Information Release Memo ENG03-01

Engine
April 2003

THE CATERPILLAR® ADEM™ III SYSTEM IS NOW

AVAILABLE TO UPGRADE G3600 ENGINES

Caterpillar is proud to announce the option to upgrade Gas 3600 series engines in the field.
ADEM III electronic controls integrate governing (engine sensing / monitoring, air / fuel
ratio control, ignition timing and detonation control) into one comprehensive engine control
system for improved performance and reliability.

The Advanced Digital Engine Management III control system is also commonly known as
the A+ or A3 control system.

PELJ0172 © 2003 Caterpillar

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Why ADEM III?

RELIABILITY

New simplified system architecture has fewer independent control modules and wiring
harnesses, and provides easier troubleshooting and more reliable engine monitoring.

TERMINAL POINTS

Improved wiring harnesses and fewer terminal connections provide improved reliability by
reducing the number of electrically related faults.

DETONATION

Separate cylinder detonation sensing provides individual cylinder detonation control for
improved engine protection, as well as reduced exhaust emissions and improved
performance.

CHOKE CONTROL

Closed-loop choke control, includes exhaust temperature sensing and a reduction in engine
wear through better control on warm-up and during light load operation.

PYROMETER

The exhaust temperature is monitored at individual cylinder exhaust ports and at

turbocharger inlet and outlet.

REMOTE MONITORING*

To maximize efficiency and availability remote data access provides nearly all engine
operating parameters for engine monitoring.

PROGRAMMING & DIAGNOSTICS*

Machine Information Display System (MIDS) display provides a single interface for the
operator for field programmability of performance maps, alarm set points, and event fault
coding. All serve to simplify engine operation and troubleshooting.

The ADEM III also uses the standard Cat® Electronic Technical (Cat ET) to view engine
parameters and diagnostic codes for Troubleshooting.
*Requires optional equipment

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Caterpillar Dealers Must Follow The Steps Below To Perform The Upgrade

Step 1: Verify If The Engine Has Hydrax Actuators Installed

The engine must have Hydrax actuators installed in order to upgrade to ADEM III.

If Hydrax actuators are not installed, please follow the Special Instructions below excluding
the electrical portion of them, as the ADEM III will replace the electrical portion.
Special Instruction for Installation of Hydrax on G3606 & G3608 – REHS0147
Special Instruction for Installation of Hydrax on G3612 & G3616 – REHS0385

The following “Hydrax Kits” are available for this upgrade:

G3606 Hydrax Kit = 234-9651
G3608 Hydrax Kit = 234-9652
G3612 Hydrax Kit = 234-9654
G3616 Hydrax Kit = 234-9657

These kits are not stocked at any Caterpillar facility. They are assembled in Morton after the
Dealer places the order. Please contact your parts order analyst for the Estimated Shipping
Date after placing the order.

Step 2: Verify if new Software is needed

A Performance Engineer may need to create new software on-site for the ADEM III system
to match the Customer's gas and engine configuration. To determine if a Performance
Engineer is required, submit the "ADEM III Software Request Form and ESS Data
Sheet ” (Appendix A). Available at
https://nacd.cat.com/infocast/frames/prodsupp/engine/comm/

Step 3: Define The Necessary Parts And Components To Upgrade The Engine
Determine the parts needed for the upgrade by following the directions in these selection
tables.
G3606: Appendix C “G3606 Selection Table”
G3608: Appendix D “G3608 Selection Table”
G3612: Appendix E “G3612 Selection Table”
G3616: Appendix F “G3616 Selection Table”

These forms are also available at

https://nacd.cat.com/infocast/frames/prodsupp/engine/comm/

The following “ADEM III Basic Kits” are available for this upgrade and are already
described at the “Selection Table”:
G3606 ADEM III Basic Kit = 234-9495
G3608 ADEM III Basic Kit = 235-5744
G3612 ADEM III Basic Kit = 233-9472
G3616 ADEM III Basic Kit = 236-7281

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These kits are not stocked at any Caterpillar facility. They are assembled in Morton after the
Dealer places the order. Please contact your parts order analyst for the Estimated Shipping
Date after placing the order.

Step 4: Receive correspondence from Caterpillar determining if a Performance Engineer

is required
This correspondence will either contain the software part number for the ADEM III or it will
notify you that you need to schedule a performance engineer.

Step 5: Get Customer’s order and plan the upgrade

Estimated downtime:
ADEM III Hardware Installation: 3.5 days
Hydrax Upgrade (if required): 3.5 days
Engine Software Mapping (if required): 5 days

Step 6: If Performance Engineer is required submit the Performance Engr. Request Form
If customer has ordered the upgrade and new software is required, submit the "Performance
Engineer Request Form” (Appendix B) to schedule the dates. This form is also available at
https://nacd.cat.com/infocast/frames/prodsupp/engine/comm/

Step 7: Provide The Update Parts Books Pages To The Customer

In order to provide Customer the Parts Book’s pages with the new configuration of the
engine, please order the respective model master (see below) and print the respective pages
resulted from the update.

