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REHS1438-03 Special Instruction
REHS1438-03 Special Instruction
March 2004
Special Instruction
i02066887 Introduction
Installation and Initial Start-Up Do not perform any procedure in this Special
Procedure for G3500C and Instruction until you read this information and you
understand this information.
G3500E Engines
This Special Instruction provides the following
SMCS Code: 1000
information for G3500C and G3500E Engines:
Electric Power Generation • Requirements for the electrical system
G3516C (S/N: RWA1-Up; TJB1-Up;
TJC1-Up; DKR1-Up) • Proper grounding practices
G3516E (S/N: GHP1-Up; SLY1-Up)
G3520C (S/N: GDB1-Up; GHC1-Up; • Proper welding practices
GHE1-Up; B9P1-Up; CWW1-Up; • Required service tools
CWY1-Up)
G3520E (S/N: HAL1-Up; GHM1-Up; • Electrical components and electronic components
GHR1-Up; SXY1-Up)
• Wiring connections and the corresponding
functions that are available to the customer
Table of Contents
Introduction ........................................................... 1
• Initial start-up procedure
Requirements for the Electrical System ................ 2
Grounding Practices ............................................. 2
• Governor adjustment procedures
Welding on Electronically Controlled Engines ...... 3 Reference: Information from the following sources
Service Tools ........................................................ 3 will be needed for this Special Instruction:
Connecting Cat ET with the 171-4401
Communication Adapter II ............................... 5
Terminal Box ......................................................... 6
• Data from a complete fuel analysis that is entered
into Caterpillar Software, LEKQ6378, “Methane
Junction Box ......................................................... 9 Number Program”
Customer’s Wiring ................................................ 10
Required Connections ....................................... 11
Optional Connections ........................................ 14
• The engine’s performance Data Sheet from the
engine’s Technical Marketing Information (TMI)
Unused Terminals ............................................. 16
Wiring for the Emergency Stop Circuit .............. 17
Wiring for the Gas Shutoff Valve (GSOV) ......... 19
• Operation and Maintenance Manual, SEBU7681
Wiring for Monitoring the Generator’s Output
Power .............................................................. 22
• Systems Operation/Testing and Adjusting,
RENR5978
Inputs for the Modes of Operation ..................... 23
Initial Start-Up Procedure ..................................... 25
Adjusting the Governor ......................................... 27
• Troubleshooting, RENR5944, “G3516C and
G3516E Engines”
1
Requirements for the Electrical Grounding Practices
System Proper grounding is necessary for optimum engine
performance and for reliability. Improper grounding
All of the wiring must conform to all of the codes that
are applicable to the site. When you route the wiring, will result in electrical current paths that are
uncontrolled and unreliable.
avoid acute bends and sharp edges. To protect the
wiring harnesses, route the harnesses through metal
conduit. A liquid tight conduit is recommended. Use Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
proper support and alignment in order to avoid strain
journal surfaces, and to aluminum components.
on the conduit.
Uncontrolled electrical circuit paths can also cause
electrical activity that may degrade the engine
Electrical power must be supplied to the junction box
electronics and communications.
that serves as the main distribution panel for the
engine control system. The engine control system
requires a clean 24 VDC power supply that is capable • For the starting motor, do not attach the battery
negative terminal to the cylinder block.
of supplying 30 amperes of continuous power.
The maximum allowable AC ripple is 150 millivolts AC • Use an electrical ground strap to connect all
metal cases that contain electrical components or
peak to peak. For the wiring, the maximum allowable
voltage drop is 1 VDC from the power supply to an electronic components to the cylinder block.
Electronic Control Module (ECM) or to an actuator.
• Do not connect the negative terminal from the
The power supply for the engine control system must electrical power supply directly to the cylinder
block. Connect the negative terminal from the
be separate from the power supply for the starting
electrical power supply to the negative terminal “−”
motor.
on the engine mounted junction box.
2
Welding on Electronically Service Tools
Controlled Engines The tools that are listed in Table 1 are required
Proper welding procedures are necessary in order to in order to enable a service technician to perform
avoid damage to electronic controls. Perform welding the electrical installation procedures and the initial
on the engine according to the following procedure. start-up.
