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Upgrade G3516 and G3512 1400 RPM Gas Compression Engines to ADEM 3 and Air/Fuel Ratio Control with a Nitrogen Oxide Sensor {1000, 1408, 1901, 191N} Caterpillar


Upgrade G3516 and G3512 1400 RPM Gas Compression Engines to ADEM 3 and Air/Fuel Ratio Control with a Nitrogen Oxide Sensor {1000, 1408, 1901, 191N}

Usage:

G3516 4EK
Engine
G3512 (S/N: 7NJ1-UP)
G3516 (S/N: 4EK1-UP)

Introduction

Do not perform any procedure that is in this Special Instructionuntil you have read and understand the instruction.

This Special Instruction describes the installation of the ADEM 3 Electronic Control Module (ECM) on G3500A Engines. The ADEM 3 electronic control improves performance and reliability by integrating the following functions:

  • Governing the engine

  • Engine monitoring

  • Air/fuel ratio control

  • Ignition timing

  • Detonation sensitive control

  • Engine prelube

ADEM 3 is commonly known as the A+ or A3 control system.

Whenever questions arise about this product or about this Special Instruction, consult your local Caterpillar dealer for the latest available information.

References

The following reference materials may be necessary for this procedure:

  • Disassembly and Assembly Manual, SENR6419

  • Systems Operation/Testing and Adjusting, KENR5473, "Exhaust Temperature Module"

  • Special Instruction, REHS2558, "Installation and Start-up Procedure for G3500 A3 Engines"

  • Troubleshooting, RENR9353, "Gas 3500 A3 Engines", "Nitrogen Oxide Sensor - Calibrate"

  • Informational Release Memo, PELJ1002, "G3512 & G3516 ENGINE Upgrade Conversion to ADEM III With AFRC and Nitrogen Oxide Sensor"

System Description

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Illustration 1g01247636
Typical engine configuration
(1) Throttle actuator
(2) Exhaust Temperature Module (ETM)
(3) Engine interface box(EIB)
(4) ADEM 3 Engine Control Module (ECM)
(5) Actuator for air/fuel ratio control
(6) Fuel valve
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Illustration 2g01527242
G3512 and G3516 engines with dual turbochargers
(7) Nitrogen oxide sensor
(8) Nitrogen oxide sensor ring
(9) Nitrogen oxide sensor buffer
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Illustration 3g01431205
View A-A
(10) Main system fuse (F3)
(11) Throttle fuse (F4)
(12) Air/fuel ratio control fuse (F5)
(13) Ground wire
(14) Jumper wire (P200-C19)
(15) - Battery
(16) + Battery

Parts List

Conversion Arrangements

Conversion arrangements are listed in Table 1. If the engine is equipped with an electric starting motor, the engine must be converted to an air starting motor.

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Table 1
Conversion Arrangements 
Model  Conversion Arrangement  Description 
G3512  452-9501  All configurations 
G3516  452-9502  All configurations 

The flash files that are needed for your application are listed in Table 2. The ECM flash files can be downloaded from Service Information System SIS.

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Table 2
ECM Flash Files 
1200 RPM or 1400 RPM 
G3512  317-5319 Engine Ratings Electronic Software Gp 
G3516  317-5317 Engine Ratings Electronic Software Gp 

If the engine is currently equipped with air/fuel ratio control, refer to Table 3 for the required parts.

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Table 3
Engines That are Currently Equipped with Air/Fuel Ratio Control 
Model  Required Part  Required Part  Required Part 
G3512  315-3578 Wiring Mounting Gp  308-3821 Sensor Wiring Gp  325-6490 Gas Conversion Gp 
G3516  315-3578 Wiring Mounting Gp  308-3821 Sensor Wiring Gp  325-6491 Gas Conversion Gp 

If you want to add air/fuel ratio control to the engine and the engine is not currently equipped with air/fuel ratio control, refer to Table 4.

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Table 4
Engines That are Not Currently Equipped with Air/Fuel Ratio Control 
Model  Required Part  Required Part  Required Part 
G3512  315-3578 Wiring Mounting Gp  308-3821 Sensor Wiring Gp  325-6493 Gas Conversion Gp 
G3516  315-3578 Wiring Mounting Gp  308-3821 Sensor Wiring Gp  325-6492 Gas Conversion Gp 

Air/fuel ratio control is required for all engines that are converting to the ADEM 3 control with a nitrogen oxide sensor.

Prepare the Engine

Take the following precautions when work is performed on the engine:

  • Disconnect the cables from the engine battery.

  • Drain the engine coolant.

  • Shut off the gas supply to the engine.

  • Ensure that any source of hydraulic pressure or any source of compressed air is relieved.

  • Ensure that any source of electrical power to the engine is disconnected.

  • Lock out the engine.

Remove the Existing Electronic Ignition System (EIS) Components

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    Illustration 4g01282629
    EIS control module and interconnect harness

  1. Remove engine harness (1) for the EIS control module. Remove all other external engine harnesses.
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    Illustration 5g01282399
    EIS control module

  2. Remove EIS control module (2).
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    Illustration 6g01282598
    Mounting plate for the EIS control module

  3. Remove mounting plate (3) for the EIS control module.
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    Illustration 7g01282645
    Remote panel

  4. Remove the remote panel for the EIS (4) and the interconnect harness.

Remove the Gauge Panel

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Illustration 8g01249980

  1. Remove gauge panel (1). Remove any mounting brackets, hoses, or metal tubing.

Remove the Sensors and Switches

  1. Remove all existing sensors and switches from the engine. Examples of sensors that are removed are the following:

    • Exhaust Temperature sensors (thermocouples)

    • Differential oil pressure sensor

    • Manifold air temperature sensor

    • Intake manifold pressure sensor

    • Engine oil temperature sensor

    • Engine coolant temperature sensor

    • Engine oil pressure sensor
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    Illustration 9g01283178
    Exhaust temperature sensor

  2. Remove the exhaust temperature sensor (1) at each cylinder. Do not plug these holes.
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    Illustration 10g01286288
    (2) 9W-0532 Temperature Sensor Gp
    (3) 4P-5646 Elbow

  3. Remove inlet air temperature sensor (2) from the elbow (3). Install a plug into the port for the inlet air temperature sensor. Apply pipe sealant to the threads of the plug.
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    Illustration 11g01282713
    Manifold air pressure sensor

  4. Remove manifold air pressure sensor (4).
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    Illustration 12g01286062
    Plug the orifice or cap the orifice for the manifold air pressure sensor.

  5. Plug or cap connection (5) at the manifold air pressure sensor. Refer to Illustration 12.
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    Illustration 13g01282730
    Coolant temperature sensor

  6. Remove coolant temperature sensor (6).
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    Illustration 14g01282792
    Detonation sensor

  7. Remove detonation sensors (7) from both the left side of the engine and the right side of the engine.
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    Illustration 15g01286108

  8. Remove oil pressure sensor (8).
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    Illustration 16g01286101
    (9) 7W-6492 Pipe Plug

  9. Install plug (9) into the orifice for the oil pressure sensor. Apply pipe sealant to the threads of the plug.
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    Illustration 17g01282805
    Oil temperature sensor

  10. Remove oil temperature sensor (10) from the side of the cylinder block.
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    Illustration 18g01286182
    (11) 8T-6765 Pipe Plug

  11. Install plug (11) into the orifice for the oil temperature sensor. Apply pipe sealant to the threads of the plug.
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    Illustration 19g01282852
    Magnetic pickups

  12. Remove magnetic pickups (12) from the flywheel housing. Remove the magnetic pickups from both the left side of the engine and the right side of the engine.
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    Illustration 20g01286083
    (13) 5F-0304 Plugs
    (14) 4B-8407 Gasket

  13. Install plugs (13) and gaskets (14) into the holes for the magnetic pickups.
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    Illustration 21g01282903
    Speed-timing sensor

  14. Remove existing speed-timing sensor (15).
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    Illustration 22g01283038
    Oxygen sensor

  15. If the engine is equipped with an oxygen sensor, remove the oxygen sensor (16) from the adapter plate (17).
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    Illustration 23g01283064
    Adapter plate for the oxygen sensor

  16. Remove adapter plate (17) for the oxygen sensor. If the engine is equipped with an exhaust heat shield, remove the exhaust heat shield. For certain applications, support the exhaust stack to access the adapter plate for the oxygen sensor.
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    Illustration 24g01283048
    Buffer for the oxygen sensor

  17. Remove buffer (18) for the oxygen sensor (if equipped).
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    Illustration 25g01283114
    Left side of the engine is shown above.
    Exhaust temperature sensor

  18. Remove exhaust temperature sensors (19) (if equipped).

    Note: Illustration 25 shows a temperature sensor that attached to a gauge panel.

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    Illustration 26g01283275
    (11) 8T-6765 Pipe Plug

  19. Plug any orifices that will not be used with the new A3 control system. The openings could include tubes, sensors, or switches that were used with the previous system. Install plug (11) into the orifices for these devices. Apply pipe sealant to the threads of the plugs.

Remove the Engine Switches

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    Illustration 27g01319943

  1. Remove all the temperature switches and all the pressure switches.

  2. Oil level regulator (2) remains on the engine. Hose (1) must be rerouted.
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    Illustration 28g01286321
    Location for installation of new coolant pressure switch
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    Illustration 29g01286333
    Hardware that has been removed

  3. Remove any hardware (3) for the installation of the jacket water pressure switch. Refer to Illustration 28 and Illustration 29.

Remove the Wiring Harnesses

  1. Remove all the external wiring harnesses. The following harnesses are the internal ignition system harness , which will remain on the engine. Refer to Table 5.

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    Table 5
    G3512  G3516 
    Part Number  Part Name 
    4P-9322  Engine Harness As 
    4P-7487  Engine Harness As 

Remove the Governors, Actuators, and Linkages

  1. Remove all governors, actuators, and linkages. Typical examples are shown in Illustrations 30 through 33.
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Illustration 30g00805672
3161 Governor
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Illustration 31g01046905
Throttle actuator
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Illustration 32g01344696
Heinzmann actuator
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Illustration 33g01250046
EG-3P actuator and linkage

Remove the Elbow for the Air Inlet Manifold

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    Illustration 34g01286468
    The lifting eyebolt has been removed from the engine block to allow access to the flange.
    (1) 7N-5085 Flange
    (2) 7N-5079 Elbow

  1. Remove elbow (2) for the air inlet manifold from the first cylinder. If necessary, remove the lifting eye to provide access to the elbow.

