AVS Manual Homa / Calera / Route And Salvage Guidotnas 1102925077 Dynamometer Testing of Caterpillar Engines SIS Information {0781, 1000} Caterpillar ynamomeer Testing ot Caterptar Engines (78, 100) Usage: macorx ‘atorpitar Products| ‘NICat Engines Introduction Revision [Summary in SEBFSOTA = ‘Operon and Malnenance 2 ‘Rado now serialnumber profes, Cort Media References ama 19-20 ng engine for DGB Ey document othe proptary processes therln without perission may 8e aston of talectualproperty av bformatn covtind ins documents considers Caerpia: Confira Yt. the necessary information to low a dese to establish a pars reussbily rogram. Reuse and alegeiformatonenaboe Catala dealers and customs to bona trom coat rections. Every ‘fer has boen mado to provide ts most curontinforaton hats krown oCatsplr.Contuing imarvemect and This Reuse and Sahage Gude ma be ud wih te lst etna formation hal aval om Calera, For techrical questions when using this document, war with your Deaor Technical Communicaar (7), “oer suspected err, nacewraces, or uggestans regarding the document sutt afr for fedbac the Servic internation Sytem (SIS Web) inate Important Safety Information Think Work safely. Most acid hal involve produ operation, maintenance nd eps afe caused by faire a cbsere base stey ruts or an accident curs. A person must be alert potental hazards. This parson seul also have he necessary raining, rape, Saetyprecatons and wazringe ae roused inhi instcton and cautons. An acidnt can often be avaidad by ecoghing polenta hazsdous stustions bare sll, an tol to pertrm thes incor (Cterpiar cannot antobate evry posse cteunsiance thst might valve a potntal azar aefre, te warnings In ths publeaton andthe wamings that ao onthe product reno inclusive tol, a procede, a work method wsoperating echique thet sno recommended by Caterplais usod, ensure he sefolyof you and ches. Ensure that the rosetwil ot be damages of mace unsafe byte oparatonlsroston, maintenance, or th eps procares hat are Improper operat, Maveaton, manteranoe or repay ofthis product ean be dangerous ara court ny or oath, oduct, unl you have res and understood the operation, tbcaton, ‘mairtonance and par ifomston. Safety precautions and warning are provided in his manual an onthe produc I those hard warings ae nt etd, badly uy oF deh coud ctr to you oto eter person “Toe hazaras are ident by th safety abs symbol wich flowed bya signal word ch as Sanger, waring of PN “Tris aot alert symbol means Became ales! “Tee message hat appears under the sft ale synblsxpans he hazard ‘Operation that may cause produel damage ae identi by "NOTICE" ibe on the oduct and in thi publiation, Cterpiar cannot antcipste evry possible crcunstance hat might ave apotntal haar. The sat ivoraton in {hs document an ha safely intrmaon on he machine arent alin, Determine hl he los, procedures, work ands, ad operating acnique are sf, Dearie hal the operation, beaten inten, and rep procedures wit not damage the machine, Also, determine that he operat, beaten, matanance, en epa procedures wi not ako the machine urea ‘The infomation the spectators and the itustations thal ext in guile re based on nfrmaton which wa satabie at ha tina of pubiezion. Tho specifcatna, orguea, retro, rosburanact,aurares, Marra, ae coer ems can change at ny tims. Thase changes can afect he sence thats ivan othe predut. Obtain the complete, mos! eurent information bear you tt any ob, Calerpis desler can sul the mst cent ifomaton, ‘Summary Ths publcaton nas been writen to provi ifrmatn othe dlc or tsting engines on a dyoamemster, For proper operation ana say an nga shoul be teste in an approved fait fr dynarorsas. The Caterer Elocronc Technician (CAT ET wil allow onl and monitoring of he orgie trough he master ECM whut derating the angina. -Araceding device wil pad obese up to document te al esl. The CAT ET does nl ecod the dala No ‘dattonal gauges are nooded lo mono the engine. Emergency shutdown systems for lw ol pressure ara ign erga temperature are recommended, Tho facies or yramometers ars éscusse in SEBDOGAZ Engr Oyraromster engine assembly or an inchasisengia aster you donot uso the CAT Eo montor be C175 Engine, ast f gauges wil be rogues Extra gauges for hoo ‘antre C175 Engine, For aditnal infomation about he recommended gauges, refer tote Product Bulli, ‘SEBDUSA2, "Engine Dynamometar Fite’, "insvumert Speitctons” (1) The components hat tfc engine prtarmance ware manufactured propery. (2) The engin was assembled prope (9) The engine setings are cae. amstine ual syst setirgs ar coecthesetings shoul ot be stored in an tempt ochangs power, torque, lates, spac ful consumpton, boost or any aher perfomance characters the fie sytem stings ae comet, confit any ofthe peirmance characarses domanaats a fauly component oan proper assembly of components Thi problem shouldbe caret, Tha daft shoul net ba adden by Improperly altered el yt segs, hie wil raquie seaoralaqusiments ate int shop. An engine wih he proper gowsr and with improper ue eytem stags Isa fauty nai. tn adation tone spt prfrmance chasctarste, cher character of he engine wil be observed. Some oer observations ar iste below + blowby + combustion ga leskage into he caaing stom + aks inthe exaust system + takin the inlet syst ‘Any engine hat xis abrormaliis nary erent aoa fay engi. Aropor tom an engine test. wich shows ne scropancos in any of te perormance charactors, snot the only rtra a an acceptable egie. The engine mut moot teal epoicatons fr orgie performance found ine Tocca! Market Ifrmaton (Ta under General Engne Date Engine Test Specfestons Service Letters and Technical Information Bulletins NOTICE “The mast racent Service Lats an Tecnica iemiion Buln that ae ‘elated ahs component hale reiowed beloreSeghning work. Oten ‘Serv ltrs and Tectia fran ulin contin upgrades repair ‘procedures, pats, and stety norman that pein the parts or omponenis beng rpaire, References References Mosia Number |™* eB o002 ‘antamnation Canal Guleings, “Cat Dealer Contanation Conta REHso18S "Removal and nsalation of Tamperprcet Caps onan RSV Govero” RENR=28 “725PLUS Dig Speed Conor RENRSESO *SPaLA Symevonaa [seap002 Product Buln, “Engrs Dyramometr Fact searasee “Punning Engine Processing Areas - Dynanometar| SEBFASES "Poston scription oa Dynamomtar Test Ara” ‘searsszy | _V2vs!lnspecion and General ornaon fer Gover Assenbiy used in New Sea Fuel Systems (NSF) of 3204, 3500, end 3400 Engnes™ ‘senrazes |‘ Wechancal Gover Grupsin 311,816, an 8128 Engines Equipped with Mechanical Unt Ito” [sersaavs | _Specal nstrcton,“Presture Lubrication Procedure for Remanufactured Engines and Sho loka? ‘seHsH916 | __“Testng ang Aauting of te Wooaward 3161 Covers on tha Fuel njecon Test Beno senaroar “Digi! Minx Pronet Cont for Caterplar 63506 Engines” sennawe "201 Elsie Governor or Generator Stand haus Engines” [Senasozs "Catepiar 3161 Governor " “ ams[senne«a0 "524 and 1724 Boccaly Ponored Governor Systome” sennease “ari 3178, and'3126 MUI Engine Govemors" [Sennosta "PSG Governor wih Cast fon Case” Table? Canceled Part Numbers and Replaced Part Numbers “This docuent may includ canceled par numbers and replaced part numbers Use NPR on SIS for infomation about carcalapart numa and elaced part aumbrs. NPR wil provide he cent pa numbers or replaced pars Tooling and Equipment NOTICE Faure to fo te recommended procedure ore spectied tetng hate requie forthe procadre could suk in camage ta components “o-avaid component damage, ow the recomeranded procedure using the Required Teoting and Equipment rt Number | Description ay arse (O-Ring Sea Ae neaded sae Band Clamp As needed 5.201 lame As neoded trate ‘casket Ae neaded zoosat Elbow As needed Cover As neoded bow As needed Ehoow As neosed 258 ‘ercooler Assay As nesded 80 Hose As neoded seta ‘Belows Aasembiy As needed Frz60 Hames As neaded Freres Hamees As nested Frere Hames As neoded Far Hemees ‘As neaded Fras Hames As neoded Fravee Hamees As neaded Fiat Ehow As neoded 1544 mm (ina) stot pipe As needed 14.4 mm (6 oh) pipe As nested ‘Stock Hose As neoded 1844 mm in) ate pipe ‘As neosed ‘Stock Hose As needed ams1544 mm @GinchBalance Tube Pipe | As neoded 154.4 mm (Sh) sce pipe wih Hose Beads [As nesded General Instructions Thee procedures on prpaig the ange fr ttng have boon developed th ong a several marta sersnne and experienced opera Engine Test [characterises of engine performance ha are specid in TMI orn this bulstn willbe motored ensure conformance oats specications. The ue ofan adv nha ange ot wl i inthe daection of ol lak x Criteria for Retesting Engines is Somatines necessary oreo an engin fle the engine has competed dynamometer lsting in acordanes with ths bulletin, To ensue proper parformancs, he engine must be retesodI one ofthe folowing eri met (1) Engines witb retested ater any charges the stings or components aecting niflow though the agi, al Injected ina the engine, or the combustion process "Neto Net includ isthe removal fanginecomsonons not lated othe performance ofthe ergne, Such as eter (2) The engine must be rested any lsaeaembly and reassembly fhe engine wich potently aftce the mechanical Intgtiyof tha engine orlakago trom the engin take lace. To inch, bringing te ot erseratre of the engine Records of Tests eect each one Te engine et record wl ales inclu thee nth equi ecormance dala which shown te ecton Performance Te under Deal Engines and Spark ned Engines. neu petormance problems nd problems wi pars Correction Factors of Engine Performance “os com ion fairs for ng parrmance found in “Appendix D (Corecon Factors for Engines wilbe uso 0 coroct obsered engine promance (power, rue, Nel aes, rd specif us cone on, (1) The corectn actors fore ot a proseue wil be babes on readng om dy Baromster Thaee values are ‘otrmind req to kp the values win the alowed accuracy and the measured at aiesicton (2) The earecton actors fore el a tamperatire are based on the lamgeralure measured i the a supply tine to ach eaine (2) The carecton factor forthe density of tafe ne ibe based on the fel desiy. These valves are determines Frequent to tay win he accuse requed fr each measurement thas shown nthe chal af lerances foe Air Supply The lt aro te engin wile iterad. The et alr wi be ran rom ouside th engine test. condone are nt afecedby engine operation The neta wil then be conveyed to he engine reunh fe aproprite Engine Data (Engine Tet Speceaion) Fuel Diesel (1) The fol rhe est ibe in aesordance wit the specestons hat are given fn "Append F (Reguemans fr Diesel Ful. Engine power, gue and elles wl be corel for vaio nthe uel deni te 36.0 APL (American Pevclaum insti) The eof ful aadtve ls permite to contol whte smoke (2) The pressure of the fl spp fll the engine fal nk wl be constr adhe prs wl at be ors (an 25 KPa (3.5 pel, The temperature wl be 30° £7°C(85.0°2 36°F). The engine elie ested al he atrance forthe uci he engine el systom Note: to ful emparatre docs not excaod 32°C (8°), thrs willbo m6 rtcsable os In powar. A fs in hortepower wie encounlorad he fel emperatre exceeds 32°C (90°F), due a decreased deri of the sms(9) The fol supaly and etumtines willbe vented othe atmospes taba fakin rym Ina manner, which permis ary gas inthe felt be ‘monitored and released Kher 0 2 fl, the eacings fore rat wl nat Natural Gas A prormance tts il be mace wth fal conforming to dy processed ata gas hat has a wheating vale Cooling Water 1. Cotng water ibe he fokovng meee 4. The ae orb ng wari tm 85°C (2080"F 108 (2198°7). Te into tho parte cet aercooler is ary species tamperatre For 20" = 3°C (660° 54°F) 0 ser esr (19t0" #547 Note:The emulation ofan starader maybe used onthe engine hal were nal preville wth atercoke See the nual engin performance speciation in TMI oth requtemens 2 he nt manifold temperature. Ta het exchanger tals sod fr simulation has ana pressure drop fom 7 4Pa (28.1 ich of HzO) {0 14a (6.3 inch 1,0). oy diferaniain te coor presse or eporaire oven the heal exchange is permites 2. Th resin of th low of coolant in he water cooing syiom fhe fact thats usd or tstng wl be ow cue fe water wi be ne more than 12°C (53.8 °F), The engine performance specications fr some anges wth an abnormal high net ejection may requ arse in tamperaue grater han 12°C (53.8 engine. "Neto: ATAAG Pressure crop it for factory has bo Exhaust Pressure “Too ast aity exhaust system wil rate asta pressure a he out of ho engine exhaust of-2 Pa (80 inch of 0) 02 KPa (6.0373 neh of HO) tulad ard sp008 changes tom 5 14 a, NOTICE For Tor M engin, exhaust back srossurs may ned ob api ring ‘Seeton Tet Engle Testing: Engine Speed Control Mechanical Engine Speed Control ‘Te logue of 8 Ne (708 to 12 Nem (108.2 in) (55 Nem (48.7 Bt 8S Ne (B41 Bn fr he Woodward 14th contol shea he mechanical gover ta maintaln he maximum speed ofthe ering 23161 govamo) Proper conrl frau onthe governor conta has requred for consistent governor setings and hgh speeds. lites, pele systems, special governors, sr overhr contol. Electronic Engine Speed Control Electonc Engines can be eantalle her y using speed overe command ary using te engine hamess rote ‘Wan mounts onthe pedal and lve, the age uy cycle shouldbe as shown n Table 4. However, the possibly acts ‘0 devi fom these vals by aching te tate consguraion win ET, ‘uout win 150 ms of he main power being sued io he sensor. sekng diver wth a fequency 2 OOH (= 0H). The sensor must ge aval PWM Throtile Parameter Configuration ” [Acceptable Signal Duty Cycle Range Released (ow ae) 19 22% Fly Deprossed| 76% 12 90% amsTables Oil Mini Patch Kit ‘Pach Kit shou be used to mani: your engine ofr debs as ho angine begins to breakin. This allows the dyno technician to monitor he ova he pach kt w removing and cating ol itor to inspec fr dab, Te Oi atch can abo he deny chaiinaes of dealer ebuild by catching parc at (lM Paton F356 FT pin canbe found on lprsent ine a dung engine operation amy [Paine rm | SONG ti aaa NT aan se srosdoe aig oma | SOREN Ais th ar aT = 2 javeroo reser pores se )[aooren era |aowrensra ca [pores vr [Ree ea cr a = tae 75sean 3 esr Ott rom a samo poten eqgne. This sods be supple r-sr 2. Olzampl po ruse sung ra aprason 4 ciate back teri, Raum ote eank case er popeetur Sump (1 Supply should have a ht of va a wel ate rlu tne This laws te lan ofthe cousing to remove he atch. 8 sure that eo sup osming fom a pret suppy. The returns Besos in the crankcase. A ‘modified valve cover oforlarger ens, a side cover has proven to wor We amsoe enon wou be en aezeplabl sou, TNs wiry by erane wall Adopting tiple check inthe rel fw inten prventalva mare of ary component wr, thi wi most ten be goss waar efron debris. Conse Itgraton ofthe min pat ito the normal walk around and engine warm up cbcks dg the dye process Forturter analysis fhe debs captured on your pan, lease rte to: ‘SCHSOT7" Parts ClaninassTestng for Caerpilar Dealers -CleaninessTesng Process ‘SEHSOTT2 Paris Cleanings Testng or CateritarDesers - Visually denying Parictte ansseat osssere2 "Wis tan exam oa post ast ar yout tom a dear is 308 practo to eocunar aw your gine an on sy + Inspect rd replace pate tern tarp ar leklnspcten ati wi ne et mses 2 Inspec td eplace pach tinermadate spot warm up 5. nsec replace pale eliarmadate speed ore opting tgeatue seiase 4 Ispect ara repac ath eter Ras speed power check 5 Inspect ard replace pte Pek rq paormanca check pont Engine Test Specifications ‘The rin ongne fos specteatons (rominal pactcaons) ae thse ales that are shown in hed orgie tea pecfeations, Mase values ar ound inte TMI General Engine Oala Engine Tel Spectator). Criteria for Evaluating Performance Test Data ‘The ope for poformance ats ae Sed into tao groups. Theke two groups we “passed” Tae (1) Perfomance tsi are pasted when las esuks are within he nominal pacteation of = 0.90 (speiaton ‘olrances) ‘tine test pases, the petrmance test wihave ante hat states "Passed Pevormance Te (2) Perfomance tsi se alo when any est rasuh souls the nominal specleaon of +.20 (Speciation Tderaneas) ‘tine test fal, tn patomance tet wihave a nol that states "Fala Perfomance Tes. (a) fhe perfomance ts as because of est asl conta byte engine Tabi), the report wil provide approetate noes. Ths report includes nota that staos "Ropar Eng (2) he perfomance ts as because ofthe esl rom test cel (Tle 2) hereof th ests provide a ote hat Hate "Rep Col - Retest Engine (at be perfomance test falls because of ts est thats conta by bo the engin forthe ost wil aves nol thal stats “Rep Engine and Repair Cal by tho test alte oper (a) fhe est ata shows the engin tobe potesalyasustate, te report om he tes wi provid a note tates "uel Systom Check and just Reged. he tat fe fora reason exceptor the ul rate, power, oor the report or he et wil ako provide ote at sale "Repair Engine, ‘Tort Results that are Controlled by the Engine a Coected Powe of Full Load ew a High ne Spee RPM 13 Low ae Speed Few se Comecte Fuel Rate gine ons19 | Conected Specie Fel Consumption (SFO) | —_gWH 0 | ___Corecea Torque 9 TC RPM No a4 rn a TORO in 2 sro a Te RPM oun 8 ‘Asjned Boos a TC RPM Pa sr Response Greek Tine . se Power Lessiynaer Rated Power a0 ‘Spocte Blowoy Lawn 8 ett Jace our) 6 es OP resi Pa 56 ‘1 Press Low le Wa sr Temperature to Bearngs e 58 Ful Posse Pa fs Engine Syston Vane vot 76 | _ Odean Torque at AF Conta Seting Nm es oh ie Sabi RPM ae ‘ow ie Siabity Few Tales “Toot Results that are Contolid hy the Gel [Fest Number | Description Unite 0 Fl Lond Spo0e Few 1% Governor Seting Speed RPM_| Mechanical Engines Gry 2» “Tere Crack Spo RPM ™ Response Grech (le Speed) | RPM | Mechanical Engines Only % ‘Response Check Speed REM Meera Engnes Gry 142 [Tempra of ackt water Pump het | "6 i rope “ Inet Manis Temperate a «© ‘Witr Tempore o SCAC e i Aopcadle 6 ‘SCAG Water Flow Unie peste ® ot Fat oesure We © inlet Ft Tempra e ° Inet Air Rasteton Pa a Inet Ai Temperate e « Fuel Deny aaa ae : @ Tempera of Engine Wor Outlet | "© sate Static Fuel System Settings Setting Point for the Governor - Mechanical Engines Only “The soting pt or the govemer (engine speed and traue) an operating pont on th cure of engine overrun thats usa fel the governor. The sng speed forthe governor ane soting Laque fo: he governor wil be specfogin te Spectatons forthe Engin Test ams2 soting port fr engine speed conta he maximum spee posion as space n Engin Speed Control ofthe 72 governor wl be set by running the angi atthe spected sting speed forthe goverar wt the al Inietons ‘cont The goveme’ conte contol the positen of he cure far the overrun. Thaotqu shuld be adustad ae eynamameter cont F Only, you nae paromad he nectar ts and need io change nrhe FS Ful Lond Stinger he FS (Ful True Soting) contact your Fld Serio Representative. Tho Fil Sonica Represeraive will provide you wt th necessary Preparation for the Engine and the Test Cell Preparing the Engine for Testing (Outside Cell) Engines through 3400 (1) Determine any aon are missing tam he engine. Obtain he (2) esta ne governor contl necessary. (2) Chak fr states, Remember a et ‘tbe aap forthe a ose alr a0 not ald. the angie has a stars, neta proper plumbing (4) sar that al quod sensors are insnloon te engine. (6) psa any requed hemocouples, 3500 and C175 En (1) Determine any ders re missing Fo the engine. Obtain hese tems anna ote ons before proceeding (2) esta gover onl necessary, (2) Check or airsater. Remember that let ares ae ol ote. He agin has a sats instal roper Plumbing an he asap othe ait hoe. (4) near that al requir sonore installs onto engine (6) tal any gues hemocaupes, (6) sta noses forte sel fa onthe supply ines and on he rot ines. (7) Connect he it pateh to te test adapt. 