Initial Start-Up Procedure for CG137 and G3300B Engines {1000} Caterpillar

Engine

CG137-08 (S/N: WWF1-UP; FPL1-UP)

CG137-12 (S/N: FYR1-UP; WRX1-UP)

G3304B (S/N: A4E1-UP)

G3306B (S/N: RJ21-UP; R6S1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

References

The following publications may be needed to perform some of the procedures in this Special Instruction

• Systems Operation/Troubleshooting/Testing and Adjusting, KENR9788, "CG137-08 and CG137-12 Engines"

• Systems Operation/Troubleshooting/Testing and Adjusting, KENR6870, "G3304B and G3306B Engines"

Program the Parameters into the Engine Electronic Control Module (ECM)

1. Obtain a complete fuel analysis. Enter the data into Caterpillar Software Program, LEKQ6378, "Methane Number Program".

   Note: For information on connecting a personal computer to the service tool connector and on communicating with Caterpillar Electronic Technician (ET), refer to the engine Troubleshooting manual.

2. Connect a personal computer to the service tool connector. Establish communication between Cat ET and the engine ECM.

3. Use the "Configuration" screen from the "Service" pull-down menu on Cat ETto view the configuration parameters.

   Note: The configuration parameters can also be accessed with the Messinger display on the engine control panel. The factory default password is 0000.

   1. View the parameters that are listed in Table 1. Program the parameters, if necessary.

      Incorrect programming of the parameters may lead to complaints about performance and/or to engine damage.

      For descriptions of the parameters and for more information, refer to the engine Systems Operation manual.

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      Table 1

      ECM Identification	Comments
      "Equipment ID"
      "Engine Serial Number"
      Timing Control
      "First Desired Timing"	Determined with the methane number of the primary fuel that is used and with the Engine Performance Sheet, "Fuel Usage Guide"
      Air/Fuel Ratio Control
      "Emissions Feedback Mode Configuration"	Set to "Oxygen Feedback"
      "Aftertreatment #1 Outlet Oxygen Sensor Voltage Offset"	Set to 0.0 V
      "Emissions Feedback Disable Fuel Actuator Position Command"	Set to 45%
      Speed Control
      "Low Idle Speed"
      "Engine Acceleration Rate"
      "Maximum Engine High Idle Speed"
      "Minimum Engine High Idle Speed"
      "Governor (Proportional) Gain Percentage"
      "Governor (Integral) Stability Percentage"
      Start/Stop Control
      "Engine State Control Input Configuration"
      "Starting System #1 Type"
      "Crank Terminate RPM"
      "Engine Purge Cycle Time"
      "Cycle Crank Time"
      "Crank Duration"
      "Driven Equipment Delay Time"
      "Engine Speed Drop Time"
      "Cooldown Duration"

Determine the Fuel Supply Pressure

Adjust the fuel supply pressure to the engine gas pressure regulator.

• For low-pressure fuel systems, the recommended pressure is 10.3 to 34.5 kPa (1.50 to 5.00 psi).

• For high-pressure fuel systems, the recommended pressure is 82.7 to 172.4 kPa (12.00 to 25.00 psi).

For high-pressure fuel systems, the fuel supply pressure to the engine gas pressure regulator can also be calculated.

Calculating the Fuel Supply Pressure to the Gas Pressure Regulator

The variables must be determined before using the equation in Table 3.

Illustration 1	g02800036
Gas supply pressure for the 2W-6022 Pressure Regulator for G3304B and G3306B Engines (X) Net effective supply pressure (NES) in psi (Y) Regulator flow capacity in standard cubic feet per hour (SCF/HR)

Example of Calculating the Required Fuel Pressure to the Gas Pressure Regulator

This example uses a G3306B TA engine.

