SOFTWARE VERSION NO.

..Z

This document contains proprietary and 1re secret information and

is given to the receive in confidence. The receiver by reception "and
retention of the document accepts the document in confidence and
agrees that, except as with the prior eressed written permlssjon of
Waukesha Engine Division. Dresser Industries, Inc. will; (1) not use
the document or y copy thereof or the confidential or tre secret
information therein; (2) not copy or ruce the documertin whole,
O in part without the prior written approval of_Waukesha Engine
Division. Desser Industries, Inc.; and (3) not dfscle to herseither
the document or the confidential or trade secret-information contained

AFM
therein.

~. . .
CUSTOM ENGINE CON[[ff(S)~
AIR/FUEL MODULE I

INSTALLATION, OPERATION AND

MAINTENANCE Second Edition

The second edition f this manual cvers AFM User

Interface P rogram version 2.8a for single fuel (or one fuel
of a d u al-fuel) stoichiometric and lean b u rn engines.
Retrofit of the AFM system to existing engine
installations should be made according to WED
in stallation drawings. All sales and information herein
s u pplied subject to Sta ndard Te rms of Sale, including
limitation of liability.

FORM 63
Coright 1996.AII rights reserved
Waukesha Engine Division

I Waesha E Dreer Industries, Inc.

Waikesha Wisconsin 53188
Pinted In U.S:A. 1/96

pecycled Pa
 cNTENTS

List Of lllustratin s Sectin 1.02 - General

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 1
List Of Tables
English/Metric Conversions . . . . . . . . . . . . . . . . . 1.02 - 4
Hw To Use This Manual Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 6
Power Requirements For Custm Engine
Control\!!) Products . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 7

Section 1.05 - Descriptin
Of Operatin
CHAPTER 1-SAFETY AND
Waukesha Custom Engine Control
GENERAL AFM Air/Fuel Module System . . . . . . . . . . . . . . . . . . 1.05 - 1
System Description . . . . . . . . . . . . . . . . . . . . . . 1.05 - 1
Section 1.01 - Safety Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 1
Safety Introduction ......... , . . . . . . . . . . . . . . 1.Q1 - 1
Engines Served . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 2
Safety Tags And Decals . . . . . . . . . . . . . . . . . . 1.01 - 1
Ope ratr Interface . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 3
Equipment Repair And Service . . . . . . . . . . . . . 1.01 - 1
Theory Of Operation . . . . . . . .. . . . . . . . . . . . . . . 1.05 - 3
Acids . .............. .. . . ........ . .... . .. 1.01 - 2
AFM
Batteries ............. . ........ . ......... 1.01 - 2 AFM System Oxygen Sensrs ............ 1.05-4
AFM
Body Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 2 AFM System Control Modes . . . . . . . . . . . . . . 1.05 - 5
Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 2
Cleaning Solvents . . . . ...... . ........ . 1.01 - 2 /
/ Liquid Nitrogen/Dry Ice . . . . . . . . . . . . . . . . 1.01 - 2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 2
CHAPTER 2-AIR/FUEL MODULE
Heated Or Frozen . . . . . . . . . . . . . . . . . . . . 1.01 - 2
SYSTEM
Interference Fit . ............ . , . . . . . . . . 1.01 - 2 INSTALLATION
coling System .................. , . . . . . . . 1.01 - 2 AFM
ectrical ................................ 1.01 - 3 Sectin 2.00- Munting AFM System
General . . ........ . ......... . ........ 1.01 - 3 cmponents
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 3 System Components ....................... 2.00 - 1
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 3 Establishing Gas/Air Pressue Setting .. . . . . .. 2.00 - 1
/
Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 3
AFM Mounting The AFM Module . . . . . . . . . . . . . . .. 2.00 - 2
Fuels ...... ... .......................... 1.01 - 3
Mounting Stoichiometric Oxygen Sensor -
General . . . . ...... . .. ........ ........ 1.01 - 3 Rich Bum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 3
/
Gaseous . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 3 Mounting Lean Burn Oxygen Sensing
Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 3 Assembly . . ....... ... .................. 2.00 - 5
Intxicants And Narcoti .................. 1.01 - 4
Lean Bum Oxygen Sensing Assembly
// Pressurized Fluids/Gas/Air . . . . . . . . . . . . . . . . . 1.01 - 4VHP Installation On VHP Engines . . . . . . . . . . . 2.00 - 5
Protective Guards . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 4
Lean Bum Oxygen Sensing Installation On
sdium cled Valve . . . . . . . . . . . . . . . . . . . . . 1.01 - 4VGF VGF Engines . . . . . . . . . . . . . . . . . . . . . . . . 2.00 7

Springs ... . ....... . ... ...... .. .. . ...... 1.01 - 4 Lean Bum Sensor Installation On
Tools ....................... . ........... 1.01 - 4ATAT Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 8
ectrical . ........... . .... .. .. . ..... . 1.01 - 4 K Mounting The K- Type Thermocuples -
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .01 - 4 Rich Burn Applicatins Only . ........... . 2.00-13

Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 4 Mounting The Intake Manifold Prsure
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 5 Transducer .............. .. . . ..... . .... 2.00-14
Mounting The Stepper Motor(s} . . . . . . . . . . . . 2.00 -14
General . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 1.01 - 5

On Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 5 Disassembling Regulator For Stepper
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 5 Motr Munting . . . . . . . . . . . . . . . . . . . . 2.00 -14

FORM 6263 Second Edition

t-l .,
 CONTENTS

Verifying Stepper Motor Operation .. . . .... 2.00-15
Section 3.05 - Prg ramming Fr Catalyst
Installing Stepper Motor To Regulator .. .. 2.00 -16 Application
AFM AFM Programming The AFM Mdule For Catalyst
Section 2.05 - AFM System Electrical Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 1
cnnections
User Interface Progm Startup Steps . . . . . 3.05 - 1
Electrical Connections . .... . . .. . .. .. .. .. . . 2.05- 1
AFM Establishing Communication With The
AFM AFM Module .... . .... ........... .. . .. 3.05 - 2
AFM Module Power Connections . . . . . . . . . 2 .05 - 1
AFM Completing AFM System Wiring e .. , ..... 2.05 - 6Initial AFM Mdule Programming For
Catalyst Control Operatin ... , .... .. . . . 3.05-4
AFM
Wiring Of Auxiliary Inputs And Outputs . . . . . 2.05 - 6
Establishing Engine Start Position . . . . . . . 3.05 - 11
Secti n 2.10 - P resta lnstallatin Mon itring The AFM System Through The
AFM View Serial Link Screen . ...... . . . . . . 3.05 - 14
Checklist
Fine-Tuning AFM Programming For
Prestart Installation Checklists . . . . . . . . . . . . . . . 2.10 - 1AFM
Catalyst Applications . . . . . . . . . . . . . . . . . 3 .05 - 17
/ Catalyst And Best Power/Eenomy
Control Mode Checklist . . . . . . . . . . . . . . . . 2. 1O- 1 Programming The Catalyst Control
Values .. -. 3.05-26
Lean Burn Control Mode Checklist . . . . . . . . . 2.1 O - 2

ROM Saving Date: SetTo ROM . . . . . . . . . .. . . 3.05 - 28
Saving Data-Set To Disk . . . . . . . . . . . . . . 3.05 - 30
/

CHAPTER 3 -AIR/FUEL MODULE Retrieving A Saved Data-Set From Disk
With A Filename ...... .... . . . . . 3.05-32
SYSTEM Post-Programming Check . 3 .05 - 33
PROGRAMMING ROM CHECK 1: Co1ming The Data- Set Save
To ROM .... .. . 3.05-33
Section 3.00 - General P rg ramming AFM CHECK 2: Final Test Of AFM System
I nfrmati n Setup ..... . . . . ... ............ . . . .. 3.05 - 34
Programming Information ......... .. ..... . .. 3 .00 - 1 /
Sectin 3.1 O - Programming Fr Best
AFM Minimum Recommended Computer For
AFM System Equipment Programming . 3.00 - 1 pwer/Ecnomy
AFM App licatins
AFM Conventions Used With AFM Programming . 3 .00 - 1
Programming The AFM Module For Best
Operator Interface . . . . . . . . . . . . . . . . . . . . 3.00 - 1
pwer Or Best Economy . . . . . . . . . . . . . . . . . 3.10 - 1
AFM AFM Use Interface Program Layut And User Interface Program Startup Steps . . . . . 3. 1O 1
Description . . . .. . ...... .. .... .. . .... 3.00 - 2
AFM Establishing Communication With The
RAM Information On Saving Data-Sets To RAM AFM Module ... ...... . .. ...... . . ..... 3. 10- 2
ROM And ROM Memory ... .. . .. ....... .. .. . . . 3 .00 - 4
/ Initial AFM Module Programming For Best
Power/Economy Applications . . . . . . . . . . 3. 1O- 4
Sectin 3.02 - Keypad And Display AFM
Information Establishing Engine Stt Position . . . . . . . . 3.10 - 12

Keypad And Display Information ............. 3.02 - 1 Monitring The AFM System Through he
View Serial Link Screen . . . . . . . . . . . . . 3 . 1O- 15
Catalyst Control Mode Displays . . . . . . . . . . . 3.02 - 1AFM
/Fine-Tuning AFM Programming FF Best
Best pwer/Economy Control Mode Power/Economy Applicatins ... ... . .. 3.10 - 18
/ Displays . 3.02 - 2 AFM
Lean Burn Control Mode Displays ... .... .. 3 .02 - 2 Programming The Best Power/Economy
/Control Veues . . . . . . . . . . . . . . . . . . . . 3. 1O - 22
AFM AFM Mdule Keypad Functions ....... , ...... 3.02 - 3 Saving Data-Set To ROM . . . . . . . . . . . 3.10 24
ROM
AFM AFM Module Control Modes .. . ... . . . , . , . . . 3.02 - 4 Saving Data-Set To Disk ....... . ... -. 3.10-27
Manual Contrl ... . ... . . . .. ........... 3.02-4 Retrieving A Saved Data-Set From Disk

Autmatic Control .... ..= .. 3.02-4 With A Fiiename . . . . . . . . . . . . . . . . . . 3.1 O - 28

IV FORM 6263 Second Edition

 CONTENTS

Post-Programming Check . . . . . . . . . . . . . . . . 3.10 - 29 CHAPTER 4 - TROUBLESHOOTING
CHECK 1: Confirming The Data-Set Save
ROM To ROM . . ... .. . , ... , . .. . ... . . .. .... 3.1 0- 29 /
Sectin 4.00 - Air/Fuel Module System
AFM CHECK 2: Final Test Of AFM System
Setup . , . .. ... . ... .. ........... . , . . 3.1 0 - 30 Troublesh ting
AFMAFM Troubleshooting .. . . . . . ... . ....... . .. 4 .00-1
Section 3.15 - Programming Fr Lean
EPROM Replacing EPROM Chips .. .. , , .. . ..... .. .. 4.00 - 6
Burn Applications
AFM Progrnming The AFM Module For Lean EPROM Core EPROM Chip Replacement . . . .. . . , . . 4.00 - 6
Burn ContrI , .. . .. . ... ... . . ..... .. ...... 3.15 - 1
EPROM Display EPROM Chip Replacement . . . . . . . . 4.00 - 9
User Interface Program Startup Steps . . . . . . 3.15 - 1
/
AFM Establishing Communication With The
AFM Module . . . . . . . . . . . . . . . . . . . . . . . 3 .15 - 2 Section 4.05 - Air/Fuel Module System
Initial AFM Module Pro~ramming For Lean Diagnsties
AFM Burn Control Operation . . . .. . . . . . . . . . . 3.15 - 4 AFM AFM System Diagnostics . ..... ..... .. . .. . 4.05 - 1

Establishing Engine Start Position . . ... . .. 3.15 - 10 AFM
AFM Module LED Display . . . . . . . . . . . . . . . 4.05 - 2
Mnitoring The AFM System Through The LED
AFM View Serial Link Screen . . . . . . . . . . . . . . 3 .15 - 13 AFM AFM Module LCD Display ...... . ....... 4.05 - 2
LCD
Fine-Tuning AFM Programming For Lean Auxiliary Error Out Alarm Output . . . . . . . . 4.05 - 2
AFM Burn Applications . . . . . . . . . . . . . . . . . . . . 3.15 - 15
Programming The Lean Bum Control
Values .. . .. ... ... . . ......... , .. .. . 3.15 - 24 Alphabetical Index .. ... . .. ...... . ... ... ... A - 1

ROM Saving Data-Set To ROM . . . . . . . . . . . . . . . 3 .1 5 - 26
Saving Data-Set To Disk . . . . . . . . . . . . . . . . 3.15 - 29
Retrieving A Saved Data-Set From Disk
With A Filename . .. . .. . , . . .... . .. . ... 3 .1 5 - 30
WARRANTY
Post-Programming Check . . .. .. .. .... . . . . . 3.15-31
ROM CHECK 1: Confirming The Data-Set Save Waukesha Engine Divisin - Dresser Industries,
To ROM . , . ....... . ... .. ..... . ...... 3.1 5-31 Inc.

AFM CHECK 2: Final Test Of AFM System

Setup 3.15-32 xpress limited Warranty For Custom Engine Control

FORM 6263 Second Edition v

CONTENTS

V FORM 6263 Second Edition


LIST OF ILLUSTRATIONS
Section 1.05 - Descr iptin Of Operation
1.05-1 CEC/
Figure 1.05-1 . CEC Air/Fuel Module. .. . . . . . . 1.05 - 1
Figure 1.05-2. AFM System Inputs And
1.05-2 AFM Outputs . ... .... . .. . . ..... . . . ... . ... .. 1.05 1
Figure 1.05-3. Air/Fuel Module System
1.05-3 AFM Block Diagram ... . . 1.05-2
1.05-4 AFM Figure 1.054. Air/Fuel Module Front Panel . . 1.05 - 3 2.00-18 8L-ATGL
Figure 1.05-5. AFM System's Clsed-Loop
1.05-5 AFM Process . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 3 2.00-19 Elbow-12V-AT27
1.05-6 Figue i .056. Sectional Vtew Of The
Stoichiometric Sensor ........ . . .... 1.05 - 4
1.05-7 Figure 1.05-7. Typical Stoichiometric Sensor
Output Curve - Rich Burn ONLY . . . . . . . . 1.05 - 4
1.05-8 Figure 1.05-8. Oxygen Sensor Response Vs.
xhaust Oxygen Concentrations For
/ Various Air/Fuel Ratios -
Ln Burn ONLY .. . . . .. . ... . . . . . . ... . 1.05 - 5
1.05-9 / Figure 1 .05-9. Air/Fuel Ratio And Stepper
Limits Vs. Lad .. . . . .. . . . . . .. ........ 1.05 - 6 2.00-23 Figure
AFM
Section 2.00 - Mounting AFM System
cmponents
2.00-1 AFM Figure 2.001 . Mounting The AFM Module . . 2.00 - 2
2.00-2 AFM Flgue 2.00-2. AFM Module Conduit Ports . . . 2.00 - 22.00-26 - 99
2.00-3 VGF G Figure 2.00-3. Oxygen Sensor Port Location
On VGF G Engines .. . . . . .. , .... .. ... 2.00 - 3
2.00-4 VGF GSID Figure 2..00-4. Oxygen Sensor Port Location
On VGF GSID Engines . . . . .. . . . . . . . . . . 2.00- 3
2.00-5 VHP G Figure 2.00-5. Oxygen Sensor Port Location
On VHP G Engines . .. . . . . . . . .. . . . . . 2.00 - 3
2.00-6 6VHP GSI gure 2.00-6. Oxygen Sensor Port Location
On 6 Cylinder VHP GSI Engines . . . . . . . . 2.00 - 3
2.00-7 1216VHP Figure 2.00-7. Oxygen Sensor Port Location
GSI On 12 And 16 Cylinder VHP GSI
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 4
2.00-8 Figure 2.00-8. Radiant Heat Shield For
Stoichiometric Sensor . . . . . . . . . . . . . . . . 2.00 - 4
2.00-9 Figure 2.00-9. Front View Of Lean Burn
Sensor Block . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 5
2.00-10 Figure 2.00-10. Lean Burn Oxygen
Sensing Assembly . . . . . . . . . . . . . . . . . . . . 2.00 - 5 2.05-1 Waukesha CEC
2.00-11 VHP Figure 2.00-11 . VHP Engine Oxygen
- Sensor prts - Lean Burn .... . ... . .. 2.00-5 2.05-2 AFM/
2.00-12 Figure 2.00-12. Lean Burn Sensor And
Sensor Block Installed On Exhaust
- VHP
Outlet Tee - VHP Engines . .. ... , . . . . . . 2.00 - 6 2.05-3 AFM -
2.00-13 Figure 2.00-13. Lean Burn Sensor Installation
VGF Location On VGF lnline Engines .. . . 2.00- 7
2.00-14 Figure 2.00-14. Lean Burn Sensor Installation
VGF Vee Location On VGF Vee Engines . . . . . . . 2.00 - 7
FORM 6263 Seoond Edition
ILLUSTRATIONS
2.00-15 VGF
gure 2.00-15. Lean Burn Sensor And
Sensor Block Installed On Exhaust
Outlet Tee - VGF Engines . . . . . . . . . . . . 2.00 - 7
2.00-16 12V-AT25GL
Figure 2.00-16. Lean Burn Sensor Location
On 12V-AT25GL Engines . . . . . . . . . . . . . 2.00 - 8
2.00-17 12V-AT27GL
Figure 2.00-17. Lean Burn Senso Location
On 12V-AT27GL Engines . . . . . . . . . . . 2.00 - 8
Figure 2.00-18. Lean Burn Sensor Location
On 8L-ATGL Engines . . . . . . . . . . . . . . . . . 2.00 - 9
Figure 2.00-19. Lean Burn Sensor And
Sensr Block Installed On Turbo Exhaust
bow-12V-AT27 Engine Shown . . . . .. 2.00- 9
2.00-20 8L-ATGL
Figure 2.00-20. Exhaust Supply Tubing On
8L- ATGL Engines . . . . . .. .... .. ... . . . 2.00 - 10
2.00-21 12V-AT25GL
Figure 2.0021. Exhaust Supply Tubing On
12V- AT25GL Engines .. , 2.00-11
2.00-22 12V-AT27GL
figure 2.00-22. Exhaust Supply Tubing On
12V-AT27GL . ... .. .... . ... ... . ..... 2.00 - 12
K
2.00-23. K- Type Thermocouple .. . . 2.00 - 13
2.00-24
Figure 2.00-24. Intake Manifold Prsure
Transducer . ....... . ... . 2.00 - 14
2.00-25 - 99
Figure 2.00-25. Removing Cap From
Regulator - 99 Regulator Shown . . . . . . 2.00 - 14
Figue 2.00-26. Removing Adjusting Screw
And Control Spring From Regulator -
99 Regulator Shown . . . . . . . . . . . . . . . . . 2.00 - 15
2.00-27 - 99
Figure 2.00-27. External Regulator Adjuster
Installation - 99 Regulator Shown . . . . . 2.00- 15
2.00-28
Figure 2.00-28. Stepper Motor Assembly
For Verifying Operation . ... . ... . . .. . . . 2.00-15
2.00-29
Figure 2.00-29. Installing Stepper Motor
Int Regulator . . . . . . . . . . . . . . . . . . . . . 2.00 - 16
2.00-30
Figure 2.00-30. Stepper Harness
Connections .. .... . .. . .. . . . . . . . . . . 2.0 17
2.00-31 AFM
Figure 2.00-31. AFM Module Stepper
Harness Connections . . . . . . . . . . . . . . . 2.00 -17
AFM
Sectin 2.05- AFM System Electrical
cnnections
Figure 2.05-1 . Waukesha CEC Products
Power Wiring Requirements . . . . . . . . . . 2.05 - 1
-
Figure 2.05-2. AFM System Wiring For
Catalyst And Best Power/Economy
Applications - Rich Burn Only . . . . . . . . . . 2.05 - 2
Figure 2.05-3. AFM System Wiring Fo Lean
Burn Applications - Lean Bum Only . . . . . 2.05 - 4
2.05-4
Figure 2.05-4. Wiring Of Auxiliary Inputs
And Outputs . . . . . . . . . .. . . . . . . . . . . . 2. 05 - 6
vii
 ILLUSTRATIONS

3.05-19
1..

Figure 3.05-19. Conrmation Message 4 . 3.05-9

Sectin 2.10 - Presta lnsta llatin 3.05-20

,
Figure 3.0520. Saving Options Menu . . . . . . . 3.05 - 9
Ch ckli st 3.05-21 RAM
2.10-1 AFM - / Figure 3.05-21. Conrmation Of Save To
Figure 2.101. AFM Module Connections - Random Access Memory (RAM) . . . . . . . 3.05 - 1O
Catalyst And Best Power/Eenomy 3.05-22 RAM
Prestart Checklist . . . . . . . . . . . . . . . . . . . . 2.10 - 1 Figure 3.05-22. Confirmation Of Save To
2.10-2 AFM - RAM ............. . ... . ............. 3.05-10
Figure 2. 10-2. AFM Module Connections - 3.05-23
Lean Bum Prestart Checklist . . . . . . . . . . 2. 1O - 2 Figure 3.05-23. Entering Stepper Motor
Start psition ... . . . ......... . ....... 3.05-11
3.05-24
Sec tin 3.00 - General Prg rammmg Figure 3.05-24. Saving Options Menu . . . . . . 3.05 - 12
3.05-25 RAM
I nf rnation Figure 3.05-25. Conrmation Of Save To
3.00-1 / Random Access Memory (RAM) .. ..... 3.05-13
Figure 3.001 . Air/Fuel Module Front Panel .. 3.00-1 3.05-26
3.00-2 AFM Figure 3.05-26. Cnfirmation Of Exit T
Figure 3.00-2. AFM User Interface Program
Main Menu . . . . .. ... . ...... . .... 3.05-13
Layut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 - 3 3.05-27 AFM
Figure 3.05-27. AFM User Interface Prigram
Section 3.02 - Keypad And Display Main Menu . ... . . . . . .. , . .. . .. . , .... 3.05-14
3.05-28
3.05-7 Figure 3.05-28. View Serial Link Screen .... 3.05-14
Infrnatin
3.02-1 / 3.05-29
Figure 3.02-1. Air/Fuel Module Front Panel . . 3.02 - 1 Figure 3.05-29. Analog Reconnection .. ... 3.05-15
3.02-2 AFM 3 .05-30 AFM
Figure 3.02-2. AFM Module Keypad Detail . . . 3.02 - 3 Figure 3 . 0530. AFM Module In Manual
Mode . ..... ' t 3.05-16
3.05-31 AFM
Section 3.05 - Programming For Catalyst Figure 3.05-31. AFM Module In Automatic
Application Mode ................ 3.05 - 16
3.05-32 /
3.05-1 AFM Figure 3.05-32. Sample Air/Fuel Ra
Figure 3.05-1 . Analog And Power Connections Curve With Stepper Limits . . . . . . . . . . . . 3.05 - 18
Inside AFM Module .. ................ 3.05 - 1 3.05-33 / -
3.05-2 DB-9AFM Figure 3.05-33. Oxygen Sensor Response Vs.
Figure 3.05-2. DE>-9 Serial Cable Connection Exhaust Gas Concentrations For Various
Inside AFM Module . . . . . . . . . . . . . . . . . . . 3.05 - 1 Air/Fuel Ratios - Rich Burn ONLY . . ... 3.05 - 20
3.05-3 3.05-34 -
Figure 3.05-3. Software Version Identification . 3.05 - 2 Figure 3.05-34. Programming Scenario For
3.05-4
Figure 3.05-4. Communications Menu . . . . . . . 3.05 - 2 Catalyst Control - Variable Oxygen
3.05-5 AFM Sensor Set-Points . . . . . . . . . . . . . . . . . . 3.05 - 21
Figure 3.05-5. AFM User Interface Program 3.05-35 /
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 2 Figure 3.05-35. Sample Air/Fuel Ratio Curve
3.05-6 / Wlth Stepper Motor Limits ... ...... ... 3.05- 22
Figure 3.05-6. Edit/Create Setup Menu . . . . . . 3.05 - 2 3.05-36 / -
3.05-7 Figure 3.05-36. Oxygen Sensor Response Vs.
Figure 3.05-7. Communicationsrror
Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .05 3 Exhaust Gas Concentrations For Various
3.05-8 Air/Fuel Ratios - Rich Burn ONLY .... 3.05 - 24
Figure 3.05-8. Test Program Message. . . . . . . . 3.05 - 3 3.05-37 -
3.05-9 AFM Figure 3.05-37. Programming Scenario Fr
Figue 3.059. AFM User Interface Prgram
Catalyst Control - Constant Oxygen
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .05 4
3.05-10 / Sensor Set-Points . . . . . . . . . . . . . . . . . 3.05 - 25
Figure 3.05-10. Edit/Create Setup Menu .. . . 3.05 - 4 3.05-38 AFM
3.05-11 Figure 3.05-38. AFM User Interface Program
Figure 3.05-11 . File Select Menu . . . . . . . . . . . 3.05 - 4 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 26
3.05-12 RSETUP01 - VHP 3.05-39 /
Figure 3. 05-12. Preprogrammed Setup File Figure 3.05-39. Edit/Ceate Setup Menu . . . . 3.05 - 26
RSETUP01 - Catalyst Equipped VHP 3.0540
Figure 3.0540. Editing The Dataet On
Applications . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 5 The Edit Screen . . . . . . . . . . . . . . . . . . . . . 3.05 - 27
3.05-13 Engine 3.05-41
Figure 3.05-13.ngine Family Selection Figure 3.05-41 . Confirmation Of Exit To Main
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 6 Menu .... . . . . ....... ..... . ......... 3.05-27
3.05-14. 3.05-42 ROM
Figure 3.05-14.ngine Model Selection Figure 3.05-42. Confirmation Of Save o
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 6 Read Only Memory (ROM) . ..... .... . 3.05 - 29
3.05-15 3.05-43 ROM
Figure 3.05-15. Engine Fuel System Selection Figure 3.05-43. Verification To Stoe New
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 7 Values To ROM .. ...... ... .. .... .... 3.05 - 29
3.05-16 3.05-44 ROM
Figure 3.05-16. Primary Fuel Selection Figure 3.05-44. Verifi.tion Screen Of Save
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 7 o ROM .. . . ...... ............. .. .. . 3.05 - 30
3.05-17 3.05-45
Figure 3. 05-17. Secondary Fuel Selection Figure 3.05-45. Programming Error
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 8 Message ... .. ... .... .. . ....... ..... 3.05-31
3.05-18 AFM 3.05-46
Figure 3.05-18. AFM System Control Mode Figure 3.0546. Input Data-Rte Name
Selection Screen . . . . . . . . . . . . . . . . . . . . . 3.05 - 8 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 31

Viii FOAM 6263 Second Edition

 ILLUSTRATIONS

3.05-47 3.10-21
Flgure 3.05-47. Confirmation Of Exit To Main Figure 3. 10-21 , Savlng Options Menu . . . . . . 3.10 - 10
Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .05 - 32 3.10-22 RAM
3.05-48 AFM Figure 3. 10-22. Conrmation Of Save To
Figure 3.05-48. AFM User Interface Program Random Access Memry (RAM) ....... 3 . 10 1 1
Main Menu . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 32 3.10-23
Figure 3.10-23. Confirmation Of Save To
3.05-49
Figure 3.05-49. File Select Menu . . . . . . . . . . 3.05 - 33 RAM .... . ......... . ....... . .. . ..... 3.10-11
3.05-50 3.10-24
Figure 3.05-50. Edit Screen . . . . . . . . . . . . . . . 3.05 - 33 Figure 3. 10-24. Locating Stepper Motor
3.05-51 AFM Start Position .. , . . . . . . . . . . . . . . . . . . 3.1 O - 12
Figure 3 .05-51. AFM User Interface Program 3.10-25
Main Menu ........ , . . . . . . . . . . . . . . . 3.05 - 34 Figure 3.10-25. Entering Stepper Motor
3.05-52 Start Position . . . . . . . . . . . .. . . . . . .. . . 3 .10 - 13
Figure 3.05-52. Communications Menu . ... 3.05- 34 3.10-26
3.05-53 AFM Figure 3.10-26. Saving Options Menu . . . . . . 3.1 O- 13
Figure 3.05-53. AFM User Interface Program 3.10-27 RAM
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . 3 .05 - 34 Figure 3.10-27. Confirmation Of Save b
3.05-54 EdiVCreate Random Access Memory (RAM) . . . . . . 3. 10 - 14
Figure 3.05-54. EdiVCreate Setup Men . ... 3.05-34 3.10-28
3.05-55 Figure 3.10-28. Confirmation Of Exit To
Figure 3.05-55. Edit Screen . . . . . . . . . . . . . . . 3 .05 - 35
Main Menu .. 3.10-14
/ 3.10-29 AFM
Secti n 3.10 - Programming For Best Figure 3.10-29. AFM User lnte Prgram
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . 3.10 - 15
pwer/Ecn omy 3.10-30
Figure 3 .10-30. View Serial Link Screen . . . 3.10 - 15
Applicatins 3.10-31
3.10-1 AFM Figure 3.10-31. Analog Reconnection . . . . . . 3.1O - 16
Figure 3.10-1. Analog And Power Connections 3.10-32 AFM
Figure 3.10-32. AFM Module In Manual
Inside AFM Module .... .... . . . ... ... 3.10-1
3.10-2 DB-9AFM Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1O- 17
Figure 3.10-2. DB-9 Serial Cable Connection 3.10-33 AFM
Figure 3.10-33. AFM Module In Autmatic
Inside AFM Module . . . . . . . . . . . . . . . . . . . 3.1 O - 1
3.1 0-3 Mode ............................. 3.10-17
Figure 3.1 0-3. Software Version Identification 3. 10 - 2 3.10-34 / -
3.10-4 Figure 3.10-34. Oxygen Sensor Response Vs.
Figure 3.10-4. Communications Menu . . . . . . . 3.10 - 2 Exhaust Gas Concentrations For Various
3.10-5 AFM Air/Fuel Ratios - Rich Burn ONLY . . . . . . 3.1 O- 20
Figure 3.10-5. AFM User Interface Program
Main Menu ........ 3.10-2 3.10-35 /
Figure 3.10-35. Programming Scenario For
3.10-.6 /
Figure 3.; Q-.6. Edit/Create Setup Menu . . . . . . 3.1 0 - 2 Best Power/Economy Control . .. ...... 3.1 O - 21
3.10-7 3.10-36 AFM
Figure 3.10-7. Communications Erro Figure 3.10-36. AFM User Interface Program
Message . .................... ....... 3.10-3 Main Menu . . . . . . . . . . . . . . . . . . . . . . . 3.1 O - 22
3.10-8 3.10-37 /
Figure 3.10-8. Test Program Message . . . . . . . 3.1 O - 3 Figure 3.10-37. Edit/Create Setup Menu . . . . 3.1 0 - 22
3.10-9 AFM 3.10-38
Figure 3.10-9. AFM User Interface Prog arn Figure 3.10-38. Editing The Data-Set On
Main Menu .. .. ...... . ... . ... . .. . 3.10- 4 The Edit Screen . . . . . . . . . . . . . . . . . . . 3.10 - 23
3.10-1O / 3.10-39
Figure 3.10-1 O. Edit/Create Setup Menu . . . . . 3.10 - 4 Figure 3.10-39. Confirmation Of Exit To
3.10-11 Main Menu . .. . ...... . ...... . . . ..... 3.10-23
Figure 3.10-11 . File Select Menu . .. . . . . . . . . 3 :10 - 4 3.10-40 ROM
3.10-12 RSETUP05 - / Figure 3.10-40. Confirmation Of Save To
Figure 3.10-12. Preprogrammed Setup File
Read Only Memory (ROM) 3.10-25
RSETUPOS-Bt Power/Economy 3.10-41 ROM
Applications . , . . .. . .. . . .. . . .. . .. .. . . 3.10- 5 Figure 3.10-41 . Verification T Store New
3.10-13 Vales To ROM .... ... .. ... .. ....... 3.10-25
Figure 3.10-13. Engine Family Selection 3. 10-42 ROM
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 - 6 Figure 3. 10-42. Verifition Screen Of Save
3.10-14 o ROM . .... .. .. . ..... .. .. ..... .. . . 3.10- 26
Figure 3.10-14. Engine Model Selection 3.10-43
Screen .. .. ... ... . .... ... ... ... . ..... 3 .10-6 Figure 3.10-43. Programming Error
3.10-15 Message . ....... . .... ........ .... . 3.10-26
Figure 3.10-15. Engine Fuel System 3.10-44
Selection Screen .......... ........ 3.10 7 Figure 3.10-44. Input Data-File Name
3.10-16 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 1O - 27
Figure 3.10-16. Primary Fuel Selection 3.10-45
Screen ............ ... ...... , . . . . . . . 3.10 - 7 Figure 3.10-45. Conrmation Of Exit To
3.10-17 Main Menu .... . . . , ................. 3.10-28
Figure 3.10-17. Secondary Fuel Selection 3.10-46 AFM
Sceen . .. ..... .. .. . ... .... .. . . ...... 3.10-8 Figure 3.10-46. AFM User Interface Program
3.1 0-18 AFM Main Menu .. .. ... ..... ,.... . 3.10-28
Figure 3.1 0-18. AFM System Control Mode 3.10-47
Figure 3.10-47. File Select Menu . . , .... 3.10-29
Selection Screen . .. .. .. .. . .. .. .. . .. .. 3.10 - 8 3.10-48
3.10-19 Figure 3.10-48. Edit Screen . . 3.10-29
Figure 3.10-19. Confirmation Message . . . . . . 3.1 O - 9
3.10-20 RSETUP05 - / 3.1049 AFM
Figure 3.1049. AFM User Interface Program
Figure 3.10-20. Preprogrnmed Setup File
Main Menu ... . ...... . .... . ........ . 3 .10-30
RSETUP05 - Best Power/Economy 3.10-50
Applications . . . . . . . . . . . . . . . . . . . . . . . . 3.1 O- 9 Figure 3.10-50. Communications Menu ..... 3.10 - 30

FORM 6263 Second Edition IX

 ILLUSTRATIONS

3.10-51 AFM 3.15-27

Figure 3.10-51. AFM User lnteface Program Figure 3.15-27. View Serial Link Screen . . . . 3.15 - 13
Main Menu , . .... . ....... . .. ..... .. . 3.10- 30 3.15-28
Figure 3.15-28. Analog And Sensor
3.10-52 / Aeconnections . . . . . . . . . . . . . . . . . . . . . 3.15 - 14
Figure 3.10-52. Edit/Create Setup Menu , .. . 3.1 O- 30
3.15-29
3.10-53 Figure 3.15-29. Ptentiometer Adjustment . . 3.15 - 14
Figure 3.10-53. Ed Screen . . .. . .......... 3.10-31 3.15-30 AFM
Figure 3.15-30. AFM Module In Manual
Section 3.15 - Programming For Lean Mode .... . .... . . . .. . ..... .. .. ... ... 3.15 - 15
3.15-31 / - AT
Burn Applications Figue 3.15-31. Sample Air/Fuel Ratio Curve
3.15-1 AFM Wh Stepper Motor Limits -
Figure 3.15-1. Analog, Sensr, And Power AT Engines ........ . .. . .. .. .. ... . . . . 3.15 - 16
Connections Inside AFM Module . . . . . . . 3.15 -1 3.15-32
3.15-2 DB-9AFM Figure 3.15-32. Potentiometer Adjustment . . 3.15 - 16
Figure 3.15-2. DB-9 Serial Cable Connection 3.15-33 /
Figure 3.15-33. Oxygen Sensor Response Vs. -
Inside AFM Module . . . . . . . . . . . . . . . . . . . 3.15 - 1
3.15-3 Exhaust Oxygen Concentrations For
Figure 3.15-3. Software Version Various Air/Fuel Ratios -
Identification . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 2 LeanBurnONLY .... . .......... . . ... 3.15-18
3.15-4 3.15-34
Figure 3.15-4. Communications Menu . . . . . . . 3.15 - 2 Figure 3.15-34. Programming Scenario For
3.15-5 AFMMalnMenu Lean Burn Control (Variable Oxygen
Figure 3. 15-5. AFM User Interface Pogram
MalnMenu ... .. ....... . . ... .. .... ... 3.15-2 Sensor SetPoints) . . . . . . . . .. . . . . . . . . 3.15 -19
3.15-6 / 3.15-35 / -
Figure 3.15-6. Edit/Create Setup Menu . . . . . . 3.15 - 2 Figure 3.15-35. Sample Air/Fuel Ratio Curve
3.15-7 Wh Stepper Limits - AT Engines . . . . . . 3. 15 - 20
Figure 3.15-7. Communications Error 3.15-36
Figure 3.15-36. Potentiometer Adjustment . . 3.15 - 20
Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 3 3.15-37 /
3.15-8 Figure 3.15-37. Oxygen Sensor Response Vs. -
Figu e 3.15-8. Test Program Message .... 3.15-3
3.15-9 AFM Exhaust Oxygen Concentrations For
Figure 3.15-9. AFM User Interface Program Various Air/Fuel Ratios -
Main Menu ... . .. .. .. . . . ..... . ... . . .. 3.15-4 Lean Burn ONLY . . .... . ... .. ... . .. . . 3.15-22
3.15-10 / 3.15-38
Figure 3.15-10. Ed iCreate Setup Menu . . . . . 3.15 - 4 Figure 3.15-38. Programming Scenario For
3-15-11 Lean Burn cntrol (Constant Oxygen
Figu e3.15-11 . FileSelectMenu ..... . ... .. 3.15-4
3.15-12 LSETUP01 - AT Sensor Set- Points) . . . . . . . . . . . . . . . . . . 3.15 - 23
Figure 3.15-12. Preprogrammed Setup File 3.15-39 AFM
Figure 3.15-39. AFM User Interface Program
LSETUP01 - Catalyst Equipped AT
Main Menu .. ... , . . . . . .. . ..... . . . 3.15-24
Applications ........... ... . ..... ... . . 3.15-5 3.15-40 /
3.15-13 Figure 3.15-40. Edit/Create Setup Menu . . . . 3.15 - 24
Figure 3.15-13. Engine Family Selection 3.15-41
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 6 Figure 3.15-41. Editing The Data-Set On
3.15-14 The Edit Screen . . . . . . . . . . . . . . . . . . . . 3.15 - 25
Figure 3.15-14.ngine Model Selection 3.15-43 ROM
Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 15 - 6 Figure 3.15-43. Confirmation Of Save To
3.15-15 - VHPVGF Read Only Memory (ROM) . . . . . . . . . . . 3.15 - 27
Figure 3.15-15. Engine Fuel System Selection 3.15-44 ROM
Figure 3.15-44. Verification To Store New
Screen - VHP And VGF Engines Only . . 3.15 - 7 Veues To ROM . . . . . . . . . . . . . . . . . . 3.15 - 27
3.15-16
Figure 3.15-16. Primary Fuel Selection 3.15-45 ROM
Figure 3.15-45. Verification Screen Of Save
Screen . . . .. ... . .. . . . .... . . . .. . .. . .. 3.15- 7 To ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 15 - 28
3.15-17 3.15-46
Figure 3.15-17. Secondary Fuel Selection Figure 3.15-46. Programming Error
Screen .. 3.15-8
o
Message . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 28
3.15-18 3.15-47
Figure 3.15-18. Confirmation Message . " 3.15-8 Figure 3.15-47. Input Data-File Name
3.15-19 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 29
Figure 3.15-19. Saving Options Menu . . . . . . . 3.15 - 9
3.15-20 RAM 3.15-48
Figure 3.15-20. Cnrmation Of Save To Figure 3.15-48. Confirmation Of Exit To
Random Access Memory (RAM) . . . . . . . 3.15 - 9 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 30
3.15-21 3.15-49 AFM
Figure 3.15-21. Confirmation of Save To Figure 3.15-49. AFM User Interface Program
RAM .. . .... . ... . ........ . ......... 3.15-10 Main Menu . .... . ....... ... .... .. . . . 3.15 - 30
3.15-22 3.15-50
Figure 3.15-22. Entering Stepper Motor Figure 3.15-50. File Select Menu . .... . . . 3.15- 31
Start Position . . . . . . . . . .. . . . . . . . . . 3.15 - 11 3.15--51
Figure 3.15--51. Edit Screen . . . . . . . . . . . . . . . 3.15 - 31
3.15-23 3.15-52 AFM
Figure 3.15-23. Saving Options Menu . . . . . . 3.15 -11 Flgu e 3.15-52. AFM User Interface Program
3.15-24 RAM Main Menu ..... . ..... . ....... . . . 3.15-32
Figure 3.15-24. Confirmation Of Save To 3.15-53
Random Access Memory (RAM) . . . . . . . 3.15 - 12 Figure 3.15-53. Communications Menu . . . . . 3.15 - 32
3.15-25 3.15-54 AFM
Figure 3.15-25. Confrrmation Of Exit To Figure 3.15-54. AFM User Interface Program
Main Menu . . .............. . .... . ... 3.15-12 Main Menu . ........... . . .. . ........ 3.15-32
3.15-55 /
3.15-26 AFM Figure 3.15-55. Edit/Create Setup Menu . . . 3.15 - 32
Figure 3. 15-26. AFM User Interface Program 3.15-56
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 13 Figure 3.15-56. Edit Screen . . . . . . . . . . . . . . . 3. 15 - 33

x FORM 6263 Second Edition

 ILLUSTRATIONS

/
Section 4.00 - Air/Fuel Module System
_ Troubleshoting
4.00-1 AFM
Figure 4.00-1. AFM Module Internal Board
Assemblies . . . . . . . . . . . . . . . . . . . . . . . 4.00 - 1
4.00-2
Figure 4.00-2. Display Board Assembly . . ... . 4.00 - 2
4.00-3
Figure 4.00-3. Home Switch Installation
Diagram . . .. , . . .... ... . . .. . .. . . .. . .. 4.00 - 3
4.004 EPROMAFM
Figure 4.004. EPROM Chip Locations Inside
AFM Module . . . . . . . . . . . . . . . . . . . . . . . . 4.00 - 6
4.00-5
Figure 4.00-5. Control Board Assembly
Disconnections . . . . . . . . . . . . . . . . . . . . . . 4.00 - 7
4.00-6
Figure 4.00-6. Control Board Assembly
Screw Locations . ..... . . ..... . ... .. 4.00- 7
4.00-7
Figure 4.00-7. Bottom Screw Lcation Of
Control Board Assembly . . . . . . . . . . . . . . . 4.00 - 7
4.008
Figure 4.008. Disassembling Circuit Board
Assembly . . .... . . . .. . ..... . ........ 4.00- 7
4.00-9 EPROM
Figure 4.00-9. Core EPROM Chip Location . . 4.00 - 7
4.00-10 EPROM
Figure 4.00-10. Removing Core
EPROM Chip . ... . .. . ... . . ......... 4.00 - 8
4.00-11 EPROM
Figure 4.00-11 . Correct cre EPROM
ChJp Direction . .. .... .. , .. .. . . .. ... 4.00 - 8
Figure4.00-12 EPROM
Figure4.00-12. Core EPROM Chip Location
And Direction ... . ... .... , . . .+ . . 4.00 - 8
4.00-13 EPROM
Figure 4.00-13. Dislay EPROM Chip
Locatin And Direction . . . . . . . . . . . . . . . 4.00 - 9
4.00-14 EPROM
Figue 4.00-14. Removing Display EPROM
Chip . . . . . .... . .... ... . . . .. . . .. , . . . . 4.00 - 9
4.00-15 EPROM
Figure 4.00-15. Correct EPROM Chip
Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 4.00 - 9
/
Sectin 4.05 - Air/Fuel Mdule System
Diagnostics
4.05-1 /
Figure 4.05-1. Air/Fuel Module Front Panel . . 4.05 - 1
4.052
Figure 4.052. View Serial Link Screen
Alarm Messages . . . . . . . . . . . . . . . . . . . . 4.05 - 1

XI
FORM 6263 Second Edition
ILLUSTRATIONS

XII FORM 6263 Second Edition

 TABLES

LIST OF TABLES
/
Secti n 1.02 - General Sectin 3.1O - Programming Fr Best
1.021
Table 1.02 1. Metric Standard Capscrew Power/Eenomy
Torque Values (Untreated Black Finish) . . 1.02 - 1 Applicatins
1.02-2
Table 1.02-2. Metric Standard Capscrew 3.10-1 /
Torque Values (Electrically Zinc Plated) . . 1 .02 - 2 Table 3.10-1. Preprogrammed Setup Files
1.02-3 For Best pwer/Economy Applications . . 3.1o- 5
Table 1.02-3. U.S. Standard Capscrew 3.10-2 /
Torque Values . . . . . . . . . . . . . . . . . . . . . 1.02 - 3 T le 3.10-2. View Serial Link Screen And
1.024 Best Power/Economy Control
Table 1.024. Metric Bolt Diameter To Hex
Head Wrench Size Conversion Tble .. . . 1.02-4 Worksheet . 3 . 10 - 1 9
1.02-5
Table 1.02-5. English To Metric Formula Section 3.15- Programming Fr Lean
Conversion Table . . .. . . . . .. .. . . .. . .. . . 1.02 - 5
1.02-6 Burn Applicati ns
Table 1.02-6. Metric To English Formula 3.15-1
Conversion Table . . . . . . . . . . . . . . . . . . . . . 1.02 - 5 Table 3.15-1. Preprogrammed Setup Files
1.027 Waukesha For Lean Burn Control Operation . . . . . . . 3.15 - 5
Table 1.027. Power Requirements for
Waukesha Custom Engine Control 3.15-2 AT -
Table 3.15-2. View Serial Link Screen And
Prducts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 7 Lean Burn cntrol Worksheet
AFM (AT Engines) - Vaable Set- Points . . . . 3. 15 - 17
Secti n 2.00- M unting AFM System 3.153 AT -
Table 3. 153. View Serial Link Screen And
cponents
2.001 AFM Lean Burn Control Worksheet
Table 2.001. AFM System Components ... .. 2.00 - 1 (AT Engines) - Constant Set- Points . . . 3.15 - 21
2.00-2 AFM
Table 2.00-2. AFM Programming /
wrksheets . .. .. .. .. . . .. ... . . .. .. . .. 2.00 - 1 Sectin 4.00 - Air/Fuel Module System
AFM
Secti n 2.05 - AFM System Electrical Troubleshting
4.00-1 AFM
cnnectins Table 4.001. AFM System Tr ubleshooting . . 4.00 - 1
2.051 AFM /
Table 2.05 1. Power Requirements For The
Secti n 4.05 - Air/Fuel Mdule System
AFM System . . . . . . . . . . . . . . . . . . . . . . . . 2.05 - 1
2.05-2 AFM Diagn sties
Table 2.05-2. AFM Module Wire Routing . . . . . 2.05 - 6
4.05-1 AFM
Table 4 .05-1 . AFM System Diagnostics . . . . . . 4 .05 - 3
Sectin 3.02 - Keypad And Display
Infornation
3.02-1
Table 3.02-1. Key Functions . . . . . . . . . . . . . . . 3 .02 - 3

Section 3.05 - Prgramming For Catalyst
Application
3.05-1
Table 3 .05-1 . Preprogrammed Setup Files
For Catalyst Control Operation . . . . . . . . . 3.05 - 5
Table 3.05-2. View Serial Link Screen And
Catalyst Control Worksheet
(GSI Aplications) - Varble
Set-Points .. .. . . . . . .. .. . . . .. . . . .. . . 3.05 -19
3.05-2 GSI -
Table 3.05-3. View Serial Link Screen And
Catalyst Control Worksheet {GSI
Applications) - Constant Set-Points . . . 3.05 - 23

FORM 6263 Second Edition X III

TABLES

xiv FORM 6263 Second Edition


Your purchase of a Custom Engine ContrI (CEC)
Air/Fuel Module (AFM) system was a wise investment.
In the industrial engine field the name, Waukesha
Engine, stands for quality and durability. With normal
care and maintenance this equipment will provide many
years of reliable service.
Before placing the Air/Fuel Module system in service
read Chapter 1 ve carefully. This chapter covers
Safety and General Information.
Section 1.01 - Safety Section - Provides a list of
warnings and cautions to make you aware of the
dangers present during operation and maintenance of
the engine. - READ HEM CAREFULLY AND
FOLLOW HEM COMPLETELY -
Section 1.02 - General Information - Provides trque
values of metric and standard capscrews, conversion
data, and wiring information.
Section 1 .05 Description of Operation - Provides
basic data on the Air/Fuel Mdu le system such as:
system description, theory of operation, and deni1ions .
FORM 6263 Second Edition
HOW T USE THIS MANUAL
ALWAYS BE ALERT FOR T E SPECIAL WARN-
INGS WITHIN THE MANUAL TEX. THESE WARN
INGS PRECEDE INFORMATION THAT IS CRUCIAL
TO YOUR SAFETY AS WELL AS OTHER PERSN
NEL WORKING N OR NEAR THE ENGINE. CA
TIONS R NOTES INHE MANUAL CONTAIN
INFORMATION THAT RELATES T POSSIBLE
DAMAGE TO THE ENGINE OR ITS COMPNENTS
DURING ENGINE OPERATION OR MAINTENANCE
PROCEDURES.
This manual contains installation. operation , and main-
tenance instructions for the Air/Fuel Module system.
There are four chapters within the manual and each
chapter contains one or more sectins. The title of each
chapter or section appears at the top of each page. 0
locate informatinon a specic topic, refer to the Table
of Contents at the front of the manual or the Index at the
back of the manual.
Recommendations and data cntained in the manual
are the latest information available at the me of this
printing and are subject to change without notice. Since
engine accessories may va due to customer
specications consult your local distributr r
Waukesha Engine Division Service Operations
Deparnent for any information on subjects beyond the
scope of this manual.
xv
HOW TO USE THIS MANUAL

xvi FORM 6263 Second Edition

 CHAPTER 1 - SAFETY AND GENERAL

CONTENTS

SECTION 1.01 - SAFETY

SECTION 1.02 - GENERAL

SECTION 1.05 - DESCRIPTION OF OPERATION

t)'

FORM 6263 Second Edition

FORM 6263 Second ion

SAFETY INTRODUCTION
The following safety precautions are published for your
information. Waukesha Engine Division, Dresser Indus-
tries, Inc., does not, by the publication of these
preutions, imply or in any way represent that they are
the sum of all dangers present near industrial engines or
fuel rating test units. If you are installing, operating or
servicing a Waukesha product. it is your responsibility to
ensure full compliance with all applicable safety codes
and requirements. All requirements of the Federal
Occupational Safety and Health Act must be met when
Waukesha products are operated in areas that are
under the jurisdiction of the United States of America.
Waukesha products operated in other countries must
be installed, operated, and serviced in compliance with
any and all applicable safety requirements of that
country.
Fr details n safety rules and regulations in the United
States, cntact your local ffice of the Occupational
Safety and Health Administration (OSHA) .
he words "danger,''warning , caution, and note
are
used throughut this manual to highlight important
information. Be certain that the meanings of these alerts
are known to all who work on or near the equipment.
E his symbol identifies information which is
NECESSARY TO THE PROPER OPERAION, MAIN-
TENANCE OR REPAIR OF HE EQUIPMENT.
I A CAUTION IThissY.mbolit in-
I formatin about hazards
or unsafe practices. Disregarding this information
could result in PRODUCT DAMAGE ANDR PEA-
SONAL INJURY.
A WARNING
This symbol identifies information about haza rds r
unsafe practices. Disregarding this information
could result in SEVERE PERSONAL INJURY OR
DEATH.
I A DANGER
This symbol identifies infrmation about immediate
hazards. Disregarding this infrmation will result in
SEVERE PERSONAL INJRY OR DEATH.
FORM62 Second Edition
SECTION 1.01 - SAFETY
SAFETY TAGS AND DECALS
A WARNING
To avid severe persnal injury or death, all
warning tags and decals must be visible and legible
to the operator while the equipment is operating.
EQUIPMENT REPAIR AND SERVICE
Proper maintenance, service, and repair are important
to the safe, reliable operation of the unit and related
equipment. Do not use any procedure not recom
mended in the Waukesha Engine manuals for this
equipment.
A WARNING
To prevent severe personal inju r death, always
stop the unit befre cleaning, servicing or repairing
the unit r any driven equipment.
Place all controls in the OFF psitin and disconnect or
lock out starters to prevent accidental restarting. If
possib lock all controls in the OFF position and take
the key. Put a sign on the cntrol panel warning that the
unit is being seviced .
Close all manual control valves, disconnect and lock out
all energy sources t the unit, including all fuel, electric,
hydraulic, and pneumatic connections.
Disconnect r lock out driven equipment to prevent the
possibility of the driven equipment rotating the disabled
engine.
A WARNING
avoid severe persnal injury or dea ensure
that all tools and other objects are remvedfromthe
unit and any driven equipment before restarting the
unit.
A WARNING
Allow the engine t cI to rm temperature
before cleaning, servicingr repairing the unit. t
components or fluids can cause severe personal
injury or death.
Some engine components and fluids are extremely hot
even after the engine has been shut down. Allow
sufficient time for all engine components and fluids to
cool to room temperature before attempting any service
procedure.
1.01 -1
SAFETY
ACIDS
A WARNING
cmply with the acid manufacturer s recmmenda
tins fr proper use and handling of acids. hnprop-
er handling or misuse culd result in severe
persnal injury or death.
BATTERIES
A WARNING
cnplywitt thebaery namfacture recmmen . A
datins fr prcedures cncerning prper bae
use and maintenance. Improper maintenance r
misuse could result in severe persnal injury or
death.
BODY PROTECTION
A WARNING
Always wear SHA apprved bdy, sight, hearing
and respiratory system protection. Never wear
loose clothing, jewelryr long hair around an
engine. The use f improper attire r failure t use
protective equipment may result in severe persnal
injury or death.
CHEMICALS
GENERAL
A WARNING
Always read and cmply with safety labels n all
containers. D not renve r deface the cntainer
labels. Improper handling r misuse culd result in
severe persnal injury or death.
CLEANING SOLVENTS
A WARNING
Comply with the slvent manufacturer s recm
mendations for proper use and handling of sol-
vents. Improper handling or misuse could result in
severe persnal injury r death. D not use gas
line, paint thinnersr ther highlyvlatile fluids fr
cleaning.
1.01-2
LIQUID NITRGEN/DRY ICE
l A WARNING
cmply with the liquid nitrogen/d ice manufactur-
er s recommendations for proper use and handling
of liquid nitrogen/dry ice. Improper handling or use
could result in severe persnal injury or death.
COMPONENTS
HEATED OR FRZEN
WARNING
Always wear protective equipment when installing
r remving heated r frozen cmpnents. Sme
cmpnents are heated r cled to extreme
temperatures fr proper installatin r remval.
Direct cntact with these parts culd cause severe
persnal injury or death.
INTERFERENCE FIT
A WARNING
Always wear protective equipment when insHing
r remving compnents with an interference fit.
lnstallatin r remval f interference compnents
may cause flying debris. Failure t use protective
equipment may result in severe persnal injury or
death.
COOLING SYSTEM
A WARNING
Always wear protective clothing when venting,
flushing or blowing dwn the cling system.
Operatinalclant temperatures can range from
180-250 F (82-121 C). cntactwith ht clant
or clant vapr can cause severe personal injury
r death.
A WARNING
D not service the cling system while the engine
is perating r when the clant is hot. Operatinal
clant temperatures can range from 180 250 F
(82 121 C). cntactwith htclant rvaprcan
cause severe persnal injur death.
FORM 6263 Second Edition
ELECTRICAL
GENERAL
A WARNING
D nt install, set up, maintainr perate any
electrical cmponents unless yu are a technically
qualified individual wh is familiar with the electri-
cal elements invlved. Electrical shock can cause
severe personal inju r death.
A WA RNING
Discnnect all electrical power supplies befre
makinganycnnectins r servicing any part of the
electrical system. Electrical shck can cause se-
vere persnal injur death.
IGNITIN
A WARNING
Avid cntact with ignition units and wiring. lgni-
tinsystem cmpnents can store electrical ener-
gy and if contacted can cause electrical shcks.
Electrical shck can cause severe persnal injury
r death.
A WARNING
Properly discharge any electrical compnent that
has the capability t store electrical energy before
connecting r servicing that cmpnent. Electrical
shck can cause severe personal injury or death.
EXHAUST
I A WARNING
D nt inhale engine exhaust gases. Exhaust gases
are highly txic and culd cause severe persnal
IOJU r death.
Ensure exhaust systems are leak free and that all
l exhaust gases are properly vented.
I A WARNING
D nuch r service any heated exhaust
cmpone nts. Allow sufficient time f exhaust
cmpents cl rm temperature before
tt_empting any service procedu Contact with hot
exnaust system cmpnents can cause severe
persnal injury or death.
SAFETY
FIRE PROTECTION
A WARNING
Refer t lcal and federal fire regulatins fr
guidelines for proper site fire prtection. Fires can
cause severe persnal injur death.
FUELS
GENERAL
A WARNING
Ensure that there are n leaks in the fuel supply.
Engine fuels are highly combustible and can ignite
or explode causing severe persnal injury or death.
GASEus
A WARNING
Dont inhale gaseus fuels. Some components f
fuel gas are drless, tasteless, and highly txic.
Inhalation of gaseus fuels can cause severe
personal injury r death.
A WARNING
Shut the fuel supply if a gaseus engine has
been cranked excessively withut starting. Crank
the engine t purge the cylinders and exhaust
system of accumulated unburned fuel. Failure t
purge accumulated unburned fuel in the engine and
exhaust system can result in an explosin resulting
in severe persnal injury r death.
LIQUID
I A WARNING
D nt ingest liquid fuels
or breathe in their vaprs.
Liquid fuels may be highly toxic and can result in
severe pesnal injury r death.
A WA RNING
Use protective equipment when wrking with liquid
fuels and related components. Liquid fuel can be
absorbed int the bdy resulting in severe pesnal
injury or death.
1.01-3
SAFETY
INTOXICANTS AND NARCOTICS
A WARNING
D nt allw anyone under the influence f intxi
cants and/or narcotics to work n or around
industrial engines. Wirkers under the influence f
intxicants andr narctics are a hazard bth to
themselves and other emplyees and can cause
severe personal injury or death to themselves or
others.
PRESSURIZED FLUIDS/GAS/AIR
A WARNING
Never use pressurized fluids/gas/air t clean clth
ing r bdypas.Neveruse bdypartst checkfr
leaks r flow rates. Pressured fluids/gas/air in-
jected int the bdy can cause severe personal
injur death.
Observe all applicable lcal and federal
relating to pressurized fluid/gas/air.
regulatins
PROTECTIVE GUARDS
A WARNING
Prvide guarding t prtect persons or structures
from rotating r heated pas.Cntact with rotating
or heated parts can result in severe persnal injury
r death.
It is the resnsibilitv of the ena ine wner to soecifv
and o rvide auardina.
SPRINGS
A WARNING
Use appropriate equipment and protective gear
when servicing r using products that cntains
springs. Springs, under tension, can eject if im-
proper equipment r procedures are used. Failure
t take adequate precautins can result in serius
persnal injury or death.
1.01 -4
SAFETY
TOOLS N ENGINE
IA CAUTINI ~~l~r~e~~~~~~
ELECTRICAL
A WARNING fore aempting to weld nor near an engine. Failure
t properly ground the welder could result in severe
Do not install, set up, maintain or perate any engine damage.
electrical tools unless you are a technically quali-
fied individual who is familiar with them. Electrical
IA CAUTION I ~~e~f~~~ ~~~~
tools use electricity and if used improperly culd
cause severe persnal injury or death.
n or near an engine to eliminate charging of an
HYDRAULIC ignitin system capacit r. Failure to discnnectthe
ignition harness could result in severe engine
danage.
A WARNING
D nt install, set up, maintain r perate any
hydraulic tIs unless you are a technically quali- WEIGHT
fied individual wh is familiar with them. Hydraulic
tools use extremely high hydraulic pressure and if
used improperly culd cause severe persnal A WARNING
injur death. Always cnsider the weight of the item being lifted
and use only properly rated lifting equipment and
approved lifting methods. Failure t take adequate
I A CAUTION ;1~fl~~~~~
J precautins can result in serious persnal inju r
when using hydraulictensining devices. Improper death.
use f hydraulic tensiningtoIs can cause severe
engine damage.
A WARNING
PNEUMATIC Never walk r stand under an engine r cmpnent
while it is suspended. Failure to adhere t this could
A WARNING result in severe persnal injury or death.
Dont install, set up, maintain or operate any
pneumatic tIs unless yu are a technically
qualified individual wh is familiar with them.
Pneumatic tIs use pressurized air and if used
improperly culd cause severe persnal injury or
death.
WELDING
GENERAL
A WARNING
cmply with the welder manufacturer s recmmen
datins for prcedures cncerning proper use f
the welder. Improper welder use can result in severe
persnal injury r death.
1.01-5
FORM 6263 Second Edition FORM 6263 Second Edition
SAFETY SECTION 1.02 - GENERAL

TORQUE VALUES
Table 1.02-1. Metric Standard Capscrew Trque Values (Untreated Black Finish)
cARSE THREAD CAPSCREWS (UNTREATED BLACK FINISH)

IS
PRO PERT'(
CLASS
@ @
SIZE TRQUE TRQUE TRQUE T RQUE

N 1 in-lb Nm in-lb Nm in-lb Nm in-lb

M3 0.6 5 1.37 12 1.92 17 2.3 20
M4 1.37 12 3.1 27 4.4 39 10.4 92
MS 2.7 24 10.5 93 15 133 18 159
M6 4.6 41 10.5 93 15 133 10.4 92
M7 7.6 67 17.5 155 25 221 29 257
MB 11 97 26 230 36 319 43 380
M10 22 195 51 451 72 637 87 770
Nm ft-lb N 1 ft-lb Nm ft-lb Nm ft-lb
M12 39 28 89 65 125 92 150 110
M14 62 45 141 103 198 146 240 177
M16 95 70 215 158 305 224 365 269
M18 130 95 295 217 420 309 500 368
M20 184 135 420 309 590 435 710 523
M22 250 184 570 420 800 590 960 708
M24 315 232 725 534 1020 752 1220 899
M27 470 346 1070 789 1519 1113 1810 1334
M30 635 468 1450 1069 2050 1511 2450 1806
M33 865 637 1970 1452 2770 2042 3330 2455
M36 1111 819 2530 1865 3560 2625 4280 3156
M39 1440 1062 3290 2426 4620 3407 5550 4093
FINE THREAD CAPSCREWS (UNTREATED BLACK FINISH)
IS
PRPEATY
CLASS
@ @ @
SIZE TORQUE TRQUE T RQUE

N ft-lb Nm lb Nm ft-lb
M8x1 27 19 38 28 45 33
M10x 1.25 52 38 73 53 88 64
M12x1 .25 95 70 135 99 160 118
M14x 1.5 150 110 210 154 250 184
M16x 1.5 225 165 315 232 380 280
M18x1.5 325 239 460 339 550 405
M20x 1.5 460 339 640 472 770 567
M22 x 1.5 610 449 860 634 1050 774
M24x2 780 575 1100 811 1300 958
NOTE: The conversion ctors used in these tables are as follows: One Nm equals 0. 7375 ft-lb and One ft-lb equals 1.355818 Nm.

