5005657 Service Manual - English JOHNSON
BJ40PL4SRS, BJ50PL4SRS
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Introduction
Do not perform any procedure that is outlined in this Special Instruction or order any parts until the entire instruction has been read and understood.This Special Instruction describes the procedures for ordering and installing the ADEM 3 control system for the G3612 and G3616 Engines.Whenever questions arise about this product or this Special Instruction, consult your local Caterpillar dealer for the latest available information.System Description
The ADEM 3 control system replaces the Caterpillar Ignition System (CIS). Upgrading an engine to the ADEM 3 control system provides the following improvements and enhancements:Increased Reliability - The simplified design of the system has fewer control modules and wiring harnesses.Improved Control of Detonation - The ADEM 3 control system provides control of the detonation level for each cylinder. This results in improved protection for the engine, reduced exhaust emissions, and improved performance.Improved Control of the Choke - Engine wear is reduced through better control of the choke during warm-up and during light load operation.Pyrometer - The exhaust temperature is monitored at the exhaust port of each cylinder, at the inlet of each turbocharger, and at the outlet of each turbocharger.Caterpillar Electronic Technician (Cat ET) - The Cat ET provides an interface for the programming of the engine parameters. Cat ET provides real-time monitoring of the engine during operation and comprehensive display of diagnostics.Machine Information and Display System (MIDS) - The MIDS is a device which enables the operator to monitor engine operation. The MIDS receives information from the Electronic Control Module (ECM). The MIDS cannot be used for programming. A screen display and a keypad provide the interface for the operator.Requirements Before Starting the Conversion
Hydraulic Actuator System (Hydrax System)
The engine must be equipped with the Hydrax system. The Hydrax system replaces the electronic actuators that control the fuel, the wastegate, and the choke. Refer to Special Instruction, REHS0147 for information on installation of the Hydrax system.Canadian Standards Association (CSA)
All of the kit components meet the certification for CSA. If your engine requires certification for CSA, contact the CSA and arrange for an inspection by a CSA auditor.Engine Operation
The engine must be mechanically sound.The engine must be tuned prior to performing this upgrade.Performance Data Sheet
Illustration 1 is the "Performance Data Sheet" for the Engine Supervisory System (ESS). Use the sheet in order to record the engine data from these systems:
Digital Diagnostic Tool (DDT)
Caterpillar Monitoring System (CMS)
Status Control Module (SCM)
ECM
PyrometerThis information serves as a reference in order to ensure that engine performance is maintained after installation of the ADEM 3 control system. This information will also be used to determine the requirements of the new software.Use an emission analyzer tool in order to test the engine emissions. Record the results on the sheet.
Illustration 1 g01056776
Request for New Software
New software will be required in order to make the engine compatible with the customer requirements. The following items are required in order to determine the software requirements:
"G3600 ESS Performance Data Sheet"
Current fuel analysis
Software Request FormThese items must be submitted to the Service Center at Caterpillar Diversified Power Products in order to determine the requirements of the new software. The Service Center will respond with the appropriate part number that can be downloaded by the Caterpillar dealer via the Service Information System.If the appropriate software is not available, on-site mapping by a Caterpillar performance engineer will be required. On-site mapping will add approximately four days to the time that is required for the conversion.Be sure to submit the three items that are listed above. The prompt submission will provide sufficient time in order to determine the software requirements. Submit the request for new software before you order any parts. Fax the request to the following number:(765) 448-5586References
Special Instruction, REHS0385, "Installation of the Hydraulic Actuator System (Hydrax)"CIS
Disassembly and Assembly, SENR5535Schematic, SENR5082, "G3612 and G3616 Engine Electrical System"Systems Operation/Testing and Adjusting, RENR2255Troubleshooting, SENR6510ADEM 3
Disassembly and Assembly, SENR5535Operation and Maintenance Manual, SEBU7563Schematic, RENR5911, "G3612 Electrical System"Schematic, RENR5912, "G3616 Electrical System"Systems Operation/Testing and Adjusting, RENR5908Troubleshooting, RENR5910Special Instruction, REHS1336, "Installation and Initial Start-Up Procedure for G3600 Engines"Preparation of the Engine
Ensure that all of the new parts are available.
