Installation of the 505-5715 Upgrade Kit For Certain G3508 Engines {1052, 1071, 1274, 1378, 5137, 5479} Caterpillar

Engine

G3508 (S/N: N8B1-UP; 9TG1-UP; WPN1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. This Special Instruction covers the installation of the 505-5715 Upgrade Kit.

Note: The low emissions upgrade kit can only be installed on the G3508 Lean Burn Gas Engines listed above equipped with an ADEM A3 Electronic Control Module (ECM), Air Fuel Ratio Control, and a NOx sensor.

Caterpillar Channel 1 Videos

For supplemental information on this procedure, refer to the following video. The previous training has been replaced with the video below.

Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or copy the link that follows.

Illustration 1	g06306276

https://channel1.mediaspace.kaltura.com/media/Introduction+to+Visualization+Service+Procedures+%28VSP%29/1_92vjr92v

Important Safety Information

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform lubrication, maintenance, or repair on this product, until you verify that you are authorized to perform this work, and have read and understood the operation, lubrication, maintenance, and repair information.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner choosing.

General Information

Graphic Color Description

Color-coding of targeted components, or sections of a part, is used to communicate a required action.

The descriptions below illustrate the different colors and what is represented when used in a graphic.

(Blue) The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.

(CAT® Yellow) Description of parts.

(Yellow) Components placed aside for access, but not removed. Highlighted areas of adjustment, inspection, or special attention.

(Cyan) Special tools or other equipment required for use in a particular step.

(Light Gray) Components used for reference.

(Magenta) Any fastener, retainer, or electrical connector used to install or remove the primary component.

Graphic Symbol Description

This section includes all the symbol graphics used throughout the Visual Service Procedure (VSP), along with a brief description of what the symbol represents.

Attach

Compress, Load - To press together, to squeeze. To transfer weight or force to an object. The weight or force carried by an object.

Discard, Do Not Reuse - To cast aside as useless or undesirable in approved and responsible manner.

Disconnect - To remove from an electrical circuit. To separate.

Finger Tighten - To apply tension or torque with one digits and unaided by a tool or lever.

Insert - To place or fit into another object

Inspect - To confirm, inspect, look, or observe to confirm or assure accuracy, conformance.

Keep, Store - To retain for reinstallation or reuse.

Loosen - To make less tight. To set free. To release.

Go in a specified direction; change position

Remove - To take off.

Replace - To restore, or return, to a former or proper place.

Rotate - Clockwise - To turn on an axis. To alternate position or orientation, for the purpose of achieving even wear.

Rotate - Counter Clockwise - To turn on an axis. To alternate position or orientation, for the purpose of achieving even wear.

Route - To install a harness, hose, or wire along a specific course or layout along or through a product, to direct along a predefined path.

Tighten - To make nearer to fully stretched, without slack, to apply tension or torque.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

Table 1

Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Table 2

Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Reused Parts Overview

Illustration 2	g06196881

Illustration 3	g06196962

Illustration 4	g06196969

Oil Cooler Group

Parts List

Illustration 5	g06061981

Table 3

Parts List
Item	Qty	Part Number	Part Name
1	3	109-2332	O-Ring Seals
2	2	247-3796	Gaskets (ENGINE OIL COOLER)
3	1	7N-4945	Gasket
4	1	313-5004	Oil Cooler Core As
5	1	111-3820	Retaining Ring
6	3	3P-0655	O-Ring Seals

Removal Procedure

Table 4

Required Tools
Tool	Part Number	Part Name	Qty
A	-	Suitable Lifting Device	1

Illustration 6	g06062003

Illustration 7	g06196973

Illustration 8	g06196994

Illustration 9	g06197031

Illustration 10	g06197046

Installation Procedure

Table 5

Required Tools
Tool	Part Number	Part Name	Qty
A	-	Suitable Lifting Device	1

Illustration 11	g06197053

Illustration 12	g06197060

Illustration 13	g06197126

Illustration 14	g06197131

Illustration 15	g06197148

Illustration 16	g06197156

Carburetor Group

Parts List

Illustration 17	g06199697

Table 6

Parts List
Item	Qty	Part Number	Part Name
1	1	7E-1569	Washer

Removal Procedure

Illustration 18	g06199767

Illustration 19	g06199780

Illustration 20	g06199792

Installation Procedure

Illustration 21	g06199802

Illustration 22	g06199809

Illustration 23	g06200278

Aftercooler Group

Parts List

Illustration 24	g06062494

Table 7

Parts List
Item	Qty	Part Number	Part Name
1	14	1A-2029	Bolts
2	12	5M-2894	Hard Washers
3	1	4W-9002	Gasket
4	1	4W-9725	Gasket
5	2	5M-3062	Bolts
6	2	8L-4964	Spacer Nuts
7	2	5P-8862	O-Ring Seals
8	1	6V-5103	O-Ring Seal
9	2	9L-9132	Washers
10	2	165-3929	Bolts
11	1	505-1220	Plate
12	1	505-1221	Aftercooler Gp
13	1	505-1557	Plate

