Operation and
Maintenance
Manual
C18 Marine Generator Set
GBM1-Up (Generator Set)
SEBU8013-01
August 2010
SAFETY.CAT.COM
i03991620
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.
When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner’s choosing.
SEBU8013-01 3
Table of Contents
Table of Contents
Foreword ……………………………………………………….. 4
Safety Section
Safety Messages ……………………………………………. 6
General Hazard Information ……………………………. 11
Burn Prevention ……………………………………………. 14
Fire Prevention and Explosion Prevention ………… 14
Crushing Prevention and Cutting Prevention …….. 16
Mounting and Dismounting …………………………….. 17
Before Starting Engine …………………………………… 17
Engine Starting …………………………………………….. 17
Engine Stopping …………………………………………… 18
Electrical System ………………………………………….. 18
Engine Electronics ………………………………………… 18
Generator Isolating for Maintenance ……………….. 19
Product Information Section
Model Views ………………………………………………… 20
Product Identification Information …………………… 27
Operation Section
Lifting and Storage ………………………………………… 34
Installation ……………………………………………………. 38
Gauges and Indicators …………………………………… 40
Features and Controls …………………………………… 42
Engine Diagnostics ……………………………………….. 74
Engine Starting …………………………………………….. 78
Engine Operation ………………………………………….. 82
Engine Stopping …………………………………………… 83
Cold Weather Operation ………………………………… 85
Generator Operation ……………………………………… 90
Maintenance Section
Refill Capacities ……………………………………………. 96
Maintenance Recommendations …………………… 104
Maintenance Interval Schedule ……………………… 110
Warranty Section
Warranty Information …………………………………… 182
Reference Information Section
Engine Ratings …………………………………………… 183
Engine Performance and Performance Analysis
Report (PAR) …………………………………………….. 185
Customer Service ……………………………………….. 186
Reference Materials …………………………………….. 189
Index Section
Index …………………………………………………………. 193
4
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information.
English is the primary language for all Caterpillar publications. The English used facilitates translation and consistency in electronic media delivery.
Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Caterpillar dealer for the latest available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.
Operation
Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.
SEBU8013-01
Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.
Recommended service should be performed at the appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.
The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be maintained as part of the engine’s permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available from your Caterpillar dealer. Consult with your dealer for information regarding these options.
SEBU8013-01
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands
after handling.
5
Foreword
6
Safety Section
Safety Messages
Safety Section
Safety Messages
SMCS Code: 1000; 7405 i03726700
SEBU8013-01
Illustration 1
View of the right side of a GS388 Marine Genset g02009714
SEBU8013-01 7
Safety Section
Safety Messages
Illustration 2
View of the left side of a GS388 Marine Genset
Universal Warning (1)
These safety messages are located on each side of the terminal box.
g01370904
Do not operate or work on this product unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
g02009494
8
Safety Section
Safety Messages
Hot Surface (2)
These messages are located on each side of the barrel of the generator.
SEBU8013-01
Hot Surface (3)
These safety messages are located on each side of the engine.
g01372256 g01384734
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
SEBU8013-01
Explosion Hazard (4)
This safety message is located on the air cleaner element.
9
Safety Section
Safety Messages
Hot Fluid Under Pressure (5)
This safety message is located next to the cap on the heat exchanger.
g02010075 g01378799
Explosion Hazard! Spraying uncontrolled ether into the air inlet system can cause explosions or fire that may result in personal injury or death. Read and follow the starting procedures in the Operation and Maintenance Manual.
Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.
10
Safety Section
Safety Messages
Lifting the Genset (6)
This safety message for lifting the genset is located on the side panels of the terminal box.
SEBU8013-01
Automatic Starting (7)
The safety message for automatic starting is located on the sides of the terminal box.
g01392484 g01433231
When the engine is in the AUTOMATIC mode, the engine can start at any moment. To avoid personal injury, always remain clear of the the engine when the engine is in the AUTOMATIC mode.
Crushing Hazard! Improper lifting could cause serious injury or death. Follow the lifting instructions in the Operation and Maintenance Manual for safe lifting procedures.
SEBU8013-01
Shock/Electrocution (8)
The safety message for electrical shock is located on the sides of the terminal box and the rear of the terminal box.
g01392482
Do not connect the generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or death.
Open and secure the main distribution switch, or if the connection is permanent, install a double throw switch to prevent electrical feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility for the applicable circumstances.
i03704500
General Hazard Information
SMCS Code: 1000; 7405
11
Safety Section
General Hazard Information
Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls.
Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.
Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside.
Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.
•
Filler caps
• Grease fittings
•
Pressure taps
•
Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.
Illustration 3 g00104545 g00702020
Illustration 4
•
Wear a hard hat, protective glasses, and other protective equipment, as required.
•
When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing.
12
Safety Section
General Hazard Information
•
Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.
•
Ensure that all protective guards and all covers are secured in place on the engine.
•
Never put maintenance fluids into glass containers.
Glass containers can break.
•
Use all cleaning solutions with care.
•
Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under the following conditions:
•
The engine is stopped. Ensure that the engine cannot be started.
• The protective locks or the controls are in the applied position.
•
Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
•
For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. This may be accomplished by shutting off the fuel supply and/or the air supply to the engine.
•
Start the engine with the operator controls. Never short across the starting motor terminals or the batteries. This could bypass the engine neutral start system and/or the electrical system could be damaged.
Pressurized Air and Water
Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.
When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.
The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi) when the air nozzle is deadheaded. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
Fluid Penetration
SEBU8013-01
Illustration 5 g00687600
Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
SEBU8013-01
Asbestos Information
g00702022
Illustration 6
Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there are several guidelines that should be followed:
•
Never use compressed air for cleaning.
•
Avoid brushing materials that contain asbestos.
•
Avoid grinding materials that contain asbestos.
•
Use a wet method in order to clean up asbestos materials.
•
A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used.
•
Use exhaust ventilation on permanent machining jobs.
•
Wear an approved respirator if there is no other way to control the dust.
13
Safety Section
General Hazard Information
•
Comply with applicable rules and regulations for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.
•
Obey environmental regulations for the disposal of asbestos.
•
Stay away from areas that might have asbestos particles in the air.
Lines, Tubes, and Hoses
Do not bend or strike high pressure lines. Do not install lines, tubes, or hoses that are damaged.
Repair any fuel lines, oil lines, tubes, or hoses that are loose or damaged. Leaks can cause fires.
Inspect all lines, tubes and hoses carefully. Do not use bare hands to check for leaks. Always use a board or cardboard for checking engine components for leaks. Tighten all connections to the recommended torque.
Check for the following conditions:
•
End fittings that are damaged or leaking
• Outer covering that is chafed or cut
•
Wire that is exposed in reinforced hose
•
Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
•
Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and the heat shields are installed correctly. This will help to prevent these effects: vibration, rubbing against other parts, and excessive heat during operation.
14
Safety Section
Burn Prevention
Dispose of Waste Properly
SEBU8013-01
Illustration 7 g00706404
Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.
Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.
i02088921
Burn Prevention
SMCS Code: 1000; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the appropriate system before any lines, fittings or related items are disconnected.
Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the cooling system is drained.
Check the coolant level after the engine has stopped and the engine has been allowed to cool. Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
If the application has a makeup tank, remove the cap for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is an acid that can cause personal injury. Do not allow electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte levels. Batteries give off flammable fumes which can explode.
Always wear protective glasses when you work with batteries. Wash hands after touching batteries. The use of gloves is recommended.
i03941492
Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 7405
Illustration 8 g00704000
Use of personal protection equipment (PPE) may be needed.
All fuels, most lubricants, and some coolant mixtures are flammable.
Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a product when a fire hazard exists. Contact your
Caterpillar dealer for service.
SEBU8013-01
Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage.
A flash fire may result if the covers for the engine crankcase are removed within 15 minutes after an emergency shutdown.
Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result.
If the application involves the presence of combustible gases, consult your Caterpillar dealer for additional information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and debris from the engine. Do not allow any flammable materials to accumulate on the engine.
All fluids that are captured in the fluid spill containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire may cause personal injury and property damage.
Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray from a failed line, tube, or seal. Exhaust shields must be installed correctly.
Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting.
Wiring must be kept in good condition. Properly route and securely attach all electrical wires. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking.
15
Safety Section
Fire Prevention and Explosion Prevention
Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires.
Properly install all oil filters and all fuel filters. The filter housings must be tightened to the proper torque.
Illustration 9 g00704059
Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.
16
Safety Section
Crushing Prevention and Cutting Prevention
SEBU8013-01
Illustration 10 g00704135
Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.
Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.
Do not charge a frozen battery. Charging a frozen battery may cause an explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.
Ether
Do not use ether as a starting aid. Refer to this
Operation and Maintenance Manual, “Starting the
Engine” for information about starting the engine.
Lines, Tubes, and Hoses
Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged.
Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Caterpillar dealer for repair or for replacement parts.
Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.
Replace the parts if any of the following conditions are present:
•
End fittings are damaged or leaking.
•
Outer coverings are chafed or cut.
•
Wires are exposed.
•
Outer coverings are ballooning.
•
Portions of the hoses are kinked.
•
Outer covers have embedded armoring.
•
End fittings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly in order to prevent vibration, rubbing against other parts, and excessive heat.
i01359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 7405
Support the component properly when work beneath the component is performed.
Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.
Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards.
Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses in order to avoid injury to the eyes.
SEBU8013-01
Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.
Mounting and Dismounting
i01372247
SMCS Code: 1000; 7405
Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.
Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.
Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.
Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.
i03560601
Before Starting Engine
SMCS Code: 1000
NOTICE
For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine.
Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.
Inspect the engine for potential hazards.
17
Safety Section
Mounting and Dismounting
Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.
Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.
If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped.
All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.
See the Service Manual for repairs and for adjustments.
i03941639
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.
All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.
Start the engine with the engine start switch.
Always start the engine according to the procedure that is described in this Operation and Maintenance
Manual, “Starting the Engine” for information about starting the engine. Know the correct procedure to prevent major damage to the engine components.
Know the correct procedure to prevent personal injury.
To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working properly, check the water temperature gauge and the oil temperature gauge during the heater operation.
18
Safety Section
Engine Stopping
Engine exhaust contains products of combustion that can be harmful to your health. Always start the engine and operate the engine in a ventilated area.
If the engine is started in an enclosed area, vent the engine exhaust to the outside.
i01462046
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.
Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.
Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. This may be accomplished by shutting off the fuel supply to the engine and/or shutting off the air supply to the engine.
To stop an electronically controlled engine, cut the power to the engine.
i02456933
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” jump start cable should be connected last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the jump start cable to the engine block.
Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is operated. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual, “Engine
Starting” for specific starting instructions.
SEBU8013-01
Grounding Practices
The electrical system for the vessel and the engine must be properly grounded. Proper grounding is necessary for optimum engine performance and reliability. Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.
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 noise. Electrical noise may degrade the performance of the vessel and of the radio.
The alternator, the starting motor, and all of the electrical systems MUST be grounded to the negative battery terminal. The alternator must meet marine isolation requirements. The starting motor must also meet marine isolation requirements.
For engines which have an alternator that is grounded to an engine component, a ground strap MUST connect that component to the negative battery terminal and the component MUST be electrically isolated from the engine.
A bus bar with a direct path to the negative “-” battery terminal is permissible and recommended for use for all components that require a negative “-” battery connection. The bus bar should be directly connected to the negative “-” battery terminal. A bonding cable should also be connected from the cylinder block to the bus bar on the negative “-” battery connection.
Use of a bus bar ensures that the Electronic Control
Module (ECM) and all of the components that are connected to the ECM have a common reference point.
Refer to Special Instruction, REHS1187, “Marine
Engine Electronic Installation Guide” for additional information on grounding procedures.
i04009632
Engine Electronics
SMCS Code: 1000; 1400; 1900
Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage.
SEBU8013-01 19
Safety Section
Generator Isolating for Maintenance
This engine has a comprehensive, programmable engine monitoring system. The engine control module
(ECM), Marine Classification Society controller (MCS controller), and the Cat Digital Voltage Regulator
(CDVR) are able to monitor the operating conditions of the engine and the generator. If any of the engine parameters extend outside an allowable range, appropriate action is taken by the engine monitoring system.
The following actions are available for engine monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes are able to limit engine speed and/or the engine power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring functions. The following parameters can be monitored as a part of the Engine Monitoring System:
•
Operating Altitude
•
Engine Coolant Level
•
Engine Coolant Temperature
•
Engine Oil Pressure
•
Engine Speed
•
Fuel Temperature
•
Intake Manifold Air Temperature
•
System Voltage
The engine monitoring system can vary for different engine models and different engine applications.
However, the monitoring system and the engine monitoring control will be similar for all engines.
Note: Many of the engine control systems and display modules that are available for Caterpillar Engines will work in unison with the Engine Monitoring
System. Together, the two controls will provide the engine monitoring function for the specific engine application. Refer to the Troubleshooting Manual for more information.
i01489970
Generator Isolating for
Maintenance
SMCS Code: 4450
When you service an electric power generation set or when you repair an electric power generation set, follow the procedure below:
1. Stop the engine.
Illustration 11 g00104545
2. Attach a “DO NOT OPERATE” or similar warning tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
3. Disconnect the generator from the distribution system.
4. Lock out the circuit breaker. Attach a “DO NOT
OPERATE” or similar warning tag to the circuit breaker. Refer to the electrical diagram. Verify that all points of possible reverse power flow have been locked out.
5. For the following circuitry, remove the transformer’s fuses:
• power
• sensing
• control
6. Attach a “DO NOT OPERATE” or similar warning tag to the generator excitation controls.
7. Remove the cover of the generator’s terminal box.
8. Use an audio/visual proximity tester in order to verify that the generator is de-energized. This tester must be insulated for the proper voltage rating. Follow all guidelines in order to verify that the tester is operational.
9. Determine that the generator is in a de-energized condition. Add ground straps to the conductors or terminals. During the entire work period, these ground straps must remain connected to the conductors and to the terminals.
20
Product Information Section
Model Views
Product Information
Section
Model Views
Model View Illustrations
SMCS Code: 1000 i03593727
SEBU8013-01
Illustration 12
Typical example
(1) Terminal strip
(2) Engine oil filler
(3) Engine oil cooler
(4) Engine oil level gauge (dipstick)
(5) Fuel priming pump
(6) Expansion tank filler cap
(7) Expansion tank
(8) Heat exchanger
(9) Water pump (jacket water)
(10) Fuel filter
(11) Isolators
(12) Engine oil filter g01922058
SEBU8013-01 21
Product Information Section
Model Views
Illustration 13
Typical example
(12) Filter change indicator
(13) Aftercooler
(14) Aftercooler condensate drain valve
(15) Air cleaner
(16) Air filter restriction indicator
(17) Sea water pump
(18) Fuel transfer pump
(19) Filter for crankcase ventilation system g01922193
(20) Electronic control module (ECM)
(21) Junction box
22
Product Information Section
Model Views
Model View Illustrations
SMCS Code: 1000 i04036313
SEBU8013-01
Illustration 14
Typical example (right-hand service)
Cooled with a heat exchanger
(1) Aftercooler
(2) Air cleaner
(3) Air filter restriction indicator
(4) Flywheel housing
(5) Aftercooler condensate drain valve
(6) Electronic control module (ECM)
(7) Filter for crankcase ventilation system
(8) CCV filter change indicator
(9) Fuel transfer pump
(10) Sea water pump g02234413
SEBU8013-01 23
Product Information Section
Model Views
Illustration 15
Typical example (right-hand service)
Keel cooled system
(11) Rear lifting eye
(12) Water temperature regulator housing
(13) Deaerator housing
(14) Front lifting eye
(15) Water outlet
(16) Water pump (jacket water)
(17) Crankshaft vibration damper
(18) Water inlet
(19) Fuel filter
(20) Fuel priming pump
(21) Engine oil filter
(22) Engine oil cooler
(23) Engine oil level gauge
(24) Engine oil filler
(25) Starting motor g02234353
24
Product Information Section
Model Views
SEBU8013-01 g02234357
Illustration 16
Typical example (left-hand service)
Keel cooled system
(26) Aftercooler
(27) Air cleaner
(28) Air filter restriction indicator
(29) Aftercooler condensate drain valve
(30) Duplex oil filter assembly
(31) Filter for crankcase ventilation system
(32) CCV filter change indicator
(33) Fuel filter
(34) Fuel priming pump
(35) Engine oil level gauge i03593358
Product Description
SMCS Code: 1000; 4450; 4491; 7000
Engine Description
The Caterpillar C18 Marine Auxiliary Generator Set
Engine provides the following features:
(36) Sea water pump
(37) Fuel transfer pump
(38) Engine oil filler
•
Four cycle
•
Direct fuel injection
• Electronic unit injection
•
Turbocharged
•
Raw/Sea water aftercooler or separate circuit aftercooler (SCAC)
SEBU8013-01
The electronic engine control system provides the following features:
•
Engine monitoring
•
Electronic governing
• Automatic air/fuel ratio control
•
Torque rise shaping
•
Injection timing control
• System diagnostics
Electronic unit injectors combine the metering of fuel (duration and timing) and the injection of fuel.
Electronic unit injectors produce very high injection pressures.
The Electronic Control Module (ECM) controls the amount of fuel that is injected by varying the signals to the electronic unit injectors. High injection pressures help to reduce fuel consumption and emissions.
The use of this type of electronic unit injector helps to provide precise control of injection timing.
The injection timing varies with engine operating conditions. This optimizes the engine’s performance for starting, emissions, noise, and fuel consumption.
The timing advance is achieved through the precise control of the firing of the electronic unit injector.
Engine rpm is controlled by adjusting the firing duration. A speed/timing sensor provides information to the ECM for detection of cylinder position and engine rpm.
The engine has built-in diagnostics that are used in order to ensure that all of the components function properly.
