0583929 JOHNSON STARTER SWITCH ASSY.,

Introduction
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 G3500C and G3500E Engines:
Requirements for the electrical system
Proper grounding practices
Proper welding practices
Required service tools
Electrical components and electronic components
Wiring connections and the corresponding functions that are available to the customer
Initial start-up procedure
Governor adjustment proceduresReference: Information from the following sources will be needed for this Special Instruction:
Data from a complete fuel analysis that is entered into Caterpillar Software, LEKQ6378, "Methane Number Program"
The engine performance Data Sheet from the engine Technical Marketing Information (TMI)
Operation and Maintenance Manual, SEBU7681
Systems Operation/Testing and Adjusting, RENR5978, "G3520C and G3520E Generator Set Engines"
Systems Operation/Testing and Adjusting, KENR6834, "G3516C and G3516E Engines"
Troubleshooting, RENR5944, "G3516C and G3516E Engines"
Troubleshooting, RENR5979, "G3520C and G3520E Engines"Requirements for the Electrical System
All of the wiring must conform to all of the 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 metal conduit. A liquid tight conduit is recommended. Use proper support and alignment in order to avoid strain on the conduit.Electrical power must be supplied to the junction box that serves as the main distribution panel for the engine control system. The engine control system requires a clean 24 VDC power supply capable of supplying 30 A of continuous power.The maximum allowable 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 an Electronic Control Module (ECM) or to an actuator.The power supply for the engine control system must be separate from the power supply for the starting motor.Grounding Practices
Proper grounding is necessary for optimum engine performance and for 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 engine mounted junction box.
Ground the cylinder block with a ground strap that 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.
Rubber couplings may connect the steel piping of the cooling system and the radiator. The rubber isolates the piping and the radiator. 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.Welding on Electronically Controlled Engines
Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass, fuel metering valve and sensors.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the welder ground cable directly to the engine component that will be welded. Place the clamp as close as possible to the weld in order to reduce the possibility of welding current damage to the engine bearings, to the electrical components and to other engine components.
Use standard welding procedures to weld the materials together.Service Tools
The tools listed in Table 1 are required in order to enable a service technician to perform the electrical installation procedures and the initial start-up.The Caterpillar Electronic Technician (ET) is designed to run on a personal computer.Cat ET can display the following information:
Parameters
Diagnostic codes
Event codes
Engine configuration
Status of the monitoring systemCat ET can perform the following functions:
Perform diagnostic tests.
Calibrate sensors.
Download flash files.
Set parameters.Table 1 is a list of required service tools.
Table 1
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) The PC is required for the use of Cat ET.
"JERD2124" Software Single user license for Cat ET
Use the most recent version of this software.
"JERD2129" Software Data subscription for all engines
275-5120 (1) Communication Adapter Gp This group provides the communication between the PC and the engine.
7X-1414 Data Link Cable As This cable connects the communication adapter to the service tool connector on the engine.
237-7547 Adapter Cable As This cable connects to the USB port on personal computers.
225-5985 Parallel Port Cable (COMMUNICATION ADAPTER) This cable connects to the parallel port on personal computers.
8T-8726 Adapter Cable As This cable is for use between the jacks and the plugs of the sensors.
1U-5804 Crimp Tool (12-GA TO 18-GA) This tool is used for work with electrical connectors.
121-9588 Wire Removal Tool (Blue) These tools are used for the removal of pins and of sockets from Deutsch connectors and AMP connectors.
151-6320 Wire Removal Tool (Red)
1U-5805 Wire Removal Tool (Green)
146-4080 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.
156-1060 or 156-1070 Emission Analyzer Tool This tool is used to measure the level of emissions in the engine exhaust. The 156-1060 measures the levels of four different compounds. The 156-1070 measures the levels of six different compounds. Either tool may be used.
(1) The 171-4400 Communication Adapter Gp and the 7X-1700 Communication Adapter Gp may also be used.