Installation Procedure

Table 8

Required Tools
Tool	Part Number	Part Name	Qty
A	-	Suitable Lifting Device	-
B	-	Suitable Lifting Devices	-

Illustration 25	g06062576

Illustration 26	g06062672

Illustration 27	g06062755

Auxiliary Lines Group

Parts List

Illustration 28	g06063158

Table 9

Parts List
Item	Qty	Part Number	Part Name
1	1	505-1223	Tube As
2	1	5G-1442	Gasket

Installation Procedure

Illustration 29	g06063200

Illustration 30	g06063203

Water Lines Group

Parts List

Illustration 31	g06063234

Table 10

Parts List
Item	Qty	Part Number	Part Name
1	2	0S-1608	Bolts
2	2	0T-0573	Bolts
3	2	1A-5183	Bolts
4	2	2D-4534	Bolts
5	1	3P-0815	O-Ring Seal
6	2	4L-3833	Gaskets
7	1	6V-1454	O-Ring Seal
8	1	6V-5066	O-Ring Seal
9	2	8S-9191	Bolts
10	1	8T-6762	Pipe Plug
11	1	8T-6765	Pipe Plug
12	3	8T-6767	Pipe Plugs
13	1	9Y-8283	Elbow
14	1	142-4280	Housing
15	2	153-9963	Rings
16	9	165-3931	Bolts
17	1	189-5779	Elbow
18	4	245-6848	Clamp As
19	1	335-2477	Elbow
20	1	387-4576	Elbow
21	2	388-4576	Flange As
22	2	388-6443	Rings
23	1	505-1224	Tube As
24	1	505-1225	Tube As

Installation Procedure

Illustration 32	g06063297

Illustration 33	g06063298

Illustration 34	g06075400

Fuel Lines Group

Parts List

Illustration 35	g06063523

Table 11

Parts List
Item	Qty	Part Number	Part Name
1	1	6L-2849	Tube Joint
2	1	8T-2657	Tube Joint
3	1	502-6409	Tube As
4	1	502-6410	Tube As
5	1	505-8451	Flange
6	2	214-7568	O-Ring Seal
7	2	360-3692	Plug
8	1	9Y-0168	Adapter

Illustration 36	g06200299

The parts highlighted in the illustration above will be reused for the installation of the fuel lines group.

Installation Procedure

Illustration 37	g06200354

Illustration 38	g06207296

Illustration 39	g06063528

Illustration 40	g06063533

Fuel Valve Group

Parts List

Illustration 41	g06063549

Table 12

Parts List
Item	Qty	Part Number	Part Name
1	4	0S-1619	Bolts
2	4	3E-9860	Locknuts
3	4	5J-5314	Bolts
4	8	5M-2894	Hard Washers
5	4	6V-5218	Bolts
6	2	6V-5778	O-Ring Seals
7	2	8W-0456	Shafts
8	4	9S-8752	Full Nuts
9	4	091-0081	Spacers
10	4	196-7878	Bolts
11	2	217-5449	Spacers
12	2	220-7286	Clamps
13	1	223-1178	Coupling
14	2	274-6333	Hex Socket Screws
15	1	285-7969	Bracket
16	1	328-0756	Valve As
17	1	353-6981	Drive Coupling As

Installation Procedure

Fuel Valve Sub-Assembly

Illustration 42	g06200366

Install the tooth and the spring pin onto the shaft of the valve assembly.

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Illustration 43	g06200371

Insert the spring pin until the pin is flush with the outside diameter of the tooth. Install one end of the spring through the spring pin.

Note: A drill bit with an outside diameter of 4.7 mm (0.185 inch)can be used to align the holes of the tooth with the holes in the shaft.

Illustration 44	g06200393

Install the yoke onto the opposite end of the spring. Rotate the yoke clockwise while installing onto the tooth. The rotation will close the spring.

Illustration 45	g06200458

Install a second spring, spring pin, and tooth into the opposite end of the yoke. Install an adapter onto the opposite end of the spring. Rotate the adapter in a clockwise direction onto the yoke. The rotation will close the spring.

Illustration 46	g06200466

Install the valve assembly onto the bracket using 4 bolts. Tighten the bolts to 41 N·m (30 lb ft).

Illustration 47	g06200771

Rotate the actuator shaft in a counterclockwise direction until the stop is reached. Install the valve assembly and bracket onto actuator by installing the adapter into coupling.

