Installation and Initial Start-Up Procedure for G3600 Engines{1000, 1900} Caterpillar

Installation and Initial Start-Up Procedure for G3600 Engines{1000, 1900}

Usage:

Engine:: G3606 (S/N: 4ZS1-UP); G3608 (S/N: BEN1-UP); G3612 (S/N: BKE1-UP); G3616 (S/N: BLB1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction provides the following information for G3600 Engines:

Requirements for the electrical system
References for electrical schematics
Required electronic service tools
Components of the main terminal box
Information about the optional control panel
Connecting the optional control panel or a Programmable Logic Controller (PLC) to the Electronic Control Module (ECM)
Wiring connections and the corresponding functions that are available to the customer
Initial start-up procedure

Before the initial start-up, an engineer that is certified by Caterpillar must perform the engine commissioning at the site.

ReferenceInformation from the following sources will be needed for this Special Instruction:

Complete analysis of the fuel
Caterpillar Software Program, LEKQ6378, "Methane Number Program"
The Data Sheet on the engine performance from the engine Technical Marketing Information (TMI)
Operation and Maintenance Manual, SEBU7563
Systems Operation/Testing and Adjusting, RENR5908
Troubleshooting, RENR5910

Requirements for the Electrical System

All of the wiring must conform to national electrical codes, to state electrical codes, and to local electrical codes.

When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through metal conduit. Use rigid conduit or use flexible conduit. A liquid tight conduit is recommended. Use proper support and alignment in order to avoid strain on the conduit.

The customer +24 VDC circuit must provide a minimum of 20 A. The return must absorb a minimum of 20 A. The voltage drop must be no more than 1 VDC at the maximum current draw with a maximum of 150 mV AC ripple voltage.

Electrical Schematics

Table 1 lists the detailed wiring diagrams for the G3600 Engines.

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Table 1
Electrical Schematics for G3600 Engines
Engine Model	Publication
G3606 S/N:4ZS1-999	Schematic, RENR5966
G3606 S/N:4ZS1000-UP	Schematic, UENR3903
G3608 S/N:BEN1-207	Schematic, RENR5967
G3608 S/N:BEN208-UP	Schematic, UENR3902
G3612 S/N:BKE1-191	Schematic, RENR5911
G3612 S/N:BKE192-UP	Schematic, UENR3901
G3616 S/N:BLB1-162	Schematic, RENR5912
G3616 S/N:BLB163-UP	Schematic, UENR3900

Electronic Service Tools

Caterpillar Electronic Service Tools are designed to help the service technician:

Obtain data
Diagnose problems
Read parameters
Program parameters
Calibrate sensors

The tools that are listed in Table 2 are required in order to enable a service technician to perform this Special Instruction.

Note: Other tools that are needed for measuring operating parameters such as pressure and temperature are not listed in Table 2.

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Table 2
Service Tools
Pt. No.	Description	Functions
N/A	IBM Personal Computer (PC) compatible	This PC configuration is recommended: Pentium IV 2.4 GHz processor 2 GB of RAM 2 GB of available hard drive space 40X speed CD-ROM drive or 8X speed DVD drive 15.4 inch XGA monitor (1280 X 1024) Microsoft Windows XP or Vista Business or Windows 7 RS-232 port with 16550AF UART Mouse USB 1.1 or 2.0 port Latest version of Microsoft Internet Explorer
N/A	IBM Personal Computer (PC) compatible	This PC configuration has the minimum requirements: Pentium 1 GHz processor or greater 1GB of RAM 500 MB of available hard drive space 24X CD-ROM drive Super VGA monitor or display (800 X 600) Microsoft Windows XP or Vista Business or Windows 7 RS-232 port with 16550AF UART Mouse USB 1.1 or 2.0 port Latest version of Microsoft Internet Explorer
"JEBD30034"	Software	Use the most recent version of this software. Once you have downloaded Cat ET onto your PC, you will need a license from your Cat dealer in order to use the software. Various licenses are available for different users with different requirements. Consult your Cat dealer.
171-4401	Communication Adapter II ⁽¹⁾	The communication adapter is connected between the PC (ET) and the ECM.
196-0055	Serial Cable As	This cable connects the PC to the 171-4401 Communication Adapter II .
7X-1414	Data Link Cable As	This cable connects the service tool connector on the engine mounted terminal box to the 139-4166 Adapter Cable As .
8T-8726	Adapter Cable As	This breakout t is for use between the jacks and the plugs of the sensors.
151-6320	Wire Removal Tool	This tool is used for the removal of pins and sockets from Deutsch connectors and AMP connectors.
1U-5804	Crimp Tool	This tool is used for work with CE electrical connectors.
9U-7330	Digital Multimeter	The multimeter is used for the testing and for the adjusting of electronic circuits.
7X-1710	Multimeter Probes	The probes are used with the multimeter to measure voltage in wiring harnesses without disconnecting the harnesses.
5P-7277	Voltage Tester	The tester is used to test for voltage in circuits, in relays, in bulbs, in wires, and in switches.

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^( 1 )

This item is included in the 171-4400 Communication Adapter Gp .

The Cat^® Electronic Technician (ET) is designed to run on a personal computer. Either of the listed communication adapters can be used for the communication between the Cat Data Link and the RS-232 serial port. However, the 7X-1700 Communication Adapter Gp is no longer serviced. For more information on the communication adapters, refer to the literature that is provided with the adapters.

Cat ET can display the following information:

Parameters
Diagnostic codes
Event codes
Engine configuration
Status of the monitoring system

Cat ET can perform the following functions:

Diagnostic tests
Sensor calibration
Flash downloading
Set parameters

Connecting Cat ET with the 171-4401 Communication Adapter II

The battery supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET to the ECM.

Turn the engine control switch to the OFF/RESET position.

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Illustration 1	g00694774
(1) PC (2) 196-0055 Serial Cable or the 160-0141 Serial Cable (3) 171-4401 Communication Adapter II (4) 207-6845 Adapter Cable (5) 7X-1414 Data Link Cable (Required with MIDS Panel, but NOT required with new Advisor Panel)

Connect cable (2) to the RS-232 serial port of PC (1) .

Connect cable (2) to communication adapter (3) .

Connect cable (4) to communication adapter (3) .

Connect cable (4) to cable (5) .

Connect cable (5) to the service tool connector on the engine mounted terminal box. Alternatively, connect the cable to the service tool connector on the optional control panel.

Turn the engine control switch to the STOP position. The engine should be OFF.
If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, RENR5910, "Electronic Service Tool Will Not Communicate".

Terminal Box

Note: The terminal box is designed to remain mounted on the engine. The mounting hardware includes isolators which minimize the engine vibrations that are transmitted to the components within the terminal box. Do not move the terminal box to a remote location. Moving the terminal box could result in wiring problems and in reduction of the electronic control module service life.

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Illustration 2	g00891827
Terminal box

The engine mounted terminal box is located on the rear right side of the engine. The ECM is inside the terminal box. The terminal box provides the point of termination for all of the wiring that is related to the engine sensors and for the ignition system. The terminal box components are identified in Illustrations 3 and 4.

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Illustration 3	g01144328
Inside of the terminal box (J2/P2) 70-pin connectors for the ECM (J1/P1) 70-pin connectors for the ECM (1) Ground strap (2) Terminal for the negative connection (24 VDC) (J7) 9-pin service tool connector (F1) 6 amp fuse (F2) 15 amp fuse (J3/P3) 70-pin connectors for the customer wiring (Removed mid 2015 since J4 performs similar function) (3) Ignition wiring for the left side of Vee engines (J6/P6) 70-pin connectors for the sensors on the left side of the engine (J5/P5) 70-pin connectors for the sensors on the right side of the engine (4) Ignition wiring for In-line engine and for the right side of Vee engines (J4) 47-pin connector for the optional control panel or for a customer connector (5) Wiring for the electrical power

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Illustration 4	g00891953
Front and bottom of the terminal box (J6) 70-pin connector for the sensors on the left side of the engine (J5) 70-pin connector for the sensors on the right side of the engine (J4) 47-pin connector for the optional control panel or for a customer connector (6) Emergency stop button (7) 27.5 mm (1.08 inch) hole for the ignition wiring on the left side of Vee engines (8) 27.5 mm (1.08 inch) hole for the ignition wiring for In-line engines and for the right side of Vee engines (9) 27.5 mm (1.08 inch) hole for the electrical power supply and/or for the customer wiring to the 70-pin connector (P3)

Note: Holes (7), (8), and (9) will accommodate a conduit with an inner diameter of 19 mm (3/4 inch). If the customer connects to the 70-pin connector (P3) in the terminal box, hole (9) may require enlargement.