The cooling system consists of the following components:
•
Gear-driven centrifugal pump
•
One water temperature regulator which regulates the engine coolant temperature
• Oil cooler
•
Auxiliary water pump or a separate circuit aftercooler (SCAC)
•
Raw/Sea water aftercooler
The engine lubricating oil that is supplied by a gear-type pump is cooled. The engine lubricating oil is also filtered. Bypass valves provide unrestricted flow of lubrication oil to the engine components during the following conditions:
Illustration 17
Cylinder and valve locations
(A) Exhaust valve
(B) Inlet valve
25
Product Information Section
Model Views
•
High oil viscosity
•
Plugged oil cooler or plugged oil filter elements
(paper cartridge)
Note: Most illustrations represent typical right hand service. The C18 Marine Auxiliary Generator Set
Engine is also available with left hand service. The following items will be located on the left side for left hand service:
•
Fuel filter
• Oil filter
•
Oil level gauge
Engine Service Life
Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. In addition, use recommended fuels, coolants and lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Expected engine life is generally predicted by the average power demand, based on the fuel consumption of the engine over a period of time.
Reduced hours of operation at full throttle and/or operating at reduced throttle settings result in a lower average power demand. Reduced hours of operation will increase the length of operating time before an engine overhaul is required. See this Operation and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).
Engine Specifications
g00904617
26
Product Information Section
Model Views
Table 1
C18 Marine Engine Specifications
Item Single
Turbocharger
Dual
Turbocharger
6 In-Line
Cylinders and
Arrangement
Bore
145 mm (5.7 inch)
Stroke
Compression Ratio
183 mm (7.2 inch)
16.5:1 14.5:1
Aspiration
Displacement
Firing Order
TA
(1)
18 L (1098 in 3 )
1-5-3-6-2-4
Rotation (viewed from flywheel)
(1) Turbocharged Aftercooled
Counterclockwise
Description of the Generator
These brushless generators are used with the following loads: mixed loads of motors and lights,
SCR-controlled equipment, computer centers, installations of communications, and petroleum drilling applications. The elimination of the brushes in the field circuit reduces maintenance. The elimination of the brushes in the field circuit increases reliability.
The elimination of brushes provides a higher degree of protection in potentially hazardous atmospheres.
The generator set packages can be utilized for prime power generation or standby power generation. The generator set packages can be used in land based applications or marine applications.
The generators have four poles. The generators have twelve lead configurations. The generators are capable of producing electrical power in either 50 Hz or 60 Hz applications.
SEBU8013-01
SEBU8013-01
Product Identification
Information
Plate Locations and Film
Locations
SMCS Code: 1000 i03596940
27
Product Information Section
Product Identification Information
Illustration 18
Serial Number Plate for the
Generator (1)
The generator identification is located on the side of the generator.
The generator identification film includes the following information:
•
Serial number for the generator
_____________________
•
Generator model number
_____________________________
Engine Serial Number (2)
The Engine Serial Number Plate is on the lower right side of the cylinder block near the rear of the engine.
g01922402
The Engine Serial Number Plate contains the following information:
•
Engine serial number
__________________________________
•
Engine model number
_________________________________
•
Arrangement number
__________________________________
Engine Information (3)
The Engine Information Plate is on the valve cover.
The Engine Information Plate contains the following information:
•
Engine serial number
__________________________________
•
Arrangement number
__________________________________
28
Product Information Section
Product Identification Information
•
Compression ratio
______________________________________
•
Aftercooler temperature
_______________________________
•
Power
_____________________________________________________
•
Full load RPM
___________________________________________ i00610276
Reference Numbers
SMCS Code: 1000
Information for the following items may be needed to order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the information for future reference.
Record for Reference
Engine Model
_______________________________________________
Engine Serial No.
__________________________________________
Engine Arrangement No.
_________________________________
Modification No.
____________________________________________
Engine Low Idle rpm
______________________________________
Engine Full Load rpm
_____________________________________
Performance Specification No.
_________________________
Primary Fuel Filter No.
____________________________________
Water Separator Element No.
___________________________
Secondary Fuel Filter Element No.
____________________
Lubrication Oil Filter Element No.
______________________
Auxiliary Oil Filter Element No.
_________________________
Supplemental Coolant Additive Maintenance Element
No. (Optional)
_______________________________________________
Total Lubrication System Capacity
_____________________
Total Cooling System Capacity
_________________________
Air Cleaner Element No.
_________________________________
Fan Drive Belt No.
_________________________________________
Alternator Belt No.
_________________________________________
SEBU8013-01
SEBU8013-01
Declaration of Conformity
SMCS Code: 1000 i02469186
29
Product Information Section
Product Identification Information
Illustration 19 g01231339
30
Product Information Section
Product Identification Information i04019095
Emissions Certification Film
SMCS Code: 1000; 7405
Note: This information is pertinent in the United
States, in Canada and in Europe.
Consult your Cat dealer for an Emission Control
Warranty Statement.
This label is located on the engine.
i03578360
Generator Lead Connections
SMCS Code: 4450
Lead Numbering
The Wye configurations and the Delta configurations are the most common generator lead connections.
The following three-phase connection diagrams illustrate the proper connection and lead identification.
The leads are numbered clockwise from the top and from the outside. The diagrams that are contained in the “Wye Configuration Diagrams” section show lead numbering for the twelve lead generators. The diagrams that are contained in the
“Delta Configuration Diagrams” section show lead numbering for the twelve lead generators.
Wye Configuration Diagrams
12 Lead
SEBU8013-01
Illustration 20
12 Lead Wye Configuration
Low Voltage g00611608
Terminals T10, T11, and T12 become neutral connections when the terminals are tied together.
Delta Configuration Diagrams
12 Lead
Illustration 21
12 Lead Delta Configuration g00669312
Terminals T6 and T9 become the neutral connections when the terminals are tied together and when the terminals are grounded.
This reflects the terminal T2 and T10 connection as the high phase.
SEBU8013-01
Grounding the Frame
In any generator set installation, the frame of the generator must be positively connected to an earth ground or the frame of the generator must be positively connected to the hull of a vessel. This connection is the first connection that should be made at the installation. This connection is the last connection that should be removed. If the generator set is on flexible pads or resilient pads, the ground connection must be flexible in order to avoid possible breakage in later operation.
Ground connection cables or straps should have at least the current carrying capacity of the largest line lead to the connected load. Joints in cables or straps must be clean, free of electrical resistance, and protected from possible oxidation. Bolted ground connection joints eventually oxidize. These joints are also frequent sources of radio frequency interference
(RFI). Joints should be silver soldered and joints should also be bolted. These bolts will be electrically reliable and mechanically reliable.
Neutral Connections
On Wye Configuration Generators, the neutral lead should be attached to ground. This connection should be made at installation. The neutral lead is grounded in order to prevent load-side equipment damage.
If the neutral wire is grounded and one of the phase leads becomes grounded, the excessive current will open a load circuit breaker. In addition, this excessive current will cause the generator voltage to collapse. The result depends on the following factors: the particular generator’s electrical characteristics, type of fault, and trip rating of the circuit breaker. An undervoltage device may be required in order to provide an adequate short circuit protection.
There are some instances when the neutral wire should not be grounded. An ungrounded generator neutral lead is acceptable when measures have been taken in order to prevent grounds to the phase leads. An example of such measures are ground fault protective circuits. When ground fault protective circuits are used, the entire group of distribution circuits should be studied. The entire group of distribution circuits should then be treated as a system. If a new distribution system is being developed, the owner should confer with a consultant that is certified and registered. If an existing system should be modified for ground fault protection, the owner should also confer with a consultant that is certified and registered.
Single Units
In a three-phase, four-wire system, the neutral wire should be grounded according to local wiring codes.
31
Product Information Section
Product Identification Information
When definite measures need to be taken in order to prevent grounds to the load leads, an ungrounded neutral can be used. Be sure to check your local wiring codes.
Multiple Units
When multiple generators are operated in parallel, all the neutral connections may be grounded. In this case, there may be circulating current through the neutral connections. In order to eliminate the possibility of circulating currents, ground the neutral of only one generator. If multiple generators are alternated on a line, a switch should be installed in each generator’s neutral ground circuit. In this case, all neutral ground circuits except one can be opened.
Be sure that one of the neutral ground circuits is closed.
Parallel to a Utility
There will be occasions when a Wye connected generator is paralleled with a utility system (infinite bus). On these occasions, the utility system’s step-down transformer may also have a Wye connection. The grounding of both of the Wye neutral connections may result in circulating currents through the neutral connections. The coordination of ground fault protection requires a study of the entire system.
This study should be done by a consultant that is familiar with generator systems. This consultant should be registered and certified. This study will determine the grounding method that should be used.
i03578355
Voltage Connections
SMCS Code: 4450
Three-Phase Voltage Connections
The Wye Configuration and the Delta Configuration are given in the following diagrams.
The terminals must be connected securely. The terminals must also be insulated with a good quality electrical tape.
If a Delta Configuration is being used, the generator winding pitch must be two-thirds. If the generator winding pitch is not two-thirds, there will be circulating current within the Delta. This circulating current will cause additional heat in the generator stator. In such cases, the generator must be derated.
32
Product Information Section
Product Identification Information
Wye Configuration Diagrams
12 Lead Generators
Delta Configuration Diagrams
12 Lead Generators
SEBU8013-01
Illustration 22 g00637319
Typical twelve lead Wye configuration (60 Hz)
This configuration is only for use with 3406E, 3412C, 3500 series, and C18 generator sets.
This is a typical high voltage connection.
Illustration 23
Typical twelve lead parallel Wye configuration (60 Hz) g00637320
This configuration is only for use with 3406E, 3412C, 3500 series, and C18 generator sets.
This is a typical low voltage connection.
g00626130
Illustration 24
Typical twelve lead Delta configuration (60 Hz)
Single-Phase Current From a
Three-Phase Generator
Three-phase current and single-phase current can be taken simultaneously from a generator that is connected for three-phase service. In the Wye Configuration, connect the load to the three-phase leads (any two of the three leads). In the Delta Configuration, connect the load to the three-phase leads (any two of the three leads). In both configurations, this will provide single-phase voltage at the same voltage as three-phase voltage.
Connect the load to any phase lead and neutral lead of the Wye Configuration. This will produce voltage at
58% of three-phase voltage.
In a Delta Configuration (240 Volts, 60 Hz, and three-phase power), the following voltages will be present: 208 Volts between the high phase and neutral and 240 Volts between either of the low phases and neutral.
Refer to Operation Section, “Generator Operation” for allowable single-phase loading unbalance.
Single-phase power that is taken from a three-phase source can be a problem. Ensure that the single-phase loading is equally distributed.
Do not exceed the nameplate current rating for any one phase.
SEBU8013-01
Wye Configuration Diagrams
12 Lead Generators
33
Product Information Section
Product Identification Information
Illustration 25 g00637321
Single-phase voltage with twelve lead Wye configuration
This configuration is only for use with 3406E, 3412C, 3500 series, and C18 generator sets.
Delta Configuration Diagrams
12 Lead Generators
Illustration 26 g00626136
Single-phase voltage with twelve lead Delta configuration
34
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
i03677044
Product Lifting
SMCS Code: 1000; 1404; 7002
NOTICE
Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.
When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.
Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.
Some removals require lifting fixtures in order to obtain proper balance. Lifting fixtures also help to provide safety.
Lifting eyes are designed and installed for the specific engine arrangement. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures for proper engine lifting.
Lifting the Entire Package
Do NOT use the engine lifting eyes or the generator lifting eyes to lift the entire package.
Lifting points have been provided on the base rails of the generator set for lifting the entire package.
However, lifting the engine and the generator together requires special equipment and procedures. Consult your Caterpillar dealer for information regarding fixtures for proper lifting of your complete package.
Lifting the Engine Only
To remove the engine ONLY, use the lifting eyes that are on the engine.
SEBU8013-01
Lifting the Generator Only
To remove the generator ONLY, use the lifting eyes that are on the generator.
i03585220
Product Storage
SMCS Code: 1000; 1404; 7002
Note: If long term storage for a period of time which exceeds one year is necessary, contact your local
Caterpillar dealer for the preferred procedure to use in your specific case.
Engine
Storage (Less Than One Year)
If an engine is not used, oil can run off the following parts that normally receive lubrication: cylinder walls, piston rings, main bearings, connecting rod bearings, crankshaft, and gears.
This lack of lubricant allows corrosion to begin to appear on the metal. This condition is worse in areas of high humidity.
When the engine is started again, metal to metal contact will cause wear before the surfaces receive oil. To minimize this wear, use the starter to turn the engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge, start the engine.
1. Clean the engine of any dirt, rust, grease, and oil.
Inspect the exterior. Paint areas that contain paint damage with a good quality paint.
2. Remove any dirt from the air cleaner(s). Check all seals, gaskets, and the filter element for damage.
3. Apply lubricant to all points in this Operation and Maintenance Manual, “Maintenance Interval
Schedule”.
4. Drain the crankcase oil. Replace the crankcase oil and change the oil filter(s). For the proper procedure, refer to this Operation and
Maintenance Manual.
5. If the engine is equipped with an air starting motor, fill the reservoir with a mixture of 50 percent volatile corrosion inhibitor oil (<nomen>VCI oil</nomen>) and 50 percent engine oil.
6. Add VCI oil to the crankcase oil. The volume of VCI oil in the crankcase oil should be 3 to 4 percent.
SEBU8013-01
Note: If the engine crankcase is full, drain enough engine oil so the mixture can be added.
7. Remove the air filter element(s). Turn the engine at cranking speed with the throttle control in FUEL
OFF position. Use a sprayer to add a mixture of
50 percent VCI oil and 50 percent engine oil into the air inlet or turbocharger inlet.
Note: The mixture of VCI oil can be added to the inlet by removing the plug for checking turbocharger boost pressure. The minimum application rate for the
VCI oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement.
8. Use a sprayer to apply a mixture of 50 percent VCI oil and 50 percent crankcase oil into the exhaust openings. The minimum application rate for the oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement. Seal the exhaust pipe and seal any drain holes in the muffler.
9. Remove the fuel from the secondary fuel filter housing. Alternately, empty and reinstall the spin-on fuel filter element in order to remove any dirt and water. Drain any sleeve metering fuel pump.
Clean the primary fuel filter. Fill with calibration fluid or kerosene. Install the primary fuel filter and operate the priming pump. This will send clean oil to the secondary filter and the engine.
Open the fuel tank drain valve in order to drain any water and dirt from the fuel tank. Apply a spray of calibration fluid or kerosene at the rate of 30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank capacity in order to prevent rust in the fuel tank. Add 0.15 mL per L (.02 oz per 1 gal US) of commercial biocide such as Biobor JF to the fuel.
Apply a small amount of oil to the threads on the fuel tank filler neck and install the cap. Seal all openings to the tank in order to prevent evaporation of the fuel and as a preservative.
10. Remove the fuel nozzles or spark plugs. Apply
30 mL (1 oz) of the mixture of oils (50 percent VCI oil and 50 percent engine oil) into each cylinder.
Use a bar or a turning tool in order to turn over the engine slowly. This puts the oil on the cylinder walls. Install all fuel nozzles or spark plugs and tighten to the correct torque.
11. Spray a thin amount of the mixture of oil (50 percent VCI oil and 50 percent engine oil) onto the flywheel, the ring gear teeth, and the starter pinion. Install the covers in order to prevent evaporation of the vapors from the VCI oil.
35
Operation Section
Lifting and Storage
12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move, such as rod threads, ball joints, linkage, etc.
Note: Install all covers. Ensure that tape has been installed over all openings, air inlets, exhaust openings, the flywheel housing, the crankcase breather(s), the dipstick tubes, etc.
Ensure that all covers are airtight and weatherproof. Use a waterproof weather resistant tape such as Kendall No. 231 or an equivalent.
Do not use duct tape. Duct tape will only seal for a short period of time.
13. Under most conditions, it is best to remove the batteries. As an alternative, place the batteries in storage. As needed, periodically charge the batteries while the batteries are in storage.
If the batteries are not removed, wash the tops of the batteries until the tops are clean. Apply an electrical charge to the batteries in order to obtain a specific gravity of 1.225.
Disconnect the battery terminals. Place a plastic cover over the batteries.
Note: For additional information, refer to Special
Instruction, SEHS7633, “Battery Test Procedure”.
14. Loosen all belts.
15. Place a waterproof cover over the engine. Ensure that the engine cover is secure. The cover should be loose enough to allow air to circulate around the engine in order to prevent damage from condensation.
16. Attach a tag with the storage date to the engine.
17. Remove the waterproof cover at two or three month intervals in order to check the engine for corrosion. If the engine has signs of corrosion, repeat the protection procedure.
Conventional Coolant System
Completely fill the cooling system before storage.
Water or water mixed with supplemental coolant additive (SCA) is not an approved coolant for use with
Caterpillar C7-C32 Marine Engines which are cooled with heat exchangers. Caterpillar C7-C32 Marine
Engines which are cooled with heat exchangers require a minimum of 30 percent glycol in order to prevent cavitation of cooling system components.
A minimum of 50 percent glycol is very strongly recommended.
36
Operation Section
Lifting and Storage
Refer to this Operation and Maintenance Manual,
“Refill Capacities and Recommendations” for more information about coolants.
Raw Water System
Completely drain the raw water system by removing all the drain plugs from the raw water pump, the water shielded manifolds, heat exchanger bonnets, and the aftercooler.
After the system has been drained, inspect all zinc plugs (normally painted red) for damage from corrosion.
Note: To ensure complete drainage and evaporation during storage, DO NOT install the drain plugs and zinc plugs. Place all removed plugs in a cloth bag and fasten the bag to the engine for storage.
Removal from Storage
1. Remove all outside protective covers.
2. Change the oil and filters.
3. Check the condition of the fan and alternator belts. Replace the belts, if necessary. Refer to this Operation and Maintenance Manual, “Belts —
Inspect/Adjust/Replace” for the correct procedure.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner elements.
6. Use a bar or a turning tool in order to turn the engine in the normal direction of rotation. The procedure ensures that no hydraulic locks or resistance exist.
7. Before starting the engine, remove the valve cover or covers. Put a large amount of engine oil on the camshaft, cam followers, and valve mechanism in order to prevent damage to the mechanism.
8. Pressure lubricate the engine before starting the engine. Pressure lubricating the engine ensures immediate lubrication and prevents damage to the engine during the first few minutes of engine operation. If the engine is not equipped with a prelube pump, contact your Caterpillar dealer for information about lubrication of the engine before the engine is started.
