ADEM 3 Conversion for G3500 Engines{1000, 1901} Caterpillar

Engine:Commercial G3500 Family

Introduction

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

This Special Instruction describes the installation of the ADEM 3 Electronic Control Module (ECM) on G3500A Engines. The ADEM 3 electronic control improves performance and reliability by integrating the following functions:

• Engine Governing

• Engine monitoring

• Air/fuel ratio control

• Ignition timing

• Detonation control

• Engine prelube

The ADEM 3 control system is also commonly known as the A+ or the A3 control system.

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

References

The following reference materials may be necessary for this procedure:

Disassembly and Assembly Manual, SENR6419 Special Instruction, REHS2558, "Installation and Start-up Procedure for G3500 A3 Engines"

System Description

Illustration 1	g01247636
Typical engine configuration (1) Throttle actuator (2) Exhaust Temperature Module (ETM) (3) Engine interface box (EIB) (4) ADEM 3 Engine Control Module (ECM) (5) Actuator for air/fuel ratio control (6) Fuel valve

Illustration 2	g01431190
Rear view (7) Oxygen sensor (8) Adapter plate for oxygen sensor (9) Oxygen buffer

Illustration 3	g01431205
View A-A (10) Fuse (F3) main system (11) Fuse (F4) throttle (12) Fuse (F5) air/fuel ratio control (13) Ground wire (14) Jumper wire (P200-C19) (15) Battery (-) () Battery (+)

Parts List

Conversion Arrangement for G3508 with Single Turbocharger

Table 1 lists the options for the following application:

• 300-4123 Engine Conversion Ar

• G3508 petroleum engine

• High-pressure gas

• Canadian Standards Association (CSA) specification

• Air start system

• Single circuit cooling system

• Single turbocharger

Table 1

Options for G3508 Conversion Arrangement with Single Turbocharger 300-4123
Qty	Part Number	Description	Remarks
1	251-9444	Control Box Gp	Remote mounted advisor panel
1	251-9466	Wiring Harness	20 foot interconnect harness EIB to remote advisor panel
1	251-9467	Wiring Harness	30 foot interconnect harness EIB to remote advisor panel
1	251-9468	Wiring Harness	50 foot interconnect harness EIB to remote advisor panel
1	251-9513	Air Starting Lines Gp	For use with vane type air start motor without prelube
1	273-3130	Air Starting Lines Gp	For use with turbine type air start motor without prelube
1	273-3107	Electronic Control Wiring Gp	Wiring group for PL 1000E for use with remote advisor panel
1	273-3110	Electronic Control Wiring Gp	Wiring group for PL 1000T for use with remote advisor panel
1	298-4719	AFRC Conversion Gp	For use with engines with existing Air/Fuel Ratio Control (AFRC)
1	298-4715	AFRC Conversion Gp	For use with engines without existing AFRC
1	300-4125	Wiring Harness Fastener Gp	For use with engines without existing AFRC and not upgrading to AFRC
1	298-4717	AFRC Conversion Wiring Gp	For use with engines with AFRC upgrading to A3
1	298-4716	AFRC Conversion Wiring Gp	For use with engines upgrading to AFRC

Conversion Arrangement for G3508 with Dual Turbochargers

Use the 251-9420 Pyrometer Wiring Gp for engines with dual turbochargers. Table 2 lists the options for the following application:

• 300-4124 Engine Conversion Ar

• G3508 petroleum engine

• High-pressure gas

• Canadian Standards Association (CSA) specification

• Air start system

• Single circuit cooling system

• Dual turbochargers

Table 2

Options for G3508 Conversion Arrangement with Dual Turbochargers 300-4124
Qty	Part Number	Description	Remarks
1	251-9444	Control Box Gp	Remote mounted advisor panel
1	251-9466	Wiring Harness	20 foot interconnect harness EIB to remote advisor panel
1	251-9467	Wiring Harness	30 foot interconnect harness EIB to remote advisor panel
1	251-9468	Wiring Harness	50 foot interconnect harness EIB to remote advisor panel
1	251-9513	Air Starting Lines Gp	For use with vane type air start motor without prelube
1	273-3130	Air Starting Lines Gp	For use with turbine type air start motor without prelube
1	273-3107	Electronic Control Wiring Gp	Wiring group for PL 1000E for use with remote advisor panel
1	273-3110	Electronic Control Wiring Gp	Wiring group for PL 1000T for use with remote advisor panel
1	298-4719	AFRC Conversion Gp	For use with engines with existing Air/Fuel Ratio Control (AFRC)
1	298-4715	AFRC Conversion Gp	For use with engines without existing AFRC
1	300-4125	Wiring Harness Fastener Gp	For use with engines without existing AFRC and not upgrading to AFRC
1	298-4717	AFRC Conversion Wiring Gp	For use with engines with AFRC upgrading to A3
1	298-4716	AFRC Conversion Wiring Gp	For use with engines upgrading to AFRC

Conversion Arrangement for G3512 Engines

Table 3 lists the options for the following application:

• 300-4122 Engine Conversion Ar

• G3512 petroleum engine

• High-pressure gas

• Canadian Standards Association (CSA) specification

• Air start system

• Single circuit or two circuit cooling system

Table 3

Options for G3512 Conversion Arrangement 300-4122
Qty	Part Number	Description	Remarks
1	251-9444	Control Box Gp	Remote mounted advisor panel
1	251-9466	Wiring Harness	20 foot interconnect harness EIB to remote advisor panel
1	251-9467	Wiring Harness	30 foot interconnect harness EIB to remote advisor panel
1	251-9468	Wiring Harness	50 foot interconnect harness EIB to remote advisor panel
1	251-9513	Air Starting Lines Gp	For use with vane type air start motor without prelube
1	273-3130	Air Starting Lines Gp	For use with turbine type air start motor without prelube
1	251-9499	Air Starting Lines Gp	For use with vane type air start motor with prelube
1	273-3131	Air Starting Lines Gp	For use with turbine type air start motor with prelube
1	296-7709	Prelube Motor Air Lines Gp	For use with engines with air prelube pump motor and vane type air start motor
1	296-6780	Prelube Motor Air Lines Gp	For use with engines with air prelube pump motor and turbine type air start motor
1	273-3107	Electronic Control Wiring Gp	Wiring group for PL 1000E for use with remote advisor panel
1	273-3110	Electronic Control Wiring Gp	Wiring group for PL 1000T for use with remote advisor panel
1	298-4718	AFRC Conversion Gp	For use with engines with existing Air/Fuel Ratio Control (AFRC)
1	298-4714	AFRC Conversion Gp	For use with engines without existing AFRC
1	300-4125	Wiring Harness Fastener Gp	For use with engines without existing AFRC and not upgrading to AFRC
1	298-4717	AFRC Conversion Gp	For use with engines with AFRC upgrading to A3
1	298-4716	AFRC Conversion Gp	For use with engines upgrading to AFRC

Conversion Arrangement for G3516 Engines

Table 4 lists the options for the following application:

• 300-4121 Engine Conversion Ar

• G3516 petroleum engine

• High-pressure gas

• Canadian Standards Association (CSA) specification

• Air start system

• Single circuit or two circuit cooling system

Table 4

Options for G3516 Conversion Arrangement 300-4121
Qty	Part Number	Description	Remarks
1	251-9444	Control Box Gp	Remote mounted advisor panel
1	251-9466	Wiring Harness	20 foot interconnect harness EIB to remote advisor panel
1	251-9467	Wiring Harness	30 foot interconnect harness EIB to remote advisor panel
1	251-9468	Wiring Harness	50 foot interconnect harness EIB to remote advisor panel
1	251-9513	Air Starting Lines Gp	For use with vane type air start motor without prelube
1	273-3130	Air Starting Lines Gp	For use with turbine type air start motor without prelube
1	251-9499	Air Starting Lines Gp	For use with vane type air start motor with prelube
1	273-3131	Air Starting Lines Gp	For use with turbine type air start motor with prelube
1	5N-8354	Prelube Motor Air Lines Gp	For use with engines with air prelube pump motor and vane type air start motor
1	296-6781	Prelube Motor Air Lines Gp	For use with engines with air prelube pump motor and turbine type air start motor
1	273-3107	Electronic Control Wiring Gp	Wiring group for PL 1000E for use with remote advisor panel
1	273-3110	Electronic Control Wiring Gp	Wiring group for PL 1000T for use with remote advisor panel
1	298-4718	AFRC Conversion Gp	For use with engines with existing Air/Fuel Ratio Control (AFRC)
1	273-3118	AFRC Conversion Gp	For use with engines without existing AFRC
1	300-4125	Wiring Harness Fastener Gp	For use with engines without existing AFRC and not upgrading to AFRC
1	298-4717	AFRC Conversion Wiring Gp	For use with engines with AFRC upgrading to A3
1	298-4716	AFRC Conversion Wiring Gp	For use with engines upgrading to AFRC

Prepare the Engine

Ensure that the engine is safe to work on by taking the following precautions:

• Disconnect the cables from the engine battery.

• Drain the engine coolant.

• Shut off the gas supply to the engine.

• Ensure any source of electrical, hydraulic, or compressed air energy is disconnected.

• Follow lock out, tag out procedures.

Remove the Existing Electronic Ignition System (EIS) Components

Remove the EIS Interconnect Harness, EIS Control Module, EIS Remote Panel (Supervisory Panel)

1. Remove engine harness (1) for the EIS control module. Remove all other external engine harnesses.

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Illustration 4	g01282629
EIS control module and interconnect harness

2. Remove EIS control module (2) .

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Illustration 5	g01282399
EIS control module

3. Remove mounting plate (3) for the EIS control module.

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Illustration 6	g01282598
Mounting plate for the EIS control module

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Illustration 7	g01282608
Mounting plate removed

4. Remove EIS remote panel (4) (supervisory panel) and interconnect harness.

Illustration 8	g01282645
Remote panel (supervisory panel with optional AFRC)

Remove the Gauge Panel

Illustration 9	g01249980

1. Remove gauge panel (1). Remove any mounting brackets, hoses, or metal tubing.

Remove the Sensors and Switches

1. Remove all existing sensors and switches from the engine. Examples of sensors that are removed are the following:
   • Exhaust Temperature sensors (thermocouples)

   • Oil filter differential pressure sensor

   • Manifold air temperature sensor

   • Manifold pressure sensor

   • Engine oil temperature sensor

   • Engine coolant temperature sensor

   • Engine oil pressure sensor

   Note: Plug the orifice or cap the orifice where a hose, sensor, or tubing was removed from the engine. Refer to the 273-3117 Conversion Gp .

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Illustration 10	g01283178
Exhaust temperature thermocouple

2. Remove exhaust temperature thermocouple (1) at each cylinder. Do not plug these holes.

3. Remove inlet air temperature sensor (2). Install a plug into the port for the inlet air temperature sensor. Apply pipe sealant to the threads of the plug.