1. Set the engine control to the “STOP” mode. The Caterpillar Electronic Technician (Cat ET) is
designed to run on a personal computer.
2. Turn OFF the fuel supply to the engine.
Cat ET can display the following information:
3. Disconnect the negative terminal from the battery.
• Parameters
4. Disconnect the engine’s electronic components
from the wiring harnesses: ECM, throttle actuator, • Diagnostic codes
actuator for the turbocharger compressor’s
bypass, fuel metering valve, and sensors. • Event codes
3
Table 1
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) The PC is required for the use of Cat ET.
“JERD2124” Software Single user license for Cat ET
Use the most recent version of this software.
“JERD2129” Software Data subscription for all engines
171-4400 (1) Communication Adapter Gp This group provides the communication between the PC and the
engine.
7X-1414 Data Link Cable As This cable connects the communication adapter to the service tool
connector on the engine.
237-7547 Adapter Cable As This cable connects to the USB port on computers that are not
equipped with a serial port.
8T-8726 Adapter Cable As This cable is for use between the jacks and the plugs of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and of sockets from
Deutsch connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with electrical connectors.
146-4080 Digital Multimeter The multimeter is used for the testing and for the adjusting of
electronic circuits.
7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage in
wiring harnesses without disconnecting the harnesses.
156-1060 or Emission Analyzer Tool This tool is used to measure the level of emissions in the engine’s
156-1070 exhaust. The 156-1060 measures the levels of four different
compounds. The 156-1070 measures the levels of six different
compounds. Either tool may be used.
(1) The 7X-1700 Communication Adapter Gp may also be used.
4
Connecting Cat ET with the 171-4401 2. Connect cable (2) to the RS-232 serial port of
Communication Adapter II PC (1).
The engine’s battery supplies the communication Note: If your PC is not equipped with a serial port,
adapter with 24 VDC. Use the following procedure to use the 237-7547 Adapter Cable As in order to
connect Cat ET to the engine’s control system. connect to the USB port. Connect one end of the
adapter to the end of cable (2). Connect the other
1. Set the engine control to the OFF/RESET mode. end of the adapter to a USB port on the PC.
20 Cylinder Engines
Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.
5
Terminal Box Terminal box (6) contains the electronic control
modules. Connectors on the back of the terminal
Note: The terminal box is designed to remain box connect the engine’s wiring harnesses to
mounted on the engine. The mounting hardware components inside the terminal box. The ignition
includes isolators. Do not move the terminal box to a harnesses are routed directly from each ECM to the
remote location. Moving the terminal box could result ignition transformers.
in wiring problems and in reduction of the service life
of the components inside the terminal box.
g01059049
Illustration 2
Rear view
(6) Terminal box
(7) Emergency stop button
6
Illustration 3 shows the components that are inside of
the terminal box of a 16 cylinder engine.
g01059113
Illustration 3
Components inside the terminal box on a 16 cylinder engine
(1) ECM (6) J10/P10 connector for the terminating (10) J7 connector for the engine harness
(2) Ground strap for the ECM resistor for the CAN data link (11) J8 connector for the detonation
(3) ECM connectors J2/P2 (7) Service tool connector J5 for Cat ET sensors
(4) ECM connectors J1/P1 (8) J6 connector for the customer
(5) Ignition harness (9) J9 connector for the engine harness
7
g01060562
Illustration 4
Components inside the terminal box on a 20 cylinder engine
(1) Master ECM (8) Ground strap for the slave ECM (13) J6 connector for the customer
(2) Slave ECM (9) Ignition harness for the left bank (14) J9/P9 connectors for the engine
(3) Ground strap for the master ECM (10) Ignition harness for the right bank harness
(4) J3/P3 connectors for the slave ECM (11) Service tool connector J5 for Cat ET (15) J7/P7 connectors for the engine
(5) Master ECM connectors J2/P2 (12) J10/P10 connectors for the harness
(6) J4/P4 connectors for the slave ECM terminating resistor for the CAN data (16) J8/P8 connectors for the detonation
(7) Master ECM connectors J1/P1 link sensors
8
Junction Box
The junction box serves as the main distribution
panel for the engine’s electrical power. The junction
box contains all of the circuit breakers for the engine.
