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2001/05/25 Conversion From 3161 Marine Governor To 723PLUS Digital Speed Control With Ug ACTUATOR{1264} (REHS1117-00)
Introduction
New electronic controls, when used in conjunction with hydra-electrical actuators, can provide many advantages over 3161 governors:
better reliability
These advantages result in lower operating costs to the customer. Many requests for upgrade information have been received by Caterpillar Large
Engine Center. The purpose of this article is to provide the information necessary to perform a successful upgrade from a marine 3161 governor to
a 723PLUS with a UG actuator.
Reference: Systems Operation Testing and Adjusting, SENR3028, "Caterpillar 3161 Governor"
Reference: Disassembly and Assembly, SENR3594, "3612 and 3616 Engines", "Governor Drive - Assemble"
Reference: Disassembly and Assembly, SENR3600, "3606 and 3608 Engines", "Disassemble and Assemble Governor Drive"
Required Parts
Parts Required for the Conversion of Either In-line Engines or Vee Engines
Part Number Description Quantity
4W-3938 Gasket (for Universal Governor (UG) Actuator) 1
5S-7433 Plug (for Mag Pickup) 2
8L-4171 Speed Sensor (for Mag Pickup) 2
116-4592 Connector Plug (for UG Actuator) 1
138-4139 UG Actuator 1
140-0996 Transmitter - 4 Bar Transducer (for throttle and boost pressure sensors) 2
165-4615 Governor Control (723PLUS Digital Speed Control 1
Table 1
Table 2
( 1 )
Part required to convert 2W-1243 Governor Drive Pinion Assembly to 1W-0607 Governor Drive Pinion Assembly
Table 3
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Table 4
Mounting Instructions
Illustration 1 g00808317
723PLUS Digital Speed Control
The 165-4615 Governor Control (723PLUS Digital Speed Control) should be mounted in a waterproof panel. Refer to Service Manual, RENR2228,
"723PLUS Digital Speed Control", "Installation" for location considerations.
The two 140-0996 Transmitters (4 Bar Transducer) can be mounted in the following locations:
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The air lines that are currently connected to the 3161 governor will need to be connected to the two 140-0996 Transmitters . The two 140-0996
Transmitters will then need to be wired to the 723PLUS. If the distance from the 3161 governor to the new panel is less than 6.1 m (20 ft), mount
the transmitters in or on the cabinet and reroute the air lines. If the distance from the 3161 governor to the new panel is greater than 6.1 m (20 ft),
mount the transmitters near the existing 3161. After the transmitters have been mounted, route the wires to the 723PLUS panel. For the
transmitter's dimensions, refer to Illustration 2.
Note: The 140-0996 Transmitters have a .25 inch BSP thread port (female). A 6V-3522 Flared Fitting can be used to adapt the .25 inch BSP
female thread port to a .25 inch 37° flared male fitting. When the 6V-3522 Flared Fitting is used, the 140-0996 Transmitters will be compatible with
standard instrument line fittings. A 6V-3522 Flared Fitting requires a 6V-0405 Seal .
Illustration 2 g00805849
140-0996 Transmitter
Mount the two 8L-4171 Speed Sensors on the engine. Refer to Illustration 3 and Illustration 4. If required, a 7E-1512 Plate Assembly (2) can be
used to mount the 8L-4171 Speed Sensors . This plate has holes for four speed sensors.
Illustration 3 g00805748
8L-4171 Speed Sensor
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Illustration 4 g00805945
8L-4171 Speed Sensor Installation
Panel Front
There are numerous lamps and switches that are used in converting the 3161 Governor to the 723PLUS. These lamps and switches are shown in
Table 5 and in Table 6. The 723PLUS accommodates the needs that are found in most marine applications. The 723PLUS provides all of the
features that are present on the 3161 Governor.
Note: The 723PLUS is very versatile. Additional configurations are available. Refer to Service Manual, RENR2228 for additional information.