1.01-6 FORM 6263 Second Edition

FORM 6263 Second Edition 1.02-1
GENERAL GENERAL

Table 1.02-2. Metric Standard Capscrew Torque Values (Electrically Zinc Plated) Table 1.02-3. U.S. Standard Capscrew Trque Values
COARSE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED)

SAE
IS
PR PEATY @ @ @
GRADE
NUMBER
CLASS Grade 1 or 2 Grade 5 Grades
T RQUE
SAE
SIZE TRQUE TORQUE TORQUE
GRADE
N m in-lb Nm in-lb N m in-lb Nm in-lb NUMBER TORQUE TRQUE TRQUE
in-lb (Nm) in-lb (Nm) in-lb (Nm)
M3 0.56 5 1.28 11 1.8 16 2.15 19
THREADS DRY OILED PLATED DRY ILED PLATED DRY ILED PLATED
M4 1.28 11 2.9 26 4.1 36 4.95 44
1/4-20 62 (7) 53 (6) 44 (5) 97 (11) 80 (9) 159 (18) 142 (16) 133 (15) 124 (14)
MS 2.5 22 5.75 51 8.1 72 9.7 86
1/. 28 71 (8) 62 (7) 53 (6) 124(14) 106 (12) 97 (11) 168 (19) 159 (18) 133 (15)
MS 4.3 38 9.9 88 14 124 16.5 146
5/16-18 133 (15) 124 (14) 106 (12) 203 (23) 177 (20) 168 (19) 292 (33) 265 (30) 230 (26)
M7 7.1 63 16.5 146 23 203 27 239
5/124 159 (18) 142 (16) 124 (14) 230 (26) 203 (23) 177 (20) 327 (37) 292 (33) 265 (30)
M8 10.5 93 24 212 34 301 40 354
3/8-16 212 (24) 195 (22) 168 (19) 372 (42) 336 (38) 301 (34) 531 (60) 478 (54) 416 (47)
M10 21 186 48 425 67 593 81 717
ft-lb (Nm) ft-lb (Nm) ft-lb (Nm)
N m ft-lb N m ft-lb Nm ft-lb Nm ft-lb
3/8-24 20 (27) 18 (24) 16 (22) 35 (47) 32 (43) 28 (38) 49 (66) 44 (60) 39
M12 36 26 83 61 117 86 140 103
7/16-14 28 (38) 25 (34) 22 (30) 49 (56) 44 (60) 39 (53) 70 (95) 63 (85) 56 (76)
M14 58 42 132 97 185 136 220 162
7/16-20 30 (41) 27 (3 24 55 (75) 50 (1 44 (60) 78 (106) 70 (95) 62 (84)
M16 88 64 200 147 285 210 340 250
1/2-13 39 (53) 35 (47) 31 (42) 75 (102) 68 (92) 60 (81) 105 (142) 95 (129) 84 (114)
M18 121 89 275 202 390 287 470 346
1/2-20 41 (56) 37 (50) 33 (45) 85 (115) 77 (104) 68 (92) 120 (163) 108 (146) 96 (130)
M20 171 126 390 287 550 405 660 486
9/16-12 51 (69) 46 (62) 41 (56) 110 (149) 99 (134) 88 (119) 155 (210) 140 (190) 124 (168)
M22 230 169 530 390 745 549 890 656
9/118 55 (75) 50 (68) 44 (60) 120 (163) 108 (146) 96 (130) 170 (230) 153 (20 136 (184)
M24 295 217 675 497 960 708 1140 840
5/8-11 83 (113) 75 (102) 66 (89) 150 (203) 135 (183) 120 (163) 210 (285) 189 (256) 168 (228)
M27 435 320 995 733 1400 1032 1680 1239
518 95 (129) 86(117) 76 (103) 170 (230) 153 (207) 136 (184) 240 (325) 216 (293) 192 (260)
M30 590 435 1350 995 1900 1401 2280 1681
3/4-10 105 (142) 95 (130) 114) 270 (366) 243 (329) 216 (293) 375 (508) 338 (458) 300 (407)
M33 800 590 1830 1349 2580 1902 3090 2278
3/4-16 115 (156) 104 (141) 92 (125) 295 (400) 266 (361) 236 (320) 420 (569) 378 (513) 336 (456)
M36 1030 759 2360 1740 3310 2441 3980 2935
7/8-9 160 (217) 144 (195) 128 (174) 395 (535) 356 (483) 316 (428) 605 (820) 545 (739) 484 (656)
M39 1340 988 3050 2249 4290 3163 5150 3798
7/8-14 175 (237) 158 (214) 140 (190) 435 (590) 392 (531) 348 (472) 675 (915) 608 (824) 540 (732)
FINE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED)
1e 235 (319) 212 (287) 188 (255) 590 (800) 531 (720) 472 (1 910 (1234) 819 (1110) 728 (987)
IS
PROPERTY
CLASS @ @ 1.0-14

NOTJ
250 (339) 225 (305) 200 (271) 660 (895) 594 (805)

Dry torque values are based on the use of clean, dry threads.
528 (716) 990 (1342) 891 (1208) 792 (1074)

SIZE TRQUE TRQUE TORQUE Oiled torque values have been reduced by 10% when engine oil is used as a lubricant.
Plated torque values have been reduced by 20% for new pted capscrews.
N m ft-lb Nm ft-lb Nm ft-lb Capscrews which are threaded into aluminum may require a torque reduction of 30% or more.
The conversion ctor from ft-lb to in-lb is ft-lb x 12 equalb.
M8x1 25 18 35 25 42 30 Oiled torque values should be reduced by 10% from dry when nickle-based antiseize compound is used as a lubricant.
Oiled torque values should be reduced by 16% from dry when copper-based antiseize compound used as a lubricant.
M10 x 1.25 49 36 68 50 82 60
M12x 1.25 88 64 125 92 150 110
M14x1 .5 140 103 195 143 235 173
M16 x 1.5 210 154 295 217 350 258
M18x1 .5 305 224 425 313 510 376
M20 x 1.5 425 313 600 442 720 531
M22 x 1.5 570 420 800 590 960 708
M24x2 720 531 1000 737 1200 885
NOTE: The conversion ctors used in these tables are as follows: One Nm equals 0.7375 ft-lb and One ft-lb equals 1.355818 Nm.

1.02-2 FORM 6263 Second Edition FORM 6263 Second Edition 1.02-3
 GENERAL
GENERAL

ENGLISH/METRIC CONVERSIONS Table 1.02-5. English To Metric Frmula cnversion Table

Table 1.02-4. Metric BIt Diameter T Hex Head Wrench
Size c nversin Table
METRIC METRIC
Inches to
CONVERSIN

Millimete E
Inches and :
multiplied b
FRM ULA

~'fi fraction in decimal equivalent

.4 equals millimeters.
EXAMPLE

2-5/8 in. = 2.625 x 25.4 = 66.7 mm

BLT THREAD STANDARD Cubic Inches to Litres Cubic inches multiplied by 0.01639 equals litres. 9388 cu. in.= 9388 x 0.01639 = 153.9 L
DIAMETER WRENCH SIZE.
Ounces to Grams Ounces multiplied by 28.35 equals grams. 21 oz. = 21x 28.35 = 595 g
M3 611
Pounds to Kilograms Pounds multiplied by 0.4536 equals kilograms. 22,550 lb.= 22,550 x 0.4536 = 10,229 kg
M4 7mm
Inch Pounds to Newton-meters ~i~o~s multiplied by 0.113 equals 360 in-lb= 360 x 0.113 = 40.7 Nm
M5 etes.
8m 1

M6 10mm ~~~~~~~~s multiplied by 1.3558 equals 145 ft-lb= 145 x 1.3558 = 197 Nm

:
Foot Pounds to Newton-meters eters.
M7 11 1m
Pounds per Square Inch to Bars ;
~~~1~s:a_ ~.square inch multiplied by 0.0690 9933 psi= 9933 x 0.0690 = 685 Bar

:
q
MB
M10
M12
13 m1
16 or 17 m1
18 o 19mm
Kilograms p
:
Pounds per !r~g~~ ~ch to
Centimeter ~~~l~skro~ square inch multig~~i!it~r?703
rams per square 45 psi = 45 x 0.0703 = 3.2 kg/cm2

Pounds per Square Inch to p~~~l~skro~ square inch multiplied by 6.8947

Kilopascals eq ascals. 45 psi = 45 x 6.8947 = 310 kPa
M14 21 or 22 m
M16 24mm Fluid ounces multiplied by 29.57 equals
Fluid Ounces to Cubic Centimeters cubic centimeters. 8 oz. = 8 x 29.57 = 237 cc
M18 27 1m
Gallons to Litres Gallons multiplied by 3. 7853 equals litres. 148 gal.= 148 x 3.7853 = 560 L
M20
M22
30mm
32 m Ce
!
De~f~~ cfeahrenheit to Degrees Degrees Fahrenheit minus 32 divided by 1.8
equals degrees Centigrade. 212 F - 32 + 1.8 = 100 c

M24 36 1m

M27 41 mm
M30 46m1 Table 1.02-6. Metric To English Formula cversion Table
M33 50m1 CONVER SIN FORMULA EXAMPLE
M36 55mm Millimeters to Inches Millimeters multiplied by 0.03937 equals inches. 67 mm = 67 x 0.03937 = 2.6 in.
M39 60m1 Litres to Cubic Inches Litres multiplied by 61.02 equals cubic inches. 153.8 L = 153.8 x 61.02 = 9385 cu. in.

M42 65mm
Grams to Ounces Grams multiplied by 0.03527 equals ounces. 595 g = 595 x 0.03527 = 21.0 oz.
Kilograms to Pounds Kilograms multiplied by 2.205 equals pounds. 10,228 kg = 10,228 x 2.205 = 22,553 lb.
Newton-meters multiplied by 8.85 equals
Newton-meters to Inch Pounds inch pounds. 40.7 Nm = 40.7 x 8.85 = 360 in-lb

Newto-meters multiplied by 0.7375 equals

Newtormeters to Foot Pounds foot pounds. 197 Nm = 197 x 0.7375 = 145 ft-lb

Bars to Pounds per Square Inch Bars mu~~~ed by 14.5 equals pounds per 685 Bar = 685 x 14.5 = 9933 psi
square in

Kili%~a~s per i~uare Centimeter
to ds per uae Inch (psi)
~~~jascals to Pounds per Square Inch
Cubic Centimeters to Fluid Ounces
Kil~JJJ~~~Ji;r square centimeter multiplied by 3.2 kg/cm2 = 3.2 x 14.22 = 46 psi
14 pounds per square inch.
Kilopascals multiplied by 0.145 equals pounds
per square inch. 310 kPa = 310 x 0.145 = 45.0 psi
Cubic centimeters multiplied by 0.0338 equals
uidounces. 236 cc= 236 x 0.0338 = 7.98 oz.

Litres to Gallons Litres multiplied by 0.264 equals gallons. 560 L = 560 x 0.264 = 148 gal.

~~;= ~~e?tentigrade to Degrees Degrees Centigrade r~~~tt~ ed by 1.8 plus 32

equals Degrees Fah
'.
100 C = 100 x 1.8 + 32 = 212 F

1.02-4
FORM 6263 Second Edition FORM 6263 Second Edition 1.02-5
GENERAL GENERAL

5. An electrical grade RTV should be applied arund POWER REQUIREMENTS FOR CUSTOM limitations. All pwer connections must be in accor-
WIRING
the wires entering all electrical devices such as Murphy dance with the applicable electrical codes.
All electrical equipment and wiring (with the exception of ENGINE CONTROL( PRODUCTS
Junction Boxes and gas valves, Syncro Start speed
the ignition system) shall comply with applicable local Table 1.02-7 prides you with the powe <requirements NTE: To power the CEC Ignition Module, a nominal
switches, microswitch boxes used in conjunction with
codes. This Waukesha standard defines additional safety equipment, solenoids, etc. An electrical grade for Waukeshas Custom Engine Control (CEC) prod- supply of 21.6 30 voe with le than a 2 volt
requirements for Waukesha engines. RTV is to be applied immediately after wire installation ucts. An oscilloscope must be used to verify ripple peak-to-peak ripple is recommended for compatibility
and prior to the engine entering the test room. with other CEC products.
A WARNING 6. A small drip loop should be formed in all wires
Table 1.02-7. Power Requirements for Waukesha Custm Engine Control Products
Dont install, set up, maintainr perate any PEAK-TO-
before entering the electrical devices. This will reduce NOMINAL TOLERANCE PERATING PEAK OPERATING CURRENT
electrical cmpnents unless yu are a technically the amunt of moisture entering electrical device via CECPRDUCT v LTAGE
(vIts DC)
RANGE RIPPLE (amps)
qualified individual wh is familiar with the electri- (volts DC) (volts DC) (vIts AC)
the wires if an electrical grade RTV does not seal
cal elements invlved. Electrical shck can cause completely. Ignition Module 24 +33%,-58% 10.0-32.0 less than 2 6
severe persnal injury or death.
7. The following procedures shuld be followed for Detonation se;;!~JmModule 24 +25%,-10% 21.6-30.0 less than 2 1.5
(DSM)
wires entering engine junctin bxes:
A WARN ING
A. Bom entrance best and side entrance second
Air/Fuel Module (AFM) System 24 +25%, -10% 21.6-30.0 less than 2 2.5
(all rich burn applitions)
Discnnect all electrical pwer
supplies betre 18.0
best. (lean burn :J'~fiaJ~~sen~gines)
VHP 6
making any connections r servicing any part of the cylinder a
electrical system. Electrical shck can cause se- B. Insert grommet in opening to protect wires. 32.0
vere personal injury or death. ~~H~m 1~1icaons on all AT
C. Wires to contain drip loop before entering box, 12 6 cylinder engines)
1. Whenever twr mre wires run together, they
should be fastened together at no more than four (4) to
six (6) inch intervals, closer where necessary, with
except where using bottom entrance.

D. When installing flexible conduit, use straight

:
Man ~~~~~~r~;;t~~n;dMS) 24 +25%,-10% 21.6-30.0 less than 2 1.5

connector fr side entrance. If tp entrance is

cable ties. Power wires (24 volts or greater) should
never be run together with any other instrument r
control wires. Spacing for these types of wires should be
four (4) inches minimum to eliminate electrical Noise
problems in the instrument or control wires.
2. All wires should be mounted o hot areas of the
engine with insulated clips, at intervals of no more than
twelve (12) inches, closer where necessa. Wires must
never be run closer than six (6) inches to exhaust
manifolds, turbochargers, or exhaust pipes.
3. In cases where wires do not run over the engine, they
should be fastened t rigid, non-moving bodies with
insulated clips when possible or cable-ties . Fasteners
should be spaced at no more than twelve (12) inch
intervals.
4. When wires run through holes, rubber grommets
should be installed in holes to protect the wires. Wires
should never be run over rough surfaces or sharp edges
withut protection (see Item 11 ).
IA CAUTION I e~~~ boxes on visible surface (vertical surface whenever
electrical RTVs can emit crrsive gases that can
damage electrical cnnectrs.
required, use elbow connector.
8. If wire harness has a covering, clamp harness so
openings of covering are downward.
9. The routing of wires should be determined for
reliability and appearance and not by shortest distance.
10. Installation connection wire must be coiled and
secured to provide protection during shipment.
11 . Each end of flexible metal conduit must have an
insulating sleeve to protect wires from chafing.
A WARN ING
Always label HIGH VOLTAGEn engine munted
equipment ver 24 v1Its. Failure to adhere to this
warning culd result in persnal injury or death.
12. All engine mounted electrical equipment ver
24vIts shall have HIGH VOLTAGE warning decal.
Decal to be attached to all the equipment and junction
possible).
13. Wiring that is routed in rigid or flexible conduit shall
have all wire splices made only in junction boxes, outlet
boxes or equipment bxes. Wire splices shall not be
located in the run of any conduit.

1.02-6 FORM 6263 Second Edition 1.02-7

FORM 6263 Second Edition
GENERAL
SECTION 1.05 - DESCRIPTION OF OPERATION

WAUKESHA CUSTOM ENGINE CONTROL
AIR/FUEL MODULE SYSTEM
SYSTEM DESCRIPTION
The Custom Engine Control((CEC) Air/Fuel Module
(AFM) system is designed to control the air/fuel ratio of
Waukesha s gaseous fueled, industrial engines (see
Figure 1.05-1). An engines air/fuel ratio defines the
amount of air in either weight or mass in relatin to a
single amount of fuel supplied to an engine for
combustion. Air/fuel ratio influences engine pwer,
emissins, and fuel economy. By controlling an engines
air/fUel ratio with the AFM system, you will benefit in fuel
savings, emissions cntrol, and/or peak engine perfor-
mance. The AFM system regulates and maintains the
engines air/fuel ratio even with changes in engine load,
speed 1el pressure, and fuel quality.
in rich bum and lean burn applications; however, the
The AFM system is programmed at the engine site and is
customized for the engine based on site specific
information with a persnal computer (PC). The mini-
mum recommended cmputer equipment for AFM
system programming is listed in Section 3.00 General
Programming Information.
TheAFM mdule is programmed with a PC to run in one
f four cntrol modes: catalyst, best power, best
economy, or lean burn. Catalyst and best power/econo-
my modes apply to stoichiometric or rich burn engines.
Lean burn mode nly applies to lean burn engines.
NOTE: This manual includes installation and program-
mg for rich burn toichiometric) applications and lean
burn applications.
COMPONENTS
NOTE: Many of the system components are the same
Ogen sensors used are different.

The basic AFM system cnsists f an oxygen sensing

Figure 1.05-1. CEC Air/Fuel
system, intake manifold pressure transducer (catalyst
and lean burn only), electronic control module (AFM
module), stepper mtr, and exhaust thermocuple.
The xygen sensr cntimally reports the concentra-
tion of oxygen in the exhaust to the AFM mdule . Based
on this signal, the AFM module then determines if a
crrection to the air/fuel rati is required. If a change is
needed, a command is sent to a stepper motor (installed
on the fuel regulatr) which influences the fuel flow to
the engine. The exhaust thermocouple ensures
exhaust temperatures are high enough to permit correct
system operatin.
A diagram of the AFM system s inputs and outputs is
shown in Figure 1.05-2. A blck diagram of the AFM
system is shown in Figure 1.05-3.
Mdule

INPUTS OUTPUTS
LEFT

AFMMODULE
EXHAUST XYGEN

EXHAUST TEMPERATURE
STEPPER HME PSITIN
LEFT

RIGHT
AIU
EXHAUST XYGEN
EXHAUST TEMPERATURE RIGHT
STEPPER HME PSITIN

INTAKE MANIFOLD
(CATALYST AND LEAN BURN CNTROL MDES)

Figure 1.052. AFM System Inputs And utputs

FORM 6263 Second Edon FRM 6263 Second Edition 1.05-1

1.02-8
DESCRIPTION OF OPERATION
DESCRIPTION OF OPERATION

OPERATOR INTERFACE THEORY OF OPERATION

LEFT BANK F ENGINE RIGHT BANK OF ENGINE
The AFM module is equipped with several features t The AFM system controls engine air/fuel ratio and
OXYGEN SENSR 1XYGENSENSR inform site personnel of system status. These features consists of three basic components: an oxygen sens
include: stepper mtor, and AFM module. The AFM system is a
clsed-loop process that looks at system outputs and
displayn the front
Power and Alarm lights (LED
adjusts system inputs according to preprogrammed
THERMOCUPLE THERMOCUPLE
panel of the AFM module (see Figure 1.05-4)
instructions.
AFM The green Power LED is lit any time power is The AFM system functions by mnitring oxygen levels
INTAKE MANIFOLD MDULE applied to the AFM mdule in the exhaust gases with an oxygen sensr located in
PRESSURE TRANSDUCER
(CATALYST MODE NLY) the engine s exhaust stream (see Figure 1.05-5). The
The yellw Alarm LED is lit any time the AFM oxygen level, detected by the sensr, is then fed to the
systems diagnostic functions are activated r AFM module through an electrical signal. If the oxygen
when AFM execution has been stopped by the level detected by the sensor is different than the

STEPPER STEPPER operator (such as during the saving of a data-set) programmed oxygen set-point, the AFM mdule directs
MOT1R MOTOR the stepper motor to adjust the gas over air pressure of
an alpha-numeric liquid crystal display (LCD display)
the fuel regulator.
visible from the front of the AFM mdule allows the
operator t monit imp rtant system parameters The stepper mtr adjusts the fuel regulator seing,
RICH BURN APPLICATIONS
within programmed limits, by increasing or decreasing
a sealed membrane keypad located on the front of the spring pressure acting on the regulator diaphragm.
the AFM module The design gives ve accurate psitioning capability.
This assembly essentially automates the manual
. ,
LEFT BANK F ENGINE RIGHT BANK OF ENGINE adjusters that are sold with many Waukesha Engines.
The regulator adjustment riches or leans out the airel
LEAN BURN SENSING ASSEMBLY rati
LEAN BURN SENSING ASSEMBLY
A thermocouple is used to assure that temperatures are
XYGENSENSR LN BURN I I f OXYGEN SENSOR LCD DISPLAY ' high enough for crrect operation of the sensor. A
pWER ;
L cNTROL j l I THERMCOUPLE programmed minimum temperature must be achieved
before closed-loop control is enabled. A programmed
maximum temperature is also incorporated as a safety
to shut dwn peration on high exhaust temperature
conditions.
AFM
MDULE The oxygen sensor provides continuus feedback of
MANIFOLD
IN:AKE
PRESSURE TRANSDUCER oxygen levels to the AFM module. The AFM module
makes the necessa stepper motor adjustments t
correctly contrl the engines air/fuel ratio.
Figure 1.05-4. Air/Fuel Mdule Front Panel
STEPPER
MOTOR STEPPER
MTOR

1
LEAN BURN APPLICATIONS
+

Figure 1.05-3. Air/Fuel Mdule System Blck Diagram

ENGINES SERVED
The AFM system is designed to function with
The AFM module is the same for all applications. The
number and type of sensor and stepper motor will
qJ

c>

Waukeshas gaseus fueled AT, VHP, and VGF engines depend n how many fuel regulatrs are on the engine.

including stoichiometric and lean burn, naturally aspi- Engines that utilize one main fuel regulator will use one
rated and turbocharged, in-line and vee models. Basic oxygen sensor and ne stepper moto Engines requir-
information about the engine model and application is ing two main fuel regulators will use tw oxygen sensors
XYGEN ELECTRICAL AFM REGULATR WITH
d two stepper motrs.
programmed to the AFM module using a PC. SENSOR SIGNAL MODULE STEPPER MTR

Figure 1.05-5. AFM Systems Closed-Lp Process

1.05-2 FORM62 Second Edition

FORM 6263 Second Edion 1.05-3
DESCRIPTION OF OPERATION DESCRIPTION OF OPERATION

AFMSYSTEM XYGEN SENSRS Operation of the sensor is based on the fact that the The particular sensitivity of the stoichiometric sensor in As with rich burn engines, the exhaust oxygen content
ceramic material is oxygen-ion conductive above tem- the range around stoichiometry permits the sensor f lean burn engines can be used as an indicator of the
Depending on your engine, the AFM system will either
peratures of apprnately567 F(300 C). If the oxygen output signal to be fed as an actual value to the AFM air/fuel mixture supplied to the engine for combustion.
utilize the stoichimetric sensr or the lean burn sens
prpns at the two ends of the probe differ, a voltage module. Any mixture deviation from the preset value is The signal frm the lean burn oxygen sensr is fed into
The stoichimetric sensr is used for stichiometric or
is generated between the tw interfaces due to the sensed by the stoichimetric sensr from the residual ttre AFM module. Any mixture deviation is sensed and
rich burn engines. The lean burn sensor is used for lean
special properties of the material used. This voltage is an oxygen cntent of the exhaust g and ansmitted to transmitted to the AFM module in the form of an
burn engines only. electrical signal. The AFM module determines whether
indication of the difference in the proprtionsof xygenat the AFM module in the form of electrical signal. The
Stichiometric Oxygen Sensr thetw ends d e probe. Characteristics of the sensor AFM module determines whether a correction to the a crrection is required and adjusts the stepper positin
include: an utput range of 0.1 - 0.9 volts when above air/ftel ratio is requir and adjusts the spper position
accordingly. Typically, service life of the lean burn
Stoichiometric r rich burn engines are served by the sensr is minimally 4000 hurs. Oil additives, fuel
662 F (350 C), ave large change in utput near accrdingly.
AFM systems catalyst, best power best economy contaminants, silicnes released from certain RTV
mode. Stoichiometric sensr applicatins for catalyst stoichiometry, and a very small change in put away
Service life of the stichiometric sensor is typically 3000 sealants, incorrectly applied anti-seize, and ver-tem
and best pwer/econmy modes are based on the from stoichiometry (see Figure 1.05-7).
hurs. Since the sensr has n wearing parts, theoreti- perature can attribute to shrtened sensor life.
output characteristics of the stoichiometric sensor. NOTE: If the sensor temperature is not above 662 F cal life is indefinite. Howeverii additives el cntami
Figure 1.05-6 illustrates the sectional view of a sensr.
IA CAUTIN I:~::!:sa~=~Re~
(350 the sensor will not provide edback b e nants, silicones released from certain RTV gasket
The sensr is constructed such that one part f the AFMmodu/e. materials, incrrectly applied thread anti-seize, and
ceramic body is lcated in the path of the exhaust, the ver-temperature can result in shortened sensor life. materials n engines with xygen sensors. Cm
ther part being in cntact with the ambient air. The
punds cntaining silicn are pisnus t
surface of the sensors ceramic bdy (zircnium
dioxide) is coated with an electrode (catalyst material)
cmposed of a thin, gas-permeable platinum layer. In 1
IA CAUTION l:~::!rss:,:.~R~::::;
materials n engines with xygen sensrs. Cm
xygen sensrs. Disregarding this inf rmatin
culd result in reduced sensr life.

addition, a porous ceramic outer layer is provided atthe punds cntaining silicn are pisnus t NOTE: Refer to Section 2.00 Mounting AFM System
0.9
| ! |
end expsed to the exhaust gases to guard against xygen sensrs. Disregarding this infrm at ion Components for sensor installation information.
I ! I l I I I N I
........
cntaminatin caused by cmbustion residues. culd result in reduced sensr life.
~ 0.8

!Ii i
AFM SYSTEM cNTRL MDES
NOTE: Rer to Section 2.00 Mounting AFM System The AFM system is programmed to operate in one f
- --,

MW
e o

hvaa
AVa

aVA
v

Components for sensor installation information.

AU

.. four cntrol mdes. Stichiometric r rich burn engines

V
o

.....
AV
ee0

Bee
are served by the AFM systems catalyst, best powerr

Lean Burn xygen Sensr

..

LF

.. best econmymde. Lean burn engines are served by

AV

All lean burn sensr applications are based n the linear the AFM s lean burn mode. The following sectins

1 1 1 11 utput characteristics of the lean burn sensr (see explain the AFM system control mdes.
Figure 1.05-8).
Catalyst cntrI Mode

iu :I Iii 11 The prima task of the AFM system is to accurately

q

contrl the air/fuel ratio of an engine. Control should be

4n
UH maintained through load variations above 60 BMEP.

h
GM
STOICHIOMETRIC
Three-way catalysts are used t oxidize CO and HC,

w
0.1 A/F-16.09

Figure 1.05-6. Sectional View f The Stichiometric and to reduce NOx n stoichiometric applications.

WZUMW

Sensr
0.0 These processes require high temperature and precise
16.5 air/fuel rati cntrol. Best performance for emissions

In the exhaust gas of internal cmbustion engines, there

q
reductin is achieved when operating near the stoichi

Sr
are still residual propions f xygen present, even SPINDT AIR/FUEL RATI
metric air/fuel rati
when cmbustin takes place with excess fuel. The NOTE cuNe was plotted for boratory data. Actual SET-POINT
residual xygen content is largely dependent on the sensor response will depend slightly upon fuel composition and RICH "' LEAN The stoichiometric air/fuel rati is the theoretical
compsitin of the air/fuel mixture supplied to the engine conditions. Air/fuel ratio values are also fuel dependent. 4 balance where exactly the required amunt of air (02) is
EXHAUST OXYGEN (DRY VOLUME PERCENT) present to cmpletely burn all of the fuel with no excess
engine for combustin. The residual oxygen permits
Figure 1.05-7. Typical Stoichiometric Sensor air. In an ideal case, the nly products of this combustion
use of oxygen content of the exhaust gas t measure utput Curve - Rich Burn NLY TYPICAL SET-POINTS:
the air.el ratio. wuld be water (H20) and carbn dioxide (C02).
Ar at 32:1 (11.S
However, because engine combustion is nt peect,
Ar&VHP at 28:1 (9.8% 2)
typical emission by-products include 02, HC, NO, and
VGF at24 .8% 02)
CO. The catalyst then converts most of these to water,
Figure 1.05-8. xygen Sensr Respnse Vs. Exhaust carbon dioxide, and nitrogen.
Oxygen cncentrations For Various Air/Fuel Ratis
Lean Burn NLY

1.05-4 FORM 6263 Second Edition FORM 6263 Se'eond Edition 1.05-5
DESCRIPTION OF OPERATION
AIR/FUEL RATIO CAN BE
VARIED WITH LOAD
SEVEN PINTS FOR EACH (AIRFUEL RATIO,
Figure 1.05-9. Air/fuel Ratio And Stepper LimS Vs.Load
A stoichiometric sensor in the exhaust seam provides
feedback to the AFM mdule. The signal provides a
means of controlling air/fuel ratio slightly rich of
stoichiometry. This is the range required to obtain best
catalyst efficiencies for methane-based fuels.
Figure 1.05-7 illustrates a typical sensr put curve
versus air/fuel rati
A stepper motr is installed nt each regulator. Within
the stepper resides a motor which adjusts the regulator
seing by increasing or decreasing the spring pressure
acting n the regulator diaphragm. Stepper motor
movement is confined between two programmable
(
electronic limits rich _and le limitsI times.
These limits may vary with engine load. Movement
between the programmable limits is governed by the
stichimetric sensr and the programmed air/fuel ratio
curve (see Figure 1.05-9).
TheAFM mdule adjusts the stepper motor to maintain
a specific input vltage frm the stoichiometric sensor.
When the sensr voltage is above the xygen target
voltage, the system is richer than desired, and the
stepper positin is decreased t reduce gas verairand
el flow to the carburetor. This will be indicated n both
the personal cmputer and the AFM module LCD
display as a lower Stepper count. Cnversely, when
the sensr voltage is belw the oxygen target voltage,
the system is leaner than desired, and the stepper
poson is increased to provide more fuel.
6 FORM 6263 Second Edition
zE
gunh
a
F
STEPPER TRAVEL IS TRAPPED BETWEEN
TW PRGRAMMABLE LIMITS
RICH LIMIT - MAX. FUEL PERMITTED
LEAN LIMIT - MIN. FUEL PERMITTED
RICHEAN LIMITS) CAN BE PRGRAMM ED
Because sensor vltage utput is nt linear with air/fuel
rati itwuld not be practical to adjust the system faster
when the signal is further frm the set-point. Therefore,
in order tpmize the control respnse, the stepper
motr adjustments becme larger as the error persists
longer. This methd provides rapid reaction character-
istics as well as gd stability.
Control target voltages must be determined with the use
of exhaust analyzer to locate the perating pint of
lowest stack emissins. These values are programmed
to the AFM mdule with a persnal cmputer. The
resuing system provides accurate and stable cntrf
air/fuel ratio across a broad power range. This, in turn,
results in high catalyst efficiencies and reduced stack
emissions.
Best pwer/BestEcnmy cntrol Mdes
As with catalyst applications, the prima task of the
AFM system in the Best Power/Eenmy cntrol mode
f peration is t precisely cntrol the engine s air/fuel
ratio. A stichiometric sensor provides feedback about
the exhaust constituents, a thermocuple assures that
the stichiometric sensor is at operating temperature,
and a stepper motor adjusts the fuel flow to the engine.
However, unlike the catalyst mde of control, one
air/fuel rati set-pint is not maintained continually.
Rather, the AFM mdule will periodically seek out
stichiometry then move, either rich or lean, a prepro-
grammed number d steps. The programmed mve
nent, rich or lean, results in operation in the best
powerr bestecnmy" range. The AFM mdulethen
waits until a delay time expires, and searches for
stichiometry again. This methd of peration permits
control of stoichiometric engines at best power or best
econmy with standard stoichimetric sensrs.
Lean Burn cntrol Mde
As with stoichiometric applications, the prima task of
the AFM system in the lean burn mode of operation is to
cntrol the engines air/fuel ratio. The lean burn sensor is
installed in an assembly consisting of a sensor, heater
(two for AT engines), and thermocouple. The lean burn
sensing assembly prvides feedback about the exhaust
oxygen content, the thermocouple assures its operating
at the correct temperure, and a stepper motor adjusts
the fuel w to the engine. As with the catalyst mode of
control ne set-point is maintained continuously. There
is nstep- operation. Also similar to the catalyst
control mode, the set-point can be mapped to change
with engine load. Control will be maintained as long as
the combustion process is stable. This is typically true
when the engine is loaded t 60 BMEP or more.
DEFINITIONS
Air/Fuel Rati Air/Fuel RatiAFR) is a term used t
define the amount of air (in either weight or mass) in
relatin to a single amunt of fuel. Typical values are:
RICH BURN
Best Power Setting 15.50: 1 AFR
Catalyst SettingypiI) 15.95: 1 AFR
Stoichiometric Setting 16.09 : 1 AFR
Best Economy 17.00: 1 AFR
LEAN BURN
AT (11 .5% 02) 32.00 : 1 AFR
AT & VHP (9.8% 02) 28.00: 1 AFR
VGF (7.8% 02) 24.50 : 1 AFR
Best Eenmy: The air/fuel ratio of rich burn engines
which will give the lowest fuel consumption while
maintaining normal engine stability, load response, and
continuous power capability. The air/fuel ratio is lean of
stichiometry.
Best pwer: The air/fuel ratio of rich burn engines
which will give the highest maximum power level at wide
open throttle. This air/fuel ratio is rich of stoichiomet
Catalyst Setting: The air/fuel ratio of rich burn engines
which will give the best performance with emissions
reductions. This air/fuel ratio is slightly rich of stoichio-
met
Closed-Lp cntrol: Closed-lop control is a lowest gas over air that is programmed at which the
method of controlling a process. It looks at the process
output and adjusts the process inputs according to
some preprogrammed instructions. In the AFM system,
the oxygen sensor provides feedback about the
combustion process and closes the loop. This is an Stepper motor operation is only permied between the
accurate form of process control.
FORM 6263 Second Edition
DESCRIPTION OF OPERATION
cmbustin Stability Limit: As engine Iad is
reduced from manufacturer s rated load, combustion
pressure within the engine diminishes. Below some
power utput, combustion is no longer stable, and
exhaust oxygen is nt agod indicator of air/fuel ratio.
This is the combustion stability limit. The stepper travel
limits (rich and lean limits) are employed at loads below
this point to prevent driving the engine into either rich or
lean misfire.
Data-Set: This is the group of site specific data points
which are created and stored within the AFM control as
pa of the setup process. (PC programmable)
Dead-Band: This is the oxygen sensor target (set-
point)tolerance or control window within which the
stepper positin remains constant. This parameter is
only used on catalyst applications of the AFM system.
(PC programmable)
Delay Time: This is the amunt of time the AFM module
waits before searching for stoichiometry when operating
in the best power/economy control mode. The unit of
measure for the displayed delay time is minutes.
Acceptable values range om 0 .1 - 25 mines.
(PC programmable)
EPROM: Erasable Programmable Read nlyMem
This is the same as ROM (permanent memry) when
speaking about programming the AFM module. The
term EPROM is used to describe an electrical chip that
resides in the AFM module. The contents of ROM
mem are not lost when power is remved.
Gain: Gain is a term that implies an "increase in
something. In the AFM system gain is a multiplier. It
influences how large a change is made to the stepper
position when the oxygen sensor signal is not within
the specified tolerance of the sensor target (set-point).
A larger gain will result in a larger change.
(PC programmable)
LCD: Liquid Crystal Display. Alpha-numerical display
visible from the front of the AFM module, that informs
the system operator of current AFM system status.
Lean AFR: When an engine has less el than required
to achieve the desired set-point.
Lean Limit: The most retracted stepper position or
engine can be safely operated. A more retracted
stepper position allows less fuel to pass to the engine.
Thus, the minimum fuel position is called the lean
limit. It is used to prevent under-fuelling of the engine.
rich and lean limits. (PC programmable}
1.05-7
DESCRIPTION OF OPERATION DESCRIPTION OF OPERATION

LED: Light Emiing Diode. A semiconductor that emits
light (not a light bulb) and is used as power and alarm
indicators, located on the front f the AFM module.
Map: A table of values which are referred to when
determining a setting. In the case of the AFM module, a
map of intake manifold pressure versus oxygen sensr
utput is used in catalyst and lean burn control mdes.
The intake manifold pressure points are prepro-
grammed based on engine model selected. The AFM
User Interface Program interpolates between each
set-pint for determining intermediate cntrl values.
ffset Steps: The number of steps the stepper mtor
will mve away from stoichiometry, either rich or lean,
when the AFM is being operated in the Best Power/
Economy cntrol mode. If the Oset Steps" value is
positive, the air/fuel ratio will be adjusted rich of
stoichiometry. If the Offset Steps value is negative,
the air/fuel ratio will be adjusted lean of stichiometry.
(PC programmable)
PC: Persnal cmputer. Refers to the IBM compatible
personal computer used for mnitoring and program-
ming the AFM system.
RM: Read Only Memory. ROM is cmputer memory in
which completed AFM system data-sets are perma-
nently stored on an electronic chip (EPROM chip) .
When the AFM module cnfigures data-sets to ROM,
the data-set informatin is nt lost when pwer to the
AFM module is removed. The AFM mdule allows a
limited number of saves to ROM (5 saves to ROM are
pssible) before core EPROM chip replacement is
required.
Search Delay: This is the amount of time, in minutes,
that the AFM module waits between searches for
stoichiometry when programmed in the Best Power/
Economy cntrol mode. (PC programmable)
Sinking Circuit: An electronic switching circuit with a
single output terminal used to provide a path to ground.
This mechanism can be used as a trigger to drive
remote devices such as alarms, lights, and relays.
When the AFM system is operating correctly it is a
CLOSED device. Any system fault will OPEN the circuit.
The circuit is designed to handle a maximum current
rating of 1 amp and a maximum voltage rating of 50 VDC
(no AC voltages are allowed).
Stichimetric AFR: The stoichiometric air/fuel ratio is
the theoretically correct air/fuel ratio for complete
combustion. That is, there is just enough air to burn all of
the fuel with no air or fuel left over. The stoichiometric
air/fuel ratio is determined by the chemical cmposition
of the fuel. Thus it will differ for each fuel mixture, or BTU
rating.
Example:
Stoichiometry for pure Methane (CH4) is 17.1
parts of air for every one part of fuel => 17.1 :1
n a weight, or mass, basis).
Stoichiometry for pure Propane (C3H8) is 15.6:1.
Waukesha Engine defines local pipeline natural
gas stoichiometry as 16.09:1.
User Interface Program: The personal computer
program that is used to create data-sets and communi-
cate with the AFM system.

psiA: punds per square inch Absolute. PsiA equals

gauge pressure plus the site barometer.
PWM: Pulse Width Modulatin. It is a technique
employed to regulate the flow f things. In the AFM
system it is used to regulate the voltage to the heater(s).
(PC programmable)
RAM: Random Access Memory. Temprary AFM
system memo used to evaluate te data-sets
before storing to ROM. The cntents of RAM are lost
whenever power to the AFM module is remved.
Rich AFR: When an engine has more fuel than required
to achieve the desired set-point.
Rich Limithe most advanced" stepper position or
highest gas over air that is programmed at which the
engine can be safely operated. Since a more ex-
tended stepper position results in more fuel being
delivered to the engine, this is the maximum fuel'
position or rich limit." The rich limit is programmable
with the personal computer and is used to prevent rich
misfire and detonation in the engine. Stepper motor
operatin is only permied between the rich and lean
limits. (PC programmable)
A WARNING
D nt set the stepper mtr(s) t the sta psitin
while the engine is running abve 40 percent of
rated load. Start psition is nly t be initiated when
the engine is stpped or running belw40 percent
f rated load. Resetting the stepper mtr(s) while
the engine is running above 40 percent of rated load
may cause engine shutdwn andr cause severe
engine damage.
Start Positin: This is a programmable stepper
positin used to set gas/air at a value that is favrable
for starting. Requires remote or manual initiation prior to
staing. (PC programmable)
Step: In the AFM system ne step of the stepper
motor equals 1/400 f 1 revolution of the stepper motor.
This small change in posion results in 0.00025 inches
of linear travel of the adjusting nut within the stepper
motor. This increases or decreases the fuel regulator
spring pressure and correspondingly changes the gas
over air pressure to the carburetor.
Stepper Mtr: This specially designed electric mtor
produces a precise steirwise' rotation f the motr
shaft instead f the "traditional cntimus rotatin f
most electric mtors. The terms stepper motor, stepper,
and actuator have the same meaning.

1.05-8 FORM 6263 Second Edition FORM 6263 Second Edition 1.05-9
DESCRIPTION OF OPERATION CHAPTER 2 - AIR/FUEL MODULE SYSTEM INSTALLATION

CONTENTS

SECTION 2.00 - MOUNTING AFM SYSTEM COMPONENTS

SECTION 2.05 - AFM SYSTEM ELECTRICAL CONNECTIONS

SECTION 2.10 - PRESTART INSTALLATION CHECKLIST

1.05-10 FORM 6263 Second Edition FORM 6263 Second Edition

 SECTION 2.00 - MOUNTING AFM SYSTEM COMPONENTS

SYSTEM COMPONENTS ESTABLISHING GAS/AIR PRESSURE

This chapter, Chapter 2 Air/Fuel Module System
Installation, explajns hw to mount the components of
the AFM system (Section 2.00), make electrical cn
nections (Sectin 2.0 and complete a preliminary
check of the AFM system before applying power
(Section 2.10).
The AFM system consists of an oxygen sensor, intake
manifold pressure transducer, electronic control mod-
ule (AFM module), stepper mot and exhaust thermo-
couple. Table 2.00-1 l_ists the components included in
the rich burn (catalyst and best power/economy) and
lean burn AFM systems.
Table 2.00-1. AFM System cmpnents
RICH
DESCRIPTION BURN
CEC Air/Fuel Module
Harness, AFM to J-Box
(4) Vibration Isolators
Stepr~~~ ?tor (S201, S211, 66, 662) or b DESCRIPTIN
(99,
Stepper Harness, Stepper to box1 F
Stepper Harness, J-box to AFM1
SETTING
Original gas/air pressure seing, prior to installation of
the AFM stepper motor(s), must be known when
programming the AFM system. The riginal gas/air
pressue seing is needed to set the gas/air pressure
after the AFM stepper motor(s) is installed to the fuel
regulator.
1. Install manometer(s) to engine.
2. Without the AFM stepper mtor(s) installed, adjust
gas/air pressure until the engine starts as desired.
3. Detach or cpy the AFM programming wrksheet
from the back of this manual that applies to your engine
LEAN application (see Table 2.00-2).
BURN
NOTE: Do not discard the worksheet. The worksheet is
necessary to complete AFM programming.
Table 2.00-2. AFM Programming Worksheets
COLR
Catalyst Control Woksheet (G Engines)
Catalyst Control Worksheet (GSI.Engines)
Blue
Blue

Best Power/Economy Control Worksheet Yellow

Stepper HanessHome Switch1
Lean Burn Control Worksheet (VHP & VGF Engines) Geen
Intake Manifold Pressure Transducer2 b

Lean Burn Control Worksheet (AT Engines) Green

Mke Manifold Pressure Transducer Haness2 v
Exhaust Thermocouple (K-type)1 / 4. Measure and record the desired gas/air pressure on
Exhaust Thermocouple Wire (K-type) 1 b the space provided on the worksheet for your engine
Stoichiometric Sensor1 applicatin.

Stoichiometric Senso Harness1

NOTE: Origal gas/air pressure setting is critical to
Lean Burn Sensing Assembly1. 3 getting the enge started after the AFM stepper
Lean Burn Sensor Harness1 motor(s) is inslied the el regular and during AFM
Exhaust Supply Tubing (AT Only) // programming.
NOTE: 1 Two components are rUd for g with two fuel
rulato
5. Shut down engine.
2 Not used in Best Power/Economy Control Modes.
3 Lean burn sensing assembly_ includes lean burn senso
gasket, heater (two for AT engine thermocouple, sensor
block, special pe npie, and sulation.

The AFM system components listed in Table 2.00-1 are

not all of the components required for AFM system
installation. The customer must supply junction bxes,
terminal blocks, brackets, conduit assemblies, and/or
ther components depending n engine configuration,
site requirements, and code requirements.

FORM 6263 Second Edition FORM 6263 Second Edition 2.00-1

MOUNTING AFM SYSTEM COMPONENTS MOUNTING AFM SYSTEM COMPONENTS

MOUNTING STOICHIOMETRIC OXYGEN ~EXHAUST UT LET

mj
SENSOR - RICH BURN iXYGEN

CMH R

E
SENSOR PRT.
The stoichiometric oxygen sensor is used in catalyst

---1...;
and best power/econmy applications. The oxygen
@ sensor reports the concentration of xygen in the

@
exhaust to the AFM module. The location of the oxygen
sensor is critical for proper sensor peration. The
NUT stoichiometric oxygen sensor must be installed in the
exhaust system where temperatures are greater than

662 F (350 C) during nrmal operation to ensure
correct operation. The f!lowing describes the mounting
AIR/FUEL MODULE
location of the stoichiometric oxygen sensor n VGF
and VHP engines: Figure 2.00-4. Oxygen Sensr Port Location On
C
VGF GSID Engines




VGF Engines: On VGF engines the stoichiometric
xygen sensor is mounted in the oxygen sensor p VHP Engines: On VHP G engines the stichiometric
that is predrilled in the exhaust outlet (see oxygen sensor is mounted in the oxygen sensr prt

Figure 2.00-3 and Figure 2.00-4). If your engine has that is predrilled in the exhaust elbow (see
a predrilled po cntinue with Step 3. If your engine Figure 2.00-5). On VHP GSI engines the stoichio-
does not have a predrilled port, continue with Step 1. metric oxygen sensor is mounted in the oxygen
sensor port that is predrilled in the exhaust elbow on

L
nlG

RH
6 cylinder VHP engines; and the exhaust utlet tee
@ @
~ on 12 and 16 cylinder VHP engines (see
Figure 2.00-6 and Figure 2.00-7). If your engine has
/ a predrilled port, continue with Step 3. If your engine

M UN N A

MH
E
D
does not have a predrilled port, continue with Step 1.

Figure 2.00-1. Munting The AFM Mdule NOTE: For lean burn sensors, complete the mounting
instructions
MOUNTING THE AFM MODULE NOTE: If the conduit ports provided are not sufficient to Assembly" on page 5.
meet your application needs, conct your local Wauke-
Mount the AFM module upright in an o engine location
sha Engine distributor or Waukesha Engine Product
using the vibration isolatrs supplied with the AFM
Support.
module (see Figure 2.00-1). Note the following con-
cerning AFM module mounting:
SUPPLY pWER WIRING (24 VDC) Figure 2.00-3. Oxygen Sensr prt Lcatinon
The maximum wire run from the AFM module to the pSITIVESIDE NLY
VGF G Engines
engine must be within 60 feet (18 meters).

NOTE: If additional wire length is required, cond

Waukesha Eng.e Application Eeering Department.

Ambient temperature may vary from -40 F(-400 to

150 F (65 C).

IA CAUTIN I ~~r:h;a~F:
module. Pressure washing or steam cleaning can
Figure 2.00-5. xygen Sensr p Lcation n
damage the AFM mdule electronics.
XYGENSENSR, THERMcUPLEME VHP G Engines
SWITCHES, INTAKE MANIFLD PRESSURE
Althugh the AFM mdule is splash-proof, expo- TRANSDUCER, AND EARTH GROUND
sure to direct sprays of water should be avoided.
ALARM OUTPU ALTERNATE FUEL INPUT,
AND REMTE START PSITIN INPUT
Do not cut any new holes in the AFM module. Wire
routing is important. The wires must be directed
Figure 2.00-2. AFM Module cnduit pS
through the holes provided in the bttom of the AFM
module as shwn in Figure 2.00-2.

2.00-2 FORM 6263 Second Edition FOAM 6263 Second Edition

2.00-3
MOUNTING AFM SYSTEM COMPONENTS MOUNTING AFM SYSTEM COMPONENTS

The location chosen shuld not result in sensor shell On engines with two el rUrs sensors are
temperatures in excess of 350 F (177 C). Shell (or required.
skin ) temperatures greer than 350 F (177 C)
?/ can.greatly reduce sensr life. If skin temperatures
are higher than this, a funnel-shaped radiant heat
Each sensor must be mounted such that is
expsed t the exhaust w from the appropriate
shield may be used (see Figure 2.00-8) . bank.
The sensors should be plad in an area before
ST1ICHI METRIC the exhaust streams merge.
SENSR............h
Do not locate the sensors where exhaust flow is
uneven due to obstructins or sharp bends.
/ 2. Drill (212 or 16.5 mm) and tap (M 18 x 1.5) sensor
mounting hole in location meeting the requirements
listed in Step 1 .
Figure 2.00-6. xygen Sensr Port Locatinon
6 Cylinder VHP GSI Engines 3. Thoroughly clean hole and area around sensor
mounting hole.
EXHAUST GAS - NOTE: Remove predril/ed mounting hole plug
EXHAUST UTLETTEE
// installed and then clean hole.
Figure 2.00-8. Radiant Heat Shield Fr Stichimetric
Sensr
IA CAUTION I ~~~$~~
ceramic cmp nent inside the sensor is vulnerable
t thermal and mechanical shck. Improper han-
dling culd damage the xygen sensr making the
the sensr unusable.

Figure 2.00-7. gen Sensor Port Location On IA CAUTION I:~::Jts~!~R~ ;!::e~

materials n engines with xygen sensrs. Cm
12 And 16 Cylinder VHP GSI Engines
pounds containing silicn are p is nous t
1. Determine stoichimetric oxygen sensr mounting xygen sens rs. Disregarding this infrmation
lcation.
Note the following cncerning oxygen sensor culd result in reduced sensr life.
mounting:
The sensor lcation should be easily accessible.
Sensrs are maintenance items and replacement will IA CAUTION I ~~a~~ t~~es~::
be required. Typically, service life of the stoichiomet- gen sensr with an anti-seize c mpund. Contact
ric xygen sensor is 3000 hours. with cmpund n the sensing element can result
The oxygen sensr must be installed in the exhaust in incrrect sensr operatin.
system where temperatures are greater than 662 F
NOTE: New sensors are packaged with an anti-seize
(350 C) during normal peration to ensure crrect
compound already applied e sensor threads. There
sensor operatin .
is no need to apply additional anti-seize unless
The tip of the sensr shuld be exposed t the reS/ling a used sensor. If required, use high mper
exhaust gas flow from all cylinders to be controlled by ature anti-seize ve,y sparingly and apply only to e
that sensor. sensor threads.
On turbocharged engines the sensors must be I.ted 4. Thread the xygen sensor into the mounting hole.
n the same side of the turbochargers as the Torque the oxygen sensor to 33 - 37 lb (45 50 Nm).
thermocouples.
NOTE: A special WED socket is available to torque the
stoichiometric oxygen senso Contact the WED
Product Training Center for order,g information.

