- Engine
- CG137-08 (S/N: WWF1-UP)
- CG137-12 (S/N: WRX1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
This Special Instruction provides the following information for CG137-08 and CG137-12 Engines:
- Required information
- Requirements for the electrical system
- Grounding practices
- Proper welding practices
- Service tools
- Wiring connections
- Initial start-up procedures
- Governor adjustment procedures
Reference: The following information is required in order to perform the installation and initial start-up:
- Complete analysis of the fuel
- Data from a complete fuel analysis that is entered into Caterpillar Software, LEKQ6378, "Methane Number Program"
- The performance data sheet for this engine located in the Technical Marketing Information (TMI) database
- Operation and Maintenance Manual, SEBU8553
- Systems Operation/Testing and Adjusting, KENR9788
- Troubleshooting, KENR9788
- Electrical Schematic, UENR1215
- Gas Compression Operator Control Panel Manual, UENR3193
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 fuel energy content and calculate the methane number. The methane number indicates the ability of the fuel to be ignited. The methane number is determined when you input the data from the fuel analysis into the Methane Number Program, LEKQ6378. Use the methane number and the Engine Performance, "Fuel Usage Guide" in order to determine the ignition timing.
Obtain several samples of fuel if the quality is expected to change. If the methane number will vary during engine operation, use the lowest expected value in order to determine ignition timing.
Maximum Load
Refer to TMI to determine the engine power level for the altitude, the temperature, and the methane number. Use the information in the Engine Performance, LEBQ6117 to determine the maximum engine load. The desired engine load must not exceed the maximum engine load.
Inlet Manifold Pressure at Full Load
Use the inlet manifold pressure to estimate the engines load. The inlet manifold pressure may be used if the engine timing and the exhaust O2 % are set properly. Refer to TMI to determine the inlet manifold pressures for specific settings of timing and emissions. If the engine power is derated, interpolate the desired inlet manifold pressure between the 100 percent and the 75 percent load ratings.
Level of Exhaust Emissions
An emissions analyzer is required to set up this engine. The engine performance Data Sheet gives the levels of emissions for engine loads of 50 percent, of 75 percent, and of 100 percent. Set up the engine in accordance with the Data Sheet at the desired full load with the data that was taken at 100 percent load.
Note: Use O2 % levels to set up the engine, when possible.
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 on all gas engines. This line compensates for changes in boost pressure or in air filter restriction.
Note: The supply line to the gas pressure regulator must be of adequate diameter 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.
Requirements for the Electrical System
When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through the metal conduit. A liquid tight conduit is recommended. Use proper support and alignment in order to avoid strain on the conduit.
The engine control system requires a clean 24 VDC power supply. The maximum allowable AC ripple voltage is 150 mV AC peak-to-peak. For the wiring, the maximum allowable voltage drop is 1 VDC from the power supply to the Electronic Control Module (ECM) or to an actuator. The power supply must be rated at 20 amp of continuous power.
Grounding Practices
Proper grounding is necessary for optimum engine performance and reliability. Improper grounding will result in electrical current paths that are uncontrolled and unreliable.
Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications.
- For the starting motor, do not attach the battery negative terminal to the cylinder block.
- Use an electrical ground strap to connect all metal cases that contain electrical components or electronic components to the cylinder block.
- Do not connect the negative terminal from the electrical power supply directly to the cylinder block. Connect the negative terminal from the electrical power supply to the negative terminal "−" on the interface box.
- Ground the cylinder block with a ground strap. The strap is furnished by the customer. Connect this ground strap to the ground plane.
- Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane or to earth ground.
- Rubber couplings may connect the steel piping of the cooling system and the radiator. This action causes the piping and the radiator to be electrically isolated. Ensure that the piping and the radiator are continuously grounded to the cylinder block. Use ground straps that bypass the rubber couplings.
- Ensure that all grounds are secure and free of corrosion.
Proper Welding Procedures
Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
- Set the engine control to the "STOP" mode.
- Turn off the fuel supply to the engine.
- Disconnect the negative terminal from the power supply.
- Disconnect the following electronic components from the wiring harnesses: ECM, throttle actuator, fuel actuator and all sensors.
