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Application Engineering Bulletin

Subject OEM Components and Interfaces Automotive Date June 2001 (Rev. May 2002) Page 1 of 44 Industrial Power Generation This AEB is for the following applications:

AEB 15.42

Engine Models included: QSB, QSC, QSL9, QSM11, QSX15, QSK19, QST30, QSK45, QSK60 Fuel Systems included: Changes in blue

Introduction
The OEM components and interfaces technical package is written to assist OEMs in designing and interfacing with electronics and electrical components.

Refer to the following other Industrial AEBs: AEB 15.40 Electronic Features AEB 15.43 Datalinks and Diagnostics AEB 15.44 Installation Recommendations

Authors: Scott Decker, Michael L. Hill, Brian Landes, Stewart Sullivan, Tiffany Walker

AEB 15.42 Page 2 of 44

Table of Contents
Introduction.................................................................................................................................... 1 Table of Contents.......................................................................................................................... 2 Section I: Connectors............................................................................................................3- 18
31-Pin OEM Connector.................................................................................................................... 4 50-pin OEM Connector - QSM11, QSX15 ......................................................................................... 5 50-Pin OEM Connector - QSB, QSC, QSL9 ...................................................................................... 6 Datalink Interface Connector ............................................................................................................ 7 J1939 Datalink Connector ................................................................................................................ 8 WIF Extension Harness ................................................................................................................... 9 23-Pin OEM Connector - CENSE ....................................................................................................10 21-Pin OEM Connector - QST30, QSK19, QSK45, QSK60................................................................11 Datalink Interface 6-Pin Connector ..................................................................................................12 23-Pin OEM Connector - QSB, QSC, QSL9 .....................................................................................13 Exhaust Brake Connector - QSB, QSC, QSL9..................................................................................14 Coolant Level Extension Harness Connector (4-Pin).........................................................................15 Coolant Level Extension Harness Connector (3-Pin) - CENSE ..........................................................16 Acceptable Coolant Level Switch.....................................................................................................17 RS232 In-Cab Connector................................................................................................................18

Section II: Lamps...................................................................................................................19-21


Lamp Specifications .......................................................................................................................19 Water-in-Fuel (WIF) Lamp...............................................................................................................19 Maintenance Lamp .........................................................................................................................19 Stop Lamp.....................................................................................................................................19 Wait-to-Start Lamp .........................................................................................................................20 Warning Lamp................................................................................................................................20 Engine Protection Lamp..................................................................................................................20 Switched Sink Driver Output Pin-out Specification ............................................................................20

Section III: Relays ..................................................................................................................22-26


Low Idle Shutdown Relay................................................................................................................22 Intake Air Heater Relay ...................................................................................................................23 24 VDC Power Relay ......................................................................................................................23 Power Relay VP44 .........................................................................................................................24 Switched Outputs Relay..................................................................................................................25 Acceptable Relay ...........................................................................................................................26

Section IV: Switches .............................................................................................................27-37


Switch Conventions ........................................................................................................................27 Switch Configuration.......................................................................................................................27 Switch Characteristics ....................................................................................................................27 Alternation Droop Switch.................................................................................................................28 Alternate Low Idle Switch................................................................................................................29 Alternate Torque Switch..................................................................................................................30 AXG On/Off Switch.........................................................................................................................31 Air Conditioner Pressure Switch ......................................................................................................32 Pressure Switches: Brake Switch ....................................................................................................33 Switches and Switch Assemblies: Rotary Clutch Switch Assembly ....................................................34 Switches and Switch Assemblies: Optional Clutch Brake Switch........................................................35

Section V: Sensors.................................................................................................................36-37
Vehicle Speed Sensor (Variable Reluctance Magnetic Pickup)..........................................................36 Water-in-Fuel Sensor and Drain Unit (For Spin-on FWS) ..................................................................37

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Section I: OEM Connectors


OEM Connector Installation Kits Application Description
QSX/QSM with EA1040 or EA2043 Option
3164585

Required Cummins Part Numbers

Part Description

OEM connectors / contacts including coolant level without J1939 datalink parts. Assumes using the 50 pin OEM connector. J1939 Stub kit which includes connectors and contacts for one stub. J1939 Termination kit includes connectors, termination resistors, and contacts

3164589

3164590

QSX/QSM with EA2036, EA2037, or EA1039 Option 3164585 OEM connectors / contacts including coolant level without J1939 datalink parts. Assumes using the 47 pin OEM connector. J1939 Stub kit which includes connectors and contacts for one stub. J1939 Termination kit includes connectors, termination resistors, and contacts

3164589 3164590

QSB/C/L9 3164589 QST30 3164590 J1939 Termination kit includes connectors, termination resistors, and contacts OEM connectors / contacts including coolant level J1939 Stub kit which includes connectors and contacts for one stub.

3164587 QSK19/45/60/78 3164588 Crimp Tool Kit 3164591

OEM connectors / contacts including coolant level

Crimp tools for the various contacts required by the various OEM installation kits

AEB 15.42 Page 4 of 44

Connector Components
Description General Connectors 31-Pin 23-Pin 23-Pin 21-Pin 3-Pin 9-Pin 6-Pin 6 Pin Switched Outputs 2-Pin Power 50-Pin 50-Pin J1939 9-Pin Extension Harness J1939 Receptacle Plug Terminal Receptacle Specialty Connectors RS422/Modular Mining GSP Interface Coolant Level Sensor Coolant Level Sensor-Connector & Seal Coolant Level Sensor Wiring Harness 4-Pin Tower 3-Pin Tower Coolant Level Sensor Shorting Plug 4-Pin Tower Water in Fuel Extension Harness WIF Receptacle WIF Plug Water in Fuel Sensor WIF Mating Connector Mfg. Mfg. Part Number QSX QSM X QST30 QSK19 QSK 45/60 X X X X Only X X X X QSM X X X Only X
Primary Optional

QSB QSC QSL9

CENSE

Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Packard Deutsch Deutsch Cummins Deutsch Deutsch Deusch Bendix Packard Packard Packard Cummins Deutsch Deutsch Packard

HD36-24-31SE HD36-24-23ST HD36-24-23PT HD36-24-21SE HD10-3-96P HD10-9-1939P HD10-6-12P DTM06-6S 1201 0973 DRC26-50S-01 DRC26-50S-05 4060578 DT04-3P-E008 DT06-3S-E008 DT04-3P-P006 (Blue) PT06-E1419P(SR) 1206 5298 1201 5797 1201 5793 3613298 DT04-2P DT06-2S 1204 0753

X X
Primary Optional Primary Optional

X X X

X X X

X X X

X X X

X X X X

X X

X X QSM QSM X X X

Connector Suppliers:
Deutsch Industrial Products Division 37140 Industrial Avenue Hemet, CA 92543 Phone: Fax (714) 929-1200 (909) 765-2250 (714) 652-9784 Packard Electric P.O. Box 431 Warren, OH 44486 1-800-722-5273

