3600 to 3600 Electronic Unit Injector (EUI) Upgrade{1000, 1250} Caterpillar

Engine:

3606 (S/N: 8RB601-604,656-657,659-660,680-681,764-767)

3608 (S/N: 6MC651-652)

3612 (S/N: 9RC256-257,259-260)

Introduction

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

Whenever questions arise about this product of this Special Instruction, consult your local Caterpillar dealer for the latest available information.

This Special Instruction provides the following information for 3600 Engines:

• Requirements for the electrical system

• References for electrical schematics

• Required electronic service tools

• Cylinder head installation

• Modifications for the cylinder head

• Fuel injector installation

• Components of the Customer Interface Panel (CIP)

• Specifications for the customer connector

• Wiring connections and the corresponding functions that are available to the customer

• Initial start-up procedure

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

• Operation and Maintenance, SEBU6965, "3600 Distillate Fuel Engines "

• Operation and Maintenance, SEBU7632, "Monitors For 3600 Diesel Monitoring Systems "

• Systems Operation/Testing and Adjusting, SENR3599, "3606 and 3608 Engines "

• Systems Operation/Testing and Adjusting, SENR3593, "3612 and 3616 Engines "

• Disassembly and Assembly, SENR3600, "3606 & 3608 Engines"

• Disassembly and Assembly, SENR3594, "3612 and 3616 Engines "

• Troubleshooting, RENR2491, "3606, 3608, 3612 and 3616 Engines Generator Monitoring System "

• Troubleshooting, RENR5084, "C280 Marine Propulsion Engines "

• Electrical Schematic, RENR5086, "C280-6 and C280-8 Marine Propulsion Engine Electrical System "

• Electrical Schematic, RENR5087, "C280-12 and C280-16 Marine Propulsion Engine Electrical System "

Engine Information Plate

Illustration 1	g01279276
(1) Engine information plate

The engine information plate is located between the last two crankcase covers on the right hand side of the engine. The engine information plate must be modified in order to show that the upgrade has been completed.

A request must be submitted to the Applications Support Center to obtain a new engine identification plate.

The phone number for the Applications Support Center is 765-448-2400. The email address for the Applications Support Center is applicationsupport@cat.com.

The request must state that the new identification plate is for the Mechanical Unit Injector (MUI) to Electronic Unit Injector (EUI) conversion. The request must include the following information.

• An email address

• A phone number

• The serial number of the engine

The new plate will include information on the timing devices for the engine and the software part numbers for the engine.

Removal and Installation

The new engine identification plate is installed over the existing plate. Ensure that the existing plate is clean. Ensure that the existing plate is free of oil.

Upgrades for the Fuel System

Replace Fuel Filters

Remove Existing Fuel Filters

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	7V-0198	Hose	1
B	4F-4879	Bolt	2
C	4C-6173	Fuel Drain Tray	1
D	5N-5566	Hose	1
E	1U-9823	Filter Scoop	1

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Shut off the fuel supply to the engine.

Note: Tool (C) is mounted on the lower fuel filter housing. This tray allows fuel to drain.

2. Install Tool (C), Tool (B), Tool (A) and Tool (D). Drain the fuel from each fuel filter bank by opening the drain valves.

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Illustration 2	g00617652

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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

3. Remove covers (1) .

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Illustration 3	g00617656

4. Pull out wire racks (3) and remove one fuel filter element (2) at a time from each housing. When the filters are being installed, always use new filters.

5. Use Tool (E) in order to handle the fuel filter elements. This will aid in disposal.

Install the 1R-0766 Fuel Filter Element As

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 4	g00617656

1. Put new filters in wire racks (3) and install the filters one at a time.

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Illustration 5	g00617652

2. Install covers (1) .

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Illustration 6	g00617646

3. Remove Tool (C), Tool (B), Tool (A) and Tool (D). Close the drain valves.

Upgrade for the Bypass Valve on the Fuel Transfer Pump

Modify the Valve

Note: This procedure may be performed without disassembling the fuel transfer pump.

Illustration 7	g01175821
(1) Fuel transfer pump (2) Bypass valve for the fuel transfer pump

Illustration 8	g01175825
(3) Cap (4) Locknut (5) Adjustment screw (6) Plug (7) Spring (8) Housing (9) Guide

1. Remove cap (3), plug (6), guide (9), and spring (7) from housing (8) .

2. Replace spring (7) with 238-0939 Spring .

   Install the new 238-0939 Spring .

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Illustration 9	g01176198

3. Loosen locknut (4). Adjust screw (5) until dimension (X) is 7 mm (0.275 inch). Tighten locknut (4) and then recheck dimension (X) .

4. Install cap (3) and plug (6) onto housing (8) .

Fuel Pressure Regulator

Remove the Fuel Pressure Regulator

1. Ensure that the fuel supply for the engine is turned off.

2. Disconnect the fuel lines from the fuel pressure regulator.

3. Remove the mounting bolts for the fuel pressure regulator.

4. Remove the fuel pressure regulator.

   The old fuel pressure regulator will not be reused.

Remove the Lines Group

1. Remove the fuel line that connects the fuel pressure regulator to the fuel rail.

2. For vee engines, Remove the 4P-0707 Clamp As from the supply line that enters the cylinder heads.

Install the Fuel Pressure Regulator on In-line Engines

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Illustration 10	g01265186
Typical example (10) 248-6654 Tube As (11) 235-3362 Valve As (12) 0T-0772 Bolt (13) 5P-8244 Hard Washer (14) 246-2904 Bracket (15) 034-3557 Locking Bolt (16) 9X-6458 Hard Washer

1. Install bracket (14).

   Use bolts (15) and washers (16) to secure the bracket.

   Note: Install the bracket in the same location as the old fuel pressure regulator.

2. Install valve (11) onto bracket (14).

   Use bolts (12) and washers (13) to secure valve (11) .

Fuel pressure is set by adjusting the bolt on the top of the fuel pressure regulator.

Fuel pressure at full load ... 820 ± 20 kPa (120 ± 3 psi)

Install the Fuel Pressure Regulator on Vee Engines

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Illustration 11	g01265215
Typical example (11) 235-3362 Valve As (12) 0T-0772 Bolt (13) 5P-8244 Hard Washer (14) 246-2904 Bracket (15) 034-3557 Locking Bolt (16) 9X-6458 Hard Washer (17) 255-7173 Tube As

1. Install bracket (14).

   Use bolts (15) and washers (16) to secure the bracket.

   Note: Install the bracket in the same location as the old fuel pressure regulator.

2. Install valve (11) onto bracket (14).

   Use bolts (12) and washers (13) to secure valve (11) .