  2. Flange (1) is reused. Note the orientation of the flange. The flange is marked TOP with raised letters.
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    Illustration 35g01286506
    (3) 102-2674 Arrestor Assembly
    (1) 7N-5085 Flange
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    Illustration 36g01286525
    Inlet elbow that has been removed

  3. The flame arrestor is located behind the flange for the inlet elbow. Note the orientation of the flame arrestor.

Remove the Oil Bypass Valve Cover

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    Illustration 37g01286729
    (1) 4W-8468 Bypass Valve Cover

  1. Remove bypass valve cover (1). The bypass valve is on the front of the engine on the upper left side. The bypass valve cover is fastened to the oil filter housing with one 0L-1143 Bolt and two 0S-1619 Bolts. Reuse these bolts.
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    Illustration 38g01286743
    The cover is removed from the bypass valve.
    (2) 6V-8001 O-Ring Seal
    (3) 5P-4892 O-Ring Seals

  2. Clean the mating surface between the bypass valve cover and the oil filter housing. Install new O-rings if the current O-rings are damaged.

Note: Install the new cover onto the oil bypass valve as soon as possible. The oil passages should not be left exposed to any contamination. Refer to "Install the New Oil Bypass Valve Cover".

Remove the Air Start Lines and the Prelube Lines

  1. Turn off the supply of pressurized air. Purge the pressurized air from the air tube assemblies and the starting motor.
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    Illustration 39g00597642

  2. Remove hose assemblies (1) for the air start motor. Remove the prelube lines.

  3. Remove bolts (2).

  4. Remove U-bolt (3) and tube assemblies (4).

Remove the Transformers

  1. Remove the valve covers.

  2. Remove the connector from each transformer.

  3. Remove bolt (1) and retainer (2) that secures the transformer to the cylinder head.

    Note: The bolt and the retainer should be reused with the new A3 transformer, if the engine is designed to Canadian Standards Association (CSA) specifications.

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    Illustration 40g01321404
    Transformer and retainer

  4. Lift the transformer out of the cylinder head.

  5. Remove the remaining transformers from the engine in the same manner. The spark plugs may be reused.

    Note: Spark plugs that are used for the new A3 control system are the same spark plugs that were used previously. The spark plugs are not listed in the new conversion arrangements.

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Illustration 41g01282660
The valve cover and the transformer have been removed from the cylinder head.

Install the Components

Install the Transformers

  1. Install the new transformers. Lubricate seals (2) with clean engine oil.

    Note: Spark plugs that are used for the new A3 control system are the same spark plugs that were used previously. The spark plugs are not listed in the new conversion arrangement.

    Note: The transformers must be changed to be compatible with the ADEM 3 control.

  2. Secure the transformer with retainer (5) and bolt (4).
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    Illustration 42g01320047
    (1) 259-2078 Ignition Transformer Gp
    (2) 135-2651 Seal
    (3) 125-1372 O-Ring Seal
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    Illustration 43g01320079
    (4) 5B-5059 Bolt
    (5) 134-4723 Retainer As
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    Illustration 44g01286639
    The transformers have been installed into the cylinder head.

  3. Connect each transformer to the internal harness connector.

  4. Install the valve covers.

Install the Control Group and Mounting

  1. Install the new ECM and the support bracket.

  2. Remove any paint or oxidation from bracket (2) to ensure a good electrical contact.
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Illustration 45g01282608
Location for installation of the new ECM and support bracket
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Illustration 46g01431439
Mounting location for engines with a single cooling circuit
(1) 154-6713 Engine Electronic Control Gp
(2) 251-9385 Bracket As
(3) 2B-2694 Bolt
(4) 8C-9987 Washer
(5) 155-0576 Isolation Mount
(6) 6I-1418 Spacer
(7) 1D-4541 Bolt
(8) 0S-1595 Bolt
(9) 7D-1649 Hard Washer
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Illustration 47g01434688
Hardware for securing the engine harness
(10) 9S-3232 Clip
(11) 6B-6205 Spacer
(12) 7X-0291 Bolt
(13) 9L-9132 Washer
(14) 9S-8752 Full Nut
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Illustration 48g01431440
View C-C (hardware for securing the engine harness)
(15) 5P-8245 Hard Washer
(16) 193-3973 Tie
(17) 9X-8874 Bolt
(18) 230-7732 Mount
(19) 9F-4831 Spacer
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Illustration 49g01431447
Mounting location for engines with a dual cooling circuit
(1) 154-6713 Engine Electronic Control Gp
(2) 251-9385 Bracket As
(3) 2B-2694 Bolt
(4) 8C-9987 Washer
(5) 155-0576 Isolation Mount
(6) 6I-1418 Spacer
(7) 1D-4541 Bolt
(8) 0S-1595 Bolt
(9) 7D-1649 Hard Washer
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Illustration 50g01436858
Hardware at rear of support bracket
(20) 4P-8134 Clip
(21) 2S-2301 Spacer
(22) 9N-0869 Hard Washer
(23) 5S-0003 Nut
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    Illustration 51g01437897
    ECM and support bracket
    (24) Ground strap

  1. Install ground strap (24) between bolt head (3) and washer (4).

Note: Install lockwashers (4) against the surface of the shock mounts to ensure a good electrical contact.

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Illustration 52g01435850
Front view

Install the Engine Interface Box (EIB) and the Exhaust Temperature Module

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    Illustration 53g01288746
    Location for the Engine Interface Box (EIB)
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    Illustration 54g01316633
    (1) 1H-3338 Lockwasher
    (2) 8T-4205 Hard Washer
    (3) 6V-8185 Nut
    (4) 4M-5281 Bolt
    (5) 7X-6035 Grounding Strap
    (6) 104-6564 Mount
    (7) 1B-4971 Spacer
    (8) 5P-2675 Bolt
    (9) 0S-1588 Bolt
    (10) 5M-2894 Hard Washer
    (11) 251-9389 Bracket
    (12) 6V-8801 Nut
    (13) 8T-4896 Hard Washer
    (14) 4P-8134 Clip
    (15) 4L-6454 Bolt
    (16) 5S-7349 Bolt

    Note: Washers (1) must be installed against shock mount (6).

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    Illustration 55g01316750
    Engine interface box and exhaust temperature module

  1. Install the bracket (11) for the EIB and the exhaust temperature module at the location. Refer to Illustration 53. Refer to Illustration 54 for the required hardware.

Install the New Elbow for the Inlet Air

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    Illustration 56g01253129
    Top View
    (1) 175-6720 Elbow

  1. Install new elbow (1). Reuse the existing bolts. An integral boss is cast into the side of the new elbow for the manifold air temperature sensor.

    Note: Removing the lifting eye may simplify the installation of the new air inlet elbow.

  2. Clean the mating surfaces before installation. Install new gaskets or fabricate new gaskets. Install the flame arrestor. Install the raised portion of the flame arrestor toward the air inlet elbow. Ensure that the connecting flange is oriented properly. The flange is marked TOP with raised letters.
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    Illustration 57g01286614
    New elbow and sensor
    (2) 102-2240 Temperature Sensor Gp
    (3) 8L-2786 O-Ring Seal
    (4) 153-8455 Manifold Gasket
    (5) 7N-5085 Flange
    (6) 7N-5089 Gasket

  3. Install manifold air temperature sensor (2) and O-Ring seal (3) in the hole that is provided in the inlet elbow. Tighten the sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Install the New Oil Bypass Valve Cover

The following part should be reused:

  • Bolts

  • Cover

  • Spring

  • Bypass valve

  1. Replace the O-ring seals. Refer to Illustration 58.
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    Illustration 58g01286905
    (1) 4W-5592 Cover
    (2) 5P-4892 O-Ring Seal
    (3) 111-8639 Bypass Valve Cover
    (4) 2W-1635 Spring
    (5) 2W-1969 Bypass Valve

  2. Use the existing bolts to secure the bypass valve cover (3).
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    Illustration 59g01286937
    (6) 274-6719 Pressure Sensor
    (7) 9X-0262 Adapter
    (8) 6V-5048 O-Ring Seal

  3. Install the filtered oil pressure sensor and the unfiltered oil pressure sensor (6). Each sensor uses an adapter (7) and an O-ring seal (8). The designation of each sensor is marked with raised letters on the bypass valve cover. Tighten the sensors to 10 ± 2 N·m (7 ± 1.5 lb ft).

Install Covers for the Governor Drive and the Accessory Drive

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    Illustration 60g01287117
    Oil hole for governor drive
    (1) 8T-6757 Pipe Plug

  1. Install covers for the governor drive and for the accessory drive. A plug (1) must be installed in the oil supply hole that is located in the engine block. Refer to Illustration 60. Apply pipe sealant to the threads of the plug.
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    Illustration 61g01287163
    (3) 8N-9885 Drive Housing Gasket
    (4) 2W-5285 Cover
    (5) 9X-7371 O-Ring Seal
    (6) 7N-8374 Cover
    (7) 0S-1566 Bolt
    (8) 5P-8247 Hard Washer

  2. Install cover (4) and gasket (3). Reuse the existing bolts. These items are required only when a Woodward EG-3P actuator is removed.

    Note: If the engine is not equipped with accessory drive, use the 6I-1392 Accessory Drive Cover Gp.

  3. Install cover (6) and O-ring seal (5). Fasten the cover with bolts (7) and hard washers (8). These items are required when either a Woodward 3161 governor or a EG3P actuator is removed.

Install the Actuators and the Actuator Linkage

G3512 and G3516 Throttle Actuator

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Table 6
Reference 
Model  Part Number 
G3512 high pressure  251-9479 Electronic Actuator Gp 
G3512 and G3516 low pressure(1)  251-9483 Throttle Gp 
G3516 high pressure  251-9478 Electronic Actuator Gp 
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(1) No linkage is required for this actuator.

The following examples are for G3512 or G3516 Engines.

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    Illustration 62g01287216
    The throttle actuator and the support assembly are shown upside-down.
    (1) 262-5580 Support As
    (2) 6V-2317 Bolt
    (3) 9M-1974 Hard Washer
    (4) 091-0081 Spacer
    (5) 254-1115 Actuator

  1. Mount the throttle actuator to the support assembly with four bolts (2), four washers (3), and four spacers (4).
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    Illustration 63g01437645
    G3512 installation
    (6) 114-9269 Sleeve
    (7) 4B-3388 Bolt
    (8) 5S-0003 Nut
    (9) 0T-0573 Bolt
    (10) 5M-2894 Hard Washer
    (11) 6W-6672 Spacer
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    Illustration 64g01458368
    G3512 installation
    View A-A
    (12) 4F-2294 Jam Nut
    (13) 7E-9748 Rod End
    (14) 8L-4496 Jam Nut
    (15) 251-9488 Rod
    (16) 6V-9163 Rod End
    (17) 263-5007 Throttle Lever
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    Illustration 65g01451035
    G3516 installation
    (6) 114-9269 Sleeve
    (7) 4B-3388 Bolt
    (8) 5S-0003 Nut
    (9) 0T-0573 Bolt
    (10) 5M-2894 Hard Washer
    (11) 6W-6672 Spacer
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    Illustration 66g01458374
    G3516 installation
    View A-A
    (12) 4F-2294 Jam Nut
    (13) 7E-9748 Rod End
    (14) 8L-4496 Jam Nut
    (16) 6V-9163 Rod End
    (17) 263-5007 Throttle Lever
    (18) 251-9487 Rod

  2. Mount the actuator and support assembly in the vee of the engine. Fasten the support assembly bracket with four bolts (9), four washers (10), and four spacers (11).

