Item Assy. Service Part No. Description Quantity Lev. Parts Remarks - - KEA07-65000 KIT, WIRE HARNESS 03-CRS, EXHAUST SIDE STARTER 1 A 1 -- KEA07-65004-INS WIRE HARNESS KIT INSTRUCTIONS 1 A 2 -- KEA07-65050 WIRE HARNESS, 03-CRS 1-3 -- 01153-50825 M8-1.25 x 25MM HEX FLANGE BOLT 4 A 4 -- KEA07-65122 BRACKET, UPPER STRESS RELIEF 03-CRS 1 A Upper Bracket 5 -- 01153-50816 M8-1.25 x 16MM HEX FLANGE BOLT 2 A 6 -- KEA06-54260 P-CLAMP 2 A 7 -- 01173-51016 M10-1.25x16MM HEX FLANGE BOLT 2 A FOR P-CLAMP 8 -- KEA05-65310 BAND, HARNESS 4 A 9 -- KEA05-65320 BAND, HARNESS 4 A A: Available as Service Parts APPLICABLE ENGINE MODELS: D1803-CR-E4 (with exhaust side starter) D1803-CR-TE4 (with exhaust side starter) V2403-CR-E4 (with exhaust side starter) V2403-CR-TE4 (with exhaust side starter) 3 8 6 9 5 4 2 7 PAGE 1 OF 7
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 7
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 24-27 Nm (18-20 ft.-lbs.). 4 PAGE 3 OF 7
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. 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 3 CABLE TIES x 4 P CLAMPS x 2 PAGE 4 OF 7
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. There are two diagrams available (standard on page 6 and Murphy PV480 on page 7). 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 7
8 7 6 5 4 3 2 1 F MAIN RELAY - FUEL FEED PUMP MAIN POWER CONNECTOR MOLEX_19432-0013 FEMALE CONN MOLEX_19434-0001 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 CAN FOR VEHICLE TWISTED PAIR E 50 AMP FUSE B DIRECT TO BATT (-) D ST ALTERNATOR VIC1 CONNECTOR MOLEX_33472-1606 FEMALE CONN MOLEX_33012-2002 TERM (SN) MOLEX_34345-0001 CAVITY PLUG D - 12V BATTERY CHARGE 337 BLACK(B)/GREEN (GR) 18 AWG 322 BROWN (BR) 18 AWG 1: MAIN RELAY COIL (-) 16: NOT USED 2: CAN2 - L 15: NOT USED 323 BROWN/WHITE 18 AWG 3: CAN2 - H 14: NOT USED C CHASSIS GND ENGINE GND 321 RED(R)/BLACK(B) 18 AWG 4: START SW INPUT 13: NOT USED C 330 WHITE(W)/RED(R) 18 AWG 340 GREEN(G)/WHITE(W) 16 AWG 5: NITION SW INPUT 12: NOT USED 6: HEATER RELAY COIL () 11: NOT USED B STARTER SOLENOID - 333 BLUE/BLACK 18 AWG 7: STARTER RELAY COIL (-) 8: NOT USED 10: HEATER RELAY COIL (-) 9: STARTER RELAY COIL () B STARTER MOTOR 332 WHITE (W) 18 AWG 341 BLACK (B) 18 AWG A 50 AMP FUSE HEATER RELAY HEATER DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: NAME KB DATE 3-11-14 KUBOTA ENGINE AMERICA TITLE: VEHICLE INTERFACE WIRING 03-CRS INTERMEDIATE HARNESS (GENRAL WIRING) SIZE USED IN CONJUNCTION WITH: REV C KEA07-65050 2 SCALE: 1:1 SHEET 1 OF 1 A 8 7 6 5 4 3 2 1