9. Check the condition of all rubber hoses. Replace any worn hoses. Replace any damaged hoses.
SEBU8013-01
10. Before start-up, test the cooling system for a three to six percent concentration of coolant conditioner. Add liquid coolant conditioner or a coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before starting.
11. If the engine is equipped with a fresh water system, ensure that the system is clean. Ensure that the system is full. Ensure that the system has the correct amount of supplemental cooling system conditioner.
If the engine is equipped with a raw water system, install all of the drain plugs and zinc plugs. Fill the system. It may be necessary to prime the raw water system pumps before operation.
12. On the first day of operation, check the entire engine several times for leaks and correct operation.
13. If the engine was removed from storage in which temperatures of less than -12°C (10°F) were encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Maintenance”.
Generator
Storage (Less Than One Year)
When a generator is in storage, moisture condenses in the windings. To minimize condensation, always place the generator in a dry storage area. Seal all openings with tape.
If a brush-type generator (SRCR) is to be in storage, lift the brushes off the slip ring in order to prevent damage to the slip ring by chemical action. Attach a tag to the generator which states that the brushes have been lifted.
Perform a resistance check of the windings. Record this reading. This check is done in order to provide a base line for determining whether moisture or winding deterioration occurs during storage.
Removal From Storage
Remove all protective covers. Reseat the brushes on the slip ring for SRCR generators.
SEBU8013-01
Before start-up of a generator, use a megohmmeter to check insulation resistance for moisture and/or foreign material. Refer to this Operation and
Maintenance Manual, “Generator Start-up Check
List” for the procedure. A resistance reading of one megohm or less indicates that the winding has absorbed too much moisture.
Use one of the following methods for drying the generator in order to remove moisture which is caused by high humidity or dampness:
1. Place the generator in an oven which is no hotter than 85°C (185°F) for four hours.
2. Use a canvas enclosure around the generator and heating lamps to increase the ambient temperature. Provide an opening in the top of the canvas in order to release the moisture.
3. Send a low voltage current through the windings in order to increase the temperature of the windings to 85°C (185°F).
Megohmmeter Checks
Test the main stator windings with a megohmmeter in the following situations:
1. Before the initial start-up of the generator set
2. Every three months if the generator operates in a humid environment
3. If the generator has not been run under load for three months or more
These intervals are only recommendations. It may be necessary to perform a megohmmeter test more frequently if the environment is extremely humid, salty, or if the last megohmmeter test was close to one megohm.
Additional Information
For additional information about storage procedures, refer to Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”.
37
Operation Section
Lifting and Storage
38
Operation Section
Installation
Installation
Generator Set Installation
SMCS Code: 7002 i03651261
For additional information about the installation of your Caterpillar C18 Generator Set, refer to the
Application and Installation Guide or contact your
Caterpillar dealer.
Receiving Inspection
If the generator is received during cold weather, allow the unit to reach room temperature before you remove the protective packing material. Warming the generator to room temperature will prevent the following problems:
• Water condensation on cold surfaces
•
Early failures due to wet windings
• Early failures due to wet insulating materials
Unpacking and Storage
Moving the Generator
Improper lift rigging can allow unit to tumble causing injury and damage.
NOTICE
Do not use the engine lifting eyes to remove the engine and generator together.
Unpack the equipment with care in order to avoid scratching painted surfaces. Move the unit to the mounting location. The unit can be moved by either of the following methods:
•
Attach an overhead crane to the lifting eyes that are installed on the generator package.
•
Use a lift truck in order to lift the generator.
The hoist and the hoist cables should have a rating that is greater than the weight of the generator.
When the unit is moved, ensure that the generator is completely supported by the lift truck’s fork tines.
Also ensure that the generator is balanced on the lift truck’s fork tines. Slide the fork tines beneath the attached skid in order to lift the generator.
SEBU8013-01
Storage
Short Time Storage
If the generator is not installed immediately, store the generator in a clean area. This area should also have the following conditions: low humidity, stable humidity, and stable temperature. Space heaters must be energized in order to keep condensation from the windings. All accessory equipment that is supplied with the unit should be stored with the generator. The combined unit should be covered with a durable cover in order to protect against the following contaminants:
•
Dust
• Dirt
• Moisture
Long Time Storage
A storage period in excess of six months should be preceded by the following preparation:
1. Install desiccant bags inside the exciter’s cover and install desiccant bags inside the screen of the fan.
2. Seal the unit in a covering of plastic or other material that has been designed for that purpose.
3. Adequately tag the generator. This will ensure that preservative greases and desiccant bags are removed before the unit is placed in operation.
Bearing Inspection
Ball bearing generators use grease. This grease is subject to deterioration. If the generator is stored longer than one year, new ball bearings should be installed. These bearings should be greased to the proper level prior to being put into operation. If inspection indicates that bearings are free of rust or corrosion, and no noise or excessive vibration appear on start-up, replacement is not necessary.
Location
The location of the generator must comply with all local regulations. The location of the generator must also comply with all special industrial regulations.
Locate the generator in an area that meets the following requirements:
• Clean
•
Dry
SEBU8013-01
•
Well ventilated
•
Easily accessible for inspection and maintenance
Do not obstruct air inlet openings. Do not obstruct discharge openings. Coolant flow must reach these openings. If the generator is exposed to harsh environmental conditions, the generator can be modified in the field in order to add filters and space heaters. In addition, a more rigid periodic maintenance schedule should be established.
Electrical Measurements
Measure the insulation resistance of each winding if the generator was exposed to the following conditions:
• Rapid changes in temperature
•
Freezing
•
Wet climate during shipment
• Wet climate during storage
Note: These tests should be conducted prior to any power connections that are being made. These tests should be conducted prior to any control connections that are being made.
Refer to the Generator Maintenance section of this manual in order to measure the following items:
•
Exciter field (stator)
• Exciter armature (rotor)
•
Generator field (rotor)
•
Generator armature (stator)
Alignment
After the generator set has been placed in the final position, the generator must be aligned. Refer to these publications:
•
Special Instruction, SEHS7654, “Alignment —
General Instructions”
•
Special Instruction, SEHS7259, “Alignment of
Single-Bearing Generators”
39
Operation Section
Installation
Protective Devices
The output to the load of the generator should always be protected with an overload protection device such as a circuit breaker or fuses. Fuses should be sized by using the lowest possible current rating. However, this rating must be above the current rating for full load. A common recommendation is 115 percent of rated current. Determine the size of fuses or determine the size of circuit breakers in accordance with NEMA, IEC, and Local Electrical Codes.
40
Operation Section
Gauges and Indicators
Gauges and Indicators
i02706567
Gauges and Indicators
SMCS Code: 1900; 7450
Your engine may not have the same gauges or all of the gauges that are described.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing the gauges over a period of time. Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your
Caterpillar dealer for assistance.
NOTICE
If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.
Engine Coolant Temperature – This gauge indicates the engine coolant temperature. The temperature may vary according to the load. Do not allow the temperature to exceed the boiling temperature of the pressurized cooling system.
The sensor for engine coolant temperature must be fully submerged in order to detect the temperature correctly. If the engine is operating above the normal temperature range, perform the following procedure:
1. Reduce the load and/or the engine rpm.
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load and/or rpm.
Engine Load – This gauge indicates a percentage of the engine’s full rated torque.
The calculation of the percentage is based on these factors: flow of fuel, engine rpm, fuel energy content, and fuel correction factor. This gauge flashes if the torque exceeds the maximum limit that is programmed into the control strategy.
SEBU8013-01
Engine Oil Pressure – The oil pressure should be greatest after a cold engine is started. The pressure will decrease as the engine warms up. The pressure will increase when the engine rpm is increased. The pressure will stabilize when the engine rpm is stable.
A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
3. Check and maintain the oil level.
Engine Oil Temperature – This gauge indicates the engine oil temperature after the oil has passed through the oil cooler.
The oil cooler is thermostatically controlled.
Exhaust Temperature – This gauge indicates the exhaust temperature at the exhaust inlets to the turbochargers. The two exhaust temperatures may vary slightly.
The exhaust temperatures at the exhaust inlets to the turbochargers provide a good indication of engine performance. For engines with dry exhaust manifolds, the temperatures are representative of the actual temperatures of the valves. Monitor this parameter frequently.
NOTICE
Severe damage to the engine can result if the exhaust temperature at the inlet to the turbocharger exceeds the extreme limit.
Fuel Level – This gauge indicates the fuel level in the fuel tank. Normally, the fuel level gauge will register the fuel level only when the switch is in the ON position.
Fuel Pressure – This gauge indicates fuel pressure to the fuel injection pump from the fuel filter. A decrease in fuel pressure usually indicates a dirty fuel filter or a plugged fuel filter. As the fuel filter becomes plugged, there will be a noticeable reduction in the engine’s performance.
SEBU8013-01
Fuel Temperature – This gauge indicates the temperature of the fuel. A high fuel temperature can adversely affect performance. If the temperature of the fuel is too low, the fuel filter may begin to plug. See this Operation and Maintenance Manual, “Fuel and the Effect from
Cold Weather” for more information.
Fuel Usage – This gauge indicates the rate of fuel usage.
Inlet Manifold Air Pressure – This gauge indicates the air pressure (turbocharger boost pressure) in the air inlet manifold after the aftercooler. The inlet manifold air pressure depends on the engine rating, the load, and the operating conditions. To establish the normal inlet manifold air pressure, compare the data from the gauge to the data from the engine commissioning and look for trends.
Inlet Manifold Air Temperature – This gauge indicates the inlet manifold air temperature after the aftercooler. As the inlet air increases in temperature the following conditions occur: expansion of the air, less oxygen in the cylinders, and less power. If the temperature of the inlet air is too high during full speed and load operation, the engine may consume excessive fuel.
Service Hour Meter – This gauge indicates the total number of clock hours on the engine.
System Voltage – This gauge indicates the voltage of the electrical system.
Tachometer – This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load.
NOTICE
To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at high idle without damage, but should never be allowed to exceed high idle rpm.
Note: The high idle rpm and the full load rpm are stamped on the Information Plate.
41
Operation Section
Gauges and Indicators
For more information, refer to Specifications,
Systems Operation, and Troubleshooting,
SENR5002, “Installation Guide for Marine Engine
Electronic Displays”.
42
Operation Section
Features and Controls
Features and Controls
i03899941
Control Panel
(Marine Classification Society
Control Panel (MCS Control
Panel) (Standard Panel, if
Equipped))
SMCS Code: 7451
General Information
The control unit has buttons for the following functions:
•
Engine starting
•
Engine stopping
•
Alarm list
•
Menu
•
Up arrow and down arrow
•
Four soft buttons with varying functionality
SEBU8013-01
SEBU8013-01 43
Operation Section
Features and Controls g02177059
Illustration 27
(1) Power indicator
(2) Alarm list
(3) Start
(4) Stop
(5) context-sensitive menu buttons
(6) Voltage adjust
(7) Frequency
(8) Emergency stop
(9) Idle/Rated
(10) Power switch (Lockout/tagout)
The screen is divided into three main sections:
(11) Scroll down
(12) Scroll up
(13) Menu
(14) LCD screen
•
The wrench symbol indicates that a maintenance interval which has been programmed into the control unit is overdue.
Status Bar
The status bar is the top line on the screen. The status bar is reserved for the engine state and status symbols.
•
The “L” symbol indicated that the control unit is in local mode. Remote commands are not permitted when the control unit is in local mode.
•
The “M” symbol indicates that the control unit is in manual mode. The “Automatic Start/Stop” function is not permitted when the control unit is in manual mode.
•
The “SO” symbol indicates that the control unit is in shutdown override mode.
•
The green“OK” symbol indicates that the following events are not present on the alarms list: warning, alarm, and shutdown. The green“OK” symbol indicates that no yellow diagnostic messages and no red diagnostic message are present on the alarms list.
44
Operation Section
Features and Controls
Main Screen (Instrument Screen)
SEBU8013-01
Illustration 28
All instruments and menu items are displayed on the main screen. The screen for the control unit may have multiple instrument screens. Press the “UP
ARROW” button and press the “DOWN ARROW” button in order to navigate between the instrument screens. If there is only one instrument screen, pressing the buttons does not change the screen.
Pressing the same button repeatedly will eventually scroll back to the first screen.
The following symbols and icons may be displayed on the instrument screen:
Yellow Triangle
The “YELLOW TRIANGLE” is the warning symbol.
When the “YELLOW TRIANGLE” flashes above an instrument, a new warning exists for that channel.
The “YELLOW TRIANGLE” stops flashing when the operator acknowledges the warning.
Red Triangle
The “RED TRIANGLE” is the alarm symbol or the shutdown symbol. When the “RED TRIANGLE” flashes above an instrument, a new alarm exists for that channel or the channel is responsible for an engine shutdown. The “RED TRIANGLE” stops flashing when the operator acknowledges the alarm.
g02176582
Soft Buttons
The bottom line on the screen is for the four soft buttons. The functions of the soft buttons vary.
SEBU8013-01
Start Engine and Stop Engine
Starting the Engine
45
Operation Section
Features and Controls
Illustration 29
The “START” button may be configured as LATCHED or as HOLD. The values for the “START” button and the values for the “STOP” button always match.
Start the engine with one of two methods:
•
If the “START” button is configured as LATCHED, perform the following sequence in order to start the engine: press the “START” button, observe the confirmation dialog, and press “YES” . The control unit will complete the starting sequence.
•
If the “START” button is configured as HOLD, press and hold the “START” button until the engine starts.
g02176581
46
Operation Section
Features and Controls
Stopping the Engine
SEBU8013-01
Illustration 30
The “STOP” button may be configured as LATCHED or as HOLD. The values for the “STOP” button and the values for the “START” button always match.
Stop the engine with one of two methods:
•
If the “STOP” button is configured as LATCHED, perform the following sequence in order to start the engine: press the “STOP” button, observe the confirmation dialog, and press “YES” . The control unit will complete the stopping sequence.
•
If the “STOP” button is configured as HOLD, press and hold the “STOP” button until the engine stops.
g02176599
SEBU8013-01
List of Alarms
47
Operation Section
Features and Controls
Illustration 31
Enter the Alarms List
Press the “ALARMS LIST” button in order to view the alarm list. Press the “ALARMS LIST” button again in order to leave the alarms list. The “EXIT” button may be pressed in order to leave the alarms list.
Alarms are displayed in several colors and texts.
•
The following entries are displayed in red text: alarm entries, shutdown entries, and automatic stop entries.
•
Warnings are displayed on a yellow background.
•
New alarms (unacknowledged alarms) are displayed in bold text.
•
Acknowledged alarms are displayed in normal text.
•
An alarm that is not acknowledged before becoming inactive is displayed in normal text on a gray background.
•
An inactive alarm that is displayed on a yellow background was either an alarm or a shutdown.
•
An inactive alarm that is displayed on a yellow background was a warning.
g02176135
Filter Alarms
The alarm list filters alarms into three groups:
•
All alarms (all alarms and all diagnostics)
•
Panel alarms (all alarms and no diagnostics)
•
Diagnostics (diagnostics only)
Use the second soft button and the third soft button in order to choose between the three groups.
Silence the Buzzer
If the buzzer sounds, press the “ALARMS LIST” button in order to silence the buzzer.
•
If the alarm list is not displayed before the
“ALARMS LIST” button is pressed, press the
“ALARMS LIST” button to display the alarms list.
•
If the alarms list is displayed when the buzzer sounds, pressing the “ALARMS LIST” button will silence the buzzer.
48
Operation Section
Features and Controls
Acknowledge Alarms
Acknowledge a Single Alarm
Use the arrow buttons in order to select an alarm for acknowledgment. The selected alarm line will expand to reveal any additional information.
Press the “ACKNOWLEDGE” button in order to acknowledge the selected alarm.
Acknowledge All Alarms
Press and hold the “ACKNOWLEDGE” button for one second in order to acknowledge all alarms.
Note: An active alarm is displayed until the active alarm becomes inactive.
Menu
SEBU8013-01
Illustration 32
The menu screen displays the following items:
• Settings
• Counters
• Generator
• Display
• Configuration
• Help g02163221
SEBU8013-01
Settings
49
Operation Section
Features and Controls
Illustration 33
Automatic/Manual
When the control unit is set to the AUTOMATIC mode, the control unit may be started from a remote signal and the control unit may be stopped from a remote signal. When the control unit is set to the
MANUAL position, the control unit may not be started from a remote signal and the control unit may not be stopped from a remote signal. When the control unit is In the MANUAL position, the M symbol is visible in the status bar.
Note: The control terminal 88 (Automatic mode) overrides a MANUAL setting in the menu. When the controller is in automatic mode, either the menu or the remote signal can issue commands.
Local/Remote
In LOCAL mode, the control unit cannot be operated remotely. An “L” symbol is visible in the status bar.
Communications commands are not operable in the
LOCAL mode.
Hard wired commands are not operable in LOCAL mode.
Start Disabled
Select the “START DISABLED” button in order to disable the starting mechanism for the engine.
g02176304
Note: Caterpillar recommends the removal of the connection to the battery before any maintenance on the engine is performed.
Prelube Override
If the engine is configured for prelube, the “PRELUBE
OVERRIDE” function can cancel the procedure. If the
“PRELUBE OVERRIDE” function is chosen during the prelube, the prelube is stopped and the control unit continues the start procedure.
50
Operation Section
Features and Controls
Counters
SEBU8013-01
Illustration 34
The “COUNTERS” screen displays the service hours for the engine.
Three options may be selected from the
“COUNTERS” screen:
• Counters
• Event Log
• Service Interval for the Engine
Total
The “TOTAL” screen displays the total service hours.
The operator may not reset the service hours.
Since Start
The “SINCE START” counter starts at ZERO each time the engine is started. The “SINCE START” counter continues to accumulate service hours until the engine is stopped. The operator may not reset the service hours.
g02177046
Since Restart
The “SINCE RESTART” screen displays the service hours which have accumulated since the reset function was last used. Press the “RESET” button in order to return the service hours which have accumulated after the last reset to zero.
SEBU8013-01
Events Log
51
Operation Section
Features and Controls
Illustration 35
Use the “UP” arrow and the “DOWN” arrow in order to navigate the event log.
An event may be any of the following items: diagnostic event, warning alarm, shutdown, and use of a button.
The control unit maintains a log of all events. The latest 500 logged entries may be displayed. When the number of events is larger than 500, the oldest events are lost.