Optional Control Panels

A choice of 2 different control panels that are installed remotely from the engine are available as an option. The MIDS control panel features are shown in Illustration 5. For details on the MIDS panel features, refer to Operation and Maintenance Manual, SEBU7563, "Control Panel".

The second control panel is the Advisor panel which previously had only been available on G3500 engines. The control module inside this panel is about five years newer than the MIDS and offers all of the same functionality as the MIDS with additional benefits including:

Cleaner package with the Product Link integrated inside the panel instead of remotely mounted on the engine. Thus, no need for external Ethernet wiring on the engine.
Some key items such as BTU content and specific gravity can be programmed directly with a custom password and without the need for an external connection to Cat ET.
Status LED's are integrated into the left buttons
Faster Display update
Four Navigation buttons on the right side of the display eliminate the need for a keypad

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Illustration 5	g01142577
Control panel (1) Display (2) Keypad (3) "EMERGENCY STOP" button (4) "ENGINE ON" indicator (5) "ACTIVE ALARM" indicator (6) "ENGINE FAILURE" indicator (7) "MANUAL PRELUBE" switch and "PRELUBE ACTIVE" indicator (8) Engine control switch (9) "DESIRED SPEED" potentiometer (10) 9-pin service tool connector

Dimensions for mounting of the control panel are shown in Illustration 6.

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Illustration 6	g01142607
Dimensions of the optional control panel

Connecting a Control Panel or a PLC to the ECM

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Illustration 7	g00891835
(J3) 70-pin receptacle for a customer connection (Removed mid 2015 since J4 performs similar functions (J4) 47-pin receptacle for the optional control panel or for a customer connection

The engine mounted terminal box has two receptacles that are wired to the ECM: 70-pin receptacle (J3) for a customer connection and 47-pin receptacle (J4) for the optional control panel or for a customer connection. Either of the receptacles or both of the receptacles may be used to communicate with the ECM.

There are several different possible configurations for connecting to the ECM. The method that is selected depends on the needs of the customer.

Connecting the Optional Control Panel to the Engine Mounted Terminal Box

Interconnect wiring harnesses of different lengths are available for connecting the optional control panel to the engine mounted terminal box. These harnesses are recommended for use with the control panel. The harnesses are listed in Table 3.

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Table 3
Interconnect Wiring Harnesses for the Optional MIDS Control Panel
Part	Length
206-6543 Harness	6.1 m (20 ft)
205-3584 Harness	15.9 m (52 ft)
206-6544 Harness	30.5 m (100 ft)
Interconnect Wiring Harnesses for the Optional Advisor Control Panel
Part	Length
480-3833 Harness	15.9 m (52 ft)
480-3834 Harness	30.5 m (100 ft)

Each harness has a 47-pin plug for connecting the harness to the J4 receptacle on the bottom of the engine mounted terminal box. The plug is attached to an adapter for a conduit that has a diameter of 3.8 cm (1 1/2 inch). The other end of the harness is routed through an access hole in the bottom of the control panel to the terminal strip. The hole in the bottom of the control panel is for a conduit that has a diameter of 3.8 cm (1 1/2 inch).

If the customer needs additional wiring to the control panel terminal strip, a cutout through the bottom right side of the box is recommended. The cutout provides convenient access to the terminal strip.

If the customer wishes to fabricate an interconnect wiring harness, these necessary parts can be obtained separately: 9X-4187 Connector Plug and 213-4749 Adapter . The minimum recommended size of wire is 16 AWG.

The plug, the adapter, and the interconnect harness are identified in Illustration 8. The Illustration shows a typical installation of a conduit between the control panel and the engine mounted terminal box.

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Illustration 8	g00891879
(1) Engine mounted terminal box (2) Optional control panel (MIDS or Advisor) (3) 9X-4187 Connector Plug (4) 213-4749 Adapter (5) Interconnect wiring harness

Connecting a Customer Supplied Control Panel or a Customer Supplied Programmable Logic Controller (PLC) to the Engine Mounted Terminal Box

Illustration 9 shows a typical example for connecting the customer equipment to the 47-pin receptacle on the bottom of the engine mounted terminal box. Plug (3) and adapter (4) must be used. The interconnect wiring harness can be supplied by the factory or by the customer.

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Illustration 9	g00891899
(1) Engine mounted terminal box (2) Customer supplied control panel or PLC (3) 9X-4187 Connector Plug (4) 213-4749 Adapter (5) Interconnect wiring harness

Illustration 10 shows a typical example for connecting the customer equipment to the 70-pin plug P3 inside of the engine mounted terminal box. The hole through the bottom of the terminal box may require enlargement in order to accommodate all of the wiring.

Note: The P3/J3 and associated circuits were removed in mid 2015. Refer to Illustration 9 and ""Connecting a Customer Supplied Control Panel or a Customer Supplied Programmable Logic Controller (PLC) to the Engine Mounted Terminal Box" " for the connection to the J4 which provides similar functionality.

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Illustration 10	g00891966
This option is not available after mid 2015 when the P3/J3 connector was eliminated. (1) Engine mounted terminal box (2) Customer supplied control panel or PLC (P3) 70-pin plug for the customer wiring (Removed mid 2015)

Connecting a Customer Supplied Control Panel or a Customer Supplied Programmable Logic Controller (PLC) to the Terminal Box or to the Control Panel

Illustration 11 shows a typical example for connecting the customer equipment to the optional control panel. With this configuration, the customer equipment communicates with the ECM via the terminal strip in the control panel and via the interconnect wiring harness. In this case, a hole is cut through the bottom of the control panel box. A cutout through the bottom right side of the box is recommended in order to provide convenient access to the terminal strip.

Plug (4) and adapter (5) must be used. The interconnect wiring harness (6) can be supplied by the factory or by the customer.

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Illustration 11	g00891974
(1) Engine mounted terminal box (2) Optional control panel (MIDS or Advisor) (3) Customer supplied control panel or PLC (4) 9X-4187 Connector Plug (5) 213-4749 Adapter (6) Interconnect wiring harness

Illustration 12 shows a typical example for connecting the customer equipment to the 70-pin plug P3 inside of the engine mounted terminal box. The hole through the bottom of the terminal box may require enlargement in order to accommodate all of the wiring.

The optional control panel is connected to the 47-pin receptacle on the bottom of the engine mounted terminal box. Plug (4) and adapter (5) must be used. The interconnect wiring harness (6) can be supplied by the factory or supplied by the customer.

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Illustration 12	g03866575
This option is not available after mid 2015 when the P3/J3 connector was eliminated. (1) Engine mounted terminal box (2) Optional control panel (3) Customer supplied control panel or PLC (P3) 70-pin plug for the customer wiring (4) 9X-4187 Connector Plug (5) 213-4749 Adapter (6) Interconnect wiring harness

Customer Wiring

For the wiring requirements of the specific application, the customer must be aware of several inputs and outputs that are associated with the ECM. The following list includes some examples of the inputs and outputs:

Emergency stop
Engine oil level switch and coolant level switch
Electrical power supply for the control system
Start-up and shutdown
Status of engine operation
Engine speed and governing

Interconnect wiring harnesses that are supplied by the factory include the wiring for most of the customer inputs and outputs. Each wiring harness is complete with a 47-pin plug for the J4 connector on the bottom of the terminal box. The terminals on the plug and the corresponding wires are identified in Illustration 13. The functions of the wires are identified in Tables 12, 14, and 15.

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Illustration 13	g01206152
Identification of the interconnect wiring harness terminals and wiring

Wiring for the Emergency Stop Circuit

The emergency stop buttons must be wired in order to stop the engine in case of an emergency situation. An emergency stop button is provided on the engine mounted terminal box and on the optional control panel.

If an emergency stop is activated, the fuel is immediately shut off. Electrical power to the ignition system is immediately removed. The postlube cycle does not operate.

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NOTICE

Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

The terminal box and the optional control panel are equipped with emergency stop buttons. The customer may supply additional emergency stop buttons. Any additional customer supplied emergency stop buttons must be wired in series in order to operate properly. Operation of all emergency stop buttons must be verified prior to the initial start-up.

Note: T-35 is the recommended return for the emergency stop circuit. If the return is going to T-31, the emergency stop circuit needs rewired to T-35.

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Illustration 14	g00892177
Components in the emergency stop circuit (J1/P1) 70-pin ECM connectors (J3/P3) 70-pin customer connectors (Removed mid August 2015) (J4/P4) 47-pin connectors for the optional control panel or for a customer connection (1) Terminal strip in the optional control panel

Illustration 15 is a wiring diagram of the emergency stop button on the engine mounted terminal box.

If the customer does not use the 70-pin P3 connector, the factory installed jumper wire between terminals P3-24 and P3-25 is necessary.

If the customer does not use the P4 connector, a jumper wire must be installed between terminals P3-48 and P3-49.