20 Cytinder 7o7F “8 S¥tind m 793F vary Pen) | HOW EO) | OTR GeO) | BEEN BD) = ‘rent 0) |e HED) fosane Ar Seguired ot Ful Load (10488. cfm) (7628.0 cfm) (7497.0 cfm) rene (coP donnie) | sereouree, | townie (Gauge Pressure) 2 5p) 2 4-5 pa) compe Arongntin'conpeser | att | csp) | tems) Senaush ues Few at Palos (2231.4 em) (8174.1 cfm) (8808.4 cfm) . » (3.23 US gpm) (2.09 US gpm) (2.28 US gpm) 26ame wrt anvsenm| ga stily, [ stcor sen a - er . a achat Water Huet aj 1780 ren) (59786 BTUImin) (48982 BTUImin) (85781 BTU/min) svi sonsonnonm | gM | agit SM | soeserUny imitiwiteweae | weamen | wennen | wemarn camara | Bees [Fer Goren Tc an samme [emis oan snc ana eas op 8) Goes) oom Goes) cuontimrteae fonnmonenn | 2m | sermon a 3,0 Jd. & ey ————— — me ee ante Hae at Erne ilargh ote asain 8 spezrasse ams75.20 Hi Atte Eras Wyler at te Eman @)Lengh ote craoe atin 9 pszrasse (mse ot (0) m0 of sate 10 ntzra8s0 cr15-18Enane yg ott Engr (G)lengh othe Sraoe ‘Test Cell Specifications Dimensions Of The Engine 20 Gylinder 16 Cylinder tow | h Jrow annase | ah entude | atte tude Helen 2505 mm | 3098mm | 2489. | 2528 mm ioainy | 123iny_| (@8inery | (5 ine) 2123 mm 2124 mm ween (e)(9) (238 cn) 3s " 3342 maya (55.2 inc) ans24699 mm | 3486 mm (1952 beh) (357 ine Distance Fer Cerone Of Crankshaft To The Batlom OfThe Ol) 1070.mm tine Pes (42 inch 914 mn (2sinen?? ‘970mm ‘200 nin TOS CORAP Flow (69620. cim) (48000 i) Test Caister Flow (600 US gat permieute | (500 US ga per minute Minrum Aonary Aerook Pp Few S00 5m 00m Engine Comecions see Teche torch Toor Em (zoey etter Sippy ne onan ct ter Rete cone ‘Aeros Wate So Line ane Aachen aren Shura en) corse vt obese mt aan 3600 and C280 Engines (1) Detemine any Heme ar missing am the engine, Oot hese ems ang instal hese Kens betore proceeding. (2) Insta he governor contal an the hams othe gover. (9) Chak or alr statre, Ramamber tat lato stares are nt ete. Ite ng has a star sal proper dapiors for plumbing and ear sos. (4) Remove the sporpata Hac lugs otal he requred sensors, ermocouples,adapee, camectr, and Hoses (6)8y using an overnsad hos, instal ho exhaust adaptor. Ensure thatthe adaptris equipped wi a functional typo K \temocousl or temperature ong er exhaust (6) ostal bbe ating ta the tube fr blow. This uber bating fe requred to bulla pole pressure the _earkeaso, wich ineeas0s tho senstvty of he los cals ptonsezures (7) etal a connscte for pressure rom bowby i the plug just above the nazz ing theo (@) esta at required sensors, homocouplos adapors, connects and hoses. Note: For ine manfoli a temperaies, do nll tb hermocaupl inthe exam rato (9) frecessry instal connectors for se fl on th supply an return nes. (10) Fah te shut of syst fr the sr ad instal te lactic connection, The sacl connacton i usualy tom te harness forthe govern sts(11) Check for any speci sts and instal the reared pressure connoctens, and mocoupls. (12) 11h engine is euippes wit the pelube pump, prepare the engine for ostg, For the engines at ate equiprad wh alr gel pur, isa the lr tne ate the pump bck noe pele syste forte ar om he pallet. This Allows te computor cal he prtue of he a Setting up the Engine in the Test Cell Note Refer to "Append (Fabreated Wing Hamesses for Electronic Engine} forte correct wrng harness for loci engines Engines through 3400 (1) Connect he hoses othe cal, nes, nd wing harnesses lo the prope’ connscton pens onthe engi. "Noto: Install ho rake man omperatur tre mano temperatirs i requsted or if ho manok emseratre is (2) Coanet the 202-2801 Portable Contamination Instructional Ktto acquire a al sample for rod connect tthe ol eoolr ante return wig inthe cps be, th. The suey (2) Ont for gos engines refer tote tet spectestion to delemine It ttle angle transducers equred The tat peofcaton indicate laren srossure actors he hot istad of he seul hot angle, (#) Lower the exaust sack forthe cel over the cept forthe engine ans lamp pce (6) Hook ne 0, sample hose up tothe exaust tack (©) Oni orgas ergs, state tring adapter othe elon eytader number, Plt natimpovat. (7 esta he eng probe (8) Ont forgas engines, remave ary ste er he MAG ground oun systoms. This one to putthe callin conto of shuting dwn the ogi. ho cal not etc the missing spark, the gas wouk conémus to flaw. The gas woul ow Lunt thecal cous detect aro Revautens Per Minute (RPM). Losing the spark cou! cae he gato Bul up the stack whic can asus He g85 0 explode (9) Tur on the wate supply ofthe Engin Jacket Water and Separale Cit Atercdlr(SCAC, Liston anook for (10) Comet ne 24v OC elcrial suns tthe star. (11) ine engine supped wih air starter, cared he supp (12) Fun aller for tn al star wh ar tooo (15) Foe quality inspection heck forthe otowing ceria Belore testing and dung testing + Loose pars, missing pans or damaged pats + Proper opeatin ofthe engine attachments pumps governors, stares, shuts and gauges) 3500 and C175 Engines (1) Comet the hoses othe al the nes, ad he wtng hares tthe proper sensor, emecouses, adapters "Noto: Ital ho rtako marfls omperatr fe tompotts guested or nocd fr roubleshootng (2) Tum on the water tof he ENN, Listen and lok for leks, Sapte atu proce a ep al asks, (2) Postion ne exanst lack forthe cll andlower ano the engine. (4) Chak andr he ol aval forthe engine the Gove, and ne nyomachancal not (6) Comet he magnet pickup wie tothe governor, Ths step i ony for engines wth a mechanical tinct, (6) Connect he wire hat activates the govern THs sep only or MU engines. "Note: B sores engines (Electric Unt hector (EU) donot rogue stops Sand 6. Those engines may require a (1 Conece ine 244 0. cal suply oho sat. (8) he engine i cupped with an ilar, cane ne sr upp (0) FU te oor fort a stan wih ar tooo ans(10) Foc quality inspection chock forthe folowing ela tos tstng and dung tosteg + Lote parts missing pats of daraged pats + Engine ot ater el, esau, or ares, less lsovere, sop andrapatrns lea, + Proper operation of engine attachment (pumps, ovemor, stares, hu, and gauge). Note:The 3512 machine engine wl any requis th us of ONE aierooler assem to provide adeauate colin. The (0175 engines will eqs tho use of TWO afercsolerassombles ‘Te hot charge athe compresses a tat i avg te ubochatgerWavalng toward the afercoler. The call ar chargo's th cooled irom na attorczcer retiring tthe exake mantol onthe engine. The connections t tha engine vw vary betweon he eforant engine dus othe fret siza connectors onthe rake mantis ‘A conactons wil use a hove bead ype conto wih standard hse clamps, The excapton fhe 20 Cynder High ‘Attuds he charge ar connecter. The 20 cynder ih atitude engines wil usa are connections wi V clamps. Tho 20 Oylnsr High Atte engines use the fare connacions because of he higher hot charge a pressure of hs hgh aude 20nd engine. tie recommandedousertrchangesbe connectors tothe engine. Then fabcating enrol aMernt ht artes uspvng ho atercooles isnt rr, Retro staon 11, lth fSrcsted ar nes shoul nize ho nor of beds an tus nd should maximize he radius te Bons when posible. This Now wil minimize the pact fait ‘to teough he ns. Thea systems can use sta bes, eb hose, 0 @ combnaten.Ensusthe mete hats sad adresses the dferant charge arpossurs and temperatures, ‘The system wi use 1514 mn (@ inc) steele. The ses utes he hota ines rom the tbocharger anf: he eld a retum nes tom the at-ooke.Diterent agape ll nee tobe consrcted depending on the engine contin you are testing tte recommended to usete ins tom te machine wrere posible lo minnie fabreton. Gdancs fo tation povided. The acta ength of he ubng andthe spac desln must be addressed for sation a ecch dealership > best sute-spectc room size and layout Imsemten 1 nearer Exar of 20 nit Hgh Aus Engne Corestr | pectic adapter (8) canbe ftricated for aan engine applet. Ths aeeper can be connected tthe eng wit he factory ines, The rat of th syst (A) ean main Bascal the same an ennocted othe space napa ih 8 othe, “The fllwing ustrations show ho two angos tha wil edo bo fected soho proper adaptors cen be used 7018Inston 4 goezra879 aero Flange Dinerions tat arash aa inane rye ™ Crear) sores 4 EA omer = station 15 pezrasas 20.Gyner High Abad Hol Ae Charge Flange Note:The 3512 mactine engine wil only aque the use of ONE aftercooler atsemby to provide adeuatecotng. The (C175 engines ll equ he use of TWO aftercooler assembles “Te comprossed st ows rom he comprosso trough 158.4 mm (6 inch) stool pipe, The hot ir ravels to oach of the sitercoolers though an bow tal oles orate aecook. Te hela then cased by Waveling you the water ‘iced atarcoolere and out ough anatar elbow, The cooled a then Wave tough a 1544 rm (6 ne) see pe backto tho engine ware it enters th take man, ‘The following stration shows he base connection ofthe iinet a placement the elbows and gaskets. The 18 Cylaerconfguratin i shown, but the bei yout wl aman th same forall engi ezes Due to he varius lyout parameters that can 69 use, exact meson forth engi of ho 154.4 mm (6 inch) tel pipe wl vary. Remember to ee th rium numba of bends wn you ao routing he 154.4 mm 8 inch) too pips. ‘Apalanc tube pipe wil ls nae abe fabictad and netallad between the tao RETURN ale, Te wl pert the normalization of agossureoferences behween the two atercoolers hat may be caused by fabreaton and other foots, ‘The balance ube pipe shoul aso be consieted of 154.4 mm (6 rc) sea ip 1544 mm (6 nc) stool pes thet rat the cold a tothe engine. rid should be place between the two Note: Speci structions on febating he engine connect fr 1 engine are shown tron i document jescription 1 Febricated bow 2 1544 mm (inch) ston ipo 3 544 mm (inc) stele 4 ‘Stock Hose 5 | tsrsz0 Gasket 6 | aovssaa Cover 7 | zoss58 ‘AercoolerAssobly ° 1544 mm (neh) sel pe ® ‘Sock Ho 0 1544 mm (GinehBalance Tube Pipe * Hose Bead ve | tessa clare anstis recommended that you instal @ dan valve inne baton fhe elbow forthe cooked a tat “Tris wl atow yout sain any condensation tat dvelps in th loo. ing te atarcolet “Te cole ately consi ot stercooler has a grove forthe 1725588 O-Ring Seal. Ts grooves onthe a INTAKE ste fhe arcole You Wl havo to cosines TWO cooler assembles forthe C176 Dyramomeer Note Fale a propery hola for th turbocharger witesulin a fed areal coe “Thor alo a rubber sale area thats athe ends of ths cover on he same side asthe groove forthe Ong Seal tis ‘cal hat the hol fromthe bocharger anlar the colons ie. Fale to propane hat a rom the \uocharge wireline atercoolr cre, Once te acto of pope a Naw i deena, mak he cection onthe outside fhe atercoker wih an arow tat shows te proper ar fw. This wl aid proper assem You can also foo to aterceler core trough te opning inthe coves forth rubber sald area aor he covers have bon the turbocharger "Note: Fale te properviwho hol a fom the turbockargerwiesutin a flo afrcoler caro as.(02008888 Cover (2) 2154258 AtacelerAesety (oy 2002818 Cover (eyzan3888 Cover (6) 1215808 Gasket, sein 21 necreser (6 roo fr be ving Sel (7) Rvver seated 08 (@)Dreten of atone “Tha back sie ofthe atorcooer cre doos not have @ groove forthe Ong seal. Ths groove canbe machinad into he {aco and ten another 1725835 O-Ring Seal canbe salod, Using 10.8848 Gaskat Sealants an optonin pace ofthe ‘machined groove or the O-%ng soa an provides good Sol The 1U-4548 Gasket Sealant has boon varied tosting ‘8.90 cegreeslbow wil ness be fabricate or adapting o each ofthe botom of he two aftercooler Use the folowing als ts nd uation fr assem ifornaton. The parts tha a led ca be arias by using the oration tht Is previously sted nis document Rete tthe Seton “Charge A Coola” fer mote niermatn. Four constr wl bo rogue tobe faricated. Tw connectors will de use for ach ofthe we atereooes Parts List Item [Description A | _ Aterodler Flange 8 [1544 mm (ine) toot pipe € ‘Coup Farge . ‘Asante ange Tet a Pc seen 22 08278500 ‘Th 20 cyndar High Aude engines hat a charge uses 154 mm (6c) steel tbe wih are connection. The $88- 1230 Boows Assemsly an tho 2-1841 \'Bard Clamps rom th angine canbe used to camect oe ATTACif ho tubes use th coract adaptors as show inthe folowing chart and stats. 2s# 1544 mm (Gine) soe ipe © 1844 mm inch) Couping Flange w ‘cock? 0 154.8 mm (inch Adaptor Flange @ Tad yeaah ieniennarn 3 = . Ee, ° msn 26 oezr1s 2008 (894m 2.18 neh (225 (020m) (0) 32838818 camo (142076 Hose “Tos 20 Gylndar Low Aude engines use a hose bead ype connector. The hat charge a pressures lower nthe ow tute engines so 8 hose bead ype connection can be use with atonal hos clamps. The stock 28-7379 Hoge can i comecid to he hate bead by using he soc 135.8261 Clamp. ns:“Tha cold al charge fort low albtde 20 Cylinder Engine ithe same coniguration asthe high tude 20 Gylndar engine, Rafer to “Cold Ai Charge for more information, The 18 Cylinder engines use hose ead ype connector. The hat charge pressures lawaran the 18 Cynder engines 50 hos bea ype connection can be used wih weatonal nose dams, Tho stock 3124784 Hose canbe connects tothe hose bead by sing the steck 135200 Clamp, An aeaptr wl ood to be Sonesta to connect he 1544 mm (inch) soa pipe rom be aferaoler tothe 127 nm (Sine) hoxe on the orgie. Rete the folowing ible sn [Part Numbor [Description “ 1544 mm (ine) stele e 1844 mm (inch Couting Fnge o coke? o, 1846 mm (inch) Adaptor Fane Tae 18 E Fe Frat taper Not sea. ]) 544m se) rer mm gh tel ieal TT a81548 mm (6 neh) Adapter Flange © 208-5261 ‘Adopter amsFabrat capa. Net sea.suggestion a one posse ans:an ean of erodes hata tng wa oat Wen you are mount he ure tha you potion he atercolers so at the water is canbe easly attached tothe wate pors. This Is especialy rif you are moving th aftercooler assombles vertically, ae std inte fllowng table. One O-ng sels usd on each elbow. The elbows ar bate ohebotom one torcoolers, as shown, Tho water connectors shuld be rotted as needed to accommodate your wae In connectons. ‘Te aero shoul operate win a range of 62 KPa (8 po 350 Pa 80 pi). The water supply uses ding esting had an nut temperature of approximately $0 (86°F) and resutd in a needed ow of approxima 600 (12 US ga por minuts ‘Te aur water pump ean be used fr wate flow a ong 35 he required pressures are aderessed, During ating, 9 ¥ cdaotr was ued o Supe) water to each aoa em te allay water pump neh cole wan lo ted wi = simple purge system lo purge anya ko heap of he cles he coca re being led wih wate Description ow zoszaeo | Bow zeraet | Show arate | ong Seat -ans:‘anal oe ar purge sytem far to aero, _Abypatt i uted ctl he water rns tothe aoa AY aperia sedoaed ech clr tn th stay water as.interne cornet elbows tre nouns the btm athe ated assent. Inset 45 pszresr9 Tho 16-1785 Housing a Rogutor Group ‘Tea 797F and 703F mechnes have fame-mountad jacket war tomportre contol syst and are not wih ha engine vwnan pled fom he veil, When the eng esladm the drarometer roam, Jacket water tamperatie control ust te adders. One pen vernedy is to lle the 70-7785 Hesing and Repu Gp om 3600 fay of engines “Ths stand alone Novsng an regulator group canbe outta on abe stand or oud n canton wih the ATAAC subsites sytem, tne stae ayetem nas been round on sma movable ito or car. 4001 Water “Temperatus Reps sould be use in place of the 4852 Wale Temperature Regus (sted wine group ‘The 4-401 Waar Temperature Regulator wil cress the 7B" (1724 Fret tomperture tat i specfad for be (C175 engine tne dyamomstr om hs itemal conto such a8 close loop sytem, mu drs the 78°C (1724 Fyiett temperate spocitcaton, A derate for igh coolant emperature wil appan fe engine gots to het A orto occurs at 101°C 2138"), a reared a the sonsor beats onthe oul fhe angins block. Tors no dette associated forow cola temperature, however a waning willbe lashed fr ow colnt emperatr. ams:no 434-8381 Asap Note:The 424391 Asap 175-18 engines and 3616 enginasin the 789 ana 703 OF ans.ha 44-392 Roa Flynt fr 617620 Engines The following sacton dott the rvoraton for connecting he Electron Techn tthe enn. nfrmatan is alsa “Toe Calla Electronic Tecan (ET) Oynamomelar Mode i desi total he single 17S modules, This ‘Tee ET Oynamometr mode wil mono te flloaing engine reacouls engine peed, engine cola temperate, ‘Bynamomter mace allows he user i inpul the desred engine speed, The dyramometsrload must bs convaed separtly. ET veran 3.9 das nt low the Dyremomeler mode ad he deta oger torn snutaneouy. Numbers mut be 109. The ET Dynamometer rade designed asthe out of chassis orgies only. £T orto med that's caused by missing sensors or one crcumsancos Dbynanomtrmase can 2 Tum onthe fsl sup. water supp and be avai to allow he engine systems to function ‘ea almounie wale pumps ae operating incor 2. Stan ths ET sofware on he compris connetes tothe agin through Data Link, 4 Run lnc at ane at ecto i fs 5. Prime the engine. Opera th ful pring pump by overng itn ET. 6 Pretbe the engine, 1 Perform he flowing operations + Chacha sgt gauge to ensue thal he rhs been purge tam the jackt water sytem, 1 Chose fel ystom for lok + Ensure tht water is coming outa he MAT dain ine wich nclas hat the aii purged rom be system. ns:8. While ET is unin, slect “Service” and "Senos Procedus" fom te dop manu. Then selec "Dynartomter ode, 8. Awarnag wil appear on the computer. Resa he warning and hen seleet"OK’ 10. The ‘Dynarometor Node Tos wil appear onthe sreen. The se"son appears identical for al onginos hat have ‘Bynamametr Mode capably 1 Wnan you star he program, the "Dested Engin Speed wil eau tothe programmed "Low I speed, Low le forthe C175 engines 700 rm. 12. Wl the deste engine speed et tow le, start he engine By Using the engl tare. AN a sate hats ‘mounted onthe dynamometer can also be uses to tara engio, Theda lw le engine speod of 700 rm ‘may be overiddonto start ne ergne, 18. Aerts eng stare, the ET Dynamat Wade wllontal the operation of e engine 14, Use the tos procedure tat outros Tate 18 to warm up he engi. 15. Wal round the engine lo ensure that he hid ystems rena aking and that he engines operating property 18.To change the engine sp00d, solort "Desires Engine RPM inthe doscinon seston a th Bottom ofthe sen, ‘Then glet “Change. Ateraen thal allows you fo ent he deed RPM over wl appear. For example, the engine wa runing the ow icf 700 ad he dese peed was 1000 RPM, te ta operator would ‘lect on “Desired Engine RPA. Tho tst el operator wou ten make the folowing solectons + Enter 1090 Rm, + Saleet-0K7 ET Dyoamometer made wi us he ful sting to nresse the engine RPM ote dese vate {7 .Afor you entrthe dosed engine RPM, asus he dramorote lod by sing the water vake othe Ayramomster conta yar 18, Selecong Disables Over at any ie wil rose the engine othe ECM programmed ‘to C175 one. Note:The Engine Rating Map Overise opine uted to eantol he contest modes. peed of 700 RPM for 10,Use the nfrmaton Table 18 and th ET to conta the Oynamervear tet, 270. Tate a Schedule Sample (S05) othe engine and wash ofthe engine wie he engine i using 21. Compete est and rou the agin to he low ia of 700 RPM. Shu oh ul sul to sop ho angie. This procedure cannot be accomplishes wt ET. Esltng the program at any tie wil rem the org to ow i. .2,ET Logged Diagnose Codes shoul! be clare ram he ECM bere you ext View te logged dag cds and oar the clagnoste codes. Codes may be logged dv o missing sensors. Codes maybe logged because of ‘rubloshoting work. The codes aud cause a dre when to engin is ald nthe chases, 23, Ex £7 Dyramameter Mode 24 Pero th owing functions fo compete the Dynamos ost + Allow the engoe acon, Shut ofthe water supp Shuto th a sup. Shut of th fl spl + Purge ne ie systms and sconnect al ofthe Dynamamaterconactons 25. te engin o coo Siaye Engin Load Tine Speed Fintoreacin | soxtogs | Smmueseramtersinereaaasopesina | erate Speed Second Brakcin | 60% Load ‘Snes 00% Rates Spoes ‘sobtzaion | 90% Load 25 rials unl 9 yale are stable 00% Rates Spoes Fuluoade | 100% Lose 2rminses Partoom Horsepower check) | 100% Rated Speed” rater 100% save Chock Fut Rates owe ‘Torq ” _sns:“Thre Response igh le Sty igh ie Lowide Sabitiy | No Load Low lle Tle 8 ‘The folowinginfamaton desenbes how ofthe default dyno tet horsepower rating in TM. and changing he dal hortepower ang (vata). 