- Protect the wiring harnesses from welding debris and/or from the welding spatter.
Show/hide table
NOTICE Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
- Connect the welders ground cable directly to the engine component that will be welded. Place the clamp as close as possible to the weld. This placement will reduce the possibility of welding current damage to the engine bearings, electrical components, and to other engine components.
- Use standard welding procedures to the weld the materials together.
Service Tools
The following tools are required in order to perform the electrical installation and the initial start-up.
- Personal computer (PC)
- Cat © Electronic Technician (ET)
- 317-7484 Communication Adapter Gp
- 1U-5470 Engine Pressure Gp or water manometer
- 1U-5804 Crimp Tool (12-GA TO 18-GA)
- 1U-5805 Wire Removal Tool (14-GA, GREEN)
- 121-9588 Wire Removal Tool (16-GA, BLUE)
- 151-6320 Wire Removal Tool
- Emissions analyzer
Connect the Wiring From the Battery
| |
| Illustration 1 | g03328678 |
|
Typical example (1) Alternator (2) Wiring harness “W” (3) Electric starter (4) Starter circuit breaker (5) Alternator circuit breaker (6) Starter relay (7) ECM panel | |
If an electric starter is used, battery power is supplied to the ECM via the electric starter harness.
If an air starter is used, an ECM panel knockout and battery power to terminal blocks in the ECM enclosure must be supplied.
| |
| Illustration 2 | g03329294 |
|
(A) Battery +
(B) Battery - | |
Reference: Refer to the main electrical wiring schematic for additional information regarding the starting circuit.
Connect the Wiring From the Driven Equipment
ECM Panel - Contains all required electrical connections for the 70 pin engine interface connector harness to the driven equipment.
Interconnect Harness - The interconnect harness (interface connector harness) is connected to the ECM panel. All of the electrical connections for the driven equipment are made to the end of the interconnect harness.
Operator Control Panel (OCP) - An optional remote panel is connected to the ECM panel via an interconnect harness. All of the electrical connections for the driven equipment are made at a terminal strip inside the OCP.
Table 1 lists the connections that are available at each of the locations. Review the Table before making the connections.
| Engine Interface Connector (EIC) | ||
|---|---|---|
| Terminal | Description | Function |
| 2 | 5V Sensor supply (1) | |
| 3 | Analog return (1) | |
| 7 | ||
| 8 | Cat Data Link + | |
| 9 | Cat Data Link - | |
| 10 | Desired speed input #2 + (2) | |
| 11 | Desired speed input #2 - (2) | |
| 15 | Desired speed input #1 analog (3) | |
| 18 | Digital return | |
| 19 | Fault lamp | The fault lamp is a normally open output that is used to illuminate the red stop lamp on the operator panel. The lamp indicates an engine shutdown caused by an electrical problem or abnormal operating condition. The driver can absorb a maximum of 0.3 amps. |
| 20 | Shutdown Notification | The shutdown notification pin is used to notify the driven equipment panel of an engine shutdown. |
| 22 | Emergency Stop (E-Stop) #2 | The E-Stop is a normally closed switch. Switch operation creates an open circuit. Customer supplied e-stop switch must be wired in series with the engine e-stop. |
| 23 | E-Stop #1 | |
| 24 | Crank Terminate Relay | Can be used as an engine run lamp. The relay is closed to run, switched to ground. The driver can absorb a maximum of 0.3 Amps. |
| 25 | Warning Relay | A normally open output to illuminate the amber warning lamp on the operator panel. The lamp indicates an electrical problem or abnormal operating condition. The driver can absorb a maximum of 0.3 Amps. |
| 34 | CAN 1 - | CAN Global Data Link - |
| 42 | CAN 1 Shield | CAN Shield connection |
| 46 | ECS Mode Switch Start #1 Start/Run/Stop1 | The engine mode is determined by which position the mode switch is grounded to. Switch returns to the ECM digital return, pin 5. The start/stop logic has two inputs ECS switch 1 J1-51 and ECS switch 2 J1-50. |
| 47 | ECS Mode Switch Start #2 Start/Run/Stop 2 | |
