REHS1336-01
July 2002
Special Instruction
i01778585
Installation and Initial Start-Up
Procedure for G3600 Engines
SMCS Code: 1900
Engine
G3606 (S/N: 4ZS1-Up)
G3608 (S/N: BEN1-Up)
G3612 (S/N: BKE1-Up)
G3616 (S/N: BLB1-Up)
Table of Contents
Introduction ........................................................... 1
Requirements for the Electrical System ................ 2
Electrical Schematics ............................................ 2
Electronic Service Tools ........................................ 2
Connecting Cat ET with the 171-4401
Communication Adapter II ............................... 4
Terminal Box ......................................................... 5
Optional Control Panel .......................................... 7
Connecting a Control Panel or a PLC to the
ECM .................................................................... 8
Connecting the Optional Control Panel to the
Engine Mounted Terminal Box ........................ 8
Connecting a Customer Supplied Control Panel
or a Customer Supplied Programmable Logic
Controller (PLC) to the Engine Mounted Terminal
Box .................................................................. 9
Connecting a Customer Supplied Control Panel
or a Customer Supplied Programmable Logic
Controller (PLC) to the Engine Mounted Terminal
Box or to the Optional Control Panel ............... 10
Customer’s Wiring ................................................ 10
Wiring for the Emergency Stop Circuit .............. 11
Wiring for an Engine Oil Level Switch and for a
Coolant Level Switch ....................................... 14
Monitoring the Mode of the Engine Control
Switch .............................................................. 16
ECM Outputs ..................................................... 17
Customer’s Inputs ............................................. 19
Other Wiring Connections ................................. 22
Initial Start-Up Procedure ..................................... 24
1
Introduction
This Special Instruction provides the following
information for G3600 Engines:
• Requirements for the electrical system
• References for electrical schematics
• Required electronic service tools
• Components of the main terminal box
• Information about the optional control panel
• Connecting the optional control panel or a
Programmable Logic Controller (PLC) to the
Electronic Control Module (ECM)
• Wiring connections and the corresponding
functions that are available to the customer
• Initial start-up procedure
Before the initial start-up, an engineer that is
certified by Caterpillar must perform the engine
commissioning at the site.
Reference: Information from the following sources
will be needed for this Special Instruction:
• Complete analysis of the fuel
• Caterpillar Software Program, LEKQ6378,
“Methane Number Program”
• The Data Sheet on the engine performance from
the engine’s Technical Marketing Information
(TMI)
• Operation and Maintenance Manual, SEBU7563
• Systems Operation/Testing and Adjusting,
RENR5908
• Troubleshooting, RENR5910
Do not perform any procedure in this Special
Instruction until you read this information and you
understand this information.
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.

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
the electrical installation procedures and the initial
start-up.

Note: Other tools that are needed for measuring

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

2
Table 2
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) This PC configuration is recommended:
Intel Pentium II 333 mHz processor
64 megabyte of RAM
4.3 GB hard drive
Drive for floppy disks (3.5 inch with 1.44 MB)
14X speed CD-ROM drive
VGA monitor or display
RS-232 port with 16550AF UART
Windows NT 4.0 (1)
Windows 95 (1)
Windows 98 (1)
Mouse
N/A Personal Computer (PC) This PC configuration has the minimum requirements:
IBM PC compatible 100 MHz processor
32 megabyte of RAM
10 MB of available hard drive space
CD-ROM drive
Drive for floppy disks (3.5 inch with 1.44 MB)
Windows NT 4.0 (1)
Windows 95 (1)
Windows 98 (1)
RS-232 port with 16550AF UART
VGA monitor or display
Mouse
“JERD2124” Software Single user license for Caterpillar Electronic Technician (Cat ET)
Use the most recent version of this software.
“JERD2129” Software Data subscription for all engines
171-4401 Communication Adapter II (1) The communication adapter is connected between the PC (ET)
and the ECM.
196-0055 Serial Cable As This cable connects the PC to the 171-4401 Communication
Adapter II.
7X-1414 Data Link Cable As This cable connects the service tool connector on the engine
mounted 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) Any of these operating systems are acceptable.
(1) This item is included in the 171-4400 Communication Adapter Gp.