1. Enlrho engine Sera Numb nts TML 2. Clekontn 5 oe He “Deta oad rang rating Torque Converter Stl andthe seconating wie te Full 5. Stan eat eT 1 Saloe"Sonica Proce 98 Solect"Enabe’ 0. To change HP to Full Load rating, Selet Engine Rating Nap Overt 1, Sols "Change"in he bom lf fhe sree 12 puta new value of 2 and clk ‘OK°- The engine shout row test at the Ful Load aig Engine Checks after Installation into Test Cell (1) Perfor pretisication because angie components requte the pelubcation bere caring. The petaveaton wil bo aozomplihosby pressuring the ubreaton sytem tear cranking, Reference Specal Instruction, SEHS8914, "Prossue Lubrication Procedure fr Remanufactured Engnes and Shr Bloks"for mar infomation on pororing ‘so an engin is equiped with 2 preube purp, to complet tartng ler ystom forthe priv pump wills ‘hacked The creckut ofthe system canbe done before the engine test oar he engine test. isnot nacessary er (2) sur thatthe ol ites as fl of land do nt he ers port instatation (2) Pie the ul sytem "Note: Referto tne Inet Contamination Cota Guldelines, PEBL0002, “Cat Dealer Contamination Conta” phatons (4) ihe ot supty or the englne does net uses the aula awe ake of then an excernalo supply must be provides (5) Check he engine ol evel, Baar teanginais arkad, he level of he i pan must be wehin Bo rang fer tating he engine. (6) Te dotermine the perormance oft engine tf load, hao evel must be batween the "acne and th kl Ine procuced ot operation wl show theo eval ran engine thats rope led wah tat postened horzantly in (7) near thathe engine i insales caretl and hal he proper adapters reused la conect the angie tthe Gramamere "Note:The adapter forthe crane mat be concentc wah the yhoel win 0.25 mn (0,01 nc) of Total inate Reading (TR) (8) Check ne intltion ofl required agnosie connections and any spacial connections for instrumentation (Samper {ing maker, ender posse ransdcor,,) (0) Very tat ne ag forte engin is cure. te og i ot erent, th og sould be updated ons,Test Cell after Installation of the Engine (1) sar that al pasture tos are outed and connected pope (2) Ensure that he mermoccuple ae installed corecty and at allne connects oh (@) near thatthe Eleevone Conl Mosul abl rte pope (4) Ensure thatthe supply vals foto operation of the dyeamametar and he conta reopen (5) Mako sve that he valves forthe transfer pear open oa he sysomsthat vo ative. (6) Check hata ational ystoms forthe tos suppor nave been installed comscty and thatthe hoses an cabo routed propery (7) Check tn he proper ue hasbeen selected Preparing the Control Console to Run a Test ‘Access tthe compute forthe ob nacesary a prt lech. "Noto: Tore are numerous manufactirers of arrometers and each ane wth various ype of Data Aeqsilon ane Conta Units. Refer the aprepite Owner's Manual or you parla syste, Performance Test for Electronic Engines Diesel Engine ‘The tx prcadre y oe phaee and condone cf te prosucn et. The spec ofth ped te, and ether conto canbe rd fe epee procera be appa, nocd wh et Spesaton ve ene stato 8 sows aneamgte wih he sages rs hey machine proud. Teta slages we eared nner etal bon Standard Schedule for Test Procedure: ‘CRANK t = Pari Tine irRequred ing an Engi WARMUP #1 " WARMUP #2 7 WARMUP #3 I RATED T evL, CUTOUT x TORQUE CHECK HIGH IDLE \ pe TC tata Sea oe Perform Brake Test Requires LOW IDLE ‘SHUTDOWN ms.Pre-Lubrication For engine components hat requ presutriation as dtemines by engiseting, peta befor ranking, Theor lubniaton sha be accomplshed by pressuring the kbenon system bor cranking. an engine equipped ih & prose pip, th camslte prose pus-staring motor sysiom shall be checked. Chacko ofthe system ca be done Auxiliary Power Take-Off An extemal ol supply shall be provided for any tale air power ake of hat not abit bythe eras ‘Before the eng i rake, theo pan filevl shuld be wl he range designated ante roductondpsek rhe spaced cpstk as safe for saring th engine ‘The tlio pstermance of he engine habe detained with he caret lpn lve Standard Engine Test Schedule ‘The partormance estng of engines should ben accordance wit this document, but can ao re procediresn TM, Data Management Sytem (nsca.com.PSD), and ENGINE Oniabase (Contact LPSO Engine tothe vcualtast Pertersance Carta, fr vrtions ole dl lt poi, an engine slapped elore contain oth ta, the ot ‘rou be run agen sarag wt te warmun achadule, The runing ne spetiad or ach point in tt chad is tho time atthe species speed and torque. Transion tie bawoon pins is ot included as pao he equrod be at Record te folowing troughou ets (or sen ealeulaingcorectinfatrs ard mantoingfaity heat) + Total Barometric Pressure kPa) + Water Vapr Pressure kPa, Ratero Step 2 ro (OES) +t A Pressure (AP) + Foal Dost (APH) «+ it Fue Tnperatue (06-6) + ttt Fool Pressure 3) Warm Up Warm up ofan engines dened as contoning of a eng to cban repeatable engine performance and to purge al from te laid handing systems cf he ongno. This lat: funcon is especialy mporart for engin quipped with an [NRS Coster. The engine speed control ha not be “pursed uring any portion of his pecormance tel, Pumping i he process of edly and llama iereasing and dereesing the engine sped convo andor engine ap "Note: Fr engines equipped wih an NRS Coole, ufcon venting of th coolant system sal be insta so that no ars -ppedin ha NRS Cooler This yal til venting bol the engine side and adits of th horosat. Some canine may algo need a desea ent tine tom te NRS cook 1. Crank 100-700 RPM wih tne eine sped cana postions i prove maximum fue doivery. Oi presse of decontoued engin has nol lard win 2 ines. Aer te engin lars, engine peed al be targeted fo an alvate spa (pel bw dle +100 RPM or cranking spd +100 RPM) at eo load to Bu ll pressre, A rinimum ol rosire of 40 KPa salle cbisined win 3 secands alert engine saris orth engine shal be stopped. The flowing warmup phases (elo Step 2 and} deine anarnaer-highway warmup cyte fren Te nent of ma warmup hasos fo got th engine upto operating temperature as quickly as posse wihout sanapng green oni. {apptcatons can ADD adetonaltme or polis based onthe pptcatiors specie Note: Observe ane listen the engine and aachents or ry unusual vation o sounds 2, Fest Warmup «omit £0.2minite 1 75% rated speed + 0 RPM (no as than low i) [See Note bla 50% aed orgs 59% aod oraue + (60% ated torque 5 ated aque XFL BMEP i 1750 KPa or mote) as,"ete: The engve speed shall not be ncrsased above 75% raed speed + 20 REM ow il speed Iw ile spead = grsierthan 75 ofrates spe, For SO HZ aux ana gost ang, BO rates speed ‘Second Warmup --minte 202 minute. Due te detent let coaing system a venng ait some estates ‘may requie mora ime to purge or te system 0 that adalon! loss wi ot ease overhestng. The ‘uncon ofthe felly and, #equies, the adobe souls be apples to al engines run in at acy, Maximum tine shoul! nt exces hat rogue oh hermosa lo each apering enperaue 1 Rats spond» 20 RPM + 75% raed tongue + 5 aad rau (ome procedures may sped torque magne) ‘Note: Fr appeston wih the NRS system he NR tel shoud Ore ding ae fhe two et warmup sages bor flo, contingent on thermostat opening. Refer Step 6 4. Teed Wormup-9 mints 40.2 minute + Rate Speed £20 RPM + Rat Torque 43%, 11% (some pocadures may speci torque magi) ‘Adetlonl wamup phases may be mplemanted er specie applestons a larger engines where mara time reeds o achieve thera ty, Governor Seng Point (Mechrial Engine) -0.25.minite 20.1 minute govero: sting Speed and governor seting torque par the ndlvaual engl ts! spctistion (a. OT. 27. OK, sevens) [tthe govemor sting pin, te engin speed conta shal beat he mum speed poston and te toaue shal boas epoctos nthe ong tot speseaton. “Tne gover conta which positon the avn cu, sal nt be adusted ater completing the governor ting pont he high dle speeds not corect when onacked the stage described in Sap 4, me governor corres shall ot bo aust. Only repang and retetng he engin can cathe high ie spood, Oat shat nat be ake ul be wale temperature meet the minimum wate lemperalure tae (tom the speciale. ‘ete: For macharcslergnes, the torque apple o mechanical goverer conta shai to main maximum engi ood sallbs 8 Nm to 121Nm (5 Nm to 9.5 Nr fr Woosward 3181 gover). Proper conta of traue ‘on the governor contel shafts eqied fo: consistent governor sting pos ad igh ine speeds For electronic engines, eter a vette nputtothe ECM or speed over contol bwough he ECM canbe uses he same pps to PEEC and he ofan vrsons offi electronic engines) 6 Full Load minutes 20.2 minuto o stabtzton: Fulload speed 10 RPM, Engine speed coral shalbe wihnspecicatn al he maximum speed poston. Engine aro fo bo considered stalized ater actiavng ho fotowing maximum variation per 2minue paid wh runing continuously load RPM + Forsystams using jacket cule wate contro: Jacket wetor pump in 8DEG © + Forsyte using acelin! war conte: sucka water panp oul DEG C + For systems using SOAC net water onvot SCAC inet 3DEG ©. For ALEnginos + on Presse -7 Pa 6 Fuel Rale-1% + Corectes Power 1% (observes power permis fr mani ts ty) ‘Ta noncontal(net or cutt) water emparatr shall be wihin spactcatonbotor ecorngflload data, Foc eninge eaupped wih separate cre lecooe, the ware! emarature shal be within speceaton betore coding fl lod dt, 7 FullLoad Chock - Wh th engine a ho flload point ad stabilized as ouliod in Stop 6, Cael ands rsoré Full Lond Parameters To Record Line # [Param Group |Paramet Unite | Notes 0° FL Power ew) 0 FL Speed om A “4 FL ‘STAT Fuset | mm | OE 6 FL FuoiRate | iin | OE 8 FL osrc [ani | OE -ans:2» FL Boost ven) mam) Boost-RE | We DE Tandem a FL ECMPCT Bee | ca aie) FuelRal Press| MPa) DE-CR no FL FoslPostion | % | OE-CR on") FL lowe % DE FL Waerintemp | -C a 8 FL Detatemp |e a “ FL trot man temp | °C x 4s") FL | WatorTeme scac | °c. al o” FL_| SCACWaterFow | min | Al son ‘Onpress-FE | KPa | DE-Tandom 552) FL o1Prese RE | HPs | DE-Tandom or FL onreesing | °c a 8 FL FuoiPress | wPa | OE 2m] FoslProse Re | we DE- Tandem 50 FL FuslinPrese | ePa | OF 0 FL Fusintomp | “6 | OE @ FL Inecareress | ePa |All em FL Imetartens | °C a 6 FL Foslonsty | APL | OE ee FL water Outteme | °C x BO FL aeastescac | “C | OE e FL | ECW FiratDerte | % 9E 5 FL | DUTAWA0Reaing | “C 1 6 FL | ECM COIvehe? | NA | DE-2007 98 FL GenPower | NA) aa oo FL [EOMOGIFLWW RT | kgihr | DE-2007 eo FL | EomTubo Specs | kom | OF woe | EOMRalPress | MPa | DE-CR ware | FouvetPes | NA | OE-vGT veo | FL | exaust Prse | wPa | OE-T4 wee) ATAAGOetaP | xPa_| _OE-TH ane 18 "cae ano eco pated, Note: 2600280 Diesel For anges equpped wh Kalo valves tka ender pressure measurements onto cadre focinlno engines tour eynders (wo on each bank) for Ve engines at adversod power. Gnarao data repo. Cylinder Cut-Out Check 1. OyInser Cutout Check - Computar Contd Ite engine i equiped to part ut-ut final endars and one of te floning condone aon: CSFC al aod fae or eorested power is more han 5% uti ie spuctcabo ni. This may be trggered erat hs ful oad e rguechace phates. ans:+ Stop combustion process in onder number + Wai uri power messurement has restatized (soveral seconds wl be rqured, Oban average corecod ower ofthe remaining jinders over a3 secon pig, and estat the combuston process + Ropoat the steps abow for each ends in numeral ode. + Power determina in Sti 7 minus power detrminadin Slap 1 i the power a ne cyinde, wich was ot out Calculate and record te percent ns by dvng tn power of the yd bythe powar determined in S07 2 Cynder CuLOut Check OperlanECM Conte - tte engin supped to pam cut-out tnd ‘nde and one of he folowing condone are seen: CSFC or carectd power utede the section Ime + Folow ECM contalineace nections fr automated test + Perform manus stps troubleshoot ndvualoytndes. Torque Check (25-minute 20.1 minut. Ti san exasl ine for n-highaay tuck ghee Fo aher appleaons, histo nun nin ne, The aca e may be mre 1. erase the dynamorstor bad unl be engine gs othe sped spcifed fr torque chock Measurements shal be ten Wii minutes afer lugging ro illo. Engine speed ac oad shall be sated for he reac ‘Stalin i trina by he speed remaining wih speciatlon fra rinmum of 5 seconds ‘ete: For appcatons that operate ata single seed (ganerato es, marine aus) torque check phase ‘may be omted due othe single sped mae of operation of he appteation, This wil bo indicated by nclaon of = ‘tg inthe ts! specleaton OMIT TORO. The ress auton wi be based only on he measurements akan at ‘he tted point, Note: Test Specification Flags re lds inthe spoc hat signal hotest alt porform a ctin operation whon an engi of hal speci Being ested. Flags, ith paar Fld, aes to # evil nue break fective ‘eral umber) of parila spec and wil only be implemented when an engine wih a sei number grester ‘han oc equal otha pareculr beak into cal, These fags are added by sing tb appropri estng caanase application to mod the tst specication Caleta anor ecrd, Table 20, Line # [Param Group [Parameter [Units [Net 6 Fr STAT FueiSet_ | mm | DE ta) FT Fuolng Na | ve 2120 | TACK | FuslRallress | MPa | OE. iv) Tack FuolPostion | NA | DE-CR zo | rack | compet Boot | % oe 2 | Tack ‘Soeea| ‘om [al z= | Tack Torque rise | a so | Tack “Tore nm | An » | tack Foal Rate | gimin | OE se | Tack osecakwty | DE. ss | Tack Boost wa | oe ain | Tack Boost: FE | APa_|DE- Tandem a2") Tack Boos-RE | Pa |OF Tandem wo | Tack Blowby % bE nn | tack — | ecw Final Dente | NA | DE e560 | tack | ecuccivaver | NA | 0€-2007 8 | Tack — |EcMocIvanerT | xahr | O&-2007 san | Tack | ECM Tube Speed | pm | OF: tae | tack | EoMRaiPass | MPa | E-cR woe | Tack | EomveTPos | NA | DE-vor rare | tack | exmmunoxPress | tea _|_OE-TH ns.Tanl 20 Note another las tor se contain i desrd inal by a sp8¢ Mo, lst shoud be pciormed aor torque check 2, Response Chock required byte inivitual ts pectcaton. (Response check for mechanical engines on) Rermowe the dynamometer lad a pil a possible nthe dynamometer i cperting witha maximum of 3% of tale eeue. Opening the dyearvemetr Bld crcl and sutanecusly cloing the war sul valve wth steroids aseauate ‘Adjust engine speed contol necessry ‘omainan the specie response check ie speed, The engine ‘ould be bough the etponte check ie apees wih he us sytem at shu. The engine speed conta does ‘ot nad oben te minimum postion, Atte pected raspanse chack il tne ater iatg load removal, Inerasa the sting othe engine ped cont thas been reseed, ae apn ae possible (1 second maxi) ‘othe maximum speed sating and ads the dymamer load as recuite o mann response check pees. Reeponae leis the tine fo te sat ol change in engine speed unt the speciied logue cbsined Recors + Responde Check lle Speed (RPM) Response Crack Specs (RPM) + Response Tine (e) Manual AF uel Contol Check-in et aiites in wien heel engine fulloss check a8 deinen Step Tie nol compulrzd aleurone ae), an engines to check tal he aul canal ting i orect it ‘aquired Win be engine runing al igh i ad wit the boos senng fe daconneted, pte angi oad epead, Measurement fhe aruelconol ting fot equce Recor Observed Torus Nm) High dle Cneok 010 minute Remove the dynamometer lad uni the dynamometer porting wih a masirum of 3% frat que With some ypes of dymamomaters, th load cat be lwo is va. Ite ocd can be lowered 10% of ated torque, exapoitng a tight ne om the govarar etng pit trough the owen ainable argue ro ‘erque a cban a high ile vale sattactary. Maaiing a oed on he eagne fo tbizng he high le speed isnot an accoptable proces Fgh lle Spoee (RPM) Fgh lle Stay (ROM) ‘uring the high i spaed cnack, ne engine speed shal not vary mors han: + Gon set and marne aux ongines + (ated sped 300, 1 Altieri enginas = (ated speed 200; ‘ete stably isa parametrin ho given spe, ts a passa cere. Knot, then teen ho duration of ‘hs toa phase unt the ete it ma, o the maxim En i eachad Ife hig le spaed isnt creat cans ceca ony byrepating and retesing the ergne Low te Point 0.10 nul, raxinum dyramomer load equal 3% fated torque. For mechanic engines, ee lw ide speed win § minutes of bsg fa load dl, Unies of temperate Isimalnainos at fillad temperature by 2 spec st conduct imdataly bor th ow ie pon. Recors + Lowi Spee + Low ide OF Presse + Low lle Spees Sablty ‘tet stably isa parametrin tho given spec tia passa cere. not, hen extands tho duraton of ‘toa phase unl tho ete it mao the maximum Ee i eachad. uring the tow te speed chock, the engin speed sal at vary mar than #10 RPM. NOx Reduction System Test NOTICE ams.Do no eave aut te NS ooo eras setting or serlng,Flie to replace cole avatersin C93 Ter 4 engnss can kad NAS alu and ‘gine damage, |ANOx Reduclon System Testis tequted for engnes with NOx Reducton Systm (MRS). The NRS Test should occur ting one of ho fa warmup siages. is agers in computerzed test cos bys ler #Rap, ‘Toe NRS ed fling ost wil ot tart ut eran contlons are mel and wil abort if cosn Diagnose Trouble Codes fe found ne ECM. The alowig a of Youbl codes shat ra eater the esto proceed "Noto: Fr engines equipped wih an NRS Cooke, ufcon voting of th coolant systom shale instal so that ars ‘rapped inthe NRS Cooter. Type ets ering bos the angie sda and rato seo th horosat Some coniguatons may also need a dedicated ent tine tom te NRS cook + Engine NRS dota prossre voltage abovs nal + Engine NS seta pressure vlogs teow nome + Engine NRS eterna pressure: Hig overs) + Engine NRS aiterntal pressure: Low (vent + Engine NRS nak pressure votage above normal + gn NAS intake pressure vage below normal + NRS temperate volage above nora + NRS temperate volage below norma + Engine NRS valve cota cunt below neal + Engine NRS vale control ewrent above normal + Turbo bance vale actustor convo erent slow noma + Iako manos prestur vag above nara + take manfots pressure votage below nema ‘Te NRS testis broken no wo sections + Seton ones to very tet he NRS valve prope unetionng and not tuck mie ly open ly lose postons. The engin is putin NRS test modo byte engin est cll computer totum of ry dlgnostis thet vould become active whle manpuling fhe NRS anno Saance valve (TBY) potions. nthe fst warmup Stage of he posuctan hotel. he engine tea call compu wl comer the NRS valet logle Ham the fay open 2 ly dosed postons for up 08 cytes 30 seconds. then sets the NRS ad turbo balance ve tothe ‘coreet potions forthe sa ofthe secon part of et + Soton Imo it a unetoal esto ensure that he NRS performs as specie by engnesring. Seton two tars ‘once the angne goes imo secand warmup and ne tea cal comput als he engine speed and load appopite forthe engine bong tstod. Tho engine speed an leads developed by Engineering, depandet onto bore size and haréware sa of re engin, and sa inte test procedure. Th les cll compute then commands the NAS sytor hugh ve tot pits a oows ‘Test Point 1 -NRS va uty lsod (0%) and TBV opon (of The test coll computer wi Wal 5 seconds ram ts tins the peed and bad are sot corey ae he sep response rede sonable in the engine ECM. The ECM hen takes a5 second average cong of NRS mas a flow, NRS dela rosea, and NRS absolute posse Hom be engine CCM, Test Poin 2 -NRS va uy apn (100%) and TSV open of, The engine ECM wil caeulte he NRS val losd io ‘pon respons ie and pass the val to ha tes cll computer. The EGM waits 5 seconds a sable and hon takes 3 5 socond average rearing o!NRS mae iow, NRS dela pressure, and NRS absolute peste tom he engine ecw, ‘Tos Point 3 -NRS vai uly open (10%) and TBVclosod (or. The est call computer was 5 secondo sabize and then lakes a5 second average recording of MRS rss ow, NR de pressure, and NRS abet presse om the engine ECW. ‘Tos Point 4 -NRS va uly open (100%) ans TBV open (fh, Tho tes ol omar wats 5 Scand to table ard then lakes a5 second average recording of MRS massa ow, NRS dea presure, and NR abecue pressure rom the engine ECW. “ans.