Installation and Initial Start-Up Procedure for G3500 TA Engines {0374, 1000, 7000} Caterpillar

Engine

G3516 (S/N: AL71-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 G3500 TA Engines:

• Required information

• Requirements for the electrical system

• Grounding practices

• Proper welding procedure

• Service tools

• Initial start-up procedures

• Unburned gas - purge

Reference: The following information is required to perform the installation and initial start-up:

• Complete analysis of the fuel provided by Gas Engine Rating Pro (GERP)

• The performance data sheet for this engine located in the Technical Marketing Information (TMI) database or located in GERP.

• Operation and Maintenance Manual, SEBU9297, "G3500 Engines"

• Systems Operation/Testing and Adjusting, M0081470

• Troubleshooting Manual, M0080340

• Special Instruction, M0073032, "Customer Interface for G3516 TA Engines"

• Systems Operation/Troubleshooting /Testing and Adjusting, UENR3193, "Gas Compression Operator Control Panel"

Required Information

Ignition Timing

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.

Maximum Load

The maximum load that the engine can handle given its operating site can be found in the fuel analysis results generated by the Gas Engine Rating Pro (GERP) tool.

Inlet Manifold Pressure at Full Load

Use the inlet manifold pressure to estimate the load on the engine. The inlet manifold pressure may be used if the engine timing and the exhaust emissions 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

The 391-8170 EMISSIONS ANALYZER TOOL GP or 393-0673 EMISSIONS ANALYZER TOOL GP 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 an emissions analyzer to setup the engine, when possible.

Note: Failure to adjust the air/guel ratio to the correct NO^x levels can result in excessive misfire and/or detonation during engine operation.

Gas Pressure Regulator

The gas pressure regulator requires adjustment when the engine is installed. Use only Caterpillar approved regulators to avoid problems with performance.

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

Note: Refer to Special Instruction, M0073032, "Customer Interface for G3516 TA Engines" for detailed wiring recommendations.

All the wiring must conform to the requirements of CSA Class 1 Division 2 Group C,D. The wiring must conform to all other codes that are applicable to the site.

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 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. A circuit breaker of the correct size must be provided by the customer for the power supply to the engine electrical system.

The circuit for the engine control system must be separate from the circuit for the electric starting motor.

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 to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.

1. Set the engine control to the "Off/Reset" mode.

2. Turn off the fuel supply to the engine.

3. Disconnect the negative terminal from the power supply.

4. Disconnect the following electronic components from the wiring harnesses: ECM, throttle actuator, fuel actuator, and all sensors.

5. 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.

6. 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.

7. Use standard welding procedures to the weld the materials together.

Service Tools

The tools that are listed in Table 1 are required to perform the electrical installation and the initial start-up.

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 ECM box. 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 1	g03794091
Connecting the Communication Adapter Ill (1) Personal Computer (PC) (2) 370-4617 Cable As (3) 317-7485 Communication Adapter (4) 327-8981 Cable As

Note: Items (2), (3), and (4) are part of the 317-7484 Communication Adapter Gp.

1. Set the engine control to the OFF/RESET mode.

   Note: The communication adapter will power up when the adapter is connected to a PC or to an ECM that is powered up.

2. Connect cable (2) to the USB port of the PC.

3. Connect cable (4) to a service tool connector.

4. Restore electrical power to the ECM. Verify that the "POWER" indicator on the communication adapter is illuminated. Make sure that the PC is powered up.

5. Establish communication between Cat ET and the ECM. If Cat ET indicates that there is more than one ECM, select the engine ECM.

6. If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".

   Refer to Troubleshooting, "Electronic Service Tool Does Not Communicate" if any of the following conditions exist:

   • Cat ET displays a message that refers to a communication problem.

   • Cat ET displays "Error #142 The interface hardware is not responding".

   • Cat ET displays a message that indicates that the firmware in the communications adapter is old.

