G-3520 H OPERATION AND MAINTENANCE

INFORMATION

Prepared By:
Khairul Hossain
B Series Engine
Contains for Engine Operation
• Daily Walk-Around Inspection before start
• How to start the generator from Terberg control panel
• After start generator and before put the load need to
inspection
• After put the load with running condition- inspection & note
down some data for safety condition.
• Partial load operation.
• How to stop the engine at normal and abnormal condition.
 Contains for Maintenance
• Basic Knowledge on lubrication system
• CAT Engine oil
• Typical Examples of Oil Related Failures
• How to inspect air cleaner element
• Engine Air cleaner element Cleaning procedure
• Why the customer doing maintenance by Bangla Cat
• Consequence Damage occurred if customer not performed maintenance by Bangla
Cat
• Alternator issues
Engine left side over view
Engine right side over view
Power distribution box
Starting Motor
Electronic Modular Control Panel 4 (EMCP 4) -
EMCP 4.3/4.4
 Key name of EMCP 4.2
• (1) Display screen (13) Event reset key
(2) F4 Soft key (14) Event log key
(3) F3 Soft key (15) Run key
(4) F2 Soft key (16) Auto key
(5) F1 Soft key (17) Stop key
(6) Control key (18) Escape key
(7) AC overview key (19) Up key
(8) Engine overview key (20) Right key
(9) Main menu (21) OK key
(10) Warning Indicator lamp (yellow) (22) Down key
(11) Alarms acknowledge key and silence key
(12) Shutdown Indicator lamp (red) (23) Left key
Engine Operation
electrolyte level is 13 mm (0.5 inch) above the top of the separators
electrolyte level is 13 mm (0.5 inch) above the top of the separators
electrolyte level is 13 mm (0.5 inch) above the top of the separators
electrolyte level is 13 mm (0.5 inch) above the top of the separators

Before Start the Engine

Walk-Around Inspection:
1. Leakage check (coolant, lube oil & fuel) 11. Gas Shut off valve check
2. Clean the engine room. 12. Gas line inspection
3. Lube oil level inspection by dip stick. 13. Starting Motor check
14. Manually turn the fly wheel for
4. Loosen Bolt and any covers checking.
5. Coolant (Water) level check…….J/W & A/C. 15. Pre lube pump check.
6. Ventilation System check 16. J/W heater check.
7. Air filter differential pressure check 17. Radiator pressure cap check.
8. Emergency stop switch check 18. All cooling circuit gate valve must be
open.
9. Main circuit breaker open condition 19. Alternator Space heater check.
10. Load side all breaker open condition 20. Reset all alarm components.
11. Alternator power cable check
12. Battery Inspection- Terminal connection
check, Electrolyte check & DC voltage check.
 Before Start the Engine
Lubrication System:
(1) "ADD" mark
(2) "FULL" mark
• Check the engine crankcase oil level.
Maintain the oil level between the "ADD"
and "FULL " marks on the "ENGINE
STOPPED" side of the oil level gauge.
• Check for leaks at the following
components: crankshaft seals,
crankcase, oil filters, oil gallery plugs,
sensors and valve covers.
How to Start from Terberg Panel
How to Start from Terberg Panel
Parallel and island mode operation
Parallel and island mode operation
 Generator start and Inspection
before put the load
• Start the engine from panel by press manual push “start” bottom.
• Waiting for the engine in normal operation.
• Generator run and warm up for engine Jacket water temp. at least 140
°F (60 °C).
• Check the panel operational data (RPM, Frequency, Oil pressure,
Cylinder Temperature, Detonation level from EMCP 4.3, Bus voltage
and Walk around inspection if any abnormal sound)
 Line Gas pressure after RMS room
• Inform to load side operators before main circuit breaker close.
 Before put the load

• If found normal operational data ,then select “Hand on load” position

by key.
• Automatically synchronizing and loaded the Generator within few
minutes as per Load setting on the panel.
• Check the all operational data and record it in log sheet.