| 48 | Battery (+) | Supply ECM power to auxiliary customer supplied input. Maximum current draw 10 Amps. |
| 49 | ||
| 50 | CAN A (+) | CAN Global Data Link (+) |
| 51 | User Defined Shut down | When the engine is not running, the customer equipment grounds this wire to the digital return. The ECM senses the closing of the digital return and the ECM permits the engine to be ready for start-up. If this input is not grounded, the driven equipment is considered to be not ready and the engine cannot be cranked. The ECM generates an event code if this input is not grounded within the programmed delay time. When the engine is running, this input normally continues to be grounded. If the engine is running and this input is disconnected from the ground, the ECM immediately generates an event code and an engine shutdown. The engine is shipped with a jumper wire from terminal 12 to terminal 11. Remove the jumper wire when the customer connection is made. Do not use this input for normal shutdown. |
| 52 | Battery (+) | Supply ECM power to auxiliary customer supplied input. Maximum current draw 10 Amps. |
| 58 | Low Idle Switch | Used as an idle/rated switch. The switch is a two position switch, return wire returns to the ECM at pin 5. |
| 61 | Battery (-) | Auxiliary ground |
| 63 | ||
| 70 | Key Switch | ECM Keyswitch: Normally open, must be powered on for the engine to start. The switch is energized to start the engine, deenergized for power save. Must supply 24 V. |
| (1) | 0 - 5V speed signal |
| (2) | 4 to 20 mA |
| (3) | 0 - 5V |
Inputs for the Engines Mode of Operation
The engine has three modes of operation. The mode of operation is determined by two inputs. The valid configurations of the inputs are described in Table 2.
| Engine Command State | Switch 1 J1-51 | Switch 2 J2-52 |
|---|---|---|
| Fault | Open | Open |
| Stop | Open | Closed |
| Start | Closed | Open |
"FAULT" Mode
When both the J1-51 and the J2-51 switches are open, the engine is in"Fault" mode.
"STOP" Mode
The J1-51 switch is open, the J2-51 switch is closed.
"START" Mode
The engine start sequence begins when the J1-51 switch closes and the J2-51 switch is open.
Remote Operator Control Panel
| |
| Illustration 3 | g03330593 |
|
(1) Operator Control Panel
(2) Service tool connector (3) Emergency stop button | |
The Operator Control Panel (OCP) provides the following capabilities:
- Emergency stop
- Engine control
- Monitor display
- Desired engine speed
- Indication of alarms and shutdowns
OCP Customer Connections
Make the connections for the interconnect harness on the right side of the left terminal strip in the OCP. Insert the wire end into the appropriate location on the terminal strip. Perform a pull test in order to verify that the connection is secure. Refer to Operator Control Panel Manual, UENR3193 for detailed information about the capabilities and connections of the OCP.
| OCP Terminal Block Connections | |||
|---|---|---|---|
| Label | Wire Code | Description | Function |
| 1 | Y799 | CAN 1 Shield | Global CAN Network |
| 2 | Y798 | CAN 1 Low | |
| 3 | Y797 | CAN 1 High | |
| 4 | R955 | Discrete Output 2 | The digital output block is used in order to relay on/off information from the OCP to operate relays, solenoids, and indicator lamps. |
| 5 | X840 | Pulse Width Modulated (PWM) Output 1 + | The OCP supports two isolated analog PWM output channels. Each channel supports a two wire conductor with a shield. The range for the PWM outputs can be configured for 0 to 100% or 5 to 95%. The data range can be configured. The range must be set to the generator voltage. The output signal is 6V peak. |
| 6 | X841 | PWM Output 1 - | |
| 7 | F530 | PWM Output 1 Shield | |
| 8 | G405 | Magnetic Pickup + | Determines the engine speed in RPM from the customer supplied magnetic pickup. |
| 9 | G404 | Magnetic Pickup - | |
| 10 | G406 | Magnetic Pickup Shield | |
| 11 | A776 | Dedicated Discrete Input 1 | Must be connected and remain connected for the engine to start and run. If the ECM is controlling the gas shutoff valve and the circuit is opened, the ECM will deenergize the gas shutoff valve. Once the gas shutoff valve is deenergized, the ignition is stopped. Additional e-stop switches can be added to the e-stop circuit. |
