REHS1336-06

15 November 2010

Special Instruction
i04144330 Initial Start-Up Procedure ..................................... 27
Installation and Initial Start-Up
Introduction
Procedure for G3600 Engines
Do not perform any procedure in this Special
SMCS Code: 1000; 1900 Instruction until you read this information and you
understand this information.
Engine
G3606 (S/N: 4ZS1-Up) This Special Instruction provides the following
G3608 (S/N: BEN1-Up) information for G3600 Engines:
G3612 (S/N: BKE1-Up)
• Requirements for the electrical system
G3616 (S/N: BLB1-Up)
• References for electrical schematics
Table of Contents
• Required electronic service tools
Introduction ........................................................... 1
Requirements for the Electrical System ................ 2 • Components of the main terminal box
Electrical Schematics ............................................ 2
Electronic Service Tools ........................................ 2 • Information about the optional control panel
Connecting Cat ET with the 171-4401
Communication Adapter II ............................... 4 • Connecting the optional control panel or a
Terminal Box ......................................................... 4 Programmable Logic Controller (PLC) to the
Optional Control Panel .......................................... 6 Electronic Control Module (ECM)
Connecting a Control Panel or a PLC to the
ECM .................................................................... 7 • Wiring connections and the corresponding
Connecting the Optional Control Panel to the functions that are available to the customer
Engine Mounted Terminal Box ........................ 7
Connecting a Customer Supplied Control Panel • Initial start-up procedure
or a Customer Supplied Programmable Logic
Controller (PLC) to the Engine Mounted Terminal Before the initial start-up, an engineer that is
Box .................................................................. 8 certified by Caterpillar must perform the engine
Connecting a Customer Supplied Control Panel commissioning at the site.
or a Customer Supplied Programmable Logic
Controller (PLC) to the Terminal Box or to the Reference: Information from the following sources
Control Panel ................................................... 8 will be needed for this Special Instruction:
Customer Wiring ................................................... 9
Wiring for the Emergency Stop Circuit .............. 10 • Complete analysis of the fuel
Wiring for an Engine Oil Level Switch and for a
Coolant Level Switch ....................................... 13 • Caterpillar Software Program, LEKQ6378,
Monitoring the Mode of the Engine Control “Methane Number Program”
Switch .............................................................. 15
ECM Outputs ..................................................... 16 • The Data Sheet on the engine performance from
Optional ECM 4 to 20 mA Inputs ....................... 18 the engine Technical Marketing Information (TMI)
Customer Inputs ................................................ 18
Other Wiring Connections ................................. 23 • Operation and Maintenance Manual, SEBU7563
Procedure for Connecting the Desired Speed Input
from the Load Sharing Module ............................ 25 • Systems Operation/Testing and Adjusting,
Connecting to the Optional Control Panel ......... 25 RENR5908
Engine Mounted Terminal Box .......................... 26

1
• Troubleshooting, RENR5910

Requirements for the Electrical

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

When you route the wiring, avoid acute bends and

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

The customer +24 VDC circuit must provide a

minimum of 20 A. The return must absorb a minimum
of 20 A. The voltage drop must be no more that 1
VDC at the maximum current draw with a maximum
of 150 mV AC ripple voltage.

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

Table 1
Electrical Schematics for G3600 Engines
Engine Model Publication
G3606 Schematic, RENR5966
G3608 Schematic, RENR5967
G3612 Schematic, RENR5911
G3616 Schematic, RENR5912

Electronic Service Tools

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

• Obtain data.
• Diagnose problems.
• Read parameters.
• Program parameters.
• Calibrate sensors.
The tools that are listed in Table 2 are required in
order to enable a service technician to perform this
Special Instruction.

Note: Other tools that are needed for measuring

operating parameters such as pressure and
temperature are not listed in Table 2.

2
Table 2
Service Tools
Pt. No. Description Functions
N/A IBM Personal Computer (PC) This PC configuration is recommended:
compatible Pentium IV 2.4 GHz processor
2 GB of RAM
2 GB of available hard drive space
40X speed CD-ROM drive or 8X speed DVD drive
15.4 inch XGA monitor (1280 X 1024)
Microsoft Windows XP or Vista Business or Windows 7
RS-232 port with 16550AF UART
Mouse
USB 1.1 or 2.0 port
Latest version o fMicrosoft Internet Explorer
N/A IBM Personal Computer (PC) This PC configuration has the minimum requirements:
compatible Pentium 1 GHz processor or greater
1GB of RAM
500 MB of available hard drive space
24X CD-ROM drive
Super VGA monitor or display (800 X 600)
Microsoft Windows XP or Vista Business or Windows 7
RS-232 port with 16550AF UART
Mouse
USB 1.1 or 2.0 port
Latest version o fMicrosoft Internet Explorer
“JEBD30034” Software Use the most recent version of this software.
Once you have downloaded Cat ET onto your PC, you will need a
license from your Cat dealer in order to use the software. Various
licenses are available for different users with different requirements.
Consult your Cat dealer.
171-4401 Communication Adapter II (1) The communication adapter is connected between the PC (ET)
and the ECM.
196-0055 Serial Cable As This cable connects the PC to the 171-4401 Communication
Adapter II.
7X-1414 Data Link Cable As This cable connects the service tool connector on the engine
mounted terminal box to the 139-4166 Adapter Cable As.
8T-8726 Adapter Cable As This breakout t is for use between the jacks and the plugs of the
sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch
connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.
9U-7330 Digital Multimeter The multimeter is used for the testing and for the adjusting of
electronic circuits.
7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage in
wiring harnesses without disconnecting the harnesses.
5P-7277 Voltage Tester The tester is used to test for voltage in circuits, in relays, in bulbs,
in wires, and in switches.
(1) This item is included in the 171-4400 Communication Adapter Gp.