  3. Connect the actuator linkage. Refer to Illustration 63 and Illustration 64 for G3512 Engines. Refer to Illustration 65 and Illustration 66 for G3516 Engines.

Actuator for Air/Fuel Ratio Control (if equipped)

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Table 7
Reference 
Model  Part Number 
G3512 high pressure  251-9481 Gas Pressure Regulator Gp 
G3516 high pressure  251-9480 Gas Pressure Regulator Gp 

  1. Install the supports for the air/fuel ratio control actuator. The top support bracket is fastened to the engine with two bolts (1). The lower support bracket is fastened to the engine with two bolts (3).

    The supports for the air/fuel ratio control actuator are installed at the following locations:

    • The actuator on the G3512 Engine is on the left side of the engine below the sixth cylinder.

    • The actuator on the G3516 Engines is on the left side of the engine below the eighth cylinder.
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    Illustration 67g01287680
    (1) 0T-0055 Bolt
    (2) 1W-8129 Support
    (3) 0S-1619 Bolt
    (4) 1W-8129 Support

  2. Install bracket (5). Use four bolts (6), four washers (7), and four nuts (9) to fasten the bracket to the supports.
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    Illustration 68g01287712
    (5) 270-0378 Bracket
    (6) 3B-1915 Bolt
    (7) 5M-2894 Hard Washer
    (8) Mounting location for actuator
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    Illustration 69g01287734
    (9) 9S-8752 Full Nut
    (10) 9M-1974 Hard Washer
    (11) 6V-2317 Bolt
    (12) 091-0081 Spacer

  3. Install the actuator onto the bracket. The actuator is fastened to the bracket with four bolts (11), four washers (10), and four spacers (12).

    Note: Install air/fuel ratio control if the engine does not currently have air/fuel ratio control.

  4. Install the linkage for the actuator and for the fuel valve.
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    Illustration 70g01450436
    Linkage for the air/fuel ratio control actuator and the fuel valve
    (13) 263-5007 Throttle Lever
    (14) 1B-7182 Bolt
    (15) 9M-1974 Hard Washer
    (16) 5S-0003 Nut
    (17) 7E-9748 Rod End
    (18) 4F-2294 Jam Nut
    (19) 119-5092 Rod
    (20) 6V-9163 Rod End
    (21) 8L-4496 Jam Nut
    (22) 6S-7721 Lever
    (23) 0S-1571 Bolt
    (24) 5M-2894 Hard Washer
    (25) 9S-8752 Full Nut
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    Illustration 71g01450635
    Left side view
    (26) 6L-2849 Tube Joint
    (27) 6I-0236 Fuel Ratio Valve
    (28) 1P-4579 Half Flange
    (29) 0S-1587 Bolt
    (30) 5P-8245 Hard Washer
    (31) 6I-0327 Adapter
    (32) 4J-0524 O-Ring Seal
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    Illustration 72g01290801
    Linkage for the air/fuel ratio control actuator

  5. Install the levers for the fuel valve and for the actuator. Both the actuator and the fuel valve must be in the open position. Adjust the linkage at the points of attachment to the angles that are shown in Illustration 70. Provide equal engagement at each rod end.

Install the Remaining Sensors

  • Jacket water pressure switch

  • Exhaust temperature sensors

  • Thermocouples for the Turbocharger

  • Manifold air pressure sensor

  • Jacket water pressure sensor

  • Coolant temperature sensor

  • Oil temperature sensor

  • Speed-timing sensor

  • Left detonation sensor

  • Right detonation sensor

  • Nitrogen oxide sensor

  • Timing calibration sensor

  • Prelube switch

Jacket Water Pressure Switch

  1. Install the jacket water pressure switch. Refer to Illustration 73 for the parts that are needed to install the switch. Apply pipe sealant to the pipe plug, the reducer bushings, and the pipe nipple. Tighten the switch to 22 ± 3 N·m (16 ± 2 lb ft).
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Illustration 73g01290888
(1) 110-1168 Pressure Switch
(2) 3B-7764 Reducer Bushing
(3) 061-9593 Reducer Bushing
(4) 4B-7770 Tee
(5) 8T-6761 Pipe Plug
(6) 3B-7749 Close Nipple
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Illustration 74g01290890
Jacket water pressure switch

Exhaust Temperature Sensor

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    Illustration 75g01290986
    Exhaust temperature sensor
    (1) 241-9591 Temperature Sensor Gp

  1. Install the exhaust temperature sensors. A new thermocouple (1) is installed at each cylinder.
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Illustration 76g01290988
(1) 241-9591 Temperature Sensor Gp
(2) 5N-2126 Exhaust Adapter

Thermocouples for the Turbochargers

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    Illustration 77g01291016
    Rear view
    (1) 180-5420 Temperature Sensor Gp

  1. Install new thermocouples (1) for the turbocharger at the locations that are shown in Illustration 77 and Illustration 79. A new bushing (2) must be installed for each new thermocouple. Apply pipe sealant to the threads of the bushings.
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Illustration 78g01291017
(1) 180-5420 Temperature Sensor Gp
(2) 6B-5072 Reducing Bushing
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Illustration 79g01291019
(1) 180-5420 Temperature Sensor Gp
(2) 6B-5072 Reducing Bushing

Manifold Air Pressure Sensor

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Illustration 80g01254649
Location for the manifold air pressure sensor
(1) 276-6793 Pressure Sensor Gp
(1) 290-4619 Sensor Buffer
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    Illustration 81g01291077
    (1) 276-6793 Pressure Sensor Gp
    (1) 290-4619 Sensor Buffer
    (2) 9X-0435 Adapter
    (3) 6V-5048 O-Ring Seal
    (4) 3B-7764 Bushing

  1. Install the manifold air pressure sensor. A plug must be removed from the front of the cylinder block to install the sensor. Apply pipe sealant to adapter (2) and to bushing (4). Torque the sensor to 10 ± 2 N·m (7 ± 1 lb ft).

Jacket Water Pressure Sensor

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    Illustration 82g01291138
    Location for the jacket water pressure sensor (turbocharged aftercooled engines)
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    Illustration 83g01344874
    Location for the jacket water pressure sensor (naturally aspirated engines)

  1. Remove plug (1) from the exhaust manifold to install the jacket water pressure sensor.
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    Illustration 84g01291139
    (2) 9X-0435 Adapter
    (3) 6V-9027 O-Ring Seal
    (4) 162-6622 Reducing Bushing

  2. Install reducing bushing (4), adapter (2), and seal (3). Apply pipe sealant to the reducing bushing and to the adapter.
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    Illustration 85g01291140
    (5) 276-6793 Pressure Sensor Gp

  3. Install jacket water pressure sensor (5). Torque the sensor to 10 ± 2 N·m (7 ± 1 lb ft).

Coolant Temperature Sensor

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    Illustration 86g01291204
    (1) 112-3231 Adapter
    (2) 6V-6609 O-Ring Seal
    (3) 264-4297 Temperature Sensor Gp

  1. Install adapter (1), O-ring seal (2), and coolant temperature sensor (3). Apply pipe sealant to the threads of the adapter. Torque the sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Oil Temperature Sensor

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    Illustration 87g01291215

  1. Remove plug (1) from the cylinder block to install the oil temperature sensor.
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    Illustration 88g01291217
    (2) 112-3231 Adapter
    (3) 8L-2786 O-Ring Seal
    (4) 102-2240 Temperature Sensor Gp

  2. Install adapter (2), O-ring seal (3), and oil temperature sensor (4). Apply pipe sealant to the threads of the adapter. Torque the oil temperature sensor to 20 ± 3 N·m (15 ± 2 lb ft).

Speed-Timing Sensor

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    Illustration 89g01291260
    Location for installation of the speed-timing sensor
    (1) 273-5041 Speed Sensor Gp

  1. Install speed-timing sensor (1). The slip head of the speed-timing sensor must extend a minimum of 4 mm (0.1575 inch) prior to installation. Torque the speed-timing sensor to 40 ± 5 N·m (29 ± 4 lb ft).

Detonation Sensors

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    Illustration 90g01254654
    Location for the detonation sensor for the right side of the engine
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    Illustration 91g01291334
    Location for the detonation sensor for the left side of the engine
    (1) 142-0215 Knock Sensor Group

  1. Install the detonation sensors for the right side of the engine and for the left side of the engine. Refer to Illustration90 and Illustration 91 for the location of the sensors. Torque the sensors to 15 ± 3 N·m (11 ± 2 lb ft).

Nitrogen Oxide Sensor

  1. Apply 5P-3931 Anti-Seize Compound to the threads of the sensor. Insert the sensor into the adapter ring for the exhaust. Tighten the sensor.

    Torque ... 50 ± 5 N·m (37 ± 4 lb ft)

  2. Install the buffer onto the two mounting posts. Verify that the buffer is flush with the mounting plate.

  3. Replace the two spacers onto the mounting posts. Replace the cover for the buffer. The cover has a slot that is located over the pin on the mounting plate. This slot ensures that the cover for the buffer will align properly onto the mounting plate.

  4. Replace the nuts and the washers onto the mounting posts. Tighten the nuts until the nuts are barely snug to allow for movement of the cover for the buffer.
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    Illustration 92g01395308
    (1) Tie-wrap
    (2) Tabs

  5. Slide one of the tie-wraps over the wiring from the buffer to the 8-pin connector. Slide the other tie-wrap over the wiring from the buffer to the sensor. Ensure that the tie-wraps go around the metal tabs on the cover for the buffer. Pull the tab to tighten the tie-wrap as firmly as possible.

  6. Tighten the nuts.

    Torque ... 5 ± 2 N·m (44 ± 18 lb in)

  7. Pull the harness straight from the end of the sensor and mark the harness 135 mm (5.3150 inch) from the end of the sensor. Secure the harness to the support bracket at the marked location by using one of the included tie-wraps. Pull the tab to tighten the tie-wrap as firmly as possible.

    Note: Do not pull the sensor harness until the sensor harness is tight. Leave an arc of slack so that there is not any pull on the sensor.