| 12 | A774 | ||
| 13 | C987 | Battery + | 24V power supply from the ECM panel |
| 13 | 105 | ||
| 14 | C988 | Battery - | Auxiliary ground |
| 15 | A775 | Digital Return | Digital return for various inputs. |
| A777 | |||
| 16 | G966 | User Defined Shutdown | Customer driven equipment shutdown signal. |
| 17 | X843 | Implement Control PWM Output 2 - | The OCP supports two isolated analog PWM output channels. Each channel supports a two wire conductor with a shield. The range for the PWM outputs can be configured for 0 to 100% or 5 to 95%. The data range can be configured. The range must be set to the generator voltage. The output signal is 6V peak. |
| 18 | F531 | PWM Output 2 Shield | |
| 19 | P735 | Analog Input 2 + | The OCP supports 3 two wire isolated analog inputs. None of the inputs are dedicated to specific functions. The inputs are individually selectable ± 10V bipolar, PWM, resistive sender, or current (0 - 20mA) inputs. |
| 20 | X842 | Implement Control PWM Output 2 + | The OCP supports two isolated analog PWM output channels. Each channel supports a two wire conductor with a shield. The range for the PWM outputs can be configured for 0 to 100% or 5 to 95%. The data range can be configured. The range must be set to the generator voltage. The output signal is 6V peak. |
| 21 | F539 | Analog Output 3 + | Each analog output can be configured for either voltage or current use. Refer to Table 4 for voltage and current ranges. |
| 22 | Y794 | CAN 2 High | OCP CAN Network |
| 23 | Y795 | CAN 2 Low | |
| 24 | Y796 | CAN 2 Shield | |
| 25 | P736 | Analog Input 2 - | The OCP supports 3 two wire isolated analog inputs. None of the inputs are dedicated to specific functions. The inputs are individually selectable ± 10V bipolar, PWM, resistive sender, or current (0 - 20mA) inputs. |
| 26 | F542 | Analog Input 2 Shield | |
| 27 | F533 | Analog Output 1 + | Each analog output can be configured for either voltage or current use. Refer to Table 4 for voltage and current ranges. |
| 28 | F536 | Analog Output 2 + | |
| 29 | F537 | Analog Output 2 Shield | |
| 30 | F535 | Analog Output 2 - | |
| 31 | F538 | Analog Output 3 - | |
| 32 | F541 | Analog Input 1 Shield | The OCP supports 3 two wire isolated analog inputs. None of the inputs are dedicated to specific functions. The inputs are individually selectable ± 10V bipolar, PWM, resistive sender, or current (0 - 20mA) inputs. |
| 33 | F534 | Analog Output 1 Shield | Each analog output can be configured for either voltage or current use. Refer to Table 4 for voltage and current ranges. |
| 34 | F532 | Analog Output 1 - | |
| 35 | F540 | Analog Output 3 Shield | |
| 36 | P734 | Analog Input 1 - | The OCP supports 3 two wire isolated analog inputs. None of the inputs are dedicated to specific functions. The inputs are individually selectable ± 10V bipolar, PWM, resistive sender, or current (0 - 20mA) inputs. |
| 37 | P733 | Analog Input 1 + | |
| 38 | F548 | Analog Input 1 Selectable Supply | |
| 39 | R968 | Discrete Output 14 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 40 | R967 | Discrete Output 13 | |
| 41 | F549 | Analog Input 2 Selectable Supply | |
| 42 | F550 | Analog Input 3 Selectable Supply | |
| 43 | R964 | Discrete Output 11 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 44 | R963 | Discrete Output 10 | |
| 45 | R961 | Discrete Output 8 | |
| 46 | R962 | Discrete Output 9 | |
| 47 | P737 | Analog Input 3 + | The OCP supports 3 two wire isolated analog inputs. None of the inputs are dedicated to specific functions. The inputs are individually selectable ± 10V bipolar, PWM, resistive sender, or current (0 - 20mA) inputs. |
| 48 | Y994 | Discrete Output 16 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 49 | R965 | Discrete Output 12 | |
| 50 | G408 | 485 Annunciator + | The OCP has an RS-485 Modbus RTU data link for customer monitoring and control. The data link will allow remote monitoring of all parameter data that is visible on the display and the service tool.