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

3
• Status of the monitoring system 5. Connect cable (4) to cable (5).

Cat ET can perform the following functions: 6. Connect cable (5) to the service tool connector on
the engine mounted terminal box. Alternatively,
• Diagnostic tests connect the cable to the service tool connector on
the optional control panel.
• Sensor calibration
7. Turn the engine control switch to the STOP
• Flash downloading position. The engine should be OFF.

• Set parameters If Cat ET and the communication adapter

do not communicate with the ECM, refer to
Connecting Cat ET with the 171-4401 Troubleshooting, RENR5910, “Electronic Service
Tool Will Not Communicate With ECM”.
Communication Adapter II
The battery supplies the communication adapter with Terminal Box
24 VDC. Use the following procedure to connect Cat
ET to the ECM. Note: The terminal box is designed to remain
mounted on the engine. The mounting hardware
1. Turn the engine control switch to the OFF/RESET includes isolators which minimize the engine
position. vibrations that are transmitted to the components
within the terminal box. Do not move the terminal
box to a remote location. Moving the terminal box
could result in wiring problems and in reduction of the
electronic control module service life.

g00891827
Illustration 2
Terminal box

The engine mounted terminal box is located on the

rear right side of the engine. The ECM is inside the
terminal box. The terminal box provides the point
of termination for all of the wiring that is related to
the engine sensors and for the ignition system. The
terminal box components are identified in Illustrations
Illustration 1
g00694774 3 and 4.
(1) PC
(2) 196-0055 Serial Cable or the 160-0141 Serial Cable
(3) 171-4401 Communication Adapter II
(4) 207-6845 Adapter Cable
(5) 7X-1414 Data Link Cable

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

(1).

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

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

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

5
 g00891953 g01142577
Illustration 4 Illustration 5
Front and bottom of the terminal box Control panel
(J6) 70-pin connector for the sensors on the left side of the engine (1) Display
(J5) 70-pin connector for the sensors on the right side of the engine (2) Keypad
(J4) 47-pin connector for the optional control panel or for a (3) “EMERGENCY STOP” button
customer connector (4) “ENGINE ON” indicator
(6) Emergency stop button (5) “ACTIVE ALARM” indicator
(7) 27.5 mm (1.08 inch) hole for the ignition wiring on the left side (6) “ENGINE FAILURE” indicator
of Vee engines (7) “MANUAL PRELUBE” switch and “PRELUBE ACTIVE”
(8) 27.5 mm (1.08 inch) hole for the ignition wiring for In-line indicator
engines and for the right side of Vee engines (8) Engine control switch
(9) 27.5 mm (1.08 inch) hole for the electrical power supply and/or (9) “DESIRED SPEED” potentiometer
for the customer wiring to the 70-pin connector (P3) (10) 9-pin service tool connector

Note: Holes (7), (8), and (9) will accommodate a Dimensions for mounting of the control panel are
conduit with an inner diameter of 19 mm (3/4 inch). If shown in Illustration 6.
the customer connects to the 70-pin connector (P3)
in the terminal box, hole (9) may require enlargement.

Optional Control Panel

A control panel that is installed remotely from the
engine is available as an option. The control panel
features are shown in Illustration 5. For details on
the features, refer to Operation and Maintenance
Manual, SEBU7563, “Control Panel”.

6
 g01142607
Illustration 6
Dimensions of the optional control panel

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

There are several different possible configurations for

connecting to the ECM. The method that is selected
depends on the needs of the customer.

Connecting the Optional Control Panel to

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

Table 3
Interconnect Wiring Harnesses for the
g00891835 Optional Control Panel
Illustration 7
(J3) 70-pin receptacle for a customer connection Part Length
(J4) 47-pin receptacle for the optional control panel or for a
customer connection 206-6543 Harness 6.1 m (20 ft)
205-3584 Harness 15.9 m (52 ft)
206-6544 Harness 30.5 m (100 ft)

7
Each harness has a 47-pin plug for connecting the
harness to the J4 receptacle on the bottom of the
engine mounted terminal box. The plug is attached
to an adapter for a conduit that has a diameter of
3.8 cm (1 1/2 inch). The other end of the harness is
routed through an access hole in the bottom of the
control panel to the terminal strip. The hole in the
bottom of the control panel is for a conduit that has
a diameter of 3.8 cm (1 1/2 inch).

If the customer needs additional wiring to the control

panel terminal strip, a cutout through the bottom right
side of the box is recommended. The cutout provides
convenient access to the terminal strip.
g00891899
If the customer wishes to fabricate an interconnect Illustration 9
wiring harness, these necessary parts can be (1) Engine mounted terminal box
obtained separately: 9X-4187 Connector Plug and (2) Customer supplied control panel or PLC
(3) 9X-4187 Connector Plug
213-4749 Adapter. The minimum recommended (4) 213-4749 Adapter
size of wire is 16 AWG. (5) Interconnect wiring harness

The plug, the adapter, and the interconnect harness Illustration 10 shows a typical example for connecting
are identified in Illustration 8. The Illustration shows the customer equipment to the 70-pin plug P3
a typical installation of a conduit between the control inside of the engine mounted terminal box. The hole
panel and the engine mounted terminal box. through the bottom of the terminal box may require
enlargement in order to accommodate all of the
wiring.