Note: Ensure that the arrow on the valve assembly is pointing in the direction of flow.

Tighten the bolts while the nuts are held to 45 N·m (33 lb ft).

Illustration 48	g06200814

Rotate the actuator shaft counterclockwise to ensure that it is against the "Closed" stop.

Illustration 49	g06200822

Inspect that the bolts are facing the incoming air and that the arrow on the valve assembly follows the direction of air flow. Inspect that the plate in the valve assembly is perpendicular to the direction of air flow (Closed).

Illustration 50	g06200829

Tighten the screws to 15 N·m (11 lb ft) while holding the plate perpendicular to the direction of the air valve (Closed).

Note: Verify that the actuator valve has the correct orientation prior to installation.

Illustration 51	g06200836

Solenoid Valve Group

Parts List

Illustration 52	g06063580

Table 13

Parts List
Item	Qty	Part Number	Part Name
1	1	3B-7296	Fitting
2	8	4K-0367	Full Nuts
3	16	5P-8247	Hard Washers
4	1	7X-7951	Union Elbow
5	8	8S-9092	Bolts
6	1	419-0893	Solenoid Valve Gp
7	2	420-8789	Gaskets
8	2	424-0851	Flanges

Installation Procedure

Illustration 53	g06063590

Illustration 54	g06063599

Air Lines Group

Parts List

Illustration 55	g06210604

Table 14

Parts List
Item	Qty	Part Number	Part Name
1	1	6V-3917	O-Ring Seal
2	1	505-1226	Air Tube As
3	1	7L-4302	Gasket
4	1	6V-2695	O-Ring Seal
5	1	032-1268(1)	Connector
6	1	330-7152(1)	Hose As
7	1	6V-0826(1)	Grommet
8	1	8T-1889(1)	Clip
9	1	8T-1890(1)	Clip
10	1	032-1267(1)	Connector

(1)	Parts are needed with serial numbers S/N:WPN1-01648

Installation Procedure

Illustration 56	g06063097

Turbocharger Group

Parts List

Illustration 57	g06063608

Table 15

Parts List
Item	Qty	Part Number	Part Name
1	4	0S-1594	Bolts
2	1	4P-4460	Gasket
3	1	4W-1456	Exhaust Coupling
4	2	4W-1478	Exhaust Seals
5	4	5M-2894	Hard Washers
6	1	7N-7559	Gasket
7	1	7N-8229	Strainer
8	1	121-5736	Gasket
9	1	154-8205	Gasket
10	2	247-0708	O-Ring Seals
11	4	341-9211	Gaskets
12	1	387-5304	Exhaust Adapter
13	1	393-0358	Turbocharger Gp

Installation Procedure

Table 16

Required Tools
Tool	Part Number	Part Name	Qty
A	-	Suitable Lifting Device	-

Illustration 58	g06063675

Illustration 59	g06063616

Illustration 60	g06063653

Illustration 61	g06063659

Illustration 62	g06063684

Illustration 63	g06063699

Air Cleaner Group

Parts List

Illustration 64	g06063718

Table 17

Parts List
Item	Qty	Part Number	Part Name
1	4	0S-1588	Bolts
2	4	1A-2029	Bolts
3	1	5P-0600	Hose Clamp
4	1	5P-3860	Hose Clamp
5	2	7B-3235	Bolts
6	2	7D-1649	Hard Washers
7	4	9S-8752	Full Nuts
8	12	9X-6458	Hard Washers
9	1	226-2773	Air Cleaner Gp
10	1	234-7960	Reducer Hose
11	1	505-1219	Support As
12	12	030-8535	Locking Bolts
13	12	8T-4896	Hard Washers
14	1	293-7467	Gasket
15	1	293-4656	Bracket As

Installation Procedure

Table 18

Required Tools
Tool	Part Number	Part Name	Qty
A	-	Suitable Lifting Device	-
B	-	Suitable Lifting Devices	-

Illustration 65	g06063760

Illustration 66	g06159708

Illustration 67	g06159709

Illustration 68	g06159711

Illustration 69	g06159715

Air Lines Group

Parts List

Illustration 70	g06200900

Table 19

Parts List
Item	Qty	Part Number	Part Name
1	2	4P-7233	Grommets
2	1	281-5916	Elbow
3	4	353-7956	Grommets
4	1	532-7717	Hose As
5	3	0S-1588	Bolts
6	2	206-5017	Spacers
7	4	2P-4437	Clamps
8	2	325-6994	Clips
9	2	325-6995	Clips
10	1	3B-1915	Bolt
11	1	3K-0360	O-Ring Seal
12	2	3S-5849	Gaskets
13	5	5M-2894	Hard Washers
14	1	7K-9197	Elbow
15	1	8L-6557	Connector
16	2	9S-8752	Full Nut
17	1	9X-6458	Hard Washer

Removal Procedure

Illustration 71	g06200915

Illustration 72	g06200972

Note: If the altitude is less than 670 m (2200 ft), use 7E-4676 Spring (INNER) as shown above and remove the outer spring. If the altitude is greater than 670 m (2200 ft), use 7E-4677 Spring (OUTER) and remove the inner spring.