G3606 – SERP3792
G3608 – SERP3793
G3612 – SERP3794
G3616 – SERP3795

G3606 ADEM III Basic Upgrade Kit Groups

210-5635 122-2083 195-5915 204-6689
213-6282 213-6286 213-6303 213-6307 213-6456
G3608 ADEM III Basic Upgrade Kit Groups
122-2083 195-5915 204-6689 213-6282 213-6456
219-9926 219-9928 219-9929 219-9932 219-9933
G3612 ADEM III Basic Upgrade Kit Groups
119-7536 122-2083 149-3999 159-4641 159-9408
195-5915 195-6243 195-6245 195-6246 195-6247
204-6689 213-6789 4P-3760 4W-0698
G3616 ADEM III Basic Upgrade Kit Groups
119-7536 122-2083 149-3999 159-4641 159-9408
195-5915 195-6243 204-6689
206-5459 206-5460 206-5461 4P-3760 4W-0698

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Additional Reference Information

Service Publications

G3600A+ Installation & Startup Guide REHS1336

G3600A+ Troubleshooting Guide RENR5910
System Operation Testing and Adjusting RENR5908
G3600A+ Specifications RENR5907
Operation and Maintenance Manual SEBU7563
G3606A+ Wiring Schematic RENR5966
G3608A+ Wiring Schematic RENR5967
G3612A+ Wiring Schematic RENR5911
G3616A+ Wiring Schematic RENR5912
CCM Special Instruction REHS0806
CCM Operation Manual (M5X) SEBU6874

CSA Certification

All of the kit components meet the CSA specification. However, if the subject engine is
required to have CSA (Canadian Standards Association) certification the installer must
contact the CSA and arrange for an inspection by a CSA auditor. Before the auditor arrives
the installer will be asked to complete a dielectric test of the primary ignitions wires and fill
out the CSA dielectric test form. The audit should be scheduled several weeks before the
conversion is scheduled so that the CSA will have ample time to make travel arrangements.
The time of the audit will depend upon the CSA auditor’s schedule. The CSA will bill the
requestor for the site audit at the rate of $189 US / hr. (includes audit and travel time) plus
expenses. Depending upon the travel expense, a typical audit would cost somewhere in the
$3500 range.
To arrange the CSA audit the installer should use the contact information listed below.

Jeff Howlett
CSA Customer Service
Phone: (780) 490-2015
Fax: (780) 461-5322
Email: jeff.howlett@csa-international.org
Web www.csa-international.org
Post CSA International
1707 - 94 Street
Edmonton, AB, Canada T6N 1E6

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Interface with Customer Control System

There are various options for the customer to get data from the ADEM III control system.
1) Manually from the MIDS panel (included in the kit)
2) From the Cat Communication Module (CCM) PC software program using desktop or
laptop PC (JERC2162 version 1.5).
3) From a CCM into the Customer’s PLC. The ADEM III system cannot communicate
directly with a PLC. All communications must go through the CCM using M5X
Protocol as described in REHS0806-02. Products that have been used successfully to
accomplish this conversion are:

(a) Allen Bradley ControLogix Processor with a 4 slot chassis and a Rockwell
Automation 1756- MVI card and an output device. In most applications the
ContoLogix Processor will have enough capacity to run the system without
using an additional PLC. Below is a picture of a similar set up; in this case an
Ethernet card is the output format.
(b) Other 3rd party converter cards are not supported by Caterpillar. For more
information contact the LEC Service Support Center in Lafayette, IN – (765)
448-2200

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Service Tool Requirements

The tools that are listed in Table 1 are required in order to enable a service technician to
perform the electrical installation procedures and the initial start-up.
Note: Other tools that are needed for measuring operating parameters such as pressure and
temperature are not listed in Table 1.

Service Tools

Pt. No. Description Functions

Single user license for Caterpillar Electronic Technician (Cat ET)

JERD2124 Software
Use the most recent version of this software.

JERD2129 Software Data subscription for all engines

This PC configuration is recommended:

Intel Pentium II 333 mHz processor
64 megabyte of RAM, 4.3 GB hard drive
Drive for floppy disks (3.5 inch with 1.44 MB) , 14X speed CD-ROM drive, VGA monitor or display
RS-232 port with 16550AF UART, Mouse, Windows NT 4.0 (1) , Windows 95 (1) ,Windows 98 (1)

171-4401 Communication The communication adapter is connected between the PC (ET)

Adapter II (1) and the ECM.

196-0055 Serial Cable As This cable connects the PC to the 171-4401 Communication
Adapter II .

Data Link This cable connects the service tool connector on the engine
7X-1414
Cable As mounted terminal box to the 139-4166 Adapter Cable As .

Adapter Cable This breakout t is for use between the jacks and the plugs of the
8T-8726
As sensors.

151-6320 Wire Removal This tool is used for the removal of pins and sockets from
Tool Deutsch connectors and AMP connectors.

1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.

Digital The multimeter is used for the testing and for the adjusting of
9U-7330
Multimeter electronic circuits.

Multimeter The probes are used with the multimeter to measure voltage in
7X-1710
Probes wiring harnesses without disconnecting the harnesses.

Voltage Tester The tester is used to test for voltage in circuits, in relays, in
5P-7277
bulbs, in wires, and in switches.
(1)
Any of these operating systems are acceptable.
(1)
This item is included in the 171-4400 Communication Adapter Gp .

