Service Lev. Parts - - KEA KIT, WIRE HARNESS 03-CR-TIE4, INTAKE SIDE STARTER 1 A 1 A
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1 Item Assy. Service Part No. Description Quantity Lev. Parts Remarks - - KEA KIT, WIRE HARNESS 03-CR-TIE4, INTAKE SIDE STARTER 1 A 1 -- KEA INS WIRE HARNESS KIT INSTRUCTIONS 1 A 2 -- KEA WIRE HARNESS, 03-CR-TIE M x 25MM HEX FLANGE BOLT 4 A For ECU Mounting 4 -- KEA BRACKET, UPPER STRESS RELIEF 03-CRS 1 A Upper Bracket M x 16MM HEX FLANGE BOLT 2 A 6 -- KEA P-CLAMP 2 A M x16MM HEX FLANGE BOLT 2 A FOR P-CLAMP 8 -- KEA BAND, HARNESS 3 A 9 -- KEA BAND, HARNESS 4 A ECU STRESS RELIEF A: Available as Service Parts APPLICABLE ENGINE MODELS: D1803-CR-TIE4 (with intake side starter) V2403-CR-TIE4 (with intake side starter) PAGE 1 OF 6
2 Installation Condition Notes Important Note: The following installation guideline must be followed during installation of the 03 Series-CRS Engine Control Unit (ECU). 1. The 03 Series-CRS ECU must be mounted on the equipment chassis. Engine mounted ECU's are not approved for warranty. 2. The ECU temperature should never exceed 105 C in any operating condition. 3. The ECU should never exceed vibration levels of 5G, 0.7 mm in any condition. 4. The wire harness should have appropriate stress relief for each connection. OR Preferred Position Optional Positions: 1) Up to 90 Rotation Clockwise 2) Up to 30 Rotation Forwards/Backwards Each check point must be checked and evaluated during the application review process. Application approval and warranty cannot be granted unless each installation condition meets/exceeds the requirements listed above. A completed installation is shown below as an example. EXAMPLE ECU INSTALLATION PAGE 2 OF 6
3 Installation Procedure 1. Mount the ECU with the four mounting bolts (Item# 3) in a location that meets the installation conditions described in the above section. Torque the bolts to 23 Nm (17 ft.-lbs.). Note: The ECU must be protected from water and or/pressure washing. 3 ECU 2. Mount "BRACKET, UPPER STRESS RELIEF 03-CRS" (Item# 4) with the two mounting bolts (Item# 5) to the intermediate connector bracket on the engine. Torque the bolts to Nm (18-20 ft.-lbs.). 4 PAGE 3 OF 6
4 Installation Procedure Continued 3. Plug in each corresponding wire harness connector into the appropriate locations as described below. Note 1: Never force a connection to the mating connector as this will result in bent terminal pins. Note 2: ECU connectors ECU1 and ECU2 are keyed differently. Take care to match the connector to the correct ECU connection. Note 3: The MAF (mass air flow) sensor wire is 1200 mm in length to accommodate many installation solutions. Take care to secure any excess wire in the event that the MAF sensor is located in close proximity. Note 4: The interface connector and the main power connector require additional wiring by the OEM. Please refer to the VIC (vehicle interface connector) wire schematic on the final pages of this installation instruction guide for detail. ECU 2 CONNECTOR ECU 1 CONNECTOR INJECTOR INTERMEDIATE CONNECTOR ENGINE INTERMEDIATE CONNECTOR MAIN POWER CONNECTOR VIC CONNECTOR 4. Secure the wire harness with the cable ties provided in the harness kit according to the image below. Install the P-clamps in a reasonable location. At least one additional stress relief on the harness is needed (depends on final ECU location). Note: Add any additional wire harness support as needed (not included in kit). CABLE TIES x 4 CABLE TIES x 2 P CLAMPS x 2 PAGE 4 OF 6
5 Installation Procedure Continued 5. Connect the interface connector and the main power connector. Please refer to the VIC (vehicle interface connector) wire schematics on the final pages of this installation instruction guide for detail. The connector pin outs are shown below (looking into the intermediate wire harness connector). Vehicle Interface Wiring Notes: A. Suppression diodes on the coil side of the relay are required on the main, starter, and Murphy PV480 relay (if used). The installed relays should meet or exceed the specification as shown below: B. Be sure battery cables are connected correctly. Disconnecting either the positive or negative battery cable while the equipment is operating may cause premature failure of electronic components. Also, never weld on equipment with the ECU connected to the wire harness. C. After connecting all terminals to appropriate locations, check the following: a) Make sure the wires do not contact the exhaust manifold or muffler and are away from all heat sources. b) Make sure the wires do not contact any sharp or abrasive surfaces. c) Use wire ties to secure the wire harness to the engine, but never secure the wires to any fuel injection lines. d) Make sure that the all non sealed relays are mounted vertically so that water can drain from the bottom of the connectors. e) Ensure that the wire harness is routed in a way that prevents water from running directly into the ECU or intermediate harness connections. PAGE 5 OF 6
6 F MAIN RELAY + - FUEL FEED PUMP KEA 03-CRS INTERMEDIATE WIRE HARNESS: MAIN POWER CONNECTOR MOLEX_ FEMALE CONN MOLEX_ FEMALE TERM (SN) F 20 AMP FUSE 002 WHITE(W)/BLACK(B) 12 AWG 1: MAIN RELAY CONTACT (12V+) 120 ohm 084 BLACK(B)/RED(R) 12 AWG 2: GND E D 50 AMP FUSE V BATTERY B+ ST IG CAN FOR VEHICLE ALTERNATOR IG CHARGE TWISTED PAIR 337 BLACK(B)/GREEN (GR) 18 AWG 322 BROWN (BR) 18 AWG DIRECT TO BATT (-) KEA 03-CRS INTERMEDIATE WIRE HARNESS: VIC1 CONNECTOR MOLEX_ FEMALE CONN MOLEX_ TERM (SN) MOLEX_ CAVITY PLUG 1: MAIN RELAY COIL (-) 16: NOT USED 2: CAN2 - L 15: NOT USED E D 323 BROWN/WHITE 18 AWG 3: CAN2 - H 14: GROUND C CHASSIS GND ENGINE GND 5 AMP FUSE 321 RED(R)/BLACK(B) 18 AWG 4: START SW INPUT 13: NEUTRAL SW C 5 AMP FUSE 330 WHITE(W)/RED(R) 18 AWG 5: IGNITION SW INPUT 12: GOV SW2 6: HEATER RELAY COIL (+) 11: GOV SW1 B BLUE/BLACK 18 AWG + STARTER SOLENOID STARTER MOTOR - 7: STARTER RELAY COIL (-) 8: WATER IN FUEL (GND INPUT ONLY) 10: HEATER RELAY COIL (-) 9: STARTER RELAY COIL (+) 332 WHITE (W) 18 AWG B 341 BLACK (B) 18 AWG A 60 AMP FUSE HEATER RELAY HEATER 340 GREEN(G)/WHITE(W) 16 AWG GND SIGNAL = WATER IN FUEL (OPEN = NO WATER IN FUEL) DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: NAME KB DATE KUBOTA ENGINE AMERICA TITLE: VEHICLE INTERFACE WIRING 03-CRS INTERMEDIATE HARNESS (GENRAL WIRING) SIZE C SCALE: 1:1 REV 3 SHEET 1 OF 1 A
Service Quantity Lev. 4 A For ECU Mounting 2 A FOR P-CLAMP
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