Switches Used in the 3161 Governor to 723PLUS Digital Speed Control Conversion
Switch Name Switch Description Switch Part Number Mounting Base Part Number Block Part Number
Local/Remote 2 Position Maintained 3P3T 131-0023 131-0021 131-0028 (3 each)
Idle/Rated 2 Position Maintained SPST 131-0023 131-0021 131-0028
3 Position, Momentary SPST
Lower/Raise 131-026 131-0021 131-0028 (2 each)
Center Off, Momentary SPST
Alarm Reset 2 Position Maintained SPST 132-7367 131-0021 131-0028
Table 5
Lamps Used in the 3161 Governor to 723PLUS Digital Speed Control Conversion
Lamp Name Lamp Description Lamp Base Part Number Lamp Lens Part Number
Status Lamp 24 DCV lamp with Amber Lens 116-9720 116-9718
Alarm Lamp 24 DCV lamp with Amber Lens 116-9720 116-9718
Power Lamp 24 DCV lamp with Green Lens 116-9720 116-9719
Table 6
Status Lamp
The Status Lamp indicates that one of the enabled items in the following list is in the indicated condition:
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LOAD SWITCH
Note: One or more of these indicators must be enabled for the indicator lamp to work. Refer to Service Manual, RENR2228 for additional
information.
Alarm Lamp
The Alarm Lamp indicates that one of the enabled items in the following list is in the indicated condition:
Note: One or more of these indicators must be enabled for the indicator lamp to work. Refer to Service Manual, RENR2228 for additional
information.
Local/Remote Switch
This switch is used to switch the speed control between the external speed reference and the Raise/Lower Switch that is located in the panel. The
external speed references provided by the 4 mA - 20 mA transducer that is connected to the air throttle line.
If only remote control is needed, this switch may be eliminated along with the Raise/Lower Switch.
Idle/Rated Switch
The IDLE position of the Idle/Rated Switch forces the 723PLUS Digital Speed Control to the idle RPM. The idle RPM is programmed into the "Idle
Speed" setting in the Speed Setting Menu of the 723PLUS. The idle position of this switch also disables the remote speed reference and the
Raise/Lower switch.
The RATED position of the Idle/Rated Switch forces the 723PLUS Digital Speed Control into the RATED SPEED parameter in the CFIG menu of
the 723PLUS.
Note: Anytime this switch changes states, any "Accel Ramp Time" or "Decel Ramp Time" that are programmed into the 723PLUS will be effective.
Note: When the Idle/Rated Switch is switched from IDLE to RATED, the engine speed will go from idle speed to rated speed. To eliminate this
problem, program "Rated Speed" in the CFIG Speed Menu to equal the "Idle Speed" setting in the Speed Setting Menu.
As an option, the Idle/Rated Switch may be eliminated. Eliminate the Idle/Rated Switch by connecting a jumper wire between 723PLUS terminal 39
and 723PLUS terminal 35. This will effectively leave the 723PLUS in the rated speed mode at all times.
Raise/Lower Switch
The Lower position of the Raise/Lower Switch allows the speed reference to lower until the lower limit is reached. The speed reference will lower at
a rate that is determined by the "Lower Speed Rate" setting. The "Lower Speed Rate" setting is located in the Speed Setting Menu of the
723PLUS.
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The Raise position of the Raise/Lower Switch allows the speed reference to raise until the upper limit is reached. The speed reference will raise at
a rate that is determined by the "Raise Speed Rate" setting. The "Raise Speed Rate" setting is located in the Speed Setting Menu of the 723PLUS.
In order for the Raise/Lower Switch to operate, the Local/Remote switch must be in the Remote position. If the Local/Remote switch is not used,
the Raise/Lower Switch is not needed.
Alarm Reset
This push button switch will reset any alarm conditions that have cleared. Any continuing alarm condition will not be reset.
723PLUS Terminals
Wiring Instructions
When using these instructions, refer to specifications that are listed in Table 7.
Wiring Specifications
Component Specification
Wire 14 AWG or 16 AWG
Cable Shielded
Insulation Rated for marine applications
Table 7
Some 723PLUS will have several wires that are attached to the same terminal. When terminals with multiple connections are necessary, terminal
strips are recommended. The following wiring instructions are for implementation of basic marine applications. For additional information, refer to
Service Manual, RENR2228.