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Illustration 11	g01286288
(2) 9W-0532 Temperature Sensor Gp (3) 4P-5646 Elbow

4. Remove manifold air pressure sensor (4) .

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Illustration 12	g01282713
Manifold air pressure sensor (maps sensor)

5. Plug or cap connection (5) at the intake plenum. Refer to Illustration 13.

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Illustration 13	g01286062
Plug the orifice or cap the orifice for the maps sensor

6. Remove coolant temperature sensor (6) .

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Illustration 14	g01282730
Coolant temperature sensor

7. Remove detonation sensors (7) from both the left side of the engine and the right side of the engine.

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Illustration 15	g01282792
Detonation sensor (left side shown)

8. Remove oil pressure sensor (8) .

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Illustration 16	g01286108

9. Install plug (9) into the orifice for the oil pressure sensor. Apply pipe sealant to the threads of the plug.

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Illustration 17	g01286101
(9) 7W-6492 Pipe Plug

10. Remove oil temperature sensor (10) from the side of the cylinder block.

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Illustration 18	g01282805
Oil temperature sensor

11. Install plug (11) into the orifice for the oil temperature sensor. Apply pipe sealant to the threads of the plug.

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Illustration 19	g01286182
(11) 8T-6765 Pipe Plug

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Illustration 20	g01282852
Magnetic pickups (right side shown)

12. Remove magnetic pickups (12) from the flywheel housing. Remove the magnetic pickups from both the left side of the engine and the right side of the engine.

13. Install plugs (13) and gaskets (14) into the holes for the magnetic pickups.

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Illustration 21	g01286083
(13) 5F-0304 Plugs (14) 4B-8407 Gasket

14. Remove existing speed timing sensor (15) .

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Illustration 22	g01282903
Speed timing sensor

15. Remove oxygen sensor (if equipped) (16) from adapter plate (17) .

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Illustration 23	g01283038
Oxygen sensor

16. Reuse adapter plate (17) for the oxygen sensor. Remove the exhaust heat shield if equipped. For certain applications, the exhaust stack may need support in order to access the adapter plate for the oxygen sensor.

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Illustration 24	g01283064
Adapter plate for the oxygen sensor

17. Reuse buffer (18) for the oxygen sensor.

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Illustration 25	g01283048
Buffer for the oxygen sensor

18. Remove exhaust temperature sensors (19) (if equipped).

    Note: Illustration 26 shows a temperature sensor that attached to a gauge panel.

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Illustration 26	g01283114
Exhaust temperature sensor (left side of engine shown)

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Illustration 27	g01283275
(11) 8T-6765 Pipe Plug

19. Plug any orifices that will not be used with the new A3 control system. The items could include tubes, sensors, or switches that were used with the previous system. Install plug (11) into the orifices for these devices. Apply pipe sealant to the threads of the plugs.

Remove the Engine Switches

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Illustration 28	g01319943

1. Remove all of the temperature switches and all of the pressure switches.

2. Oil level regulator (2) remains on the engine. Hose (1) must be rerouted.

3. Remove any hardware (3) for the installation of the jacket water inlet pressure switch. Refer to Illustrations 29 and 30.

Illustration 29	g01286321
Location for installation of new coolant pump inlet pressure switch

Illustration 30	g01286333
Hardware removed

Remove the Wiring Harnesses

1. Remove all the external wiring harnesses. The following engine harnesses remain on the engine. These harnesses are the internal ignition system harnesses.
   • 4P-9321 Engine Harness As , G3508

   • 4P-9322 Engine Harness As , G3512

   • 4P-7487 Engine Harness As , G3516

Remove the Governors, Actuators, and Linkages

1. Remove all governors, actuators, and linkages. Typical examples are shown in Illustrations 31 through 34.

Illustration 31	g00805672
3161 Governor

Illustration 32	g01046905
Throttle actuator

Illustration 33	g01344696
Heinzmann actuator

Illustration 34	g01250046
EG-3P actuator and linkage

Remove the Elbow for the Air Inlet Manifold

1. Remove elbow (2) for the air inlet manifold from cylinder number one. If necessary, the lifting eye in order to provide access to the elbow.

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Illustration 35	g01286468
Inlet elbow with lifting eye removed (1) 7N-5085 Flange (2) 7N-5079 Elbow

2. Flange (1) is reused. Note the orientation of the flange. The flange is marked TOP with raised lettering.

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Illustration 36	g01286506
(3) 102-2674 Arrestor Assembly (1) 7N-5085 Flange

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Illustration 37	g01286525
Inlet air elbow removed

3. The flame arrestor is located behind the flange for the inlet elbow. Note the orientation of the flame arrestor.

Remove the Oil Bypass Valve Cover

1. Remove bypass valve cover (1). The bypass valve is located on the front of the engine on the upper left side. The bypass valve cover is fastened to the oil filter housing with one 0L-1143 Bolt and two 0S-1619 Bolts . Reuse these bolts.

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Illustration 38	g01286729
(1) 4W-8468 Bypass Valve Cover

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Illustration 39	g01286743
Bypass valve cover removed (2) 6V-8001 O-Ring Seal (3) 5P-4892 O-Ring Seals

2. Clean the mating surface between the bypass valve cover and the oil filter housing. Replace the O-rings if necessary.

Note: Install the new oil bypass cover as soon as possible. The oil passages should not be left exposed to any contamination. Refer to ""Install the New Oil Bypass Cover" ".

Remove the Air Start Lines and the Prelube Lines

1. Turn off the supply of pressurized air. Purge the pressurized air from the air tube assemblies and the starting motor.

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Illustration 40	g00597642

2. Remove hose assemblies (1) for the air start motor. Remove the prelube lines.

3. Remove bolts (2) .

4. Remove U-bolt (3) and tube assemblies (4) .

Remove the Transformers

1. Remove the valve covers.

2. Remove the connector from each transformer.

3. Remove bolt (1) and retainer (if equipped) (2) that secures the transformer to the cylinder head.

   Note: If the engine was designed for CSA, the bolt and retainer will already be installed in the engine. Retain the bolt and retainer for reuse with the new A3 transformer.

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Illustration 41	g01321404
Transformer and retainer

4. Lift the transformer out of the cylinder head.

5. Remove the remaining transformers from the engine in the same manner. The spark plugs may be reused.

   Note: Reuse spark plugs unless the spark plugs need replacement. Replacement is based on the scheduled service interval for that engine. Spark plugs for the new A3 control system are the same previously used with EIS. New spark plugs are not part of the A3 conversion arrangements.

Illustration 42	g01282660
Valve cover and transformer removed

Install the Components

Install the Transformers

1. Install the new transformers. Lubricate seals (2) with clean engine oil.

   Note: Reuse spark plugs unless the spark plugs need replacement. Replacement is based on the scheduled service interval for that engine. Spark plugs for the new A3 control system are the same previously used with EIS. New spark plugs are not part of the A3 conversion arrangements.

   Note: The transformers must be changed in order to be compatible with the ADEM 3 control.

2. Secure the transformer with retainer (5) and bolt (4) .

   Note: If the engine was designed for CSA, the bolt and retainer will already be installed in the engine. Reuse the bolt and retainer with the new A3 transformer.

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Illustration 43	g01320047
(1) 259-2078 Ignition Transformer Gp (2) 135-2651 Seal (3) 125-1372 O-Ring Seal

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Illustration 44	g01320079
(4) 5B-5059 Bolt (5) 134-4723 Retainer As

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Illustration 45	g01286639
Transformers installed

3. Connect each transformer to the internal EIS harness connector.

4. Install the valve covers.

Install the Control Group and Mounting

1. Install the new ECM and the support bracket.

2. Remove any paint or oxidation from bracket (2) in order to ensure a good electrical contact.

Illustration 46	g01282608
Location for installation of the new ECM and support bracket

Illustration 47	g01431439
Mounting location for engines with single circuit cooling (1) 154-6713 Engine Electronic Control Gp (2) 251-9385 Bracket As (3) 2B-2694 Bolt (4) 8C-9987 Washer (5) 155-0576 Isolation Mount (6) 6I-1418 Spacer (7) 1D-4541 Bolt (8) 0S-1595 Bolt (9) 7D-1649 Hard Washer

Illustration 48	g01434688
Hardware for securing the engine harness (10) 9S-3232 Clip (11) 6B-6205 Spacer (12) 7X-0291 Bolt (13) 9L-9132 Washer (14) 9S-8752 Full Nut

Illustration 49	g01431440
View C-C (hardware for securing the engine harness) (15) 5P-8245 Hard Washer (16) 193-3973 Tie (17) 9X-8874 Bolt (18) 230-7732 Mount (19) 9F-4831 Spacer

Illustration 50	g01431447
Mounting location for engines with two circuit cooling (1) 154-6713 Engine Electronic Control Gp (2) 251-9385 Bracket As (3) 2B-2694 Bolt (4) 8C-9987 Washer (5) 155-0576 Isolation Mount (6) 6I-1418 Spacer (7) 1D-4541 Bolt (8) 0S-1595 Bolt (9) 7D-1649 Hard Washer

Illustration 51	g01436858
Hardware at rear of support bracket (20) 4P-8134 Clip (21) 2S-2301 Spacer (22) 9N-0869 Hard Washer (23) 5S-0003 Nut

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Illustration 52	g01437897
ECM and support bracket installed (24) Ground strap

1. Install ground strap (24) between bolt head (3) and washer (4) .

Note: Install lockwashers (4) against the shock mount surfaces in order to ensure a good electrical contact.

Illustration 53	g01435850
Front view

Install the Engine Interface Box (EIB) and the Exhaust Temperature Module

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Illustration 54	g01288746
Location for the Engine Interface Box (EIB)

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Illustration 55	g01316633
(1) 1H-3338 Lockwasher (2) 8T-4205 Hard Washer (3) 6V-8185 Nut (4) 4M-5281 Bolt (5) 7X-6035 Grounding Strap (6) 104-6564 Mount (7) 1B-4971 Spacer (8) 5P-2675 Bolt (9) 0S-1588 Bolt (10) 5M-2894 Hard Washer (11) 251-9389 Bracket (12) 6V-8801 Nut (13) 8T-4896 Hard Washer (14) 4P-8134 Clip (15) 4L-6454 Bolt (16) 5S-7349 Bolt

Note: Washers (1) must be installed against shock mount (6).

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Illustration 56	g01316750
Engine interface box and exhaust temperature module installed

1. Install the bracket (11) for the EIB and the exhaust temperature module at the location shown in Illustration 54. Refer to Illustration 55 for the required hardware.

Install the New Elbow for the Inlet Air

1. Install new elbow (1). Reuse the existing bolts. The new elbow has an integral O-ring boss for the manifold air temperature sensor.

   Note: Removing the lifting eye may simplify the installation of the new air inlet elbow.

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Illustration 57	g01253129
Top View (1) 175-6720 Elbow

2. Clean the mating surfaces before installation. Install new gaskets or fabricate new gaskets. Install the flame arrestor. Install the raised portion of the flame arrestor toward the air inlet elbow. Ensure that the connecting flange is oriented properly. The flange is marked TOP with raised lettering.

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Illustration 58	g01286614
New elbow and sensor installed (2) 102-2240 Temperature Sensor Gp (3) 8L-2786 O-Ring Seal (4) 153-8455 Manifold Gasket (5) 7N-5085 Flange (6) 7N-5089 Gasket

3. Install manifold inlet air temperature sensor (2) and O-Ring seal (3) in the hole provided in the inlet elbow. Tighten the sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Install the New Oil Bypass Valve Cover

1. Some parts from the former bypass valve cover must be reused. The bolts, cover, spring, and bypass valve must be reused. Replace the O-ring seals if necessary. Refer to Illustration 59.