Note: Every one hour record the operational data in log sheet and
any abnormalities “shutdown” the engine. During starting, if engine
shutdown with any alarm, then shutdown the engine and run with
proper diagnostic.
 Daily Walk-Around Inspection of Generator at
Running Condition
 Air Filter Differential pressure----------- Check (Max- 0.522 PSI)
 Bearing Temperature---------------------- Check/Measure (Below 70º C)
 Cooling System Coolant Level---------- Check
 Temperature—J/W-Max 95º C, After cooler (54 to 63º C) & Oil--Max 95º C
 Engine Oil Level----------------------------- Check
 Battery Water Level------------------------- Check
 Leakage check-Oil, Fuel and water systems
 Abnormal vibration
 Abnormal sound
 Cylinder Temperature
 Maintain the Log sheet every hour which having all the
parameters (See next slide)
Daily Walk-Around Inspection of Generator at
Running Condition
Engineer's / Operator's Name:
Engine Serial No: Date:
S/L No Particulars S/L No Particulars
1 Engine SMU : 16 AC/OC out temperature
2 Manifold Air temperature 17 AC/OC in temperature
3 Air inlet pressure 18 J/W in temperature
4 J/W Coolant temperature 19 J/W out temperature
5 Lube oil pressure 20 Jecket water pressure
6 Lube oil temperature 21 Ambient temperature
7 Engine speed 22 Detonation Lavel
8 Engine load 23 Alternator Bearing temperature
9 Cylinders Temperature 24 Genset Voltage
10 Oil filter deferential pressure 25 Genset Current
11 Fuel filter deferential pressure 26 Genset Frequency
12 Throttle possition 27 Power fector
13 Fuel metering valve possition 28 KVAR
14 Winding temperature 29 Engineer's/ Operator's Comments:
15 Gas Pressure 30 Engineer's Signature
 Partial Load Operation
• Extended operation at low idle or at reduced load may
cause increased oil consumption and carbon buildup in
the cylinders. Carbon buildup results in a loss of power
and/or poor performance.
• When possible, apply a full load at least on an hourly
basis. This will burn excess carbon from the cylinders.
 Engine Stopping at Normal and
Abnormal Condition
• Automatic stopping will occur when the engine is operating in the
automatic mode and the remote start/stop initiate contact opens.
• Select Generator “Hand off load” by selection key.
• Wait until the breaker open.
• Cool down feature is utilized, the engine will operate for a
programmed period of time before the engine stops. Otherwise, the
engine will immediately shut off.
• The Engine will run cool down mode at least five minutes .
• Select the switch at OFF position.
NOTE: If any abnormality with the engine press “Emergency switch” for
shut down the engine. Please do not use emergency switch for normal
stop.
 Block Loading and Transient Capability
• The block loading capability (transient response) of a generator set that is
powered by a gas engine is less than a diesel engine. Most of this difference is
directly attributed to the inherently different fuel systems of the two engines.
When the governor calls for more power, a diesel engine reacts by adding fuel
directly into the cylinder. This method permits the diesel engine to accept 100%
block loads with acceptable voltage dips and frequency changes. When the
governor on a gas engine calls for more power, the throttle opens. This process
causes a larger flow of the air/fuel mixture to move through the aftercooler core
and the air intake manifold and into the cylinder. This time delay reduces the
gas engine capability for accepting large block loads.
What is preventive maintenance
Preventive maintenance is a
schedule of planned
maintenance actions aimed at
the prevention of breakdowns
and failures. The primary
goal of preventive
maintenance is to prevent the
failure of equipment before it
actually occurs.
 Why do we perform PM works
 Improved engine reliability.
 Maximize generators
productivity & longevity.
 Cost saving of parts
replacement.
 Decreased engine downtime.
 For preventing equipment
failure before it occurs.
 Engine performance improved.
 Quality of engine lube oil
maintained.
 What is effect without carry out PM
• Valve bridge and Valve lash adjustment will be
changed.
• Engine may not take more load.
• Cylinder temp. will be unbalanced.
• Timing may change.
• Engine would vibrate.
• Back fire may occur
• Knocking could happened
• RPM and Frequency fluctuate occurs
• Bearing wear occurs due to loss of lube oil
lubrication property
• Low lube oil pressure obtain
• Jacket water temperature will increase
• Manifold air temperature will increase
• Waiting for Alternator bearing premature failure
• Using the table in the service manual, determine which valves can be adjusted.
• The example table shown lists the valves that can be adjusted for each cylinder with
the crankshaft in this initial position.
• STANDARD CYLINDER FIRING ORDER==1-2-11-12-3-4-15-16-7-8-19-20-9-10-17-18-5-6-13-14