2
Alarm Lamp (-)
3 No Connection
4 No Connection
5 Jumper to 723PLUS Terminal 1
6 Status Lamp (+)
7 Jumper to 723PLUS Terminal 1
8 Alarm Lamp (+)
9 No Connection
10 No Connection
11 Speed Sensor 1 Pin B
12 Speed Sensor 1 Pin A
13 Speed Sensor 2 Pin B
14 Speed Sensor 2 Pin A
15 No Connection
16 No Connection
17 No Connection
18 No Connection
19 Governor Actuator Pin B
20 Governor Actuator Pin A
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21 No Connection
22 No Connection
23 No Connection
24 No Connection
25 No Connection
26 No Connection
27 No Connection
28 No Connection
29 No Connection
30 Alarm Reset (N.O.)
31 No Connection
32 No Connection
Raise Lower Switch (N.O.)
33
Local/Remote (N.O.)
Idle/Rated (N.O.)
35
Local/Remote (N.O.)
36 Shutdown Relay (N.O. for ETS, N.C. for ETR)
37 Jumper to 723PLUS Terminal 38
38 Jumper to 723PLUS Terminal 37
Idle/Rated Switch (common)
Table 8
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Illustration 5 g00808615
723PLUS Terminal Strips
Power
Wire the 24 VDC power supply to 723PLUS terminal 1 (+) and 723PLUS terminal 2 (-). Ensure that the power source is protected with fuses or with
circuit breakers. At start-up, the 723PLUS draws approximately 7 amperes. The 723PLUS draws less than 2 amperes during normal operation.
Lamps
Wire the Status Lamp to 723PLUS terminal 2 and 723PLUS terminal 6. Use a jumper wire to connect 723PLUS terminal 5 to 723PLUS terminal 1.
Wire the Alarm Lamp to 723PLUS terminal 2 and 723PLUS terminal 8. Use a jumper wire to connect 723PLUS terminal 7 to 723PLUS terminal 1.
Discrete Input
The internal power supply of the 723PLUS is used to power up the discrete inputs. To utilize the internal power supply, use a jumper wire to
connect 723PLUS terminal 37 to 723PLUS terminal 38. Connect 723PLUS terminal 39 to the common connections of the following switches:
Idle/Rated switch
Install the Idle/Rated switch. Connect the normally open (N.O.) contact of the Idle/Rated switch to 723PLUS terminal 35. When the N.O. contact is
open, the corresponding switch position should be labelled "Idle". When the N.O. contact is closed, the corresponding switch position should be
labelled "Rated".
Install the Raise/Lower switch. Connect one N.O. contact of the Raise/Lower switch to terminal 34 of the 723PLUS. Connect another N.O. contact
of the Raise/Lower switch to 723PLUS terminal 33. When the N.O. contact that is connected to 723PLUS terminal 34 is closed, label the
corresponding switch position "Lower Speed". When the Raise/Lower switch is operated in the opposite direction, the N.O. contact that is
connected to 723PLUS terminal 33 should close. Label this switch position "Raise Speed".
Install the Alarm Reset switch. Connect the N.O. contact of the Alarm Reset switch to 723PLUS terminal 30.
Install the Local/Remote switch. Install the first N.O. Local/Remote switch contact to 723PLUS terminal 35. Install the second N.O. Local/Remote
switch contact to 723PLUS terminal 34. Install the third N.O. Local/Remote switch contact to 723PLUS terminal 33. When the N.O. Local/Remote
switch contacts are open, label the corresponding switch position "Local". When the N.O. Local/Remote switch contacts are closed, label the
corresponding switch position "Remote".
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Shutdown Circuit
In order for the engine to be shutdown, the existing protection system must be wired to the 723PLUS. Mount a relay in the 723PLUS panel. Label
this relay "Shutdown Relay". The two wires that currently go to the 3161 shutdown solenoid must be extended to the shutdown relay's coil. Connect
the common of the shutdown relay contact to 723PLUS terminal 39.
If the existing 3161 is an energized-to-shutdown version, connect the Shutdown Relay's N.O. contact to 723PLUS terminal 36.
If the existing 3161 is an energized-to-run version, connect the Shutdown Relay's N.C. contact to 723PLUS terminal 36.