1. Determine the required fuel consumption per hour of full load operation.
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   Table 5

   (8066 × 205) ÷ 905 = 1827 standard cubic feet per hour

2. Use the result from Step 1 to find the approximate value SCF/HR for the pressure regulator. Because the engine is a G3306, refer to Illustration 1 to determine the corresponding NES.
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   Table 6

   SCF/HR = 1827

   Corresponding NES = 5.75 psi

3. Add 5 percent to the compressor outlet pressure to determine the adjusted boost pressure.
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   Table 7

   43.7 in Hg × 0.05 = 2.185

   43.7 + 2.185 = 45.9 adjusted boost pressure

4. Determine the corrected atmospheric pressure at the site. Use the standard atmospheric pressure and subtract the altitude in feet times 0.001.
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   Table 8

   Standard atmospheric pressure = 29.92 in Hg

   Altitude = 500 ft

   500 × 0.001 = 0.5

   29.92 - 0.5 = 29.42 corrected atmospheric pressure

5. Calculate the minimum require pressure to the gas pressure regulator by using the equation in Table 2.
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   Table 9

   [(Adjusted boost pressure - corrected atmospheric pressure) × 0.4912] + NES

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   Table 10

   [(45.9 - 29.42) × 0.4912] + 5.75

   [16.48 × 0.4912] + 5.75

   8.1 + 5.75 = 13.85 psi minimum required pressure for the gas pressure regulator

   Rounded up, the example requires a minimum of 14 psi for the gas pressure regulator.

Setting for the Gas Pressure Regulator

Set the gas pressure regulator output according to the type of engine and pressure that is listed in Table 11.

Note: The regulator pressure values are for pipeline natural gas. The setting may need adjustment for changes in fuel quality.

Tune the Air/Fiel Ratio Control (AFRC)

The air/fuel ratio must be adjusted properly to comply with the emissions requirements of the site. The correct air/fuel ratio also helps ensure stable operation.

Perform the following procedure to tune the AFRC.

1. For CG137 engines, turn the adjustment screw 3 turns out from bottom. Check engine out emissions (may require small emission screw adjustments to set the engine emissions).

   For G3300 engines, set the carburetor emission valve to the fully open "R" position.

2. Install an emissions analyzer in the exhaust stack after the catalyst.

3. Start the engine. Allow the engine to warmup to normal operating temperature. After the warmup, apply the load.

   Note: Operation at rated speed with a 100 percent load is recommended for the tuning procedure. The minimum acceptable load for tuning is 50 percent.

4. Establish communication between Cat ET and the engine Electronic Control Module (ECM). Access the "Configuration" tab. Set the emissions feedback to "Feedback Disable" to operate in the open loop mode.

   Note: Do not allow the engine to run unattended during open loop mode.

5. Allow the engine operation to stabilize. Check the readings on the emissions analyzer.

6. Use Cat ET to adjust the "Emissions Feedback Disable Fuel Actuator Position Command". Adjust the percentage of the fuel valve position. Gradually change the percentage and monitor the emissions analyzer.

   Adjusting the position of the actuator affects the exhaust emissions by allowing more fuel or less fuel for combustion.

   Engine operation is sensitive to changes in the air/fuel ratio. Adjust the percentage in small increments. After each adjustment, allow a few minutes for the emissions to stabilize.

   If the level of CO in the exhaust is greater than the site requirement, decrease the percent of the fuel valve position. A high concentration of CO indicates an air fuel ratio that is too rich.

   If the level of NO_X in the exhaust is greater than the site requirement, increase the percent of the fuel valve position. A high concentration of NO_X indicates an air fuel ratio that is too lean.

7. When the emissions are within the required limit, record the values for the following factors:

   • Percent of the fuel valve position

   • Setting of the gas pressure regulator

   • Engine rpm

   • Engine load

8. Use Cat ET to set the "Emissions Feedback Mode Configuration" to "Feedback Enabled". Wait for the emissions to stabilize.

9. Access the "Service" tab in Cat ET Use the "Service Procedure" "Engine Control System Tuning".

10. Monitor the following parameters

    • "Actual Aftertreatment # 1 Intake Oxygen sensor"

    • "Desired Aftertreatment # 1 Intake Oxygen sensor"

    • "Actual Aftertreatment # 1 Outlet Oxygen sensor"

    • "Desired Aftertreatment # 1 Outlet Oxygen sensor"

11. Determine whether the system is in a rich state or a lean state by monitoring the voltage for the 0₂ sensors.

    A higher voltage corresponds to a rich state and a lower voltage corresponds to a lean state.

