0211139 OWNERS'S MANUAL Ev. EVINRUDE
E155WTLZ
OWNERS
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E155WTLZ
EVINRUDE
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Information:
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction provides the following information for G3516C. Engine:
Requirements for the electrical system
Proper grounding practices
Proper welding practices
Required service tools
Electrical components and electronic components
Wiring connections and the corresponding functions that are available to the customer
Initial start-up procedure
Governor adjustment proceduresReference: Information from the following sources will be needed for this Special Instruction:
Data from a complete fuel analysis that is entered into the Caterpillar® Gas Engine Rating Pro (GERP) software program.
The engine performance Data Sheet from the engine Technical Marketing Information (TMI)
Operation and Maintenance Manual, SEBU7681
Systems Operation/Testing and Adjusting, KENR6834, "G3516C and G3516E Engines"
Troubleshooting, RENR5944, "G3516C and G3516E Engines"
Schematic, M0108531, "G3516C Genset Engine Electrical System"
Schematic, UENR3961, "High Voltage - Generator Off Package with EMCP 4.3 Controller Electrical System"Requirements for the Electrical System
All the wiring must conform to all the codes that are applicable to the site. When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through metal conduit. A liquid tight conduit is recommended. Use proper support and alignment to avoid strain on the conduit.Electrical power must be supplied to the junction box that serves as the main distribution panel for the engine control system. The engine control system requires a clean 24 VDC power supply capable of supplying 30 A of continuous power.The maximum allowable ripple voltage is 150 mV AC peak to peak. For the wiring, the maximum allowable voltage drop is 1 VDC from the power supply to an Electronic Control Module (ECM) or to an actuator.The power supply for the engine control system must be separate from the power supply for the starting motor.Grounding Practices
Proper grounding is necessary for optimum engine performance and for reliability. Improper grounding will result in electrical current paths that are uncontrolled and unreliable.Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications.
For the starting motor, do not attach the battery negative terminal to the cylinder block.
Use an electrical ground strap to connect all metal cases that contain electrical components or electronic components to the cylinder block.
Do not connect the negative terminal from the electrical power supply directly to the cylinder block. Connect the negative terminal from the electrical power supply to the negative terminal "−" on the engine-mounted junction box.
Ground the cylinder block with a ground strap that is furnished by the customer. Connect this ground strap to the ground plane.
Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane.
Rubber couplings may connect the steel piping of the cooling system and the radiator. The rubber isolates the piping and the radiator. Ensure that the piping and the radiator are continuously grounded to the cylinder block. Use ground straps that bypass the rubber couplings.
Ensure that all grounds are secure and free of corrosion.Welding on Electronically Controlled Engines
Proper welding procedures are necessary to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass, fuel metering valve, and sensors.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the welder ground cable directly to the engine component that will be welded. Place the clamp as close as possible to the weld to reduce the possibility of welding current damage to the engine bearings, to the electrical components and to other engine components.
Use standard welding procedures to weld the materials together.Service Tools
Refer to Troubleshooting , "Electronic Service Tools" for information.Connecting Cat ET to the Engine ECM
Note: The 538-5051 is the latest version of the Communication Adapter Group. Older service tool versions can still be used.Follow the instructions for the communication adapter. Use the following procedure to connect Cat ET and the communication adapter to a PC.
Remove the electrical power from the ECM.
Illustration 1 g02051513
(1) PC
(2) 353-5083 Cable As (USB)
(3) 478-0235 Communication Adapter (3)
(4) 457-6114 Cable As (DATA LINK)
Connect cables (2) and (4) to communication adapter (3).Note: The communication adapter will power up when the adapter is connected to a PC or to an ECM that is powered up.
Connect cable (2) to the USB port of the PC.
Connect cable (4) to a service tool connector.
Restore electrical power to the ECM. Verify that the "POWER" indicator on the communication adapter is illuminated. Make sure that the PC is powered up.
Establish communication between Cat ET and the ECM. If Cat ET indicates that there is more than one ECM, select the engine ECM.
If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".Refer to Troubleshooting, "Electronic Service Tool Does Not Communicate" if any of the following conditions exist:
Cat ET displays a message that refers to a communication problem.
Cat ET displays "Error #142 The interface hardware is not responding".
Cat ET displays a message that indicates that the firmware in the communications adapter is old.Terminal Box / ECM Box
Note: The terminal box is designed to remain mounted on the engine. The mounting hardware includes isolators. Do not move the terminal box to a remote location. Moving the terminal box could result in wiring problems and in reduction of the service life of the components inside the terminal box.
Illustration 2 g01298930
Typical terminal box
The terminal box contains the electronic control modules. Connectors on the terminal box connect the engine wiring harnesses to components inside the terminal box. The ignition harnesses are routed directly from each ECM to the ignition transformers.