Connect Gauges and Instruments

Water Manometer

Illustration 2	g06254561
(1) Tap for the pressure gauge

1. Turn off the main gas valve.

2. Remove the plugs from tap (1).

3. Connect a 1U-5470 Engine Pressure Group or pressure gauge.

Emissions Analyzer

Install the emissions analyzer to monitor the exhaust emissions in the engine exhaust outlet. Analyzer should be installed ahead of any exhaust aftertreatment (catalysts). Remove the plug that is located in the exhaust inlet of the turbocharger, or in the exhaust elbow on naturally aspirated engines. Connect the emissions analyzer in accordance with the manufacturers instructions.

Note: An emissions analyzer that can measure NO and NO₂ separately must be used to check the air/fuel ratio control. 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 NO_X emissions level. Calibrate the emissions analyzer for both NO and NO₂ as needed to maintain this accuracy 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

Specifications

Introduction

This Test and Adjust Procedure covers the initial setup of G3500 TA Engines. Before performing any of this procedure, read and understand all the information below.

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. To adjust the air/fuel ratio.

Required Tools

For engines above 1524 m (5000 ft) use the following tools:

• 146-4080 Digital Multimeter Gp

• 343-3320 Speed Sensor

• 344-2650 Wiring Harness

Illustration 3	g01397982
(1) 370-4617 CA3/PC Cable As (2) 317-7485 Communication Adapter (3) 327-8981 CA3/data Link Cable As (4) NETG5057

Test Preparation

Note: An emissions analyzer that measures NOx and CO separately must be used to check and 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 NOx emissions level. Calibrate the emissions analyzer for both NOx and CO as needed to maintain this accuracy level.

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. The methane number is determined when you input the data from the fuel analysis into the Caterpillar Software, "Gas Engine Rating Pro (GERP)".

Fuel Analysis

1. Obtain current fuel analysis.

   1. Use the methane number to determine desired timing for engine setup.

   2. Enter the "First Desired Timing" in the appropriate blank in the "Configuration" screen in ET.

   3. Input the "Low Heat Value (LHV)" into "Fuel Quality" in the "Configuration" screen.

   4. Input the "Specific Gravity (SG)" into the appropriate blank in the "Configuration" screen.

   5. Input the "Specific Heat Ratio (SHR)" into the appropriate blank in the "Configuration" screen.

Desired Emissions Gain Adjustment Percentage

1. Input the "Desired Emissions Gain Adjustment Percentage" by following the Adjustment Procedure - "Desired Emissions Gain Adjustment Percentage" section.

Adjustment Procedure - Engine Speed Settings

1. Select "Engine Speed Parameters" in the "Configuration" tab using ET.

   1. Set the "Minimum High Idle" to 1050 rpm or higher.

   2. Set the "Maximum High Idle" to 1400 rpm.

   3. Set "Governor Gain (Proportional)" to 100.

   4. Set the "Governor Stability (Integral)" to 100.

Fuel Pressure

1. Check the fuel supply pressure to the gas pressure regulator. If the pressure is not 32 to 35 psi, make the correction to engine fuel supply.

2. Check the engine gas pressure to the fuel metering valve. If pressure is not 1.2 to 2.5 psi, refer to the adjustment procedure.

Adjustment Procedure - Gas Pressure to Fuel Metering Valve

Illustration 4	g03046277

1. Remove cap (2).

2. Loosen the jam nut and adjust bolt (1) to achieve desired fuel pressure to the fuel metering valve.

   Note: This pressure can be viewed on the remote display or in ET as "Engine Fuel Valve #1 Inlet Absolute Pressure". Subtract the site barometric pressure to obtain the fuel pressure regulator setting.

3. After desired pressure is reached, tighten the jam nut and install cap (2).

Initial Air Fuel Ratio Setup

This procedure is primarily used for initial setup the first time the engine is started up on site to give the best performance results. If the engine becomes unstable or hard to start at a later date, perform this initial procedure again. This procedure is not routine and not performed often.

Changes to the fuel and emissions gain adjustment can be performed during normal engine operation. This procedure is included in the emissions gain adjustment procedure.