Fuel pressure is set by adjusting the bolt on the top of the fuel pressure regulator.

Fuel pressure at full load ... 820 ± 20 kPa (120 ± 3 psi)

Install the Lines Group

1. Install the new tube assembly that connects the fuel pressure regulator to the fuel rail. Refer to Illustrations 10 and 11.

   For in-line engines, use tube (10). For vee engines, use tube (17) .

2. Connect the tubes to valve (11) .

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Illustration 12	g01254529
Typical example (18) 265-2907 Bracket (19) 4P-0707 Clamp As

3. For vee engines, install bracket (18) by using existing hardware.

Update the Engine Timing Group (6 Cylinder and 8 Cylinder)

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Be sure that the engine cannot be started while service work is being done. This is very important when the engine is equipped with an Automatic Start-Stop System. On engines equipped with an air starting system, close the air supply valve that supplies air to the starter motor before service work is begun.

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Improper lift rigging can allow unit to tumble causing injury and damage.

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NOTICE
When it is necessary to remove a component at an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension.

1. Remove the 4P-7003 Camshaft Drive Gear Cover Gp

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Illustration 13	g01179000
(1) Clamps (2) Rod (3) Actuator assembly (4) Control rod housing

2. Remove the 112-5051 Governor Fastener .

   1. Remove clamps (1) and rod (2). The clamps and rod will not be reinstalled.

3. Remove actuator (3) .

   1. Disconnect the electrical connectors from the actuator.

   2. Remove the bolts that secure the actuator to the governor drive.

   3. Remove the actuator.

4. Remove housing (4) .

5. Remove the fuel injection control linkage.

   Refer to the Disassembly and Assembly manual for more information.

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Illustration 14	g01179065
Governor drive group (5) Bolts (6) Bevel gear (7) Camshaft

6. Remove the 2W-1242 Governor Drive Group .

   1. Remove bolts (5) .

   2. Remove the governor drive.

   3. Remove the governor drive housing.

      Note: Bevel gear (6) that is mounted on camshaft (7) does not need to be removed.

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Illustration 15	g01179159
Standard rotation (8) Speed/timing wheel (9) Secondary 191-8305 Speed Sensor Gp (10) Extra tooth (11) Primary 191-8305 Speed Sensor Gp (12) 1D-4569 Bolts

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Illustration 16	g01179194
Reverse rotation (8) Speed/timing wheel (9) Secondary 191-8305 Speed Sensor Gp (10) Extra tooth (11) Primary 191-8305 Speed Sensor Gp (12) 1D-4569 Bolts

7. Install the 213-6456 Timing and Speed Drive .

   1. Ensure that the engine is in time by inserting the timing pin into the camshaft.

   2. Install the two speed sensors (9) and (11) .

   3. Install the 196-6043 Spacer and the 154-2709 Wheel on the camshaft drive gear.

      Ensure that extra tooth (10) on speed/timing wheel (8) is close to primary speed sensor (11). Install 5P-8245 Hard Washers on bolts (12). Do not tighten bolts (12) .

      Note: Note the position of extra tooth (10) in relation to primary speed sensor (11) .

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Illustration 17	g01179324
(8) Speed/timing wheel (11) Primary speed sensor (13) First tooth after the extra tooth

8. Adjust the 154-2709 Wheel .

   1. Rotate speed/timing wheel (8) in the direction of the camshaft.

   2. Align the first tooth after the extra tooth (13) with the center of primary speed sensor (11) .

      Refer to Illustration 17.

   3. Torque bolts (12) to 120 N·m (88.5 lb ft).

   4. Recheck the alignment of first tooth after the extra tooth (13) and primary speed sensor (11) .

9. Install the 248-6764 Camshaft Cover Gp .

   The 248-6764 Camshaft Cover Gp replaces the 112-5051 Governor Fastener and the 138-4139 Governor Actuator As .

10. Install the 4B-3140 Cover . Use a 1W-1960 Gasket , 3V-3308 Hard Washers and 0S-1594 Bolts .

    The 4B-3140 Cover replaces the opening in the block for the fuel control rod.

11. Install the 237-5389 Camshaft Cover Gp .

Update the Engine Timing Group (12 Cylinder)

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Be sure that the engine cannot be started while service work is being done. This is very important when the engine is equipped with an Automatic Start-Stop System. On engines equipped with an air starting system, close the air supply valve that supplies air to the starter motor before service work is begun.

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Improper lift rigging can allow unit to tumble causing injury and damage.

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NOTICE
When it is necessary to remove a component at an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension.

1. Remove the 7E-1291 Camshaft Drive Gear Cover Gp .

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Illustration 18	g01179367
(1) Clamps (2) Rod (3) Actuator assembly (4) Control rod housing

2. Remove the 120-4508 Governor Fastener .

   1. Remove clamps (1) and rod (2). The clamps and rod will not be reinstalled.

3. Remove actuator (3) .

   1. Disconnect the electrical connections for the actuator.

   2. Remove the bolts that secure the actuator to the governor drive.

   3. Remove the actuator.

4. Remove housing (4) .

5. Remove the fuel injection control linkage.

   Refer to the Disassembly and Assembly manual for more information.

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Illustration 19	g01179443

6. Remove the 4P-9212 Governor Drive Group .

   1. Remove bolts (11) that are aside block (9) .

   2. Remove ten bolts (6). Remove cover (8) .

   3. Fasten a hoist to housing assembly (5). Remove bolts (10) that hold the housing assembly to the rear housing. Install two 3/8 - 16 NC forcing screws in housing assembly (5). Tighten the forcing screws evenly and separate the housing assembly from the rear housing. Remove housing assembly (5). The weight of housing assembly (5) is approximately 25 kg (55 lb).

   4. Remove the O-ring seal from housing assembly (5) .
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   Illustration 20	g01179444

   5. Remove four bolts (12). Remove adapter (13) .

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Illustration 21	g01245278
Standard rotation (14) Speed/timing wheel (15) Primary 191-8305 Speed Sensor Gp (16) 2A-1531 Bolts (17) Tooth after the extra tooth (18) Extra tooth (19) Secondary 191-8305 Speed Sensor Gp

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Illustration 22	g01245280
Reverse rotation (14) Speed/timing wheel (15) Primary 191-8305 Speed Sensor Gp (16) 2A-1531 Bolts (17) Tooth after the extra tooth (18) Extra tooth (19) Secondary 191-8305 Speed Sensor Gp

7. Install the 213-6456 Timing and Speed Drive .

   1. Ensure that the engine is in time by inserting the timing pin into the camshaft.

   2. Install the two speed sensors (15) and (19) .

   3. Install the 154-8716 Spacer and speed/timing wheel (14) on the camshaft drive gear.

      Note: Note the position of extra tooth (18) in relation to primary speed sensor (15) .