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Illustration 59	g01286905
(1) 4W-5592 Cover (2) 5P-4892 O-Ring Seal (3) 111-8639 Bypass Valve Cover (4) 2W-1635 Spring (5) 2W-1969 Bypass Valve

2. Install bypass valve cover (3) using the existing bolts.

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Illustration 60	g01286937
New bypass valve cover, filtered oil pressure sensor, unfiltered oil pressure sensor installed (6) 161-1705 Pressure Sensor (7) 9X-0262 Adapter (8) 6V-5048 O-Ring Seal

3. Install the filtered and the unfiltered oil pressure sensors (6). Each sensor uses an adapter (7) and an O-ring seal (8). The designation of each sensor is marked with raised lettering on the bypass valve cover. Tighten the sensors to 10 ± 2 N·m (7 ± 1.5 lb ft).

Install Covers for the Governor Drive and the Accessory Drive

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Illustration 61	g01287117
Oil hole for governor drive (1) 8T-6757 Pipe Plug

1. Install covers for the governor drive and for the accessory drive. A plug (1) must be installed in the oil supply hole as indicated in Illustration 61. Apply pipe sealant to the threads of the plug.

2. Install cover (4) and gasket (3). Reuse the existing bolts. These items are required only when a Woodward EG-3P actuator is removed.

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Illustration 62	g01287163
Covers installed (3) 8N-9885 Drive Housing Gasket (4) 2W-5285 Cover (5) 9X-7371 O-Ring Seal (6) 7N-8374 Cover (7) 0S-1566 Bolt (8) 5P-8247 Hard Washer

Note: If the engine is not equipped with accessory drive, use the 6I-1392 Accessory Drive Cover Gp .

3. Install cover (6) and O-ring seal (5). Fasten the cover with bolts (7) and hard washers (8). These items are required when either a Woodward 3161 governor or EG3P actuator is removed.

Install Actuators and Actuator Linkage

G3508 Throttle Actuator

Table 5

Reference
Model	Part Number
G3508 high pressure	289-8546 Throttle Gp

The following examples are for a G3508 Engine.

The throttle actuator for G3508 engines is mounted to the top of the exhaust manifold.

1. Install bracket (3) and strap (2). Strap (2) is installed around the exhaust manifold and secured to bracket (3). Do not tighten the nuts for the tee bolts of the strap.

2. Toward the rear of the engine, remove two existing bolts from the mounting plate of the aftercooler. Install plate (1) to the mounting plate for the aftercooler with two bolts (15) and two washers (14). Toward the front of the engine, attach plate (1) to bracket (3) with two bolts (18) and two washers (14). Tighten the four bolts that fasten plate (1) to the engine.

3. Torque the nuts for strap (2) to 8 to 9 N·m (70 to 80 lb in).

4. Install the throttle actuator to plate (1) with four bolts (17), four spacers (16) and four hard washers (4) .

5. Connect the actuator linkage. Refer to Illustrations 63 through 66.

Illustration 63	g01388177
Mounting hardware for the throttle actuator (1) 289-8500 Plate (2) 309-4572 Strap (3) 309-4571 Bracket

Illustration 64	g01346932
Top view (4) 9M-1974 Hard Washer (5) 5S-0003 Nut (6) 4B-3388 Bolt

Illustration 65	g01446424
Rear view (7) 119-5092 Rod (8) 4F-2294 Jam Nut (9) 7E-9748 Rod End-Bearing (10) 114-9269 Sleeve (11) 263-5007 Throttle Lever (12) 8L-4496 Jam Nut (13) 6V-9163 Rod End

Illustration 66	g01347018
Right side view (14) 5M-2894 Hard Washer (15) 0S-1591 Bolt (16) 091-0081 Spacer (17) 6V-2317 Bolt (18) 1A-2029 Bolt

G3512 and G3516 Throttle Actuator

Table 6

Reference
Model	Part Number
G3512 high pressure	251-9479 Electronic Actuator Gp
G3512/G3516 low pressure (1)	251-9483 Throttle Gp
G3516 high pressure	251-9478 Electronic Actuator Gp

( 1 )

No linkage is required for this actuator.

The following examples are for G3512 or G3516 Engines.

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Illustration 67	g01287216
Throttle actuator and support assembly shown upside down (1) 262-5580 Support As (2) 6V-2317 Bolt (3) 9M-1974 Hard Washer (4) 091-0081 Spacer (5) 254-1115 Actuator

1. Mount the throttle actuator to the support assembly with four bolts (2), four washers (3) and four spacers (4) .

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Illustration 68	g01437645
G3512 installation (6) 114-9269 Sleeve (7) 4B-3388 Bolt (8) 5S-0003 Nut (9) 0T-0573 Bolt (10) 5M-2894 Hard Washer (11) 6W-6672 Spacer

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Illustration 69	g01458368
G3512 installation View A-A (12) 4F-2294 Jam Nut (13) 7E-9748 Rod End (14) 8L-4496 Jam Nut (15) 251-9488 Rod (16) 6V-9163 Rod End (17) 263-5007 Throttle Lever

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Illustration 70	g01451035
G3516 installation (6) 114-9269 Sleeve (7) 4B-3388 Bolt (8) 5S-0003 Nut (9) 0T-0573 Bolt (10) 5M-2894 Hard Washer (11) 6W-6672 Spacer

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Illustration 71	g01458374
G3516 installation View A-A (12) 4F-2294 Jam Nut (13) 7E-9748 Rod End (14) 8L-4496 Jam Nut (16) 6V-9163 Rod End (17) 263-5007 Throttle Lever (18) 251-9487 Rod

2. Mount the actuator and support assembly in the vee of the engine. Fasten the support assembly bracket with four bolts (9), four washers (10) and four spacers (11) .

3. Connect the actuator linkage. For G3512 engines, refer to Illustrations 68 and 69. For G3516 engines, refer to Illustrations 70 and 71.

Actuator for Air/Fuel Ratio Control (if equipped)

Table 7

Reference
Model	Part Number
G3508 high pressure	290-3419 Gas Pressure Regulator Gp
G3512 high pressure	251-9481 Gas Pressure Regulator Gp
G3516 high pressure	251-9480 Gas Pressure Regulator Gp

1. Install the supports for the air/fuel ratio control actuator. The top support bracket is fastened to the engine with two bolts (1). The lower support bracket is fastened to the engine with two bolts (3) .

   The supports for the air/fuel ratio control actuator are installed at the following locations:

   • G3508, left side of the engine below the number four cylinder

   • G3512, left side of the engine below the number six cylinder

   • G3516, left side of the engine below the number eight cylinder

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Illustration 72	g01287680
Support brackets installed (1) 0T-0055 Bolt (2) 7N-6986 Support (Upper support for G3508) (3) 0S-1619 Bolt (4) 1W-8129 Support (Lower support for G3508 only)

2. Install bracket (5). Use four bolts (6), four washers (7) and four nuts (9) in order to fasten the bracket to the supports.

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Illustration 73	g01287712
Bracket installed (G3512/G3516) (5) 270-0378 Bracket (6) 3B-1915 Bolt (7) 5M-2894 Hard Washer (8) Mounting location for actuator

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Illustration 74	g01287734
Air/fuel ratio control actuator installed (9) 9S-8752 Full Nut (10) 9M-1974 Hard Washer (11) 6V-2317 Bolt (12) 091-0081 Spacer

3. Install the actuator onto the bracket. The actuator is fastened to the bracket with four bolts (11), four washers (10) and four spacers (12) .

Note: For engines that do not currently have air/fuel ratio control, install the air/fuel ratio control valve.

4. Install the linkage for the actuator and for the fuel valve.

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Illustration 75	g01450436
Linkage for the air/fuel ratio control actuator and the fuel valve (13) 263-5007 Throttle Lever (14) 1B-7182 Bolt (15) 9M-1974 Hard Washer (16) 5S-0003 Nut (17) 7E-9748 Rod End (18) 4F-2294 Jam Nut (19) 175-6830 Rod G3508 (19) 119-5092 Rod G3512 and G3516 (20) 6V-9163 Rod End (21) 8L-4496 Jam Nut (22) 6S-7721 Lever (23) 0S-1571 Bolt (24) 5M-2894 Hard Washer (25) 9S-8752 Full Nut

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Illustration 76	g01450635
Left side view (26) 6L-2849 Tube Joint (27) 6I-0236 Fuel Ratio Valve (28) 1P-4579 Half Flange (29) 0S-1587 Bolt (30) 5P-8245 Hard Washer (31) 6I-0327 Adapter (32) 4J-0524 O-Ring Seal

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Illustration 77	g01290801
Linkage for the air/fuel ratio control actuator installed

5. Install the levers for the fuel valve and for the actuator. Both the actuator and the fuel valve must be in the open position. Adjust the linkage at the attachment points to the angles that are shown in Illustration 75. Provide equal engagement at each rod end.

Install the Remaining Sensors

• Jacket water inlet pressure switch

• Exhaust temperature thermocouples

• Turbocharger thermocouples

• Manifold inlet air pressure sensor

• Jacket water outlet pressure sensor

• Coolant temperature sensor

• Oil temperature sensor

• Speed timing sensor

• Detonation sensor left

• Detonation sensor right

• Oxygen sensor

• Oxygen sensor buffer

• Timing calibration sensor

• Prelube switch

Jacket Water Inlet Pressure Switch

1. Install the jacket water inlet pressure switch. Refer to Illustration 78 for the parts that are needed to install the switch. Apply pipe sealant to the pipe plug, the reducer bushings, and the pipe nipple. Tighten the switch to 22 ± 3 N·m (16 ± 2 lb ft).

Illustration 78	g01290888
(1) 110-1168 Pressure Switch (2) 3B-7764 Reducer Bushing (3) 061-9593 Reducer Bushing (4) 4B-7770 Tee (5) 8T-6761 Pipe Plug (6) 3B-7749 Close Nipple

Illustration 79	g01290890
Jacket water inlet pressure switch installed

Exhaust Temperature Thermocouples

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Illustration 80	g01290986
Exhaust temperature thermocouple (1) 241-9591 Temperature Sensor Gp

1. Install the exhaust temperature thermocouples. A new thermocouple (1) is installed at each cylinder.

Illustration 81	g01290988
Thermocouples installed (1) 241-9591 Temperature Sensor Gp (2) 5N-2126 Exhaust Adapter

Turbocharger Thermocouples

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Illustration 82	g01291016
Rear view Location for the turbocharger thermocouples (1) 180-5420 Temperature Sensor Gp

1. Install new thermocouples (1) for the turbocharger at the locations shown in Illustrations 82 and 84. A new bushing (2) must be installed for each new thermocouple. Apply pipe sealant to the threads of the bushings.