MODEL STROKE INTEL VALVE EXHAUST VALVE GAP

COMP 1-2-5-6-9-10-11-13-14-17-18 1-2-3-4-11-12-13-14-15-16

G3520H Special tools

EXH 3-4-7-8-12-15-16-19-20 5-6-7-8-9-10-17-18-19-20

Valve mechanism with Hydraulic push-rod
Valve mechanism with Hydraulic push-rod
Valve lash Tools
Valve lash and valve stem projection
 Why the customer doing maintenance by Bangla Cat
Our Strength :

Bangla CAT having the diagnostic tools

which are highly expensive and sophisticated.

1. DDT- Digital Diagnostic tools

2. Valve Recession Tool
3. Oxygen Analyzer
4. Nox Analyzer
5. Blow By
6. Cylinder Pressure Measure Tool
7. Pressure Group
8. ET- Electronic Technician
 Maintenance Intervals of G-3520 H Series
When Battery -Replace Daily Coolant Level - Check
Required Battery - Recycle Engine Air Cleaner Differential Pressure -
Battery - Replace Check
Battery or Battery Cable - Disconnect Engine Oil Filter Differential Pressure - Check
Coolant Sample (Level 2) - Obtain Engine Oil Level - Check
Engine Air Cleaner Element - Fuel Filter Differential Pressure - Check
Clean/Replace Fumes Disposal Filter Differential Pressure -
Generator - Dry Check
Generator Set - Test Generator Bearing Temperature - Test/Record
Generator Set Alignment - Check Generator Load - Check
Generator Winding - Test Jacket Water Heater - Check
Overhaul Considerations Power Factor - Check
Stator Winding Temperature - Test Voltage and Frequency - Check
Throttle Control Valve - Check Walk-Around Inspection
Varistor - Inspect,
Fuel Filter:--Operate the engine at
the rated rpm and at the rated load.
Check the fuel filter differential
pressure. Service the fuel filter and o-
rings when the fuel filter differential
pressure reaches 10 kPa (1.5 psi).
 Maintenance Intervals of G-3520 H Series