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The Caterpillar Electronic Technician (Cat ET) is designed to run on a personal computer.
Either the 171-4401 Communication Adapter II or the 7X-1700 Communication Adapter Gp
can be used for the communication between the Cat Data Link and the RS-232 serial port.
However, the 7X-1700 Communication Adapter Gp is no longer serviced. For more
information on the communication adapters, refer to the literature that is provided with the
adapters.

ESS to ADEM III Comparison Table

ESS ADEM III

Gauges/Display
System parameters and fault codes are
displayed on a variety of gauges
Air start pressure displayed on ESS panel
Actual inlet air restriction can be read on ESS
with an alarm at 15” H2O and a shutdown at
21” H2O
ESS displays detonation codes but does not
identify which cylinder is detonating
No EJW pressure sensors are used in ESS
Customer Interface Signals
Generator Remote speed control is as PWM
signal from the Loadshare Module
CCM uses M5O protocol
Crank Terminate, Run Relay, Alarm and
Engine Shutdown relay signal is Battery
Positive (+)
Speed control setting (Local/Remote) is
indicated using lamps which provide a
discrete(on/off) output
Customer Remote Emergency Stop contacts
are normally open
Prelube light is on when the engine is ready to
run and when it’s running (after the prelube is
OK)
All system parameters and fault codes are
displayed on the MIDS
Air start pressure is not monitored or
displayed
An alarm code is generated when inlet air
restriction reaches 21” H2O (no shutdown)
Detonation levels and fault codes for each
cylinder are displayed on the MIDS and Cat
ET
2 EJW sensors are used, a switch at the
pump outlet and a sensor for engine outlet
pressure
Generator remote speed control is a 0-5 volt
signal from the loadshare module (Special
Loadshare Module Required: 202-4869)
CCM uses M5X protocol (requires 188-
3080 CCM)
Crank Terminate, Run Relay, Alarm and
Engine Shutdown relay signal is Battery (-)
Speed control setting is displayed in ET
only. No lamp or discrete output.
Customer Remote Emergency Stop contacts
are normally closed
Prelube light is on only when the prelube
driver output is active

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Control Functions
Speed Control can be switched manually
between Local and Remote on the fly at the
ESS panel
A/F pressure module calibration is performed
by installing a jumper in the ESS
Manual choke trim adjustments
DDT required to service engine
Software programmed into personality
module
Thermocouple data not available on the data
link
Potentiometer is used to set the fuel BTU
value.
Speed Control can be switched between
Local and remote with Cat ET only
A/F pressure module calibration is
performed using Cat ET
Closed loop choke strategy
Cat ET required to service engine
Software is downloaded into the control
module using Cat ET
Thermocouple data is available on the data
link for display and enhanced combustion
diagnostics
Cat ET is used to enter the fuel BTU value
and specific gravity

Training

The technicians performing the installation of the G3600 ADEM III Upgrade Kit should have
previous G3600 experience and be familiar with basic gas engine operations and it is highly
recommended that they attend the following classes provided by the Cat Learning Center:

Gas Engines I (2900) G3500/G3600 A+ Engine Controls (3100)

Gas Engines II (2950) G3600 Lean Burn Gas Engine Control (2980)
G3600 Master Mechanics (2860)

This background will provide a solid understanding of the G3600 and minimize problems
encountered during the conversion and startup.

Appendixes

Appendix A: File “ADEM III Software Request Form & ESS Data Sheet”
Appendix B: File "Performance Engineer Request Form”
Appendix C: File “G3606 Selection Table”
Appendix D: File “G3608 Selection Table”
Appendix E: File “G3612 Selection Table”
Appendix F: File “G3616 Selection Table”

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Questions

Any questions can be directed to:

Technical Questions:
• LEC Service Support Center in Lafayette, IN – (765) 448-2200

Parts Availability:
• Morton : 1-800-566-7782

Jose-Eduardo M. Fonseca
Engine Parts Business Unit
AC6214 – (309) 578-7304

This IRM can be viewed and downloaded electronically from the Internet. Please refer to your
marketing organization specific site for access to the Electronic Sales Library which contains all of the
active IRMs and product support communication materials.

Electronic Sales Library

NACD Dealers - https://nacd.cat.com/infocast/frames/machine/doc/
EAME Dealers - https://cosa.cat.com/infocast/frames/literatur/external-link/
LACD Dealers - https://caco.cat.com/infocast/frames/PSE/media/esl/
APD Dealers - https://apdnet.cat.com/infocast/frames/
Internal Caterpillar Employees - http://cds.cat.com/PSMprev.nsf/$$MediaNumber

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Appendix A

ADEM III Software Request Form

Please return this completed form to Gina Abbott at the Lafayette, IN (Fax 765-448-5586 / Phone:765-448-5281 /
e-mail Abbott_Gina_M@CAT.COM). A current fuel analysis and ESS data sheet must also accompany this
form. This will allow us to determine if new software is needed. If new Software is required, a factory performance
engineer will need to create the software on- site. The dealer must pay for this software mapping.

Installing Dealer Information

Dealer Name:
Dealer Contact Name:
Contact’s Phone Number:
Contact’s email address:
Dealer Code

General (Please circle or fill in Answer)

Packager Name Requested A+ Retrofit
Installation Date
Customer Name Site Altitude (feet)
Site Name Is a CCM used on this YES / NO
engine?
Site Location Does the CCM interface YES / NO
with a PLC?
Selling Dealer PLC Brand Name
Servicing Dealer PLC Model #
Customer Engine I.D. Prelube Type Electric / Air
Application Genset / Industrial Is an Alternator going to be YES / NO
used?

