9/19/2017 Electronic Control Module (ECM)...

G3500 Engines Caterpillar | Spare parts

Electronic Control Module (ECM)... G3500 Engines

Caterpillar

Programming the Air/Fuel Ratio Control

The air/fuel ratio control must be programmed for the particular installation.
For information on using Cat ET, refer to the information that is provided with the software.
For information on using the DDT, refer to Special Instruction, SEHS9122, "Using the 7X-
1400 Digital Diagnostic Tool (DDT) ".
For information on the programmable parameters, refer to Systems Operation, "Electronic Control
System Parameters".

Recommendations for Programming Some of the

Parameters
Gain for the Governor
For the governor gain, select a value of zero for the adjustments on initial start-up. These values
should enable speed control, but the values may not provide optimum performance.
After you adjust the governor, always test the governor stability by interrupting the engine speed. To
interrupt the engine speed, use Cat ET or use the DDT. Test the ability of the governor to adjust to
changes in the load. Operate the engine through the entire range of speeds and loads in order to
ensure stability.
Illustration 1 shows some typical curves for transient responses.
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"AUX1 GOV GAIN" - To enable the proportional gain, stability, and compensation of the auxiliary
governor, terminal 328 must be grounded to the Battery side. A switch may be installed between
terminal 328 and the Battery side. When the switch closes terminal 328 to the Battery side, the
auxiliary governor gain is enabled. The status can be viewed on Cat ET or on the DDT. When the
circuit is opened, the auxiliary governor is disabled and the primary governor is enabled.
"GOV P-GAIN" and "AUX1 GOV P-GAIN" - Slowly increase the proportional gain until the engine
becomes slightly unstable. Slowly reduce the gain until performance is stable. If the gain is too low,
the engine may have excessive overshoot. Overshoot can cause an engine shutdown during changes
in load.
"GOV STAB" and "AUX1 GOV STAB" - If the engine is slowly hunting, increase the stability. If the
adjustment does not stabilize the engine, slowly reduce the gain or increase the compensation.
"GOV COMP" and "AUX1 GOV COMP" - Raise the compensation until the throttle actuator becomes
unstable or until the actuator reaches the maximum acceptable level of activity. After you raise the
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compensation, possibly raise the proportional gain. Use the compensation to achieve the most stable
engine speed.
Illustration 2 is a graphic representation of adjusting the compensation.
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"LOW IDLE SPEED"

The programmed idle speed must always be less than the programmed rated speed. If the
programmed idle speed is greater than the programmed rated speed, the engine will run at the idle
speed. The engine will run at the idle speed regardless of the idle/rated switch position. To avoid
possible problems, program the idle speed at least 300 rpm less than the rated speed.

"RATED SPEED"
For generator sets, the maximum allowable desired speed is equal to the rated speed plus 12 percent.
If droop is used, increase the programmable rated speed in order to achieve the rated speed at full
load.
For example, if the droop is programmed to 5 percent, add 5 percent to the value for the rated speed.
If the droop is 5 percent and the desired speed is 1000 rpm at full load, program the rated speed to
1050 rpm.

"SPEED DROOP"
To program the percent of speed droop, set the "Governor" parameter for droop operation. The droop
can be programmed to a value between 0 and 10 percent.

Gain for the Air/Fuel Ratio Control

For the air/fuel ratio gain, the default values are zero. Use these values for initial start-up. These
values do not need adjustment unless the exhaust oxygen is unstable or the actuator does not
respond quickly.
Adjust the proportional gain and the stability at the same time.
After adjustment, change the desired oxygen content by at least 1 percent in order to observe the
stability of the air/fuel ratio control. Make sure that the actuator and the fuel valve are in the mid-
position during normal operation. If the fuel valve is at the minimum or maximum position, the air/fuel
ratio control may not be able to adjust the air/fuel mixture.
"A/F RATIO P-GAIN" - If the desired exhaust oxygen is rapidly fluctuating, reduce the proportional
gain in order to stabilize the engine. If the gain is too high, the fuel valve may have excessive
overshoot. Overshoot can also cause the engine speed to fluctuate.
"A/F RATIO STAB" - An increase of the stability reduces the time that is required to achieve the
desired exhaust oxygen. If the stability is too high, large variations of exhaust oxygen and engine
speed instability can occur. If the stability is too low, the actuator for the fuel valve will respond slowly
to changes in the exhaust oxygen.

Calibration of the Oxygen Sensor

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This feature enables you to initiate calibration of the oxygen sensor. Calibration is required periodically
as part of normal maintenance. Calibration can only be initiated with the engine stopped.
Approximately 12 minutes are required for the calibration.
When the oxygen sensor is removed from the exhaust stack and the calibration is performed, the
correct oxygen level is approximately 21 percent.
For instructions on calibrating the oxygen sensor, refer to Electronic Troubleshooting, SENR6413,
"G3500 Engines".

Removing Power from the Oxygen Buffer

This feature is used primarily for troubleshooting. This feature enables manual control of power to the
oxygen buffer. The feature is used for testing the relay for the oxygen buffer and calibrating the
oxygen sensor. The relay is normally energized when engine speed is detected. When engine speed
is not detected, the relay is de-energized after a delay.
The ECM will not allow this relay to be turned off during engine operation.
To remove power from the oxygen buffer, use Cat ET or use the DDT.

Disabling the Air/Fuel Ratio Control

Note: Disabling the air/fuel ratio does not disable the engine speed governor.
When the air/fuel ratio control is disabled, the actuator holds the fuel valve at the latest position.
If this feature is used at low loads, there is a potential for detonation that is caused by a rich mixture of
air and fuel. You may need to adjust the carburetor load adjustment in order to lean the air/fuel
mixture.
The air/fuel ratio control is automatically enabled when the engine is restarted. Restarting prevents
inadvertent disabling of the control.
To disable the air/fuel ratio control, use Cat ET or use the DDT.

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