1. Connect ET using the tools shown in illustration 3.

2. Start the engine, allow proper engine warm up and begin engine loading. Verify that there are no active Oxygen sensor codes.

   Note: The engine must be running at the least 1200 rpm and at the least 50% load.

3. Connect an accurate Emission Analyzer to the exhaust connection after the catalyst. Allow the analyzer NOx and CO reading to stabilize while the engine is under load.

4. Do not adjust the "Fuel Quality" parameter when the engine is in emissions feedback or closed loop mode to obtain an FCF of 100.

5. Adjustment to the wastegate must be made while the engine is under maximum available load and speed. Adjust the wastegate to obtain "Turbocharger Compressor Bypass Valve" desired position, following table 5.

   Note: At altitudes of 1524 m (5000 ft) and below, adjust the wastegate based on compressor bypass position. Monitoring turbocharger speed is not required.

   If site conditions prevent obtaining rated load, use Table 4 to adjust the wastegate at altitudes below 1524 m (5000 ft). At loads less than rated, the throttle position is less and the bypass position greater than specifications.

   Show/hide table

   Table 4

   Part Load Throttle Position
   	G3516 TA
   Full load throttle position	50-60%
   75 % load throttle position	35-45%
   50 % load throttle position	32-42%

   Show/hide table

   Table 5

   Part Load Turbo Compressor Bypass Position
   	G3516 TA
   Full load bypass position	1-5% (1)
   75 % load bypass position	1-5% (2)
   50 % load bypass position	0%

   Show/hide table

   (1)	If the current ambient temperature is between 35°-38°C (95-100°F)
   (2)	If the current ambient temperature is greater than 35° C (95° F), no bypass will be attainable. Utilize method B for the wastegate adjustment.

6. Check the "Fuel Correction Factor (FCF)".

   1. The FCF should be at 100% ± 10%.

   2. If the FCF is out of range, do not adjust the "BTU value" in the configuration screen to obtain 100%. The ECM may have to move the FCF to obtain the desired emissions. The FCF range is 100%±10%.

   3. Recheck the "Turbo Compressor Bypass Position". Adjust the wastegate as needed.

7. The initial air fuel ratio setup is complete.

Setting the Air/Fuel Ratio (AFR) Control

Before setting up the AFR control check for the following conditions below.

1. Verify installation of the catalyst inlet/outlet thermocouples and O2 sensors.

   1. The thermocouples need installed within 30.5 cm (12 inch) from the catalyst and at least 6.4 cm (2.5 inch) into the exhaust stream. The thermocouples should be installed at the bottom of the exhaust pipe on either side of the catalyst.

   2. The O2 sensors need installed within 30.5 cm (12 inch) from the catalyst. The O2 sensors should be installed at the top of the exhaust pipe on either side of the catalyst.

2. Follow the Application and Installation Guidelines for insulation of the exhaust pipe to the catalyst. The catalyst and the O2 sensors shouldNOT be insulated.

3. Since stoichiometric varies with fuel property, the AFR control needs set up to deliver the optimum AFR for the fuel quality at the site. Setting up the AFR control involves adjustment of the input "Desired Emissions Gain Adjustment Percentage" as needed to meet emissions with the fuel quality on site. This input can be adjusted using either Cat^® Electronic Technician (ET) or by the Operator Control Panel (OCP 4.3). Follow the procedure described in the next section to set this input. The parameter needs set upon first commissioning and thereafter verified & adjusted upon changes in fuel quality. Check the parameter every 750 hours for the initial 3000 service hours and every 1500 hours afterwards to ensure that emissions are met over time. Verify the parameter when the fuel quality changes by 5MN.

Adjustment Procedure - "Desired Emissions Gain Adjustment Percentage"

1. With the ECM powered up and the engine not running, check the Malfunction Indication Lamp (MIL) indicator. The MIL light should not be lit to proceed with adjustment of "Desired Emissions Gain Adjustment Percentage" parameter.

