Service Information System Page 1 of 7

Testing and Adjusting

G3612 and G3616 Engines
Media Number -SENR5528-06 Publication Date -01/05/2004 Date Updated -18/05/2004

i00961206

Choke Trim
SMCS - 1294

Adjusting the position of the inlet manifold choke plate can significantly improve the stability of the
engine during low speed and/or low load engine operating conditions. Also, the load acceptance
capability of the engine can be affected depending on the position of the choke plate at low engine load.

In generator set applications, idle stability is critical for synchronization of the generator set with the
electrical grid. Follow the chart for the Recommended Inlet Manifold Pressure, with no load on the
engine.

Table 1

Recommended Inlet Manifold Pressure

Engine RPM Inlet Manifold Pressure (1)
900
40 ± 5 kPaa (5.8 ± .7 psia)
1000
50 ± 5 kPaa (7.3 ± .7 psia)
(1) kPaa is kilopascal measured in absolute pressure.

These recommended values are provided for reference only. Parasitic loads affect the required inlet
manifold pressure. The engine choke trim can and should be adjusted to a manifold pressure level that
provides the optimum engine stability and the load acceptance capability for the specific application of
the engine.

Use the following guidelines for the proper adjustment of the choke trim.

1. The choke trim should be adjusted in order to get an average exhaust port temperature of 500 to
550°C (932 to 1022°F) when the engine is operating below 40 percent load.

2. If the wastegate is in the closed position, the engine may be over choked. The choke trim setting
on the DDT needs to be made more negative in order to reduce the choking. This will permit the
wastegate to help control the desired air fuel ratio.

3. If the exhaust port temperatures are all lower than 500°C (932°F), then the engine is operating too
lean. This can result in a high rate of cylinder misfires. The choke trim on the DDT needs to be
made more positive in order to increase the choking.

4. The maximum exhaust port temperature should not exceed 600°C (1112°F). If the exhaust port

https://127.0.0.1:444/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/media... 1/30/2015
Service Information System Page 2 of 7

temperatures are higher than 600°C (1112°F), the engine is not getting enough air. This can result
in detonation and/or component thermal degradation. The choke trim needs to be made more
negative in order to reduce the amount of choking. If only one cylinder exhaust port temperature
is exceeding 600°C (1112°F), then investigate for a mechanical problem with that cylinder.

Electronic Choke Trim Procedure

1. Set the engine operating condition to the rated speed and no load (or minimum load possible).

2. Connect the DDT to the Engine Supervisory System (ESS). Display the DDT screen "number 33"
by pressing the "SELECT MODE" key in order to display the "CSP MENU" (customer selectable
parameters) screen "number 03". Then press the "SELECT FUNC" key to display screen "number
33". Or simply enter the "number 33" and then press the "ENTER" key.

Screen "number 33" on the DDT will display the following:

"CHOKE TRIM"

"00 40/0900 33<"

The numbers on the second line of the display are: The choke trim "OFFSET" number which
indicates the amount of offset that has been entered through the "ALT1" and the "ALT2" keys.
The amount of the choke trim offset "00" represents the factory default setting. "40/0900"
represents the Inlet Manifold Pressure (kPaa)/Engine speed (rpm).

Note: kPaa is kilopascal measured in absolute pressure.

3. On the DDT screen "number 33", when the "ALT1" or "ALT2" keys are pressed, a command
signal is sent to the choke actuator in order to change the position of the choke plate.

To raise the inlet manifold pressure, press the "ALT2" key. (The offset number on the DDT screen
will decrease by one every time the "ALT2" key is pressed.)

To lower the inlet manifold pressure, press the "ALT1" key. (The offset number on the DDT
screen will increase by one every time the "ALT1" key is pressed.)

This process should be done slowly. Pause after every adjustment in order to allow the engine to
respond to the change in the inlet manifold pressure.

