823685A 1 Mercury SOUND BLANKET KIT

Table 1
Tools Needed Qty
391-8170 EMISSIONS ANALYZER TOOL GP - (Bluetooth Module) (1) 1
393-0673 EMISSIONS ANALYZER TOOL GP (1) 1
(1) Either emissions analyzer may be used.
Connect a properly calibrated emissions analyzer to the exhaust stack.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Systems Operation/Testing and Adjusting, "General Information (Electronic Control System)".Note: The engines control system must receive accurate information on the generators power output in order to control the air/fuel ratio.
Verify the information on the generators output power.
If the generator is equipped with an Electronic Modular Control Panel (EMCP), verify that the voltmeter and the ammeter are programmed with the correct values. Refer to the applicable service information for the control panel.
If the generator is equipped with a generator output power sensor (wattmeter), verify that the parameters for the wattmeter are programmed with the correct values. Refer to Systems Operation/Testing and Adjusting, "Electronic Control System Parameters" for information on the "Power Monitoring" parameters.
Verify that the "Fuel Quality" and "Gas Specific Gravity" parameters are programmed correctly. Use the values that are obtained from the Caterpillar Software, LERW4485, "Gas Engine Rating Pro (GERP)".
Verify that the value for the "Fuel Specific Heat Ratio" parameter is correct. Only enter a value of 1.4.
Start the engine. Increase the engine speed to high idle rpm. Verify that the engine is stable.If the engine is unstable, perform the following procedure.
Record the values for these parameters:
"Governor Proportional Gain"
"Governor Integral Gain"
"Governor Derivative Gain"
Set the values for the "Governor Proportional Gain", "Governor Integral Gain", and "Governor Derivative Gain" parameters to zero.
Adjust the "Fuel Quality" parameter until the engine becomes stable and the exhaust oxygen is approximately four percent. Verify that the exhaust port temperatures are below the setpoint for a warning.
Adjust the auxiliary governor. Refer to Systems Operation/Testing and Adjusting, "Engine Governing - Adjust".
Close the main circuit breaker for the generator in order to engage the generator.Note: When the engine load becomes greater than 25 percent, the air/fuel ratio control will operate in the feedback mode.
Slowly ramp the load up to 30 percent.Note: When the air/fuel ratio control is in the feedback mode, the Fuel Correction Factor (FCF) may no longer be 100 percent. The Electronic Control Module may adjust the FCF in order to compensate for the fuel quality and for the ambient conditions.
Set the "Desired Emission Gain Adjustment" parameter to a value of "100".
Verify that the value of the "Generator Real kW" parameter in Status Group 1 is within one percent of the generators output power.If the reading on Cat ET is not within one percent of the generators output power, refer to Troubleshooting, "Generator Output Power Readings Do Not Match".When the value of the "Generator Real kW" parameter is within one percent of the generators output power, continue with this procedure.
Slowly ramp up to 70 percent load. Verify that the engine is stable.If the engine is unstable, adjust the auxiliary governor. Refer to Systems Operation/Testing and Adjusting, "Engine Governing - Adjust".
Verify that the NOx emissions are above the desired full load setting.
Slowly ramp up to 100 percent load or up to the normal load for the site.Note: Watch the "Fuel Valve Position" parameter. This parameter is in status group 9. Watch the "Throttle Position" parameter. This parameter is in status group 7. 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.
If the "Throttle Position" has reached 80 percent, adjust the exhaust bypass valve IN in order to decrease the throttle angle.Adjust the exhaust bypass valve until the throttle is between 65 percent and 75 percent at full load or at the normal load for the site.
If the "Fuel Valve Position" has reached 100 percent, 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.
Verify that the reading on Cat ET for the generators power output agrees with the switchgears reading.
Adjust the "Desired Emission Gain Adjustment" parameter in order to obtain the values of emissions that are required at the site.
To lean the air/fuel mixture, decrease the gain adjustment.
To richen the air/fuel mixture, increase the gain adjustment.A small change in the "Desired Emission Gain Adjustment" causes a large change in the actual exhaust emissions. For example, an adjustment of one percent in the parameters value will result in a change of 20 to 40 ppm in the actual level of NOx.When you adjust the exhaust emissions, make a small change in the value of the gain. Wait until the system stabilizes. Check the emissions again. Repeat the process until the desired emissions level is achieved.Use the emissions analyzer in order to verify that the values of emissions meet the requirements of the site.
Verify that the throttle position at the rated load is approximately 70 percent. Refer to Systems Operation/Testing and Adjusting, "Exhaust Bypass Valve".
Record the data from all of the status groups on Cat ET. Save the data for future reference.