“Test Point 8 ~NRS va uy closed (0%) and TBV open (tf As the NR vale is moved fom fly open to fl close, the engine ECM wil alcate he opan ocd valva response tm. The est cll computer wats 8 secondo sabre from be engine ECM. The engine ECM then passes the ealeated response tn othe tes al compu fos calli fet rele control ofthe TV. then wl she NR vale to completely open (100%) before relesing cnt! Backohe engine ECM. The engine tel cel computer wl hen wa S seconds to tke the eng ou of MRS test mode “The following data is colaced as pasa ceri as part ofthe production et + ECMNGS TEST MASS FLOW RATE PT1 fg) + EOM NAS TEST MASS FLOW RATE PT2 (eh) $F MASS FLOW RATE PT3 (gh) + ECM NAS TEST MASS FLOW RATE PTA (eg) + ECMNGS TEST MASS FLOW RATE PTS fea) + ECMNRS VIVE RESP TIME PT2 (msec) + ECMNS VIVE RESP TIME P15 (nse) "Noto: How passallentea are sat Fst tert by mechani for NP plot buds. Once infil praucton retin the rominals and tlrance wih factory averages Venting the NRS Cooler “Toare are sovorl rica requtemets for ht testing EGR engines. These requramants are led below, Faure t follow these requcemens cou result in posse thermal damage to he EGR cole resung meaty fl hue fares, Note Tee te cooler vant ne wth tha engne vent Ine. The vt ne am the EGR alr (C8 & C13 engin nly) needs tobe canna thing, no pap cock ype valves alone, The C1S and Vee engine col set-vetin the engine AR and theraor 69 not ne0d a Seca vont tn, The RAD ado of he engin ea ox) enould be voted a wal 1. Adequate venting of engin requed inst et a. Vontbth engin an ct sides of hemos housing, corresponding coolant nos », Vantne an EGR coolers must be ntl and connected to ngiatacy 2. Do not tum on EGR unt alrapped airhas boon purge fom he sytem «lial no EGR gas fow un ater hermostts onan dung testing (EGR col vert ine (@) Ena ee vention (RAD entre ‘onal Rnuiromenis 1. Use S050 Ciycot when posi, to avid EGR cote bong 2, Flow tn cract Operation and Wainirance Manus for props eacla ling, vetng, andl ta, 2. waar is usd, nen the flow restrcons spp: 8 Waitin and monitor water pup int lperatirs not to exes $0 degC, bs Pressurze ystems rue + Mont: pump int pressure during the tot ro lwar than 20 KPa gage press) «6: Nomere than 3 minutes contmuous oparaton at Pas forqu conn, ns:4. Recor omoratre and pressure dta dung the estan retin "Note:The eter patent item or desler esting ito allow enough warn time before apphing lsat the engine. The engine souls warmup unl a thermostat cscks ope, 1 alow any remaining aio atl cut of the syst. Functionality Tests Irmay be necestary tun nconalty ets wih the standard porforanos ts dtd inthis ocument to tst ‘elton nine systems. Funcbonaly tests can be inserted ater hs high ale check oa other shasas of he agreement wih Engineean, This wll rovde a ast Sequance, wich wil mata tbe noma ergine operating temperatura forthe terque check and he rsponsa check funcional tess re nsred iro te ts! sequencs, |udgmont shou be exercises obs corn hat nora opratng fonpertues are maine forthe high le check and ‘he lie ain. These unctonality test en be enable by sang aferent Mago parameters the test spec. 1. Referto Seaton “Apponsi:: CRS Tost Prococus” Net Curent In Uso forte ORS test, 2. Engira Brat Tet (2.3 Ergiras Only) - This st shal be perermed on ll C93 aplication eaipped wth a Ct Constant Lt Brake Associated lst specs shal have the BRKSVR lg assoctes wih tam. The est sequences composes of 3 sos: Lube Oil Purge Wile insing the tote command at 100% and zr london te dynamometer, command tie brake valve to pen, When he dyramomeer speed ledback reaches 1400 RPM, comand the opts. bse ane the engine caver thigh de seed, Repest wo mate nes fra total of ee vane ‘rake Funetnal Test 1- Wh the engine steady a igh ile and er od (al wate removed om edly cuont yramometers, command the ECM to oo ow ie. The est cl shal acre time fam when he command is Issues to when tho pees feecbsck ls 1500 RPM. Tis ta isthe bastne te. tun te engine to ss sate atin ile ane zr oa, ‘Brake Functional Test 2- Wh the engine sland aight ard zo od (al wate removed tom ey cent ynamometers), maintain 100% trotle command and command te bake valet open, The test col hall rors ‘he tie For whon ts command issued to when the speed fodback i 1500 APM. This nes the brake engaged tne Retun he engin o sendy seat igh ie adn oa. Patel Analyse Calodat he dterence in tine between he baeelne messurenent andthe brake engeges ‘measurement psi vale greater than o equals th spc nominal value epcaly dorved atts tst ‘sat inca that he aake i a propery an nearing cael. Ay vaso lot hans nominal value Ainuding negative vals i a td tt and requis a repr and retest completed Connector #: | AEC-16-40-SU_ |) 0 Connector # Seco: | t sets Bate s.209 Connector #: DRC16.24SA CATH: 7X-8222 | Imseaton 50 sossiseee 8. Warring: Remove 234-5013 It Manel Ar Temperature (AT) Sensor bsfre tng Not dong so cou rosut Intiting bal damaging senso ‘Dynamic Gas Blansing- This uncon let wil be ined byte Ful Sym Type Cade ofthe spac bang sat 1 DGB, Refer to ustaon 50. For Lange Mining Tick D6 engines, tis requed ie enable gas substuton hot test moe node o bypass he cofengine LNG lank senor a ruck methane deacon aster ha a regent is he angio kt ‘To enable gas sbsttuton hotest mode, the Primary Engine ECM pin J:47noods to be grounded By grounding ‘hat pin athe EOM, wl surpces the missing Santos an low he engine fo enter gas bering mode when all other aparaing condos re mat. Ore ton can be a aute he JT an grou wea into they test console room and enable the Nt test mode With simple swich. Almaty te a may be grounded at he EGM, and hen tho paraor can utlze CatET for Enablg o Disabling the Gas Substuton Systm Slats for salecon weno enter gas sbeiiton mode, Noe aftr suecessl hal this pin wil eed be removed, sms:‘Tha ther gas condtions ar as folows(onengine sensors): Coolant mp 2600 Gas suply pressure >850 KP ap Intake mantel ai tompsratire 35 No gas systor ful orlagostsprosot Adlon, gas substuton can vary ws many factors ing: Engine speed Engine oss Intake manok ai temperature (SCAC water temperate) (supa pessure ‘Combustion sensing and hasware protection Ecaust temperate Turbo sosed “Te speci ea pec vas prove the el boundary conditons fr esting n oat achive ne ful get ‘subsuton percentage, Natural Gas supey opened crng cranking squares ‘Ator Ful Load Pint, test cl stars substi 93st FL GAS SUB RATIO paranster value and shat main +10 RAR stay, ‘termina ol mites, the fotowing parameters are recorded in Table 30. + FLGB Engine Speed + FLGS Conscted Power + FLGB Fost Rate 1 + FUG Fuel Rate D1 1 FLGB Adjusted Boost + FLGE Fuetng Vale (ADEM 4 Stat Fuel Set (Nar-ADEM 4) + FLG8 Gas Svotiton Ratio + FLGB Gas Fuel Valve Poston Multiple Rating Engines "osng of mip rangi rogue, tar are two optons ether chooso foun a socond compet eto go by the fotowing sk stops. The choice ofthe opin to ue i et toe eration of tein acy 1. Run standard test 25 dofned in Level"Dasel Engine" trough Lovel"Funconaly Toss forthe highest power andor he torque rata 2 Acvate he rating change uncon or devo. 2. Inerease engine speed hig le (rasirum engine speed contel position) 4 Lod engine unl ugged to th Aotnod in Step 6 andor Seo & semat lina andor Torque check sped, The angle sal b tablized 2s 5. Caleulbe andor record a equted bythe ating + FullLoad Speed + Caretod Full oad Power 1 Torque Check Spe0d rected Torque TC REM 6 adional ratings are required repeat Stes 2 though foreach successively lowering. Electronic engines all rot bo rosot ding his process. Spark Ignited Engines Te tex proce yo peer and condo of te prodacnel-The smith ped. ead ther conor can be tdi sect pce unbe'"h apation ase wih est ‘outing in TM Oats Maraperer Sym msc can, angENGNE Dts (Cone .PSD. Emin Peromence Catt lutaron 8 shows an oxo wi soos re hea el machine procedure. The SI procedures snl in conesot Each ofthe et sages Is desrbod in more tli th olowing ans:Preparation for Running 2, Ailny Power Take-OF - Same as Level ‘Alar Power Take-OF* 4 FullLoad 01 Pan FilLovel Samo asin “Ausilny Poor Take-O*F 5. Engi inet tela th ga pasture regulator shall be supped athe progres shown a he nda enine perfomance specfesns. 18, Trcte Poston Cock to onsuro that th hols pate can be opena tothe max positon. Do rt aust the tage ta ctin nema poston auch a manne Di te ttl plae wi ot lose comply 1. Air Foal Ratio Setinge Selihecarurtor mie enrol ata “nominal vale” spaced inthe facty work ruts and donot ast {or be reminder ofthe tes excep ae species belo. * Engines equpped with carburetors wih a rotary mitre coniol- oe (1 the val assigned fo the rar ato cal nearest ote Ilan), (5s the val of he ark rearst tothe + Engines equbpped wih carburetor wih screw adjusted mixture contol -te murs cont sting isthe rumbor of tums th screws backed out om the fl "hr (maximum lockwiso) postion, For ongnas ha hve procharters, a the needle values for each elindor 93.5 uns open For elacroncllycontzalled engines congue th lower hes valve (sl quality) an fuskspecte gravy fo curant 98 chromatograph essing (For GIE00 ao callrats ressire mod). Foc engines eaupped wih adjustable watega Warm Up ‘Warm up ofan engin is dened as conitoring of an engine te obian repeatable engine performance and io purge ait ‘rom te laid handing syes ofthe angie. The ange speed conta sal rot bo "purring any potion of hs perfomance ts. Pumping athe process ol ai and atemaely erasing and decreasing te engine spe conta sytem andor engine speed us soe to midway pion, "Noe: Observe and Inte othe engine an aachmenks ding warmup fo ny usual vnton or sound, 1. Staring Procedure Crank at 200-600 RPM (8600 a 100-200 RPM). Minimum ol proscure of 40 Pa shall bo obtained win 0.5 mints cranking shall be stopped. Cranking sal continue 0.25 minutos str rang 40 Pa botore starting engine. Cranking shoul be eaconnued engin ha tari win 2 mints. For G3800 isin prlibe ol posture shat be me! blo cranking can bein.) Note: Fr engines equpped wth elcronicallyconfgurate jnton tng st ha peel gnton ting to the ‘value specie in ho ngine peormance specication. 2 Fea Pon (Low dle Spd) mint, Run a 20 eu manu of 3% of te ou, + Forengines eqo9ped wih mechanical govern wit he thot late completes closes, aust te cexburlortolte stop szow ul he stom touches he sop Iver. The vate pst shoud tbe held open any amour byte slp sre + For ngs tat require foretalslpessurosetngs the prekminary ferential ful pressure tothe norinal vali speed for igh iin the engine perfomance specication. Drea ua posse i the Hale ge pressure maintained ote carbo, relative to he sate component of te exbuetr et el prossus + For engines eqiped wih Woodard goverors operat al he speci span or the west atainaa ‘speed the species sped canal be atined he goverar ia aqupped wi a synenonzng mete, creck for engin speed increase and decrease wnen he appropiate wie rom the meta are energized 4 Secon Point High le Spd) -5 minutes, Run Zr torque - maxi of 3 of at rg. + For engnes equpped wih machaicalycongurabl gnlton timing, the gion ing tothe vale spaced fo fil load nthe ongine ost speciation. + oranges tat ogure ferent! ul pasture sans, conf that he farnta el pressure sto ‘he vat specie fr igh ile inthe engine test specteston 4. The Point 1 minute 0.2 minute (a roa. + For engnes equpped wih crower: ihe exces oxygen i the engine perfomance spocfcaton fil loads greater nan 4%, st the primary excess oxygen 1.0% bs than hs value species or fulload. ams+ the excess oxygon' 444 or ss, st ho prolminary excess axon tthe vale speitd ia the engine prfomancespecfeaon fl oad, 5. Fouts Pit -3 minutes 20.2 minute (2nd Sreakt}, Run a8 deine i ts procedure. 6. Fan Point Fo 63500 engines, apply lad appropriately fo achive aercoolr and. Jckat Water tmperaies dened in engine lst speateaton. For 62600 engines, appl 75% load ante needle vas. ‘Tha namin ful nad est pomeris deinen the eng tet spacicaton as coveted ulead power. Nominal ast spond dofnodin the engine test specication a lload soso, emit Test Torque = NTT NTT = (Com Ful Lone Power (kt) * 60000 (Arai) / (RPM *2pl* Total Coocton Factor) ‘ine ul loss test pn, the anglng specs canto shal bea the maximum speed poston "Note: For macharicalergines. the trque apple to mechanical governor conta shat to main maximum angie sped ena be 8 Nm to 72m (55 Ni fo 9.5 Ne for Wooaward 3161 governar). Proper conta of rave ‘onthe governor contel satis equied fx consistent governor sing pos an hgh ite speeds For electronic rote npit othe ECM or speed overs conte trough the ECM can be vs alo appeabe {9 PEEC and he iterontvorsions of ul electric engines Test Spacd 25 RPM Test Trav #5% Tost Tore Itt engin ast specication spc high ile speed greater han the ful oad speed (¢norstorhonous over run care), te test trque canbe nctesed or decreased wih the agustmantcontolng the poston ofthe over the masa vales for spc pararater are win lerancas tin he engine lst specication, te nominal actul ato setngie scceptate the measred vals for spec pacers are not ii leancos sein he engin test speciation the ial ‘ato seling shale reso as rqured to rng these paraator win speciicaon. For engines wh esable astegses, e-une to trng parameters win spect, Pevor oqo addtional sts a fllad sh as 62600 mise an whan tet Engines ae to be considered stablized ater achieving he ftowlng maximum varaon per 2 mine period whe runing ates s5e06 and rave 1 Pump nTomp- SEG 1 Atorootr Waar n Temp -3 DEG C + on Presse -74Pa 6 Fuel Rate-1% + Caectod Power 1% (cbeer6d power permissible for marl tes ty) ‘The engine water cute temperature end, So equipped the sparse cel tarcodlerwalrel tamperture nal be wit speciation Defoe recording ful lo est sont cae Foc erginge wits a rachael governor, he over curve sal ot be repstiond ater completing the load ot except as spedtedin Step 8 {Wah be engine a he flo point and sabre as olin in Step 7, clelale andor record parameters below ‘8 roqured byte engine prlermance spctieaon and as deed in lusvatonE2: Full Lond 81 Parameters To Record Line # [Param Group [Parameter [Units [Notes a Power ww | we ” FL Speed om | ae 1a FL Fusing | tae | st et FL FooiRate-st | NA | SI at FL csrc-st | wa | st 2 FL Boor wa | ans:2 FL Waerintemp | °c | AB ° FL Detatemp | | At “ FL writen Tome | °c | AD 6”) FL | WatorTem scac | unin | Ae e” FL___| ScacwiaterFow | Umin | Al a FL oirpress | ta | st ") FL Dares it | wea | St 0 FL compour | wa | st = FL Iritwanson | NA | SI # FL Exoess Oxygen | NA | SI 5 FL corpse [wa | Ae sre FL onreeaing |e | Ae 03 FL FootPress-st_ | wa | Si 2 FL rnecarPross | wea | A ® FL Ton airReat | Wa | Ae oo FL Inivartome [oo | At = FL For wa | st or a Now catracor | a | st 1 FL onteme [vo | st we FL waterourenp | -c | Al ro FL co wa | st oo a Tolle | Na | st ao FL Nox wa | st a FL TrotteAngie | NA | SI 250 FL [DLtAH@0/Beame | -c | st wo FL NOx-Aralyzer | NA | SI 230) FL nox-ecw | wa | st Toole 21 .caatate ae oor apa, ‘ete tst manual wih a ea shasta shown in lstaton 62 the estimatad at a temperate shall bo within 2°C ofthe tomeratre aquired inthe soins ts spectcaon, 1 Torque Check? mioute 2.1 mite Decrease spood to toaue check spoed, Measurements shalbo taken win 3 minus ater leaving fu oa. Engine spood and lad shal be stabilzed fr sean Stabilization i dstormine by the speod raining win speccato for 0.25 mint. Calelateancorecors Toqueriso | | All wo | Tack tom | Nm | A sit | Tack | FuetRatest | wa | st wi | tack | cores | wa | ot rack —|covpouer | wpa | st yack —[rustPue-ai [ «Pa |) ans:Tale 2 Remove the dynamometer lad ual tbedynamomter's operating wth a masivum of 3% ots torque, Recor + Test High ee Speed (RPM), Hg te Stat RM. During te tast hig la speed check, the engine spoos shal ot vary more than (tod sposd5O, spect rye the adjustment consoling te overrun 5 pecfcaton It. Load ho engine tthe ullose on. the lod ost pos conforms to speciation, oth he loa est pana the et igh ile speed are ea ees characte a he fled tet pont do nol conto othe specseatan, te et igh lle speed can ont be comected by repsing and retesting the engine. ‘Maxirum dynamometer ad equate 3% oft xque Sethe ow il speed ae within 5 minutos of bing a load dal. uniess al tamparatur is maininad at flea temperature by add funcional test conducted immosatelybofre he low il pot, reco: © Low ll ot Pressure + Lowi Saity uring the ow espe check, the engin ses onal nat vary more than 210 RPM Engine Performance Correction Factor: Engloe poner ana pero acted by uel deny, i pressure, nocassary fo covet he obsorad angine perfomance data to a standard so of conditns to reduce data varity Note: Corton fate ae not abe use orate drain, Standard Conditions “Te standard atmosphere possi ad emperalre use incalelang correction factors are the arn a shown in SAE |. Total Baromic Pressure - 100.0 6a 2. Water Vapor Pressure 1.0Pa Water vapor pressure may be calustodinthe folowing method SP _ ((BP—SP)=3.38638]t,., —tya:)1.8 x 1.016 aoe eee Ee «3.98638 338638 2800—1.3 ((tyaix 1.8) +32) (rer) 236.1107 vp = 0.13332 Where: ‘+ VP = Vapor Pressure in kPa ‘= SP = Saturation Pressure at Wet Bulb Temperature in kPa (om st) = 8P=0.13332 eb ET ‘+ BP = Total Barometric Pressure in KPa * tay = Dry Bulb Temperature in Degrees C ‘tet = Wet Bulb Temperature in Degrees C + DP = Dew Point in Degrees C hock that the sotings fr the ar ane fel conte ae corec Run ho engine unit engin reachos the ‘ated op spec. This should be done while the sre fanning a high ile ae helne for sensing the boost i dscoonected. The messurement fhe satings for he a cota and setings fhe uel anol ar net requred, Racor he fatowing torn. gh dle Case (0.10 minus) Remove te dynamomets fad unl the dynamometer is oporatng wih a maxirum of 3% of Rated Torus. 