Illustration 83	g01291017
(1) 180-5420 Temperature Sensor Gp (2) 6B-5072 Reducing Bushing

Illustration 84	g01291019
Turbocharger thermocouples installed (1) 180-5420 Temperature Sensor Gp (2) 6B-5072 Reducing Bushing

Manifold Inlet Air Pressure Sensor

Illustration 85	g01254649
Location for the manifold inlet air pressure sensor (1) 276-6793 Pressure Sensor Gp (1) 290-4619 Sensor Buffer

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Illustration 86	g01291077
Manifold inlet air pressure sensor installed (1) 276-6793 Pressure Sensor Gp (1) 290-4619 Sensor Buffer (2) 9X-0435 Adapter (3) 6V-5048 O-Ring Seal (4) 3B-7764 Bushing

1. Install the manifold inlet air pressure sensor. A plug must be removed from the front of the cylinder block in order to install the sensor. Apply pipe sealant to adapter (2) and to bushing (4). Torque the sensor to 10 ± 2 N·m (7 ± 1 lb ft).

Jacket Water Outlet Pressure Sensor

1. Remove plug (1) from the exhaust manifold in order to install the jacket water outlet pressure sensor.

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Illustration 87	g01291138
Location for the jacket water outlet pressure sensor (turbocharged aftercooled engines)

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Illustration 88	g01344874
Location for the jacket water outlet pressure sensor (naturally aspirated engines)

2. Install reducing bushing (4), adapter (2) and seal (3). Apply pipe sealant to the reducing bushing and to the adapter.

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Illustration 89	g01291139
(2) 9X-0435 Adapter (3) 6V-9027 O-Ring Seal (4) 162-6622 Reducing Bushing

3. Install jacket water outlet pressure sensor (5). Torque the sensor to 10 ± 2 N·m (7 ± 1 lb ft).

Illustration 90	g01291140
(5) 276-6793 Pressure Sensor Gp

Coolant Temperature Sensor

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Illustration 91	g01291204
Coolant temperature sensor installed (1) 112-3231 Adapter (2) 6V-6609 O-Ring Seal (3) 264-4297 Temperature Sensor Gp

1. Install adapter (1), O-ring seal 2, and () coolant temperature sensor (3). Apply pipe sealant to the threads of the adapter. Torque the sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Oil Temperature Sensor

1. Remove plug (1) from the cylinder block in order to install the oil temperature sensor.

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Illustration 92	g01291215

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Illustration 93	g01291217
Oil temperature sensor installed (2) 112-3231 Adapter (3) 8L-2786 O-Ring Seal (4) 102-2240 Temperature Sensor Gp

2. Install adapter (2), O-ring seal 3, and () oil temperature sensor (4). Apply pipe sealant to the threads of the adapter. Torque the oil temperature sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Speed Timing Sensor

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Illustration 94	g01291260
Location for installation of the speed timing sensor (1) 273-5041 Speed Sensor Gp

1. Install speed timing sensor (1). The slip head of the speed timing sensor must be extended a minimum of 4 mm (0.1575 inch) prior to installation. Torque the speed timing sensor to 40 ± 5 N·m (29 ± 4 lb ft)

Detonation Sensors

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Illustration 95	g01254654
Location for the detonation sensor for the right side of the engine

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Illustration 96	g01291334
Location for the detonation sensor for the left side of the engine (1) 142-0215 Knock Sensor Group

1. Install the detonation sensors for the right side of the engine and for the left side of the engine. Refer to Illustrations 95 and 96 for the location of the sensors. Torque the sensors to 15 ± 3 N·m (11 ± 2 lb ft).

Oxygen Sensor and Adapter Plate

1. Install the adapter plate (1). One side of the adapter plate is marked UP for proper orientation. Install a new gasket (4) between the adapter plate and the exhaust stack. Install a new gasket (4) between the adapter plate and the exhaust elbow.

2. Fasten the adapter plate to the exhaust elbow with eight bolts (2) and eight hard washers (3) .

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Illustration 97	g01316947
Oxygen sensor and adapter plate installed (1) 200-6984 Adapter As (2) 0S-1590 Bolt (3) 5M-2894 Hard Washer (4) 5L-3773 Exhaust Elbow Gasket (5) 196-5391 Oxygen Sensor

3. Install oxygen sensor (5) .

Buffer for the Oxygen Sensor

1. Remove two bolts from cover plate (4). Install bracket (3) for the oxygen sensor buffer. Fasten the bracket to the rear housing with two bolts (1) and two hard washers (2) .

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Illustration 98	g01291413
Bracket for the oxygen sensor buffer (1) 0S-1588 Bolt (2) 5M-2894 Hard Washer (3) 112-3225 Bracket (4) Rear housing cover plate

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Illustration 99	g01291414
Oxygen buffer installed (5) 190-6470 Sensor Buffer (6) 3B-1915 Bolt (7) 9S-8752 Full Nut

2. Install oxygen buffer (5) to the bracket with two bolts (6), two hard washers (2) and two nuts (7). The connections for the oxygen buffer must face the vee of the engine.

Prelube Switch

1. Remove the knockout from the front door of the remote panel.

2. Remove the heat shrink covering from the ends of the prelube wires in the remote panel.

3. Connect the wires to the prelube switch terminals as shown in Illustration 100.

Illustration 100	g01319822
(1) 251-9444 Control Box Gp (2) 3E-1813 Push Button Switch (3) 150-1240 Pressure Switch

Wiring for the air/fuel Ratio Control

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Illustration 101	g01431264

1. Install the fuse holders for the air/fuel ratio control in the engine interface box.

2. Install fuse F4 (1) for the throttle actuator.

3. Install fuse F5 (2) for the air/fuel ratio control actuator.

4. Install jumper wire (3) (P200-C19).

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Illustration 102	g01431286
Oxygen buffer

5. Connect the oxygen buffer to the main engine harness (4) .

6. Connect the oxygen sensor to the oxygen buffer (5) .

7. Secure the harnesses. Refer to Illustrations 103 and 104.

Illustration 103	g01431299
Left side view (6) 9X-6772 Cable Strap (7) 0S-0509 Bolt (8) 4P-8134 Clip (9) 5M-2894 Hard Washer

Illustration 104	g01431311
Rear view (6) 9X-6772 Cable Strap (7) 0S-0509 Bolt (8) 4P-8134 Clip (9) 5M-2894 Hard Washer

Timing Calibration Connector and Service Tool Connector

The timing calibration connector and the service tool connector are part of the engine harness assembly. The connectors are located at the left rear of the engine. Refer to Illustration 105.

Illustration 105	g01344886
(1) Service tool connector (2) Timing calibration connector

Install the Remote Advisor Panel (if equipped)

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Illustration 106	g01290823
Typical remote advisor panel support

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Illustration 107	g01316757
Remote advisor panel

1. Install the remote advisor panel.

2. The remote advisor panel must be installed within 50 feet of the engine.

Air Start Lines

Illustration 108	g01250147
Typical installation (air start with prelube) (1) Air start solenoid 251-9396 Solenoid Valve Gp (2) Air start motor (3) Prelube solenoid 251-9396 Solenoid Valve Gp (4) Prelube relay valve 4N-3411 Relay Valve Gp (5) Air supply line (6) 119-6284 Air Motor Lubricator Group (7) Relay valve for air start 4N-3411 Relay Valve Gp

G3508, G3512, and G3516 Vane Type Air Start without Prelube

Illustration 109	g01347188
Vane type air start without prelube (1) 8N-8451 Gasket (2) 8N-8446 Elbow (3) 9X-8875 Bolt (4) 3L-8893 Nipple-Close (5) 6V-8252 Pipe Union (6) 6B-3685 Elbow (7) 4P-8134 Clip (8) 9X-6772 Cable Strap (9) 0L-1143 Bolt (10) 8M-9024 Hard Washer (11) 6W-6672 Spacer (12) 4S-6399 Connector (13) 030-7961 Elbow (14) 298-4521 Bracket (15) 1H-2815 Pipe Nipple (16) 119-6284 Air Motor Lubricator Group (17) 5B-7666 Elbow (18) 5B-7442 Pipe Nipple (19) 5T-4373 Hose As (20) 6K-1972 Flared Elbow (21) 295-5743 Bracket (22) 9S-8752 Full Nut (23) 5L-2534 U-Bolt (24) 6L-5699 Pipe Nipple (25) 1L-2782 Pipe Tee (26) 8F-7800 Pipe Cap (27) 6F-5985 Hose As (28) 146-5215 Air Lines Strainer Gp (29) 5P-1076 Hard Washer (30) 0S-1573 Bolt (31) 4N-3411 Relay Valve Gp (32) 7J-8611 Pipe Elbow (33) 5P-2657 Elbow (34) 251-9396 Solenoid Valve Gp

G3508, G3512, and G3516 Turbine Type Air Start without Prelube

Illustration 110	g01347623
Turbine type air start without prelube (1) 3P-1823 Pipe Adapter (2) 2N-1931 Pipe Elbow (3) 003-4711 Pipe Nipple (4) 7N-2539 Hose As (5) 4P-8134 Clip (6) 0S-1571 Bolt (7) 8M-9024 Hard Washer (8) 2A-2677 Spacer (9) 9X-6772 Cable Strap (10) 0S-1590 Bolt (11) 6K-1972 Flared Elbow (12) 299-2408 Bracket (13) 9M-1974 Hard Washer (14) 1A-9579 Bolt (15) 6F-8857 Pipe Nipple (16) 5L-2534 U-Bolt (17) 9S-8752 Full Nut (18) 105-0428 Pipe Nipple (19) 6B-3685 Elbow (20) 143-5177 Pipe Nipple (21) 6L-5699 Pipe Nipple (22) 6F-5985 Hose As (23) 146-5215 Air Lines Strainer Gp (24) 5B-7666 Elbow (25) 6V-8252 Pipe Union (26) 3L-8993 Fitting (27) 4N-3411 Relay Valve Gp (28) 1L-2782 Pipe Tee (29) 8T-6760 Pipe Plug (30) 299-0698 Bracket (31) 251-9396 Solenoid Valve Gp

G3512 and G3516 Vane Type Air Start with Prelube

Illustration 111	g01347652
Vane type air start with prelube (1) 8N-8451 Gasket (2) 8N-8446 Elbow (3) 9X-8875 Bolt (4) 3L-8993 Fitting (5) 6V-8252 Pipe Union (6) 6B-3685 Elbow (7) 4S-6399 Connector (8) 030-7961 Elbow (9) 298-4521 Bracket (10) 1H-2815 Pipe Nipple (11) 0L-1143 Bolt (12) 8M-9024 Hard Washer (13) 6W-6672 Spacer (14) 119-6284 Air Motor Lubricator Group (15) 5B-7442 Pipe Nipple (16) 5T-4373 Hose As (17) 6K-1972 Flared Elbow (18) 295-5743 Bracket (19) 9S-8752 Full Nut (20) 5L-2534 U-Bolt (21) 6L-5699 Pipe Nipple (22) 161-8071 Hose As (23) 1L-2782 Pipe Tee (24) 7J-8611 Pipe Elbow (25) 3E-2303 Pipe Fitting (26) 4N-3411 Relay Valve Gp (27) 6F-7732 Reducer Bushing (28) 004-7626 Connector (29) 5B-7666 Elbow (30) 6F-5985 Hose As (31) 146-5215 Air Lines Strainer Gp (32) 5P-1076 Hard Washer (33) 0S-1573 Bolt (34) 4P-8134 Clip (35) 9X-6772 Cable Strap (36) 5P-2657 Elbow (37) 251-9396 Solenoid Valve Gp