The event log may be sorted in four ways:
• The oldest entry is displayed first.
• The most severe entry is displayed first.
• The least severe entry is displayed first.
• Count
Timestamp – The selected event will be expanded.
The second line displays the service hour at which the event occurred. For alarms, the second line also displays the service hours for an acknowledged inactive situation.
g02176307
Service Intervals for the Engine
Service intervals for four maintenance procedures may be programmed into the control unit. When a programmed interval occurs, the alarms list displays a wrench key beside the maintenance procedure.
When the maintenance is completed, select the maintenance procedure and press “SERVICE DONE” in order to restart the counter for the service hours for the service interval.
52
Operation Section
Features and Controls
Generator
SEBU8013-01
Illustration 36
A Power Analyzer Module (PAM) may be connected to the control unit in order to allow the control unit to read the parameters for the generator. The connection is shown by a “GENERATOR” symbol which is displayed on the generator screen.
Note: The page which displays the values for the generator may be accessed by pressing the “UP” button or by pressing the “DOWN” button from the normal instrument view.
g02177054
SEBU8013-01
Display
53
Operation Section
Features and Controls
Illustration 37
Screen Backlight
Select between the following settings for the screen backlight:
•
10 percent backlighting for the darkest setting.
•
50 percent backlighting for the medium setting.
•
100 percent backlighting for the setting with the most backlighting.
• The automatic setting uses an ambient light detector in order to vary the backlighting between
10 percent and 100 percent.
Units of Measure
Select the unit of measure:
• “METRIC”
• “US” (English)
Language
Select the language which will be displayed on the panel from the following languages: English,
French, Spanish, Italian, German, Dutch, Russian,
Norwegian, and Chinese.
g02176308
Note: Text for the configured instruments must be manually translated during the installation process. Selecting a language which has no manual translation causes the default language to be used.
Use the soft buttons while viewing an instrument screen to adjust the preferred language.
54
Operation Section
Features and Controls
Configuration
SEBU8013-01
Illustration 38
Test for Engine Overspeed
When the control unit is in the “ENGINE
OVERSPEED TEST” mode, the automatic procedure for shutting down the engine due to an overspeed condition may be tested by lowering the overspeed setpoint to the nominal speed. Use the following procedure to perform this test:
1. Make sure that the engine is not running. The
“ENGINE OVERSPEED TEST” mode cannot be entered if the engine is running.
2. Observe the red arc on the “RPM METER” in order to make sure that the overspeed setpoint has been lowered.
3. Start the engine and adjust the rpm until the rpm rises above the overspeed setpoint.
4. Observe the engine shutdown.
The test for engine overspeed is timed out after
5 minutes or when an actual overspeed situation occurs. The test can be stopped by selecting the
“Engine Overspeed Test” again.
g02176309
SEBU8013-01
Help
Illustration 39
A number of troubleshooting screens exist for the control unit.
g02176580 g02176619
Illustration 40
55
Operation Section
Features and Controls
56
Operation Section
Features and Controls
Supply
The two power supplies are listed. Information about voltage and information about supply selection may be viewed.
Switch Channels
Each of the eight switch channels may be viewed for information about whether the switch is open (“OV”) or closed (“24v INPUT”).
4-20mA Channels
The following information may be displayed for each of the 4-20mA channels:
•
Current, 2-25mA which is indicated in mA
• Broken wire (<2mA)
•
Short circuit (>25mA)
•
Channel use
PT100 Channels
The following information may be displayed for each of the four PT100 channels:
•
Value
•
Faulty circuit
• Channel use
COM (Communications)
This section lists the communication status for communication ports 1, 2, 3, 4, and 6.
Output
This section lists the output status on terminals 63 through 84 for the control unit.
Input
This section lists the input status on terminals 86 through 97 for the control unit.
Run Indication Sources
A number of different sources may be configured to indicate engine operation. The “RUN INDICATION” page indicates which source is providing the information about engine operation to the control unit.
SEBU8013-01
Button Test
This section allows all control unit buttons to be tested. To exit the “BUTTON TEST” tab, press and hold the second soft button. Press the fourth soft button to exit. Press the first soft button to change tabs.
SEBU8013-01
Version Information
57
Operation Section
Features and Controls
Illustration 41
This section displays the following information:
• Hardware version
• Software version
• ECM version (if applicable)
• Internet Protocol (IP) number of the control unit g02176577
58
Operation Section
Features and Controls i04001712
Control Panel
(Marine Classification Society
Remote Control Panel (MCS
Remote Control Panel) (If
Equipped))
SMCS Code: 7451
SEBU8013-01
Illustration 42
MCS Remote Panel
(1) LCD display
(2) Status bar
(3) Home
(4) Alarms list
(5) Start button
(6) Stop button
The four buttons have the following functions:
•
The “START” button starts one or more engines
•
The“STOP” button stops one or more engines
•
The“ALARMS LIST” button displays the alarms list
•
The “HOME” button displays the top-level instrument display
The display is divided into three main sections:
• The “STATUS BAR” is reserved for status symbols.
• The instruments and menu icons are displayed g02177257
(7) Soft keys
•
The “SOFT BUTTON” line is reserved for soft buttons whose meaning varies depending on the selected display.
SEBU8013-01 59
Operation Section
Features and Controls
Illustration 43
Symbols and Indication Icons
Status Bar
Local Mode (L)
When the symbol “L” is displayed, the corresponding
MCS Controller engine panel is in local mode. The remote panel cannot acknowledge alarms or activate the start or stop functions. The “LOCAL/REMOTE” setting may be used to activate the remote function.
Manual Mode (M)
When the symbol “M” is displayed, the corresponding
MCS Controller engine control unit is in manual mode. The automatic start and automatic stop functions are inactive when the MCS Controller is in the manual mode.
Shutdown Override (SO)
When the symbol “SO” is displayed, the corresponding MCS Controller engine panel is in shutdown override mode. The automatic shutdown function is inactive when the MCS Controller is in the shutdown override mode. The following functions are not affected by the shutdown override mode:
•
Overspeed shutdown functions g02163222
•
Oil mist detection
Service and Diagnostics (Service Wrench Icon)
The service wrench symbol is displayed in the status bar during the following circumstances:
•
Scheduled service is due.
•
A white diagnostic from the engine control module
(ECM) is active.
Active Station (Rectangular Symbol)
One active station symbol is a large rectangular symbol in the top right corner of the display. Three meanings are possible when the rectangular active station symbol is displayed:
•
If the symbol is black and the text “Inactive Station” is displayed, the remote panel is not an active station for any engine.
•
If the symbol is orange and black and the text
“Active Station” is displayed, the remote panel is the active station for one or more engines, but not for all engines in the network.
•
If the symbol is orange and the text “Active Station” is displayed, the remote panel is the active station for all of the engines in the network.
60
Operation Section
Features and Controls
Active Station (Star Symbol)
One active station symbol is star shaped. An orange star is displayed when the display is for a single engine and the remote panel is the active station for the engine. When the display is divided into two or four quadrants, the active station star is displayed in the name and engine status banner.
Warning and Alarm Triangles
A yellow triangle is displayed when a warning exists on this channel. If the triangle flashes, the warning is unacknowledged. A red triangle is displayed when an alarm or a shutdown situation exists on this channel.
If the triangle flashes, the alarm or shutdown situation is unacknowledged.
Press the “ALARMS LIST” button for details of the warning or the alarm.
Start and Stop Engines
Start One or More Engines
Use the following procedure to start one or more engines:
1. Press the “START” button.
2. Select one or more engines to start by pressing the touch display. Each selected engine icon will be displayed inside a white rectangle.
3. Press the “OK” button again to start the selected engines.
Stop One or More Engines
Multiple engines may be stopped at the same time.
1. Press the “STOP” button
2. Select one or more engines to start by pressing the touch display. Each selected engine icon will be displayed inside a white rectangle.
3. Press the “OK” button again to stop the selected engines.
Alarms List
Press the “ALARMS LIST” button to enter the alarm list. All current alarms will be visible on the display.
Press the “ALARMS LIST” button again to leave the alarms list.
Alarms are displayed in several colors and texts.
SEBU8013-01
•
The following entries are displayed in red text: alarm entries, shutdown entries, and automatic stop entries.
•
Warnings are displayed in yellow text.
•
New alarms (unacknowledged alarms) are displayed in bold text.
•
Acknowledged alarms are displayed in normal text.
•
An alarm that is not acknowledged before becoming inactive is displayed in normal text on a gray background.
•
An inactive alarm that is displayed on a red background was either an alarm or a shutdown.
•
An inactive alarm that is displayed on a yellow background was a warning.
Silence the Alarm
If the alarm sounds, press the “ALARMS LIST” button to silence the alarm. If the alarms list is not displayed when the alarm sounds, pressing the “ALARMS
LIST” button will display the alarms list.
Acknowledge an Alarm
When a star is displayed before an engine name, the remote panel is the active station of that engine. An alarm with a star displayed before the engine name may be acknowledged with the remote panel. An alarm without a star before the engine name may not be acknowledged with the remote panel unless the remote panel become the active station for that engine.
Acknowledge a Single Alarm
Touch the alarm that you want to acknowledge.
The alarm line will expand to reveal any additional information. Press the “ACKNOWLEDGE .” button to acknowledge the selected alarm
Acknowledge All Alarms
In the alarm list, press and hold for at least one second the “ACKNOWLEDGE” button. This action acknowledges all alarms.
Note: Alarms that are still active remain displayed until the alarms become inactive. The active acknowledged alarms are displayed with a gray background.
SEBU8013-01
Filter Alarms
The remote panel may receive alarms from up to eight different MCS Controller engine panels (MCS
Controller engine panels) at one time. Two buttons may be used for filtering the alarms:
• The “ENGINE VIEWS” button (soft button 2)
•
The “ALARM VIEWS” soft button 3
Note: A yellow dot in the center of the button indicates that a filter is applied.
Engine Views
Press “ENGINE VIEWS” for a selection of engine filters. All engines connected to the remote panel appear on the list. The list also includes the following selections: “THIS STATION” and “ALL”.
Selecting “THIS STATION” only displays alarms built into the remote panel. Selecting an only engine name displays alarms from the selected engine.
Selecting“ALL” displays all alarms from all sources.
Alarm Views
Press “ALARM VIEWS” to filter alarm types from the MCS Controller engine panels. Select “PANEL
ALARMS” to display only panel alarms and not alarms from the ECM. Select “ECM DIAGNOSTICS” to display only the diagnostic messages and alarms from the ECM. Select “ALL” to display all alarms from all sources.
Home Button
Press the “HOME” button to display the top-level engine instruments. Press and hold the “HOME” button for 1 second to display the menu.
Menu
The menu may be accessed by the following methods:
•
Press the “HOME” button then press soft button 1.
•
Press and hold the “HOME” button for 1 second.
Active Station
The “ACTIVE STATION” selection is useful when there are multiple remote panel stations in the installation. Press “ACTIVE STATION” to bring up the active station dialog.
61
Operation Section
Features and Controls
Camera
An Internet Protocol camera (IP camera) may be connected to the ethernet network. The image may be displayed on the remote panel display. As many as four cameras may be connected to one remote panel.
All four images may be displayed simultaneously.
The image update rate is 4 to 5 frames per second.
Touch any small image to enlarge the image or touch any full sized image to reduce the image to one fourth of the display.
Backlight
Select between the following settings for the display backlight:
•
10 percent backlighting for the darkest setting.
•
50 percent backlighting for the medium setting.
•
100 percent backlighting for the setting with the most backlighting.
•
The automatic setting uses an ambient light detector in order to vary the backlighting between
10 percent and 100 percent.
In the “AUTOMATIC” mode, an ambient light detector is used to determine the correct amount of backlighting. In the “NIGHT” mode, the display is turned off when no activity is present for 10 seconds. The display will activate upon an alarm or an operator action. The display will stay lit as long as unacknowledged alarms exist.
Generator
Any generator images or values are displayed when the MCS Controller engine panel is reading generator parameters from the PAM.
Languages
Select the operator language for the remote control panel . The instruments text descriptions reside in the
MCS Controller engine panel and must be translated for each language during the installation of the MCS
Controller engine panel. If a language is selected for which no translation exists, the default language is used.
Counters
The counters page displays service hours for all engines.
62
Operation Section
Features and Controls
SEBU8013-01
Illustration 44
Information
The information page displays IP addresses and revision numbers. The MCS Controller engine panel section displays the IP addresses of the connected engine panels.
Configuration
Pressing “CONFIGURATION” opens the configuration sub-menu section. The configuration page is not password protected.
Wallpaper
The wallpaper is the background image for the instrument displays. The following wallpaper options are available:
•
A wallpaper may be selected from the selection of available wallpapers.
•
A personal wallpaper may be uploaded using an internet web site interface.
Button Beep
Select the “ON” position to enable sound to accompany each button activity and each touch display activity. Select“OFF” to turn off the sound.
g02176297
Sound Configuration
The remote panel includes two speakers for sound and a buzzer. Use this function to choose the source for sound.
Note: The speaker sound is also available on the
3.5 mm (0.14 inch) standard minijack output on the rear of the panel.
Home Page Layout
Press the “HOME” button to access the home page.
The home page displays engine instrument screens.
The following configurations are available.
•
Selecting “SINGLE SCREEN” displays the engine with the lowest IP number. Any other engines may be accessed with the “PREVIOUS” button and the
“NEXT” button.
•
Selecting “DUALSCREEN” displays the engine with the lowest IP number on the left side of the display and the engine with the next IP number on the right side. Any other engines ay be accessed with the “PREVIOUS” button and the “NEXT” button.
SEBU8013-01
•
Selecting “QUAD SCREEN” displays the engine with the lowest IP number on the top left portion of the display. The engine with the next IP number is displayed on the top right portion of the display.
The engine with the next IP number is displayed on the lower left portion of the display. The information for as many as five additional engines may be accessed on the lower right portion of the display with the “PREVIOUS” and “NEXT” buttons.
Calibrate Touch Screen
The touch display may be recalibrated. If the touch function is not operational, press and hold the
“HOME” button for 10 seconds and the calibration screen will be displayed.
Units
Use this function to choose the preferred units of measure.
Troubleshooting
Selecting “TROUBLESHOOTING” displays the troubleshooting information.
System Configuration
The system configuration submenu is password protected. The password in a four-digit number. If an incorrect password is entered, the panel issues an encrypted code. This code is used by the factory to revert to the original password.
63
Operation Section
Features and Controls
64
Operation Section
Features and Controls
Electronic Modular Control
Panel 3 (EMCP 3)
(If Equipped)
i04033308
SMCS Code: 4490
Electronic Control Module 3
(ECMP3)
SEBU8013-01
Illustration 45
(1) Display screen
(2) AC overview key
(3) Engine overview key
(4) Yellow warning lamp
(5) Red shutdown lamp
(6) Acknowledge key
(7) Lamp test key
(8) Run key
(9) Auto key
(10) Stop key
(11) Up key
(12) Escape key
Navigation Keys
AC Overview (2) – The “AC OVERVIEW” key will navigate the display to the first screen of AC information. The “AC OVERVIEW” information contains various AC parameters that summarize the electrical operation of the generator set.
Engine Overview (3) – The “ENGINE OVERVIEW” key will navigate the display to the first screen of engine information. The “ENGINE OVERVIEW” information contains various engine parameters that summarize the operation of the generator set.
g01045431
(13) Right key
(14) Enter key
(15) Down key
(16) Left key
Acknowledge Key (6) – Pressing the
“ACKNOWLEDGE” key will cause the horn relay to turn off and will silence the horn. Pressing this key may also cause the red flashing light or yellow flashing light to turn off. Pressing this key may also cause the red flashing light or the yellow flashing lights to come on continuously. The
“ACKNOWLEDGE” key may be configured to send a global alarm silence signal on the J1939data link which will silence the horns on the annunciators.
SEBU8013-01
Lamp Test Key (7) – Pressing and holding the
“LAMP TEST” key will cause each LED and the display screen pixels to turn on continuously until the key is released.
RUN Key (8) – Pressing the “RUN” key will start the engine.
AUTO Key (9) – Pressing the “AUTO” key will cause the engine to enter the “AUTO” mode. The engine will start if the module receives a start command from a remote source.
STOP Key (10) – Pressing the “STOP” key will stop the engine.
Up Key (11) – The “UP” key is used to navigate through the various menus and monitoring screens.
The “UP” key is also used when a setpoint is entered.
When numeric data is entered, the “UP” key is used in order to increment the digits (0-9). If the setpoint requires selection from a list, the “UP” key is used to navigate UP through the list.
Escape Key (12) – The “ESCAPE” key is used in order to navigate through the menus. When the key is pressed, the user moves backward or the user moves upward through the menus. The “ESCAPE” key is also used to exit out of entering data when the user is programming the setpoints. If the “ESCAPE” key is pressed during setpoint adjustment, changes that are made on the screen will not be saved.
Right Key (13) – The “RIGHT” key is used during setpoint adjustment. The “RIGHT” key is used to select a digit that will be edited as numeric data is entered. The “RIGHT” key is also used to select a check box as setpoint adjustments are made. The
“RIGHT” key is also used to unselect a check box as setpoint adjustments are made. If a check box has a check mark, the function has been enabled. Pressing the “RIGHT” key will disable the function. Pressing the “RIGHT” key will also cause the check mark to disappear. If the check box does not have a check mark, the function is disabled. Pressing the “RIGHT” key will enable the function. Pressing the “RIGHT” key will also cause a check mark to appear.
Enter Key (14) – The “ENTER” key is used in order to navigate through the menus. When the key is pressed, the user moves forward or the user moves downward through the menus. The “ENTER” key is also used to save any changes while the setpoints are being programmed. Pressing the “ENTER” key during programming the setpoints causes the changes to be saved to memory.
65
Operation Section
Features and Controls
Down Key (15) – The “DOWN” key is used to navigate downward through the various menus or screens. The “DOWN” key is also used to program the setpoints. The “DOWN” key is used to decrease the digits as numeric data is entered. If the setpoint requires selection from a list, the “DOWN” key is used to navigate DOWN through the list.