The junction box also contains the magnetic switches
for the electric starting motors.
g01059145
Illustration 5
The junction box is located on left side of the engine.
(1) Junction box (4) 35 amp circuit breaker for the engine (6) Positive terminal for the connection of
(2) 2.5 amp circuit breaker for the engine control’s main power supply the engine’s power supply
control (5) 2.5 amp circuit breaker for the start (7) Negative terminal for the connection
(3) 10 amp circuit breaker for the command from the ECM of the engine’s power supply
customer
9
Customer’s Wiring Some of the wiring connections are required. Some of
the wiring connections are optional. The connections
To properly wire the engine for the requirements of that are required are identified in Table 2. The
the specific application, the customer must be aware connections that are optional are identified in Table 3.
of several inputs and outputs that are associated
with the engine’s control system. The following list
includes some examples of the inputs and outputs:
• Emergency stop
• Electrical power supply for the control system
• Start-up and shutdown
• Engine speed and governing
• Status of engine operation
The 9X-7147 Connector Plug is available for the
customer in order to fabricate a wiring harness to
the customer connector on the engine mounted
terminal box. A 16 to 18 AWG size of wire may be
used. The 9X-7147 Connector Plug mates with the
J6 connector on the back of the terminal box. Refer
to Illustration 6.
g01060191
Illustration 6
40−pin J6 connector
10
Required Connections
Table 2
40-Pin Connector J6
Required Connections
Terminal Description Functions and Comments
10 Emergency stop Terminal 10 is provided as an option for a customer supplied
emergency stop button.
20 Digital return
Terminal 10 must be connected to terminal 20 in order for the
engine to run. If this circuit is open, the engine will not start.
When this circuit is opened during operation, an emergency
stop shutdown is activated:
If the ECM is controlling the gas shutoff valve, the ECM will
de-energize the gas shutoff valve. The fuel is immediately
shut off.
Auto
Start/Run
Stop
Timing setting
On/Off grid
Driven equipment
Normal stop
Idle/rated input
21 Fuel control relay’s +Battery The Gas Shutoff Valve (GSOV) may be controlled by the
engine’s control system or by the customer’s equipment.
31 Fuel control relay’s +Battery
For details on these terminals, refer to “Wiring for the Gas
Shutoff Valve (GSOV)”.
9 Driven equipment This input indicates when the driven equipment is ready for
operation. This input must be connected to terminal J6-36 in
order for the engine to run.
11
(Table 2, contd)
40-Pin Connector J6
Required Connections
Terminal Description Functions and Comments
29 Start/Run If these inputs are not wired correctly, the ECM will activate a
diagnostic code.
19 Stop
These inputs are provided by the customer’s equipment. The
inputs control the engine’s mode of operation.
When this input is open, the engine will run at the idle speed
that is programmed with Cat ET.
When the engine oil pressure is greater than the setpoint for
the engine speed and this terminal is grounded to terminal
J6-36, the engine will run at rated speed.
30 Normal stop This input must be grounded to terminal J6-36 in order for
the engine to run.
If the ECM is controlling the gas shutoff valve, the ECM will
remove the voltage from the GSOV. The engine will shut
down. The cooldown does not operate.
Because the cooldown will not operate for this input, this
input is not recommended for normal shutdown.
(continued)
12
(Table 2, contd)
40-Pin Connector J6
Required Connections
Terminal Description Functions and Comments
4 Unswitched +Battery (2.5 amp) These terminals provide the primary source of switched
electrical power to the engine control system.
14 Switched + Battery
The unswitched 24 VDC is always available as an output at
terminal 4 when the 2.5 amp circuit breaker in the junction
box is switched ON. The output is intended for use by a
customer supplied engine control switch.
Master ECM
The method for the desired speed input must be selected with Cat ET.
5 +5 V for the speed potentiometer The ECM provides the +5 V supply to the potentiometer. The
potentiometer provides the signal input for the desired speed.
The signal input ranges from 0 to 5 volts.