G3512 and G3516 Turbine Type Air Start with Prelube

Illustration 112	g01347793
Turbine type air start with prelube (1) 3P-1823 Pipe Adapter (2) 2N-1931 Pipe Elbow (3) 003-4711 Pipe Nipple (4) 4P-8134 Clip (5) 0S-1571 Bolt (6) 8M-9024 Hard Washer (7) 9X-6772 Cable Strap (8) 2A-2677 Spacer (9) 0S-1590 Bolt (10) 6K-1972 Flared Elbow (11) 299-2408 Bracket (12) 5L-2534 U-Bolt (13) 9S-8752 Full Nut (14) 1A-9579 Bolt (15) 9M-1974 Hard Washer (16) 6F-8857 Pipe Nipple (17) 6F-7732 Reducer Bushing (18) 004-7626 Connector (19) 105-0428 Pipe Nipple (20) 6B-3685 Elbow (21) 143-5177 Pipe Nipple (22) 7J-8611 Pipe Elbow (23) 3E-2303 Pipe Fitting (24) 6L-5699 Pipe Nipple (25) 6F-5985 Hose As (26) 146-5215 Air Lines Strainer Gp (27) 5B-7666 Elbow (28) 6V-8252 Pipe Union (29) 3L-8993 Fitting (30) 4N-3411 Relay Valve Gp (31) 1L-2782 Pipe Tee (32) 299-0698 Bracket (33) 161-8071 Hose As (34) 7N-2539 Hose As (35) 251-9396 Solenoid Valve Gp

Install the Wiring Harnesses

Table 8

Reference
CSA Engines with Single Circuit Cooling
Model	Part Number
G3508	251-9508 Engine Wiring Gp
G3512	251-9512 Engine Wiring Gp
G3516	251-9516 Engine Wiring Gp
CSA Engines with Two Circuit Cooling
Model	Part Number
G3512	251-9510 Engine Wiring Gp
G3516	251-9511 Engine Wiring Gp

The letter designation and the description of the wiring harnesses that are used for CSA engines are listed in Table 9. The part numbers listed in Table 9 give detailed information about each wiring harness.

Table 9

Wiring Harnesses (CSA)
Harness As.	Part Number	Description
A	251-9463	Ignition protection system (G3516 A+)
AA	251-9462	Ignition protection system (G3512 A+)
AC	251-9461	Ignition protection system (G3508 A+)
AP	4P-9321	G3508 Internal ignition harness
AP	4P-9322	G3512 Internal ignition harness
AP	4P-7487	G3516 Internal ignition harness
AR	273-3111	Gateway harness ( PL1000T only)
AT	273-3103	Gateway harness ( PL1000E only)
C	251-9471	Engine Interface box (CSA)
CC	298-8840	Alternator/air starting
F		Customer wiring
G	251-9446	Remote panel
H	251-9426	Exhaust temperature scanner (G3516 A+)
H	251-9425	Exhaust temperature scanner (G3512 A+)
H	251-9424	Exhaust temperature scanner (G3508 A+) (dual turbo)
H	251-9423	Exhaust temperature scanner (G3508 A+) (single turbo)
K	273-3121	AFRC
T	251-9466	interconnect harness (20 ft interconnect unbraided)
T	251-9467	interconnect harness (30 ft interconnect unbraided)
T	251-9468	interconnect harness (50 ft interconnect unbraided)

Install the Engine Harness Assembly

Table 10 lists the part numbers for the hardware that is used in order to secure the wiring harness to the engine. The numbers that are called out in Illustrations 113 through 115 correspond to the item numbers that are listed in column 1 of Table 10.

Illustration 113	g01317786
Hardware for securing engine harness (G3516 A+ shown)

Illustration 114	g01317788
Hardware for securing engine harness (G3516 A+ shown)

Illustration 115	g01317790
Hardware for securing engine harness (G3516 A+ shown)

Table 10

Installation Hardware
Item	Qty	Part No	Description	Remarks
1	1	2P-8977	Plate
2	1	2S-2301	Spacer
3	1	4W-9149	Spacer
4	8	7K-1181	Cable Strap
5	1	9F-4831	Spacer
6	2	9S-3232	Clip
7	1	9X-3495	Clip As
8	38	9X-6772	Cable Strap
9	2	193-3973	Tie
10	1	251-9389	Bracket
11	1	251-9463	Engine Harness As
12	2	132-5789	Clip
13	1	204-8000	Tie Anchor
14	1	230-7732	Mount
15	1	0L-1351	Bolt
16	1	0L-1352	Bolt
17	13	0S-0509	Bolt
18	1	0S-1571	Bolt
19	4	0S-1594	Bolt
20	6	4P-7581	Clip
21	32	4P-8134	Clip
22	24	5M-2894	Hard Washer
23	1	5P-8245	Hard Washer
24	1	5S-0003	Nut
25	4	6B-6205	Spacer
26	2	7X-0291	Bolt
27	4	9L-9132	Washer
28	2	9N-0869	Hard Washer
29	4	9S-8752	Full Nut
30	1	9X-6458	Hard Washer
31	1	9X-8874	Bolt
32	2	0S-1594	Bolt	Use as required to secure the harness assembly under the turbocharger
33	2	4P-8134	Clip	Use as required to secure the harness assembly under the turbocharger
34	4	5M-2894	Hard Washer	Use as required to secure the harness assembly under the turbocharger
35	2	9S-8752	Full Nut	Use as required to secure the harness assembly under the turbocharger
36	1	7K-1181	Cable Strap	Use as required for applications with landfill breathers
37	1	4P-8134	Clip	Use as required for applications with landfill breathers
38	1	9X-6772	Cable Strap	Use as required with single circuit cooling when a water regulator is mounted next to the G3500A+ "Z" bracket
39	1	0S-1590	Bolt	Use as required with single circuit cooling when a water regulator is mounted next to the G3500A+ "Z" bracket
40	1	4P-8134	Clip	Use as required with single circuit cooling when a water regulator is mounted next to the G3500A+ "Z" bracket
41	1	5M-2894	Hard Washer	Use as required with single circuit cooling when a water regulator is mounted next to the G3500A+ "Z" bracket
42	1	9X-6772	Cable Strap	Use as required for wet manifolds only
43	1	4P-7581	Clip	Use as required for wet manifolds only
44	1	9X-6772	Cable Strap	Use as required for dry manifolds only
45	1	132-5789	Clip	Use as required for dry manifolds only
46	1	0S-0509	Bolt	Use as required for dry manifolds only
47	1	5M-2894	Hard Washer	Use as required for dry manifolds only
48	2	0S-1595	Bolt	Use as required to secure the harness assembly under the turbocharger
49	2	1F-7958	Full Nut	Use as required to secure the harness assembly under the turbocharger
50	2	4P-7429	Clip	Use as required to secure the harness assembly under the turbocharger
51	4	5P-8245	Hard Washer	Use as required to secure the harness assembly under the turbocharger

Note: For more connection details for the thermocouple harness and for the exhaust temperature module, refer to ""Wiring for the Exhaust Temperature Module" ".

Orientation of the Engine Harness Fasteners (Clip Orientation)

The following illustrations show the clip orientation for the wiring harnesses. The notations TOP, BOTTOM, RIGHT, LEFT, FRONT, and REAR are used with the position callout POS. These positions are in reference only to the current view in which the clip mounting orientation is shown on the engine. The positions are not necessarily the customary Top View, Front View, Rear View, Left Side View and Right Side View of the engine.

The harness must be tied to a clip with a tie strap. Install the tie straps through the appropriate slot in the clip. Tighten the strap to the harness in order to prevent any motion between the harness and the clip. The clips must be oriented to minimize any contact between the wiring harness and the engine.

Reuse all existing washers unless otherwise specified.

Illustration 116	g01293103

G3508 CSA with Single Circuit Cooling

Refer to Illustrations 117 through 120.

Illustration 117	g01314499
Clip orientation for G3508 CSA with single circuit cooling

Illustration 118	g01314524
Clip orientation for G3508 CSA with single circuit cooling

Illustration 119	g01314539
Clip orientation for G3508 CSA with single circuit cooling

Illustration 120	g01445567
Clip orientation for G3508 CSA with single circuit cooling

G3512 CSA with Single Circuit Cooling

Refer to Illustrations 121 through 125.

Illustration 121	g01314606
Clip orientation for G3512 CSA with single circuit cooling

Illustration 122	g01314620
Clip orientation for G3512 CSA with single circuit cooling

Illustration 123	g01445570
Clip orientation for G3512 CSA with single circuit cooling

Illustration 124	g01314631
Clip orientation for G3512 CSA with single circuit cooling

Illustration 125	g01314644
Clip orientation for G3512 CSA with single circuit cooling

G3516 CSA with Single Circuit Cooling

Refer to Illustrations 126 through 130.

Illustration 126	g01314653
Clip orientation for G3516 CSA with single circuit cooling

Illustration 127	g01314670
Clip orientation for G3516 CSA with single circuit cooling

Illustration 128	g01445570
Clip orientation for G3516 CSA with single circuit cooling

Illustration 129	g01314672
Clip orientation for G3516 CSA with single circuit cooling

Illustration 130	g01314675
Clip orientation for G3516 CSA with single circuit cooling

G3512 CSA with Two Circuit Cooling

Refer to Illustrations 131 through 135.

Illustration 131	g01314685
Clip orientation for G3512 CSA with two circuit cooling

Illustration 132	g01314789
Clip orientation for G3512 CSA with two circuit cooling

Illustration 133	g01314807
Clip orientation for G3512 CSA with two circuit cooling

Illustration 134	g01315002
Clip orientation for G3512 CSA with two circuit cooling

Illustration 135	g01315003
Clip orientation for G3512 CSA with two circuit cooling

G3516 CSA with Two Circuit Cooling

Refer to Illustrations 136 through 140.

Illustration 136	g01315018
Clip orientation for G3516 CSA with two circuit cooling

Illustration 137	g01315023
Clip orientation for G3516 CSA with two circuit cooling

Illustration 138	g01315076
Clip orientation for G3516 CSA with two circuit cooling

Illustration 139	g01315046
Clip orientation for G3516 CSA with two circuit cooling

Illustration 140	g01315068
Clip orientation for G3516 CSA with two circuit cooling

Install the Thermocouple Wiring Harness

Table 11

Reference
Model	Part Number
G3508 with single turbocharger	251-9419 Pyrometer Wiring Gp
G3508 with dual turbochargers	251-9420 Pyrometer Wiring Gp
G3512 with dual turbochargers	251-9421 Pyrometer Wiring Gp
G3516 with dual turbochargers	251-9422 Pyrometer Wiring Gp

Table 12 lists the part numbers for the hardware that is used in order to secure the thermocouple harness to the engine. The numbers that are called out in Illustrations 141 and 142 correspond to the item numbers that are listed in column 1 of Table 12.