Left Key (16) – The “LEFT” key is used during setpoint adjustment. The “LEFT” key is used to select the digit that is edited during the entry of numeric data. The “LEFT” key is also used during some of the setpoint adjustments to select a check box. The key is also used to unselect a check box. If a check box has a check mark, pressing the “LEFT” key will disable the function. Pressing the key will also remove the check mark. Pressing the “LEFT” key will also cause the check mark to disappear. If the check box does not have a check mark, pressing the “LEFT” key will enable the function. Pressing the
“LEFT” key will also cause a check mark to appear.
Alarm Indicators
Yellow Warning Lamp (4) – A flashing yellow light indicates that there are active warnings that have not been acknowledged. A continuous yellow light indicates that there are acknowledged warnings that are active. If there are any active warnings, the yellow light will change from flashing yellow to continuous yellow after the “ACKNOWLEDGE” key is pressed. If there are no longer any active warnings, the yellow light will turn off after the “ACKNOWLEDGE” key is pressed.
Red Shutdown Lamp (5) – A flashing red light indicates that there are active shutdowns that have not been acknowledged. A continuous red light indicates that there are active shutdowns that have been acknowledged. If there are any active shutdowns, the red light will change from flashing red to continuous red after the “ACKNOWLEDGE” key is pressed. Any condition that has caused a shutdown must be manually reset. If there are no longer any active shutdowns, the red light will turn off.
Digital Inputs
Note: There are eight digital inputs on “EMCP 3.2” and “EMCP 3.3”. There are six digital inputs on
“EMCP 3.1”.
66
Operation Section
Features and Controls
Digital Input 1 – Digital Input 1 is used for the emergency stop. This input should be wired to
GROUND through an Emergency Stop switch.
The input can be set to activate on an active high
(normally closed contact) or an active low (normally open contact). Activating the emergency stop input will cause the generator set to stop immediately. The emergency stop input will also prevent the generator set from starting. As Digital Input 1 is activated, the engine will not start until the event has been cleared.
Refer to System Operation, Troubleshooting, Testing and Adjusting, RENR7902, “Digital Input Resetting”.
Digital Input 2 – Digital Input 2 is used for remotely starting and stopping the generator set. This input should be wired to GROUND through a switch that can be initiated remotely. The input can be set to activate on an active high (normally closed contact) or an active low (normally open contact). If the input is active and the engine is in AUTO, the engine will attempt to start. If the input is inactive, the engine will enter cooldown mode and the engine will stop.
The remainder of the inputs can be configured. The
“DIGITAL” input adds additional monitoring of the engine and generator. The inputs can be configured by going to the “EVENT I/P FUNCTIONS” parameter under the “SETPOINTS” menu. The “DIGITAL
INPUTS” parameter can only be set to “ACTIVE
HIGH” or “ACTIVE LOW”to initiate a High Warning,
Low Warning, High Shutdown, Low Shutdown, or
Status.
The inputs can be programmed to monitor the following parameters or components. Refer to
System Operation, Troubleshooting, Testing and
Adjusting, RENR7902, “Digital Input Programming”.
Pressures
•
Air filter differential pressure
•
Engine oil pressure
•
Fire extinguishing system
•
Fuel filter differential pressure
•
Oil filter differential pressure
•
Starting air pressure
Temperatures
•
Ambient air temperature
•
Engine coolant temperature
•
Engine oil temperature
•
Exhaust temperature
Illustration 46
SEBU8013-01
•
Rear bearing temperature
•
Right exhaust temperature
•
Left exhaust temperature
Levels
•
Engine coolant level
•
Engine oil level
•
Fuel level
•
External fuel tank level
Other
•
Closed air damper
•
ATS in normal position
•
ATS in emergency position
•
Battery charger failure
•
Closed breaker
•
Closed utility breaker
•
Detected fuel leak
•
Custom event
For detailed information about the electronic control module, see Systems Operation, Troubleshooting,
Testing and Adjusting, RENR7902, “EMCP3”.
Annunciator Module
g01101388
SEBU8013-01
General Information
The annunciator module is used to indicate various system events and conditions. The annunciator module uses indicator lights and an audible horn to give the operator information about the current status of the system. The annunciator module can be used to announce faults and/or status signals to the operator. The annunciator module allows the operator to silence the horn. The annunciator module also allows the operator to acknowledge faults to the system.
There are 17 pairs of LED indicators on the front panel of the annunciator. Sixteen pairs of LED indicators are used to announce events, diagnostics, and ready signals. The seventeenth pair of led indicators is used as a combined network operation and module information. The seventeenth pair of LED indicators alerts the operator if there is a problem with the J1939 data link connection.
Basic Operation
Each pair of LED indicators on the annunciator consists of two of the following three colors: green, yellow, and red. For example, a pair of red and yellow LED indicators may be configured for engine oil pressure. If a low engine oil pressure condition is read over the data link, the annunciator will flash the yellow LED and the audible horn will sound. If the low oil pressure shutdown is read over the data link, the annunciator will flash the red LED and the audible horn will sound.
Press the “Alarm Acknowledge” key in order to acknowledge a shutdown condition. Press the
“Alarm Acknowledge” key to acknowledge an alarm condition . In order to silence the horn, press the
“Alarm Acknowledge” key that is located near the middle of the annunciator.
Test the led indicators by pressing the “Lamp Test” key near the top of the annunciator. Test the horn when the data link is connected by holding in the
“Lamp Test” key. Test the horn when the data link is disconnected by pressing the “Lamp Test” key that is located near the top of the annunciator.
Configuration
The annunciator module can be customized in order to signal many different conditions that are related to the system. Each pair of LED lights must be configured by using the appropriate service tool.
Once the service tool has been connected to the annunciator, the user must enter the “Configuration” screen. Each pair of LED lights has four settings:
SPN, Trigger Type, Trigger Severity Level, and
Failure Mode Identifier (FMI).
67
Operation Section
Features and Controls
For detailed information about the annunciator module, see Systems Operation, Troubleshooting,
Testing and Adjusting, RENR7902, “EMCP3”.
68
Operation Section
Features and Controls i03996173
Sensors and Electrical
Components
(Engines Equipped with MCS
Control Unit)
SMCS Code: 1439; 1900; 7400
SEBU8013-01
Illustration 47
View of the left side of a C18 Marine Engine with left side service
(1) Low oil pressure alarm
(2) Low coolant level alarm
(3) Low oil pressure shutdown
(4) High coolant temperature shutdown
(5) Oil pressure (after filter)
(6) Oil pressure (pre-filter)
(7) Low air pressure for starting motor alarm (engines equipped with air starting motor)
(8) Low oil level alarm
(9) Fuel pressure (after filter)
(10) Fuel pressure (pre-filter) g02173989
SEBU8013-01 69
Operation Section
Features and Controls
Illustration 48
View of the right side of a C18 Marine Engine with left side service
(11) High oil temperature alarm (12) Low coolant pressure alarm g02173990
Illustration 49
View of the left side of a C18 Marine Engine with right side service
(1) Low oil pressure alarm
(2) Low coolant level alarm
(3) Low oil pressure shutdown
(4) High coolant temperature shutdown g02173991
(7) Low air pressure for starting motor alarm
(8) Low oil level alarm
70
Operation Section
Features and Controls
SEBU8013-01
Illustration 50
View of the right side of a C18 Marine Engine with right side service
(5) Oil pressure (after filter)
(6) Oil pressure (pre-filter)
(9) Fuel pressure (after filter)
(10) Fuel pressure (pre-filter)
(11) High oil temperature alarm
(12) Low coolant pressure alarm g02173993
SEBU8013-01
Battery Disconnect Switch
(If Equipped)
i03646563
SMCS Code: 1411-B11; 1411
The battery disconnect switch and the engine start switch perform different functions. Turn off the battery disconnect switch in order to disable the entire electrical system. The battery remains connected to the electrical system when you turn off the engine start switch.
Turn the battery disconnect switch to the OFF position and remove the key when you service the electrical system or any other components.
Also turn the battery disconnect switch to the OFF position and remove the key when the engine will not be used for an extended period of a month or more.
This will prevent drainage of the battery.
NOTICE
Never move the battery disconnect switch to the OFF position while the engine is operating. Serious damage to the electrical system could result.
To ensure that no damage to the engine occurs, verify that the engine is fully operational before cranking the engine. Do not crank an engine that is not fully operational.
Perform the following procedure in order to check the battery disconnect switch for proper operation:
1. With the battery disconnect switch in the ON position, verify that electrical components are functioning. Verify that the hour meter is displaying information. Verify that the engine will crank.
2. Turn the battery disconnect switch to the OFF position.
3. Verify that the following items are not functioning: electrical components, hour meter, and engine cranking. If any of the items continue to function with the battery disconnect switch in the OFF position, consult your Caterpillar dealer.
71
Operation Section
Features and Controls i01097127
Engine Shutoffs and Engine
Alarms
SMCS Code: 1900; 7400; 7418
Shutoffs
Shutoffs and alarms are one of two types:
•
Electrical
•
Mechanical
All electric shutoffs and all electronic alarms operate through components that actuate switches in a sensing unit.
Shutoffs are set at critical levels for the following conditions:
•
Operating temperature
•
Operating pressure
•
Operating level
•
Operating rpm
A particular shutoff may need to be reset before the engine will start.
NOTICE
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart the engine.
Make sure that you are familiar with the following items:
• Types and locations of shutoff
•
Conditions that cause each shutoff to function
•
Resetting procedure for engine restart
Alarms
Engines may be equipped with alarms that are used to alert the operator when undesirable operating conditions occur.
NOTICE
When an alarm is activated, corrective measures must be taken before the situation becomes an emergency in order to avoid possible engine damage.
72
Operation Section
Features and Controls
Once an alarm is activated, corrective measures need to be taken within a reasonable amount of time, or engine damage could result. The alarm will continue until the condition is corrected. The alarm may need to be reset.
A switch may be installed in the alarm for silencing.
This may be installed while the engine is stopped for repairs. Check for this switch before you start the engine. Make sure that the switch is moved to the
ON position and that the warning lights are flashing.
The engine will not be protected if the switch is left in the OFF position.
Testing the Shutoff and Alarm
System
Most control panels are equipped with a lamp test switch. Turn the switch to the ON position in order to check the indicator lights for proper operation.
Replace defective bulbs immediately.
NOTICE
During testing, abnormal operating conditions must be simulated. Perform the tests correctly in order to help prevent possible engine damage.
Refer to the Service Manual for more information on testing procedures, or consult your Caterpillar dealer.
i04009894
Voltage Regulators
SMCS Code: 4467
Cat Digital Voltage Regulator (Cat
DVR)
The Cat Digital Voltage Regulator presents an electrical shock/electrocution hazard. This hazard will cause serious injury or death.
Service by trained personnel only.
The terminals and heat sinks are live at hazardous voltages when power is applied and for up to 8 minutes after power is removed.
SEBU8013-01 g01115009
Illustration 51
The Cat DVR is a microprocessor-based voltage regulator. Control power for the Cat DVR is supplied from an external source of 24 VDC. The power stage of the Cat DVR is supplied from a multiple pole high frequency permanent magnet generator which is mounted on the end of the generator shaft.
Connections to the Cat DVR are made through three connectors. The communication between the Cat
DVR and the service tool is accomplished by using a
CANBUS protocol.
The Cat DVR has the following features:
• Three control modes:
1. Automatic voltage regulation (AVR)
2. Power factor (PF) regulation
3. Reactive power (VAR) regulation
•
Programmable stability settings
• Soft start control with an adjustable time setting in AVR mode
•
Dual slope voltage versus frequency (V/Hz) characteristic
• Three-phase or single-phase voltage sensing
• Single-phase current sensing
SEBU8013-01
•
Field current sensing and field voltage sensing
•
Ten protection functions
Adjusting the Cat DVR
In order to view and configure the parameters of the
Cat DVR, a PC with the Caterpillar DVR software is required.
Refer to Specifications, Systems Operation, Testing and Adjusting, RENR7941, “Cat Digital Voltage
Regulator” for complete information.
73
Operation Section
Features and Controls
74
Operation Section
Engine Diagnostics
Engine Diagnostics
Configuration Parameters
i03568753
SMCS Code: 1000; 1900; 1901; 1902
System configuration parameters are parameters that are configured to specify the engine’s emissions levels, the power rating, and the specific application.
Default values for the parameters are programmed at the factory. Some parameters may be changed in order to equip the engine for a specific application.
The system configuration parameters must be reprogrammed if the electronic control module (ECM) is replaced. It is not necessary to reprogram the system configuration parameters if you update the
ECM flash file. Certain configuration parameters are stamped into the engine information plate.
Note: If the parameters that are protected with the factory passwords are changed, the Caterpillar warranty may be voided.
Table 2
Parameter Worksheet
Security Access Parameters
Equipment ID
ECM Serial Number
Software Group Part Number
Software Group Release Date
Software Group Description
Selected Engine Rating
Rating Number
Rated Frequency
Rated Engine Speed
Rated Real Genset Power
Rated Apparent Genset Power
Rating Configuration
Test Spec
Engine/Gear Parameters
Engine Acceleration Rate
Low Idle Speed
Engine Speed Droop
Droop/Isochronous Switch Enable
Droop mode selection
Remote Emergency Stop (E-Stop) Switch Input Type Configuration
SEBU8013-01
(continued)
SEBU8013-01 75
Operation Section
Engine Diagnostics
(Table 2, contd)
Desired Speed Input Configuration
Secondary Desired Speed Input Configuration
(2)
Parameter Worksheet
I/O Configuration Parameters
Fuel Enable Input Configuration
Secondary Fuel Enable Input Configuration
Coolant Level Installation Status
Maintenance Parameters
Engine Oil Capacity
“Maintenance Indicator Mode”
“PM1 Interval”
System Settings
Governor Gain Factor
Governor Minumum Stability Factor
Governor Maximum Stability Factor
Injector Serial Numbers
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
Cylinder 5
Cylinder 6
Information from the Engine Information Plate
Engine Serial Number
FLS
FTS
(2) The configuration of this parameter is dependent on the configuration of the throttle controls for the application. Refer to Troubleshooting,
“Speed Control — Test” for additional information.
Parameter Descriptions
Equipment ID
This parameter allows the customer to enter a description into the electronic control module (ECM) in order to identify the engine’s application. A maximum of 17 characters can be entered in the field.
Engine Serial Number
The engine serial number must be programmed to match the engine serial number that is stamped on the engine information plate. The engine serial number is not preprogrammed into a replacement
ECM.
ECM Serial Number
The serial number of the ECM that is stored in the
ECM memory
Software Group Part Number
The part number of the flash file that is currently installed in the ECM
Software Group Release Date
The release date of the flash file that is currently installed in the ECM
76
Operation Section
Engine Diagnostics
Software Group Description
The description of the application for the flash file that is currently installed in the ECM
Rating Number
The rating number corresponds to the selected set of performance maps that has been selected for this application. There may be more than one set of performance maps that are available for this engine.
All of the maps are resident in the flash file for the engine.
Rated Frequency
The line frequency of the generator set
Rated Engine Speed
The optimum speed of the engine
Rated Real Genset Power
The output power of the generator set in kilowatts
Rated Apparent Genset Power
The kVA rating of the generator set
Rating Configuration
The performance maps in the software
Test Spec
This is the engine’s “Test Specifiction Number”. Use this number to retrieve data that is related to the engine’s specifications from the Technical Marketing
Information System (TMI). The following information can be retrieved from TMI:
•
“As shipped consists”
•
“Engine test specifications”
• “Systems data”
•
“Physical data”
•
“Gasket kit data”
• “Reman parts”
•
“Performance data”
A link to TMI Web can be found on the web site for the Service Information System (SIS).
SEBU8013-01
Engine Acceleration Rate
This parameter defines the maximum rate of engine acceleration.
Low Idle Speed
This parameter defines the low idle rpm of the engine.
Engine Speed Droop
This parameter enables the engine to be operated in a load sharing system.
Droop/Isochronous Switch Enable
This parameter defines the installation status of a switch that is used to select droop or isochronous mode.
Droop Mode Selection
This parameter allows the customer to select droop or isochronous mode.
Remote Emergency Stop (E-Stop) Switch
Input Type Configuration
This parameter sets the installation status and the configuration of the emergency stop switch.
Desired Speed Input Configuration
This parameter defines the type of signal that is used for throttle control. This parameter will be used while a valid signal is present at the expected input.
The following input types are available:
PWM – A Pulse Width Modulated signal (PWM) is received via terminal P1-66 at the ECM connector.
CAN Input – A J1939 signal is received via the CAN data link.
0 — 5 VDC – An analog signal is received via terminal
P1-15 at the ECM connector.
Secondary Desired Speed Input
Configuration
This parameter defines the type of signal that is used as a secondary throttle control. If the signal for this input becomes unavailable, the ECM will revert to this type of signal for the throttle control. Refer to
“Desired Speed Input Configuration” for the input types that are available.
SEBU8013-01
Fuel Enable Input Configuration
This parameter allows the selection for the type of input that is used to enable the fuel for the engine.
Secondary Fuel Enable Input Enable
Status
This parameter sets the installation status of a secondary switch that can be used to enable the fuel for the engine.
Coolant Level Sensor
This parameter can be set to either “Installed” or “Not
Installed”.
Engine Oil Capacity
Program this parameter to the capacity of engine oil for the engine.
Maintenance Indicator Mode
The ECM records data that is related to equipment maintenance. The ECM will activate the maintenance indicator lamp when scheduled maintenance is due. The maintenance indicator lamp can be reset by actuating the maintenance clear switch. The maintenance interval may be based on operating hours or fuel consumption. The ECM provides information that pertains to maintenance intervals and the last maintenance that was performed.
PM1 Interval
This parameter allows the customer to define the maintenance interval if “Maintenance Indicator Mode” is programmed to one of the manual options. Refer to the Operation and Maintenance Manual for more information.
Governor Gain Factor
This parameter is used in determining the engine’s rate of response to an engine load.
Governor Minimum Stability Factor
This parameter is used by the ECM to offset the steady state speed error when the steady state speed error is less than 20 rpm.
Governor Maximum Stability Factor
This parameter is used by the ECM to offset the steady state speed error when the steady state speed error is greater than 20 rpm.