Every 250 Service Hours Every 1000 Service Hours

Spark Plug- Clean/Resistance Check/Gap Adjust Battery Electrolyte Level –Check
Battery Electrolyte Level -Check Spark Plug- Clean/Resistance Check/Gap Adjust
Cooling System Coolant Level (SCA) -Test/Add Ignition Transformer- Clean/Resistance Check
Engine Oil - Change Engine Valve Lash And Bridge- Check/Adjust
Engine Oil Filter -Change Valve Stem Projection- Measure/Record
Engine Protective Devices –Check Throttle Actuator Linkage- Lubricate
Hydraulic Oil & Filter- Changed (If Required)
Hydraulic Oil & Filter –Changed
Cooling System Coolant Level -Check
Valve Stem Projection- Measure/Record
Speed Timing Sensor- Inspect
Engine Valve Lash And Bridge- Check/Adjust
Engine Oil -Change (If Required)
Hoses and Clamps -Inspect/Replace Engine Oil Filter -Change (If Required)
Radiator/ Cooling Tower –Clean (If Required) Starting Motor Connection- Check
Cylinder Pressure-Measure Electrical Connections -Check
Engine Crankcase Breather –Clean Generator –Inspect
Blow By – Measured Nitrogen Oxide Sensor - Calibrate
Instrument Panel –Inspect
Oil sample collect & SOS test
Alternator Bearing- Lubricate (Every After 2000 Hrs.)
Fumes Disposal Filter - Drain
Cylinder Compression- Check (Every After 4000 Hrs.)
Space Heater - Test
Crankcase pressure measure & breather clean
 Maintenance Intervals of G-3520 H Series
• Every 2000 Service Hours • Starting Motor - Inspect
• Compressor Bypass - Check Ignition System Timing - Check/Adjust
Engine Oil and Filter - Change • Every 8000 Service Hours
Flexible Coupling - Inspect • Coolant Temperature Regulator - Replace
Gas Filter Condensation - Drain Engine Speed/Timing Sensor -
Generator Bearing - Lubricate Clean/Inspect
Generator Set Vibration - Inspect Generator Bearing - Inspect
Spark Plugs - Inspect/Adjust/Replace Generator Winding Insulation - Test
Engine Valve Lash and Bridge - Check Ignition Transformer Extender - Replace
Stator Lead - Check Rotating Rectifier - Check
Valve Stem Projection - Measure/Record • Every 10 000 Service Hours
• Every 4000 Service Hours • Nitrogen Oxide Sensor - Replace
• Crankcase Blowby - Test/Record • Between 16 000 and 24 000 Service
Cylinder Pressure - Test/Record Hours
Engine Mounts - Inspect • Engine Oil Temperature Regulator -
Engine Protective Devices - Check Replace
Fuel Metering Valve - Check
 Maintenance Intervals of G-3520 H Series
• Between 18 000 and 22 000 Service Hours
• Overhaul (Top End)
Turbocharger - Inspect

• Every 24 000 Service Hours or 3 Years

• Coolant (NGEC) - Change

• Between 35 000 and 45 000 Service Hours

• Overhaul (In-Frame)

• Between 70 000 and 90 000 Service Hours

• Overhaul (Major)
 Spark plug issue
. Condensation can form in spark plugs that have pre-combustion chambers. This
condition can cause difficulty for cold start-ups. To avoid condensation, maintain the
coolant in the cylinder block at a minimum temperature of 43 °C (110 °F) continuously.

• The service life of the spark plugs is affected by fouling due to deposits from the oil and by
peak voltage. Maintenance of the ignition system is also affected by voltage. Higher voltage is
required by higher inlet manifold air pressure, lower emissions levels, a higher compression
ratio, or retardation of the timing. Higher voltage reduces the service life of components such
as spark plugs, wires, and transformers.
• The service life of the spark plug is approximately 2000 service hours (up to 3500/4000). If a
diagnostic code is generated for the ignition transformer secondary circuit, the spark plug
should be replaced. Misfire and a cold cylinder are other indications of a worn spark plug.
 Spark Plug Issue
• Inspect O-ring seal (9). If the seal is hard, cracked, or
melted, install a new seal.
• Make sure that holes (4) in the spark plug pre-
combustion chamber are not blocked.
• A light brown deposit or a beige deposit is produced by
normal operation.
• Deposits that are gray or black may be caused by the
following substances:
----Excessive oil
----Use of the wrong oil
----A substance that is introduced through the fuel system
or the air system
----Poor combustion-n because of a rich air/fuel mixture
…..Cleaning is not recommended for this
spark plug.
Always use a new gasket when a spark plug is installed.
9Y-6792 Spark Plug Gasket
 Fumes Disposal Filter Differential Pressure - Check
Check the differential pressure across the
filter element.
Observe the pressure that is indicated by
the pressure gauge on top of the filter.
Record the measurement.
The restriction of a new element is
approximately 1.7 kPa (7 inches of H2O).
The normal restriction of the element is
approximately 5.7 to 9.95 kPa (23 to 40
inches of H2O).
•Replace the filter element when the
differential pressure reaches 11.2 kPa (45
inches of H2O).
•Replace the element after every year
regardless of the differential pressure.
Crankcase Ventilation System
Designed to Separate Oil and fuel mist.