g00891879
Illustration 8
(1) Engine mounted terminal box
(2) Optional control panel g00891966
Illustration 10
(3) 9X-4187 Connector Plug
(4) 213-4749 Adapter (1) Engine mounted terminal box
(5) Interconnect wiring harness (2) Customer supplied control panel or PLC
(P3) 70-pin plug for the customer wiring

Connecting a Customer Supplied Connecting a Customer Supplied

Control Panel or a Customer Supplied Control Panel or a Customer Supplied
Programmable Logic Controller (PLC) to Programmable Logic Controller (PLC) to
the Engine Mounted Terminal Box the Terminal Box or to the Control Panel
Illustration 9 shows a typical example for connecting
Illustration 11 shows a typical example for connecting
the customer equipment to the 47-pin receptacle on
the customer equipment to the optional control panel.
the bottom of the engine mounted terminal box. Plug
With this configuration, the customer equipment
(3) and adapter (4) must be used. The interconnect
communicates with the ECM via the terminal strip
wiring harness can be supplied by the factory or by
in the control panel and via the interconnect wiring
the customer.
harness. In this case, a hole is cut through the bottom
of the control panel box. A cutout through the bottom
right side of the box is recommended in order to
provide convenient access to the terminal strip.

8
Plug (4) and adapter (5) must be used. The Customer Wiring
interconnect wiring harness (6) can be supplied by
the factory or by the customer. For the wiring requirements of the specific application,
the customer must be aware of several inputs and
outputs that are associated with the ECM. The
following list includes some examples of the inputs
and outputs:

• Emergency stop
• Engine oil level switch and coolant level switch
• Electrical power supply for the control system
• Start-up and shutdown
• Status of engine operation
g00891974
Illustration 11 • Engine speed and governing
(1) Engine mounted terminal box
(2) Optional control panel Interconnect wiring harnesses that are supplied by
(3) Customer supplied control panel or PLC the factory include the wiring for most of the customer
(4) 9X-4187 Connector Plug
(5) 213-4749 Adapter inputs and outputs. Each wiring harness is complete
(6) Interconnect wiring harness with a 47-pin plug for the J4 connector on the bottom
of the terminal box. The terminals on the plug and
Illustration 12 shows a typical example for connecting the corresponding wires are identified in Illustration
the customer equipment to the 70-pin plug P3 13. The functions of the wires are identified in Tables
inside of the engine mounted terminal box. The hole 5, 7, and 8.
through the bottom of the terminal box may require
enlargement in order to accommodate all of the
wiring.

The optional control panel is connected to the 47-pin

receptacle on the bottom of the engine mounted
terminal box. Plug (4) and adapter (5) must be used.
The interconnect wiring harness (6) can be supplied
by the factory or supplied by the customer.

g00891992
Illustration 12
(1) Engine mounted terminal box
(2) Optional control panel
(3) Customer supplied control panel or PLC
(P3) 70-pin plug for the customer wiring
(4) 9X-4187 Connector Plug
(5) 213-4749 Adapter
(6) Interconnect wiring harness

9
 g01206152
Illustration 13
Identification of the interconnect wiring harness terminals and wiring

Wiring for the Emergency Stop Circuit

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

If an emergency stop is activated, the fuel is

immediately shut off. Electrical power to the ignition
system is immediately removed. The postlube cycle
does not operate.

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

The terminal box and the optional control panel are

equipped with emergency stop buttons. The customer
may supply additional emergency stop buttons. Any Illustration 14
g00892177
additional customer supplied emergency stop buttons Components in the emergency stop circuit
must be wired in series in order to operate properly.
(J1/P1) 70-pin ECM connectors
Operation of all emergency stop buttons must be (J3/P3) 70-pin customer connectors
verified prior to the initial start-up. (J4/P4) 47-pin connectors for the optional control panel or for a
customer connection
(1) Terminal strip in the optional control panel

Illustration 15 is a wiring diagram of the emergency

stop button on the engine mounted terminal box.

10
If the customer does not use the 70-pin P3 connector,
the factory installed jumper wire between terminals
P3-24 and P3-25 is necessary.

If the customer does not use the P4 connector, a

jumper wire must be installed between terminals
P3-48 and P3-49.

g00892043
Illustration 15

Illustration 16 is a wiring diagram of the emergency

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

g00900660
Illustration 16

Illustration 17 is a wiring diagram of the emergency

stop buttons on the engine mounted terminal box and
on the optional control panel.

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

g00900659
Illustration 17

Illustration 17 is a wiring diagram of the emergency

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

g00900609
Illustration 18

12
Wiring for an Engine Oil Level Switch and
for a Coolant Level Switch
The ECM has one switch input that serves both an
engine oil level switch and a coolant level switch. The
switches are optional. The switches may be supplied
by the factory or supplied by the customer.

The switches are installed by the customer. If the

switches are used, operation of the switches must be
verified prior to the initial start-up.

When fluid is not present, the engine oil level switch

and the coolant level switch have normally open
contacts. Illustration 21
g00892267

Components in the circuit for the engine oil level switch and the
The switch input to the ECM must be closed in coolant level switch
order to run the engine.
(J2/P2) 70-pin ECM connectors
(J3/P3) 70-pin customer connectors
(J5/P5) 70-pin connectors for the wiring harness on the right side
of the engine

If the switches are not used, install jumper wires

according to the wiring diagram in Illustration 22.