Operate the prelube pump and the barring device in order to put the number 1 cylinder in the top center position on the compression stroke. Pin the camshaft. For instructions, refer to Systems Operation/Testing and Adjusting, SENR5528, "Finding the Top Center Compression Position for No. 1 Cylinder".
Lock out the gas and the electrical power.
Drain the coolant from the engine. Refer to Operation and Maintenance Manual, SEBU6496, "Cooling System Coolant - Change".Remove the Existing Components and Systems
Remove the ESS Panel
At the ESS panel, identify each connection from the customer wiring. Label each connection.
Disconnect the wiring from the ESS panel and remove the panel.Remove the Thermocouples, If Necessary
Note: Do not remove the thermocouples for the outlets of the turbochargers.Each thermocouple for the cylinders must have a round 3-pin connector. If the thermocouples are incorrect, remove the thermocouples and replace the thermocouples with 152-0807 Temperature Sensor Gp .Remove the harness for the thermocouples. Remove any clips and brackets that attached the harness to the engine.Remove the Combustion Sensing System
Perform the following steps in order to remove the combustion sensing system:
Illustration 2 g01066614
Left side view (1) Cable (2) Connector for the detonation sensor (3) Harness (4) Tie strap (5) Tie strap (6) Harness (7) Junction box (8) Clips
For each cylinder, remove cable (1) that runs between the transformer and the combustion buffer.
Disconnect the remaining connectors at each combustion buffer.
Cut all of the tie straps (4) between the combustion buffers and the junction box for the combustion buffers and detonation sensors.
Remove harnesses (3) that run between each combustion buffer and the junction box for the combustion buffer and detonation sensors.
Disconnect connector
Do not perform any procedure that is outlined in this Special Instruction or order any parts until the entire instruction has been read and understood.This Special Instruction describes the procedures for ordering and installing the ADEM 3 control system for the G3612 and G3616 Engines.Whenever questions arise about this product or this Special Instruction, consult your local Caterpillar dealer for the latest available information.System Description
The ADEM 3 control system replaces the Caterpillar Ignition System (CIS). Upgrading an engine to the ADEM 3 control system provides the following improvements and enhancements:Increased Reliability - The simplified design of the system has fewer control modules and wiring harnesses.Improved Control of Detonation - The ADEM 3 control system provides control of the detonation level for each cylinder. This results in improved protection for the engine, reduced exhaust emissions, and improved performance.Improved Control of the Choke - Engine wear is reduced through better control of the choke during warm-up and during light load operation.Pyrometer - The exhaust temperature is monitored at the exhaust port of each cylinder, at the inlet of each turbocharger, and at the outlet of each turbocharger.Caterpillar Electronic Technician (Cat ET) - The Cat ET provides an interface for the programming of the engine parameters. Cat ET provides real-time monitoring of the engine during operation and comprehensive display of diagnostics.Machine Information and Display System (MIDS) - The MIDS is a device which enables the operator to monitor engine operation. The MIDS receives information from the Electronic Control Module (ECM). The MIDS cannot be used for programming. A screen display and a keypad provide the interface for the operator.Requirements Before Starting the Conversion
Hydraulic Actuator System (Hydrax System)
The engine must be equipped with the Hydrax system. The Hydrax system replaces the electronic actuators that control the fuel, the wastegate, and the choke. Refer to Special Instruction, REHS0147 for information on installation of the Hydrax system.Canadian Standards Association (CSA)
All of the kit components meet the certification for CSA. If your engine requires certification for CSA, contact the CSA and arrange for an inspection by a CSA auditor.Engine Operation
The engine must be mechanically sound.The engine must be tuned prior to performing this upgrade.Performance Data Sheet
Illustration 1 is the "Performance Data Sheet" for the Engine Supervisory System (ESS). Use the sheet in order to record the engine data from these systems:
Digital Diagnostic Tool (DDT)
Caterpillar Monitoring System (CMS)
Status Control Module (SCM)
ECM
PyrometerThis information serves as a reference in order to ensure that engine performance is maintained after installation of the ADEM 3 control system. This information will also be used to determine the requirements of the new software.Use an emission analyzer tool in order to test the engine emissions. Record the results on the sheet.