1a same types of gmamamaters, te load cama! be lowered os level the bad an be lowered 6 10% of th rated torque, tis acepitle to cea a straight Ie tom the seting point f he govern teough he west arate tore o zoo trqu to obtain high le vals, Maintaining a bad en tho engine fr tailing the igh ile sped is nolan sceapate process. Record ta folowing ifrmaton. gh dle Spe ‘unng the chack at high speed, he engine speed wi ot ary more than te follwing, + Generator Set nd Marne Avtiay Engines Rated Speed 300 Tae 24 + Alot sisal engines ated Speed ane 25 Ifthe high ile seeds not correc, nt repaiing and etsting th ergne can cache espe, 4. Low il Pin (2.10 minute) Maxim dynamometer ad equals 3% ofthe Rate Toque Sat haw ile sped, Racod he falowing Information win 5 minut of cetanng ho da or flea unless he ol tmperturos ratanod at he tempers fr illo by using a special est thats conde medal before he low i point (Low de Spee (2) 0l1ressue (Low ll) ‘uring checking of te kw dle speed th enghe speed wl nol vary mae than 210 RPM. Noto: tmay be necossary torn pec toss with he standard perfomance tets hat ao dofinod inthis bln ‘Special tet canbe inserted ter he high ale check. The wllrovide et sequence, which wil ata he normal operating temperature fr cheching he trque and checking the response, Spec eis rinsed ito ‘he tst saquance, judgment shoul be used o be carn that neem open temperatures ae maintained for ‘he lide check and ho lowe po, ‘Schedule for Testing Engines with Multiple Ratings 1. Ran the Standard Tea hal detned in he Performance Test under the Dieel Engine for he highest power andor ‘he gest orgie rating. 2 Activate he dev forth change of rang. {Increase ne engine speed Io igh dle (aston of maximum engine speed cant, 4 Lond he engine unt ne engine rns othe ate floss anor the speed of he toraue check, The engine wi be sabes accorsing lth sop at FulLoad of he Standard Seed or Testing Engines 5. Calculate te follwing and roca he flowing according tthe ating 8 Fullload Speed . Comected Power at FullLead«.Sped of he True Check 6. Haddeonalratingsaerequrd, en ep step 2 ough por each ang a ie coneecitety onet Spark Ignited Engine Per te flowng cocks aon the erecta ae tao Properatonarthe Engin and ie Test Cal Fuel Pressure the nail engine perfomance spectestons Throttle Position Ensure that he rote pate can be opene oth maxim postion, Oo nt adit henkage so tha he hoe sate iol lose completly bln he maxsrsn postion Setting of the Carburetor ‘Sethe control forthe mature fr the carburetor a th Nominal Va pfomance,O> not ast th conte for he more or he maine ofthe at, st he conta, necass8y, nati pectes nthe specfeabon for engine 1. Tha foloingis or engines tht ae equiped wth carburetors that have aotry conor the mre, + One (1s te value that i sagneto the mar thas nearest othe 1" (Lean on he scale. + Frvo(6)6 the value that i essgnodto the mare hats nosresto he" (Reh) onthe sae of ums ofthe see that ar from the macmum ease poo, Standard Schedule for an Engine Test Tre tesing of he parformanc fea erg flow he stacl, Soa the nil roca fren any begining ofthe warmup schedule. The rung ime thats spect fr each pot nhs schedule of testing she ime st ech spected paed and torus. The ne of ranstion bebe he ponte notched apart he requred ne for eachpoint Warm Up, The warmup condaing te engin to handing syst ofr engine, se repatable perfomance of the ange ano purge arm he il process tat conto apy nceasing and decreasing the speed conto a he engine anda the speed of te engine. 1. Stating Proceso Crank engin a 00 RPA to 800 RPM. (Cran the 3800 saris 100 RPM 200 RPM) A mii it resus of 40 KPa wl be obi win 05 minute rhe cranking wit be slopped. Te cranking wil continue {20.28 mites ator obtaining an ol prossur reading of 0 KPa bore the engines slatod, Cranking should 62 ‘topped ifthe engine doesnot tat within 2 minutes. ‘Selthepretninary ting forte grton tothe valu thats atons for engine pertrmence cfs nthe ope Trav. Masia of 2% ofthe test ove Comrloaly close te vote pte and aus te screw tat i sod to tp he that the ser touches be stop lever. The sren sould nat hol te ate plate open at Selihe pressure ferent for he pliminry fue ibe #5 KPa of te vale tats specie fr high ile inthe ‘mantaned oe coroueter Pat eltve to te ste component af hee the a pressure of he stainable speed. the governors equnped wih a moor for eyneronaing, check he eease and decrease ie engine seed whan te aperoprise wires are utlzes, Refer "Append (AcstnslRefrencs Materia or ‘he ropa publeation for addtional iforetion Test Seed ans."0" Torus . Maxum of 3% ofthe ast orgs Selihe ining of he ignitor fo the value tats species or tefl load in the specieations fore esting af the engine Selihe prossus rental forth ful the value thats spocfed for igh el in the speeations forthe testing ofthe engine ‘Td pint (1 mnute £02 minutos) 75% of the Test Speed 20 RPM, bu ot oes than tho fw ike 50% of he torque ve or the test. 58 Note: For he 2800, usa 25% ofthe Tt Toaue Ye excess cnygen for flonase than 4, the preliminary excess ong o 1.0% le thane value ‘hati species inte engine spectatons for flac the excess onygen sores, the preliminary ‘xcess oxygen ote vale tats spied in the engine performance speciation for loa, Fourth Plt (5 minutes 0.2 minutes) ‘est Spaed = 20 RPM 60% of he tore val or the test. + 5% 6 Test Ponta FullLoed (4 minutos +02 minutes or stabilaton) ‘Tre nominal ower a filloas done as casted power a fill, Nomina. pood|s tne as flload speed minal Torque Value ‘The Nominal Trque Vaso for bh esti calelts by using he folowing equation. Comet Ful Loas Power 4) * £0009 ( ‘Nomina Torque Value Newer 1201 Teal Caracton Factor RPM Tae 28 [Nh ost pont for lla, be speed cana ofthe orgne willbe athe maxim speed positon, Refer t6 Engine Speed Conta he General nstuctons Test Spsed = 5 RPM Torque Value 2 5% Itt spsofcatons fer the engine tes spec a righ ile speed tha is grater than te sped ttl loa (a non Isochenous oven curve, forge valu ci be ncrested or decreased wit he austen thal canal he poston ofthe ovenun cave ‘Toa nominal murs conta sotngs are acceptable ho excess oxygen, te corcted spoil consumpton, ‘he ts speed, the os terqu, sin manifold prose, ante ot pressure of th compressor ar win the lta har spac in th angins el epeiations ne excoss oxygen the comes specif ue consumption tots speed, the argu val, he lt manifold pressure, ante ot pasture of the conpresto cannot be obtained simutansoy, he contol forthe mitre and be wastegate wi be rset ob these charactors within the specteans. Fora manualtst tbe CSFC inthe preesing wo paragraphs Wil need tobe omits Engine ae considered slabized slr activin ne owing maximum vcabon pe 2 minute pat wie the engines are running ats! spac and ores. Ink temperate fhe jacket water pump 3° (97.47F) on Pressure. 7 4Pa (1.02 pa) ‘The Fun Rate. 1% ‘Ta comocta power. 1% (dbseres power for facies hat use @ manual et) ‘The emperaiure of te waar the oie for be engine willbe inthe specietons before recoring he data fo: {helt at fu lad. The tmpertune of he lt wale othe sparse cei atarcacler wi bein the speceatons bore recording the data forth os at ul oad, ‘The overran uve wil nal be ropsione afer camping th ul load pon wxcop as rpositonng te space in ‘he High lle Check a he Perfomance Check 1 Performance Check mms.«a Fortho check et Ful Lod, the engjino's at the point ful load andthe engine i stabizedaccorsing to tem oft Pectormance Test for Spark gnted Engines, Caleslats tho folowing iforaton andlor ecors te fotoweg iforitin (1) Fuca sped (2) Tore (marca test (2) et et tempertce (4) Fal poss att iat (2) oat ate (0) Corectd fl ata (otpreesue (2) Often othe uel presse (2) Out pressure forthe comoressor(Absoie pressure) (10) et mane pressure (Absolute esse) (11) Temperature fe it the ck water pump (12) Temperate ofthe out forthe engine wat (19) Dea jctet cute temperature minus intemperate) (14) et air tomperature, dy baromtic pressure lt iescton, angina presse Note The eotsted ie i temperate wllbe win 2 °C (95.8°F of he test temperate, (15) Observed per at iba iran osd (16) Coredes power at titoed (17) Garcte Speci Fuel Consumption (5FC) (10) Temperate ofthe water tothe SCAC (19) SAC wate ow (20) Caecton factor fore eet (21) Gena sotng of he mire (2 Excess Onygen (23) Boy (Marval est), (24) specie Btomey (25) Lower hosting val for ho fs Torque Check (28 mites = 0 minut) (1) reas to las of he eyrarometer unl he engine igs up the spees tat pected forthe Torque Check, Measurerants wt be takes within 3 minutes af leaving Fuld, Tho engine sped and oad tbe stbiizes fr hi easing. Stablzation is determined by the speed thats emaring whine speccaon or 25 minutes. (2) reroass to fas ofthe dymaramstr an ads he speed conta of ths engin unt te engines runing the speed and torque tals specie for he Torque Check. Measurements wl be taken wih 3 nutes ater lesving ful lod, The engin speed an oad wl be lablized forbs een, tabilzaton is atermined by 0 spoes that rains within he speciation fr 0.25 mines. (9) Cebit he folowing ntormation an recor he allowing iforation. (@) Speed othe tora check (0) Toque (rae) (6) Gonected torque at TC RPM (a) Temperature othe ra el (o)Prssur (abso press) othe inlet el (f Fuctate at 16 RPM ans.(hyesroerTo RPM (9 The out pressure abso pressure) othe compressor at TC RPM. (4) Hi a ck (0.4 mints) Fermove te lad of he dynamometer url he eyramoreter ls operating wih a maximum of 3% of he torque vl or the tat. Record he folowing norman, + gh lo Spoes fg tt tainty Dring the cack forthe nigh ite speed te engine speed mus nol vary mre than the folowing ‘he ied speed 50 te tat igh le Speedie not correct and # he specication fo te engine ts! specie high ile peed ‘nat is gretertnanthe fl lsd spe, hen change he adusmet thal cntuls he postion af he verun curve to bing ho teat gn il spoos tthe mt ofthe specication, Lead te angina he ful ead pon. ‘ett point allan conforms the specientons en Bots te ft pon at lla ad he righ le speed are accplable, In al I tet characters athe ul laa esp carer othe speceto, ‘han ont fepsrng andres the engine can cect hee gh al pees 4. The Reset al Full Lona 2. The ese tf les (25 Mts) ‘oo flioa spsed = 10 RPM ‘The comsetad owe lions. 3% ‘Thelin point fhe engine reset by using the following precede (1 Keep the orgie speed contd at ha manna speed postion. {2} Chang he trqu of to ynamometer io ths valu ats spaces in tha Tar the powar an spose. ‘The logue etermine in accordance wits he infrmaton hati oundin Her Bf he Standard Schedule for an Engine Test. {9} Chang ho sp00¢ oft engine a fl oad wh tho adjustment hat coro the poston ofthe overun ‘evel the speed at lla tat pecfad nthe TMI (4) Readjst tne convo forthe mire hat i requlred to manain the excess xygen thats spaces forthe Powor at Ful Load. This se (4) shoul be comsleted before achstng the wasopao in the next sop asi (6) React tne setng ot te wsstagat ta obtan the eam fren between the oi pressure one ‘compressor andthe ink ross forthe manfeld a the flea pont. (6) Readius! tne torque of he dyramometr oobi the power ats specie in be TH Regus the ‘speed ofthe engine to oblain the speed thats space inthe TML, Cala the folowing Information and record he folowing information. + Futons Speed + Obsorved Torus (manval et) + Observed Powe manus) + Coneeted Powor at FllLoad 1 Toe Compressor Outlet mins the nt Mano Pressures a st (6) Fig le ack (0.4 minute) Remove te lad ofthe dynamometer unl he mamoreterit operating wh maximin of 3% of he ‘org vl or the tt. Record he folowing formato, (1) Hig lle Spood (amp onthe Engine Infomation Plt) (2) ig te stay During the check forthe High le Speed, the engine speed must nt vary mar than he flowing, erated speed ans:Tone 28 98. Low lle Pin (0.10 minute) Maxirum ad forte eynamomete equal 3 of he torque vai othe el. Set the lowe apes an ecard ‘he fling information wth 5 minutes of etsning he dat tl loa utes the tamperture of the ols conducted mmadataly before tho point of ew (1) ow te Specs (2) 01 Pressure owt) (2) Low te stabity uring the cnck for he Low le Speed, ho engine pod shal ot vary rors than #10 RPM. Note pedal tests are rogues wih te standard peformance test hat desi In tsb, te test should be nar ne stand test has ban complete, Lug Test “The let invls messing ho vaius parameters engine pstomanc a vaaus speeds on the ig curv or the engine “Tistests pafonred aftr the basic potomance asing has boon completed arte resis are records. "Note The folowing orocadures pefxmad sfr he fans removed. 1. Star he engin and warmup the engine at an angie spo0d ae angie fad thal reasonable. Gradua increase the s06 and gradcalyrerease the oe ul he power suits ebtaned and he aul lanperature of be Jacket water hasbeen stablze, The tate pelion should bea the maxcmum posi, 2. th etl positon athe maxim positon, move he entre load from the dynamo ans rear the igh le speed 8. Gradually a a load unl ho engine aod is alway botwesn high de and the rated spss, Recor te data at isrogred onthe fom fr each tes. Refer lo “Appentx C Formats fhe Reports for he Engines for an xara ofthe orm that i ued forthe test 4. Ths procedure contuod foreach reduced sped hat ss onto frm othe tt data ul he ong wl not sian lad, Record te data that i rogue, 65, Remove th ene loa am the aynamomstar and move the tote poston tthe minum polio, Racard the low le spec Fuel Consumption “Tis tests pefonnad tr the base prfrmance esting hasbeen comple and te resus recoded. No adjustments willbe made t ay engin stings. "Noto ti ts sbng performed sirstaneocsly wih he basic perfomance fest, the aging maybe inserted int the base peformance est neatly ater te completon of the Teque Check Pan. The engine may be neers Immesatay int th base parormance lst ater the completion of he FllLoadi tm Torue Checks nt equted 1. State engine and warmup the engin a ilload speed an filial power in secodarce wih he spaced rating. a. Th vot poston witb 3 ne maximum speed positon, The engines consserad warmed up and stabized af he anglne | ‘minutes, The angn sale considered aed up and sailed ater ne engin vation thats no reas than heal thats alowodin the tos of ts FulLoas Test ofthe Performance Tet. at he pected speed and power or wonaves arate ot 6. The temperature fhe water om he ou wil be wit tbe spectiaton bets roaring the data from trots. 2, Redo the lod ote flowin, 75% ofthe rated power 1% fhe rad power a tefl oad speed ane 28 -ans:a. The mossurements sal laken when the sped andthe load have been mantsined continuously for 0S minutes and within 2 minutes afer te competion of he precoding poi Repeatep 216 50% ofthe rte power 1 fhe ated power Post Test Procedures Removing the Engine from the Cell Engines through 3400 2. Nar stares ar instal, chk tear starts for sop operation. 3. Remove the ilmin-pten. Send te a an he path to he S OS larson Inst 8 new min-pate or te next 4. Remove the ilsreans Fam te spy Ines forth uboeharger onsale lies. 5. Open be doors ofthe et cal 6. Remove alist hoses, connectors and adapters, and cap te les wih ne apap lg othe approncae 7st a rosz lug inthe wastegate, 4. Remove athe specal equprant suc a ning probes, tote angle aneducer, and thermocouple wes. 8, Remove th bos hat ars connecting the coulng oth dynaemetarto re fywheal and move he c=uping. 10.Lite exhaust forthe cal off he adapter fore engine and romans te adept or the engine ssh. 1. Remove the hol own bots (ongin stand 0 bo 18. Cotoct and complet al he paperwork (iouPah (2) 01 Sate (1) Werimanship (2) Engine Dseopaney (9) Engine Test 3500 Engi 1. Toko the lst sale, Ten complete he abl forthe al sample 2 Shutoff the anne an sacwe the shutt ever 2, Remove the minipseh, Sed the al andthe patch he S OS abort, 4. Remove the allseren forthe engin et rm the of mani Remove the ollscrens fom the trbochige ol supply Ine. nstal he al ines, ‘open th doors and th cover othe hah of he et el Rao te exau stack rom the engine 9, sconnec he righ-nandiniake hose forthe trbocharge, 12,Disconnect he alocteal cable, wae nas uly dared ams.18. Spray he engine to remove any tel ral hat may have ied on he engine during the removal the hos. 18.Move he engine away tam the dynamometer and athe dainng sop belts ary hoses are eves, 17. Remove ali noses, connectors, and adepes 18. Collect and complete al paper wore Labels (oath (2) 01 same bs Reports (1 eerenanship ee Engine Tost 19, Remove te engine tom thecal 270. Remove the Byahea adapt: 3600 Engine 4.11 angi is going tobe packaged remove he cena i fer hat is in th ower housing an sad the ito ‘he S05 lboratay Mark the er wih ba engine sel number ite of ie assmoly tat aks place afer te tet wile done nt the engine isin he aoa for packaging 2. the engine ent going to packaging, apace theo ites. Mark he engine wth as lower center ier othe S OS abot, ‘Neto to operator notices 2foragnobectin too sample ofthe ol shoul’ be sats the SO S laboratory for analy. Recor his information an be Engine Discrepancy Repo Also, inspect ier caetly for darage belre nlaling th la, Do nt ntl damaged tars, Drain the syst forthe engine coon. 5, Remove the exhaust ace, 6. Remove the ns for beading the engin jacket war 7. Dsengage the eng rom the dyarramste. Remove th ul ines am the engine 9, Capa connectons forthe iso wate: canna ont the ol syst. 10. Spray he engine lo emave any Wel rl hal may Nave ippd on he engine dung he removal fhe cables. 11 aiestares are instale, check the asa forthe props operaton, Rafer othe section on Star Systm. Energze thea oh contra pane. Then kim on the sich one glen a "manual And very tate staer 12. Remove te engine om te tst al. 13.Take te final ol sample ana omeove the min-paleh. Send th ian ha pach to the S 0S labraay "14. Remow the harnesses ftom th ongin. No parla err of romovalis roquted. Te operator shoul devlen a technique that is ule and ein. 18.Remove tea it adapters, xtaust tacks, and tb coupe forthe dynam. 