Installation Procedure

Illustration 73	g06200987

Illustration 74	g06201049

Illustration 75	g06201058

Illustration 76	g06201064

Start-Up Procedure

Connect to Cat^® Electronic Technician (ET)

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Illustration 77	g03634848
(1) Personal Computer (PC) (2) 237-7547 Adapter Cable As (3) 196-0055 Adapter Cable As (4) 225-5985 Parallel Port Cable (5) 466-6258 Communication Adapter As (6) 207-6845 Adapter Cable As

Note: Items (3), (5), and (6) are a part of the 466-6258 Communication Adapter As

1. Turn the engine to OFF.

2. Connect communications adapter (5) to a port on the PC by using one of the methods that follows:

   1. Connect parallel port cable (4) between the computer end of the communications adapter and parallel port of the PC.

      Note: Configure Cat ET for the parallel port. This configuration is the fastest connection.

   2. Connect adapter cable assembly (3) between the computer end of the communications adapter and the RS232 serial port of the PC.

   3. Connect adapter cable assemblies (2) and (3) between the computer end of the communications adapter and the USB port of the PC.

3. Connect adapter cable assembly (6) to the communication adapter.

4. Connect adapter cable assembly (6) to the service tool connector.

5. Verify that the "POWER" indicator on the communication adapter is illuminated.

6. Establish communication between Cat ET and the Electronic Control Module (ECM).

7. Download the 539-2026 Engine Software from SIS web.

8. Install the 539-2026 Engine Software on a blank ECM.

Connecting Gauges and Instruments

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Illustration 78	g06201077
Typical configuration and plug locations for the connection of the manometer on a high-pressure Fuel system (1) Tap for manometer (2) Tap for measurement of the gas supply pressure

1. Turn the main gas valve to OFF.

2. Remove the plugs from taps (1) and (2).

3. Install the shutoff valve at tap (1).

4. Connect the differential gauge on the 1U-5470 Engine Pressure Gp or a water manometer between the two pressure taps with the proper adapter fittings.

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

Emissions Analyzer

There are two different emissions analyzers that are listed below:

• 391-8170 EMISSIONS ANALYZER TOOL GP with Bluetooth

• 393-0673 EMISSIONS ANALYZER TOOL GP without Bluetooth

Install the emissions analyzer group to monitor the exhaust emissions after the turbocharger. Remove the plug that is located in the exhaust elbow of the engine. Connect the emissions analyzer group in accordance with the manufacturer instructions.

Note: An emissions analyzer that measures NO and NO₂ separately must be used. The analyzer is used to check the air/fuel ratio control and adjust the air/fuel ratio control. The accuracy of the emissions analyzer must be within 10% of a standard at the desired engine NOx emissions level. Calibrate the emissions analyzer for both NO and NO2 as needed to maintain this accuracy level.

Inlet Manifold Pressure

Illustration 79	g06139674

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.

Supply Pressure to the Gas Pressure Regulator

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Illustration 80	g06201093
Typical configuration and plug locations for the connection of the manometer on a high-pressure Fuel system (1) Tap for manometer

1. Refer to the illustration above, remove the plug from tap (1).

2. Connect a pressure gauge to the tap.

   Note: This pressure tap will monitor the supply pressure to the gas pressure regulator.

Prepare the Engine for Start-Up

Ensure that all these factors are in proper working condition prior to the initial start-up: engine installation, driven equipment, all the related hardware, and electrical connections. Failure to perform the commissioning procedure could result in unsatisfactory operation.

A complete fuel analysis must be conducted prior to putting the engine into service. Obtain a fuel analysis to determine the fuel energy content and calculate the methane number. The methane number indicates the ability of the fuel to be ignited and is used to determine desired ignition timing. Both the methane number and the ignition timing will be provided by GERP when a fuel analysis is done. The fuel usage guide on the engine performance sheet can be used to determine the desired ignition timing for the fuel being used.

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 to determine ignition timing.

Perform the following procedure for the initial start-up and for start-up after major maintenance and/or after repair.