Increases efficiency

Reduces Oil consumption

Reduces Emissions

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Presentation Title
Crankcase Ventilation System
(1) Differential pressure gauge

(2) Blower and motor

(3) Silencer and air outlet

(4) Filter element

(5) Bracket with mounting holes

(6) Oil drain

(7) Condensation trap drain valve

(8) Bypass port

(9) Inlet for the fumes disposal filter

(10) Filter Part Number – 191-2373

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Presentation Title
Maintenance Information

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Presentation Title
 Gas Train GAS OUTLET
DN100
Specifications: ¾” NPTF VENT

• Max inlet pressure 7psi

• Outlet pressure ~ 1.7psi
Braided
• Includes: Flex Hose

• Manual shutoff Double

GAS INLET Solenoid
• Fuel Filter DN100 Valve
Pressure
• Pressure Regulator Regulator
Fuel
• Double solenoid shutoff valve Filter
Manual
• Pressure gages Shutoff
valve
• Stainless Steel Braided Fuel
Connection.
 Gas Filter Condensation - Drain
• 1) Gas supply valve
• (2) Gas filter condensation drain

• Close gas supply valve (1) .

• Place a suitable container under gas
filter drain (2) .
• Remove drain plug (2). Allow fluid to
drain into a suitable container.
• Inspect drain plug. Replace drain
plug if damaged. Install drain plug.
• Open gas supply valve slowly. Check
for leaks.
• Fuel Filter Part Number- 390-8986
Engine Cooling System
 Engine Cooling System

Experience proves that 40 to 50

percent of engine failures were
caused by some problem with the
engine cooling system !!
 Engine Cooling System

In practice the three biggest cooling

system problems are :
1 Inadequate or no system pressure
2 Leaks
3 Inadequate chemical treatment of the coolant
 Engine Cooling System
Maintains engine J/W temperature
within narrow range:
ideal range 85 to 95 C
o

should not drop below 80 Co

should not exceed 99 C o

 Engine Cooling System
This is the item that controls and maintains
system pressure:
 Engine Cooling System
Leaks need to be fixed as soon as
possible, no matter how small !
Leaks, low/no system pressure and
lack of coolant treatment all contribute
to cavitations erosion and rust.
 Engine Cooling System
• Scale in JW heat exchanger causes:
–Engine overheating: eventual shutdown
–Potential for engine damage

• Scale in Aftercooler causes:

–Increased intake manifold temps
–Detonation at higher loads
–Reduced load carrying capability
–Potential for severe engine damage
 Water Quality

First choice is DISTILLED

or DEIONIZED water
 Water Quality
Second choice is:
Table 2
Caterpillar Minimum Acceptable Water Requirements
Property Maximum Limit ASTM Test

Note: Do not use Chloride (Cl) 40 mg/L (2.4 gr per US "D512", "D4327"
gal)
sea water, softened
water that has been Sulfate (SO4) 100 mg/L (5.9 gr per US
gal)
"D516"

conditioned with
Total Hardness 170 mg/L (10 gr per US "D1126"
salt, hard water and gal)

tap water. Total Solids 340 mg/L (20 gr per US "D1888"

gal)
Acidity pH of 5.5 to 9.0 "D1293"
 Recommended Coolant/Antifreeze and Service Life of the
Coolant/Antifreeze

Coolant/Antifreeze Service Life (1)

Cat NGEC
Three Years
Cat DEAC

Commercial Heavy-Duty Coolant/Antifreeze that meets

Two Years
"ASTM D6210"

Commercial Heavy-Duty Coolant/Antifreeze that meets

One Year
"ASTM D4985"

Cat SCA (supplemental coolant additives) and Water Two Years

Commercial SCA and Water One Year

WHAT ABOUT COOLANT ADDITIVES ?

They are very necessary !!

 Functions of Coolant Additives
 Cast iron & steel protection
 Aluminum protection
 Copper protection
 Liner cavitations protection
 Scale & deposit control
 Defoamer
 Rust/Corrosion
Rust generally occurs due to a lack of coolant
additive
 Rust deposits on outside cylinder wall surface
 Rusting inside a water pump
 Temperature regulator failure as a result of rust
and scale
Coolant (SCA) Recommendations

 UseCAT SCA mixed at 6 to 8%

concentration with acceptable
quality water.
 Lube Oil, J/W & A/C Capacity
Model Lube Oil Capacity J/W Capacity A/C Capacity

285.2 L (75.3 US
G 3520 H 568 L (150 US gal) 31 L (8 US gal)
gal)

1) Add 6% to 8% Supplementary Cooling Additives (SCA) of the total Volume Of

Water.