1a coupler forthe «yramomster was iniated fr test, index heals top dos canta te hel rom to Factory. 18. Colect and comps he paper work Labels (noipach (@)01Sarete bs Reports (1 Wlrennshio (2) Engine Discrepancy (Gh ngine Test ams.Engine Storage Refer to reference tbl for storage of engine, Powerdown Sequence for the Test Cell Perfor i ta checks tat re requited to powerdown, Sign fhe compute forte cal Note: There ate numerous manutactirars of yarmetars wih various types of Dts Acqton an Canto! Unis Refer tothe appropriate owns manual thats used for your parte syste Starter Systems Air Starters "Note: Check the 3300 ait stator and the 30 a starters afer he basi sto alow the tre lo be baled wih 3 "Note: Check he 2500 asters and 3600 rsa tar the basi ttt alle starter oe hbase Starters out Solenoids 1. Wile the engine sin he cl, comet he sbow othe a supp andthe hose. 2, Puen the “on but for hear stares, 4. Check he nest the sta for leaks and re 6. Engoge the ai state. Starters with Solenoid 1. Wale the engine ea the ce, conn he eto or tha ac supey and hoee 2, Push he on btn fo hear stro, 4. Opan be manual ave 65. Secure the manulful lever nto “af” posten 7. Coach ne stat fone per oan and very ith angne seeds gest han 109 RPM by usog he est a Prelube Pumps 1. Whe the engine itn the cel, comet he so for he a surely and hoes 2. Opon tie manual ave 4. Check the anes tthe sta fr leaks. Repal he eas. 5 Seco the man fuseverin te “oF poston 6. Engage e a state 7. Chack hat he polite ump enerszes, thatthe prelube pump run inthe proper decton an tat he peu 8. Chock he starter ‘achomlr forthe fost ol ‘etaton an vty the orgie speed i greater han 100 RPM by using to cont ing Air Starters After T 2. Chee te manual a va ans.2. Open be pure va. Electric Starters ‘actedin te ca ofthe dynamometer Eletle moles ae checked in the clothe gerarato. 1. forte engin the cal, connect he battery pref the starter ominas tr for tne requraments of vege (24 V 0126 VDC), 8 Sotthobatry power othe proper vatago. engine tom mec 4, Seco the manual us Ieverin te “oF poston 5. Engage the state 8. Chock ho starr for propor rotation and very te engin sped is greater han TOD RPM by using be Electric Starters with Prolube Pum) Note: Test cal stare protesting the engin. the engine gts an EMCP panel elctc moors are no checked Inthe ca ofthe dynaromste. Elect stars are checked in th cl of he gonoror. 4. afer tne engin nthe a check the starter for requiem of vatage (24V oF 26 V BC). 2 Sotho batery power othe proper vag. 3. Connect the batary power tee sate termina Note Leave the aay power-on unl he tetng ofthe ange is done andthe operator recy to remove the engine tom he co 4 Secure the manual eleven the “fF poston 5, Engoge te starter. 6. Check te prune pump fr soper operation 17. Chackthe arte for propa rotation and vente engine spe is greater than 10D RPM by vsing he Tier IV Engine Testing r engines crates a pressure crop. Both elect power ans power stings. Engines ar ested repeating this back pressure stores systars fund on some ter V engines cross a back pressure. Th ATAAC system on some ter WV fd ATAAC kop ec n pace Ta there opravent rbocnarger ove peed ad the eau “Tha dale must repeat tis testing proces to achive the sare ross Reasons for Additional Backpressure Requirements The atervatment stor on some or Vong rossi ofthe stetesiment must be ropicated in att ol 2 roaes bacpressure, To slate real worécondons, he Back NOTICE “Tostng & lr IV engine wihout simulating the back-sossur rated by ter atervaatmen! systems can cause ito overspeed an incorrect st data. Recognizing which engines need to control exhaust back pressure and ATAAC pressure drop. Nota ences needa have ete iow coil sue back ses crele by aerretnensysems. Oy tar eng node heve i eral requeret ry etn CObian tots! speciestions forth engine beng tested fom TML Ths information for ATAAC and Eshavst pressures ae Inthe fa the tins of da (usaton 56) howe fds do nol canis, then the agin as does rol ned | faetess ATAAC and Eshaus presses (station 57). ns.ot a sik Additional Back Pressure Requirements for Tier IV En ATAAC EGR Vave Out P AIRS Restrictor Tier 1V Final Engine enturt " sensor Asymmetie Restrictor Turbo. ‘Yoel st of eyo st, ‘Te ers tution 58 eae the adionel requrements odo testa er IV engine, The adlenlrequrements area conolateturtine-out restrictor and a conolable ATAAC rt, rare ofa Turme-Out Restor and an ATAAC Restor for Tar V angne dyno teats, sms:sss Appendix A (Additional Reference Material) fine om J ussse nite |rominar [2 |e umber rou» Vesta ay | a0 wos Eero 2 Corrected FLSETS s.00y | *190% te0 oo | rato vow | ne 1 ona FLSIFTS: wae a alee vs vw | alee s we | nae | 10 | 210 | oomina | 2x0 Son “ tree td | #100 wee (eh Ronin ans,09 a) w]e ° 5% Reguaton) se | ate ae 3 endo) tae] te 109 8) sion | 98 we sion) zm | 2008 eo TUE, store coo) 33/3400 Hydra Fulless Lay 230 1854 soars raid | 3 | sso 0 ' nai | a |, , Tato '3500 WOWRO- Fabled sa 210 1818 225 (0) eee [aw | em 0 ne wee aso | sso = ‘vaso om a r/c , ator RPM =1500 wean r000 eo (0) wo oo Low lols At 19 | spooe |'si-s600Raeerew=| RPM soe we so | ee ona > a ven vn 1920 Ras = co ow to Rac = fe ve v= a ne m= Von Bay 6 vos on noe Full Load (MR (C7, C9) 4062 Ses | WRIe93.69)35 ow Fat 42 Jomaorine] "MLC lama | nae | 20 | 20 | avec | as ie [Barone | ew Bay oe ro Suicfo |i, 00D Seta (MR (C7, C8) £062 Tena, 0 as v mms154 FubToRUe | For ADEM engines | mmrdist | Note | 20 40 Decimal | 1000 fame Vota Carpe dn abe 16 ns 177 | a Decinat +38 oe ca] cs TTS Fa Br) Cop td ncn een ees we | ree oonina | 22 rain | 08 | on say | #8 i | come sow torn rte i am aio Toe 258 son a NADE + 38%) -6.3% a 19 csrcm Turbo Si fn Note | -3.0% | -6.3% | 1 Decimal 0 mast | wn a] Sem ‘8 cmmoo | a an | 9 Feecurct| ob wh enw . We rere! aor 2 Valve Fultoss Gap % Note | £5 45 1 Decimal 197 ‘hos poston not 223 ‘Substtution Fultoss Gas % Note | 45 45 ‘Decimal | 23.5 hose a [Peso etn =P Ft ag le = [esos a stn =F Sc Fe 8) x [Baoarr a tae F oa ans:Tore DE wih ent Nt or | omacrose | Naw eas town | 30 Ciwekeou | ee sepiesie oe was? | si0 | 10 3 se ony Tk cated oy | oy : Engines: jack =| * 0 1200 I 00 Eee sh wali | cw ue Output” Electronic} oom sho Syms oven mh ond ookren 219 | 219 0 Tore » on 22 |encsped oo oct > vere Sign spon > wl ol a . (eB voor | a ro0 AL-No tow iy | 20 0 si- susie caret ne 21 | 210 to 0 Fond 203 [ombierdra] FUL | poy | naw | 230 | 210 [ovat | 1500 Spee oe vais | so | eon asi SAL NO oon) at [a oon 2-387 2100 Gera oe aoe at | ons s0% Si 30t0 Got cosa see ene toe a fot 0% | tweens | oO voeana 2 Me RO) x on 81-3500 Genset 50% at “4 5.0% veneers) {3-200 Gane (oR , , storten) tome at tt o — ve a | 0% cen consans | 9 Merona say | 270% 9 wo | was [7 eeerone | um | nam [280%] =30% | pom | 700 Ct ae =7o% | 80% 8s 5 sion) 10% sito aon carton] Fulton Gar wo lt te sent | ot Corrected ‘Blanding, ww Ne 3.0% 3.0% | 1 Deck ee once Fon Rot a | oes Same a Fond Coc Ft ie 1) ork spews _ans.re a1 |SesBlendig| —Fulload Gas GIMIN, | Note - 27.0% | 1 Decimar | 4830 uatRae | end som ey ton ara |SusBlendng)|—FulLoad Gat ww | now | 2. | aow | toecina | 20000 Fost Rate ‘Blending ‘om X 40% Deck a Src Al HO - Turbo DE ‘Same as Full Load CSFG (Line 13) 2 Torque evn | Note ‘Check m ne vk vubo BE 20%] ses | toeama | 200 spose snes fost 20 | rms Sea ul Land est oon rmx Sond ALLoe was® [=e | 0 arate ro | aso | 1 ‘sto wam | apy | tom sso | 1 soo ag [Ramone | 0 vo feo) me | oe00 sia0 | aso | TOK Rese Resor | ppteaan Tipe 205 pos igh | MAST ar above ventas | a0 | TOOK, a de eps Sp response as | Greece | ane e |e far | ar fone | as "ne fasorae . a chock speed | _SesPorse Check Check idle + 60. +60 Spd’ Respowe | EM 10 Cu sped | Sant Resse Sheet | cao | 40 Response) "00 ws bce penn | Type= OS other son Fut check Spat tow seed eons Fay | a sao (pens | heck ped ton cee Response) idle Spe poe | Porbowsee |e eirm | 43mm a 7 Res Note * 1 Decimal Check Time ‘3406 Truck . £20% | 235% 38 eons = oe som occa! | 90 “ecto cares “ wee That = we was ra Response) TeRPM “4 % Response Cow sore Gina | Low Seed Response feszoe Tore ot| le Cec Spee ace 6 Speed | Lowe Spend Tonge ft espn 00) we] Pome * r Cem | ones nine ne » | 3, | sso » sven as 43) 3 | 2 | as onsHEU 6 2 a " sano eu 2am | . “0 Fallboad (MR Marine Umin £35% | 250% | 1Decimal | 1250 casa) | Un san) 2808 was Tee a | Gem | cizteeciamm | umn | owe [2s | ason | ron | sora oy AIL Others a3 a3 2 3208/3116 MP cf +3 e Dolta-Ter ‘3606/3612 4 +3 ° 19 _| Patazore oreo 1 | omni | 5 = poe can 7 [| ® . ex CERT Be a ijel? . wernme| Gitwes 066 | az | ss | sa [ote] = 19SCAC | other SCAC Engines | DEGC | Nolo | 23 43 9Decimal 55 we [SCM sce eronee | Lin za | sain [open | i ruany | NUSI-NONCOSA te 05) 8 “ ont |S Sonam TL -c08a cabs : o.com oan | sos ‘ ac se01 nor ag | Ditsrenial | g1-3500-1P6 | pg 07 | 202 | 202 | 4peima | OF rr conor ss [onpenee) Tomes! BE ar sowed | 8 wsInlt Mani SISTA "a 275% ot x |Paetot Nee | nono | 20% — Bese oven ‘SI-SINA Nowe | 202 | 202 2 me cow wa (hy aon ot erorora 55 Loss 01 3300 Pa 270% | °° | Decimal 390 mene sent sone |e sax | See ene | c.c0.cr3 troratg | oath | Su orwmoe onre 12, C10, C11, 612, Noto 20% | 835 an 38 Fuel on Pa 308 | oDecimat nee et saa coz ave von |eson | 9, so orien nes | Sete = Pressure - Si ‘Spec apne pre ow we P) & cS ‘TA Standard Pressure 270 “= ae 270 08 " o 10 ” TALow Pressure 110, 72 110 ‘3500 ae o 320 ao ALL) ws a 216sHt0-166 ae [sw | 20 a ee wo [ae] ew oa Sit -HF6TASTO wel as ee ans |evs| oo ans ae0-ene [se [=e 7 3500/9800'6175/6260 20 770 “ 2 so | Sea Fost we 19 | 1 | eccina ober DE as = as Mec 30 rs = 80 ‘tet Fast Deg c 0 Decimal 0 Temp LEC AMCOE- 0 as a cravat, a «| mae a we |e [ce | [econ | oe o [tm | ow we 8 8 Front | as ca v=) @ Pa a |ococ| a |**| fovea | ae ss [rtbeny| moe foeoarr] a | ar | 2% | soma | ans ruta = Correction | from Section XB.2 we = = 10 toner noe toner o | oe es bun pec stg Tb tons ov Sotng 7 scion mie ® a Ev asd on cabo ode fom Ai 44 AIDE (unr Stand tet Ena ov Sotng sow ort | osama ed ee — Oe Toe mn | Kae ve um | oo |e10% | s10% fovea | ate cont vase » | os wuss [2raanae| woe | see | osama | ane te |r) ere | how seteg 80 anion st DES Note | 44.0 | 1.0 | 2Decimal | 13.50 re em ame | nm) fate ve 20 noe ° 29 ah oo | tet ozpenemaar | wom [rau] 2, |, /eoeina |, vay sound 20 Oe (Gr rh aad 5 incon 2) Sutin amsLow te ow | pe | oom 4 comin | FullLoad ‘S1-3500 SITA 6 +7 +7 8 | wot oe oon Nah mo si | 10 20 7 buco AS TALUET 470 210 +10 170 obit wo f rato Pacem | oy |e aie | aie | soins | a0 S500 ke 310, 210 210 170 a - , ana » |e] ce ” stew «e |e ” 2-30-60 » [2] ce ” a | tee [ecawoncoe | gay [oe PT | gamma | we tows | "eaten so |e (wowRD) a “0 10 °° ‘St 3500 IND (3161) | 5 8 7 6 1 co8h este ye le e Fat Tors (DE with Supporting ow Jommeou | memes ox |e |e | se |ronint | Fatt Delis m | * yecimal Teoxeu os | core [ocwmens sym | x | naw | 210 | 210 | zene | 27 owen or [ane oem ens sys | com | naw | eco | 280 | beam | at omcn acco rn amsFl oad vest Falta ont 99 FullLoad sl PPM Note | +30 £30 | 1 Decimal 60 nove 100, TOCKECH | OE with Tbe Speed pny Note +5000 | 4500 | oDecimai | 125K TeveSpent | Sow Oe wh ORS ww lawl ceed or ene CE HDum CRD 1750 | £180 | 4180 we | pe ws 2osina | 746 relay [Bei os vem | oa Sone te | he CE HD wm oR ECM Mein Systems) ws | pe ss aos | 2 et, oe mri wners wpe os ve os | le oe pow ons so» | a2 | 2200 sn Etre orse tonint | 20 one SE no we pm] ome oom “0 | 0 rrmare_| Sipoeg san sea | Seeman wea | nae) to) 210 | 20min |e proms spony sae Falta Tacxeou wwe [Nor | oewnvornise | | naw | sr | 220 | oetna | 6 eosin (Mass Flow NBS Rao PY HO - Engines with Ege |e mo 151 Mass Flow Ms « “ 1 7 re so | 200 waa oe 0 | 0 oe Lea ihrscoduend £30 230 2150 Mass Flow Lated © rane | ioe i acre 1 enone wel or | ae via Te) MF | WR Emgroowin | RGR | Raw Toda va Fon | a zo | as 00 sits1 Ener eh wl ae on MR Eoginee win sa | s30 880 (Mass Flow RS. rare HO -Engres wah 260) 260 1750 me vate | MR Ergon si0 | a0 soo | rome mse | Na ool on wo | ao ™ Foto wo] Sem | are | ape | now | az | a2 | rom | ano Te oo ton Tato Ree | cya erent oo [rm] +000 |e m0 | emetie | comcntnamse | * | * flsqn | coon [20001 | 12 “ane 39 "pecan: vats shan Tolan, Clings, ard Fears repaint of nominal spdceon. Megntids vais shown for Telarc, Cogs an For ar eed he rrinal So Tale 30 er exeplsone asus of clingor alton routes employed inthe spe datas. ‘alee tor the aera vals shaw on inal specication par runbere eT, OK, seven dig eRe 6 mel Spc Engh Test Sesteaton vara 1 cua” ten requtents ns acral hss arate doped paar The Gover Seting Paint (mechanical engine ea on tae othe eque cue. The sling ans ave the -eeseclon pit fe curves (Sevewete betwsen 2 a 40 RP ss han the pve sling pee. PCC na NRS Parameter Toren, etn, ae Flot Vie are yay fcr al, Rletohe spec ngs at spectator aration duo to csions even equrers an ear ebiy ol these equremens. "Te Bors: Va nomaly mess on an eng uncon of ome, Te val ot ae ued for asceplane oF on _sccopace of engin pafomance shalt he seared hos! abe ase in ccardence wth equations oe flowing ‘erm: juste Boot = Observe So! - Goo! Casi! Ca Falland Power Spaiied Power) *100/ Species Power "Note C (Cont The Ses! Cortant equal he change in boos h KPa Be "% devon Nom spaced poner Pune etl lond pir natu ane ore hick ont can be as archangel in equaton above, The Seas Corea we ipl he Erne Deneer (Se Tata #OTESNEDUIOTE2501485~ ). Cuanty ane bos! epoe ie vray rq cack pend shoul hve eed 20 ns spat rounded up oh nas 100 RPM ne arise seoctad by PeromranceEngree Foal omer mca cri gh, led and torue chek sped 8 detemined by Appendix B (Minimum Recommended Hardware for Testing Engines) 1. ware ne arin vaa i peated Paremance Spcenon Reqs (PSR) ora rea Ot prossio 0 Kato 700K (0 pst 1018 ss) Water pump pressure. KPa to 700 KPa (0 pst 10.5 pi) Compressor att. KPa to 700 KPa (0 plo 101.8 i) rial for tn ul pressure, 4 KPa 4 KP (0.58 po 058 pi) Inet rant. Pao 342 4Pa (0 ps0 408 ps) antsNatural gs meteiAnsote Pressure} (mezzanine love) ..0KPa to S18 KPa (0 pita 74.85) Natural gas pressure (Absolute Presse} (messin the ls eon the ping thls used for supplying he gs) O4Ps to 344 4Pa (09010409 ps) ‘SCC water pressure. 0KPat 700 KPa psito 1015 psi) Int ar pressure (sole Pressure) ..04Pe to 137 KPa (0 pl 19:99 ‘Spare transducer ..0 Pao 700 KPa 0 pl 0101.5 ps) ‘Boost pressure - The boos presse ate the turbochargers and belre heatercooler {04 10 7OD KPa (Opsite 1015 psi) Fuel pressure ~The uel press of hein oe er (0 KPato 700 KPa (psi to 700 ps) Engine oss -1 vansducerpor cet setup, Ws sould be sad to match te Dyrometors capably, Engine tomperatre sensors + Exraust pot omperatures + ghtoshaust + Lehemauet + Inet aitomperatre + Water tomperetur forthe éyamometar + Oltemperatire + Temperate ofthe int orth Engine Jacks Water + Temperate ofthe oiler the Engin Jacket Water + Inet manos + SCACinlt orperature + SCAC outlet tomparatiro + Temperate ofthe gas meter + Temperate ofthe Test cal + Temperate ofthe SCAG hoster Engine Rates (analog rots) vata + Lose Frequency + gine spood + Lot erbocharger seed + Raght trbocharger speed ‘Status mentors + Emargney top + Water ow forthe dynaromater + Lubrication possi fr the dyramometer + “Uw Tevelot the Engine Jacket War + "Futraaay Engine ck Water + Solecton of ean forthe Engin Jacket Water + "ed igh velo the Engh Jacke Weler + ScAC on 75+ Int aleeeticton + Analyze tin th cll + Status of te tast "contrast atthe pedestal + Status ofthe tot "eee ate pedetal + Status of tne natural gas + Analyze forthe iin heel + Naural ga vaves closed + Natural ga vas open + age ration forthe ow othe Engine Jacket Water + 1S shutdown ‘uiputs for dtl controle + Dra inducer + Contalforhe cogeneration + Emargney stop + Lamp for calng he operator + ator contol fo he aynaromeler + SCAC Hester conte + Fan forthe iin he eal + Stan te ach, + Star he crank clocks + Stan te crank countecocose + Cantal forthe natural gat + High natural gas prossus and low natural gas prossura + SCAG da + Contel power enable" + ypass forthe Now metro te gas Variable outputs per ot + Set pont forthe natal gat + Troe contol + Temperature cntal or he Engine sack Water + Conte forthe water tamperatir fhe SCAC Engine Rates 1 mor tna Foe Ra 1 Tachometer forte Engine Speed Appendix C (Formats of the Reports for the Engines) 1 Repro Teing el Erg 2. Repo Tsing Prensa Enne 4 apr Tsing Patan oa pr pe ng «Repo ig Spe res Ege A rapt un ane 8. Repot forthe Fuel Consumpton ants5s ddd, nage ansExarle Marsal park gion Test Data Sheet, late Lopate owe Pee Spee eat to Ieraroemert ‘Shoo One Eaine, lecashaa" Bye Conan ‘age Ho ossszean #00, 3500 MUI ard Standard Soke EUI Les than 186 KW per Cynder - Manual Test- Manual Data Report ar Ex Tes OeslErane one = oat | aomare Tester ‘araonant | Shenae Tex canoer ‘Serial Number Pramene " Indent. Number Nera ao Ta 7) = Rae owe 1.257 Rao No are Tore Ge nse nha nn Mn fo ood Serre tne Tore Ome Spne ar 0-1 Ming Cone orie # TCAPH wo Sri Tie Fon ae a 1 nn Ores spe | | Rew a0 Corecess TERP ine oso | Nmee% caren Re nn Serna Tine Aaja Son TRF cS Fats Speut | PZ ans:1.50 (NT) Nmss% Hoh lo -2 Minutos 20% 9 nutes igh de Spee ‘Staring Time (Observed Torque Rated Spec | RPM #20 ‘Seity : 0 (NRT) No Lowe Minutes {Governor Seng Poin - Mines Winn § Mines ae Falla ‘Govemor Seting ooo | Wee Ohned Ton Fate ¢Hnae co Tenet | Wow ay 7 atone | [Wm aed Te AF Twig Fl | oy earn Comectes Power st ey ee = eome | ef nee : SS ee wa | Jocks Wiles Pam “c (Ory Bar minus Inlet Restriction) ”) Water Terpertire second, (2) Greater ha he tow ie Set tescac | SCAG Wester Flow | Umin (3) The temperature of the water outlet shal be tothe specification before InotArResticton | wPa ‘coring ho daa fo uo, Inetentoa Teme. [og eanac Blowby un Specie Blowby unwen ‘State Fuel Sot Fulosd Me Fuloessiterte| as.‘atle 31 3500 Standard Soke EUI Greater han 185 KW per Cynder Marsal Test- Marval ala Ropar caterer ne Engine Teet-Diesl Engine Date Operator ode Pesan ‘est Number Speatiestin Jarangerant | Shipping Onder Test Cl Number erat Number |YEMmater aanteaton nero ss Constant i Nominal Rated Toque NRT) ates Power = 954,297 | Rated RPM Nm mente = ware i 3a Fuld saera Te tay To one rare | [an [com ean TOP om Sa oe nebo TO we fawt toe | Ra ua ohn en om Sara Ts cor We tate | 0rwa0[ sy [tee son) | Wns [ivi Sa eres i aa Felnt Sa oe awit ma Panto | __APG29 [oer Tn ie zon) | Wa [orPeewe ve Goon Snae Fone [tay ao Gomer | apt [ee ene AF Mo Feet Anat Seta wa utc pat wa Fawr w nero ww Fereamsrorst | an renronuanceconaecnonracrons meetin | a a fn ~ Cte re Ss ret ams:Seal Number [acusted Boost ea | mar Temp c Jon Presse a | nr Pros, a Font Pressure Pa | Fl Loss Total Creston Factor rot Fuel Pressure 2a | Tore Check Total Coreeton Factor, ret Fat 7 Temperate © sack Water Pump (Ory Barina et Reston) Enon at % pat nat ox: (0 9 ow rn eee a an Per m cn ts Tea “© | ay cmnernn wide [SCAG Wr Flow ‘Umin| (9) The temperate of the wate oul shall be tothe specication before ie ain fem |g nao ai a son, ° eaaae wey th sec ty en act " a ont SF oe st Te? 2a Daa Tana Caer Ee Tet Dewl re one op ssa | etomance Tener Aaraonant | Srepaor ‘ecu sastnerour | Pmarenetr teen nor oi ido) ed Po 7 Nm are "Gc iin nha nn ke Fad Sas toe Te chek ons wu 2 Mae Goad TE AP No Sri ie Fe 76 RO oni Ors Rat spee | | RW=20 Cora Fon Ra TRE cin ozo | Nm6% coronene ox 2 oon ws Sng Te ‘eid so TORE ee Pauses | RZD ee oan 2a So nae erie Se ie ans.