GENERATOR GP 4W7424 - Caterpillar

@@@-->Wire Size Requirements
The wire size to all Caterpillar components must be of adequate size to handle the maximum current of the circuit. All +Battery and -Battery connections to the ECM Customer connector should be made with 14 AWG wire, this includes the -Battery connections from the Engine Room -Battery Bus Bar. The connection from the Engine Room -Battery Bus Bar to the Station -Battery Bus Bar displays should be made with a minimum of 12 AWG wire. The CAT Data Link connection should be made with the 143-5018 data wire. Caterpillar recommends the use of 143-5018 for ALL Cat Data Link Connections.All other connection should be made with 16 AWG wire minimum. No other components are allowed to be connected to the Caterpillar -Battery wire to the bridge displays.
Figure 1.14 Wire Size RequirementsWiring Harnesses
The ECM uses an integral 40-Pin Deutsch Connector (J14/P14) and a 24-Pin Deutsch Customer Connector (J31/P31) to interface the engine electronics to the customer wiring harness. The control system has been designed to operate on 12 VDC or 24 VDC electrical systems. The control system is protected against jump start conditions and short circuits to the battery. As stated previously for ECM connectors J14/P14 and all unused J31/P31 Customer Connector socket slots must be filled with plugs to ensure connector proper sealing.OEM Harness Routing/Design
Figure 1.15 Improper Harness Routing At ECM and Customer ConnectorsRouting of the harness should ensure the connector seal is not stressed because the harness wiring curvature is too close to the connector. This applies to the engine sensors and all connections to the J31 Customer Connector.The previous diagram illustrates the problem if the harness curvature is too close to the connector. When this occurs the connector seal is stretched away from the wire, providing an opening for moisture entry. The wire should exit perpendicular to the connector with 25 mm (1.0 in) of straight length before curving as necessary for routing. The harness bundle should have a bend radius greater than twice the harness diameter.
Figure 1.16 Harness Routing At ECM and Customer ConnectorsTwisted pair wiring should be used for the CAT Data Link. There should be a minimum of three twist per 25.4 mm (1.00 in) within the harness. All twisted pair wires should not be twisted within an in of the connector to avoid seal stress.The acceptable range for the wire insulation outside diameter is 2.54 to 3.43 mm (0.100 to 0.135 in) for the J3/P31 40-Pin Customer Connector and 2.54 to 3.81 mm (0.100 to 0.150 in) for the HD Connectors. DT Connectors wire insulation diameter is 2.4 to 3.68 mm (0.088 to 0.145 in).Caterpillar requires all ring terminals and splices connected to the Customer Connector be sealed using Raychem ES2000 adhesive lined heat shrink sleeve (Caterpillar 1E2358 Specification) or equivalent.Service Tools
The Caterpillar Electronic Service Tools for the electronic control system are designed to help the service technician analyze and locate faults or problems within the system. It is required to perform some sensor calibrations electronically, and to