3803944 Volvo.Penta Injector

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 Engines:
Requirements for the electrical system
References for electrical schematics
Required electronic service tools
Components of the main terminal box
Information about the optional control panel
Connecting the optional control panel or a Programmable Logic Controller (PLC) to the Electronic Control Module (ECM)
Wiring connections and the corresponding functions that are available to the customer
Initial start-up procedureBefore the initial start-up, an engineer that is certified by Caterpillar must perform the engine commissioning at the site.ReferenceInformation from the following sources will be needed for this Special Instruction:
Complete analysis of the fuel
Caterpillar Software Program, LEKQ6378, "Methane Number Program"
The Data Sheet on the engine performance from the engine Technical Marketing Information (TMI)
Operation and Maintenance Manual, SEBU7563
Systems Operation/Testing and Adjusting, RENR5908
Troubleshooting, RENR5910Requirements for the Electrical System
All of 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 in order 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 S/N:4ZS1-999     Schematic, RENR5966    
G3606 S/N:4ZS1000-UP     Schematic, UENR3903    
G3608 S/N:BEN1-207     Schematic, RENR5967    
G3608 S/N:BEN208-UP     Schematic, UENR3902    
G3612 S/N:BKE1-191     Schematic, RENR5911    
G3612 S/N:BKE192-UP     Schematic, UENR3901    
G3616 S/N:BLB1-162     Schematic, RENR5912    
G3616 S/N:BLB163-UP     Schematic, UENR3900    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 in order 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     IBM Personal 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     IBM Personal 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 in order to use the software. Various licenses are available for different users with different requirements. Consult your Cat dealer.    
171-4401     Communication Adapter II (1)     The communication adapter is connected between the PC (ET) and the ECM.    
196-0055     Serial Cable As     This cable connects the PC to the 171-4401 Communication Adapter II .    
7X-1414     Data Link Cable As     This cable connects the service tool connector on the engine mounted terminal box to the 139-4166 Adapter Cable As .    
8T-8726     Adapter Cable As     This breakout t is for use between the jacks and the plugs of the sensors.    
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.    
( 1 ) This item is included in the 171-4400 Communication Adapter Gp . The Cat® Electronic Technician (ET) is designed to run on a personal computer. Either of the listed communication adapters can be used for the communication between the Cat Data Link and the RS-232 serial port. However, the 7X-1700 Communication Adapter Gp is no longer serviced. For more information on the communication adapters, refer to the literature that is provided with the adapters.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 171-4401 Communication Adapter II
The battery supplies the communic