0207117 OWNER'S MANUAL EVINRUDE
2402E
OWNER
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Number on catalog scheme: 20711
Compatible models:
2402E
EVINRUDE
BRP EVINRUDE entire parts catalog list:
Information:
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction includes the initial start-up procedures for G3500 engines. The correct initial start-up of the engine is essential for the following reasons:
Engine service life
Fuel economy
Acceptable emissionsService technicians should have a thorough understanding of the relationship between the fuel system and the ignition system. The technician must also be familiar with the literature that is listed in the ""References"" section.References
Engine Service Manual, SENR6415
Industrial Engine Performance, LEBQ6117
Engine Performance, LEBQ6169
Systems Operation Testing and Adjusting, SENR6412
Troubleshooting, SENR6413
Specifications, SENR6417 and Specifications, SENR6411
Operation and Maintenance, SEBU6711 and Operation and Maintenance, SEBU7551
Table 1
Tools Needed
Part Number Description
7X-1400 Electronic Tool Gp (1)
NEXG4511 Service Program Module For Gas Engines (1)
140-2304 Governor Electronic Control Programmer
(2)
8T-0452 Manometer Gauge
156-1060 Emissions Analyzer Gp
1P-2385 Protractor
237-5130 Digital Multimeter Gp
( 1 ) Refer to Using the DDT NEXG4511 Industrial Application Function Service Program Module, SEHS8806 for more information on using the digital diagnostic tool. Also refer to Service Program Module For Spark Ignited Engines, NEXG4511. You must have the chip in order for the 7X-1400 Electronic Tool Group to work.
( 2 ) This is for engines that are equipped with 701A Woodward governors.Required Information
Ignition Timing
A complete fuel analysis must be conducted prior to putting the engine into service. Obtain a fuel analysis in order to determine the energy content and calculate the methane number. The methane number indicates the ability of the fuel to be ignited. The methane number is determined when you input the data from the fuel analysis into the Methane Number Program, LEKQ6378. Use the methane number and the Engine Performance, "Fuel Usage Guide" in order to determine the ignition timing.Obtain several samples of fuel if the quality is expected to change. If the methane number will vary during engine operation, use the lowest expected value in order to determine ignition timing.Maximum Load
Refer to the Engine Performance, LEBQ6169 in order to determine the engine power level for the altitude, the temperature and the methane number. Use the information in the Engine Performance, LEBQ6169 in order to determine the maximum engine load. The desired engine load must not exceed the maximum engine load.Inlet Manifold Pressure at Full Load
For generator set applications, use the generator power output to determine the engine load. For other applications, use the inlet manifold pressure to estimate the engine load. The inlet manifold pressure may be used if the engine timing and the exhaust oxygen are set properly. The Engine Performance, LEBQ6169 provides inlet manifold pressures for specific setting for timing and emissions. This information may be used to estimate the output power of the engine. If the engine power is derated, interpolate the desired inlet manifold pressure between the 100 percent and the 75 percent load ratings.Exhaust Oxygen Level
The 156-1060 Emissions Analyzer or another emissions analyzer is required in order to properly set up a gas engine. The Engine Performance, LEBQ6169 gives the levels of oxygen for engine loads of 50 percent, for 75 percent, and for 100 percent. Set up the engine in accordance with the Engine Performance, LEBQ6169 at the desired full load with the data that was taken at 100 percent load. Do not exceed the maximum load.Carburetor Adjustments
The carburetor and the gas pressure regulator require adjustment when the engine is installed. The initial factory settings are based on the following conditions:
An ambient temperature of 25 °C (77 °F)
A barometric pressure of 100 kPa (29.92 in Hg)
The use of a natural gas pipeline with a Low Heating Value of 33.74 kJ/L (905 BTU/cu ft)The factory ratings comply with SAE J1349 Standards. An engine with a low pressure fuel system that does not use natural gas may be shipped with optional orifices and valves. The optional orifices and the valves should be ordered with the engine. Contact your Caterpillar dealer for more information.Gas Pressure Regulator
The gas pressure regulator requires adjustment when the engine is installed. Use only Caterpillar approved regulators in order to avoid problems with performance. A balance line for the regulator is required in all gas engines. This line compensates for changes in boost pressure or in air filter restriction. Refer to the Systems Operation Testing and Adjusting, SENR6412 for details.Note: The supply line to the gas pressure regulator must be of adequate diameter in order to provide constant pressure to the regulator from idle to full load. Do not use supply lines that are smaller than the inlet to the pressure regulator.Connect Gauges and Instruments
Caterpillar Electronic Service Tools are designed to help the service technician perform the following procedures:
Obtain data.
Diagnose problems.
Read parameters.
Program parameters.
Calibrate sensors.The tools that are listed in Table 2 are required in order to enable a service technician to perform the procedures.
Table 2
Service Tools
Pt. No. Description Functions
8T-8726 Adapter Cable As This breakout harness is for use between the jacks and the plugs of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch connectors and from AMP connectors.
1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.
6V-7070 Digital Multimeter The multimeter is used for the testing and the adjusting of electronic circuits.