Illustration 141	g01318005
Thermocouple wiring harness. G3516 shown

Illustration 142	g01318008
Thermocouple wiring harness. G3516 shown

Table 12

Parts List and Installation Hardware
Item	Qty	Part No	Description	Remarks
1	34	3S-2093	Cable Strap
2	16	5N-2126	Adapter
3	20	9X-6772	Cable Strap
4	2	180-5420	Temperature Sensor Gp
5	16	241-9591	Temperature Sensor Gp
6	1	251-9426	Sensor Harness As
7	33	0S-0509	Bolt
8	1	0S-1594	Bolt
9	16	4P-7581	Clip
10	36	4P-8134	Clip
11	36	5M-2894	Hard Washer
12	2	6B-5072	Reducing Bushing
13	1	9S-8752	Full Nut
14	21	9X-6772	Cable Strap	Use as required to secure the thermocouple harness to the engine harness assembly
15	1	0S-0509	Bolt	Use as required. Bolts and washers are not required when the regulator housing is in the location shown
16	1	5M-2894	Hard Washer	Use as required. Bolts and washers are not required when the regulator housing is in the location shown

Note: For more connection details for the thermocouple harness and for the exhaust temperature module, refer to ""Wiring for the Exhaust Temperature Module" ".

Orientation of the Thermocouple harness Fasteners

Refer to ""Orientation of the Engine Harness Fasteners (Clip Orientation)" ".

The fastener positions for securing the thermocouple harness to the engine are shown in Illustrations 143 through 145.

Illustration 143	g01318728
G3516 with dual turbochargers shown

Illustration 144	g01318092
G3516 with dual turbochargers shown

Illustration 145	g01318093
G3516 with dual turbochargers shown (1) Avoid damage to the locking mechanisms of the wires that insert into the 70-pin connectors. Always remove the connector from the A3 control or the ETM before inserting or removing wires from the 70-pin connectors.

Install the Alternator Wiring Harness (if equipped)

Table 13

Reference

Part Numbers for CSA Applications

298-8838 Alternator

298-8839 Alternator Wiring Gp

298-8840 Alternator Harness Assembly

Part Numbers for non-CSA Applications

251-9474 Alternator Wiring Gp

251-9475 Power Harness As

Table 14 lists the part numbers for the hardware that is used in order to secure the alternator harness to the engine. The numbers that are called out in Illustrations 147 and 148 correspond to the item numbers that are listed in column 1 of Table 14.

Illustration 146	g01319109
G3516 shown

Illustration 147	g01319111
G3516 shown

Illustration 148	g01432507
(16) Fuse F5 actuator for air/fuel ratio control (17) Interconnect harness connection (18) Factory test connector

Table 14

Installation Hardware
Item	Qty	Part No	Description	Remarks
1	10	9X-6772	Cable Strap	Use as required to secure harness to adjacent harnesses
2	5	9X-6772	Cable Strap
3	3	0S-0509	Bolt
4	4	5M-2894	Hard Washer
5	3	4P-7581	Clip
6	1	0S-1588	Bolt
7	1	4P-8134	Clip
8	3	4P-8134	Clip	Use as required for G3508
9	10	9X-6772	Cable Strap	Use as required for G3508
10	1	273-3127	Connector
11	1	156-6175	Clip
12	2	5P-0537	Hard Washer
13	1	0S-1616	Bolt
14	1	9S-8750	Nut
15	1	298-8840	Harness As

Orientation of the Alternator Harness Fasteners

Refer to ""Orientation of the Engine Harness Fasteners (Clip Orientation)" ".

The fastener positions for securing the thermocouple harness to the engine are shown in Illustrations 149 and 150.

Illustration 149	g01319292

Illustration 150	g01319294

Visual Aids (Clip Orientation)

The following illustrations are for use as a visual aid for securing the wiring harnesses.

Illustration 151	g01436890
Left side view (ECM)

Illustration 152	g01435850
Front view (ECM)

Illustration 153	g01436864
Hardware behind the support bracket for the ECM

Illustration 154	g01435928
Front view

Illustration 155	g01433009
Right side view

Illustration 156	g01435853
Right side view

Illustration 157	g01435870
Right side view

Illustration 158	g01435874
Right side view

Illustration 159	g01435881
Left side view

Illustration 160	g01435890
Left side view

Illustration 161	g01435895
Left side view

Illustration 162	g01435911
Left side view (harness for the throttle actuator)

Illustration 163	g01432542
Left side view (harness for the throttle actuator)

Illustration 164	g01436870
Top view (harness for throttle actuator ) G3508

Illustration 165	g01438279
Left side view (harness for the air/fuel ratio control actuator)

Illustration 166	g01438282
Left side view (harness for the air/fuel ratio control actuator)

Illustration 167	g01436873
Rear view

Illustration 168	g01438276
Rear view

Illustration 169	g01435940
Rear view (exhaust temperature module)

Illustration 170	g01435950
Rear view

Illustration 171	g01319980
Left side view

PL1000 Customer Communications Module

The PL1000E or the PL1000T Customer Communication Module (CCM) can be used with the G3500 ADEM 3 conversion. The following publications are available for detailed information on these modules.

• PL1000E Special Instruction, REHS2362, "Installation Guide for the 256-7512 PL1000E Communications ECM"

• PL1000E Systems Operation, Testing and Adjusting, RENR8091, "PL1000E Communication ECM"

• PL1000T Special Instruction, REHS2125, "Installation Guide for the 256-7511 PL1000T Communications ECM"

• PL1000T Systems Operation, Testing and Adjusting, RENR7945, "PL1000T Communication ECM "

Wiring for the Exhaust Temperature Module

For more information on the exhaust temperature module, refer to Systems Operation Testing and Adjusting, KENR5473.

Illustration 172	g01431685
(1) 232-4674 Connector Seal (2) 288-4678 Connector As (3) 232-4675 Connector Seal (4) 288-4677 Connector As (5) Pyrometer display (6) Engine interface box (7) Main engine harness (8) Interconnect harness

Note: Spiral wrap must cover the following interconnect harness circuits inside the engine interface box and inside the remote advisor panel:

• Battery + (P200-T4 RD)

• Battery - (P300-T39 BK)

• Keyswitch (P600-T18 WH)

• Prelube pushbutton (C293-T26 BK)

• Prelube light (A320-T33 RD)

Illustration 173	g01431715
View B-B (9) 8T-9006 Bolt (10) 232-4673 Plug (11) 3S-2093 Cable Strap (12) 121-0199 Spiral Wrap (13) 237-4356 Adapter (14) 9X-6772 Cable Strap (15) Thermocouple harness

1. Five pins (pins 5 through 9) must be inserted into the 70-pin connector at the back of the exhaust temperature module. These five pins are located on two separate cables that break out from the main engine harness. Refer to Table 15. Refer to Illustrations 175 and 176.

2. Spiral wrap must be installed over the power wires B+ and B− at the 70-pin connector on the exhaust temperature module. Bundle the five wires (pins 5 through 9) and ensure that the connector retaining screw is accessible for attaching to the exhaust temperature module. Use cable strap (11) in order to bundle the wires inside the connector assembly. Install connector assembly (2), seal (1), connector assembly (4), seal (3), and adapter (13) .

3. Secure thermocouple harness (15) to main engine harness (7) with cable straps (14) in order to protect the connections at the 70-pin connector.

Illustration 174	g01431924
Remote panel (8) Interconnect harness

Note: Spiral wrap must cover the following interconnect harness circuits inside the engine interface box and inside the remote advisor panel:

• Battery + (P200-T4 RD)

• Battery - (P300-T39 BK)

• Keyswitch (P600-T18 WH)

• Prelube pushbutton (C293-T26 BK)

• Prelube light (A320-T33 RD)

Table 15

70-pin Connector at the Back of the Exhaust Temperature Module
Pin	Description	Circuit ID	Color
5	CAN Shield	D200-A8	CU
6	B +	P600-A165	WH or RD
7	B −	P300-A164	BK
8	CAN +	D200-A168	YL
9	CAN −	D200-A167	GN

Illustration 175	g01432431
Power and CAN data link connections for the exhaust temperature module (16) Socket connector

Illustration 176	g01431934
Power and CAN data link connections for the exhaust temperature module

Connect the Wiring From the Battery

Illustration 177	g01272958
Typical view of the engine (1) Engine interface box (2) CSA approved enclosure provided by the customer

Requirements for Engines That are Not Equipped With an Alternator

The customer is responsible for providing overcurrent protection for the battery circuit. The battery circuit must be protected by a CSA approved fuse. The maximum allowable rating of the fuse is 20 A.

Install the fuse in a fuse holder that is CSA approved. Mount the fuse holder in a CSA approved enclosure (2), if necessary. Mount the fuse holder or the enclosure as close as practical to interface box (1) .

Requirements for Engines That are Equipped With an Alternator

The customer is responsible for providing overcurrent protection for the charging circuit. The charging circuit includes the wiring from the battery and the wiring from the alternator. This wiring is connected at terminal 12 inside interface box (1). The circuit must be protected by a CSA approved fuse. The maximum allowable rating of the fuse is 60 A. This rating limits the charging current between the alternator and the battery. The gauge of the wiring from the battery may require a fuse rating that is lower than 60 A.

Install the fuse in a fuse holder that is CSA approved. Mount the fuse holder in a CSA approved enclosure (2), if necessary. Mount the fuse holder or the enclosure as close as practical to interface box (1).

Illustration 178	g01272967
Bottom view of the engine interface box (3) 50.8 mm (2 inch) hole (4) 25.4 mm (1 inch) hole (5) 25.4 mm (1 inch) hole

Refer to Illustration 178. The bottom of the engine interface box has two holes (3) and (5) when the engine is shipped from the factory. Fabricate hole (4) if the engine is equipped with an alternator. Refer to Table 16.

Table 16

Holes in the Bottom of the Engine Interface Box
Hole	Size	Purpose
(3)	50.8 mm (2 inch)	Wiring from the driven equipment
(4)	25.4 mm (1 inch)	Hole for the wiring from the battery (customer installed)
(5)	25.4 mm (1 inch)	Wiring from the alternator when the engine is equipped with an alternator Route the wiring from the battery through this hole when the engine is not equipped with an alternator.

Perform the following procedure to make the connections from the battery.

1. Verify that the wiring from the battery is de-energized.

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Illustration 179	g01272968
Connections for the battery (6) Main fuse

2. Remove main fuse (6) .

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Illustration 180	g01272969
Hardware for connecting the wiring from the battery (7) 119-8044 Wire Ends (6 Gauge) (8) 4P-4891 Terminal Bushing (9) 273-3127 Connector

3. Use connector (9) and terminal bushing (8) to attach the wiring from the battery to the engine interface box.

4. Use a 139-2789 Ferrule Crimp Tool to crimp a wire end (7) to the end of each wire.

5. Connect wire ends (7) to the appropriate locations. Be sure to observe the polarity of the connections.

6. Connect the wiring to the battery.

   Note: Do not install main fuse (6) until all of the wiring from the driven equipment is connected to the engine.

Connect the Wiring From the Driven Equipment

Illustration 181	g01432607
Typical installations

Refer to Illustration 181. Make the electrical connections for the driven equipment at one of the following locations:

Engine Interface Box - All of the electrical connections for the driven equipment are made inside the engine interface box. The following connections are also made inside the engine interface box: switched power, unswitched power and prelube switch.

Interconnect Harness - The interconnect harness is connected to the engine interface box. All of the electrical connections for the driven equipment are made to the end of the interconnect harness.

Remote Panel - A remote panel is connected to the engine interface box via an interconnect harness. All of the electrical connections for the driven equipment are made at a terminal strip inside the remote panel.