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

g00902969 g01142669
Illustration 20 Illustration 22
Right side view
Engine harness connector for the engine oil level switch and the
coolant level switch (Vee engines)

13
If the switches are supplied by the factory, the
switches will be connected to this engine harness. In
this case, jumper wires must be installed between
terminals J3-56 and J3-57 and between J3-69 and
J3-70. Illustration 23 is a wiring diagram that shows
the connection of the switches to the engine harness.

g01142742
Illustration 23

If the switches are connected to the J3 customer

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

14
 g01142842
Illustration 24

Monitoring the Mode of the Engine Certain terminals on the control panel terminal strip
Control Switch can be monitored in order to determine the position
of the engine control switch. The output from the
If the optional control panel is used, the customer can terminals is provided to the ECM. The customer
perform the start/stop control with the control panel. can connect wiring from the terminals to a device
that monitors the mode of the engine control switch.
The positions of the engine control switch and the
corresponding terminals are identified in Table 4.

Table 4
Positions of the Engine Control Switch and
Corresponding Terminals in the Optional
Control Panel
Position of the Engine Corresponding Closed
Control Switch Terminals
Off/Reset 27 and 26
Stop 30 and 26
Start 29 and 26
g00892917
Illustration 25 Auto 28 and 26
Terminal strip in the control panel

15
ECM Outputs
Table 5
ECM Outputs
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
Engine Failure 9 P 17 P908-BK This output is activated if the ECM requests an
engine shutdown. Normally, the output circuit
is open. If the output is activated, the output is
grounded. The “ENGINE FAILURE” indicator
on the optional control panel is illuminated. The
sinking driver can absorb a maximum of 0.3 A.
Active Alarm 8 H 16 P907-BK This output is activated if the ECM detects an alarm
condition. Normally, the output circuit is open. If
the output is activated, the output is grounded. The
“ACTIVE ALARM” indicator on the optional control
panel is illuminated. The sinking driver can absorb
a maximum of 0.3 A.
Run Relay 19 Z 14 M040-BK This output is activated when the engine is cranked.
The output remains active until the beginning of
an engine shutdown. Normally, the output circuit
is open. When the output is activated, the output
is grounded. The “ENGINE ON” indicator on the
optional control panel is illuminated. The sinking
driver can absorb a maximum of 0.3 A.
Crank Terminate 7 C 15 P906-BK This output is activated when the engine crank
terminate speed is achieved. Typically, the crank
terminate speed is 250 rpm. The output remains
active until the engine speed is reduced to 0 rpm.
Normally, the output circuit is open. When the
output is activated, the output is grounded. The
optional control panel does not have an indicator
for this output. The sinking driver can absorb a
maximum of 0.3 A.
Gas Shutoff Valve 60 m 20 A330-RD This output is activated when the pressure switch
Voltage for the electrohydraulic actuator system closes.
The gas shutoff valve (GSOV) is energize-to-run.
To enable fuel flow to the engine, voltage is
supplied to the solenoid for the GSOV. The voltage
is removed for an engine shutdown and the output
is deactivated.

The circuit driver can supply 2.0 A at 24 VDC.

The output can be used to provide a signal for
control of multiple valves that are installed by the
customer. Alternatively, the signal can be used by
the customer monitoring system.
Prelube Valve Voltage 59 c 19 A320-RD This output is activated when the ECM requests
operation of the prelube pump. The circuit driver
can supply 2.0 A at 24 VDC to the prelube
pump solenoid. When the output is activated, the
“PRELUBE ON” indicator on the optional control
panel is illuminated.

The output can be used to provide a signal for

control of multiple valves that are installed by the
customer. Alternatively, the signal can be used by
the customer monitoring system.
(continued)

16
(Table 5, contd)
ECM Outputs
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
Auxiliary 2 Amp 5 j 12 A340-RD This output is provided for future expansion and
Positive Output the output is not presently available for use.
Auxiliary 2 Amp 6 u 13 A340-BK This output is provided for future expansion and
Return the output is not presently available for use.
4 to 20 mA positive 28 G 44 X100A-GY This output is provided for future expansion and
Output #1 the output is not presently available for use.
4 to 20 mA Negative 29 M 45 X100B-GY This output is provided for future expansion and
Output #1 the output is not presently available for use.
4 to 20 mA Positive 30 W 46 X100C-GY This output is provided for future expansion and
Output #2 the output is not presently available for use.
4 to 20 mA Negative 31 f 47 X100D-GY This output is provided for future expansion and
Output #2 the output is not presently available for use.
PWM Output 1 36 k 48 X110B-GY This output is temporarily used by the integrated
combustion sensing module. At the time of this
publication, the output is unused. The wire is
disconnected from the ECM.
PWM Output 2 37 s 49 X110A-GY This output is provided for future expansion and
the output is not presently available for use.
Spare 01 38 t 52 SP01-GY Spare wire
Spare 02 39 v 53 SP02-GY Spare wire
Spare 03 52 R 50 X273-GY Spare wire
Desired Analog 10 N 36 X171-RD The preferred method for the desired speed input
Speed (+5 V Supply) must be selected with Cat ET.
Desired Analog 11 X 37 X173-WH The optional control panel has the appropriate
Speed Signal analog speed potentiometer. The wiring must be
Desired Analog 12 g 38 installed according to the information in this Table.
X172-BK
Speed Signal Return
The ECM provides the +5 V supply to the
Desired Analog 13 p 39 X170-CU potentiometer. The potentiometer provides the
Speed Signal Shield signal input for the desired speed. The signal input
ranges from 0 to 5 V.

The potentiometer signal must be in the same

circuit as the return.

The cable shield must be connected to the signal

return.