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Illustration 15	g03868835

Illustration 16 is a wiring diagram of the emergency stop button on the engine mounted terminal box. The Illustration includes an additional customer supplied emergency stop button attached to the P3 connector. The factory installed jumper wire between terminals P3-24 and P3-25 is removed.

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Illustration 16	g03868836

Illustration 17 is a wiring diagram of the emergency stop buttons on the engine mounted terminal box and on the optional control panel.

The optional control panel has a factory installed jumper wire between terminals 10 and 11. If the customer connects another emergency stop button to the control panel, the jumper wire must be removed.

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Illustration 17	g03868838

Illustration 18 is a wiring diagram of the emergency stop buttons on the engine mounted terminal box and on the optional MIDS control panel. Additional customer supplied emergency stop buttons are connected to the terminal box and to the control panel. The factory installed jumper wire between terminals 10 and 11 on the terminal strip is removed. The factory installed jumper wire between terminals P3-24 and P3-25 is removed.

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Illustration 18	g03868839

Wiring for an Engine Oil Level Switch and for a Coolant Level Switch

The ECM has one switch input that serves both an engine oil level switch and a coolant level switch. The switches are optional. The switches may be supplied by the factory or supplied by the customer.

The switches are installed by the customer. If the switches are used, operation of the switches must be verified prior to the initial start-up.

When fluid is not present, the engine oil level switch and the coolant level switch have normally open contacts.

The switch input to the ECM must be closed in order to run the engine.

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Illustration 19	g00902902
Right side view Engine harness connector for the engine oil level switch and the coolant level switch (In-line engines)

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Illustration 20	g00902969
Right side view Engine harness connector for the engine oil level switch and the coolant level switch (Vee engines)

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Illustration 21	g00892267
Components in the circuit for the engine oil level switch and the coolant level switch (J2/P2) 70-pin ECM connectors (J3/P3) 70-pin customer connectors (Removed mid 2015) (J5/P5) 70-pin connectors for the wiring harness on the right side of the engine

If the switches are not used, install jumper wires according to the wiring diagram in Illustration 32.

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Illustration 22	g01142669

If the switches are supplied by the factory, the switches will be connected to this engine harness. In this case, jumper wires must be installed between terminals J3-56 and J3-57 and between J3-69 and J3-70. Illustration 23 is a wiring diagram that shows the connection of the switches to the engine harness.

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Illustration 23	g01142742

If the switches are connected to the J3 customer connector, install jumper wires between terminals 3 and 4 and between terminals 2 and 1. Illustration 24 shows the connection of the switches to the P3 customer connector.

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Illustration 24	g01142842

Wiring for the Emergency Stop Circuit without the P3/J3 Connector

If an emergency stop is activated, the fuel is immediately shut off. Electrical power to the ignition system is immediately removed. The postlube cycle does not operate.

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NOTICE

Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

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Illustration 25	g03867670
Components in the emergency stop circuit (J1/P1) 70-pin ECM connectors (J4/P4) 47-pin connectors for the optional control panel or for a customer connection (1) Terminal strip in the optional control panel

Illustration 26 is a wiring diagram of the emergency stop buttons on the engine mounted terminal box and on the optional MIDS control panel.

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Illustration 26	g03867674
MIDS panel

Illustration 27 is a wiring diagram of the emergency stop buttons on the engine mounted terminal box and on the optional Advisor control panel. Additional customer supplied emergency stop buttons are connected to the terminal box and to the control panel. The factory installed jumper wire between terminals 28A and 28B on the terminal strip is removed.

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Illustration 27	g03867676
Advisor panel

Wiring for an Engine Oil Level Switch and for a Coolant Level Switch without the P3/J3 Connector

The switches are installed by the customer. If the switches are used, operation of the switches must be verified prior to the initial start-up.

When fluid is not present, the engine oil level switch and the coolant level switch have normally open contacts.

The switch input to the ECM must be closed in order to run the engine.

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Illustration 28	g00902902
Right side view Engine harness connector for the engine oil level switch and the coolant level switch (In-line engines)

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Illustration 29	g00902969
Right side view Engine harness connector for the engine oil level switch and the coolant level switch (Vee engines)

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Illustration 30	g03867712
Components in the circuit for the engine oil level switch and the coolant level switch (J2/P2) 70-pin ECM connectors (J5/P5) 70-pin connectors for the wiring harness on the right side of the engine

If the switches are not used, install jumper wires according to the wiring diagram in Illustration 31.

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Illustration 31	g03867717

If the switches are supplied by the factory, the switches will be connected to this engine harness. In this case, jumper wires must be installed between terminals J3-56 and J3-57 and between J3-69 and J3-70. Illustration 32 is a wiring diagram that shows the connection of the switches to the engine harness.

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Illustration 32	g03867719

Monitoring the Mode of the Engine Control Switch

If the optional control panel is used, the customer can perform the start/stop control with the control panel.

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Illustration 33	g00892917
Terminal strip in the control panel

Certain terminals on the control panel terminal strip can be monitored in order to determine the position of the engine control switch. The output from the terminals is provided to the ECM. The customer can connect wiring from the terminals to a device that monitors the mode of the engine control switch. The positions of the engine control switch and the corresponding terminals are identified in Tables 4 and 5.

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Table 4
Positions of the Engine Control Switch and Corresponding Terminals in the Optional MIDS Control Panel
Position of the Engine Control Switch	Corresponding Closed Terminals
Off/Reset	27 and 26
Stop	30 and 26
Start	29 and 26
Auto	28 and 26

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Table 5
Positions of the Engine Control Switch and Corresponding Terminals in the Optional Advisor Control Panel
Position of the Engine Control Switch	Corresponding Closed Terminals
Off/Reset	No Connection
Stop/Cool Down	31
Start	16
Auto	24

ECM Outputs

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Table 6
ECM Outputs
Description	Options for Customer Connections			Interconnect Wiring Harness	Functions and Comments
Description	J3	J4	Optional MIDS Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
Engine Failure	9	P	17	P908-BK	This output is activated if the ECM requests an engine shutdown. Normally, the output circuit is open. If the output is activated, the output is grounded. The "ENGINE FAILURE" indicator on the optional control panel is illuminated. The sinking driver can absorb a maximum of 0.3 A.
Active Alarm	8	H	16	P907-BK	This output is activated if the ECM detects an alarm condition. Normally, the output circuit is open. If the output is activated, the output is grounded. The "ACTIVE ALARM" indicator on the optional control panel is illuminated. The sinking driver can absorb a maximum of 0.3 A.
Run Relay	19	Z	14	M040-BK	This output is activated when the engine is cranked. The output remains active until the beginning of an engine shutdown. Normally, the output circuit is open. When the output is activated, the output is grounded. The "ENGINE ON" indicator on the optional control panel is illuminated. The sinking driver can absorb a maximum of 0.3 A.
Crank Terminate	7	C	15	P906-BK	This output is activated when the engine crank terminate speed is achieved. Typically, the crank terminate speed is 250 rpm. The output remains active until the engine speed is reduced to 0 rpm. Normally, the output circuit is open. When the output is activated, the output is grounded. The optional control panel does not have an indicator for this output. The sinking driver can absorb a maximum of 0.3 A.
Gas Shutoff Valve Voltage	60	m	20	A330-RD	This output is activated when the pressure switch for the electrohydraulic actuator system closes. The gas shutoff valve (GSOV) is energize-to-run. To enable fuel flow to the engine, voltage is supplied to the solenoid for the GSOV. The voltage is removed for an engine shutdown and the output is deactivated. The circuit driver can supply 2.0 A at 24 VDC. The output can be used to provide a signal for control of multiple valves that are installed by the customer. Alternatively, the signal can be used by the customer monitoring system.
Prelube Valve Voltage	59	c	19	A320-RD	This output is activated when the ECM requests operation of the prelube pump. The circuit driver can supply 2.0 A at 24 VDC to the prelube pump solenoid. When the output is activated, the "PRELUBE ON" indicator on the optional control panel is illuminated. The output can be used to provide a signal for control of multiple valves that are installed by the customer. Alternatively, the signal can be used by the customer monitoring system.
Auxiliary 2 Amp Positive Output	5	j	12	A340-RD	Auxiliary Out + (2 A)
Auxiliary 2 Amp Return	6	u	13	A340-BK	Auxiliary Out - (2 A)
4 to 20 mA positive Output #1	28	G	44	X100A-GY	4 mA to 20 mA (+) Output 1
4 to 20 mA Negative Output #1	29	M	45	X100B-GY	4 mA to 20 mA (-) Output 1
4 to 20 mA Positive Output #2	30	W	46	X100C-GY	4 mA to 20 mA (+) Output 2
4 to 20 mA Negative Output #2	31	f	47	X100D-GY	4 mA to 20 mA (-) Output 2
PWM Output 1	36	k	48	X110B-GY	This output is temporarily used by the integrated combustion sensing module. At the time of this publication, the output is unused. The wire is disconnected from the ECM.
PWM Output 2	37	s	49	X110A-GY	PWM Output 2
Spare 01	38	t	52	SP01-GY	Spare wire
Spare 02	39	v	53	SP02-GY	Spare wire
Spare 03	52	R	50	X273-GY	Spare wire
Desired Analog Speed (+5 V Supply)	10	N	36	X171-RD	The preferred method for the desired speed input must be selected with Cat ET. The optional control panel has the appropriate analog speed potentiometer. The wiring must be installed according to the information in this Table. The ECM provides the +5 V supply to the potentiometer. The potentiometer provides the signal input for the desired speed. The signal input ranges from 0 to 5 V. The potentiometer signal must be in the same circuit as the return. The cable shield must be connected to the signal return.
Desired Analog Speed Signal	11	X	37	X173-WH
Desired Analog Speed Signal Return	12	g	38	X172-BK
Desired Analog Speed Signal Shield	13	p	39	X170-CU