2. Start the engine.

3. Monitor the coolant and oil temperatures and when appropriate, apply load as needed to reach maximum operating load, ensuring at least 400° C (752° F) at the catalyst inlet and outlet. Ensure that load is maintained as steady as possible. Verify that the catalyst temperatures have stabilized.

4. If the service tool is connected to the ECM, check if the AFR control is operating in closed loop feedback by following the procedure below.
   Show/hide table

   Illustration 5	g03823277

   1. At the menu bar, go to the "Diagnostics" menu and select "Diagnostic Tests".
      Show/hide table

      Illustration 6	g03823324

   2. Double-click on "System Troubleshooting Settings".
      Show/hide table

      Illustration 7	g03823326

   3. Double-click on "Emissions Feedback Mode". The current value should read "Oxygen Feedback".

   4. Click "Cancel" and exit the screen.

      Note: Once the service tool is disconnected, the AFR control will continue to operate in closed loop control once the appropriate conditions are met.

5. Measure and record emissions downstream of the catalyst. Record the initial value of the input "Desired Emissions Gain Adjustment Percentage", if the emissions data was recorded with the input set to 0%, record 0%.

   Note: Adjust the parameter, in the section below, to meet the emissions. At each adjustment setting, wait at least 10 minutes between each adjustment. This will allow enough time for the catalyst temperature and emissions to stabilize.

   1. Decrease the percentage value in 10% increments, from the initial value, with a 10 minute interval between each increment to allow catalyst to stabilize. At each set point, measure and record catalyst out emissions once the emissions have stabilized. Decreasing the percentage value will result in richer air/fuel ratio through the engine. Once the air/fuel ratio is richer than stoichiometric for the fuel, total hydrocarbon emissions will increase as shown below, NOx emissions will decrease and stay at the lowest level that can be achieved. Take several data points, with the richer set point to confirm the low emissions with NOx and higher emissions in total hydrocarbons. Based on the results from the preceding steps, interpolate within a narrow range to determine an optimum setting for "Desired Emissions Gain Adjustment Percentage" that meets emissions requirements.

   2. Increase the percentage value in Cat ET in 10% increments, from the initial value, with a 10 minute interval between each increment to allow catalyst to stabilize. The increments need to be whole numbers. At each set point, measure and record catalyst out emissions once the emissions have stabilized. Increasing the percentage value in Cat ET , or OCP 4.3, will result in leaner air/fuel ratio through the engine. Air/Fuel ratio leaner than stoichiometric for the fuel, will result in increase of NOx and total hydrocarbon (THC) emissions as shown below. Take several data points, with the leaner set point to confirm the increase in NOx emissions.
      Show/hide table

      Illustration 8	g06246076
      This graph is for reference use only.

      Note: Illustration 8 is for reference use only.

   3. Repeat the "Desired Emissions Gain Adjustment Percentage" adjustment procedure described at 10% load (or the lowest operating point that the application will run). Select an optimized "Desired Emissions Gain Adjustment Percentage" that will satisfy emissions requirements at both 10% and maximum operating load.

   4. Input the optimized set point in Cat ET or OCP 4.3. The input may need a minor readjustment to meet emissions across all operating conditions.

      Note: The input is retained across power cycles. However, this value will need to be reentered when software is reflashed on the engine.

6. Exit Cat ET. The engine will continue to operate "Oxygen Feedback" mode (closed loop control) as part of normal operation.

As part of normal operation, engine control will calibrate to the catalyst using the new value for the "Desired Emissions Gain Adjustment Percentage" once all the enablement criteria are met. The calibration will be attempted after 1 hour since this input was last updated in Cat ET. The calibration process could take up to 30 minutes to complete. The catalyst calibration is performed to ensure that optimum AFR is maintained as the catalyst ages over time. During the catalyst calibration period, the emissions may be outside the allowable limits. This mode of operation has been declared to the appropriate regulatory authorities.

