Electrical Connections for the G3600A+ Customer Connectors{7426} Caterpillar

Engine:

G3606A+ (S/N: 4ZS1-UP)

G3608A+ (S/N: BEN1-UP)

G3612A+ (S/N: BKE1-UP)

G3616A+ (S/N: BLB1-UP)

Introduction

Illustration 1	g00786697
Junction Box (J3) Customer connector mounted inside of the junction box with contacts "1 thru 70" (J4) Customer connector mounted on the side of the junction box with contacts "A thru z" (J5) Connector for the engine wiring harness (J6) Connector for the engine wiring harness

Illustration 2	g00778565
Front view of the customer connector (J4) that is mounted on the junction box

Illustration 3	g00786300
Front view of the customer connector (J3) that is mounted inside the junction box

Outputs of the Customer Connectors

Active Alarm (H) or (8)

Output (H) or (8) will actuate when the engine control module has detected an active alarm. This output will remain actuated while the alarm is active. When this output is actuated, the signal that is connected to the output will be grounded. Output (H) or (8) is capable of sinking 0.3 amperes.

Auxiliary 2.0 Amp Output (j) or (5)

Output (j) or (5) will actuate when the engine control is in a ready to run state. The output is capable of supplying 2.0 amperes at 24 VDC. Connection (u) or (6) is the signal return for output (j) or (5) .

Battery Positive Fused (y), (1), or (3)

Connection (y), (1), or (3) is a 6 ampere fused circuit that should be used by the following equipment.

• Keyswitch (w)

• Host Equipment

Crank Terminate (C) or (7)

Output (C) or (7) will actuate when the engine speed is above the crank terminate speed. This output will remain actuated until the engine speed is less than 50 rpm. When this output is actuated, the signal that is connected to the output will be grounded. Output (C) or (7) is capable of sinking 0.3 amperes.

Engine Failure (P) or (9)

Output (P) or (9) will actuate when the engine control module causes the engine to be shutdown. When this output is actuated, the signal that is connected to the output will be grounded. Output (P) or (9) is capable of sinking 0.3 amperes.

Gas Shutoff Active Signal (m) or (60)

GSOV - Gas Shutoff Valve

Output (m) or (60) will actuate when the engine control wants to supply fuel to the engine. The GSOV driver is capable of supplying 2.0 amperes at 24 VDC. Connector (J6) is designed to directly energize the GSOV that is mounted on the engine. Output (m) or (60) provides a signal in order to control multiple valves that are installed by the customer or as a monitor for other equipment. If connector (J6) is not used, output (m) or (60) may be used.

Prelube Active Signal (c) or (59)

Output (c) or (59) will actuate when the engine begins to prelube. This output is capable of supplying 2.0 amperes at 24 VDC which is used by the solenoid valve that is on the engine. This output should only be used by a device with a low current drain. The other device output drivers should be used to drive additional solenoids.

Pulse Output #1 (R) or (52)

Output (R) or (52) is used by the ICSM in order to determine the events in the cylinder. This output is only available for troubleshooting purposes. Output (R) or (52) is capable of supplying 1.0 amperes at 24 VDC. This output is not currently used.

Pulse Output #2 (a) or (62)

Output (a) or (62) is used by the ICSM to determine the events in the cylinder. This output is only available for troubleshooting purposes. Output (a) or (62) is capable of supplying 1.0 amperes at 24 VDC. This output is not currently used.

PWM Output #1 (k) or (36)

Output (k) or (36) is being temporarily used in order to provide the functions of the Pulse Output. In the future, this output will be used for various unique functions. Output (k) or (36) is capable of supplying 1.0 amperes at 24 VDC. This output is not currently used.

PWM Output #2 (s) or (37)

Output (s) or (37) is being temporarily used to provide the functions of the Pulse Output. In the future, this output will be used for various unique functions. Output (s) or (37) is capable of supplying 1.0 amperes at 24 VDC. This output is not currently used.

Run Relay (Z) or (19)

Output (Z) or (19) will actuate when the engine begins to crank. This output will remain actuated until the beginning of the engine shutdown cycle. When this output is actuated, the signal that is connected to the output will be grounded. Output (Z) or (19) is capable of sinking 0.3 amperes.

4-20mA Output #1 (G) and (M) or (28) and (29)

Output (G) and (M) or output (28) and (29) are provided for future expansion.

4-20mA Output #2 (W) and (f) or (30) and (31)

Output (W) and (f) or output (30) and (31) are provided for future expansion.

Inputs of the Customer Connectors

CAN Data Link (F), (L), and( V) or (63),(64), and (65)

Connection (F), (L), and (V) or connection (63), (64), and (65) is used to communicate the status of the engine systems to the site controller. The data link adheres to the "CAN Data Link 2.0 hardware standard". The data link also adheres to the "J1939 software standard".

CAT Data Link (D) and (I) or (66) and (67)

Do not use connection (D) and (I) or connection (66) and (67). This connection is used in the manufacturing process.

Desired Speed Analog (X) or (11)

Input (X) or (11) is used to control the desired speed of the engine. The service tool can be used to determine the scaling of this input. This input is a 0 volt to 5 volt input. Input (X) or (11) must be referenced to the desired speed return (g) or (12). The desired speed supply (N) or (10) should be used with a "10 KOhms" potentiometer. The service tool can be used to select either the analog input or the "4-20mA" input. The connection for the shield for input (X) or (11) is connection (p) or (13) .