2.00-4 FORM62 Second Edition FORM62 Second Edition 2.00-5

MOUNTING AFM SYSTEM COMPONENTS
MOUNTING LEAN BURN OXYGEN LEAN BURN OXYGEN SENSING ASSEMBLY
SENSING ASSEMBLY INSTALLATION ON VHP ENGINES
The lean burn oxygen sensr sends a signal based on On VHP engines the lean burn xygen sensing
assembly is mounted in the oxygen sensor port that is
exhaust oxygen content to the AFM module. The lean
predrilled in the turbo exhaust outlet tee (see
burn sensor is installed to the engine in an assembly
Figure 2.00-11). If yur engine has a predrilled port,
consisting of a sensor, gasket, heater (two for AT
cntinue with Step 3. If your engine des not have a
engines), thermcuple, sensor blck, special pipe
nipple, and insulation (see Figure 2.00-9 and predrilled port, continue with Step 1.
Figure 2.00-10).
Location and installation f the lean burn sensing EXHAUST OUTLET TEE
assembly is dependant on engine family (VHP, VGF, //
and A.cmplete the steps in the section that applies
toyur engine application.
Fs~~UtT
t)) Figure 2.00-11. VHP Engine xygen Sensor ps
Lean Burn
1. Determine lean burn oxygen sensing assembly
mounting location. Note the following concerning
munting:
The assembly location should be easily accessible.
Sensors are maintenance items and replacement will
be required. Typically, service life of the lean burn
oxygen sensr is minimally 4000 hours.
On engines with two el regulators, two sensrs
required.
Figure 2.00-9. FrntView f Lean Burn Sensor Blck
Each assembly must be munted such that is
exposed to the exhaust flow frm the appropriate
bank.
1e assembly should be placed in an area before
the exhaust reams merge.
The lean burn oxygen sensing assembly must be
located downstream of the turbocharger.
2. Drill (45/64) and tap (1 W NPmunting hle for
nipple in the mounting location meeting the require-
ments listed in Step 1.
SAMPLE PRT 3. Thoroughly clean hole and area around tapped hle.
(AT NLY)
SENSR NOTE: Remove predrilled mounting hole plug if
BLOCK installed and then clean hole.
HEATER
NOTE: The AT lean burn assembly uses two heaters.
Insulation over assembly not shown
Figure 2.00-10. Lean Burn xygen Sensing Assembly
2.00-6 FORM 6263 Second Edition
NO'E: On lean burn oxygen sensing assembly com-
ponents requiring an anti-seize compound, use only
oxygen sensor safe anti-seize (such as Permate>f3J
133AR or equivalent).
4. Apply anti-seize to nipple threads. Thread nipple
into munting hle on the engine.
5. Apply anti-seize to threads on sensor block. Thread
the sensor block onto the threaded nipple.
6. Thread sensor block until hand tight. Then turn
sensor block an additional 1/4 -1/2 turn until the sensor
block is vertical with the compnent munting prts
located on the downside as shown in Figure 2.00-12.
NOTE: Heater must be installed in port next to the
thermocouple.
sensr unusable.
are
NOTE: Insulation over assembly not shown.
Figure 2.00-12. Lean Burn Sensor And Sensr Blck
Installed On Exhaust utlet Tee - VHP Engines
FORM 6263 Second Edition
MOUNTING AFM SYSTEM COMPONENTS
7. Apply anti-seize t the large end of the thermocou-
pie connectr. Thread the thermocouple into thermo-
couple port on the sensor block.
8. Apply Permatex 133ARr equivalent, to the
heater. Slide the heater into the heater prt on the
sensor blck.
IA CAUTION J ~~~~~ a;na~~i~
burn sensr. Cntact with c mpund n the sensr
culd result in incorrect sensr peratin.
IA CAUTI Nl 0 n drp rmhan
die xygen sensr. The
cmpnents inside the sensr are vulnerable t
thermal and mechanical slck. Improper handling
culd damage the xygen sensr making the the
9. Bolt the lean burn sensor to the sensor block using
the flange, gasket, and bolts provided. Verify that the
sensor flange is holding the heater in place. Use an
anti-seize compound as required on the bolts but
DO NOT contact the lean burn sensr with anti-seize.
A WA RNING
D not touch r service any hot cmpnents of the
lean burn oxygen sensing assembly. Allow suffi
cient time for cmpnents to cl torm tempera-
ture before aempting any service procedure.
cntact with hot lean burn sensing assembly
cmponents culd cause severe persnal injury.
A
WA RNING
Always keep lean burn xygen sensing assembly
insulation installed ver cmpnents. Lean burn
sensing assembly cmpnents becme extremely
ht in use. Failure t keep insulation installed over
assembly culd cause severe personal injury.
NOTE: Insulation MUST be installed around lean burn
oxygen sens.g assembly for correct sensor operation.
10. IJI insulation around bum nsing assembly.
2.00-7
MOUNTING AFM SYSTEM COMPONENTS
LEAN BURN XYGEN SENSING INSTALLATIN
ON VGF ENGINES
On VGF engines the lean burn sensing assembly is
mounted in the sensor prt that is predrilled in the
exhaust outlet (see Figure 2.00-13 and
Figure 2.00-14). If your engine has a predrilled port,
continue with Step 3. If your engine does nt have a
predrilled port, continue with Step 1.
A~ EXHAUST OUTLET
1XYGEN
SENSOR PORT ZI
l 3. Thoroughly clean hole and area around tapped hole.
Figure 2.00-13. Lean Burn Sensor Installation
Locatin n VGF lnline Engines
/ located n the downside as shown in Figure 2.00-15.
Figure 2.00-14. Lean Burn Sensor lnstallatin
Locatln n VGF Vee Engines
1. Determine lean burn sensing assembly mounting
location. Note the following concerning munting:
The sensor lcation should be easily accessible.
Sensrs are maintenance items and replacement will
be required. Typical! service life of the lean burn
oxygen sensor is minimally 4000 hours.
The lean burn xygen assembly must be located
downstream of the turbcharger.
2.00-8
On engines w two fuel regulators, two sensors are
required.
Each sensor must be mounted such that is
exposed to the exhaust ow from the appropriate
bank.
The senrs should be placed in an area before
the exhaust streams merge.
2. Drill (454 and tap (1/2 NPT) mounting hole for
nipple in the mounting locatin meeting the require-
ments listed in Step 1.
NOTE: Remove predril/ed mounting hole plug if
installed and then clean hole.
NOTE: On lean burn sensing assembly components
requiring an antseize compound, use only oxygen
sensor safe anti-seize (such as Permate~ 133AR or
equivalent).
4. Apply anti-seize to nipple threads. Thread nipple
into mounting hole on the engine.
5. Apply ant seize t threads n sensor block. Thread
the sensor block nto the threaded nipple.
6. Thread sensor block until hand tight. Then turn
sensor block an additional 1/4 - 1/2 turn until the sensor
block is vertical with the cmponent mounting ports
K-TYPE
THERMcUPLE
/ lean burn sensing assembly. Allow sufficient time for
LEAN BURN
XYGENSENSR
N TE: Insulation over assembly not shown.
Figure 2.00-15. Lean Burn Sensor And Sensor Block
Installed On Exhaust utlet Tee - VGF Engines
FORM 6263 Second Edition
MOUNTING AFM SYSTEM COMPONENTS
NOTE: Heater must be installed in port next to the LEAN BURN SENSOR INSTALLATION ON
thermocouple. AT ENGINES
On AT engines the lean burn sensing assembly is
7. Apply anti-seize to the large end of the thermocu
mounted to the turbo exhaust elbow on the left bank of
pie connector. Thread the thermocouple into thermo-
12V-ATGL engines (see Figure 2.00-16 and
couple po on the sensor block.
Figure 2.00-17) and the exhaust elbow on 8L-ATGL
8. Apply Permatex( 133AR, or equivalent, to the engines (Figure 2.00-18).
heater. Slide the heater into the heater port on the On AT engines an exhaust sample line is required from
sensor blck. the exhaust manifold to the lean burn oxygen sensing
assembly. This supply line brings undiluted exhaust to
IA CAUTI NI ~a;na~~i~i~
the lean burn sensor for analysis because the CEC
Turbocharger Control Management System (TCMS)
burn sensr. Contact with cmpound n the sensr dilutes the exhaust gas at the turbo exhaust elbow with
culd result in incrrect sensr peratin. air. The undiluted exhaust travels through the assembly
for analysis and is discharged into the exhaust elbw.
-I A CAUTION I ~~~~~~~h~
If your engine has a predrilled port, continue with Step 3.
If your engine does not have a predrilled port, continue
compnents inside the sensr are vulnerable to with Step 1.
thermal and mechanical shck. Improper handling
LEAN BURN SENSOR
c uld damage the xygen sens making the the INSTALLATIN PRT
sensr unusable.
9. Bolt the lean burn sensor to the sensor block using
the flange, gasket, and bolts provided. Verify that the
sensor flange is holding the heater in place. Use an
anti-seize compound as required on the bolts but
D NOT contact the lean burn sensor with ant seize.
A WARNING
D not touch r service any hot cmpnents of the
exhaust compnen b cool to room temperature
befre aempting any service procedure. Cntact
with hot lean burn sensing assembly compnents
culd cause severe persnal injury. Figure 2.00-16. Lean Burn Sensr Locatinon
12V-AT25GL Engines
A WARNING LEAN BURN SENSR
INSTALLATION PRT
Always keep lean burn xygen sensor assembly
insulation installed ver cmpnents. Lean burn
sensing assembly cmpnents becme extremely
ht in use. Failure t keep insulatin installed ver
assembly culd cause severe persnal injury.
NOTE: Insulation MUST be installed around lean burn
oxygen sensing assembly for correct sensor operat
10. Install insulation around lean burn sensing assembly.
Figure 2.00-17. Lean Burn Sensor Locatinon
12V-AT27GL Engines
FORM 6263 Second Edition 2.00-9
MOUNTING AFM SYSTEM COMPONENTS
LEAN BURN SENSOR
INSTALLATION PRT
Figure 2.00-18. Lean Burn Sensor Locatinon
SL-ATGL Engines
1. Determine lean burn sensing assembly munting
location. Note the following concerning munting:
The sensor locatin should be easily accessible.
Sensrs are maintenance items and replacement will
be required. Typicall sevice life of the lean burn
oxygen sensor is minimally 4000 hurs.
The lean burn oxygen assembly must be located
downstream of the tuocharger.
2. Drill (31/32 ) and tap (1 -20 UNEF) mounting hole
for nipple in the mounting location meeting the require-
ments listed in Step 1.
3. Thoroughly clean hole and area around tapped hole.
NOTE: Remove predrilled mounting hole plug if
installed and then clean hole.
NOTE: On lean burn sensing assembly components
requiring an ant seize compound, use O[IIY oxygen
sensor safe ant, seize (such as Permate; @ 133AR r
equivalent).
4. Apply ant seize to 3/4 NPT nipple threads. Thread
nipple into sensor block.
5. Thread jam nut completely onto threaded nipple.
6. Apply anti-seize t 1 20 UNEF nipple threads.
Thread sensor block with jam nut into the mounting hole
on the exhaust outlet and hand tighten. Adjust sensor
block so block is vertical with the component mounting
port for the thermocouple located on the downside as
shown in Figure 2.00-19.
7. Tighten jam nut to lock sensr block into place.
2.00-10
MOUNTING AFM SYSTEM COMPONENTS
11. Complete exhaust supply tubing connections (see
Figure 2.00-20, Figure 2 . 00-21 r Figure 2.00-22). I A WARNING I
Always keep lean burn xygen sensr assembly
I A WARNING 1 insulatin installed ver cmpnents. Lean burn
sensing assembly cmponents becme extremely
D not tuch or service any hot c mpnents of the hot in use. Failure t keep insulatin installed ver
lean burn sensing assembl Allow sufficient time for assembly culd cause severe persnal injury.
haust cmpnents to cl to rom temperature
before aempting any service procedure. Contact NOTE: Insulation MUST be installed around lean burn
with hot lean burn sensing assembly components oxygen sensg assembly for correct sensor operation.
culd cause severe personal injury.
12. Install insulation around lean bum sensing assembly.
K-TVPE HEATER
THERMCOUPLE
Figure 2.00-19. Lean Burn Sensr And Sensor Blck
Installed nTurb Exhaust Elbw-
12V.AT27 Engine Shwn
///
8. Apply anti-seize to the large end of the thermocou- 1/4 TUBING
pie connector. Thread the thermocouple into thermo- /42-3/4 m
couple prt n the sensor blck.
9. Apply Permatex 133ARr equivalent, to the
heater. Slide the heaters int the heater ports on the
sensor block.
1/4 TUBING
IA CAUTION I~~~ a;na~~i;~:i:~ 6-1/4(158.75 mm)
burn sensr.Cntact with c mpund n the sensr
could result in incrrect sensr operatin.
IA CAUTION I ~p s~~ i:h;;; :
c mpnents inside the sensr are vulnerable to >ELBw
thermal and mechanical shck. Improper handling
culd damage the xygen sensor making the the
sensor unusable.
10. Bolt the lean burn sensor to the sensr block using
the flange, gasket, and bIts provided. Verify that the
sensor flange is hlding the heater in place. Use an
ant seize cmpund as required n the bolts but
DO NOT contact the lean burn sensor with anti-seize. cNNECTR
NOTE: An exhaust sample line is required from the
exhaust manifold to the lean burn oxygen sensing
assembly. This supply line brings undiluted exhaust to Figure 2.00-20. Exhaust Supply Tubing On SL-ATGL Engines
the lean burn sensor for analysis. The undiluted exhaust
travels through the sembly for analysis and is
discharged into the exhaust outlet elbow.
FORM 6263 Second Edition 2.00-11
FORM 6263 Second Edition
MOUNTING AFM SYSTEM COMPONENTS MOUNTING AFM SYSTEM COMPONENTS

21 5.4mm

ELBw~

~
/
CONNECT1R

NOTE: 1All 1/4 tubing is sless steel. cNNECT1R

2Lean burn sensg assembly, tubing, elbows, and
connectors MUST be installed in locations shown for proper
system operation. Alterations to components and/or
mounting locations could result in improper system operan.

Figure 2.00-21. Exhaust Supply Tubing n 12V-AT25GL Engines

NOTE: 1All 1/4 tubing is stainless steel.

2Lean burn sensing assembly, tubing, elbows, and
connectors MUST be installed in locations shown for proper
system operation. Alterations to components and/or
mounting locations could result improper system operation.

Figure 2.00-22. Exhaust Supply Tubing n 12V-AT27GL

2.00-12 FORM 6263 Second Edition FORM 6263 Second Edition 2.00-13
MOUNTING AFM SYSTEM COMPONENTS
MOUNTING THE K-TYPE
THERMOCOUPLES - RICH BURN
APPLICATIONS <;)NLY
Thermocouples are used to monitor the temperature of
exhaust gases near the stoichiometric oxygen sensor
(see Figure 2.00-23).
THERMCOUPLE
cNNECTR
Figure 2.00-23. K-Type Thermcuple
1. Determine thermcuple mounting lcation. Nte
the following cncerning thermocouple mounting:
If your engine has a predrilled port for thermocouple
mounting, continue with Step 3.
Mount thermcouple within 6 inches (152 mm) of the
appropriate oxygen sensor. On turbocharged
engines, the thermocuple must be placed on the
same side of the turbcharger as the oxygen senso
Locate the thermocouple in an accessible lcation.
The tip of the thermocouple should be surrounded by
unobstructed exhaust flow.
If there is concern about a thermocouple failure, a
thermowell filled with a heat transfer cmpound can
be used. Should a thermowell be used, be sure to
apply ant seize to the thermowell to make removal
easier if replacement is required.
2.00-14
I A CA UTION IAlway se u
therm c uple pr bes
with the AFM system. Resistance fr m either
ungrounded thermcuple lead to the thermcu
pie shell shuld be 2 megohms r greater. Disre-
garding this information will lead t incorrect input
from a grounded thermcuple to the AFM mdule.
2. Drill (7/16 ) and tap (1/4 NPthermocouple
mounting hole in location meeting the requirements
listed in Step 1.
3. Thoroughly clean hle and area around tapped hole.
NOTE: Remove predrilled mounting hole plug if
installed and then clean hole.
4. Apply Permatex( 133AR, or equivalent, to the large
end of the thermocouple connector (see
Figure 2.00-23).
5. Thread the connector into the thermocuple mount-
ing hole.
6. Insert the ferrule nut, back ferrule, and front ferrule
onto the stem of the thermcouple (see
Figure 2.00-23). The lip on the back fern le must face
the large end of the front ferrule, while the tapered end of
the front ferrule faces the connector body.
7. Insert the stem of the thermocouple into the connec-
tor and finger tighten the ferrule nut.
8. Center the tip of the stem in the exhaust passage.
The thermocouple must not contact the metal casting or
an inaccurate pyrometer reading will result.
9. Tighten the ferrule nut.
10. Cnnect the male and female ends of the plug and
slip protective boot ver female end of plug. The
different size prongs prevent the plug from being
improperly hooked up.
FORM 6263 Second Edition
MOUNTING THE INTAKE MANIFOLD
PRESSURE TRANSDUCER
The intake manifold pressure transducer is used in
catalyst and lean burn applications only.
1. Determine intake manifold pressure transducer
munting location. Note the following cncerning intake
manifold pressure transducer munting:
Mount pressure transducer in a convenient location
n the intake manifold. Typical location is center of
intake manifold.
If existing, use port already predrilled in the intake
manifold.
Intake manifold pressure transducer must be
mounted perpendicular to air flow.
On VHP engines, d not mount pressure transducer
n either end of the intake manifold. Mount pressure
transducer in center of intake manifold.
2. Drill (7/16) and tap (1 /4 NPmounting hle.
3. Thoroughly clean hole and area around tapped hle.
4. Apply Tefln tape to threads. Thread pressure
transducer into mounting hole and hand tighten. Then
tighten an additional turn (see Figure 2.00-24).
5. Support mating conduit assemblies so there is no
stress on the pressure transducer s 1/4 ' NPT fitting.
PRESSURE
TRANSDUCER
1/4 NPT I
TIGHTEN HERE
Figure 2.00-24. Intake Manifold Pressure Transducer
FORM62 Second Edin
MOUNTING AFM SYSTEM COM PONENTS
MOUNTING THE STEPPER MOTOR(S)
In order to control the air/fuel ratio, a stepper motor is
installed to each fuel regulator. The stepper mtor
influences fuel flow by increasing or decreasing
pressure n the regulatr contrI spring.
NOTE: Field retrofit of some models may require
relocation of the fuel regulators to permit installation of
the stepper motors.
DISASSEMBLING REGULATOR FOR STEPPER
MOTOR MOUNTING
A WARNliNG
Discnnect all electrical pwer supplies before
making any cnnectins r servicing any part of the
electrical system. Electrical shock can cause se-
vere personal injury or death.
1. Verify that all pwer to the AFM system is OFF.
A WARNING
Use appropriate equipment and protective gear
when servicing r using products that cntain
springs. Springs, under tensin, can eject if im-
proper equipment r procedures are used. Failure
t take adequate precautins can result in serius
personal injury or death.
2. Remove the cap, rubber seal, adjusting screw, and
cntrol spring from the regulator (see Figure 2.00-25
and Figure 2.00-26) .
Figure 2.00-25. Remving Cap From Regulatr-
99 Regulator Shown
2.00-15
MOUNTING AFM SYSTEM COMPONENTS MOUNTING AFM SYSTEM COMPONENTS

VERIFYING STEPPER MOTR OPERATION
Stepper mtr operation should be verified prior t
REGULATOR BOD installation to the fuel regulator following the steps
below. Don t install stepper motr to fuel regulator
until stepper motor operation is verified.
1. Complete the electrical connections in Section 2.05
6. Press and release <F1 > and then <START POS>
on the AFM module keypad.
7. The AFM LCD display will shw MOVING L
STEPPER TO START POSITION." Verify that the shaft
inside the left stepper motor first moves counterclock-
wise and the control spring mves partially into the
\

AFM System Electrical Connections including wiring
connectins to stepper motor(s) (see Step 4 in the next
section Installing Stepper Motor to Regulator'' fr
harness connectins).
2. Cmplete the checklist in Sectin 2.10 Prestart
Installation Checklist.
3. With the engine not running, apply pwer to the
AFM module.
stepper motr assembly until the home psition is
reached. Then the stepper motr shaft must rotate
clockwise and the control spring must move out of the
stepper motor assembly. On engines with two regula-
tors, the AFM module will move the right stepper motor
once the le stepper motor is reset. Verify correct
peration of the right stepper motr by observing the
direction of shaft rotation and mvement of the contrl
spring. Allow up to three minutes for this process.

4. Install the control spring remved frm the regula-

Figure 2.00-26. Remving Adjusting Screw And
Control Spring From Regulatr - 99 Regulatr Shwn
N'E: On fuel regulatrs with a regulator adjuster
installed, remove the cmponents of the regulator
highlighted in Figure 2.00-27.
4t
tor into the end of the stepper motor (see
Figure 2.00-28).
5. If the yellw alarm LED is lit on the AFM module,
press <ALARM ACK> on the module keypad to
acknowledge the alarm.
8. Once stepper motor functin has been verified,
remove power to the AFM system and continue with
Installing Stepper Motor to Regulatr.
INSTALLING STEPPER MOT1R TO REGULATOR
1. Install the cntrol spring remved from regulator
into the end of the stepper motor (see
Figure 2.00-29).
2. Install 0-ring provided on stepper mtor.

NOTE: The 0-ring is used to make sure the stepper

CECEEEE
3333333 motor to regulator interface is well sealed. The 0-ring

makes electrical connection convenient and minimizes

mechanical stress on the connecto
m

2

MM
ON

EN
3. Install the stepper motor into the end of the
W

NG regulator. Orient the stepper motor s that the

electrical cnnection faces the conduit which runs t
the junction box (see Figure 2.00-29).

\ RUBBER SEAL 4. Connect stepper harnesses (see Figure 2.00-30). Figure 2.00-29. Installing Stepper Mtor Into Regulator

CL1SING CAP / Nte the following concerning stepper motor harness

cnnectins:
Enclose the wiring in conduit to prevent damage.
Figure 2.00-27. External Regulatr Adjuster
Installation - 99 Regulator Shown Two types of stepper cables may be provided. Some
are color coded and must be reconnected with each
wire color matching. Others are labeled directly on
Figure 2.00-28. Stepper Motr Assembly FrVerifying the wire. Similar labels must be matched. Example:
Operatin
STEPPER A must be connected to STEPPER A .'
The upper harness connector on the side of the AFM
module is for the left bank stepper motor (see
Figure 2.00-31 ). This connection is also used on
engines that have only ne regulator (in-lines,
ATvees, and sme VGF vees).
The lwer harness connector on the side of the AFM
module is for the right bank stepper motor for engines
with tw fuel regulators (see Figure 2.00-31).

None of the AFM system wiring is t be run in the NOTE: All wiring must be run per local codes.
same conduit as the ignition primar other wires.

A minimum distance of 4 inches should be main-

tained between AFM system wiring and ignition
wiring.

2.00-16 FORM 6263 Secnd Edition FORM 6263 Second Edition 2.00-17

2.05-1

AFM

AFM
MOUNTING AFM SYSTEM COMPONENTS SECTION 2.05 - AFM SYSTEM ELECTRICAL CONNECTIONS

ELECTRICAL CONNECTIONS See Table 2.05-1 f AFM system pwer requirements.

An oscilloscope must be used to verify that the AC ripple

AFM MODULE POWER CONNECTIONS meets the 2 volt AC peak-to-peak requirement with the
The power cnnectins made for the AFM system must engine running.
JUNCTION
be in accordance with the applicable local electrical

Bx NOTE: Refer to Section 1.02 Geneal Power Require-
codes. All power wire sizing must be in accordance with
ments for Custom Engine Control Products for the
ALIU Figure 2 .05-1, Waukesha CEC Products Power Wiring
power requirements of all Waukesha Engine CEC
Requirements. All external cnnections on the AFM
system are intended to be used with flexible conduit. products.

NOTE: Although the input power has a 3 amp internal
prctivefuse, an external 3 amp fuse (fast blow) is
Continue with electrical connections on page 6.

~x~~~f~
required between the AFM and the power source.
@.

WAUKESHA CEC PRDUCTS

POWER WIRING REQUIREMENTS
ASSUME 40 AMP AVERAGE TTALCURRENT
Figure 2.00-30. Stepper Harness Connections
AIR/FUEL
pWER MDULE
,
_ FRM LEFT BANK STEPPER (AFM)
- - r MOTOR OR NLYSTEPPER DC PWER LEADS
Y
0
I MTOR

A: 4AWG,30 MAX; 2 AWG, 50 MAX; 0 AWG, 75 MAX
B: 16AWG,20 MAX

F C, D, E: 18 AWG, 20 MAX
F: 14AWG,50 MAX
G: SAWG,25 MAX (LEAN BURN NLY)
' - FRM RIGHT BANK A
STEPPER MTR (ENGINES
WITHTW REGULATORS)
NOTE: Wires sized for 1tem A" are based on the pulsed
loading of pacitive discharge ignitions like the CEC
Ignition Module and the 2 volt peak-to-peak maximum
ripple requirements of the CEC products.

Figure 2.00-31. AFM Mdule Stepper Harness c DSM

BOX FILTER
Connections

DETNATIN

TURBOCHARGER SENSING
MDULE
CEC cNTRL
(DSM)
LEAN BURN IGNmON MDULECM)
XYGENSENSR MDULE
pWER CNTR (IM)

Figure 2.os-1. Waukesha CEC Products Power Wiring Requirements

Table 2.05-1. Pwer Requirements Fr The AFM System

NMINAL OPERATING RIPPLE OPERATING CURRENT
T LERANCE PEAK-T-PEAK
v LTAGE RANGE (amps)
(volts DC) (volts DC) {VOS AC)
(volts DC)
24 +25%,-10% 21.6-30.0 less than 2 2.5
(all rich burn applications)

(lean b:~
cylind
18.0
a1cf~fiations on VHP 6
VGF engines)
32.0
12~Ircyl
J~H~m lin~~aJIAT
engines)

2.00-18 FORM 6263 Second Edition FORM 6263 Second Edition 2.05-1
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3. ILINE ENGINES USE LEFT ENGINE BANK CONNECTIONS AND
"ENGINE GROUND" ONLY.

4. IN ORDER TO INSURE CORRECT OPERATION. AND FACILITATE WIRING
BETWEEN THE AFM AND THE ENGINE MOUNTED JUNCTION BOX.

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AFM SYSTEM ELECTRICAL CONNECTIONS SECTION 2.10 - PRESTART INSTALLATION CHECKLIST
NOTE: Voltage and current supplied must be sufficient
TERMINALS WITHIN CUSTOMER SUPPLIED PRESTART INSTALLATION CHECKLISTS the yellow and red wires. The voltage shuld be

----
to operate all transducers used in the installation. AFM MODULE RELAY 0.80 - 1 .50 mV for temperatures 60 - 100 F
CATALYST AND BEST POWER/ECONMY (16 38 C). If the engine was running recently,
Supply power wiring and signal (transduce wiring
ERRROU
CONTROL MODE CHECKLIST measurements will be higher, reflecting higher
must be in separate conduits. To avoid the possibility of
undesired electrical interaction, the wires must be 1. Before applying power to the AFM system (engine actual temperatures. This step verifies that ther-
routed through the bottom of the AFM mdule as shown not running): mocuple wires are terminated crrectly.
in Table 2.05-2. E. With the thermcouple connections discon-
A. Visually inspect AFM system installatin to be
Table 2.05-2. AFM MduleWire Ruting sure that all wiring conforms to the requirements nected, measure the resistance between the red
REM TE wire and the connected engine ground terminal.
Left Conduit Supply:O~w~r Wiring ~T,4 VDC) START INPUT T CUSTOMER
SUPPLIED LGIC
of this manual, local codes, and regulatry
Entry e Sideony bdies. Verify that each connection to the AFM Resistance should be very high (or open circuit).

Entry :
Center Conduit Swttc~ ~f~t;k~n~o;;,J~1~r~~
and Engine Ground
:LIJ::i"~~~cf ucer
Right Conduit Alarm O~~~ Alternate Fuel Input,
Entry and Re Start Positio1 Input
An input power wire (14 AWG minimum) should enter
the left conduit entry and connect to the left most
terminal block which is labeled 24 VDC. This should be
the only wire coming to the AFM module from the power
supply (from the junction box on AT engines). An engine
ground wire (14 AWG minimum) should also be
connected to this same terminal block at the point
labeled GND, and be run through the center conduit
entry to the engine mounted junction box. From the
junctin box this ground wire must gn and be
attached rmly to the engine crankcase (not a gasketed
cover or other component bolted to the crankcase). The
surface of the crankcase where the connection is made
must be free f paint and other non-cnducting
substances.
Connections between the junction box and the AFM
module are made with factory supplied wiring harness.
The center conduit ent of the AFM module must be
used. Attach all wires as labeled on the terminal
identification strip. Care must be taken to identify the left
ALTERNATE
FUEL INPUT
NOTE. :
NT USED AT
THIS TIME
Current sking configuration. Components internal
toAFMare pable of handling so voe, 1 amp.
Figure 2.05-4. Wiring f Auxiliary Inputs And utputs
Error ut: The Error Out terminal is a sinking circuit
with a maximum current rating of 1 amp and a maximum
voltage rating of 50 VDC (no AC voltages are allowed) .
The Error Out terminal can be used as a trigger t drive
relays, alarms, and lights. When the AFM system is
operating crrectly it is a CLOSED device connected
internally to ground. Any system fault will OPEN the
alarm circuit including iss of power and diagnostic
warnings. The Error Out terminal will be OPEN when-
ever the yellw alarm LED on the front of the AFM
module is on.
I A WARNING
D nt s the stepper mtr(s) t the start psitin
while the engine is running abve 40 percent of
rated load. Start psitin is only t be initiated when
the engine is stpped r running below 40 percent
of rated load. Reseing the stepper mts) while
module is routed through the correct conduit.
Refer to Section 2.05 AFM System Electrical
Connections for power specifications to the AFM
Repeat the measurement between the yellw
wire and engine ground. This verifies that
thermcouples are ungrounded and that wires
module and rich burn (catalyst and best power/ are not shorted in the conduit. Reconnect the
econ my) wiring diagram. thermocouple connections terminal blck after
the test is complete.
B. Discnnect the pwer connections terminal block
inside the AFM module (see Figure 2.10-1). 2. After applying power to the AFM system (engine nt
Measure the power supply voltage at the AFM running):
module and verify that the power supply is within
specification. Make this measurement with an A. Reconnect the power connections terminal
scilloscope. block.
NOTE: Power requirements theenge runng are B. Reconnect the analog connections terminal
verified during AFM system programmg (Chapter blck to the header. Measure the voltage
between the stoichiometric sensor ground wire
C. Disconnect the intake manifold pressure trans- and engine ground terminal. The voltage should
ducer and oxygen sensor(s) by removing the be O volts 50 mV. This step tests for potential
analog connections terminal block from the ground lop problems.
header inside the AFM module (see
I Figure 2.10-1). Measure the resistance between
the positive and negative sensor wires. Resis-
tance should be higher than 2 megohms if
NOTE: Ground loops could be more significant when
the engine is runng. The addition of other electrical
devices may adverse influence AFM system opera-
sensors are cool. This step verifies that wires are tion by causing "signal osets."
not shorted in the conduit.
When all of these checks have been made successfully,
D. Disconnect the thermocouple connectins termi- cntime with Chapter 3.00 Air/Fuel Module System
nal block inside the AFM mdule (see Programmg.

from right bank connections. the engine is running abve 40 percent of rated load Figure 2.10-1). Measure the voltage between
may cause engine shutdwn and/or cause severe
COMPLETING AFM SYSTEM WIRING
engine damage. INSIDE AFM MODULE
Complete AFM system electrical connections. Refer to nunununu

U
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Start: The Remote Start terminal permits 1

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Figure 2.05-2 for AFM system wiring diagram for

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catalyst and best power/ecnomy applications (rich
burn only). Refer to Figure 2.05-3 fr AFM system
wiring diagram for lean burn applications (lean burn
only).
WIRING OF AUXILIARY INPUTS AND OUTPUTS
Ml
--
movement of the stepper motors to the start psition
from external, customer supplied logic. To use this
feature, ground this terminal for three seconds, then
unground it. The preprogrammed start position will then
be sought by the stepper mtors. Allow three minutes
50 :::>0.. :::>0..
a: z
fr stepper motor repsitioning.

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Alternate Fuel (ALT FUEL): The Alternate Fuel

20zo
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Z2 z

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00Z
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devices. They include the Error Out, Remote Start, and

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will be used to invoke a second set of contrl values that
Alternative Fuel (ALT FUEL) ps. These pos must be < <

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are appropriate fr the secondary fuel of dual fuel
~(@)

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applications.

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pWEA cNNECTIONS ANALG CONNECT!NS THERMcUPLE CONNECTIONS

Figure 2.10-1. AFM Module Connections-Catalyst And Best pwer/Ecnomy Prestart Checklist

2.05-6 FORM 6263 Second Edition 2.10-1

FORM 6263 Second Edition
PRESTART INSTALLATION CHECKLIST CHAPTER 3 - AIR/FUEL MODULE SYSTEM PROGRAMMING

LEAN BURN CONTROL MDE CHECKLIST (16 38 C). If the engine was nning recently,
measurements will be higher reflecting higher
Before applying power to the AFM system (engine not
actual temperatures. This step verifies that
running):
thermocouple wires are terminated.
A. Visually inspect AFM system installation to be
sure that all wiring conforms t the requirements D. With the thermocouple connections still discon-
of this manual, local codes, and regulatory nected, measure the resistance between the red
bodies. Verify that each connection to the AFM wire and the still connected engine grund
module is routed through the correct conduit. terminal. Resistance shuld be ve high (or
Refer to Section 2.05 AFM System Electrical open circuit). Repeat the measurement between
Connections for the pwer specifications to AFM the yellow wire and engine ground. This verifies
mdule and lean burn wiring diagram.
that thermocuples are ungrounded and that
wires are nt shorted in the conduit. CONTENTS
B. Discnnect the power connections terminal blck
inside the AFM module (see Figure 2.10-2). E. Reconnect the thermocouple connections termi-
Measure the power supply voltage at the AFM nal block. SECTION 3.00 - GENERAL PROGRAMMING INFORMATION
module and verify that the power supply is within F. Reconnect the power connections terminal block.
specification. Make this measurement with an SECTION 3.02 - KEYPAD AND DISPLAY INFORMATION
oscillscope. NOTE: Ground loops could be more significant when
NOTE: Power requirements with the enge running are the engine is running. The addition of other electrical
devices may adversef/uence AFM system opera- SECTION 3.05 - PROGRAMMING FOR CATALYST APPLICATIONS
verified during AFM system programming (Chapter 3).
tion bycausg "signal osets.
C. Disconnect the thermocouple connections termi- When all of these checks have been made successfully, SECTION 3.10 - PROGRAMMING FOR BEST POWER/
nal block inside the AFM module (see continue with Chapter 3.00 Air/Fuel Module System ECONOMY APPLICATIONS
Figure 2.10-2). Measure the voltage between
Programming.
the yellow and red wires. The voltage shuld be
0.80 - 1.50 mV for temperatures 60 100 F SECTION 3.15 - PROGRAMMING FOR LEAN BURN
APPLICATIONS
INSIDE AFM MODULE

9999 99
|| || || ||
88 1 1 I I ~ I
::, ::,
O a.
::,
Z z
O
a:
1OHVX
120zuh

l20
lNOZ
l Z2 z

z20

Z20zzo

lNZ 00Z

lnz 00Z
lzL

lzz z

lNOZJL
ZEOO

a: w

20

2z
NOZ
ZLF

NOZ
NZ
Zz

ug

HLF

i::c :< ;:::>

OH LJ
OHhh

w fi, t
F
hkJ
Z2 z

mu

OE
Hh

E

z
z

@
pWER
THERMOCOUPLE
cNNECNS
CONNECTIONS

Figure 2.10-2. AFM Module Connections - Lean Burn Prestart Checklist

2.10-2 FORM 6263 Second Edition FOAM 62 Second Edition

 SECTION 3.00 - GENERAL PROGRAMMING INFORMATION

PROGRAMMING INFORMATION NOTE: This manual assumes you are already miliar
with basic MS-DOS commands for viewing directories,
MINIMUM RECOMMENDED COMPUTER FOR AFM copying files, and other MS-DOS concepts. If you need
SYSTEM EQUIPMENT PRGRAMMING more formation on these sut.c refer to a MS-DOS

The AFM system is customized for each engine instruction manual.

application based on site specific information with a
personal computer (PC). The following is a list of the
minimum recommended computer equipment for AFM
system programming:
M PC or Compatible Computer
80286-12 Mhz Microprocessor
640K RAM (512K RAM free)
Single 3.5 High Density (1.44 MB) Floppy Drive
OPERATOR INTERFACE
The AFM module is equipped with several features for
site personnel use in determining system status. These
features include:
Power and Alarm lights (LED displayn the front
panel of the AFM module (see Figure 3.00-1)
The green Power" LED is lit any time power is
applied to the AFM module

NOTE: Although the AFM User Interface Program is
provided on a floppy disk, it is intended to be executed
from e hard drive. A minimum of 1 megabyte of free
disk space on the hard drive is required.
RS-232 Serial Port
Microsoft MS-DOS 3.3
DB-9 Serial Cable (male to female)
The yellow Alarm LED is lit any time the AFM
systems diagnostic functions are activated or
when AFM system execution has been stopped
by the user (such as during the saving of
data-set)
an alpha-numeric liquid crystal display (LCD display)
visible from the front of the AFM module allows the
user to monitor important system information

Optional: Printer Port (Centronics Type Parallel Po
Optional: Portable Printer (Printouts of computer
screens can be used to aid in troubleshooting and
filed for future reference.)
NOTE: Other CEC products may have dierent mini-
mum recommended computer requirements.
a sealed membrane keypad located on the front of
the AFM module
LCD display information available to the operator
includes exhaust temperature, oxygen sensor output,
oxygen sensor rget, intake manifold pressure, step-
per psition, stepper travel limits, heater output percent-
age, and any system faults that might be present.

CONVENTIONS USED WH AFM PROGRAMMING
The following is a list of conventions used in the AFM
User Interface Program and documentation:
All commands enclosed in brackets, [ ], are t be
fund on the PC keyboard.
All commands enclosed in modified parenthesis,<>,
are to be executed frm the AFM module keypad.
NOTE: For more formation on how to use the AFM
keypad and explanation on display information, refer to
Section 3.02 Keypad and Display Information. For
diagnostic information refer to Section 4.05 Air/Fuel
Mdule System Diagnostics.

If an errant keystroke is made with the persnal

computer, simply press [Es to return to the previous
enu.

You can highlight menu options by using the arrow

keys or mouse.

Highlighting and then pressing [Enter] accesses a

menu chice.

If you have a potable printer connected to your PC,

press [Print Screen] to make a printout of the screen
you are viewing.

1e [Return) key is the same as the [Ente key (on

Figure 3.00-1. Air/Fuel Mdule Front Panel
sme keyboards [Return) is used instead of [Enter]}.

FORM 62 second Edition FORM 6263 Second Edition 3.00-1

 GENERAL PROGRAMMING INFORMATION
..

GENERAL PROGRAMMING INFORMATION

~gii
...,..

AFM USER INTERFACE PROGRAM LAYOUT AND

DESCRIPTION
Refer to Figure 3.00-2 for an illustrated menu layout of AFM system operating paramerers. COMMUNICATINS
MENU
the AFM User Interface Program.
c. Save Menu
1. Communications Menu

~~~th~~ho~o;;u~~r~~t
1) save to Filename
Saves the data-set displayed on the Edit
screen to disk. The filename can be up to eight
serial cable. characters and is saved to the hard drive or disk
2. Main Menu where the AFM User Interface Program was
accessed.
A. Edit/Create Setup
2) Test Data n AFM
1) Retrieve from AFM
. Allows user to save data-set to RAM (tempo-
~t~i~1:e~p~ir;;tr~n~~~~~~ ~n~b~ :; ~1~d~~
~~s:;t~~~e:;::r:
whe1e data is stored will be Med n setso AFM module before saving to RO
VIEW
the PC screen (RAM r ROM# location)
:~:
SERIAL

r~~~t~z~~nl~~~ ;i~~
LINK
2) Retrieve from Filename
disconnected from the AFM module. Make sure
~~~~1/s~~d t~cs::
[ESC]
to save the final data-set to ROM.
hard drive or disk as the AFM User Interface
3) Congure AFM Memory
Program. Permits user to select a file to be
Allows user to save the data-set t ROM
retrieved into the Edit screen.
(permanent memory within the AFM). The
3) Create New Data-Set Lviol
1placeithttew data-set. The conterl t s
RETRIEVE CREATE
, Displays most recent data-set accessed by P FROMAFM NEW
DATASET
or a blank data-set if there is no data-set m f ROM are not lost when pwer is discon-
nected frm the AFM module.

i
PC's memory.

B. Edit Screen
After selecting Retrieve from AFM ,Retrieve
from Filename r Create New Data-Set" from [ESC]
the Edit/Creat~ Setup menu, the appropriate
EDIT
data-set will be displayed on the Edit screen. This to permit rther saves to permanent memory. SCREEN
allows the user t view and edit the system
parameters. o. View Serial Link
Allows operator to mon current em p
mance. The View Serial Link screen aids m

Figure 3.00-2. AFM User Interface Program Layout

FORM G263 Second Edition FORM 6263 Second Edition 3.00-3

3.00-2
GENERAL PROGRAMMING INFORMATION SECTION 3.02 - KEYPAD AND DISPLAY INF R M ATI ON

KEYPAD AND DISPLAY INFORMATION Each of the four control modes (catalyst, best pwer,
INFORMATION ON SAVING DATA-SETS
best economy, and lean burn) has a unique list of
TO RAM AND ROM MEMORY messages that are displayed on the AFM mdule. The
The AFM system is designed to be used with many LED DISPLAY following three sections list and describe the different
engine families of various configurations. Consequent-
ly, it must be tailored to work with site specific
# LCD display messages for each control mode.
NOTE: If an alarm condition occurs, a diagnostic
information. This is achieved by creating and installing a
message is displayed on the LCD display. Refer to
data-set' that is appropriate for your specific site LCD DISPLAY '. . t )U"'' Section 4.05 Air/Fuel Module System Diagnstics for
application. diagnostic and troubleshooting information.
Data-sets are developed on the PC with the AFM User
Interface Program at the engine site. Once a data-set is CATALYST CONTROL MODE DISPLAYS
created, the data-set can be saved t a hard/flppydisk Listed below are the messages displayed on the AFM
for later recall, tested on the AFM system in RAM mdule for catalyst cntrol mode. The LCD display
(tempora AFM memo or used t configure AFM information is in bId.
ROM (permanent AFM mem
RAM (temporary memory) is used t evaluate 'test' . System Status:
data-sets before storing to permanent memo. There
is no limit to the number of data-sets that can be Left/Right Engine Bank (If Tw Regulators)
Figure 3.02-1. Air/Fuel Mdule Front Panel
evaluated in tempora memory. The contents of RAM Autmatic or Manual Mode f Operation
are lost whenever power to the AFM module is TheAFM mdule is equipped with several features for Sensr Voltage
removed. Be sure to save values to ROM after a est site personnel use in determining system status (see Stepper Position
data-set is carefully evaluated and is found acceptable. Figure 3.02-1). These features include:

NO'E: The term EPROM is used to describe an . Power and Alarm lights (LED display) on the front
electrical chip that resides in the AFM module. The cre panel of the AFM module
EPROM chip houses ROM memory. L Auto 0.75 10000
.. The green Power LED is lit any time power is
When saving to ROM (permanent memo five applied to the AFM module R Man o. 75 10000
data-sets can be saved before the core EPROM chip
..
must be replaced. Once a data-set is stored to ROM,
the previus save to ROM is not accessible/retrievable.
The yellw Alarm LED is lit any time the AFM
system s diagnostic functions are activated r
. 0ygen Sensor Voltage:
The AFM module can only access the most recently when AFM system execution has been apped 02 SENSOR = X.XXv
saved data-set. When the AFM module saves a by the operator (such as during the saving f a
data-set to ROM, the data-set informatin is not lost
when power to the AFM module is removed.
data-set)
. Oxygen Sensor Target Voltage:
an alpha-numeric liquid crystal display (LCD display) 02 TARGET= X.XXv
N1TE: The cre EPROM chip has six locations for visible from the front of the AFM module allows the
ROM saves; however, the rst location is prepro-
grammed for testing purposes. Five ROM locations are
operator t monitor impant system information
Information displayed on the LCD display on the AFM
. Intake Manifold Pressure:
available to AFM system programmers. Intake Manifold
module includes exhaust temperature, oxygen sensor
utput, oxygen sensor target, intake manifold pressure, Pressure = XXXpsiA
NOTE: Refer to Section 4.00 Air/Fuel Module System
Troubleshooting "RepCg EPROM Chs for stepper psition, stepper travel limits, heater output
EPROMch replacement instructions. percentage, and any system faults that might be
present.
. Stepper Position:
STEPPER = XXXXX
NOTE: To scroll through the list of system displays,
press <DISP SEL> on the AFM module keypad. If an
alarm condition is present, you must press . Stepper Minimum and Maximum Limits:
<ALARM ACK acknowledge e alarm and wait for mn XXXXX mx XXXXX
e WORNG" message on e LCD display
disappear before pressing <DISP SEL>.

NOTE: If your engine has only one el regu.e

. Oxygen Sensor Temperature:

"left'' buttons on the AFM module keypad control the 02 TEMP = XXXXC
enge's air/fuel ratio. If your enge has two fuel
regu.'ators, the 1eft'' keypad buttons control the engine s
left bank and the "righf keypad buttons control the
enge right bank.
3.02 1
3.00-4 FORM 6263 Second Edition FORM 6263 Second Edition
KEYPAD AND DISPLAY INFORMATION KEYPAD AND DISPLAY INFORMATION

BEST POWER/ECONMY CNTROLMODE

Stepper Minimum and Maximum Limits: AFM MODULE KEYPAD FUNCTIONS
DISPLAYS mn XXXXX mx XXXXX
Listed below are the messages displayed n the AFM
module for best power/econmy control mde. The Oxygen Sensor Temperature:
ro
LCD display information is in bId. 02 TEMP = XXXXC
,
POW!R AL

System Status (when waiting for delay to expire):

LEAN BURN CONTROL MODE DISPLAYS

E
Left or Right Engine Bank (If Two Regulators)
Listed below are the messages displayed n the AFM /
Automatic or Manual Mode of Operation /
module for lean burn contrl mode. The LCD display
AIR/ MODULE / /
Delay Time Remaining information is in bId.
Stepper Position /
/

System Status:
Left or Right Engine Bank (If Two Regulatrs)
Automatic or Manual Mde of Operation
L Aut 5.0m 10000
Sensor Voltage
R Man 5.0m 10000
Stepper Position

10 or
System Status (when searching for stoichiometry, :
Left or Right Engine Bank (If Two Regulators)
Automatic or Manual Mode of Operation L Aut 2.50 5800 Figure 3.02-2. AFM Mdule Keypad Detail

Sensr Voltage R Man 2.50 5800

Table 3.021. Key Functi ns
Stepper Position KEY DESCRIPTIN KEY DESCRIPTION
Oxygen Sensor Voltage: <AUTO PER> ~:;~ffr~mthemanual to ~Ef~~~~c.for both
mode of <LEFT FAST> Pressed before <LEFT RICH> or

f~rotrnodtianiine.
02SENSR =X.XXv

rg~i~~~as~~e
p':iI:trTt?Js
<STRT POS>
L Aut 0.80 10000 ;r
:n
R Man 0.80 10000
Oxygen Sensor Target Voltage:
2TARGET = X.XXv <RIGHT FAST> Pressed before <RIGHT RICH> or

~ef~o~~fMh~nrlIr em~~ii~
A. WARNING
Oxygen Sensor Voltage: Do not set the stepper motor(s) to the
Intake Manifold Pressure:
2SENSR =X.XXv start position while the engine is running
Intake ManifId above 40 percent of rated load. Start

E~~mNhi:i7ftffi1tliiJkpdonesw
Pressure = X:XXpsiA position is only to be initiated when the <LEFT RICH>
engine is stopped or running below 40 engines
Oxygen Sensor Target Voltage: itionwill
percent of rated load. Resetting the step- each
02 TARGET = X.XXv per motr(s) while the engine is running p
Stepper Position: above 40 percent of rated load may

t~le{rf~t 1~~iin~kt ~ l ~i;:

cause engine shutdown and/or cause se- <LEFT LEAN>
STEPPER = XXXXX
Delay Time Remaining: vere engine damage.
82
DlyTimer X.Xm <ALARM ACK>

rcE~~i~~1~1~1; ~:
Reactivates the keypad whenever an alarm

;
Stepper Minimum and Maximum Limits: condition has occurred. All r~~~kes will

fi~~~ f;%f~E~
<RIGHT RICH> Enriches the air/fuel ratio of the right bank
mn XXXXX mx XXXXX is ac nowledged.
Programmed Delay Time: tB padJ~i~~to
con
result in the D di~ t~e~~er
will
! fuel
n willregulators.
increase 25The
depression of this si:r
DlyTime X.Xm "ALARMS MUST B DGED.
Oxygen Sensor Temperature: <RIGHT LEAN> Leans the ai el ratio of the right bank of
<DISP SEL> Permits scrolling through the various engines with two tur~e~~~~~~rs. The right
0set Steps:
02 TEMP = XXXXC system LCD display messages.
trr
! !!~fnr~~ion wil depression
r each e 25ofsteps
this
<LEFT MAN> modea~~de~~on
~~t~J:ifctr; manu from with

r~i~~?J~~t~~~rt~~~~
for engines
OffSteps xxx Oxygen Sensor Heater Duty Cycle: one :iulator or the left bank of engines <F1>
with regulators.

Stepper Position:
HEATER AT XXX%
<RIGHT MAN>
~~t~~:irctri :~iia?~0ide:~~on
from
for the
bank of engines with two regulators.
right <F2>-<F4>
prog
None are used at this time.
t g o\~r(s)

STEPPER = XXXXX

FORM 6263 Second Edition FORM 6263 Second Edition 3.02-3

3.02-2
KEYPAD AND DISPLAY INFORMATION
NOTE: Execution of keypad commands does not
happen instantaneously. Whenever a command is
beg carried out by e AFM module, the message
WORKING is displayed on e LCD display. To be sure
any subsequent commands will be accepted, wait until
the WORKING message has cleared from the AFM
moduledispY. The keypad functions a "press-and-
release manne Continuously depressing a keypad
button will either result in the desired action on being
executed once or not at all.
AFM MODULE CONTROL MODES
MANUAL CONTROL
NOTE: If an alarm condition exists, the AFM module
keypad will not function until the alarm is acknowledged
by pressing <ALARM ACK> on the keypad.
The AFM module must be in manual cntrol when AFM
system adjustments are made. Manual cntrol mode
can be used during system setup, troubleshooting r
when a sensor failure has occurred.
For engines with one regulator, press <LEFT MAN n
the AFM module keypad to put the module in manual
control. For engines with two regulators, press
<LEFT MAN> to put the left bank into manual cntrl
and press <RIGHT MAN> to put the right bank into
manual control. The AFM module can be operated with
one bank in manual control and the other bank in
automatic control.
In manual cntrol, large manual ustments to the
air/fUel ratio can be made. One press of the <LEFT/
RIGHT LEAN> or <LEFT/RIGHT RICH> buttons moves
stepper position 25 steps. By preing <LEFT/
RIGHT FAST> prior to pressing the lean or rich buttns,
a 400 step change is made to stepper psition.
AUTOMATIC CONTRL
When system adjustments are complete, put the AFM
module in automatic control mde by pressing
<AUTO OPER>.
NOTE: For engines with two regulators, when
<AUTO OPER> is pressed both enge banks will be
returned to automatic operation. If you only want one
engine bank in automatic, press <AUTO OPER>, then
the appropriate <LERIGHT MAN> button.
3.02-4
SECTION 3.05 - PROGRAMMING FOR CATALYST APPLICATIONS
PROGRAMMING THE AFM MODULE FOR
CATALYST CONTROL
USER INTERFACE PROGRAM STARTUP STEPS
NOTE: This manual assumes you are already miliar
with basic MDOS commands for viewing directories,
copying files, and other MS-DOS concepts. If you need
more information on these subjects, refer to a MS-DOS
instruction manual.
1. Review Section 3.00 General Programming lnfor-
mation for computer requirements, program layout, and
saving infornation.
2. Review Section 3.02 Keypad and Display lnforma-
tion for a detailed explanation of the AFM modules
keypad functions and LCD display messages.
3. Cmplete the preprogramming checklist in
Section 2.10 Prestart Ins1/ation Checklist before con-
tinuing.
4. With the engine NOT running and power OFF,
disconnect the intake manifold pressure transducer and
xygen sensr(s) by removing the analg connections
terminal block frm the header inside the AFM mdule
(see Figure 3.05-1).
pWER CNNECTINS
Figure 3.05-1. Analg And pwer Connections Inside
AFM Mdule
5. Apply power to the AFM mdule. The Power and
Alarm LEDs on the front covef the AFM mdule
light. The LCD display on the AFM module briefly
displays Waukesha CEC TEST the core EPROM
chip has not been previously programmed. If the core
EPROM was previously programmed, the LED displays
the current cntrl mode (fr example:
Stichimetric").
FORM 6263 Second Edition FOAM 6263$ond Edion
NOTE: A list of system errors will be displayed on the
LCD display. Messages on the display may include, but
not necessarily be limited to, 02 SIGNAL LO,
"IMP INPUT LO, and "02 TEMP LO. These mes-
sages are normal since these enge parameters are
below the test program limits with the intake manifold
pressure transducer and oxygen sensor(s) discon-
nected.
6. The AFM module must be programmed to work with
site specific infrmation in order for the AFM system to
function properly. li program the AFM mdule,connect
a standard DB-9 serial cable (male t female) t the
communications plabeled P1 A) within the AFM
module. This is the communications port on the right
(see Figure 3.05-2). Connect the other end of the cable
to the PC's communications port. Typical this is po 1
(also referred to as COM 1, serial Ar serial 1).
IA CAUTIN I;;:j~r
c!:r: i!h:e
cnnected t the appropriate c mputer p. If the
serial cable is disturbed r discnnected during the
saving prcess,the cre EPRM chip in the AFM
mdule will bee me crrupted and will need to be
replaced. Even previusly stred data-sets will n
lnger be functinal.
P1A cMMUNICATINS PRT
O FRONT VIEW DOOR PANa OPEN O
Figure 3.05-2. DB-9 Serial Cable cnnectin Inside
AFM Mdule
3.05-1
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

ESTABLISHING COMMUNICATION WITH THE

AFM MODULE I CEC AFM Control x .xx I I CEC AFM Control - Ver . X. xx I
cmplete Steps 1 - 7 in this section to establish
communication between yur PC and the AFM mdule.
1. Start the AFM User Interface Program n yu PC by
Communications Menu
accessing the drive and directory where the AFM
software is installed (typically: A: [Enter]). Select cm prt
Error Message
Com Device I/0 Errz Occurred
2. pe the name of the executable file e) for the AFM Check Parameters and Connectins
User Interce Program and press [Entetypically:
1 02 03 04 and Try Again.
AFMXXX [Enter] where XXX is the revisin level). Press ANY KEY t Continue

NOTE: To find e name of the executable file (.exe) for EE

the AFM User Interface Program, view the directory of Tesc er
nqp m Pa
ot #
r te

Lm
-

4
the drive on which your AFM User Interface Program is Figure 3.05-4. Cmmunications Menu o F -- AU

L

saved by typing DIR at the drive prompt and then -
pressing [Enter]. Listed the directory will be an 5. The AFM User Interface Program S Main Menu
executable file for the AFM User Interlace Program. The appears showing various program options available _
executable file for the AFM program is typically the (see Figure 3.05-5). Highlight Edit/Create Setup" and Figure 3.05-7. Cmmunications Error Message
letters AFMXXX.exe where XXX is the revision level. press [Ente
NOTE: The core and display EPROM chs must be
"matched with the AFM User Interface Program
version number. If the versions of the EPROM chips are I CEC AFM Control - Ver. X. Xx I I CEC AFM Control - Ver. X. Xx I
not the same as the User Interface Program version
number, the potential for errant operation exists and
programming will not work. Rer to Section 4.00
Edit/Create Setup
Air/Fuel Mdule System Trubleshooting Replacing
EPROMChs for more information.
View Serial Link
Quit Current Program is TEST PROGRAM
3. e enuine Waukesha Pa logo screen appears
No Configuration Data Exists.
briefly, followed by the screen shwn in Figure 3.05-3. e Retrieve Data from Filename
bottom line 1f this screen indicates what version of the r Create New Dataset.

AFM User Interface Program you are using.

Retrieve Data f rom AFM, File z Create New
Press ANY KEY t Continue

Figure 3.05-5. AFM User lnteace Program Main Menu

6. The Edit/Create Setup Menu shwn in Figure 3.05-6

CEC AFM Control
appears. Highlight Retrieve from AFM and press
user Interface Program
[Enter].
version x.xx
Figure 3.053. Sware Version Identification
4. Automatically the Communications Menu appears
(see Figure 3.05-4). A black dt is lcated in a circle
next b which indicates that the selected cornmunica-
tions pon yur computer is p 1 . Press [Enter] t
select communications port 1. If the DB-9 cable is
cnnected to a different port on your PC, use the arrow
keys on the keyboard to select the crresponding port
m the crnrnunications menu and press [Ente
(typilly: p 1 is correct).
I CEC AFM ntrol . x.xx
Retrieve from AFM
Retrieve from Filename
Create New Dataset
p.load Dat a From AFM va serial.
Figure 3.05-6. Edit/Create Setup Menu
Figure 3.058. Test Program Message
NOTE: If a communications error message appears
ee 1gure3.05 there is a communication problem
between your PC and the AFM module. Either there is
I no power to the AFM module, the seril cable is not
connected to the correct communications port, the
computer is not configured correcte core EPROM
ch corrupt, or the cable is defective. Veriat the
cable is connected to the correct communications port
on your PC. If it is not connected correctly, move the
cable to the correct communications port. Check the
general condition of the serial cable and replace the
cable if defective. Rer Section 4.00 Air/Fuel Module
the Main Menu to begin AFM module programming.
System Troubleshting for more troubleshooting for-
mation and core EPROM ch replacement structions.
Port
Press any key to continue.
7. If the AFM mdule has never been programmed for
an engine application, a message appears stating the
AFM mdule has been corgured for test purposes nly
(see Figure 3.05-8). Press any key to return to the Main
Menu. If the AFM system has been previusly pr
grarnmed for another engine applition, the data-set for
that engine applition is displayed. If you want to
program the AFM system using the data-set displayed
as a staing point continue with the section "Editing
Engine Applicaon Information. ' If you want to start from
a preprogrammed setup file (a completely new, nonsit,
specific data-s press [Esc] and then M to rern to
By completing Steps 1 - 7, communication between the
AFM module and your PC has been established.
cntime programming the AFM mdule with the next
section , Initial AFM Module Programming for Catalyst
Control Operation."

3.05-2 FORM 6263 Second Edition FORM 6263 Second Edition 3.05-3
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

INITIAL AFM MODULE PROGRAMMING FOR

CATALYST CONTROL OPERATION I CEC AFM Control - v. x.xx I CEC AFM cNTROL
LEFT RIGHT

After cmmunication has been established between 2 Lean Rich 02 Lean Rich
psiA S- P Limit Limit S- P Limit Limit
your PC and the AFM module, programming for your
Engine Family: VHP GAS ENGINE
specific engine applicatin can begin . File Select Engine Model: L7042GSI V-12 s.o 0.70 1 20000 0.70 1 20000
8.5 0.70 1 20000 0.70 1 20000
Sensor: 2-CATALYST CONTROL 12.0 0.70 1 20000 0.70 1 20000
NOTE: For the purposes of this manual, the examples ,Primary Fuel Type:
RSETUPOl.AFM 15.S 0.70 1 20000 0.70 1 20000
and gures used are based on e programming of a NATURAL GAS PIPELINE QUALITY
19.0 0.70 1 20000 0.70 1 20000
RSETUP02.AFM ,Secondary Fuel Type:
12 cylinder VHP L5790GSI engine. Although there are 22.s 0.70 1 20000 0.70 1 20000
RSETUP03.AFM NONE
slight screen variations for each enge mily, the 26.0 0.70 1 20000 0.70 1 20000

START P
programmg steps presented this manual are the RSETUP04.AFM
same. The values in the examples and figures are for RSETUPOS.AFM H
..
.. Comments:
LEFT= 10000 RIGBT=lOOOO

REFERENCE ONLY. Actual values are specific to your RSETUP06.AFM ....

.. RICHBURN SETUP FILE #1
engine applicatio RSETUP07.AFM ..
..
RSETUPOS.AFM ..
PWM Out= 0
1. With the AFM User Interface Programs Main Menu RSETUP09.AFM EE LTemp=350 c Hi-Temp=760 c
showing on your screen, highlight EdiVCreate Setup" RSETUPlO.AFM
and press [Enter] (see Figure 3.05-9). Deadband 0.005 Gain= 5.000
2. Highlight Retrieve from Filename on the EdiVCreate
Setup Menu and pss [Ensee Figure 3.05-10). A list Figure 3.05-11. File Select Menu SA 11 ESC NU I
of preprogrammed files (RSETUP##.AFM) appears (see
Figure 3 .05-11 ).
Selecting A Preprogrammed Setup File
Figure 3.05-12. Preprogrammed Setup File RSETUP01 - Catalyst Equipped VHP Appllcatins
Preprogrammed setup files were developed to make
AFM module programming easier and faster. The Table 3.05-1. Preprogrammed Setup Files Fr Catalyst 2. After answering the four questions in Step 1,
cntrol peration
I CEC AFM Control - Ver. X.Xx I values stored in these files will get you started in
VHP VEE ENGINES WITH CATALYST cNTRL
carefully select the setup file from Table 3.05-1 that was
created for your engine application. Selecting the wrng
creating a data-set for your specific engine applicatin .
The values of the preprogrammed files are generic and Filename Use Fr ... setup file may result in air/fuel control that is less than
must be edited for optimum air/fuel ratio contrl following optimum.
Edit/Create Setup ~~F~es with two 5211, 5201, 66, or 662
the programming procedures in this manual. It is R5ETUP01 d step20,000 ste of aust-
View Serial Link
Quit
recmmended that you use a preprogrammed file from
this listing to program the AFM module instead of starting
with a compitely new, nonsite-specific data-set.
R5ETUP02 :
GSI engines with two 99 or 1~ e~fulators and
steppers (5800 steps of adju
NOTE: The preprogrammed files listed on the File
Select Menu but not included in Table 3.05-1 are
preprogrammed setup files used when programmg

The preprogrammed setup files va with engine

configuration and fuel regulator model. Example: All
R5ETUP03 ~i1l~! ~f.n~ steppers
two 5211(2i~grio 66, or of
steps 662
non-catalyst control modes (best power/economy or
lean burn control modes).
Retri eve Data rom A.FM, Fi. le r Create New.
VHP GSI vee engines with Fisher 66, 662, 5201, and G engines with two 99 oa~u~~~w~tors and 3. Highlight the appropriate preprogrammed file on the
R5ETUP04 steppers (5800 steps of
S211 regulators, which includes VHP models 5108, File Select Menu and press [Entesee
Figure 3.05-9. AFM User Interface Program Main Menu 5790, 7042, and 9390, use setup file RSETUP01. Figure 3.05-11). The Edit Screen appears displaying
VHP IN-LINE ENGINES WITH CATALYST cNTRL
Similarly, VHP models 2895 and 3521 use a commn the preprogrammed setup file information (see
setup file.

1 . Answer the f!lowing four questins before selecting

Filenane

R5ETUP07
Use Fr ...
:
G51 engines with one 99 or s~ eanf;'.9ulator and
Figure 3.05-12).