77
Operation Section
Engine Diagnostics
FLS
This parameter represents the fuel system adjustment that was made at the factory in order to fine tune the fuel system to the engine. The correct value for this parameter is stamped on the engine information plate. Only change this value if the engine is rerated or if a new ECM has been installed. Factory passwords are required to change this parameter.
FTS
This parameter is another parameter that represents a fuel system adjustment that was performed at the factory in order to fine tune the fuel system to this engine. Only change this value if the engine is rerated or if a new ECM has been installed. Factory passwords are required to change this parameter.
Total Tattletale
The total tattletale counts the number of changes to system parameters.
78
Operation Section
Engine Starting
Engine Starting
i01486758
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information.
•
For the maximum service life of the engine, make a thorough inspection before the engine is started.
Look for the following items: oil leaks, coolant leaks, loose bolts, and trash buildup. Remove trash buildup and arrange for repairs, as needed.
•
Inspect the cooling system hoses for cracks and for loose clamps.
• Inspect the alternator and accessory drive belts for cracks, breaks, and other damage.
•
Inspect the wiring for loose connections and for worn wires or frayed wires.
• Check the fuel supply. Drain water from the water separator (if equipped). Open the fuel supply valve.
NOTICE
All valves in the fuel return line must be open before and during engine operation to help prevent high fuel pressure. High fuel pressure may cause filter housing failure or other damage.
If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have entered the filter housing. Also, when fuel filters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance
Manual, “Fuel System — Prime” for more information on priming the fuel system.
SEBU8013-01
•
Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.
•
Ensure that the areas around the rotating parts are clear.
•
All of the guards must be put in place. Check for damaged guards or for missing guards. Repair any damaged guards. Replace damaged guards and/or missing guards.
• Disconnect any battery chargers that are not protected against the high current drain that is created when the electric starting motor (if equipped) is engaged. Check electrical cables and check the battery for poor connections and for corrosion.
•
Reset all of the shutoffs or alarm components.
•
Check the engine lubrication oil level. Maintain the oil level between the “ADD” mark and the “FULL” mark on the oil level gauge.
•
Check the coolant level. Observe the coolant level in the coolant recovery tank (if equipped). Maintain the coolant level to the “FULL” mark on the coolant recovery tank.
• If the engine is not equipped with a coolant recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant level in the sight glass.
• Observe the air cleaner service indicator (if equipped). Service the air cleaner when the yellow diaphragm enters the red zone, or when the red piston locks in the visible position.
•
Ensure that any driven equipment has been disengaged. Minimize electrical loads or remove any electrical loads.
Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.
SEBU8013-01 i02377318
Starting the Engine
(EMCP 3 (If Equipped))
SMCS Code: 1000; 1450
1. Start the engine by one of these three methods.
•
The operator presses the “RUN” Key.
•
The control is in “AUTO” and the remote initiate contact (IC) becomes active.
•
The operator presses the “AUTO” Key and a start command is sent via the RS-485 SCADA
Data Link.
2. The EMCP 3 checks the system before the crank cycle begins. The EMCP 3 checks that no system faults are present. The EMCP 3 checks that all previous shutdown faults have been reset. The
EMCP 3 also checks that the engine is not already running. If the engine is equipped with prelube, the EMCP 3 checks the status of the prelube. If the prelube is not complete, the EMCP 3 will not crank the engine.
3. The EMCP 3 begins the crank cycle.
4. The EMCP 3 cranks the engine until the crank cycle time reaches the setpoint for total crank time or until the engine starts.
5. The EMCP 3 deactivates the starting motor relay (SMR) when the engine speed reaches the setpoint for crank terminate speed.
SMCS Code: 1000; 1450
79
Operation Section
Engine Starting i03900529
Starting the Engine
(If Equipped with Marine
Classification Society Control
Unit (MCS Control Unit))
g02174258
Illustration 52
MCS Control Unit
(1) “START” button
(2) “STOP” button
The “START” button may be configured as LATCHED or as HOLD. The values for the “START” button and the values for the “STOP” button always match.
Start the engine with one of two methods:
•
If the “START” button is configured as LATCHED, perform the following sequence in order to start the engine: press the “START” button., observe the confirmation dialog, and press “YES” . The control unit will complete the starting sequence.
•
If the “START” button is configured as HOLD, press and hold the “START” button until the engine starts.
i02706577
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Refer to the Owner’s Manual of the OEM for your type of controls. Use the following procedure in order to start the engine.
80
Operation Section
Engine Starting
SEBU8013-01
DO NOT USE ETHER (starting fluids) unless specifically instructed to do so. If the engine is equipped with an Air Inlet Heater (electrically or fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result in engine damage and/or personal injury.
Startability will be improved at temperatures below
10°C (50°F) from the use of a cylinder block coolant heater or from other means that are used to heat the crankcase oil. Some engine applications use a jacket water heater to improve startability. This will help reduce white smoke and misfire during start-up in cold weather.
NOTICE
When using ether (starting fluid), follow the manufacturer’s instructions carefully, use it sparingly and spray it only while cranking the engine. Excessive ether can cause piston and ring damage. Use ether (starting fluid) for cold weather starting purposes only.
For engines that are not equipped with an Air Inlet
Heater, use ether when temperatures are below 0°C
(32°F). If the engine is equipped with an injection system for starting fluid, crank the engine. Depress the ether switch for three seconds. Additional injections may be necessary in order to start the engine.
Note: If the engine has not been run for several weeks, fuel may have drained. Air may have moved into the filter housing. Also, when fuel filters have been changed, some air will be left in the filter housing. Refer to the Operation and Maintenance
Manual, “Fuel System — Prime” (Maintenance Section) for more information on priming the fuel system.
NOTICE
Do not engage the starting motor when flywheel is turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again.
1. Turn the ignition switch to the ON position.
The “CHECK ENGINE/DIAGNOSTIC” lamp will flash while the engine is cranking. The lamp should turn off after proper engine oil pressure is achieved. If the lamp fails to flash, notify your authorized Caterpillar dealer. If the lamp continues to flash, the Electronic Control Module (ECM) has detected a problem in the system. Refer to the
Operation and Maintenance Manual, “Diagnostic
Flash Code Retrival” for more information.
2. Push the start button or turn the ignition switch to the START position in order to crank the engine.
Do not push down or hold the throttle down while the engine is cranked. The system will automatically provide the correct amount of fuel that is needed to start the engine.
3. If the engine fails to start within 30 seconds, release the start button, or the ignition switch. Wait for two minutes in order to allow the starting motor to cool before attempting to start the engine again.
NOTICE
Oil pressure should rise within 15 seconds after the engine starts. Do not increase engine speed until the oil pressure gauge indicates normal. If oil pressure is not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investigate and correct the cause.
Note: The “CHECK ENGINE/DIAGNOSTIC” lamp may come on after the engine is started. If this occurs, the Electronic Control Module (ECM) has detected a problem with the system. Refer to the
Operation and Maintenance Manual, “Diagnostic
Flash Code Retrival” for more information.
4. Allow the engine to idle for approximately three minutes. Idle the engine until the water temperature gauge has begun to rise. Check all gauges during the warm-up period.
Note: The oil pressures and fuel pressures should be in the normal range on the instrument panel. Do not apply a load to the engine or increase engine rpm until the oil pressure gauge indicates at least normal pressure. Inspect the engine for leaks and/or unusual noises.
i04009931
After Starting Engine
SMCS Code: 1000
Note: In temperatures from 0 to 60 °C (32 to 140 °F), the warm-up time is approximately 5 minutes. In temperatures below 0 °C (32 °F), additional warm-up time may be required.
SEBU8013-01
Note: Ensure that the self-test for the monitoring system is completed before you operate the engine under load.
1. Operate the engine at low idle rpm for 5 minutes.
Perform these checks during the warm-up:
• Check for any fluid leaks and for any air leaks.
•
Check all the gauges.
Observe the gauges and record the data frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge and will help to detect abnormal operating developments. Investigate any significant changes in the readings.
2. After the engine has idled for 5 minutes and the inspections have been made, increase the engine speed to the rated rpm.
NOTICE
To avoid engine overheating and possible engine damage, ensure that water discharge is visible at the sea water outlet and/or the water flow is not restricted.
If the water flow is restricted and/or water discharge is not visible at the sea water outlet, follow the recommended procedure.
3. Observe the water discharge at the sea water outlet. If water discharge is not visible or the water flow is restricted, perform the following procedure:
a. Stop the engine immediately.
b. Inspect the inlet screen and the sea water strainer for debris. Remove any debris that is found.
c. Inspect the cooling system and the auxiliary water pumps for evidence of leaks.
4. Check for any fluid leaks and for any air leaks.
5. Perform any necessary repairs before you operate the engine.
6. After the inspections have been made, move the throttle control to the rated position and proceed with operation.
81
Operation Section
Engine Starting i00627907
Air Starting
SMCS Code: 1451
For good life of the air starting motor, the air supply must be free from dirt and water.
1. Open the drain valve and close the drain valve in order to drain condensation and oil carryover. This drain valve is located on the bottom of the air tank.
2. Check the air supply pressure. The air starting motor requires a minimum of 620 kPa (90 psi) air pressure to operate properly. The maximum air pressure must not exceed 1034 kPa (150 psi).
Illustration 53
Air Valve g00104406
3. Press the air valve or press the start button for the engine in order to crank the engine. After the engine starts, release the air valve or release the start button.
82
Operation Section
Engine Operation
Engine Operation
i01646252
Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be minimized and engine service life can be maximized.
The time that is needed for the engine to reach normal operating temperature can be less than the time taken for a walk-around inspection of the engine.
The engine can be operated at the rated rpm after the engine is started and after the engine reaches operating temperature. The engine will reach normal operating temperature sooner during a low engine speed (rpm) and during a low power demand. This procedure is more effective than idling the engine at no load. The engine should reach operating temperature in a few minutes.
Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge.
Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated.
SEBU8013-01 i01316674
Fuel Conservation Practices
SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel economy. Caterpillar’s design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine.
•
Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, if necessary.
•
Be aware of the properties of the different fuels.
Use only the recommended fuels.
• Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of time.
•
Observe the service indicator frequently. Keep the air cleaner elements clean.
•
Ensure that the turbochargers are operating correctly so that the proper air/fuel ratio is maintained. Clean exhaust indicates proper functioning.
•
Maintain a good electrical system.
•
Ensure that all of the connections of the hoses are tight. The connections should not leak.
• Keep heat exchangers, and water pumps clean.
Keep the components in good repair.
•
Ensure that all of the accessory pumps are repaired. The pumps should operate efficiently.
• Do not exceed the maximum oil level.
•
Never operate without water temperature regulators.
Water temperature regulators regulate heat. Water temperature regulators help to provide efficient operating temperatures. Cold engines consume excessive fuel. Water temperature regulators also help prevent engine overheating.
SEBU8013-01
Engine Stopping
i03353845
Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.
Ensure that any components for the external system that support the engine operation are secured after the engine is stopped.
Emergency Stop Button (If
Equipped)
83
Operation Section
Engine Stopping i03900530
Manual Stop Procedure
(If Equipped with Marine
Classification Society Control
Unit (MCS Control Unit))
SMCS Code: 1000
Illustration 54
Typical emergency stop button g00104303
The emergency stop button is in the OUT position for normal engine operation. Push the emergency stop button. The engine will not start when the button is locked. Turn the button clockwise in order to reset.
Refer to Operation and Maintenance Manual,
“Features and Controls” for the location and the operation of the emergency stop button.
g02174258
Illustration 55
MCS Control Unit
(1) “START” button
(2) “STOP” button
The “STOP” button may be configured as LATCHED or as HOLD. The values for the “STOP” button and the values for the “START” button always match.
Stop the engine with one of two methods:
•
If the “STOP” button is configured as LATCHED, perform the following sequence in order to start the engine: press the “STOP” button, observe the confirmation dialog, and press “YES” . The control unit will complete the stopping sequence.
•
If the “STOP” button is configured as HOLD, press and hold the “STOP” button until the engine stops.
84
Operation Section
Engine Stopping i04010070
Manual Stop Procedure
SMCS Code: 1000
NOTICE
Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of engine components.
Excessive temperatures in the turbocharger centerhousing will cause oil coking problems. Excessive temperatures in the turbocharger centerhousing may damage the turbocharger bearing/shaft system and significantly shorten the life of the turbocharger.
Allow the engine to gradually cool before stopping the engine
Open the main circuit breaker in order to disengage the driven equipment.
Note: If the cooldown feature is not utilized, operate the engine for a cooldown period before stopping the engine. After the driven equipment is disengaged, allow the engine to operate at rated rpm for 5 minutes.
Stop the engine by pressing the “STOP” key on the control panel.
The engine will coast to a stop. Ensure that any system that provides external support to the engine is secured after the engine is stopped.
Automatic Stopping
Automatic stopping will occur when the engine is operating in the automatic mode and the remote start/stop initiate contact opens. If the cooldown feature is utilized, the engine will operate for a programmed period before the engine stops.
Otherwise, the engine will immediately shut off.
SEBU8013-01 i02702528
After Stopping Engine
SMCS Code: 1000
•
Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes.
•
Check the crankcase oil level. Maintain the oil level between the “ADD” mark and the “FULL” mark on the oil level gauge.
•
If necessary, repair any leaks.
•
If necessary, perform minor adjustments or tighten loose bolts.
•
Note the service hour meter reading. Perform the maintenance that is in the Operation and
Maintenance Manual.
• Fill the fuel tank in order to help prevent accumulation of moisture in the fuel. Do not overfill the fuel tank.
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.
NOTICE
Only use antifreeze/coolant mixtures recommended in the Refill Capacities and Recommendations topic that is in this Operation and Maintenance Manual. Failure to do so can cause engine damage.
•
Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch) from the bottom of the pipe for filling. The cooling system can also be maintained between the
“COLD FULL” mark and the “LOW ADD” mark on the coolant recovery bottle (if equipped).
•
If freezing temperatures are expected, check the coolant for proper antifreeze protection. The cooling system must be protected against freezing to the lowest expected outside temperature. Add the proper coolant/water mixture, if necessary.
•
If freezing temperatures are expected, drain the keel cooling system (if equipped).
•
Perform all required periodic maintenance on all driven equipment. This maintenance is outlined in the instructions from the OEM.
SEBU8013-01
Cold Weather Operation
i04010071
Cold Weather Operation
SMCS Code: 1000; 1250
Cat Diesel Engines can operate effectively in cold weather. The starting and the operation of the diesel engine is dependent on the following items in cold weather:
•
The type of fuel that is used
•
The viscosity of the oil
•
Optional starting aids
•
Optional warm-up aids
Refer to Special Publication, SEBU5898, “Cold
Weather Recommendations for Cat Machines”.
The purpose of this section will cover the following information:
•
Explain potential problems that are caused by cold-weather operation.
•
Suggest steps which can be taken in order to minimize starting problems and operating problems when the ambient air temperature is colder than
0 to −55 °C (32 to −67 °F).
The operation and maintenance of an engine in freezing temperatures is complex because of the following conditions: the unlimited differences in weather conditions, engine applications, and the supplies that are available in your area. These factors, recommendations from your Caterpillar dealer, past proven practices, and the information that is contained in this section should be combined in order to provide guidelines for cold-weather operations.
Hints for Cold Weather Operation
•
If the engine is started, operate the engine until a minimum operating temperature of 71 °C (160 °F) is achieved. Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking.
85
Operation Section
Cold Weather Operation
•
The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut down for a few hours and the engine will start readily. If the engine is shut down for at least
8hours, the engine should be considered cooled to outside temperature.
•
Install the correct lubricant in each compartment before the beginning of cold weather.
•
Check all rubber parts (hoses, fan drive belts, and so on) weekly.
•
Check all electrical wiring and connections for any fraying or damaged insulation.
•
Keep all batteries fully charged and warm.
• Fill the fuel tank at the end of each shift.
•
Check the air cleaners and the air intake daily.
Check the air intake more often when you operate in snow.
Personal injury or property damage can result from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in injury or property damage.
DO NOT USE ETHER (starting fluids) unless specifically instructed to do so. If the engine is equipped with an Air Inlet Heater (electrically or fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result in engine damage and/or personal injury.
NOTICE
The optional automatic ether injection system is the only starting fluid system that is recommended. Excessive starting fluid can cause piston and ring damage. Use starting fluid for cold starting purposes only.
•
Inject starting fluid only when the engine is cranking.
• Dryers for the air system may be effective in reducing moisture condensation and the formation of ice in air systems.
•
The injection of alcohol may prevent moisture from freezing the air compressor governor and other components of the air system.
86
Operation Section
Cold Weather Operation
•
For jump starting with cables in cold weather, refer to the Operation and Maintenance Manual for jump starting instructions.
Viscosity of the Engine Lubrication
Oil
Proper engine oil viscosity is essential. Oil viscosity affects the amount of torque that is needed to crank the engine. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations” for the recommended viscosity of oil.
Lubricating Oil Heaters
Note: Oil pan immersion heaters are not recommended for heating the lube oil. To ensure the compatibility of the components, only use equipment that is recommended by Caterpillar.
NOTICE
Heating elements that are in direct contact with the lubricating oil can cause coking of the oil.
To aviod coking of the oil when the oil is heated, follow these recommendations:
The temperature of the heating surface must not exceed 150 °C (300 °F). The maximum heat density of the heating surface must not exceed 1.24 w/cm
2
(8W/in
2
).
Engine oil pan heaters are useful devices that provide the following functions:
•
Assist in reducing the cold cranking amperage that is needed to start the engine.
•
Improve the flow of oil at start-up.
• The time that is needed to warm up the engine is reduced.
•
The service life of bearings is increased.
Engine oil pan heaters can reduce the minimum ambient temperatures that are normally recommended for multigrade oil. Consult your dealer for more information.
Recommendations for the Coolant
Provide cooling system protection for the lowest expected outside temperature. Refer to the Operation and Maintenance Manual, “Refill Capacities and
Recommendations” for the recommended coolant mixture.
SEBU8013-01
In cold weather, check the coolant often for the proper glycol concentration in order to ensure adequate freeze protection.
Jacket Water Heater
A jacket water heater heats the coolant that surrounds the combustion chamber providing the following functions:
• Startability is improved.
•
Warm up time is reduced.
•
The required temperature for ether is reduced.