1. Verify that the connections between the engine control system and the driven equipment are connected properly.

2. Install the main 15 amp fuse.

3. Set the engine control to the "COOLDOWN/STOP" mode. Test each emergency stop button before the engine is started to verify that the engine control system generates an E264 event code.

   1. After the operation of each emergency stop has been verified, set the engine control to the "OFF/RESET" mode. Reset the control system.

4. Turn on the jacket water heater if equipped.

5. Inspect the inlet air system. Make sure that the system does not leak. Make sure that the system is free of debris.

6. Inspect the fuel supply system. Make sure that the system does not leak and is free of debris. Blow any debris from the fuel lines.

7. Perform the daily inspection and all the daily maintenance procedures. Refer to the Operation and Maintenance Manual, Maintenance Interval Schedule.

8. Verify that the driven equipment is ready for operation.
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   Illustration 81	g06139699
   (1) Power screw on the carburetor

9. Locate power screw (1). Turn the screw clockwise until fully seated. Then turn the screw 3.5 times in the counterclockwise direction.

   Note: Turn the power screw clockwise for a leaner fuel mixture that will open the Electronic Fuel Valve. Turn the power screw counterclockwise for a richer fuel mixture that will close the fuel valve.

10. Set the gas line pressure to the gas pressure regulator between 275 kPa (40 psi) to 310 kPa (45).

11. Set the gas pressure regulator differential output setting. Refer to the Connect Gauges and Instruments section for more information. Make sure that the differential pressure setting is at least 1.3 kPa (5.2 inch of H₂O) to 1.5 kPa (6 inch of H₂O).

12. Set the engine control to the "STOP" mode. Use the "Monitoring System" screen from the "Service" drop-down menu on Cat ET to view the default settings of the trip points for the alarms. Adjust the settings, if necessary.

    Note: For the necessary values of the operating parameters, refer to the applicable Data Sheet on engine performance in the engine Technical Marketing Information (TMI).

13. Use the "Configuration" screen from the "Service" drop-down menu on Cat ET to view the configuration parameters.
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    Table 20

    Parameter Name	Default Value	Min Value	Max Value
    First Desired Timing	22	10	40
    Second Desired Timing	14	10	40
    Emissions Feedback Mode Configuration	NOx Feedback	Feedback disabled	NOx Feedback
    Desired Engine Exhaust NOx Level Setting	240.00 ppm	40	600
    Air/Fuel Proportional Gain	0	—50	50
    Air/Fuel Integral Gain	0	—50	50
    Desired Fuel Valve Position Offset	0.00%	-20%	20%
    Low Idle Speed	900 rpm	500	1200
    Minimum Engine High Idle Speed	1000 rpm	900	1100
    Maximum Engine High Idle Speed	1500 rpm	100	1900
    Engine Acceleration Rate	50 rpm/s	1	50000 rpm/s
    Rated Engine Speed	1400 rpm	500	2000
    Desired Speed Input Configuration	0–5 VCD Input	4–20 mA Input	0–5 VDC input
    Governor Type Setting	Isochronous	Droop	Isochronous
    Engine Operation Type	Compressor	N/A	N/A
    Engine Speed Droop	0.00%	0.00%	10%
    Governor Gain Factor	0	—50	50
    Governor Stability Factor	0	—50	50
    Governor Compensation Factor	0	—50	50
    Starting System #1 Type	Electrical	Air	Not Installed
    Driven Equipment Delay Time	120 sec	0 sec	600 sec
    Crank Terminate RPM	250 rpm	100 rpm	600 rpm
    Engine Purge Cycle Time	0 sec	0 sec	60 sec
    Cooldown Duration	0 min	0 min	30 min
    Cycle Crank Time	15 sec	5 sec	300 sec
    Engine Overcrank Time	120 sec	5 sec	360 sec
    Engine Speed Drop Time	15 sec	5 sec	120 sec
    Engine Pre-Lube Time Out Period	480 sec	0 sec	3600 sec
    Engine Post Lube Duration	240 sec	0 sec	3600 sec
    Engine Pre-Lube	Disabled	Disabled	Enabled
    Full Load Intake Manifold Pressure Configuration	240 kpa	140	280
    No Load Intake Manifold Pressure Configuration	25 kpa	3	100
    High Inlet Air Temperature Engine Load Set Point	50%	0%	200%
    Exhaust Temperature Module Installation Status	Installed	Installed	Not Installed