SHEET 1 OF 1 MAIN RELAY FUEL FEED PUMP - MAIN POWER CONNECTOR MOLEX_19432-0013 FEMALE CONN MOLEX_19434-0001 FEMALE TERM (SN) 20 AMP FUSE 002 WHITE(W)/BLACK(B) 12 AWG 1: MAIN RELAY CONTACT (12V) 084 BLACK(B)/RED(R) 12 AWG 2: GND 50 AMP FUSE HEATER DIRECT TO BATT (-) 50 AMP FUSE B N-SW RELAY HEATER RELAY 341 BLACK (B) 18 AWG VIC1 CONNECTOR MOLEX_33472-1606 FEMALE CONN MOLEX_33012-2002 TERM (SN) MOLEX_34345-0001 CAVITY PLUG ST 337 BLACK(B)/GREEN (GR) 18 AWG 1: MAIN RELAY COIL (-) 16: NOT USED TWISTED PAIR 322 BROWN (BR) 18 AWG 2: CAN2 - L 15: NOT USED - 12V BATTERY CHASSIS GND ENGINE GND NOTES: 1: RELAY SPECIFICATIONS SHOWN IN TABLE ALTERNATOR CHARGE - STARTER SOLENOID STARTER MOTOR USB PROGRAMMING 120 Ω MURPHY PV480 26: CAN2 - H 14: CAN2 - L 27: N SW INPUT 28: BATT () 7: WATER IN FUEL SW () 3: D OUTPUT 1 (MAIN RELAY COIL SW) 29: BATTERY (-) 21: A/D (-) GND 6: PARK BRAKE SW 18: NEUTRAL SW 5: FREQUENCY INPUT (VEHICLE SPEED) 17: FREQUENCY INPUT RETURN 20: FUEL LEVEL SENSOR (A/D 3, 0-5V) 9: HYD. PRESSURE SENSOR (A/D 4, 0-5V) 19: ACCEL 1 SENSOR (A/D 1, 0-5V) 8: ACCEL 2 SENSOR (A/D 2, 0-5V) 10: ANALOG OUTPUT (0-5V) 22: ANALOG OUTPUT GND 13: USB SHIELD 24: USB D 1: USB D- 25: USB Vbus 323 BROWN/WHITE 18 AWG 321 RED(R)/BLACK(B) 18 AWG 330 WHITE(W)/RED(R) 18 AWG 340 GREEN(G)/WHITE(W) 16 AWG 333 BLUE/BLACK 18 AWG 3: CAN2 - H 14: NOT USED 4: START SW INPUT 13: NOT USED 5: NITION SW INPUT 12: NOT USED 6: HEATER RELAY COIL () 11: NOT USED 7: STARTER RELAY COIL (-) 10: HEATER RELAY COIL (-) 8: NOT USED 9: STARTER RELAY COIL () WIF B SNAL GROUND 12V (12V) 5.0 V SENSOR SUPPLY (PV480 Pin 10) SENSOR RETURN (PV480 Pin 9) SENSOR GND (PV480 Pin 22) 5.0 V SENSOR SUPPLY (PV480 Pin 10) SENSOR RETURN (PV480 Pin 19) SENSOR GND (PV480 Pin 22) 332 WHITE (W) 18 AWG VEHICLE SPEED SENSOR FUEL LEVEL SENSOR (OPTIONAL) HYDRAULIC PRESSURE SENSOR (OPTIONAL) ACCEL 1 SENSOR OPTIONAL: IF NOT USING CAN THROTTLE NOT REQUIRED ON MACHINE. REQUIRED ONLY FOR SOFTWARE UPDATES. 5.0 V SENSOR SUPPLY (PV480 Pin 10) SENSOR RETURN (PV480 Pin 8) SENSOR GND (PV480 Pin 22) ACCEL 2 SENSOR OPTIONAL: IF NOT USING CAN THROTTLE 2: DASHED CIRCUITS ARE OPTIONAL CIRCUITS. THESE CIRCUITS WILL VARY BY APPLICATION. REFER TO PV480 INSTALLATION MANUAL FOR SENSOR DETAILS -WATER IN FUEL SENSOR SWITCH, FUEL LEVEL SENSOR, HYDRAULIC PRESSURE SENSOR, ACCEL 1, ACCEL 2, VEHICLE SPEED 3: IN CASES WHERE THE KEA INTERMEDIATE WIRING HARNESS IS NOT USED: -THE WIRES FOR "VIC1" and "MAIN POWER CONNECTOR" SHOULD BE INTEGRATED INTO THE OEM WIRE HARNESS PER THE ABOVE DIAGRAM (OR EQUIVALENT). KUBOTA ENGINE AMERICA NAME SNATURE DATE DRAWN KB 10-4-13 CHK'D APPV'D MFG Q.A MATERIAL: TITLE: DO NOT SCALE DRAWING REVISION: 1 03 SERIES VIC SCHEMATIC - PV480 USED IN CONJUNCTION WITH HARNESS: KEA07-65050 A1 WEHT: SCALE:1:1