SCADA data link will provide the data link based control of the outputs. |
| 51 | P738 | Analog Input 3 - | The OCP supports 3 two wire isolated analog inputs. None of the inputs are dedicated to specific functions. The inputs are individually selectable ± 10V bipolar, PWM, resistive sender, or current (0 - 20mA) inputs. |
| 52 | F543 | Analog Input 3 Shield | |
| 53 | Y988 | Discrete Input 8 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 54 | R957 | Discrete Output 4 | |
| 55 | R958 | Discrete Output 5 | |
| 56 | G407 | 485 Annunciator - | The OCP has an RS-485 Modbus RTU data link for customer monitoring and control. The data link will allow remote monitoring of all parameter data that is visible on the display and the service tool.
SCADA data link will provide the data link based control of the outputs. |
| 57 | G409 | 485 Annunciator + | |
| 58 | Y990 | Discrete Input 8 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 59 | Y986 | Discrete Input 4 | |
| 60 | R959 | Discrete Output 6 | |
| 61 | R952 | Modbus - | - |
| 62 | R951 | Modbus + | |
| 63 | R953 | Modbus Reference | |
| 64 | Y989 | Discrete Input 7 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 65 | Y987 | Discrete Input 5 | |
| 66 | R960 | Discrete Output 7 | |
| 67 | F408 | Discrete Input 4 | |
| 68 | F407 | Discrete Input 3 | |
| 69 | F405 | Discrete Input 1 | |
| 70 | A380 | 485 Annunciator Shield | The OCP has an RS-485 Modbus RTU data link for customer monitoring and control. The data link will allow remote monitoring of all parameter data that is visible on the display and the service tool.
SCADA data link will provide the data link based control of the outputs. |
| 71 | Y984 | Discrete Input 2 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 72 | Y983 | Discrete Input 1 | |
| 73 | F547 | Isolated Discrete Input Reference | |
| 74 | F406 | Discrete Input 2 | The OCP discrete input/output (I/O) module can be installed on a package or remotely. The module provides the auxiliary switch inputs or outputs or relay contact outputs. |
| 75 | Y993 | Discrete Output 15 | |
| 76 | Y985 | Discrete Input 3 | |
| 77 | 879 | Start Input | Start signal broadcasted over the CAN to the ECM. Customer supplied start signal from the display panel. |
| 78 | G966 | User Defined Shutdown | Customer driven equipment shutdown signal.
If you would like to use this feature, remove the jumper wire between T-15 and T-16. If you do not use this feature, using a jumper wire, jump pin 51 of the EIC to ground. |
| 79 | T789 | Crank Terminate Relay | Engine run lamp. Closed to run. |
| References for Analog Output Programming | |
| Item | Description |
| Number of analog outputs | 3 |
| Conductors per output | 2 (plus shield) |
| Type of output channel | Isolated |
| Current range | 0 - 20mA |
| 4 - 40mA | |
| 0 - 10mA | |
| Voltage range | 0 - 5V |
| 1 - 5V | |
| -3 - +3V | |
| -2.5 - +2.5V | |
| -5 - +5V | |
| -10 - +10V | |
| 0.5 - 4.5V | |
| -1 - +1V | |
| Full resolution | Minimum of 8 bits (256 points) of data |
| Input/Output Module Specifications | |
| Operating voltage | 5 - 32V |
| Nominal voltage | 12 - 42V |
| Over voltage capability | 32V for 1 hour at |
| Ambient operating temperature | |
| Resistive load | 3A at 30V |
| Output relay contact | 2A at 125VAC |
| 2A at 30VDC | |
| Maximum current draw | 400mA plus 50mA per energized relay at 12V |
Wiring for the E-Stop Circuit
The e-stop circuit is complete after installing the remote panel. An additional e-stop switch may be added to the circuit.
Refer to the Engine Electrical Schematic for additional information.
Wiring for the Gas Shutoff Valve (GSOV)
The GSOV circuit is complete after installing the remote panel.
Refer to the Engine Electrical Schematic for additional information.