  8. Pull the sensor harness straight from the buffer. Verify that the slack in the harness from the point between the buffer and the support bracket is correct. Refer to the recommended slack that is listed in Table 8. Secure the sensor harness to the support bracket near the buffer by using one of the included tie-wraps. Pull the tab to tighten the tie-wrap as firmly as possible.

  9. Reconnect the 8-pin connector of the buffer to the engine harness.

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Table 8
Engine  Slack In Harness (A) (1)  Slack In Harness (B) (2)  Illustration 
G3512  135 mm (5.3150 inch)  110 mm (4.3307 inch)  93, 94, and 95 
G3516  135 mm (5.3150 inch)  110 mm (4.3307 inch)  93, 94, and 95 
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(1) The distance of the slack in the harness that is between the sensor and the support bracket
(2) The distance of the slack in the harness that is between the buffer and the support bracket
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Illustration 93g01438808
Typical example
(A) The distance of the slack in the harness that is between the sensor and the support bracket
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Illustration 94g01395328
Typical example
(B) The distance of the slack in the harness that is between the buffer and the support bracket
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Illustration 95g01432807
Rear view
(1) Adapter ring
(2) Sensor
(3) Support bracket
(4) Sensor harness
(5) Tie-wrap
(A) The distance of the slack in the harness that is between the sensor and the support bracket
(B) The distance of the slack in the harness that is between the buffer and the support bracket

Note: The nitrogen oxide sensor must be calibrated before the engine is put into service. Use the 156-1060 Emissions Analyzer Gp or the 156-1070 Emissions Analyzer Gp to calibrate the sensor. Refer to Operating Manual, NEHS0713, "156-1060 & 156-1070 GAS EMISSION ANALYZER" and Operating Manual, NEHS0714, "156-1060 & 156-1070 EMISSION ANALYZER GROUP POCKET CARD TOOL OPERATING TIPS".

Prelube Switch

  1. Remove the knockout panel from the front door of the remote panel.

  2. Remove the covering from the ends of the wires for the prelube. These wires are located in the remote panel.

  3. Connect the wires to the terminals of the prelube switch. Refer to Illustration 96.
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Illustration 96g01319822
(1) 251-9444 Control Box Gp
(2) 3E-1813 Push-Button Switch
(3) 150-1240 Pressure Switch

Wiring for the Air/Fuel Ratio Control

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    Illustration 97g01431264

  1. Install the fuse holders for the air/fuel ratio control in the engine interface box.

  2. Install fuse F4 (1) for the throttle actuator.

  3. Install fuse F5 (2) for the air/fuel ratio control actuator.

  4. Install jumper wire (3) (P200-C19).
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    Illustration 98g01528214

  5. Connect the nitrogen oxide sensor buffer to the main engine harness.

Timing Calibration Connector and Service Tool Connector

The timing calibration connector and the service tool connector are part of the engine harness assembly. The timing calibration and the service tool connector are at the left rear of the engine. Refer to Illustration 99.

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Illustration 99g01344886
(1) Service tool connector
(2) Timing calibration connector

Install the Remote Advisor Panel (if equipped)

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    Illustration 100g01290823
    Typical remote advisor panel support
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    Illustration 101g01316757
    Remote advisor panel

  1. Install the remote advisor panel.

  2. The remote advisor panel must be installed within 50 ft of the engine.

Air Start Lines

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Illustration 102g01250147
Typical installation (air start with prelube)
(1) 251-9396 Solenoid Valve Gp
(2) Air start motor
(3) 251-9396 Solenoid Valve Gp
(4) 4N-3411 Relay Valve Gp
(5) Air supply line
(6) 119-6284 Air Motor Lubricator Group
(7) 4N-3411 Relay Valve Gp

G3512 and G3516 Vane Type Air Starting Motor without Prelube

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Illustration 103g01347188
Vane type air starting motor without prelube
(1) 8N-8451 Gasket
(2) 8N-8446 Elbow
(3) 9X-8875 Bolt
(4) 3L-8893 Nipple-Close
(5) 6V-8252 Pipe Union
(6) 6B-3685 Elbow
(7) 4P-8134 Clip
(8) 9X-6772 Cable Strap
(9) 0L-1143 Bolt
(10) 8M-9024 Hard Washer
(11) 6W-6672 Spacer
(12) 4S-6399 Connector
(13) 030-7961 Elbow
(14) 298-4521 Bracket
(15) 1H-2815 Pipe Nipple
(16) 119-6284 Air Motor Lubricator Group
(17) 5B-7666 Elbow
(18) 5B-7442 Pipe Nipple
(19) 5T-4373 Hose As
(20) 6K-1972 Flared Elbow
(21) 295-5743 Bracket
(22) 9S-8752 Full Nut
(23) 5L-2534 U-Bolt
(24) 6L-5699 Pipe Nipple
(25) 1L-2782 Pipe Tee
(26) 8F-7800 Pipe Cap
(27) 6F-5985 Hose As
(28) 146-5215 Air Lines Strainer Gp
(29) 5P-1076 Hard Washer
(30) 0S-1573 Bolt
(31) 4N-3411 Relay Valve Gp
(32) 7J-8611 Pipe Elbow
(33) 5P-2657 Elbow
(34) 251-9396 Solenoid Valve Gp

G3512 and G3516 Turbine Type Air Starting Motor without Prelube

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Illustration 104g01347623
Turbine type air starting motor without prelube
(1) 3P-1823 Pipe Adapter
(2) 2N-1931 Pipe Elbow
(3) 003-4711 Pipe Nipple
(4) 7N-2539 Hose As
(5) 4P-8134 Clip
(6) 0S-1571 Bolt
(7) 8M-9024 Hard Washer
(8) 2A-2677 Spacer
(9) 9X-6772 Cable Strap
(10) 0S-1590 Bolt
(11) 6K-1972 Flared Elbow
(12) 299-2408 Bracket
(13) 9M-1974 Hard Washer
(14) 1A-9579 Bolt
(15) 6F-8857 Pipe Nipple
(16) 5L-2534 U-Bolt
(17) 9S-8752 Full Nut
(18) 105-0428 Pipe Nipple
(19) 6B-3685 Elbow
(20) 143-5177 Pipe Nipple
(21) 6L-5699 Pipe Nipple
(22) 6F-5985 Hose As
(23) 146-5215 Air Lines Strainer Gp
(24) 5B-7666 Elbow
(25) 6V-8252 Pipe Union
(26) 3L-8993 Fitting
(27) 4N-3411 Relay Valve Gp
(28) 1L-2782 Pipe Tee
(29) 8T-6760 Pipe Plug
(30) 299-0698 Bracket
(31) 251-9396 Solenoid Valve Gp

G3512 and G3516 Vane Type Air Starting Motor with Prelube

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Illustration 105g01347652
Vane type air starting motor with prelube
(1) 8N-8451 Gasket
(2) 8N-8446 Elbow
(3) 9X-8875 Bolt
(4) 3L-8993 Fitting
(5) 6V-8252 Pipe Union
(6) 6B-3685 Elbow
(7) 4S-6399 Connector
(8) 030-7961 Elbow
(9) 298-4521 Bracket
(10) 1H-2815 Pipe Nipple
(11) 0L-1143 Bolt
(12) 8M-9024 Hard Washer
(13) 6W-6672 Spacer
(14) 119-6284 Air Motor Lubricator Group
(15) 5B-7442 Pipe Nipple
(16) 5T-4373 Hose As
(17) 6K-1972 Flared Elbow
(18) 295-5743 Bracket
(19) 9S-8752 Full Nut
(20) 5L-2534 U-Bolt
(21) 6L-5699 Pipe Nipple
(22) 161-8071 Hose As
(23) 1L-2782 Pipe Tee
(24) 7J-8611 Pipe Elbow
(25) 3E-2303 Pipe Fitting
(26) 4N-3411 Relay Valve Gp
(27) 6F-7732 Reducer Bushing
(28) 004-7626 Connector
(29) 5B-7666 Elbow
(30) 6F-5985 Hose As
(31) 146-5215 Air Lines Strainer Gp
(32) 5P-1076 Hard Washer
(33) 0S-1573 Bolt
(34) 4P-8134 Clip
(35) 9X-6772 Cable Strap
(36) 5P-2657 Elbow
(37) 251-9396 Solenoid Valve Gp

G3512 and G3516 Turbine Type Air Starting Motor with Prelube

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Illustration 106g01347793
Turbine type air starting motor with prelube
(1) 3P-1823 Pipe Adapter
(2) 2N-1931 Pipe Elbow
(3) 003-4711 Pipe Nipple
(4) 4P-8134 Clip
(5) 0S-1571 Bolt
(6) 8M-9024 Hard Washer
(7) 9X-6772 Cable Strap
(8) 2A-2677 Spacer
(9) 0S-1590 Bolt
(10) 6K-1972 Flared Elbow
(11) 299-2408 Bracket
(12) 5L-2534 U-Bolt
(13) 9S-8752 Full Nut
(14) 1A-9579 Bolt
(15) 9M-1974 Hard Washer
(16) 6F-8857 Pipe Nipple
(17) 6F-7732 Reducer Bushing
(18) 004-7626 Connector
(19) 105-0428 Pipe Nipple
(20) 6B-3685 Elbow
(21) 143-5177 Pipe Nipple
(22) 7J-8611 Pipe Elbow
(23) 3E-2303 Pipe Fitting
(24) 6L-5699 Pipe Nipple
(25) 6F-5985 Hose As
(26) 146-5215 Air Lines Strainer Gp
(27) 5B-7666 Elbow
(28) 6V-8252 Pipe Union
(29) 3L-8993 Fitting
(30) 4N-3411 Relay Valve Gp
(31) 1L-2782 Pipe Tee
(32) 299-0698 Bracket
(33) 161-8071 Hose As
(34) 7N-2539 Hose As
(35) 251-9396 Solenoid Valve Gp

Install the Wiring Harnesses

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Table 9
Reference 
Model  Part Number 
G3512  391-8346 Engine Harness As 
G3516  391-8347 Engine Harness As 

Install the Engine Harness Assembly

Table 10 lists the part numbers for the hardware that is used to secure the wiring harness to the engine. The numbers that are called out in Illustrations 107 through 109 correspond to the item numbers that are listed in column 1 of Table 10.

