Connectors and Wiring Harness Requirements ECU wire size requirements per connection are: (1) 143-5018 Cable (Twisted Pair) (2) 153-2707 Cable (Shielded Twisted Pair) 5.1.6.3 Wire Insulation NOTE: Thermoplastic Polyvinyl Chloride (PVC) insulation shall not be used in wire harness designs because of its low operating temperature range (-40 to 85° C), and melt and flammability characteristics. Cross Linked Polyethylene (XLPE) is the primary wire insulation type used in chassis, cab, and engine compartment locations. It has a temperature rating of -50 to 120° C. The voltage rating for Caterpillar 1E0815 wire and SAE J1128, Type SXL is 50 volts.
The circuit voltage shall be considered when making wire selections. This wire insulation is also available with 50, 150, 300, or 600-volt ratings. Outside diameter insulation range is 2.26 to 3.33 mm (0.089 to 0.131 in.). The table below provides insulation diameter range for each gauge and wire type. A P P L I C A T I O N A N D I N S T A L L A T I O N G U I D E 31 Circuit Size (AWG) Battery Negative 14 Positive Battery: Switched 14-18 Positive Battery:
Un-switched 14 Digital Sensor Power 16-18 Digital Sensor Return 16-18 Analog Sensor Power 16-18 Cat Data Link(1) 18 J1939 (CAN) Data Link(2) 18 Switch to Ground Input 18 Low Side (300 mA) Driver 18 High Side (2 A) Driver 14-16 Active Analog Input 18 Passive Analog Input 16-18 PWM Input 18 ECU CONNECTOR WIRE INSULATION AND GAUGE SIZE Wire Type Wire Gauge Insulation Diameter GXL 14 0.114 - 0.125 16 0.098 - 0.112 18 0.089 - 0.098 SXL 16 0.116 - 0.131 18 0.103 - 0.118 METRIC EQUIVALENTS FOR AWG WIRE NUMBERS AWG 20 19 18 16 14 12 4 Diameter (mm2) 0.5 0.65 0.8 1 2 3 19