17
Optional ECM 4 to 20 mA Inputs
Table 6
ECM 4 to 20 mA Inputs
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
4 to 20 mA Desired 20 E 40 X183A-GY The 4 to 20 mA is an optional method for providing
Speed (Input) the desired speed input.
4 to 20 mA Desired 21 J 41 X183B-GY The preferred method for the desired speed input
Speed (Return) must be selected with the Cat ET.

The potentiometer on the optional control panel (if

equipped) must be disabled.

The 4 to 20 mA is an isolated input. The positive “+”

input must be in the same circuit as the negative
“-” return.
4 to 20 mA Remote 22 S 42 X000A-GY The 4 to 20 mA input for providing remote Btu input.
Desired Fuel Quality
Btu (Input) The 4 to 20 mA input for providing remote Btu input
return line.
4 to 20 mA Remote 23 b 43 X000B-GY
Desired Fuel Quality This optional input can be used at sites with varying
Btu (Return) fuel quality.

The 4 to 20 mA is an isolated input. The Positive

“+” input must be in the same circuit as the negative
“−” return.

Customer Inputs
Table 7
Customer Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
(continued)

18
(Table 7, contd)
Customer Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
+Battery Supply - z 1 P100-RD This connection is not available on the J3 connector.
-Battery Return - x 2 P300-BK The circuit for the customer +24 VDC must provide
a minimum of 20 A. The sinking return must absorb
a minimum of 20 A.

There are two methods for connecting the 24 VDC

power supply for the engine control system:

The 24 VDC power supply can be connected directly

to the 15 amp fuse in the engine mounted terminal
box. If this method is selected, connect the negative
side to the terminal immediately above the 15 amp
fuse.

The 24 VDC power supply can be connected to

terminal 1 in the optional control panel. Connect
the negative return to terminal 2. Also, connect the
P100-RD wire in the engine mounted terminal box
to the power supply side of the 15 amp fuse.
Idle/Rated Input 40 d 22 M030-BK When the engine oil pressure is greater than the
setpoint for the engine speed and this input is
grounded to the -Battery side, the ECM senses the
grounding of the input. The engine operates at the
setting for the desired speed.

When this input is not grounded to the -Battery side,

the engine operates at the setting for the low idle
speed.
Auxiliary Governor 34 n 24 M020-BK The settings for the governing are adjusted during
Gain the engine commissioning and during the initial
start-up. The auxiliary governing is used primarily
for generator sets.

When the “Grid Status” is ON and this input is

grounded to the -Battery side, the ECM senses the
grounding of the input. The ECM governs the engine
according to the settings for the auxiliary governing.

When this input is not grounded to the -Battery

side, the ECM governs the engine according to the
settings for the primary governing.
(continued)

19
(Table 7, contd)
Customer Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
Driven Equipment 32 U 21 M000-BK When the engine is not running, the customer
Input equipment grounds this wire to the -Battery side.
The ECM senses the grounding of the wire and the
ECM permits the engine to be ready for start-up.

If this input is not grounded, the driven equipment is

considered to be NOT ready and the engine cannot
be cranked. The ECM generates an event code if
this input is not grounded within the programmed
delay time.

When the engine is running, this input normally

continues to be grounded. If the engine is running
and this input is disconnected from the ground, the
ECM immediately generates an event code and an
engine shutdown.

Because the cooldown is not performed, do not use

this input for normal shutdown.
(continued)

20
(Table 7, contd)
Customer Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
Engine Control Switch - - - - These functions can be controlled by the ECS on the
(ECS) optional control panel or by customer equipment.
OFF/RESET
If these inputs are not wired correctly, the ECM
ECS 14 O 5 P913-BK will generate a diagnostic code. If these inputs
STOP are controlled by the customer equipment, the
ECS 16 h 6 P915-BK transitions between the inputs must occur within
START 1/10 of a second.

ECS 15 Y 7 P914-BK All of the positions of the ECS must return through
AUTO the P500-BK wire for the digital return.
Remote Start Input 17 h 6 P915-BK When the ECS is in the “OFF/RESET” position, the
Digital Return 43 r 8 P500-BK keyswitch power is removed. The start, stop, and
auto inputs to the ECM are open.

When the ECS is in the “STOP” position, the

keyswitch power is available. The ECM input
for the stop function is grounded to the digital
return. If the engine is running and the ECS is
turned to the “STOP” position, the sequence for
a normal shutdown is initiated. If the cooldown is
programmed, the engine operates for the cooldown
period prior to shutdown.

When the ECS is in the “START” position, the

keyswitch power is available. The start input to the
ECM is grounded to the digital return. The normal
sequence for start-up is initiated. When the start
input is removed, a normal shutdown is initiated. If
the cooldown is programmed, the engine operates
for the cooldown period prior to shutdown.

When the ECS is in the “AUTO” position, the

keyswitch power is available and the auto input is
activated. This position is used for a remote start-up
that is supplied by the customer.

The remote start input will only function when the

auto input is activated. The remote start input to the
ECM must be grounded to the digital return. There
are two methods for wiring the remote start input:

One method is connecting between terminals 17

and 43 in the J3 customer connector.

The other method is connecting terminals 6 and 8

on the terminal strip in the optional control panel.

When either method is used, the normal sequence

for start-up is initiated. When the remote start input
is removed, a normal shutdown is initiated. If the
cooldown is programmed, the engine operates for
the cooldown period prior to shutdown.
(continued)

21
(Table 7, contd)
Customer Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
Normal Stop 26 K 25 M010-BK Because the cooldown will not operate for this input,
this input is not recommended for normal shutdown.
The functions of the ECS are recommended for
normal shutdown.