3
The Caterpillar Electronic Technician (Cat ET) is
designed to run on a personal computer. Either
the 171-4401 Communication Adapter II or the
7X-1700 Communication Adapter Gp can be used
for the communication between the Cat Data Link
and the RS-232 serial port. However, the 7X-1700
Communication Adapter Gp is no longer serviced.
For more information on the communication
adapters, refer to the literature that is provided with
the adapters.

Cat ET can display the following information:

• Parameters
• Diagnostic codes
• Event codes
• Engine configuration
• Status of the monitoring system
Cat ET can perform the following functions:

• Diagnostic tests
• Sensor calibration g00694774
Illustration 1
• Flash downloading (1) PC
(2) 196-0055 Serial Cable or the 160-0141 Serial Cable
(3) 171-4401 Communication Adapter II
• Set parameters (4) 207-6845 Adapter Cable
(5) 7X-1414 Data Link Cable
Connecting Cat ET with the 171-4401
Communication Adapter II 2. Connect cable (2) to the RS-232 serial port of
PC (1).
The battery supplies the communication adapter
with 24 VDC. Use the following procedure to 3. Connect cable (2) to communication adapter (3).
connect Cat ET to the ECM.
4. Connect cable (4) to communication adapter (3).
1. Turn the engine control switch to the OFF/RESET
position. 5. Connect cable (4) to cable (5).

6. Connect cable (5) to the service tool connector

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

7. Turn the engine control switch to the STOP

position. The engine should be OFF.

If Cat ET and the communication adapter

do not communicate with the ECM, refer to
Troubleshooting, RENR5910, “Electronic Service
Tool Will Not Communicate With ECM”.

4
Terminal Box
Note: The terminal box is designed to remain
mounted on the engine. The mounting hardware
includes isolators which minimize the engine
vibrations that are transmitted to the components
within the terminal box. DO NOT move the terminal
box to a remote location. Moving the terminal box
could result in wiring problems and in reduction of
the electronic control module’s 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’s sensors and for the ignition system.
The terminal box’s components are identified in
Illustrations 3 and 4.

5

Illustration 3
Inside of the terminal box
(J2/P2) 70-pin connectors for the ECM
(J1/P1) 70-pin connectors for the ECM
(1) Ground strap
(2) Terminal for the negative connection
(24 VDC)
(J7) 9-pin service tool connector
(CB1) 16 amp circuit breaker
(CB2) 6 amp circuit breaker
(J3/P3) 70-pin connectors for the
customer’s wiring
(3) Ignition wiring for the left side of Vee
engines
(J6/P6) 70-pin connectors for the sensors
on the left side of the engine
(J5/P5) 70-pin connectors for the sensors
on the right side of the engine
6
g00892898
(4) Ignition wiring for In-line engine and
for the right side of Vee engines
(J4) 47-pin connector for the optional
control panel or for a customer
connector
(5) Wiring for the electrical power
 g00891953 g00891738
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 for the Machine Information Display System (MIDS)
(J5) 70-pin connector for the sensors on the right side of the engine (2) Keypad for the MIDS
(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’s 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). shown in Illustration 6.
If 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’s
features are shown in Illustration 5. For details on
the features, refer to Operation and Maintenance
Manual, SEBU7563, “Control Panel”.

7
 g00891464
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)

8
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’s terminal strip, a cutout through the bottom
right side of the box is recommended in order to
provide 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
are identified in Illustration 8. The Illustration shows
a typical installation of a conduit between the
control panel and the engine mounted terminal box.
Illustration 10 shows a typical example for
connecting the customer’s equipment to the 70-pin
plug P3 inside of the engine mounted terminal box.
The hole through the bottom of the terminal box
may require enlargement in order to accommodate
all of the wiring.