   4. Ensure that extra tooth (18) on speed/timing wheel (14) is close to primary speed/timing sensor (15). Install 5P-1076 Hard Washers on bolts (16). Do not tighten bolts (16) .

8. Adjust the 154-2709 Wheel .
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   Illustration 23	g01179524
   (14) Speed/timing wheel (15) Primary speed/timing sensor (17) Tooth after the extra tooth

   1. Rotate speed/timing wheel (14) in the direction of camshaft rotation.

   2. Align the first tooth after the extra tooth (17) with the center of primary speed/timing sensor (15) .

      Refer to Illustration 23.

   3. Torque bolts (16) to 120 N·m (88.5 lb ft).

   4. Recheck the alignment of first tooth after the extra tooth (16) and primary speed/timing sensor (15) .

9. Install the 240-9736 Cylinder Block Cover Gp .

10. Install the 240-9740 Camshaft Cover Gp .

Cylinder Heads

The cylinder head must be upgraded in order to use the new injector. Choose one of the following options.

• New cylinder heads

• Remanufactured cylinder heads

• Modifying the existing cylinder heads

Using New Engine Cylinder Heads to Upgrade the Engine

Table 2

Engine Cylinder Head Assembly Part Numbers
4W-0017	175-6342
7C-0011	176-3599
7E-9011	188-7491
7E-9011	234-6918
7W-0011	252-5415
9Y-6231	252-5535
107-0273	252-5580
165-7592	252-5613
175-6334	252-5625
175-6339

1. Remove the old cylinder head.

   Refer to the Disassembly and Assembly manual.

Note: When the cylinder head is disassembled, keep the bridges and the respective valves together.

2. Disassemble the old head.

3. Inspect the 1W-8444 Shaft Supports .

   Replace the 1W-8444 Shaft Supports if the shaft supports are change level 06 or below. The shaft supports must be change level 07 or above.

4. Inspect the existing parts for the engine cylinder head. If the parts are in good condition, the parts can be reused.

5. Assemble the new cylinder head.

6. Install the new cylinder head.

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Illustration 24	g01265474
Locations for seal installation (1) 276-1354 Spacer Ring (2) 269-4659 Seal (3) Open O-Ring groove (4) 061-9455 O-Ring Seal

7. Install the seals onto the 288-2403 Fuel Injector Gp .

   Note: Lubricate spacer (1), seal (2), and O-Ring (4) with engine oil or diesel fuel prior to installation on the fuel injector.

   1. Install spacer (1) onto the fuel injector.

   2. Install seal (2) onto the fuel injector.

   3. Install O-Ring (4) onto the fuel injector.

8. Install the 288-2403 Fuel Injector Gp using the 198-8832 Injector Clamp , the 7S-3224 Bolt and a 198-8833 Washer .

9. Install the 6I-2491 Bridge Assemblies .

10. Install the 128-5682 Rocker Arms .

11. Install the 198-8839 Rocker Arm Base .

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Illustration 25	g01248252

12. Connect the injector wiring harness to the 9X-0352 Receptacle As .

    Ensure that the wiring harness for the injector is correctly routed through tabs (5) of the 198-8839 Rocker Arm Base .

13. Install the 7E-0733 Valve Mechanism Cover after the valves and valve bridges have been adjusted.

Using Remanufactured Engine Cylinder Heads to Upgrade the Engine

The remanufactured engine cylinder head has the correct mounting hole size for the injector.

1. Remove the old cylinder head.

   Refer to the Disassembly and Assembly manual.

2. Disassemble the old head.

3. Inspect the 1W-8444 Shaft Supports .

   Replace the 1W-8444 Shaft Supports if the shaft supports are change level 06 or below. The shaft supports must be change level 07 or above.

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Illustration 26	g01265474
Locations for seal installation (1) 276-1354 Spacer Ring (2) 269-4659 Seal (3) Open O-Ring groove (4) 061-9455 O-Ring Seal

4. Install the seals onto the 288-2403 Fuel Injector Gp .

   Note: Lubricate spacer (1), seal (2), and O-Ring (4) with engine oil or diesel fuel prior to installation on the fuel injector.

   1. Install spacer (1) onto the fuel injector.

   2. Install seal (2) onto the fuel injector.

   3. Install O-Ring (4) onto the fuel injector.

5. Install the 288-2403 Fuel Injector Gp using the 198-8832 Injector Clamp , the 7S-3224 Bolt and a 198-8833 Washer .

6. Install the 10R-4829 Cylinder Head Gp .

7. Install the 6I-2491 Bridge Assemblies .

8. Install the 128-5682 Rocker Arms .

9. Install the 198-8839 Rocker Arm Base .

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Illustration 27	g01248252

10. Connect the injector wiring harness to the 9X-0352 Receptacle As .

    Ensure that the wiring harness for the injector is correctly routed through tabs (5) of the 198-8839 Rocker Arm Base .

11. Install the 7E-0733 Valve Mechanism Cover after the valves and valve bridges have been adjusted.

Upgrade the Engine Cylinder Heads by Modifying Existing Cylinder Heads

Table 3

Required Tools
Tools	Part Number	Part Description
(A)		6 mm (0.25 inch) round stock that is 76 mm (3 inch) long
(B)	4C-4999	Taper Tap
(C)		13.8 mm drill bit
(D)	4C-5026	Tap Wrench
(E)	4C-4981	Bottom Tap
(F)		Chamfer cutting tool DB 26-90 degree
(G)	1U-7262	Telescoping Magnet
(H)		Magnetic Drill
(I)		Plate
Additional Required Tools
Wet/dry shop vacuum
Tape

Illustration 28	g01175343
Machining tools for the cylinder head

Illustration 29	g01175344
Typical example of magnetic drill

The standard 3600 cylinder head must be modified to accept the 235-3336 Fuel Injector Gp .

Table 4

Fuel Injector Parts
Standard Mechanical Unit Injector (MUI) Cylinder Heads		EUI Cylinder Heads
7C-1903	Fuel Injection Pump Gp	288-2403	Fuel Injector Gp
1W-0019	Injector Clamp	198-8832	Injector Clamp
150-4810	Studs	7S-3224	Bolt
Not Applicable		198-8833	Washer

Before any machining work is performed, the cylinder head must be protected from the debris that is generated by the machining process. Plate (I) covers the opening in the cylinder head casting for the camshaft. Plate (I) also covers the injector bore. The plate is installed by using the 6V-6869 Bolts that are used for the support assemblies. 19 mm (0.75 inch) washers are used as spacers for the plate.