14. Verify that the PMS parameters are set correctly.
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    Table 21

    PMS Parameter Name	Default State	Default Value	Min Value	Max Value	Default Delay Time	Min Delay Time	Max Delay Time
    Engine Above Tope Engine Speed Limit
    Least Severe	Off	1540 rpm	1100	1770	0	0	60
    Most Severe	Off	1610 rpm	1100	1770	0	0	60
    Engine Overspeed
    Most Severe	Always On	1770 rpm	1100	1770	0	N/A	N/A
    High Engine Oil to Engine Coolant Differential Temperature
    Least Severe	Always On	14°C	0	20	20 sec	1	60
    Most Severe	Always On	20°C	0	20	20 sec	1	60
    High Engine Coolant Temperature
    Least Severe	On	109	80	129	20	1	60
    Moderate Severity	Off	111	80	129	20	1	60
    Most Severe	Always On	113	80	129	20	1	60
    High Engine Oil Temperature
    Least Severe	Always On	102	80	110	20	1	60
    Most Severe	Always On	105	85	110	20	1	60
    High Exhaust Temperature
    Least Severe	Off	710	100	710	20	1	60
    Most Severe	Off	720	100	720	0	0	60
    High Inlet Air Temperature at High Engine Load
    Least Severe	On	64	32	100	20	1	60
    Moderate Severity	Off	100	32	100	20	1	60
    Most Severe	Always On	70	32	100	20	1	60
    High Inlet Air Temperature at Low Engine Load
    Least Severe	On	69	32	85	20	1	60
    Moderate Severity	Off	100	32	100	20	1	60
    Most Severe	Always On	80	32	100	20	1	60
    High Oil Filter Differential Pressure
    Least Severe	Always On	103	80	138	10	1	60
    Most Severe	Always On	138	80	138	10	1	60
    High System Voltage
    Least Severe	On	34	18	34	20	1	60
    High Turbo Turbine Inlet Temperature
    Least Severe	On	710	100	710	20	1	60
    Most Severe	Always On	720	100	720	0	0	60
    Low Engine Coolant Temperature
    Least Severe	On	5	5	80	20	1	60
    Low Oil Filter Differential Pressure
    Least Severe	Always On	35	7	80	10	1	60
    Most Severe	Always On	7	7	80	10	1	60
    Low System Voltage
    Least Severe	On	20	18	24	20	1	60
    Most Severe	Always On	18	18	24	10	1	60

15. Verify that the value of the "First Desired Timing" parameter is according to the recommended timing from Gas Engine Rating Pro (GERP) or the fuel usage guide on the engine performance sheet. Enter the correct value if the existing value is incorrect.

16. Verify that the values for all other specified parameters are correct. Refer to Systems Operation/Testing and Adjusting, RENR9352, Electronic Control System Parameters, for additional information on the parameters.

17. Set the "Full Load Intake Manifold Pressure Configuration" to the inlet manifold pressure specified on the tech data sheet.

18. Set the "Desired Engine Exhaust NOx Level Setting".

19. Turn the fuel supply to the engine on. Verify that no gas is leaking and does not flow past the Gas Shutoff Valve (GSOV).

20. Turn the boost regulator adjustment fully clockwise to set the maximum boost pressure to its greatest allowable setting.

Start the Engine

Note: Several attempts may be required for the initial start-up before the air is purged from the fuel lines.

1. Start the engine.

   Note: If the engine starts, proceed to Step 2. If the engine will not start or the idle rpm is unstable, perform the following procedure.

   1. Use Cat ET to check for diagnostic codes and for event codes. Correct any active conditions before you continue.

   2. Check to make sure that the GSOV is being energized to allow fuel flow to the engine.

   3. Check the gas pressure regulator differential output setting, refer to "Connect Gauges and Instruments" for more information. Make sure that the differential pressure setting is at least 1.3 kPa (5.2 inch of H₂O) to 1.5 kPa (6 inch of H₂O).

   4. If engine is not starting due to being overly rich, the "Desired Fuel Valve Offset Position" parameter can be lowered to help close the fuel valve.

   5. Start the engine.

2. The engine will accelerate too low idle rpm. Operate the engine at low idle. Verify the following conditions:

   • Proper engine oil pressure

   • No fluid leaks

   • No gas leaks
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   NOTICE
   Do not remove the cap from the regulator until the load has been removed from the engine. The cap is pressurized by turbocharger boost pressure that is present when the engine is operated under load.

3. Run the engine at high idle speed with no load. Then adjust the gas pressure regulator to obtain the correct differential pressure of 1.3 kPa (5.2 inch of H₂O) to 1.5 kPa (6 inch of H₂O).

4. If required, 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 counterclockwise will increase differential pressure. Turning the disk clockwise will decrease the differential pressure.