2) Total Volume of Water= Total Volume of Engine Water in J/W & A/C + Pipe Line+
Expansion Tank.
Basic Knowledge on lubrication system
• The engine is lubricated by a wet sump
oil system where lubricated oil is mainly
topping up by manually.

• The main functions for the oil lubrication

are preventing metal to metal contact at the
bearing surfaces, heat transfer and
cleaning.
Table 1

Cat NGEO ULTRA 40 Viscosity Grade

Properties
Table 1 Cat NGEO ULTRA 40 Viscosity Grade Properties

Cat NGEO ULTRA 40 Viscosity Grade Properties

Characteristic ASTM Test NGEO ULTRA 40

API Gravity at
"D0287" 35
16.0 ° C (60.8 ° F)

Flash Point
"D0092" 220 minimum
0 ° C (32 ° F)

Pour Point
"D0097" −21
0 ° C (32 ° F)

Viscosity (cSt) at
"D0445" 13.0
100 °C (212 °F)

Viscosity Index "D2270" 95 minimum

Weight (Percent) of Sulfated Ash "D0874" 0.54

Total Base Number "D2896" 6.0

Replace the oil filter elements when the oil filter differential pressure reaches 160 kPa (23.2 psi).

Oil Filter issue

Replace the oil filter elements---Every oil change OR when the oil filter differential pressure reaches 160 kPa
(23.2 psi).

Nominal Oil Differential Pressures

Engine Pressure

G3512H 60 kPa (9 psi)

G3516H 125 kPa (18 psi)

G3520H 85 kPa (12 psi)

 Remember !
A Good Quality Engine oil will

Optimise Engine Life

Increase Rebuild Options
And

Reduce Operating Costs

• Oil consumption - 0.06 g/bkwhr (G3520 H)
• Change Oil filter at every oil change.
• Use Caterpillar recommended oil filter.
• Do not used non CAT oil filter because the
result in severe engine damage can happened.

 Please send oil sample to our Bangla CAT office at

every 250 hrs. for SOS test.
Typical Examples of Oil Related Failures
 Engine Air cleaner element Cleaning
procedure
• Remove the air cleaner cover. Remove the air cleaner element.
• Cover the air inlet with tape in order to keep dirt out.
• Clean the inside of the air cleaner cover and body with a clean, dry
cloth or compressed air. If not proper clean, can be effect to Turbo
blade.
• Pressurized air can be used to clean air cleaner elements. Use dry
air with a maximum pressure of 20 psi.
• Vacuum cleaning is a good method for cleaning air cleaner
elements which require daily cleaning because of a dry, dusty
environment.
• Remove the tape for the air inlet. Install an air cleaner element that
is new or cleaned.
• Install the air cleaner cover.
 How to inspect air cleaner element
• Clean the air cleaner element or replace the air cleaner element
when the service indicator yellow diaphragm enters the red zone.
Air Inlet & Exhaust System

Maintenance
Air Filter Life – 4,000 Running Hours.

Depends on Site condition

Fuel Supply System - Filtering
 Fuel System (Air/Fuel Ratio Control)
The fuel system includes these components:--
• Fuel metering valve
• Engine control module (ECM)
• Inlet Manifold Pressure Sensor
• Inlet manifold temperature sensor
• Nox (Nitrogen Oxide) sensor
• Knock sensor
• Load Signal (Out put KW sensor)
• Engine speed/Timing sensor
• Throttle differential pressure sensor
• Compressor out let pressure sensor
NOx (Nitrogen Oxide) Sensor

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Presentation Title
NOx Engine Control

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Presentation Title
 Mode of Operation

• Open loop
• NOX feedback
• The mode of operation is determined by the "Emissions Feedback
Mode Configuration" parameter. Cat ET is used to change the
mode of operation.
• Select "Disable" in order to activate the open loop mode.
• Select "Enable" in order to activate the feedback mode.