Relays Used in the 3161 Governor to 723PLUS Digital Speed Control Conversion
Relay Part Number Relay Description Quantity
179-8829 Relay 2PDT 1
179-8828 Relay Base 1
Table 9
Illustration 6 g00793751
179-8829 Relay
Transmitter
Remove the throttle air line from the 3161 governor. Connect this air line to one of the transmitters. Connect this transmitter's positive terminal to
723PLUS terminal 52. Connect this transmitter's negative terminal to 723PLUS terminal 2. Install a jumper wire from 723PLUS terminal 1 to
723PLUS terminal 51 and 723PLUS terminal 50. The transmitter that is connected to the throttle air line should be labelled "Remote Speed
Reference".
Remove the Inlet Manifold (Boost) line from the 3161 governor. Connect the throttle air line that was removed from the 3161 governor to the
second transmitter. Connect the transmitter's positive terminal to 723PLUS terminal 49. Connect the transmitter's negative terminal to 723PLUS
terminal 2. Install a jumper wire from 723PLUS terminal 1 to 723PLUS terminal 48 and 723PLUS terminal 47. The transmitter that is connected to
the Inlet Manifold (Boost) line should be labelled "Air Manifold Sensor".
Speed Sensors
Speed Sensor 1
Connect a wire from 723PLUS terminal 11 to connector Pin B of Speed Sensor 1. Connect a wire from 723PLUS terminal 12 to connector Pin A of
Speed Sensor 1. Connect one end of the shield to the ground stud on the 723PLUS. Do not connect the shield on the speed sensor end.
Speed Sensor 2
Connect a wire from 723PLUS terminal 13 to connector Pin B of Speed Sensor 2. Connect a second wire from 723PLUS terminal 14 to connector
Pin A of Speed Sensor 2. Connect one end of the shield to the ground stud on the 723PLUS. Do not connect the shield on the speed sensor end.
Note: When only one speed sensor is used, connect this sensor as Speed Sensor 1.
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Transmitter Calibration/Verification
Perform the following steps in order to calibrate each transmitter. The following steps can also be used to check the calibration of each transmitter.
Note: On reverse rotating engines, the pump rotation needs to be changed. For information on changing the direction of rotation and governor
linkage adjustment, refer to Service Manual, RENR1338, "UG Actuator". For information regarding Pinion and Gear assembly, refer to Disassembly
and Assembly, SENR3594, "3612 and 3616 Engines", "Governor Drive - Assemble", and Disassembly and Assembly, SENR3600, "3606 and 3608
Engines", "Disassemble and Assemble Governor Drive".
Configuration Settings
Config Menu Setting
Use 2nd Dynamics = false
CFIG Options
Use Torsional Filter = false
Rated Speed RPM = Rated Speed of Engine
ASPD #1 Teeth = 255
ASPD #1 Max Freq (Hz) = 5100
CFIG Speed Control ASPD #2 Teeth = 255
ASPD #2 Max Freq (Hz) = 5100
DSPD #1 Teeth = 255
DSPD #2 Teeth = 255
Set AI Units Remote SR @ 20 mA = HI Idle RPM
Table 10
https://3600.cat.com
Press "Enter".
2. Enter your login and enter your password. If you do not have a login, request a login. You are now at the Caterpillar 3600 Web Site.
3. Click on "Service Information". You are now at the "3600 Diesel Service Information" page.
4. Click on "Woodward Watch Window Software Download". You are now at the "download page".
6. When the download is complete, execute the file that was downloaded. This will install the software on your computer.
For additional information on Watch Windows Standard Software, refer to Service Manual, RENR2228, "723PLUS Digital Speed Control".
723PLUS Startup
The engine can be started only when the following jobs have been completed.
wiring completed
transmitters calibrated
UG actuator installed
After the default 723PLUS settings and the initial settings have been made, the engine should start and run at idle. However, the engine will not be
optimized. The engine will likely create smoke on start-up, acceleration, and load changes. The engine will likely experience poor transient
response. Dynamic tuning of the various 723PLUS settings must be done in order to eliminate any performance problems. For start-up information
and assistance in adjusting the 723PLUS dynamic parameters, refer to Service Manual, RENR2228.
Note: The performance parameters of the 723PLUS must be matched to the engine configuration. Trial and error is the most effective method of
determining the optimum setting for a specific installation.
PPS-000A679B
2022/07/11
07:36:34+03:00
i01547500
Caterpillar:
Confidential Green
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