13
Optional Connections
Table 3
40-Pin Connector J6
Optional Connections
Terminal Description Functions and Comments
1 Fused 24 VDC This connection provides a fused 24 VDC
power supply for the customer. The electrical
11 -Battery power is provided to terminal 1 via the junction
box. The electrical power is always available
when the 10 amp circuit breaker in the junction
box is switched ON.
14
(Table 3, contd)
40-Pin Connector J6
Optional Connections
Terminal Description Functions and Comments
23 Engine failure The engine’s control system will activate this
output when the control system causes the
engine to be shut down.
15
(Table 3, contd)
40-Pin Connector J6
Optional Connections
Terminal Description Functions and Comments
7 Cat Data Link + These connections provide the means for
communicating the status of the engine control
17 Cat Data Link − system, of various engine components, and
of sensors.
Unused Terminals
Table 4
40-Pin Connector J6
Unused Terminals
6
16
26
34
38
16
Wiring for the Emergency Stop Circuit
NOTICE
The emergency stop buttons must be properly wired Emergency shutoff controls are for EMERGENCY
in order to immediately stop the engine in case of an use ONLY. DO NOT use emergency shutoff devices
emergency situation. An emergency stop button is or controls for normal stopping procedure.
provided on the engine.
In addition to the normally closed electrical circuit
for emergency stopping, the emergency stop button
is mechanically connected to another circuit that is
normally open. When the emergency stop button is
pressed, the other circuit is closed. This other circuit
does not affect engine operation. This other circuit
is available to the customer via terminals J6-2 and
J6-12. These terminals are provided for the customer
to use as an indicator of an emergency stop.
g01060570
Illustration 7
Rear view of a 20 cylinder engine
The 16 cylinder engine does not have a J3/P3 connector.
(1) J6 connector
(2) J1/P1 connectors
(3) J3/P3 connectors on engines with 20 cylinders
(4) J9 connector
(5) Engine mounted emergency stop button
17
g01060931
Illustration 8
Schematic of the engine mounted emergency stop button’s circuit
The configuration for a 20 cylinder engine is shown. The 16 cylinder engine does not have a slave ECM.
g01064395
Illustration 9
Schematic of the engine mounted emergency stop button’s circuit and a customer supplied emergency stop button
The configuration for a 20 cylinder engine is shown. The 16 cylinder engine does not have a slave ECM.
18
Wiring for the Gas Shutoff Valve (GSOV)
The GSOV must be energize-to-run. The GSOV may
be supplied by the customer or by Caterpillar. The
GSOV may be controlled by the engine’s control
system or by the customer’s equipment. The GSOV
is also called the fuel control relay.
g01060579
Illustration 10
Left side view of a 20 cylinder engine
The 16 cylinder engine is similar.
(1) J1/P1 connectors (4) Engine harness connector for the fuel
(2) J7 connector control relay
(3) J6 connector
19
There are three options for wiring the GSOV. The
options are described in the following paragraphs.
g01063416
Illustration 11
The GSOV is controlled by the customer’s equipment.
The circuit for the engine’s control system is closed.
20
g01063421
Illustration 12
The GSOV is controlled by the engine’s control system.
g01063423
Illustration 13
The GSOV is controlled by the engine’s control system.
The GSOV is connected via a harness that is provided by the customer.
21
Wiring for Monitoring the Generator’s For details on these parameters, refer to Systems
Output Power Operation, Testing and Adjusting, RENR5978,
“Electronic Control System Parameters”.
The ECM monitors the generator’s output power in
order to accurately control the air/fuel ratio. The ECM Illustration 14 is a wiring diagram for a typical power
uses an output from one of the following sources in sensor.
order to monitor the generator’s output power:
g01064159
Illustration 14
Schematic of the power sensor’s input
For the actual wiring, refer to the generator’s schematic diagram.
The potentiometer is optional. For further information, refer to
Troubleshooting, “Ganerator Output Power Sensor - Calibrate”.
22
Inputs for the Modes of Operation
The engine’s control system has three active modes
of operation: Start/Run, Auto, and Stop. The mode
of operation is determined by three inputs on the J6
connector. A mode is activated when the terminal for
the mode is connected to the digital return.