5. If the engine is unstable, perform the following procedure:

   1. Record the values for these parameters:

      • "Governor Gain Factor"

      • "Governor Stability Factor"

      • "Governor Compensation Factor"

   2. Set the values for the "Governor Gain Factor" and for the "Governor Stability Factor" to zero.

   3. Adjust the governor. Refer to "Adjusting the Governor".

6. Allow the engine to reach full operating temperature. The correct setting will provide the most stable rpm.

Adjust the Engine for the Correct Emissions

1. Turn off the emissions feedback in the Cat ET configuration screen.

2. Increase the load to 50% while adjusting the power screw to maintain the desired emissions.

   1. If detonation occurs, temporarily retard the ignition timing with Cat ET.

      Note: Detonation may cause severe engine damage. Slowly make all adjustments and pay close attention to the level of the exhaust oxygen/NO_x and to the detonation level.

   2. If the engine does not reach the desired load, the throttle is wide open, the NOx level is close to the performance data, and the engine may need more air or turbocharger boost pressure. Turn the adjustment screw for the wastegate clockwise to increase the turbocharger boost pressure.

3. Increase the load to 100% while adjusting the power screw to maintain the desired emissions.
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   Illustration 82	g06140210
   Section view of the wastegate (1) Plug (2) Setscrew (3) Nut

4. Set the wastegate to obtain 60±5% throttle position at full load.

   1. Remove plug (1) from the wastegate and loosen nut (3).

   2. Turn setscrew (2) for the wastegate to obtain a throttle position of 60% ± 5% at full load.

   3. Turn the adjustment screw clockwise to increase the turbocharger boost pressure and close the throttle. Turn the adjustment screw counterclockwise to decrease the turbocharger boost pressure and open the throttle.

      Note: If the wastegate set screw it at the lowest limit before reaching the desired throttle position, replace the wastegate spring with the original 7E-4677 Spring (OUTER). If the wastegate set screw is at the highest limit before reaching the desired throttle position, replace the wastegate spring with the original 7E-4676 Spring (INNER).

   4. To obtain the correct throttle position and exhaust emissions at full load, you may need to readjust the following components several times:

      • Power screw

      • Regulator differential pressure

      • Wastegate

   5. When the adjustment of the wastegate is correct, tighten nut (3) and install plug (1).

      Note: The throttle position is reported in Cat ET as "Throttle Actuator Position Command".

5. Access the "Service/Calibrations/Engine Exhaust NOx Level Sensor" calibration screen on Cat ET, while the engine is operating under full load in the open loop. Follow the prompts that guide you through the calibration procedure.

   1. Use the buttons at the bottom of the screen to adjust the NOx slope to generate a NOx value on Cat ET that matches the NOx value on the emissions analyzer within 10 ppm.

   2. Make small adjustments to the slope during the calibration procedure. Allow the NOx value to stabilize after each adjustment. If large changes are made, engine operation may become unstable.

   3. After adjusting the NOx slope level on Cat ET to within ± 10 ppm of the NOx value on the emissions analyzer, the calibration is complete.

      Note: Make sure that you select "Finish" at the end of the calibration procedure to save the new settings.

6. Enable the "NOx Feedback" in the Cat ET configuration screen.

7. Continue to run the engine for 3 minutes or until the emissions stabilize to verify NOx emissions and to verify stable operation.

8. Operate the engine throughout the expected load range. Verify that the engine rpm is stable, and verify that the throttle positions at full load and the exhaust emissions are correct.

   Note: Fluctuations of the fuel pressure can change the air/fuel ratio. For high-pressure gas fuel systems, the maximum fluctuation that is allowed in the fuel pressure to the engine is 3.4 kPa (0.50 psi). If the pressure in the gas supply line is within acceptable limits, the governor settings may need adjustment. Refer to "Adjusting the Governor".

9. Change the engine load to the load that is required at the site. Check the emissions level. Verify that the emissions meet the requirements of the site.

10. Verify that the cooling system temperatures and the cooling system pressures are within the correct operating ranges.

11. Select the "Information" drop-down menu to view the status parameters. Review the values of the status groups in Cat ET. Record the values of the parameters and save the values for future reference.

Adjusting the Governor

The response of the throttle actuator can be adjusted with Cat ET. Use Cat ET to change these parameters:

• "Governor Gain Factor"

• "Governor Stability Factor"

• "Governor Compensation Factor"

Gain - Gain determines the speed of the control response in adjusting for the difference between the desired condition and the actual condition. Increasing the gain provides a faster response to the difference between the desired condition and the actual condition.

Stability - Stability controls the speed for elimination of the error in the difference between the desired condition and the actual condition. The stability dampens the response to the error. Increasing the stability provides less damping.

Compensation - Compensation is used to adjust the time delay between the control signal and the movement of the actuator. If the compensation is too low, the engine speed will slowly hunt. If the compensation is too high, the engine speed will rapidly fluctuate.