Connect Cat ET
Cat ET is designed to run on a personal computer. Cat ET can display the following information:
- Parameters
- Diagnostic codes
- Event codes
- Engine configuration
- Status of the monitoring system
Cat ET can perform the following functions:
- Perform diagnostic tests.
- Calibrate sensors.
- Download flash files.
- Set parameters.
Note: For more information regarding the use of Cat ET and the PC requirements for Cat ET, refer to the documentation accompanying your Cat ET software.
There are two locations for connecting the communication adapter to the engines control system. One connection is on the right rear corner of the engine. The other connection is on the remote panel.
The engines power supply provides the communication adapter with 24 VDC. An indicator on the communication adapter indicates when the adapter is receiving power. Use the following procedure to connect Cat ET to the engines control system.
| |
| Illustration 4 | g03347515 |
|
Connecting the Communication Adapter II (1) Personal Computer (PC) (2) (3) (4) | |
Note: Items (2), (3), and (4) are part of the 317-7484 Communication Adapter Gp.
- Set the engine control to the OFF/RESET mode.
- Connect communications adapter (3) to a communications port on the PC by using one of the following methods:
- Connect cable (2) between the "COMPUTER" end of communications adapter (3) and the parallel port of PC (1). Be sure to configure Cat ET for the parallel port. This configuration provides the fastest connection.
- Connect cable (2) between the "COMPUTER" end of communication adapter (3) and the RS232 serial port of PC (1).
- Connect cables (2) between the "COMPUTER" end of communication adapter (3) and the USB port of PC (1).
- Connect cable (4) to communication adapter (5).
- Connect cable (4) to a service tool connector.
- Verify that the "POWER" indicator on the communication adapter is illuminated.
- Establish communication between Cat ET and the ECM.
Connect Gauges and Instruments
Water Manometer
| |
| Illustration 5 | g03331485 |
|
(1) Air filter service indicator
(2) Plug | |
The water manometer or the differential pressure gauge is not required for the Deltec mixer systems with zero pressure regulators.
- Turn off the main gas valve.
- Remove the air filter service indicator (1) from the air cleaner.
- Remove the plug (2) from the gas line.
- Connect a 1U-5470 Engine Pressure Group or a water manometer between the two pressure taps with the proper adapter fittings.
Emissions Analyzer
Install the emissions analyzer after the three-way catalyst in order to monitor the exhaust emissions. Connect the emissions analyzer in accordance with the manufacturers instructions.
Note: Use an emissions analyzer that can measure NO and NO2 separately, CO and O 2. Use the emissions analyzer to adjust the air/fuel ratio control. The accuracy of the emissions analyzer must be within 10 percent of a standard at the desired engine O 2 emissions level.
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.
Initial Start-Up Procedure
Ensure that all of these factors are in proper working condition prior to the initial start-up: engine installation, driven equipment, all of the related hardware and electrical connections. Failure to perform the commissioning procedure could result in unsatisfactory operation.
Perform the following procedure for the initial start-up and for start-up after major maintenance and/or after repair.
Adjusting the Gas Pressure Regulator
| |
| Illustration 6 | g03331529 |
| (1) Adjusting screw | |
- Turn the adjusting screw (1) in counterclockwise direction until the screw stops. The carburetor is set to full rich.
- Set the gas line pressure into the gas regulator to
10 to 35 kPa (1.5 to 5 psi) .Show/hide table
Illustration 7 g03331548 (2) Cap - Remove cap (2) from the gas pressure regulator.
- While the engine is OFF, adjust the gas pressure regulator using the 8T-5160 Gas Regulator Setting Tool in order to obtain a differential pressure of
1.74 kPa (7 inch of H2O) .Note: Turning the disk clockwise will increase the differential pressure. Turning the disk counterclockwise will decrease the differential pressure.
Tuning The Air/Fuel Ratio Control (AFRC)
Note: Only applicable to engines with AFRC.
- Start the engine
- Verify the differential pressure with the engine running. If necessary, readjust the regulator.
- Establish communication between Cat ET and the ECM.
- Access the "Configuration" tab.
- Set the emissions feedback to "Feedback Disable" in order to operate in the open loop mode.
Note: Do not run the engine in open loop mode unattended.
- Once the engine is at operating temperature, load the engine to 100 percent.