Table 17 lists the connections that are available at each of the locations. Review the Table before making the connections.

Note: The customer must furnish and install metal conduit for all customer connections including, but not limited to battery power and the interconnect harness. Customer installed conduit and site wiring must conform to all local, state, regional, and national electrical codes. Customer installed wiring must conform to the standards of the Canadian Standards Association if CSA is one of the desired certifications.

Table 17

Connections for the Driven Equipment
Description	Engine Interface Box	Interconnect Harness	Remote Panel (Terminal Strip)	Function and Comments
Prelube ON	Terminal 1 on the Terminal Block	A320-T33 Cable 91-Red	33	This output indicates that the prelubrication is ON. The prelube indicator on the remote panel will illuminate when the prelubrication is ON.
"Manual Prelube" Input	Terminal 2 on the Terminal Block	C293-T26 Cable 91-White	26	This input must be connected to the keyswitch input via a switch. The manual prelube switch on the remote panel provides this connection.
Unswitched +Battery	Terminal 4 on the Terminal Block	P200-T4 Cable 105-Red	4	These connections provide the electrical power to the remote panel. Current flow through these connections must be limited to 5 A If the remote panel is not installed.
−Battery	Terminal 8 on the Terminal Block	P300-T39 Cable 105-Black	39
−Battery	Terminal 8 on the Terminal Block	P300-T40 Cable 91-Black	40
Keyswitch	Terminal 7 on the Terminal Block	P600-T18 Cable 105-White	18	This connection is the keyswitch input for the ECM. This connection must be powered when the engine control is in "COOLDOWN/STOP", "AUTO", or "START" when the remote panel is not installed.
+5 VDC for the Input for the Desired Engine Speed	Terminal 6 on the Customer Connector	M170-T6 Cable 50-Red	6	An input for the desired engine speed is required. The input can be either 0 to 5 VDC or 4 to 20 mA. The method for the desired speed input must be selected with Cat ET. Terminals 6 and 8 provide a 5 VDC supply for the desired engine speed. These terminals must be connected to the potentiometer for the desired speed. Terminal 7 is the input for the desired engine speed. An input of 0 VDC causes the engine rpm to equal the value of the "Minimum High Idle Speed" parameter. An input of 5 VDC causes the engine rpm to equal the value of the "Maximum High Idle Speed" parameter.
Input for the Desired Engine Speed	Terminal 7 on the Customer Connector	M170-T7 Cable 50-White	7
Return for the Desired Engine Speed	Terminal 8 on the Customer Connector	M170-T8 Cable 50-Black	8
Shield for the Wiring for the Desired Engine Speed	Terminal 9 on the Customer Connector	M170-T9 Cable 50-Shield	9
"+" Input for the 4 to 20 mA Desired Speed Signal	Terminal 10 on the Customer Connector	M180-T10	10	An input for the desired engine speed is required. The input can be either 0 to 5 VDC or 4 to 20 mA. The method for the desired speed input must be selected with Cat ET. The 4 to 20 mA is an optional method for providing the desired engine speed input. If the 4 to 20 mA method is used to control the desired speed, the 0 to 5 VDC input must be disabled. The 4 to 20 mA input is an isolated input. The "+" input must be in the same circuit as the "-" input. An input of 4 mA causes the engine rpm to equal the value of the "Minimum High Idle Speed" parameter. An input of 20 mA causes the engine rpm to equal the value of the "Maximum High Idle Speed" parameter.
"-" Input for the 4 to 20 mA Desired Speed Signal	Terminal 12 on the Customer Connector	M180-T12	12
"Grid Status" Input	Terminal 11 on the Customer Connector	M120-T11	11	This input is not normally used in industrial applications. Primary governor gains are used when this input is not connected to digital return. Auxiliary governor gains are used when this input is connected to digital return.
Cat Data Link +	Terminal 13 on the Customer Connector	D100-T13	13	These connections provide the means for communicating the status of the engine control system, of various engine components, and of sensors. The Advisor Monitor Display on the remote panel is connected to these terminals. The Cat Data Link can be connected to the Customer Communication Module (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 personal computer, the program uses the CCM in order to obtain engine information via this data link.
Cat Data Link −	Terminal 14 on the Customer Connector	D100-T14	14
Digital Return	Terminal 15 on the Customer Connector	P500-T15	15	This connection provides a return for various inputs.
Input for the "START" Mode	Terminal 16 on the Customer Connector	P615-T16	16	If these inputs are not wired correctly, the ECM will activate a diagnostic code. Typically, these inputs are connected to an engine control switch. Refer to "Inputs for the Engine's Mode of Operation" for additional information on these inputs. These inputs must be connected to a switch or logic device. The switch or logic device must connect the inputs to digital return. When terminal 24 is connected to digital return, the ECM is in "STANDBY" mode. The engine mode of operation is determined by the "Input for the START Mode". When the "Input for the START Mode" is connected to digital return, the normal sequence for start-up is initiated. When the "Input for the START Mode" is disconnected from digital return, a normal shutdown is initiated. If the engine is running and the "Input for the Cooldown/STOP Mode" is connected to digital return, the sequence for a normal shutdown is initiated.
Input for the "AUTO" Mode	Terminal 24 on the Customer Connector	P614-T24	24
Input for the "COOLDOWN/STOP" Mode	Terminal 31 on the Customer Connector	P613-T31	31
"Driven Equipment Ready" Input	Terminal 17 on the Customer Connector	M530-T17	17	This input indicates when the driven equipment is ready for operation. This input must be connected to digital return in order for the engine to run. When this input is connected to digital return, the engine can be started. When this input is not connected to digital return, the engine will not crank. The ECM generates an event code if this input is not connected to digital return within the programmed delay time. When the engine is running, this input normally continues to be connected to digital return. If the engine is running and this input is disconnected from digital return, the ECM immediately generates an event code. The ECM also de-energizes the GSOV. Because the cooldown is not performed, do not use this input for normal shutdown.
Keyswitch	Terminal 7 on the Terminal Block	P600-T18	18	When this input is connected to +Battery, the ECM will power up. The Advisor Monitor Display on the remote panel will power up.
Normal Stop	Terminal 19 on the Customer Connector	M510-T19	19	This input must be connected to digital return in order for the engine to run. This input is not recommended for normal shutdown. Connecting the "Input for the COOLDOWN/STOP Mode" to digital return is the recommended method for initiating a normal shutdown. If the engine is not running and this input is not connected to digital return, the engine will not crank. No diagnostic codes or event codes are provided for this condition. If the engine is running and this input is disconnected from digital return, the ECM will remove power from the GSOV. The cooldown does not operate.
Output for Active Alarm	Terminal 20 on the Customer Connector	P697-T20	20	This output is activated if the ECM detects an alarm condition. When this output is activated, the output is connected to ground. Sinking 0.3 A output.
Idle/Rated Input	Terminal 22 on the Customer Connector	M190-T22	22	When this input is not connected to digital return, the engine will run at the idle speed that has been programmed with Cat ET. When the engine oil pressure is greater than the setpoint for the engine speed and this terminal is connected to digital return, the engine will run at rated speed.
Emergency Stop	Terminal 2 on the 2 Terminal Connector	C256-T23	23	These terminals must be connected in order for the engine to start. These terminals must remain connected in order for the engine to run. If the ECM is controlling the gas shutoff valve and this circuit is opened, the ECM de-energizes the gas shutoff valve. The fuel is immediately shut off. The ignition is immediately shut off. Additional emergency stop buttons may be added to the emergency stop circuit. For details, refer to "Wiring for the Emergency Stop Circuit".
	Terminal 28 on the Customer Connector	C256-T28	28
Output for Engine Failure	Terminal 25 on the Customer Connector	P698-T25	25	The ECM connects this terminal to ground when the ECM causes the engine to be shut down. Sinking 0.3 A. output
Input for Manual Prelube	Terminal 22 on the Customer Connector	C293-T26	26	This terminal is for the manual prelube. Prelube occurs when this input is connected to the +Battery and the logic in the ECM determines that prelubrication is required.
Gas Shutoff Valve	Terminal 5 on the Terminal Block	A330-T30 Cable109-Red	30	These connections are part of the circuit for the Gas Shutoff Valve (GSOV). For details on these terminals, refer to "Wiring for the Gas Shutoff Valve (GSOV)".
	Terminal 1 on the 2 Terminal Connector	A330-T37 Cable 109-White	37
CAN Data Link +	Terminal 35 on the Customer Connector	D200-T35 Cable 45-Yellow	35	The Advisor Monitor Display on the remote panel is connected to these terminals.
CAN Data Link -	Terminal 36 on the Customer Connector	D200-T36 Cable 45-Green	36
CAN Data Link Shield	Terminal 38 on the Customer Connector	D200-T38 Cable 45-Shield	38
Spare	No Connection	P300-T41 Cable 109-Black	No Connection	Spare

Refer to the appropriate procedure in order to make the connections.

Engine Interface Box

Illustration 182	g01254409
Locations for connections inside the engine interface box

Wiring for the Emergency Stop Circuit

Illustration 183	g01254366
Options for the wiring for the emergency stop circuit (A) Only the engine emergency stop button is used. (B) The circuit contains an additional emergency stop button that is provided by the customer. (1) 155-2269 Connector Plug As and 8T-8730 Connector Socket (2) 8T-8729 Connector Pin

An emergency stop button is provided on the engine interface box. An additional emergency stop button may be connected to the circuit. Properly wire emergency stop buttons in order to stop the engine in case of an emergency situation. Wire the emergency stop circuit according to (A) or (B) in Illustration 183. Use 16 gauge wiring for this circuit.

The GSOV is immediately de-energized when an emergency stop button is activated. The ignition is disabled.

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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.

Wiring for the Gas Shutoff Valve (GSOV)

The GSOV must be energize-to-run. The GSOV may be supplied by the customer or by Caterpillar. Usually, the GSOV is installed when the piping for the fuel is installed at the site. The GSOV is also called the fuel control relay.

The GSOV may be controlled by the engine control system or by the customer equipment. The recommended configuration is for the engine control system to control the GSOV. There will be fewer problems if this configuration is used. When the customer equipment controls the GSOV, the equipment must include the necessary logic. The logic must ensure that the GSOV opens and the GSOV closes at the appropriate times.

The ECM can supply a maximum continuous current of 1.5 A to the GSOV. A relay must be installed if the GSOV requires a continuous current that is greater than 1.5 A.

When the engine control system controls the GSOV, the ECM supplies voltage to the GSOV. The valve opens in order to allow fuel to flow to the engine. When voltage is removed from the GSOV, the valve closes and the fuel flow stops.

The following section describes the two configurations for the circuit for the GSOV.

The GSOV is controlled by the engine control system. The customer may supply an additional switch in the electrical circuit for the GSOV. Refer to Illustration 184 for examples of these types of installations.

Illustration 184	g01254747
The GSOV is controlled by the engine control system. (A) Only the engine emergency stop button is used. (B) The circuit contains an additional emergency stop button that is provided by the customer. (1) 155-2269 Connector Plug As and 8T-8730 Connector Socket (3) 109-3038 Wire End

The GSOV is controlled by the customer equipment.

Refer to Illustration 185 for an example of this type of installation.