Monitor the following:

¡ inlet manifold pressure

¡ stability of the engine rpm

¡ position of choke actuator

¡ position of wastegate actuator

¡ individual cylinder combustion burn times

https://127.0.0.1:444/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/media... 1/30/2015
Service Information System Page 3 of 7

¡ individual cylinder exhaust port temperatures

To monitor individual cylinder misfire during the choke trim process, alternate between the choke
trim mode and precombustion chamber calibration mode.

a. Press "SELECT MODE" key in order to display "PC CAL MODE" .

b. Press "SELECT FUNC" key in order to operate the engine in the precombustion chamber
calibration mode.

c. Press "ALT2" key in order to display combustion BT as a non-averaged number.

d. Press "ENTER" key in order to monitor the individual cylinders.

A combustion BT of greater than 10 ms should be considered a misfire. The frequency of

misfire will be reduced when the engine is properly choke trimmed.

Note: Do not over choke the engine. Load acceptance capability may be reduced.

4. If engine stability is unacceptable after properly completing the choke trim procedure, refer to the
Testing and Adjusting, "Governor Adjustment Procedure" of this manual.

Note: The position of the choke plate can be returned to the factory setting that is programmed
into the personality module by pressing the "0" key while the DDT screen "number 33" is
displayed.

Pressing the "ENTER" key, while DDT screen "number 33" is displayed will change the choke
trim screen to display the following:

"CHOKE TRIM"

"00 00/00 kPa 33<"

The numbers on the second line are: Choke trim offset, Actual Inlet Manifold Pressure
(kPaa)/Desired Inlet Manifold Pressure (kPaa).

Note: A change in the fuel consumption due to a change in the engine stability (misfire), will
change the DESIRED manifold pressure.

As described above, the actual inlet manifold pressure can be changed from this screen by the use
of the "ALT1" and the "ALT2" keys in order to adjust the position of the choke plate.

Pressing the "ENTER" key while the DDT screen "number 33" is displayed will return the choke
trim screen to display the Actual Inlet Manifold Pressure and the Engine rpm.

Note: To prevent zeroing out any adjustments that have been made, always use the "SELECT
MODE" key in order to exit the screen "number 33" .

Mechanical Choke Trim Procedure

https://127.0.0.1:444/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/media... 1/30/2015
Service Information System Page 4 of 7

The inlet manifold pressure can be adjusted by changing the length of the connecting rod linkage
between the choke actuator and the choke plate. Refer to the Specifications Manual for the choke
linkage setting specifications.

1. Set engine operating condition to the rated speed and no load (or minimum load possible).

2. Loosen the jam nuts on the linkage rod that connects the choke actuator to the choke plate. This
connecting rod has LH and RH threads on the opposite ends.

3. To change the inlet manifold pressure, adjust the length of the linkage rod.

Note: Increasing the length of the connection may disengage the connecting rod from the rod end
assembly.

This process should be done slowly. Pause after every adjustment in order to allow the engine to
respond to the change in the inlet manifold pressure.

Monitor the following:

¡ inlet manifold pressure

¡ stability of the engine rpm

¡ position of choke actuator

¡ position of wastegate actuator

¡ individual cylinder combustion burn times

¡ individual cylinder exhaust port temperatures

4. After completion of the choke trim process, tighten the jam nuts on the linkage rod.

5. Confirm that all the cylinders are firing by checking the combustion burn times for the cylinders
(screen "number 14" on the DDT). A combustion burn time greater than 10 ms will indicate that
the cylinder is misfiring. Also, check the cylinders for low exhaust port temperatures. If engine
stability is unacceptable after properly completing the choke trim procedure, refer to the Testing
and Adjusting, "Governor Adjustment Procedure" of this manual.

Air Lines (Choke)

View Image

https://127.0.0.1:444/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/media... 1/30/2015
Service Information System Page 5 of 7

Illustration 1 g00476757
(1) Aftercooler inlet line. (2) Choke plate housing. (3) Air inlet from turbocharger. (4) . Choke plate and shaft. (5) Thrust
washer. (6) Choke plate lever. (7) Cross shaft lever angle. (8) Choke plate adjusting bolt and locking nut. (9) Choke plate
housing bolts. (10) Choke plate mounting bolts. (11) Choke plate rod and rod ends. (12) Cross shaft and levers. (13)
Actuator shaft and indicator. (14) Actuator rod and rod ends. (15) Actuator lever angle. (16) Cross shaft bearings.

