Connectors and Wiring Harness Requirements 5.1.6.4 Battery Cable Insulation The preferred minimum cable size for the starting system is 2/0 AWG wire size with a wire specification that meets SAE J1127 for Low Voltage Battery Cable, type SGX. The start motor to frame ground cable shall be no smaller than the battery cables but may need to be larger for dual starting motor systems. This is to ensure that starting currents will be adequately handled in jump-start conditions. 5.1.7 Connector Seal Plug All unused cavities for sockets and pins must be filled with seal plugs in order to ensure that the connector is sealed. Two options are available for plugging unused connector cavities.
Either the Deutsch 114017 (Caterpillar part number 8T-8737) or PEI Genesis 225-0093-000 (Caterpillar part number 9G-3695) sealing plugs can be used. Figure 2: Plug Insertion in Unused Connector Cavity Correct AVOID The seal plugs are installed from the wire insertion side of the plug or receptacle. Correct installation of either of these cavity plugs is critical to maintain connector sealing integrity. Figure 2 illustrates the correct insertion of the plug. The seal plug cap is designed to rest against the seal, not inserted in the hole in the seal. 5.2 Wiring Harness Design 5.2.1 Harness Routing Wiring shall be routed to ensure reliability and to offer protection from the following: 1.
Chafing/rubbing/vibrating against other parts. 2. Use as handholds or as support for personal equipment. 3. Damage by personnel moving within the vehicle. 4. Damage by impact, or thrown or falling debris. 5. Damage by battery acid fumes, engine and hydraulic oil, fuel, and coolant. 6. Abrasion or damage when exposed to rocks, ice, mud, etc. 7. Vandalism damage (to the maximum extent practicable). 8. Damage by moving parts. 9. Harsh environment such as nitrite mines, high temperatures, or areas susceptible to significant fluid or fume concentration. I N D U S T R I A L E N G I N E E L E C T R O N I C S 32