Deutsch Distributor Ladd Industrial Sales 1-800-223-1236 1-513-438-0033

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Connector Descriptions
31-Pin OEM Connector QSM11, QSX15, QSK19, QST30
Application This connector mates with the 31-pin general disconnect which is mounted on an engine bracket. This connector carries multiple OEM signals to and from components located in the engine compartment and at remote locations. Consult OEM Interfaces to determine which signals interface via this connector. Hardware This connector is a 31-pin Deutsch HD30 series. Terminals are nickel-plated sockets. assembly shown below is the 059, which includes a backshell kit. This backshell kit is recommended. The

31-Pin OEM Connector

31-Pin OEM Connector Part List Item Connector Connector & Backshell Kit Backshell Kit Only Terminal Reel Sealing Plug Manufacturer Deutsch Deutsch Deutsch Deutsch Deutsch Manufacturer Part No. HD36-24-31SE HD36-24-31SE-059 0409-201-2400 1062-16-0122 HD10-114017 Cummins Part No. 3659012 3171028 3615978 3824002

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50-Pin OEM Connector QSM11, QSX15


Application This connector system utilizes 20 AWG gold sockets with 20 AWG cavity plugs, and a convoluted wire seal. It has an environmentally sealed, hard-shell connector. The plug is keyed to fit the mating module header and is secured to the ECM with one socket head capscrew. The OEM connector is used as an integral part of an electronic control module for the wiring harness interface. Cavity plugs should be inserted in any unused cavities, which are labeled NC in the connector illustration. Hardware This connector is a 50-pin Deutsch DRC series, key 01. Terminals are gold-flashed sockets. The o assembly shown below includes a 90 backshell. This backshell is required for all installation.

50-Pin OEM Connector

50-Pin OEM Connector Part List Item Connector, Key-01 Terminal Reel o 90 Backshell Manufacturer Deutsch Deutsch Deutsch Manufacturer Part No. DRC26-50S-01 1062-20-0144 0528-001-5005 Cummins Part No. 3657520 3658470 3658522

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50-Pin OEM Connector QSB, QSC, QSL9


Application This connector system utilizes 20 AWG gold sockets with 20 AWG cavity plugs, and a convoluted wire seal. It has an environmentally sealed, hard-shell connector. The plug is keyed to fit the mating module header and is secured to the ECM with one socket head capscrew. The OEM connector is used as an integral part of an electronic control module for the wiring harness interface. Cavity plugs should be inserted in any unused cavities, which are labeled NC in the connector illustration. Hardware This connector is a 50-pin Deutsch DRC series, key 05. Terminals are gold-flashed sockets

50-Pin OEM Connector Part List Item Connector Gold Sockets Manufacturer Deutsch Deutsch Manufacturer Part No. DRC26-50S-05 1062-20-0144 Cummins Part No.

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Datalink Interface Connector


Application This connector mates with a Cummins service tool such as Insite to allow service, parameter adjustment, and calibration download. A Datalink Interface connector is required on every machine. Connector installation must meet requirements defined in AEB 15.44 Installation Recommendations. Hardware This connector is a 9-pin Deutsch HD10 series. Two types of terminals are available, a solid and a stamped and formed (S&F). Both types are gold-plated.

Datalink Interface Connector

Datalink Interface Connector Part List Item 9-Way Connector 9-Way Solid Terminal 9-Way S&F Terminal Protective Cap * Manufacturer Deutsch Deutsch Deutsch Deutsch Manufacturer Part No. HD10-9-1939P 0460-202-1631 1060-16-0144 HDC16-9 Cummins Part No. 3658643 3658462 3658431

Tiewrap the protective cap to the main engine harness to prevent loss.

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J1939 Datalink Connector


Application These connectors are used throughout the SAE J1939 datalink backbone and stubs. The 3-pin receptacle connects a node to the backbone; it is located on the node side. The 3-pin plug connects the backbone to a node; it is located on the backbone side. The 3-pin termination receptacle is located at each end of the backbone. Hardware Two connectors are a 3-way Deutsch DT series receptacle and a mating 3-way Deutsch DT series plug. Terminals are gold-plated. A wedge lock and locking insert are required. There is a pre-assembled Deutsch termination receptacle assembly, which consists of a DT04-3P receptacle, W3S-1939-P012 wedge lock, gold-plated pins, cavity plugs, and a 120-ohm resistor.

J1939 Backbone Connectors

J1939 Backbone Connectors Part List Item Receptacle Receptacle Pin Reel Receptacle Wedge Lock Plug Plug Terminal Reel Plug Wedge Lock Termination Receptacle Termination Wedge Lock Manufacturer Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Manufacturer Part No. DT04-3P-E008 1060-16-0144 W3P (orange) DT06-3S-E008 1062-16-0144 W3S (orange) DT04-3P-P006 (Blue) W3S-1939-P012 (Blue) Cummins Part No. 3659369 3658431 3616471 3659400 3658430 3616472 3942041

AEB 15.42 Page 10 of 44

WIF Extension Harness


Application The WIF Extension harness connects a remotely mounted Water-In-Fuel (WIF) sensor to the Cummins engine harness. The WIF sensor is located on the bottom of a special fuel filter, and sometimes must be installed somewhere other than the stock engine location. When this occurs, the OEM must construct a WIF Extension harness between the sensor and the WIF Disconnect on the Cummins engine harness. For QSX15 the WIF harness is not needed because it is a part of the standard engine harness. Hardware The WIF Extension harness includes two Deutsch DT series connectors, one plug and one receptacle. All terminals are gold-plated. Wedge locks are required. Harness length and construction details vary according to application.

Insert Picture Here Need New Picture

WIF Extension Harness

WIF Extension Harness Part List Item Receptacle Receptacle Wedgelock Pin Reel Plug Plug Wedgelock Socket Reel Manufacturer Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Manufacturer Part No. DT04-2P W2P 1060-16-0144 DT06-2S W2SA 1062-16-0144 Cummins Part No. 3616616 3616614 3658431 3616615 3658856 3658430

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23-Pin OEM Connector CENSE


Application This connector mates with the 23-pin OEM CENSE breakout connector which is mounted below the OEM A & B engine bracket. This connector carries signals for components that interface with the CENSE subsystem. This connector is required with application. For QSKV engines the only connection that needs to be made is for RS232 and RS422. Hardware This connector is a 23-pin Deutsch HD30 series. Terminals are nickel-plated sockets.

