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7/11/22, 10:37 AM SIS 2.

2001/05/25 Conversion From 3161 Marine Governor To 723PLUS Digital Speed Control With Ug ACTUATOR{1264} (REHS1117-00)

SMCS - 1264 i01547500 


Engine:
3606 (S/N: 8RB1-UP)
3608 (S/N: 6MC1-UP)
3612 (S/N: 9RC1-UP)
3616 (S/N: 1PD1-UP)

Introduction
New electronic controls, when used in conjunction with hydra-electrical actuators, can provide many advantages over 3161 governors:

superior engine control

longer useful life

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: Service Manual, RENR2228, "723PLUS Digital Speed Control"

Reference: Systems Operation Testing and Adjusting, SENR3028, "Caterpillar 3161 Governor"

Reference: Service Manual, RENR1338, "UG Actuator"

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

Additional Parts Required for Conversion of In-line Engines    


Part Number     Description     Quantity    
0T-0573     Bolt (for UG Actuator)     4  
9Y-1027     Governor Drive Pinion (1)     1  
9Y-1026     Bevel Gear     1  

Table 2
( 1 )
Part required to convert 2W-1243 Governor Drive Pinion Assembly to 1W-0607 Governor Drive Pinion Assembly

Additional Parts Required for the Conversion of In-line Engines    


Part Number     Description     Quantity    
7W-3596     Pinion     1  
137-1382     Gear     1  

Table 3

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Miscellaneous Parts Needed for Terminal Strip    


Part Number     Description     Quantity    
114-1142     Circuit Breaker     1  
9X-9615     Single Terminal     17    
125-9969     Rail     1  
9X-9616     End Cover     2  
9X-9675     End Bracket     2  
3E-5503     Fixed Bridge Bar     2  
109-6539     Separator Plate     2  
146-6775     Terminal Marker     4  

Table 4

Mounting Instructions

Illustration 1 g00808317
723PLUS Digital Speed Control

(1) Ground stud

(A) 415.8 mm (16.37 inch)

(B) 314.2 mm (12.37 inch)

(C) 277.6 mm (10.93 inch)

(D) 50.8 mm (2.00 inch)

(E) 285.8 mm (11.25 inch)

(F) 50.8 mm (2.00 inch)

(G) 196.3 mm (7.73 inch)

(H) 365 mm (14.37 inch)

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:

in the same panel as the 723PLUS

on the back or the side of the 723PLUS

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near the location of the 3161 governor that is being replaced

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

(2) .25 inch BSP thread port (female)

(I) 116 mm (4.56 inch)

(J) 68 mm (2.68 inch)

(K) 103 mm (4.06 inch)

(L) 115 mm (4.53 inch)

(M) 68 mm (2.7 inch)

(N) 120 mm (4.7 inch)

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

(O) 19 mm (0.75 inch)

(P) 91 mm (3.6 inch)

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Illustration 4 g00805945
8L-4171 Speed Sensor Installation

(3) 7E-1512 Plate Assembly

(4) 8L-4171 Speed Sensor

(Q) Air gap

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

Operation of Controls and Indicators


Power Lamp
The Power Lamp indicates that power is being supplied to the panel.

Status Lamp
The Status Lamp indicates that one of the enabled items in the following list is in the indicated condition:

ON MAX LIMIT (recommended to be enabled)

ON AIR PRESSURE LIMIT (recommended to be enabled)

ON TORSIONAL LIMIT (recommended to be enabled)

ON TORQUE LIMIT (recommended to be enabled)

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ACTUATOR SHUTDOWN (recommended to be enabled)

SPEED SWITCH (recommended to be enabled)

OIL TRANSMITTER FAULT

WATER TRANSMITTER FAULT

AIR TRANSMITTER FAULT

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:

SPEED #1 FAIL (recommended to be enabled)

SPEED #2 FAIL (recommended to be enabled)

SPD #1 & SPD #2 FAIL (recommended to be enabled)

REMOTE SPEED REFERENCE FAIL (recommended to be enabled)

LOW OIL PRESSURE ALARM

HIGH FUEL DEMAND ALARM

HIGH SPEED ALARM

LOW WATER PRESSURE ALARM

HIGH TORSIONAL LEVEL

SPEED SWITCH ALARM

LOAD SWITCH ALARM

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.

723PLUS Wiring Table    

723PLUS Terminal     Connected To    


24 DCV (+)

Jumper to 723PLUS Terminal 5


Jumper to 723PLUS Terminal 7

1   Jumper to 723PLUS Terminal 47

Jumper to 723PLUS Terminal 48

Jumper to 723PLUS Terminal 50

Jumper to 723PLUS Terminal 51  


 
24 DCV (-)

Power Lamp (-)


Status Lamp (-)

2  
Alarm Lamp (-)

Remote Speed Reference


(-)
Air Manifold Sensor (-)    

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.)    

Raise Lower Switch (N.O.)


34    
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)

Raise Lower Switch (common of both sections)


39     Local/Remote switch (common of both sections)

Alarm Reset (common)

Shutdown Relay (common)


   
40     No Connection    
41     No Connection    
42     No Connection    
43     No Connection    
44     No Connection    
45     No Connection    
46     No Connection    
47     Jumper to 723PLUS Terminal 1    
48     Jumper to 723PLUS Terminal 1    
49     Air Manifold Sensor (+)    
50     Jumper to 723PLUS Terminal 1    
51     Jumper to 723PLUS Terminal 1    
52     Remote Speed Reference (+)    
Ground Stud     All shields should be terminated at this point only    

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.

Wire the Power Lamp to 723PLUS terminal 1 and 723PLUS terminal 2.

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

Raise/Lower Speed switch (both sections)

Alarm Reset switch

Local/Remote switch (all three sections)

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.

138-4139 Governor Actuators


Connect a wire from 723PLUS terminal 19 to the Governor Actuator connector (Pin A). Connect a second wire from 723PLUS terminal 20 to the
Governor Actuator connector (Pin B). Connect one end of the shield to the ground stud on the 723PLUS. Do not connect the shield on the governor
actuator end.

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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.

1. Install an ammeter in series with the transmitter that is going to be calibrated.

2. Ensure that no pressure is applied to the transmitter.

3. Adjust the zero control for 4 milliamperes.

4. Apply 413.7 kPa (60 psi) of air pressure to the transmitter.

5. Adjust the span control for 20 milliamperes.

6. Repeat Step 2 through Step 5 until no further adjustment is needed.

Universal Governor (UG) Actuator Installation


Remove the 3161 governor. Determine if the UG actuator is used in an in-line application or in a vee application. Install the correct pinion/gear
assembly. Install the UG actuator. Adjust the linkage. Fill the actuator with governor oil (1.42 L (1.5 qt)). The recommended oil is 136-9642
Governor Oil .

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".

Initial 723PLUS Settings


Before starting, the following settings must be programmed into the 723PLUS. These settings can be done with a 140-2304 Governor Electronic
Control Programmer or with Watch Windows Standard Software. The 140-2304 Governor Electronic Control Programmer is the same programmer
that is used on the 721 governor.

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

Watch Windows Standard Software


Watch Windows Standard Software is a diagnostic tool and a service tool. This software will work with the 165-4615 Governor Control . Watch
Windows Standard Software is available as a free download from the Caterpillar 3600 Web Site. To download Watch Windows Standard Software,
perform the following steps.

1. Type in the following URL:

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".

5. Follow the downloading instructions on the "download page".


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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

initial settings made

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

© 2022 Caterpillar Inc.


Caterpillar:

Confidential Green

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