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Product: GAS ENGINE

Model: G3516 GAS ENGINE 4EK
Configuration: G3516 Engine Electronic Ignition System 4EK00001-UP

Troubleshooting
G3500 Engines
Media Number -SENR6413-08 Publication Date -01/06/2008 Date Updated -05/06/2008

i02024660

Oxygen Sensor - Calibrate

SMCS - 1096-524

System Operation Description:

Periodic calibration of the oxygen sensor is required in order to ensure accurate readings and optimum
engine performance. Refer to the Operation And Maintenance Manual for the maintenance interval schedule.
The engine must be stopped and the sensor must be removed. The sensor must be placed in uncontaminated
air in order to calibrate the sensor. The air must be free of exhaust.

During the calibration, the Electronic Control Module (ECM) first establishes the reference for zero percent
of oxygen by reading the sensor after the sensor has cooled for two minutes. The ECM energizes the heater
in the sensor for five minutes. Last, the ECM reads the percent of oxygen in the surrounding air. The
surrounding air is assumed to be clean with approximately 20.95 percent oxygen. The calibration offset and
the calibration range are determined from these two points.

Test Step 1. Inspect the Electrical Connectors and the Wiring

During operation, the oxygen sensor may reach temperatures that

exceed 700 °C (1292 °F). Severe personal injury and property damage
will result from contact with a hot oxygen sensor.

Do not touch the sensor during engine operation, calibration, or testing.

Allow the sensor to cool before moving the sensor. Wear gloves that
resist heat. Do not place the sensor on or near any flammable material
or any surface that can be damaged by high temperatures.

A. Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.

B. Thoroughly inspect the following connectors:

Connectors for the ECM

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Connectors for the oxygen sensor and the oxygen buffer

C. Check the harness and wiring for abrasion and pinch points from the oxygen sensor to the ECM.

Expected Result:

All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of
corrosion, abrasion, and pinch points.

Results:

 OK - The components are in good condition with proper connections. Proceed to Test Step 2.

 Not OK - At least one of the connectors, pins, or sockets are not connected properly. At least one of
the connectors or the wiring has corrosion, abrasion, and/or pinch points.

Repair: Perform the necessary repairs and/or replace parts, if necessary.

STOP

Test Step 2. Check the Atmospheric Conditions

A. Determine the ambient temperature, relative humidity, and barometric pressure.

B. Use Table 1 to determine whether your relative humidity is within the permissible range for calibration
of the oxygen sensor.

a. Find the row for your ambient temperature.

If the temperature is less than 12 °C (54 °F), use the 12 °C (54 °F) row.

If the temperature is more than 38 °C (100 °F), do not calibrate the sensor.

b. Find the column for your barometric pressure.

c. Find the relative humidity in the cell that intersects your column and your row.

If your relative humidity is equal to the humidity or greater than the humidity that is
listed in the Table, do not calibrate the sensor.

If the humidity is 90 percent or more, do not calibrate the sensor.

Table 1

Ambient Temperature, Barometric Pressure, and Relative Humidity for Calibration of the Oxygen
Sensor
Barometric Pressure

Ambient 96 97 99 101 102 104 105 107 109 110 112 113

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Temperature kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa
(13.9 (14.7 (14.4 (14.6 (14.8 (15 (15.2 (15.5 (15.8 (16 (16.2 (16.4
psi) psi) psi) psi) psi) psi) psi) psi) psi) psi) psi) psi)

Relative Humidity

90 90
12 °C (54 °F) 90 90 90 90 90 90 90 90 90 90

90 90
14 °C (57 °F) 85 85 85 85 90 90 90 90 90 90

80 85
16 °C (61 °F) 75 75 75 75 80 80 80 85 85 85

70 75
18 °C (64 °F) 65 65 65 70 70 70 75 75 75 75

65 65
20 °C (68 °F) 60 60 60 60 60 65 65 65 65 70

55 60
22 °C (72 °F) 50 50 55 55 55 55 60 60 60 60

50 55
24 °C (75 °F) 45 45 45 50 50 50 50 50 55 55

45 45
26 °C (79 °F) 40 40 40 45 45 45 45 45 50 50

40 40
28 °C (82 °F) 35 35 40 40 40 40 40 40 45 45

35 40
30 °C (86 °F) 35 35 35 35 35 35 35 35 40 40

30 35
32 °C (90 °F) 30 30 30 30 30 35 35 35 35 35

30 30
34 °C (93 °F) 25 25 30 30 30 30 30 30 30 30

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25 30
36 °C (97 °F) 25 25 25 25 25 25 25 25 30 30

25 25
38 °C (100 ° 20 25 25 25 25 25 25 25 25 25
F)

Expected Result:

The temperature is less than 38 °C (100 °F). The ambient relative humidity is within the permissible range
for calibration of the oxygen sensor.

