Installation And Initial Start Up Procedures For G3300 And G3400 Engines{1000} Caterpillar

Installation And Initial Start Up Procedures For G3300 And G3400 Engines{1000}

Usage:

Engines:: G3304 (S/N: 37Y); G3306 (S/N: 07Y); G3406 (S/N: 4FD; 1RK); G3408 (S/N: 6NB; 6FW); G3408B (S/N: 6RJ); G3408C (S/N: 3WR; 8YR); G3412 (S/N: 7DB; 3NK; 8LW); G3412C (S/N: 6ZM; 9RR)

Introduction

This Special Instruction includes the installation procedures and the start up procedures for G3300 and G3400 engines. The correct start up adjustment of the engine is essential for the following reasons:

long engine life
good fuel economy
acceptable emissions

Service technicians should have a thorough understanding of the relationship between the fuel system and the ignition system. The technician must also be familiar with the Service Manual, "Systems Operation Testing And Adjusting" Section and the Service Manual, "Operation And Maintenance" Section.

References

G3300 Gas Engine Performance, LEBQ4197
G3400 Industrial Engine Performance, LEBQ6483
G3400 Generator Set Engine Performance Data Books, LEBQ6484
G3300 Service Manual
G3400 Service Manual
Methane Number Program, LEKQ6378
EIS Diagnostic Code Card, RENR1234

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Table 1
Tools Needed
Part Number	Description
7X-1400	Electronic Tool Group ⁽¹⁾
NEXG4511	Electronic Tool Group ⁽¹⁾
140-2304	Electronic Control Programmer ⁽²⁾
8T-0452	Manometer Gauge
156-1060	Emissions Analyzer Group
8T-5160	Setting Tool Group

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^( 1 )	For 3400 EIS engines only. Refer to Using The NEXG4511 Spark Ignited Engine Service Program Module, SEHS8806 for more information on using the Digital Diagnostic Tool. Also refer to Service Program Module For Spark Ignited Engines, NEXG4511. You must have the chip in order for the 7X-1400 Electronic Tool Group to work.
^( 2 )	For Engines equipped with ProAct Speed Control.

Required Information

Ignition Timing

A complete fuel analysis must be conducted prior to putting the engine into service. Obtain a fuel analysis in order to determine the BTU content and calculate the Methane Number. The BTU content indicates the amount of energy that is available in the fuel. The Methane Number indicates the ability of the fuel to be ignited. The Methane Number is determined when you input the constituents of the fuel into the Methane Number Program, LEKQ6378. Use the Methane Number and the Engine Performance Book, "Fuel Usage Guide" in order to determine the ignition timing.

Obtain several samples of fuel if the quality is expected to change. If the chemistry of the fuel will vary during engine operation, use the lowest expected value in order to determine ignition timing.

Maximum Load

Refer to the Engine Performance Book in order to determine the engine power derates for altitude, temperature and Methane Number. Use the derate range in order to determine the maximum engine load.

Inlet Manifold Pressure At Full Load

For generator set applications, use the generator power output to determine the engine load. For other applications, use the inlet manifold pressure to estimate the engine load. The Engine Performance Book provides inlet manifold pressures for a specific timing and emissions setting. If the engine power is derated, interpolate the desired inlet manifold pressure between the 100 percent and the 75 percent load ratings.

Note: The inlet manifold pressure may be used if the engine timing and the exhaust oxygen are set properly.

Exhaust Oxygen Level

The 156-1060 Emissions Analyzer or equivalent is required in order to properly set up a gas engine. The engine should be set up at the desired full load with the data that was taken at 100 percent load. Do not exceed the maximum load.

Carburetor Adjustments

The carburetor and the gas pressure regulator require adjustment when the engine is installed. The initial factory settings are based on the following conditions:

an ambient temperature of 25 °C (77 °F)
a barometric pressure of 96 kPa (28.4 in Hg)
the use of a natural gas pipeline with a Low Heating Value of 33.74 kJ/L (905 BTU/cu ft)

The factory ratings comply with SAE J1349 Standards. An engine that does not use natural gas may be shipped with optional orifices and valves. An engine of this type will be run with a catalyst and an air/fuel ratio control. Engine applications that do not use dry pipeline gas may be shipped with carburetor jets and valves for field installation. Contact your Caterpillar dealer for more information.

Gas Pressure Regulator

The gas pressure regulator requires adjustment when the engine is installed. Use only Caterpillar approved regulators in order to avoid problems with performance. A balance line for the regulator is required in all gas engines. This line compensates for changes in boost pressure or air filter restriction. Refer to the Systems Operation Manual for details.

Note: The supply line to the gas pressure regulator must be of adequate diameter in order to provide constant pressure to the regulator from idle to full load. Do not use supply lines that are smaller than the inlet to the pressure regulator.