Illustration 3 g06446165
(1) Terminal box / ECM box
(2) Engine ECM
(3) J2 connector
(4)
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction provides the following information for G3516C. Engine:
Requirements for the electrical system
Proper grounding practices
Proper welding practices
Required service tools
Electrical components and electronic components
Wiring connections and the corresponding functions that are available to the customer
Initial start-up procedure
Governor adjustment proceduresReference: Information from the following sources will be needed for this Special Instruction:
Data from a complete fuel analysis that is entered into the Caterpillar® Gas Engine Rating Pro (GERP) software program.
The engine performance Data Sheet from the engine Technical Marketing Information (TMI)
Operation and Maintenance Manual, SEBU7681
Systems Operation/Testing and Adjusting, KENR6834, "G3516C and G3516E Engines"
Troubleshooting, RENR5944, "G3516C and G3516E Engines"
Schematic, M0108531, "G3516C Genset Engine Electrical System"
Schematic, UENR3961, "High Voltage - Generator Off Package with EMCP 4.3 Controller Electrical System"Requirements for the Electrical System
All the wiring must conform to all the codes that are applicable to the site. When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through metal conduit. A liquid tight conduit is recommended. Use proper support and alignment to avoid strain on the conduit.Electrical power must be supplied to the junction box that serves as the main distribution panel for the engine control system. The engine control system requires a clean 24 VDC power supply capable of supplying 30 A of continuous power.The maximum allowable ripple voltage is 150 mV AC peak to peak. For the wiring, the maximum allowable voltage drop is 1 VDC from the power supply to an Electronic Control Module (ECM) or to an actuator.The power supply for the engine control system must be separate from the power supply for the starting motor.Grounding Practices
Proper grounding is necessary for optimum engine performance and for reliability. Improper grounding will result in electrical current paths that are uncontrolled and unreliable.Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications.
For the starting motor, do not attach the battery negative terminal to the cylinder block.
Use an electrical ground strap to connect all metal cases that contain electrical components or electronic components to the cylinder block.
Do not connect the negative terminal from the electrical power supply directly to the cylinder block. Connect the negative terminal from the electrical power supply to the negative terminal "−" on the engine-mounted junction box.
Ground the cylinder block with a ground strap that is furnished by the customer. Connect this ground strap to the ground plane.
Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane.
Rubber couplings may connect the steel piping of the cooling system and the radiator. The rubber isolates the piping and the radiator. Ensure that the piping and the radiator are continuously grounded to the cylinder block. Use ground straps that bypass the rubber couplings.
Ensure that all grounds are secure and free of corrosion.Welding on Electronically Controlled Engines
Proper welding procedures are necessary to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass, fuel metering valve, and sensors.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the welder ground cable directly to the engine component that will be welded. Place the clamp as close as possible to the weld to reduce the possibility of welding current damage to the engine bearings, to the electrical components and to other engine components.
Use standard welding procedures to weld the materials together.Service Tools
Refer to Troubleshooting , "Electronic Service Tools" for information.Connecting Cat ET to the Engine ECM
Note: The 538-5051 is the latest version of the Communication Adapter Group. Older service tool versions can still be used.Follow the instructions for the communication adapter. Use the following procedure to connect Cat ET and the communication adapter to a PC.
Remove the electrical power from the ECM.
Illustration 1 g02051513
(1) PC
(2) 353-5083 Cable As (USB)
(3) 478-0235 Communication Adapter (3)
(4) 457-6114 Cable As (DATA LINK)
Connect cables (2) and (4) to communication adapter (3).Note: The communication adapter will power up when the adapter is connected to a PC or to an ECM that is powered up.
Connect cable (2) to the USB port of the PC.
Connect cable (4) to a service tool connector.
Restore electrical power to the ECM. Verify that the "POWER" indicator on the communication adapter is illuminated. Make sure that the PC is powered up.
Establish communication between Cat ET and the ECM. If Cat ET indicates that there is more than one ECM, select the engine ECM.
If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".Refer to Troubleshooting, "Electronic Service Tool Does Not Communicate" if any of the following conditions exist:
Cat ET displays a message that refers to a communication problem.
Cat ET displays "Error #142 The interface hardware is not responding".
Cat ET displays a message that indicates that the firmware in the communications adapter is old.Terminal Box / ECM Box
Note: The terminal box is designed to remain mounted on the engine. The mounting hardware includes isolators. Do not move the terminal box to a remote location. Moving the terminal box could result in wiring problems and in reduction of the service life of the components inside the terminal box.
Illustration 2 g01298930
Typical terminal box
The terminal box contains the electronic control modules. Connectors on the terminal box connect the engine wiring harnesses to components inside the terminal box. The ignition harnesses are routed directly from each ECM to the ignition transformers.
Illustration 3 g06446165
(1) Terminal box / ECM box
(2) Engine ECM
(3) J2 connector
(4)
Parts owners EVINRUDE:
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