.5 ECM connector sealing plug installation guidelines ............................................................. 49
5.1.6 OEM harness Dress Cover With Integrated Strain Relief ..................................................... 49
5.1.7 Machine Crimping For High Volume Production ................................................................. 50
5.2 E NGINE ECM J1 C ONNECTOR I/O ................................................................................................. 50
5.3 ECM C ONNECTOR A SSEMBLY & D ISASSEMBLY ........................................................................... 53
5.3.1 Connector Assembly .............................................................................................................. 53
5.3.2 Connector Disassembly ......................................................................................................... 55
5.4 D IAGNOSTIC C ONNECTOR ............................................................................................................. 56
5.4.1 Diagnostic Connector Layout ................................................................................................ 56
5.4.2 Diagnostic Connector Wire Gauge Size ................................................................................ 56
5.4.3 Pin Information ..................................................................................................................... 57
5.5 M ANDATORY E NGINE & A FTERTREATMENT C ONNECTORS .......................................................... 58
5.6 C ONNECTOR T ERMINAL C ONTACTS .............................................................................................. 58
5.7 W IRE S PECIFICATION R EQUIREMENTS .......................................................................................... 58
5.7.1 Wire Thickness Overview ...................................................................................................... 59
5.8 H ARNESS W IRING S TANDARDS ..................................................................................................... 60
5.8.1 Connectors ............................................................................................................................ 60
5.8.2 Harness Bends Near Connectors ........................................................................................... 61
5.8.3 Cable routing ......................................................................................................................... 61
5.8.4 Electromagnetic Compatibility (EMC) .................................................................................. 62
5.8.5 Insulation Selection and Thermal Protection ........................................................................ 62
6.0 CUSTOMER CONNECTION OF ENGINE COMPONENTS .................... 63
6.1 W ATER I N F UEL S WITCH ............................................................................................................... 63
6.1.1 WIF Switch Operation ........................................................................................................... 63
6.1.2 WIF Switch Configuration ..................................................................................................... 63
6.1.3 WIF Switch Installation ......................................................................................................... 64
6.2 A MBIENT A IR T EMPERATURE S ENSOR .......................................................................................... 64
6.2.1 Ambient Air Temperature Sensor Operation ......................................................................... 64
6.2.2 Ambient Air Temperature Sensor Configuration ................................................................... 65
6.2.3 Ambient Air Temperature Sensor Installation ....................................................................... 65
6.3 E NGINE E LECTRICAL F UEL L IFT P UMP .......................................................................................... 66
6.3.1 Engine Electrical Fuel Lift Pump Operation......................................................................... 66
6.3.2 Engine Electrical Fuel Lift Pump Configuration .................................................................. 66
6.3.3 Engine Electrical Fuel Lift Pump Installation....................................................................... 66
7.0 1204F CONNECTING TO THE ENGINE AFTERTREATMENT.............. 70
7.1 DOC + DPF + SCR ....................................................................................................................... 70
7.1.1 System Architecture ............................................................................................................... 70
7.1.2 Electrical Connections .......................................................................................................... 71
7.1.3 Component I/O ...................................................................................................................... 72
7.2 DOC + SCR .................................................................................................................................. 74
7.2.1 System Architecture ............................................................................................................... 74
7.2.2 Electrical Connections .......................................................................................................... 74
7.2.3 Component I/O ...................................................................................................................... 76
7.3 1204F DEF S YSTEM ...................................................................................................................... 77
7.3.1 System Architecture ............................................................................................................... 77
7.3.2 PEU Electrical Connections & Component Installation Requirements ................................ 78