23-Pin OEM CENSE Connector

23-Pin OEM CENSE Connector Part List Item Connector Connector & Backshell Kit Terminal Manufacturer Deutsch Deutsch Deutsch Manufacturer Part No. HD36-24-23PT HD36-24-23PT-059 0460-202-16141 Cummins Part No. 3824814

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21-Pin OEM Connector QST30, QSK19, QSK45, QSK60


Application This connector mates with the 21-pin OEM breakout connector which is mounted on an engine bracket. This connector carries signals for components that interface with the QSK19, QST30, QSK45 and QSK60. This connector is required for all applications. Hardware This connector is a 21-way Deutsch HD30 series. Terminals are nickel-plated sockets. assembly shown below is the 059, which includes a backshell kit. The

21-Pin OEM Connector

21-Pin OEM Connector Part List Item Connector Connector & Backshell Kit Backshell Kit Only Terminal Reel (16AWG) Terminal Reel (12AWG) Manufacturer Deutsch Deutsch Deutsch Deutsch Deutsch Manufacturer Part No. HD36-24-21SE HD36-24-21SE-09 0462-201-16141 0460-203-12141 Cummins Part No. 3824826

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Datalink Interface 6-Pin Connector


Application - This connector mates to a service tool. This connector carries signals for J1587 datalink and service tool operating power. It is recommended to use a 9-pin connector for new installations. Hardware - This connect is a 6-pin Deutsch HD10 series. Terminals are gold-plated pins.

Datalink Interface 6-Pin Connector

Item Connector Terminal

Manufacturer Deutsch Deutsch

Manufacturer Part No. HD10-6-12P 0460-204-12141

Cummins Part No. 3824805

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23-Pin OEM Connector - QSB, QSC, QSL9


Application - This connector is a 23-pin circular Deutsch connector with bayonet coupling. This connector will replace the connectors identified below. This connector is environmentally sealed and accommodates both low level signals and battery currents for the fuel pump. Hardware - Sealed circular Deutsch connectors are useful in severe environments ranging from under hood to on chassis. A lubricant applied to the mating surfaces of the terminals is recommended to preclude fretting and corrosion of terminals.

23-Pin OEM Connector

OEM Engine Access Connector Part List Item Connector Connector Pins Manufacturer Deutsch Deutsch Manufacturer Part No. HD36-24-23ST 1062-14-0122 Cummins Part No.

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Exhaust Brake Connector - QSB, QSC, QSL9


Application - This is a 2-position connector. The in-line connectors are environmentally sealed, have positivelocking hard shells and are used on both wiring harness and devices employing pigtail wiring. Low signal levels as well as those carrying significant current levels are accommodated. The units employ silicone connector seals. Hardware - Sealed connectors are useful in severe environments ranging from under hood to on chassis. A lubricant applied to the mating surfaces of the terminals is recommended to preclude fretting and corrosion of terminals.

Exhaust Brake Connector

OEM Engine Access Connector Item Plug Receptacle Manufacturer Deutsch Deutsch Manufacturer Part No. DT06-2S DT04-2P Cummins Part No.

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Coolant Level Extension Harness Connector (4-Pin)


Application - This connector is a 4-position weather pack tower. The in-line connectors are environmentally sealed, have positive-locking hard shells and are used on both wiring harnesses and devices employing pigtail wiring. Low signal levels as well as those carrying significant current levels are accommodated. The units employ convoluted silicone wire seals and connector seals. Hardware - Sealed tower and shroud connectors are useful in severe environments ranging from under hood to on chassis. A lubricant applied to the mating surfaces of the terminals is recommended to preclude fretting corrosion terminals.

Coolant Level Connector

Coolant Level Extension Harness Connector (4-Pin) Part List Item Connector Manufacturer Packard Manufacturer Part No. 1201 5797 Cummins Part No.

AEB 15.42 Page 17 of 44

Coolant Level Extension Harness Connector (3-Pin) - CENSE


Application - This connector is a 4-position weather pack tower. The in-line connectors are environmentally sealed, have positive-locking hard shells and are used on both wiring harnesses and devices employing pigtail wiring. Low signal levels as well as those carrying significant current levels are accommodated. The units employ convoluted silicone wire seals and connector seals. Hardware - Sealed tower and shroud connectors are useful in severe environments ranging from under hood to on chassis. A lubricant applied to the mating surfaces of the terminals is recommended to preclude fretting corrosion terminals.

Coolant Level Extension Harness Connector (3-Pin) Part List Item Connector Manufacturer Packard Manufacturer Part No. 1201 5793 Cummins Part No.

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Acceptable Coolant Level Switch


Application - This device is suitable for use as a Coolant Level switch. Its complementary outputs satisfy the unique functional requirements of the ECM interface. The switch is mounted with the sensor probe extending into the radiator or overflow tank at the minimum coolant level. The radiator or overflow tank requires a 1/4 NPT boss to mount the switch. Apply thread sealant before installing the switch, omit sealant on first full thread. The switch is available in limited quantities through Cummins distributors. Hardware - The switch is manufactured by Robert Shaw. The switch is an electronic switch which operates on the capacitance sensing principle. The probe of the component detects a change in electrical capacitance when the liquid displaces the air immediately surrounding the probe. The change is converted within the component into the required logic. The sensor requires a +5V power supply for operation, which is available from the ECM. The switch mates to a Packard Metri-Pack 150 series connector. A cable seal and secondary lock are available and required.

Acceptable Coolant Level Switch

Acceptable Coolant Level Switch Part List Item Switch Connector & Seal Secondary Lock (TPA) Cable Seal (White) Manufacturer Robert Shaw Packard Packard Packard Manufacturer Part No. 85927-C1 1206 5298 1206 6176 1208 9678 Cummins Part No. 3612521 3617139 3620902

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RS232 In-Cab Connector


Application - This connector is a round 3-pin Deutsch connector. It uses Deutsch 1060-16-0122 terminal pins that will accept 16-18 AWG wire.

RS232 Datalink 3-Pin Plug (CENSE only)

RS232 In-Cab Connector Part List Item Connector Terminal Cap Manufacturer Deutsch Deutsch Deutsch Manufacturer Part No. HD10-3-96P 1060-16-0122 HDC16-3 Cummins Part No. 3657367 3824851

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Section II: Lamps


Lamp Specification Maximum current draw Leakage current when lamp driver is off Maximum voltage Suggested Luminosity Recommended Lamps Maintenance Engine Protection (EP) Stop Wait-to-Start Warning Water-in-Fuel X X X X X X X X X X X X X X X X X X X X X X QSX/QSM
600 mA@28V

QST30
600 mA@28V

QSB/C/9
600 mA@28V

QSK19
600 mA@28V

QSKV45/60
600 mA@28V

CENSE
600 mA@28V

.51ma-.25ma 32V 2 CP

32V 2 CP

32V 2 CP

32V 2 CP

32V 2 CP

.51ma-.25ma 32V 2 CP

Supplier Information Cutler - Hammer Products Eaton Corporation 310 West Lake Street Elmhurst, IL 60126 Use of LEDs is generally not recommended due to the leakage current. LEDs may be dimly lit instead of completely off.