Engine Data (Please circle or fill in Answer)

Sales Model Engine Hours
Engine Serial Number Orifice Plate Size
Current Personality Module Part # Camshaft (std or lo Btu)
Test Spec. Number Camshaft Part #
Rating (Hp / Kw) GAV Part #
Rated RPM Combustion Sensor Part #
Compression Ratio Combustion Sensor Adapter # *
Aftercooler Inlet Temp (0F / 0C) Fuel Valve Type (std / lo Btu) **
EJW Outlet Temp (0F / 0C) Fuel Valve Part # **
Aftercooler Type (1 or 2 stage) NOx Rating (g/bhp-hr)
Aftercooler Core Part # Fuel Methane Number
Turbo Type VTC254 / TPS57 Fuel BTU
Turbo Part Number Fuel Specific Gravity
Actuators Hydrax / Heinzmann A/F Pressure Module Part # ***
*Requires 188-4926 Connector
** Hint: The standard inline fuel valve has a 1”NPT and the Low Btu has a 1½”NPT. The standard vee
fuel valve has a 1½”NPT and the Low Btu has a 2”NPT connection.
*** A 162-7290 or 211-6713 module required ( high pressure A/F pressure module).

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Appendix A
ADEM III Software Request Form Continued

G3600 ESS Performance Data Sheet

Engine : Date: Project :

Serial No. Time: Altitude:
Ambient Temp: Barometric Pressure:
Desired Stack
B/T Temp
DDT L / R
RPM Act B/T Needle Exh Temp Act B/T Needle Exh Temp
Timing 1 9
A/F Ratio 2 10
Air Press 3 11
Air Temp 4 12
Air Flow 5 13
Fuel Cmd 6 14
Fuel Press 7 15
Fuel Flow 8 16
Fuel Temp
BTU Gov Gain SCM Emissions
Fuel Factor Gov Stab Hours Fuel Nat Gas
Load Gov Comp RPM Air Temp
Choke Cmd Bat V Fuel Temp
W/G Cmd W/G Gain Oil Press O2
Detonation W/G Stab Oil Temp CO
Choke Trim W/G Comp NO
NO2
CMS Cooling System NOx
Air Temp JW SCAC CO2
Cool Temp press/temp press/temp Eff.
Fuel Corr Pump In Losses
Air In Press Pump Out Excess Air
Oil Press Circuit Out Exh Draft ” H2O
Load Personality Module Number:
Notes:
O/F Diff
L Air Rstr
Crank Press
R Air Rstr
Start Air Pr

Supply Fuel Press:

Reg. out Fuel Press:
Active Fault Codes:
Fuel LHV :
Methane No. :
Specific Gravity:

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Appendix B

G3600 ADEM III Performance Engineer REQUEST FORM

This form is for the request of G3600 ADEM III Upgrade. The Dealer is responsible for the completion and submittal of
this form. Preferably, four weeks prior to desired upgrade date. Once the form is completed by the dealer it should
then be emailed or faxed to:

Gina Abbott
Email: Abbott_Gina_M@CAT.COM
Fax: 765-448-5586
Phone: 765-448-5281

Any changes to the start of retrofit date entered below must be submitted by E-mail to Gina Abbott. If the start
of retrofit date lapses without timely re-scheduling notification, the project will be dropped from the retrofit
schedule.

Date Service
Required:
Requested By:
Requestors Phone
Number:
Requestors email address:

Project Name:

Selling Dealer:

Complete Address:

Dealer Code:

Engine Sales Model:

Serial Number(s):

Site Location (i.e. City, State,

Country, etc..):
Customer’s Name:

Check the Appropriate Box ELECTRIC POWER COMPRESSOR

The following list, while not all-inclusive, must be performed prior to the Performance Engineer’s arrival.
Completed all Valve Adjustments
All Spark Plugs Serviced
Emission Analyzer is scheduled to be available for the performance engineer
Clean Check Valves
ADEM III Control System completely installed

Performance Engineer Charges: $1200 USD/day plus travel expenses

By submitting this form the Selling Dealer acknowledges the installation is complete and agrees to reimburse Caterpillar
all costs associated with any delays not in Caterpillar’s control including daily rate and travel expense. Actual expenses
will be invoiced at cost.

______________________________
Requesting Dealer Person’s Signature

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Appendix C

“G3606 Selection Table” This is for Caterpillar Internal and Dealer Use Only

Follow the 3 steps below to configure a ADEM III upgrade kit for a G3606 engine.

Requirements of the installation in preparation for the upgrade:

1. New Software may be required for the ADEM III system to match the customer's gas and engine configuration.
To determine if new software is available for ADEM III system for your site requirements, submit the "ADEM III Software Request Form**
2. If new software is required submit the "Performance Engineer Request Form" to schedule the software mapping dates.
3. Approximate Site Downtime: 3.5 days for ADEM III hardware installation, 3.5 days for Hydrax Upgrade (if Required), 5 days for Engine
Software Mapping (if Required)
4. The engine must be tuned(I.E. Emissions Tuning(needle valve adj & BTU potentiometer),Valve Adjustments, Check Valve & Spark
Plug Service) and running correctly before the upgrade is started.