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’s wiring

Connecting a Customer Supplied

Control Panel or a Customer Supplied
Programmable Logic Controller (PLC) to
the Engine Mounted Terminal Box
Illustration 9 shows a typical example for connecting
the customer’s equipment to the 47-pin receptacle
on the bottom of the engine mounted terminal
box. Plug (3) and adapter (4) must be used. The
interconnect wiring harness can be supplied by the
factory or by the customer.

9
Connecting a Customer Supplied
Control Panel or a Customer Supplied
Programmable Logic Controller (PLC) to
the Engine Mounted Terminal Box or to
the Optional Control Panel
Illustration 11 shows a typical example for
connecting the customer’s equipment to the
optional control panel. With this configuration, the
customer’s equipment communicates with the ECM
via the terminal strip in the control panel and via the
interconnect wiring harness. In this case, a hole is
cut through the bottom of the control panel’s box.
A cutout through the bottom right side of the box g00891992
Illustration 12
is recommended in order to provide convenient
access to the terminal strip. (1) Engine mounted terminal box
(2) Optional control panel
(3) Customer supplied control panel or PLC
Plug (4) and adapter (5) must be used. The (P3) 70-pin plug for the customer’s wiring
interconnect wiring harness (6) can be supplied by (4) 9X-4187 Connector Plug
the factory or by the customer. (5) 213-4749 Adapter
(6) Interconnect wiring harness

Customer’s Wiring
To properly wire the engine for the 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

g00891974 • Electrical power supply for the control system

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

10
 g00891599
Illustration 13
Identification of the interconnect wiring harness’ terminals and wiring

Wiring for the Emergency Stop Circuit

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

11
If the customer does not use the 70-pin P3
connector in the engine mounted terminal box, the
factory installed jumper wire between terminals
P3-24 and P3-25 is necessary.

If the customer does not use the P4 connector in the

engine mounted terminal box, 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
and 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

12
Illustration 17 is a wiring diagram of the emergency
stop buttons on the engine mounted terminal box
and on the optional control panel.

The optional control panel has a factory installed

jumper wire between terminals 10 and 11. If the
customer connects another emergency stop button
to the control panel, the jumper wire must be
removed.

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

13
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.

The switch input to the ECM must be closed in

order to run the engine.
g00892267
Illustration 21
Components in the circuit for the engine oil level switch and the
coolant level switch
(J2/P2) 70-pin ECM connectors
(J3/P3) 70-pin customer connectors
(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
Illustration 20
Right side view
Engine harness connector for the engine oil level switch and the
coolant level switch (Vee engines)
g00909527
Illustration 22

14
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.

g00909528
Illustration 23

If the switches are connected to the J3 customer

connector, jumper wires must be installed between
terminals 3 and 4 and between terminals 2 and 1
on the engine harness connector. Illustration 24 is
a wiring diagram that shows the connection of the
switches to the P3 customer connector.

15
 g00909529
Illustration 24

Monitoring the Mode of the Engine Certain terminals on the control panel’s terminal
Control Switch strip can be monitored in order to determine the
position of the engine control switch. The output
If the optional control panel is used, the customer from the terminals is provided to the ECM. The
can perform the start/stop control directly with the customer can connect wiring from the terminals to a
engine control switch on the front of the control device that monitors the mode of the engine control
panel. 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 28 and 26
Start 29 and 26

g00892917 Auto 30 and 26

Illustration 25
Terminal strip in the control panel

16
ECM Outputs
Table 5
ECM Outputs
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel’s Terminal
Strip
Engine Failure 9 P 17 P908-BK This output is activated if the ECM requests an
engine shutdown. Normally, the output’s 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 is capable of absorbing a maximum
of 0.3 amperes.
Active Alarm 8 H 16 P907-BK This output is activated if the ECM detects an
alarm condition. Normally, the output’s 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 is capable of absorbing a maximum of 0.3
amperes.
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’s 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 is capable of
absorbing a maximum of 0.3 amperes.
Crank Terminate 7 C 15 P906-BK This output is activated when the engine’s 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’s 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 is capable of
absorbing a maximum of 0.3 amperes.
Gas Shutoff Valve’s 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 is capable of supplying 2.0

amperes 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’s monitoring
system.
(continued)