This input is currently connected to the -Battery

side via a jumper wire that is internal to the wiring
harness.

This input must be connected to the -Battery side in

order for the engine to operate. When the input is
removed from the ground, the following shutdown
sequence occurs:

Power is removed from the GSOV and the fuel is

shut off.

Power is removed from the ignition system when the

engine speed is reduced to less than 50 rpm.

The postlube occurs.

The cooldown does not operate.

(continued)

22
(Table 7, contd)
Customer Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel Terminal
Strip
Multi Strike Enable 62 a 51 X283-GY This input is used to enable the Multi Strike feature.
When this feature is ON, the ECM will send two
ignition pulses to the transformer for each cycle of
combustion. Multi Strike is typically used in low Btu
applications.

When this input is grounded to −Battery, the engine

will operate in Multi Strike.

Other Wiring Connections

Table 8

Other Wiring Connections

Description Options for Customer Connections Interconnect Functions and Comments
Wiring Harness
J3 J4 Optional
Control Panel
Terminal Strip
Fused 6 Amp 1 y 3 P600-RD This connection provides the fused 24 VDC
+Battery power supply (6 amp) for these functions:

Cat ET

Customer Communication Module (CCM)

Engine Control Switch (ECS)

Keyswitch power for the ECM and for the

optional control panel

Status indicators on the optional control

panel

Manual prelube switch

Keyswitch Power 4 w 4 P700-RD The keyswitch power is available when
the ECS is at the “STOP” position, at
the “START” position, or at the “AUTO”
position. The fused 24 VDC power supply
(6 amp) is available to these components:

ECM

Air/fuel pressure module

Integrated combustion Sensing Module

(ICSM)

Optional control panel

(continued)

23
(Table 8, contd)
Other Wiring Connections
Description Options for Customer Connections Interconnect Functions and Comments
Wiring Harness
J3 J4 Optional
Control Panel
Terminal Strip
Cat Data Link + 67 D 31 CL100-PK These connections provide the means
for communicating the status of the
Cat Data Link - 66 l 32 CL100-PU engine control system, of various engine
components, and of sensors.

The Cat Data Link can be connected to the

CCM. For information on connecting the
CCM, refer to the most recent literature for
the CCM.

When the Caterpillar software for the CCM

is loaded on a PC, the program uses this
data link to obtain engine information via
the CCM.
CAN Data Link + 63 F 33 CL200-YL At the time of this publication, this option
is not available.
CAN Data Link − 64 L 34 CL200-GN
CAN Data Link 65 V 35 CL200-CU These connections are designed to provide
Shield the means for communicating the status
of the engine control system, of various
engine components, and of sensors.

This data link conforms to the “CAN Data

Link 2.0 Hardware Standard” and the
“J1939 Software Standard”.
Manual Prelube 58 T 18 C290-RD If the optional control panel is used, the
manual prelube switch on the control panel
can be operated when the ECS is in the
“STOP” position.

If the prelube is controlled by the customer

equipment, the function can be activated
by providing a 24 VDC power supply to the
input.

Activation of the manual prelube switch

or of the 24 VDC power supply will cause
the prelube pump to operate. The pump
will operate until the switch for prelube oil
pressure closes. If either method continues
to activate the input, the prelube pump will
operate again when the switch for prelube
oil pressure opens.
Second Timing 42 e 23 M050-BK This function is not available for G3600
Engines. Do not attempt to wire this
connection.
Emergency Stop 24 B 9 C256B-BK For details, refer to “Wiring for the
Emergency Stop Circuit”.
Emergency Stop 25 A 10 C256C-BK
Return

24
Procedure for Connecting the
Desired Speed Input from the Load
Sharing Module
There are two options for wiring the
202-4869 Governor Control input to the
G3600 engine. The desired speed input can be
connected to a terminal strip inside the optional
control panel. The input can also be connected to a
connector that is inside the engine mounted terminal
box.

g01022372
Illustration 27
Terminals 37, 38, and 39 inside the optional control panel

3. Six wires are connected to the left side of terminals

37, 38, and 39. Disconnect the three wires that
are connected between the left side of terminals
37, 38, and 39 and the speed potentiometer.

The other three wires that are connected to the

left side of terminals 37, 38, and 39 are routed
to the engine. These three wires must remain
connected.

4. Insulate the ends of the disconnected wires in

order to ensure that the wires do not create a
short circuit.

5. Perform these steps in order to connect the new

Illustration 26
g01022340 wiring:
202-4869 Governor Control
a. Connect the shield to terminal 39.
(1) Terminal 19 is the positive terminal.
(2) Terminal 20 is the negative terminal.
b. Connect the remaining two wires to terminals
37 and 38.
The desired speed signal from the 202-4869
Governor Control is available at terminals 19 and 20.
Use shielded twisted pair cable in order to make the
connection.

Connecting to the Optional Control Panel

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

1. Remove electrical power from the engine.

2. Open the control panel. The connections for the

desired speed signal are on terminals 37, 38, and
39.

25
 g01022372
Illustration 29
Terminal strip for the optional control panel
Terminals 37, 38, and 39 inside the control panel

3. Disconnect the six wires that are connected to the

left side of terminals 37, 38, and 39.

Disconnection of the wires disconnects the wiring

for the desired speed potentiometer on the control
panel. The wiring from those terminals to the
engine is effectively disconnected.

g01156366
4. Insulate the ends of the wires in order to ensure
Illustration 28 that the wires do not create a short circuit.
Schematic diagram for the connection between the governor
control and the optional control panel

6. Refer to Illustration 28. Perform these steps in

order to connect the wiring to the governor control:

a. Connect the wire from terminal 37 in the control

panel to terminal 19 on the governor control.

b. Connect the wire from terminal 38 in the control

panel to terminal 20 on the governor control.