A wet/dry shop vacuum must be used to capture machining debris as the head is machined. Tool (G) is used to clean debris from the machined hole.

Machining procedure for the Engine Cylinder Head

The following procedure may be performed while the engine cylinder head is installed on the engine. The following procedure may also be performed while the engine cylinder head is removed from the engine. Ensure that all openings in the engine are covered or plugged.

1. Disassemble the following parts.
   • Rocker arms

   • Support assembly

   • Pushrods

   • Valve bridges

   • Fuel injector

   • Hold down studs for the fuel injector

   Refer to the Disassembly and Assembly manual for more information.

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Illustration 30	g01175345
(I) Plate

2. Install plate (I) .

   1. Place plate (I) onto the cylinder head.

   2. Use two 6V-6869 Bolts to secure the plate to the cylinder head.

      4B-4283 Washers may be used as spacers for the bolts.

3. Ensure that all of the openings in the cylinder head have been covered and/or plugged.

   Ensure that the valve springs are covered and/or protected.

4. Measure 41 mm (1.61 inch) from the tip of tools (B), (C) and (E) .

   Use the tape to mark the tools at 41 mm (1.61 inch).

5. Place magnetic drill (H) onto plate (I) .

6. Install tool (A) into the chuck of the magnetic drill.

   Leave 63 mm (2.5 inch) of tool (A) exposed.

   Note: Do not move the switch for the base of the magnetic drill to the ON.

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Illustration 31	g01175188
(6) Hole

7. Lower the chuck of the magnetic drill until tool (A) is centered at the bottom of hole (7) .

8. Once tool (A) is centered in hole (6), move the switch of the base of the magnetic drill to the ON. This will keep the drill in place while the hole is machined.

9. Raise the chuck of the magnetic drill and remove tool (A ) from the chuck of the magnetic drill.

10. Install tool (C) into the chuck of the magnetic drill.

11. Drill hole (6) to a depth of 41 mm (1.61 inch).

12. Use the shop vacuum and Tool (G) to remove any machining debris from the head casting and from the machined hole.

13. Using tool (B) and tool (D) tap the machined hole.

14. Repeat Step 12.

15. Use tool (E) and tool (D) to clean the threads of the machined hole.

16. Remove tool (C) from the chuck of the magnetic drill. Install tool (F) into the chuck of the magnetic drill.

17. Chamfer the machined hole.

18. Turn the switch for the base of the magnetic drill to the OFF position. Remove the magnetic drill.

19. Repeat Step 12.

20. Remove plate (I) from the cylinder head.

21. Ensure that all of the engine cylinder head and the valve springs are free off machining debris.

22. Remove any covers or plugs that were installed onto the cylinder head.

23. Assemble and/or install the following parts.
    • Hold down clamp for the fuel injector

    • Fuel Injector

    • Valve bridges

    • Pushrods

    • Support assembly

    • Rocker arms

    Refer to the Disassembly and assembly manual for more information.

Finding the Top Center Position for the No. 1 Piston

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Illustration 32	g00311103
Timing pin location (1) Manual barring group (2) Storage position for timing pin

1. Remove the crankshaft timing pin from the timing pin's storage position (2). The timing pin's storage position is located below manual barring group (1) on the right side of the rear housing.

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Illustration 33	g00311105
Installation of crankshaft timing pin (3) Bracket on flywheel for timing (4) Mounting bracket for timing pin (5) Crankshaft timing pin

2. Prelube the engine. Use the electrically driven manual barring group in order to turn the engine flywheel in the direction of normal engine rotation. Turn the engine flywheel in the direction of normal engine rotation until crankshaft timing pin (5) can be installed through bracket (4). Then, install crankshaft timing pin (5) so that the pin is engaged in bracket (3) .

   Note: Prelube the engine before you rotate the crankshaft in order to perform service work. Rotating the crankshaft before prelube may cause damage to the crankshaft bearings if the mating surface is dry.

   Note: If the flywheel is turned beyond the point of installing the timing pin in the flywheel's bracket for timing, the flywheel must be turned opposite the direction of normal rotation. Turn the flywheel opposite the direction of normal rotation for approximately 20 degrees. Then, turn the flywheel in the direction of normal engine rotation until the timing pin can be installed in the flywheel's bracket for timing. This procedure is required to ensure that the play is removed from the timing gears when the No. 1 piston is put on the top center position of the compression stroke.

3. Remove the valve cover from the No. 1 cylinder head.

4. The inlet and exhaust valves for the No. 1 cylinder are fully closed if No. 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the exhaust stroke. Refer to Crankshaft Position For Fuel Timing And Valve Lash Setting.

   Note: If the actual stroke position that is identified is incorrect and the other stroke position is needed, it is necessary to remove all timing pins from the engine. After all of the timing pins have been removed, rotate the flywheel for 360 degrees in the direction of normal rotation.

Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting

Illustration 34	g01283090
3606 cylinder and valve location (A) Inlet (B) Exhaust

Table 5

Crankshaft Positions for Fuel Injector Timing and Valve Lash Setting
3606 Engine	Check And Adjust With No. 1 Piston On The Following Stroke: (1)
	Top Center Compression Stroke	Top Center Exhaust Stroke
SAE Standard Rotation Engines (2)
Inlet Valves	1-2-4	3-5-6
Exhaust Valves	1-3-5	2-4-6
Fuel Injectors	3-5-6	1-2-4
Firing Order	1-5-3-6-2-4
SAE Opposite Rotation Engines (3)
Inlet Valves	1-3-5	2-4-6
Exhaust Valves	1-2-4	3-5-6
Fuel Injectors	2-4-6	1-3-5
Firing Order	1-4-2-6-3-5

( 1 )	Put the No. 1 piston at the top center position and identify the correct stroke. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". After the top center position for a particular stroke is found and the adjustments are made for the correct cylinders, remove the timing pin. Turn the flywheel for 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders that remain.
( 2 )	SAE Standard Rotation Engines turn in the counterclockwise direction when the engines are viewed from the flywheel end.
( 3 )	SAE Opposite Rotation Engines turn in the clockwise direction when the engines are viewed from the flywheel end.