Governors

It may be necessary to make one or more of the following governor adjustments during start-up:

low idle speed
high idle speed
droop
gain

Refer to the Service Manual for further information.

Hydramechanical

The Hydramechanical Governor is a simple governor for the G3300 and some of the G3400 applications that do not require close speed regulation. The standard Hydramechanical Governor has approximately 7 percent droop at 1800 rpm. Special springs can be ordered in order to lessen the droop.

Pressure Compensated Simple Governor (PSG)

The PSG Governor is a mechanical-hydraulic governor that is capable of isochronous speed control. The speed is controlled by a simple hand lever. A pneumatic control is available for remote speed control. A motor (24 VDC) is also available for remote speed control. Refer to Service Manual, SENR6514, "PSG Governor".

Flo-Tech

The Flo-Tech system is an electronic governor with an electrical actuator for the throttle. The electronic governor control provides a 0 - 200 mA signal to the Flo-Tech actuator in order to position the throttle. The position of the Flo-Tech actuator can not be observed. Instead, a signal voltage that indicates the throttle position is provided. A DC feedback voltage of 0.5 VDC corresponds to a closed throttle position. A signal voltage of 4.5 VDC corresponds to a fully open throttle position. Refer to Service Manual, RENR1356, "Flo-Tech Speed Control" for details.

The EG3P Hydraulic Actuator And The 2301A Electronic Governor

The 2301A electronic governor is used primarily for generator set applications. The EG-3P hydraulic actuator responds to electrical signals from the 2301A governor in order to position the throttle. Refer to Service Manual, SENR1196, "2301A Electric Governors".

ProAct Digital Speed Control

The ProAct digital speed control is an electronic governor that is based on a microprocessor. Adjustment of the ProAct control module requires the 140-2304 Electronic Control Programmer . The ProAct Actuator is electrically driven and connected directly to the throttle shaft. Refer to Service Manual, SENR1196, "ProAct Digital Speed Control".

Connect Gauges And Instruments

7X-1400 Electronic Tool Group

The Digital Diagnostic Tool (DDT) is used only for engines with the Caterpillar Electronic Ignition System (EIS). The DDT is used to program customer specified parameters such as information on the status of the engine and the DDT also reads the diagnostic codes.

Note: The DDT must have the Service Program Module For Spark Ignited Engines, NEXG4511 installed.

Measuring The Fuel/Air Delta Pressure

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Illustration 1	g00529363
Low Pressure Gas Regulator (1) Gas Plug (2) Air Plug

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Illustration 2	g00529597
High Pressure Gas Regulator (3) Gas Plug (4) Air Plug

The Water Manometer or the differential pressure gauge is required for the Impco fuel system and the Fisher gas regulator.

Turn the main gas valve OFF.
Remove the plug (1,3) from the gas supply line to the mixer.
Remove the plug (4) from the balance line on a high pressure system. Remove the plug (2) from the air cleaner on a system that has low pressure.
Connect an 1U-5470 Engine Pressure Group or a water manometer between the two pressure taps with the proper adapter fittings.

Note: Install a shutoff valve between the carburetor and the manometer for the high pressure systems. Close this valve when you start the engine or you stop the engine.

Emissions Analyzer

Install the 156-1060 Emissions Analyzer in order to monitor the exhaust oxygen levels before the turbocharger. Remove the plug that is located in the exhaust inlet of the turbocharger, or in the exhaust elbow on naturally aspirated engines. Connect the 156-1060 Emissions Analyzer in accordance with the manufacturer's instructions.

Note: The measurements of the NOx and the CO may also be required.

Inlet Manifold Pressure

The inlet manifold pressure is measured below the throttle plate with a pressure gauge. The inlet manifold pressure is used to indicate the engine load.

Gas Supply Line Pressure

Remove the plug from the gas supply line and install a pressure gauge.

Flo-Tech Actuator Position

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Illustration 3	g00545623
Flo-Tech Actuator (A) (Red) Positive Actuator Supply (12 gage) (B) (Blue) Negative Position Command (16 gage) (C) (Orange) Positive Position Command (16 gage) (D) (Black) Negative Actuator Supply (12 gage) (E) (White) Position Feedback (16 gage) (F) Not Used

The throttle position may be monitored by a DC voltmeter on engines that are equipped with a Flo-Tech actuator. Connect the negative probe of the DC voltmeter to the black terminal "B" of the controller. Connect the positive probe of the DC voltmeter to the white terminal "E". The signal for the position will only be present when the actuator is provided with voltage. The voltage is applied between the terminals "A" and "B" of the actuator.

Adjustment Of The High Pressure And The Low Pressure IMPCO Carburetor Mixer Systems

Ensure that the throttle linkage is correctly adjusted if the engine has this linkage. Refer to the Service Manual, "Systems Operation Testing And Adjusting " Section.
Note: The angle of the throttle can not be observed on engines that are equipped with a Flo-Tech actuator.