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Illustration 107g01528500
G3516 A+
Hardware for securing engine harness
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Illustration 108g01528515
G3516 A+
Hardware for securing engine harness
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Illustration 109g01317790
G3516 A+
Hardware for securing engine harness

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Table 10
Hardware for the Engine Harness 
Item  Qty  Part Number  Description  Remarks 
1  1  2P-8977  Plate  N/A 
2  1  2S-2301  Spacer 
3  1  4W-9149  Spacer 
4  8  7K-1181  Cable Strap 
5  1  9F-4831  Spacer 
6  2  9S-3232  Clip 
7  1  9X-3495  Clip As 
8  38  9X-6772  Cable Strap 
9  2  193-3973  Tie 
10  1  251-9389  Bracket 
11  1  251-9463  Engine Harness As 
12  2  132-5789  Clip 
13  1  204-8000  Tie Anchor 
14  1  230-7732  Mount 
15  1  0L-1351  Bolt 
16  1  0L-1352  Bolt 
17  13  0S-0509  Bolt 
18  1  0S-1571  Bolt 
19  4  0S-1594  Bolt 
20  6  4P-7581  Clip 
21  32  4P-8134  Clip 
22  24  5M-2894  Hard Washer 
23  1  5P-8245  Hard Washer 
24  1  5S-0003  Nut 
25  4  6B-6205  Spacer 
26  2  7X-0291  Bolt 
27  4  9L-9132  Washer 
28  2  9N-0869  Hard Washer 
29  4  9S-8752  Full Nut 
30  1  9X-6458  Hard Washer 
31  1  9X-8874  Bolt 
32  2  0S-1594  Bolt  Use these parts in order to secure the harness under the turbocharger.  
33  2  4P-8134  Clip  Use these parts in order to secure the harness under the turbocharger. 
34  4  5M-2894  Hard Washer  Use these parts in order to secure the harness under the turbocharger. 
35  2  9S-8752  Full Nut  Use these parts to secure the harness under the turbocharger. 
36  1  7K-1181  Cable Strap  Use for applications with landfill breathers 
37  1  4P-8134  Clip  Use for applications with landfill breathers 
38  1  9X-6772  Cable Strap  Use with a single cooling circuit, which has a water regulator that is mounted next to the "Z" bracket 
39  1  0S-1590  Bolt  Use with a single cooling circuit, which has a water regulator that is mounted next to the "Z" bracket 
40  1  4P-8134  Clip  Use with a single cooling circuit, which has a water regulator that is mounted next to the "Z" bracket 
41  1  5M-2894  Hard Washer  Use with a single cooling circuit, which has a water regulator that is mounted next to the "Z" bracket 
42  1  9X-6772  Cable Strap  Use for wet manifolds only 
43  1  4P-7581  Clip  Use for wet manifolds only 
44  1  9X-6772  Cable Strap  Use for dry manifolds only 
45  1  132-5789  Clip  Use for dry manifolds only 
46  1  0S-0509  Bolt  Use for dry manifolds only 
47  1  5M-2894  Hard Washer  Use for dry manifolds only 
48  2  0S-1595  Bolt  Use these parts to secure the harness under the turbocharger. 
49  2  1F-7958  Full Nut  Use these parts to secure the harness under the turbocharger. 
50  2  4P-7429  Clip  Use these parts to secure the harness under the turbocharger. 
51  4  5P-8245  Hard Washer  Use these parts to secure the harness under the turbocharger. 

Note: For more details on the connection of the thermocouple harness and the connection of the exhaust temperature module, refer to "Wiring for the Exhaust Temperature Module".

Orientation of the Fasteners for the Engine Harness

The following illustrations show the orientation of the clips for the wiring harnesses. The notations TOP, BOTTOM, RIGHT, LEFT, FRONT, AND REAR are used to provide orientation for the clips. These positions are in reference to the current view , which shows the mounting orientation of the clips on the engine. These positions are not the customary views of the engine.

The harness must be secured to a clip with a tie strap. The tie straps must be installed through the appropriate slot in the clip. The tie straps must be tightened to the harness to prevent any rubbing of the harness on the clip. The clips must be oriented to minimize any contact between the wiring harness and the engine.

Reuse all the existing washers.

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Illustration 110g01293103

G3512 CSA with a Single Cooling Circuit

Refer to Illustrations 111 through 115.

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Illustration 111g01314606
Orientation of the clips on G3512 CSA with single cooling circuit
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Illustration 112g01314620
Orientation of the clips on G3512 CSA with single cooling circuit
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Illustration 113g01445570
Orientation of the clips on G3512 CSA with single cooling circuit
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Illustration 114g01528620
Orientation of the clips on G3512 CSA with single cooling circuit
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Illustration 115g01314644
Orientation of the clips on G3512 CSA with single cooling circuit

G3516 CSA with a Single Cooling Circuit

Refer to Illustrations 116 through 120.

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Illustration 116g01314653
Orientation of the clips on G3516 CSA with a single cooling circuit
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Illustration 117g01314670
Orientation of the clips on G3516 CSA with a single cooling circuit
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Illustration 118g01445570
Orientation of the clips on G3516 CSA with a single cooling circuit
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Illustration 119g01528638
Orientation of the clips on G3516 CSA with a single cooling circuit
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Illustration 120g01314675
Orientation of the clips on G3516 CSA with a single cooling circuit

G3512 CSA with a Dual Cooling Circuit

Refer to Illustrations 121 through 125.

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Illustration 121g01314685
Orientation of the clips on G3512 CSA with a dual cooling circuit
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Illustration 122g01314789
Orientation of the clips on G3512 CSA with a dual cooling circuit
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Illustration 123g01314807
Orientation of the clips on G3512 CSA with a dual cooling circuit
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Illustration 124g01528646
Orientation of the clips on G3512 CSA with a dual cooling circuit
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Illustration 125g01315003
Orientation of the clips on G3512 CSA with a dual cooling circuit

G3516 CSA with a Dual Cooling Circuit

Refer to Illustrations 126 through 130.

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Illustration 126g01315018
Orientation of the clips on G3516 CSA with a dual cooling circuit
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Illustration 127g01315023
Orientation of the clips on G3516 CSA with a dual cooling circuit
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Illustration 128g01315076
Orientation of the clips on G3516 CSA with a dual cooling circuit
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Illustration 129g01528661
Orientation of the clips on G3516 CSA with a dual cooling circuit
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Illustration 130g01315068
Orientation of the clips on G3516 CSA with a dual cooling circuit

Install the Thermocouple Wiring Harness

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Table 11
Reference 
Model  Part Number 
G3512 with dual turbochargers  251-9421 Pyrometer Wiring Gp 
G3516 with dual turbochargers  251-9422 Pyrometer Wiring Gp 

Table 12 lists the part numbers for the hardware that is used in order to secure the thermocouple harness to the engine. The numbers that are called out in Illustration 131 and Illustration 132 correspond to the item numbers that are listed in column 1 of Table 12.

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Illustration 131g01318005
G3516
Thermocouple wiring harness
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Illustration 132g01528675
G3516
Thermocouple wiring harness

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Table 12
Parts List and Hardware 
Item  Qty  Part Number  Description  Remarks 
1  34  3S-2093  Cable Strap  N/A 
2  16  5N-2126  Adapter 
3  20  9X-6772  Cable Strap 
4  2  180-5420  Temperature Sensor Gp 
5  16  241-9591  Temperature Sensor Gp 
6  1  251-9426  Sensor Harness As 
7  33  0S-0509  Bolt 
8  1  0S-1594  Bolt 
9  16  4P-7581  Clip 
10  36  4P-8134  Clip 
11  36  5M-2894  Hard Washer 
12  2  6B-5072  Reducing Bushing  
13  1  9S-8752  Full Nut 
14  21  9X-6772  Cable Strap  Use parts in order to secure the thermocouple harness to the engine harness assembly. 
15  1  0S-0509  Bolt  Bolts and washers are not required when the regulator housing is in the location that is shown. 
16  1  5M-2894  Hard Washer  Bolts and washers are not required when the regulator housing is in the location that is shown. 

Note: For more details on the connection of the thermocouple harness and for the exhaust temperature module, refer to "Wiring for the Exhaust Temperature Module".

Orientation of the Fasteners on the Thermocouple Harness

Refer to "Orientation of the Fasteners for the Engine Harness".

The position of the fasteners for securing the thermocouple harness to the engine are shown in Illustrations 133 through 135.

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Illustration 133g01318728
G3516 with dual turbochargers is shown.
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Illustration 134g01318092
G3516 with dual turbochargers is shown.
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Illustration 135g01528684
G3516 with dual turbochargers is shown.
Avoid damage to the locking mechanisms of the wires that are inserted into the 70-pin connectors. Always remove the connector from the A3 control or the exhaust temperature module before inserting or removing wires from the 70-pin connectors.

Install the Wiring Harness for the Alternator (if equipped)

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Table 13
Reference 
Part Numbers for CSA Engines 
298-8838 Alternator 
298-8839 Alternator Wiring Gp 
298-8840 Alternator Harness Assembly 
Part Numbers for non-CSA Engines 
251-9474 Alternator Wiring Gp 
251-9475 Power Harness As 

Table 14 lists the part numbers for the hardware that is used in order to secure the alternator harness to the engine. The numbers that are called out in Illustration 137 and Illustration 138 correspond to the item numbers that are listed in column 1 of Table 14.

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Illustration 136g01528722
G3516
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Illustration 137g01319111
G3516
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Illustration 138g01432507
(16) Fuse F5 actuator for air/fuel ratio control
(17) Connection for the Interconnect Harness
(18) Test connector

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Table 14
Hardware 
Item  Qty  Part Number  Description  Remarks 
1  10  9X-6772  Cable Strap  Use to secure harness to adjacent harnesses 
2  5  9X-6772  Cable Strap  N/A 
3  3  0S-0509  Bolt 
4  4  5M-2894  Hard Washer 
5  3  4P-7581  Clip 
6  1  0S-1588  Bolt 
7  1  4P-8134  Clip 
8  3  4P-8134  Clip 
9  10  9X-6772  Cable Strap 
10  1  273-3127  Connector 
11  1  156-6175  Clip 
12  2  5P-0537  Hard Washer 
13  1  0S-1616  Bolt 
14  1  9S-8750  Nut 
15  1  298-8840  Harness As 

Orientation of the Fasteners on the Alternator Harness

Refer to "Orientation of the Fasteners for the Engine Harness".

The position of the fasteners that secure the thermocouple harness to the engine are shown in Illustration 139 and Illustration 140.

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Illustration 139g01319292
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Illustration 140g01319294

Visual Aids

The following illustrations are for use as a visual aid for securing the wiring harnesses.