Illustration 35	g01283092
3608 cylinder and valve location (A) Inlet (B) Exhaust

Table 6

Crankshaft Positions for Fuel Injector and Valve Lash Setting
3608 Engine	Check and Adjust with No. 1 Piston on the Following Stroke: (1)
	Top Center Compression Stroke	Top Center Exhaust Stroke
SAE Standard Rotation Engines (2)
Inlet Valves	1-4-6-7	2-3-5-8
Exhaust Valves	1-2-4-6	3-5-7-8
Fuel Injectors	2-3-5-8	1-4-6-7
Firing Order	1-6-2-5-8-3-7-4
SAE Opposite Rotation Engines (3)
Inlet Valves	1-2-4-6	3-5-7-8
Exhaust Valves	1-4-6-7	2-3-5-8
Fuel Injectors	3-5-7-8	1-2-4-6
Firing Order	1-4-7-3-8-5-2-6

( 1 )	Put the No. 1 piston at the top center position and identify the correct stroke. Refer to Testing And Adjusting, "Finding the Top Center Position for the No. 1 Piston". After the top center position for a particular stroke is found and the adjustments are made for the correct cylinders, remove the timing pin. Turn the flywheel for 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders that remain.
( 2 )	SAE Standard Rotation Engines turn in the counterclockwise direction when the engines are viewed from the flywheel end.
( 3 )	SAE Opposite Rotation Engines turn in the clockwise direction when the engines are viewed from the flywheel end.

Illustration 36	g01192815
3612 Cylinder And valve location (A) Exhaust (B) Inlet (C) Flywheel

Table 7

Crankshaft Positions for Fuel Injector and Valve Lash Adjustment
3612 Engine	Check And Adjust With No. 1 Piston On The Following Stroke: (1)
	Top Center Compression Stroke	Top Center Exhaust Stroke
SAE Standard Rotation Engines (2)
Inlet Valves	1-3-6-7-10-12	2-4-5-8-9-11
Exhaust Valves	1-4-5-6-9-12	2-3-7-8-10-11
Fuel Injectors	2-4-5-8-9-11	1-3-6-7-10-12
Firing Order	1-12-9-4-5-8-11-2-3-10-7-6
SAE Opposite Rotation Engines (3)
Inlet Valves	1-4-5-6-9-12	2-3-7-8-10-11
Exhaust Valves	1-3-6-7-10-12	2-4-5-8-9-11
Fuel Injectors	2-3-7-8-10-11	1-4-5-6-9-12
Firing Order	1-6-7-10-3-2-11-8-5-4-9-12

( 1 )	Put the No. 1 piston at the top center position and identify the correct stroke. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". After the top center position for a particular stroke is found and the adjustments are made for the correct cylinders, remove the timing pin. Turn the flywheel for 360 degrees in the direction of normal engine rotation. This will put the No. 1 piston at the top center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders that remain.
( 2 )	SAE Standard Rotation Engines turn in the counterclockwise direction when the engines are viewed from the flywheel end.
( 3 )	SAE Opposite Rotation Engines turn in the clockwise direction when the engines are viewed from the flywheel end.

Valve Bridge Adjustment

When the cylinder head is disassembled, keep the bridges and the respective valves together. To make an adjustment to the bridges, use the procedure that follows:

Note: The bridges can be adjusted without removal of the rocker arms and shafts. Valves must be fully closed when the adjustment is made. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". Also refer to ""Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting" ". These references contain information regarding the valve position.

Illustration 37	g01267748
Bridge Installation (1) Top contact surface (2) Locknut (3) Bridge

Illustration 38	g00565733
Bridge Adjustment (2) Locknut (3) Bridge (4) Adjustment screw (5) Bridge dowel

1. Lubricate bridge dowel (5) in the cylinder head and the bore in bridge (3) with 8T-2998 Lubricant .

2. Install bridge (3). The adjustment screw (4) should be positioned toward the exhaust manifold.

3. Loosen locknut (2) and adjustment screw (4) for several turns.

4. Put a force of 50 ± 10 N (11 ± 2 lb) by hand straight down on top contact surface (1) of bridge (3) .

5. Turn adjustment screw (4) clockwise, until the adjustment screw makes contact with the valve stem. Turn the adjustment screw clockwise for another 45 degrees in order to make bridge (3) straight on the bridge dowel (5). Also, this additional rotation compensates for the clearance in the threads of the adjustment screw.

6. Hold adjustment screw (4) in this position and tighten locknut (2) to a torque of 100 ± 15 N·m (75 ± 11 lb ft).

7. Put clean engine oil on top contact surface (1) at the contact point between the rocker arm and bridge (3) .

Valve Lash Adjustment

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NOTICE
The procedures for engine valve lash should be performed according to the information in the Service Manual. Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

Table 8

Setting The Valve Lash (1)
Valves	Dimension Of The Feeler Gauge
Inlet	0.60 mm (.024 inch)
Exhaust	1.0 mm (.039 inch)

( 1 )

The valve lash should only be adjusted while the engine is stopped.

1. Rotate the No. 1 piston to the Top Center position. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". With the No. 1 piston at the Top Center position of the compression stroke, adjust the valves. Refer to ""Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting" ".

2. Ensure that the valve bridges are adjusted. Refer to ""Valve Bridge Adjustment" ".

3. Insert the 6V-3075 Dial Indicator from the timing group into the 4C-6593 Adjustment Tool . Tighten the retaining screw finger tight.

   Note: Make sure that the 6V-3075 Dial Indicator is used with the short contact point.

4. Use the threaded hole that is nearest to the end of the rocker arm that will be adjusted in order to install the adjustment tool on the rocker base. Position the dial indicator stem over the flat area on the end of the rocker arm. Tighten the knob. Rotate the dial indicator so that the dial indicator can be easily read. Make sure that the adjustment tool is rigid and that the dial indicator stem moves freely.

5. Loosen the locknut on the rocker arm adjustment screw and turn the rocker arm adjustment screw clockwise until there is no valve lash. Loosen slightly. The valve lash should be zero. The valves should not be open any amount.

6. Set the dial indicator to zero.

7. Lift up firmly on the valve end of the rocker arm and turn the rocker arm adjustment screw until the dial indicator shows 0.60 mm (.024 inch) for the inlet valves, and 1.00 mm (.039 inch) for the exhaust valves.

8. Try to move the rocker arm while you are lifting up on the rocker arm. The dial indicator reading will vary. Read the dial indicator when the rocker arm is positioned in the groove of normal operation.

9. Tighten the locknut on the adjustment screw to a torque of 200 ± 25 N·m (150 ± 18 lb ft).

10. Recheck the valve lash setting in order to ensure that the valve lash is correct. Reset, as required.

11. After completing all of the valve lash checks and the valve lash adjustments for this crankshaft position, remove the timing pin from the crankshaft. Rotate the crankshaft to the next position. Install the timing pin in the crankshaft. Repeat Steps 2 through 10.