Water-in-Fuel (WIF) Lamp


The water-in-fuel lamp indicates there is water in the fuel. driver/operator should release the water from the fuel filter. When the lamp is illuminated the vehicle

As an option the WIF lamp may be eliminated and the maintenance lamp can be used to provide the water-infuel indication. This can be done by routing a wire from the ECM OEM connector WIF lamp signal in parallel with the wire from the ECM OEM connector maintenance lamp signal. The WIF lamp should be installed on the operator switch panel.

Maintenance Lamp
The Maintenance lamp indicates that routine engine maintenance should be performed. The Maintenance lamp should be installed on the operator switch panel. The lamp is used by the following features. Maintenance Monitor Real Time Clock (RTC) Water-in-Fuel (WIF) optional

Stop Lamp
The Stop lamp provides critical operator messages. These messages require immediate and decisive operator response. The Stop lamp is also used to flash out Diagnostics fault codes. Refer to AEB15.43 Diagnostics Datalinks for description of the fault code flashout procedure. The lamp should be prominently installed on the operator switch panel. This lamp is used by the following features: Diagnostic Fault Code Flashout Engine Protection

AEB 15.42 Page 21 of 44

Wait-to-Start Lamp
The Wait-to-Start lamp indicates that the pre-start intake manifold heater warm-up sequence is active. An OEM-supplied grid heater will automatically heat the intake manifold when needed prior to engine starting. Intake manifold heating improves engine starting in cold temperatures and reduces white smoke. The operator should delay engine starting until after the lamp has extinguished. This lamp is used by the follow feature: Grid Heaters

Warning Lamp
The Warning lamp provides important operator messages. These messages require timely operator attention. The Warning lamp is also used to delineate Diagnostics fault codes. Refer to AEB 15.43 Datalink and Diagnostics for a description of the fault code flashout procedure. The lamp should be prominently installed on the operator switch panel. 0 Engine Protection for QSB, QSC, QSL9

Engine Protection Lamp


The engine protection lamp indicates that the engine protection feature has detected a fault. This lamp requires immediate and decisive operator response. This lamp need to be installed in the operator switch panel. This lamp is used by the following feature: Engine Protection

Switched Sink Driver Output Pinout Specifications


Applications
The Switched Sink Driver Output Pinout type sinks an OEM-supplied load, which are typically dashboard lamps. The Pinout is connected to one side of the OEM load. A voltage source, typically Vbatt+, is connected to the other side of the OEM load.

Operation
The Switched Sink Driver Output Pinout can exist in one of two states: Sink (low impedance) or Off (high impedance). These states are dictated by a microprocessor-controlled FET switch. Sink State - Pinout Voltage can be measured at the pinout with respect to ECM ground. When the FET switch is opened, Pinout Current is present through the pinout by way of the FET switch. Load Resistance can be measured between the pinout and the OEM voltage source. The OEM load is on or energized. Off State - When the FET switch is closed, some leakage Pinout current is still present by way of the 47K resistor. The OEM load is off or de-energized.

Switched Sink Driver Output Pinout Simplified Circuit

AEB 15.42 Page 22 of 44

Switched Sink Driver Output Pinout Specifications Item Number of States Maximum Pinout Voltage Maximum Pinout Current (Non-Inductive Load) Minimum Load Resistance Maximum Peak Current (Non-Inductive Load) Maximum Pinout Current (Inductive Load) Maximum Load Induction Requirement Two: SINK or OFF 32V 600 mA 20 @ 12V, 40 @ 24V 6.0A @ 12V, 1 A @ 24V 2.5 A @ 12V, 130 mH @ 24V 40 mH @ 12V, 130 mH @ 24V

AEB 15.42 Page 23 of 44

Section III: Relays


Low Idle Shutdown Relay
The Low Idle Shutdown relay removes power from high-current machine devices when the engine is shut down by the Low Idle Shutdown feature. This feature shuts down the engine in the presence of excessive engine idling with no operator interaction, in the effort to increase fuel economy. When shutdown occurs, battery drain may occur because the engine is stopped but the keyswitch is on. To reduce battery drain, the Low Idle Shutdown relay disconnects power from high-current devices such as the HVAC blower. The relay is usually installed on the fuse panel. The Low Idle Shutdown relay has two states, powered and shutdown. When the relay is in the powered state, the engine is keyed off, running, or in any condition other than a shutdown condition initiated by the Low Idle Shutdown feature. The relay is de-energized, high-current devices receive electrical power through normally closed contacts of the relay. When the relay is in the shutdown state, the engine has been shut down by the Low Idle Shutdown feature. The relay is energized, the high-current devices are unpowered. The relay remains in this state until the keyswitch is turned off or the engine is cranked for restart.

Low Idle Shutdown Relay Diagram Low Idle Shutdown Relay Specifications Item Relay Type Minimum No. of Terminals Minimum No. of States - Powered - Shutdown Nominal Coil Voltage Maximum Coil Current Minimum Coil Resistance Maximum Coil Induction Contact Rating Requirement 1 Form B or better Four: Terminals 1,2,3, and 4 (reference only) Two: POWERED or SHUTDOWN De-energized: Terminals 3-4 Closed Energized: Terminals 3-4 Open 12 VDC/24 VDC 2A 6 @ 12V, 12 @ 24V 130 m H OEM Responsibility

AEB 15.42 Page 24 of 44

Intake Air Heater Relay (Grid Heater)


Applications
The Air Heater relay controls operating power to an OEM-supplied grid heater. The grid heater heats the intake manifold immediately before and after the engine is started, which improves cold engine starting and reduces white smoke. The grid heater is automatically activated by the Intake Air heater feature when the engine is cold. The Intake Air Heater relay is normally installed in the engine compartment. The Intake Air Heater relay has two states, heat or off. Intake manifold heating will occur immediately before and after engine start depending on a combination of intake manifold temperature and coolant temperature. When intake manifold heating is required, the relay assumes heat. Operating power is applied to the grid heater through normally open contacts of the relay. When intake manifold heating is no longer required, the relay assumes off. Operating power is removed from the grid heater.