Desired Speed "4-20mA" (E) and (J) or (20) and (21)

Input (E) and (J) or input (20) and (21) is used to control the desired speed of the engine. The service tool can be used to determine the scaling of this input. This input is isolated. Therefore, input (E) or (20) must be referenced to input (J) or (21). The service tool can be used to select either the analog input or the "4-20mA" input.

Driven Equipment (U) or (32)

The Engine Is Not Running

When input (U) or (32) is connected to ground (battery negative), the engine will follow the normal start sequence. When this input is not connected to ground (battery negative), the engine will not crank. An event code will be generated if input (U) or (32) is not connected to ground within a certain period of time.

The Engine Is Running

The engine will be shutdown and a driven equipment event code will be generated when input (U) or (32) is removed from ground (battery negative). This shutdown bypasses the cooldown period.

Emergency Stop (A, B, 24, and 25)

The emergency stop circuit must be continuous through the diagram in illustration 4 in order to run the engine.

Illustration 4	g00786323

An emergency stop shutdown will occur if the circuit in illustration 4 is disconnected at any point. An emergency stop shutdown initiates the following events.

• The fuel immediately turns off.

• The ignition immediately turns off.

• The postlube does NOT run.

Idle/Rated (d) or (40)

When input (d) or (40) is not connected to ground (battery negative), the engine will run at idle speed. The engine will run at rated speed, when both of the following conditions are met:

• Input (d) or (40) is connected to ground (battery negative).

• The oil pressure is above the low idle setting.

Manual Prelube (T/58)

Prelube is active when input (T) or (58) is connected to battery positive terminal (y), (1), or (3). Prelube is inactive when one of the following conditions are met.

• The engine prelube pressure switch is closed.

• The engine is running.

Mode Control Switch

There are four inputs related to the mode control switch.

• AUTO (Y) or (15)

• START (h) or (16)

• STOP (O) or (14)

• Keyswitch (w) or (4)

Input (w) or (4) must be connected to battery positive terminal (y), (1), or (3) in order to activate the electronic control module. Input (w) or (4) must be connected to battery positive terminal (y), (1), or (3) in order for the four inputs that are listed below to be valid. If the four inputs that are listed below are disconnected, the electronic control module will be in the OFF mode.

• Input (Y) or (15)

• Input (h) or (16)

• Input (O) or (14)

• Input (w) or (4)

There are only five valid configurations for the other three mode switch inputs. The configurations are described in table 1.

AUTO MODE

In the AUTO mode, the electronic control module is in standby. The engine start sequence will be initiated when input (h) or (17) is connected to ground (r) or (18). When this input is disconnected from ground (r) or (18), the shutdown sequence will be initiated. In the AUTO mode, input (h) or (17) is used to control both the engine start sequence and the shutdown sequence. The shutdown sequence that is initiated with input (h) or (17) will include a cooldown period, if the engine is programmed for a cooldown period.

SHUTDOWN MODE

In the SHUTDOWN mode, the shutdown sequence will begin.

START MODE

When the START input (h) or (16) is connected to ground (r) or (18), the engine start sequence will begin. When the START input is disconnected from ground (r) or (18), the shutdown sequence will be initiated with a cooldown period. When the START input (h) or (16) is reconnected to ground (r) or (18), the engine start sequence will begin.

Normal Stop (K) or (26)

Input (K) or (26) must be connected to ground (battery negative) in order to run the engine. The normal shutdown sequence will begin when input (K) or (26) is disconnected from ground (battery negative). A normal shutdown sequence initiates the following events.

• The fuel turns off.

• The ignition turns off when the engine speed is less than 50 RPM.

• The postlube will run.

• The cooldown period will not occur.

Second Governor Gains (n) or (34)

When input (n) or (34) is not connected to ground (battery negative), the governor gain will be set to the primary settings. When input (n) or (34) is connected to ground (battery negative), the governor gain will be set to the secondary settings.

Second Timing (e) or (42)

Input (e) or (42) is provided in order to control the base timing of the engine. When input (e) or (42) is connected to ground (battery negative), the secondary base timing will be used. The secondary base timing can be updated with the service tool.

Speed and Timing (44), (45), and (46)

Input (44), (45), and (46) is not used at this time.

Water Level (56) and (57) and Oil Level (69) and (70)

The two wires that are returning to the ECM from Pin (J3-56) and Pin (J3-70) must be electrically connected together in order to run the engine. The engine is equipped with a connector that is located at the front right side of the engine for the two switches that are connected to connector (J5). If connector (J3) is used for the level switch installation, the connector at the front must be disconnected. Illustration 5 is the diagram for the level switches.

Note: Only one set of contacts (J3) or (J5) can be used for the level switches at one time.

Illustration 5	g00786608
Diagram for the level switches

4-20mA Input (S) and (b) or (22) and (23)

Input (S) and (b) or input (22) and (23) is provided for future expansion.

Battery Connections

Battery Negative (x) or (2)

Connection (x) or (2) is the return circuit for the control system. The return circuit must be capable of sinking up to 30 amperes.

Battery Positive (z)

Connection (z) is the primary circuit for power to the control system. The supply must be capable of supplying up to 30 amperes. This connection is not available on connector (J3) .

Battery Positive Connection for Customer Connector(J3)

The primary circuit for power to the control system can be connected directly to the circuit breakers inside the junction box. The connection can be made without going through connector (J4) .

Signal Returns of the Customer Connectors