17
(Table 5, contd)
ECM Outputs
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel’s Terminal
Strip
Prelube Valve’s 59 c 19 A320-RD This output is activated when the ECM requests
Voltage operation of the prelube pump. The circuit driver
is capable of supplying 2.0 amperes at 24 VDC
to the prelube pump’s 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’s monitoring system.
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.
4 to 20 mA Positive 6 u 13 A340-BK This output is provided for future expansion and
Output 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 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 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 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 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 SP03-GY Spare wire
Spare 04 62 a 51 SP04-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 X171-WH The optional control panel has the appropriate
Speed Signal analog speed potentiometer. The wiring must be
g installed according to the information in this Table.
Desired Analog 12 38 X171-BK
Speed Signal’s The ECM provides the +5 V supply to the
Return potentiometer. The potentiometer provides the
Desired Analog 13 p 39 signal input for the desired speed. The signal input
Speed Signal’s ranges from 0 to 5 volts.
Shield The potentiometer’s signal must be in the same
circuit as the return.

The cable’s shield must be connected to the signal

return.
(continued)

18
(Table 5, contd)
ECM Outputs
Description Options for Customer Interconnect Functions and Comments
Connections Wiring
Harness
J3 J4 Optional Control
Panel’s 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.

Customer’s Inputs
Table 6
Customer’s Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring Harness
J3 J4 Optional
Control
Panel’s
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’s +24 VDC must be
capable of providing a minimum of 20 amperes.
The sinking return must be capable of absorbing a
minimum of 20 amperes.
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 16 amp circuit breaker in the engine mounted
terminal box. If this method is selected, connect the
negative side to the terminal immediately above the 16
amp circuit breaker.
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 16 amp circuit breaker.
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.
(continued)

19
(Table 6, contd)
Customer’s Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring Harness
J3 J4 Optional
Control
Panel’s
Terminal
Strip
Auxiliary 33 n 24 M020-BK The settings for the governing are adjusted during the
Governor Gain engine commissioning and during the initial start-up.
The auxiliary governing is used primarily for generator
sets.

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

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

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

the ECM governs the engine according to the settings
for the primary governing.
Driven 32 U 21 M000-BK When the engine is not running, the customer’s
Equipment 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 6, contd)
Customer’s Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring Harness
J3 J4 Optional
Control
Panel’s
Terminal
Strip
Engine Control - - - - These functions can be controlled by the ECS on the
Switch (ECS) optional control panel or by customer’s 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 are
STOP controlled by the customer’s equipment, the transitions
between the inputs must occur within 1/10 of a second.
ECS 16 Y 6 P915-BK
START All of the positions of the ECS must return through the
ECS 15 - 7 P914-BK P500-BK wire for the digital return.
AUTO When the ECS is in the “OFF/RESET” position, the
Remote Start 17 6 P915-BK keyswitch power is removed. The start, stop, and auto
Input inputs to the ECM are open.

Digital Return 43 r 8 P500-BK 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 6, contd)
Customer’s Inputs to the ECM
Description Options for Customer Interconnect Functions and Comments
Connections Wiring Harness
J3 J4 Optional
Control
Panel’s
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.