Intake Air Heater Relay Diagram Intake Air Heater Relay Specifications Item
Relay Type Minimum No. of Terminals Minimum No. of States - HEAT - OFF Nominal Coil Voltage Maximum Coil Current Minimum Coil Resistance Maximum Coil Induction Contact Rating

Requirement
1 Form A or better Four: Terminals 1,2,3, and 4 (reference only) Two: HEAT or OFF Terminals 3-4 Closed Terminals 3-4 Open 12 VDC/24 VDC 2A 6 @ 12V, 12 @ 24V 130 mH OEM Responsibility

Item 12v Relay 24v Relay

Manufacturer White-Roger White-Roger

Manufacturer Part No. 120-105111-5 120-114751-5

Cummins Part No. 3916301 3916302

24 VDC High Power Relay

AEB 15.42 Page 25 of 44

Power Relay VP44 - QSB


The VP44 Power Relay controls the power to the VP44 module. It is controlled by the Quantum control and the control signal follows the key switch state. The VP44 Power Relay along with a 5 foot extension harness is shipped with the engine. The OEM is responsible for choosing an appropriate location for the relay and mounting it in the equipment. The relay can be mounted in any loacation where exposure to road splash is absent and vibration is minimized. It should be mounted with the tab up (wires down) in a vertical orientation.

Power Relay

Item Operate Voltage Coil Resistance Maximum Break Current Maximum Continuous Current Contact Material 3.0 - 7.2V 90 Ohms +/- 10% 40A @ 14 VDC Resistive 30 Amp max Silver Plated, over Nickel

Requirement

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Switched Outputs Relay


The Switched Outputs feature can drive one or both relays, Switched Outputs Relay A and/or Switched Outputs Relay B. Each relay may be used for any desired purpose, such as control of heaters, valves, etc. Solenoids are also acceptable that meet the coil specifications shown below. Each relay may respond to trigger parameters such as engine speed, engine torque, boost pressure, shaft speed, oil pressure, coolant temperature, commanded throttle, ISC status. Refer to AEB 15.40 for all parameters. Each relay is configured separately and operates independently.

Switched Outputs Relay A & B Diagram

Switched Outputs Relay A & B Specifications Item Relay Type Minimum No. of Terminals Minimum No. of States - DEENERGIZED - ENGERIZED Nominal Coil Voltage Maximum Coil Current Minimum Coil Resistance Maximum Coil Inductance Contact Rating Requirement 1 Form C or as required by application Five: Terminals 1,2,3,4, and 5 (reference only) Two: ENERGIZED or DEENERGIZED Terminals 3-4 closed, Terminals 3-5 open Terminals 3-4 open, Terminals 3-5 closed 12 VDC/24 VDC 2A 6 @ 12V, 12 @ 24V 130 m H OEM Responsibility

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Acceptable Relay
This relay is suitable for use as a Low Idle Shutdown relay, Switched Outputs Relay A, or Switched Outputs Relay B. The relay can be mounted anywhere, engine compartment or in-cab mounting is preferred. There are actually two visually identical relays which differ by solenoid voltage, 12V or 24V. Choose the relay that corresponds to your machine system voltage. Both relays are available in limited quantities through Cummins distributors. It is a Form C relay rated at 30 amps continuous. It can operate at temperatures from -40 to +125 C and is water-resistant. The 12V relay has a coil resistance of 90 ohms, the 24V relay has a coil resistance of 360 ohms. The relay will mate to any standard DIN base, it is shown mating a Packard bracket mount socket which is supplied with a terminal retainer. This socket can be mounted individually on a single stud, or it can be interlocked with other relays.
o

Acceptable Relay

Acceptable Relay Part List Item 12V Relay 24V Relay Base Terminal TPA Seal Manufacturer Siemens Siemens Packard Packard Packard Packard Manufacturer Part No. VF28-65F14-Z03/S01 VF28-65H14-Z03/S08 12110539 12129409 12110540 1215323 Cummins Part No. 3658948 3658780

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Section IV: Switches


Switch Conventions
Introduction
This document has standardized the manner in which switches are defined in order to promote maximum comprehension of the switch requirements. There are two features of every switch, configuration and characteristics. Each feature may be described for a switch using words or symbols. This document uses both methods.

Switch Configuration
A switch configuration is the number of poles and the number of throws. Poles are the number of electrically independent switch contacts that are simultaneously switched. Throws are the number of switch positions that result in a switch contact. Descriptions - When defining switch configuration by words, the number of poles are indicated by prefix (S for single, D for double, 3,5,etc.) followed by the letter P. The number of throws is indicated by the same prefixes, followed by the letter T. For example, a single-pole, double-throw switch is written as SPDT. Symbols - When defining switch configuration using a picture, the number of poles are indicated by the number of switch wipers connected by a dashed line. The number of throws are typically indicated by the number of terminals (numbered open circles) to which a wiper connects.

Switch Diagram Legend

Switch Characteristics
A switch characteristic is the contact and action at each switch position. Contact is whether the switch position makes or breaks an electrical connection at that position. Action is whether the switch position is momentary or latched. Descriptions - When defining switch characteristics by words, contact is indicated by an on or an off which is supplied for each switch position. Momentary action is indicated by parenthesis around (on) or (off); latched action is indicated by an absence of parenthesis Symbols - When defining switch characteristics by pictures, contact is indicated if a terminal (numbered open circle) is present at that switch position. Momentary action is indicated by a filled triangle at that switch position; latched action is indicated by a filled circle at that switch position.

AEB 15.42 Page 29 of 44

Alternate Droop Switch


Application
The Alternate Droop switch selects different droop characteristics for the High Idle Governor feature or the All Speed Governor (ASG) feature or both. This is desirable when the machine is transitioning to a different mode of operation, for example from loading to hauling. The transition may be performed by any dedicated switch contacts, including a relay or a manual operator switch. Installation depends on the type of switch that is used..

Alternate Droop Switch Diagram

Alternate Droop Switch Specifications Item Switch Type Minimum No. of Terminals Minimum No. of States - BASE DROOP - ALTERNATE DROOP Contact Resistance (Closed) Contact Resistance (Open Nominal Current Contact Material Requirement SPST Contacts Two: Terminal 1 and Terminal 2 (reference only) Two: BASE DROOP and ALTERNATE DROOP Terminals 1-2 Open Terminals 1-2 Closed < 10 Ohm > 50 KOhm 10 mA Gold Flash

AEB 15.42 Page 30 of 44

Alternate Low Idle Switch


Application
The Alternate Low Idle switch selects a different low idle engine speed. A higher low idle engine speed is useful for warming up the engine, or when an application operates the engine on low idle governor. The alternate low idle engine speed may be selected by any dedicated switch contacts, including a relay or a manual operator switch. Installation depends on the type of switch that is used.

Operation
The Alternate low Idle switch has two positions, base low idle or alternate low idle. The switch operates in the Normal or Transition mode depending on an optional customer selection. Normal Mode - When the switch is in the base low idle position, the engine's low idle speed is defined by the Low Idle Governor feature. When the switch is in the alternate low idle position, engine low idle speed is instead defined by the Switchable Low Idle feature. Transition Mode - This mode requires a switch transition from base low idle to alternate low idle subsequent to key-on to select the alternate low idle. Until this transition has occurred, or when the switch is in the Base Low Idle position, engine low idle speed is defined by the Low Idle Governor feature. If the transition has occurred and the switch is in the alternate low idle position, engine low idle speed is instead defined by the Switchable Low Idle feature.