:
stepper (5800 steps of adju NOTE: When the setup file appears on the Edit Screen,
it will show engine mily, model, and fuel type informa-
I CEC AFM Cont Ver. x.xx I a preprogrammed setup file.
RSETUP08 G
s~~d~
tep~ (20 6 adjustm
52~JcJ ~6of 662
tion for an enge model. This applicationformation is
A. What is the engine family: VHP or VGF? for reference only and will not affect AFM system control.
R5ETUP09 ~U~a~ste:e~1
11 ~e
m,forune
Z
B. What is the engine configuration: in-line or
Retrieve from AFM vee? RSETUP10 stepper (5800 steps of adjustm
!
G engines with one 99 or 1098 ~ij~lator and
Retrieve from Filename
C. What air induction conguration (aspiration) VGF IN-LINE ENGINES WITH CATALYST cNTRL
Create New pataset
does the engine have: natural (Gr turbo-
Filename Use Fr ...
charged (GSI
RSETUP13 ~5~~~~~
tep~ ~%~~e1i;sof
or~Znent).
D. What fuel regulator(s) is installed: Fisher
Retri eve nata f rOJII a Di.sk Fi le.
ContrIs Mdel 66, 662, 8201 , S211 , 99r
1098?
Figure 3.05-10. Edit/Create Setup Menu

3.05-4 FORM 6263 Second Edition FORM 6263 Second Edition 3.05-5
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

Editing Engine Application Information 2. Highlight the correct engine family and press [Enter]. 4. H ighlight the crrect engine air inductin cnfigura 5. Highlight the type of primary fuel the engine is using
tion (aspirationn the Engine Fuel System Selectin on the Primary Fuel Selection Screen and press [Ente
1 . With the Edit Screen displayed on your PC, press the 3. Highlight the correct engine model on the Engine
Screen and press [Entesee Figure 3.05-15). (see Figure 3.05-16).
"UP arrow key until th~. Engine Family Selection Screen Model Selectin Screen and press [Enter] (see
appears as shown in Figure 3.05-13. Figure 3.05-14).
LEFT RIGHT
CEC AFM CONTROL
LEFT RIGHT 02 Lean Rich 02 Lean Rich
psiA s - p Limit Limit s - p Limit zmit
CEC AFM CONTROL Lean Rich Engine Family: VHP GAS ENGNE
2 Lean Rich 02

s - p Limi t Limit 0.70 20000 0.70 20000
psiA s - p Limit Limit Engine Model : L7042GSI V-12
0.70 20000 0 . 70 20000
Engine Family: VHP GAS ENGINE p Sensor: 2-CATALYST CONTRL 0.70 20000 0.70

E
s.o 0.70 1 20000 0.70 1 20000 20000
Engne Model: L7042GSI V-12 .Primary Fuel Type: 0.70 20000 0.70

E EA 4
20000

E A
r 8.5 0.70 1 20000 0.70 1 20000
NATURAL GAS PIPELINE QUAL
Sensor: 2-CATALYST CONTROL i 12.0 0.70 1 20000 0.70 1 20000 0.70 20000 0.70 20000
,Secondary Fuel Type:

L
rimary Fuel Type: .70 1 20000 0.70 1 20000 0.70 20000 0.70 20000
7 NONE

4
NATURAL GAS PIPELINE QUALI ~ ATGL Gas Engines 0.70 1 20000 0.70 1 20000 0.70 20000 0.70 20000
cse~~~~ary Fuel Type: VBP Gas Engines 0.70 1 20000 0.70 1 20000
VGF Gas Engines 0.70 1 20000 0.70 1 20000 POS. LEFT= 10000 RIGHT=lOOOO
VSG Gas Engines Comments:
- - , <HA.r\ POS. LEFT= 10000 RIGHT=lOOOO
RICHBURN SETUP FILE #1
cmments:

RICHBURN SETUP FLE #1 PWM Out= 0

Lo-Temp=350 c
PWM Out= 0

Lo-Temp=350 c Hi-Temp=760 c
Deadband =:1:0.005 Gain= 5.000

Deadband 0.005 Gain= 5.000

FlO = SAVE 11 ESC NU I
I FlO = SAVE II ESC
Figure 3.05-15. Engine Fuel System Selection Screen

Figure 3.05-13. Engine Family Selection Screen

LEFT RIGHT
CEC AFM CONTRL
LEFT RIGHT 02 Lean Rich 02 Lean Rich
s - p Limit Limit s - p Limit Limit
CEC AFM CONTROL Rich Engine Family: VHP GAS ENGINE
02 Lean Rich 02 Lean

E A

L
20000 0.70 20000
ps.iA s - p Limit Limit s - p Limit Limit Engine Model: L7042GSI V-12

20000 0.70 20000
,

Sensor: 2-CATALYST CONTROL

A
Engine Family: VHP GAS ENGINE 0.70 20000 0.70 ..
20000 20000 0.70 20000

4

Engine Model: L7042GSI V-12 0.70 20000 ,Primary Fuel Type: 20000 0.70 20000
0.10 20000
NATURAL GAS PIPELINE QUALI 20000 0.70 20000
Sensor: 2-CATALYST CNTROL 0.70 20000 0.70 20000

1Secondary Fuel Type: 20000

44
..
4

,Primary Fuel Type: 0.70 20000 0.70 20000

...., NONE

L NATURAL GAS PIPELINE QUALI 0.70 20000 0.70 20000 Natural Gas Pipeline Quality (119 c:tane) 20000
,Secondary Fuel Type: 0.70 20000 0.70 20000 Field Gas (115 - 119 Octane)
NONE 0.70 20000 0.70 20000 Propane RIGHT=lOOOO
Comments: Digester Gas
POS. LEFT= 10000 RGHT= lOOOO Landfill Gas
RICHBURN SETUP FILE #1
Connts:

RICHBURN SETUP FILE #1 PWM Out= 0

LTeinp=350 c Hi-Temp=760 c
m oe
PL um==nue3
tD nu

Deadband 0.005 Gain= 5.000

Deadband 0.005 Gain= 5.000

FlO = SAVE ||
FlO = SAVE I[ ESC
Figure 3.05-16. Primary Fuel Selection Screen

Figure 3.05-14. Engine Mdel Selection Screen

3.05-6 FORM 6263 Second Edition FORM 6263 Second Edition 3.05-7
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

6. Currently, the AFM system is designed for single fuel 8. After the engine application information .is selected,
engine applications F ne fuel of dual-fuel engines). confirm your selections by pressing M at the confirma- LEFT RIGHT
Highlight NONE and press [Entern the Secndary tin message (see Figure 3.05-19.he engine applica- CEC AFM cNTROL
02 Lean Rich 2 Lean Rich
Fuel Selection Screen (see Figure 3.05-17). Always tin block will now be updated to reflect your changes. psiA s - p Limit Limit s - p Limit Limit
select NONE frm this screen. Engine Family: VHP GAS ENGINE
Engine Mdel: L7042GSI V-12 :I s.a
R i:;
II 0.10
n 70
1
1
20000
nnn,
0.70
0.70
1
1
20000
20000
7. Highlight Catalyst cntroln the cntrol Mode Sensor: 2-CATALYST C
0.70 1 20000
1.;rimary Fuel Type:
Selection Screen and press [Entesee NATURAL GAS PIPELI
0.70 1 20000
yu Have Changed Options 0.70 1 20000
Figure 3.05-18). econdary Fuel Type:
That May Invalidate and 0.70 1 20000
NONE
Change Other Data! 0.70 1 20000
LEFT RIGHT
CEC AFM CONTROL Do You Want To Continue? RIGHT=lOOOO
02 Lean Rich 02 Lean Rich Comments:
s - p Limit Limit s - p Limit Limit
R CHBURN SETUP FILE ,
Engine Family: VHP GAS ENGINE 1111111

A
20000
Engine Model: L7042GSI V-12

4
20000 PWM Out
Yes N esc

Sensor: 2-CATALYST CONTROL

4
20000
Lo--Temp=350 c

4
,Primary Fuel Type: 20000
NATURAL GAS PPELINE QUALI 20000
,Secondary Fuel Type: 20000
Deadband 0.005 Gain= 5.000
~ NONE 20000
NONE
Natural Gas Pipeline Quality (119 Octane)

cmments:
Field Gas ( 115 - 119 Octane)
Prpane
Digester Gas
RIGHT=lOOOO
I FlO = SAVE ESC NU I
RICHBURN SETUP FILE #1
Landfill Gas

PWM Out= 0
Figure 3 .05-19. Cnfirmation Message
Lo--Temp=350 c Hi-Temp;:760 c Saving Setup File T RAM NOTE: The contents of RAM are lost whenever power
to the AFM module is removed.
The initial setup file must be saved to RAM (temporary
Deadband =:0.005 Gain= 5.000
mem to permit testing and editing of this data-set. 1 . Press [F1 OJ to save the preprogrammed file data and
edited application information to RAM (temporary
NOTE: Each time modifications are made to the
mem
FlO = SAVE 11 ESC data-set, the data-set must be saved to RAM before
the edited values aect control of the AFM system and 2. Highlight ''"Test Data on AFMn the Saving Options
can be tested. Simply editing the values on e AFM Menu and press [Enter] (see Figure 3.05-20).
Figure 3.05-17. Secndary Fuel Selection Screen User Interce Program screens will not change AFM
system operation.
LEFT RIGHT
LEFT RIGHT
CEC AFM CONTROL
2 Lean Rich 02 Lean Rich CEC AFM CONTROL
psiA s - p Lnit Limit s - p Limit Limit 2 Lean Rich 02 Lean Rich
Engine Family: VHP GAS ENGINE psiA s - p Limit Limit s - p Limit Limit
p s.o 0.70 1 20000 0.70 1 20000 Engine Family: VHP GAS ENGINE
Engine Model: L7042GSI V-12 r p 5.0 0.70 1 20000 0.70 1 20000
8.5 0.70 1 20000 0.70 1 20000 Engine Model: L5790GSI V-12
Sensor: 2-CATALYST CONTRL i 12.0 0.70 1 20000 0.70 1 20000 r 8.5 0.70 1 20000 0.70 1 20000
rimary Fuel Type:
NATURAL GAS PIPELINE QUALI
- 'II!" !"
0.70
0.70
1
1
20000
20000
0.70
0.70
1
1
20000
20000
Sensor: 2-CATALYST cNTRL
Primary Fuel Type:
i 12.0 0.70

1
1
20000
20000
0.70
0.70
1
1
20000
20000
Application Type L NATURAL GAS PIPELINE QUALI
e~~~~ary Fuel Type:
s 0 . 70 1 20000 0.70 1 20000 Save Data to Filename
1 20000 0.70 1 20000
n
1 20000 0.70 1 20000 e~~~~ary Fuel Type:
~s 1 20000 0.70 1 20000
Test Data on AFM 1 20000 0.70 1 20000
LEFT= 10000 RIGHT=l OOOO Configure AFM Memory
.C atalyst Control LEFT= 10000 RIGHT=lOOOO
cmments:

Best pwer /Economy

Commer.ts: I
RICHBURN SETUP FILE #1
RICHBURN SETUP FILE #1

PWM Out= 0
PWM Out= 0
Lo--Temp=350 c Hi-Temp=760 c
Lo--Temp=350 C Hi-Temp=760 C

Deadband .005 Gain= 5.000

Deadband =%0.005 Gain= 5.000

I FlO = SAVE II ESC = MENU I I FlO = SAVE II ESC NU I

Figure 3.05-18. AFM System cntrol Mde Selection Screen
Figure 3.05-20. Saving ptins Menu

3.05-8 FORM 6263 Second Edition 3.05-9

FORM 6263 Second Edition
PROGRAMMING FOR CATALYST APPLICATIONS
PROGRAMMING FOR CATALYST APPLICATIONS

LEFT RIGHT
CEC AFM CONTROL LEFT RIGHT
2 Lean Rich 2 Lean Rich CEC AFM CONTROL
psiA s - p Limit Limit s - p Limit Limit 2 Lean Rich 02 Lean Rich
Engine Family: VHP GAS ENGINE p psiA s - p Limit Limit s - p Limit Limit
Engine Model: L5790GSI V-12 5.0 0.70 1 20000 .70 1 20000 Engine Family: VHP GAS ENGINE
r 8.5 0.70 1 20000 0.70 1 20000 Engine Model: L5790GSI V-12 5. 0 0.70 1 20000 .70 1 20000
Sensor: 2-CATALYST CONTROL n n '7 n 1 ,nn .70 1 20000 8.5 0.70 1 20000
~rima Fuel pe: Sensor: 2CATALYST CONTROL 0.70 1 20000
IO 0.70 1 20000 12.0 0.70 1 20000 0.70 1 20000
NATURAL GAS PIPE bO ,Primary Fuel Type: 15.5 0.70
0.70 1 20000 7 NATURAL GAS PIPELINE QUALITY
1 20000 0.70 1 20000
s e~~~~ary Fuel Typ Store Test Values 0.70 1 20000 ,secondary Fuel Type:
19.0 0.70 1 20000 0.70 1 20000
0.70 1 20000 22.5 0.70 1 20000 0.10 1 20000
NONE
This will Stop Program Execution y 26.0 0.70 1 20000 0.70 l 20000
START
and RESTART Program when finished. DO RIGHT=lOOOO
Comments: LEFT= 10500 RIGHTc10750
RICHBURN SETUP FIL Comments:
RICHBURN SETUP FILE #1
Yes No esc
PWM Out= 0
Lo-Temp=350 c PWM Out= 0
LoTemp=350 c Hi-Temp=760 c STEPPER START
pSITIN
Deadband .005 Gain= 5. 000
Deadband =:0.005 Gain= 5.000

I FlO = SAVE I I ESC FlO = SAVE J I ESC NU I

Figure 3.05-21. Cnfirmation f Save T Randm Access Memory (RAM)
Figure 3.05-23. Entering Stepper Motor Start psitin

LEFT RIGHT NOTE: Data-sets that are created can be saved to a 1. Press <LEFT MAN> and <RIGHT MAN> (if applica-
CEC AFM CONTROL filename for future rerence. Data-sets are assigned ble) on the AFM module keypad to put the AFM module
02 Lean Rich 02 Lean Rich filenames and saved on disk so the user can retain and
psiA s - p Limit Limit s - p Limit Limit in manual control.
Engine Family: VHP GAS ENGINE p retrieve the data-set late When saVig to disk, the
Engine Model: L5790GSI V-12 5.0 0.70 1 20000 .70 1 20000 data-set will be saved to the drive and directory where 2. Review the riginal gas/air pressure seing re-
Sens r : 2-CATALYST cNTROL
8.5 0.10 1 20000 .70 1 20000
n - n oo
0.70 1 20000 the AFM User Interface Program was accessed. See corded BEFRE the stepper motor was installed.
Primary Fuel Type boo 0.70 1 20000
L NATURAL GAS PIP 'Saving Data-Set to Disk" in this section to save your
)00 0.70 1 20000 3. Measure current gas/air pressure with a manometer.

Se~~~~ary Fuel Ty Starting RAM Program. 000 20000
data-set to a filename.
0.70 1
boo 0.70 1 20000 4. Use the manual adjus1ent keys on the AFM module
Program is Running. ESTABLISHING ENGINE START POSITION
DOO RIGHT=lOOOO keypad to change gas/air pressure as required to
Test Values are Saved in RAM. Most values stored in the preprogrammed files should duplicate original gas/air seing. Once current gas/air
Comments:
RICHBURN SETUP FI be reasonable for initial programming of the AFM setting is equal t original gas/air, the stepper motor
module. Hwever, some modication to the stepper sta psitin can be set.
Press ANY KEY to Continue motor start position setting may be required to
PWM Out= 0
Lo-Temp=350 c facilitate engine starting. To determine start position 5. Press [Enter] or use arrow keys until the cursor is in
complete the steps in this section. the left/right STARTPOS field on the Edit Screen (see
Deadband =:!:0.005 Figure 3.05-23).
NOTE: If your enge has on. one fuel regulator, the
'left" buttons on the AFM module keypad control the 6. Read the stepper position displayn the AFM
I FlO = SAVE I I ESC NU I engine's aifi1el ratio. If your engine has two fuel
regub the keypad buttons control the engine's
modules LCD display R STEPPER = XXXX:. Pr
<DSPL SEL> on keypad to scroll through LCD meages.
left bank and the "right keypad buttons control the
Figure 3.05-22. Cnflrmatin f Save To RAM engine's right bank. 7. Enter the stepper position in the left/right
STARTPOS.eld on the Edit Screen and press
3. The confirmation screen shown in Figure 3.05-21 CEC Stoichiometric, then the normal AFM LCD dis- If your engine has two fuel regulators, complete
[Enter] (see Figure 3.05-23).
appears. Press M to confirm save to RAM. plays will appear. Steps 1 - 7 fr each fuel regulator.

4. Several screens will appear indicating that the
data-set is being saved to RAM. The LCD display on the
AFM module will read EXECUTION STOPPED BY
USER. Once the data-set has been saved to RAM, the
message shown in Figure 3.05-22 appears. The LCD
display on the AFM module will briefly read Waukesha
5. Press any key t cntinue. NOTE: If an alarm condition exists, the AFM module
keypad will not function until the alarm is acknowledged
NOTE: If the 'E XECUON STOPPED BY USER by pressing <ALARM ACK> on the keypad.
message persists on e AFM display for more than five
minutes, refer to Section 4.00 Air/Fuel Module System
Troubleshooting.

3.05-10 FORM 6263 Second Edition FORM 6263 Second Edition 3.05-11
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

LEFT RIGHT LEFT RIGHT

CEC FM CONTROL cEc AFM CNTROL
02 Lean Rich 02 Lean Rich 2 Lean Rich 02 Lean Rich
psiA s - p Limit Limit s - p Limit Limit psiA s - p Limit L:unit s - p Limit Limit
Engine Family: VHF GAS ENGINE Engine Family: VHF GAS ENGINE
p s.o 0.70 1 20000 0.70 1 20000 p 5.0 0.70 1 20000 0.70 1 20000
Engine Mode z L5790GSI V-12 20000 Engine Model: L5790GSI V-12
r 8.5 0.70 1 20000 0.70 1 8.5 0.70 1 20000 0.70 1 20000
Sensor: 2-CATALYST CONTROL 20000 0.70 1 20000 Sensr: 2-CATALYST CONTROL i , ., n n 7n
i 12.0 0.70 1 n 0 . 70 1 20000
rimary Fuel Type: 1 20000 .70 1 20000 ary F Type:
0.70 1 20000
NATURAL GAS PIPELINE QUALI 1 20000 0.70 1 20000 NATURAL GAS PIPE
0.70 1 20000
Save Data to Filename 0.70 1 20000 econdary F Typ
e~~~~ary Fuel Type:
s 1 20000
NONE Store Test Values 0.70 1 20000
1 20000 0.70 1 20000

.
Test Data OD AFM )0 0.70 1 20000
configure AFM Memory This will Stp Prgram Execution
LEFT"' 10500 RIGHT"'l0750 and RESTART Program when finished. RIGHT=l0750
comments: Comments:
RICHBURN SETUP FILE #1 RICHBURN SETUP FIL

Yes N esc
PWM Out"' 0
PWM Out= 0%
Hi-Temp=760 c Lo-Temp=350 c
Lo-Temp"'350 c

oeadband 0.005 Gain"' 5.000 Deadband 0.005 Gain= 5.000

I FlO ; SAVE II ESC ; MENU I I FlO = SAVE II NU I

Figure 3 .05-24. Saving ptinsMenu Figure 3.05-25. Cnfirmation Of Save T Randm Access Memry (RAM)

NOTE: Each time modifications are made to the NOTE: If the "EXECUTION STOPPED BY USER
data-set, the data-set must be saved to RAM before message persists on e AFM display for more than five LEFT RIGHT
the edited values aect control of the AFM system and minutes, rer to Section 4.00 Air/Fuel Module System CEC AFM CNTR1L
02 Lean Rich 2 Lean Rich
can be tested. Simply editing the values on e AFM Troubleshooting.
psiA s - p Linu.t Limit s - p Limit Limit
User Interface Program screens will not influence AFM Engine Fnily: VHP GAS ENGINE
12. Return t the Main Menu by pressing [Esc]. p s.o 0.70 1 20000 0 . 70 1 20000
system operation. Engine Model: L5790GSI V-12
Figure 3.05-26 appears on the screen warning you to r 8.5 0.70 1 20000 0.70 1 20000
Sensor: 2-CATALYST CONTROL
l. 12.0 0.70 1 20000 0.70 1 20000
NOTE: The contents of RAM are lost whenever power save any changes made to the data- set before exiting. Primary Fuel Type:
0.70 1 20000
Since the data-set has already been saved to RAM, L NATURAL GAS PIPEL 0.70 1 20000
to the AFM module is removed. D
~econda Fuel Type
press Mt return to the Main Menu. NONE Exit to Main Menu
0.70 1 20000
0.70 1 20000
8. Press [F1 OJ t save the edited sta psition informa-
tion to RAM (tempera memo NOTE: Data-sets that are created can be saved to a Changes Will be Lost i f
RIGHT=l0750
filename for future rerence. Data-sets are assigned Comments:
you Have Not Saved Them.
9. Highlight lest Data on AFM on the Saving Optins filenames and saved on disk so the user can retain and RICHBURN SETUP FILE Do you REALLY Want t EXIT?
Menu and press [Entesee Figure 3.05-24). retrieve the data-set late When saving to disk, the
data-set will be saved to the drive and directory where PWM Out= 0
1 o. Press M to confirm save to RAM (see e AFM User terface Program was accessed. See LTemp=3soc Yes No esc
Figure 3.05-25). "Saving Data-Set to Dik this section to save your
data-set to a filename. Deadband 0.005
11 . Several screens will appear indicating that the
data-set is being saved to RAM. The LCD display on the
AFM module will read EXECUTION STOPPED BY I FlO = SAVE 11 ESC = MENU I
USER. Press any key to continue after the save to RAM
is complete.
Figure 3.05-26. Cnfirmation Of Exit T Main Menu

FORM 6263 Second Edition FORM 6263 Second Edition 3.05-13

3.05-12
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

10. Enable AUTOMATIC cntrl by pressing the programmable limits required in programming the AFM
CEC AFM Contr1
<AUTO OPER> key on the AFM mdule keypad. The left module.
and right status shwn on the View Serial Link Screen
Engine Model: I,,5790GSI V-12 Sensor Type: CATALYST CONTROL If your engine application requires very precise cntrol
will change to AUTOMATIC (see Figure 3.05-31 ). The
of air/fuel ratio at varius engine loads to meet
AFMmdule will begin adjusting the stepper pasion to
I emissions regulations, follow the procedure labeled
Left Bank I Right Bank control the engines air/fuel ratio.
Gathering Data for Variable Oxygen Sensor Set-
NOTE: If any alarm messages come on dur,g opera- Points. If, however, such precise control is not required,
SENSOR: tion of the AFM system, rer to Section 4.00 Air/Fuel follow the procedure labeled Gathering Data for
Voltae 0.692 volts 0.692 volts
Mdule System Troubleshooting and Section 4.05 cnstant Oxygen Sensr Set-Pints.
SetPoint o. 700 volts O. 700 volts
Temperature 552 c 551 C Air/Fuel Module System Diagnsties to troubleshoot the NOTE: If your engine has only one fuel re
PWM Output 0 % O
system. 'RICH LIMITr"L4.N LIMIT errors are good "left'' buttons on the AFM module keypad control the
indicators that e carburetor screw(s) needs adjusting. eng.e's air/fuel ratio. If your engine has two fuel
STEPPER:
Position 10500 10750 regulars, the "left" keypad buttons control e enge
11. To permit significant rich and lean adjustments t
Lean L:unit 1 1 le bank and e "right' keypad buttons control the
Rich Limit 20000 20000 the AFM system, it may be necessary to adjust the
eng.e's right bank. When completing the steps is
carburetor screw(s) so the AFM system controls close
INT. MAN.
Pressure 13.1 psiA
u to the middle of the stepper motor range. Once the AFM
system has gained control of the aifuel ratisensor
volge readings are very near sensor set-pint), aust
the carburetor screws until the AFM system is control-
section, eng.es with one fuel regulator require only "left
values to be determed; enges w two fuel regulators
require independent "left'' and ht" values to be
determined.

j
L Status: MANUAL
Enclosure Temp. R Status: MANUAL ling close to the middle of the stepper motor range which Gathering Data Fr Variable Oxygen Sensr
is 10,000 steps fr 66, 662, S201 , S211 regulators or Set-Pints
2900 steps fr 99, 1098 regulators.
VEW SERIAL LINK <ESC> to EXIT Very precise control of air/fuel ratio to meet emissions
12. Once you are satiS'ed that the AFM system is regulations is achieved by determining and program-
Figure 3.05-30. AFM Mdule In Manual Mde controlling air/fuel ratio for the engine and no errors ming sensor voltage and lean/rich limits at various
occur, cntime with Fine-Tuning AFM Programming engine loads. Cmplete the Catalyst Control Worksheet
For Catalyst Applications to adjust the system for for variable oxygen sensor set-points by following the
CEC AFM Contrl
optimum air/fuel ratio cntrol. steps in this sectin.
Engine Model: L5790GSI V-12 Sensr Type: CATAYST cNTROL
NOTE: If very precise air/fuel ratio control is NOT
FINE-TUNING AFM PRGRAMMING FOR
CATALYST APPLICATIONS required at various enge loads to meet emissions
regu.tions, follow the procedure labeled 'Gathering
Left Bank I Right Bank I Once initial programming of the AFM module is Data for Constant Oxygen Sensor Set-Points."
complete and the preliminary data-set is saved to RAM,
soeew
Rtpmvl
E mvSTF
the AFM module must be fin tuned for optimum The AFM system adjusts the stepper motor between

CM --
ltmm

aoeO
enat
q7lru 0.697 v lts 0.694 volts air/fuel ratio contrI. li fine-tune the AFM module it will two programmable limits to maintain the xygen sensor
ttp
e
rt
O. 700 volts O. 700 volts be necessa to determine oxygen sensor target set-pint voltage. The lean and rich limits, which define
uu 551 C 552 C
O O
voltage(s) and stepper motor rich/lean limits. A work- the stepper motor adjustment range, are determined by
sheet is provided to help you in determining the establishing an air/fuel ratio curve.
STEPPER:
psition 10400 10890
Lean Limit 1 1
Rich Limit 20000 20000

INT. MAN.
Pressure 13.1 psiA

j
L Status: AUTOMATIC
Enclosure Temp. R Status: AUTOMATIC

VIEW SERIAL LINK <ESC> to EXIT

Figure 3.05-31. AFM Module In Autmatic Mde

3.05 -6 FORM 6263 Second Edition FORM 6263 Second Edition 3. 17

PROGRAMMING FOR CATALYST APPLICATIONS
PROGRAMMING FOR CATALYST APPLICATIONS

1 s~mT i --- R'EH EER ilMITS..;::::::: Table 3.05-2. View Serial Link Screen And Catalyst Control Worksheet (GSI Applications) -Variable Set-Pints

! ! ; l

/
! j

l
. CEC AFM cntrol

Engine Model: L5790GSI V-12 Sensor Type: CATALYST CONTROL

I I
r
Left Bank Right Bank

S
SENSOR:
Voltae
SetPoint ~
0.700 vlts 9 ~~~ ~
ts";)
Temperature 551 C 552 c
PWM Output

STEPPER
NOTE: Desired air/fuel ratio andsP_er limits can be programmed for various loads. 7i e STEPPER:
Position
g;:>/ PSITION
Lean Limit 1 1
Rich Limit 20000 20000
Figure 3.05-32 illustrates a sample air/fuel rati curve. 3. Adjust engine load for generator ss, or load and INT. MAN.
Combustion instability occurs when combustion pres- speed for cmpressors, until the HIGHEST rnap-pint Pressure G
sure within the engine diminishes as load is reduced. (intake manifold pressure, psiA) achievable with
The combustion stability limit is the pint where manufacturers ratings is met as indicated n the View
combustion is no longer stable and exhaust xygen is Serial Link Screen (see Table 3.05-2). INTAKE L Status: MANUAL
Enclosure Temp. MANIFLD
R Status: MANUAL
not a gd indicator f air/fuel rati PRESSURE
NOTE: The highest map-point in Table 3.05-2 is
The cmbustion stability limit can be found by gradually 26.0 psiA. If, however, manufacturer s rated load is VIEW SERAL LINK <ESC> to EXIT =
decreasing engine load until the exhaust oxygen and in-between map-points, adjust engine load to the next
carbon monxide concentrations bth increase sharply lower map-point. For example, if rated load is 24.5 psiA,
(using CO and 02 meters). This sharp increase
indicates the combustin stability limit. If detection is
then adjust engine load to map-point 22.5 psiA (see MAP-PO IN s~.JN~ CURRENT
STEPPER LEAN LIMIT RICH LIMIT
Table 3.05-2). (volts) POSITION
difcult, an alternative is to make the combustin INTAKE MANIFLO
stability limit point 60 BMEP. Generally, Iads greater PRESSURE (psiA) LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT
NOTE: One press of the <LEFT/RIGHT LEAN> or RIGHT
than 60 BMEP are stable. <LEFRIGHT RICH> buttons moves stepper psion
5.0
25steps (1/16turn). By pressing <LEFT/RIGHT .ST>
1. Detach or copy the blue Catalyst Control Worksheet
prior to pressing the lean or rich buttons, a 400 step 8.5
from the back of this manual (see Table 3.05-2 for
(1 turn) change is made to stepper positiin.
sample worksheet).
12.0
NOTE: One side of the Calyst Control Worksheet 4. Using exhaust analyzers (CO and 02 meters), adjust
applies to G enges and the other applies to GS/ the air/fuel rati by pressing <LEFT LEAN> and 15.5
enges. The map-points are different for G and GS/ <LEFT RICH n the keypad until a desired ernissins
engines. Make sure you use the side of the worksheet level is met for the map-point. If your engine has two 19.0
that applies to your engine application. fuel regulatrs, repeat this step for the engine s right
bank using the "right' keypad buns. 22.5
NOTE: If an alarm condition e:xi the AFM module
keypad will not nction until the alarm is acknowledged 5. Record the sensor voltage displayed on the View 26.0 .82 .82 10,650 11,750
by pressing <ALARM ACK> on the keypad. Serial Link Screen in the 02 Sensor Set-Point" column
on yur worksheet (see Table 3.05-2). NOTE: The values in this ble are for reference ONLY. Actual values are specific to your engine appli1tion.
2. Put the AFM mdule into manual mode by pressing
<LEFT MAN> and <RIGHT MAN> (if applicablen the 6. Record the stepper position displayed n the View
AFM module keypad. Serial Link Screen in the Current Stepper psition
column on yur worksheet (see Table 3.05-2) .

3.05-18 FORM 6263 Second Edition

FORM 6263 Second Edition 3.05-19
PROGRAMMING FOR CATALYST APPLICATIONS
PROGRAMMING FOR CATALYST APPLICATIONS

A WARNING
Never set the rich limit abvesf mercury gas/air PROGRAMMING SCENARIO (VARIABLE OXYGEN SENSOR SET-POINTS)
pressure. Setting the rich limit abve this pressure
"setting culd result in product damage andr NOTE: The values and readings used in is programming scenario are sample values only. Actual values and
severe personal inju readings will va depending on engine app/i.1tion. Guidelines presented apply to most engine applications.

7. Determine a lean and rich limit for the map-point
f!lowing the guidelines belw and Figure 3.05-33:
At engine loads above the combustin stability limit,
current recmmendations are to set the lean/rich
limits 2 air/fuel ratios or less.
At engine lads below the combustion stability limit,
the lean/rich limits shuld be set to prevent driving
the engine into rich and/or lean misfire. A stang
pint fr determining the rich limit is the riginal
gas/air pressure seing. The starting point can then
be mdified as required to achieve desired operation.
Fr example: If prior t installation of the AFM system
the gas/air setting was 6 H20, use the stepper limits
to permit only 6 H20 gas/air belw the combustin
stability limit. Use a manometer to make this
measurement.
0 0
NOTE: Stepper motor lean and rich limits 2aiiiel
The following programming scenario demonstrates how a technician fine-tuned the AFM module program
while following the steps in the AFM manual {Form 6263). Within the text of the scenario below, the
programming step the technician is completing is indicated.
A technician is programming a L5790GSI Waukesha
Engine with Fisher 8211 regulators following the program-
ming procedures in the AFM manual (Form 6263). After
completing the initial programming requirements, the
technician is ready to continue with the section Fine-Tun-
ing AFM Programming for Catalyst Applicatins.
Step 1: The technician makes a copy of the blue Catalyst
Control Worksheet from the back of the AFM manual.
Step 2: The <LEFT MAN> button and then <RIGHT MAN>
button on the AFM module keypad are pressed to put bth
engine banks in manual mode. Step 3: With the engine
running, engine load is adjusted to map-point 22.5 psiA.
(Since rated load for the engine being pogammed is 24.0
psiA, the maximum achievable map-point is 22.5 psiA.)
Step 4: The technician desires to run the engine at best
14 15 16 17 18 19 20 21 catalyst out emissions. Using an exhaust analyzer.r/fuel

ratios) can be determed by moving 1 ailiel ratio and
doubling the change in stepper position. For example: An
engine at desired runng point has a stepper position of
1500 steps. The engine is acsted + 1 air1el ratio and
stepper position is 1400 steps. 1e change stepper
position for + 1 a.1el ratio is 100 steps (1500 - 1400 =
100}. Doubling is value, stepper motor change for + 2
a1e/ ratios is 200 steps. Therefore, the lean limit
stepper position is 1300 steps (1500 - 200 = 130
8. Adjust the air/fuel ratio by pressing <LEFT LEAN>
on the keypad until the desired lean limit is achieved
based on the guidelines in Step 7. If your engine has two
fuel regulators, repeat this step for the engines right
bank using the right keypad buns.
9. Recrd the stepper psition displayed on the View
Serial Link Screen in the Lean Limit" column of the
Catalyst Control Worksheet (see Table 3.05-2).
10. Adjust the air/fuel ratio by pressing <LEFT RICH>
on the keypad until the desired rich limit is achieved
based on the guidelines in Step 7. If your engine has two
fuel regulators, repeat this step for the engines right
bank using the right keypad buttns.
11 . Record the stepper position displayed on the View
Serial Link Screen in the Rich Limit column of the
--
RICH AIR/FUEL RATIO LEAN
BEST POWER A/F = 15.50
CATALYST A/F = 15.95VPICAL)
STICHIMETRIC A/F = 16.09
BEST ECONOMY A/F = 17.00
NOTE. 1e oxygen, carbon monoxide, and oxygen sensor
signal cuNes were plotted for laboratory data. Actual sensor
response and desired air/fuel ratio will depend slightly on fuel
comp~sition; however, the relations between CO and 02 will
remain constant.
Figure 3.05-33. xygen Sensr Respnse Vs. Exhaust
Gas Concentrations For Varius Air/Fuel Ratis-
Rich Burn NLY
12. Reduce engine load to the next lower map-point
and repeat Steps 4 - 11. Complete the Catalyst Contr
Worksheet.
13. After the Catalyst Control Worksheet is complete,
continue with Programming the Catalyst Control
Valuesn page 26.
NOTE: Figure 3.05-34 provides a scenario of a techni-
cian fine-tuning the AFM system following the program-
ming steps this section,'G athering Data for Variable
Oygen Sensor Set-Points. The values in the scenario
'
ratio is adjusted by pressing the adjustment buns on the
AFM mdule until the best catalyst out emissions is
achieved for both engine banks. Step 5: With the View
Serial Link Screen displayed on the PC, the sensor volge
is read and then recorded in the 02 Sensor Set-Point' the lean and rich limits and recording stepper posion n the
column on the worksheet. Step 6: Stepper position is also
read and recorded in the Current Stepper Position" column
on the worksheet.
Step 7: Now the technician needs to ~etermine the rich
and lean limits by establishing an air/fuel ratio curve
following the recmmendations in the AFM manual
and Figure 3.05-33. Step B: The technician presses
<LEFT LEAN> on the AFM module until the oxygen meter
indicates 2.4 percent (+ 2 air/fuel ratios). Step 9: The
stepper position displayed on the View Serial Link Screen is
then recorded in the "Lean Limit" column on the worksheet.
Step 10.b determine the rich limit, the technician presses
<LEFT RICH> until the carbn monoxide meter reads
3.7 percent (-2 air/fuel ratios). Step 11:The stepper posi-
tin displayed on the View Serial Link Screen is then
recorded in the Rich Limit column on the worksheet.
Map-points greater than rated load are given the same
values as the rated map-point values.
Continuing, the technician reduces engine load to the next
map-point, 19.0 psiA, and repeats the procedure of setting
worksheet. Using 2 air/fuel ratios as a guide, the air/fuel
rati curve is determined until engine load is reduced to
map-point 12.0 psiA. At this map-point the engine is
running nticeably rougher and both CO and 02 readings
are high-the combustion stability limit. Combustion is no
longer stable and exhaust oxygen is not a good indicator of
r/fuel ratio. At this map-point and below, the technician
adjusts stepper position to achieve best operation. Using a
manometer, gas/air values are set near 6 H20, which was
the o~inal gas/air se ng (before AFM installation). The
technician fine-tunes the gas/air seing to achieve best
operation.
Rich and lean limits are determined for the remaining
map-points and the stepper position is recorded n the
worksheet. Now that an air/fuel ratio curve is established
and the Catalyst Control Worksheet is complete, the
technician is ready to continue with "Programming the
Catalyst Control Values in the AFM manual.

Catalyst cntrI Worksheet (see Table 3.05 are given for example only. Actual values will vary
depending on engine application.
NOTE: For map-po.ts greater m rated 'oad, use e
same values e table columns as e rad map-point. Figure 3.05-34. Programming Scenari Fr Catalyst cntrol - Variable xygen Sensr Set-Points
3.05-20 FORM 6263 Second Edition
FORM 6263 Second Edition 3.05-21
PROGRAMMING FOR CATALYST APPLICATIONS
Gathering Data Fr cnstant xygen Sensr
Set-Pints
Control of air/fuel ratio fo meet emissions regulations at
a constant oxygen sensor set-pint is achieved by
determining sensor voltage and rich/lean limits at rated
engine load. Complete the Catalyst Control Worksheet
fr cnstant xygen sensor set-points by following the
steps in this section.
NOTE. : very precise air/fuel ratio control is required at
various engine loads to meet emissions regulations,
follow the procedure labeled Gathering Data for
Variable Oxygen Sensor Set-Points."
The AFM system adjusts the stepper motor between
two programmable limits t maintain the oxygen sensor
set-point voltage. The lean and rich limits, which define
NOTE: One side of e Catalyst Control Worksheet
applies to G enges and the other applies to GS/
engines. The map-pots are different for G and GS/
engines. Make sure you use the side of the worksheet
Never set the rich limit above 5" of mercu gas/air
that applies to your engine application.
NOTE: If an alarm condition exists, the AFM module
keypad will not function until the alarm is acknowledged
by pressing <ALARM ACK> on the keypad.
2. Put the AFM module into manual mode by pressing
<LEFT MAN> and <RIGHT MAN> (if applicablen the
AFM module keypad.
3. Adjust engine load to manufacturer's rated load and
rated speed.
PROGRAMMING FOR CATALYST APPLICATIONS
A WARNING
7. With the engine running at manufacturers rated
lad, determine a lean and rich limit for the map-points
above the combustion stability limit. Current recom-
mendatins are to set the lean and rich limit t 2
pressure. Setting the rich limit abve this pressure
air/fuel ratios r less when programming constant
setting could result in product damage andr
xygen sensr set-pints (see Figure 3.05-36).
severe personal injury.
Table 3.05-3. View Serial Link Screen And Catalyst cntrol Worksheet (GSI Applications) - Cnstant Set-Pints
CEC AFM cntrol
Engine Model: L5790GSI V-12 Sensor Type: CATALYST CONTROL

the stepper motor adjustment range, are determined by
establishing an air/fuel rati curve.
Figure 3.05-35 illustrates a sample air/fuel rati curve
E~i
NOTE: One press of the <LEi'RIGHTLN> or
<LEF'RIGHT RICH> buttons moves stepper position
25 steps (1 /16 m). By pressg<LEi'RIGHT FAST>
prior to pressing the an or rich buttons, a 400 step SENSOR:

with constant oxygen sensor set-points. Cmbustion (1 turn) change is made to stepper position. Volta'?e
SetPint
C0
.7~
VO~
instability occurs when combustion pressure within the Temperature 551 c 552 c
4. Using exhaust analyzers (CO and 02 meters), adjust PWM Output
engine diminishes as load is reduced. The cmbustion
air/fuel rati by pressing <LEFT LEAN> and
stability limit is the point where combustion is n 1nger STEPPER
<LEFT RICH n the AFM module keypad until a
stable and exhaust oxygen is not a gd indicatr of
desired emissions rating (best emissions perfrmance)
STEPPER:
Position i::>/ pSITION
airJel ratio.
is met. lfyur engine has two fuel regulators, repeat this Lean Limit l l
The combustin stability limit can be found by gradually step for the engines right bank using the "right keypad Rich Limit 20000 20000
decreasing engine load until the exhaust xygen and buns.
carbn monoxide concentrations both increase sharply INT, MAN.
(using CO and 02 meters). This sharp increase is the 5. Record the sensor vltage displayed on the View Pressure ~
Serial Link Screen in the 02 Sensor Set-Point clumn
combustion stability limit. If detection is difficult, an
alternative is to make the combustion stability limit pint fr each map-point on yur worksheet (see
Table 3.05-3) . INTAKE L Status: MANUAL
60 BMEP. Generally, Iads greater than 60 BMEP are Enclosure Temp. R Status: MANUAL
MANIFLO
stable. 6. Record the stepper position displayed on the View PRESSURE
1. Detach or cpy the blue Catalyst Control Worksheet Serial Link Screen in the Current Stepper psitin
VIEW SERIAL LINK <ESC> to EXIT =
from the back of this manual (see Table 3.05-3 fr clumn n your worksheet for each map-point abve
sample worksheet). the cmbustin stability limit (see Table 3.05-3).

s~.~~~
MAP-PINT
CURRENT
STEPPER EAN LIMIT RICH LIMIT
2 INTAKE MANIFLD
PRESSURE (psiA)
(vIts) pSITION

LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT

5.0 .83 .83

1ii t
8.5 .83 .83

l
12.0 .83 .83

, , ~( 15.5 .83 .83 10,450 11,250

i l ! i LEAt1~W:PER I
19.0 10,450 11 ,250
L LLL_ _____ __i_JL
.83 .83

22.5 .83 .83 10,450 11,250

SURE (psiA)
NOTE: Desired air/fuel ratio andsiper/imi can be programmed for rious/oad. The Juesin 26.0 .83 .83 10,450 11 ,250
Jues are specific to your 1e olication.
NOTE: The values this ble are for rerence ONLY. Aua Jues are specific to your eng.e application.

3.05-22 FORM 6263 Second Edition

FRM 6263 Second Edition 3.05-23
PROGRAMMING FOR CATALYST APPLICATIONS
PROGRAMMING FOR CATALYST APPLICATIONS
10. Using exhaust analyzers (CO and 02 meters},
richen air/fuel ratio by - 4 air/fuel ratis (- 2 frm
desired emissions rating value) by pressing
<LEFT RICH> on the keypad. If your engine has two
PROGRAMMING SCENARIO (CONSTANT OXYGEN SENSOR SET-POINTS)
fuel regulators, repeat this step fr the engines right
bank using the right' keypad buttns. NOTE: The values and readings used in this programming scenario are sample values only. Actual values and
readings will vary depending on engine application. Guidelines presented apply to most engine applications.
11. Record the stepper position displayed on the View
3 U ; ! I I i i i e I Serial Link Screen in the Rich Limit column on your The following programming scenari demonstrates how a technician ine-tuned the AFM module prgram

~
Catalyst Control Worksheet for each map-point abve
the combustion stability limit (see Table 3.05-3).
12. At map-points below the combustion stability limit,
the lean and rich limits should be set to prevent driving
the engine int rich and/or lean misfire. A starting pint
for determining the rich limit is the original gas/air
pressure seing. The starting point can then be
mdified as required to achieve desired operation. For
example: If prir to installation of the AFM system the
~ gas/air seingwas6 H20, use the stepper motor limits
to permit nly 6" H20 gas/air below the combustion
stability limit. Use a manometer to make this measure-
ment. cmplete the steps below for each map-point
belw the combustion stability limit.
A Reduce load to a map-point below the combus-
tion stability limit.
B. Adjust air/fuel ratio by pressing <LEFT LEAN n
0 0 the keypad until the desired lean limit is achieved
14 15 16 17 18 19 20 21 based on the guidelines in Step 12. If yurengine
while following the steps in the AFM manual (Frm 6263). Within the text of the scenario below, the
programming step the technician is completing is indicated.
A technician is programming a L5790GSI Waukesha
Engine with Fisher S211 regulators fllowing the program-
ming procedures in the AFM manual (Form 6263). After
completing the initial programming requirements, the
technician is ready to continue with the section Fine-Tun-
ing AFM Programming for Catalyst Applications.
Step 1: The technician makes a copy f the blue Catalyst
Control Worksheet from the back of the AFM manual. Step 8: The technician presses <LEFT LEAN n theAFM
Step 2:The <LEFT MAN> buttn and then <RIGHT MAN> module until the oxygen meter indicates 2.4 percent (+ 2
bun on the AFM module keypad are pressed to put both air/fuel ratios). Step 9: The stepper position displayed on the
engine banks in manu mode. Step 3: The engine is View Serial Link Screen is then recorded at each map-point
adj to manufacturers rated load and rated speed.
above the combustion stability limit in the Lean Limit"
column on the worksheet. Step 10o determine the rich
Step 4: The technician desires to run the engine at best limit, the technician presses <LEFT RICH> until the rbon
catalyst out emissions. Using an exhaust analyzer, air/fuel monoxide mer reads 3. 7 percent (- 2 air/fuel ratios).
ratio is adjusted by pressing the control buttons on the AFM Step 11: The stepper position displayed on the View Serial
module until the best .talyst out emissions is achieved for Link Screen is then recorded at each map-point above the
both engine banks. Step 5: With the View Serial Link combustin stability limit in the Rich Limit column n the

--
RICH AIR/FUEL

BEST PWER A/F = 15.50

RAo

CATALYST SET-POINT A/F = 15.95YPICAL)

LEAN

--I
has tw fuel regulatrs, repeat this step fr the
engines right bank using the "right' keypad
buns.

C. Record the stepper position displayed n the

STOICHIMETRIC A/F = 16.09
BEST ECONMY A/F = 17.00
NOTE.,on mono. andoyen sens signal
cur /aborati dJal re
and desin air/flb will depend sligy on fuel npos.
le ipbE co and D.?
will nainCOflSi
Figure 3.05-36. xygen Sensr Res~nse Vs. Exhaust
Gas Concentrations Fr Various Air/Fuel Ratis-
Rich Bum NLY
NOTE: Stepper motor limits ( 2 air/fuel ratios) can be
determined by mo1ng 1 air/fuel ratio and doubling the
change in stepper position. For example: An engine at
desired running point has a stepper position of 1500
steps. 1e engine is adjusted + 1 air,ilel ratio d
stepper posn is 1400 steps. 1e change in stepper
position for 1 air/ft.el rauo is 100 steps (1500 - 1400 =
100). Doubling this value, stepper motor change for+ 2
air, ratios is 200 steps. Therefore, the lean limit
stepper position is 1300 steps (1500 - 200 = 1300).
8. Using exhaust analyzers (CO and 02 meters), lean
air/fuel rati by + 2 air/fuel ratis by pressing
<LEFT LEAN> on the keypad. If your engine has two
fuel regulators, repeat this step for the engines right
bank using the right' keypad buttons.
9. Record the stepper position displayed on the View
Serial Link Screen in the Lean Limit'' column on your
Catalyst cntrol Worksheet for each map-pint abve
the combustion stability limit (see Table 3.05-3).
3.05-24
Screen displayed on the PC, the sensor voltage is read and
then recorded at each map-point in the 02 Sensor
Set-Point column on the worksheet. Step 6: Stepper
position is read and recorded at each map-point above the
worksheet.
Step 12: The thnician usts engine load to the highest
m~p--point below the combustion stability limit, 12.0 psiA. At
this map-point and belw, stepper position is adjusted to
View Serial Link Screen in the Lean Limit" combustion stability limit in the "Current Stepper psition achieve best operation. Using a manometer, gas/air values
column n the wrksheet. are set near 6 H20, which was the oginal gas/air setting
clumn f the Catalyst Control Worksheet (see
Table 3.05-3).
(before AFM installation). The tech ician fine-tunes the
gas/air setting to achieve best operation.
D. Adjust the air/fuel ratio by pressing
Rich and lean limits are determined for the map-points
<LEFT RICH n the keypad until the desired
below the combustion stability limit and the stepper position
rich limit is achieved based on the guidelines in is recorded on the worksheet. Now that a constant air/fuel
Step 12. If your engine has two fuel regulators, ratio curve is established and the Catalyst Control Work-
repeat this step for the engines right bank using sheet is complete, the technician is ready.to cntinue with
the right" keypad buns . Programming the Cataly~ cntrol Values in the AFM
E. Record the stepper poson displayed on the View manual.
Serial Link Screen in the Rich Limit' column fthe
Cayst cntrl wrksheet (s Table 3.05-3).
F. Repeat Steps A - E for each intake manifold
pressure map-point belw the cmbustion sta-
bility limit to complete the Catalyst cntrol
Worksheet.
13. After the Catalyst Control wrksheet is cmplete,
continue with Programming the Catalyst Control Val-
uesn page 26.
NOTE.gure 3.05-37 provides a scenario of a techni-
cian fine-tung the AFM system following the program-
ming steps this section,Gathering Data for Constant
Oxygen Sensor Set-Points. The values the scenario
are given for example only. Actual values will vary Figure 3.05-37. Programming Scenari Fr Catalyst Control - Cnstant xygen Sensr Set-Points
depending on engine application.
FORM 6263 Second Edition
FORM62 Second Edition 3.05-25
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING. FOR CATALYST APPLICATIONS

PRGRAMMING THE CATALYST CONTROL 5. Press [Enter] t mve from the cmmentseld t
VALUES the PWM ut field. Leave the PWM Out'' value set to LEFT RIGHT
zero for unheated rich burn oxygen sensors. CEC AFM CONTROL
Lean Rich 2 Lean Rich
1 . Press [Esc] to returo t the Main Menu. Limit Limit
6. Using the down arrow key, position the cursr in the S- P Limit Limit
Engine Family: VHP GAS ENGINE
2. Highlight Edit/Create Setupn the Main Menu and Lo-Temp field. Although the high and low temperature Engine Model: L5790GSI V-12 0.55 8000 12000 0.55 8000 12000
0.65 5000 17000 0.65 5000 17000
press [Enter]. See Figure 3.05-38. limits can be modified, it is not recommended that these Sensor: 2-CATALYST CONTROL 0.74 1000
.Primary Fuel Type: 20000 0.74 1000 20000
two values be changed. The Lo-Temp value should L NATURAL GAS PIPELINE QUALITY
0.79 1000 20000 0.79 1000 20000
not be set below 350 C (662 because that tempera- ,Secondary Fuel Type: 0.82 1000 20000 0.82 1000 20000
0.82 1000 20000 0.82 1000 20000
I CEC AFM Control - Ver. x. xx I ture is the minimum for correct oxygen sensor opera-
tion. If required, the Hi-Temp value can be modified to
NONE
0.82 1000 20000 .82 1000 20000

provide a safety against high exhaust temperatures. LEFT= 10500 RIGHT=l0750

Comments:
Edit/Create Setup 7. Positin the cursor in the Dead band field. The ENGINE #l 9/15/95
view serial Link default value for the deadband is 0.005. This value is
PWM Out= 0
Quit appropriate for mst applications. Deadband is the
Lo-Temp=350 c Hi-Temp=760 c
oxygen sensr target lerancer control limit within
which the stepper psitin remains constant.
Dead.band =:1:0.005 Gain= 5.000
8. psitin the cursor in the Gain field. Gain in-
E.etrieVi .Data from f' Fil or create lew. fluences how large a change is made to the stepper
psition when the xygen sensor signal is not within the l I ESC NU I
Figure 3.05-38. AFM User Interface Program Main Menu specified tolerance around the sensor target (set-point)
voltage. A larger gain value will result in a larger change.
Adjust the gain value to give the desired rate of Figure 3.05-40. Editing The Data-Set n The Edit Screen
3. The Edit/Create Setup Menu shown in
Figure 3.05-39 appears. Highlight Retrieve from AFM response.
LEFT RIGHT
and press [Enter].
9. Press [Enter] until the cursor is positioned in the left CEC AFM CONTROL
02 S-P column. Using your completed Catalyst 02 Lean Rich 02 Lean Rich
psiA s - p Linu.t Limit s - p Limit Limit
cntrol Worksheet, enter all the 02 Set-Points (S-P), Engine Family: VHP GAS ENGINE p
I CEC AFM Control - Ver. x. Xx I Lean Limit', and Rich Limit'' values for each intake
manifold pressure map-point. Press [Enter] after each
Engine Model: L5790GS V-12
Sens r : 2-CATALYST CONTROL
r
5.0
8.5
0.55
0.65
8000
5000
12000
17000
0.55
0.65
8000
5000
12000
17000
l. 12.0 0.74 1000 20000 0.74 1000 20000
Primary Fuel Type:
value is entered to work dwn through each column. L NATURAL GAS PIPEL
,
0.79 1000 20000
Secondary Fuel Type : 0.82 1000 20000
NOTE: Data-sets that are created can be saved to a L NONE
0.82 1000 20000
Retrieve from AFM Exit to Main Menu 0.82 1000 20000
filename for ture reference. Data-sets are assigned
Retrieve from Filename Changes Will be Lost if
filenames and saved on disk so the user can re and RIGHT=l0750
Create New Dataset yu Have Not Saved Them.
retrieve the data-set te When saving to de Comments:
data-set will be saved to the drive and directory where ENGINE #l 9/15/95 Do yu REALLY Want t EXIT?

the AFM User Interface Program was accessed. See

'Saving DataSet to Disk this section to save your PWM Out= 0%
Lo-Temp=350 c Yes N esc
Uplod Data FroB AFM via serial Port. data-set to a filename.
Figure 3.05-39. Edit/Create Setup Menu NOTE: The contents of RAM are lost whenever power Dead.band 0.005

to the AFM module is removed.

NOTE: Refer to Figure 3.05-40 while editing the
data-set.
4. After the Edit Screen appears, type in any comments
regarding AFM programming or revise existing com-
ments at the Comments : field. Typically, comments
include site, engine number, and date information.
NOTE: When the cursor is moved between enti
litions, the boom line of the Edit Screen will show a
brief explanatin and limits for that entry.
NOTE: Each time modifications are made to the
data-set it must be saved to AFM RAM (temporary
memo evaluation. S1ply editg e values on e
PC screen will not change AFM operation.
1o. Press [F1 O] to save the Edit Screen values to RAM
(temporary memry) for testing.
11 . Highlight Test Data on AFM on the Saving Options
Menu and press [Enter].
12. Press M to confirm save to RAM.
I FlO = SAVE I I ESC NU I
Figure 3.05-41.
13. Several screens will appear indicating that the
data-set is being saved to RAM. The LCD display oh the
AFM mdule will read EXECUTION STOPPED BY
USER. Press any key on the cmputer to continue after
the save to RAM is cmplete.
Cnfirmation f Exit T Main Menu
14. To return t the Main Menu, pSS [Esc].
Figure 3.05-41 appears on the screen warning to save
changes that were made to the data-set before exiting.
Since the data-set has already been saved to RAM,
press M to return to the Main Menu.

3.05-26 FORM 6263 Second Edition FORM 6263 Second Edition 3.05-27
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

NOTE: If the "EXECUTION STOPPED BY USERn

message persists on e AFM display for more an five
20. Press and release <F1 >, then <STRT POSn the
AFMmdule keypad to test the srt positin. TheAFM
4. Highlight Configure AFM Mem
Options Menu and press [Enter].
on the Save
IA CAUTION I D not disturb the se
I cable, interrupt the AFM
minutes, refer to Section 4.00 Air/Fuel Module System LCD display will show MOVING L STEPPER TO START mdule pwerr interrupt cmputer pwer while
Troubleshooting. POSITION. The left and right Status" messages n the 5. When the cntirmatin screen appears as shwnin
c nfiguring memry. If disturbed or discnnected
View Serial Link Screen will change to MOTOR RESIT Figure 3.05-42 press M during the saving prcess, the c re EPRM chip in
15. Highlight during the positioning activity. Once the left bank has
and press [Ente t return t the View Serial Link the AFM mdule may beeme crrupted and may
been moved, the AFM mdule will move the right bank 6. When the verification screen appears as shown in
need to be replaced.
Screen. stepper mtor. Allw up to thr minutes fr this proce Figure 3.05-43 press M,
After the stepper motors have been moved t the start
NOTE: If an arm condition exists, the AFM module
position, the nrmal LCD displays resume. If the normal LEFT RIGHT
keypad will not function until the alarm is acknowledged
LCD displays do not resume within ve minutes, refer to CEC AFM CONTROL
by pressing <ALARM ACK> on the keypad. 02 Lean Rich 02 Lean Rich
Sectin 4.00 Air/Fuel Module System Troubleshooting.
psiA s - p Limit Limit s - p Limit Limit
16. Place the AFM module in automatic mode by
pressing <AUTO OPER> on the AFM keypad.
21. Aempt to sta the engine t check ease of
starting.
Engine Family: VHP GAS ENGINE
Engine Model: L5790GSI V-12
Sensor: 2-cATALYST co----
;I 5.0
8.5
II 0.55
0.65
8000
5000
12000
17000
0.55
0.65
0. 74
8000
5000
1000
12000
17000
20000
17. Monitr AFM system performance. The response Primary Fuel Type: 0.79 1000 20000
NOTE: Gnsider ''cold starts when modifying start L NATURAL G PIPELIN
must be fast enough to meet site requirements, Fuel Type: 0.82 1000 20000
positin.
Secndary This will Stp Prgram Execution 0.82 1000 20000
however, not so fast that it causes instability. If the L NONE 0.82 1000 20000
system is to slow, go back to the Edit Screen and and RESTART Program when finished.
22. If engine does not stat as desired, modify the start
increase the Gain Setting. To test the gain setting positin by changing the start position on the Edit RIGHT=10750
K Stre Values To ROM?
changes, you must save your changes t RAM by Screen and saving changes to RAM to test. Repeat the
Comments:
pressing [F1 selecting lest Data on AFM from the ENGNE #1 9/15/95
check until the engine starts well.
Saving Options Menu, pressing [Enter], and then
PWM Out= 0% Yes No esc
pressing M Return to the View Serial Link Screen t 23. Once you are satisfied with AFM system perfr Lo-Temp=350 c
mnitor AFM system performance. Cntinue adjusting mance and ease of starting, return t the Main Menu.
the Gain Seingn the Edit Screen until the speed f
24. Cntime with Saving Data-Set t ROM. Deadband =:1:0.005 Gain= 5.000
response is satisfactory.
Steps 18 - 22 are completed to check ease of starting SAVING DATA-SET T ROM
the engine based on the sta positin programmed.
Once you create a data-set, test the data-set in RAM
I FlO m SAVE I I ESC NU I
18. Press <LEFT MAN> and <RIGHT MAN> (if appli- (tempora memory), and are satisfied with the AFM s
cable) on the AFM module keypad to put the AFM air/fuel control, the data-set must be saved to perma-
Figure 3.05-42. Cnflrmation Of Save T Read nlyMemRM)
module in manual cntrol. nent memry (ROM). Complete the steps in this section
to save yurdata-set t ROM.
NOTE: The contents of RAM are lost whenever power LEFT RIGHT
to the AFM module is removed. NOTE: The AFM system allows five saves to ROM CEC AFM CONTROL
(permanent memor. All data-sets should be carefully 2 Lean Rich 02 Lean Rich
psiA s - p Limit Limit s - p Limit Limt
19. DO NOT TURN OFF POWER TO THE AFM evaluated RAM (temporary memory) before sring to Engine Family: VHP GAS ENGINE p 5.0 0.55 8000 12000 0.55 8000 12000
MODULE. Shut dwn the engine and allow it to cool for ROM. Once ROM has been y configured.e core Engine Model: L5790GS V-12 r 8.5 0.65 5000 17000 .65 5000 17000
several minutes. EPROMchip e AFM module must be repcedto Sensor: 2-cATALYST CONTROL i 12.0 0.74 1000 20000 0.74 1000 20000
permit rther saves to permanent memory. Refer to Primary Fuel Type: 0.79 1000 20000
Section 4.00 Air/Fuel Mdule System Troubleshoting L NATURAL GAS PIPELIN 0.82 1000 20000
A WARNING for core EPROM replacement instructions.
Secondary Fuel Type:
L NONE
OK t Store New Values?
.82
0.82
1000
1000
20000
20000
D nt set the stepper motr(s) t the sta psitin 1. Highlight Edit/Create Setup" from the Main Menu to RIGHT=10750
while the engine is running abve 40 percent f return to the Edit Screen and press [Enter]. Comments:
rated load. Start psition is nly to be initiated when
ENGINE #1 9/15/95
the engine is stpped r running belw40 percent 2. Highlight Retrieve from AFM and press [Enter].
.f rated load. Reseing the stepper mtr(s) while PWM Out:a O
the engine is running abve 40 percent f rated load 3. With the Edit Screen displayed, press [F1 O] to save Yes N esc
LTemp=350 c
may cause engine shutdwn andr cause severe the data-set to ROM (permanent memory).
engine damage. NOTE: The "Test Data on AFM option from the Save Deadband 0.005

Options Menu allows a program to be run e AFM

modulemporary memory (RAM. is may be used
for troubleshooting so that e ROM memory space is I FlO .. SAVE I I ESC = MENU I
conserved. The contents of RAM are lost whenever
power to the AFM module is removed. Figure 3.05-43. Verificatin T Store New Values To ROM

3. 28 FORM 6263 Second Edition FORM 6263 Second Edition 3.05-29

PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

LEFT RIGHT LEFT RIGHT

CEC AFM CONTROL CEC AFM CONTRL
2 Lean Rich 02 Lean Rich 02 Lean Rich 02 Lean Rich
psiA s - p Limit Limit s - p Limit Limit psiA s - p Limit Limit s - p Limit Limit
Engine Family: VHP GAS ENGINE p 5.0 12000 0.55 8000 12000 Engine Family: VHP GAS ENGINE p
o.ss 8000 5.0 0.55 8000 12000 0.55 8000 12000
Engine Model: L5790GSI V-12 r 8.5 0.65 5000 17000 0.65 5000 17000 Engine Model: L5790GSI V-12 r 8.5 0.65 5000 17000 0.65 5000 17000
Sensor: 2-CATALYST CONTROL i 12.0 0.74 1000 20000 0.74 1000 20000 Sensor: 2-CATALYST CONTROL 12.0 0.74 1000 20000 1000
Primary Fuel Type: Primary Fuel Type:
l. .74 20000
0.79 1000 20000 . <
0.79 1000 20000
L NATUR GAS PIPELili 0.82 1000 20000 L NATURAL GAS PIPELIN
0.82 1000 20000
Secndary Fuel Type: 0.82 1000 20000 Secndary Fuel Type:
0.82 1000 20000
l NONE Starting ROM2 Program. 0.82 1000 20000 4 NONE Pro grmning Errr has Occurred. .82 1000 20000
AFM Memory has been Configured. RIGHT=l0750 Program is NOT Running. RIGHT=l0750
Comments: Program Is Running. Comments: Check EPROM or Vpp for Error.
ENGINE #1 9/15/95 ENGINE #1 9/15/95
EPROM Must Be Replaced.
PWM Out= 0
Press ANY KEY to cntinue PWM ut= 0%
Lo-Temp=350 c Lo-Temp=350 c
Press ANY KEY to Continue
Deadband 0 . 005 Gain= 5. 000 Deadband 0.005

I FlO = SAVE I I ESC NU I I FlO = SAVE I I ESC

Figure 3.05-44. Verification Screen Of Save T ROM Figure 3.05-45. Programming Error Message
7. Several screens will appear indicating that the SAVING DATA-SET T DISK
LEFT RIGHT
data-set is being saved to ROM (permanent memory on The new data-set should be stored to a floppy/hard disk CEC AFM CONTROL
the core EPROM chip inside the AFM module). Once and tpermanent memry (ROM) as the previous 02 Lean Rich 02 Lean Rich
the data-set has been saved to ROM, the message section explains. Data-sets are assigned filenames psiA s - p Limit Limit s - p Limit Limit
Engine Family: VHP GAS ENGINE p
shown in Figure 3.05-44 appears. and saved on disk so the user can retain the data-set for Engine Model: L5790GSI V-12 5.0 0.55 8000 12000 0.55 8000 12000
future reference. Each time a new program is saved to r 8.5 0.65 5000 17000 0.65 5000 17000
Sensor: 2-CATALYST CNTROL l. 12.0 0.74 1000 20000 0.74 1000 20000
NOTE: The AFM allows five saves to ROM. Once ROM ROM, the previous program can no longer be retrieved. Primary Fuel Type: m 15.S 0.79 1000 20000 0.79 1000 20000
has been '/ly configured, the core PROM ch the The only way to keep track of old programs is to save the L NATURAL GAS PIPELINE OUALITY
< -- 0.82 1000 20000
econdary Fuel Type
AFM module must be ed to permit rther saves to data-file to disk or with printed copies. D 0.82 1000 20000
NONE 0.82 1000 20000
permanent memory.
NOTE: If you want to retrieve a data-set saved to disk, Save Choices to Disk
8. Press any key to return t the Edit Screen. refer to the next section 'Retrieving a Saved Data-Set. " D RIGHT=l0750
Comments:
NOTE: If e power e AFM is inadequate (less than 1. With the Edit Screen displayed, press [F10] to save ENGINE #1 9/15/95 Input DataFile Name
21.6 volts) or excessive.dirty more an 2 volts your data-s to disk.
peak-to-peak r1p/e), the programmg operation may
PWM Out
Lo-Temp=350 c
not be successful. An unsuccessful store to "ROM will 2. Highlight Save Data t Filename" frm the Saving
result e error message illustrated in Figure 3.05-45. Options Menu and press [Enter].
Should this error occue core PROM ch must be Deadband 0.005 Gain= 5.000
3. Enter a filename according to the following proce-
replaced and the true cause for the ilure corrected.
dure (see Figure 3.05-46). Read all three steps prior to
Refer to Section 4.00 Air/Fuel Module System Trouble-
shoting for core PROM replacement nstructions.
saving the file t the disk. I FlO = SAVE ESC = MENU I
Press any key on your computer to continue. A. Locate the engines serial number n the name- ENTER VALID, SiAACTER NA
plate.
NOTE: Save a copy of your data-set to disk for future Figure 3.05-46. Input Data-File Name Screen
reference. If a pr.ter is connected your PC, press B. If the engine has a C-" number, remove the C-''
[Print Screen] on e keyboard for a printout. C. The first time the cnfiguration is saved to the Once eight characters have been entered, the file will
and the f from the number. Example:
disk add an A t the end. This is to indicate that automatically be saved to the persnal computer disk
C-1 0768/01 would give a root file name of
this is the first save of this configuratin . If from where the AFM User Interface Program was
1076801 . If the engine does not have a C-"
changes are made to the cnfiguration, save the accessed. If the filename is less than eight characters,
number use all six digits in the serial number for
next file with the same numerical information and press [Ente to save.
the filename.
change the suffix leer tB. Continue in this NOTE: When saving to diske data-set will be saved
manner fr each revision to the file. to the drive and directory where the AFM User Interce
Program is accessed.