Table 5
g01060955
Illustration 15
Schematic of the inputs and of the switched +Battery supply to the engine’s control system
The configuration for a 20 cylinder engine is shown. The 16 cylinder engine does not have the slave ECM.
23
Off/Reset – When none of the inputs are connected, When terminals J6-29 and J6-39 are connected
the engine is in the Off/Reset mode. The switched to terminal J6-36, the engine start sequence will
+Battery supply to the engine’s control system is off. be initiated. The engine will run until terminal
Any active diagnostic codes are cleared. J6-29 is disconnected from terminal J6-36. When
terminal J6-29 is disconnected, the normal shutdown
Start/Run – The engine start sequence will begin sequence is initiated. If the cooldown feature is
when terminal J6-29 is connected to terminal programmed, the engine will operate for the cooldown
J6-36. Switched +Battery power is supplied to the period prior to shutdown. The engine’s control system
engine’s control system. The engine will run until will remain in the Auto mode.
terminal J6-29 is disconnected from terminal J6-36.
When terminal J6-29 is disconnected, the normal In the Auto mode, terminal J6-29 is used to control
shutdown sequence is initiated. If the cooldown both the engine start sequence and the shutdown
feature is programmed, the engine will operate for sequence.
the cooldown period prior to shutdown.
Stop – If the engine is running, the shutdown
Auto – When terminal J6-39 is connected to terminal sequence will begin when terminal J6-29 or terminal
J6-36, the engine’s control system is in the AUTO J6-39 is disconnected from terminal J6-36 and
mode. Switched +Battery power is supplied to the terminal J6-19 is connected to terminal J6-36. If the
ECM. The engine will not start unless terminal J6-29 cooldown feature is programmed, the engine will
is also connected to terminal J6-36. This can be operate for the cooldown period prior to shutdown.
accomplished with a customer supplied remote start In this mode, the switched +Battery power is still
switch. supplied to the ECM.
24
Initial Start-Up Procedure 9. Connect a properly calibrated emissions analyzer
to the exhaust stack.
Ensure that all of these factors are in proper condition
prior to the initial start-up: engine installation, driven 10. Perform the daily inspection and all of the daily
equipment, all of the related hardware, and electrical maintenance procedures that are scheduled in
connections. Failure to perform the commissioning Operation and Maintenance Manual, SEBU7681,
procedure could result in unsatisfactory operation. “Maintenance Interval Schedule”.
Perform the following procedure for the initial start-up 11. Set the engine control to the STOP mode. Use
and for start-up after major maintenance and/or the “Monitoring System” screen from the “Service”
repair. drop-down menu on Cat ET to view the default
settings of the trip points for the alarms. Adjust
1. Verify that the connections between the engine’s the settings, if necessary.
control system and the customer’s equipment are
connected properly. For the necessary values of the operating
parameters, refer to the applicable Data Sheet
2. If the information on the generator’s output power on engine performance in the engine’s Technical
is provided by a power sensor, check the power Marketing Information (TMI).
sensor’s offset voltage. Refer to Troubleshooting,
“Generator Output Power Readings Do Not 12. Use the “Configuration” screen from the
Match”. Continue with this procedure after you “Service” drop-down menu on Cat ET to view the
have minimized the power sensor’s offset voltage. configuration parameters.
3. Connect Cat ET to the service tool connector. Note: Use the data from the gas analysis and from
Refer to “Connecting Cat ET with the 171-4401 Caterpillar Software, LEKQ6378, “Methane Number
Communication Adapter II”. Program” in order to determine the correct settings
for the “Fuel Quality” and the “Gas Specific Gravity”
4. Set the engine control to the STOP mode. Test parameters.
each emergency stop button before the engine is
started in order to verify that the engine’s control a. View the parameters that are listed in Table 6.
system generates a E264 event code. Program the parameters, if necessary.
