Converting to Charge Density{1000} Caterpillar

Engine:

G3516B (S/N: 7EZ1-UP; CTW1-UP)

Generator Set:

G3516B (S/N: CSC1-UP)

Introduction

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

This Special Instruction provides the information for changing the engine's emission control from a system that is controlled by oxygen feedback to a system that is controlled by charge density feedback. The following references are also needed:

• Installation and Initial Start-Up Procedure, REHS0531

• Systems Operation/Testing and Adjusting, RENR2268

• Troubleshooting, RENR2270

• Operation and Maintenance Manual, SEBU7201

Required Parts

Disable the Engine

1. Secure the engine.

   1. Switch off DC power to the engine. Switch off AC power to the engine.
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   Illustration 1	g00104545

   2. Attach warning signs to the engine.

   3. Disconnect the power source from the starting system.

   4. Close the manual shutoff valve for the gas supply.

2. Drain the engine coolant to a level that is below the vent line.

Modify the Water Lines Group

Illustration 2	g01119068
Top view (1) 190-7446 Tube As

1. Drain the engine coolant to a level that is below tube (1) .

2. Remove tube (1) .

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Illustration 3	g01119070
Top view (2) 240-8928 Bracket (3) 4D-9517 Clip (4) 240-8927 Tube As

3. Install bracket (2). Use a 0S-1571 Bolt and a 9X-6458 Hard Washer to mount the bracket.

4. Install tube (4) and clip (3) .

5. Be sure that all of the fittings on the vent line are tight. Be sure that the vent line is secured with clips.

6. Refill the engine with coolant. Refer to Operation and Maintenance Manual, SEBU7201, "Cooling System".

Modify the Fuel System

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Illustration 4	g01115420
Fuel valve (1) Fuel valve (2) Support bracket

1. Disconnect the wiring harness from fuel valve (1) .

2. Remove fuel valve (1) and support bracket (2). Retain the bolts.

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Illustration 5	g01114657
New brackets (3) 240-3496 Plate As (4) 240-3497 Bracket

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Illustration 6	g01114664
Top view (3) 240-3496 Plate As (4) 240-3497 Bracket

3. Install plate (3) and bracket (4). Use the original bolts and new 5M-2894 Hard Washers for plate (3). Use 0L-1351 Bolts and 9X-6458 Hard Washers for bracket (4) .

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Illustration 7	g01119188
Side view (5) 239-5791 Fuel Valve Gp

4. Install fuel valve (5) onto plate (3) and bracket (4) .

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Illustration 8	g01115845
(6) Insert (7) Carburetor

5. Remove inserts (7) from carburetors (6). Both inserts must be removed.

Sensor Removal

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Illustration 9	g01115709
Left side view (1) 149-7064 Pressure Sensor Gp (2) 207-8603 Bracket As (3) 209-4395 Bracket (4) 6V-8628 Elbow (5) 196-5391 Oxygen Sensor (6) 204-5286 Humidity Sensor Gp (7) 199-7151 Sensor Harness As (8) 3E-7565 Electronic Control Gp

1. Remove harness (7). Remove oxygen sensor (5). Install a 3E-2331 Plug and a 9Y-6792 Spark Plug Gasket into the opening.

2. Remove pressure sensor (1), bracket assembly (2), bracket (3), and elbow (4) .

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Illustration 10	g01115859
Mounting bolts

3. Install 0S-1594 Bolts and 5M-2894 Hard Washers in location (9) .

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Illustration 11	g01115348
Plug and spacer (10) 3E-2331 Plug (11) 109-1086 Spacer

4. Remove humidity sensor (6). Install plug (10) and spacer (11) .

Modify the Terminal Box

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Illustration 12	g01115659
The connectors on the terminal box connect the Electronic Control Module (ECM) to various engine controls, sensors, actuators, etc. (1) Electronic Control Module (ECM) (2) Ground strap for the ECM (3) ECM connector J2 (4) ECM connector J1 (5) Service tool connector J23 for the Caterpillar Electronic Technician (6) Connector for the 168-2028 Wiring Harness (7) Harness to the ignition transformers (8) 16 amp circuit breaker for the engine (9) 6 amp circuit breaker for the switched +Battery (10) Connectors J5/P5 for the harness to the Integrated temperature sensing module (11) This connector is not used. (12) Junction box harness (13) P50 connector for calibration of the speed/timing sensor (14) Connectors J9/P9 for the wiring to the customer's connections (15) Connectors J10/P10 for the harness to the speed/timing sensor, throttle actuator, and oxygen buffer (if equipped) (16) Connectors J11/P11 for the harness to the detonation sensors (17) Connectors J12/P12 for the harness to the analog sensors (18) Connectors J13/P13 for the wiring to the gas shutoff valve (19) Connectors J14/P14 for the wiring to the starting motor (20) This connector is not used. (21) Connectors J16/P16 for the harness to the fuel metering valve

1. Remove harness (12) from the junction box.

   Note: The gaskets and the fasteners can be reused. Check for damage before reusing the gaskets and the fasteners. Refer to Table 2 for replacement part numbers.