Note: The wire for the shield has no connection at

the governor control.
g01022374
7. Restore electrical power to the engine. Illustration 30
Connector J3 inside the engine mounted terminal box
Engine Mounted Terminal Box
5. Perform the following steps in order to connect the
Perform the following procedure in order to connect new wiring to the P3 connector:
the desired speed signal to the engine mounted
terminal box. a. Crimp a 8T-8730 Connector Socket onto the
ends of the wires that will be connected to the
1. Remove electrical power from the engine. P3 connector:

2. Open the optional control panel. The connections b. Connect the shield to terminal P3-13.
for the desired speed signal are on terminals 37,
38, and 39. c. Connect the remaining two wires to terminals
P3-11 and to P3-12.

26
 2. Perform the daily inspection and all of the daily
maintenance procedures that are scheduled in
Operation and Maintenance Manual, SEBU7653,
“Maintenance Interval Schedule”.

3. Connect Cat ET to the service tool connector.

Refer to “Connecting Cat ET with the 171-4401
Communication Adapter II”.

4. Use the “Monitoring System” screen from the

“Service” pull-down menu on Cat ET to view the
default settings of the trip points for the alarms.
Adjust the settings, if necessary.

For the necessary values of the operating

parameters, refer to the appropriate Data Sheet
on engine performance in the engine Technical
Marketing Information (TMI).

5. Use the “Configuration” screen from the

“Service” pull-down menu on Cat ET to view the
Illustration 31
g01023100 configuration parameters.
Schematic diagram for the connection between the governor
control and the engine mounted terminal box Note: Use the data from the gas analysis and the
data on engine performance to determine the settings
6. Refer to Illustration 31. Perform these steps in for the fuel quality and the specific gravity.
order to connect the wiring to the governor control:
a. View the parameters that are listed in Table 9.
a. Connect the wire from terminal J3-11 to Program the parameters, if necessary.
terminal 19 on the governor control.
Incorrect programming of the parameters
b. Connect the wire from terminal J3-12 to may lead to complaints about performance
terminal 20 on the governor control. and/or to engine damage. For descriptions of
the parameters, refer to Systems Operation,
Note: The wire for the shield has no connection at RENR5908, “Electronic Control System
the governor control. Parameters”.

Table 9
7. Restore electrical power to the engine.
Configuration Parameters for G3600 Engines
Initial Start-Up Procedure Air/Fuel Ratio Control
“Fuel Quality”
Before the initial start-up, an engineer that is certified
by Caterpillar must perform the engine commissioning “Gas Specific Gravity”
at the site. The engineer is responsible for ensuring
“Desired Engine Exhaust Port Temp”
that all of these factors are in proper working condition
prior to the initial start-up: engine installation, driven “Maximum Choke Position”
equipment, all of the related hardware, and electrical
“Engine Start Choke Position”
connections. Failure to perform the commissioning
procedure could result in unsatisfactory operation. “Wastegate (Proportional) Gain Percentage”
“Wastegate (Integral) Stability Percentage”
Note: As part of the commissioning procedure, all of
the emergency stop buttons are tested before the “Wastegate (Derivative) Compensation Percentage”
engine is started. The testing verifies that the ECM
“Choke (Proportional) Gain Percentage”
generates the shutdown and the event code.
“Choke (Integral) Stability Percentage”
Perform the following procedure for the initial start-up
and for start-up after major maintenance and/or “Choke (Derivative) Compensation Percentage”
repair. Speed Control

1. Connect a properly calibrated emissions analyzer “Low Idle Speed”

to the exhaust stack. “Minimum Engine High Idle Speed”
(continued)

27
(Table 9, contd) When sufficient engine oil pressure is achieved,
Configuration Parameters for G3600 Engines the switch for prelube oil pressure will remove
power from the prelube pump. The “PRELUBE
“Maximum Engine High Idle Speed” ACTIVE” indicator will turn off.
“Engine Accel. Rate”
b. After the “PRELUBE ACTIVE” indicator turns
“Desired Speed Input Configuration” off, release the “MANUAL PRELUBE” switch.
“Governor Type Setting”
c. Make sure that the fuel supply is OFF. Turn
“Engine Speed Droop” the engine control switch to the “START”
“Governor (Proportional) Gain Percentage” position. Verify that the prelube pump and the
“PRELUBE ACTIVE” indicator operate prior to
“Governor (Integral) Stability Percentage” activation of the starting motor.
“Governor (Derivative) Compensation Percentage”
d. After the “PRELUBE ACTIVE” indicator turns
“Governor Auxiliary 1 (Proportional) Gain Percentage” off, verify that the starting motor cranks the
“Governor Auxiliary 1 (Integral) Stability Percentage” engine. Then turn the engine control switch to
the “STOP” position.
“Governor Auxiliary 1 (Derivative) Compensation
Percentage” 7. Verify that the fuel supply is OFF. Make sure that
Start/Stop Control the pressure for the electrohydraulic actuator
system is sufficient for start-up.
“Driven Equipment Delay Time”
“Crank Terminate Speed”
“Engine Purge Cycle Time”
“Engine Cooldown Duration”
“Cycle Crank Time”
“Engine Overcrank Time”
“Engine Speed Drop Time”
“Engine Pre-lube Time Out Period”
Monitoring and Protection
“High Inlet Air Temp Engine Load Set Point”
g00907346
Information for the Electronic Control Module (ECM) Illustration 32

“Engine Serial Number” (1) Sight gauge

(2) Plug
“Equipment ID”
a. Check the oil level in sight gauge (1). Fill the
“Customer Password #1”
tank to the “FULL” mark on the sight gauge.
“Customer Password #2”
b. Remove plug (2) and install a pressure gauge
“Total Tattletale”
in the fitting after the oil filter.