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Illustration 4	g00529416
(5) Carburetor Adjusting Screw (Low Pressure Gas)

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Illustration 5	g00529421
(6) Carburetor Adjusting Screw (High Pressure Gas)

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Illustration 6	g00545666
Impco 400 Low And High Pressure Carburetor (7) Carburetor Adjusting Screw

Locate the carburetor adjusting screw (5,6). Refer to illustration 4 for carburetors of this type. Turn the screw clockwise until the screw is fully seated. Next, turn the screw 3.5 times in the counterclockwise direction. Refer to illustration 5 for carburetors of this type. Set the screw (6) halfway between the rich "R" setting and the lean "L" setting.

Set the gas line pressure into the gas pressure regulator. The proper range of the pressure settings follow:
- 10 kPa (1.5 psi) to 35 kPa (5 psi) for engines with low pressure
- 138 kPa (20 psi) to 207 kPa (30 psi) for turbocharged engines
- 10 kPa (1.5 psi) to 138 kPa (20 psi) for naturally aspirated engines
Note: Authorization from the local utility may be required in order to obtain these supply pressures.

While the engine is OFF, adjust the gas pressure regulator in order to obtain a differential pressure of 10 cm (4 inch) to 12.7 cm (5 inch) of water. Adjust the differential pressure by removing the cap from the regulator. Turn the threaded disk with the 8T-5160 Gas Regulator Setting Tool . Turning the disk clockwise will increase differential pressure. Turning the disk counterclockwise will decrease the differential pressure.
Note: Check the differential pressure once the engine is started. If necessary, readjust the regulator. Obtain a differential pressure of 10 cm (4 inch) to 12.7 cm (5 inch) of water.

If the engine is equipped with a magneto, set the timing with a timing light. Refer to the Service Manual, "Testing And Adjusting " for the correct procedure. Use the DDT to program the desired timing in engines that use the EIS. Refer to ""Required Information" " and to the Service Manual, "Electronic Troubleshooting". Ensure that the timing is set based on the Fuel Usage Guide.
Note: Before you start the engine, be sure that the engine and the driven equipment are ready for operation. Ensure this operation by performing the daily maintenance items.

Start the engine.

Allow the engine to reach full operating temperature.

Gradually increase the load until the engine is carrying the desired full load. Do not exceed the maximum load that is determined in ""Required Information" ".
Slowly adjust the power adjustment screw on the carburetor if the full load can not be reached. This adjustment will increase the gas supply to the carburetor. Monitor the reading on an emissions analyzer such as the 156-1060 Emissions Analyzer , while turning the carburetor adjusting screw. The emissions are monitored in order to prevent adding too much fuel to the fuel air mixture.
Note: It may be necessary to turn the adjustment screw (10) on engines with an adjustable exhaust bypass valve. Perform this adjustment if the engine will not make the full load. This adjustment will increase the boost pressure and this adjustment will allow the engine to operate at full load.

While the engine is at full load, adjust the carburetor adjusting screw. Perform this adjustment in order to obtain the exhaust oxygen level that was determined in ""Required Information" ".

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Illustration 7	g00529461
(8) Cap (9) Locknut (10) Adjustment Screw

For engines with an adjustable exhaust bypass valve, remove the cap (8) and loosen the locknut (9). Turn the adjustment screw (10) in order to obtain a throttle angle of 60° to 70° at full load. It may be necessary to readjust the carburetor adjusting screw and the exhaust bypass valve several times. This adjustment is made in order to obtain the correct angle of the throttle at full load. This adjustment is also made in order to obtain the correct exhaust oxygen level.
Note: The angle of the throttle can not be observed on engines that are equipped with a Flo-Tech actuator. Adjust the exhaust bypass valve until a signal voltage of 4.0 VDC is generated between the terminals "E" and "B" at full load. Refer to the ""Flo-Tech Actuator Position" " for details.

Operate the engine throughout the expected load range. Verify that the engine rpm is stable. Verify that the angle of the throttle and the exhaust oxygen level at full load is correct. If the engine rpm is unstable, verify that the gas line pressures at no load and at full load are within acceptable limits. The pressure must not vary more than 1.7 kPa (0.25 psi) for low pressure fuel systems. The pressure must not vary more than 6.9 kPa (1 psi) for high pressure fuel systems. If the gas line pressure is within acceptable limits, it may be necessary to adjust the governor settings. Refer to the Governor Service Manual for details.

Check the final adjustments to the engine in order to ensure compliance with the emissions requirement. Use a NOx meter or a CO meter, or use both of these meters together in order to perform this check. In order to obtain desired emission levels, it may be necessary to make slight adjustments to the following settings:
- the carburetor adjusting screw
- the differential pressure
- the setting of the exhaust bypass valve
These adjustments are particularly important for low emissions engines and for engines that are equipped with a catalyst.