Illustration 185	g01254388
The GSOV is controlled by the customer equipment. (1) 155-2269 Connector Plug As and 8T-8730 Connector Socket (3) 109-3038 Wire End

Wire the circuit for the gas shutoff valve according to the appropriate illustration. Use 16 gauge wiring for this circuit.

Illustration 186	g01432979
Bundling of the harness for the gas shutoff valve

CAN Data Link

A termination resistor must be added to the CAN data link. Select one of the following locations for the resistor.

Inside the Engine Interface Box - Use this location when the CAN data link does not extend past the engine interface box.

Outside the Engine Interface Box - Use this location when the CAN data link extends past the engine interface box.

Illustration 187 describes a typical connection inside the engine interface box. Wire the connection according to SAE standards.

Illustration 187	g01254499
Typical installation for the termination resistor inside the engine interface box (2) 3 8T-8729 Connector Pins (4) 153-2707 Electrical Cable (5) 3E-3370 Connector Receptacle As (6) 174-3016 Plug As

Illustration 188 describes a typical connection outside the engine interface box. Wire the connections according to SAE standards.

Illustration 188	g01254713
Typical installation for the termination resistor that is outside of the engine interface box (2) 3 8T-8729 Connector Pins (4) 153-2707 Electrical Cable (5) 3E-3370 Connector Receptacle As (6) 174-3016 Plug As (7) Splice (8) 119-3662 Heat Shrink Tube

Customer Connector

Make the connections to the customer connector according to the following procedure:

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Illustration 189	g01254403
Orientation of the customer connector

1. Route the wiring for the driven equipment into the engine interface box. Use 16 gauge wiring for the connections to the customer connector. Use hardware that provides a water tight connection at the hole in the engine interface box.

2. Crimp a 8T-8729 Connector Pin onto the end of each wire that will be inserted into the customer connector.

3. Make the connections to the customer connector according to Illustration 189 and Table 17. Insert each pin into the appropriate location on the customer connector. Pull on each wire in order to verify proper installation of the pin.

Terminal Block

Make the connections to the terminal block according to the following procedure:

1. Table 17 lists the functions that are available. Use 16 gauge wiring for the connections to the terminal block. Crimp a 109-3038 Wire End onto the end of each wire that will be inserted into the terminal block.

2. Make the connections according to Illustration 182 and Table 17.

Harness Connectors for the Engine Interface Box

Illustration 190	g01346883
Side view of engine interface box (1) Harness connectors

Note: Before removing either harness connector from the engine interface box, cut the tie wraps that secure the harness to the ladder clip on the side of the water regulator housing. Cutting the tie wraps relieves strain from the connector pins and prevent damage to the connectors.

Interconnect Harness

Interconnect harnesses of different lengths are available. Table 18 lists the interconnect harnesses that are available. The harnesses can be shortened, if necessary.

Table 18

Interconnect Harnesses
Part Number	Length	CSA	Braided
251-9466	6.1 m (20 ft)	Yes	No
251-9467	9.1 m (30 ft)	Yes	No
251-9468	15.2 m (50 ft)	Yes	No

Illustration 191	g01241390
The end of the interconnect harness for the engine interface box

Refer to Illustration 191. Pins and wire ends are crimped to the ends of the wires at one end of the interconnect harness. This end of the harness is for the engine interface box.

The interconnect harness must be routed through conduit. A 50 mm (2 inch) hole is provided for attaching the conduit to the engine interface box.

The following parts are provided with each interconnect harness:

Pieces of Heat Shrink Tube - Each piece of heat-shrink tube is labeled with a wire identification. The tubes are used to identify each wire if the wire is cut to a shorter length.

14 Gauge Wire Ends, 16 Gauge Wire Ends, and 18 Gauge Wire Ends - These parts are only required if the remote panel is used. A wire end will be crimped to the end of each wire. The crimp is to connect the wire to the terminal strip inside the remote panel.

Note: Spiral wrap is provided with the interconnect harness. Spiral wrap must cover the following interconnect harness circuits inside the engine interface box and the remote advisor panel:

• Battery + (P200-T4 RD)

• Battery - (P300-T39 BK)

• Keyswitch (P600-T18 WH)

• Prelube push button (C293-T26 BK)

• Prelube light (A320-T33 RD)

Perform the following procedure in order to connect the interconnect harness to the engine interface box:

1. Pull the harness through the conduit to the engine interface box. Be sure to orient the harness so that the wire ends with crimped terminals are inside the engine interface box.

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Illustration 192	g01432967
Connections on the terminal block (1) Fuse 4 is for the throttle actuator and is required for all engines. (2) Fuse 5 is for the AFRC actuator and is required for air/fuel ratio control.

2. Make the connections to the terminal block first. Refer to Illustration 192 and Table 19. Each wire is labeled. Insert each wire end to the appropriate location on the terminal block. Pull on each wire in order to verify proper installation of the wire end.
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   Table 19

   Connections for the Terminal Block
   Interconnect Harness		Location on the Terminal Block
   Cable Identification	Wire Identification
   91-Red	A320-T33 (1)	1
   91-White	C293-T26 (1)	2
   105-Red	P200-T4 (1)	4
   109-Red	A330-T30	5
   105-White	P600-T18 (1)	7
   105-Black	P300-T39 (1)	8
   91-Black	P300-T40
   91-Black	P300-T41	Spare

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   ( 1 )

   These circuits must be contained in spiral wrap at the engine interface box and at the remote advisor panel.

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Illustration 193	g01256097
Connections for the wiring to the customer connector

3. Refer to Illustration 193. Make the connections for wiring to the customer connector. Each wire is labeled. Insert each pin into the appropriate location on the connector. Pull on each wire in order to verify proper installation of the pin.

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Illustration 194	g01256115
Connections for the wires from the cables to the customer connector

4. Refer to Illustration 194. Connect the wiring from the cables to the customer connector. The wire in each cable is labeled. Insert each pin into the appropriate location on the connector. Pull on each wire in order to verify proper installation of the pin.

5. Connect the two terminal connector on the interconnect harness to the two terminal connector inside the engine interface box. This connection is for the emergency stop circuit and the circuit for the GSOV.

6. Connect the wiring from the driven equipment to the end of the interconnect harness.

Remote Panel

Illustration 195	g01256226
Dimensions and components of the remote panel (9) Advisor monitor display (10) Manual prelubrication switch and indicator (11) Emergency stop button (12) Engine control (13) Desired speed potentiometer (14) Service tool connector

The remote panel provides the following capabilities:

• Emergency stop

• Engine control

• Advisor monitor display

• Desired engine speed

• Manual prelubrication

• Indication of alarms, derates, and shutdowns via the Advisor monitor display

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

1. Refer to "Interconnect Harness". Route the interconnect harness from the engine interface box to the remote panel. Make the connections for the interconnect harness inside the engine 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. This procedure 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 tube into the end of each wire in the cable. This technique helps to ensure that each connection is made correctly.

   Note: Each wire in the harness is identified with the circuit identification.

   1. Select a wire. Identify the location on the terminal strip for the wire. Refer to Table 20.

   2. Cut the wire to the appropriate length.

   3. Slide the appropriate heat shrink tube onto the end of the wire. Shrink the tube onto the wire.

   4. Attach the wire end that is the appropriate gauge onto the end of the wire.
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   Illustration 196	g01243294
   Location for the connections for the interconnect harness inside the remote panel

   5. Refer to Illustration 196. 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.

      Note: Spiral wrap is provided with the interconnect harness. Spiral wrap must cover the following interconnect harness circuits inside the engine interface box and the remote advisor panel:

      • Battery + (P200-T4 RD)

      • Battery - (P300-T39 BK)

      • Keyswitch (P600-T18 WH)

      • Prelube push button (C293-T26 BK)

      • Prelube light (A320-T33 RD)

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      Table 20

      Connections for the Interconnect Harness on the Terminal Strip
      Interconnect Harness Wire Identification	Gauge of the Wire End	Location on the Terminal Strip	Function
      P200-T4 (1) Cable 105-Red	16	4	+Battery for the operation of the remote panel
      M170-T6 Cable 50-Red	16	6	Desired Engine Speed
      M170-T7 Cable 50-White	16	7	Desired Engine Speed
      M170-T8 Cable 50-Black	16	8	Desired Engine Speed
      M170-T9 Cable 50-Shield	16	9	Shield for the Desired Engine Speed
      M180-T10	16	10	Desired Engine Speed 4−20 mA
      M120-T11	16	11	Grid Status
      M180-T12	16	12	Desired Engine Speed 4−20 mA −
      D100-T13	16	13	Cat Data Link +
      D100-T14	16	14	Cat Data Link −
      P500-T15	16	15	Return
      P615-T16	16	16	Start Command
      M530-T17	16	17	Driven Equipment
      P600-T18 (1) Cable 105-White	14	18	Keyswitch
      M510-T19	16	19	Normal Stop
      P697-T20	16	20	Active Alarm
      SC01-T21	16	21	Spare
      M190-T22	16	22	Idle/Rated Input
      C256-T23	16	23	Emergency Stop
      P614-T24	16	24	Auto
      P698-T25	16	25	Engine Failure
      C293-T26 (1) Cable 91-White	16	26	Manual Prelube Input
      P696-T27	16	27	Crank Terminate
      C256-T28	16	Bottom 28	Emergency Stop
      M140-T29	16	29	Run Relay
      A330-T30 Cable 109-Red	16	30	Gas Shutoff Valve
      P613-T31	16	31	Cooldown/Stop
      M164-T32	16	32	Desired Timing
      A320-T33 (1) Cable 91-Red	16	33	Prelube ON
      D200-T35 Cable 45-Yellow	18	35	CAN Data Link +
      D200-T36 Cable 45-Green	18	36	CAN Data Link −
      A330-T37 Cable 109-White	16	37	Gas Shutoff Valve
      D200-T38 Cable 45-Shield	18	38	CAN Data Link Shield
      P300-T39 (1) Cable 105-Black	14	39	−Battery
      P300-T40 Cable 91-Black	16	40
      P300-T41 Cable 109-Black	Unconnected		Spare

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      ( 1 )

      These circuits must be contained in spiral wrap at the engine interface box and at the remote advisor panel.

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

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Illustration 197	g01242443
Location for the customer connection inside the remote panel

3. Refer to Illustration 197. Make the connections for the driven equipment on the right side of the terminal strip. Table 17 lists the connections that are available.

Wiring for the Emergency Stop Circuit

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 198. Remove the bridge and connect the additional button according to the Illustration.

Illustration 198	g01242557
Emergency stop circuit with an additional emergency stop button

Wiring for the Gas Shutoff Valve

The circuit for the emergency stop buttons is complete when the remote panel is installed. Refer to Illustration 198.

Illustration 199	g01256413
Circuit for the gas shutoff valve

Initial Start-up of the Engine

Refer to Special Instruction, REHS2558-02, "Installation and Initial Start-Up Procedure for G3500 A3 Engines"

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

1. When performing a retrofit installation, record the vital information in Table 21.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 21

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number (1)
   Removed Component Serial Number (1)
   Installed Component Part Number (2)
   Installed Component Serial Number (3)

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   ( 1 )	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
   ( 2 )	Record the highest level retrofit kit, arrangement, or group part number.
   ( 3 )	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 21 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".