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   Table 2

   Replacement Parts for the Junction Box
   Quantity	Part Number	Description	Location
   32	6V-2480	Screw	(5), (10), (11), (16), (18), (19), (20), (21)
   16	9X-6258	Screw	(6), (14), (15), (17)
   3	159-2927	Cap As	(18), (19), (20)
   	154-3250	Gasket
   	156-9335	Ring Nut
   2	131-4888	Gasket	(5), (21)
   	132-8487	Ring Nut
   3	131-4890	Gasket	(10), (11), (16)
   	132-8488	Ring Nut
   3	138-4730	Ring Nut	(6), (15), (17)
   	138-4731	Gasket
   1	154-3254	Gasket	(14)
   	156-9336	Ring Nut

2. One by one relocate each of the wires for the ignition transformers. These wires are located on the J2 connector (3). Install each of the wires for the ignition transformers into the J2 connector of the 236-8215 Harness . Refer to Table 3.
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   Table 3

   Location of the Wires for the Ignition Transformers
   Circuit Identification	Wire Color	Location on the J2 Connector
   J011	Red	1
   J012	Black	2
   J021	Red	3
   J022	Black	4
   J031	Red	24
   J032	Black	25
   J041	Red	26
   J042	Black	27
   J051	Red	14
   J052	Black	15
   J061	Red	16
   J062	Black	17
   J071	Red	5
   J072	Black	18
   J081	Red	52
   J082	Black	62
   J091	Red	32
   J092	Black	33
   J101	Red	34
   J102	Black	35
   J111	Red	48
   J112	Black	49
   J121	Red	50
   J122	Black	51
   J131	Red	58
   J132	Black	59
   J141	Red	60
   J142	Black	61
   J151	Red	40
   J152	Black	41
   J161	Red	42
   J162	Black	43

Note: For S/N:CSC167-UP, the J16 connector on the original harness has 14 pins. The hole in the junction box does not need to be enlarged. Proceed to Step 5. Steps 3 and 4 are only necessary if the J16 connector on the original harness has 10 pins. If the J16 connector on the original harness has 14 pins, proceed to Step 5. The new 236-8215 Harness uses a J16 connector that has 14 pins.

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Illustration 13	g01115546
Junction box (22) 31.75 mm (1.25 inch) Hole

3. Enlarge hole (22) in the junction box for the J16 connector. The new connector is too large for the existing hole.

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Illustration 14	g01115625
Side view of the terminal box (23) New mounting holes

4. Drill four new 3.2 mm (0.125 inch) mounting holes (23) .

5. Install the 236-8215 Harness into the terminal box.

6. Reconnect the emergency stop switch on the junction box door.

7. Reconnect 16 amp fuse (8) and reconnect 6 amp fuse (9) .

8. Secure all of the junction box wiring.

Note: If the engine is not equipped with an EMPC2 panel, a 190-4784 Module and three 122-6591 Current Transformer As are required. Refer to Special Instruction, REHS0531 for information on connecting these items.

Replace the Electrical Harnesses

1. Remove the harness for the throttle actuator. This harness plugs into the J10 connector on the junction box. Install the 247-0280 Harness .

2. Remove the harness for the engine sensors. This harness plugs into the J12 connector on the junction box. Install the 174-7914 Sensor Harness As .

3. Install the 241-6867 Engine Harness As . This harness is for the fuel valve. This harness plugs into the J16 connector on the junction box.

4. Be sure that all of the connectors in the junction box are properly connected.

5. Use 9X-6772 Cable Straps and the existing 4P-8134 Clips to secure the new harnesses.

6. Check all of the wiring for loose connections. Be sure that all of the wiring is secure.

Flash the Engine Control Module (ECM)

Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, RENR2270, "Connecting Cat ET with the 171-4401 Communication Adapter II".

Contact the Dealer Solution Network in order to verify the correct flash file. Flash the ECM. Refer to Troubleshooting, RENR2270, "Flash Programming".

Return the engine to service.