Use the following procedure in order to assemble and adjust the linkage for the air lines (choke).

1. Assemble the choke plate and shaft (4) , leaving the choke plate mounting bolts (10) loose.

2. Assemble thrust washer (5) . Tighten the choke plate housing bolts (9) .

Tighten the choke plate housing bolts to the following torque. ... 47 ± 9 N·m (35 ± 7 lb ft)

3. Fully close the choke plate and tighten the choke plate mounting bolts (10) .

Tighten the choke plate mounting bolts to the following torque. ... 12 ± 3 N·m (9 ± 2 lb ft)

4. Install the choke plate housing (2) . Install the gaskets between the aftercooler housing (1) and the
air inlet from turbocharger (3) .

5. With the choke plate and the housing installed, hold the choke plate in the closed position. Tighten
the adjusting bolt (8) until it makes contact with the stop plate.

6. Tighten the adjusting bolt an additional 90 ± 15 degrees. Tighten the locking nut.

Tighten the locking nut to the following torque. ... 25 ± 6 N·m (18 ± 4 lb ft)

https://127.0.0.1:444/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/media... 1/30/2015
Service Information System Page 6 of 7

Note: Do not allow the set screw to turn while tightening the locking nut.

Use the following procedure in order to adjust the actuator and the choke linkage:

1. Install the cross shaft (12) through the cross shaft bearings (16) . The stamped end of the shaft
should be toward the wastegate. Install the lever on the stamped end of the shaft.

2. Assemble choke plate lever (6) on the shaft of the choke plate.

3. Providing equal thread engagement of the rod ends. Install adjustable rod (11) between the choke
plate and the cross shaft.

4. Adjust the rod length until the choke is in the closed position and the cross shaft lever angle (7) is
28.0 ± 1.5 degrees from the horizontal position.

5. Tighten the rod end nuts.

Tighten the rod end nuts to the following torque. ... 25 ± 6 N·m (18 ± 4 lb ft)

6. Put the actuator shaft and indicator (13) in the closed position (100 percent), Install the actuator
lever. The actuator lever angle (15) should be 68.0 ± 2.5 degrees from the horizontal position.

7. Install the lever on the actuator end of the cross shaft that is not stamped.

8. Provide equal thread engagement of the rod ends. Install adjustable rod (14) to the actuator lever
and the cross shaft lever.

9. Put the choke in the fully closed position. Adjust the rod length until the actuator indicator
(pointer) is between the 100 and the 97 percent position.

Note: The 97 percent position is equal to 2.7 degrees CCW from the 100 percent position.

10. Tighten stop nuts on the rod ends.

Torque for the stop nuts on the rod ends ... 25 ± 6 N·m (18 ± 4 lb ft)

Note: The actuator indicator is calibrated to show the percentage NOT THE ANGLE that the choke
plate is open or closed. An actuator indicator reading of 2.7 degrees is equal to approximately 2.5
percent.

Correct adjustment and lubrication of the mechanical actuator linkage should result in good engine
operation over the entire speed/load range of the engine. If no load instability is encountered, and the
mechanical linkage is adjusted correctly, the Digital Diagnostic Tool can be used to electronically fine
tune the actuator in order to improve the engine operation at no load conditions. Use the "TRIM" mode
and the instructions that are included with the DDT in order to make the adjustments.

Copyright 1993 - 2015 Caterpillar Inc. Fri Jan 30 22:56:40 UTC+0330 2015
All Rights Reserved.
Private Network For SIS Licensees.

https://127.0.0.1:444/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/media... 1/30/2015
Service Information System Page 7 of 7

https://127.0.0.1:444/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/media... 1/30/2015