Illustration 1 g01056776
Request for New Software
New software will be required in order to make the engine compatible with the customer requirements. The following items are required in order to determine the software requirements:
"G3600 ESS Performance Data Sheet"
Current fuel analysis
Software Request FormThese items must be submitted to the Service Center at Caterpillar Diversified Power Products in order to determine the requirements of the new software. The Service Center will respond with the appropriate part number that can be downloaded by the Caterpillar dealer via the Service Information System.If the appropriate software is not available, on-site mapping by a Caterpillar performance engineer will be required. On-site mapping will add approximately four days to the time that is required for the conversion.Be sure to submit the three items that are listed above. The prompt submission will provide sufficient time in order to determine the software requirements. Submit the request for new software before you order any parts. Fax the request to the following number:(765) 448-5586References
Special Instruction, REHS0385, "Installation of the Hydraulic Actuator System (Hydrax)"CIS
Disassembly and Assembly, SENR5535Schematic, SENR5082, "G3612 and G3616 Engine Electrical System"Systems Operation/Testing and Adjusting, RENR2255Troubleshooting, SENR6510ADEM 3
Disassembly and Assembly, SENR5535Operation and Maintenance Manual, SEBU7563Schematic, RENR5911, "G3612 Electrical System"Schematic, RENR5912, "G3616 Electrical System"Systems Operation/Testing and Adjusting, RENR5908Troubleshooting, RENR5910Special Instruction, REHS1336, "Installation and Initial Start-Up Procedure for G3600 Engines"Preparation of the Engine
Ensure that all of the new parts are available.
Operate the prelube pump and the barring device in order to put the number 1 cylinder in the top center position on the compression stroke. Pin the camshaft. For instructions, refer to Systems Operation/Testing and Adjusting, SENR5528, "Finding the Top Center Compression Position for No. 1 Cylinder".
Lock out the gas and the electrical power.
Drain the coolant from the engine. Refer to Operation and Maintenance Manual, SEBU6496, "Cooling System Coolant - Change".Remove the Existing Components and Systems
Remove the ESS Panel
At the ESS panel, identify each connection from the customer wiring. Label each connection.
Disconnect the wiring from the ESS panel and remove the panel.Remove the Thermocouples, If Necessary
Note: Do not remove the thermocouples for the outlets of the turbochargers.Each thermocouple for the cylinders must have a round 3-pin connector. If the thermocouples are incorrect, remove the thermocouples and replace the thermocouples with 152-0807 Temperature Sensor Gp .Remove the harness for the thermocouples. Remove any clips and brackets that attached the harness to the engine.Remove the Combustion Sensing System
Perform the following steps in order to remove the combustion sensing system:
Illustration 2 g01066614
Left side view (1) Cable (2) Connector for the detonation sensor (3) Harness (4) Tie strap (5) Tie strap (6) Harness (7) Junction box (8) Clips
For each cylinder, remove cable (1) that runs between the transformer and the combustion buffer.
Disconnect the remaining connectors at each combustion buffer.
Cut all of the tie straps (4) between the combustion buffers and the junction box for the combustion buffers and detonation sensors.
Remove harnesses (3) that run between each combustion buffer and the junction box for the combustion buffer and detonation sensors.
Disconnect connector
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5005658