3.05-30 FORM 6263 Second Edition FRM 6263 Second Edition 3.05-31
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

LEFT RIGHT CHECK 1: cNFIRMING THE DATA-SET SAVE TO

CEC AFM CONTROL
psiA
2
s - p
Lean
Limit
Rich
Limit
02
s - p
Lean Rich
Limit Limit
I CEC AFM Control - Ver X Xx
RM

Check 1 cnfirms that the data-set was successfully

Engine Family: VHP GAS ENGINE p stored in ROM on the core EPROM chip.
Engine Model: L5790GSI V-12 s.o o.ss 8000 12000 o.ss 8000 12000
r s.s 0.65 5000 17000 0.65 5000 17000 NOTE: Programs saved to the core EPROM will be
Sensor: 2-CATALYST CONTROL File Select
l. 12.0 0.74 1000 20000 0.74 1000 20000
Primary Fuel Type: 0.79
retained even if power to the AFM module terrupted.
L NATURAL GAS PIPEL 1000 20000
0.82 1000 20000 1076801A.AFM Programs saved to RAM will be lost when power the
econry Fuel Type
NONE 0.82 1000 20000 AFM module is disconnected. The AFM can detect
Exit to Main Menu 0.82 1000 20000 RSETUPOl.AFM
when an evaluation daset is being tested in RAM and
RSETUP02,AFM
Changes Will be Lst if has not been saved to ROM. If you attempt to leave the
you Have Nt Saved Them. RIGHT=l0750 RSETUP03.AFM
Comments: AFM User Interface Program without saving the evalua-
ENGNE #1 9/15/95 Do you REALLY Want to EXIT?
RSETUP04.AFM ;; tion data to ROM, a warning will be displayed.
RSETUP05.AFM
PWM Out= 0 RSETUP06.AFM ::..
..
1. With the Main Menu showing on yur screen,
Lo-Temp=350 c Yes No esc RSETUP07.AFM .. highlight Edit/Create Setup" and press [Enter].
RSETUPOS.AFM 2. Highlight Retrieve frm AFM on the next menu and
Deadband =0.005 RSETUP09.AFM press [Enter]. Several messages appear indicating that
the data-set is being retrieved from ROM .

I FlO = SA 11 ESC Figure 3.05-49. File Select Menu

3. The Edit Screen appeasee Figure 3.05-50).
Verify th the data on the Edit Screen is the same
data-set chosen to be saved t ROM.
Figure 3.05-47. Confirnation f Exit T Main Menu POST-PROGRAMMING CHECK
If the correct data does not appear n the Ed Screen,
4. Press [ESCJ to return to the Main Menu. RETRIEVING A SAVED DATA-SET FROM DISK Tw pst-programming checks must be completed t verify that the DB-9 serial cable connected between the
WITH A FILENAME confirm that the data-set created was successfully PC and the AFM module is secure and in good
5. If the data-set for your engine has been saved t stored to ROM. The procedures that follow take you cndition. In addition, verify the power to the AFM
ROM and a file on disk, confirm the exit to the Main The data-sets that are saved to disk (not RAM or ROM) step-by-step through the pst-programming checks. module is within specification. Attempt a secnd store
Menu by pressing M (see Figure 3.05-47). The Main and assigned a filename can be retrieved following the
of the correct data-set to ROM (refer to Retrieving a
Menu appears (see Figure 3.05-48). If you have nt steps in this section. NOTE: Print copies of your data-set or save your
Saved Data-Set From Disk With a Filename to retrieve
saved the data-set to ROM (permanent mem data-set to a file for future reference before completing
NOTE: If you want to save a data-set to disk, refer to data-set from filename). If difficulty continues, contact
press [NJ and refer tSaving Dataetto ROM in this the two post-programming checks. yur local Waukesha Engine distributor r Waukesha
the previous section 'Saving Data-Set to Disk.
section. Engine Product Support.
1. With the AFM User Interface Programs Main Menu
showing on yur screen, highlight Edit/Create Setup" LEFT RIGHT
and press [Entesee Figure 3.05-48). CEC AFM CONTROL
I CEC AFM Control - v I
psiA
2
s - p
Lean
Limit
Rich
Limit
02
s - p
Lean Rich
Limit Limit
2. On the next menu highlight Retrieve from Filename" Engine Family: VHP GAS ENGINE p 5.0 0.55 8000 12000 0.55 8000 12000
and pSS [Ente Engine Model: L5790GSI V-12 r 8. 5 0.65 5000 17000 0.65 5000 17000
Sensz : 2-cATALYST CONTROL i 12.0 0.74 1000 20000 0.74 1000 20000
Edit/Create Setup
3. Highlight th filename (serial number) you want to Primary Fuel Type: m 15.5 0.79 1000 20000 0.79 1000 20000
View Serial Link open and preEnter] (see Figure 3.05-49) . The L NATURAL GAS PIPELINE QUITY a 19.0 0.82 1000 20000 0.82 1000 20000
Quit Secondary Fuel Type: r 22.5 0.82 1000 20000 0.82 1000 20000
infrmatin that is shwn n your PC screen is NONE y~ 0.82 1000 20000 0.82 1000 20000
information that has been saved in a file and was nt
retrieved from the AFM modules RAM or ROM. START Ps LEFT = 10500 RIGHT=l0750
Comments:
NOTE: The retrieved file's data-set must be saved to
aetrieve Data f r om AF File, or Create New. ENGINE #1 9/15/95
RAM or ROM before e disptyed data-set values
affect control of the AFM system. PWM Out= 0
Figure 3.05-48. AFM User Interface Program Main Menu Lo-T1p=350 c Hi-Temp=760 c
NOTE: The contents of RAM are lost whenever power
to the AFM module is removed.
Deadband 0.005 Gain= 5.000
NOTE: If you want to save an opened file to ROM
(permanent memory), refer to "Sag Data-Set to
ROM. " I FlO = SAVE I I ESC NU I
Figure 3.0550. Edit Screen

3.05-32 FORM 6263 Second Edition 3.05-33

FORM 6263 Second Edition
PROGRAMMING FOR CATALYST APPLICATIONS PROGRAMMING FOR CATALYST APPLICATIONS

CHECK 2: FINAL TEST OF AFM SYSTEM SETUP

LEFT RIGHT
Check 2 confirms that the data-set is nt lost when the CEC AFM CONTROL
AFM system is powered down and that the AFM system 02 Lean Rich 2 Lean Rich
psiA s - p Limit Limit s - p Limit Limit
will power up with the data stored in ROM.
Engine Family: VHP GAS ENGINE p 8000 12000 0.55
s.o o.ss 8000 12000
Engine Model: L5790GSI V-12
1 . Highlight Quitn the Main Menu and press [Enter] r 8.5 0.65 5000 17000 0.65 5000 17000
Communicatins Menu Sensor: 2-CATAYST CONTROL l. 12.0 0.74 1000 20000 0.74 1000 20000
(see Figure 3.05-51). .Prnary Fuel Type: 20000
m 15.5 0.79 1000 .79 1000 20000
Select Com Port L NATURAL GAS PIPELINE QUALITY 19.0 0.82 1000 20000 .82 1000 20000
,Secondary Fuel Type: 22.5 0.82 1000 20000 0.82 1000 20000
7 NONE .82 1000 20000 .82 1000 20000
1 02 03 04 U2

START LEFT= 10500 RIGHT=l0750

Comments:
ENGINE #1 9/15/95
Edit/Create Setup
View Serial Link Figure 3.05-52. Cmmunications Menu PWM Out= 0
Ler-Temp=350 c Hi-Temp=760 c
Quit
8. The AFM User Interface Program S Main Menu
appears shwing various program ptions available Deadband 0.005 Gain= 5,000
(see Figure 3.05-53). Highlight Edit/Create Setup" and
press [Enter].
Retrieve Pata from AF Filez Create Ne3"'. 10 E 11 ESC NU I

Figure 3.05-51. AFM User lnteace Prgram

Main Menu
2. Press t confirm that the program is to be exited.
3. Disconnect power from the AFM mdule for a
minimum of five minutes.
4. Restore power t theAFM mdule.
5. Start the AFM User Interface Program on your PC by
accessing the drive and directory where the AFM
soware is installed (typilly: A: [Ente
6. Type the name of the executable file and press
[Enpically: AFMXXX [En where XXX is the
revisin level).
NOTE: To nd e name of the-executable file (.exe) for
the AFM User Interface Program, view the directory of
the drive on which your AFM program is saved by typg
DIR at the drive prompt and then pressing [Enter]. Listed
in the directory will be an executable file for the AFM
User Interface Program. The executable file for e AFM
program is typically e letters AFMXXX.exe where
XXX is the revision level.
7. The "Genuine Waukesha Pa logo and version
identificatin screens appear briefly, fwed by the
communications menu (see Figure 3.05-52). A black
dot is located in parentheses next to which indicates
that the selected cmmunications port on the computer
is po 1. Press [Enter] to select cmmunicatins p 1.
If the DB-9 ble is connected to a different port on your
PC, use the arrow keys n the keyboard t select the
crresponding po from the communications menu and
press [Enter] (typically: p 1 is crrect).
I CEC AFM Control - Ver. X.Xz I Figure 3.05-55. Edit Screen
10. Observe which ROM number (ROM is being
retrieved.
Edit/Create Setup
11. The Edit Screen appears (see Figure 3.05-55}.
View Serial Link
Verify that the data n the Edit Screen is the same
Quit
data-set chsen to be saved to ROM.
If the crrect da des not appear on the Edit Screen,
verify that the D.9 serial cable cnnected between the
PC and the AFM module is secure and in god
Ret-r ieve Daa from AF File, .o r create New.
condition. In addition, verify the power to the AFM
Figure 3.05-53. AFM User Interface Prgram module is within specification. Attempt a second store
Main Menu f the correct data-set to ROM (refer tRetrieving a
Saved Data-Set From Disk With a Filename" to retrieve
9. The menu shown in Figure 3.05-54 appears. High- data-set from a filename). If difficulty continues, cntact
light Retrieve from AFM and press [Enter]. your local Waukesha Engine distributor r Waukesha
Engine Product Support.
Retrieve from AFM
Retrieve from Filename
Create New Dataset
Figure 3.05-54. Edit/Create Setup Menu

3.05-34 FORM62 Second Edon

3.05-35
FORM62 Second Edition
PROGRAMMING FOR CATALYST APPLICATIONS
3.05-36
SECTION 3.10 - PROGRAMMING BEST POWER/ECONOMY APPLICATIONS
PROGRAMMING THE AFM MODULE FOR
BEST POWER OR BEST ECONOMY
USER INTERFACE PROGRAM STARTUP STEPS
NOTE: This manual assumes you are already miliar
with basic M~DOS commands for viewing directories,
COPg files, and other M~DOS concepts. If you need
more information on these subjects, refer to a MS-DOS
instruction manual.
1. Review Section 3.00 General Programming lnfor-
mation for computer requirements, program layout, and
saving information.
2. Review Section 3.02 Keypad and Display lnforma-
tion for a detailed explanation of the AFM modules
keypad functins and LCD display messages.
3. Complete the preprogramming checklist in
Section 2.10 Prestart Installation Checklist before
continuing.
4. With the engine NOT running and power OFF,
disconnect the oxygen sensr{s) by removing the
analog connectins terminal block from the header
inside the AFM mdule {see Figure 3.10-1 ).
pWER CONNECTIONS
Figure 3.10-1. Analg And pwer cnnectins Inside
AFM Mdule
FORM 6263 Second Edition FORM 6263 Second Edition
5. Apply pwer to the AFM module. The Power and
Alarm LEDs n the front cover f the AFM mdule
light. The LCD display on the AFM module briefly
displays Waukesha CEC TEST the cre EPROM
chip has not been previously programmed. If the cre
EPROM was previously programmed, the LED displays
the current cntrl mode 0r exampleWatkesha CEC
Custom CntrI").
NOTE.:'Custom Control" is the Best Power/Economy
control modes.
6. The AFM module must be programmed to work with
site specific information in order for the AFM system to
function propey. To program the AFM mdule,connect
a standard DB-9 serial cable {male to female) t the
cmmunications port {labeled P1 A) within the AFM
module. This is the cmmunicatins prt on the right
{see Figure 3.10-2). Cnnect the other end f the cable
to the PC's communiions port. ypicall this is port 1
{also referred to as COM 1, serial A, or serial 1).
:
IA CA UTION I ii~rc~~~ i!h:ec~~~
connected to the appropriate cmputer p. If the
serial cable is disturbed r discnnected during the
saving prcess, the cre EPROM chip in the AFM
mdule will beeme crrupt and will need to be
replaced. Even previously ared datse will n
Inger be functinal.
P1A cMMUNICATINS PRT
O FRONT VIEW DOOR PANEL OPEN O
Figure 3.10-2. DB-9 Serial Cable cnnectin Inside
AFM Mdule
3.10-1
 PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

ESTABLISHING COMMUNICATION WITH THE

AFMMODULE
I AFM control - Ver. x.xx 1 I CEC AFM Control - Ver. X.Xx I
~i~~~e~y:urt ~~~~ l~Me~~~r:.
1. Start the AFM User Interface Program on your PC by Coilllllunicatins Menu
Error Message
. g the drive and directory where the AFM select Com Port
~ i ailed pically: Device I/0 Errr Occurred
cm

Check Parameters and cnnections

~s;;fnt~x~~~~~rt
@l 0 2 03 04 and Try Again.
Press ANY KEY to Continue
AXXX [Enter) where xxx is the revisin level) .

~11
Test -L nq c m -D 0 E+ #

4
L

~: :
com por F aL L ed

Figure 3.1 4.Cmmunications Menu

~~
v~~v~ n;ing DIR at e prompt and then 5. The AFM User lnteface Programs Main Menu
appears showing various program optins available
(see Figure 3.10-5). Highlight Edit/Create Setup and Figure 3.10-7. Cmmunlcations Error Message
press [Eer].

NOTE: The core and dispy EPROM chips must be

~~i~t
matched" with the AFM User ace version number. ~ AFM Control . x.x I CEC AFM Control - Ver . X. Xx I

work. Refer to Section 4.00 Air/Fuel Module System Edit/Create Setup

Eubleshng, "Rep/a EPROM Chips" for more view serial Link
Current Program is TEST PROGRAM
information. Quit
No Configuration Data Exists.
~ri~f~olg~~~1i'f; Retrieve Data from Filename
r Create New Dataset.

mli o is SCen indit wt~ers

of the AFM User lnteace Prram yu are us1ny. aetrieve Pa.t a f rom AFM, Fi or create New. Press ANY KEY t Continue

Figure 3.10-5. AFM User Interface Program Main Menu

rm

:p;:;;d~i~t~t~~iri~u~~~ig~~~ 3~~~~

mwmm

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Retrieve from AFM

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Figure 3.10-3. Sttware version Identification

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Retrieve from Filename

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4. Autmatically the Communications Menu appears

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create New Dataset

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wm

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(see Figure 3.10-4). A black dot is located in a ci~cle

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tins pn your cmpur is p 1 . Press [Enter] to

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select communications po 1. If the DB-9 cable is

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Figure 3.1 o-s. Edit/Create Setup Menu
fr m the communications menu and press [En
(typically: po 1 is correct).
FORM 6263 second Edition FORM 6263 Second Edition 3.10 - 3
3.10-2
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

INITIAL AFM MODULE PROGRAMMING FOR

BEST POWER/ECONOMY APPLICATIONS CEC AFM Control - Ver. X.Xx CEC AFM CONTROL
Left Right
After cmmunication has been established between Bank Bank
your PC and the AFM module, programming for your Engine Family: VHP GAS ENGINE p
File Select Engine Model: L7042G V-12 Lean Limit = 1 1
specific engine applicatin can begin. R

T MHP VA
Sensor: 2-CC (0-lv) STEP AWAY Rich Limit = 20000
,Primary Fuel Type: 20000
NOTE: For e purposes of this manual.e examples RSETUPOl.AFM NATURAL GAS PIPELINE QUALITY Start Pos. = 10000 10000
and fiaures used are based on the programmg of a
12 cylinder VHP L7042G ee for Bt Economy
RSETUP02.AFM :5 ,Secondary Fuel Type:
NONE Offset Steps = +100 +100
RSETUP03.AFM
Control Mode. Although there are slight screen varia-
RSETUP04.AFM
tions for each enge family, the programmg steps
presented this manual are the same. The values in
RSETUP05 . AFM H
..
..
Collll!lents:
the examples and figures are for REFERENCE RSETUP06 .AFM ..
.. RICHBURN SETUP FILE #5
RSETUP07.AFM
..
..
ONLY. Actual values are specific to your engine ..
.. PWM Out= 0%
application. RSETUP08.AFM
L 350 c Bi-Temp"'760 c
RSETUP09.AFM
1. With the AFM User Interface Program s Main Menu
RSETUPlO.AFM
sh,wing on your screen, highlight Edit/Create 5etup Search Delay= 5.00 Minutes
and press [Enter] {see Figure 3.10-9).
FlO = SAVE J I ESC NU I
2. Highlight Retrieve from Filenamen the Edit/Create Figure 3.10-11. File Select Menu
5etup Menu and press [Entesee Figure 3.10-1 O). A list
of preprogrammed files {R5ETUP##.AFM) appears (see Selecting A Preprogrammed Setup File
Figure 3.10-11). Figure 3.10-12. Preprogrammed Setup File RSETUPOS- Best pwer/Ecnmy Applications
Preprogrammed setup files were developed to make
AFMmdule programming easier and faster. The values
2. After answering the fur questions in Step 1 , Table 3.10-1. Preprogrammed Setup Files For Best
stored in these files will get yu srted in creating a carefully select the setup file from Table 3.10-1 that was Power/Economy Applications
data-set for your specific engine application. The values
CC FM Control - Ver. X.Xx created for your engine application. Selecting the wrng VHP VEE ENGINES WITH BEST PWER/ECNOMY
of the preprogrammed les are generic and must be setup file may result in air/fuel control that is less than
edited for ptimum air/fuel ratio control fllowing the Filename Use Fr .
optimum.
programming procedures in this manual. It is recm G or GSI engin W1 two S211, S201 or66Z
Edit/Create Setup mended that you use a preprogrammed file from this RSETUP5 gulators d steppers (20000 steps of adjust-
NOTE: The preprogrammed files listed on the File me
View Serial Link listing to program the AFM mdule instead of sing Select Menu but not included in Table 3. 10-1 are
Quit
with a completely new, nonsit specific data-set. preprogrammed setup files used when programmg RSETUP6 G or GSI engines with two 99 or 1098 regulators
and steppe5800 steps of adjustment).
The preprogrammed setup files va with engine catalyst or lean burn control modes.
VHP IINE ENGINES WITH BEST PWEECNOMY
configuratin and fuel regulator model. Example: All
3. Highlight the appropriate preprogrammed file on the Filenae
VHP G51 vee engines with Fisher 66, 662, 5201, and Use Fr ...
Retrieve t>ata fro: AF File, or Create Eew. File Select Menu and pss [Enter] {see
5211 regulators, which includes VHP models 5108, G or GSI engines with one S211, S201, 66, or 662
Figure 3.10-11). The Edit 5creen appears displaying RSETUP11 regulator and stepper (20000 steps of adjust-
5790, 7042, and 9390, use setup file R5ETUP01. 1entl.
the preprogrammed setup file information {see
Figure 3.10-9. AFM User Interface Program Main Menu 5imilarly, VHP models 2895 and 3521 use a cmmon
Figure 3.10-12). G or GSI engines with one 99 or 1098 regulato
setup file. RSETUP12 and stepper (5800 steps of adjustment).
1. Answer the following four questions before selecting
NOTE: When the setup file appears on e Edit Screen,
it will show enge mily, model, and el type informa-
a preprogrammed setup file.
CEC AFM control - Ver. x.xs tion for an engine model. This "applicationformation is
A. What is the engine family: VHP for reference only and will not a'ect AFM system control.

B. What is the engine configuration: in-line or

Retrieve romAFM vee?
Retrieve from Filenae C. What air induction configuration {aspiration)
Create New Dataset des the engine have: natural {G) or turbo-
charged {GSI)?

D. What fuel regulatr{s) is installed: Fisher

Retri.eve Data frOl!l a Di.sit File, cntrols Model 66, 662, 5201, 5211, 99, or
1098?
Figure 3.10-10. EditlCreate Setup Menu

FORM 6263 Second Edition FORM 6263 Second Edition 3.10-5

3.10-4
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

Editing Engine Application Infrmatin 2. Highlight the crrect engine family and press [Enter]. 4. Highlight the correct engine air induction configura- 5. Highlight the type of primary fuel the engine is using
tion (aspiration) on the Engine Fuel System Selection on the Primary Fuel Selection Screen and press [Enter]
1. With the Edit Screen displayed on your PC, press the 3. Highlight the correct engine mdel n the Engine
Screen and press [Enter] (see Figure 3 .10-15). (see Figure 3.10-16).
UP arrow key until th Engine Family Selection Screen Model Selectin Screen and press [Enter] (see
appears as shown in Figure 3.10-13. Figure 3.10-14) .

CEC AFM CONTRL

Left Right
Bank Bank
Engine Family: VHP GAS ENGINE p
Engine mdel: L7042G V- 12 Lean Limit= 1 1
R
Sensor: 2-CC (0-lv) STEP AWAY I Rich Limit= 20000 20000
r;rimary Fuel Type:
NATURAL GAS PIPELINE QUAL ATGL Gas Engines Start Pos. = 10000 10000
e~~i;;,ary Fuel Type: VBP Gas Engines
VGF Gas Engines Offset Steps= +100 +100
VSG Gas Engines
Comments:
RICHBURN SETUP FILE #5
Comments:
RICHBURN SETUP FILE #5
PWM Out= 0%
Lo-Temp=350 c
PWM Out= 0%
LTemp=350 c Hi-Temp=-760 c
Search Delay= 5.00 Minutes
-
Search Delay= 5.00 Minutes
11 ENU I
I FlO = SAVE II ESC NU I
Figure 3.10-15. Engine Fuel System Selection Screen

Figure 3.10-13. Engine Family Selection Screen

CEC AFM CONTROL

Left Right
CEC AFM CNTROL Bank Bank
Left Right Engine Family: VHP GAS ENGINE p
Bank Bank Engine Model: L 7042G V-12 Lean Limit= 1 1

I;
R
Engine Family: VHP GAS ENGINE p
Engine Mdel: L7042G V-12 R
Lean Limit= 1 1 r: 2-CC (0-1:)
rimary Fuel Type:
SI Prima Fuel M
Rich Limit = 20000 20000

Sensor: 2-CC (0-lv) STEP AWAY I Rich Limit= 20000 20000 NATURAL GAS P IPELINE e .... - , nnl't.n
10000
rimary Fuel pe: M econdary Fuel Type: -
Natural Gas Pipeline Quality (119 Octane)
NATURAL GAS PIPELINE QUAL ATGL Gas Engines Start Pos. = 10000 10000 NONE +100
Field Gas (115 - 119 Octane)
t!econdary Fuel Type: VBP Gas Engines Propane
NONE v ngines Offset Steps= +100 +100
Digester Gas
v P9390 ng1.nes Landfill Gas
Comments:
L7042
L5790 RICHBURN SETUP FILE #5
cmments:
L5108
RICHBURN SETUP FILE #5
F3521 PWM Out= 0
F2895 Lo-Temp=Jso c Hi-Temp=760 c
PWM Out= 0

Lo-Temp=350 c Hi-Temp=760C
Search Delay = 5 . 00 Minutes

Search Delay= 5 . 00 Minutes

I Fl O = SA: I I ESC = MENU I
I FlO = SAVE 11 ESC
Figure 3.10-16. Primary Fuel Selection Screen

Figure 3.10-14. Engine Mdel Selection Screen

3.10-6 FORM 6263 Second Edition 3.10 7

FORM 6263 Second Edition
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

6. Currently, the AFM system is designed for single fuel a. After the engine application information is selected,
engine applications F ne fuel f dual-fuel engines). confirm your selections by pressing M the conrma CEC AFM CONTRL
tion message (see Figure 3.10-19). The engine applica- Left Right
Highlight NONE and press [Enter] on the Secndary Bank Bank
tion block will now be updated to reflect your changes.
Fuel Selectin Screen (see Figure 3.10-17). Always Engine Family: VHP GAS ENGINE p
Engine Model: L7042G V-12 R Lean Limit= 1 1
select NONE from this screen.
Sensor: 2-CC (0-lv ) 20000
7. Highlight Best Power/Eenmyn the Control c;rimary Fuel Type:
NATURAL GAS PIPE! 10000
Mode Selection Screen and pss [Enter] (see You Have Changed Options
e~~~~ary Fuel Type
s That May Invalidate and
Figure 3.05-18). 00 +100
Change Other Data!
D You Want To Continue?
CEC AFM CONTROL Left Right Conunents:
Bank Bank
RICHBURN SETUP FILE
Engine Fily P GAS ENGINE I I I p Lean Limit= 1 1
Engine Model: L7042G V-12 l I I ll PWM Out= 0 Yes No esc
sensor: 2-CC (0-lv) STEP AWAY 11 I : Rich Limit= 20000 20000
Lo-Temp=350 c
,Primary Fuel Type: . , : 10000 10000
4 NATURAL GAS PILINE Q Secondary Fuel I ; Start Pos. =
,Secondary Fuel Type: I +100 Search Delay== 5.00 Minutes
NE I NOHE
Natural Gas Pipeline Quality (119 Octane)
SA 11
I

Field Gas (115'- 119 Octane) I FlO = ESC

Comments: I Propane
RICHBURN SETUP FI II Landfill
Digester S
Gas
Figure 3.10-19. Cnfirmation Message
PWM Out= 0
Editing set Steps" Value Fr Best Eenmy Complete the steps below ONLY if desired running point
Lo-Temp=350 c
Applicatins is best econmy.
Search Delay= 5.00 Minutes The preprogrammed setup file is programmed for best 1 . Press [Enterr use the arrow keys until the cursor is
pwer applications (15.50:1 air/fuel ratios). In best in the left 0set Steps" field on the Edit Screen.
power applications the Oset Steps" value is positive
l FlO ESC NU I (0set Steps = + 100). If your desired running point is 2. Enter a negative value (- 100) and press [Ente
best economy (17.00:1 air/fuel ratios), change the
Offset Steps" value frm positive to negative. In best 3. If applicable, also change the right 0set Steps"
Figure 3.10-17. Secndary Fuel Selection Screen ecnmy applications, the Oset Steps value is field from positive(+ 100) to negative (-100).
negative (0set Steps= - 100) (see Figure 3.10-20).

CEC AFM CONTROL Left Right CEC AFM CONTROL

Bank Bank Left Right
Bank Bank
Engine Fy: VHP GAS ENGINE 11 I p Lean Limit= 1 l
Engine Family: VP GAS ENGINE p
Engine Model: L7042G V-12 11 I R Engine Model: L7042G V-12 R Lean Limit= 1 1
Sensor: 2-CC (0-1 STEP AWAY II II MI Rich Limt = 20000 20000
I I Sensor: 2-CC (0-lv) STEP AWAY I Rich Limit= 20000 20000
,Primary Fuel Type: 1 1 , 10000 10000 M
c;rim Fuel Type:
NATURGAS PIPELINE QU. ll I Start Pos. == A 10000 10000
,Secondary Fuel Type: I Application Type I ffset Steps= NATURAL GAS PIPELINE QUALITY Start Pos. =
+100 +100 R
~ NOE L I Se~~~~ary Fuel Type: y Offset Steps= -100 -100

Catalyst cntrol
cmments:
Best Pwer/Economy
Conunents:
RICHBURN SETUP FILE #5
RICHBURN SETUP FILE #5

m
PL
-
T
E -
C
E
PWM Out= 01
Lo-Temp=350 c Hi-Temp=760 c

Search Delay= 5.00 Minutes

Search Delay = 5.00 Minutes

I FlO = SAVE I I ESC NU I I FlO = SAVE MENU I

Figure 3.10-18. AFM System cntrI Mode Selectin Screen Figure 3.10-20. Preprgrammed Setup File RSETUPOS - Best Power/Ecnomy Applicatins

FORM 6263 Second Edition FORM 6263 Second Edition 3.10-9

3.10-8
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

Saving Setup File To RAM USER. Once the data-set has been saved to RAM, the
message shown in Figure 3.10-23 appears. The LCD
The initial setup file must be saved to RAM (temporary CEC AFM CONTROL
display on the AFM module will briefly read Waukesha Left Right
memo to permit testing and editing of this data-set. Bank
CEC Custom Control , then the normal AFM LCD Bank
Engine Family: VP GAS ENGINE p
NOTE: Each time modifications are made to the displays will appear. Engine Model: L7042G V-12 Lean Limit= 1 1
R
data-set, the data-set must be saved to RAM before Sensor: 2-CC (0-lv) STEP AWAY
NOTE: "Custom Control" is the Best Power/Economy Rich Limit= 20000 20000
the edited values affect control of the AFM system and ri.ma Fuel Type
control mode.
can be tested. Simply editing the values on e AFM NATURAL GAS PU 000 10000
econdary Fuel
User Interlace Program screens will not change AFM 5. Press any key to cntime. NONE Store Test Values 100 -100
system operation.
This will Stop Program Executin
NOTE: If the "EECUTION STOPPED BY USER" and RESTART Prgram when finished.
NOTE: The contents of RAM are lost whenever power message persists on the AFM display for more than five Comments:
to the AFM module is removed. minutes, rer to Section 4.00 Air/Fuel Mdule System RICHBURN SETUP FI
1. Press [F1 O] to save the preprogrammed file data and Troubleshooting.
Yes N esc
edited application" information to RAM (tempora PWM Out= 0

memo NOTE: Data-sets that are created can be saved to a LT emp=350 c

2. Highlight est Data on AFM on the Saving Options
Menu and press [Entesee Figure 3.10-21).
3. The confirmation screen shwn in Figure 3.10-22
appears. Press M to confirm save t RAM.
4. Several screens will appear indicating that the
data-set is being saved to RAM. The LCD display on the
AFM module will read EXECUTION STOPPED BY
filename for future reference. Data-sets are assig, ed
filenames and saved on disk so the user can retain and Search Delay= 5.00 Minutes
retrieve the data-set later. When saving to disk, the
data-set will be saved to the drive and directory where
the AFM User Interlace Program was accessed. See
I FlO = SAVE II
"Saving Data-Set to Disk in this section to save your
data-set to a filename.
Figure 3.10-22. Cnflrmation f Save To Random Access Memory (RAM)

CEC AFM CONTROL

CEC AFM CONTROL Left Right
Left Right
Bank Bank Bank Bank
Engine Family: VHP GAS ENGNE PRZ

.
Engine Family : VHP GAS ENGINE p Lean Limit= l 1
Lean Limit= 1 1 Engine Model: L7042G V-12
Engine Model: L7042G V-12 R

Sensor: 2-CC (0-lv) STEP AWAY Rich Limit= 20000 20000
Sensr : 2-CC (0-lv) STEP AWAY Rich Limit= 20000 20000
,Primary Fuel Typ
r;rimary Fuel Type: NATURAL GAS P l 0000 10000
NATURAL GAS PIPELINE QUAI t:. ps. = 10000 10000
Save Data to Filename ,Secondary Fuel Ti
t!ecndary Fuel Type: NONE Starting RAM Prgram. -100 -100
NONE et Steps= -100 -100
Test Data on AFM
Configure AFM Memory Program is Running .

Comments: Test Values are Saved in RAM.

Comments:
RICHBURN SETUP F
RICHBURN SETUP FILE #5

PWM ut= 0
Press ANY KEY to Continue
PWM Out= 0
Lo-Temp=350 c
Lo-T1p=350 c Hi-Temp=760 c

Search Delay= 5.00 Minutes

Search Del 5.00 Minutes I
I FlO = SAVE II ESC = MENU I 10 11 ESC NU I

Figure 3.10-21. Saving ptins Menu I Figure 3.1023. Confirmatin Of Save T RAM

3.10-10 FORM 6263 Second Edition FORM 6263 Second Edition 3.10-11
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

ESTABLISHING ENGINE START POSITION 4. Use the manual adjustment keys on the AFM module
keypad to change gas/air pressure as required to
Most values stored in the preprogrammed files should CEC AFM CONTROL
dupli.te original gas/air seing. Once current gas/air
be reasonable for initial programming of the AFM Left Right
setting is equal to original gas/air, the stepper motr Bank Bank
module. Hwever, some modification to the stepper PR
start" position can be set. Engine Family: VHP GAS ENGINE
motr start position setting may be required to Engine Model: L7042G V-12 Lean Limit= l l
facilitate engine starting. Tc determine start psition IMARY
5. Press [Enter] or use the arrow keys until the cursor is Sensor: 2-CC (0-lv) STEP AWAY Rich Limit= 20000 20000
complete the steps in this section. ,Pr nary Fuel Type:
in the left/right STARTPOS. field n the Edit Screen
NATURAL GAS PIPELNE QUALITY Start ps. = 10000 10000
(see Figure 3.10-24). ,Secondary Fuel Type:
NOTE: If your enge has only one fuel regulae
NONE Offset Steps= -100 -100
'leff' buttons on e AFM module keypad control the 6. Read the stepper positin displayed n the AFM
enge's ael ratio. If your ee has twel mdules LCD display R STEPPER= XXXXX). Press
regulatoe 1eff' keypad buttons control the enge's <DSPL SEL> on keypad to scroll rough LCD mesges. Comments:
left bank and the 'right" keypad buttons control the RICHBURN SETUP FILE #5
enge's right bank. 7. Enter the stepper positin in the left/right
STARTPOS. field on the Edit Screen and press PWM Out"' 0
If yur engine has tw fuel regulatrs, complete [Enter] (see Figure 3.10-25). Lo-Temp-=350 C Hi-Temp=760 C
Steps 1 - 7 fr each fuel regulator.
NOTE: The contents of RAM are lost whenever power
NOTE: If an alarm condition exists, the AFM module Search Delay= 5.00 Minutes
to the AFM module is removed.
keypad will not function until the alarm is acknowledged
by pressing <ALARM ACK> on e keypad. 8. Press [F1 OJ to save the edited sta psition informa-
tion to RAM (tempora memo
FlO "' SAVE 11
1. Press <LEFT MAN> and <RIGHT MAN> (if applica-
bln the AFM module keypad t puttheAFM mdule 9. Highlight Test Data on AFMn the Saving Optins
in manual control. Menu and press [Enter] (see Figure 3.10-26). Figure 3.10-25. Entering Stepper Mtr Start Position

2. Review the riginal gas/air pressure setting you NOTE: Each time modifications are made to the
recorded BEFORE the stepper mtor was installed. data-set, the data-set must be saved to RAM before
the edited values aect control of the AFM system and
3. Measure current gas/air pressure with a manometer. can be tesd. Simply editing the values on the AFM CEC AFM CONTROL
Left Right
User Interface Program screens will not influence AFM Bank Bank
system operation. Engine Family: VHP GAS ENGINE p
Engine Model: L7042G V-12 R Lean Limit= 1 1
Sensor: 2--CC (0-lv) STEP AWAY I Rich Limit= 20000 20000
rary Fuel Type: M

CEC AFM CNTRL NATURAL GAS PIPELINE QUA! Pos. = 8000 8000
Left Right i!econda Fuel Type: Save Data to Filename
Bank Bank NONE Test Data on AFM t Steps"' -100 -100
Engine Family: VHP GAS ENGNE PRI
Engine Model: L7042G V-12 Lean Limit= 1 1 , Configure AFM Memory
Sensor: 2-CC (0-lv) STEP AWAY Rich Limit-=
MARY 20000 20000
, Prnary Fuel Type:
Comments:
NATURAL GAS PIPELINE QUALITY Start Pos. = 10000 10000 RICHBURN SETUP FILE #5
,Secondary Fuel Type:
7 NONE Offset Steps= -100 PWM Out= 0
Lo-Terop:350 C Hi-Temp:760 c

cmments:
Search Delay"' 5.00 Minutes
RICHBURN SETUP FILE #5
STEPPER START
POSITIN
PWM OUt= 0
Lo-Temp=3soc Hi-Temp=760 c
I FlO "' SAVE I I NU I
search Delay= 5.00 Minutes
Figure 3.10-26. Saving Options Menu

FlO = SAVE J I ESC NU I

Figure 3.10-24. Leating Stepper Mt Sta psitin

3.10-12 FORM 6263 Second Edition 3.10-13

FORM 6263 Second Edition
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

10. Press confirm save to RAM (see NOTE: If the "EXECUTION STOPPED BY USER MONITORING THE AFM SYSTEM THROUGH THE 2. If the L Status and R statuselds are in
Figure 3.10-27). message persists on the AFM display for more than five VIEW SERIAL LINK SCREEN automatic, press <LEFT MAN> and <RIGHT MAN> (if
minutes, refer to Section 4.00 Air/Fuel Module System applicablen the AFM module to put the AFM module
11 . Several screens will appear indicating that the Troubleshooting. 1. Highlight in manual cntrI.
data-set is being saved to RAM. The LCD display on the press [Enter] (see Figure 3.10-29) .
12. Return to the Main Menu by pressing [Esc].
AFM module will read EXECUTION STOPPED BY
Figure 3.10-28 appears on the screen warning you to The information shown on the View Serial Link Screen
USER. Press any key to continue after the save t RAM
save any changes made t the data-set before exiting. (see Figure 3.10-30) represents the current status of
is complete. Since the data-set has already been saved t RAM, your AFM system. This includes information on the
press M to return t the Main Menu.
oxygen sensor voltage and stepper positin.
No alarms will be active unless the warm-up delay

,,

diure
EVQ ata
er eta
SL

F gmw
el
CEC AFM CONTROL timer has expired (1 O minutes has passed since the

k
Left Right program was stored to RAM and the thermocouples L
- -L

Bank Bank
Engine Family: VP GAS ENGINE p have not yet exceeded the low temperature threshId).
Engine Model: L7042G V-12 R Lean Limit= 1 1
Sensor: 2-CC (0-lv) STEP AWAY NOTE: If an alarm condition exists, acknowledge e
Rich Limit= 20000 20000

Pr~~uel Type AFM system alarms by pressg <ALARM ACK> on e
GAS PIF 000 8000 AFM module keypad. Wait for the WORKING" mes- onitor AtM Operatia via Seri al Port
e~
0r;!ary Fuel Ty sage to disappear from e AFM LCD display (about 5
Store Test values 100 -100
seconds. 1e yellow alarm LED will turn off, the Figure 3.10-29. AFM User Interce Program Main Menu
This will Stop Program Execution
and RESTART Program when finished. "ALARM OUTPUT ACTIVE message on the PC screen
Comments: will clear, and the Error Out terminal within the AFM
RCHBURN SETUP FI module will close.

PWM Out= 0 Yes No esc

Lo-Temp=350c
CEC AFM Cntr1

Search Delay= s.oo Minutes

Engine Model: L7042G V-12 Sensor Type: CC (0-lV) STEP AWAY

I FlO = SAVE I I ESC

Left Bank I Right Bank I

Figure 3.10-27. Confirmatin f Save T Randm Access Memry (RAM) SENSOR:

Voltage (0.4) 0. 003 vlts 0.004 volts
Delay (S.00) 4.30 minutes 4. 30 minutes
Temperature 32 c ALARM 32 c ALARM
CEC AFM cNTROL PWM Output
Left Right
Bank Bank
Engine Family: VHP GAS ENGINE p STEPPER:
Engine Model: L7042G V-12 R Lean Ll.llll.t = 1 1 Position 9200 8750
Offset Steps -100 -100
Sensor: 2-CC (0-lv) STEP AWAY
Rich Limit= 20000 20000 Lean Limit 1 1
Fuel Type: M 20000 20000
NATURAL GAS PIPEl Rich Limit
vO 8000
t!econdary p Typ
NONE Exit to Main Menu DO - 100

Comments:
Changes Will be Lost if
you Have Nt Saved Them.
Enclsure Temp.
d L Status: MAN. WARM-UP
R Status: MAN. WARM-UP

RICHBURN SETUP FILE D you REALLY Want to EXIT? VIEW SERIAL LINK <ESC> t EXT

PWM Out= 0
Lo-Temp=350C Yes No esc Figure 3.10-30. View Serial Link Screen
Search Delay - 5. 0(

I FlO = SAVE I I ESC z

Figure 3.10-28. Cnfirnation Of Exit T Main Menu

3.10-14 FORM 6263 Second Edition FORM 6263 Second Edition 3.10-15
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

I A WARNING l SIDE AFM MODULE

rE
_r

.
CEC AFM Control
[;:~)
../

Do not set the stepper mtr(s) to the sta psn JC]

..,,::,;::!

J []DJOD H i~H ;H
i... ;i i
while the engine is running above 40 percent of Engine Model: L7042G V-12
rated lad. Start psitin is nly t be initiated when
[... ----i r- :J C~J rll=,~~=j Sensor Type: cc (0-lV) STEP AWAY

the engine is stpped or running belw 40 percent I ~t I

of rated load. Reseing the stepper mtr(s} while
the engine is running above 40 percent f rated lad
may cause engine shutdwn andr cause severe
engine damage.
!
'

~~ E~~ ~inn H
j

! -- r--<.:,:.

L m _.J

!:..

-~
'
..
" i UH
'

-

'7'!:
t

,:::,::
.
~ 5
.. ~
.

(~, ,s~
;,.;,:
"

"'

!.
SENSOR:
Voltage (0.4)
( 5tp oe
ozt
Left Bank

0.275 voltst eM
I Right Bank

0.275 volts
I

eew yeo 4.30 my

- ap
DTP ) nu e --nu es

m
ANAL;G CONNECTIONS emM - 4.30
zu
atuu c

550 = 551
3. Verify that the stepper motor(s) is properly con- 0 0
nected. -Set the stepper motor(s) to the Start Position' Figure 3.10-31. Analg Recnnectin
by pressing and releasing <F1 >, then <STRT POS> on As sn as the left and right exhaust temperatures STEPPER:
the AFM module keypad. The AFM LCD display will exceed 350 C (662 the left and right Status psition 9450 9390
show MOVING L STEPPER TO START POSITION. Offset Steps -100 -100
messages on the View Serial Link Screen will cha_nge
1e left and right Status messages on the View Serial
Link Screen will change to MOTOR RES during the Figure 3.10-32).

from MAN. WARM-UP tMANUAL" (see
Lean Limit
Rich Limit
1
20000
1
20000

positioning activity. Once the le bank has been moved,

the AFM module will mve the right bank stepper motor. 9. Enable AUTOMATIC control by pressing the L Status: MANUAL
<AUTO OPER> button on the AFM module keypad. The Enclosure Temp. 26 c R Status: MANUAL
Allow up to three minutes for this process. After the
stepper motor(s) has been moved to the start psition, left and right S.tus" shown on the View Se Link
Screen will change to AUTOMATIC (see
the norm LCD displays resume. If the normal LCD VIEW SERIAL LINK <ESC> to EXIT
Figure 3.10-33.e AFM module will begin adjusting
displays d not resume within five minutes, refer to
the stepper position to control the engines air/fuel rati
Sectin 4.00 Air/Fuel Module System Troubleshooting.
NOTE: If any alarm messages come on during opera- Figure 3.10-32. AFM Mdule In Manual Mode
4. Start the engine. tion of the AFM system, refer to Section 4.00 Air/Fuel
5. Recheck the power at the AFM module under worst Module System Trubleshooting and Section 4.05
case conditions. The engine ignition and any other Air/Fuel Module System Diagnstics to troubleshoot the
system. 'RICH LIMIT or"LA.N LIMIT' errors are good CEC AFM Contr1
electrical devices to be driven by the same power supply
as the AFM mdule must be perating. Peak-to-peak dicaat the carburetor screw needs acst,g.
Engine Model: L7042G V-12 Sensor Type: cc (0-lV) STEP AWAY
voltage variations must not exceed tw volts. This
1o. To permit significant rich and lean adjustments to
measurement must be taken with an oscilloscope.
the AFM system, it may be necessary to adjust the
Refer to Section 2.05 AFM System Electrical Connec- carburetor screw(s) s the AFM system controls close
Left Bank I Right Bank I
tions fr AFM system power specifications.
to the middle of the stepper motor range. Once the AFM
system has gained cntrol of the air/fuel ratio (sensor soeew
Rtapi
euw NVDTP
zaveeO

6. Reconnect the analg connectins terminal block tu --tu

llgm
e - )
gru lnst st

nunuv

vm

vm
lc
A

LFW
voltage readings are very near sensor set-pointust

r
oe 0.276 0.276

3
containing the intake manifold pressure transducer and ( 5tp
,.. es n egH

the carburetor screws until the AFM system is cntrI 4.30 4.30
oxygen sensor(s) t the header inside the AFM module at

uu
550 551
(see Figure 3.10-31 ). ling close to the middle of the stepper motr range which
is 10,000 steps for 66, 662, S201, S211 regulators or
7. Allow the engine to warm up. 2900 steps for 99, 1098 regulators. STEPPER:
8. Set the engine speed to normal operating conditions Position 9400 9450
11. Once yu are satisfied that the AFM system is Offset Steps -100 -100
and the load to at least 60 BMEP. controlling air/fl.el ratio for the engine and no errors Lean Limit 1 1
ccur, continue with Fine-Tuning AFM Programming
Rich Limit 20000 20000
Once the engine is running to at least 60 BMEP, the
sensor vltages shuld begin to fluctuate and the For Best Power/Econmy Applicatins t adjust the
sensr temperatures should rise as mnitored on the system fr optimum air/fuel rati contrI. L Status: AUTOMATIC
View Serial Link Screen. Enclsure Temp. 26 c R Status: AUTOMATIC
NOTE: If any alarm messages come on during opera-
tion of the AFM system, refer to Section 4.00 Air/Fuel VIEW SERIAL LINK <ESC> to EXIT
Mdule System Troubleshting to troubleshoot the
system.
Figure 3.10-33. AFM Module In Autmatic Mode

3.10-16 FORM62 Second Edition FORM 6263 Second Edition 3.10-17

PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

FINE-TUNING AFM PROGRAMMING FOR BEST
POWER/ECONOMY APPLICATIONS
Once initial programming of the AFM module is
complete and the prelimlnary data-set is saved to RAM,
the AFM module must be fine-tuned for ptimum
air/fuel rati cntrol. The AFM module is fine-tuned to
achieve the desired running point: best power or best
economy. To fin tune the AFM module it will be
necessa to determine the number of steps, either
rich or lean, that the AFM module will take to move away
from stichiometry to achieve best pwer or best
4. Put the AFM module int manual mde by pressing Table 3.10-2. View Serial Link Screen And Best pwer/Econmy cntrol Worksheet
<LEFT MAN> and <RIGHT MAN> (if applicablen the
AFM module keypad.
NOTE: One press of the <LEFT/RIGHT LEAN> or CEC AFM Control
<LEFT/RIGHT RICH> buttons moves stepper position
25 steps (1/16 m). By press.1g <LEFT/RIGHT FAST> Engine Model: L7042G V-12 Sensor Type: cc (0-lV) STEP AWAY
prior to pressing the lean or rich buttons, a 400 step
(1 turn) change is made to stepper position.
SENSR
VOLTAGE
Right Bank I
SENSR SET-PINT
vLTAGE
5. Using exhaust analyzers (CO and 02 meters), adjust
the air/fUel ratio by pressing <LEFT RICH> and/or - - --

vm
SENSOR:

O 5
P Rdaaz

qZlW

esL

-Rnu-dnuvAUo-- l- t-
H4F

J
ecnomy. A wrksheet is provided to help yu in <LEFT LEANn the keypad until stoichiometry is v ltage(0.4) I

h a
LC nu

S
Delay (5.00) e
4. 33 11Unutes

determining the offset steps required in programming achieved. The sensor set-point vltage should be met as

Temperature 601 c
the AFM module. Complete the Best Power/Eenomy indicated on the View Serial Link Screen (0.4 volts for PWM Output
Contrl Worksheet by fwing the steps in this section. best economy, 0.6 volts for best power) (see
STEPPER
In best power/econmy cntrol, the AFM module seeks Table 3. 2). If your engine has tw fuel regulators, STEPPER: ,....-- ~ pSITIN

ut stoichimetry then moves, either rich or lean, a repeat this step for the engines right bank using the POSJ.tJ.on K 40 .
Offset Steps -100
programmed number of steps 0set Steps'). If the right' keypad buttons. Lean Limit
Oset Steps" value is positive, the air/fuel ratio will be Rich Limit 20000
NOTE: It may be difficult to distinguish between the two
rich of stoichiometry (b power). If the set
sensor set-poin The oxygen sensor signal may be
Steps" value is negative, the airel ratio will be L Status: AUTOMATIC
very erratic near stoichiometry.
adjusted lean of stoichiometry (best ecnomy). Enclosure Temp. 26 c R Status: AUTOMATIC
NOTE: If your enge has only one fuel reguto the 6. Record the stepper position displayed on the View
"left" buttons on the AFM module keypad control the Serial Link Screen in the Stepper Position at Stoichio- VIEW SERIAL LINK <ESC> to EXIT
enge's ailel ratio. If your engine has twel
metry column on your worksheet (see Table 3.10-2).
regulatorse "left" keypad buttons control the enge's
7. Using exhaust analyzers (CO and 02 meters}, adjust
left bank and the "right" keypad buttons control e
air/fuel ratio by pressing <LEFT RICH> and/or STEPPER
enges right bank. When comptg e steps is STEPPER
<LEFT LEAN n the AFM module keypad until the SENSR SET-PINT
PSITIN
AT
PSITIN
AT LEAN LIMIT RICH LIMIT
section, englnes with one 1el regulator require only "left" desired running point is achieved (best power r best DESIRED RUNNING
STICHIETRY POINT
valies to be determined; eng.es w two fuel regulators (CIRCLE ONE)
econmy). If your engine has two fuel regulators, repeat
requdependent "left' and "righr values to be LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
this step for the engines right bank using the right'
determed.
keypad buttons.
vBTECN~
1. Detach or copy the yew Best Power/Ecnomy Best Power Setting 15.50:1 AFR 7500 7500 4000 4000
Contrl wrksheet from the back of this manual (see Best Ecnmy Setting 17.00:1 AFR .6 v BEST POWER
Table 3.10-2 for sample worksheet).
8. Recrd the stepper positin displayed on the View LEFT RIGHT
2. On the worksheet, circle the desired running point Serial Link Screen in the Stepper psition at Desired
STEPPER POSITION 4000 4000
(best pwer r best econmy) fr the engine. Running Point'' column n your worksheet (see AT DESIRED RUNNING POINT
Table 3.10-2).
3. The sensr set-point voltage is different fr best STEPPER POSITION
9. Subtract the stepper position at stichiomet found - 7500 - 7500
economy (0.4 volts) and best power (0.6 volts). Verify AT STOICHIOMETRY
that the View Serial Link Screen is displaying the correct in Step 6 frm the stepper psition at desired running
sensor set-point vltage fr yur application (see point fund in Step 8. This value is the Offset Steps
Table 3.10-2). value. Use the space provided on the worksheet to OFFSET STEPS -3500 -3500
determine the Offset Steps value(s) (see
NOTE: If the wrong sensor set-point voltage is dis- Table 3.10-2). NOTE: The values this table are for reference ONLY. Actual values are specific to your engine application.
played, return to the Edit Screen, change the Offset
Steps" value to a negative value for best economy or a NOTE: The result of subtracting these values will be
positive value for best power, and save this new negative if desired running pot is best economy. The
data-set RAM. Return e View Serial Lk Screen result of subtracting these values will be positive if
and the sensor set-pot will display the correct voltage desired runn 'ng point is best power.
for your desired running po.t
NOTE: If an arm condition exists, the AFM module
keypad will not function une alarm is acknowledged
by pressrng <ALARM ACK> on the keypad.

3.10-18 FRM 6263 Second Edition FORM 6263 Second Edition 3.10-19
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS
10. The AFM system adjusts the spper motor be-
tween two programmable limits to maintain the sensor
set-point voltage. Current recommendations are to set
the lean and rich limits 2 air/fuel ratios r less.
Determine a lean and rich limit, to define the stepper
motr adjustment range following the guidelines below
and Figure 3. 10-34:
NOTE: Stepper motor lean and rich limits 2 air/fuel
ratios) can be determined by moving 1 air/fuel ratio
and doubling the change in stepper posin. For
example: An engine at desired running point has a
stepper position of 1500 Sps. The engine is adjusted
+ 1 air/fuel ratio and stepper position is 1400 steps. The
change in stepper position for + 1 air/fuel ratio is 100
steps (1500 -1400 =100). Doubling this value, stepper
motor change for + 2 air/ftel ratios is 200 steps.
Therefore, the lean limit stepper position is 1300 steps
(1500 - 200 = 130
A Using exhaust analyzers, lean air/fuel ratio by
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS
PROGRAMMING SCENARIO
NOTE: The values and readings used is programming scenario are sample values only. Actual values and
readings will vary depending on engine application. Guidelines presented apply to most enge applications.
The following programming scenario demonstrates how a technician fine-tuned theAFM mdule program
while following the steps in the AFM manual (Form 6263). Within the text of the scenario below, the
programming step the technician is completing is indicated.
A technician is programming a L7042G Waukesha Engine
with Fisher S211 regulatrs following the programming
procedures in the AFM manual (Form 6263). After complet-
ing the inial programming requirements, the technician is
ready to continue with the sectin Fine-Tuning AFM
Programming for Best Power/Econmy Applications.
Step 1: The technician makes a copy of the yellow Best
Power/Ecnomy Control Worksheet from the back f the
AFM manual. Step 2: The desired running point is best
pwer and is circled on the worksheet. Step 3: The View

+ 2 air/fuel ratios (3.4 percent xygen for best Serial Link Screen is displaying the correct sensor set-
point voltage (0.6 volts). Step 4: The <LEFT MAN> bun
Step 10: Now the technician needs to determine e rich and
ecnomy; 1.8 percent xygen for best power) by lean limits following the 2 air/fuel rati recommendation in
and then <RIGHT MAN> button on the AFM module
pressing <LEFT LEAN> on the keypad. If your the AFM manual and Figure 3.10-34. The technician
keypad are pressed to put both engine banks in manual
engine has two fuel regulators, repeat this step for presses <LEFT LEAN> until the oxygen meter indicates 1.8
mode. Step 5: Air/fuel ratio is adjusted until the sensor
e engines right bank using the rig keypad percent(+ 2 air/fuel ratios). The stepper position displayed
0 0 set-point voltage reads 0.6 volts on the View Seial Link
14 15 16 17 18 19 20 21 buns. on the View Serial Link Screen is then recorded in the Lean
Screen for both engine banks. Step 6: With the View Serial
RICH LEAN Limit' column on the worksheet. The technician presses
AIR/FUEL RATIO Link Screen displayed on the PC, the stepper positin for
B. Record the stepper psition displayed on the <LEFT RICH> until the carbon monoxide meter indicates
--., both engine banks is read and recorded in the Stepper
View Serial Link Screen in the Lean Limit" 4.5 percent. The stepper position displayed on the View
Position At Stoichiometry column on the worksheet.
INCREASING STEPPER POSITION
--
BEST PWER Alf = 15.50
CATALYST A/F = 15.95YPICAL)
--
DECREASING column on your wrksheet.