Optional ECM 4 to 20 mA Inputs

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Table 7
ECM 4 to 20 mA Inputs
Description	Options for Customer Connections			Interconnect Wiring Harness	Functions and Comments
Description	J3	J4	Optional MIDS Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
4 to 20 mA Desired Speed (Input)	20	E	40	X183A-GY	The 4 to 20 mA is an optional method for providing the desired speed input. The preferred method for the desired speed input must be selected with the Cat ET. The potentiometer on the optional control panel (if equipped) must be disabled. The 4 to 20 mA is an isolated input. The positive "+" input must be in the same circuit as the negative "-" return.
4 to 20 mA Desired Speed (Return)	21	J	41	X183B-GY
4 to 20 mA Remote Desired Fuel Quality Btu (Input)	22	S	42	X000A-GY	The 4 to 20 mA input for providing remote Btu input. The 4 to 20 mA input for providing remote Btu input return line. This optional input can be used at sites with varying fuel quality. The 4 to 20 mA is an isolated input. The Positive "+" input must be in the same circuit as the negative "−" return.
4 to 20 mA Remote Desired Fuel Quality Btu (Return)	23	b	43	X000B-GY

Customer Inputs

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Table 8
Customer Inputs to the ECM
Description	Options for Customer Connections			Interconnect Wiring Harness	Functions and Comments
Description	J3	J4	Optional MIDS Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
+Battery Supply	-	z	1	P100-RD	This connection is not available on the J3 connector. The circuit for the customer +24 VDC must provide a minimum of 20 A. The sinking return must absorb a minimum of 20 A. There are two methods for connecting the 24 VDC power supply for the engine control system: The 24 VDC power supply can be connected directly to the 15 amp fuse in the engine mounted terminal box. If this method is selected, connect the negative side to the terminal immediately above the 15 amp fuse. The 24 VDC power supply can be connected to terminal 1 in the optional control panel. Connect the negative return to terminal 2. Also, connect the P100-RD wire in the engine mounted terminal box to the power supply side of the 15 amp fuse.
-Battery Return	-	x	2	P300-BK
Idle/Rated Input	40	d	22	M030-BK	When the engine oil pressure is greater than the setpoint for the engine speed and this input is grounded to the -Battery side, the ECM senses the grounding of the input. The engine operates at the setting for the desired speed. When this input is not grounded to the -Battery side, the engine operates at the setting for the low idle speed.
Auxiliary Governor Gain	34	n	24	M020-BK	The settings for the governing are adjusted during the engine commissioning and during the initial start-up. The auxiliary governing is used primarily for generator sets. When the "Grid Status" is ON and this input is grounded to the -Battery side, the ECM senses the grounding of the input. The ECM governs the engine according to the settings for the auxiliary governing. When this input is not grounded to the -Battery side, the ECM governs the engine according to the settings for the primary governing.
Driven Equipment Input	32	U	21	M000-BK	When the engine is not running, the customer equipment grounds this wire to the -Battery side. The ECM senses the grounding of the wire and the ECM permits the engine to be ready for start-up. If this input is not grounded, the driven equipment is considered to be NOT ready and the engine cannot be cranked. The ECM generates an event code if this input is not grounded within the programmed delay time. When the engine is running, this input normally continues to be grounded. If the engine is running and this input is disconnected from the ground, the ECM immediately generates an event code and an engine shutdown. Because the cooldown is not performed, do not use this input for normal shutdown.
Engine Control Switch (ECS) OFF/RESET	-	-	-	-	These functions can be controlled by the ECS on the optional control panel or by customer equipment. If these inputs are not wired correctly, the ECM will generate a diagnostic code. If these inputs are controlled by the customer equipment, the transitions between the inputs must occur within 1/10 of a second. All of the positions of the ECS must return through the P500-BK wire for the digital return. When the ECS is in the "OFF/RESET" position, the keyswitch power is removed. The start, stop, and auto inputs to the ECM are open. When the ECS is in the "STOP" position, the keyswitch power is available. The ECM input for the stop function is grounded to the digital return. If the engine is running and the ECS is turned to the "STOP" position, the sequence for a normal shutdown is initiated. If the cooldown is programmed, the engine operates for the cooldown period prior to shutdown. When the ECS is in the "START" position, the keyswitch power is available. The start input to the ECM is grounded to the digital return. The normal sequence for start-up is initiated. When the start input is removed, a normal shutdown is initiated. If the cooldown is programmed, the engine operates for the cooldown period prior to shutdown. When the ECS is in the "AUTO" position, the keyswitch power is available and the auto input is activated. This position is used for a remote start-up that is supplied by the customer. The remote start input will only function when the auto input is activated. The remote start input to the ECM must be grounded to the digital return. There are two methods for wiring the remote start input: One method is connecting between terminals 17 and 43 in the J3 customer connector. The other method is connecting terminals 6 and 8 on the terminal strip in the optional control panel. When either method is used, the normal sequence for start-up is initiated. When the remote start input is removed, a normal shutdown is initiated. If the cooldown is programmed, the engine operates for the cooldown period prior to shutdown.
ECS STOP	14	O	5	P913-BK
ECS START	16	h	6	P915-BK
ECS AUTO	15	Y	7	P914-BK
Remote Start Input	17	h	6	P915-BK
Digital Return	43	r	8	P500-BK
Normal Stop	26	K	25	M010-BK	Because the cooldown will not operate for this input, this input is not recommended for normal shutdown. The functions of the ECS are recommended for normal shutdown. This input is currently connected to the -Battery side via a jumper wire that is internal to the wiring harness. This input must be connected to the -Battery side in order for the engine to operate. When the input is removed from the ground, the following shutdown sequence occurs: Power is removed from the GSOV and the fuel is shut off. Power is removed from the ignition system when the engine speed is reduced to less than 50 rpm. The postlube occurs. The cooldown does not operate.
Multi Strike Enable	62	a	51	X283-GY	This input is used to enable the Multi Strike feature. When this feature is ON, the ECM will send two ignition pulses to the transformer for each cycle of combustion. Multi Strike is typically used in low Btu applications. When this input is grounded to −Battery, the engine will operate in Multi Strike.

Other Wiring Connections

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Table 9
Other Wiring Connections
Description	Options for Customer Connections			Interconnect Wiring Harness	Functions and Comments
Description	J3	J4	Optional MIDS Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
Fused 6 Amp +Battery	1	y	3	P600-RD	This connection provides the fused 24 VDC power supply (6 amp) for these functions: Cat ET Customer Communication Module (CCM) Engine Control Switch (ECS) Keyswitch power for the ECM and for the optional control panel Status indicators on the optional control panel Manual prelube switch
Keyswitch Power	4	w	4	P700-RD	The keyswitch power is available when the ECS is at the "STOP" position, at the "START" position, or at the "AUTO" position. The fused 24 VDC power supply (6 amp) is available to these components: ECM Air/fuel pressure module Integrated combustion Sensing Module (ICSM) Optional control panel
Cat Data Link +	67	D	31	CL100-PK	These connections provide the means for communicating the status of the engine control system, of various engine components, and of sensors. The Cat Data Link can be connected to the CCM. For information on connecting the CCM, refer to the most recent literature for the CCM. When the Caterpillar software for the CCM is loaded on a PC, the program uses this data link to obtain engine information via the CCM.
Cat Data Link -	66	l	32	CL100-PU
CAN Data Link +	63	F	33	CL200-YL	At the time of this publication, this option is not available. These connections are designed to provide the means for communicating the status of the engine control system, of various engine components, and of sensors. This data link conforms to the "CAN Data Link 2.0 Hardware Standard" and the "J1939 Software Standard".
CAN Data Link −	64	L	34	CL200-GN
CAN Data Link Shield	65	V	35	CL200-BU
Manual Prelube	58	T	18	C290-RD	If the optional control panel is used, the manual prelube switch on the control panel can be operated when the ECS is in the "STOP" position. If the prelube is controlled by the customer equipment, the function can be activated by providing a 24 VDC power supply to the input. Activation of the manual prelube switch or of the 24 VDC power supply will cause the prelube pump to operate. The pump will operate until the switch for prelube oil pressure closes. If either method continues to activate the input, the prelube pump will operate again when the switch for prelube oil pressure opens.
Second Timing	42	e	23	M050-BK	This function is not available for G3600 Engines. Do not attempt to wire this connection.
Emergency Stop	24	B	9	C256B-BK	For details, refer to ""Wiring for the Emergency Stop Circuit" ".
Emergency Stop Return	25	A	10	C256C-BK

Procedure for Connecting the Desired Speed Input from the Load Sharing Module

There are two options for wiring the 202-4869 Governor Control input to the G3600 engine. The desired speed input can be connected to a terminal strip inside the optional control panel. The input can also be connected to a connector that is inside the engine mounted terminal box.