12. Remove the timing pin from the crankshaft when all valve lash adjustments have been completed.

Fuel Injector Adjustment

Table 9

Tools Needed	Quantity
4C-6594 Timing and Fuel Setting Tool	1
6V-3075 Dial Indicator	1
6V-9058 Fixture As	1
8S-3675 Indicator Contact Point	1
6V-9056 Setting Gauge	1

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The Electronic Control Module produces high voltage. To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected.

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NOTICE
The camshafts must be correctly timed with the crankshaft before an adjustment of the unit injector lash is made. The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result.

Note: This adjustment is critical. Ensure that the adjustment of the fuel injector is made properly.

1. Refer to ""Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting" ". All of the injectors can be checked or adjusted with the two crankshaft positions in the chart. This will make sure that the pushrod lifters are off of the lobes and on the base circles of the camshaft.

   Before a check or an adjustment can be made, the tooling must be set to the correct dimension. Use the following procedure in order to set the tooling to the correct dimension:

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   Illustration 39	g00359732
   Adjustment Of Fuel Timing Tools (1) 6V-3075 Dial indicator (2) 6V-9058 Fixture assembly (3) 6V-9056 Setting gauge (4) 8S-3675 Indicator contact point

   1. Install 8S-3675 Indicator Contact Point (4) on the 6V-3075 Dial Indicator (1) .

   2. Install 6V-3075 Dial Indicator (1) in the collet of 6V-9058 Fixture Assembly (2) .

   3. Install 6V-3075 Dial Indicator (1) with 6V-9058 Fixture Assembly (2) onto 6V-9056 Setting Gauge (3). Ensure that the magnetic base of the timing fixture is on the top surface and that the contact point is on the bottom step.

      Note: The 6V-3075 Dial Indicator (1) has two or three dials that register. The larger dial has marks for every 0.01 mm (0.0004 inch). The red numbers on the dial are for minus readings. The black numbers on the dial are for plus readings. The smaller dial has marks for 1.00 mm (0.040 inch) (one complete revolution of the large dial).

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Illustration 40	g01186891

2. Ensure that the top surface of fuel injector's retainer (5) and shoulder (6) are clean and dry.

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Illustration 41	g01186906
Fuel timing tools in position Typical example (1) 6V-3075 Dial indicator (2) 6V-9058 Fixture assembly (7) Rocker arm adjustment screw (8) Rocker arm adjustment screw locknut

3. Put 6V-3075 Dial Indicator (1) that is installed in 6V-9058 Fixture Assembly (2) into position on the fuel injector. Make sure that the magnetic base of the timing fixture is on the top surface of the fuel injector's retainer and that the contact point is on the top surface of shoulder (6) .

   Note: The pointer on both dials on the dial indicator must indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch).

4. If the dial indicator pointers are within the range of 0.00 ± 0.20 mm (0.000 ± 0.008 inch), no adjustment is necessary. Proceed to Step 10.

5. If the dial indicator pointers are not within the range of 0.00 ± 0.20 mm (0.000 ± 0.008 inch), complete Steps 6 through 10.

6. Loosen the rocker arm adjustment screw locknut (8) on the fuel injector that requires adjustment.

7. Put 6V-3075 Dial Indicator (1) that is installed in 6V-9058 Fixture Assembly (2) into position on the fuel injector. Make sure that the magnetic base of the timing fixture is on the top surface of the fuel injector's retainer and that the contact point is on the top surface of shoulder (6) .

8. Turn rocker arm adjustment screw (7) until the dial indicator indicates "0".

   A setting of "0" means that the height of the spring has been set to 118.2 mm (4.6535 inch).

9. Tighten rocker arm adjustment screw locknut (8) to a torque of 200 ± 25 N·m (150 ± 18 lb ft), and check the adjustment again. If necessary, do this procedure until the adjustment is correct.

10. Remove the timing pin from the crankshaft when the fuel injector adjustment check is completed.

Engine Wiring System

The engine wiring system consists of the following components.

• Primary Electronic Control Module (ECM)

• Backup ECM

• Rigid rail

• Customer Interface Panel (CIP)

1. Remove the 157-5187 Control Panel Gp .

   The control panel will not be reused.

2. Remove the 147-2968 Pressure Sensor Gp .
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   Illustration 42	g01267015
   (1) 147-2968 Pressure Sensor Gp

   1. For in-line engines, sensor (1) is located on the exhaust manifold.
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   Illustration 43	g01267013
   (1) 147-2968 Pressure Sensor Gp

   2. For vee engines, sensor (1) is located on the aftercooler.

Rigid Rail

Illustration 44	g01164903

The rigid rail provides a protected, serviceable conduit for the following engine wiring harnesses.

• Inlet manifold air pressure sensor

• Primary speed timing sensor

• Secondary speed timing sensor

• Fuel injector solenoids

Install the Rigid Rail

Table 10

Required Parts
Sales Model	Part Number	Description
3606	273-4807	Engine Wiring Gp
3608	273-4806	Engine Wiring Gp
3612	273-4769	Engine Wiring Gp

1. Install the wiring group onto the engine.

2. Replace the thermocouples on the engine with the 283-6459 Temperature Sensor Gps .

3. Connect all of the harnesses for the fuel injectors to the fuel injectors.

Primary ECM

The main function of the primary ECM is to control fuel delivery and engine timing. The primary ECM also provided the following functions.

• Diagnostic and event information

• Sensor parameters

• Messenger communications

• Smoke control

• Load feedback

• Fuel usage data

Secondary ECM

The secondary ECM provides a means to operate the engine if the primary ECM fails. The secondary ECM monitors the Cat data link and the primary ecm heartbeat signal. The secondary ECM also provides a backup for the Marine Monitoring System (MMS) and/or the Marine Monitoring System II (MMSII) overspeed protection.

The secondary ECM does not support the following functions.

• Messenger communications

• Smoke control

• Timing control

• Load feeback

Install the ECM Mount and the ECMs (6 Cylinder and 8 Cylinder)

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Illustration 45	g01265814
(1) 273-4776 Bracket As (2) 273-4775 Bracket As (3) 285-4386 Cover As (4) Primary ECM (5) Secondary ECM (6) 236-7534 Pressure Sensor Gp (7) 273-4797 Control Harness As (8) 132-5789 Clip (9) 4P-7581 Clip

1. Assemble the 273-4777 Engine Electronic Control and Mounting Gp .

   1. Install ECMs (4) and (5) onto bracket (1) using 8T-9655 Isolation Mounts , 6I-1418 Spacers , 9N-0869 Hard Washers and 7X-0818 Bolts .