C. Using exhaust analyzers, richen air/fuel rati by

- 2 air/fuel ratios (2.0 percent carbn monxide
Step 7: Air/fuel ratio is adjusted again until best power
(15.50:1 air/fuel ratios), the desired running point, is
achieved. Step 8: The stepper positions displayed on the
View Serial Link Screen are then recorded in the Stepper
Serial Link Screen is then recorded in the Rich Limir
column on the worksheet.
Once the Best Power/Economy Control Worksheet is
complete, the technician is ready to continue with Program-
for best economy; 4.5 percent carbon monoxide Position At Desired Running Point column of the work- ming the Best Power/Economy Control Values in theAFM
ST1ICHIMETRIC A/F = 16.09
for best power) by pressing <LEFT RICH nthe sheet. Step 9: Using the worksheet, the technician sub- manual.
BEST ECN MY A/F = 17.00
keypad. If your engine has two fuel regulators, tracts the stepper position at stoichiometry from the stepper
NOTE: The oxygen, carbon monoxide, and oxygen sensor repeat this step fr the engines right bank using position at the desired running point. The result is positive
SIalcurves were plotted for laboratory data. Actual sensor since the desired running point is best power.
response and desired air/fuel ratio will depend slightly on fuel the right'' keypad buttons.
composition; however, the relationsh between CO and 02 will
remain constant. D. Record the stepper position displayed on the
View Serial Link Screen in the Rich Limit"
Figure 3.10-34. Oxygen Ssor Response Vs. Eaust
column on yur worksheet.
Gas cncentrations For Various Air/Fuel Ratios -
Rich Burn NLY
NOTE: Figure 3. 10-35 provides a scenario of a techni-
cian ne-tuning the AFM system following the program-
ming steps in this section. The values in the scenario are
given for example on~ Actual values will vary depend-
ing on engine application.

11. After completing the Best pwer/Economy Contrl

Worksheet, continue with Programming the Best
Power/Economy Control Valuesn page 22.

Figure 3.1D-35. Programming Scenario Fr Best pwer/Econmy Control

3.10-20 FORM 6263 Second Edition

FORM 6263 Second Edition 3.10-21
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

PROGRAMMING THE BEST POWER/ECONOMY 6. Using the down arrow key, position the cursor in the
NOTE: If the 'EXECUTION STOPPED BY USER save changes that were made to the data-set before
CONTROL VALUES "Lo-Temp field . Although the high and low temperature
message persists-on the AFM display for more than five exiting. Since the data-set has already been saved to
limits can be modified, it is nt recommended that these
1. Press [Esc] to returl') to the Main Menu.

two values be changed. The L Temp value should
minutes, rer to Section 4.00 Air/Fuel Module Trouble-
shting.
RAM, press M to return to the Main Menu.
2. Highlight Edit/Create Setupn the Main Menu and not be set below 350 c (662 because that mpera 14. Highlight
press [Enter] (see Figure 3.10-36). ture is the minimum for correct oxygen sensor opera- 13. To return to the Main Menu, press [Esc). and press [Enter] to return to the View Serial Link
tin. If required, the Hi-Temp value can be modified to Figure 3.10-39 appears on the screen warning you to Screen.
provide a safety against high exhaust temperatures.
I CEC AFM Control - Ver . X. Xx I 7. psition the cursor in the Search Delay field. The CEC AFM CONTROL
Left
default value for the search delay is five minutes. Right
Bank Bank
Search delay is the amunt of time, in minutes, that the Engine Family: VHP GAS ENGINE p
Engine Model : L7042G V-12 R Lean Limit= 1 1
Edit/Create Setup AFM waits between searches for stoichiometry. Adjust
the search delay value as desired. For stable fuels and Sensor : 2-CC (0-lv) STEP AWAY I Rich Limit= 20000
View Serial Link c;rimary Fuel Type: M 20000
Quit maximum benefits, set search delay value at maximum. NATURAL GAS PIPELINE QUALITY A Start ps ... 8000 8000

Se~0~~ary Fuel Type: R
NOTE: When entering e Offset Steps" valie(s), a y Offset Steps= -100 -100
negative value moves the AFM Jean from stoichiometry
toward the best economy operating point. A positive
value moves the AFM rich from stoichiometry toward comments:
Retrieve Data fr.om AF. File, or Create New. RICHBURN SETUP FILE #5
the best power operating pot
Figure 3.10-36. AFM User lnteace Program PWM Out== 0
8. Press [Enter] or use arrow keys until the cursor is
Main Menu Lo-Temp= 350 c Hi-Temp:760 c
positined in the left Lean Limit' clumn on the Edit
3. The Edit/Create Setup Menu shown in Screen. Using your completed Best pwer/Ecnmy
Control Worksheet, enter the Lean Limit',Rich Limit, Search Delay= 5.00 Minutes
Figure 3.10-37 appears. Highlight Retrieve from AFM
and press [Ente and Offset Steps" values for each engine bank. Press
[Ente after each value is entered to work down through
each column.
I FlO = SAVE I I ESC = MENU I
NOTE: Data-sets that are created can be saved to a
filename for future reference. Data-sets are assigned Figure 3.10-38. Editing The Data-Set On The Edit Screen
filenames and saved on disk so the user can retain and
retrieve the data-set late. When saving to disk, the
Retrieve from AFM data-set will be saved to the drive and directory where CEC AFM CONTROL
Left Right
Retrieve from Filename the AFM User Interface Program was accessed. See Bank Bank
Create New Dataset 'Saving Data-Set to Diskis section to save your Engine Family: VHP GAS ENGINE p
Engine Model: L7042G V-12 R Lean Limit= 800 800
data-set to a filename.
Sensor: 2-CC (0-lv) STEP AWAY
Rich Limit: 12000 12000
i:;rimary Fuel Type: M
NOTE: The contents of RAM are lost whenever power NATURAL GAS PIPEl 0 8000
to the AFM module is removed. t!econd Fuel TypE
1plo.ad Data Fr om AFM vi.a Serial Port. NONE Exit to Main Menu DO -3500
NOTE: Each time modifications are made to the
Figure 3.10-37. Edit/Create Setup Menu data-set it must be saved to AFM RAM (temporary Changes Will be Lost if
memory) for evaluation. S.1ply editing e values on e Comments: you Have Not Saved Them.
NOTE: Refer to Figure 3. 10-38 while editing e PC screen will not influence AFM operation. RICHBURN SETUP FILl
data-set. Do you REALLY want t EXIT?

9. Press [F1 O] to save the Edit Screen values to RAM PWM Out= 0
4. After the Edit Screen appears, type in any comments (temporary memory) for testing. LTemp=350 c Yes
regarding AFM programming or revise existing com- N esc
ments at the cmments field. Typical! comments 10. Highlight '1est Data on AFM on the Saving Options
include site, engine number, and date infornation. Menu and press [Enter]. Search Delay = 5. 01
11 . Press confirm save to RAM.
NOTE: When the cursor is moved between entry
locations, the bottom line of the Edit Screen will show a 12. Several screens will appear indicating 'that the
I FlO = SAVE ESC = MENU I
brief explanation and limits for that entry. data-set is being saved to RAM. The LCD display on the
5. Press [Enter) to move from the cmments field to AFM module will read EXECUTION STOPPED BY
the WM out field. Leave the PWM Out" value set to USER. Press any key on yur cmputer t continue Figure 3.10-39. Cnfirmation Of Exit T Main Menu
zero fr unheated sensrs. after the .ve to RAM is complete.

3.10-22 FORM 6263 Second Edition 3.10-23

FORM 62 Second Edition
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAM MING FOR BEST POWER/ECONOMY APPLICATIONS

NOTE: If an alarm condition exists, the AFM module SAVING DATA-SET TO RM

keypad will not function until the alarm is acknowledged Once yu create a data-set, test the data-set in RAM
by pressing <ALARM ACK> on the keypad. CEC AFM CONTROL
(tempra memo and are satisfied with the AFM s Left Right
15. Place the AFM module in automatic mde by air/fuel cntrol, the data-set must be saved to perma- Bank Bank
nent memory (ROM). Complete the steps in this section Engine Family: VHP GAS ENGINE p
pressing <AUTO OPER> on the AFM keypad.

to save yur date set to ROM.
Engine Model: L7042G V-12 R Lean Limit= 800 800
Sensor: 2-CC (0-lv) m 'D T
atJ V .
12000
16. Monitor AFM system perfrmance. NOTE: The AFM system allows five saves to ROM r;rimary Fuel pe:
NATURAL GAS PIPELI 8000
Steps 17 - 21 are completed t check ease of starting (permanent memory). All data-sets should be carefuli econdary Fuel Type: This will Stop Program Execution
the engine based on the start posion programmed. evaluad RAM (temporary memory) before storing NONE -3500
ROM. Once ROM has been fully configured, the core and RESTART Prgram when finished.
17. Press <LEFT MAN> and <RIGHT MAN> (if appli- EPROM chip in the AFM module must be replaced to
cable) on the AFM mdule keypad t put the AFM permit rlher saves to permanent memory. Refer to Comments: OK Store Values To ROM?
module in manual contrI. Section 4.00 Air/Fuel Module System Troubleshooting RICHBURN SETUP FILE
for core EPROM replacement instructions.
NOTE: The contents of RAM are lost whenever power PWM Out= 0 Yes N esc
to the AFM module is removed. 1. Highlight Edit/Create Setup" from the Main Menu to Lo-Temp=350 c
return to the Edit Screen and press [Enter).
18. DO NOT TURN OFF POWER TO THE AFM
2. Highlight Retrieve from AFM and press [Enter]. Search Delay= 5.00 Minutes
MODULE. Shut dwn the engine and allw it to cool for
several mimtes.
3. Wh the Edit Screen displayed, press [F10) to save
the data-set to ROM (permanent memory).
I FlO = SAVE MENU I
A WARNING NOTE: The 'Test Data on AFM option from the Save
D nt set the stepper mtor(s) to the sta psitin Options Menu allows a program to be run theAFM Figure 3.10-40. Confirmation Of Save T Read nly Memory (RM)
while the engine is running abve 40 percent f module temporary memory (RAM). This may be used
rated lad. Start psitin is nly t be initiated when for troubleshootg so that the ROM memory space is
e engine is stpped or running belw40 percent conserved. The contents of RAM are lost whenever
of rated lad. Resetting the stepper mtr(s) while CEC AFM CONTROL
power to the AFM module is removed. Left Right
the engine is running abve 40 percent f rated lad Bank Bank
may cause engine shutdwn and/or cause severe 4. Highlight cnfigure AFM Memryn the Save Engine Family: VHP GAS ENGINE p
Engine Model: L7042G V-12 Lean Limit= BOO 800
engine damage. Oions Menu and press [Enter]. R
Sensor: 2-CC (0-lv) STEP AWAY
Rich Limit= 12000 12000
,Primary Fuel Type:
19. Press and release <F1>, then <STRT POSn the 5. When the confirmation screen appears as shown in NATURAL GAS PIPELI 8000
AFMmdule keypad to test the start psitin. TheAFM Figure 3.10-40 press M. ,Secondary Fuel Type:
NONE --3500
LCD display will show MOVING L STEPPER TO START
POSITION". The left and right Status mes.ges on the
View Serial Link Screen will change to MOTOR RESET
IA CAUTI Nl 0 not.d~b the al
cable, interrupt the AFM Comments:
OK to Store New Values?

during the posining activity. Once the le bank has mdule pwer interrupt cmputer pwer while
been mved, the AFM module will move the right bank RICHBURN SETUP FILE
cnfiguring memory. If disturbed r disc nnected
stepper motor. Allow up to three minutes for this process. during the saving process, the cre EPROM chip in PWM Out= 0
After the stepper motors have been moved to the start Yes No esc
the AFM mdule may beeme crrupted and may Lo-Temp=350 c
position, the nrmal LCD displays resume. If the normal
need t be replaced.
LCD displays do not resume within five minutes, refer to
Sectin 4.00 Air/Fuel Module System Troubleshoot9
Search Delay = 5. 00 J
6. When the verification screen appears as sh,wn in
Figure 3.10-41 press M.
20. Attempt to start the engine to check ease of
starting.
I FlO I I ESC NU I
7. Several screens will appear indicating that the
NOTE: Consider cold starts when modifying start data-set is being saved to ROM (permanent memory on
position. the core EPROM chip inside the AFM module). Once Figure 3.1<>-41. Verificatin To Store New Values T RQM
the data-set has been saved to ROM, the message
21 . If nece modify the start posn by changing the shwn in Figure 3.10-42 appears.
s posn on the Ed screen and ting changes to
RAM tott Repeat the check until the engine s well. NOTE: The AFM allows five saves to ROM. Once ROM
has been fully conrgured, the core EPROM ch the
22. Once you are satisfied with AFM system perfor- AFM module must be replaced permit rther saves
mance and ease of starting, return to the Main Menu. permanent memory.

23. Cntime with Saving Data-Set to ROM. 8. Press any key to return t the Edit Screen.
3.10-24 FORM 6263 Second Edition FORM 6263 Second Edition 3.10-25
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

CEC AFM CONTROL
Engine Family: VHP GAS ENGINE
Engine Model: L7042G V-12
Sensor: 2-CC (0-lv) STEP AWAY
rimary Fuel Type:
NATURAL GAS PIPELI
e~0~~ary Fuel Type:
s shooting for core EPROM replacement instructions.
cmments:
RICHBURN SETUP FILE
PWM Out= 0 Press ANY KEY
Lo-Temp=350 c
Search Delay : 5.00 Minutes
I FlO = SA: 11 ESC
CEC AFM CONTROL
Engine Family: VHP GAS ENGINE
Engine Model: L7042G V-12
Sensor: 2-CC (0-lv) STEP AWAY
t.;rimary Fuel Type:
NATURAL GAS PIPELI
t!econdary Fuel Type:
NONE
Comments:
RICHBURN SETUP FILE
NOTE: If the power to the AFM is adequate (less than 3. Enter a filename according to the fwing proce-
21.6 volts) or excessively 'irty more than 2 volts dure (see Figure 3.10-44). Read all three steps prir to
Left Right peak-to-oeak r1ple), the programmg operation may saving the file t the disk.
Bank Bank
not be successful. An unsuccessful store to "ROMn will
p
Lean Limit= BOO 8 00 result in the error message illustrated Figure 3. 10-43. A. Lcate the engines serial number n the name-
R
Should this error occur, the core EPROM chip must be plate.
Rich Limit= 12000 120 00
M replaced and the true cause for the ilure corrected.
80 00 Rer to Section 4.00 Air/Fuel Module System Trouble- B. If the engine has a C-" number, remove the C-"
and the f frm the number. Example:
Starting ROM2 Program. -35 00
Press any key on your computer to continue. C-10768/01 would give a root file name of
AFM Memory has been Configured. 1076801 . If the engine des not have a e-.:
NOTE: Save a copy of your data-set to disk for future number use all six digits in the serial number for
Prgram Is Running. reference. If a printer is connected to your PC, press the filename.
[Print Screen] on e keyboard for a printout.
t Continue C. The first time the configuration is saved to the
SAVING DATA-SET TO DISK disk add an A to the end. This is to indicate that
The new data-set should be stored to a floppy/hard disk this is the first save of this configuration. If
and to permanent memory (ROM) as the previous changes are made to the configuration, save the
section explains. Data-sets are assigned filenames next file with the same numerical information and
and saved on disk s the user can retain the data-set for change the suffix letter to B. Continue in this
NU I future reference. Each time a new program is saved to manner for each revisin to the file.
ROM, the previus program can n longer be retrieved.
Once eight characters have been entered, the file will
The only way to keep track of old programs is to save the
automatically be saved to the persnal computer disk
Figure 3.10-42. Verification Screen Of Save T RM data-file to disk r with printed copies.
from where the AFM User Interface Program was
NOTE: If you want to retrieve a daset saved to dis. accessed. If the filename is less than eight characters,
refer to the next sectionRetrieVig a Saved Data-Set." press [Enter] t save.
NOTE: When saViing to dh the data-set will be saved
Left Right 1. With the Edit Screen displayed, press [F1 t save
Bank Bank your data-set to disk. to the drive and directory where the AFM User Interlace
p Program is accessed.
Lean Limit= 800 8 00
R 2. Highlight Save Data to Filename" from the Saving
Rich Limit= 12000 120 00 Options Menu and press [Enter].
M
8 000
Programming Error has Occurred. -3 500 CEC AFM CONTROL
Left Right
Program is NOT Running. Bank Bank
Engine Faily, VHP GAS ENGINE p
Engine Model: L7042G V-12 Lean Limit= BOO BOO
Check EPROM or Vpp for Error. R
Sensor: 2-CC (0-lv) STEP AWAY
Rich Limit= 12000 12000
EPROM Must Be Replaced. t.;rimary Fuel Type: M

PWM Out= 0 NATURAL GAS P IPE 8000

Lo-Temp=350 c s e~~~ary Fuel Typ 00 -3500
Press ANY KEY to Continue
Save Choices to Disk
Search Delay= 5.00
Comments:
I FlO = SAVE II ESC NU I RICHBURN SETUP FILl nput DataFile Name

PWM Out= 0

Lo-Temp=350 c

Figure 3.10-43. Programming Error Message

Search Delay 5 . 00 Minutes

I FlO = SAVE II ESC MENU I

ENTER vAt.io 8 CHAACER NA

Figure 3.10-44. Input Data-File Name Screen

3.10-26 FORM62 Second Edition FORM 6263 Second Edition 3.10-27

PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

CHECK 1: CONFIRMING THE DATA-SET SAVE TO

CEC AFM CONTROL
Left Right
Bank
I c M ol - Ver x XX
RM
Check 1 confirms that the data-set was successfully

sm
Bank stored in ROM on the core EPROM chip.
Engine Family: VHP GAS ENGINE p
Engine Model: L7042G V-12 R
Lean Limit= 800 NOTE: Programs saved to e EPROM will be retained
Sensor: 2-CC (0-lv) STEP AWAY File Select even if power to the AFM module is interrupted.
Rich Limit= 12000
,Primary Fuel Type: M
Programs saved to RAM will be lost when power to the
1076801A.AFM
NATURAL GAS PIPE 8000
,Secondary Fuel TypE AFM module is disconnected. The AFM can detect

b
..
NONE Exit to Mai:g. Menu -3500 RSETUPO l . AFM . ... when an evaluation data-set is being tested in RAM and
....
..
RSETUP02.AFM has not been saved to ROM. If you attempt to leave the
Changes Will be Lost if AFM User Interface Program without saving the evalua-
RSETUP03.AFM .... .
Comments:
RICHBURN SETUP FIU
you Have Not Saved Them.
Do you REALLY Want t EXIT?
RSETUP04.AFM :I.. '
tion da to ROM, awamg will be displayed.
RSETUPOS.AFM .::. 1 . With the Main Menu showing on yur screen,
..
PWM Out= 0
RSETUP06.AFM .. .. highlight Edit/Create Setup" and press [Enter].
Lo-T 350 c Yes No esc RSETUP07.AFM .. ..
...... 2. Highlight Retrieve m AFMn the next menu that
RSETUPOS.AFM
appears and press [Enter]. Several messages appear
Search Delay= 5.0( RSETUP09.AFM indicating that the data-set is being retrieved from
ROM.
0 = SA 1 1 ESC NU I 3. The Edit Screen appears (see Figure 3.10-48).
Figure 3.1o-47. File Select Menu
Verifv that the data n the Edit Screen is the same
data.:...set chosen t be saved to ROM.
Figure 3.1 o-45. Cnfirmation f Exit To Main Menu POSTPROGRAM M ING CHECK If the correct data does nt appear n the Edit Screen,
4. Press [ESC] t return to the Main Menu. RETRIEVING A SAVED DATA-SET FROM DISK Twopst-programming checks must be cmpleted t verifv that the DB-9 serial cable connected between the
WITH A FILENAME cnfirm that the data-set created was successfully PC and the AFM module is secu and in gd
5. If the data-set fr yur engine has been saved to stored to ROM. The procedures that follw take yu condition. In addition, verify the power to the AFfv1_
ROM and a file on disk, confirm the exit to the Main The data-sets that are saved to disk (not RAM or ROM) module is within specification. Attempt a second store"
step-by-step through the pst-programming checks.
Menu by pressing M (see Figure 3.10-45). The Main and assigned a filename can be retrieved following the of the correct data-set to ROM (refer tRetrieving a
Menu appears (see Figure 3.10-46). If yu have nt steps in this section. NOTE: Print copies of your data-set or save your Saved Data-Set From Disk With a Filename" t retrieve
data-set to a file for future reference before comp/etg data-set from a filename). If difficulty continues, contact
saved the data-set to ROM (permanent memo NOTE: If you want to save a data-set to disk, rer to your local Waukesha Engine distributor or Waukesha
press [N] and refer to Saving Data-Set to ROM in this e previous section "Savlng Data-Set to Disk. e two post-programming checks.
Engine Product Support.
section.
1. With the AFM User Interface Program s Main Menu
showing on yur screen, highlight Edit/Create Setup"
and press [Enter] (see Figure 3.10-46). CEC AFM CONTROL Left Right
Bank
I CEC AFM Cont Ver. x.xx I 2. On the next menu highlight Retrieve from Filename" Engine Family: VHP GAS ENGNE p
Bank
Lean Limit= 800 800
and press [Enter]. Engine Model: L7042G V-12 R
Sensr : 2-CC (0-lv) STEP AWAY I Rich Limit= 12000 12000
3. Highlight the filename (serial number) you want t rimary Fuel Type:
M
Edit/Create Setup A Start Pos. = 8000 8000
open and press [Enter] (see Figure 3.10-47). The NATURAL GAS PIPELINE QUALITY
View Serial Link R
!e~0~~ary Fuel Type: y Offset Steps= -3500 -3500
Quit infrmatin that is shwn n your PC screen is
infrmation that has been saved in a file and was not
retrieved from the AFM modules RAM or ROM.
COllll!lents:
NOTE: The retrieved filez data-set must be saved to RICHBURN SETUP FILE #5
Retrieve Dati from AFM, File Create New. RAM or ROM before the displayed data-set values
a-ect control of the AFM system. PWM Out= 0
Lo-Temp=350 c Hi-Temp=760 c
Figure 3.1 o-46. AFM User Interface Program NOTE: The contents of RAM are Jost whenever power
Main Menu to the AFM module is removed.
Search Delay= 5.00 Minutes
NOTE: If you want to save an opened file to ROM
(permanent memo refer Sav,g Data-Set to
ROM.
I FlO = SAVE I I ESC
Figure 3.10-48. Edit Screen

3.10-28 3.10-29
FORM 6263 Second Edition FORM 6263 Second Edition
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS

CHECK 2: FINAL TEST OF AFM SYSTEM SETUP

Check 2 confirms that the data-set is not lost when the CEC AFM Control - Ver. x.xx CEC AFM CONTROL
AFM system is powered down and that the AFM system Left Right
Bank Bank
will pwer up with the aata stored in ROM. Engine Family: VHP GAS ENGINE PRIMARY
Engine Model: L7042G V-12 Lean Limit = 800 800
1. Highlight Quitn the Main Menu and press [Enter]
cmmunications Menu Sensor: 2-CC (0-lv) STEP AWAY Rich Limit= 12000 12000
(see Figure 3.10-49). ,Primary Fuel Type:
Select cm Port NATURAL GAS PIPELINE QUALITY Start Pos. = 8000 8000
,Secondary Fuel Type:
~ NONE Offset Steps= -3500 -3500
@ l 02 03 04
CEC AFM Control - Ver. x.xx
Comments:
RICHBURN SETUP FILE #5
Edit/Create Setup
Figure 3.10-50. Cm1unicatins Menu PWM Out= 0
View Serial . Link Hi-Temp=760C
Lo-Temp=350 C
Quit
8. The AFM User Interface Program s Main Menu
appears showing varius program options available Search Delay= 5.00 Minutes
(see Figure 3.10-51). Highlight Edit/Create Setup" and
press [Enter].
Retrve Data f. ro AF File, or Create New.
FlO SAVE ||
Figure 3.1 o-49. AFM User Interface Program
CEC AFM Control - Ver. x.xx Figure 3.10-53. Edit Screen
Main Menu
10. Observe which ROM number (ROM is being
2. Press to confirm that the program is to be exited. retrieved.
Edit/Create Setup
3. Disconnect power from the AFM module for a 11. The Edit Screen appears (see Figure 3.10-53).
View Serial Link
minimum of five minutes. Verify th the data on the Ed Screen is the same
Quit
data-set chsen to be saved to ROM.
4. Restore pwer to the AFM module.
If the correct data does not appear on the Edit Screen,
5. Start the AFM User Interface Program n your PC by verify that the DB-9 serial cable connected between the
accessing the drive and directory where the AFM PC and the AFM module is secure and in good
sftware is installed (typically: A: [Enter]). Retrieve t>ata fro AF File, or Create 'New. cndition. In additin, verify the power to the AFM
module is within specification. Attempt a second store
6. Type the name f the executable file and press Figure 3.10-51. AFM User Interface Program f the crrect data-set to ROM (refer tRetrieving a
[Enter] (typily: AFMXXX [Ent where XXX is the Main Menu Saved Data-Set From Disk With a Filename" to retrieve
revisin level).
data-set from a filename). If difficulty continues, contact
9. The menu shown in Figure 3.10-52 appears. High- your ll Waukesha Engine distributr or Waukesha
NOTE: To nd the name of the execuble file (.exe) for
light Retrieve from AFM and press [Enter]. Engine Prduct Support.
the AFM User Interface Program, view the directory of
e drive on which your AFM program is saved by typg
DIR at the drive prompt and then press.ing [Enter). Listed
the directory will be an executable file for e AFM
User Interlace Program. The executable file for e AFM
program is typically the letters AFMXXX.exe where CEC AFM Control - Ver. X.Xx
XXX is the revision level.

7. The Genuine Waukesha Pa lgo and version

identification screens appear briefly, followed by the Retrieve from AFM
cmmunicatins menu (see Figure 3.10-50). A black
Retrieve from Filename
dot is located in parentheses next to 1 which indicates
that the selected communications po on the ci'nputer Create New Dataset
is p 1 . Press [Enter] t select cmmunications po 1.
If the DB-9 cable is connected to a different port on your
PC, use the arrow keys n the keyboard to select the
crrespnding prt from the communications menu and
press [Enter] (typically: p 1 is crrect). Figure 3.1 52. Edit/Create Setup Menu

3.10-30 FORM 6263 Second Edition 3.10-31

FORM 6263 Second Edition
PROGRAMMING FOR BEST POWER/ECONOMY APPLICATIONS SECTIN 3.15- PRGRAMMIN G FOR LEAN BURN APPLICATIONS
PROGRAMMING THE AFM MODULE FOR
LEAN BURN CONTROL
USER INTERFACE PROGRAM STARTUP STEPS
NOTE: This manual assumes you are already miliar
with basic MS-DOS commands for viewing directories,
copying files, and other MS-DOS concepts. If you need
more information on these subjects, rer a MS-DOS
instruction manual.
1. Review Section 3.00 General Programming lnfor-
mation for computer requirements, program layout, and
saving information.
2. Review Section 3.02 Keypad and Dispy lnforma-
tion for a detailed explanatin f the AFM modules
keypad functions and LCD display messages.
3. Complete the preprogramming checklist in
Section 2.1 O Prestart Installation Checklist before
continuing.
4. With the engine NOT running and power OFF,
discnnect the intake manifold pressure transducer and
lean bum xygen sensor(s) by removing the analog and
lean burn oxygen sensor cnnections terminal block
from the headers inside the AFM module (see
Figure 3.15-1).
INSIDE AFM MODULE
Figure 3.15-1. Analog, Sensr,And pwer
cnnections Inside AFM Mdule
5. Apply power to the AFM mdule. The Power and
Alarm LEDs n the front cover of the AFM module
light. The LCD display on the AFM mdule briefly
displays Waukesha CEC TEST if the cre EPROM
chip has not been previously programmed. If the core
EPROM was previusly programmed, the LED displays
the current control mode (for exampleWalkesha CEC
Lean-Burn
3.10 FORM 6263 Second Edition
FORM 6263 Second Edition
NOTE: A list of system errors will be dispyed on the
LCD display. Messages on the display may clude, but
not necessarily be limited to, '02 SIGNAL LO,
'IMP INPUT LO,' and "02 TEMP LO. These mes-
sages are normal since these engine parameters are
below the test program limits with the intake manifold
pressure transducer and lean burn oxygen sensor
disconnected.
6. The AFM module must be programmed to work with
site specific information in order for the AFM system to
f1,mction properly. To program the AFM mdule,connect
a standard DB-9 serial cable (male to female) t the
communications port (labeled P1 A) within the AFM
module. This is the communications port n the right
(see Figure 3.15-2). Connect the other end of the cable
to the PCs communications p Typically, this is port 1
(als referred to as COM 1, serial A serial 1).
IA CAUTIN 1_::;ii~
cE1ected t the appr1priate cmputer p. If e
serial cable is disturbed r discnected during the
saving process, the cre EPRM chip in the AFM
mdule will beeme crrupted and will need t be
replaced. Even previusly stred data-se will no
Inger be functinal.
P1A COMMUNICATIONS PORT
O FRONT VleN DOOR PANEL OPEN O
Figure 3.15-2. DB-9 Serial Cable cnnectin Inside
AFM Module
3.15-1
PROGRAMMING FOR LEAN BURN APPLICATIONS
ESTABLISHING COMMUNICATION WITH THE
AFM MODULE
Complete Steps 1 - 7 in this section to establish
communication between your PC and the AFM mdule.
1. Start the AFM User Interface Program on your PC by
accessing the drive and directry where the AFM
software is installed {typically: A: [Enter]}.
2. Type the name of the execuble file {.exe} for the AFM
User Interce Prgram and pss [Enter] {typilly:
AFMXXX[En where XXX is the revision level}.
NOTE: To find the name of the executable file (.exe) for
e AFM User Interface Program, view the directory of
the drive on which your AFM User Interface Program is
saved by typing DIR at the drive prompt and then
pressing [En. Lisd e directory will be an
executable file for the AFM User Interce Program. The
executable file for the AFM program is typically e
letters 'AFMXXX.exe where XXX is the revision level.
NOTE: The core and display EPROM chips must be
matched" with the AFM User Interlace Program
version number. If the versions of the EPROM chips are
not the same as the User ace Program version
number, the potential for errant operation exists and
programm19 will not work. Rer to Section 4.00
Air/Fuel Module System Troubleshoting'Replacing
EPROMChs"formore formation.
3. The Genuine Waukesha Pa ig screen appears
briefly, follwed by the reen shown in Figure 3.15-3. The
bottom line of this screen indicates what software version
of the AFM User Interface Program you are using.
CEC AFM Control
User Interface Program
Version X.Xx
Figure 3.15-3. Sftware Version ldentificatin
4. Automatically the Communications Menu appears
{see Figure 3.15-4). A black dot is lcated in a circle
next t1 which indicates that the selected communica-
tions pn your cmputer is port 1 . Press [Enter] t
select communicatins port 1. If the DB-9 cable is
cnnected to a different port on yur PC, use the arrow
keys n the keybard to select the crrespnding prt
m the communications menu and press [Enter]
{typically: po 1 is crrect}.
3.15-2
PROGRAMMING FOR LEAN BURN APPLICATIONS
I CEC AFM Control - Ver. x.xx I I c AFM Contr1 - Ver. X.Xx I
Communications Menu
Error Message
Select Com Port com Device I/0 Error Occurred
Check Parameters and Connections
l O 2 03 0 4 and Try Again.
Press ANY KEY to Continue
Testing Com Port #l
Figure 3.15-4. Communicatins Menu Com Port Failed
5. The AFM User Interface Program s Main Menu
appears shwing various program ptions available
Figure 3.15-7. Cmmunications Error Message
{see Figure 3.15-5). Highlight Edit/Create Setup" and
press [Enter].
I CEC AFM Control - V. X.Xx I I CEC AFM cntrol - Ver. x.xx I
Edit/Create Setup
View Serial Link Current Program is TEST PROGRAM
Quit
No Configuration Data Exists.
Retrieve Data frm Filename
r Create New Dataset.
Retrieve oat.a from AF ll'ile, or create New . Press ANY KEY to Continue
Figure 3.15-5. AFM User Interface Program Main Menu
6. The Edit/Create Setup Menu shown in Figure 3.15-6
appears. Highlight Retrieve from AFM and press Figure 3.15-8. Test Program Message
[Enter]. 7. If the AFM mdule has never been programmed for
NOTE: If a communications error message appears
ee Figure 3. 15 there is a communication problem an engine appli.tion, a message appears stating the
AFM mdule has been congured for test purposes only
between your PC and the AFM-module. Either there is
{see Figure 3.15-8). Press any key to return to the Main
I CEC Control - Ver. x.xx I no power to the AFM module, the serial cable is not
connected to the correct communications port, the
Menu. If the AFM system has been previously pro-
gram med fr another engine applin, the data-set for
computer is not con1gured correcte coreEPROM that engine applition is displayed. If you want to
ch is corrupt, or the cable is dective. Veri that e program the AFM system using the data-set displayed
cable is connected to the correct communications port as a starting point continue with the section Editing
Retrieve from AFM
on your PC. If it is not connected correct move e Engine Applicatin Information. If you want to start from
Retrieve from Filename
Create New Dataset
cable to the correct communications port. Check the
general condition of the serial cable and replace the
a preprogrammed setup file {a completely new, nonsit
specific data-set}, press [Es and then M to rturn to
cable if defective. Refer to Section 4.00 Air/Fuel Mdule the Main Menu t beginAFM mdule programming.
System Troubleshting for more troubleshooting b By cmpleting Steps 1 - 7, communication between the
mation and core EPROM chip replacement instructions. AFM module and your PC has been established.
pload Dt From A via Srial Port. Press any key to continue. Continue programming the AFM module with the next
section ,Initial AFM Module Programming for Lean
Figure 3.15-6. Edit/Create Setup Menu Burn Control Operation."
3.15 3
FORM 6263 Second Edition FORM 6263 Second Edition
PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

INITIAL AFM MODULE PROGRAMMING FOR

LEAN BURN CONTRL OPERATION I CEC AFM Control - Ver. X.Xx I LEFT
After communication has been established between CEC AFM CONTRL
02 Lean Rich
your PC and the AFM- mdule, programming for your psiA s - p Limit Lnit
specific engine application can begin. File Select Engine Family:ATGL GAS ENGINE
P 10.0 2.35 l 5800
Engine Model :12V-ATGL r 15.0 2.40 l 5800
NOTE: For the purposes of this manual, the exam- Sensor: 1-LEANBURN (0-40MA) i 20.0 2.45 1 5800
LSETUPOl.AF ~rim F Type:
pies and figures used are based on the programming m 25.0 2.50 l 5800
LSETUP02.AFM NATURAL GAS PIPELINE QUALITY a 30.0 2.50 1 5800
of a 12V-ATGL engine. Although there are slight
LSETUP03.AFM ~Se~~~~ary Fuel Type: r 35.0 2.50 l 5800
screen variations for each engine family, the program- y 40.0 2.50 l 5800
ming steps presend is manual are e same.

II
LSETUP04.AFM
The values in the examples and figures are for LSETUPOS.AFM m POS LEFT= 2900
REFERENCE ONLY. Actual values are specific to LSETUP06.AFM Comments:
....
..
your engine application. LSETUP07.AFM ..
LEANBURN SETUP FILE #1
..
..
1. With the AFM User Interface Programs Main Menu LSETUPOB.AFM
RSETUPOl.AFM
H Setpoint=SlO c Gain= 150
shwing on your screen, highlight Edit/Create Setup" Lo-Temp =475 c Hi-Temp=545 c
and press [Enter] (see Figure 3.15-9). RSETUP02.AFM

2. Highlight Retrieve from Filenamen the Edit/Create

Setup Menu and press [Entesee Figure 3.15-10). A list I FlO = SAVE 11 ESC = MENU
of preprogrammed files appears (s Figure 3.15-11). Figure 3.15-11. File Select Menu

Selecting A Preprogrammed Setup File

Edit/Create Setup
View Serial Link
Quit
Retrieve Data fr()t!l AFM, or Create New.
Fil
Fi~ure 3.15-9. AFM User Interface Program Main Menu
I CEC AFM Control - Ver. x.xz
Figure 3.15-12. Preprogrammed Setup File LSETUP01 -Catalyst Equipped AT Applications
Preprogrammed setup files were developed to make
AFM module programming easier and faster. The Table 3.15-1. Preprgrammed Setup Files For Lean 2. After answering the three questions in Step 1,
values st1red in these files will get you started in Burn cntrol peratin carefully select the setup file from Table 3.15-1 that was
creating a data-set for your specific engine application. LEAN BURN cNTRL SETUP FILES created for your engine application. Selecting the wrong
The values of the preprogrammed files are generic and setup file may result in airel control that is less than
Filenane Use Fr ...
must be edited for optimum air/fuel ratio cntrl optimum.
following the programming procedures in this manual. It LSETUP01 ~~-;
1 ~0~L re(S~ggs with one 99 or 1098 regulator
an steppe steps of adjustment)
is recommended that you use a preprogrammed file
from this listing to program the AFM module instead of LSETUP02 regulato
;
8L-ATG~ ~tnes with one 99 or 1098 fuel
stepper (5800 steps of adjustment)
NOTE: The preprogrammed files listed on the File
Select Menu but not included in Table 3. 15-1 are
preprogrammed setup files used when programmg
staing with a comptely new, nnsite-specic data-
set. The preprogrammed setup files va with engine.
LSETUP03 VH~l;t:rse~~~n:e;pers1i~990
r 1g;~fa~unt) rich burn applications st or best power/economy
control modes).
The preprogrammed setup files vary with engine LSETUP04 VHP inline en~~~~~:r.i~~~ 99 or 1098 el
regulator and steps of adjustment) 3. Highlight the appropriate preprogrammed file on the
configuration and fuel regulatr model. Example: All
VHP GL vee engines with Fisher 99 and 1098 regula-
~l[i~[f~ines
and with one(20,000
stepper 66, 66Z, 5201, or 5211
steps of
File Select Menu and press [Enter] (see
L5ETUP05
tors, which includes VHP mdels 5108, 5790, 7042, and adj Figure 3.15-11). The Edit Screen appears displaying
9390, use setup file LSETUP03. Similarly, VHP mdels the preprogrammed setup file informati1 (see
I 2895 and 3521 use a commn setup file. LSETUP06
VGF inline e~9i~t~~ with one ~~otfc2~t~ or
S 2~~~~rit)g and stepper ps of Figure 3.15-12).

1. Answer the following three questins before select- NOTE: When the setup file appears on the Edit Screen,
ing a preprogrammed setup file. LSETUP07 Vairii~~~ni~dw~~r:12g~5~iso~f5211 it will show engine mily, model, and el type informa-
tion for an engine model. This "application" information is
Retrieve from AFM
Retrieve from Filename
Create New Dataset
A. What is the engine family: AT, VHP, or
VGF? LSETUP08
VHP inli~5e
5211 se
steps of adjustm
~:
ng~nei, with one 66, 662, 5201, or
I t ator and steppe20,000
for reference only and will not act AFM system control.

B. What is the engine cguration: in-line or

vee?
llet;rieve Oata from a Disk File. C. What fuel regulatr(s) is installed: Fisher
cntrols Model 66, 662, S201, 8211, 99r
Figure 3.15-10. Edit/Create Setup Menu 1098?

3.15-4 FORM 6263 Second Edition 3.15-5

FORM 6263 Second Edition
PROGRAMMING FOR LEAN BURN APPLICATIONS
PROGRAMMING FOR LEAN BURN APPLICATIONS

Editing Engine Appllcatin Infrmatin 2. With the Edit Screen displayed on your PC, press the
5. For VHP and VGF engines nly, highlight GL" (the 6. Highlight the type of prima fuel the engine is using
UP" arrow key until the Engine Family Selection Screen
N1TE: For safety reaso. the valu. in the 02$-P" applicable engine fuel systemn the Engine Fuel on the Prima Fuel Selection Screen and pSS [Ente
appears as shown in Figure 3.15-13.
column(s) and the 'Lo-Tem field on the Edi Screen are System Selection Screen and press [Enter] (see (see Figure 3.15-16) .
de/efj after the ip/i1n information is ed. These 3 . Highlight the correct ngine family and press [Enter] . Figure 3.15-15).
values will have to be re-entered before saving the setup
file to RAM. 4. Highlight the correct engine model n the Engine
Mdel Selection Screen and press [Enter] (see LEFT
1. Before editing the applition information, write
Figure 3.15-14). CEC AFM CONTROL
down the values displayed in the 028-P column(s)

and the L Temp field n the Edit Screen.
Engine Family:VHP GAS ENGINE
2
s - p
Lean
Limit
Rich
Limit

4
LEFT Engine Model :F3521GL I-6 2.35 5800

2.40 5800
CEC AFM cNTROL Sensr: 1-LEANBURN (0-40MA)
. 45 5800
02 Lean Rich .Primary 1el Type:

4
.so 5800

1
psiA s - p Limit Limit L NATURAL GAS PIPELINE QUALITY
.so 5800

Engine Family:ATGL GAS ENGINE ,Secndary Fuel Type:

2.35 ..
5800 .so 5800
Engine Model :12V-ATGL "7 NONE

2.40 5800 .so 5800
Sensor: 1-LEANBURN (0-40MA) 2.45 5800

e
.Primary Fuel Type: ATGL 2.50 5800 LEFT= 2900
NATURAL GAS PIPELINE QUALITY VHP 2.50 5800
VGF Comments:
,Secondary Fuel Type: 2.50 5800
L NONE VSG LEANBURN SETUP FILE #4
2.50 ..
5800

START POS. 2900 Setpoint=425 C Gain"' 150

LEFT"'
Lo-Temp .. 390 c Hi-Temp,,,460 c
Comments:
LEANBURN SETUP FILE #1

Setpoint,,,510 C
Lo-Temp ,,,4 7 5 c
Gain"' 150
i-Temp,,,545 c Ir ESC ..

FlO "' SAVE Figure 3.15-15. Engine Fuel System Selectin Screen - VHP And VGF Engines nly
ESC "' MENU
11
LEFT
Figure 3.15-13. Engine Family Selection Screen CEC AFM CONTROL
2 Lean Rich
psiA s - p Limit Limit
LEFT Engine Family:ATGL GAS ENGINE

p 2.35 5800
CEC AFM CONTROL Engine Model :12V-ATGL r 2.40 5800
02 Lean Rich Sensor: 1-LEANBURN (0-40MA) 2.45 5800
psiA s - p Limit Limit .Primary Fuel Type: Primary Fuel

A
2.50 5800
Engine Family:ATGL GAS ENGINE 4 NATURAL GAS PIPELINE QUALIT

2.35 5800
Engine Model :12V-ATGL ,secndary Fuel Type: Natural Gas Pipeline Quality (119 Octane)
2.40 5800
AE

Sensor: 1-LEANBURN (0-40MA) .. "7 NONE Field Gas (115 - 119 Octane)
2.45 5800

.Primary Fuel Type: 2.50 5800 Propane

4 NATURAL GAS PIPELINE QUALITY 2.50 5800 Digester Gas
A

.secondary Fuel Type: 2.so 5800 Landfill Gas

cmments:
NONE 2.50 5800
LEANBURN SETUP FILE #1

LEFT"' 2900 SL Fh
Lmt
nD cc
==nue3

RJA

e
a
Gain"' 150

cDU11ents:

i-Temp,,,545 c
LEANBURN SETUP FILE #1
M
F

SLPT

+-
3

Gain"' 150

Ir
aa

ED

..
i-Temp=545C
ESC

FlO "' SAVE Ir ESC ..NU Figure 3.15-16. Primary Fuel Selection Screen

Figure 3.15-14. Engine Mdel Selection Screen

3.15-6 FORM 6263 Second Edition 3.15-7

FORM 6263 Second Edition
PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

7. Currently, the AFM system is designed for single tu
engine applications r one fuel of dua- fuel engines).
Highlight NONE and press [Enten the Secondary
Fuel Selection Screen. (see Figure 3.15-17). Always
select NONE from this screen.
8. After the engine application infrnation is selected,
confirm your selections by pressing M at the confirma-
tion message (see Figure 3.15-18). The engine applica-
tin block will now be updated to reflect your changes.
The Lo-Temp field value and oxygen set-point values
in the 025-P columns(s) are deleted.
9. To re-enter the values in the 025-P column and
"Lo-Temp field, press [Enter] or use arrow keys until
the cursor is in the Le Temp field or first 025-P
field. R enter the deleted values recorded in Step 1.
Press [Enter] after each value is entered t work down
through the column(s).
NOTE: Whenever the enge application information is
edited, the deleted values will have to be re-entered.
Saving Setup File To RAM
The initial setup file must be saved to RAM (tempora
memory) to permit testing and editing of this data-set.
NOTE: Each time modifications are made to the
data-set, the data-set must be saved to RAM before
the edited values affect control of the AFM system and
can be tested. Simply editing the values on the AFM
User Interface Program screens will not change AFM
system operation.
NOTE: The contents of RAM are Jost whenever power
to the AFM module is removed.
1 . Press [F1 O] t save the preprogrammed file data and
edited application information to RAM (temporary
mem
2. Highlight "lest Data on AFMn the Saving Options
Menu and press [Enter] (see Figure 3.15-19).
3. The confirmatin screen shown in Figure 3.15-20
appears. Press M to confirm save to RAM.

LEFT LEFT
CEC AFM CONTROL CEC AFM CONTROL
02 Lean Rich 02 Lean Rich
psiA s - p Limit Limit psiA s - p Limit Limit
Engine Family:ATGL GAS ENGNE Engine Family:ATGL GAS ENGINE

Ea4 4
P 10.0 2.35 l 5800 2.35 5800
Engine Model :l2V-ATGL r 15.0 2.40 l 5800 Engine Model :l2V-ATGL 2.40 5800
Sensor: l-LEANBURN (0-40MA) i 20.0 2.45 l 5800 Sensr : l-LEANBURN (0-40MA) 2.45 5800
rim F Type: m 25.0 2.50 l 5800 .Primary Fuel Type: 2.50 5800
NATURAL GAS PIPELINE QUALITY a 30.0 2.50 l 5800 L NATURAL GAS PIPELIN 2.50 5800
,Secondary Fuel Type:
te~0~~ary Fuel Type :j Secondary Fue ~
r
y
35.0 2.50 1 5800
c:.an
2.50 5800

40 . 0 2 o; o 1 NONE
2.50 5800

E
NONE Test Data on AFM
Natural Gas Pipeline Quality (119 Octane) configure AFM Memory LEFT= 2900
Comments: Field Gas ( 115 - 119 Octane)
Coim!lents:
LEANBURN SETUP FILE #1 Propane LEANBUN SETUP FILE #l
Digester Gas

Landfill Gas SL = ,..

puv
HP

nu J
EJ

o

nb
Gain= 150
Setpoint=SlO c

-
mA =

A
to-Temp :4 75C 11:i-Temp=545C i-Temp=545 c

I FlO = SAVE 11 ESC lI ESC

Figure 3.15-17. Secondary Fuel Selection Screen Figure 3.15-19. Saving ptions Menu
LEFT
LEFT
CEC AFM CONTROL Lean Rich CEC AFM CONTROL
02 02 Lean Rich
psiA s - p Limit Limit
ps A s - p Limit Limit
Engine Family:ATGL GAS ENGINE P l 11 2.3s 1 5800 Engine Family:ATGL GAS ENGINE FZ

e
2.35 5800

Engine Mode o l 1-11 T 1 5800 Engine Model : 12V-ATGL

E
1 5800 2.40 5800
Sensor: 1-I Sensor: l-LEANBURN (0-40MA) L -

4
1 5800 2.45 5800
Primary FUE _Primary 5800
L NATURAL I You Have Changed Options 1 5800 4 NAT

E
5 00

4
That May nvalidate and 1 5800
Se~~~ary f Change Other Data! 1 5800
.Secondary]
Store Test Values 5800

4 NONE 5800
D yu want To Continue? T = 2900 This will Stop Program Execution
and RESTART Program when finished. EFT= 2900
Comments: Coim!lents:
LEANBURN SJ: LEANBURN
Yes No esc
Setpoint Yes No esc
Set poi
Lo-Temp . Lo-Tem

I FlO = SAVE 11 ESC || ESC = MENU

Figure 3.15-18. Confirmation Message

Figure 3.15-20. Cnfirmation f Save To Randm Access Memry (RAM)

FORM 6263 Second Edition FORM 6263 Second Edition 3.15-9

3.15-8
PROGRAMMING FOR LEAN BURN APPLICATIONS
PROGRAMMING FOR LEAN BURN APPLICATIONS

LEFT 7. Enter the stepper position in the left/right NOTE: The contents of RAM are Jost whenever power
STARTPOS. field on the Edit Screen and press to the AFM module is removed.
CEC AFM CONTROL
02 Lean Rich [Enter] (see Figure 3.15-22).
psiA s - p Limit Limit 8. Press [F1 OJ to save the edited start position informa-
Engine Family:ATGL GAS ENGINE PE NOTE: Each time modifications are made to the tin to RAM (temporary memry).

2.35 5800

E
Engine Model :12V-ATGL 2.40 5 00 data-set, the data-set must be saved to RAM before
Sensor: 1-LEANBURN (0-40MA)
-L
2.45 5800 the edited values aect control of the AFM system and 9. Highlight
.Primary F 5800 Menu and press [Enter] (see Figure 3.15-23).
NATURAL 5800 can be sted. S.1p/y editg the values on e AFM

aA
, Secndary 5800 User Interce Program screens will not fluenceAFM
NONE Starting RAM Program. 5800 system operation.
Prgrn is Running.
EFT= 2900
LEFT
cmments: Test Values are Saved in RAM.
CEC AFM CONTROL
LEANBURN 2 Lean Rich
psiA s - p Limit Limit
Setpin
Press ANY KEY to Continue Engine Family:ATGL GAS ENGINE

6
Engine Model :12V-ATGL 2.35 5800

:
LTemp 2.40
Sensor: 1-LEANBURN (0-40MA) 5800
,Primary Fuel Type: 2.45 5800
NATURAL GAS PIPELINE QUALITY
2.50 5800
2.50 5800

,Secondary Fuel Type:

2.so 5800

FlO = SAVE NONE
ESC = MENU
11 2.50 5800

LEFT"' 2900

Comments,:
Figure 3.15-21. Cnfirmation of Save T RAM LEANBURN SETUP FILE #1
4. Several screens will appear indicating that the NOTE: If your eng.e has only one el regulator, the
Setpoint=510 C Gain= 150
data-set is being saved to RAM. The LCD display n the "left" buttons on the AFM module keypad control the Lo-Temp =475 c
STEPPER START
i-Temp=545 c
pSITION
AFM module will read EXECUTION STOPPED BY engine's a.ii1el ratio. If your engine has two fuel
USER Once the data-set has been saved to RAM, the regulators, the "left" keypad buttons control the enge
message shown in Figure 3.15-21 appears. The LCD left bank and the "righf keypad buttons control e
display on the AFM module will briefly read "Waukesha enge's right bank. J jEsc = MENU
CEC Lean-Burn", then the normal AFM LCD displays
will appear. If your engine has two fuel regulators, cmplete
Steps 1 - 7 fr each fuel regulator.
NOTE: If the "EXECUTION 5TOPPD BY U5R Figure 3.15-22. Entering Stepper Motr Start Positin
message persists on the AFM display for more than five NOTE: If an alarm condition exists, the AFM module
minutes, refer to Section 4.00 Air/Fuel Mdule System keypad will not function until the alarm is acknowledged
Troubleshting.
by pressing <ALARM AC on the keypad. LEFT
CEC AFM CONTROL
5. Press any key to continue. 1. Press <LEFT MAN> and <RIGHT MAN> applica 02 Lean Rich
blen theAFM mdule keypad to put the AFM module psiA s - p Limit Limit
NOTE: Data-sets that are created can be saved to a Engine Family:ATGL GAS ENGINE
in manual control.
Engine Model :12V-ATGL P 10.0 2.35 1 5800
filename for ture reference. Dasets are assigned r 15.0 2.40 1 5800
filenames and saved on disk so the user can reta and 2. Review the original gas/air pressure setting you Sensor : 1-LEANBURN (0-40MA) i 20.0
Primary Fuel Type: 2.45 1 5800
retrieve the data-set te When sav1g to disk, the recorded BEFORE the stepper motor was installed. m 25.0 2.50 1 5800
NATUR GAS PIPELINE ITY
data-set will be saved to the drive and directory where Secondary Fuel Type: 2.50

1 5800
3. Measure current gas/air pressure with a manmeter. L NONE 2.50 1 5800
the AFM User Interface Program was accessed. See Save Data to Filena.It 2.50 1 5800
"Saving Data-Set to Diskis section save your 4. Use the manual adjustment keys on the AFM module Test Data on AFM
data-set to a filename. keypad to change gas/air pressure as required to Configure AFM Memory POS. LEFT = 2700
duplicate original gas/air seing. Once current gas/air Comments:
ESTABLISHING ENGINE START POSITION LEANBURN SETUP FILE #1
seing is equal to original gas/air, the stepper motor
Most values stored in the preprogrammed files should start position n be set.
Setpint=s10c Gain= 150
be reasonable for initial programming of the AFM
5. Press [Enter] or use the arrow keys until the cursor is Lo-Temp =475c Hi-Temp=545 c
mdule. However, some nodification t the stepper
motor start positin setting may be required to in the left/right START POS field on the Edit Screen
facilitate engine starting. To determine sta psition (see Figure 3.15-22).
complete the steps in this sectin. 6. Read the stepper psition displayed n the AFM
mdules LCD display R STEPPER = XXXXX). Press
I Flo = SAVE I G sc = MENU j
<DSPL SEL> on keypad to scroll through LCD display
messages.
Figure 3.15-23. Saving OptinsMenu
--...,;,
3.15-10 FORM 6263 Second Edition FRM 6263 Second Edition 3.15-11
PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

10. Press M t confirm save to RAM (see NOTE: If the 'EXECUTION STOPPED BY USER MONITRING THE AFM SYSTEM THROUGH THE
Figure 3.15-24). message persists on e AFM display for more than five VIEW SERIAL LINK SCREEN
mutes, refer to Section 4.00 Air/Fuel Mdule System
11 . Several screens will appear indicating that the 1. Highlight "View Serial Link" from the Main Menu and CEC AFM Control - Ver. X.Xx
Trubleshooting.
data-set is being saved to RAM. The LCD display on the press [Enter] (see Figure 3.15-26).
12. Return to the Main Menu by pressing [Esc].
AFM module will read EXECUTION STOPPED BY

The informatin shwn on the View Serial Link Screen

U
Figure 3.15-25 appears on the screen warning you to EVQ,,, re
diu ta
er e P

F enw
SL
el

a
USER. Press any key to continue after the save to RAM
save any changes made t the data-set befre exiting. (see Figure 3.15-27) represents the current status of
L
-
is complete. Since the data-set has already been saved to RAM, your AFM system. This includes information on the
press M to return to the Main Menu. oxygen sensor, stepper position, and intake manifold
pressure.
LEFT
Since the engine is not running and the oxygen sensors
-CEC AFM cNTROL and intake manifold pressure transducer are nt nitor AFM Oper a:tion vi a Serial :Port
2 Lean Rich
psiA s - p Limit Limit connected, the alarms shown are correct for the current
Engine Family:ATGL GAS ENGINE ,..
5800 conditins.These me alarms will also be indicated on Figure 3.15-26. AFM User lnteace Program
Engine Model : 12V-ATGL

5800 the AFM LCD display. Main Menu
Sensor: 1-LEANBURN (0-40MA) 5800
_Primary Fu .. , "'"~

A
5800 2. Acknowledge the AFM system alarms by pressing NOTE: If an alarm condition exis the AFM module
4 NATURAL

Ea
5800 <ALARM ACKn the AFM mdule keypad. Wait fr keypad will not function until the alarm is acknowledged

,Secndary 5800
L NONE Store Test Values ..
5800 the WORKING message to disappear from the AFM by pressg <ALARM ACK> on the keypad.
LCD display (abut 5 seconds). The yellow alarm LED
This will Stop Program Executin FT= 2700 will turn off, the ALARM OUTPUT ACTIVE message 3. If the L Status" and R Status" fields are in
and RESTART Program when finished. automatic, press <LEFT MAN> and <RIGHT MAN> (if
n the PC screen will clear, and the Error Out terminal
applicable) on the AFM module to put the AFM module
within the AFM module will close. in manual control.
AF

oe
SLPT np
-Lm
Yes No esc
CEC AFM Cntrol

Engine Model: 12V-ATGL Sensor Type: LEANBURN (0-40MA)

FlO = SAVE
II ESC = MENU ALARM OUTPUT ACTIVE Left Bank I

SENSOR: tt
ss ALARM
ooc

vv
1
Figure 3.15-24. Cnfirmation f Save To Random Access Memry (RAM) Voltage 0.003
SetPint 2.500

Temperature 32 ALARM
LEFT PWM Output 39

CEC AFM CONTROL

02 Lean Rich STEPPER:
psiA s - p Limit Limt psition 2500
Engine Family:ATGL GAS ENGINE PE Lean Limit 1

2.35 5800 Rich Limit 5800

Engine Model : 12V-ATGL 2.40 5800
--
Sensor: 1-LEANBURN (0-40MA) 2.45 ..
5800
.Primary FU ..
5800 INT. MAN.