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Illustration 34	g01022340
202-4869 Governor Control (1) Terminal 19 is the positive terminal. (2) Terminal 20 is the negative terminal.

The desired speed signal from the 202-4869 Governor Control is available at terminals 19 and 20. Use shielded twisted pair cable in order to make the connection.

Connecting to the Optional MIDS Control Panel

Perform the following procedure in order to connect the desired speed signal to the optional control panel.

Remove electrical power from the engine.

Open the control panel. The connections for the desired speed signal are on terminals 37, 38, and 39.

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Illustration 35	g01022372
Terminals 37, 38, and 39 inside the optional control panel

Six wires are connected to the left side of terminals 37, 38, and 39. Disconnect the three wires that are connected between the left side of terminals 37, 38, and 39 and the speed potentiometer.
The other three wires that are connected to the left side of terminals 37, 38, and 39 are routed to the engine. These three wires must remain connected.

Insulate the ends of the disconnected wires in order to ensure that the wires do not create a short circuit.

Perform these steps in order to connect the new wiring:
1. Connect the shield to terminal 39.
1. Connect the remaining two wires to terminals 37 and 38.

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Illustration 36	g01156366
Schematic diagram for the connection between the governor control and the optional control panel

Refer to Illustration 36. Perform these steps in order to connect the wiring to the governor control:
1. Connect the wire from terminal 37 in the control panel to terminal 19 on the governor control.
1. Connect the wire from terminal 38 in the control panel to terminal 20 on the governor control.
  Note: The wire for the shield has no connection at the governor control.

Restore electrical power to the engine.

Engine Mounted Terminal Box

Perform the following procedure in order to connect the desired speed signal to the engine mounted terminal box.

Remove electrical power from the engine.

Open the optional control panel. The connections for the desired speed signal are on terminals 37, 38, and 39.

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Illustration 37	g01022372
Terminal strip for the optional control panel Terminals 37, 38, and 39 inside the control panel

Disconnect the six wires that are connected to the left side of terminals 37, 38, and 39.
Disconnection of the wires disconnects the wiring for the desired speed potentiometer on the control panel. The wiring from those terminals to the engine is effectively disconnected.

Insulate the ends of the wires in order to ensure that the wires do not create a short circuit.

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Illustration 38	g01022374
Connector J3 inside the engine mounted terminal box

Perform the following steps in order to connect the new wiring to the P3 connector:
1. Crimp a 8T-8730 Connector Socket onto the ends of the wires that will be connected to the P3 connector:
1. Connect the shield to terminal P3-13.
1. Connect the remaining two wires to terminals P3-11 and to P3-12.

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Illustration 39	g01023100
Schematic diagram for the connection between the governor control and the engine mounted terminal box

Refer to Illustration 39. Perform these steps in order to connect the wiring to the governor control:
1. Connect the wire from terminal J3-11 to terminal 19 on the governor control.
1. Connect the wire from terminal J3-12 to terminal 20 on the governor control.
  Note: The wire for the shield has no connection at the governor control.

Restore electrical power to the engine.

Remote Advisor Panel

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Illustration 40	g03863090
Dimensions and components of the remote panel (3) Advisor monitor display (4) Manual prelubrication switch and indicator (5) Emergency stop button (6) Engine control (7) Desired speed potentiometer (8) Service tool connector

The remote Advisor Panel provides the following capabilities:

Emergency stop
Engine control
Advisor monitor display
Desired engine speed
Manual pre-lubrication
Indication of alarms, de-rates, and shutdowns via the Advisor monitor display

Make the connections to the remote panel according to the following procedure:

Refer to "Interconnect Harness". Route the interconnect harness from the ECM interface box to the remote panel. Make the connections for the interconnect harness inside the interface box.
Note: The wires and the cables that make up the interconnect harness may be cut to the appropriate length, if necessary. Do not cut all of the wires and the cables at the same time. Cut one wire and connect the wire to the appropriate location on the terminal strip. The practice is important when a cable that contains several wires is cut. The cable does not have an external marking that identifies the cable. Cut the cable. Then slide the appropriate heat shrink circuit identification tube into the end of each wire in the cable. This technique helps to ensure that each connection is made correctly.
1. Select a wire. Identify the location on the terminal strip for the wire. Refer to Table 6
1. Cut the wire to the appropriate length.
1. Slide the appropriate heat shrink tube onto the end of the wire. Shrink the tube onto the wire.
1. Attach the wire end that is the appropriate gauge onto the end of the wire.
1. Refer to Illustration 41. Make the connections for the interconnect harness on the left side of the terminal strip. Insert the wire end into the appropriate location on the terminal strip. Pull on the wire in order to verify that the connection is secure.

Perform the following procedure to connect the wiring from the driven equipment.

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Illustration 42	g03869139
Location for the customer connection inside the remote panel

Note: T13 and T14 are reserved for Product Link CAT data link + and CAT data link - (Factory Connections).

Note: T35, T36, and T38 are reserved for Product Link CAN data link + and CAN data link -. CAN data link is for factory use only.

Refer to Illustration 42. Make the connections for the driven equipment on the right side of the terminal strip. Table 3 lists the connections that are available.

Wiring for the Emergency Stop Circuit

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Illustration 43	g03867733
Emergency stop circuit with an additional emergency stop button

The circuit for the emergency stop buttons is complete when the remote panel is installed. An additional emergency stop button may be added to the circuit. Refer to Illustration 43. Remove the bridge and connect the additional button according to the Illustration.

Wiring for the Gas Shutoff Valve

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Illustration 44	g03867734
Circuit for the gas shutoff valve

Inputs for the Engine Mode of Operation when Advisor Panel is Used

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Table 10
Valid Configurations of the Terminals on the Customer Connector for Selection of the Engine Mode of Operation
Mode	Terminal P9-14	Terminal P9-15	Terminal P9-13
"OFF/RESET"	No ⁽¹⁾	No	No
"AUTO"	Yes ⁽²⁾	No	No
"START"	Yes	Yes	No
"START"	No	Yes	No
"COOL-DOWN/STOP"	No	No	Yes

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^( 1 )	The "No" indicates that the terminal is not connected to terminal 15.
^( 2 )	The "Yes" indicates that the terminal is connected to terminal 15.

The engine has four modes of operation. The mode of operation is determined by three inputs. The valid configurations of the inputs are described in Table 10.

The configurations that are not shown in Table 10 will activate a diagnostic code.

The transition between inputs must occur within 1/10 of a second. If the transitions do not occur within 1/10 of a second, a diagnostic code is activated.

"OFF/RESET Mode"

When none of the inputs are connected, the engine is in the "OFF/RESET" mode. Any active diagnostic codes are cleared.

"AUTO Mode"

When terminal 24 is connected to terminal 15, the engine is in the "AUTO" mode. The ECM is in standby. In the "AUTO" mode, terminal 16 controls both the engine start sequence and the shutdown sequence.

The engine start sequence is initiated when terminal 16 is connected to terminal 15. When terminal 16 is disconnected, the shutdown sequence is initiated.

"START Mode"

The engine start sequence begins when terminal 16 is connected to terminal 15.

"COOL-DOWN/STOP Mode"

Cool-down begins when terminal 16 is disconnected from terminal 15 and terminal 31 is connected to terminal 15. The cool-down is followed by the shutdown sequence.