After the operation of each emergency stop Incorrect programming of the parameters may
has been verified, set the engine control to the lead to complaints about performance and/or to
Off/Reset mode. engine damage. For details, refer to Systems
Operation, Testing and Adjusting, RENR5978,
Note: Check the generator’s protective devices “Electronic Control System Parameters”.
prior to start-up. Some of the generator’s protective
devices can only be checked during engine operation. Note: If the generator set is equipped with an
EMCP II+ system, it is not necessary to program the
5. Check the generator’s protective devices for “Generator Output Power Sensor Scale Factor” and
proper operation. the “Generator Output Power Sensor Offset”.
Note: The engine may be difficult to start if the jacket Timing Control
water coolant temperature is below 43 °C (110 °F). “First Desired Timing”
Note: The spark plugs may become fouled with “Second Desired Timing”
moisture condensation if the engine is cranked and Air/Fuel Ratio Control
the jacket water coolant temperature is below 43 °C
(110 °F). “Fuel Quality”
“Gas Specific Gravity”
7. Inspect the inlet air system. Make sure that the
system does not leak. Make sure that the system “Fuel Specific Heat Ratio”
is free of debris. “Desired Emission Gain Adjustment”
8. Inspect the fuel supply system. Make sure that “Air/Fuel Proportional Gain”
the system does not leak. Make sure that the “Air/Fuel Integral Gain”
system is free of debris. Blow any debris from the
fuel lines. Speed Control
(continued)
25
(Table 6, contd)
Configuration Parameters for G3500C Engines
“Low Idle Speed” Unburned gas in the inlet manifold and/or in the
exhaust manifold can ignite when the engine is
“Minimum High Idle Speed” started. Personal injury and/or property damage
“Maximum High Idle Speed” can result. Use this procedure to clear the engine
and the exhaust system of unburned gas:
“Engine Accel. Rate”
“Desired Speed Input Configuration” Before starting an engine that was stopped by ter-
minating the ignition system, turn the gas supply
“Governor Type Setting” OFF. Crank the engine for approximately 15 sec-
“Engine Speed Droop”
onds in order to clear any unburned gas from the
engine and the exhaust system.
“Governor Proportional Gain”
“Governor Integral Gain” 14. Start the engine.
“Governor Derivative Gain”
The engine will accelerate to low idle rpm.
“Auxiliary Proportional Governor Gain 1” Operate the engine at low idle. Verify the following
conditions:
“Auxiliary Integral Governor Gain 1”
“Auxiliary Derivative Governor Gain 1” • Proper engine oil pressure
Start/Stop Control
• No fluid leaks
“Driven Equipment Delay Time”
“Crank Terminate Speed”
• No gas leaks
“Engine Purge Cycle Time” Several attempts may be required for the initial
start-up before air is purged from the fuel lines.
“Engine Cooldown Duration”
“Cycle Crank Time” Note: If the engine will not start, use Cat ET to check
for diagnostic codes and for event codes. Correct
“Engine Overcrank Time”
any active conditions before you attempt to start the
“Engine Speed Drop Time” engine again.
“Engine Pre-lube Time Out Period” 15. After the engine is running, test the operation of
Monitoring and Protection each emergency stop button.
“High Inlet Air Temp Load Set Point” After each test, reset the emergency stop button
Power Monitoring and set the engine control to the Off/Reset mode.
Then restart the engine. After all of the emergency
“Generator Output Power Sensor Scale Factor” buttons have been tested, use Cat ET to clear the
“Generator Output Power Sensor Offset” event codes from the ECM.
“Engine Output Power Configuration” Note: Some of the generator’s protective devices can
“Engine Driven Accessory Load Configuration” be checked prior to start-up. Some of the generator’s
protective devices can only be checked during engine
Information for the ECM operation.
“Engine Serial Number”
16. Check the generator’s protective devices for
“Equipment ID” proper operation.
“Customer Password #1”
17. Increase the engine speed to high idle rpm. Verify
“Customer Password #2” that the engine is stable.
“Total Tattletale”
If the engine is unstable, perform the following
procedure.
13. Turn ON the fuel supply to the engine. Verify that
no gas is leaking. Verify that the gas does not flow a. Record the values for these parameters:
past the GSOV.