‘Staring Tne ‘Observed Toque Nm Rated Spee | RPM20 steity Rew “20 NRT) Ne Low ae § wines 75% 10 Minos ‘itn 5 Mints ite Full ond ‘Staring Time Low de Speed RPM Rated Speed | RPM #20 ‘Observed Torque Nm 75.NRT Nem on Pressure ‘Governor SatingPoit- 10 Mtoe ‘staity z overeat | pats Observed Torque at NF Set Nm 80 NRT) Net Et Tat Tina | Flood Mines (2) ‘Staring Tine PM Ful Los Spess Nm oe a ‘ow (bsorved Power Kw Camected Pome at Ful Load coments | oh conwcvate | ra on Poo cea Ton | aloo mi ‘anton | we | mao "© otPowe | Whe | Ars e rare [we Tan a oe Fas TialPowure | Te hes il Goran Fac verre waiicPone | (Bris enn gwen oe |e ta noida) 4g |) Bxk dom ore i ln tn OP " ‘coms ‘Wate Temperature “ ster than the low idle 10 SCAC © (2)Gme : SCAG Water Flow ein 3) The temperature of the water outlet shall be to the specification before: meaner |e corny en eos viewer | og nano ey a Sees by | tah ans.FlLond State Foal a Mn Tanle29 3600 Engine Marval Teat- Marsal ala Report Caterer Engin Tet Osel Ergo Date Operator estormance Modal core “est Number rangement | Shipping Ore “Tost Cal Number ‘sara Numer | DYDatansler entfeston number “constant Nominal Red Toru (NRT) = Rated Power = 9548297 | Rates RPM Nm ele Te Chea ae enna) WM ae Fd ‘trae Tee ek pnt oo stones Care oe TF We ated |) | RownzO | Goce an a TERPH oan omen | _Wmese caro u TORN tin Saino Fad tn TOW me Reto | ROW Tiana Tae Sd om oo Ohne Tee tn ao Wn kn ae Fad Stra Tari Se oI Re towe | RPwa Obed Te wn ton9an | wm orPsars me Gv a Pina ey = | cour iro | a hand Tn AF xn ooo | mee Ea Fal Lond Mines (2) ‘Staring Tina RM FulLo8d Speed Nm “rave vob ul oa) a ose Power co Comectes Power at Sole inn PERFORMANCE CORRECTION FACTORS observed FuotRate | ginin conectesFuctRae | ghivn ‘Observed Vue Factor este wa _sms:Date Pago2 Boor we Feat Density aL Paste Boost Wa RAFT, c 1 Pressure We Ine Pass Wa Fuel Pressure Wa Fl Lad Tol Cavecton Factor Inet FuelPreseure | wa Torque Check Total Coracton Factor Ine Fost “ “Temperature © vesatvanerane |e (Ory Barminus et Reston) nine Water Ou etet acto) og (1) Shutdown the engine he ol pressure sos than 40 KPa ater 3 n) seconds. Water Temperate (2) Greater han ha tow ite ‘wscac SScAC WiatorFow | LUmin | (3) The temperate ofthe water aut shall be oho specication before inietAr Rosicton | __ Pa recoring the dala fo lad inet anteu Tome | ag ARG Blot un Soest Biowby | UKWH Sor a ie FanontsinFot yy Tate 34 Diesel Ergina- Manual Tos - Comper Data Repo Cater Engine Tea Diesel Engine TheiDate Peromance Specteton | Operator del Rotaton ‘Tost Number 2rangement “Ten Proceaire el Number Sera Number ‘Shipping Orer Test Reals | Nominal | Maxaman | Minium ranking Tne With <40 KPa Oreste in 05 Cranking Tine With >40 KPa OF Prestre min | 028 [2 | 02s 50% Point Engne Seed Few — [— ro Obseved Toque | __Nm — [= 75% Pont _ RPA — |— 00% Pint —_ Rew | — | — ans,Governor Seting Point 025 inte ‘Governor Sting Speed | __ REM — [— Goverer SetingToase | __ Nm — |— re or FullLoed Speed | __ RPM — |— Observed Tove | x _ Nim Str Tne ‘Observed FuelRate | __*_glmin Observed Boost [ Pressure beard Power Foal Pressure Correctes Power at FullLons | Il Fuel Presse (Observed Fuel Rata | tlt Fuel emperatie _ _ CCorectod Fuel Rats_—_| Jacket WatorPump int | __» °C sre Engine Water (ute) _ _ Boost Water Tenp. To SCAG _ _ Timeate Page2 ‘Seta! Number Test Number ‘Aajusies Boost ‘SCAG Water Few —Umin | _ Inet Ae Restriction ie Ine A Temparatre Inet Man, Temp, IARC Blowoy Torque Grace 025 Mine Within 3 mites ater Ful Load “Torque Cheek Speed (Observed Terque Observe Fuel Rate Hi te Hg ae Spee 210 Mine (Observed Torque ‘Sbity towiate Wohin 5 mutes ater Fu Load 210 Mine Low ide Speed bsorved Torque 1 Preenre ‘saiy ‘Observed Trgue at AF Conta Sting mms.“ane 26 Dosa Engine -Conputrzed Tost port hr ve va Engine Test Diese! Caterp os cone ode ‘rangement, ‘Seva Number. Date Sentine | EreTine speciation “ea Number, “eat Gall amber “Amour fom Nominal Speciation sre _* ‘Corsctad Fuel Rate _* Corrects Full Lone Powor _* ‘usted Boost _* Ful Load Spe0d eM onPresee _ ia Ine va Pressure = Inet Fe! Torperatre _ _e Engine Water Out _ “e Dot Jacko (Otte) _e Water Tarp 1a SCAG _ SSCAC ister Flow _ min Ine anol Temperate se ‘Specie Bloway UK (Grinder NumborPower Loss % , Tes ws ow es —senoninat | I eo CSFC-at Torque Creek RPM an ‘Correct Fue Rate at Torus Chock » we _% TT orected Torue at Tomue check |g. hm RPM S oa usted Boost at Torque Chock REM ie “Torque Check Speed _ Rew Response Check Tine _* __ seconde Response Check Speed Rew Response Check lle Spoes Rew igh ale Speed _ REM High le Stbiy a = FPM Low ee Speed aM TimaDate Page ans:Seta Number ‘Tost Number Toners = Se a _ scm = Ine Ar Prossire Diy Barometer Ine Ar Restriction Ful Lone Total Corton Factor “Torque Chek Tete Carocton Factor ol Load State Fuel Setng| Ful Log Sine Fuel Seting tee cours et See et Peter Tene cos Teaco sents |_| Baran Con Teter ore Fond ovr vnnaeromue | Tn nn woe ond © Schone ow nn Ee Ile Cores Inet Air Restriction Ps rece Conteris | ny a Up Tate ony wn emt a25 an Tei hs -028 ae Sings ‘ins Ws Fd Tea coe Te sk en 7 Sane Cores m en vewreaos via Psa seston Teed. wine | RPvaTO ana aT oa Tne Sensi Coed FitRae TCR | Fotroanes | sapasos cerow tone san oan Po Sea ans.Compressor Outel Press at TC RPM | Pa Absolue String Tine Test gh ce -070 Mute 0.75 Tost Speed RPM 20 “est igh le Speed Rew 030 (NT Nas ‘bvervedTorave Nm 75-3 Minos Fal Presse ifort Pa ‘Staring Tne satiy + | Rew 075 Test Speed Rewa20 ‘Reet Vacs 0.25 Minute os0(Tn Nma5% Fl Led Speed Rew Fu Load 4 Nira 2) ‘Soserved Tove i Staring Tine Conected Fl Load Power ww Tos Speed + REM ‘Samp. Out =i Man, Pressure Pa met wm Hh ie Seca Pw Observed Power w Sy + | RN Conreceg Ful Load w Low le -0.10 inte Ine Fut Tempera ° Win 5 Mines ater Ful Les Inet Fue Presse 1a posatte tom ee Speed Rew FusiRae Un ‘Obeerved Tore nm CorecesFus ate amin OiPressure Pa co reese ute ka Absolute End of Tost Time ‘1 Prossure Wa ‘PERFORNANCE CORRECTION FACTORS ee kPa Inlet Ai Temperature ‘ix Cont Sting inet Ar Presure Pa Excess Oxgen| % FalLond & TC net Coneron Factor eo! Water Purp mist net evan eer © (01y Bae minus ret Reston) rane Waar Gatet © 1) ter ting 40 KPa ol presse Temperature © " Dota Jacke (Out) e (2) Water Out Temperature shal be to specfeaton before Water Temperate : recording FulLoad Data Tate a7 ‘Spark pnts Engne - Manual Tat- Computer Data Report attr. Engine Tont- Spark le Engines TiaiDate Peromance Specfeaton Opera. Nest Rotation Tost Number -eangement Test Prooedue Test Got Number Seri Number ‘Shaping Odor TestReaute | Nominal | Maximum | Minimum Esinaed ret Ar Temperature _ — | — -ans:‘raking Tie wih 40 KPa iPro io os ‘rang Tire wih 40 KPa Press ie om | 2 | oa lator Ting Days 106 [fy ‘Pont Exge Speed Rew — |— ‘Obeened Tere = — Ful Poseurs Ditere _ Wa — 2 Pont “ot Speed Rew — |— ‘Obeened Tesi one — [— Ianion Teng —_beesser00 | — Ful Posse Doren! _a _ | xa Pont Exgne Sees ew — |— 1 in ‘Obeenes Tor Nm — “Point Eran Speed Rew — |— aMinaos ‘Obeoned Tere Nm _— |— Fal oad Full Los Spee Rew — |— “Mites ‘Obeoned Ter _!/ | inet ue Temperate InetFoelPresne |= aaa | || Fos Rate Unie Comoracar Oat Preaure |x kPa Rosana | — InetMantolPossue |= _aPaAteokie | || FuslProssueDierenisl |» _ Pa Mie Con! Sting —|[— |[— xcs Oxygen os —/[—f— Tinea Page? Sera Nmber Test Nombor “ace itr Pa lst se Engre Wor Oat ce | | | ‘Water Ten 6 SAC a 'SCAC Wiser Flow Ine i Reston Inet Ar Temperate Blowby Torque Cheek Pat aad 025 Mine Winn mites ae Full Load “Torque Chock Speed Few —_ (scene Torque ee ams.Inet Fut Temperature sc Fos Rate at TC RPM nin Comp. Ouet Press TC RPM | __*_KPa Absolde Test igh ie 70 nie | Test 20h le Spoes aw | | ‘Obeened Tore Nn Foot Presowe Diernaat | __» _WPa Stbity Fultoed Ful Load Speed rw | — 025 ir ‘Oteor68 Tome = = Comp. Owet-inet an. Press | _» wpa | _ ih te ih le Speed 0% Casenes Torqve Subiy 070 nso Low le Spee _ — ‘Observe Oi Presse = _ Stbily Tate 38 Spark nied Eoin - Compueried Text Report ati Operate. nga Tost Spark toa Engine toa ‘Arangemert Dae Serine | EndTine:___ | _Speieaton: “Test Number Test Cet Number ‘Amount fom Nomina Speotcaton ore _* sk Comeced Fal Load Power _% ow Compressor Out Pessue-Abealte | | | | | __APaAbsote inet Mnf Presse Asoo _* We Abs FuLond Speed _ eM OnPressie _% _W Fool Pressure Diterentia _ = Miura Contol Sting I ian _ Excess Onen| _ _* Inet Ful Presture- Aosta _ APs Able Engine Water Out ~ _e Date Jacket (Outen ~ = Wit Temp. To SCAG - ams.'SCAC Wiser Flow Specie Blow = tw (CSFC at Toque Chock RPM _* ure Corrected Fue Rate a Torque Check RP % _ Umi ‘Coractd Torque at Torque Check RPM _% Nm Compressor wet Press. TC RPM - Absolute _% 1a Abotte “Torque Check Speed _% Rew Tet Hig le Spee _ Rw Wea oat Pressure Diteental High ele High ol Say RPM Low ile Speed _ _rew ‘ot Pressure Low el _ _'a Low lle Sty _ sem Inet Ar Temperate _ _e Inot Pressure _ _lea Dry Barometer — _ Tiree Page 2 ‘Seva Number “est Number Inet air Rostton _ haa RESET VALUES Full Load Speed _ _rew (Comecton Full Lead Power _% ke Comrossor Out nt anid Prassure _ _'a igh lle Speed -Observad Vale —_ NONE High eo Stay _ ROM atte 39 Engine Lg Test- Manual Test Roport Target | Speed Observed Covered || Fuel ace, spcca_| RPM sap | ane Pate FE aay Overn arrangement, Engine Sv | 20 Faing__ Iw @_RPH fe | s10 [Rate Data at Fula s| 20 CO pos KW, Pp) 1 = | -80 Tota fe Water a | -100 nt, | on on 200 Peeps | TPC ans.0 Mon He tle 0 Combunion Sytem 0 eneecy | Marotr owacy ao ropention | cone any 700 enn | acac-0) ° GA _| scaccio) 300 Gover | (SCAC-30) «erco) = (P50) “88 (use) eos) | Men +100 conen | Ovvoven 4200 Fue. | Gap “co rear | coe tere | Gay Oy |e ‘Over speed approxi way btn gh ard ata apd a Date | Onrstor__ cau | Braet Tate 40 Engine Fos ConsumtonTast- Test Repat Foal Consumption Tost ‘arrecton Fear epi Ie Engine te Performance 0 ‘mee Speciation: esr rangement, “eat Cal Naber, “sev Nember ‘Shiping| Ieanteaton Stbizaton 15 Minos Staring Tine oad Point Fultoss | 75% Roles | 50% Rates Flood Speed Rew ‘Observed Trae Nm Wotor Outlet Temperate (3) ° ‘Observed Power w Parasite Power ew Corrected Power (Observed Power + Corecea Power) ew Desel ns.(Observed Fust rate amin Ccomacted Fue Rate gine — | | __ sre omen — | | __ ‘Observed Furl Rate Umin — | | __ Gas Tempest ° — | — | (cae Presue| We — | | __ Coecte Fuel Rate (2) min — |__| Perlman Comeeton Factors ‘vane [Com [van | Corr |vaue | Cor Deel Dewsonrt || |_| Fel Donat . a Inet Al Temparatre Wa Ino Ar Prossure (2) Factor Tne Page ‘Seal Neer Natura Gas Inet Al Tomparatre Ino Pressure 2) Wea Tota Coreston Factor (1) Temperature of he ue forthe engine water ard wale frmperalir to he afaroolr must ba tothe speceaton bore aco (2) Dry Barometer maus net A Restriction (@)Goncted Fuel Rate ane at Appendix D (Correction Factors for Engines) ‘Te equations hat are snow in tis scton are sed ocala he cacton fairs fer oreting he engine perfomance tthe standard conions. Te cleulatins are natinlerded conform tthe Engine Pe Test Coe or ‘Spark lit Engines and Dies Engines by the SAE J7349, Determine he appropiate correcta factor for te pe af engine an er te ossrvad canton, Mull ne correcton ‘ctor ogee fo ban he total oretion atr. The coocted valu are fund by ruling the observed vales of perfomance forthe engine byte total comocton fac. ‘These equations ae not utd fo alte dering Standard Conditions “The standard atmosphere posse and th standard arospharclarperatire wre define according tote "Engine Power Test Code" for Spar gate Engines and Dasa Engines by he SAE 41548 [ota Barometric Pressure | 100.0 KPa Water Vepor Pressure | 1.04 a _sms:Dry Baronets Pressure | 9.00 Inet Temperature | 25°C FustDensty [350° APL ‘Te vapor pressure forte waar may be cleat by Using he allowing equations, nfs ig apes age ce satin 62 oszrest2 \VP-Vaper Pasture ina ‘SP Saturation Pressure at wet bulb emperatrs In KPa 4060.1 ji9.717-— 4060.1 _| esi 256.11 +t wal Istton 6 oezrsate 1 - Tota baromatrsprossur in kPa “ery Dry bute in T wot Wet ul emprat in“ 1? Dewpoint "Neto: The a prossirs for he ongins rat dines to late hoa pressure he eng nt ots atmosphere ‘Ta et al proseue of he engine e equal oto arom pressure mau evap presse or ha war and nus te net ai retro, Dry barometic posture qual lll Baer pressure minus the vapor pressure fr the wate ‘Standard Condtons for Gas (GasPressure [101.059 6Pa ‘Gas emperatire | 15555676 Lower Heating Voie | 3877 kat, Tone 49 Correction Factors for a Diesel Engine Fuel Density (API) Correction Factors [Fuet API at 60° F [Correction Factor | |Fuol API at 60°F | Correction Factor 220 0907 408 ‘02s 325 0.989 #0 1.026 0 ose 4s “028 a 0.994 420 031 8 0.908 ‘80 {036 35.000 1.000 5 soar ans.385 1.002 40 040 385 1.008 450 cry so | 08 455 1.048 a son a0 a0 sno 1018 465 1.051 aes 1088 70 1.058 380 107 as +055 ses | to 480 1.058 onl 44 Te Stare! Van th measures APO“ he us and carespoang hl¥mparare must be cored 60" etre silecingsconectonacrfrthe AP A Chart of Gravity Correction for Diesel Fuel API ‘Ghsrved APL Gray aes] a | el |_| aa a a “corrected API Gravity at 60 Degrees F EE ER ERC) ES I CE EE ed farofesoy arose] 961] 7a] pe [s0] aL or rs[ ae sia] rea rsa laes a rsa] ei] as] a6 a5] 5363 0a] 33| 45 3. fsrafaeat mafaoal ar afe2] era aaa) feralaea! m2] aoal 3] 2| ca] a0] fera{oo2! 92] aoa a1 2]a22] a2] aa2| foe. 39]. 4.1] 324493 [ae [se0] 801 sao} soo] s1-0}s20] 30) 20) [asa] 79 393} 0a] 0] o[ 29) 39) [sea[a70] wal eal wafer ea] <371 sear a37fs07| 07] ai 7] 27 38) [350] 576] s3ef 295] 05] ste] 26) 35) fseslars|wosfaas|ios|ste] 425] 05] fss3[979 303} 293] 403]s12] 22] 021 fsea[ar} wea] aoa] wo] ar a| sa [ans fsea[arswsfoas [eofer ala} aaa] ssi] 73 seafsaal coo] ofaa0} al fss0[a7o|woofsealses|aoe| 1a} za) fsse[ae8] 379} 9031 20] <00] «1.01 <20) [ss8]s681 3.0} 383] 08] e07]e17) 27) “Feee ROG aInID TUT TNA PORIESIO ation 65 pezrast7 mms.Obaarvec AM Gray SCS. S SSCs, se So aa a Ears aaa say on ew Se 9 TAT 7 aa s0a[ sal] 307[ 9-267 [367 [sre| sea] 00s] aT s[ eas a 2s[303| 315 926[ 504] 3t [ae] 3e9[a73| 303] 99 soa|at Z| <2 cl aa soa[ ora} ]saaloe 21384136 [srs [sealoaol sas] os| et 3 {Bi aos[ ara so] sno[s9-9{3ea[3e3| see 9700] sol ane| ste cl 0) s00[sto[3t9]3ra1 5. 8]3001 58[soa]377 [3071398 ]aaeL a3 3] asl saa[ana[ sa] ze 7[se7[ se0| wal ars[ one selena a i= en sez |a07| a8] se6| 9 ¢|oes| a 5|eal ara 93] e0a[ 7 \3 = ee aeafana| es sral ee sea[ ae [aes raf fanol ere is pet sns [val sea] seals s seas seat ars fatal aval ga [3 283[ 021-2] 204[o9-1]se4| 360 seal37 9] 367 [307[ 08 is eat sea[ana[ati|zt [oe ‘| seala7a|m lone] ane =a 264[ s80[200[ sus" alaz e|sa7[ 347 [2e6| ea[3rs| 304305] 03 zai ral sea[se7|s07|sr es 8 [e3[ara] se font [aoe a eat srs [an [see sna| ae ae] seal se aso ara 7a e737 [nas |soal or [sra[ soz] [aeolasalsesl 77 is e374 anal 3]sna[ sr s|seo{aza| seal ea[s7|se}ore| 09 Factors for Correcting Fuel Temperature Factors for Correcting Fuel Temperature Fuet Temp. [Correction | |Fuel Temp. | Correction te Fact +. Fact 5 0920 a +010 10 0.925 +00 1018 2 0938 10 1.028 25 250 15 +030 2» os 120 1036 3 0.980 1 +040 6 0.980 186 1.080 0 0.965 “0 1.058 pszranze ans.o 0976 180 1.085 70 oes 160 1078 6 0.990 08 +080 a +000 Correction Factors for the Inlet Air Pressure Naturally Aspirated Engines and Mechanically Turbocharged Engines [air Pressure Air Pressure are reere pg) (correction Factor | METOSW | Correction Factor 315 (085) 0309 255,062) 008 310 (1048) 0.995 250(048) sort 205 108.187 1.000 245 (828) 078 sno 014) 1.006 240,01) +086 295002) 1012 255(704) 004 290980) 1018 worn, 08 285 (863) 1028 225,761) a 2.0 (088) 1.030 0 (744) +420 275 (880) 1.096 25(727) 120 270 (813) 003 z19(70) 138 255 (888) 1.050 205,603) se 2500678) 1057 200,688) 158 Tone 46 ‘a0 neha gis nada th saad val to scount fr rsctn of he clan, apr presi (hy) a exh “Turbocharged, JWAG", SCAGand ATA” Engines Incas ara [ETACHON ASI es 315 (1068), 0908 255 (062) 103 s19 04a) 987 250 (045) 1.008 305 03394 +000 245 (628) 1002 soot) 4.009 2401811) 1086 235 (682) +008 251784) 1.050 230 980) 010 z0(rnn) 1.088 285 063) 018 225176.) 1.088 230 646) s018 220 (748) 1.088 218 (920) 1.020 21572) 1.088 2701618) 4.023 aorta) 1073 255 (086) sa2r 205 (683) 1079 28.0 (07) 1.030 200 (078) 1.085 ans:"305 nches Has uses the anda valio account resrcon othe a clone vapor possum) an exnast Correction Factors for the Inlet Air Temperature Naturally Aspirated Engines and Mechanically Turbocharged Engines [air Temp. °F [Correction Factor | [Ar Tomp.’F | Correction Factor s os 6 one ° ses 70 0995 0 0969 7 1.000| 1s 957 0 1.002 2 0980 88 1.008 25 see ” 1.008 % oan 100 1018 «0 97s 505 1018 6 are 10 ‘022 0 0982 16 1.025 5s 0905 00 1028 Tea Te Standort Vai. Massie one Standort Vie betaean tha a haner and lt mane “Turbocharged Engines and JWAG" Engines: [air Temp. “F [Correction Factor | |Alr Temp. F | Correction Facto 0 aso | ao O95 ° ase | [70 0908 5 ose 75 0999 10 876 78 1.000 6 ase | | ao +00, 25 ose * 1.004 20 oes a 1.908 % 065 100 +068 0 oer 108 1.009 0 oso 46 1012 56 0992 v0 19M Tate a9 © ea Wa Atco Te tarde Vue Mesure one Sadr Vase eweon tte a cane and he mt a hberaaee ATARG Engines [air Tom. F | Correction Factor Correction Factor «6 oer 8 ans56 0966 ‘08 1.900 66 oar 120 1907 ” sre 15 1910 0 0900 15 1016 oo 0986 0 1920 # 987 46 1923 96 0990 160 1.926 ane 9 peta Atroond The Stand Vb, Massie one Start Vas net mantle Equation for the Correction Factor for Spark Ignited Engines yearap® Ys278| -on8 99.0 18829] Iseten 67 cnz7e003 XA pressure at th iat ortho angie om 87.0 Pao 104.0 KPa (12.6 pst 15." ps) °Y “Engin let a emperatca rm 10°C to $0 °C (50°F Wo 122°F) Appendix E (Suggested tolerances for Performance) "Neto: Refer to TM for mor information on he Suggested Tolerances for Perfomance, ‘Maximum Tolerances for the Performance of the instrumentation [Measurement Toque (io ean) 205% Enoine Speed s5RPH ‘State Fun Stings {£0.05 mm 40.002 ich sal Fue Rate (of eadng) 205% ‘Spark ote Fol Raat fea) 10% ‘Spark nite Low Heat Valu (of ecg) 0% Boost = 1HPa(030 09) Tino ofthe Response Chock 40. oven Blowby (aad) 2% Water Temperatures VeseF ret ManflsTenperatare 1e(87A Water Flow oe Fue Presse ferent (Spark iad) 0.140145 ps) Pressure of Gampressor Oat Spank ged) | 11 KPa (0.0 inches Hg) Manis Abeate Pressure it Spark ones) | 11 KPa 0.30 inches Ho) Inet Fel Torperature (Spar gntes) esa7A et Fue Abaco Pressure Spar ited) 1% Excess Oxygen (Sark antes) 0% i Prese 10 KPa (14555) (1 Temperature to Bearings 1e(s38A timsFualPressire tora (1.4555) Ink Fue Presure 54Ps (0725 pe) net Fual Temperature Vesey Brome Pasture 024 (0.08) Wale vapor Pressure 0.40.03.) Int AlrResticion 0.14 (0039) Int Ar Temperature eseA FueiDensiy ara “Tinng (bof Engine Ful Load Reading) | 1° 9F 0.05 mm (002 neh) Tate st For engine pefamanoe tolerances, ear to the MIT General Engine Data (Engine Test Spec), Th measured perfomance characters nou wit the mmm ane minum vakes hat are given TM Appendix F (Requirements for Diesel Fuel) “Ts append dling ne requteets of low aur us, rd hl fr tees wth conte gravy or ise gies “Tris et used fran engine teat el fr rune ad an engine tt ft for power outa checks. The ls also ved for stings for remanufactured desl engines or rel sol engines, This el eseuld not be used or an omson caniaton "Note:The este sal in accordance with TEAS18 er ura war fel and E0262 forall oes. Engine power, torque, an fo rates shallb cored for ul deri varaton, Tho fel density variaton shal not be mere than the lit som in Tale 90 Diesel Fuel Specification Description Permitted Tolerances APL Gray 15°C (0287) om ‘cor (01500), ‘30 max Dare Flash Pant (083) 52°C min Pose Port 07) ~i8C mae ‘tout Point (02500) = eo mae ‘ter and Semen by Volume (D1798) 008% mae Ramstoton Carbon Resies (0524 (on 10% Ressuum) | __025% max ‘Ash by weight (0482) Dot mae Copper Sip Corosion 3h at 100°C (0730) (ss max ‘Goiano nx (0976) 40min ‘Sula by weight (0128) 005% mae Kinematic scoiy at 40° (D445) “Lo ms tot mls Distitaton (088) rsa Bating Pon 220°C mae 10% Pont 240°C mae, Ent Pont 355°C max, Woar Sear at 25 °C 180 12156 1.8 0.300 mm ma oar Seat at 80°C 150 12156-13) (2450 mn max Te 52 Appendix G (Adjusting Air Actuators) Gi structions ‘Twstest provides mstctons fr adusting te govemerinkage andthe Carpi Ar Actua. These est nstucons ont 5p tote Caterlar Ar Actuate, 218Test Conditions Th supey a eresaur tats eguiredr his process must be manta and a maximum of 20.5 Ka (90 ps 1 tween amino of 448.2 KP (65 ps) ‘vai sressure eputori raquied to conta he a pressure lis supp oes acs nou nave range rom 0 KPa (0 palo 6895 Pa 100 ps) and ee accra up to 3% oT pressure gauge Test Procedure 1. Vent that he movement ft actuator begin aa gauge proceso 6.9475 be nasa ta aut the peoad forte apring onthe actus. The procedure Called Sating te Prload onthe Spring forthe A Actuator. 