Service Information System Page 1 of 4

Testing and Adjusting

G3500B Engines
Media Number -RENR2268-08 Publication Date -01/04/2007 Date Updated -16/04/2007

i02165427

Air/Fuel Ratio Control - Adjust - Oxygen Feedback - Generator

Set Application
SMCS - 1266-025

S/N - CFD1-UP

S/N - CME1-UP

S/N - BGW1-UP

S/N - CWD1-UP

S/N - CTK1-UP

S/N - ZBC1-UP

S/N - 7EZ1-UP

S/N - CTW1-UP

S/N - GZP1-UP

S/N - CSC1-UP

S/N - ZBB1-UP

S/N - CEY1-UP

The air/fuel ratio must be adjusted properly in order to comply with the emissions requirements of the
site. The correct air/fuel ratio also helps ensure stable operation. To adjust the air/fuel ratio, perform the
following procedure.

Table 1

Tools Needed Qty

156-1060 Emissions Analyzer Gp (1) 1
156-1070 Emission Analyzer Tool (1) 1
(1) Either emissions analyzer may be used.

1. Connect a properly calibrated emissions analyzer to the exhaust stack.

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2. Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Systems
Operation/Testing and Adjusting, "General Information (Electronic Control System)".

3. Use the data from the gas analysis in order to determine the correct settings for the "Fuel Quality"
and for the "Gas Specific Gravity" parameters.

4. Calibrate the oxygen sensor. Refer to the engine's Troubleshooting manual for the procedure.

5. Start the engine.

6. Engage the driven equipment.

7. Select "Configuration" from the "Service" drop-down menu. Select "Air Fuel Ratio Tuning" from
the selection menu. Set the "Oxygen Feedback Enabled Status" to "Disabled".

The engine will now operate in open loop mode.

8. Slowly ramp the load up to 100 percent or to the normal load for the site.

Note: Watch the "Fuel Valve Position" parameter and the "Throttle Position" parameter. If either
the "Fuel Valve Position" or the "Throttle Position" reaches 80 percent, reduce the load at least 5
percent. Perform the following steps before proceeding to add load.

a. If the "Fuel Valve Position" has reached 100 percent, there is a problem with the fuel
supply. Consider the following conditions as potential problems:

Verify that the values of the "Fuel Quality", the "Gas Specific Gravity", and the "Fuel
Specific Heat Ratio" parameters are correct.

The fuel pressure to the fuel control valve may be too low.

The Low Heat Value (LHV) of the fuel may be too low. If the LHV is too low, the
fuel system will not be able to supply enough fuel for the rating.

b. Adjust the exhaust bypass valve. Refer to Systems Operation, Testing and Adjusting,
"Exhaust Bypass Valve (Adjust)".

9. Select "Configuration" from the "Service" drop-down menu. Adjust the "Fuel Quality" parameter
in order to obtain the values of emissions that are required at the site.

 To make the air/fuel ratio leaner, increase the "Fuel Quality" parameter.

 To make the air/fuel ratio richer, decrease the "Fuel Quality" parameter.

When you adjust the "Fuel Quality" parameter, make small changes in the value of the parameter.
Wait until the system stabilizes. Check the emissions again. Repeat the process until the desired
level of emissions level is achieved.

Use the emissions analyzer in order to verify that the values of emissions meet the requirements of
the site.

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10. Once the correct emissions are obtained, review the "Actual Oxygen" and "Desired Oxygen"
values. The engine must still be in the open loop mode.

If the "Actual Oxygen" is higher than the "Desired Oxygen", use the following equation. This
equation is used in order to determine the new value for the "Desired Oxygen at Full Load"
parameter:

Table 2

Equation for the Calculation of a New Value for the "Desired Oxygen at Full Load"
Parameter
N=(A-D)+C
N is the new "Desired Oxygen at Full Load" value.
A is the "Actual Oxygen" value.
D is the "Desired Oxygen" value.
C is the current "Desired Oxygen at Full Load" value.

If the "Actual Oxygen" is lower than the "Desired Oxygen", use the following equation in order to
determine the new value for the "Desired Oxygen at Full Load" parameter:

Table 3

Equation for the Calculation of a New Value for the "Desired Oxygen at Full Load"
Parameter
N=C-(D-A)
N is the new "Desired Oxygen at Full Load" value.
C is the current "Desired Oxygen at Full Load" value.
D is the "Desired Oxygen" value.
A is the "Actual Oxygen" value.

11. Enter the new value for the "Desired Oxygen at Full Load" parameter with Cat ET.

12. Ensure that the "Desired Oxygen" and the "Actual Oxygen" parameters are the same value.

13. Select "Configuration" from the "Service" drop-down menu. Select "Air Fuel Ratio Tuning" from
the selection menu. Set the "Oxygen Feedback Enabled Status" to "Enabled".

The engine is now operating in closed loop mode.

14. The engine's operation should not change in closed loop mode. If the engine operation changes,
change the "Oxygen Feedback Enabled Status" to "Disabled" and perform the necessary

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troubleshooting steps.

Note: When the engine is running in closed loop mode, the Fuel Correction Factor (FCF) will
change. The FCF will change in order to compensate for the fuel quality and for the ambient
conditions.

15. Check the emissions level. Verify that the emissions meet the requirements of the site.

16. Record the data from all of the status groups on Cat ET. Save the data for future reference.

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