Other Wiring Connections

Table 7
Other Wiring Connections
Description Options for Customer Connections Interconnect Functions and Comments
Wiring Harness
J3 J4 Optional
Control Panel’s
Terminal Strip
Fused 6 Amp 1 v 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

(continued)

22
(Table 7, contd)
Other Wiring Connections
Description Options for Customer Connections Interconnect Functions and Comments
Wiring Harness
J3 J4 Optional
Control Panel’s
Terminal Strip
Keyswitch Power 4 w 4 P700-RD The keyswitch power is available when
the ECS is at the “STOP” position, at
the “START” position, or at the “AUTO”
position. The fused 24 VDC power supply
(6 amp) is available to these components:
ECM

Air/fuel pressure module

Integrated combustion Sensing Module

(ICSM)

Optional control panel

Cat Data Link + 67 D 31 CL100-PK These connections provide the means
for communicating the status of the
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 personal computer,
the program uses this data link to obtain
engine information via the CCM.
CAN Data Link + 63 F 33 CL100-YL At the time of this publication, this option
is not available.
CAN Data Link − 64 L 34 CL100-GN
These connections are designed to provide
CAN Data Link’s 65 V 35 CL100-CU
the means for communicating the status
Shield
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’s equipment, the function can be
activated by providing a 24 VDC power
supply to the input.

Activation of the manual prelube switch or

activation of the 24 VDC power supply will
cause the prelube pump to operate until
the prelube pressure switch closes. If either
method continues to activate the input, the
prelube pump will operate again when the
prelube pressure switch opens.
(continued)

23
(Table 7, contd)
Other Wiring Connections
Description Options for Customer Connections Interconnect Functions and Comments
Wiring Harness
J3 J4 Optional
Control Panel’s
Terminal Strip
Second Timing 11 X 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’s 25 A 10 C256C-BK
Return

Initial Start-Up Procedure
Before the initial start-up, an engineer that is
certified by Caterpillar must perform the engine
commissioning at the site. The engineer is
responsible for ensuring that all of these factors
are in proper working condition prior to the initial
start-up: engine installation, driven equipment, all of
the related hardware, and electrical connections.
Failure to perform the commissioning procedure
could result in unsatisfactory operation.
Note: As part of the commissioning procedure, all
of the emergency stop buttons are tested before
the engine is started in order to verify that the ECM
generates the shutdown and the event code.
Note: Use the data from the gas analysis and the
data on engine performance in order to determine
the correct settings for the fuel quality and the
specific gravity of the fuel.
a. View the parameters that are listed in Table 8.
Program the parameters, if necessary.
Incorrect programming of the parameters
may lead to complaints about performance
and/or to engine damage. For descriptions of
the parameters, refer to Systems Operation,
RENR5908, “Electronic Control System
Parameters”.

Perform the following procedure for the initial

start-up and for start-up after major maintenance
and/or repair.

1. Connect a properly calibrated emissions analyzer

to the exhaust stack.

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’s Technical
Marketing Information (TMI).

5. Use the “Configuration” screen from the

“Service” pull-down menu on Cat ET to view the
configuration parameters.