6. Check the operation of the prelube pump. Note: You can use Cat ET or the display on the
optional control panel to monitor the status of the
Note: You can use Cat ET or the display on the switch for prelube oil pressure.
optional control panel to monitor the status of the
prelube pump solenoid. c. To fill the hydraulic hoses and lines, crank the
engine and observe the pressure gauge. Do
a. If the optional control panel is used, make sure not crank the engine for more than 30 seconds
that the engine control switch is in the “STOP” at a time. If necessary, crank the engine
position. Press the “MANUAL PRELUBE” repeatedly in order to achieve a pressure of
switch. 1200 ± 175 kPa (174 ± 25 psi).

If the system is operating correctly, the

“PRELUBE ACTIVE” indicator will illuminate
and the prelube pump will operate.

28
Note: The ECM will generate event codes and Note: If the engine will not start, use Cat ET to check
diagnostic codes during this procedure. After each for diagnostic codes and event codes. Correct any
crank cycle, reset the engine control switch. Continue active conditions before you attempt to start the
to crank the engine until the pressure is achieved. engine again. Refer to Troubleshooting, RENR5910.
After the electrohydraulic system is filled with oil, use
Cat ET to clear the codes. Note: In the screen for relay status of Cat ET,
check the position of the following relays. The check
d. Stop cranking the engine and check the oil level ensures that the relays are in the ready position:
in sight gauge (1) again. Add oil, if necessary.
• Normal stop
The correct oil level is between the “ADD” and
“FULL” marks on the sight gauge. • Emergency stop
e. After the hydraulic system is primed, crank • Prelube
the engine again and verify that the reading
on the pressure gauge is 1200 ± 175 kPa • Driven equipment
(174 ± 25 psi) during cranking.
• Multi strike (OFF except Bio-Gas)
This pressure is adequate for attempting
start-up. 11. After the engine is running, test the operation
of each emergency stop button. After each test,
Note: Sometimes, the pressure must be increased reset the emergency stop button and reset the
in order to avoid the generation of diagnostic engine control switch. Restart the engine until you
codes during start-up. Usually, the codes are due verify that each emergency stop button is working
to restarting an engine that has a low viscosity of properly. After the testing, use Cat ET to clear the
hydraulic oil because the oil is hot. If codes are event codes from the ECM.
activated, use an Allen wrench to turn the pressure
relief valve adjusting bolt clockwise for approximately 12. Adjust the gain, stability, and compensation for
1/4 of a turn (90 degrees). Refer to Illustration 34. the following functions, if necessary.

8. Turn the engine control switch to the “STOP” • Primary governor

position. Turn ON the fuel supply to the engine.
• Auxiliary governor
9. Verify that no gas is leaking. Verify that the gas
does not flow past the GSOV. • Start choke position
• Maximum choke position

Unburned gas in the inlet manifold and/or in the

• Exhaust bypass (wastegate)
exhaust manifold can ignite when the engine is
started. Personal injury and/or property damage
• Desired engine exhaust port temperature
can result. Use this procedure to clear the engine For instructions, refer to Systems Operation,
and the exhaust system of unburned gas: RENR5908, “Electronic Control System
Parameters” and Testing and Adjusting,
Before starting an engine that was stopped by ter- RENR5908, “Engine Governing - Adjust”.
minating the ignition system, turn the gas supply
OFF. Crank the engine for approximately 15 sec- 13. Apply a load of 25 percent.
onds in order to clear any unburned gas from the
engine and the exhaust system. 14. Slowly ramp the load to 75 percent.

10. Turn the engine control switch to the “START” 15. Use Cat ET to switch the engine control to the
position. prechamber calibration mode.

After the prelube pump operates and the starting

motor cranks the engine, the engine will accelerate
to low idle rpm.

Several attempts may be required for the initial

start-up before the air is purged from the fuel lines.
Several attempts may be required before the
electrohydraulic system has sufficient pressure.

29
 21. When the engine operation is stable and the
engine achieves normal operating temperature,
adjust the electrohydraulic system pressure
relief valve in order to obtain a pressure of
1550 ± 35 kPa (225 ± 5 psi). For instructions, refer
to Testing and Adjusting, RENR5908, “Engine
Governing - Adjust”.

22. Continue to monitor the engine operation. Record

the operating parameters frequently and keep the
records for future reference.

g00815515
Illustration 33
Needle valves for the precombustion chambers

16. Adjust the needle valves for the precombustion

chambers in order to achieve the desired
combustion burn time. For instructions, refer to
Testing and Adjusting, RENR5908, “BTU and
Precombustion Chamber Adjustments”.

17. Use Cat ET to switch the engine control to

the mode for combustion feedback. Adjust the
governor gain, stability, and compensation again,
if necessary.

18. Increase the load to 100 percent.

19. After the engine has been operating at full load in

the feedback mode for a minimum of ten minutes,
verify that the fuel correction factor remains within
± 2 percent of 100 percent.

20. Check the exhaust emissions. If the emissions

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

g00892836
Illustration 34
Adjusting bolt for the pressure relief valve

30
31
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