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Illustration 45	g03863359
Backside of the Advisor Panel door

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Illustration 46	g03863358
Inside the Advisor Panel box

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Table 11
Positions of the Engine Control Switch and Corresponding Terminals in the Optional Advisor Control Panel
Position of the Engine Control Switch	Corresponding Closed Terminals
Off/Reset	No inputs are connected
Stop/Cool-Down	31 and 15
Start	16 and 15
Auto	24 and 15

ECM Outputs

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Table 12
ECM Outputs
Description			Interconnect Wiring Harness	Functions and Comments
Description	J4	Optional Advisor Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
Engine Failure	P	25	P908-BK	This output is activated if the ECM requests an engine shutdown. Normally, the output circuit is open. If the output is activated, the output is grounded. The "ENGINE FAILURE" indicator on the optional control panel is illuminated. The sinking driver can absorb a maximum of 0.3 A.
Active Alarm	H	20	P907-BK	This output is activated if the ECM detects an alarm condition. Normally, the output circuit is open. If the output is activated, the output is grounded. The "ACTIVE ALARM" indicator on the optional control panel is illuminated. The sinking driver can absorb a maximum of 0.3 A.
Run Relay	Z	29	M040-BK	This output is activated when the engine is cranked. The output remains active until the beginning of an engine shutdown. Normally, the output circuit is open. When the output is activated, the output is grounded. The "ENGINE ON" indicator on the optional control panel is illuminated. The sinking driver can absorb a maximum of 0.3 A.
Crank Terminate	C	27	P906-BK	This output is activated when the engine crank terminate speed is achieved. Typically, the crank terminate speed is 250 rpm. The output remains active until the engine speed is reduced to 0 rpm. Normally, the output circuit is open. When the output is activated, the output is grounded. The optional control panel does not have an indicator for this output. The sinking driver can absorb a maximum of 0.3 A.
Gas Shutoff Valve Voltage	m	30	A330-RD	This output is activated when the pressure switch for the electrohydraulic actuator system closes. The gas shutoff valve (GSOV) is energize-to-run. To enable fuel flow to the engine, voltage is supplied to the solenoid for the GSOV. The voltage is removed for an engine shutdown and the output is deactivated. The circuit driver can supply 2.0 A at 24 VDC. The output can be used to provide a signal for control of multiple valves that are installed by the customer. Alternatively, the signal can be used by the customer monitoring system.
Prelube Valve Voltage	c	33	A320-RD	This output is activated when the ECM requests operation of the prelube pump. The circuit driver can supply 2.0 A at 24 VDC to the prelube pump solenoid. When the output is activated, the "PRELUBE ON" indicator on the optional control panel is illuminated. The output can be used to provide a signal for control of multiple valves that are installed by the customer. Alternatively, the signal can be used by the customer monitoring system.
Auxiliary 2 Amp Positive Output	j	44	A340-RD	This output is provided for future expansion and the output is not presently available for use.
Auxiliary 2 Amp Return	u	45	A340-BK	This output is provided for future expansion and the output is not presently available for use.
4 to 20 mA positive Output #1	G	46	X100A-GY	This output is provided for future expansion and the output is not presently available for use.
4 to 20 mA Negative Output #1	M	47	X100B-GY	This output is provided for future expansion and the output is not presently available for use.
4 to 20 mA Positive Output #2	W	48	X100C-GY	This output is provided for future expansion and the output is not presently available for use.
4 to 20 mA Negative Output #2	f	49	X100D-GY	This output is provided for future expansion and the output is not presently available for use.
Desired Analog Speed (+5 V Supply)	N	6	X171-RD	The preferred method for the desired speed input must be selected with Cat ET. The optional control panel has the appropriate analog speed potentiometer. The wiring must be installed according to the information in this Table. The ECM provides the +5 V supply to the potentiometer. The potentiometer provides the signal input for the desired speed. The signal input ranges from 0 to 5 V. The potentiometer signal must be in the same circuit as the return. The cable shield must be connected to the signal return.
Desired Analog Speed Signal	X	7	X173-WH
Desired Analog Speed Signal Return	g	9	X172-BK
Desired Analog Speed Signal Shield	p	8	X170-CU

Optional ECM 4 to 20 mA Inputs

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Table 13
ECM 4 to 20 mA Inputs
Description			Interconnect Wiring Harness	Functions and Comments
Description	J4	Optional Advisor Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
4 to 20 mA Desired Speed (Input)	E	10	X183A-GY	The 4 to 20 mA is an optional method for providing the desired speed input. The preferred method for the desired speed input must be selected with the Cat ET. The potentiometer on the optional control panel (if equipped) must be disabled. The 4 to 20 mA is an isolated input. The positive "+" input must be in the same circuit as the negative "-" return.
4 to 20 mA Desired Speed (Return)	J	12	X183B-GY
4 to 20 mA Remote Desired Fuel Quality Btu (Input)	S	41	X000A-GY	The 4 to 20 mA input for providing remote Btu input. The 4 to 20 mA input for providing remote Btu input return line. This optional input can be used at sites with varying fuel quality. The 4 to 20 mA is an isolated input. The Positive "+" input must be in the same circuit as the negative "−" return.
4 to 20 mA Remote Desired Fuel Quality Btu (Return)	b	42	X000B-GY

Customer Inputs

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Table 14
Customer Inputs to the ECM
Description			Interconnect Wiring Harness	Functions and Comments
Description	J4	Optional Advisor Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
+Battery Supply	z	4a	P100-RD	This connection is not available on the J3 connector. The circuit for the customer +24 VDC must provide a minimum of 20 A. The sinking return must absorb a minimum of 20 A. There are two methods for connecting the 24 VDC power supply for the engine control system: The 24 VDC power supply can be connected directly to the 15 amp fuse in the engine mounted terminal box. If this method is selected, connect the negative side to the terminal immediately above the 15 amp fuse. The 24 VDC power supply can be connected to terminal 1 in the optional control panel. Connect the negative return to terminal 2. Also, connect the P100-RD wire in the engine mounted terminal box to the power supply side of the 15 amp fuse.
-Battery Return	x	40	P300-BK
Idle/Rated Input	d	22	M030-BK	When the engine oil pressure is greater than the setpoint for the engine speed and this input is grounded to the -Battery side, the ECM senses the grounding of the input. The engine operates at the setting for the desired speed. When this input is not grounded to the -Battery side, the engine operates at the setting for the low idle speed.
Auxiliary Governor Gain	n	43	M020-BK	The settings for the governing are adjusted during the engine commissioning and during the initial start-up. The auxiliary governing is used primarily for generator sets. When the "Grid Status" is ON and this input is grounded to the -Battery side, the ECM senses the grounding of the input. The ECM governs the engine according to the settings for the auxiliary governing. When this input is not grounded to the -Battery side, the ECM governs the engine according to the settings for the primary governing.
Driven Equipment Input	U	17	M000-BK	When the engine is not running, the customer equipment grounds this wire to the -Battery side. The ECM senses the grounding of the wire and the ECM permits the engine to be ready for start-up. If this input is not grounded, the driven equipment is considered to be NOT ready and the engine cannot be cranked. The ECM generates an event code if this input is not grounded within the programmed delay time. When the engine is running, this input normally continues to be grounded. If the engine is running and this input is disconnected from the ground, the ECM immediately generates an event code and an engine shutdown. Because the cooldown is not performed, do not use this input for normal shutdown.
Engine Control Switch (ECS) OFF/RESET	-	-	-	These functions can be controlled by the ECS on the optional control panel or by customer equipment. If these inputs are not wired correctly, the ECM will generate a diagnostic code. If these inputs are controlled by the customer equipment, the transitions between the inputs must occur within 1/10 of a second. All of the positions of the ECS must return through the P500-BK wire for the digital return. When the ECS is in the "OFF/RESET" position, the keyswitch power is removed. The start, stop, and auto inputs to the ECM are open. When the ECS is in the "STOP" position, the keyswitch power is available. The ECM input for the stop function is grounded to the digital return. If the engine is running and the ECS is turned to the "STOP" position, the sequence for a normal shutdown is initiated. If the cooldown is programmed, the engine operates for the cooldown period prior to shutdown. When the ECS is in the "START" position, the keyswitch power is available. The start input to the ECM is grounded to the digital return. The normal sequence for start-up is initiated. When the start input is removed, a normal shutdown is initiated. If the cooldown is programmed, the engine operates for the cooldown period prior to shutdown. When the ECS is in the "AUTO" position, the keyswitch power is available and the auto input is activated. This position is used for a remote start-up that is supplied by the customer. The remote start input will only function when the auto input is activated. The remote start input to the ECM must be grounded to the digital return. There are two methods for wiring the remote start input: One method is connecting between terminals 17 and 43 in the J3 customer connector. The other method is connecting terminals 6 and 8 on the terminal strip in the optional control panel. When either method is used, the normal sequence for start-up is initiated. When the remote start input is removed, a normal shutdown is initiated. If the cooldown is programmed, the engine operates for the cooldown period prior to shutdown.
ECS STOP	O	31	P913-BK
ECS START	h	16	P915-BK
ECS AUTO	Y	24	P914-BK
Remote Start Input	h	16	P915-BK
Digital Return	r	15	P500-BK
Normal Stop	K	19	M010-BK	Because the cooldown will not operate for this input, this input is not recommended for normal shutdown. The functions of the ECS are recommended for normal shutdown. This input is currently connected to the -Battery side via a jumper wire that is internal to the wiring harness. This input must be connected to the -Battery side in order for the engine to operate. When the input is removed from the ground, the following shutdown sequence occurs: Power is removed from the GSOV and the fuel is shut off. Power is removed from the ignition system when the engine speed is reduced to less than 50 rpm. The postlube occurs. The cooldown does not operate.
Multi Strike Enable	a	21	X283-GY	This input is used to enable the Multi Strike feature. When this feature is ON, the ECM will send two ignition pulses to the transformer for each cycle of combustion. Multi Strike is typically used in low Btu applications. When this input is grounded to −Battery, the engine will operate in Multi Strike.