STEP 1:Review the comment below to determine what components you need to order to upgrade to the ADEM III Control System

Guidance:
1. You must choose one of the three Remote Harnesses
2. If you do not have 152-0807 Thermocouples on the engine you will need to order the 152-0807 thermocouples
3. If you do not have the 188-4926 Connector (Combustion Senor), then you will need to order all the parts in the 188-4926 Section

4. If you do not have the 211-6713 pressure module, then you will need to order one of these
5. If the customer uses the Cat Communication Module, then you will need to order a new one. Note: The control system interfaced
should be reviewed to determine what customer connections would change. See the CCM Special Instruction for more information
6. If new software needs to be developed onsite, then a Caterpillar Performance Engineer is required and must be paid for by the dealer.
7. If Site CSA approval is required, then a CSA surveyor needs to approve the final installation of the Caterpillar CSA approved components.
These expenses must be paid for by the dealer.
8. Engine must have new Spark Plugs, if Cat has to develop new software onsite
9. Cover Group vs Alternator Drive Group: If the engine has a Cat Alternator then the Lines, Guard, and Drive groups are required, otherwise
the cover group should be order.
10. Determine which Turbocharger is on the engine and then choose the appropriate harness assembly.
11. If the engines does not have Hydrax Actuators, then the Hydrax Upgrade kit must be ordered

STEP 2: Write the Dealer Net or Suggested Consumer List Prices to the right of the table

STEP 3: Sum all prices at the bottom of the worksheet

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Appendix C

Part
Question Comments Numbers Description Quantity Price
1. Remote Harness - 100 100 Foot Harness- (to MIDS Panel) 206-6544 HARNESS AS (100 FOOT LENGTH)) 1
1. Remote Harness - 20 20 Foot Harness- (to MIDS Panel) 206-6543 HARNESS AS (20 FOOT LENGTH)) 1
1. Remote Harness - 50 50 Foot Harness- (to MIDS Panel) 205-3584 HARNESS AS (50 FOOT LENGTH)) 1 =
Do Not need if you have 152-0807
2. 152-0807 Thermocouple 152-0807 SENSOR GP-TEMP 6 =
3. 188-4926 Do Not need if you have 188-4926 125-5356 DISC-INSULATOR 12
Connector 136-4605 EXTENSION AS 6
159-3219 SENSOR-COMB 6
188-4926 CONNECTOR AS 6
6V-5050 SEAL-O-RING 6 =
Do Not need if you have 162-7290 or 211-
4. Pressure Module 6713 Pressure Module 211-6713 CONT GP -E 1 =

5. CCM If you need the Cat Communication Module 188-3080 Cat Communication Module 1 =
6. Cat Performance $1200 per day, plus travel expenses
Engineer (estimate) n/a Cat Performance Engineer 1 7000 est =
$900 USD per day + Travel Expenses-
7. CSA Surveyor (estimate) Contact CSA Surveyor n/a CSA Surveyor 1 3500 est =

8. Spark Plugs - Needed Engine must have new Spark Plugs, if Cat
for software mapping has to develop new software onsite 194-8518 PLUG-SPARK 6 =
9. Cover Group Cover Group Required if you do not have an 0L-1352 BOLT 2
alternator installed 0S-1588 BOLT 4
1W-7117 DOWEL-HOLLOW 2
206-7468 PLATE 1
3B-1915 BOLT 6
3V-3308 WASHER-HARD 12
4F-4585 PLUG-CORE 1
6V-5060 SEAL-O RING 1
5P-9147 SEAL-O RING 1
196-6039 HOUSING 1
206-7469 COVER 1 =
9. Alternator Drive Groups Altenator Lines groups for oil is required for 6V-5049 SEAL-O-RING 1
the Cat alternator 5H-0275 NUT-FITTING 1
030-7942 ELBOW 1
030-7962 ELBOW 1
030-8145 REDUCER-FLARED 1
061-8284 TEE-SWIVEL 1
196-6042 TUBE AS 1
Altenator Guard Gp Required if you have a 0S-0509 BOLT 4
Cat Alternator Installed 0S-1590 BOLT 3
1B-4971 SPACER 3
3V-3308 WASHER-HARD 7
7E-5639 SPACER 2
138-6804 GUARD AS-ALT 1
221-2542 GUARD AS 1
221-2543 GUARD AS-BELT 1
232-3759 BOSS-WELD 2
Altenator Drive Gp Required if you have a 3B-1915 BOLT 6
Cat Alternator Installed 3V-3308 WASHER-HARD 10
5P-8245 WASHER-HARD 8
5P-9147 SEAL-O RING 1
0S-1587 BOLT 4
1A-5964 BOLT 1
1D-4706 BOLT 3
1F-7958 NUT-FULL 2
1S-4698 ROD 1
4K-0367 NUT-FULL 2
5P-8247 WASHER-HARD 3
7D-9766 BOLT 1
7E-5485 GEAR 1
7E-6218 PULLEY 1
7N-2597 SPACER 1
8S-5383 BLOCK 1