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Illustration 141g01436890
Left side view (ECM)
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Illustration 142g01435850
Front view (ECM)
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Illustration 143g01436864
Hardware behind the support bracket for the ECM
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Illustration 144g01435928
Front view
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Illustration 145g01433009
Right side view
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Illustration 146g01435853
Right side view
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Illustration 147g01435870
Right side view
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Illustration 148g01435874
Right side view
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Illustration 149g01435881
Left side view
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Illustration 150g01435890
Left side view
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Illustration 151g01435895
Left side view
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Illustration 152g01435911
Left side view (harness for the throttle actuator)
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Illustration 153g01432542
Left side view (harness for the throttle actuator)
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Illustration 154g01438279
Left side view (harness for the air/fuel ratio control actuator)
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Illustration 155g01438282
Left side view (harness for the air/fuel ratio control actuator)
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Illustration 156g01438276
Rear view
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Illustration 157g01435940
Rear view (exhaust temperature module)
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Illustration 158g01435950
Rear view
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Illustration 159g01319980
Left side view

PL1000 Customer Communications Module CCM

The PL1000E or the PL1000T Customer Communication Module (CCM) can be used with the G3500 ADEM 3 conversion. The following publications are available for detailed information on these modules.

  • Special Instruction, REHS2362, "Installation Guide for the 256-7512 PL1000E Communications ECM"

  • Systems Operation/Testing and Adjusting, RENR8091, "PL1000E Communication ECM"

  • Special Instruction, REHS2125, "Installation Guide for the 256-7511 PL1000T Communications ECM"

  • Systems Operation/Testing and Adjusting, RENR7945, "PL1000T Communication ECM"

Wiring for the Exhaust Temperature Module

For more information on the exhaust temperature module, refer to Systems Operation/Testing and Adjusting, KENR5473.

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Illustration 160g01431685
(1) 232-4674 Connector Seal
(2) 288-4678 Connector As
(3) 232-4675 Connector Seal
(4) 288-4677 Connector As
(5) Pyrometer display
(6) Engine interface box
(7) Main engine harness
(8) Interconnect harness

Note: Wrap-up sleeves must cover the following circuits of the interconnect harness that is located inside the engine interface box. Wrap-up sleeves must also cover the circuits of the interconnect harness inside the remote advisor panel:

  • + Battery (P200-T4 RD)

  • - Battery (P300-T39 BK)

  • Keyswitch (P600-T18 WH)

  • Push button for the prelube (C293-T26 BK)

  • Prelube light (A320-T33 RD)
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Illustration 161g01431715
View B-B
(9) 8T-9006 Bolt
(10) 232-4673 Plug
(11) 3S-2093 Cable Strap
(12) 121-0199 Spiral Wrap
(13) 237-4356 Adapter
(14) 9X-6772 Cable Strap
(15) Thermocouple harness

  1. Five pins (pins 5 through 9) must be inserted into the 70-pin connector at the back of the exhaust temperature module. These five pins are located on two separate cables that break out from the main engine harness. Refer to Table 15. Refer to Illustration 163 and Illustration 164.

  2. A wrap-up sleeve must be installed over the power wires +B and - B at the 70-pin connector on the exhaust temperature module. Gather the five wires (pins 5 through 9) and ensure that the connector retaining screw is accessible for attaching to the exhaust temperature module. Use cable strap (11) in order to gather the wires inside the connector assembly. Install connector assembly (2), seal (1), connector assembly (4), seal (3), and adapter (13).

  3. Secure thermocouple harness (15) to main engine harness (7) with cable straps (14) in order to protect the connections at the 70-pin connector.
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Illustration 162g01431924
Remote panel
(8) Interconnect harness

Note: The spiral wrap must cover the following circuits for the interconnect harness that are located inside the engine interface box. The spiral wrap must also cover the following circuits for the interconnect harness inside the remote advisor panel:

  • + Battery (P200-T4 RD)

  • - Battery (P300-T39 BK)

  • Keyswitch (P600-T18 WH)

  • Push button for the prelube (C293-T26 BK)

  • Prelube light (A320-T33 RD)

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Table 15
70-pin Connector at the Back of the Exhaust Temperature Module 
Pin  Description  Circuit Number 
5  CAN Shield  D200-A8 CU 
6  + B  P600-A165 WH or RD 
7  − B  P300-A164 BK 
8  + CAN  D200-A168 YL 
9  - CAN  D200-A167 GN 
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Illustration 163g01432431
Pins for the power and CAN on the connector of the exhaust temperature module
(16) Socket connector
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Illustration 164g01431934
Pins for the power and CAN on the connector of the exhaust temperature module

Connect the Wiring From the Battery

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Illustration 165g01272958
Typical view of the engine
(1) Engine interface box
(2) The enclosures that are provided by the customer must be CSA approved.

Requirements for Engines That are Not Equipped With an Alternator

The customer is responsible for providing overcurrent protection for the battery circuit. The battery circuit must be protected by a CSA approved fuse. The maximum allowable rating of the fuse is 20 A.

Install the fuse in a fuse holder that is CSA approved. Mount the fuse holder in a CSA approved enclosure (2), if necessary. Mount the fuse holder or the enclosure as close as practical to interface box (1).

Requirements for Engines That are Equipped With an Alternator

The customer is responsible for providing overcurrent protection for the charging circuit. The charging circuit includes the wiring from the battery and the wiring from the alternator. This wiring is connected at terminal 12 inside interface box (1). The circuit must be protected by a CSA approved fuse. The maximum allowable rating of the fuse is 60 A. This rating limits the charging current between the alternator and the battery. The gauge of the wiring from the battery may require a fuse rating that is lower than 60 A.

Install the fuse in a fuse holder that is CSA approved. Mount the fuse holder in a CSA approved enclosure (2), if necessary. Mount the fuse holder or the enclosure as close as practical to interface box (1).

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Illustration 166g01272967
Bottom view of the engine interface box
(3) 50 mm (1.9685 inch) hole
(4) 28 mm (1.1024 inch) hole
(5) 28 mm (1.1024 inch) hole

Refer to Illustration 166. The bottom of the engine interface box has two holes (3) and (5) when the engine is shipped from the factory. Fabricate hole (4) if the engine is equipped with an alternator. Refer to Table 16.

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Table 16
Holes in the Bottom of the Engine Interface Box 
Hole  Size  Purpose 
(3)  50 mm (1.9685 inch)  Wiring from the driven equipment 
(4)  28 mm (1.1024 inch)  Hole for the wiring from the battery, which should be drilled out by the customer 
(5)  28 mm (1.1024 inch)  Wiring from the alternator

Route the wiring from the battery through this hole when the engine is not equipped with an alternator. 

Perform the following procedure to make the connections from the battery.

  1. Verify that the wiring from the battery is de-energized.
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    Illustration 167g01272968
    Connections for the battery
    (6) Main fuse

  2. Remove main fuse (6).
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    Illustration 168g01272969
    Hardware for connecting the wiring from the battery
    (7) 119-8044 Wire Ends (6 Gauge)
    (8) 4P-4891 Terminal Bushing
    (9) 273-3127 Connector

  3. Use connector (9) and terminal bushing (8) to attach the wiring from the battery to the engine interface box.

  4. Use a 139-2789 Ferrule Crimp Tool to crimp a wire end (7) to the end of each wire.

  5. Connect wire ends (7) to the appropriate locations. Be sure to observe the polarity of the connections.

  6. Connect the wiring to the battery.

    Note: Do not install main fuse (6) until all of the wiring from the driven equipment is connected to the engine.

Connect the Wiring From the Driven Equipment

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Illustration 169g01432607
Typical installations

Refer to Illustration 169. Make the electrical connections for the driven equipment at one of the following locations:

Engine Interface Box - All of the electrical connections for the driven equipment are made inside the engine interface box. The following connections are also made inside the engine interface box: switched power, unswitched power and prelube switch.

Interconnect Harness - The interconnect harness is connected to the engine interface box. All of the electrical connections for the driven equipment are made to the end of the interconnect harness.

Remote Panel - A remote panel is connected to the engine interface box via an interconnect harness. All of the electrical connections for the driven equipment are made at a terminal strip inside the remote panel.

Table 17 lists the connections that are available at each of the locations. Review the Table before making the connections.

Note: The metal conduit must be provided by the customer. The metal conduit must be installed by the customer for all customer connections. The connections include the battery power and the interconnect harness. Customer installed conduit and wiring which is performed at the site must conform to all electrical codes. Customer installed wiring must conform to the standards of the Canadian Standards Association if CSA is one of the desired certifications.

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Table 17
Connections for the Driven Equipment 
Description  Engine Interface Box  Interconnect Harness  Remote Panel (Terminal Strip)  Function and Comments 
Prelube ON  Terminal 1 on the Terminal Block  A320-T33
Cable 91-Red 		 33  This output indicates that the prelubrication is ON.

The prelube indicator on the remote panel will illuminate when the prelubrication is ON. 
"Manual Prelube" Input  Terminal 2 on the Terminal Block  C293-T26
Cable 91-White 		 26  This input must be connected to the keyswitch input via a switch.

The manual prelube switch on the remote panel provides this connection. 
Unswitched +Battery  Terminal 4 on the Terminal Block  P200-T4
Cable 105-Red 		 4  These connections provide the electrical power to the remote panel.

Current flow through these connections must be limited to 5 A If the remote panel is not installed. 
−Battery  Terminal 8 on the Terminal Block  P300-T39
Cable 105-Black 		 39 
−Battery  Terminal 8 on the Terminal Block  P300-T40
Cable 91-Black 		 40 
Keyswitch  Terminal 7 on the Terminal Block  P600-T18
Cable 105-White 		 18  This connection is the keyswitch input for the ECM.

If a remote panel is not installed on the engine, the connection for the keyswitch must be powered when the engine control is in "COOLDOWN/STOP", "AUTO", or "START". 
+5 VDC for the Input for the Desired Engine Speed  Terminal 6 on the Customer Connector  M170-T6
Cable 50-Red 		 6  An input for the desired engine speed is required. The input can be either 0 to 5 VDC or 4 to 20 mA. The method for the desired speed input must be selected with Cat ET.

Terminals 6 and 8 provide 5 VDC for the desired engine speed. These terminals must be connected to the potentiometer for the desired speed.

Terminal 7 is the input for the desired engine speed.

An input of 0 VDC causes the engine rpm to equal the value of the "Minimum High Idle Speed" parameter.

An input of 5 VDC causes the engine rpm to equal the value of the "Maximum High Idle Speed" parameter. 
Input for the Desired Engine Speed  Terminal 7 on the Customer Connector  M170-T7
Cable 50-White 		 7 
Return for the Desired Engine Speed  Terminal 8 on the Customer Connector  M170-T8
Cable 50-Black 		 8 
Shield for the Wiring for the Desired Engine Speed  Terminal 9 on the Customer Connector  M170-T9
Cable 50-Shield 		 9 
"+" Input for the 4 to 20 mA Desired Speed Signal  Terminal 10 on the Customer Connector  M180-T10  10  An input for the desired engine speed is required. The input can be either 0 to 5 VDC or 4 to 20 mA. The method for the desired speed input must be selected with Cat ET.

The 4 to 20 mA is an optional method for providing the desired engine speed input.

If the 4 to 20 mA method is used to control the desired speed, the 0 to 5 VDC input must be disabled.