   2. Use 5P-4116 Hard Washers and 8T-4908 Bolts to install bracket (2) .

   3. Use 5P-4116 Hard Washers and 8T-4189 Bolts to install cover (3) .

   4. Install harness (7). Use 7K-1181 Cable Straps and clips (8) and (9) to secure the harness.

   5. Use 7K-1181 Cable Straps to install sensor (6) .

   6. Install the bulkhead connector for the rigid rail.

   7. Install the bulkhead connector for the Marine Monitoring System (MMS).

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Illustration 46	g01265828
Typical example (10) Center line (11) 273-4778 Access Cover As

2. Install the 273-4779 Engine Electronic Control and Mounting Gp onto the right side of the engine.

   For 3606 engines, centerline (10) is the centerline for the number five cylinder of the engine. For 3608 engines, centerline (10) is the centerline for the number seven cylinder of the engine.

   1. Use 5P-1075 Hard Washers and 5S-7383 Bolts to install bracket (1) onto the engine.

   2. Use 5P-1075 Hard Washers and 7X-0288 Bolts to install bracket (2) onto the engine.

   3. Connect harness (7) to the wiring harness for the rigid rail.

   4. Ensure that all electrical connections are properly secured.

   5. Use 5P-4116 Hard Washers and 8T-4189 Bolts to install cover (11) .

Install the ECM Mount and the ECMs (12 Cylinder)

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Illustration 47	g01265886
(4) Primary ECM (5) Secondary ECM (6) 236-7534 Pressure Sensor Gp (7) 273-4797 Control Harness As (8) 132-5789 Clip (12) 273-4726 Mounting Bracket As

1. Assemble the 273-4730 Engine Electronic Control and Mounting Gp .

   1. Install the ECMs (4) and (5) onto bracket (12) using 8T-9655 Isolation Mounts , 6I-1418 Spacers , 9N-0869 Hard Washers and 7X-0818 Bolts .

   2. Install harness (7). Use 7K-1181 Cable Straps and clips (8) to secure the harness.

2. Install the primary and the secondary ECMs on the 273-4730 Engine Electronic Control and Mounting Gp .

3. Connect all wiring harness connections.

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Illustration 48	g01266142
273-4728 Support As

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Illustration 49	g01266190
Flywheel side of the engine (13) 9X-8887 Bolt (14) 0S-1591 Bolt (15) 8T-2502 Bolt (16) 1A-2029 Bolt

4. Install the 273-4728 Support .

   1. Install bolts (13) in location (A) by using 5P-8248 Hard Washers .

   2. Install bolts (14) in location (B) by using 5M-2894 Hard Washers .

5. Install the 273-4730 Engine Electronic Control and Mounting Gp .

   1. Install bolts (15) in location (C) by using 8T-4121 Hard Washers .

   2. Install sensor (6) at location (E) .

   3. Install the bulkhead connectors for the rigid rail.

   4. Install the bulkhead connectors for the MMS.

6. Install the 273-4727 Cover onto the 273-4728 Support .

   Install bolts (16) in location (D) by using 5M-2894 Hard Washers .

235-5200 Instrument Mounting Group

Illustration 50	g01266318
Typical example of the 235-5195 Instrument Panel Gp (17) Messenger (18) Speed control (19) Speed control potentiometer (20) Local/Remote Switch (21) General alarm relay or shutdown notify relay (22) General alarm relay or shutdown notify relay (23) Secondary ECM ready lamp (24) Secondary ECM active lamp (25) Diagnostic primary lamp (26) Diagnostic secondary lamp (27) Isolator for load feedback (28) Breaker for main power 20A (29) Breaker for primary ECM 10A (30) Breaker for secondary ECM 10A (31) Breaker for other loads 10A (32) Isolator for secondary throttle (33) Isolator for primary throttle

Note: The instrument panel can be mounted remotely.

1. Install the 235-5200 Instrument Mounting Group in a suitable location.

   Mount the 235-5200 Instrument Mounting Group close to the MMS panel. This will minimize the length of wiring that is needed to connect the two panels. Refer to the Electrical Schematic for the engine to aid in connecting the two panels.

2. On 3606 and 3608 engines, install the 235-5147 Engine Harness As from the 273-4777 Engine Electronic Control and Mounting Gp to the 235-5195 Instrument Panel Gp .

3. On 3612 engines, install the 235-5147 Engine Harness As from the 237-4730 Engine Electronic Control and Mounting Gp to the 235-5195 Instrument Panel Gp .

Customer Connector

Illustration 51	g01185928

Table 11

Customer Connector
Pin Number	Function	Pin Number	Function
1	Positive battery	21	Shutdown notify relay (NC)
2	Negative battery	22	Unused
3	Negative battery	23	Backup diagnostic lamp
4	Unused	24	Primary diagnostic lamp
5	Positive battery	25	Load feedback signal negative
6	CAT data link negative	26	Load feedback signal positive
7	CAT data link positive	27	Backup ECM active
8	Positive battery	28	Backup ECM ready
9	Negative battery	29	Unused
10	Remote throttle position (PWM)	30	Key switch input
11	Air shutoff signal	31	Local/remote throttle select
12	Air shutoff driver return	32	Unused
13	Unused	33	Local speed potentiometer 1
14	Key switch output	34	Local speed potentiometer 2
15	Unused	35	Local speed potentiometer 3
16	Shield for the CAN data link	36	Remote shutdown
17	CAN data link positive	37	Unused
18	CAN data link negative	38	Unused
19	Shutdown notify relay (C)	39	Remote throttle position (4-20) negative
20	Shutdown notify relay (NO)	40	Remote throttle position (4-20) positive

The customer connector is a 40 pin connector that is mounted on the bottom of the Customer Interface Panel (CIP). The customer connector provides the following.

• Power output

• Customer interface

• MMS/MMSII interface

228-7424 Monitor Display Gp (Messenger)

Illustration 52	g01185757
Panel mounted display (1) 228-7424 Monitor Display Gp

The 228-7424 Monitor Display Gp connects to the CAN data link. The display on the unit shows the following menus.

• "System Parameters"

• "Totals Information"

• "Diagnostic Data"

• "Display Configuration"

Note: All wiring must meet local requirements. All wiring must be 16 gauge wire or larger.

Illustration 53	g01185069

The 228-7424 Monitor Display Gp can be remotely mounted up to 30.5 m (100 ft) from the 235-5195 Instrument Panel Gp .