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Appendix C

Part
Question Comments Numbers Description Quantity Price
Altenator Drive Gp Required if you have a 8T-9392 BOLT 1
Cat Alternator Installed Continued 9X-8877 BOLT 4
9X-8880 BOLT 1
100-3725 BELT 1
130-5195 PULLEY AS 1
130-5199 SHAFT 1
130-7921 GEAR 1
189-5178 SEAL-LIP TYPE 1
196-6041 SUPPORT 1
196-6044 COVER AS 1 =
10. Rear/Left Side Required for all engines with a TPS Model
Harness Assembly Turbocharger 213-6305 HARNESS AS 1
Required for all engines with a VTC Model
Turbocharger 219-9942 HARNESS AS 1 =
11. Hydrax Actuator Kit Required if engine does not have Hydrax
Actuators 234-9651 Upgrade Kit to Hydrax Actuators 1 =

ADEM III Basic Kit-3606 Required for the upgrade 234-9495 Upgrade Kit - ADEM III 1 =

Grand Total:

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Appendix D

“G3608 Selection Table” This is for Caterpillar Internal and Dealer Use Only

Follow the 3 steps below to configure a ADEM III upgrade kit for a G3608 engine.

Requirements of the installation in preparation for the upgrade:

1. New Software may be required for the ADEM III system to match the customer's gas and engine configuration.
To determine if new software is available for ADEM III system for your site requirements, submit the "ADEM III Software Request
2. If new software is required submit the "Performance Engineer Request Form" to schedule the software mapping dates.
3. Approximate Site Downtime: 3.5 days for ADEM III hardware installation, 3.5 days for Hydrax Upgrade (if Required), 5 days for
Engine Software Mapping (if Required)
4. The engine must be tuned(I.E. Emissions Tuning(needle valve adj & BTU potentiometer),Valve Adjustments, Check Valve & Spark
Plug Service) and running correctly before the upgrade is started.

STEP 1: Review the comment below to determine what components you need to order to upgrade to the ADEM III Control System

Guidance:
1. You must choose one of the three Remote Harnesses
2. If you do not have 152-0807 Thermocouples on the engine you will need to order the 152-0807 thermocouples
3. If you do not have the 188-4926 Connector (Combustion Senor), then you will need to order all the parts in the 188-4926 Section
4. If you do not have the 211-6713 pressure module, then you will need to order one of these
5. If the customer uses the Cat Communication Module, then you will need to order a new one. Note: The control system interfaced
should be reviewed to determine what customer connections would change. See the CCM Special Instruction for more information
6. If new software needs to be developed onsite, then a Caterpillar Performance Engineer is required and must be paid for by the
dealer.
7. If Site CSA approval is required, then a CSA surveyor needs to approve the final installation of the Caterpillar CSA approved
components. These expenses must be paid for by the dealer.
8. Engine must have new Spark Plugs, if Cat has to develop new software onsite
9. Cover Group vs Alternator Drive Group: If the engine has a Cat Alternator then the Lines, Guard, and Drive groups are required,
otherwise the cover group should be order.
10. Determine which Turbocharger is on the engine and then choose the appropriate harness assembly.
11. If the engines does not have Hydrax Actuators, then the Hydrax Upgrade kit must be ordered

STEP 2: Write the Dealer Net or Suggested Consumer List Prices to the right of the table

STEP 3: Sum all prices at the bottom of the worksheet

IRM\302271234.DOC
 ENG03-01 19
Appendix D

Part
Question Comments Numbers Description Quantity Price
1. Remote Harness - 100 100 Foot Harness- (to MIDS Panel) 206-6544 HARNESS AS (100 FOOT LENGTH)) 1
1. Remote Harness - 20 20 Foot Harness- (to MIDS Panel) 206-6543 HARNESS AS (20 FOOT LENGTH)) 1
1. Remote Harness - 50 50 Foot Harness- (to MIDS Panel) 205-3584 HARNESS AS (50 FOOT LENGTH)) 1 =
Do Not need if you have 152-0807
2. 152-0807 Thermocouple 152-0807 SENSOR GP-TEMP 8 =
3. 188-4926 Do Not need if you have 188-4926 Connector 125-5356 DISC-INSULATOR 16
136-4605 EXTENSION AS 8
159-3219 SENSOR-COMB 8
188-4926 CONNECTOR AS 8
6V-5050 SEAL-O-RING 8 =
Do Not need if you have 162-7290 or 211-
4. Pressure Module 6713 Pressure Module 211-6713 CONT GP -E 1 =
5. CCM If you need the Cat Communication Module 188-3080 Cat Communication Module 1 =
6. Cat Performance $1200 per day, plus travel expenses
Engineer (estimate) n/a Cat Performance Engineer 1 7000 est =
$900 USD per day + Travel Expenses-
7. CSA Surveyor (estimate) Contact CSA Surveyor n/a CSA Surveyor 1 3500 est =
Engine must have new Spark Plugs, if Cat
8. Spark Plugs - Needed for has to develop new software onsite 194-8518 PLUG-SPARK 8 =
9. Cover Group Cover Group Required if you do not have an 0L-1352 BOLT 2
alternator installed 0S-1588 BOLT 4
1W-7117 DOWEL-HOLLOW 2
206-7468 PLATE 1
3B-1915 BOLT 6
3V-3308 WASHER-HARD 12
4F-4585 PLUG-CORE 1
6V-5060 SEAL-O RING 1
5P-9147 SEAL-O RING 1
196-6039 HOUSING 1
206-7469 COVER 1 =
9. Alternator Drive Groups Altenator Lines groups for oil is required for 6V-5049 SEAL-O-RING 1
the Cat alternator 5H-0275 NUT-FITTING 1
030-7942 ELBOW 1
030-7962 ELBOW 1
030-8145 REDUCER-FLARED 1
061-8284 TEE-SWIVEL 1
196-6042 TUBE AS 1
Altenator Guard Gp Required if you have a 0S-0509 BOLT 4
Cat Alternator Installed 0S-1590 BOLT 3
1B-4971 SPACER 3
3V-3308 WASHER-HARD 7
7E-5639 SPACER 2
138-6804 GUARD AS-ALT 1
221-2542 GUARD AS 1
221-2543 GUARD AS-BELT 1
232-3759 BOSS-WELD 2
Altenator Drive Gp Required if you have a Cat 3B-1915 BOLT 6
Alternator Installed 3V-3308 WASHER-HARD 10
5P-8245 WASHER-HARD 8
5P-9147 SEAL-O RING 1
0S-1587 BOLT 4
1A-5964 BOLT 1
1D-4706 BOLT 3
1F-7958 NUT-FULL 2
1S-4698 ROD 1
4K-0367 NUT-FULL 2
5P-8247 WASHER-HARD 3