Note: The three-way catalyst outlet temperature should be greater than the catalyst inlet temperature prior to tuning the engine emissions. An outlet temperature value that is greater than the inlet value indicates the catalyst has reached effective operating temperature.
- Allow the engine to stabilize
- Observe the values shown on the emissions analyzer.
- Use Cat ET to adjust the "Emissions Feedback Disable Fuel Actuator Position Command".
- Adjust the percentage of the fuel valve position in small increments.
- Allow the emissions to stabilize before monitoring.
Adjusting the position of the actuator affects the exhaust emissions by allowing more or less fuel for combustion.
Engine operation is sensitive to changes to the air/fuel ratio. Allow a few minutes after each adjustment for the emissions to stabilize.
If, the level of CO in the exhaust is greater than the site requirement, decrease the fuel valve position percentage. A high concentration of CO indicates an air/fuel ratio that is too rich.
If, the level of NOx in the exhaust is greater than the site requirement, increase the fuel valve position percentage. A high concentration of NOx indicates an air/fuel ratio that is too lean.
- When the emissions are within the required limit, record the values for the following factors:
- Fuel valve position percentage
- Gas pressure regulating setting
- Engine RPM
- Engine load
- Use Cat ET to set the "Emissions Feedback Mode Configuration" to "Feedback Enabled". Allow the emissions to stabilize.
- Access the "Service" tab in Cat ET.
- Access "Service Procedure", "Engine Control System Tuning"
- Monitor the following parameters:
- "Actual Aftertreatment #1 Intake Oxygen sensor"
- "Desired Aftertreatment #1 Intake Oxygen sensor"
- "Actual Aftertreatment #1 Outlet Oxygen sensor"
- Determine whether the system is in a rich state or a lean state by monitoring the voltage for the O2 sensors.
A higher voltage corresponds to a rich state and a lower voltage corresponds to a lean state.
Voltage is greater than 0.7V corresponds to a rich state.
Voltage is less than 0.4V corresponds to a lean state.
- Determine whether the oxygen sensor voltage is acceptable. Allow the voltage to stabilize.
- The actual oxygen sensor voltage should switch between 0.1V and 0.9V. The desired oxygen sensor voltage is 0.5V to 0.7V.
- Monitor the emissions analyzer. Verify that the exhaust emissions after the catalyst are within limits. Refer to the engine Technical Marketing Information (TMI), "Emissions Data".
- If, the exhaust emissions are not within the acceptable limit, adjust the "Aftertreatment #1 Outlet Oxygen Sensor Voltage Offset".
If the CO level is high, decrease the offset.
If the NOx is high, increase the offset.
Adjust the offset in small increments. Allow approximately 5 minutes for the emissions to stabilize after an adjustment.
Note: The "Aftertreatment #1 Outlet Oxygen Sensor Voltage Offset" can also be adjusted using the OCP. The parameter is located under "Configuration", "Air Fuel Ratio Control", "AT 1 Outlet O2 Voltage Offset". To change the parameter, select "OK", enter the value, and select "OK" again to save the change.
- Make the appropriate adjustments in order to obtain the correct emissions limits.
Show/hide table
Illustration 8 g03331586 (3) Cap
(4) Locknut
(5) Adjustment screw - For engines with an adjustable exhaust bypass valve, adjust the valve in order to obtain a throttle angle of 60 to 70 degrees at full load. The adjustment is made in order to obtain the correct angle of throttle at full load.
- Remove cap (3).
- Loosen locknut (4).
- Turning adjustment screw (5) will increase the boost. Increasing the boost will decrease the throttle angle.
Note: The bypass valve may require adjustment several times.
Note: If, the engine RPM is unstable, verify that the gas line pressures at no load and full load are within the correct range. The pressure must not vary more than
Operate the engine throughout the expected load range. Verify that the engine RPM is stable. Verify that the following parameters are within the correct range at full load:
- Throttle angle
- Exhaust oxygen
- CO
- NOx
Check the final adjustments to the engine in order to ensure the compliance with the emissions requirement. Monitor the emissions analyzer. Verify that the exhaust emissions after the catalyst are within the limit. Refer to the engine TMI "Emissions Data".