L NATURAL 5800 Pressure o.o psiA ALARM

,Secondary 5800
4 NONE Exit to Main Menu 5800
Changes Will be Lost if
you Have Not Saved Them.
T = 2700 Enclsure Temp. 26 C L s WUP I
Do you REALLY Want to EXIT?
VIEW SERIAL LINK <ESC> t EXIT
F

CMTU oe
nrmLm
-
np
+--

& Yes No esc Figure 3.15-27. View Serial Link Screen

FlO = SAVE ESC = MENU

!|

Figure 3.15-25. Cnfirnation f Exit To Main Menu

3.15-12 FORM 6263 Second Edition FOAM62 Second Edition 3.15 13

PROGRAMMING FOR LEAN BURN APPLICATIONS
I A WARNING
D nt set the stepper mtor(s) to the start psitin
while the engine is running abve 40 percent f
rated load. Start psitin is nly to be initiated when
the engine is stopped r running below 40 percent
f rated load. Resetting the stepper mt r(s) while
the engine is running abve 40 percent of rated load
may cause engine shutdwn andr cause severe
engine damage.
4. Verify that the stepper motor(s) is properly cn
nected. Set the stepper mtor(s) to the Start Position
by pressing and releasing <F1>, then <STRT POS> on
the AFM module keypad. The AFM LCD display will
show MOVING L STEPPER TO START POSITION
The left and right Status" messages n the View Serial
Link Screen will change tMOTOR RESET' during the
positioning activity. Once the left bank has been moved,
theAFM mdule will move the right bank stepper mott
Allw up to three minutes fr this prcess. After the
stepper motor(s) has been moved to the start position,
the normal LCD displays resume. If the normal LCD
displays do not resume within five minutes, refer to
Section 4.00 Air/Fuel Module System Troubleshooting.
5. Start the engine.
6. Recheck the pwer at the AFM mdule under worst
case conditions. The engine ignition and any ther
electrical devices to be driven by the same power supply
as the AFM module must be perating. Peak-to-peak
voltage variations must not exceed two vIts. This
measurement must be taken with an sci IIscope.
Refer t Section 2.05 AFM System Electrical Connec-
tions fr AFM system pwer specificatins.
7. Reconnect the analog and lean burn oxygen sensor
connectins terminal blocks to the headers inside the
AFM module (see Figure 3.15-28).
INSIDE AFM MODULE
I~ [j D[JODC O HH 4 ~ I
! 12. Tl permit significant rich and lean adjustments to
5 (:
....
1
II lillJII1 i
\ ~~T~~EN
Figure 3.15-28. Analog And Sensr Recnnectins
3.15-14
PROGRAMMING FOR LEAN BURN APPLICATIONS
I 8. Allow the engine to warm up.
9. Set the engine speed to normal perating conditions
CEC AFM Control
and the load to at least 60 BMEP. Engine Model: 12V-ATGL Sensor Type: LEANBURN (0-40MA}
Once the engine is running to at least 60 BMEP, the
sensor voltages should begin to fluctuate and the intake Left Bank I
manifold pressure readings will begin to change accord-
ing to speed and load. These can be monitored easily on oltmm
cuEmVSTP
Rtpp
s
--
the View Serial Link Screen. aoeO
genat tt
eew
vv
SE
2.500
ttp
-lru
e
2.500
NOTE: If any alarm messages come on dur.g opera- uu
zt
c
-
510
tion of the AFM system, refer to Section 4.00 Air/Fuel 39
Mdule System Troubleshooting to troubleshoot the
system. STEPPER:
Position 1800
As soon as the left and right exhaust temperatures Lean Limit 1
exceed the "Lo-Temp value (390 C (734 for Rich Limit 5800
VHPNGF and 475 c (887 for A the left and right
Status messages n the View Serial Link Screen will INT. MAN.
Pressure 25.0 psiA ALARM
change from MAN. WARM-UP to MANUAL' (see
Figure 3.15-30). Use the manual adjustment keys n
the front of the AFM module and an oxygen meter to
adjust the air/fuel to the desired running point. Enclosure Temp. 26 C L Status: MANUAL
NOTE.1e warmup process for the sensor block can
VEW SERIAL LINK <ESC> to EXT
take up to 30 minutes for AT engines and 50 minutes for
VHPNGF engines.
Figure 3.15-30. AFM Mdule In Manual Mde
10. Locate the potentiometer labeled TP1A (left bank; 11. Enable AUTOMATICl by preing the FINE-TUNING AFM PRGRAMMING FOR LEAN
inlines, ATs, and some VGF vees) and TP1 B (right bank;
<AUTO OPER> key on the AFM module keypad. 1e left BURN APPLICATINS
engines with two regulatrs) inside the AFM mdule and right status shwn on the View Serial Link Screen
Once initial programming of the AFM module is
(see Figure 3.15-29). Using a small screwdriver, adjust will change to AUTOMATIC. The AFM mdule will begin cmplete and the preliminary data-set is saved to RAM,
the potentimeter(s) inside the AFM mdule until the adjusting the stepper" psin to contrl the engines the AFM module must be ne-tuned for optimum
sensor voltage on the View Serial Link Screen is 2.500 air/flel ratio. air/fuel ratio control. T fine-tune the AFM module it will
volts. Turning clockwise decreases the voltage; turning
be necessary to determine xygen sensor target
counterclockwise increases the voltage. NOTE: If any alarm messages come on during opera-
vltage(s) and stepper motor rich/lean limits. A wrk
tion of the AFM system, refer to Section 4.00 Air/Fuel
sheet is provided to help you in determining the
Module System Trubleshooting and Section 4.05
programmable limits required in programming the AFM
Air/Fuel Module System Diagnsties to troubleshoot the
module.
system. 'RICH LIMIT r "LEAN L/Mi errors are good
indicators that the carburetor screw(s) needs adjusting. If yur engine application requires very precise control
of air/fuel ratio at varius engine loads to meet
emissins regulations, follow the procedure labeled
the AFM system, it may be necessary to adjust the Gathering Data for Variable Oxygen Sensor Set-
POTENTIOMETE
carburetor screw(s) so the AFM system contrIs close pints. If, however, such precise control is not required,
to the middle of the stepper motor range. Once the AFM follow the procedure labeled Gathering Data for
system has gained contrI of the air/fuel ratio (sensor
voltage readings are very near sensr set-point), adjust
the carburetr screws until the AFM system is cntrol
cnstant Oxygen Sensr Set-Points.
NOTE: If your engine has only one el regulator, e
ling close to the middle of the stepper motor range which
is 20,000 steps for 66, 662, S201, S211 regulatrs or
"left'' buttons on the AFM module keypad control the
eng ai1el ratio. If your engine has two fuel
5800 steps for 99, 1098 regulators. regu.tors, the ''left" keypad buttons control the enges
Figure 3.15-29. Ptentineter Adjusnent left bank and e "righf' keypad buons control the
13. Once yu are satisfied that the AFM system is enge's right bank. When completg e steps is
cntrolling air/fuel rati fr the engine and no errors section, eng with one fuel regu.ator require only "left"
ccur, cntime with Fine-Tuning AFM Programming values to be determined; eng.eswii twel regulators
Fr Lean Burn Applicatins to adjust the system fr require ndependent "left'' and "righf' valu be
ptimum air/fuel rati control. determined.
FORM 6263 Second Edition 3.15-15 .
FORM62 Second Edition
r- PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

Table 3.15-2. View Serial Link Screen And Lean Burn cntrol Worksheet (AT Engines) - Variable Set-Points

; ! . --~--. - ---.---RMITS. ..

st~ f ::ii

j Engine Model: 12V-ATGL e, LEANBURN ( 0--4

~IRED1 I

b= ~~
Left Bank

SENSOR: I
Volta'!e I G:so vol
SetPint I
Temperature I
PWM Output I

STEPPER:

..J~~1~i:n~prog
INTAKE MANIFOLD PRESSURE (psiA) Position
Lean Limit
Rich Limit

INT. MAN ,
|

~~
I

PR S E D
NOTE: One side of the Lean Burn Control Worksheet Pressure
Gathering Data Fr Variable xygen Sensr
2~~~t~tr~~~o~~~
Set-Pints
Ve precise control of air/fuel ri~ to meet emissions
regulatins is achieved by determining and pm
VHP/VGF engines. Make sure you use the side of the
worksheet that applies to your engine application.
Enclosure Temp.
d
mino sensor vltage and lean/rich limits at various 2. Put the AFM mdule into manual mode by pressing VIEW SERIAL LIN;K - <ESC> to EXIT =- I
~h:e~io~~~t~~I f:::: <LEFT MAN> and <RIGHT MAN> (if applicablen the
AFM module keypad. SENSOR CURRENT
MAP-PINT
ing the steps in this section. 3. Adjust engine load fr generator setsr Iad and SET-PINT STEPPER LEAN LIMIT RICH LIMIT
(volts) POSITION
NOTE: If ve precise airu speed fr cmpressrs until the HIGHEST map-point INTAKE MANIFLO
PRESSURE (psiA)
required at various enge loads to meet emissions (inke manifold pSl psiA) acli LEFT LEFT LEFT LEFT
regutions, follow e procedure labeled Gathering mamfactLrer's ratings is met as indicated n the View

Data for Constant Oxygen Sensor Set-Points."
The AFM system adjusts the stepper motor between two
programmable limits while trying to maintain the xygen
sens set-pintvoage. The lean and rich limits, which
dene el:epper motr adjlstment range, are deter- enaine load to the next lower map-point. For example, if
mined by establishing uel ratio curve.
Figure 3.15-31 illustrates a sample air/fuel rati curve.
Combustion instability occurs when cmbustin pres-
sure within the engine diminishes as load is reduced.
The cmbustion stility limit is the point wher_e
cmbustin is n longer stable and exhaust xygen 1s
nt a gd indicator of air/fuel ratio.
The combustion stability lim can be found by gradually
decreasing engine lad until the exhaust oxygen
increases sharply (using an 02 meter). This sharp
increase indicates the combusti?n stability limit. If
detection is difficult, an alternative is to make the
combustion stability limit point 60 BMEP. Generally,
loads greater than 60 BMEP have stable combustion.
1. Detach or copy the green Lean Burn Control
Worksheet from the back of this manual (see
Table 3.15-2 for sample worksheet).
3.15-16
Serial Link Screen (see Table 3.15-2).
NOTE: The highest map-point Table 3. 15-2
40.0ps If, however, manufacturers rated load for
your application is between map-pots, adjust
rad load 3O psen adjust engine load to
map-pot 35.0 psiA (see Table 3.15-2).
Figure 3.15-32. Ptentimeter Adjustment
-,,-
FORM 6263 Second Edition
:
25.0
30.0
35.0
40.0 2.s
NOTE: The vafu in this tJe are for reference ONLY. Ac values are specific to your engine applion.
NOTE: One press of the <LEFT/RIGHT LEAN r
<LEFT/RIGHT RICH> buttons moves stepper position
25seps (1/16 tur,. By pressing <LEFT/RIGHT FAST>
prior to pre.ing the ler rich buttons, a 400 step
(1 turn) change is made to stepper pos'ion.
4. Using an exhaust analyzer {02 me adjust the
air/fuel ratio by pressing <LEFT LEAN> and
<LEFT RICH> on the keypad until the desired oxygen
level is met for the map-point. If yur engine has tw
fuel regulators, repeat this step for the engines right
bank using the right' keypad buons.
FORM 6263 Second Edition
I 2soo
5. Lcate the potentiometer labeled TP1 A (le bank;
inlines, ATs, and some VGF vees) and TP1 B (right bank;
engines with two regu1tors) inside the AFM module
(see Figure 3.15-32). Using a small screwdriver, adjust
the potentimeter(s) inside the AFM module until the
sensor vltage on the View Serial Link Screen is 2.500
volts. Turning clckwise decreases the vltage; turning
counterclockwise increases the voltage.
NOTE: The potentiometer is only adjusted for e
highest achievable map-pot
3.15-17
PROGRAMMING FOR LEAN BURN APPLICATIONS
6. Record the sensor vltage displayed on the View
Serial Link Screen in the 02 Sensor Set-Pint clumn
on yur worksheet (see Table 3.15-2).
7. Recrd the stepper -position displayed n the View
Serial Link Screen in the Current Stepper Position"
column n your worksheet (see Table 3.15-2).
I A WARNING
Never set the rich limit abve5f mercury gas/air
pressure. Seing the rich limit abve this pressure
setting culd result in product damage andr
severe pers nal injury.
8. Determine a lean and rich limit for the map-point
following the guidelines below and Figure 3.15-33:
. At engine loads above the combustin stability limit,
current recommendations are to set the lean/rich
limits 2 air/fuel ratis ( 1 percent xygen) or less.
. At engine Iads below the cmbustion stability limit,
the lean/rich limits should be set to prevent driving
the engine into rich and/or lean misfire. A starting
point for determining the rich limit is the original
gas/air pressure setting. The staing pint can then
be mdified as required to achieve desired operation.
Fr example: prior to installatin of the AFM system
the gas/air setting was 1O H20, use the stepper
motor limits to permit nly 10 H20 gas/air below the
cmbustion stability limit. Use a manometer to make
this measurement.
NOTE: Stepper motor lean and rich limits ( 2 air/fuel
ratios) can be determined by moving 1 air/fuel ratio and
doubling the change stepper position. For example: An
enge at desired running pot has a stepper position of
1500 steps. The enge is adjusted + 1 aiiuel ratio and
stepper position is 1400 steps. 1e change in stepper
position for + 1 ait1el ratio is 100 steps (1500 - 1400 =
10 Doubling is value, stepper motor change for + 2
aiiel ratios is 200 steps. Therefore, the lean limit
stepper position is 1300 steps (1500 - 200 = 130
9. Adjust the air/fuel rati by pressing <LEFT LEAN>
on the keypad until the desired lean limit is achieved
based on the guidelines in Step 8. If your engine has two
fuel regulatrs, repeat this step for the engines right
bank using the right keypad buns.
10. Recrd the stepper position displayed on the View
Serial Link Screen in the Lean Limit' clumn of the
Lean Burn cntrl Worksheet (see Table 3.15
3.15-18
11 . Adjust the air/fuel ratio by pressing <LEFT RICH>
on the keypad until the desired rich limit is achieved
based on the guidelines in Step 8. If your engine has two
fuel regulators, repeat this step for the engines right
bank using the right keypad buns.
12. Record the stepper psition displayed on the View
Serial Link Screen in the Rich Limit' column fthe Lean
l Burn Control Worksheet (see Table 3.15-2).
NOTE: For map-pots greater m rated load, use e
same values in e ble columns as the rated map-point.
13. Complete the Lean Burn cntrol wrksheet. Adjust
engine load to the next lower map-point and adjust the
air/fuel ratio until the desired oxygen level is met. Then
complete Steps 6 - 12 on this page. Repeat procedure
for each intake manifold pressure map-point to com-
plete the worksheet.
14. After the Lean Burn Control wrksheet is complete,
cntinue with Programming the Lean Burn Contrl
Valuesn page 24.
N'E: Figure 3. 15-34 provides a scenario of a techni-
cian ne-tuning the AFM system following the program-
ming steps in this section,Gathering Data for Variable
Oxygen Sensor Set-Points." The values in the scenario
are given for example only. Actual values will vary
depending on engine application.
ifloz
q
4n
h
M
m4Ez
W
MWZMHMWShhq
SET-POINT
RICH
----
EXHAUST OXYGEN (DRY VOLUME PERCEN
TYPICAL SET-POINTS:
A1 at 32:1 (11.5% 12)
Ar&VHP at 28:1 (9.8% 2)
VGF at 24.5:1.8%
Figure 3.15-33. xygen Sensr Respnse Vs. Exhaust
xygen Concentrations For Various Air/Fuel Ratios -
Lean Burn NLY
FORM 6263 Second Edition
PROGRAMMING FOR LEAN BURN APPLICATIONS
PROGRAMMING SCENARIO (VARIABLE OXYGEN SENSOR SET-POINTS)
NOTE: The values and readings used in isprogrammg scenario are sample values on Actual values and
readings v vary depending on engine application. Guidelines presented app to most engine applications.
The following programming scenario demonstrates how a technician fine-tuned the AFM module program
while following the steps in the AFM manual (Form 6263). Within the text f the scenario below, the
programming step the technician is completing is indicated.
A technician is programming a 12V-ATGL Waukesha
Engine with a Fisher 99 regulator following the program-
ming procedures in the AFM manual (Form 6263). After
completing the initial programming requirements, the
technician is eady to continue with the section Fine-Tun-
ing AFM Programming for Lean Burn Applications.
Step 1: The technician makes a copy of the green Lean
Burn Control Worksheet from the back of the AFM manual.
Step 2: The <LEFT MAN> buon on the AFM module
keypad is pressed to put AFM control in manual mode.
Step 3: With the engine running, engine load is adjusted to
map-point 35.0 psiA. (Since rated load for the engine being
programmed is 36.0 psiA, the maximum achievable map-
point is 35.0 psiA.) Step 4: The technician desires to run the
engine at 9.8 percent oxygen. Using an exhaust analyzer,
ai fuel ratio is adjusted by pressing the adjustment buttons
on the AFM module until 9.8 percent oxygen is achieved. Continuing, the technician reduces engine load to the next
Step 5: With the View Serial Link Screen displayed on the map-point, 30.0 psiA and records sensor voltage and
stepper position on the worksheet. The procedure of setting
PC, the sensor voltage is set to 2.50 vIts by adjusting the
the lean and rich limits is repeated and stepper position is
potentiometerP1A) inside the AFM module. Step 6: The
recorded on the worksheet. Using :!: ~ air/fuel ratios as a
sensor voltage is recorded in the 02 Sensor Set-Pint' guide, the air/fuel ratio curve is determined until engine load
column on the worksheet. Step 7: Stepper position is read is reduced to the combuion stabilio/ limit. At the map-pint
on the View Serial Link Screen and recorded in the Current below the combustion stability limit, the engine is running
Stepper psition" clumn n the worksheet. noticeably rougher and 02 readings are high. Combustion is
no longer stable and exhaust oxygen is not a good indicator
Step 8". Nw the technician needs to determine the rich
of airel ratio. At this map-point and below, the technician
and lean limits by establishing an air/fuel ratio curve adjusts stepper position to achieve best operation. Using a
following the recommendations in the AFM manual manomete gas/air values are set near 10 H20, which was
and Figure 3.15-33. Step 9: The technician presses
the original gas/air seing (before AFM installation). The
<LEFT LEAN> on the AFM module until the oxygen meter technician fine-tunes the gas/air seing to achieve best
indicates 1.0 percent greater than set-point (+ 2 air/fuel
ratios). Step 1O: The stepper position displayed on the View
operation.
Serial Link Screen is then recorded in the Lean Limit' Rich and lean limits are determined for the remaining
column on the worksheet. Step 11 b determine the rich map-points and the stepper position is recorded on the
LEAN worksheet. Now that an air/fuel ratio curve is established
limit, the technician presses <LEFT RICH> until the oxygen
meter reads 1.0 percent less than set-point (- 2 air/fuel and the Lean Burn Control wrksheet is complete, the
ratios). Step 12:The stepper position displayed on the technician is ready to continue with Programming the Lean
View Serial Link Screen is then recorded in the Rich Limit' Burn Control Values in the AFM manual.
column on the worksheet. Mapoints greater than rated
load are given the same values the rated map-point
values.
Figure 3.15-34. Programming Scenario For Lean Burn cntrol (Variable Oxygen Sensr Set-Pints)
FORM 6263 Second Edition 3.15 19
PROGRAMMING FOR LEAN BURN APPLICATIONS
PROGRAMMING FOR LEAN BURN APPLICATIONS

L ml
i1tJ

Ul

iah

B

cntrol wrksheet Cnstant Setpints

Table 3.15-3. View Serial Link Screen And Lean Bum (AT Engines) -

JE
m

Mm

s
E E

m
m

A ilili

agi1

e

J

fi
r

l
CEC AFM Control

i4

Ei

r
l

m
i

Engine Model: 12V-ATGL

i
lil i
Sensor Type: LEANBURN (0-40MA)
M

ii
i

DJ

mf
I

Esti

D


c

l

l
$ i

l
Left B l

d
l

J Rmdab

l
i

i3

~---T

MM
i i3

u
E

wt

R

T
SENSOR:

UJ

Voltage

mL

i a
E

o m c a l d j u m
i

SetPoint

gi

mm

tMm

OMeMDdnJ

Temperature

510 c

a
2
2
PWM Output 39

Jmme
Aeese
pvw

MM
M

Z
r

STEPPER PSITIN

mk

LDrAU

VL
NA

uvr

S
STEPPER:
W


M m
rrmmL

Position
m
UMmw

w WD m

M
Lean Limit 1
m mM

uhzlm

Em M m
m

m aymm
ttli
Rich Limit 5800

FM

wuubg

INTAKE MANIFLO
m

mg mu
MMaa1
mMm

Ude
3PTf
JH ek

unnh


M
r m

LHMF

HABM

WM

NT. MAN.

mM
Pressure

Mm
o

aw
bM MmMd

t
m

mMm mm Cm

m m

U


b

b W
Mhmm

Enclosure Temp. L Status: MANUAL
hMm


m

2. Put the AFM mdule into manual mode by pressing

M
heoMSm

<LEFT MAN> and <RIGHT MAN> (if applicablenthe

=
ZmmHrz

VIEW SERIAL LINK <ESC> to EXIT

mawmM

AFMmdule keypad.
m

blMA umh

da

Z
M m

mA

3. Adjust engine load to manufacturers rated lad and

Mmd n mb
mMAmw

wm

wmAwmMmcrM

CURRENT
rated speed. MAP-POINT se~J1N~
m

STEPPER LEAN LIMIT RICH LIMIT

Ub
umm

NOTE: One press of the <LEFT/RIGHT LEAN> or (vIts) pSITION

INTAKE MANIFLO
m

<LEFT/RIGHT RICH> buttons moves stepper position PRESSURE (psiA) LEFT LEFT LEFT LEFT


m

sdmobhb

25 steps (1/16 turn). By pressing <LERIGHT FAST>

mwm mmW

prior to pressg the lean or rich buttons, a 400 step

m

10.0 2.50
a
M
M

mHmu

(1 turn) change is made to stepper position.

g
M

mi

15.0 2.50
a
t

4. Using an exhaust analyzer (02 meter), adjust air/fuel

Z

ratio by pressing <LEFT LEAN> and <LEFT RICH n 20.0 2.50 2500
m
w

a

the AFM module keypad until the desired xygen level is

SHU WdwmMa w

Mwm

met. If yur engine has tw fuel regulators, repeat this

m
mmm 1

25.0 2.50 2500

m
s
M

m
m

step for the engines right bank using the right keypad
m
e

MJmgh

btons.
m

m d e

30.0 2.50 2500

22th

2



M
d

J mwhmwn

35.0 2.50 2500

3

u
m

2.50 2500
m

40.0

mHm

w
M
s

NOTE: The values 'is table are for rerence ONLY. Actual values are specific to your engine application.
Mbpu
H
m
m

MM

6. Record the sensr vltage displayed on the View

e

5. Locate the potentiometer labeled TP1 A (left bank;

t

mMm
l

inlines, ATs, and some VGF vees) and TP1 B (right bank; Serial Link Screen in the 02 Sensor Set-P column

BhE
whm

engines with two regu.tors) inside the AFM module for each map-point on your worksheet (see
m

m
Mmhp
m

(see Figure 3.15-36). Using a small screwdriver, adjust Table 3.15-3).

h

mm
Mh

the potentiomer(s) inside the AFM module until the

d

M

7. Record the stepper position displayed on the View

sensor voltage on the View Serial Link Screen is 2.500

m
g

Serial Link Screen in the Current Stepper Position

vs. Turning clockwise decreases the voltage; turning

w
s
m

cunterclckwise increases the voltage.

column on your worksheet for each map-point above
the cmbustion stability limit (see Table 3.15-3).
NOTE: The potentiometer is only adjusted for the
Figure 3.15-36. Potentiometer Adjustment highest achievable map-point.

3.15-20 FORM 6263 Second Edition

FORM 6263 Second Edition 3.15-21
PROGRAMMING FOR LEAN BURN APPLICATIONS
I A WARNING
Never set the rich limit abve 5" of mercury gas/air
pressure. Setting the rich limit above this pressure
setting culd result in product damage andr
severe persnal inju
8. With the engine running at manufacturer s rated
load, determine a lean and rich limit for the map-pints
above the combustion stability limit. Current recom-
mendations are to set the lean and rich limit t 2
air/fuel ratios (= 1 percent oxygenr less when
programming cnstant oxygen sensor set-pints (see
Figure 3.15-37).
9. Using an exhaust analyzer, lean air/fuel ratio by + 2
air/fuel atios by pressing <LEFT LEAN n the keypad.
If your engine has two fuel regulators, repeat this step
fr the engine s right bank using the right" keypad
buns.
10. Record the stepper positin displayed on the View
Serial Link Screen in the Lean Limit' clumn on yur
Lean Burn cntrol Worksheet for each map-point
above the cmbustion stability limit (see Table 3.15-3).
11 . Using an exhaust analyzer, richen air/fuel rati by
- 4 air/fuel ratis (- 2 from desired oxygen level) by
pressing <LEFT RICH n the keypad. If your engine
hastw fuel regulators, repeat this step fr the engines
right bank using the right keypad buns.
12. Recrd the stepper positin displayed on the View
Serial Link Screen in the Rich Limit' column on yur
Lean Burn Control Worksheet for each map-point
abve the combustin stability limit (see Table 3.15-3).
13. Atmap-pints belw the combustion stability limit,
the lean and rich limits shuld be set to prevent driving
the engine into rich and/or lean misfire. A starting point
for determining the rich limit is the riginal gas/air
pressure setting. The starting point can then be
mdified as required to achieve desired operation. Fr
example: prior to installatin f the AFM system the
gas/air setting was 10 H20, use the stepper mtor
limits to permit only 1O H20 gas/air below the
cmbustion stability limit. Use a manometer to make
this measurement. Cmplete the steps below fr each
map-point belw the combustin stability limit.
A. Reduce load to a map-point below the cmbus
tion stability limit.
B. Adjust air/fuel rati by pressing <LEFT LEAN n
the keypad until the desired lean limit is achieved
based on the guidelines in Step 13. If your engine
has two fuel regulators, repeat this step for the
engines right bank using the right keypad
buons.
3.15-22
I
SET-POINT
RICH LEAN
4 -
EXHAUST OXYGEN (DRY VOLUME PERCENT)
TYPICASET-POINTS:
Ar at 32:1 (11.5% 2)
Ar&VHP at 28:1 (9.8%
VGF at24.5:1.8% 2)
Figure 3.15-37. xygen Sensr Response Vs. Exhaust
xygen Concentrations For Varius Air/Fuel Ratios -
Lean Burn ONLY
C. Recrd the stepper position displayed on the
View Serial Link Screen in the Lean Limit
column of the Lean Burn Control Worksheet (see
Table 3.15-3).
D. Adjust the air/fuel ratio by pressing
<LEFT RICH n the keypad until the desired
rich limit is achieved based on the guidelines in
Step 13. If your engine has two fuel regulators,
repeat this step for the engines right bank using
the right keypad buttns.
E. Record the stepper psitin displayed on the
View Serial Link Screen in the Rich Limit'
column of the Lean Burn cntrIWrksheet (see
Table 3.15-3).
F. Repeat Steps A - E fr each intake manifold
pressure map-point belw the combustion sta-
bility limit to cmplete the Lean Burn Control
wrksheet.
14. After the Lean Burn Control Worksheet is complete,
continue with Programming the Lean Burn Control
Valuesn page 24.
NOTE: Figure 3. 15-38 provides a scenario of a techni-
cian fine-tuning the AFM system following the program-
ming steps in this section,Gathering Data for Constant
Oxygen Sensor Set-Points." The values in the scenario
are given for example only. Actual values will vary
depending on engine application.
FORM 6263 Second Edition
PROGRAMMING FOR LEAN BURN APPLICATIONS
PROGRAMMING SCENARIO (CONSTANT OXYGEN SENSOR SET-POINTS)
NOTE: The values and readings used in this programming scenario are sample values on~ Actual values and
readings will va depending on engine appliittion. Guidelines presend apply tomst engine app/icatii ns
The fwing programming scenario demnstrates how a technician fine-tuned the AFM module program
while following the steps in the AFM manual (Form 6263). Within the text of the scenari below, the
programming step the technician is completing is indicated.
A technician is programming a 12V-ATGL Waukesha
Engine with a Fisher 99 regulator following the program-
ming procedures in the AFM manual (Form 6263). After
completing the initial programming requirements, the
technician is ready to continue with the section Fine-Tun-
ing AFM Programming for Lean Burn Applications.
Step 1: The technician makes a copy of the green Lean
Burn Control Worksheet from the back of the AFM manual. Step 9: The technician presses <LEFT LEAN n theAFM
Step 2: The <LEFT MAN> bun on the AFM module module until the oxygen meter indicates 1.0 percent (+ 2
keypad is pressed to put the AFM in manual mode. Step 3: air.el ratios) greater than desired running point. Step 10:
The engine is adjusted to manufacturers rated load and The stepper position displayed on the Vie'!' Serial Link
rated speed. Step 4: The technician desires to run the Screen is then recorded at each map-point above the
combustion stability limit in the Lean Limit'' column on the
engine at 9.8 percent oxygen. Using an exhaust analyzer, worksheet. Step 11: To determine the rich limit, the techni-
air/fuel ratio is adjusted by pressing the control buns on cian presses <LEFT RICH> until the oxygen meter reads
the AFM module until desired oxygen level is achieved. 1.0 percent (- 2 air/fuel ratios) less than desired running
Step 5: With the View Serial Link Screen displayed on the point. Step 12: The stepper position displayed on the View
PC, the sensor voltage is set to 2.50 volts by adjusting the Serial Link Screen is then recorded at each map-point
potentiometer inside the AFM module. Step 6: The sensor above the combustion stability limit in the Rich Limit'
column on the worksheet.
voltage is recorded at each malrJ)oint on the 02 Sensor
Set-Poi column on the worksheet. Step 7: With the View Step 13: The technician adjusts engine load to the highest
Serial Link Screen displayed on the PC, stepper posion is map-point below the combustion stability limit. At this
read and recorded at each map-point above the combus- map-point and below, stepper position is usted to
tion stability lim in the Current Stepper Position" column achieve best operan. Using a manometer, gas/air values
on the wrksheet. are set near 1O H20, which was the riginal gas/air setting
(before AFM installation). The technician fine-tunes the
Step 8'. Now the technician needs to determine the rich gas/air setting to achieve best operation.
d lean limits by establishing an air/fuel ratio curve
Rich and lean limits are determined for the map-points
following the :t 2 air/fuel ratio recommendation in the AFM
below the combustion stability limit and the stepper posion
manual and Figure 3.15-37 for the map--pints above the is recorded on the worksheet. Now that a constant air/fuel
combustion stability limit.
ratio curve is established and the Lean Burn Control
wrksheet is complete, the technician is ready to continue
with Progrnming the Lean Burn Control Values" in the
AFM manual.
Figure 3.15-38. Programming Scenario Fr Lean Burn cntrol (Consnt 1xygen Sensr Set-Points)
FORM 6263 Second Edition 3.15-23
PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

PROGRAMMING THE LEAN BURN cNTROL 6. Positin the cursor in the Gain field. Gain in-
VALUES fluences how large a change is made to the stepper LEFT
mtr position when the xygen sensor signal is not CEC AFM CONTROL
1. Press [Esc] t rwn to the Main Menu. 02 Lean Rich
within the specified tolerance around the sensr target psiA s - p Limit Limit
2. Highlight Edit/Create Setup on the Main Menu and (set-pint) vltage. A larger gain value will result in a Engine Family:ATGL GAS ENGINE
Engine Model :12V-ATGL P 10.0 2.35 1 5800
press [Enter] (see Figure 3.15-39). larger change. Adjust the gain value to give the desired r 15.0 2.40 1 5800
rate of response. Sensor: 1-LEANBURN (0-40MA) l. 20. 0 2.45 1 5800
Primary Fuel Type: m 25.0 2.50 1 5800
l NATUR GAS PIPELINE QUALITY a 30.0 2.50 1 5800
7. Using the down arrow key, position the cursor in the Secondary Fuel Type:
I CBC AFM Control - Ver. X. Xx I 1Tempeld. Althugh the high and low temperature L
r 35.0
y 40.0
2.50
2.50
1
1
5800
5800
limits can be modified, it is not recommended that these
tw values be changed. The Lo-Temp value shuld START POS LEFT= 2700
Edit/Create Setup not be set below 475 C (887 for AT engines and cmments:

390 C (734 for VHPNGF engines because that LEANBURN SETUP FILE #1
View Serial Link
temperature is the minimum for correct oxygen sensr
Quit Setpoint=510 c Gain= 150
operation. The Hi-Temp value shuld not be set above
Lo-Temp =475 c Hi-Temp=545C
545 C (1013 fr AT engines and 460 C (860 for
VHPNGF engines.

Retreve Data f r om 1iE F i. le , or <::r.eae New. 8. Press [Ent until the cursor is positioned in the left
I FlO = SAVE 11 ESC = MENU I
02 S-P column. Using your completed Lean Burn
Control Worksheet, enter all the 2 Set-Pints (S-P):
Figure 3.15-39. AFM User Interface Program
Main Menu Lean Limit', and Rich Limit" values for each intake
man ifId pressure map-pint. Press [Enter] after each Figure 3.15-41. Editing The Data-Set On The Edit Screen
3. The Edit/Create Setup Menu shown in value is entered to work down through each clumn.
Figure 3.15-40 appears. Highlight Retrieve from AFM LEFT
and press [Enter]. NOTE: Data-sets that are created can be saved to a CEC AFM CONTROL
filename for 1ture reference. Data-sets are assigned 02 Lean Rich
psiA s - p Limit Limit
filenames and saved on disk so the user can re and Engine Family:ATGL GAS ENGINE
retrieve the data-set la When saving de 400 4800
Engine Model : 12V-ATGL r 300 5200
data-set will be saved to the drive and directory where Sensor: 1-LEANBURN (0-40MA) l. 200 5500
the AFM User Interce Program was accessed. See .Primary "- 200 5500
k NATU 200 5500
"Saving Data-Set to Diskis section save your ,Secondary 200 5500
'-7 NONE
Exit to Main Menu
data-set to a filename. 200 5500
Retrieve from AFM Changes W11 be Lost if
Retrieve from Filename NOTE: The contents of RAM are lost whenever power you Have Nt Saved Them. EFT= 2700
Create New Dataset to the AFM module is removed. Comments:
Do you REALLY Want to EXIT?
ENGINE #1
NOTE: Each t1e modifications are made to the
data-set it must be saved to AFM RAM (temporary
Yes No esc
memo for evaluation. S1ply editing e values on e
upload Data F~om AFM via Seri al Por t. PC screen will not change AFM operation.

Figure 3.15-40. Edit/Create Setup Menu 9. Press [F1 O] to save the Edit Screen values to RAM

NOTE: Refer to Figure 3. 15-41 while editing the

data-set.
4. After the Edit Screen appears, type in any comments
regarding AFM programming or revise existing com-
ments at the cmments field . Typical! comments
include site, engine number, and date infrmatin.
NOTE: When the cursor is moved between entry
locations, the bottom line of the Edit Screen will show a
brief explanation and limits for that entry.
5. Press [Enter] to mvefrom the Commentseld to
the Setpoint'eld. It is not recommended that this
temperature value be changed.
3.15-24
(temprary memory) for testing.
10. Highlight Test Data on AFMn the Saving Options
Menu and preEnter].
11 . Press M to confirm save to RAM.
12. Several screens will appear indicating that the
data-set is being saved to RAM. The LCD display on the
AFM module will read EXECUTION STOPPED BY
USER. Press any key on yur computer to cntinue
after the save to RAM is cmplete.
NOTE: If the "EXECUTION STOPPED BY USER"
message persists on the AFM display for more than five
minutes, refer to Section 4.00 Air/Fuel Module System
Troubleshooting.
FORM 6263 Second Edition
I FlO = SAVE I I ESC NU I
Figure 3.15-42.
13. To return to the Main Menu, press [Esc].
Figure 3.15-42 appears on the screen warning to save
changes that were made to the data-set before exiting.
Since the data-set has already been saved to RAM,
press M to return to the Main Menu.
14. Highlight
and press [Enter] t return to the View Serial Link
Screen.
15. Place the AFM module in automatic mde by
pressing <AUTO OPERn the AFM keypad.
FORM62 Second Edition
Cnfirnation f Exit T Main Menu
16. Mnitor AFM system peormance. The response
must be fast enough to meet site requirements, however,
nt so fast that it causes instability. If the system is too
slow, go back to the Edit Screen and increase the Gain
seing. To test the setting changes, you must save your
changes to RAM by pressing [F10], selecting "Test Data
n AFM from the Saving Options Menu, pressing
[Enter], and then pressing M- Return to the View Serial
Link Screen to monitr AFM sysm performance.
Continue adjusting the Gain" setting on the Ed Screen
until the speed of response is satisfactory.
3.15-25
PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

Steps 17 - 21 are cmpleted to check ease of starting SAVING DATA-SET TO ROM

the engine based on the start psition programmed. Once you create a data-set, test the data-set in RAM LEFT
17. Press <LEFT MAN.> and <RIGHT MAN> (if appli- (tempora memo , and are satisfied with the AFM s CEC AFM CONTROL
Lean Ri ch
cablen the AFM module keypad to put the AFM air/fuel control, the data-set must be saved to perma- Limit Limit
mdule in manual cntrol. nent memory (ROM). Complete the steps in this section Engine Family:ATGL GAS ENGINE
Engine Model :12\7.ATGL 400 4800
to save your data-set t ROM. 5200
NOTE: The contents of RAM are lost whenever power Sensor: 1-I- 5500
NOTE: The AFM system allows five saves to ROM .Primary Fu 00 5500
to the AFM module is removed. NATURAL 00 5500
(permanent memory). All data-sets should be carefully This will Stop Program Execution
.Secondary 00 5500
18. DO NOT TURN OFF POWER TO THE AFM evaluated in RAM (temporary memory) before srg to ~ NONE 00 5500
and RESTART Program when finished.
MODULE. Shut down the engine and allow it to cool for ROM. Once ROM has been fully configured, the core
several minutes. EPROMch in the AFM module must be replaced to T = 2700
OK Store Values To ROM?
permit rther saves to permanent memory. Rer to
Section 4.00 Air/Fuel Module System Troubleshting
A WARNING for EPROM replacement instructions.
Setpoint Yes N esc

D not set the stepper mtr(s) t the start psitin 1. Highlight EdiVCreate Setup" from the Main Menu to Ler-Temp
while the engine is running abve 40 percent f return to the Edit Screen and press [Ente
rated lad. Start psitin is nly to be initiated when
2. Highlight Retrieve from AFM and press [Enter].
the engine is stpped r running belw 40 percent
f rated load. Reseing the stepper mtr(s) while NOTE: The Test Data on AFM option from the Save I FlO = SAVE ESC
the engine is running abve 40 percent f rated load Options Menu allows a program be run e AFM
may cause engine shutdwn andr cause severe
module's temporary memory (RAM). This may be used
engine damage.
for troubleshooting so that the ROM memory space is Figure 3.15-43. Confirmation f Save To Read nlyMemry (RM)
conserved. The contents of RAM are lost whenever
19. Press and release <F1 >, then <STRT POS> on
power to the AFM module is removed.
the AFM module keypad to test the start psition. The
LEFT
AFM LCD display will show MOVING L STEPPER TO 3. Highlight Congure AFM Memoryn the Save
START POSITION. The left and right Status mes- CEC AFM CONTROL
Optins Menu and press [Enter]. 02 Lean Rich
sages on the View Serial Link Screen will change t psiA s - p Limit Limit
MOTOR RESET' during the psitining activity. Once 4. When the confirmation screen appears as shown in Engine Family:ATGL GAS ENGINE 400 4800
Engine Model : 12V-ATGL
the left bank has been moved, the AFM module will Figure 3.15-43 press M- 300 5200
move the right bank stepper motor (if applicable). Allow Sensor: 1-LEANBURN (0- 40MA 00 5500
.Primary Fu- 00 5500
up to three minutes for -this process. After the stepper
motors have been mved t the start positin, the IA CAUTI N j Donsturb tt
cable, interrupt the AFM
L

L
NATURAL
.Secondary
NONE
00
00
00
5500
5500
5500
normal LCD displays resume. If the nrmal LCD mdule pwer interrupt cmputer pwer while
OK to Stre New Values?
displays d nt resume within five minutes, refer to cnfiguring memry. If disturbed or discnnected T = 2700
Section 4.00 Air/Fuel Module System Troubleshooting. during the saving prcess, the cre EPROM chip in
the AFM mdule may bee me c rrupted and may
20. Attempt to start the engine to check ease of
starting. need t be replaced.
Setpoint Yes No esc
5. When the verification screen appears as shwn in Ler-Temp
NOTE: Consider cold starts when modiing start
position. Figure 3.15-44 press M.

21 . If necessary, mdify the sta positin by changing 6. Several screens will appear indicating that the
the start position on the Edit Screen and saving changes data-set is being saved to ROM (permanent memory on I FlO = SAVE 11 ESC U
to RAM to test. Repeat the check until the engine starts the core EPROM chip inside the AFM module). Once
well. the data-set has been saved to ROM, the message
shwn in Figure 3.15-45 appears. Figure 3.15-44. Verification T Store New Values T ROM
22. Once you are satisfied with AFM system per
mance and ease of starting, return to the Main Menu. NOTE: The AFM allows five saves to ROM. Once ROM
has been 1/y configured e core EPROM ch the
23. Cntime with Saving Data-Set to ROM. AFM module must be replaced to permit further saves to
permanent memory.

7. Press any key on your computer t return to the Edit

Screen.

3.15-26 FORM 6263 Second Edition FORM 6263 Second Edition 3.15-27
PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

NOTE: If the power the AFM is inadequate (less than 3. Enter a filename according to the follwing proce-
LEFT 21 .6 volts) or excessively V1" (more an 2 volts dure (see Figure 3.15-47). Read all three steps prior to
CEC AFM CONTRL peak-terpeak r,pie), the programmg operation may saving the file to the disk.
02 Lean Rich not be successful. An unsuccessful store to 'ROM will
psiA s - p Limit Limit
Engine Family:ATGL GAS ENGINE result in the error message illustrated Figure 3. 15-46. A. Locate the engines serial number on the name-
400 4800 Should this error occur, e core EPROM chip must be plate.
Engine Model :12V-ATGL 300 5200
Sensor: 1-LEANBURN (0-40MA 5500 replaced and the true cause for the ilure corrected.
.Pr 1ary Fu- 5500 Refer to Section 4.00 Air/Fuel Module System Trouble- B. If the engine has a C- number, remove the C-"
'

L NATURAL 00 5500 shoting for core EPROM replacement instructions. and the frm the number. Example:
1~econdary '"I Starting ROM2 Progr 5500
Press any key on your computer to continue. C-10768/01 would give a rt file name f
"7 NONE 5500
1076801 . If the engine does not have a C-"
AFM Memory has been Configured.
T = 2700 NOTE: Save a copy of your data-set to disk for future number use all six digits in the serial number for
Comments: Program Is Running. reference. If a printer is connected to your PC, press the filename.
ENGINE #1 [Pr,t Screen] on the keyboard for a printout.
C. The first time the cnfiguration is saved t the
...

SLpT
oe Press ANY KEY to Continue
Lm
np SAVING DATA-SET TO DISK disk add an A to the end. This is t indicate that
this is the first save f this configuratin. If
The new data-set shOlId be stored to a floppy/hard disk
and tpermanent' memROM) as the previous changes are made to the configuration, save the
sectin explains. Data-sets are assigned filenames next file with the same numerical information and
and saved on disk so the user can retain the data-set for change the suffix letter to B.' Continue in this
I FlO 11 ESC = MENU future reference. Each time a new program is saved to manner for each revision to the file.
ROM, the previous program can no longer be retrieved. Once eight characters have been entered, the file will
The only way to keep track f Id programs is to save the automatically be saved to the personal computer disk
data-file to disk or with printed copies. from where the AFM User Interface Program was
Figure 3.15-45. Verlficatin Screen f Save T RM
NOTE: If you want to retrieve a data-set saved to disk, accessed. If the filename is less than eight characters,
rer to the next section "Retrieving a Saved Data-Set. press [Ente to save.
LEFT
1. With the Edit Screen displayed, press [F1 O] to save NOTE: When saving to disk, the data-set will be saved
CEC AFM CONTRL
2 Lean Rich your data-set to disk. to the drive and directory where the AFM User lnte.ce
psiA s - p Limit Limit Program is accessed.
Engine Family:ATGL GAS ENGINE 2. Highlight Save Data to Filename" from the Saving
2.20 400 4800
Engine Model :12V-ATGL 2.33 300 5200
Sensor: 1-LEANBURN (0-40MA) Options Menu and press [Ente
2.40 200 5500
,Primary Fu 00 5500
4 NATURAL 5500
,Secondary 00 5500 LEFT
~NNE
Prgramming Error has ccurred.
00 5500 CEC AFM CONTROL
2 Lean Rich
Prgram is NOT Running. psiA s - p Limit Limit
T = 2700
Check EPROM or Vpp for Error. Engine Family:ATGL GAS ENGINE 400 4800
Comments:
Engine Model :12V-ATGL 300 5200
ENGINE #1
EPROM Must Be Replaced. Sensor: 1-LEANBURN (0-40MA) 200 5500
_ Prnary F 200 5500
Setpoint 4 NAT 200 5500
Lo-Temp Press ANY KEY to Continue 200 5500
Save Choices to Disk 200 5500

EFT= 2700
FlO = SAVE ESC = MENU cmm.ents:
Input OataFile Name
ENGINE #1

Setpoi
Figure 3.15-46. Programming Error Message Lo-Tem

I FlO = SAVE I [ ESC = MENU

ENTERVALI:D 8 CARACTER NAME

Figure 3.15-47. Input Dati File Name Screen

3.15-28 -FORM 6263 Second Edition FORM 6263 Second Edition 3.15-29
 ,_.
-,
PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

CHECK 1: CONFIRMING THE DATA-SET SAVE TO

CEC AFM CONTROL

2
LEFT

Lean Rich
I cM l - Ver X Xx
ROM
Check 1 confirms that the data-set was successfully
psiA s - p Limit Limit stored in ROM n the cre EPROM chip.
Engine Family:ATGL GAS ENGINE 2.20 400 4800
Engine Model :l2VATGL 2.33 300 5200 File Select NOTE: Programs saved to the EPROM will be retained
Sensor: 1-LEANBURN (0-40MA) 2. 40 200 5500 even if power to the AFM module terrupted.
.Prnary F. 200 5500
4 NATU 200 5500 1076801A.AFM Programs saved to RAM will be lost when power the
,Secondary 200 5500 LSETUPOl.AFM AFM module is disconnected. The AFM can detect
L NONE
Exit to Main Menu
200 5500 when an evaluation data-set is be.g tested RAM and
LSETUP02 .AFM
Changes Will be Lost if has not been saved to ROM. If you attempt to leave the
you Have Nt Saved Them. EFT= 2700 LSETUP03 .AFM
LSETUP04 .AFM AFM User Interface Program without saving the evalua-
Comments: ..
ENGINE #l Do you REAY Want to EXIT? LSETUP05 .AFM .. tion data ROM, a warning will be displayed.
::
..
LSETUP06.AFM ..
.. 1. With the Main Menu shwing on yur screen,
Yes N esc LSETUP07.AFM .. highlight Edit/Create Setup" and press [Enter].
LSETUPOS.AFM
RSETUPOl.AFM 2. Highlight Retrieve from AFMn the next menu and
press [Enter]. Several messages appear indicating that
I FlO = SAVE ESC the data-set is being retrieved from ROM.

Figure 3.1550. File Select Menu 3. The Edit Screen appears (see Figure 3.15-51).
Verify that the data n the Edit Screen is the same
POST-PROGRAMMING CHECK data-set chsen to be saved to ROM.
Figure 3.15-48. Cnfirmation f Exit T Main Menu
Tw post-programming checks must be completed t If the correct data does not appear on the Edit Screen,
4. Press [ESC] to return to the Main Menu. RETRIEVING A SAVED DATA-SET FRM DISK
cnfirm that the data-set created was successfully verify that the DB9 serial cable connected between the
WITH A FILENAME PC and the AFM mdule is secure and in god
5. If the data-set fr your engine has been saved t stored to ROM. The procedures that follow take yu
The data-sets that a saved to disk (not RAM or ROM) step-by-step through the pst-programming checks. conditin. In addition, verify the power to the AFM
ROM and a file on disk, cnfirm the exit to the Main
and assigned a filename n be retrieved following the module is within specification. Aempt a secnd store
Menu by pressing M (see Figure 3.15-48). The Main of the correct data-set to ROM (refer to Retrieving a
steps in this section. NOTE: Print copies of your data-set or save your
Menu appears (see Figure 3.15-49). If yu have not Saved Data-Set From Disk With a Filename" to retrieve
data-set to a file for ture reference before completg
saved the da-set to ROM (permanent memory), NOTE: If you want to save a data-set to disk, refer to data-set from filename) . If difficulty continues, contact
e two post-programming checks.
press [N] and refer tSaving Data-Set to ROM in this e previoussection 'Saving Data-Set Disk. yur ical Waukesha Engine distributor r Waukest
section. Engine Product Supprt.
1. With the AFM User Interface Program s Main Menu
shwing on your screen, highlight Edit/Create Setup" LEFT
and press [Enter] (see Figure 3.15-49).
CEC AFM CONTROL
02 Lean Rich
2. On the next menu highlight Retrieve from Filename" psiA s - p Limit L:uru.t
and preEnte Engine Family:ATGL GAS ENGINE P 10.0 2.20 400 4800
Engine Model : 12V-ATGL r 15.0 2.33 300 5200
Edit/Create Setup 3. Highlight the filename (serial number) you wantto Sensor: 1-LEANBURN (0-40MA) 1 20.0 2.40 200 5500
View Serial Link Primary Fuel Type: m 25.0 2.43 200 5500
open and press [Enter] (see Figure 3.15-50). The 4 NATURa GAS PIPELINE QU.ITY a 30.0 2.45 200 5500
Quit information that is shwn on your PC screen is Secndary Fuel Type: r 35.0 2. 50 200 5500
informatin that has been saved in a file and was not L NONE Y L....i2..:. 2.50 200 5500
retrieved from the AFM mdules RAM r ROM.
START POS LEFT= 2700
NOTE: The retrieved s data-set must be saved to Comments:
Retrieve D f .rom AF File, or Create New. RAM or ROM before the displayed data-set values ENGINE #1 9/15/95
a-ect control of the AFM system.
Figure 3.15-49. AFM User lntece P ram Setpoint=510 c Gain= 150
Main Menu NOTE: The contents of RAM are lost whenever power Lo-Temp =475c Bi-Temp=545 c

to the AFM module is removed.

NOTE: If you want to save an opened file to ROM

(permanent memo refer to 'Saving Data-Set to I FlO = SAVE 11 ESC
ROM."

Figui:e 3.15-51. Edit Screen

3.15-30 FORM62 Second Edition FORM 6263 Second Edition 3.15-31

PROGRAMMING FOR LEAN BURN APPLICATIONS PROGRAMMING FOR LEAN BURN APPLICATIONS

CHECK 2: FINAL TEST OF AFM SYSTEM SETUP

Check 2 confirms that the data-set is not lost when the I CEC AFM Control - Ver. X.Xx I CEC AFM CONTROL
LEFT
AFM system is powered down and that the AFM system 02 Lean Rich
will power up with the aata stred in ROM. psiA s - p Limit Limit
Engine Family:ATGL GAS ENGINE P 10.0 2.20 400 4800
1. Highlight Quitn the Main Menu and press [Enter] Engine Model :12V-ATGL r 15.0 2.33 300 5200
Communications Menu Sensor: 1-LEANBURN (0-40MA) 20 .0
(see Figure 3.15-52). l. 2.40 200 5500
.Primary Fuel Type: m 25.0 2.43 200 5500
Select Com Port NATURAL GAS PIPELINE QUALITY a 30.0 2.45 200 5500
.Secndary Fuel Type: r 35.0 2.50 200 5500
~ NONE Y 40.0 2.50 200 5500
1 0 2 03 0 4
I CEC AFM Control - vx.xx I START POS LEFT= 2700
Comments:
ENGNE #1 9/15/95
Edit/Create Setup
View Serial Link Figure 3.15-53. C1unications Menu Setpoint=510 C Gain= 150
Quit Lo-Temp =475 c Hi-Temp=545 c
8. The AFM User Interface Program s Main Menu
appears shwing various program ptins available
(see Figure 3.15-54). Highlight Edit/Create Setup" and
press [Enter]. I FlO ESC NU
Retrieve Data f.rom AFM, File z create New.

Figure 3.15-52. AFM User Interface Program

Main Menu I CEC AFM Control - Ver. X. Xx I Figure 3.15-56. Edit Screen
1O. Observe which ROM location (ROM is being
2. Press to confirm that the program is to be exited. retrieved.
Edit/Create Setup
3. Disconnect pwer from the AFM module for a 11. The Edit Screen appears (see Figure 3.15-56).
View Serial Link
minimum of five minutes. Verify that the data n the Edit Screen is the same
Quit
data-set chsen to be saved to ROM.
4. Restore power to the AFM mdule.
If the correct data does not appear on the Ed Screen,
5. Start the AFM User Interface Program on your PC by verify that the DB--9 serial cable connected between the
accessing the drive and directory where the AFM PC and the AFM mdule is secure and in gd
sftware is installed (typically: A: [Enter]). Retri.eve Data f .rom AFM: File., or Creat New.
condition. In addition, verify the pwer to the AFM
mdule is within specification. Attempt a second stre
6. Type the name of the executable file and press Figure 3.15-54. AFM User Interface Program f the crrect data-set to ROM (refer tRetrieving a
[Enter] (typically: AFMX> Enter) where is the Main Menu Saved Data-Set From Disk With a Filename" to retrieve
revision level).
data-set from a filenam. If difficulty continues, contact
9. The menu shown in Figure 3.15-55 appears. High- your local Waukesha Engine distributor or Waukesha
NOTE: To find e name of the executable file (.exe) for
light Retrieve from AFM and press [Enter]. Engine Product Supprt.
the AFM User Interlace Program, view the directory of
the drive on which your AFM program is saved by ping
DIR at the drive prompt and then press.g [Enter]. Usted
in the directory will be an executable file for the AFM
User Interce Program. The executable file for the AFM
program is typical the letters 'AFMXXX.exe where
xx is the revision level.
7. The Genuine Waukesha Pa logo and version
identificatin screens appear briefly, followed by the Retrieve froB AFM
com nunications menu (see Figure 3.15-53). A black Retrieve frm Filename
dt is located in parentheses next t1 which indicates
Create New Dataset
that the selected communications port on the computer
is po 1. Press [E to select communications port 1.
If the DB--9 cable is connected to a different port on your
PC, use the arrow keys n the keybard to select the
crrespnding prt from the cmmunications menu and
Figure 3.15-55. Edit/Create Setup Menu
press [Enter] (typically: p 1 is correct).

3.15-32 FORM 6263 Second Edition 3.15-33

FORM 6263 Second Edition
PROGRAMMING FOR LEAN BURN APPLICATIONS CHAPTER 4 - TRUBLESHOOTI NG

CONTENTS

SECTION 4.00 - AIR/FUEL MODULE SYSTEM

TROUBLESHOOTING

SECTION 4.05 - AIR/FUEL MODULE SYSTEM DIAGNOSTICS

3.15-34 FORM 6263 Second Edition FORM 6263 Second Edition

 SECTION 4.00 - AIR/FUEL MODULE SYSTEM TROUBLESHOOTING
AFM TROUBLESHOOTING
Table 4.00-1 is provided to assist the user in determin-
ing the possible ~auses of unsatisfactry AFM system
operation, as weli as point out the corrective action that
may,be taken to remedy the problem.
Inside the AFM module are three circuit bard assem-
blies: control bard assembly, display board assembly,
and stepper driver board assembly (see Figure 4.00-1).
Troubleshooting the AFM system can involve some
disassembly of circuit board assemblies, remval and
replacement of mult -pin components (chips), and
ther work f similar nature. Only qualified technicians
shuld undertake these activities. Improper handling of
circuit boards and electronic compnents can cause
damage that may render them unusable.
Table 4.00-1. AFM System ubleshoting
SYMPTOM I PROBABLE CAUSE
Green power LED is not lit d .
LCD display is blank on AFM I Power is interrupted.
module.
KEYPAD CONNECT1R
HARNESS Figure 4.00-1. AFM Module Internal
(Continued)
FORM 6263 Second Edition FORM 6263 Second Edition
NOTE: 7Je 4.00-1 is only provided as a service to our
customers. It should not be viewed as a reflection of
Waukesha Engine's actual experience with this product.
A WARNING
Allow the engine t cool to rm temperature
befre cleaning, servicingr repairing the unit. t
compnents r fluids can cause severe persnal
injury or death.
A WARNING
Always wear OSHA apprved bdy, sight, hearing,
and respirato system protection. Never wear
lse clothing, jewelryr long hair around an
engine. The use .f improper attire may result in
severe persnal injur death.
REMEDY
a. Veri the power supply voltal;)e at the AFM module power
terminal block is within soecification. Refer to Section 2.05
AFM System Electrical onnections tor correct power
specitions.
b. Disconnect power from the AFM module d check the
resistance of the on-board fuses F2 (see
Figu 4.001). Resistance should be less than 1 ohm.
c. Verify that the cable connections within the AFM module
between the control board assembly and display board
assembly are secure (see Figure 4.00-1).
INTERCNNECTCABLE
Bard Assemblies
4.00-1
AIR/FUEL M ODUE SYSTEM TROUBLESHOOTING AIR/FUEL MODULE SYSTEM TROUBLESHOOTING

SYMPTM PRBABLE CAUSE REMEDY SYMPT1M PRBABLE CAUSE REMEDY

sd!t~~6wi~le
PENDED.
LCD display on the AFM
module reads EXECUTION
SUSPENDED B'( USER for
more than ve minutes.
NOTE: "EXECUTION STOPPED
BY USER" is a normal message
dpryed during e stong Example. A new test data-set is being
process and some other stored to RAM (temporary memory).
activities. DO NOT disc.onne
e power to the AFM module
unless this mge persists for
more than e minutes.
Control board is not running .
Software execution has been temp
rarily stopped due to user activity at
the personal computer.
a. Disconnect power from the AFM module for two minutes. a. Check for 5.0 VDC on the display board assembly at the test
Reapply power and check LCD display. goint (see F
gu 4 00 Check for 5.0 voe on t1ecor
oard assemb.lY at the Home (+) and Home termin
b. Disconnect power from the AFM module. Remove and block conneions .
separate the control board assembly. (For instruction on how
to remove and disassemble the control board assembly, refer b. If voltage is less than 5.0 voe at the control board assembly
to the m Son Rep/ac.g EPROMChips reEPROM LCD display on the AFM mod- Power supply to the display board
ule is blank, but red stepper Home {+) and Home ( terminal block connections,
Chip Replacement.') Examine both blue socketed chips for assembly is not adequate. replace control board assembly.
secure installation by pressing both chips into their sockets driver board LED is lit.
mly. Reassemble and install the control board assembly. c. If voltage is 5.0 VDC at control board assembly but less than
Then reconnect power to the AFM module. 5.0 VDC at the display board assembly test point, replace
display board assembly.
c. If the problem persists, replace the control board assembly.
d. If the problem peists, replace the cntrol board assembly.
a. If the yellow alarm LED is ss <ALARM ACK> on e
k~y_pad. Wait for the WORKING message to disa pear on the
LCD display before prsing any addional keypad tons.
Keypad on AFM module cau Keypad is not communicating with b. Vefy the connection of the keypad connector harness to the
a. Disconnect pwer from AFM module fo two minutes. Reapply no LCD display response. display board assembly.
power and check LCD display. bottom of the display board assembly inside the AFM module
(see Figure 4.0
b. If the problem persists, replace the control board aembly.
c. Replace the AFM module.
a. Read the warning message on the LCD display. Refer to
Section 4.05 Air/Fuel Module Stern Diagnos for
information on LCD displays.

LCD displa on the AFM mod-
ule reads EXECUTION SUS-
PENDED (NoDat).
LCD display on the AFM mod-
ules top row is dark id bot-
tom row is light.
The coe EPROM chip (pemanent
a. Replace the core EPROM chip inside the AFM module. Refer
memory) inside the AFM module is to the next section Replacing EPROM Chs CoreEPROM
either installed upside down or is Chip Replacement. ncorrectly installing the EPROM chip
corrupt. In either case, the chip is no results in a nonfunctioning AFM module.
longer usable and must be replaced.
a. Disconnect power from AFM module for two minut. Reapply
power and check LCD display.
b. Examine both socketed chips on the back of the display board
assembly (see Figure 4.00. Press both chips firmly into
Display boad assembly is not run- their sockets.
ning.
c. Verify atthe cable connections within the AFM module
between the control board assembly and display board
assembly are secure (see Figure 4.00-1).
d. If the problem persists, replace the display board assembly.
Yellow alarm LED is lit.
LCD display on the AFM
module reads MOVING
STEPPER TO START
P9SITION for more than ve
minutes.
b. Press <ALARM ACK> on the keypad to permit normal keypad
AFM system software is detecting a operation and disable the ERROR OUT terminal.
system fault.
c. T1oubleshoot errant condition.
d. If the problems persist, contact your local Waukesha Engine
distributor or Waukesha Engine Product Suppo
a. Check all wiring connections between the AFM module and
the stepper motors. Refer to Section 2.00 Mounting AFM
System Components Mounting the Stepper Motor(sd
Section 2.05 AFM System Electrical Connections.
b. Check to see that the Home switch is propey installed (see
Figure 4.00-3).
The Home switch on the stepper
c. Use a small piece of wire to short the terminals labeled
motor does not detect the presence of
the adjusting nut in the home lly Home In and Home (-) within the AFM module for the
retracted) position. aected ste 1oer motor. This will clear the MOVING
STEPPER TO START POSITION message from the LCD
display. Remove the stepper motors from the regulators and
check for proper operation.

IA IDo not short rminals

CAUTION Ho.. and Home togher.
label

Shorting these terminals can cause damage to the AFM module.

[]- 3
c

E
INSERT SWITCH UNTIL cNTACT IS MADE
WITH ADJUSTING NT. THEN BACK OUT

/
1/4 TURN, AND TIGHTEN LCK NUTS.