The 4 to 20 mA input is an isolated input. The "+" input must be in the same circuit as the "-" input.

An input of 4 mA causes the engine rpm to equal the value of the "Minimum High Idle Speed" parameter.

An input of 20 mA causes the engine rpm to equal the value of the "Maximum High Idle Speed" parameter. 
"-" Input for the 4 to 20 mA Desired Speed Signal  Terminal 12 on the Customer Connector  M180-T12  12 
"Grid Status" Input  Terminal 11 on the Customer Connector  M120-T11  11  This input is not normally used in industrial applications.

Primary governor gains are used when this input is not connected to the digital return.

Auxiliary governor gains are used when this input is connected to the digital return. 
Cat Data Link +  Terminal 13 on the Customer Connector  D100-T13  13  These connections provide the means for communicating the status of the engine control system, of various engine components, and of sensors.

The Advisor Monitor Display on the remote panel is connected to these terminals.

The Cat Data Link can be connected to the Customer Communication Module (CCM). For information on connecting the CCM, refer to the most recent literature for the CCM.

Caterpillar Software for the CCM loaded on a personal computer uses the CCM in order to obtain engine information via this data link. 
Cat Data Link −  Terminal 14 on the Customer Connector  D100-T14  14 
Digital Return  Terminal 15 on the Customer Connector  P500-T15  15  This connection provides a return for various inputs. 
Input for the "START" Mode  Terminal 16 on the Customer Connector  P615-T16  16  If these inputs are not wired correctly, the ECM will activate a diagnostic code.

Typically, these inputs are connected to an engine control switch. Refer to "Inputs for the Engine's Mode of Operation" for additional information on these inputs.

These inputs must be connected to a switch or to a logic device. The switch or the logic device must connect the inputs to the digital return.

When terminal 24 is connected to the digital return, the ECM is in "STANDBY" mode. The engine mode of operation is determined by the "Input for the START Mode". When the "Input for the START Mode" is connected to the digital return, the normal sequence for start-up is initiated. When the "Input for the START Mode" is disconnected from the digital return, a normal shutdown is initiated.

If the "Input for the Cooldown/STOP Mode" is connected to the digital return, the sequence for a normal shutdown is initiated. 
Input for the "AUTO" Mode  Terminal 24 on the Customer Connector  P614-T24  24 
Input for the "COOLDOWN/STOP" Mode  Terminal 31 on the Customer Connector  P613-T31  31 
"Driven Equipment Ready" Input  Terminal 17 on the Customer Connector  M530-T17  17  This input indicates when the driven equipment is ready for operation. This input must be connected to the digital return in order for the engine to run.

When this input is connected to the digital return, the engine can be started.

When this input is not connected to the digital return, the engine will not crank.

The ECM generates an event code if this input is not connected to the digital return within the programmed delay time.

When the engine is running, this input normally continues to be connected to the digital return. If the engine is running and this input is disconnected from the digital return, the ECM immediately generates an event code. The ECM also de-energizes the GSOV.

Because the cooldown is not performed, do not use this input for normal shutdown. 
Keyswitch  Terminal 7 on the Terminal Block  P600-T18  18  When this input is connected to the +Battery, the ECM will power up.

The Advisor Monitor Display on the remote panel will power up. 
Normal Stop  Terminal 19 on the Customer Connector  M510-T19  19  This input must be connected to the digital return in order for the engine to run.

This input is not recommended for normal shutdown.

Connecting the "Input for the COOLDOWN/STOP Mode" to the digital return is the recommended method for initiating a normal shutdown.

If the engine is not running and this input is not connected to the digital return, the engine will not crank. No diagnostic codes or event codes are provided for this condition.

If the engine is running and this input is disconnected from the digital return, the ECM will remove power from the GSOV. The cooldown does not operate. 
Output for Active Alarm  Terminal 20 on the Customer Connector  P697-T20  20  This output is activated if the ECM detects an alarm condition.

When this output is activated, the output is connected to ground.

Sinking output up to 0.3 A. 
Idle/Rated Input  Terminal 22 on the Customer Connector  M190-T22  22  When this input is not connected to the digital return, the engine will run at the idle speed that has been programmed with Cat ET.

When the engine oil pressure is greater than the setpoint for the engine speed, the engine will run at rated speed. 
Emergency Stop  Terminal 2 on the 2 Terminal Connector  C256-T23  23  These terminals must be connected in order for the engine to start. These terminals must remain connected in order for the engine to run.

If the ECM is controlling the gas shutoff valve and this circuit is opened, the ECM de-energizes the gas shutoff valve. The fuel is immediately shut off.

The ignition is immediately shut off.

Additional emergency stop buttons may be added to the emergency stop circuit. For details, refer to "Wiring for the Emergency Stop Circuit". 
Terminal 28 on the Customer Connector C256-T28  28 
Output for Engine Failure  Terminal 25 on the Customer Connector  P698-T25  25  The ECM connects this terminal to ground when the ECM causes the engine to be shut down.

Sinking output up to 0.3 A. 
Input for Manual Prelube  Terminal 22 on the Customer Connector  C293-T26  26  This terminal is for the manual prelube.

The logic of the ECM determines when prelube is required. The input for the manual prelube should be connected to the + Battery. 
Gas Shutoff Valve  Terminal 5 on the Terminal Block  A330-T30
Cable109-Red 		 30  These connections are part of the circuit for the Gas Shutoff Valve (GSOV).

For details on these terminals, refer to "Wiring for the Gas Shutoff Valve (GSOV)". 
Terminal 1 on the 2 Terminal Connector A330-T37
Cable 109-White 		 37 
CAN Data Link +  Terminal 35 on the Customer Connector  D200-T35
Cable 45-Yellow 		 35  The Advisor Monitor Display on the remote panel is connected to these terminals. 
- CAN Data Link  Terminal 36 on the Customer Connector  D200-T36
Cable 45-Green 		 36 
CAN Data Link Shield  Terminal 38 on the Customer Connector  D200-T38
Cable 45-Shield 		 38 
Spare  No Connection  P300-T41
Cable 109-Black 		 No Connection  Spare 

Refer to the appropriate procedure in order to make the connections.

Engine Interface Box

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Illustration 170g01254409
Locations for connections inside the engine interface box

Wiring for the Emergency Stop Circuit

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Illustration 171g01254366
Options for the wiring for the emergency stop circuit
(A) Only the engine emergency stop button is used.
(B) The circuit contains an additional emergency stop button that is provided by the customer.
(1) 155-2269 Connector Plug As and 8T-8730 Connector Socket
(2) 8T-8729 Connector Pin

An emergency stop button is provided on the engine interface box. An additional emergency stop button may be connected to the circuit. Wire the emergency stop circuit according to graphic (A) or graphic (B) in Illustration 171. Use 16 gauge wiring for this circuit.

The GSOV is immediately de-energized when an emergency stop button is activated. The ignition is disabled.

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NOTICE

Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

Wiring for the Gas Shutoff Valve (GSOV)

The GSOV must be energize-to-run. The GSOV may be supplied by the customer or by Caterpillar. Usually, the GSOV is installed when the piping for the fuel is installed at the site. The GSOV is also called the fuel control relay.

The GSOV may be controlled by the engine control system or by the customer equipment. The recommended configuration is for the engine control system in order to control the GSOV. There will be fewer problems if this configuration is used. When the customer equipment controls the GSOV, the equipment must include the necessary logic in order to ensure that the GSOV operates correctly.

The ECM can supply a maximum continuous current of 1.5 A to the GSOV. A relay must be installed if the GSOV requires a continuous current that is greater than 1.5 A.

When the engine control system controls the GSOV, the ECM supplies voltage to the GSOV. The valve opens in order to allow fuel to flow to the engine. When voltage is removed from the GSOV, the valve closes and the fuel flow stops.

The following section describes the two configurations for the circuit for the GSOV.

The GSOV is controlled by the engine control system. The customer may supply an additional switch in the electrical circuit for the GSOV. Refer to Illustration 172 for examples of these types of installations.

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Illustration 172g01254747
The GSOV is controlled by the engine control system.
(A) Only the engine emergency stop button is used.
(B) The circuit contains an additional emergency stop button that is provided by the customer.
(1) 155-2269 Connector Plug As and 8T-8730 Connector Socket
(3) 109-3038 Wire End

The GSOV is controlled by the customer equipment.

Refer to Illustration 173 for an example of this type of installation.

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Illustration 173g01254388
The GSOV is controlled by the customer equipment.
(1) 155-2269 Connector Plug As and 8T-8730 Connector Socket
(3) 109-3038 Wire End

Wire the circuit for the gas shutoff valve according to the appropriate illustration. Use 16 gauge wiring for this circuit.

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Illustration 174g01432979
Routing of the wiring harness for the gas shutoff valve

CAN Data Link

A termination resistor must be added to the CAN data link. Select one of the following locations for the resistor.

Inside of the Engine Interface Box - Use this location when the CAN data link does not extend past the engine interface box.

Outside of the Engine Interface Box - Use this location when the CAN data link extends past the engine interface box.

Illustration 175 describes a typical connection inside the engine interface box. Wire the connection according to SAE standards.

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Illustration 175g01254499
Typical installation for the termination resistor inside the engine interface box
(2) 3 8T-8729 Connector Pins
(4) 153-2707 Electrical Cable
(5) 3E-3370 Connector Receptacle As
(6) 174-3016 Plug As

Illustration 176 describes a typical connection outside the engine interface box. Wire the connections according to SAE standards.

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Illustration 176g01254713
Typical installation for the termination resistor that is outside of the engine interface box
(2) 3 8T-8729 Connector Pins
(4) 153-2707 Electrical Cable
(5) 3E-3370 Connector Receptacle As
(6) 174-3016 Plug As
(7) Splice
(8) 119-3662 Heat Shrink Tube

Customer Connector

Make the connections to the customer connector according to the following procedure:

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    Illustration 177g01254403
    Orientation of the customer connector

  1. Route the wiring for the driven equipment into the engine interface box. Use 16 gauge wiring for the connections to the customer connector. The hardware that is used should provide a water tight connection at the hole in the engine interface box.

  2. Crimp a 8T-8729 Connector Pin onto the end of each wire that will be inserted into the customer connector.

  3. Make the connections to the customer connector according to Illustration 177 and Table 17. Insert each pin into the appropriate location on the customer connector. Pull on each wire in order to verify proper installation of the pin.

Terminal Block

Make the connections to the terminal block according to the following procedure:

  1. Table 17 lists the functions that are available. Use 16 gauge wiring for the connections to the terminal block. Crimp a 109-3038 Wire End onto the end of each wire that will be inserted into the terminal block.