Other Wiring Connections

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Table 15
Other Wiring Connections
Description			Interconnect Wiring Harness	Functions and Comments
Description	J4	Optional Advisor Control Panel Terminal Strip	Interconnect Wiring Harness	Functions and Comments
Fused 6 Amp +Battery	y	4b	P600-RD	This connection provides the fused 24 VDC power supply (6 amp) for these functions: Cat ET Customer Communication Module (CCM) Engine Control Switch (ECS) Keyswitch power for the ECM and for the optional control panel Status indicators on the optional control panel Manual prelube switch
Keyswitch Power	w	18	P700-RD	The keyswitch power is available when the ECS is at the "STOP" position, at the "START" position, or at the "AUTO" position. The fused 24 VDC power supply (6 amp) is available to these components: ECM Air/fuel pressure module Integrated combustion Sensing Module (ICSM) Optional control panel
Cat Data Link +	D	13	CL100-PK	These connections provide the means for communicating the status of the engine control system, of various engine components, and of sensors. The Cat Data Link can be connected to the CCM. For information on connecting the CCM, refer to the most recent literature for the CCM. When the Caterpillar software for the CCM is loaded on a PC, the program uses this data link to obtain engine information via the CCM.
Cat Data Link -	l	14	CL100-PU
CAN Data Link +	F	35	CL200-YL	At the time of this publication, this option is not available. These connections are designed to provide the means for communicating the status of the engine control system, of various engine components, and of sensors. This data link conforms to the "CAN Data Link 2.0 Hardware Standard" and the "J1939 Software Standard".
CAN Data Link −	L	36	CL200-GN
CAN Data Link Shield	V	38	CL200-BU
Manual Prelube	T	26	C290-RD	If the optional control panel is used, the manual prelube switch on the control panel can be operated when the ECS is in the "STOP" position. If the prelube is controlled by the customer equipment, the function can be activated by providing a 24 VDC power supply to the input. Activation of the manual prelube switch or of the 24 VDC power supply will cause the prelube pump to operate. The pump will operate until the switch for prelube oil pressure closes. If either method continues to activate the input, the prelube pump will operate again when the switch for prelube oil pressure opens.
Second Timing	e	32	M050-BK	This function is not available for G3600 Engines. Do not attempt to wire this connection.
Emergency Stop	B	28	C256B-BK	For details, refer to ""Wiring for the Emergency Stop Circuit" ".
Emergency Stop Return	A	23	C256C-BK

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Table 16
Connections for the Interconnect Harness on the Advisor Panel Terminal Strip (Descending Order by Terminal#)
Interconnect Harness Wire Identification	J4	Optional Advisor Panel Terminal Strip	Function and Comment
P100-RD	z	4a	+Battery for the operation of the remote panel
P600-RD	y	4b	Fused Power
X171-RD	N	6	Desired Engine Speed Supply
X173-WH	X	7	Desired Engine Speed Signal
X170-CU	p	8	Desired Engine Speed
X172-BK	g	9	Shield for the Desired Return
X183A-WH	E	10	Desired Engine Speed 4−20 mA
		11	No Connection
X183B-WH	J	12	Desired Engine Speed 4−20 mA Return
CL100-PK	D	13	Cat Data Link +
CL100-PU	I	14	Cat Data Link -
P500-BK	r	15a	Digital Return
P915-BK	h	16	ECS Remote Start Command
M000-WH	U	17	Driven Equipment
P700-RD	w	18a	Keyswitch
M010-WH	K	19	Normal Stop
P907-WH	H	20b	Active Alarm
X283-GY	a	21	Multi-Strike Enable
M030-WH	d	22	Idle/Rated Input
C256C-BK	A	23	Emergency Stop
P914-BK	Y	24	ECS Auto
P908-BK	P	25	Engine Failure
C290-RD	T	26	Manual Prelube Input
P906-WH	C	27	Crank Terminate
C256B-BK	B	28b	Emergency Stop
M040-WH	Z	29	Run Relay
A330-WH	m	30	Gas Shutoff Valve (+)
P913-BK	O	31	ECS Cool-down/Stop
M050-WH	e	32	This function is not available for G3600 Engines. Do not attempt to wire this connection. (Desired Timing on G3500)
A320-RD	c	33	Prelube ON
CL200-YL	F	35	CAN Data Link +
CL200-GN	L	36	CAN Data Link -
	N/C	37	Gas Shutoff Valve
CL200-CU	V	38	CAN Data Link Shield
		39	−Battery
P300-BK	x	40b	−Battery
X000A-GY	S	41	4 to 20 mA input remote Btu input
X000B-GY	b	42	4 to 20 mA Remote Desired Fuel Quality Btu (Return)
M020-BK	n	43	Auxiliary Governor Gain
A340-RD	j	44	Auxiliary Out + (2A)
A340-BK	u	45	Auxiliary Out - (2A)
X100A-GY	G	46	4 mA to 20 mA (+) Output 1
X100B-GY	M	47	4 mA to 20 mA (-) Output 1
X100C-GY	W	48	4 mA to 20 mA (+) Output 2
X100D-GY	f	49	4 mA to 20 mA (-) Output 2

Advisor Display

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Illustration 47	g03863345
Advisor Panel (1) Status LED's integrated in left buttons (2) Navigation buttons

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Illustration 48	g03863347
(3) Product Link and wiring

Main Menu

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Illustration 49	g03863057
Main Menu-Status Screen Menu (4) Down arrow button (5) Previous screen button (6) Home button (7) OK button

Using the up and down arrow buttons on the right side, toggle up or down the list until desired parameter is highlighted.

Next press "OK" to view details for that screen. Refer to Illustration 50.

Status Screen Menu

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Illustration 50	g03863059
Status Screen Menu-Speed Status (8) Up arrow indicates more screens above (9) Down arrow indicates more screens above

Engine Status

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Illustration 51	g03863061
Status Screen Menu-Speed Status (4) Down arrow button (7) OK button

Push the down arrow button until "Speed Status" is highlighted.

Press "OK" to accept. "Speed Status"Main Menu-Detonation Levels

Detonation Levels

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Illustration 52	g03863062
Main Menu-Detonation Levels

Burn Times

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Illustration 53	g03863064
Main Menu-Burn Times

Secondary Voltages

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Illustration 54	g03863128
Main Menu-Secondary Voltages

Display Setup

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Illustration 55	g03863130
Status Screen Menu-Display Setup (4) Down arrow button (7) OK button

Press the "Down arrow" button until "Display Setup" is highlighted.

Press the "OK" button to move to the next screen.

Enter Configuration Password

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Illustration 56	g03863132

The dealer level "Configuration Password" is the same for the G3600 as for the G3500 and is user configurable.

Size and Mounting

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Illustration 57	g03863172
257-5889 Control Panel Box Gp (G3600A MIDS Panel) (A) 518 mm (20.394 inch) (B) 508 mm (20 inch) (C) 184 mm (7.244 inch)

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Illustration 58	g03863173
443-6061 Control Box Gp (G3500 ULB Advisor Panel) (A) 508 mm (20 inch) (B) 508 mm (20 inch) (C) 227.2 mm (8.945 inch)

Note: Dimension (B) for the 443-6061 Control Box Gp (G3500 ULB Advisor Panel) is 10 mm (0.394 inch) shorter than the 257-5889 Control Panel Box Gp (G3600A MIDS Panel) .

Initial Start-Up Procedure

Before the initial start-up, an engineer that is certified by Caterpillar must perform the engine commissioning at the site. The engineer is responsible for ensuring that all of these factors are in proper working condition prior to the initial start-up: engine installation, driven equipment, all of the related hardware and electrical connections. Failure to perform the commissioning procedure could result in unsatisfactory operation.