Alternate Low Idle Switch Diagram Alternate Low Idle Switch Specifications Item Switch Type Minimum No. of Terminals Minimum No. of States - BASE LOW IDLE - ALTERNATE LOW IDLE Contact Resistance (Closed) Contact Resistance (Open Nominal Current Contact Material Requirement SPST Contacts Two: Terminal 1 and Terminal 2 (reference only) Two: BASE LOW IDLE and ALTERNATE LOW IDLE Terminals 1-2 Open Terminals 1-2 Closed < 10 Ohm > 50 KOhm 10 mA Gold Flash

AEB 15.42 Page 31 of 44

Alternate Torque Switch


Applications
The Alternate Torque switch toggles between the normal 100% curve and up to two alternate torque curves. A different torque curve results in an engine with different HP ratings. Different horsepower ratings are desirable when the same engine is used for dual modes of operation, for example hauling vs. loading. A torque curve may be selected by any dedicated switch contacts, including a relay or a manual operator switch. Installation depends on the type of switch that is used.

Operation without Boost Power


The following operational description applies when the Automatic Boost Power feature is not enabled. The Alternate Torque switch has two or three switch positions (see switch diagram). When the switch is in the Low position, a lower calibratible torque curve is used. Engine torque is limited to the lower curve. The ECM may be calibrated for either a Normal or Failsafe configuration of the switch. Alternate Torque Switch Diagram
a) Two-Position Switch Open 2 1

1: Normal 100% curve 2: Alternate torque curve

b) Three-Position Switch Open resistive 3 1.5K 1% 1/8 watt 2

1: Normal 100% curve 2: Alternate torque curve 2 3: Alternate torque curve 1 ground

Figure 1-5 Switches Configuration Alternate Torque Switch Specifications Item Configuration Type Switch Type Minimum No. of Terminals Minimum No. of States - HIGH - LOW Contact Resistance (Closed) Contact Resistance (Open Nominal Current Contact Material Requirement Normal SPST Contacts Two: Terminal 1 and 2 (ref only) Two: HIGH or LOW Terminal 1-2 Open Terminals 1-2 Closed < 10 Ohm > 50 KOhm 10 mA Gold Flash Failsafe SPST Contacts Two: Terminal A and B (ref only) Two: HIGH or LOW Terminal A_B Closed Terminals A-B Open

AEB 15.42 Page 32 of 44

AXG On/Off Switch


Application
The AXG On/Off switch selects operation of the Auxiliary Speed Governor (AXG), AXG is an auxiliary fueling governor that varies engine torque in an attempt to control either shaft speed or an application-specific pressure, depending upon the engine configuration. The AXG On/Off switch has two positions, on or off. When the switch is in the off position, the engine fueling is not controlled by the AXG. When the switch is in the on position and there are no AXG faults, engine fueling is controlled by the AXG, permitting shaft speed control or pressure control from a commanded throttle input.

AXG on/off Switch Diagram Alternate Low Idle Switch Specifications Item Switch Type Minimum No. of Terminals Minimum No. of States - OFF - ON Contact Resistance (Closed) Contact Resistance (Open Nominal Current Contact Material Requirement SPST on-off Toggle Two: Terminal 1 and Terminal 2 (reference only) Two: OFF or ON Terminals 1-2 Open Terminals 1-2 Closed < 10 Ohm > 50 KOhm 10 mA Gold Flash

AEB 15.42 Page 33 of 44

Air Conditioner Pressure Switch


Applications
The Air Conditioner Pressure switch detects air condition refrigerant pressure relative to two pressure thresholds defined by the switch. It generates a control signal for the Electronic Fan Clutch feature which in turn operates an air conditioning condenser fan. This switch is inserted into the high-pressure side of the air conditioner refrigerant system. A hysteresis of 2-4 PSI is recommended between the two pressure thresholds to prevent an excessive number of fan clutch state transitions. The Air Condition Pressure switch has two positions, pressure high or pressure not high, and two thresholds, upper and lower. On rising refrigerant pressure, the switch will transition to the Pressure High position when pressure exceed the upper threshold. In this position, On/Off fan will operate at its characteristic RPM, a Variable-Speed fan will operate at selectable rpm. On falling refrigerant pressure, the switch will transition to the pressure not high position when pressure falls below the lower threshold. In this switch position, the fan does not operate due to refrigerant pressure. However, the fan may still run in response to some other need such as high coolant temperature.

Air Conditioner Pressure Switch Diagram Air Conditioner Pressure Switch Specifications Item Switch Type Minimum No. of Terminals Minimum No. of States - PRESSURE NOT HIGH - PRESSURE HIGH Contact Resistance (Closed) Contact Resistance (Open) Nominal Current Contact Material Requirement SPST (On)-Off Activated Two: Terminal 1 and Terminal 2 (reference only) Two: PRESSURE NOT HIGH or PRESSURE HIGH Latched Action: Terminals 1-2 Closed Momentary Action: Terminals 1-2 Open < 10 Ohm > 50 KOhm 10 mA Gold Flash

AEB 15.42 Page 34 of 44

Pressure Switches: Brake Switch


Description
This normally closed sing pole, single throw (SPST) plunger design limit switch is rated for one million switch cycles. It has an actuation force of 4.17 N [0.937 lbf] (15 ounces) and the total plunger movement is 4.928 mm [0.1938 in]. The recommended switch actuation is 3.175 mm [0.1249 in] to avoid undesirable bottoming out. An elastomeric sealing boot keeps harsh abrasive from damaging the plunger body and guide. Gold contacts make the switch reliable for low voltage and current switching.

Application
The signal from the brake pressure is used to disable cruise control and ISC operations. It is mounted directly, or with a T-fitting, into the low pressure control side of the truck's pneumatic brake system. When the brake pedal is actuated or the trailer brake is applied, the pneumatic pressure rises from 0 psig to 90 psig. An open circuit to the control module, whether by this switch or a wiring circuit failure, will disable the cruise control function. This switch is qualified for under-the-dashboard mounting only. A molded rubber boot is recommended for use with the mating connector.

Pressure Switch

Item Contact Regulator Prime Accuracy Switch Threshold Proof Pressure

Requirement 10mA through contacts; 2A max +/- 2psig 4 psig 150 psig

AEB 15.42 Page 35 of 44

Switches and Switch Assemblies: Rotary Clutch Switch Assembly


Description
The Clutch Switch Assembly is comprised of a rotary switch, lever and rod assembly and a switch bracket. The rotary switch is a normally closed single pole, single throw switch that is designed to exceed one million switch cycles. Gold contacts make it reliable for low voltage and current switching. The shaft is 7.87 millimeters [0.309 in] in diameter. At the open position, actuation torque is 1.34 N-m [0.988 ft-lbf] (190 inch-ounces). Total mechanical travel is 40 degrees of maximum rotation with 35 degrees of maximum pretravel and 3 degrees of differential travel. The ruggedness of this switch allows it to be used in high vibration environments.