Results:

 OK - The ambient conditions are acceptable. Proceed to Test Step 3.

 Not OK - The humidity is not acceptable.

Repair: Do not calibrate the sensor until the humidity is acceptable.

STOP

Test Step 3. Check for Diagnostic Codes

A. Restore the electrical power to the engine. Set the engine control to the STOP mode.

B. Use an electronic service tool in order to check for the following codes. If the following codes are
activated, clear the codes:

550-02 Noisy or Loss of Oxygen Signal

551-01 Oxygen Sensor not connected to buffer

555-02 Noisy Oxygen signal

Expected Result:

None of the above diagnostic codes are activated.

Results:

 No Codes - The circuit for the oxygen sensor is OK. Proceed to test Step 4.

 Codes - There is at least one diagnostic code for the oxygen sensing system.

Repair: Refer to Troubleshooting, "Oxygen Sensor Signal".

STOP

Test Step 4. Calibrate the Oxygen Sensor

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A. Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.

During operation, the oxygen sensor may reach temperatures that

exceed 700 °C (1292 °F). Severe personal injury and property damage
will result from contact with a hot oxygen sensor.

Do not touch the sensor during engine operation, calibration, or testing.

Allow the sensor to cool before moving the sensor. Wear gloves that
resist heat. Do not place the sensor on or near any flammable material
or any surface that can be damaged by high temperatures.

B. Disconnect the oxygen sensor from the oxygen buffer.

C. Allow the sensor to cool sufficiently for removal. Then remove the sensor from the exhaust system.

D. Connect the oxygen sensor to the oxygen buffer. Suspend the sensor in uncontaminated air.

E. Restore the electrical power to the engine. Set the engine control to the STOP mode.

F. Activate the switch for oxygen calibration.

Approximately 12 minutes are required for the calibration.

During the calibration, the ECM will display "O2 CALIB".

Expected Result:

Successful calibration is indicated by the electronic service tool.

Results:

 OK - Successful calibration is indicated by the electronic service tool. Proceed to Test Step 5.

 Not OK - The calibration was not successful. The electronic service tool will display a diagnostic
code.

Repair: Troubleshoot the diagnostic code. Check the connectors for the oxygen sensor and the oxygen
buffer. Repeat the calibration procedure. If the procedure is not successful after three attempts, obtain
a new oxygen sensor and repeat the calibration procedure.

STOP

Test Step 5. Verify the Calibration of the Sensor

Use the electronic service tool in order to verify the calibration of the oxygen sensor.

A. For the Digital Diagnostic Tool (DDT), perform the following procedure:

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a. Use the "MODE" key in order to scroll to the "O2/TEST" screen. Then use the "FUNC" key in
order to scroll to the "OXYGEN POWER" screen. Press the "ALT1" key in order to turn ON the
oxygen sensing system.

b. Use the "MODE" key in order to scroll to the "STATUS" menu. Use the "FUNC" key in order
to scroll to the "ACT/DES O2" screen. Wait for the value of the actual oxygen to stabilize.

B. For the Caterpillar Electronic Technician (ET), perform the following procedure:

a. Access the "Diagnostic Override" screen. Select "Diagnostics/Diagnostic Tests/Override

Parameters".

b. Turn ON the "Oxygen Sensor Override" parameter.

Expected Result:

The "Actual Oxygen" reading stabilizes to approximately 20.95 percent in about 30 seconds.

Results:

 OK - The "Actual Oxygen" reading stabilizes to approximately 20.95 percent in about 30 seconds.
The calibration of the oxygen sensor is verified. Allow the oxygen sensor to cool before you install the
sensor.STOP

 Not OK - The "Actual Oxygen" reading does not stabilize to approximately 20.95 percent in about 30
seconds. The calibration of the oxygen sensor was not successful.

Repair: Calibrate the oxygen sensor again. Then verify the calibration. Repeat the calibration
procedure. If the procedure is not successful after three attempts, obtain a new oxygen sensor and
repeat the calibration procedure.

STOP

Copyright 1993 - 2010 Caterpillar Inc. Mon Jul 26 18:36:47 UTC-0300 2010
All Rights Reserved.
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