Remote Mounting of the 228-7424 Monitor Display Gp

Illustration 54	g01185070

1. Construct a harness that is the desired length.

   Refer to Illustration 54 for the connector pin out information.

2. Mount the 228-7424 Monitor Display Gp in the desired location.

   The 227-4283 Mounting Bracket Gp is used when the display is mounted remotely.

Marine Monitoring System (MMS) and Marine Monitoring System II (MMSII)

Power Connections to the Customer Interface Panel (CIP)

Illustration 55	g01185446

Note: The power supplies for the MMS/MMSII and the EUI may be the same. If the power supplies for the MMS/MMSII and the EUI are different, the B negative must be grounded in the same location.

Illustration 56	g01266411
156-1460 Receptacle (1) 235-5200 Instrument Mounting Group (2) 156-1460 Receptacle

The power connection supplies power to the electronic fuel injector (EUI) system. The receptacle (3) connects to the 172-3998 Plug As . The wire size for the power connections must be at least 12 AWG.

Connections for the Air Shutoff to the CIP

Illustration 57	g01185501

Connections for the Shutdown Signal to the CIP

Illustration 58	g01185520

The shutdown signal connections allow the MMS/MMSII to shutdown the engine. The engine is shutdown by energizing the fuel control relay.

The relay will be energized when any of the following conditions are met.

• Fuel duration is set to zero.

• RPM is below 60 RPM.

• Shutdown input is active from the MMS/MMSII

Connections for the Shutdown Notification Output to the Customer Connection

Illustration 59	g01185531

The shutdown notify relay will be energized when any of the following conditions are met.

• Fuel duration is set to zero.

• RPM is below 60 RPM.

• Shutdown input is active from the MMS/MMSII

Load Feedback Signal Connections to the Customer Connector (if Installed)

Illustration 60	g01262005

The 283-9351 Sensor Harness As load feedback isolator provides a signal to the primary ECM. This signal is proportional to the percent of available power that the engine can produce. The signal from the isolator must be isolated. The load feedback isolator replaces the position indicator on the Heinzmann rack. Refer to the Troubleshooting manual for information on calibrating the load feeback isolator.

The load feeback isolator is installed in the CIP. Refer to Illustration 50.

Throttle Input Connections to the CIP

Illustration 61	g01185789
(3) 8D-2676 Toggle Switch (4) 9X-9591 Electrical Converter Gp (5) 127-9069 Potentiometer

The throttle input provides a throttle signal to the primary ECM and the to the backup ECM. The throttle input also allows for local control of the engine speed.

EUI Wiring Check

Power Up the EUI system

1. Energize the breakers.

2. Ensure that the breakers remain energized.

Connect Caterpillar Electronic Technician (ET) to the CIP

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.

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

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Illustration 62	g01266529
(1) PC (2) 196-0055 Serial Cable or the 160-0141 Serial Cable (3) 171-4401 Communication Adapter II (4) 207-6845 Adapter Cable

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

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

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

5. Connect cable (4) to the service tool connector on the engine mounted CIP.

6. Turn the engine control switch to the LOCAL position or to the REMOTE position. Turn the fuel control switch to the FUEL OFF 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 With ECM".

Troubleshooting

Refer to Troubleshooting, RENR5084 for more information on the following components.

• Sensor faults

• Injector faults

• Response checks for the throttle input

• Shutdown input response checks

Requirements for the Electrical System

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

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 12 are required in order to enable a service technician to perform the electrical installation procedures and the initial start-up.

Note: Other tools that are needed for measuring operating parameters such as pressure and temperature are not listed in Table 12.

Table 12

Service Tools
Pt. No.	Description	Functions
N/A	Personal Computer (PC)	This PC configuration is recommended: Intel Pentium II 333 mHz processor 64 megabyte of RAM 4.3 GB hard drive Drive for floppy disks (3.5 inch with 1.44 MB) 14X speed CD-ROM drive VGA monitor or display RS-232 port with 16550AF UART Windows NT 4.0 (1) Windows 95 (1) Windows 98 (1) Mouse
N/A	Personal Computer (PC)	This PC configuration has the minimum requirements: IBM PC compatible 100 MHz processor 32 megabyte of RAM 10 MB of available hard drive space CD-ROM drive Drive for floppy disks (3.5 inch with 1.44 MB) Windows NT 4.0 (1) Windows 95 (1) Windows 98 (1) RS-232 port with 16550AF UART VGA monitor or display Mouse
"JERD2124"	Software	Single user license for Caterpillar Electronic Technician (Cat ET) Use the most recent version of this software.
"JERD2129"	Software	Data subscription for all engines
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 junction 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.

( 1 )	Any of these operating systems are acceptable.
( 1 )	This item is included in the 171-4400 Communication Adapter Gp .

The Caterpillar Electronic Technician (Cat ET) is designed to run on a personal computer. Either the 171-4401 Communication Adapter II or the 7X-1700 Communication Adapter Gp 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

Start-up Procedure

Refer to the Operation and Maintenance, "Starting the Engine". Verify that the throttle control switch is in the LOCAL position.

Verify that the fuel pressure for the engine is set correctly. The fuel pressure must be 820 ± 20 kPa (120 ± 3 psi). Measure the fuel pressure by using the MMS or by using a mechanical fuel pressure gauge (if equipped).

Verify that the Fuel Injectors are Operating Properly

Perform an injector solenoid test using Cat ET. Verify that each of the injectors is operating properly.

Verify that the Messenger Display is Operating Properly

1. Verify that the display is operating properly.

2. Verify that the data screens are functioning properly.

Transfer Control to the Remote Speed Control

1. Ensure that the remote throttle is in the IDLE position.

2. Ensure that the local throttle is in the IDLE position.

3. Switch the remote/local throttle control switch to the REMOTE position. Refer to (20) in Illustration 50 that is located in "" 235-5200 Instrument Mounting Group " ".

Control the Engine Speed by Using the Remote Speed Control

Verify that the engine operates properly using the remote speed control.

Ensure the Electrical System is Operating Properly

Disable Sensors

Unplug each sensor. Verify that Cat ET shows the fault for each sensor.

Disable the Primary ECM

Switch the breaker for the primary ECM to the OFF position. Refer to Illustration 50 for the location of the breaker. Verify that the secondary ECM active lamp of the CIP is illuminated.

Check for the Proper Operation of the Shutdown Notify

Verify that the shutdown notify relay is energized when the engine is running.

Check for the Proper Operation of the Load Output

Use Cat ET to calibrate the load output isolator. Refer to Troubleshooting, RENR5084, "Load Feedback - Calibrate" for more information.