    Voltage is greater than 0.6 V corresponds to a rich state.

    Voltage is less than 0.4 V corresponds to a lean state.

    For information on 0₂ sensor calibration, refer to the engine Testing and Adjusting.

    1. For CG137 Engines, monitor the intake 0₂ sensor voltages.

    2. For G3300B Engines, monitor the intake and outlet 0₂ sensor voltages.

12. Determine whether the 0₂ sensor voltage is acceptable. Allow the voltage to stabilize.

    1. For CG137 Engines, the actual 0₂ sensor voltage should switch between 0.1 V and 0.9 V. The desired 0₂ sensor voltage should be 0.5 V to 0.7 V.

    2. For G3300B Engines, determine whether the actual outlet sensor voltage matches the desired outlet sensor voltage.

13. Monitor the emissions analyzer. Verify that the exhaust emissions after the catalyst are within the limit. Refer to the engine Technical Marketing Information (TMI), "Emissions Data".

    1. If the emissions are within the limit for G3300B Engines, set the actual and desired 0₂ sensor voltage to the same value. To set the value, adjust the "Aftertreatment #1 Outlet Oxygen Sensor Voltage Offset.".

14. If the exhaust emissions are not within the acceptable limit, adjust the "Aftertreatment #1 Outlet Oxygen Sensor Voltage Offset".

    • If the level of CO is high, decrease the offset.

    • If the level of NO_x is high, increase the offset.

    Adjust the offset in small increments. Allow approximately 5 minutes for the emissions to stabilize after an adjustment.

    Note: Refer to "Gas Engine Rating Pro (GERP)" to convert grams per brake horsepower-hour (g/bhp-hr) to parts per million (PPM).

    Note: The "Aftertreatment #1 Outlet Oxygen Sensor Voltage Offset" can also be adjusted by using the Messenger control panel. The parameter is located under "Configuration", "Air Fuel Ratio Control", "AT1 Outlet O2 Voltage Offset". To change the parameter, select "OK", enter the value, and select "OK" again to save.

15. Continue to make adjustments until the emissions are well within the required limit.

Gas Engine Rating Pro (GERP)

Illustration 2	g06162733

1. Navigate to the "ENGINE SELECTION" screen on the left.
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   Illustration 3	g06162743

2. Locate and select rating by double-clicking on the rating.
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   Illustration 4	g06162749

3. Once the engine is selected, select what output parameters you want in the upper right.
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   Illustration 5	g06162752

4. Change the output parameters to ppm and uncorrected O2 to align with a emissions analyzer (TEST-O).
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   Illustration 6	g06162755

5. Set up the site results in the bottom right.
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   Illustration 7	g06162757

6. Click the "Calculate" button at the bottom.
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   Illustration 8	g06162764

7. Select "TECH DATA OUTPUT" on the left to see the datasheets.
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   Illustration 9	g06162766

8. Navigate to the site and standard datasheets at the top.
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   Illustration 10	g06162770

9. The emissions should be displayed in ppm.

   The following notes apply to Illustration 9.

   • 12 - Emission data is post Caterpillar provided catalyst, values are dependent on proper engine and catalyst maintenance.

   • 13 - NOx values are the maximum values expected under steady state conditions.

   • 14 - CO, CO2, THC, NMHC, NMNEHC, and HCHO values are "Not to Exceed" levels. THC, NMHC, and NMNEHC do not include aldehydes.

   • 15 - Volatile Organic Compounds (VOCs) as defined in US EPA 40 CFR 60, subpart JJJJ.

   • 16 - Exhaust Oxygen tolerance is ± 0.2, Lambda tolerance is ± 0.05.

   Ratings that include a Caterpillar supplied catalyst (integrated catalyst) will show emissions after the catalyst that should represent Not to Exceed (NTE) values over the life span of the catalyst. To see engine out (pre catalyst emissions) look for a "sister rating" that is labeled as "catalyst setting".