PRECLEANER 8H2021 - Caterpillar

Engine: G3508 (S/N: 4WD1-UP; 9TG1-UP; CPJ1-UP; 2TJ1-UP; CPS1-UP; 9AW1-UP; CPY1-UP) G3512 (S/N: 5JD1-UP; 7NJ1-UP; CRN1-UP; CSP1-UP; 6JW1-UP) G3516 (S/N: ZBA1-UP; 8LD1-UP; CPG1-UP; 4EK1-UP; 8PW1-UP; CSZ1-UP; ZAZ1-UP) G3524 (S/N: 7SZ1-UP; 5ZZ1-UP) G3532 (S/N: 8BZ1-UP; 8JZ1-UP)Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction includes the initial start-up procedures for G3500 engines. The correct initial start-up of the engine is essential for the following reasons:
Engine service life
Fuel economy
Acceptable emissionsService technicians should have a thorough understanding of the relationship between the fuel system and the ignition system. The technician must also be familiar with the literature that is listed in the ""References"" section.References
Engine Service Manual, SENR6415
Industrial Engine Performance, LEBQ6117
Engine Performance, LEBQ6169
Systems Operation Testing and Adjusting, SENR6412
Troubleshooting, SENR6413
Specifications, SENR6417 and Specifications, SENR6411
Operation and Maintenance, SEBU6711 and Operation and Maintenance, SEBU7551
Table 1
Tools Needed    
Part Number    Description    
7X-1400     Electronic Tool Gp (1)    
NEXG4511     Service Program Module For Gas Engines (1)    
140-2304     Governor Electronic Control Programmer
(2)    
8T-0452     Manometer Gauge    
156-1060     Emissions Analyzer Gp    
1P-2385     Protractor    
237-5130     Digital Multimeter Gp    
( 1 ) Refer to Using the DDT NEXG4511 Industrial Application Function Service Program Module, SEHS8806 for more information on using the digital diagnostic tool. Also refer to Service Program Module For Spark Ignited Engines, NEXG4511. You must have the chip in order for the 7X-1400 Electronic Tool Group to work.
( 2 ) This is for engines that are equipped with 701A Woodward governors.Required Information
Ignition Timing
A complete fuel analysis must be conducted prior to putting the engine into service. Obtain a fuel analysis in order to determine the energy content and calculate the methane number. The methane number indicates the ability of the fuel to be ignited. The methane number is determined when you input the data from the fuel analysis into the Methane Number Program, LEKQ6378. Use the methane number and the Engine Performance, "Fuel Usage Guide" in order to determine the ignition timing.Obtain several samples of fuel if the quality is expected to change. If the methane number will vary during engine operation, use the lowest expected value in order to determine ignition timing.Maximum Load
Refer to the Engine Performance, LEBQ6169 in order to determine the engine power level for the altitude, the temperature and the methane number. Use the information in the Engine Performance, LEBQ6169 in order to determine the maximum engine load. The desired engine load must not exceed the maximum engine load.Inlet Manifold Pressure at Full Load
For generator set applications, use the generator power output to determine the engine load. For other applications, use the inlet manifold pressure to estimate the engine load. The inlet manifold pressure may be used if the engine timing and the exhaust oxygen are set properly. The Engine Performance, LEBQ6169 provides inlet manifold pressures for specific setting for timing and emissions. This information may be used to estimate the output power