NECTOR_-U. E
Figure 4.00-2. Display Bard Assembly

a. On back of the dpl~y board assembly, adjust the contrast

LCD display on the AFM
module is too light making it
difficult to read.
(Continued)
Contrast adjustment to the LCD
display is requir
eotentiometer (see F11;iure 4.00-2). Turning clockwise is
lighter; cunterclockw1se is darker.
b. If the _E>rQ~pers~e the display board aembly.
Figure 4.00-3. me Switch Installation Diagram
(Continued)

4.00-2 FORM 6263 Second Edition FORM 6263 Second Edition 4.00-3
AIR/FUEL MODULE SYSTEM TROUBLESHOOTING AIR/FUEL MODULE SYSTEM TROUBLESHOOTING

SYMPT1M PRBABLE CAUSE REMEDY PR BABLE CAUSE REMEDY

SYMPTOM
a. The created data-set has been lost. If the data-set is stored a. Check oxygen sensor wiring for shorts or opens.
to a filename on disk it can be retrieved and then stored to

AFM module loses the created

data-set whenever the power
~~ld~F!:;7~~e"mp~r~~raon
ecti Savin~~ i~~
Menu. The data-set should
: ROM. If not, recreate the
:i!amt~~l~i~~~~~e;
daset ~~r~i2~Jl:em
~: ata-set, sto
b. Check to see that the correct voltage is being applied to the
sensor heater: 6.90 voe.

pr
o~r~g~~i~~
ro~te
.s
e
k p~u~BJieP.as admiss

:
The oxygen sensor signal is outside C.~~
~at~~~A_k~~~Nalarm
~~:
is disconnected. to ROM ~t~r~~nent mem~me : r is
eJ~2~a:;n the peprogrammed limits.
~!
NLY

~: ~~:r~~ii~~
ft~t~f~~ir~~En
inRAMw
~~~er is disconnected from the
AFM ule. b. the A
If the pi:lfrili~~~~ d. e f~t~inrich
sensor
and I ~ ~t~nr:ieEralt int. ~tsting thesen-
~0~
i~sp chip results ii~ a nonfunctioning AFM module. sor doe~~
NOTE:
\~:;rg~;f,;
p ace e sensor.
e oxygen
sensor signal to the AFM module is a
a. Check that the data-set was not created using a diffeent current, not a voltage.
version of the AFM User Interface Program.
a. Check thermocouple wiring for shorts or opens.
b. Check that the User lnte~~:a~ was not accessed from
a different location where the was saved. When b. Check AFM systems prramm limits areplible.
~ievi~gm a lename, the AFM module ~7trt':i~eves files
Saved to a different location than c. ~~~cki~rrnocou~~ee~peratio~a removing thermocouple and

:J
the locaon the AFM User Program was

~:
Saved filename not found. expected. accessed. in air. If rmocoupl oes not respond, replace the
Thermocouple signal is below or thermocouple.
~Jti~.MliJ-~ alarm is
c. Invalid le format ~~
e ~h::rd~ev!:rive er
to J~a. w
RN ONLY above the preprogrammed limits.

r~fu~~~~.~ri.t~i1~~~iM~~e p
used before saved
d. Use a file management program to try and locate programs

:
The EPROM f~~f~~re and displ~~i
and the User ~~gram m
and/or les .
;;~ pe~~rere disp
tempe
disp :~~:1g e od
the calibration tool.
q
<ii

be matched. If versio software a. Check thermocouple wiring for shorts or opens.

is used with version 2.6 EPROM
b. Chee ifAFM WmS Wrammlits are coUible.

comm ini~J>~~nf ~~t!~! ~lish

v;r{il~~ri;~:~~~~irr~~;~fl~a~~r~iiRL~r
Y5~if
When

nUR~~cbMWn~ieHreteoi
nPm~~h.d~rt~A~
JIYeRf~fr.::
the
c.
~;;~~;~tiilii~: !~;:1 E
are incompatible is displayed
a.
alarm

d. If HEATER AT 39% is i~rt~Jtt~~~~~ LED display and an

2 TEMP LO alarm is i eck thermocouple.
on the computer screen. Thermocouple signal is below or
~c1i:;MPek~/ ~IURN
alarm is
NLY above the preprogrammed limits. e. ~~~i~r~~~~~e~~~~a
n t~o~eb~~moving
p thermocouple
es not respond, replaceand
the
thermocouple.

= MlW
~aAe~het~i1mJ~o
~1
it
Fpf~u.
1~g:t~~up.~k;
a. g~p~rJ{r
e~f~~1Y.~.n
nnednand
f.
ste~~~: o~~~
Wrong
when aco
sent in either MANUAL or
nds
The
som
!'!i"e~re.has been crossed
AUTOMATIC operation. temperature on the calibration tool.

a. V
~jro

atg~io~
rattg~~
. sr
k p~L B
M
EP.as admion
a
AF
MS
260

23J
C
1ecteRefer
tomodu~r~
Secti
power to correct b. Check with exhaust analers to see that the oxygen sensor
RICHEAN LIMIT arm is The stepper motor has reached one has not failed.
The core EPROM chip : : i have active. of the programmed travel limits.

~~r~RnMt;en:or
~M~~
E
A;i
i.o~~~e
A:MEPmR~UPc~gM
The AFM module cannot be been damaged during i lation or c. ~d~~s~: per motor is at the rich limit, back the carburetor
programmed. until the stepper motor moves.
handling. b.
d. Confirm AFM program limits are set properly.

COM Port Failed message is
displayed on the PC screen.
If !~tftit~~l~~~fi~
c. di !:ac~~~~~
g /~~;cJical Waukesha Engine
uct Support. Theinke manifold pres~~~~in is
a. Check intake manifold pressure transducer wiring for shorts or
opens.
IMP INPUT LO/HI alarm is below/above the preprog
a. Verify that the serial cable is connected to the correct active. limits. b. ~~~~t~~~1 manifold pressure transducer for correct
communications po the serial cable is not connected to transducer does not respond, replace transducer.
communications port 1, move the cable to COM 1 or choe
the correct COM po when beginning the programming
procedure.
Cannot establish communications
between the PC and the AFM module. b. c~~i~
If !~!i9;:;i~4si~ttion and or~ ai ~e~f e serial cable.
lty, replace !:

c. i~~iji~i~~JI~~~~i~~~~~ifl~Rid~
M p results
a. Check oxygen seor wiring for shorts or opens.
a nonflnctioning AFM module.

The oxygen sensor signal is outside

~ai~~~~i61i
C L~ml alarm is
URN NLY the preprogrammed limits. b. v~~iisenso
and lean ~r~~~ro~e~1r~~~u~~o~h~o~~1 ratio
respond, replace the sensor.
(Continued)

4.00-4 FORM 6263 Second Edition 4.00-5

FORM 6263 Second Edition
AIR/FUEL MODULE SYSTEM TROUBLESHOOTING
REPLACING EPROM CHIPS
TheAFM mdule has tw internal EPROM chips: core
and display (see Figure 4.00-4} . The core EPROM chip
stores up to five AFM data-sets configured for the
engine application in permanent memry. The display
EPROM chip cntrols the operation of the LCD display
on the front of the AFM mdule.
The core and display EPROM chips must be matched
with the AFM software version number. If the versions of
the EPROM chips are nt the same software version
number, the potential for errant operation exists and
programming will not work. The version number is
labeled on the back of the EPROM chips. AFMD.XX is
labeled on the display EPROM and AFMCXX is labeled
on the core EPROM (where XX is the version number).
For exnple: AFMD28 (display EPROMd AFMC28
(core EPROM} are the chips that have been programmed
for AFM User Interface Program versin 2.8x (where x is
the resion level as in 2.8a}.
The display EPROM is visible inside the AFM module on
the back of the door. Tc view the core EPROM, the
control bard assembly must be removed and disas-
sembled. See next sectin Core EPROM Chip Replace-
ment' for disassembly instructions.
~ 3
[3-
NOTE: Right side view of a1 module with door open.
Figure 4.00-4. EPRM Chip Lcatins Inside
AFM Module
4.00-6
AIR/FUEL MODULE SYSTEM TROUBLESHOOTING
Damaged r crrupt EPROM chips have been referred 2. Disconnect all wiring inputs connected to the control 5. Remove the screw from the back of the control board
to several times in the troubleshooting suggestions. A board assembly inside the AFM mdule (see assembly that holds the two circuit boards together (see
damaged r corrupt EPROM chip could be caused by Figure 4.00-5). Figure 4.00-7).
any of the following:
. Serial cable became disconnected from AFM module DISCONNECT
r cmputer while the data-set was being saved to
the core EPROM chip (permanent memo .
The pwer to the AFM module or computer was
disconnected or interrupted.
. The power to the AFM module was inadequate or
excessively di during EPROM chip save.
. EPROM chip was installed improperly (for example,
with indentation ntch installed facing the wrong
direction or pins nt aligned in socket}.
The following sections explain hw to replace the cre
and display EPROM chips within the AFM module. Figure 4.00-7. Bottom Screw Lcation f Control
IEE
Board Assembly
319
cRE EPROM CHIP REPLACEMENT
AFM data-sets fr your engine are saved n a cre 6. On the right side of the contrl board assembly is a
@ blue connector which holds the circuit boards together.
EPROM chip (ROM} inside the AFM module. Replace-
ment of the core EPROM chip is necessary because the Using a small at screwdriver, pry apart the blue
EPROM chip is "full of saved data-sets; the EPROM cnnector at the three notches (see Figure 4.00-8).
chip is damagedr cre EPROM chip version number DISCONNECT ALL
TERMINAL BLOCKS CONTROL BOARD ASSEMBLY
does not match the display EPROM and/or the User
Interface Program versin numbers. Figure 4.00-5. Control Bard Assembly
Discnnections
NOTE: The AFM module allows ve saves to the core
EPROM chip. Once the EPROM chip has been fully 3. Remvethe ve screws securing the control bard
1 A
n l I
configured, the chip must be replaced. assembly in the AFM module (see Figure 4.00-6).
NOTE: Contact your local Waukesha Engine distribu- 4. Carefully lift the control board assembly ut of the
tor for EPROM ch replacement parts. AFM module.
Inside the AFM module is a cntrol board assembly
comprised of two circuit boards. The core EPROM chip SCREW LCATINS
is lcated on the bttm circuit board (between the two Figure 4.00-8. Disassembling Circuit Board Assembly
circuit bards}. Tc replace the core EPROM chip, it is
necessary to remove the cntrl board assembly from 7. Lcate the core EPROM chip n the bttom circuit
the AFM module, disassemble the assembly, and board (see Figure 4.00-9).
remove the full or damaged cre EPROM chip. Fllow
the steps belw when replacing a cre EPROM chip.
IA CAUTI N I Always u~e a sttic mat
and electrical wrist strap
when remving circuit bards r replacing EPROM
chips. Static charges can permanently damage the
@ e
circuit bards andr EPROM chips.
1. Turn 24 VDC power to the AFM mdule.
Figure 4.00-6. Cntrol Bard Assembly Screw
Lcations
Figure 4.00-9. Cre EPROM Chip Lotlon
FOAM 6263 Second Edition FOAM62 Second Edition 4.00-7
AIR/FUEL MODULE SYSTEM TROUBLESHOOTING
8. At the same time, press dwn the tw blue tabs
located on both sides of the core EPROM chip and the
chip will pop up (see Figure 4.00-1
CORE
EPROMCHIP
Figure 4.00-10. Remving creEPRM Chip
9. Remove the full or damaged core EPROM chip from
the circuit board.
NOTE: The core and display EPROM chips must be
"matched with the same AFM User Interface Program
version number. If the versions of the EPROM chs are
not the same as the program version number, the
pntial for errant operation exists and programming
will not work.
10. Verify that the veion number of the new c
EPROM matches the version number of the display
EPROM and the AFM User Interface Program (see
Figure 4.00-11). Fr example: AFMD28 (display EPROM)
and AFMC28 (core EPROM) are the chips that have been
programmed for AFM User lnteface Program versi1
2.Sx here x is the resion level as in 2.
Figure 4.00-11. Crrect creEPRM Chip Direction
IA CAUTION I ~~re.?ctsi~~
indentatin notch on the chip in installed t face up
toward the top of the circuit bard. Failure t install
the cre EPROM chip c rrectly will result in a
nn-functinal AFM mdule and the EPRM chip
will need t be replaced.
4.00-8
NOTE: All other chs on the circuit board are pos
tioned with their notch in the same direction as the core
EPROMch
11 . Carefully place a new core EPROM chip in place on
the circuit board. Make sure the notched side of the
EPROM chip is installed to face up toward the top of the
circuit board as shown in Figure 4.00-11 and
Figure 4.00-12.
NOTE: If the pins on the new core EPROM ch do not
align with the socket on the circuit board, press on e
side of the ps ve,ycare1/y until pin alignment allows
for installation.
Figure 4.00-12. Core EPROM Chip Lcation And
Directin
12. Press the EPROM chip into place making sure that
all the pins of the EPROM chip are aligned with the
socket. Failure to install the core EPROM correctly will
result in non-functional AFM module.
13. After the new core EPROM chip is installed,
carefully align the top circuit board with the bottm
circuit board.
14. Press the circuit bards together so the blue
connector on the right sides f the circuit bards snap
together.
15. Secure the two circuit bards with the one screw
removed in Step 5.
16. Place the cntrol board assembly into the AFM
module.
17. Secure the control board assembly t the AFM
module with the five screws removed in Step 3.
18. Reconnect all the wires to the cntrol bard
assembly disconnected in Step 2.
FORM 6263 Second Edition
AIR/FUEL MODULE SYSTEM TROUBLESHOOTING
DISPLAY EPROM CHIP REPLACEMENT
The display EPROM controls the LCD display on the AFM
module. Replacement of the display EPROM is neces-
sary because the display EPROM chip is damagedr the
display EPROM version number does not match the core
EPROM and/or User Interface Program version number.
NOTE: Contact your lol Waukesha Engine distribu-
tor for EPROM chip replacement parts.
: ; ;:~~!
IA CAUTION I
~~a:i:c~~ a~ cs::;
when remving circuit bards r replacing EPROM
chips. Static charges can permanently damage the
circuit bards andr EPROM chips.
Figure 4.00-14. Remving Display EPRM Chip
1. Locate the display EPROM chip on the display board
assembly (see Figure 4.00-13).
2. At the same time, press down the two blue tabs
located on both sides of the display EPROM chip and
the chip will pop up (see Figure 4.00-14).
3. Remve the damaged r Id display EPROM chip
from the circuit board.
NOTE: The core and dis EPROM chips must be
natched with the same AFM User Interface Pragm
1e1 ion numr. the wions of the EPROM chips are not
S1e program Viion number.e fX?tl~al for
errant OJsts and prmming will not work.
4. Ver that the version number of the new display
EPROM matches the versin number of the core Figure 4.00-15. Correct EPRM Chip Direction
EPROM and the AFM User Interface Program (see
Figure 4.00-15). For example: AFMD28 (disp
EPROM) and AFMC28 (core EPROM) are the chips that
have been programmed for AFM User Interface Program
IA CAUTIN l ~1~oc~~
version 2.8x (where xis the revision level as in 2.Sa). indentatinntch n the chip in installed t face up
toward the top of the circuit bard. Failure t install
the display EPROM chip crrectly will result in a
nn-functional display n the AFM module.
NOTE: All other chips on the circuit board are po_~i-
tioned with their notch in the same dirtion as the
display EPROM chip.
5. Carefully place a new display EPROM chip in place
on the display board assembly. Make sure the notched
side of the EPROM chip is installed to face up toward the
top of the assembly as shwn in Figure 4.00-13 and
Figure 4.00-15.
NOTE: If the pins on the new display EPROM chip do
not align w the socket on the circua Psso~
the side of the pins. ve. carefully until pin alignment
allows for installation.
6. Press the EPROM chip int place making sure that
all the pins of the EPROM chip are aligned with the
socket. Failure to install the display EPROM crrectly
Figure 4.00-13. Display EPRM Chip Lcatin And will result in non-functional LCD display operatin.
Directin
4.00-9
FORM 6263 Second Edition
AIR/FUEL MODULE SYSTEM TROUBLESHOOTING SECTION 4.05 - AIR/FUEL MODULE SYSTEM DIAGNOSTICS

AFM SYSTEM DIAGNOSTICS ALARM is displayed next to the system parameter on

This section is provided to explain diagnostic codes f
the AFM system, as well as, possible corrective actions
th may remedy diagnostic problems.
The AFM module is equipped with features to inform site
personnel of system status. These features include:
Power and Alarm lights (LED display) on the front
panel of the AFM module (see Figure 4.05-1)
your computer (View Serial Link Screen). The message
ALARM OUTPUT ACTIVE is als displayed on the
View Serial Link Screen until the alarm is acknowledged
r the system fault is crrected (see Figure 4.05-2). At
this time, movement of the stepper motor(s) is stopped
(except when the IMP INPUT LO/HI alarm is indicated).

an alpha-numeric liquid crystal display (LCD display)

visible from the front of the AFM module allows the
user t monitor important system parameters
alarm messages that appear on the PC screen when
viewing the View Serial Link Screen in the AFM User
Interface Prgram.
an Error Out terminal that can be used to drive a relay,
alarms, and/or lights
AFM system diagnstics included in the AFM are
designed to identify conditins which are not cnsid
ered normal operation. Tests are performed cntim
ously. Whenever a fault occurs, the yellow LED is lit, the
Error Out terminal is activated, a diagnostic message is
displayed on the AFM LCD display, and the wrd Figure 4.05-1. Air/Fuel Mdule Frnt Panel

CEC AFM Control

Engine Model: L5790GSI V-12 Sensor Type: CATALYST CONTROL

Left Bank I ALARM

MESSAGE
Right Bank I

SENSOR:
/
Voltage .003 volts GBV 0.005 volts ALARM
O. 700 volts O. 700 volts
ALARM SetPoint 31 c ALARM
MESSAGE Temperature 32 c ALARM

PWM Output 0 %

STEPPER:
Position 10500 10750
Lean Limit 1 1
Rich Limit 20000 20000

INT. MAN.
Pressure
I o.o .7~1 1
Enclosure Temp. 26 C

VIEW SERIAL LINK <ESC> to EXIT

Figure 4.05-2. View Serial Link Screen Alarm Messages

4.05-1
4.00-10 FORM 6263 Second Edition FORM 6263 Second Edition
AIR/FUEL MODULE SYSTEM DIAGNOSTICS
AFM MODULE LED DISPLAY
Tw LEDs on the front f the AFM module inform site
personnel of system status.
Green LED: The green pwer' LED is lit any time
power is applied to the AFM module
Yellow LED: The yellow Alarm LED is lit any time the
AFM system s diagnostic function is activated r
when AFM execution has been stopped by the user
(such as during the saving of data-set)
Alarm LED indicates that the mdule is
operating correctly or in the warm-up mode
waiting for the exhaust temperatures to increase.
Alarm LED on indicates that the unit is aempting
automatic control, howeverne of the diagnostic
criteria has nt been satisfied. The AFM mod-
ules keypad (except for the <ALARM ACK>
button) will nt functin and the ERROR our
terminal within the AFM will be activated. The
yellow alarm LED will remain lit until either the
alarm condition is acknwledged by pressing the
<ALARM ACK> button on the keypad r the fault
is corrected n the engine.
NOTE: If after an alarm condition has been acknowl-
edged a second arm condition occurs, the keypad will
cease to function again and the second alarm must be
acknowledged.
AFM MODULE LCD DISPLAY
The alpha-numeric LCD display visible from the front of
the AFM module allows the user to mnitor imprtant
system parameters. The LCD display continually shows
the current status of the AFM system. The AFM s LCD
display scrolls through its messages at a rate of about
one eve three secnds. In alarm conditins, specific
problems are displayed.
4.05-2
NOTE: During normal operation, LCD display informa-
tion includes: exhaust temperature, oxygen sensor
OUut, oxygen sensor take manifold pressure,
stepper position, heater output percentage, and stepper
travel limits. Refer to Section 3.02 Keypad and Display
Information for LCD displays shown on e LCD display
durlng normal operation.
Whenever an alarm conditin exists, the LCD display
provides a diagnstic message. A general warning
message also appears on the LCD display showing the
engine bank n which there is a problem and the
stepper position.
For Example:L WARNING! 90 on the LCD display
indicates that the left engine bank is in an alarm
cndition and the stepper position is at 900 steps.
Table 4.05-1 describes the possible diagnostic mes-
sages displayed in an alarm cnditi1.
AUXILIARY ERROR UT' ALARM UTPUT
The Error Out terminal within the AFM module can be
used as a trigger to drive a relay, alarms, and lights.
When the AFM system is operating correctly the Error
Out terminal is a CLOSED device connected internally
to ground. Any system fault will open the alarm circuit
including loss of power, diagnstic warnings, etc. The
Errr Out terminal is OPEN whenever the yellow alarm
LED is lit on the front of the AFM module. The Error Out
terminal is a sinking circuit with a maximum current
rating of 1 amp and a maximum voltage rating of 50 VDC
(n AC vltages are allowed).
NOTE: Refer to Section 2.05 AFM System Electrical
Connectins Wiring of Auxiliary Inputs and Outputs" for
rther Stallation information.
FORM62 Second Edition
Table 4.05-1. AFM System Diagnostics
LCD DISPLAY
this alarm is active. This warning indicates that the sensor has failed ::::~~l~e~~~~~~r~~y~~en.
2SIGNAL LHI
(RICH BURN APPLICATIONS)
2SIGNAL LHI
EAN BURN APPUCATINS)
The 02 TEMP LO/HI alarm is active when the sensor temperature is outside of the programmed limits
2TEMP LHI
(RICH BURN APPLICATINS)
exceeded. 1is value defaults to 1400 F (760 C). Like the low limit, it can be reprogrammed required.
{AT engines: LO = 475 C (887 and HI= 545 C (1013 {VHPNGF: LO = 390 C{734 and
EAN
2TEMP LHI
BURN APPLICATIONS)
RICH/LEAN LIMIT
IMP INPUT LOii
F1 STRT PS REQUIRED
A WARNING
Do not set the stepper mo-
tor(s) to the start position
while the engine is running
above 40 percent of ated
load. Start position is only to
be initiated when the engine
is stopped or running below
40 percent f rated load. Re-
setting the stepper motor(s)
while the engine is running
above 40 percent of rated
load may cause engine shut-
down and/or cause severe
enaine damaae.
FORM 6263 Second Edition
AIR/FUEL MODULE SYSTEM DIAGNOSTICS
DESCRIPTIN
The 02 SIGNAL LO/HI alarms are activated when operating in the catalyst control mode and the oxygen
:
sensor input voltage falls below 0.01 volts or exceeds 1.1 volts. The stepper motors are disabled when
Manipul~ t~ the air/fuel ratio towards best economy or best power c near
voltage which are essentially the peormance limits of the oxyg , g limits
are no longer a good test of system integrity.
NOTE: When operatg the Best Power/Economy mode, these alarms are not used.
The 02 SIGNAL LO/HI alarms are activated when operating in the lean burn control mode and the lean
burn oxygen sensor input voltage falls below 0.5 volts or exceeds 4.5 volts. The stepper motors are
disabled when this alarm is active. This warning indicates that the sensor has failed OR that the wiing is
shorted/open.
{defaults are 350 C (662 and 760 C (1400. The stepper motors are disabled when this alarm is
active. When power is first applied, the AFM system remains in warm-up (waiting) mode until the
thermocouple reaches the programmed low limit. This helps ensure that the data being generated by the
~~i~! n sensor is accurate. If the thermocouple does not reach the low limit within ten minutes, or if it falls
the low limit at any time during AFM system operation, the 02 TEMP LO alarm will be activated.
The 02 TEMP HI alarm is triggered when the maximum safe exhaust temperature for the engine is
The 02 TEMP LO/HI alarm is active when the sensor temperature is outside of the programmed limits
HI= 460 C (860. The stepper motors ae disabled when this alarm is active. When power is first
programmed low limit. This helps ensure that the data bei~it~fnn ~a
accurate. If the thermocouple does not reach the low limit
; :~
applied, the AFM system remains in wamup {waiting) mode until the thermocouple reaches the
by the lean burn oxygen sensor is
utes tor AT engines and
50 minutes tor VHPNGF engines, or if it tails below the low limit at any time during system operation, the
02 TEMP LO alarm will be activated. The 02 TEMP HI alarm is triggered when the maximum safe
exhaust temperature tor the engine is exceeded.
The RICH/LEAN LIMIT alarms are activated when the stepper position reaches either the rich or lean
limits that were programmed. The RICH LIMIT and LEAN LIMIT alarms indicate that the engine may be
too lean or too rich, respectively, for the AFM system to control to the desired point. The AFM system
cannot richen or lean the mixture any her to correct the error. Verify proper engine operation by using
exhaust analyzers. Typically, an oxygen sensor has failed or an adjustment to the carburetor screw is in
order.
The IMP INPUT LO/HI alarm indicates that the AFM systems intake manifold pressure has violated either
the low or high limit respectively. The pressure limits are determined when the engines fuel system
configuration GSI, GL) is chosen during programming. Stepper motor operation is unaffected when
this alarm is active.
The F1 STAT POS REQUIRED alarm is a safety feature of the AFM system that is designed to prevent
unsafe resetting of the stepper motors during programming. This .fety feature prevents stepper limits
from being programmed that are out of range. This message will be displayed whenever stepper limits are
entered that invalidate the current stepper motor position. For example: The stepper motor is at 3000
steps and a new position limit is 2000 steps. With the engine shutdown or running below 40 percent rated
load, set the stepper motors to the Start Position by pressing and releasing <F1 >, then <STAT POS> on
the AFM module keypad. The AFM LCD display will show MOVING L STEPPER TO START POSITION
The left and right Status messages on the View Serial Link Screen will change to MOTOR RESET
during the positioning activity. Once the left bank has been moved, the AFM control will move the ght
bank stepper motor. Allow up to three minutes to this process. After the stepper motors have been moved
to the start position, the normal LCD displays resume.
4.05-3
AIR/FUEL MODULE SYSTEM DIAGNOSTICS APPENDIX A

ALPHABETICAL INDEX
A Values ........................... 3.10 -22
AFM Module Mounting . . . . . . . . . . . . . . . . . . . 2.00 - 2
Air/Fuel Mdule System . . . . . . . . . . . . . . . . . . 1.05 - 1
Best Power cntrol
Mode Programming . . . . . . . . . . . . . . . . 3.1 0 1
Catalyst Control Mde Programming . . . . . 3.05 - 1
Components .................... ... . .. 1.05 1
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . 1 .05 - 5
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 1
Diagnsties . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.05 - 1
Engines Served - .. 1.05-2 Establishing Communication With
Keypad And Display Information ......... 3.02-1
Lean Burn Control Mode Programming . . . 3.15 1
Operator Interface ........... .. . . .. .. .. 1.05 - 3
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 1
Programming Information . . . . . . . . . . . . . . . 3.00 - 1
Thery Of Operatin . 1.05-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 4.00 - 1
Air/Fuel Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Automatic Control . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 4
Auxilia Inputs and Outputs - Wiring . . . . . . 2.05 - 6
Alternate Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 2.05 - 6
Error Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.05 - 6
Remote Start . . . . . . . . . . . . . . . . . . . . . . . . . 2.05 - 6
B Programming Best Power
Best Economy Control Mode . . . . . . . . . . . . . . 1.05 - 6
Definitin ...... . ... . .............. ... . 1.05- 7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 6
LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 2
Programming . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 O - 1
Best Eenmy Control Programming . . . . . . 3.10 - 1
Establishing Communication With
AFM Module ............... ..... . . 3.10-2
Establishing Engine Start Position . . . . . . 3.10 - 12
Fine-Tuning AFM Programming . . . . . . . . 3.10 - 18
Initial AFM Mdule Programming . . . . . . . . 3.10 - 4
Editing Engine Applicatin
Infonation ............ . .. . ..... 3.10- 6
Editing Oset Steps Value . . . . . . . . . . . . 3.10 - 9
Saving Setup File To RAM . . . . . . . . . . . 3.10 - 10
Selecting A ~reprogrammed
Setup File ................. .... .. 3.10- 4
Monitoring Through View Serial
Link Screen ...................... 3.10-15
Post-Programming Check . . . . . . . . . . . . . 3.10 - 29
Check 1: Cnfirming Data-Set Save
T ROM .................... . . . 3.10-29
Check 2: Final Test Of AFM System
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 O - 30
Programming Best Eenomy Control
Retrieving Saved Data-Set From Disk . . 3.10 - 28
Saving Data-Set To Disk . . . . . . . . . . . . . . 3.10 - 27
Saving Data-Set To ROM . . . . . . . . . . . . . 3.10 - 24
User Interface Program Statup ......... 3.10-1
Best Power Control Mde ................ 1.05-6
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 7
Descripti1 ....... . .. . .... .. . . ........ 1.05- 6
LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 2
Programming . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 - 1
Best Power Control Prgramming . . . . . . . . . 3.10 1
AFM Module .................. ... . 3.10-2
Establishing Engine Start Position . . . . . . 3.1 O - 12
Fine-Tuning AFM Programming . . . . . . . . 3.10 - 18
Initial AFM Mdule Programming . . . . . . . . 3.1 O - 4
Editing Engir:ie Application
lnformatin ........... .. ......... 3.10-6
Saving Setup File To RAM . . . . . . . . . . . 3.10 - 1O
Selecting A ~reprogrammed
Setup File .............. .. .... .. . 3.10-4
Monitoring Through View Serial
Link Screen .............. ... . . . .. 3.10-15
Post-Programming Check . . . . . . . . . . . . . 3.10 - 29
Check 1: Confirming Data-Set Save
To ROM ....................... 3.10-29
Check 2: Final Test Of AFM System
Setup ....................... ... 3.10-30
Control Values . . . . . . . . . . . . . . . . . . . . 3.10 - 22
Retrieving Saved Data-Set From Disk . . 3.10 - 28
Saving Data-Set To Disk . . . . . . . . . . . . . . 3.1 O - 27
Saving Data-Set T ROM ............. 3.10-24
User Interface Program Startup Steps . . . . 3.10 - 1
c
Catalyst Control Mode . . . . . . . . . . . . . . . . . . . 1.05 - 5
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 5
LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . 3.02 1
Programming .. . 3.05-1
Catalyst Control Programming . . . . . . . . . . . . 3.05 - 1
Establishing Communication With
AFM Module . . . . . . . . . . . . . . . . . . . . . . 3.05 - 2
Establishing Engine Start Position . . . . . . 3.05 - 11
Fine-Tuning AFM Programming . . . . . . . . 3.05 - 17
Constant O~gen Sensor
Set-Points . . . . . . . . . . . . . . . . . . . . . 3.05 22
Variable Oxygen Sensr Se Points . . . 3.05 17
Initial AFM Module Programming . . . . . . . . 3.05 - 4
E1~1o~i~7it.I.~ 3.05-6

A-1
4.05-4 FORM 6263 Second Edition FORM 6263 Second Edition
APPENDIX A APPENDIX A

Saving Setup File To RAM . . . . . . . . . . . . 3.05 - 9
Selecting A preprogrammed
Setup File . . . . . . . . . . . . . . . . . . . . . . . 3.05 - 4
Monitoring Through View Serial
Link Screen . . . . . . . . . . . . . . . . . . . . . . 3.05 - 14
Post-Programming Check .... ... . .... . 3.05 - 33
Check 1: Confirming Data-Set Save
To ROM . . .. .. . . . .. .. . .. .. .. .. . 3.05 - 33
Check 2: Final Test Of AFM
System Setup .................. 3.05- 34
Programming Catalyst Control Values . . . 3.05 26
Retrieving Saved Data-Set From Disk . . 3.05 - 32
Saving Data-Set To Disk . . . . . . . . . . . . . . 3.05 - 30
Saving Data-Set To ROM . . . . . . . . . . . . . 3.05 - 28
User Interface Program Startup Steps .... 3.05 -1
Clsed-Loop Control . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Combustion Stability Limit . . . . . . . . . . . . . . . . 1.05 - 7
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 1
cmputer Requirements . . . . . . . . . . . . . . . . . 3.00 - 1
Contrl Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -
Best Economy . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -
Best Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .05 -
Catalyst ................... ..... . ..... 1.05 -
Lean Burn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -
Conventions Used In Programming ........ 3.00 - 1
Core EPROM Chip Replacement . . . . . . . . . . 4.00 - 6
D Errr
Data-Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Dead-Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Air/Fuel Ratio . ......... . ........ . ..... 1.05 - 7
Best Ecnomy ........... ....... . ..... 1.05-7
Best Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Catalyst Setting . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Closed-Loop cntrol .................. 1.05 7
Combustion Stability Limit . . . . . . . . . . . . . . 1.05 7
Data-Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Dead-Band . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Delay Time . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
EPROM .. ...... . ....... . .... . ... . . 1.05 7
Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .05 - 7
LCD ....................... ........ . . 1.05-7
Lean AFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
Lean Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
LED ................................. 1.05-8
Map ................................. 1.05-8
0set Steps . ... . ..... . ............. . . 1.05 - 8
PC .. .. . ..... . ..... . ........ . .... . . 1.05-8
psiA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 8
PWM ..... . .. ........................ 1.05-8
RAM . ..... ........................... 1.05-8
Rich AFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 8
A-2
Rich Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .05 - 8
ROM ................................. 1.05-8
Search Delay . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 8
Sinking Circuit . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 8
Start Position . . . . . . . . . . . . . . . . . . . . . . 1.05 - 8
Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05-8
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 8
Stoichiometric AFR . . . . . . . . . . . . . . . . . . . . 1.05 - 9
User Interface Program . . . . . . . . . . . . . . . . 1.05 - 9
Delay Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 7
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.05 1
AFM Module LCD Display . . . . . . . . . . . . . .
AFM Module LED Display . . . . . . . . . . . . . .
4.05 - 2
4.05 2
Auxiliary Error Out Alarm Output . . . . . . . . 4.05 - 2
Display EPROM Chip Replacement . . . . . . . . 4.00 - 9
E Catalyst Control Mode Displays . . . . . . . . .
Electrical cnnections
. . . . . . . . . . . . . . . . . . 2.05 - 1
5 Lean AFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .05 - 7
Auxilia InputsAnd Outputs . . . . . . . . . . . . 2.05 - 6
6 Power Connections . . . . . . . . . . . . . . . . . . . . 2.05 - 1
6 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines Served . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 2
5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 English/Metric Conversions . . . . . . . . . . . . . . . 1.02 - 4
EPROM Definition . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
EPROM Chip Replacement . . . . . . . . . . . . . 4.00 - 6
cre EPROM Chip . . . . . . . . . . . . . . . . . . 4.00 - 6
Display EPROM Chip . .. . .. . . .. . . . .. . . . 4.00 - 9
Out Terminal Wiring . . . . . . . . . . . . . . . . 2.05 6
Establishing Gas/Air Pressure Setting ...... 2.00 - 1
G Variable Oxygen Sensr Set-Points . . . 3.15 - 16
Gain ................................... 1.05 7
Gas/Air Pressure Setting . . . . . . . . . . . . . . . . . 2.00 - 1
H Setup File ............. . . . .. .. .. 3.15-4
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . ix
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 1
AFM Module . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 2
Electrical Connections . . . . . . . . . . . . . . . . . 2.05 - 1
Establishing Gas/Air Pressure Setting . . . . 2.00 - 1
Intake Manifold Pressure Transducer ... 2.00 - 14
K-Type Thermocouple . . . . . . . . . . . . . . . . 2.00 - 13
Lean Burn Oxygen Sensing Assembly . . . 2.00 - 5
Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . 2.10 - 1
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 14
Stoichiometric Oxygen Sensr .......... 2.00-3
FORM 6263 Second Edition
Intake Manifold Pressure Transducer
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 14
K Map .. . ... . .. . . ........................ 1.05-8
Keypad Functions . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 3
Keypad Information .............. ....... . 3.02 -1
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 4
Keypad Functions . . . . . . . . . . . . . . . . . . . . . 3.02 - 3
L Intake Manifold Pressure Transducer . . . 2.00 - 14
LCD - Definition . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 7
LCD Display Information . . . . . . . . . . . . . . . . . 3.02 - 1
Best Econmy Contri Mode Displays . . . . 3.02 2
Best pwer Control Mode Displays . . . . . . 3.02 - 2
3.02 - 1
Lean Burn Control Mode Displays . . . . . . . 3.02 - 2
Lean Burn Control Mode . . . . . . . . . . . . . . . . . 1 .05 7
1.05 7
1.05 - 7
LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 2
Programming . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 - 1
Lean Burn Control Programming . . . . . . . . . . 3.15 - 1
Establishing Communication With The
AFM Module . . . . . . . . . . . . . . . . . . . . . . 3.15 2
Establishing Engine Start Position . . . . . . 3.15 - 10
Fine-Tuning AFM Programming . . . . . . . . 3.15 - 15
Constant Oygen Sensor
Set-Points ................ ... .. 3.15 - 20
Initial AFM Module Programming . . . . . . . . 3.15 - 4
Editing Engir:ie Application
Information ...................... 3.15-6
Saving Setup File To RAM . . . . . . . . . . . . 3.15 - 9
Selecting A preprogrammed
Monitoring Through View Serial
Link Screen ................. ..... 3.15-13
Post-Programming Check . . . . . . . . . . . . . 3.15 - 31
Check 1: Confirming Data-Set
Save To ROM ........ .... ...... 3.15 -31
Check 2: Final Test Of AFM
System Setup . . . . . . . . . . . . . . . . . . 3.15 - 32
Programming Lean Burn
Control Values . . . . . . . . . . . . . . . . . . . 3.15 24
Retrieving Saved Data-Set From Disk . . 3.15 - 30
Saving Data-Set To Disk . . . . . . . . . . . . . . 3.15 - 29
Saving Data-Set To ROM . . . . . . . . . . . . . 3.15 - 26
User Interface Program Startup Steps . . . . 3.15 - 1
Lean Burn Oxygen Sensr ............ . . . 1.05-5
Lean Burn Sensing Assembly Munting . . . . 2.00 - 5
AT Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 8
VGF Engines . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 7
FORM 6263 Second Edition
VHP Engines . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 5
Lean Limit .............. '. . . . . . . . . . . . . . . . 1.05 7
LED Definition . . . . . . . . . . . . . . . . . . . . . . . . . 1 .05 - 8
M
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 4
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 1
AFM Module . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 2
K-Type Thermocouple . . . . . . . . . . . . . . . . 2.00 - 13
Lean Burn Sensing Assembly ........ ... 2.00- 5
AT Engines . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 8
VGF Engines . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 7
VHP Engines . . . . . . . . . . . . . . . . . . . . . . . . 2.00 - 5
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . 2.0 14
Disassembling Regulator . . . . . . . . . . . . 2.00 - 14
Installing To Regulator ... ........... . 2.00 - 16
Verifying Operation . . . . . . . . . . . . . . . . . 2.00 15
Stoichiometric Oxygen Sensor . . . . . . . . . . 2.00 - 3
Offset Steps ......... ...... . . ... ........ 1.05 - 8
Operator Interface ...................... . 1.05 - 3
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 4
Lean Burn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 5
Stoichimetric . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 4
p
PC Definition . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - 8
Power Connections ........ . . .. . .... ..... 2.05 1
Lean Burn Wiring Diagram . . . . . . . . . . . . . . 2.05 - 4
Rich Burn Wiring Diagram . . . . . . . . . . . . . . 2.05 - 2
Power Requirements . . . . . . . . . . . . . . . . . . . . 1 .02 - 7
Prestart Installation Checklist . . . . . . . . . . . . . 2.10 - 1
Best Economy Control Mode . . . . . . . . . . . . 2.10 - 1
Best Power Control Mode . . . . . . . . . . . . . . 2.10 - 1
Catalyst Control Mode . . . . . . . . . . . . . . . . . 2.1 O - 1
Lean Burn Control Mode . . . . . . . . . . . . . . . 2.1 0 2
Programming . . 3.0 1
Best Economy Contrl Mode ............ 3.10-1
Best Power Control Mode . . . . . . . . . . . . . . 3.10 - 1
Catalyst Control Mode . . . . . . . . . . . . . . . . . 3.05 - 1
Lean Burn Contrl Mode ..... ..... ..... 3.15-1
Programming Information . . . . . . . . . . . . . . . . 3.00 - 1
AFM Programming Conventions . . . . . . . . . 3.00 - 1
Operator Interface . . . . . . . . . . . . . . . . . . . . . 3.00 - 1
Recommended Computer Equipment . . . . 3.00 - 1
Saving To RAM And ROM . . . . . . . . . . . . . . 3.00 - 4
A-3
 APPENDIX A
User Interface Program Description . . . . . . 3.00 - 2
User Interface Progr.am Layout . . . . . . . . . . 3.00 - 3
PsiA - Definition . . . . . . . . . . . . . . . . . . . . . . . . 1.05 _ a
PWM - Definition . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - a Start Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -
R Stepper Mtr Mounting . . . . . . . . . . . . . . . . .
RAM - Definition . . . . . . . . . . . . . . . . . . . . . . . . 1.05 - a Disassembling Regulator . . . . . . . . . . . . . .
Remote Start Terminal Wiring . . . . . . . . . . . . . 2.05 - 6
Rich AFR 1.05-8
Rich Limit . 1.05-8
ROM - Definition . . . . . . . . . . . . . . . . . . . . . . . . 1.05 _ a Stoichiometric Oxygen Sensor Mounting . . . 2.00 - 3
s T
Safety lntroductil . .. . ................ 1.01 -1
Acids ....
1.01 -2
Batteries . . 1.01 - 2
Body Prtection . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 2
Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 2
Cleaning Solvents . . . . . . . . . . . . . . . . . . . 1.01 - 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 2
Liquid Nitrgen/Dry Ice . . . . . . . . . . . . . . . 1.01 - 2
Compnents . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 2
Heated Or Frozen ... . ......... . . .... 1.01 - 2
Interference Fit . . . . . . . . . . . . . . . . . . . . . . 1.01 - 2
Cooling System . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 2
Electrical ..
General .
1.01 -3
1.01 -3
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 3
Equipment Repair And Sevice . . . . . . . . . . 1.01 - 1
Exhaust ... 1.01 -3
Fire Protection ............... . ..... . .. 1.01 _ 3
Fuels . 1.01 -3
Gaseous . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 3
Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 3
Intoxicants And Narcotics ............... 1.01 _ 4
Pressurized Fluids/Gas/Air ............. 1.01 _ 4
Protective Guards . . . . . . . . . . . . . . . . . . . . . 1.01 _ 4
Safty Tags And Decals . . . . . . . . . . . . 1.01 - 1
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 4
Tools ..... 1.01 -4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 4
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 4
Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 4
Weig~t . . . . . . . . . . . . . . . . . . . . . . . 1.01 - 5
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 _ 4
General .. 1.01 - 4
On Engine . . ..... . ................ . . 1.01 -5
A-4
Search Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -
Sinking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 -
Step. . ..... .. . . . . ............ . 1.05-8
Stepper Motr ................... .. . .. .. 1.05- 8
2.00 - 14
2.00 - 14
Installing To Regulator . . . . . . . . . . . . . . . . 2.0 16
Verifying Operation . . . . . . . . . . . . . . . . . . . 2.00 - 15
Stoichiometric AFR . . . . . . . . . . . . . . . . . . . . . . 1.05 - g
Stoichiometric Oxygen Sensr .. . ... . ..... 1.05-4
The OfOperatin . . ........ . . . ........ 1.05-3
Best Economy Control Mode . . . . . . . . . . . . 1 .05 - 6
Best Power Control Mode . . . . . . . . . . . . . . 1.05 - 6
Catalyst Control Mode . . . . . . . . . . . . . . . . . 1.05 - 5
Lean Burn Control Mde . . . . ... . ....... 1.05-7
Lean Burn Oxygen Sensor . . . . . . . . . . . . . . 1.05 - s
Stoichiometric Oxygen Sensor . . . . . . . . . 1.05 - 4
Thermocouple Mounting .... . ... ........ 2.00-13
rque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 1
Troubleshoting . . . . . . . . . . . . . . . . . . . . . . . . 4.00 - 1
u The obligations of Waukesha under this express limited warranty shall be waived and void and Waukesha shall not, thereafter, be responsible for:
User Interface Program . . . . . . . . . . . . . . . . . . 1.05 _ g
Best Economy Control
Mode Programming . . . . . . . . . . . . . . . . 3.10 - 1
Best Power cntrol
Mode Programming . . . . . . . . . . . . . . . . 3.10 - 1
Catalrst Control Mode Programming ..... 3.05-1
Denition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 _ g
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 - 2
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 _ 3
Lean Burn Control Mode Programming . . . 3.15 1
w VI. APPLICABILITY AND
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.05 _ 1
Lean Burn Wiring Diagram . . . . . . . . . . . . . . 2.05 - 4
Rich Burn Wiring Diagram . . . . . . . . . . . . . . 2.05 - 2
Wiring Requirements . . . . . . . . . . . . . . . . . . . . 1.02 - 6
FORM 6263 Second Edition
WAUKESHA ENGINE DIVISION - DRESSER INDUSTRIES, INC.
EXPRESS LIMITED WARRANTY FR CUSTOM ENGINE cNTRL
a INTRODUCTIN
a Custom Engine Control((CEC) are sold as standardr as options on new Engines or as Genuine Waukesha Service Parts, and include the Detonation Sensing Module
(DSM), Air Fuel Module (AFM), Turbocharger Control Management System CMS). and Ignition Module (IM), or any other control device identified as a CEC product.
a I. TERMS F EXPRESS LIMITED WARRANTY
WaukhaEngivision warrants that it will repair or eplace, AT ITS ELECTION AND EXPENSE, any CEC install onanerine, or Enginator product (hereina
ferr to as Products) manuctured by Waukesha, or purchased as a Genuine Service Part, which proves to have had a dect in material or workmanship.
UMITATINS OF EXPRESS LIMITED WARRANTY
II. TERM
A. This coverage shall commence upon initial new Products start-update or the purchase date, in the case of service parts sales, and shall expire upon the earlier
of the followi
1. New Products
A. 12 months after the initial new Products start-up date; or
B. 24 months after the original shipment date of the covered Products by Waukesha Engine Division.
2. Genuine Service Parts
A. 12 months from the date the CEC is put into service; or
B. 18 months from the purchase date.
B. Notwithstanding the foregoing, Waukesha further warrants that it will repair or eplace, AT ITS ELECTION AND EXPENSE, any component of t!:l
EQJ.1l.1 damaged as the direct result of a warrantable defect in a CEC product.
Ill. WAUKESHA S RESPNSIBILIES UNDER THE EXPRESS LIMITED WARRANTY
'
Waukesha shall be responsible for:
A. The repair or replacement, at Waikesha's election, of covered defective parts and all resonable labor required regarding a warranted failure during the express
limited warranty term. All such labor shall be povided by Waukess authorized cntractor or distributor.
B. For the repair of CECs installed on Products shipped from Waukes resonable and necessary travel and expenses incurred by Waukeshas authorized
contractor or distributor.
C. Replacement of lubricating oil, coolant, filter elements, Waukesha supplied engine components, or other normal maintenance items that are contaminated
and/or damaged as a direct result of a warranted failure.
1WNERS RESPNSIBILmES UNDER THE EXPRESS LIMITED WARRANTY
Owner shall be responsible for:
A. The operation and maintenance of the Products within the guidelines established by Waukesha.
B. Making the Products available to Waukesha or Waukeshas authorized contractors or distributors for any warranty repair, during normal business hours.
C. All additional costs incurred for premium or ovetime labor, should owner request that repairs be made on a premium or overtime schedule.
. All costs incurred the result of removal or reinstallation of the Products as may be ruired to effect any warranted repair.
E. All administrative csts and expenses resulting from a waanted failure.
F. Any costs of transportation, towing, repair facilitiesr assated costs.
G. l travel, mileage, and other related Distributor costs and expenses associated with repair under the terms of the Service Parts Warranty.
H. All additional labor me in excess of WaukesS Labor Guide for the warrantable repair.
I. Loss of revenue and loss of/or damage to real and/or personal property.
V. LIMITATION F WAUKESHA S OBLIGATIONS
A. Any failure resulting from owner or operator abuse or neglect, including but not by way of limitation, any operation, installation, application, or maintenance
practice not in accordance with guidelines or specifications establiShed by Waukesha; or
B. Any failure esulting from unauthorized modifications or repairs of the Products; or
C. Any failure resulting frm overloadverspeed, overheat, accident, improper storage; or
D. Failure of owner to promptly provide notice of a claimed defect; or
E. Failure of Products for which Waukesha did not receive properly completed start-up reports; or
F. Repairs of a covered failure permed with non-genuine Waukesha parts; or
G. Repairs of a covered failure performed by non-authorized contractors or distributors; or
H. Failure to make Products available to Waukesha or its authorized representativesr
I. Failure to supply documents such as drawings and specifications relating to the specific application of the Products; or
J. Improper diagnosis of a Product problem for which a CEC product iS replaces.
K. FailureofSevice Parts for which Waukesha did not receive proper documentation concerning the Service Parts purchase date from an Authorized Waukesha
Engine Distributor; or
l. Any failure of a Service Part resulting from misapplication or improper repair procedures; or
M. Any failure or damage resulting from the improper or extended strage of a Service Part; or
N. Freight, Gustms, Broker Fees, and Import Duties appropriate documentation is not provided.
EXPIRATIN
The warranties set out above are extended to all owners in the original chain of distribn The warranties and obligations of Waukesha shall expire and be of no
further effect upon the dates f expiration of the applicable warranty periods.
VII. WARRANTY ADMINISmATIN
This warranty is administered exclusively by an Authorized Waukha Distributor. The invoice for the failed Service Part must be provided to the Distributor to
determine whether the warranty is applicable. Contact the nearest Authorized Waukesha Distributorfor assistance with warranty matters or questions. The location
of the nearest Authorized Distributor iS av.;iilable by contacting Waukesha Engine Division at (414) 547-3311.
THE FOREGOING SETS FRTH WAUKESH <SONLY OBLIGATIONS AND WNERS EXCLUSIVE REMEDY FOR BREACH FWARRANTY, WHETHER SUCH
CLAIMS ARE BASED ON BREACH F CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABIL'Y), OR OTHER THEORIES, AND THE
FREGOING IS EXPRESSLY IN LIEU OF THER WARRANTIES WHATSEVER EXPRESSED, IMPLIED, AND STATUTORY, INCLUDING WITHOUT
LIMITATION, THE IMPLIED WARRANTIES F MERCHANTABILITY AND FNESS.
Notwithstanding the preceding, In no event shall Waukesha be liable for any direct, special, incident orensequential damages (whether denominated In
contract, to strict liability, negligencer other theories) arising out of this Agreement or the use of any Products provided under this Ageement.
Any action arising hereunder orrelating hereto, whether based on breach of contract, tort (including negligence and strict liability), or other theriesmustbe
commenced within tw years after the cause of action accrues or it sha l be barred.
All disputes and claims betwnthepaies which may arise out of or in connection with this Contract shall be settled by good faith negotiation betwn an
executive level representative of each party. If the parties are n1etheless unable to reach agreement, such dispute shall be resolved by SIl!1iQQ.
The arbitration shall be administered by the American ArbitratioI Association according to its rules of Cmmercial Arbitratinthen in force. The arbitration
shall take place in Milwaukee, Wisconsin, before one arbitrator. The language to be used In the arbitratin shall be English. The law of Texas shall govern.
Judgment upon the award of the arbitrators may be entered in any court of competent jurisdiction.
M-763 Effective March 1, 1995
W-4
 CATA LYST CONTROL WORKSHEET (G ENGINES)
The Catalyst Control wrksheet (G applicatins) is to be used to assist yu when programming the AFM module in
Catalyst Control Mode nly. Detach or copy this worksheet when use of the worksheet is required for AFM mdule
programming.
NOTE: This side of the worksheet applies to G engines. map-points are different for G and GS/ enges. Make
sure you use the side of the worksheet that applies to your engine application.

Catalyst Control Worksheet For G Engine Applications

CURRENT
MAP-POINT si~~~s~~ STEPPER LEAN LIMIT RICH LIMIT
(volts) pSITION
INTAKE MANIFOLD
PRESSURE (psiA) LEFT RIGHT LEFT RIGHT LEFT RIGHT
LEFT RIGHT

2.5

4.5

6.5

8.5

10.5

12.5

14.5

LEFT RIGHT
LEFT RIGHT STEPPER START
RIGINALG/A pSITIN
SEmNG

4 1.0

OXYGEN SENSOR RESPONSE VS.

0.9 EXHAUST GAS CONCENTRATIONS
FOR VARIOUS AIR/FUEL RATIOS
0.8
3

0.7 :iB BEST POWER A/F = 15.50

CATALYST SET-POINT A/F = 15.95YPICAL)
~
STOICHIOMETRIC A/F = 16.09

Q
.J
\0.6

I
BEST ECONOMY A/F = 17.00

hh
(:)

H
.
i I "'

MHS3

~m:1
4
tHu
1
ii NOTE. 1e ogen, carbon monoxide, and oxygen
0.1 sensor signal curves were plotted for laboratory data.
u Actual sensor response and desired ai1uel ratio will
depend slightly on d composition; however, e
? 16 7 18 19 20 21
0
relationsh between CO and 02 will remain constant.
LEAN
AIR/FUEL RATIO
--

Form 63 Second Edition

 CATALYST CONTROL WRKSHEET (GSI ENGINES) BEST POWER/ECNONI CNTROL WORKSHE~ & GSI ENGINE~
The Catalyst Cntrl Worksheet (GSI applications) is to be used to assist yu when programming the AFM module in The Best pwer/Economy cntrol wrksheet is to be used t assist yu when programming the AFM mdule in Best
Catalyst cntrol Mode only. Detach r cPY this wrksheet when use of the worksheet is required for AFM module Power/Economy Control Mode only. Detach r copy this wrksheet when use of the worksheet is required for AFM
programming. module programming.
NOTE. 1is side of therksheet applies to GS/ engines. The map-pots are dierent for G and GS/ engines. Make
Best Power/Etnmy cntrol wrksheet
sure you use the side of the worksheet that applies to your enge application.
STEPPER
STEPPER pSITINAT RICHUMIT
Catalyst cntrol Worksheet For GSI Engine Applicatins pSITIN AT LEAN LIMIT
SENSR SET-PINT DESIRED RUNNING
STOICHIOMETRY pINT
MAP-PINT s~s CURRENT
STEPPER LEAN LIMIT RICHUMIT
(CIRCLEON1
LEFT RIGH LEFT RIGHT LEFT RIGHT
LEFT RIGHT
(volts) POSIT!N
INTAKE MANIFOLD
PRESSURE (psiA) LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
0.4vBESTECNOMY II

5.0 0.6vBEST PWER

8.5 LEFT RIGHT
LEFT RIGHT STEPPER START
RIGINALG/A POSIT!N
12.0 SETI"ING

15.5 LEFT RIGHT

STEPPER POSITION
19.0
AT DESIRED RUNNING POINT
22.5

26.0
STEPPER POSITION
AT STOICHIOMETRY - -
RIGINALG/A
LEFT RIGHT STEPPER START LEFT RIGHT FFSETSTEPS
SETTING pSITIN

4 4 1.0

WNSE
, SIGNAL OXYGEN SENSOR RESPONSE VS.
OXYGEN SENSOR RESPONSE VS.
0.9 EXHAUST GAS CONCENTRATIONS

EXHAUST GAS CONCENTRATIONS
FOR VARIOUS AIR/FUEL RATIOS

FOR VARIOUS AIR/FUEL RATIOS
0.8
3f 3

lTl
H
IU ! BEST POWER NF = 15.50
IU
BEST POWER NF = 15.50
CATALYST SET-POINT NF = 15.95 YPICAL)

l\l ~J
(j
CATALYST SET-POINT NF= 15.95YPICAL)
15
~
U
! ! SOICHIOMERIC NF = 16.09
ct
IU
a. '
STOICHIOMETRIC NF = 16.09
BEST ECONOMY NF = 17.00
2 2t

M:I
BEST ECONOMY NF = 17.00
..J

> i\
>-
IX:
Q
>.
a:
Cl

1
.38 i

.1
NOTE: The oxygen, carbon monoxide, and oxygen
sensor signal curves were plod for laboratory da
r~i~iE: NOTE: The oyen, carbon monoxide, and oxygen
sensor sinn';ives wereploedfor boratoryda
Actual s nsor response and de?,[red air/fuel ratio will

14 0
Actual sensor response and desired air,'uel ratio will
depend slightly on el compos.on; however, the
18 19
~~~ihiri~:n~%J~0;h1~~tant.
15 16 17 18 19 20 21 16 17
relation sh between CO and 02 will remain constant.
RICH AIR/IJELRAo
EAN AIR/FUEL RATIO

FORM 62 Second Edition Form 62 Second Edition

 LEAN BURN CONTRL WR KSHEET (VHP & VGF ENGINES)
The Lean Burn Control Worksheet (VHP & VGF engines) is to be used to assist yu when programming the AFM
module in Lean Burn Contrl Mde only. Detach r copy this worksheet when use of the worksheet is required for AFM
module programming.
NOTE: This side of the worksheet applies to VHP & VGF engines. The map-points are different for AT enges.Make
sure you use the side of the worksheet that applies to your engine application.

Lean Burn cntrol Worksheet For VHP & VGF Engines

CURRENT
MAP-POINT ~E~~51N~ STEPPER LEANUMIT RICHUMIT
(Vis) POSITION
INTAKE MANIFOLD
PRESSURE (psiA) LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT

10.0

13.0

16.0

19.0

22.0

25.0

28.0

RIGHT LEFT RIGHT

LEFT STEPPER START
RIGINALG/A
POSlN
SETTING

OXYGEN SENSOR RESPONSE VS.

i t EXHAUST GAS CONCENTRATIONS

i SET-PINT
TYPICAL SET-PINTS:
VHP" at 28:1 (9.
VGF at 24.5:1.8% v

RICH LEAN
.-- .-,..
EXHAUST OXYGEN (ORY VOLUME PERCENT)

.
FRM 6263 Second Edition Form 6263 Second Edition
 LEAN BURN c NTROL WORKSHEET (AT ENGINES) Waukesha Engine Division
The Lean Burn cntrol Worksheet (AT engines) is to be used to assist you when programming the AFM module in [wau ~ Welc mes Your c mments
Lean Burn Control Mode only. Detach r cpythis wrksheet when use of the worksheet is required for AFM mdule
programming.
NOTE: This side of the worksheet applies to AT engines on. The map-pots are di:erent for VHP and VGF In order to continue bringing you the BEST in Waukesha product information, we
eng.es. Make sure you use the side of the worksheet that applies to your eng.e application. ask that you take a moment to let us know about any errors or omissions in this
publication. Comments and suggestions are also welcome. Please use one of the
self-addressed, postage paid cards attached below.
Lean Burn cntrol Worksheet For AT Engines
Thank you for your comments!
CURRENT
MAP-PINT si~~g1N~ STEPPER LEAN LIMIT RICH LIMIT
INTAKE MANIFOLD (volts) pSITIN
Technical Communications Department
PRESSURE (psiA) LEFT LEFT LEFT LEFT M-991

10.0
15.0 I Waukesha E WAUKESHA ENGINE DIVISION
COMMENT CARD
20.0
PUBLICATION NAME
25.0 PUBLICATION NUMBER ISSUE DATE

30.0 HOW WOULD YOU RATE THIS PUBLICATION?

EXCELLENT VERY GOOD GOOD FAIR POOR

z42OZHKm30
35.0
COMMENTS
40.0

ORIGINAL G/A
SETTING
LEFT STEPPER START
pSITIN
LEFT

. NAME
COMPANY
PHONE (
FAX (
ADDRESS
Ill

hq

OXYGEN SENSOR RESPONSE VS. CITY STATE ZIP

4
h

EXHAUST GAS CONCENTRATIONS

MG

ez
E2

mgoz

lllili
hHMWShkq

2.SOV
( Waua E2
LJ_J TYPICAL SET-PIN'S: WAUKESHA ENGINE DIVISION
L COMMENT CARD
AT" at 1 (11.
Ar at 28:1 (9.8% 2)

PUBLICATION NAME

-- --
SET-PINT
RICH LEAN PUBLICATION NUMBER ISSUE DATE
EXHAUST OXYGEN (DRY VOLUME PERCENT) HOW WOULD YOU RATE THIS PUBLICATION?
EXCELLENT VERY GOOD GOOD FAIR POOR

COMMENTS
--

llls PHONE (
NAME
COMPANY FAX (
ADDRESS
FORM 6263 Second Edition CITY STATE ZIP
 .. CUSTOM ENGINE CONTROL

AIR/FUEL MODULE
USER INTERFACE PROGRAM
NOPSTAGE
NECESSARY
IF MAILED
INTHE
UNITED STATES

BUSIN ESS REPLY MAIL

FIRST CLASS PERMIT NO. 903 WAUKESHA WI

pSTAGE WILL BE PAID BY ADDRESSEE

Technical cmmunicatins Department

Waukesha Engine Divisin
Dresser Industries, Inc.
1000 W. St. Paul Avenue
Waukesha, Wiscnsin 53188-4951
.
1,1,111,ll, ,.. lll .. l, I 1.1.1 1.1 ... 1.1 .... 11 ... 111

NO POSTAGE
NECESSARY
IF MAILED
INTHE
UNITED STATES

BUSINESS REPLY MAIL

Technical cnmunications Department

Waukesha Engine Divisin
Dresser Industries, Inc.
1000 W. St. Paul Avenue
Waukesha, Wiscnsin 53188-4951
I Waukesha E

1.1.1 11 111 .. 1.1 1.1.1 .. 1.1 1.1 .... 11 111