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Presentation Title
 Open Loop
• The open loop mode of operation uses no feedback.
• During operation in this mode, the ECM controls the air/fuel ratio with maps and with
calculations for the desired air/fuel ratio.
• The air/fuel ratio is controlled in the open loop mode from start-up until the engine load
becomes greater than 40 percent. Above 40 percent the engine operates in feedback mode.
When, operating in feedback mode the engine load must be dropped below 25 percent for the
control system to switch to open loop mode.
• The ECM uses a Fuel Correction Factor (FCF) to help determine the fuel command to the fuel
metering valve. During operation in the open loop mode, the FCF is always 100 percent.
• The ECM uses the LHV to help determine the fuel command to the fuel metering valve.
• The LHV can be varied in the customer programmable "Fuel Quality" parameter in order to
affect the air/fuel ratio.

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Presentation Title
 NOx Feedback
• During operation in the feedback mode, the ECM continues to
calculate the desired air/fuel ratio. The result is still used to
calculate the fuel command.
• The ECM uses the following in order to calculate the desired NOX
factor.
- "Desired Engine Exhaust NOx Level Setting"
- Engine load
- Engine speed
• The measured NOX level in the exhaust.
• Exhaust NOX concentration is communicated to the ECM from the
NOX sensor via the CAN data link.
• The customer programmable "Desired Engine Exhaust NOx Level
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Setting" can be varied in order to affect the air/fuel ratio.
Presentation Title
 NOx Feedback
• The calculation for the desired NOX level is used to adjust the
FCF.
• Because some of the factors for calculating the desired NOX level
will vary during operation, the FCF will also vary during operation.
• The reaction of the FCF can be adjusted further with the following
configuration parameters:
– Desired Engine Exhaust NOx Level Setting
– Air/Fuel Proportional Gain
• The ECM determines the fuel command to the fuel metering valve.
The command is sent to the fuel metering valve via the CAN data
link.
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Presentation Title
 NOx Sensor

Change Every Once a Year

Gas consumption—8.04 MJ/kw-hr or

Gas consumption –0.228 M3/kw-hr
 Welding on Engines with Electronic Controls
• Proper welding procedures are necessary in order to avoid damage to the engine ECM,
sensors, and associated components.
• Perform the welding in areas that are free from explosive hazards.
• Stop the engine. Turn the switched power to the OFF position.
• Disconnect the negative battery cable from the battery. If a battery disconnect switch is
provided, open the switch.
• Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the harness to a position
that will not allow the harness to move back accidentally, and contact any of the ECM pins.
• Disconnect any component with a microprocessor from the engine harness, such as:
– Engine ECM
– Product Link
– Cell/Sat Radio
– DOC Identity Modules
Trouble shooting issue
Trouble shooting issue
 Engine trouble code
Table 1
Cross-Reference from Diagnostic Trouble Codes to Functional Test or Procedure
J1939 Code and Description Troubleshooting Procedure
51-9
Troubleshooting, "Data Link - Test"
Engine Throttle Position : Abnormal Update Rate
173-9
Troubleshooting, "Data Link - Test"
Engine Exhaust Gas Temperature : Abnormal Update Rate
898-9
Troubleshooting, "Data Link - Test"
Engine Requested Speed/Speed Limit : Abnormal Update Rate
1442-9
Troubleshooting, "Data Link - Test"
Engine Fuel Valve #1 Position : Abnormal Update Rate
2241-9
Troubleshooting, "Data Link - Test"
Source Address 241 : Abnormal Update Rate
2452-9
Troubleshooting, "Data Link - Test"
Generator Total Real Power : Abnormal Update Rate
3216-9
Troubleshooting, "Data Link - Test"
Aftertreatment #1 NOx : Abnormal Update Rate
3542-9
Troubleshooting, "Data Link - Test"
Requested Engine Control Mode : Abnormal Update Rate

3470-9
Troubleshooting, "Data Link - Test"
Engine Turbocharger Compressor Control : Abnormal Update Rate