24
Table 8
Configuration Parameters for G3600 Engines
“Fuel Quality”
“Gas Specific Gravity”
“Low Idle Speed”
“Minimum Engine High Idle Speed”
“Maximum Engine High Idle Speed”
“Engine Accel. Rate”
“Desired Speed Input Configuration”
“Governor Type Setting”
“Engine Speed Droop”
“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”
“Engine PostLube Time Out Period”
“High Inlet Air Temp Engine Load Set Point”
6. Check the operation of the prelube pump.
Note: You can use Cat ET or the MIDS display on
the optional control panel to monitor the status of
the prelube pump’s solenoid.
a. If the optional control panel is used, make
sure that the engine control switch is in
the “STOP” position. Press the “MANUAL
PRELUBE” switch.
If the system is operating correctly, the
“PRELUBE ACTIVE” indicator will illuminate
and the prelube pump will operate.
When sufficient engine oil pressure is
achieved, the prelube pressure switch will
remove power from the prelube pump. The
“PRELUBE ACTIVE” indicator will turn off.
b. After the “PRELUBE ACTIVE” indicator turns
off, release the “MANUAL PRELUBE” switch.
c. Make sure that the fuel supply is OFF. Turn
the engine control switch to the “START”
position. Verify that the prelube pump and the
“PRELUBE ACTIVE” indicator operate prior to
activation of the starting motor.
25
d. After the “PRELUBE ACTIVE” indicator turns
off, verify that the starting motor cranks the
engine. Then turn the engine control switch to
the “STOP” position.
7. Verify that the fuel supply is OFF. Make sure that
the pressure for the electrohydraulic actuator
system is sufficient for start-up.
Illustration 26 g00907346
(1) Sight gauge
(2) Plug
a. Check the oil level in sight gauge (1). Fill the
tank to the “FULL” mark on the sight gauge.
b. Remove plug (2) and install a pressure gauge
in the fitting after the oil filter.
Note: You can use Cat ET or the MIDS display on
the optional control panel to monitor the status of
the prelube pressure switch.
c. To fill the hydraulic hoses and lines, crank
the engine and observe the pressure gauge.
Do not crank the engine for more than 30
seconds at a time. If necessary, crank the
engine repeatedly in order to achieve a
pressure of 1200 ± 175 kPa (174 ± 25 psi).
Note: The ECM will generate event codes and
diagnostic codes during this procedure. After
each crank cycle, reset the engine control switch.
Continue to crank the engine until the pressure is
achieved. After the electrohydraulic system is filled
with oil, use Cat ET to clear the codes.
d. Stop cranking the engine and check the
oil level in sight gauge (1) again. Add oil,
if necessary.
The correct oil level is between the “ADD”
and “FULL” marks on the sight gauge.
e. After the hydraulic system is primed, crank
the engine again and verify that the reading
on the pressure gauge is 1200 ± 175 kPa
(174 ± 25 psi) during cranking.
 This is an adequate pressure for attempting
start-up.
Note: Sometimes, the pressure must be increased
in order to avoid the generation of diagnostic codes
during start-up. This is usually due to restarting
an engine that has a low viscosity of hydraulic oil
because the oil is hot. If this occurs, use an Allen
wrench to turn the pressure relief valve’s adjusting
bolt clockwise for approximately 1/4 of a turn (90
degrees). Refer to Illustration 28.
8. Turn the engine control switch to the “STOP”
position. Turn ON the fuel supply to the engine.
• Auxiliary governor
• Air choke
• Exhaust bypass (wastegate)
For instructions, refer to Systems Operation,
RENR5908, “Electronic Control System
Parameters” and Testing and Adjusting,
RENR5908, “Engine Governing - Adjust”.
13. Apply a load of 25 percent.
14. Slowly ramp the load to 75 percent.

9. Verify that no gas is leaking. Verify that the gas 15. Use Cat ET to switch the engine control to the
does not flow past the GSOV. prechamber calibration mode.

Unburned gas in the inlet manifold and/or in the

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

Before starting an engine that was stopped by ter-

minating the ignition system, turn the gas supply
OFF. Crank the engine for approximately 15 sec-
onds in order to clear any unburned gas from the
engine and the exhaust system.
10. Turn the engine control switch to the “START”
position.
After the prelube pump operates and the
starting motor cranks the engine, the engine will
accelerate to low idle rpm.
Several attempts may be required for the initial
start-up before the air is purged from the fuel
lines and before the electrohydraulic system has
sufficient pressure.
Note: If the engine will not start, use Cat ET to check
for diagnostic codes and event codes. Correct any
active conditions before you attempt to start the
engine again. Refer to Troubleshooting, RENR5910.
11. After the engine is running, test the operation of
each emergency stop button. After each test,
reset the emergency stop button and reset the
engine control switch. Restart the engine until
you verify that each emergency stop button is
working properly. After the testing, use Cat ET to
clear the event codes from the ECM.
12. Adjust the gain, stability, and compensation for
the following functions, if necessary.
g00815515
Illustration 27
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 combustion feedback mode. Adjust the
governors’ 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”.

• Primary governor

26
 g00892836
Illustration 28
Adjusting bolt for the pressure relief valve

21. When the engine operation is stable and the

engine achieves normal operating temperature,
adjust the electrohydraulic system’s 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’s operation.

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

27
©2002 Caterpillar
All Rights Reserved Printed in U.S.A.