Adjustment Procedure For Deltec Mixer And Zero Pressure Regulators

Note: Gas can leak through the zero pressure regulator into the fuel system when the gas shutoff valve is open. Do not leave the gas shutoff valve open for a longer time than the time necessary to make adjustments. Before starting the engine, purge the inlet system and the exhaust system by disabling the ignition system. Then crank the engine with the gas supply OFF for three to five seconds.

Ensure that the throttle linkage is adjusted correctly. Refer to the Service Manual, "Systems Operation Testing And Adjusting Section".

Set the pressure from the gas supply line to the zero pressure regulator at 3 kPa (0.45 psi) to 7 kPa (0.95 psi).

Remove the cover (12) and the cap (15) from the zero pressure regulator.

Open the gas shutoff valve in order to supply gas to the zero pressure regulator.

If gas flows out of the valve (11), turn the screw (14) counterclockwise until the flow stops.

Turn the screw (14) clockwise in order to begin to lift the regulator valve (11) off the valve seat (13). The flow of gas is now heard in the regulator valve.

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Illustration 8	g00529472
Zero Pressure Regulator (11) Valve (12) Cover (13) Seat (14) Screw (15) Cap

De-energize the gas shutoff valve.

Clean the cover (12) and install the cover.

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Illustration 9	g00529503
Deltec Mixer System (16) Main Adjusting Screw (17) Locknut

Loosen the locknut (17). Turn the main adjustment screw (16) clockwise until the screw is fully seated.

Turn the main adjustment screw (16) four times in the counterclockwise direction. These turns open the fuel passage. Tighten the locknut (17) .

If the engine is equipped with a magneto, set the timing with a timing light. Refer to the Service Manual, "Testing And Adjusting " for the correct procedure. Use the DDT to program the desired timing in engines that have the EIS. Refer to ""Required Information" " and to the Service Manual, "Electronic Troubleshooting".

Start the engine. Verify that the supply pressure to the regulator is within 3 kPa (0.45 psi) to 7 kPa (0.95 psi). Continue to run the engine at low load in order to reach the normal operating temperature.
Note: For the best performance at starting, open the gas shutoff valve after the engine has been cranking for three to five seconds.

Adjust the exhaust oxygen level with the adjusting screw (16) for the regulator. Make this adjustment while the engine is at low load and high idle. The exhaust oxygen level should be within 3 to 5 percent.

Increase the load on the engine to approximately 50 percent of the load. Use the main adjusting screw (16) to adjust the exhaust oxygen level. Adjust the level to the 50 percent rating that is given in the Engine Performance Book.

Gradually increase the load until the engine is carrying the desired full load. Do not exceed the maximum load that was determined in ""Required Information" ". Slowly adjust the main adjustment screw (16), if the engine can not reach full load with the throttle in the wide open position. This adjustment increases the gas supply. Monitor the 156-1060 Emissions Analyzer reading while you turn the main adjustment screw (16). Monitor this reading in order to avoid adding too much fuel to the mixture. For engines with an adjustable exhaust bypass valve, adjustment may be necessary. Turn the adjustment screw (10) for the exhaust bypass valve in order to obtain the inlet manifold pressure at full load. This pressure is determined in the information for the prestart.

While the engine is at full load, adjust the main adjustment screw (16) in order to obtain the desired NOx level.

Operate the engine at low load and high idle rpm. Readjust the main adjustment screw (16) in order to obtain a 3 to 5 percent oxygen level and maximum stability.

Operate the engine at full load and readjust the main adjustment screw (16) in order to obtain the desired NOx level.

For engines with an adjustable exhaust bypass valve, remove the cap (8) and loosen the locknut (17). Turn the adjustment screw (10) in order to obtain a throttle angle of 60° to 70° at full load. It may be necessary to readjust the main adjustment screw (16) and the exhaust bypass valve several times. This adjustment is made in order to obtain the correct angle of the throttle at full load. This adjustment is also made in order to obtain the correct exhaust oxygen level.
Note: The angle of the throttle can not be observed on engines that are equipped with a Flo-Tech actuator. Adjust the exhaust bypass valve until a signal voltage of 4.0 VDC is generated between the terminals "E" and "B" at full load. Refer to the ""Flo-Tech Actuator Position" " for details.

Stop the engine and start the engine several times. If the engine is difficult to start, it may be necessary to make further adjustments to the regulator adjustment screw (10). Repeat this procedure starting at Step 13 if it is necessary to readjust the zero pressure regulator.

Operate the engine throughout the expected load range. Verify the following parameters:
- engine stability
- the angle of the throttle at full load
- the O₂ level
If the engine rpm is unstable, it may be necessary to adjust the governor settings. Refer to the Service Manual for details.