16131 3 Mercury O-RING

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 G3600 A4 Engines:
Requirements for the electrical system
References for electrical schematics
Required electronic service tools
Components of the main Electronic Control Module (ECM) panel
Initial start-up procedureBefore 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
Site-specific technical data sheet from Gas Engine Rating Pro (GERP) software. Download at https://engines.cat.com/gerp
Operation and Maintenance Manual, SEBU9207
Systems Operation / Testing and Adjusting, KENR9773
Troubleshooting, KENR9774Requirements for the Electrical System
All 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 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 than 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 A4 Schematic, UENR4714
G3608 A4 Schematic, UENR4715
G3612 A4 Schematic, UENR4716
G3616 A4 Schematic, KENR8604 Electronic Service Tools
Caterpillar Electronic Service Tools are designed to help the service technician:
Obtain data
Diagnose problems
Read parameters
Program parameters
Calibrate sensorsThe tools that are listed in Table 2 are required 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.
Table 2
Service Tools
Pt. No. Description Functions
N/A IBMPersonal Computer (PC) compatible This PC configuration is recommended:
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 of Microsoft Internet Explorer
N/A IBMPersonal Computer (PC) compatible This PC configuration has the minimum requirements:
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 of Microsoft 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 to use the software. Various licenses are available for different users with different requirements. Consult your Cat dealer.
317-7484 Communication Adapter 3 The communication adapter is connected between the PC (ET) and the ECM.
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. The Cat® 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:
Diagnostic tests
Sensor calibration
Flash downloading
Set parametersConnecting Cat ET with the 317-7485 Communication Adapter (3)
The battery supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET to the ECM.
Illustration 1 g02051513
(1) PC
(2) 370-4617 Cable As (USB)
(3) 317-7485 Communication Adapter (3)
(4) 457-6114 Cable As (DATA LINK)
Connect cable (2) to the RS-232 serial port of PC (1).
Connect cable (2) to communication adapter (3).
Connect cable (4) to communication adapter (3).
Connect cable (4) 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.If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, KENR9774, "Electronic Service Tool Will Not Communicate".ECM Panel
Note: The ECM panel 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 ECM panel. Do not move the ECM panel to a remote location. Moving the ECM panel could result in wiring problems and in reduction of the electronic control module service life.
Illustration 2 g03802573
ECM Panel
The engine-mounted ECM panel is on the rear right side of the engine. The ECM is inside the ECM panel. The ECM panel provides the point of termination for all the wiring that is related to the engine sensors and for the ignition system. The ECM panel components are identified in Illustrations 3, 4, and 5.