Application
The device can be mounted either in the cab or under the cab. The rod is cut or bent to fit the top or front side of the clutch arm so that the clutch rest position has the switch in the closed-circuit mode. As the clutch pedal is depressed, the linkage arm will move and the spring preload in the switch will cause the rod to follow and open the switch circuit. When mounted under the cab, a shield should be added to prevent direct road splash on the rotary shaft area.

Switch and Switch Assembly Item Current Rating Voltage Maximum Contact Material 10 mA +/- @ 5V +/- 0.25 16V Gold-Plated Requirement

AEB 15.42 Page 36 of 44

Switches and Switch Assemblies: Optional Clutch Brake Switch


Description
This normally closed single pole, single throw (SPST) plunger design limit switch is rated for one million switch cycles. It has an actuation force of 4.17 N [0.937 lbf[ (15 ounces) and the total plunger movement is 4.928 mm [0/1938 in]. The recommended switch actuation is 3.176 mm [0.1249 in] to avoid undesirable bottoming out. An elastomeric sealing boot keeps harsh abrasives from damaging the plunger body and guide. Gold contacts make the switch reliable for low voltage and current switching.

Application
The limit switch may be closed as an optional clutch switch instead of the rotary clutch switch assembly. It is mounted on the bell housing of the transmission and is operated by an actuating bracket attached to the bell crank. The slim packaging of this harsh environment plunger switch allows it to be easily mounted for limited switch application. Two mounting holes 5.08 mm [0.199 in] in diameter accommodate number 10 capscrews for bracket compatibility. The actuators that impinge on the plunger should be adjusted to the specified range of the switch.

Optional Clutch Switch Item Current Rating Output Voltage Supply Voltage Contact Material Requirement 10 mA +/- @ 5V +/- 0.25 Inductive load of 2.7 ohms @ 50 mH 16 Vdc maximum 5V Gold-Plated

AEB 15.42 Page 37 of 44

SECTION V: SENSORS
Vehicle Speed Sensor (Variable Reluctance Magnetic Pickup)
Application - This sensor is mounted through the transmission case and senses passing teeth from a 16-tooth or optional 11-tooth gear. Each revolution of the gear produces 16 or 11 cycles of quasi-sinusoidal voltage. The sensor responds down to 1 mph which is 31 rpm of the 16-tooth speedometer gear shown in the accompanying illustration. At the time of installation, the sensor is to be hand turned until it touches the target, then backed off one-half turn and the jam nut tightened. The sensor is polarity sensitive and a sharp positiveto-negative transition is accomplished by using the white lead wire as the positive reference and the black wire as the negative reference. It can also be used as a dual output engine speed sensor, mounted through the ring gear housing to sense ring gear teeth. Hardware - This sensor is a single pole piece, dual output variable reluctance magnetic pickup in which each output is physically isolated from the other. The output swings positive when the target approaches, passes through zero when the target and pole piece are coincident, and then swings negative when the target leaves. Voltage amplitude is a function of gap, target size and angular velocity.

Magnetic Pickup Sensor

Magnetic Pickup Sensor Part List Item Shrouds Terminals Seals Manufacturer Packard Packard Packard Manufacturer Part No. 12010973 12089040 12015323 Cummins Part No.

AEB 15.42 Page 38 of 44

Water-in-Fuel Sensor and Drain Unit (For Spin-on FWS)


Application - The WIF sensor drain unit is designed to be installed at the bottom of the spin-on fuel water separator (FWS). This fuel water separator is designed for the QSB, QSC & QSL9 engines. The 1.25-10uns 2A threads are required in the filter shell to accept the unit. Hardware - The design includes a water drain unit, WIF sensor, harness, and Packard connector. This water in fuel sensor is a double pin injection molded part. The pins are injection molded and sealed from possible fuel leakage. The drain valve is a push-up type of water drain valve. The assembly has a 0-ring in the threaded area for an installation seal between the WIF sensor and the filter shell nut. The Packard connector is a type of weather tight sealed connector.

Water-in-Fuel Sensor (Spin-on)

Water-in-Fuel Sensor Part List Item Connector Mating Connector Manufacturer Packard Packard Manufacturer Part No. 12066016 12040753 Cummins Part No.

AEB 15.42 Page 39 of 44

ANALOG SENSORS OEM Pressure Sensor


Application -The OEM Pressure sensor may be used to detect the pressure of any desired liquid or gas. OEM pressure can be used to switch any device on or off, to initiate an engine shutdown, or to control a fan. OEM Pressure can be governed to a reference pressure in order to drive air- or hydraulically-powered equipment. Any or all applications can be met at once. Installation varies according to application. Operation - The OEM Pressure sensor converts detected pressure into a DC voltage. This voltage is detected by the ECM and converted into OEM pressure using a calculation that performs a linear interpolation between two breakpoints. OEM pressure may be used by any or all of the following features: Auxiliary Governor - This feature converts throttle input into a reference OEM pressure. Then using a feedback loop, engine torque is varied as required to maintain this OEM pressure. Depending on the application, OEM pressure can be maintained at a pre-selected value, or continuously variable OEM pressure control is possible. Electronic Fan Clutch - If the fan type is Variable-Speed, OEM pressure is applied to a calibration table to generate a characteristic PWM frequency. The fan will operate at the minimum fan speed corresponding to the characteristic PWM frequency. If the fan type is On/Off, the fan will turn on or off when OEM pressure transitions through a pressure threshold. Switched Outputs - OEM pressure is one of several trigger parameters for three options: Relay A, Relay B, and Engine Shutdown. Each option has one or more associated pressure thresholds. Depending on OEM pressure value relative to these thresholds, the OEM pressure trigger parameter is either ACTIVE or INACTIVE for each option. When the desired combination of trigger parameters is ACTIVE for the Relay A option, that relay energizes or de-energizes. When the desired combination of trigger parameters is ACTIVE for the Relay B option, that relay energizes or de-energizes. When the desired combination of trigger parameters is ACTIVE for the Engine Shutdown option, an engine shutdown is initiated. Increasing Pressure
SUPPLY (+) PRESSURE RETURN

OEM Pressure Sensor Diagram

OEM Pressure Sensor Specifications Item Sensor Type Minimum No. of Terminals Default Pressure Range Supply Voltage Maximum Supply Current Output Voltage Range Default Output Voltage @ Pressure Maximum Output Current Requirement Ratiometric Pressure Three: Supply (+), Return, and Pressure 0-350 PSI 5V + 5% 50 mA 0.5-4.5 V [(4xPSI)/350] + 0.5 V 100 A