  2. Make the connections according to Illustration 170 and Table 17.

Harness Connectors for the Engine Interface Box

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Illustration 178g01346883
Side view of engine interface box
(1) Harness connectors

Note: Cut the tie strap that secures the harness to the harness clip. The harness clip is located on the side of the water regulator housing. Cutting the tie straps helps to ensure that strain will be relieved from the connector pins. Relief of the strain will help prevent damage to the connectors.

Interconnect Harness

Interconnect harnesses of different lengths are available. Table 18 lists the interconnect harnesses that are available. The harnesses can be shortened, if necessary.

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Table 18
Interconnect Harnesses 
Part Number  Length  CSA  Braided 
251-9466  6.1 m (20 ft)  Yes  No 
251-9467  9.1 m (30 ft)  Yes  No 
251-9468  15.2 m (50 ft)  Yes  No 
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Illustration 179g01241390
The end of the interconnect harness for the engine interface box

Refer to Illustration 179. Pins and wire ends are crimped to the ends of the wires at one end of the interconnect harness. This end of the harness is for the engine interface box.

The interconnect harness must be routed through conduit. A 50 mm (2 inch) hole is provided for attaching the conduit to the engine interface box.

The following parts are provided with each interconnect harness:

Pieces of Heat Shrink Tube - Each piece of heat shrink tube is labeled with a wire identification. The tubes are used to identify each wire if the wire is cut to a shorter length.

14 Gauge Wire Ends, 16 Gauge Wire Ends, and 18 Gauge Wire Ends - These parts are only required if the remote panel is used. A wire end will be crimped to the end of each wire. The crimp connect the wire to the terminal strip inside the remote panel.

Note: A wrap-up sleeve is provided with the interconnect harness. A wrap-up sleeve must cover the following circuits for the interconnect harness. These circuits are located inside the engine interface box and the remote advisor panel:

  • + Battery (P200-T4 RD)

  • - Battery (P300-T39 BK)

  • Keyswitch (P600-T18 WH)

  • Push button for the prelube (C293-T26 BK)

  • Prelube light (A320-T33 RD)

Perform the following procedure in order to connect the interconnect harness to the engine interface box:

  1. Pull the harness through the conduit to the engine interface box. Be sure to orient the harness so that the wire ends with crimped terminals are inside the engine interface box.
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    Illustration 180g01432967
    Connections on the terminal block
    (1) Fuse 4 is for the throttle actuator. The fuse for the throttle actuator is required for all engines.
    (2) Fuse 5 is for the air/fuel ratio control actuator. The fuse for the air/fuel ratio control actuator is required.

  2. Make the connections to the terminal block first. Refer to Illustration 180 and Table 19. Each wire is labeled. Insert each wire end to the appropriate location on the terminal block. Pull on each wire in order to verify proper installation of the wire end.

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    Table 19
    Connections for the Terminal Block 
    Interconnect Harness  Location on the Terminal Block 
    Cable  Wire Identification 
    91-Red  A320-T33(1)  1 
    91-White  C293-T26(1)  2 
    105-Red  P200-T4(1)  4 
    109-Red  A330-T30  5 
    105-White  P600-T18(1)  7 
    105-Black  P300-T39(1)  8 
    91-Black  P300-T40 
    91-Black  P300-T41  Spare 
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    (1) These circuits must be contained in the wrap-up sleeve at the engine interface box and at the remote advisor panel.
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    Illustration 181g01256097
    Connections for the wiring to the customer connector

  3. Refer to Illustration 181. Make the connections for wiring to the customer connector. Each wire is labeled. Insert each pin into the appropriate location on the connector. Pull on each wire in order to verify proper installation of the pin.
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    Illustration 182g01256115
    Connections for the wires from the cables to the customer connector

  4. Refer to Illustration 182. Connect the wiring from the cables to the customer connector. The wire in each cable is labeled. Insert each pin into the appropriate location on the connector. Pull on each wire in order to verify proper installation of the pin.

  5. Connect the two terminal connectors on the interconnect harness to the two terminal connectors that are located inside the engine interface box. This connection is for the emergency stop circuit and the circuit for the GSOV.

  6. Connect the wiring from the driven equipment to the end of the interconnect harness.

Remote Panel

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Illustration 183g01256226
Dimensions and components of the remote panel
(9) Advisor monitor display
(10) Manual prelubrication switch and indicator
(11) Emergency stop button
(12) Engine control
(13) Desired speed potentiometer
(14) Service tool connector

The remote panel provides the following capabilities:

  • Emergency stop

  • Engine control

  • Advisor monitor display

  • Desired engine speed

  • Manual prelubrication

  • Indication of alarms, derates, and shutdowns via the remote advisor panel display

Make the connections to the remote advisor panel according to the following procedure:

  1. Refer to "Interconnect Harness". Route the interconnect harness from the engine interface box to the remote advisor panel. Make the connections for the interconnect harness inside the engine interface box.

    Note: The wires and the cables that make up the interconnect harness may be cut to the appropriate length, if necessary. Do not cut all of the wires and the cables at the same time. Cut one wire and connect the wire to the appropriate location on the terminal strip. Connection of each wire is important when a cable that contains several wires is cut. The cable does not have an external marking that identifies the cable. Cut the cable. Then slide the appropriate heat shrink tube into the end of each wire in the cable. This technique helps to ensure that each connection is made correctly.

      Note: Each wire in the harness is identified with the circuit identification.

    1. Select a wire. Identify the location on the terminal strip for the wire. Refer to Table 20.

    2. Cut the wire to the appropriate length.

    3. Slide the appropriate heat shrink tube onto the end of the wire. Shrink the tube onto the wire.

    4. Attach the wire end that is the appropriate gauge onto the end of the wire.
      Show/hide table
      Illustration 184g01243294
      Location for the connections for the interconnect harness inside the remote panel

    5. Refer to Illustration 184. Make the connections for the interconnect harness on the left side of the terminal strip. Insert the wire end into the appropriate location on the terminal strip. Pull on the wire in order to verify that the connection is secure.

      Note: A wrap-up sleeve is provided with the interconnect harness. A wrap-up sleeve must cover the following circuits of the interconnect harness. These circuits are located on the inside of the engine interface box and the remote advisor panel:

      • + Battery (P200-T4 RD)

      • - Battery (P300-T39 BK)

      • Keyswitch (P600-T18 WH)

      • Push button for the prelube (C293-T26 BK)

      • Prelube light (A320-T33 RD)

      Show/hide table
      Table 20
      Connections for the Interconnect Harness on the Terminal Strip 
      Interconnect Harness
      Wire Identification       		 Gauge of the Wire End  Location on the Terminal Strip  Function 
      P200-T4(1)
      Cable 105-Red       		 16  4  +Battery for the operation of the remote advisor panel 
      M170-T6
      Cable 50-Red       		 16  6  Desired Engine Speed 
      M170-T7
      Cable 50-White       		 16  7  Desired Engine Speed 
      M170-T8
      Cable 50-Black       		 16  8  Desired Engine Speed 
      M170-T9
      Cable 50-Shield       		 16  9  Shield for the Desired Engine Speed 
      M180-T10  16  10  Desired Engine Speed 
      M120-T11  16  11  Grid Status 
      M180-T12  16  12  Desired Engine Speed 
      D100-T13  16  13  + Cat Data Link 
      D100-T14  16  14  - Cat Data Link 
      P500-T15  16  15  Return 
      P615-T16  16  16  Start Command 
      M530-T17  16  17  Driven Equipment 
      P600-T18(1)
      Cable 105-White       		 14  18  Keyswitch 
      M510-T19  16  19  Normal Stop 
      P697-T20  16  20  Active Alarm 
      SC01-T21  16  21  Spare 
      M190-T22  16  22  Idle/Rated Input 
      C256-T23  16  23  Emergency Stop 
      P614-T24  16  24  Auto 
      P698-T25  16  25  Engine Failure 
      C293-T26(1)
      Cable 91-White       		 16  26  Manual Prelube Input 
      P696-T27  16  27  Crank Terminate 
      C256-T28  16  Bottom
      28       		 Emergency Stop 
      M140-T29  16  29  Run Relay 
      A330-T30
      Cable 109-Red       		 16  30  Gas Shutoff Valve 
      P613-T31  16  31  Cooldown/Stop 
      M164-T32  16  32  Desired Timing 
      A320-T33(1)
      Cable 91-Red       		 16  33  Prelube ON 
      D200-T35
      Cable 45-Yellow       		 18  35  + CAN Data Link 
      D200-T36
      Cable 45-Green       		 18  36  - CAN Data Link 
      A330-T37
      Cable 109-White       		 16  37  Gas Shutoff Valve 
      D200-T38
      Cable 45-Shield       		 18  38  CAN Data Link Shield 
      P300-T39(1)
      Cable 105-Black       		 14  39  −Battery 
      P300-T40
      Cable 91-Black       		 16  40 
      P300-T41
      Cable 109-Black       		 Unconnected  Spare 
      Show/hide table
      (1) These circuits must be contained in a wrap-up sleeve at the engine interface box and at the remote advisor panel.

  2. Perform the following procedure to connect the wiring from the driven equipment.
    Show/hide table
    Illustration 185g01242443
    Location for the customer connection inside the remote panel

  3. Refer to Illustration 185. Make the connections for the driven equipment on the right side of the terminal strip. Table 17 lists the connections that are available.

Wiring for the Emergency Stop Circuit

The circuit for the emergency stop buttons is complete when the remote panel is installed. An additional emergency stop button may be added to the circuit. Refer to Illustration 186. Remove the bridge and connect the additional button according to the Illustration.

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Illustration 186g01242557
Emergency stop circuit with an additional emergency stop button

Wiring for the Gas Shutoff Valve

The circuit for the emergency stop buttons is complete when the remote panel is installed. Refer to Illustration 186.

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Illustration 187g01256413
Circuit for the gas shutoff valve

Initial Start-up of the Engine

Refer to Special Instruction, REHS2558, "Installation and Initial Start-Up Procedure for G3500 A3 Engines".

Refer to Troubleshooting, RENR9353, "Gas 3500 A3 Engines", "Nitrogen Oxide Sensor - Calibrate".

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

  1. When performing a retrofit installation, record the vital information in Table 21.

    Note: If the procedure is performed by the customer, ask the customer to record the proper information.

    Show/hide table
    Table 21
    Repair Date   
    Product Serial Number   
    Service Hours or Service Meter Units   
    Removed Component Part Number(1)   
    Removed Component Serial Number(1)   
    Installed Component Part Number(2)   
    Installed Component Serial Number(3)   
    Show/hide table
    (1) Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
    (2) Record the highest level retrofit kit, arrangement, or group part number.
    (3) Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

  2. Update the product configuration by entering the information from Table 21 into SIMSi and AIMS.

    Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

  3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".

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