Note: In general, most emissions analyzers report total hydrocarbon emissions (THC). However, emissions need reported for non-methane, non-ethane hydrocarbons (NMNEHC) portion of the total hydrocarbons (THC). More emissions measurements may be needed to subtract the methane & ethane emissions from total hydrocarbons emissions since the catalyst cannot oxidize/convert methane emissions across it.

Adjust the Turbocharger Waste Gate Setting

Adjustment Procedure - Wastegate

Note: There are two procedures indicated on the Engine Set Up Requirement Matrix. Procedure "A" allows the engine to be set up using the throttle and compressor bypass position to attain the correct turbocharger speed. Procedure "B" requires the use of the turbocharger speed sensor and the turbocharger speed charts to determine the target turbocharger speed setting. If the indicated load falls between the values noted in the charts, you will have to interpolate to obtain the correct speed setting. Procedure "B" can be used at any time, but, procedure "A" can only be used where noted in the Engine Set Up Requirement Matrix.

Illustration 9	g00814530
(1) Plug (2) Locknut (3) Adjusting screw

1. Remove plug (1) and the seal.

2. Loosen the locknut (2).

3. Turn the adjusting screw (3) to obtain the correct turbocharger speed.

4. After the desired compressor bypass position or turbo speed is obtained, tighten locknut (2) and install plug (1).

Procedure A

1. Turbocharger speed setting procedure.

   Note: The speed of the turbocharger will increase with an increase in temperature for a given speed, load, emission setting, and altitude.

   Note: Wastegate adjustment cannot be performed if the available load is less than 75% or the engine speed is less than 1200 rpm.

   1. Use the tables in Illustrations 7 and 8 to determine which turbocharger speed setup procedure can be used.

   2. Procedure "A" utilizes compressor bypass actuator position to determine proper turbocharger speed. Procedure "B" utilizes turbocharger speed sensors to determine proper turbocharger speed.

      Note: When adjusting the exhaust bypass valve to attain target compressor bypass position, avoid adjusting the bypass valve adjustment screw all the way to its lowest setting and/or until the exhaust bypass is completelyclosed. If this should occur during the setup process, the procedure for turbocharger speed setup should be restarted. Shut down the engine, reset the exhaust bypass to initial setting and begin the process again. Also, as throttle delta pressure and compressor bypass position increase, turbocharger speed increases. If compressor bypass position and turbocharger speed stop increasing, the exhaust bypass valve should be checked for proper operation, the adjusting screw should be reset back to the initial position, and the procedure should be restarted.

1. Start the engine

2. Allow the engine to warmup and gradually load the engine until available load is reached.

3. Monitor the compressor bypass position on Cat ET

4. The correct compressor bypass position is matches table 5.

5. If, the compressor bypass is out of range refer to the Adjustment Procedure - Wastegate (Engines Below 1524 m (5000 ft).

   Note: Set the engine speed to the 1200-1400 rpm and 100 percent load.

Procedure B

1. Turbocharger speed setup procedure B: Turbocharger speed sensors.

   1. Determine maximum turbocharger speed for the site as indicated by the turbocharger speed charts.

   2. Determine maximum inlet air temperature for the site.

   3. Identify what the engine speed and load percentage will be for the site.

   4. Using engine speed, engine load, and emissions set point, identify the correct turbocharger speed charts (Following the below steps) to use for turbocharger setup.

   5. Once the appropriate chart is identified, determine the correct temperature line to utilize for finding turbocharger maximum speed set point. The temperature line selected should be the highest expected to be seen at the turbocharger compressor inlet during the time period between this speed calibration and the next.

      Note: Engine speed instability can occur if there is excess boost (instability can occur with compressor bypass actuator position at or above 45%). If instability does occur and excess boost is suspected as root cause, utilize a temperature line on the turbocharger speed graph that corresponds to a lower ambient/compressor inlet air temperature than the one currently being used.

1. Start the engine

2. Allow the engine to warm up and gradually apply load in order to match any of the following combinations for the respective emission settings.