Note: As part of the commissioning procedure, all of the emergency stop buttons are tested before the engine is started. The testing verifies that the ECM generates the shutdown and the event code.

Perform the following procedure for the initial start-up and for start-up after major maintenance and/or repair.

Connect a properly calibrated emissions analyzer to the exhaust stack.

Perform the daily inspection and all of the daily maintenance procedures that are scheduled in Operation and Maintenance Manual, SEBU7653, "Maintenance Interval Schedule".

Connect Cat ET to the service tool connector. Refer to ""Connecting Cat ET with the 171-4401 Communication Adapter II " ".

Use the "Monitoring System" screen from the "Service" pull-down menu on Cat ET to view the default settings of the trip points for the alarms. Adjust the settings, if necessary.
For the necessary values of the operating parameters, refer to the appropriate Data Sheet on engine performance in the engine Technical Marketing Information (TMI).

Use the "Configuration" screen from the "Service" pull-down menu on Cat ET to view the configuration parameters.

Note: Use the data from the gas analysis and the data on engine performance to determine the settings for the fuel quality and the specific gravity.

View the parameters that are listed in Table 17. Program the parameters, if necessary.

Incorrect programming of the parameters may lead to complaints about performance and/or to engine damage. For descriptions of the parameters, refer to Systems Operation, RENR5908, "Electronic Control System Parameters".

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Table 17
Configuration Parameters for G3600 Engines
Air/Fuel Ratio Control
"Fuel Quality"
"Gas Specific Gravity"
"Desired Engine Exhaust Port Temp"
"Maximum Choke Position"
"Engine Start Choke Position"
"Wastegate (Proportional) Gain Percentage"
"Wastegate (Integral) Stability Percentage"
"Wastegate (Derivative) Compensation Percentage"
"Choke (Proportional) Gain Percentage"
"Choke (Integral) Stability Percentage"
"Choke (Derivative) Compensation Percentage"
Speed Control
"Low Idle Speed"
"Minimum Engine High Idle Speed"
"Maximum Engine High Idle Speed"
"Engine Accel. Rate"
"Desired Speed Input Configuration"
"Governor Type Setting"
"Engine Speed Droop"
"Governor (Proportional) Gain Percentage"
"Governor (Integral) Stability Percentage"
"Governor (Derivative) Compensation Percentage"
"Governor Auxiliary 1 (Proportional) Gain Percentage"
"Governor Auxiliary 1 (Integral) Stability Percentage"
"Governor Auxiliary 1 (Derivative) Compensation Percentage"
Start/Stop Control
"Driven Equipment Delay Time"
"Crank Terminate Speed"
"Engine Purge Cycle Time"
"Engine Cooldown Duration"
"Cycle Crank Time"
"Engine Overcrank Time"
"Engine Speed Drop Time"
"Engine Pre-lube Time Out Period"
Monitoring and Protection
"High Inlet Air Temp Engine Load Set Point"
Information for the Electronic Control Module (ECM)
"Engine Serial Number"
"Equipment ID"
"Customer Password #1"
"Customer Password #2"
"Total Tattletale"

Check the operation of the prelube pump.
Note: You can use Cat ET or the display on the optional control panel to monitor the status of the prelube pump solenoid.
1. If the optional control panel is used, make sure that the engine control switch is in the "STOP" position. Press the "MANUAL PRELUBE" switch.
  If the system is operating correctly, the "PRELUBE ACTIVE" indicator will illuminate and the prelube pump will operate.
  When sufficient engine oil pressure is achieved, the switch for prelube oil pressure will remove power from the prelube pump. The "PRELUBE ACTIVE" indicator will turn off.
1. After the "PRELUBE ACTIVE" indicator turns off, release the "MANUAL PRELUBE" switch.
1. Make sure that the fuel supply is OFF. Turn the engine control switch to the "START" position. Verify that the prelube pump and the "PRELUBE ACTIVE" indicator operate prior to activation of the starting motor.
1. After the "PRELUBE ACTIVE" indicator turns off, verify that the starting motor cranks the engine. Then turn the engine control switch to the "STOP" position.

Verify that the fuel supply is OFF. Make sure that the pressure for the electrohydraulic actuator system is sufficient for start-up.
1. Check the oil level in sight gauge (1). Fill the tank to the "FULL" mark on the sight gauge.
1. Remove plug (2) and install a pressure gauge in the fitting after the oil filter.
1. To fill the hydraulic hoses and lines, crank the engine and observe the pressure gauge. Do not crank the engine for more than 30 seconds at a time. If necessary, crank the engine repeatedly in order to achieve a pressure of 1200 ± 175 kPa (174 ± 25 psi).
  Note: The ECM will generate event codes and diagnostic codes during this procedure. After each crank cycle, reset the engine control switch. Continue to crank the engine until the pressure is achieved. After the electrohydraulic system is filled with oil, use Cat ET to clear the codes.
1. Stop cranking the engine and check the oil level in sight gauge (1) again. Add oil, if necessary.
  The correct oil level is between the "ADD" and "FULL" marks on the sight gauge.
1. After the hydraulic system is primed, crank the engine again and verify that the reading on the pressure gauge is 1200 ± 175 kPa (174 ± 25 psi) during cranking.
  This pressure is adequate for attempting start-up.
  Note: Sometimes, the pressure must be increased in order to avoid the generation of diagnostic codes during start-up. Usually, the codes are due to restarting an engine that has a low viscosity of hydraulic oil because the oil is hot. If codes are activated, use an Allen wrench to turn the pressure relief valve adjusting bolt clockwise for approximately 1/4 of a turn (90 degrees). Refer to Illustration 61.

Turn the engine control switch to the "STOP" position. Turn ON the fuel supply to the engine.

Verify that no gas is leaking. Verify that the gas does not flow past the GSOV.

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Unburned gas in the inlet manifold and/or in the exhaust manifold can ignite when the engine is started. Personal injury and/or property damage can result. Use this procedure to clear the engine and the exhaust system of unburned gas:

Before starting an engine that was stopped by terminating the ignition system, turn the gas supply OFF. Crank the engine for approximately 15 seconds in order to clear any unburned gas from the engine and the exhaust system.

Turn the engine control switch to the "START" position.
After the prelube pump operates and the starting motor cranks the engine, the engine will accelerate to low idle rpm.
Several attempts may be required for the initial start-up before the air is purged from the fuel lines. Several attempts may be required before the electrohydraulic system has sufficient pressure.
Note: If the engine will not start, use Cat ET to check for diagnostic codes and event codes. Correct any active conditions before you attempt to start the engine again. Refer to Troubleshooting, RENR5910.
Note: In the screen for relay status of Cat ET, check the position of the following relays. The check ensures that the relays are in the ready position:
- Normal stop
- Emergency stop
- Prelube
- Driven equipment
- Multi strike (OFF except Bio-Gas)

After the engine is running, test the operation of each emergency stop button. After each test, reset the emergency stop button and reset the engine control switch. Restart the engine until you verify that each emergency stop button is working properly. After the testing, use Cat ET to clear the event codes from the ECM.

Adjust the gain, stability, and compensation for the following functions, if necessary.
- Primary governor
- Auxiliary governor
- Start choke position
- Maximum choke position
- Exhaust bypass (wastegate)
- Desired engine exhaust port temperature
For instructions, refer to Systems Operation, RENR5908, "Electronic Control System Parameters" and Testing and Adjusting, RENR5908, "Engine Governing - Adjust".

Apply a load of 25 percent.

Slowly ramp the load to 75 percent.

Use Cat ET to switch the engine control to the prechamber calibration mode.

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Illustration 60	g00815515
Needle valves for the precombustion chambers

Adjust the needle valves for the precombustion chambers in order to achieve the desired combustion burn time. For instructions, refer to Testing and Adjusting, RENR5908, "BTU and Precombustion Chamber Adjustments".

Use Cat ET to switch the engine control to the mode for combustion feedback. Adjust the governor gain, stability, and compensation again, if necessary.

Increase the load to 100 percent.

After the engine has been operating at full load in the feedback mode for a minimum of ten minutes, verify that the fuel correction factor remains within ± 2 percent of 100 percent.

Check the exhaust emissions. If the emissions levels are not satisfactory, use Cat ET to adjust the fuel quality. Adjust the needle valves for the precombustion chambers again. Refer to Testing and Adjusting, RENR5908, "BTU and Precombustion Chamber Adjustments".

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Illustration 61	g00892836
Adjusting bolt for the pressure relief valve

When the engine operation is stable and the engine achieves normal operating temperature, adjust the electrohydraulic system pressure relief valve in order to obtain a pressure of 1550 ± 35 kPa (225 ± 5 psi). For instructions, refer to Testing and Adjusting, RENR5908, "Engine Governing - Adjust".