3807239 Volvo.Penta Decal

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 G3500B Engines:
Requirements for the electrical system
Proper welding practices
Grounding procedures
Required service tools
Electrical components and electronic components
Wiring connections and the corresponding functions that are available to the customer
Initial start-up procedures
Governor adjustment proceduresReferenceInformation from the following sources will be needed for this Special Instruction:
Complete analysis of the fuel
Data from a complete fuel analysis that is entered into Caterpillar Software, LEKQ6378, "Methane Number Program"
The engine's performance data sheet from the engine's Technical Marketing Information (TMI)
Engine Operation and Maintenance Manual, SEBU7201
Generator set Operation and Maintenance Manual, SEBU7566
Power module Operation and Maintenance Manual, SEBU7647
Systems Operation/Testing and Adjusting, RENR2268
Troubleshooting Manual, RENR2270
The Troubleshooting Manual, RENR5927 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.The engine control system requires a clean 24 VDC power supply. The maximum allowable AC ripple voltage is 150 millivolts 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 must be capable of supplying 20 amperes of continuous power.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 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. This 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 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's electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor's 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 ECM sensors) or electronic component grounding points for grounding the welder.
Connect the welder's 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 that are 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
Service Tools    
Pt. No.    Description    Functions    
N/A     Personal Computer (PC)     The PC is required for the use