IRM\302271234.DOC
 ENG03-01 20
Appendix D

Part
Question Comments Numbers Description Quantity Price
Altenator Drive Gp Required if you have a Cat 8T-9392 BOLT 1
Alternator Installed Continued 9X-8877 BOLT 4
9X-8880 BOLT 1
100-3725 BELT 1
130-5195 PULLEY AS 1
130-5199 SHAFT 1
130-7921 GEAR 1
189-5178 SEAL-LIP TYPE 1
196-6041 SUPPORT 1
196-6044 COVER AS 1 =
10. Rear/Left Side Harness This harness is required for all engines with a
Assembly TPS Model Turbocharger 213-6305 HARNESS AS 1
This harness is required for all engines with a
VTC Model Turbocharger (e.g. 4P6747 or
7C0428) 219-9942 HARNESS AS 1 =
11. Hydrax Actuator Kit Required if engine does not have Hydrax
Actuators 234-9652 Upgrade Kit to Hydrax Actuators 1 =

ADEM III Basic Kit-3608 Required for the upgrade 235-5744 Upgrade Kit - ADEM III 1 =
Grand Total:

IRM\302271234.DOC
 ENG03-01 21
Appendix E

“G3612 Selection Table” This is for Caterpillar Internal and Dealer Use Only

Follow the 3 steps below to configure a ADEM III upgrade kit for a G3612 engine.

Requirements of the installation in preparation for the upgrade:

1. New Software may be required for the ADEM III system to match the customer's gas and engine configuration.
To determine if new software is available for ADEM III system for your site requirements, submit the "ADEM III Software Request Form**
2. If new software is required submit the "Performance Engineer Request Form" to schedule the software mapping dates.
3. Approximate Site Downtime: 3.5 days for ADEM III hardware installation, 3.5 days for Hydrax Upgrade (if Required), 5 days for Engine
Software Mapping (if Required)
4. The engine must be tuned(I.E. Emissions Tuning(needle valve adj & BTU potentiometer),Valve Adjustments, Check Valve & Spark
Plug Service) and running correctly before the upgrade is started.

STEP 1:Review the comment below to determine what components you need to order to upgrade to the ADEM III Control System

Guidance:
1. You must choose one of the three Remote Harnesses
2. If you do not have 152-0807 Thermocouples on the engine you will need to order the 152-0807 thermocouples
3. If you do not have the 188-4926 Connector (Combustion Senor), then you will need to order all the parts in the 188-4926 Section
4. If you do not have the 211-6713 pressure module, then you will need to order one of these
5. If the customer uses the Cat Communication Module, then you will need to order a new one. Note: The control system interfaced
should be reviewed to determine what customer connections would change. See the CCM Special Instruction for more information
6. If new software needs to be developed onsite, then a Caterpillar Performance Engineer is required and must be paid for by the dealer.

7. If Site CSA approval is required, then a CSA surveyor needs to approve the final installation of the Caterpillar CSA approved
components. These expenses must be paid for by the dealer.
8. Engine must have new Spark Plugs, if Cat has to develop new software onsite
9. If the engines does not have Hydrax Actuators, then the Hydrax Upgrade kit must be ordered

STEP 2: Write the Dealer Net or Suggested Consumer List Prices to the right of the table

STEP 3: Sum all prices at the bottom of the worksheet

IRM\302271234.DOC
 ENG03-01 22
Appendix E

Part
Question Comments Number Description Quantity Price
1. Remote Harness-100 100 Foot Harness- (Engine to MIDS Panel) 206-6544 HARNESS AS (100 FOOT LENGTH)) 1
1. Remote Harness-20 20 Foot Harness- (Engine to MIDS Panel) 206-6543 HARNESS AS (20 FOOT LENGTH)) 1
1. Remote Harness-50 50 Foot Harness- (Engine to MIDS Panel) 205-3584 HARNESS AS (50 FOOT LENGTH)) 1 =
Do Not need if you have 152-0807
2. 152-0807 Thermocouple 152-0807 SENSOR GP-TEMP 12 =
3. 188-4926 Do Not need if you have 188-4926 125-5356 DISC-INSULATOR 24
Connector 136-4605 EXTENSION AS 12
159-3219 SENSOR-COMB 12
188-4926 CONNECTOR AS 12
6V-5050 SEAL-O-RING 12 =
Do Not need if you have 162-7290 or 211-
4. Pressure Module 6713 Pressure Module 211-6713 CONT GP -E 1 =

