0304019 JOHNSON GROMMET,Control shaft

Introduction
Table 1
Revision History
Revision Summary of Changes
10 Added serial number prefixes FE8 and XLL.
09 Step 6 has been updated in "Initial Start-Up Procedure" Section. Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction provides the following information for G3500B and G3500J Engines:
Required information
Requirements for the electrical system
Grounding practices
Proper welding practices
Service tools
Wiring connections
Initial start-up procedures
Governor adjustment proceduresReference: The following information is required to perform the installation and initial start-up:
Complete analysis of the fuel provided by Gas Engine Rating Pro (GERP)
The performance data sheet for this engine located in the Technical Marketing Information (TMI) database or located in GERP.
Operation and Maintenance Manual, SEBU8332, "G3500 Engines"
Systems Operation/Testing and Adjusting, KENR6892
Troubleshooting Manual, KENR6893
Service Manual, RENR4911, "Exhaust Temperature Scanner"Required Information
Ignition Timing
A complete fuel analysis must be conducted prior to putting the engine into service. Obtain a fuel analysis to determine the fuel energy content and calculate the methane number. The methane number indicates the ability of the fuel to be ignited and is used to determine desired ignition timing. Both the methane number and the ignition timing will be provided by GERP when a fuel analysis is done. The fuel usage guide on the engine performance sheet can be used to determine the desired ignition timing for the fuel being used.Obtain several samples of fuel if the quality is expected to change. If the methane number will vary during engine operation, use the lowest expected value to determine ignition timing.Maximum Load
The maximum load that the engine can handle given its operating site can be found in the fuel analysis results generated by the Gas Engine Rating Pro (GERP) tool.Inlet Manifold Pressure at Full Load
Use the inlet manifold pressure to estimate the load on the engine. The inlet manifold pressure may be used if the engine timing and the exhaust NOX are set properly. Refer to TMI to determine the inlet manifold pressures for specific settings of timing and emissions. If the engine power is derated, interpolate the desired inlet manifold pressure between the 100 percent and the 75 percent load ratings.Level of Exhaust Emissions
The 391-8170 EMISSIONS ANALYZER TOOL GP or 393-0673 EMISSIONS ANALYZER TOOL GP is required to set up this engine. The engine performance Data Sheet gives the levels of emissions for engine loads of 50 percent, of 75 percent, and of 100 percent. Set up the engine in accordance with the Data Sheet at the desired full load with the data that was taken at 100 percent load.Note: Use NOx levels to set up the engine, when possible.Note: Failure to adjust the air/guel ratio to the correct NOx levels can result in excessive misfire and/or detonation during engine operation.Gas Pressure Regulator
The gas pressure regulator requires adjustment when the engine is installed. Use only Caterpillar approved regulators to avoid problems with performance.Note: The supply line to the gas pressure regulator must be of adequate diameter to provide constant pressure to the regulator from idle to full load. Do not use supply lines that are smaller than the inlet to the pressure regulator.Requirements for the Electrical System
All the wiring must conform to the requirements of CSA Class 1 Division 2 Group C,D. The wiring must conform to all other codes that are applicable to the site.When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through the metal conduit. A liquid tight conduit is recommended. Use proper support and alignment to avoid strain on the conduit.The engine control system requires a clean 24 VDC power supply. The maximum allowable AC ripple voltage is 150 mV AC peak-to-peak. For the wiring, the maximum allowable voltage drop is 1 VDC from the power supply to the Electronic Control Module (ECM) or to an actuator. The power supply must be rated at 20 amp of continuous power. A circuit breaker of the correct size must be provided by the customer for the power supply to the engine electrical system.The circuit for the engine control system must be separate from the circuit for the electric starting motor.Grounding Practices
Proper grounding is necessary for optimum engine performance and reliability. Improper grounding will result in electrical current paths that are uncontrolled and unreliable.Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications.
For the starting motor, do not attach the battery negative terminal to the cylinder block.
Use an electrical ground strap to connect all metal cases that contain electrical components or electronic components to the cylinder block.
Do not connect the negative terminal from the electrical power supply directly to the cylinder block. Connect the negative terminal from the electrical power supply to the negative terminal "−" on the interface box.
Ground the cylinder block with a ground strap. The strap is furnished by the customer. Connect this ground strap to the ground plane.
Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane or to earth ground.
Rubber couplings may connect the steel piping of the cooling system and the radiator. This action causes the piping and the radiator to be electrically isolated. Ensure that the piping and the radiator are continuously grounded to the cylinder block. Use ground straps that bypass the rubber couplings.
Ensure that all grounds are secure and free of corrosion.Proper Welding Procedures
Proper welding procedures are necessary to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "Off/Reset" mode.
Turn off the fuel supply to the engine.
Disconnect the negative terminal from the power supply.
Disconnect the following electronic components from the wiring harnesses: ECM, throttle actuator, fuel actuator, and all sensors.
Protect the wiring harnesses from welding debris and/or from the welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the welders ground cable directly to the engine