Note: The default value for these parameters is "0". The default values should be sufficient for initial start-up. However, the values may not provide optimum performance.

These adjustments are provided to obtain optimum responses to changes in the engine load and in the engine speed. The adjustments also provide stability during steady state operation.

If you have a problem with instability, always investigate other causes before you adjust the governor. For example, diagnostic codes and unstable gas pressure can cause instability.

When you adjust the governor, make sure that the "Grid Status" parameter is "Off".

To change the "Governor Gain Factor" or the "Governor Stability Factor" , use the "Real Time Graphing" feature on the "Information" drop-down menu of Cat ET. The graph provides the best method for observing the effects of your adjustments.

After adjustments, always test the stability by interrupting the engine speed and/or load. Operate the engine through the entire range of speeds and of loads to ensure stability.

Note: Adjustment of the "Governor Gain Factor" directly affects the speed of the throttle actuator when there is a difference between the actual engine speed and the desired engine speed. An excessive increase of the "Governor Gain Factor" may amplify instability.

To set the "Governor Gain Factor", increase the value until the actuator becomes unstable. Slowly reduce the value to stabilize the actuator. Observe that the engine operates properly with little overshoot or undershoot.

Adjustment of "Governor Stability Factor" dampens the actuator response to changes in load and in speed. Increasing the value provides less damping. Decreasing the value provides more damping. To reduce an overshoot, decrease the value. To reduce any undershoot, increase the value.

Note: An increase of the "Governor Stabillity Factor" may require a decrease of the "Governor Gain Factor" to maintain engine stability.

Illustration 83 shows some typical curves for transient responses.

Illustration 83	g01017530
Typical curves for transient responses (Y) Engine speed (X) Time (1) The "Governor Gain Factor" is too high and the "Governor Stabillity Factor" is too low. There is a large overshoot on start-up and there are secondary overshoots on transient loads. (2) The "Governor Gain Factor" is slightly high and the "Governor Stabillity Factor" is slightly low. There is a slight overshoot on start-up but the response to transient loads is optimum. (3) The "Governor Gain Factor" is slightly low and the "Governor Stabillity Factor" is slightly high. There is optimum performance on start-up but slow response for transient loads. (4) The "Governor Gain Factor" is too low and the "Governor Stabillity Factor" is too high. The response for transient loads is too slow. (5) The response to transient loads is adjusted for optimum performance.

The default value of the "Governor Compensation Factor" is acceptable for most applications. Do not adjust the "Governor Compensation Factor" unless the engine response to changes in load is unacceptable.

Decrease the "Governor Compensation Factor" until a slow, periodic instability is observed. Then, slightly increase the value. Repeat the adjustments of the "Governor Gain Factor" and of the "Governor Stability Factor". Continue to increase the "Governor Compensation Factor". Readjust the "Governor Gain Factor" and the "Governor Stability Factor" until stability is achieved. Adjustments until the engine response to changes in load and in speed is optimized.

Illustration 84 is a graphic representation of adjusting the "Governor Compensation Factor".

Illustration 84	g01017541
The width of the line for the actuator voltage indicates that the throttle actuator is more active as the "Governor Compensation Factor" is increased. (Y) Actuator voltage (X) Time in seconds

Unburned Gas − Purge

The following events cause unburned gas to remain in the air inlet and in the exhaust manifold:

• Emergency stop

• Engine overspeed

• The GSOV is commanded to close and the GSOV does not close.

• Unsuccessful successive attempts to start the engine

Unburned gas may remain in the air inlet and exhaust system after several unsuccessful attempts to start the engine. The unburned gas may increase to a concentration that may ignite during a successive attempt to start the engine.

Perform the following procedure to purge the unburned gas:

Note: This procedure will not work if the engine control does not control the GSOV.

1. Connect Cat ET to the engine.

2. Verify that the value of the "Engine Purge Cycle" parameter is equal to 10 seconds less than the value of the "Crank Cycle" parameter.

3. Set the engine control to the START mode. The engine will crank for the "Engine Purge Cycle" time. Then, the gas shutoff valve will be energized and the ignition will be enabled. The engine will start.

4. Continue with your previous procedure.

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

1. When performing a retrofit installation, record the vital information in Table 22.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 22

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number(1)
   Removed Component Serial Number(1)
   Installed Component Part Number(2)
   Installed Component Serial Number(3)

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   (1)	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
   (2)	Record the highest level retrofit kit, arrangement, or group part number.
   (3)	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 22 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".

References

If further assistance or information is needed, refer to the manuals that are listed below:

• Operation and Maintenance Manual, SEBU8099

• Troubleshooting, RENR9353

• Systems Operation/Testing and Adjusting, RENR9352

• Parts, SEBP4747