AEB 15.42 Page 40 of 44

Acceptable OEM Pressure Sensor


Application This sensor is suitable for use as an OEM pressure sensor when the default calibration is used. Its pressure vs. voltage curve is compatible with the baseline CM570 calibration for the OEM pressure sensor. This sensor is especially suited to detect hydraulic fluid pressure, compressed air pressure, and fuel pressure. The sensor cannot be used to detect coolant pressure. The sensor has been exhaustively qualified by Cummins, resulting in a highly accurate, highly reliable, low cost component. The sensor is available in limited quantities through Cummins distributors. Hardware This sensor is a Kavlico P165 series. It is a 0-350 PSIA sensor with a brass housing and a o fluorocarbon o-ring. It can operate at temperatures from 40 to +125 C. Its output voltage is accurate to +4% (160 mV) over its entire temperature and pressure range. However, in the critical 200-300 PSIA pressure o range and 26 to 85 C temperature range, accuracy is +0.5% (20 mV). The sensor mates to a Packard MetriPack 150 series connector. A connector boot is available and recommended for external applications.

Acceptable OEM Pressure Sensor

Acceptable OEM Pressure Sensor Part List Item Sensor Only Sensor + O-Ring Mating Connector Connector Socket Connector Boot Manufacturer Kavlico Cummins Packard Packard Ell-Tron Manufacturer Part No. P165-5383 3330998 12162280 12124075 3656059 Cummins Part No. 3330999 3330998 3657184 3656059

AEB 15.42 Page 41 of 44

OEM Temperature Sensor Specifications


Application The OEM temperature sensor may be used to detect the temperature of any desired liquid or gas. The detected temperature can be used to switch any device on or off, to initiate an engine shutdown, or to control a fan. Any or all applications can be met at once. Installation varies according to application. Operation The OEM temperature sensor converts detected temperature into a resistance. This resistance is detected by ECM and converted into OEM temperature using a table with 20 breakpoints. OEM temperature may be used by either or both of the following features. a. Electronic Fan Clutch If the fan type is variable-speed, OEM temperature is applied to a calibration table to generate a characteristic PWM frequency. The fan will operate at the minimum fan speed corresponding to the characteristic PWM frequency. If the fan type is on/off, the fan will turn on or off when OEM temperature transitions through a temperature threshold. Switched Outputs OEM temperature is one of several trigger parameters for three options: Relay A, Relay B, and Engine Shutdown. Each option has one or more associated temperature thresholds. Depending on OEM temperature relative to these thresholds, the OEM temperature trigger parameter is either ACTIVE or INACTIVE for each option. When the desired combination of trigger parameters is ACTIVE for the Relay A option, that relay energizes or deenergizes. When the desired combination of trigger parameters is ACTIVE for Relay B option, that relay energizes or deenergizes. When the desired combination of trigger parameters is ACTIVE for the engine Shutdown option and Engine Shutdown is initiated.

b.

OEM Temperature Sensor Specifications Item Sensor Type Minimum No. of Terminals Default Temperature Range Output Voltage Range Default Resistance @ Temperature Maximum Output Current Requirement Resistive Temperature Two: Return and Temperature o o -15 to + 150 C (5 to 302 F) 0.28-4.82 V Refer to OEM Temperature Sensor Baseline Calibration table 1.7 mA

AEB 15.42 Page 42 of 44

OEM Temperature Sensor Baseline Calibration


BP 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Counts 58 74 96 109 125 143 161 185 211 242 276 357 453 554 663 765 850 915 958 987 Deg. F 302 282 262 252 242 232 223 213 203 193 183 163 143 124 104 84 64 44 25 5 Volts .28 .36 .47 .53 .61 .70 .79 .90 1.03 1.18 1.35 1.74 2.21 2.71 3.24 3.74 4.15 4.47 4.68 4.82 K Ohms .17 .22 .30 .34 .40 .47 .54 .63 .74 .89 1.06 1.53 2.27 3.40 5.28 8.52 14.01 24.20 41.97 76.85 Deg. C 150 139 128 122 117 111 106 101 95 89 84 73 62 51 40 29 18 7 -1 -15

AEB 15.42 Page 43 of 44

Acceptable OEM Temperature Sensor


Application There are four Cummins-qualified sensors suitable for use as an OEM Temperature sensor. Their temperatures vs. resistance curves are compatible with the baseline CM570 calibration for the OEM Temperature sensor. The sensors are listed in the Acceptable OEM Temperature Sensor Application table. The variations among these sensors ensure that one of these sensors should be capable of detecting the temperature of almost any type of gas or liquid in an internal or external environment. The sensors cannot be used to detect coolant temperature. The sensors are available in limited quantities through Cummins distributors. Acceptable OEM Temperature Sensor Application # 1 2 3 4 Assembly 3865312 3865346 3085185 3408345 Hardware English English Metric Metric Medium Gas or Liquid Gas Gas or Liquid Gas Environment External Internal External Internal
o

Probe Style Unvented Vented Unvented Vented

Hardware All sensors are manufactured by Hi-Stat. They are 40 to +150 C sensors with a fluorocarbon oring. They can operate at pressures as high as 350 PSIB. Their resistance is highly accurate in the critical o o upper temperature ranges: +1.65% from 100 to 145 C, +2.1% from 85 to 100 C. The sensors mate to a Packard Metri-Pack 150 series connector. A connector boot is available and recommended for external applications. Dimensions are identical for every sensor except as noted in the Acceptable OEM Temperature Sensor Dimensions table.

Acceptable OEM Temperature Sensor

AEB 15.42 Page 44 of 44

Acceptable OEM Temperature Sensors


Acceptable OEM Temperature Sensor Part List Item Sensor 1 Only Sensor 1 + O-Ring Sensor 2 Only Sensor 2 + O-Ring Sensor 3 Only Sensor 3 + O-Ring Sensor 4 Only Sensor 4 + O-Ring Mating Connector Connector Socket Connector Boot Manufacturer Hi-Stat Cummins Hi-Stat Cummins Hi-Stat Cummins Hi-Stat Cummins Packard Packard Ell-Tron Manufacturer Part No. 8316-202 3865312 8416-206 3865346 8316-201 3085185 8416-211 3408345 1216 2193 1212 4076 3656057 Cummins Part No. 3865323 3865312 3096153 3865346 3085198 3085185 3408346 3408345 3657186 3656057

Acceptable OEM Temperature Sensor Dimensions # 1 2 3 4 Assembly Part Number 3865312 3865346 3085185 3408345 Integral Hex Across Flats 13/16 in. 13/16 in. 21 mm 21 mm Thread Size 9/16-18 UNF-2A 9/16-18 UNF-2A M14 X 1.5-6H M14 X 1.5-6H