1.7495 Pa (10 2p). tay 2 Aut the tag for the goveno la achieve low ie wi a gauge pressure othe atta af 0 KPa p16 18.940 (10 ps). Th procedure sti inthe secon hat eld Setg the Slap Postion forthe Low lle one Actor, 4. Weasxce he information arrears the information hats raquested on he data shoe. Setting the Preload on the Spring for the Air Actuator “The alto pring i preloaded athe factory to aow the ping fo star moving wien he apres othe actuator rach 68.9 KPa (10 pe, Pesorm the following steps an adjutant i equied. |- Insta ana pressure gauge inthe ins at 2 convanint pin batwsen the regulator forthe ar supoWy an tne 2. Stout erase the al suse. The plunge shout 83.9. 18.8 Pa (10 #295. 10 mave whan he a pressure gauge ragitrs a eating of The proload must be decrossod ithe plunger moves at a rossurs ha gator than 68.9 KPa 10 i, The peaad eanged by overage ao sr far enought permite retains nt ot. a. Tum he rine nut ockwiso to increas the oa of he sprig 4. Once a pressure fh preloas of 6.8 + 13.8 Pa (10-2 ps) hasbeen cbanod ighton he Stscrew to ock he relinr natin pace Setting the Low Idle Stop Position for the Actuator ‘oud not be catated 2 ts lw le lop ore govemer. The ow ie may be edule by changing Belang fhe rod nkago. Use te folowing procedure oe the low ae stop fr he artuat 2, Set the nad cont ever forte engine governrto lw 4 Eneurethatno ar pressure ls being debra othe ctstr, stop nthe engine govenar. {8 Connect th roa nkage othe prope ol inthe govero ler. Cesk the fw ie spoes ofthe engin. the ow asta to ener hat the ois seated on the fod sprig. Perfor he olowing procedure to make adjustment Remove te pin fom the ve rodtinkage. 4 aus th lng by loosning the eckutsantring the yokes on he 7 Altar the ia is inserted inthe governor ever, neraase hear pressure petl vote poston. The tun be ‘a pressure toa ow le postion. Check the ow ile RPM ofthe engine. Th operation's repeated when the hack ans‘shows a reading thats nthe low ile RPM ofthe engine. The operation mustelio bo repeated the rd isnt 8a ont 0 sping Setting the High Idle Position for the Actuator “The high ile top forthe govern an asssin obaning the cme high ele austen on the ar actus. 1.Do ne flowing sens whe the engine is unting and tne engine ia warm, Remove he high docking srewa for he actuator. Back ou the igh ile stp screws for tout uh ange reaches th igh la RPM, Tum the tw igh dle lop sro forthe acta elocwie unt he serows have coract who plunger the actuetr. De nt um a screw beyond he pont of contact hand contol ine 4 Return he a roglatr for tba actuate tthe low ie poston (68.9 KPa (10 pl) and mv ‘on the govenorto the ll open pation, 65. When the eng sopra manly bythe hang con ver onthe governor, tum the high le tetas in the engne govemer nto courtrcleckwsedocton unl the hig ile increases approxmataly 10 RPM above ‘he spociod hgh ile RPM. This wil prvont damage tothe governor. Damage I roveriod by onsuing at hi 18, Wake any corrective atjstment thats necossary on he govero”’ high il ero to maintain he necessary 10 "Note: Bath a ho high il stop szrews on the actor must be tumadin th same dtanceandin he game drcton. “This nocossarybocauss tho plunger must contact both sows al the same tno. Answo arsipoy (@)SetSe0w (Chg le Lose Sew othe Acute Roe RedLniage Phrase (C)Red Spine (e Aewatr Serna (0 ee Sep Sons (Acar) pRataner nat (6 GoverarLave: (9 covemor set ‘Catorpil eine Srl Number 1 Air Actuator Data Shoot customer E80. ‘Actuator Pressure (PSIG) | Engine Speed (ROM) Low ae ah ao gh ae 0 RM Rated Spee Note Thats! sould be partomed ato ad peter spect co Tae 53 Appendix H (Glossary) |NF Conte BysamieSeting- The namie setng of @ device on he engine tat ints he amount of ust hat ected or stroke asa uncton ofthe boost ‘Atercooles-Aheat exchanger thatsinerted ino the induction system ofan engineer ary davies used to compress the combustion a ‘Analog -A coninvous sal of perfaance ha ropresents ho value ofa characteris of engine performance Slowby -Blowby is combustion ga that oak into he engin crankcese, The leakages normalleakage om the combustion chamber past he piston rng or throug he vale guides, Spec bowby is eluted by ang he ‘lume of towoy tat at atnospherc pressure by ested powcr of ho engin. ‘Boos -The gauge pressure smeared the it manols of «desl engine Austad boost the clodatd value of boost that would xt fan engin was runing at nominal power. Boosts net equa inkt mar pressure, ‘rake Specie Fuel Cneumption (BSFC) -BSFC ie tte a ual consumption. The BSFC sats he ably of te engine ‘e-eamert ne energy in dese fat engin horsepower. BSF-Cs measured inthe uns pounds of uel consumes each hours prods ane brats horsapower. As the value of he BSEC incraases, the ecaney ofthe engine docroasas, AS the efcincy ofthe engine decreases, ef thats eqied er hour increases, Each mode of engine has aunque SFC, which ie deteined on a test tan ‘ling - The maximum rote high im ofan engine perfomance specication Compressor Out Prssure The gauge pressure ofthe eomtuson sr a he turbocharger compressor aul for park lente engines CCorectionFactor- The number hats used ofthe vale ofthe characte fer engin prfrmance under front operating condtons ‘ranking - Rotating an engine wi 2 source of power thats xtomalts ho angine 518‘yelic-Varaton in ho pafomancecharctestcs wich vary as ho angine uns. This is especialy fr ose ‘characteris whieh vary ina repetitive fston Detis-T- the isan temperature fhe engine coolant Hom te kt of he Jacke water pump othe let forthe engine Dens (Fue - Deny for sthe mas ffs pe volume. The uns of oy tat are uta hie puleaton| se degrees Amarean Patclum aut APH a 15.8 °C (60) Fal Pressure Dorota - Tho gas pressure that suppl othe crburctor on a spark iis gine minus the rossi ofthe carturtor nat Diital-A numarc vu thst represants he value of a charatensto fr engine perfomance Displacement Te aea of a piston mutiped by the length a aoke tes the numb of etaders ‘Droop - Drops the decease fom no oad spood to fl lnad sped when fleas apple to a goneratr st. Droop ‘oxpressos a 8 prcoriago of fu load spec, butt Cooled Engi -An engine cated by beling water. The coangsaccomplshes by turing wale io steam ‘ha ltentnsatof evaporation at is absorad in tis recess cools the angi. Engine Fuol Consumpin Tho value that found by maltphing the corresponding BSFC by th Mrsapower and hen ving he resul by 7.078 the weght n pounds per gallon o standart) Foal consumpton in pounds por hours the weight of standar ul hats buried by the engine por hour under standard condtons to produce ad horsepower Excess Oxygen Excess Oxygen Is the aunt of fee oxygen inthe pradus of combuston, Excass Oxygen may be ‘xoresses as a perceriage of eter vol or mass. Flor Tha lore the mnimum tat alowed forthe law nt on anne performance speciation tal. Flyfoo Broke Hrsopower(BHP) This sth actual horsepower thats avalablo athe yhoo. The measurements ae taken hehe engine i tipped of he accossary equipment and wil the aerator ad he ar compressor ae beng operted under @"no load coditon.Caterpllr nds! engines an ruck englnes ara measured in ams ot Brake Horsepower. Feel Rae Dias) - The mass of uel bumeslby an engine in a species tine. The coecte ual ate he ctl el rata rte observed ul rate thats corectad for h ueldany Fool Rate (Spark lated Engines) ~The fel ales the volo sl hls umes by an engin 8 specs ie. The corecte ulate found by mulling the volume of fue a standard condton by he lower heating vale of he Foal Pressure The fel ressue tat supped othe jecton system ofa Case engine Ful Load The manu power ta can be developed by an ange thats tuning ate ted spac an the ul sytem is opened tothe maxum spectiad condo, Ful Lod Spaod The Full Load Spoods tho sped hat proses the aod horsepower. The ack is ako poston to ‘low the rsx recommended amount offal tthe engine par ni of tne. The governor should reach a balance ont aout when the engine reaches load speed. n ome applications the cu fhe engin performance s "odie to provid an ineoasein horsepower when he fora springs defected. In hs instance, the fl load spesd ‘andthe blanc pn donot oes" athe same me. Th increase in horsepower bates te bale pot an he fl load speed i calod the "BHP sped’ ‘Goreror Balance Point- This point occurs athe engine speed when th fue seing Screw opin just tuchas te toraue ping or stop bar. The pits set by aking wo eal adjusted and raaturabesetings (high bl sped sting an the sti ped sting for the rack, ‘nus System - Tha components of an engine ha ar inves in providing coméuston art an engine Int Air Prossure- tA Pressure i the dy a pressure ats supple Io hein of an engine. Thiet nly barometie pressure minus water vapor mus net retin, Ink AirResticion The proces of sopping the combustion nr rom abrospherc pressure fo he comoressor inlet of turbocharged engi orto tenet marl of wnatualy wap engine Inet Foal Pressure The el pressure thats supe to he fal net of esol ngine bt Fu Pressure (Absolule Pressure) - The gas pressure tha supe ote el nel of a spark igi orine Ine Fuel Temperature - The temperature of he Ignited engine ats ppl th ulin of ener a ese nie o 8 eparc 88Ino: Manila Pressure - This teint anol pressure that is above amospherepossue. The pressures aso referodto as "voos. The presse alo ncaas to ant ofa tats boing Severed to he engine, The 46-2007 Narita Test Gauge ats lated inthe esti othe engine wl read absolute pressure. The abslue pressure is "ood plus he stmospheric prossure Luyg- Ths isthe apeleton of loss on an engine that causes the eng spe o arp blow the ates pees. ihe engine i aged opin ha alow he son of maximus logue, the engine wl sal unless same af hela it esturo Cont A scrw or ajstable va that is usd to roguato th Ar or the Fuel tats provides by acarburctor tiple Ratag Engine An engine which hs avaiable Sting othe ul aul oad o provide mare than one emcurt of power at ful oad Naturaly Aspirated torn tat i pi fo an eng, hich has no method f compressing test ats supple e Nominal ~The Nominal alo i th spocied value orth argo value ofa pefomancs charactors for an engine. The nominal value i accompanied ws olarances thal deine te accoplable range of the charactor vale relate othe COllPressvre- Th engine al presse a fills at = spate Iacono he engine ‘ovarun Specs - Ihe potion a broke Nersapower (SHE) or larque curve hats between Nigh dle an a led specs. tn tis spo0d rang, the engi is conte by he governor. Power-The ate af ing wor. Powers the actual power ofthe observed power halt covreced to standard contin of apart pressure, i a erpersture, and el dena. Rated The specie value of characters ofthe engine perfomance Regulaton ~The ineaate inte speed fan engine tal okes place ater te fllaad is removed, Regulton is orsrossos a percentage ofl lad speed Response Check -A measure othe engin’ billy to devel incrasing logue at a constant speed, ‘Response Check (He Spsed)-The engine spood tats spect fr he col own portion fhe rasponss chock Response Check Speed. The constant engine speed that is se to delemine the ne ate necessary o develop 8 spec aque Response Tins Ameasir ofthe tine tat requ fran engine to develop a spociid torque or powsr Rotatlon of Engne- The dracon of ton fhe engine thee 35 He tywhels viewed rom he rear ofthe engine. Rotational reztons expresso as cockviso rotation or counterlockwis rotation. The rotaton ofan engines normaly counterlchwse, ‘Separate Cec AMrCooer- Aa changer that used for coal combuston aha cote bya source of water that ie eatomal othe ergne ‘Slobbr - Oo uel ats charge with he exhaust gases into the exhaust syst ‘Significant Figures ~The umber fags rumber that define he precision of the number ‘Spark nt Engine - Fr this puteaton, a spark ites engin gaseous fled engin. ‘Speci Fuel Consumpton - Tha ful rae vied bythe powor. Coracted spect fel consumption sth vl thats bined when the corrected fel needed by the coected power ‘tai Te seat concton or cyte conden a characte of engine perfomance that rains unchanged wh tme ae ho angie i runing undor a gin steady site contin, ‘State Fue! System Sang -Asating of the fuel system att made oobi the dosed a ate aa pater operating pont of te engine, The setngs are normally mate provide ether the flats afl looo the ulate st torque check RPM. The stings are dened asthe Slate Fuel Satin atfulload othe Sate Fuel Sting at lorie “ining (Diesel) The angler poston of he cranks lave lo lop da carer a hese of incon “ining (Spark Ign Engine) The angular poston of he crenshat relatve to op doas canta at the start ones lugs boing snorize, “Edorances The value tat used specty the range fer @ characters fhe engine performance “Top Dest Cone: (TDC) The positon of th cranks as the piston a he highest poston. Torque -Torgue i n fot a wisting, Toru fon usd i engine speciotons. mgasur fhe tendency of foes io eauserolaton an tare Is “TM6“Torque at Toque Check(TC) RPM - Tha steady tte torqua thats developed by an engine atthe Torq Check Spaed Torque Check Spec -Thespaad thal suse to check he performance charactors allow sped ofthe engine ate Lash- The clarance thats set he vale mecharom o prevent an int vaNe oan exhaust vate fom Sng hol opon while the machanism is hot Water pe res -Te patil presse ofthe ater vapor in te combustion aatisblng supped 1 2 rene Appendix | (Fabricated Wiring Harnesses for Electronic Engines) Ce fifi sili ante nice mec eaten 69 oatrez0s aiN18aston 70 oatresse aimsasin 72 oot7ee04 statin 74 soarerse ams= as SS Fee asin 78 ores stein 77 ootesie amssion 78 ootrecar a E88 pane 26sean 80 oor76845 Imsenten sores state 62 opts Throttle Control "Noto: Using the rate pin for tote contel isan open when Cat ET is not aval for spoos over. For 9- pn connactr (Mustaton 68), the brote Inputs pin For M4 (270 pn connactors) and Aé (170 pn connector, 1120 gn conracor) ECM he trot pin inputs I-88. For 2 EONS (240 Pin connscta), the thet npn 37. Formos the tna, tb hots inputs av not used ns hot st ols, Tho tet cols stead use the engine sofware esired engine speed ovarid (CamET Ud 0100040020, Appendix J: CRS Test Procedure Requires funcional et or engines with engine-meured CaterparRegereraton Systom (CRS) ‘Toe CRS testis broken ino wo Secon. Secon ane i o peo¥idevrfcaton a te ie, el nes, end conta ‘valves are tuntaning and oe fom malorleaks. Scion Wo funciona lst to ensue tat the CRS pariorms 28 spoofed by Engnacting, amsCRS Test - Section 1 ‘Secon ane CRS leak check detain ss flows: Colect a base tne om the engine electronics (ECM) othe GRS Air Flow, ORS Plt Pressure, and CRS Main Protere wit) al contel valves dosed (vei the CRS A Contra Vave o constant value and messue the CRS Air Flow to ensue hat chs above the ba ine 5 Recose te Ar Conte Valve and vent he a flow eur toe baseine value, “4 Open ony the CRS Fuel Enable Convo! Valve are vty tha the CRS Pt and Main Pressures do not inreaseto check or leaks past he CRS Plt an Main Ves. 5 Recose the CRS Fuel Enable Conta! (Open ony the CRS Ful Pressure Conte Vae (Plt ar Main) and veya he Plt an Man presses do not ieee to chek for leaks pst Pe CRS Fuel Erte Cool Va 7 Recose th CRS Fuel Pressure Contrl Va, ‘any ofthe above ao perform as described, eecton one is consid fale, and wil neta the CRS pertormanca ‘20k tobe run. n acon BOTH Fue Vaves fa each indepensent leak check atthe engine wl be shit dwn CRS Test - Section 2 ‘CRS Perormance check detntion sa follows ‘Selihe engine to define loscepecd point a defined or the mde! being tested (sit between Heavy Duty ad a Range. (verde the CRS Systom to pero regeneration, Wat forthe CRS Flame Detect Tenperature and CRS Mae Presture to reach tha ow Ei, hen wal 2 dctona 15 saconds fr sabi 0 be reached ‘4 The Petormance check willbe aborted after 90 seconds if CRS Flame Onect Temperature or CRS Main Presse For heavy-duty pplcatons the CRS Air Purge Pump. appcale, wi nays be activated athe ond of his chock This pump wilbe vrifed by montoring the CRS Plt an Main Pressures during the Nozze only functon vwth he pup in High-Speed mode. Tho folowing datas coleced as passa ceria as partof the production est, + ORS Pt reese © CRS Main Pressure + ORS Ar Contes Pressure + ORS Flame Detect Temperature 1 ORS Air Pump Functon (Heavy-Duty Ony) Inne cose ot any tal companent rea a rplaemant tothe Catrpilar Regeneration System,» pressurized astm look tes shal be performed prior o complete retest, Caterpillar Information System: (C2.Geneatr Set Ennis Al net nd Exhaust System, ans(92400 Ene (EIS osnacing Eccl Connectors cota The names Cater, Jahn Deere 0, JC8, Hyunl a anyother orginal aqupment menuactwers ate registred yas ‘rademarks ofthe especie aginl equipment mautecturers. ll names, desertion, rumbers and symbels ae used Iorroerenes purposes ony (CH-Par.com tn no way assoc wth any ofthe manulacuters we have listed. ll manuacurers names and eserptons ar for reference onl sms