7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage in wiring harnesses without disconnecting the harnesses. There are two electronic service tools that can be used on the engine. The tools are the Caterpillar Electronic Technician (ET) and th
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction includes the initial start-up procedures for G3500 engines. The correct initial start-up of the engine is essential for the following reasons:
Engine service life
Fuel economy
Acceptable emissionsService technicians should have a thorough understanding of the relationship between the fuel system and the ignition system. The technician must also be familiar with the literature that is listed in the ""References"" section.References
Engine Service Manual, SENR6415
Industrial Engine Performance, LEBQ6117
Engine Performance, LEBQ6169
Systems Operation Testing and Adjusting, SENR6412
Troubleshooting, SENR6413
Specifications, SENR6417 and Specifications, SENR6411
Operation and Maintenance, SEBU6711 and Operation and Maintenance, SEBU7551
Table 1
Tools Needed
Part Number Description
7X-1400 Electronic Tool Gp (1)
NEXG4511 Service Program Module For Gas Engines (1)
140-2304 Governor Electronic Control Programmer
(2)
8T-0452 Manometer Gauge
156-1060 Emissions Analyzer Gp
1P-2385 Protractor
237-5130 Digital Multimeter Gp
( 1 ) Refer to Using the DDT NEXG4511 Industrial Application Function Service Program Module, SEHS8806 for more information on using the digital diagnostic tool. Also refer to Service Program Module For Spark Ignited Engines, NEXG4511. You must have the chip in order for the 7X-1400 Electronic Tool Group to work.
( 2 ) This is for engines that are equipped with 701A Woodward governors.Required Information
Ignition Timing
A complete fuel analysis must be conducted prior to putting the engine into service. Obtain a fuel analysis in order to determine the energy content and calculate the methane number. The methane number indicates the ability of the fuel to be ignited. The methane number is determined when you input the data from the fuel analysis into the Methane Number Program, LEKQ6378. Use the methane number and the Engine Performance, "Fuel Usage Guide" in order to determine the ignition timing.Obtain several samples of fuel if the quality is expected to change. If the methane number will vary during engine operation, use the lowest expected value in order to determine ignition timing.Maximum Load
Refer to the Engine Performance, LEBQ6169 in order to determine the engine power level for the altitude, the temperature and the methane number. Use the information in the Engine Performance, LEBQ6169 in order to determine the maximum engine load. The desired engine load must not exceed the maximum engine load.Inlet Manifold Pressure at Full Load
For generator set applications, use the generator power output to determine the engine load. For other applications, use the inlet manifold pressure to estimate the engine load. The inlet manifold pressure may be used if the engine timing and the exhaust oxygen are set properly. The Engine Performance, LEBQ6169 provides inlet manifold pressures for specific setting for timing and emissions. This information may be used to estimate the output power of the engine. If the engine power is derated, interpolate the desired inlet manifold pressure between the 100 percent and the 75 percent load ratings.Exhaust Oxygen Level
The 156-1060 Emissions Analyzer or another emissions analyzer is required in order to properly set up a gas engine. The Engine Performance, LEBQ6169 gives the levels of oxygen for engine loads of 50 percent, for 75 percent, and for 100 percent. Set up the engine in accordance with the Engine Performance, LEBQ6169 at the desired full load with the data that was taken at 100 percent load. Do not exceed the maximum load.Carburetor Adjustments
The carburetor and the gas pressure regulator require adjustment when the engine is installed. The initial factory settings are based on the following conditions:
An ambient temperature of 25 °C (77 °F)
A barometric pressure of 100 kPa (29.92 in Hg)
The use of a natural gas pipeline with a Low Heating Value of 33.74 kJ/L (905 BTU/cu ft)The factory ratings comply with SAE J1349 Standards. An engine with a low pressure fuel system that does not use natural gas may be shipped with optional orifices and valves. The optional orifices and the valves should be ordered with the engine. Contact your Caterpillar dealer for more information.Gas Pressure Regulator
The gas pressure regulator requires adjustment when the engine is installed. Use only Caterpillar approved regulators in order to avoid problems with performance. A balance line for the regulator is required in all gas engines. This line compensates for changes in boost pressure or in air filter restriction. Refer to the Systems Operation Testing and Adjusting, SENR6412 for details.Note: The supply line to the gas pressure regulator must be of adequate diameter in order to provide constant pressure to the regulator from idle to full load. Do not use supply lines that are smaller than the inlet to the pressure regulator.Connect Gauges and Instruments
Caterpillar Electronic Service Tools are designed to help the service technician perform the following procedures:
Obtain data.
Diagnose problems.
Read parameters.
Program parameters.
Calibrate sensors.The tools that are listed in Table 2 are required in order to enable a service technician to perform the procedures.
Table 2
Service Tools
Pt. No. Description Functions
8T-8726 Adapter Cable As This breakout harness is for use between the jacks and the plugs of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch connectors and from AMP connectors.
1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.
6V-7070 Digital Multimeter The multimeter is used for the testing and the adjusting of electronic circuits.
7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage in wiring harnesses without disconnecting the harnesses. There are two electronic service tools that can be used on the engine. The tools are the Caterpillar Electronic Technician (ET) and th