An electric jacket water heater can be activated once the engine is stopped. An effective jacket water heater is typically a 1500 W unit. Consult your marine dealer for more information.
Idling the Engine
While the engine is idling, the application of a light load (parasitic load) will assist in maintaining the minimum operating temperature. The minimum operating temperature is 71 °C (160 °F). Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand throttle. An idle speed of 1200 rpm is preferred for all engines.
Recommendations for Coolant
Warm Up
Warm up any system that has cooled below normal operating temperatures due to inactivity. The warm-up should be performed before the engine is returned to full operation. During operation in very cold temperature conditions, damage to engine valve mechanisms can result from engine operation for short intervals. This damage can happen if the engine is started and the engine is stopped many times without being operated in order to warm up completely.
When the engine is operated below normal operating temperatures, fuel and oil are not completely burned in the combustion chamber. This fuel and oil causes soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and the deposits are burned off during operation at normal engine operating temperatures.
When the engine is started and stopped without operating long enough to warm up completely, the carbon deposits become thicker. The carbon deposits will cause the following problems:
•
Free operation of the valves is prevented.
SEBU8013-01
•
Valves become stuck.
•
Pushrods are bent.
•
Other damage to valve train components can result.
For this reason, when the engine is started, the engine must be operated until the coolant temperature is 71 °C (160 °F) minimum. Carbon deposits on the valve stems are kept at a minimum and the free operation of the valves and the valve components are maintained.
Warm the engine thoroughly to keep other engine parts in better condition. The service life of the engine will be extended. Lubrication will be improved. There will be less acid and less sludge in the oil. The better condition of the oil will provide longer service life for the engine bearings, the piston rings, and other parts.
However, limit unnecessary idle time to 10 minutes.
Engine wear is greatest at low idle and unnecessary idling wastes fuel.
On/Off Fan Clutch
Viscous fans continuously rotate in cold weather, which creates unnecessary movement of the air. For better control of the operation of the fan, an ON/OFF fan clutch may be used. ON/OFF fan clutches can help prevent excessive cooling in cold weather. In the “OFF” position, the fan is kept stationary by the
ON/OFF fan clutch. The unnecessary movement of the air is reduced in order to maintain adequate engine operating temperatures in cold weather.
Purge Valve and Insulated Heater Lines
During periods of operations with a light load, The coolant must bypass the radiator in order to help prevent excessive cooling of the engine. Coolant that passes through the radiator must be minimized in order to maintain the engine operating temperature in cold weather.
Excessive cooling of the engine is prevented by a
“jiggle” valve that performs two functions. The valve allows the flow of air and the valve prevents the flow of coolant. These valves prevent the unnecessary coolant flow, which may be diverted around the water temperature regulator to the radiator.
Insulated cab heater lines for very cold weather are also beneficial. These lines provide more available heat from the coolant to the cab and less heat is lost to the outside air.
87
Operation Section
Cold Weather Operation
Insulating the Air Inlet and Engine
Compartment
When temperatures below −18 °C (−0 °F) will be frequently encountered, an air cleaner inlet that is located in the engine compartment may be specified.
The special air cleaner inlet is sometimes referred to as a snow valve. An air cleaner that is located in the engine compartment may also minimize the snow that is packed in the air cleaner. Heat that is rejected by the engine warms the inlet air.
Additional heat can be retained around the engine by insulating the engine compartment.
i02237624
Fuel and the Effect from Cold
Weather
SMCS Code: 1000; 1250
The following fuels are the grades that are available for Caterpillar engines:
•
No. 1
•
No. 2
•
Blend of No. 1 and No. 2
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2 is best suited for cold weather operation.
Quantities of No. 1 diesel fuel are limited. No. 1 diesel fuels are usually available during the months of the winter in the colder climates. During cold weather operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary.
There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following properties:
•
Lower cloud point
•
Lower pour point
•
Lower rating of kJ (BTU) per unit volume of fuel
When No. 1 diesel fuel is used, a decrease in power and in fuel efficiency may be noticed. Other operating effects should not be experienced.
88
Operation Section
Cold Weather Operation
The cloud point is the temperature when a cloud of wax crystals begins to form in the fuel. These crystals can cause the fuel filters to plug. The pour point is the temperature when diesel fuel will thicken. The diesel fuel becomes more resistant to flow through fuel pumps and through fuel lines.
Be aware of these values when diesel fuel is purchased. Anticipate the average ambient temperature of the area. Engines that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result due to changes in temperature.
Before troubleshooting for low power or for poor performance in the winter, check the type of fuel that is being used.
When No. 2 diesel fuel is used the following components provide a means of minimizing problems in cold weather:
•
Starting aids
•
Engine oil pan heaters
•
Engine coolant heaters
•
Fuel heaters
•
Fuel line insulation
For more information on cold weather operation, see Special Publication, SEBU5898, “Cold Weather
Recommendations”.
i03353862
Fuel Related Components in
Cold Weather
SMCS Code: 1000; 1250
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after operating the engine.
Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe.
Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important.
SEBU8013-01
Drain the water and sediment from any fuel storage tank at the following intervals:
•
Weekly
•
Oil changes
• Refueling of the fuel tank
This will help prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank.
Fuel Filters
NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
NOTICE
In order to maximize fuel system life and prevent premature wear out from abrasive particles in the fuel, a four micron[c] absolute high efficiency fuel filter is required for all Caterpillar Hydraulic Electronic Unit Injectors. Caterpillar High Efficiency Fuel Filters meet these requirements. Consult your Caterpillar dealer for the proper part numbers.
When the engine is equipped with a primary filter/water separator, the primary filter/water separator must use a 10 micron filter to a 15 micron filter. The filters are becoming more critical as fuel injection pressures increase to 209 MPa (30000 psi) and higher psi. For more information on priming the fuel system, see the Operation and Maintenance
Manual, “Fuel System — Prime” topic (Maintenance
Section).
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging in cold weather due to waxing. A fuel heater should be installed in order for the fuel to be heated before the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet adequate for the application. The fuel heater should also help to prevent overheating of the fuel. High fuel temperatures reduce engine performance and the availability of engine power. Choose a fuel heater with a large heating surface. The fuel heater should be practical in size. Small heaters can be too hot due to the limited surface area.
Disconnect the fuel heater in warm weather.
SEBU8013-01
Note: Fuel heaters that are controlled by the water temperature regulator or self-regulating fuel heaters should be used with this engine. Fuel heaters that are not controlled by the water temperature regulator can heat the fuel in excess of 65° C (149° F). A loss of engine power can occur if the fuel supply temperature exceeds 37° C (100° F).
Note: Heat exchanger type fuel heaters should have a bypass provision in order to prevent overheating of the fuel in warm weather operation.
For further information on fuel heaters, consult your
Caterpillar dealer.
89
Operation Section
Cold Weather Operation
90
Operation Section
Generator Operation
Generator Operation
i04010770
Generator Operation
SMCS Code: 4450
Loading of the Generator
When a generator is installed or reconnected, be sure that the total current in one phase does not exceed the nameplate rating. Each phase should carry the same load, allowing the engine to work at the rated capacity. If one phase current exceeds the nameplate amperage, an electrical unbalance can result in an electrical overload and overheating.
Allowable combinations of unbalanced loads are shown in Illustration 56. When you operate with significant single-phase loads, the combinations of single-phase load and three-phase load may be used. Such combinations should be located below the line on the graph.
SEBU8013-01 g00627416
Illustration 56
Allowable Combinations of Unbalanced Loads
Block Loading
Block loading is the instantaneous application of an electrical load to a generator set. This load may be anywhere from a moderate percentage of the rated load up to the rated load.
The block loading capability of a generator set depends on the following factors.
• Engine transient response
•
Voltage regulator response
•
Type of the voltage regulator
• Altitude of operation of the generator set
•
Type of load
•
Percent of load before the block load is applied
SEBU8013-01
If derating for the block load is required, refer to ISO
3046 Standards or SAE J1349 Standards. Also, reference Engine Data Sheet, LEKX4066, “Loading
Transient Response” and Engine Data Sheet,
LEKX4067, “Block and Transient Response”.
Note: ISO stands for International Standards
Organization.
Power Factor
The power factor represents the efficiency of the load. Power factor is the ratio of apparent power to total power. The power factor is expressed as a decimal. The power factor represents that portion of the current which is doing useful work. The portion of current which is not doing useful work is absorbed in maintaining the magnetic field in motors or other devices.
In most applications, electric motors and transformers determine the power factor of the system. Induction motors usually have a 0.8 or smaller power factor.
Incandescent lighting is a resistive load of about 1.0
power factor, or unity.
The power factor of a system may be determined by a power factor meter or by calculations. Determine the power requirement in kW by multiplying the power factor by the kVA that is supplied to the system. As the power factor increases, the total current supplied to a constant power demand will decrease. For example, a 100 kW load at a 0.8 power factor will draw more current than a 100 kW load at 0.9 power factor. high-power factor will result in full engine load at less than the rated amperage of the generator.
A lower power factor increases the possibility of overloading the generator.
Note: Caterpillar generators are designed for a 0.8
power factor unless otherwise specified.
91
Operation Section
Generator Operation
Excitation System
Permanent Magnet Pilot Excited
Generators
Permanent Magnet Pilot Excited (PMPE) generators receive power for the voltage regulator from a pilot exciter, rather than the main armature. The pilot exciter consists of a permanent magnet rotor and a permanent magnet stator. The pilot exciter operates independently from the generator output voltage.
Constant excitation during a large load application is possible because the irregularities that occur in generator output voltage are not fed back into the exciter. Such irregularities can be caused by load conditions. The independent operation also allows the generator to better sustain an overload for a short duration. The pilot exciter also ensures that the generator will start properly even if the rotating field becomes completely demagnetized.
Low Idle Adjustment
Generator sets normally have a higher low idle setting than industrial engines. Low idle will be approximately 66% of the full load speed of 60 Hz units. Low idle will be approximately 80% of the full load speed of 50 Hz units.
Note: Operating the generator set at low idle speed for an extended time will cause some voltage regulators to shut off. The generator set must be completely shut down and restarted in order for the voltage regulator to operate.
Standby Generator Sets
Most standby units are installed with controls that will start the unit automatically. Standby units start, pick up the load, run, and stop without an operator in attendance.
Standby units cannot automatically change the governor control. Standby units cannot automatically change the voltage settings. The governor speed and voltage level must be preset for the proper operation of the standby unit. Whenever the set is operated manually, be sure that the governor speed and voltage levels are correct for automatic operation.
Check all switches for the proper setting. The start select switch should be in the AUTOMATIC position.
Emergency Stop Switches should be in RUN position.
92
Operation Section
Generator Operation
Generator Options
Space Heaters
All Cat Marine Generators are provided with space heaters. These space heaters are installed for operation in high humidity conditions. For more information on space heaters, refer to this Operation and Maintenance Manual, “Space Heater — Check”.
Embedded Temperature Detectors
All Cat Marine Generators are available with embedded resistance type temperature detectors
(RTDs). The detectors are installed in the slots of the main armature. The main armature is also called a stator. If the Marine Classification Society control panel (MCS Control Panel) is installed, the detectors are connected to the RIO and are monitored by the
MCS controller. Otherwise, the detectors are used with the equipment that is provided by the customer.
Bearing Temperature Detectors
Bearing temperature detectors are standard equipment. If an MCS system is installed, the detectors are connected to the RIO and are monitored by the MCS controller. Otherwise, the bearing temperature detectors are used with the equipment that is provided by the customer. Thus, the temperature of the bearing can be measured or monitored. Bearing temperature measurements may help to prevent premature bearing failure. Contact your Cat dealer for more information.
SEBU8013-01 i04010972
Single Unit Operation
SMCS Code: 4450
Initial Start-Up
Before the initial start-up, perform the megohmmeter test on the main stator winding. Refer to the Special
Instruction, SEHS9124, “Cleaning and Drying of
Electric Set Generators” for the procedure.
Starting
1. Make all of the preliminary checks listed in this
Operation and Maintenance Manual, “Before
Starting Engine” topic.
2. Be sure that the main circuit breaker or the line circuit breaker is open.
3. Start the engine according to this Operation and
Maintenance Manual, “Starting the Engine” topic.
Allow the engine to warm up.
4. Adjust to the full-load engine speed.
5. Close the main circuit breaker.
6. Apply the load. Apply the load in increments in order to maintain system frequency and voltage at a constant level.
7. Readjust the governor for rated frequency.
Stopping
Refer to this Operation and Maintenance Manual,
“Manual Stop Procedure” for the required procedures for stopping the generator set.
i04010991
Parallel Operation
SMCS Code: 4450; 4480
Initial Start-Up
Preparing a generator for parallel operation requires special attention. Before you attempt to parallel units for the first time, check all the units for the following three conditions.
•
Same phase rotation
•
Same alternating current frequency
•
Same winding pitch
SEBU8013-01
•
Same voltage adjustment
1. Check the phase rotation.
Units that operate in parallel must have the same phase rotation. Two methods may be used to determine if the incoming unit and the unit that is on-line have the same phase rotation. These methods are listed below:
•
Using a phase rotation meter
•
Using a set of three light bulbs
Use the procedure below to determine the proper phase rotation by using three light bulbs.
Illustration 57 g00695380
When servicing or repairing electric power generation equipment:
Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE.
Remove all fuses.
a. Connect the light bulbs with rated voltage between the generator leads and the corresponding line phase. For example, connect terminal 1 to line 1 across the open circuit breaker.
b. Start the units that will be in operating in parallel. Bring the units up to speed. As the units approach the same speed, the lights will start to blink.
93
Operation Section
Generator Operation
•
If the lights blink in sequence, one of the units is connected backward. In order to correct the problem, stop the units. Remove generator leads 1 and 3 at the circuit breaker.
Exchange generator leads 1 and 3, thus reversing the direction of phase rotation.
Terminal 2 should always be connected to line 2.
•
Both generators have the same phase rotation when the lights blink in unison. The first condition of “Initial Start-Up” has been met.
2. Adjust the frequency.
The units that will be operating in parallel must operate at the same speed. Speed is proportional to the alternating current frequency. Verify that the generator set is programmed to run at the correct frequency.
3. Adjust the voltage.
Refer to this Operation and Maintenance Manual,
“Voltage Regulators”.
Note: Make sure that the speed droop is identical for all of the engines before adjustments are made to the generator.
a.
Note: Do not change the voltage settings after this step.
b.
4. Check the winding pitch.
The units that operate in parallel must have the same winding pitch to reduce the effect of circulating currents. It is possible to parallel units with different winding pitches after the amount of circulating current flow between each of the units has been determined. Contact your Cat dealer for further information.
Starting Multiple Units
Use the procedure for starting single units in order to start multiple units. Refer to Operation Section,
“Single Unit Operation”.
Paralleling Multiple Units
Units may be paralleled at no load. Units may also be paralleled with units under load. After the initial conditions for start-up are satisfied, verify for the following requirements:
94
Operation Section
Generator Operation
•
One of the governors can be an isochronous governor. Electronic load sharing governors are an exception.
•
Generators must have voltage droop compensation or cross current compensation.
1. Start the unit which will be paralleled.
2. Turn on the synchronizer lights.
3. After the engine has run a few minutes, bring the engine up to synchronous speed. This means that the frequency of the incoming unit will be the same frequency as the unit that is on-line. The synchronizing lights will begin to blink.
Note: The frequency of the incoming unit should be slightly greater than the line frequency. This will allow the incoming unit to assume some of the load instead of adding to the system load.
4. By using the governor control, adjust the engine speed until the lights blink very slowly.
5. The lights are off when the voltages of the two units are in-phase. Very quickly close the breaker while the lights are out.
6. Use governor controls in order to share kW load between engines.
7. Generator temperature will be stabilized in approximately 1 hour. After the generator temperature has been stabilized, adjust the voltage droop rheostat of each generator. This adjustment will share the reactive load and thus will limit the circulating currents. Less droop increases the reactive current that is carried by the generator. Adjusting the voltage droop rheostat in a counterclockwise direction will decrease the droop. Adjusting the voltage droop rheostat in a clockwise direction will increase droop.
Load Division and Speed Droop (If
Equipped)
Once two units have been paralleled, the share of the kW load for each unit is determined by the governor control setting. If two units of the same capacity and the same governor characteristics have the same governor control settings, the units will share the load equally. The total load must not exceed the capacity of the one engine.
In order to transfer the load from one engine to another engine, use the following procedure:
1. Increase the governor speed control of one unit in order to increase the load.
SEBU8013-01
2. Reduce the governor speed control of the other unit in order to decrease the load on that unit.
3. Raise the governor speed control or lower the governor speed control of both units in order to change system frequency.
Parallel Operation Of Governors
Illustration 58
Load Sharing Module (Typical Example) g00630841
The generator set load sharing module provides either the droop load sharing or the isochronous load sharing for parallel applications. The load sharing module has a synchronizing parallel module SPM-A input. The module provides the proportional load sharing. More information is available in the System
Operation, Testing and Adjusting, SENR6565,
“Generator Set Load Sensor and Generator Load
Sharing Module”.
Function of The Engine Governor
This section describes the function of the engine governor in relation to load division between parallel electric sets.
It is very important to understand two basic facts about load division between generator sets which are operating in parallel.
1. The power which is supplied to the generator and to the load is a function of the engine. The setting of the engine governor and the position of the engine governor control determine the amount of power that is delivered by the engine.
Therefore, the governor setting and the position of the governor control determine the kW load which is carried by the generator. A change in the engine power of any unit in a parallel operation will result in the same change in engine power for each unit in that parallel operation. In other words, the units that are in parallel operation will stay in parallel operation.
SEBU8013-01
2. The division of power is not determined by generator excitation or terminal voltage. The excitation will determine the power factor for a generator when the generator is operating in parallel with other generators.
Governors that are used with Caterpillar powered electric sets can be of two types:
•
Governors with fixed speed droop
•
Governors with adjustable speed droop
The values of speed droop which are commonly used are 5 percent. Governors with adjustable speed droop can be adjusted so the characteristics match closely with the characteristics of governors with fixed speed droop. If the governor is adjusted for 0 percent speed droop or isochronous operation, the same speed from no load to full load can be obtained.