5. CCM If you need the Cat Communication Module 188-3080 Cat Communication Module 1 =
6. Cat Performance $1200 per day, plus travel expenses
Engineer (estimate) n/a Cat Performance Engineer 1 7000 est =
$900 USD per day + Travel Expenses-
7. CSA Surveyor (estimate) Contact CSA Surveyor n/a CSA Surveyor 1 3500 est =
Engine must have new Spark Plugs, if Cat
8. Spark Plugs has to develop new software onsite 194-8518 Spark Plugs 12 =
9. Hydrax Actuator Kit Required if engine does not have Hydrax
Actuators 234-9654 Upgrade Kit to Hydrax Actuators 1 =

ADEM III Basic Kit-3612 Required for the upgrade 233-9472 Upgrade Kit - ADEM III 1 =
Grand Total:

IRM\302271234.DOC
 ENG03-01 23
Appendix F

“G3616 Selection Table” This is for Caterpillar Internal and Dealer Use Only

Follow the 3 steps below to configure a ADEM III upgrade kit for a G3616 engine.

Requirements of the installation in preparation for the upgrade:

1. New Software may be required for the ADEM III system to match the customer's gas and engine configuration.
To determine if new software is available for ADEM III system for your site requirements, submit the "ADEM III Software Request
2. If new software is required submit the "Performance Engineer Request Form" to schedule the software mapping dates.
3. Approximate Site Downtime: 3.5 days for ADEM III hardware installation, 3.5 days for Hydrax Upgrade (if Required), 5 days for
Engine Software Mapping (if Required)
4. The engine must be tuned(I.E. Emissions Tuning(needle valve adj & BTU potentiometer),Valve Adjustments, Check Valve & Spark
Plug Service) and running correctly before the upgrade is started.

STEP 1:Review the comment below to determine what components you need to order to upgrade to the ADEM III Control System

Guidance:
1. You must choose one of the three Remote Harnesses
2. If you do not have 152-0807 Thermocouples on the engine you will need to order the 152-0807 thermocouples
3. If you do not have the 188-4926 Connector (Combustion Sensor), then you will need to order all the parts in the 188-4926 Section

4. If you do not have the 211-6713 pressure module, then you will need to order one of these
5. If the customer uses the Cat Communication Module, then you will need to order a new one. Note: The control system interfaced
should be reviewed to determine what customer connections would change. See the CCM Special Instruction for more information

6. If new software needs to be developed onsite, then a Caterpillar Performance Engineer is required and must be paid for by the
dealer.
7. If Site CSA approval is required, then a CSA surveyor needs to approve the final installation of the Caterpillar CSA approved
components. These expenses must be paid for by the dealer.
8. Engine must have new Spark Plugs, if Cat has to develop new software onsite
9. If the engines does not have Hydrax Actuators, then the Hydrax Upgrade kit must be ordered

STEP 2: Write the Dealer Net or Suggested Consumer List Prices to the right of the table

STEP 3: Sum all prices at the bottom of the worksheet

IRM\302271234.DOC
 ENG03-01 24
Appendix F

Part
Question Comments Number Description Quantity Price
1. Remote Harness - 100 100 Foot Harness- (Engine to MIDS Panel) 206-6544 HARNESS AS (100 FOOT LENGTH)) 1
1. Remote Harness - 20 20 Foot Harness- (Engine to MIDS Panel) 206-6543 HARNESS AS (20 FOOT LENGTH)) 1
1. Remote Harness - 50 50 Foot Harness- (Engine to MIDS Panel) 205-3584 HARNESS AS (50 FOOT LENGTH)) 1 =
Do Not need if you have 152-0807
2. 152-0807 Thermocouple 152-0807 SENSOR GP-TEMP 16 =
3. 188-4926 Do Not need if you have 188-4926 125-5356 DISC-INSULATOR 32
Connector 136-4605 EXTENSION AS 16
159-3219 SENSOR-COMB 16
188-4926 CONNECTOR AS 16
6V-5050 SEAL-O-RING 16 =
Do Not need if you have 162-7290 or 211-
4. Pressure Module 6713 Pressure Module 211-6713 CONT GP -E 1 =

5. CCM If you need the Cat Communication Module 188-3080 Cat Communication Module 1 =
6. Cat Performance $1200 per day, plus travel expenses
Engineer (estimate) n/a Cat Performance Engineer 1 7000 est =
$900 USD per day + Travel Expenses-
7. CSA Surveyor (estimate) Contact CSA Surveyor n/a CSA Surveyor 1 3500 est =
Engine must have new Spark Plugs, if Cat
8. Spark Plugs has to develop new software onsite 194-8518 Spark Plugs 16 =
9. Hydrax Actuator Kit Required if engine does not have Hydrax
Actuators 234-9657 Upgrade Kit to Hydrax Actuators 1 =
ADEM III Basic Kit-3616 Required for the upgrade 236-7281 Upgrade Kit - ADEM III 1 =
Grand Total:

IRM\302271234.DOC