• “Governor Proportional Gain”
• “Governor Integral Gain”
26
• “Governor Derivative Gain” 25. Verify that the NOx emissions are above the
desired full load setting.
b. Set the values for the “Governor Proportional
Gain”, “Governor Integral Gain”, and “Governor 26. Slowly ramp up to 100 percent load. Verify that
Derivative Gain” parameters to zero. the engine is stable.
c. Adjust the “Fuel Quality” parameter until the If the engine is unstable, adjust the auxiliary
engine becomes stable and the exhaust governor. Refer to “Adjusting the Governor”.
oxygen is approximately four percent. Verify
that the exhaust port temperatures are below 27. Verify that the value of the “Generator Real kW”
the setpoint for a warning. parameter is within 1 percent of the generator’s
output power.
d. Adjust the primary governor. Refer to “Adjusting
the Governor”. 28. Adjust the “Desired Emission Gain Adjustment”
parameter in order to obtain the values of
18. Select the “Information” drop-down menu in order emissions that are required at the site.
to view the status parameters. Review the values
of the status groups on Cat ET. Verify that the • To lean the air/fuel mixture, decrease the gain
pumps for the cooling system are operating. Verify adjustment.
that the cooling system temperatures and the
cooling system pressures are within the correct • To richen the air/fuel mixture, increase the gain
operating ranges. adjustment.
19. Close the main circuit breaker for the generator in A small change in the “Desired Emission Gain
order to engage the generator. Adjustment” causes a large change in the actual
exhaust emissions. For example, an adjustment of
Note: When the engine load exceeds 25 percent, one percent in the parameter’s value will result in a
the air/fuel ratio control will operate in the feedback change of 20 to 40 ppm in the actual level of NOx.
mode.
When you adjust the exhaust emissions, make a
20. Slowly ramp the load up to 30 percent. small change in the value of the gain. Wait until
the system stabilizes. Check the emissions again.
Note: When the air/fuel ratio control is in the Repeat the process until the desired emissions
feedback mode, the Fuel Correction Factor (FCF) level is achieved.
may no longer be 100 percent. The ECM may adjust
the FCF in order to compensate for the fuel quality Use the emissions analyzer in order to verify that
and for the ambient conditions. the values of emissions meet the requirements
of the site.
21. Set the “Desired Emission Gain Adjustment” to a
value of “100”. 29. Record the data from all of the status groups on
Cat ET. Save the data for future reference.
22. Verify that the value of the “Generator Real kW”
parameter in Status Group 1 is within 1 percent of
the generator’s output power.
Adjusting the Governor
The response of the throttle actuator can be adjusted
If the reading on Cat ET is not within one
with the Caterpillar Electronic Technician (Cat ET).
percent of the generator’s output power, refer
Use Cat ET to change these three parameters:
to Troubleshooting, “Generator Output Power
Readings Do Not Match”.
• Proportional gain
When the value of the “Generator Real kW”
parameter is within 1 percent of the generator’s • Integral gain
output power, continue with this procedure.
• Derivative gain
23. Slowly ramp up to 50 percent load. Allow the
The default values should be sufficient for initial
jacket water coolant temperature to reach 75 °C
start-up. However, the values may not provide
(167 °F). optimum performance.
24. Slowly ramp up to 70 percent load. Verify that the
These adjustments are provided in order to obtain
engine is stable. optimum responses to changes in the load and in the
speed. The adjustments also provide stability during
If the engine is unstable, adjust the auxiliary
steady state operation.
governor. Refer to “Adjusting the Governor”.
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If you have a problem with instability, always
investigate other causes before you adjust the
governor. For example, diagnostic codes and
unstable gas pressure can cause instability.
Illustration 16 shows some typical curves for transient Decrease the derivative gain until a slow, periodic
responses. instability is observed. Then, slightly increase the
derivative gain. Repeat the adjustments of the
proportional gain and of the integral gain. Continue
to increase the derivative gain and readjust the
proportional gain and the integral gain until stability
is achieved and the engine’s response to changes in
load and in speed is optimized.
28
g01017541
Illustration 17
The increased width of the line for the actuator voltage indicates
that the throttle actuator is more active as the derivative gain
increases.
(Y) Actuator voltage
(X) Time in seconds
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