   Note: Set the engine speed to the 1200-1400 rpm and 100 percent load.

   • Engine speed of 1200 rpm with a load of 100 percent refer to illustration 13

   • Engine speed of 1200 rpm with a load of 75 percent refer to illustration 14

   • Engine speed of 1400 rpm with a load of 100 percent refer to illustration 15

   • Engine speed of 1400 rpm with a load of 75 percent refer to illustration 16

3. Check the ambient temperature, site altitude, and emission setting.

   Note: The speed of the turbocharger will increase with an increase in temperature for a given speed, emission setting, and load. Refer to Table 6.

   Show/hide table

   Table 6

   Ndesired = Nmax x Fcorr

   N_desired - Desired turbocharger speed in Hz

   N_max - Maximum turbocharger speed from setup charts in Hz

   F_corr - Temperature correction factor from Table 9

   Note: There are two procedures indicated on the Engine Set Up Requirement Matrix. Procedure "A" allows the engine to be set up using the throttle and compressor bypass position to attain the correct turbocharger speed. Procedure "B" requires the use of the turbocharger speed sensor and the turbocharger speed charts to determine the target turbocharger speed setting. If the indicated load falls between the values noted in the charts, you will have to interpolate to obtain the correct speed setting. Procedure "B" can be used at any time, but, procedure "A" can only be used where noted in the Engine Set Up Requirement Matrix.

   1. If using procedure "B", install the turbo speed sensor using these steps.

   2. Remove all debris from the threaded plug and the surrounding area. Foreign material must be kept out of the turbocharger housing.

   3. Remove the threaded plug and the o-ring seal. Store the plug in a clean place to be reinstalled.

   4. Check the condition of the o-ring on the 343-3320 Speed Sensor. Replace the o-ring if necessary with 8T-9521 O-Ring Seal. Install the 343-3320 Speed Sensor.

   5. Using a deep well socket to prevent damage to the speed sensor, torque the speed sensor to 12 to 15 N·m (8.85 to 11 lb ft). Connect the sensor harness to the multimeter. The black plug is ground and the red plug is the signal. Set the multimeter to 60 VAC range frequency measurement.

Illustration 10	g03046218
(1) 343-3320 Speed Sensor

Illustration 11	g03046219
(2) 344-2650 Wiring Harness

Illustration 12	g03794085

Note: Maximum operating load is the load % indicated on the ECM panel.

Note: Maximum operating load is the load % indicated on the ECM panel.

Illustration 13	g06243162

Illustration 14	g06243148

Illustration 15	g06243169

Illustration 16	g06243174

T_max - Maximum ambient temperature for the month in deg F

T_current - Current ambient temperature in deg F

Test Procedure - Fuel Correction Factor (FCF)

1. Start the engine

2. Monitor the FCF value using Cat ET

3. The FCF should be at 100 percent ± 10 percent above 50 percent load.

4. If, the FCF value is out of range, refer to "Adjustment Procedure - FuelCorrection Factor."

Test Procedure - Fuel Analysis

1. Obtain Current Fuel Analysis

   1. Use the methane number to determine desired timing.

   2. Low Heat Value (LHV) is used for engine setup (configuration)

   3. Specific Gravity (SG) is used for engine setup (configuration)

   4. Specific Heat Ratio (SHR) (K) is used for engine setup (configuration)

2. With the system powered up and before starting the engine, use Cat ET to disable the feedback system.

   Disabling the feedback system will put the engine in open loop mode so the air/fuel ratio can be adjusted manually.

3. Start the engine

4. Allow the engine to warm up, then load the engine.

5. Verify that the engine O2 sensor is warmed up and operating.

6. Allow the emission analyzer NO_x reading to stabilize.

7. If the engine speed is unstable, refer to the Testing and Adjusting procedures for Adjusting the following:

   • Engine Speed Parameters

   • Fuel Parameters

   • Waste-gate Adjustment

   • Desired Emissions Gain Adjustment Percentage

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 an 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.