Summary on Governor Operation
The preceding discussion of governor operation can be summarized below:
•
Each governor should have a 5 percent speed droop to provide the simplest combination of governors for electric sets that are connected in parallel. If a constant frequency from no load to full load is required, one governor can be adjusted for isochronous operation. This isochronous unit will be called a “lead unit”.
• In order for all paralleled units to accept the full share of the load, the following governor adjustments are required. The governors should have the same full load speed. The governors should have the same high idle speed in the case of governors which are adjusted for speed droop operation. Governor controls should be set to the high idle position so that the full range of the governor is available.
•
Operating an isochronous governor in parallel with a speed droop governor requires special techniques.
•
Any number of electric sets can be operated in parallel. However, only one governor of the group can be adjusted for isochronous operation. The exception will be some special cases of electronic governors with automatic load sharing.
Stopping
In order to remove a generator from the line, perform the following procedure.
1. Check the load. The load must be less than the rated capacity of the remaining units.
95
Operation Section
Generator Operation
2. Be sure that the neutral of one of the remaining units is grounded.
3. Remove the load from the outgoing unit. See the Parallel Operation, “Load Division — Speed
Droop”. The amperage may never go to zero due to circulating currents.
4. Open the circuit breaker.
5. Allow the engine to cool for 5 minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes very important when the units are paralleled. These circulating currents are flowing between generators in parallel operation. The circulating currents are caused by voltage differences between the generators. The circulating currents are not doing useful work. The amount of the circulating current can be determined by subtracting the amperage which is going to the load from the total generator amperage.
The circulating current may be as high as 25 percent of rated amperes with cold generator sets.
Such current may not even be considered harmful.
The total generator current should not exceed the amperage rating.
As the generators warm, the circulating currents will decrease. The ammeter readings should decrease slightly, but the voltage meter readings should remain constant.
96
Maintenance Section
Refill Capacities
Maintenance Section
Refill Capacities
i04039453
Refill Capacities and
Recommendations
SMCS Code: 1348; 1395; 7560
NOTICE
Every attempt is made to provide accurate, up-to-date information. By use of this document you agree that
Caterpillar Inc. is not responsible for errors or omissions.
NOTICE
These recommendations are subject to change without notice. Contact your local Cat dealer for the most up-to-date recommendations.
Note: Instructions for the installation of the filter are printed on the side of each Cat spin-on filter. For non-Cat filters, refer to the installation instructions that are provided by the supplier of the filter.
For more information, refer to Special Publication,
SEBU6251, “Caterpillar Commercial Engine Fluids
Recommendations”.
Diesel Engine Oil
NOTICE
Faulty engine coolant temperature regulators, or operating with light loads, short operation cycles, excessive idling, or operating in applications were normal operating temperature is seldom reached can contribute to excessive water in the crankcase oil. Corrosive damage, piston deposits and increased oil consumption can result. If a complete oil analysis program is not followed or if the results are ignored, the potential for corrosive damage and piston deposits increases.
Cat Diesel Engine Oil (Cat DEO)
Cat oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Cat engines. Cat oils are currently used to fill diesel engines at the factory.
These oils are offered by Cat dealers for continued use when the engine oil is changed. Consult your Cat dealer for more information on these oils.
SEBU8013-01
Due to significant variations in the quality and in the performance of commercially available oils,
Caterpillar makes the following recommendations:
•
Cat DEO (Diesel Engine Oil) (10W-30)
•
Cat DEO (Diesel Engine Oil) (15W-40)
•
Cat DEO-ULS (Diesel Engine Oil — Ultralow
Sulfur) (10W-30)
•
Cat DEO-ULS (Diesel Engine Oil — Ultralow
Sulfur) (15W-40)
Note: Cat DEO-ULS multigrade is the preferred oil for use in all Cat diesel engines for which SAE
15W-40 is the preferred viscosity grade.
Commercial Oil
Note: Non-Cat commercial oils are not the best oils for your engine.
NOTICE
Caterpillar does not warrant the quality or performance of non-Cat fluids.
The three current Cat ECF specifications are:
Cat ECF-1-a, Cat ECF-2, and Cat ECF-3. Each higher Cat ECF specification provides increased performance over lower Cat ECF specifications.
Note: The Cat ECF-1-a and Cat ECF-2 specifications replaced the Cat ECF-1 specification on 1 March
2007.
Note: If Cat DEO multigrade or DEO-ULS multigrade oils are not used, use only commercial oils that meet the following categories/specifications:
• Commercial oils that meet the requirements of the
Cat ECF-1-a, Cat ECF-2, and/or the Cat ECF-3 specification are acceptable. API category of oils that have not met the requirements of at least one
Cat ECF specification may cause reduced engine life.
•
The preferred commercial oils meet at least one of the following requirements: Cat ECF-3 specification and API CJ-4.
Oils that meet the requirements of the API CJ-4 category are compliant with the Cat ECF-3 specification.
The following categories of oils are not approved for use in your Cat Engine:API CF, API CF-4, and API
CG-4.
SEBU8013-01
In selecting oil for any engine application, both of the following must be satisfied: the oil viscosity and the oil performance category or the oil performance specification. Using only one of these parameters will not sufficiently define oil for an engine application.
The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.
Refer to Table 3 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.
Refer to Table 3 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.
Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.
If ambient temperature conditions at engine start-up require the use of multigrade SAE 0W oil, SAE
0W-40 viscosity grade is generally preferred over
SAE 0W-30.
Table 3
Lubricant Viscosities for Ambient Temperatures for DI Diesel Engines
Ambient Temperature
Viscosity Grade
SAE 0W-30
Minimum
−40 °C (−40 °F)
Maximum
30 °C (86 °F)
SAE 0W-40
SAE 5W-30
SAE 5W-40
SAE 10W-30
SAE 10W-40
SAE 15W-40
−40 °C (−40 °F)
−30 °C (−22 °F)
−18 °C (0 °F)
−9.5 °C (15 °F)
40 °C (104 °F)
30 °C (86 °F)
−30 °C (−22 °F) 50 °C (122 °F)
−18 °C (0 °F) 40 °C (104 °F)
50 °C (122 °F)
50 °C (122 °F)
Note: Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature. Supplemental heat may be necessary for cold soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. Cold soaked starts occur when the engine has not been operated recently. The idle period allows the oil to become more viscous due to cooler ambient temperatures.
97
Maintenance Section
Refill Capacities
Cat S·O·S Services Oil Analysis
Caterpillar has developed a maintenance tool that evaluates oil degradation. the maintenance management also detects the early signs of wear on internal components. The Caterpillar tool for oil analysis is called S·O·S oil analysis and the tool is part of the S·O·S Services program. S·O·S oil analysis divides oil analysis into four categories:
•
Component wear rate
•
Oil condition
•
Oil contamination
•
Identification of oil
These four types of analysis are used to monitor the condition of your equipment. The four types of analysis will also help you identify potential problems.
A properly administered S·O·S oil analysis program will reduce repair costs and the program will lessen the impact of downtime.
The S·O·S oil analysis program uses a wide range of tests to determine the condition of the oil and of the lubricated compartment. Guidelines that are based on experience and a correlation to failures have been established for these tests. Exceeding one or more of these guidelines could indicate serious fluid degradation or a pending component failure. A trained person at your Cat dealership should make the final analysis.
NOTICE
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
Refer to Special Publication, SEBU6251, “Caterpillar
Commercial Engine Fluids Recommendations” in order to obtain additional information about S·O·S
Services oil analysis. You can also contact your local
Cat dealer.
Refill Capacities
The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter.
98
Maintenance Section
Refill Capacities
Table 4
Approximate Refill Capacities
Compartment or System Liters
Engine Crankcase 68.1
Quarts
72
Fuel
Filter the fuel coming into the bulk storage fuel tank to 20 microns(c) absolute or less.
Caterpillar strongly recommends the filtration of distillate fuel and/or biodiesel/biodiesel blends through a fuel filter with a rating of four microns(c) absolute or less. The filtration should be located on the device dispensing fuel to the fuel tank for the engine, and on the devise dispensing fuel from the bulk storage tank. Series filtration is recommended.
Diesel engines may burn a wide variety of fuels.
These fuels are divided into two general groups. The two groups are called the preferred fuels and the permissible fuels.
The preferred fuels provide maximum engine service life and performance. The preferred fuels are distillate fuels. These fuels are commonly called diesel fuel, furnace oil, gas oil, or kerosene. These fuels must meet the Caterpillar specification for distillate diesel fuel that is found in Special Publication,
SEBU6251, “Caterpillar Commercial Engine Fluids
Recommendations”.
Note: The permissible fuels are some crude oils, some blends of crude oil with distillate fuel, some biodiesel, and some marine diesel fuel. These fuels are not suitable for use in all engine applications.
The acceptability of these fuels for use is determined on an individual basis. A complete fuel analysis is required. Consult your Cat dealer for further information.
There are many different types of fuel additives that are available to use. Caterpillar does not generally recommend the use of fuel additives.
Distillate Diesel Fuel
Caterpillar recommends that all distillate diesel fuel, including ULSD fuel (fuel ≤ 15 ppm sulfur using ASTM
D5453, ASTM D2622 or ISO 20846, ISO 20884) meet the requirements of the Caterpillar Specification for Distillate Diesel Fuel that are specified in Table 5.
Note: ULSD has less electrical conductivity than
LSD. Follow all grounding and safety practices that are standard for the industry.
SEBU8013-01
Table 5
Caterpillar Specification for Distillate Fuel for
Off-Highway Diesel Engines
Specifications
Requirements
ASTM
Test
ISO Test
Aromatics 35% maximum “D1319”
“ISO
3837”
Ash
Carbon
Residue on
10% Bottoms
Cetane
Number
(1)
Cloud Point
0.01% maximum
(weight)
0.35% maximum
(weight)
40 minimum
(DI engines)
35 minimum
(PC engines)
The cloud point must not exceed the lowest expected ambient temperature.
“D482”
“D524”
“D613” or
“D6890”
“D2500”
“ISO
6245”
“ISO
4262”
“ISO
5165”
“ISO
3015”
Copper Strip
Corrosion
“D130”
“ISO
2160”
Distillation
No. 3 maximum
10% at 282 °C
(540 °F) maximum
90% at 360 °C
(680 °F) maximum
“D86”
“ISO
3405”
Flash Point legal limit “D93”
“ISO
2719”
Thermal
Stability
API Gravity
(2)
Minimum of 80% reflectance after aging for
180 minutes at 150 °C
(302 °F)
30 minimum
“D6468”
“D287”
45 maximum
No equivalent test
No equivalent test
Pour Point
6 °C (10 °F) minimum below ambient temperature
“D97”
“ISO
3016”
Sulfur (3)
“D5453” or
“D2622”
ISO
20846 or
ISO
20884
(continued)
SEBU8013-01
(Table 5, contd)
Caterpillar Specification for Distillate Fuel for
Off-Highway Diesel Engines
ISO Test Specifications Requirements ASTM
Test
Kinematic
Viscosity
1.4 cSt minimum and 20.0 cSt maximum as delivered to the fuel injection pumps
—
1.4 cSt minimum and 4.5 cSt maximum as delivered to the rotary fuel injection pumps
—
Water and
Sediment
Water
0.05% maximum
0.05% maximum
“D1796”
“D1744”
“ISO
3734”
No equivalent test
Sediment
Gums and
Resins
(4)
0.05% maximum
(weight)
10 mg per 100 mL maximum
“D473”
“D381”
“ISO
3735”
“ISO
6246”
Lubricity
0.52 mm
(0.0205 inch) maximum at
60 °C (140 °F)
“D6079”
No equivalent test
(1)
(2)
(3)
(4)
Alternatively, to ensure a minimum cetane number of 35 (PC engines), and 40 (DI engines), distillate diesel fuel should have a minimum cetane index of 37.5 (PC engines), and 44.2 (DI engines) when the “ASTM D4737-96a” test method is used. A fuel with a higher cetane number may be required for operation at a higher altitude or in cold weather.
Via standards tables, the equivalent kg/m
3
(kilograms per cubic meter) using the “ASTM D287” test method temperature of
15.56° C (60° F) for the minimum API gravity of 30 is 875.7
kg/m 3 , and for the maximum API gravity of 45 is 801.3 kg/m 3 .
Follow the federal, state, local, and other governing authorities for guidance concerning the fuel requirements in your area.
Follow the engine Operation and Maintenance Manual and the details provided in this Fuel section. ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 engines and engines with aftertreatment devices. ULSD and LSD 0.05% (≤500 ppm S) are strongly recommended for pre-Tier 4 engines.
Diesel fuel with > 0.05% (>500 ppm) sulfur is acceptable for use where allowed by law. Consult your Caterpillar dealer for guidance when sulfur levels are above 0.1% (1000 ppm).
Certain Caterpillar fuel systems and engine components can operate on fuel with a maximum sulfur content of 3%. Refer to the specific engine Operation and Maintenance Manual and consult your Caterpillar dealer.
Follow the test conditions and procedures for gasoline (motor).
99
Maintenance Section
Refill Capacities
Biodiesel
Biodiesel that meets the requirements that are listed in the Caterpillar specification for biodiesel,
ASTM D6751, or EN 14214 are acceptable blending stock. Biodiesel may be blended in amounts up to a maximum of 30 percent with an acceptable diesel fuel. This blend is acceptable if the biodiesel constituent meets the requirements that are outlined in Table 6 prior to blending. In addition, the final blend must meet the requirements for distillate diesel fuel that are listed in the “Caterpillar Specification for
Distillate Diesel Fuel”, Table 5.
Note: A complete Cat S·O·S Services oil analysis program is strongly recommended when using biodiesel blends above 5 percent.
100
Maintenance Section
Refill Capacities
SEBU8013-01
Table 6
Property
Density at 15°C
Viscosity at 40°C
Flash Point
Cold Filter Plugging
— Summer
— Winter
Pour Point
— Summer
— Winter
Sulfur Content
Caterpillar Specification for Biodiesel Fuel
(1)
Test Method
United States
“ASTM D1298”
Test Method
International
“ISO 3675”
Units
Specific
Properties of Fuel
g/cm
3
“ASTM D445”
“ASTM D93”
“ASTM D4539”
“ASTM D97”
“ISO 3104”
“ISO 3679”
“DIN EN 116”
“ISO 3016” mm
°C
°C
°C
2
/s
Limits
0.86-0.90
4.0-6.0
130 minimum
0
6 below ambient
-9 maximum
-20 maximum
0.0015 maximum
“ASTM D5453”
“ISO 20846”
“ISO 20884”
% weight
Distillation
— 10% Evaporation
— 90% Evaporation
Carbon Residue, Conradson
(CCR)
Cetane Number
Sulfated Ash
Water/Sediment Content
“ASTM D1160”
“ASTM D4530”
“ASTM D613”
“ASTM D874”
“ASTM D2709”
“ISO 10370”
“ISO 5165”
“ISO 3987”
“ISO 12937”
°C
% weight
% weight g/m
3
To Be Determined
345
0.05 maximum
45 minimum
0.02 maximum
500 maximum
Copper Corrosion
Oxidation Stability
Esterification
Acid Value
Methanol Content
Monoglycerides
Diglycerides
Triglycerides
Free Glycerine
Total Glycerine
“ASTM D130”
“ASTM D2274”
“ASTM D664”
GC Method
“ASTM D6584”
“ASTM D6584”
“ASTM D6584”
“ASTM D6584”
“ASTM D6584”
“ISO 2160”
“EN 14112”
“EN 14103”
“EN 14104”
“EN 14110”
“EN 14105”
“EN 14105”
“EN 14105”
“EN 14105”
“EN 14105” mg/100mL
% volume mg NaOH/g
% weight
% weight
% weight
% weight
% weight
% weight
No. 1
15 maximum
98.0 minimum
0.5 maximum
0.2 maximum
0.8 maximum
0.2 maximum
0.2 maximum
0.02 maximum
0.240 maximum
Iodine Number “EN 14111” cg I
2
/g 110 maximum
Phosphorus Content “ASTM D4951” “EN 14107” mg/kg
0.001
(1)
The final blend of biodiesel as used in the engine must meet the requirements that are stated in the “Caterpillar Specification for Distillate
Diesel Fuel for Diesel Engines” in Table 5.
Note: Fuels that meet “ASTM D6751” or “EN 14214” may be used for blending with an acceptable distillate fuel. The conditions, recommendations, and limits that are noted in this biodiesel section apply.
SEBU8013-01
Cooling System
Coolant Recommendations
NOTICE
Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators. Removing the regulators allows some coolant to bypass the radiator, potentially causing overheating.
The following two types of coolants may be used in
Cat Diesel Engines:
Preferred – Cat ELC (Extended Life Coolant) or a commercial extended life coolant that meets the
Caterpillar EC-1 (Engine Coolant -1) specification
Acceptable – Cat DEAC (Diesel Engine
Antifreeze/Coolant) or a commercial heavy-duty antifreeze/coolant that meets “ASTM D4985” or
“ASTM D6210” specifications
NOTICE
Do not use a commercial coolant/antifreeze that only meets the ASTM “D3306” or equivalent specification.
This type of coolant/antifreeze is made for light duty automotive applications.
Use only the coolant/antifreeze that is recommended.
NOTICE
Water alone and/or water mixed with SCA are not approved coolants for use with C7-C32 Heat Exchanger cooled marine engines. C7-C32 heat exchanger cooled marine engines require a minimum of 30 percent glycol to prevent cavitation of cooling system components, with a minimum of 50 percent glycol very strongly recommended. Use only glycol based coolants that meet one or more of the coolant specifications that are defined as preferred or acceptable in Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” and that also comply with any additional requirements that are stated in Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluids Recommendations” (i.e. chemical composition, the use of
SCA, the use of Extender, etc.).
The following coolant require a treatment of SCA at the initial fill:
•
Coolants which only meet the requirements of
“ASTM D4985”
The following coolant do not require a treatment of
SCA at the initial fill:
101
Maintenance Section
Refill Capacities
•
Coolants which only meet the requirements of
“ASTM D6210”
•
Cat DEAC
The following coolant require treatment with SCA on a maintenance basis:
•
Cat DEAC
•
Coolants which only meet the requirements of
“ASTM D4985”
• Coolants which only meet the requirements of
“ASTM D6210”
102
Maintenance Section
Refill Capacities
SEBU8013-01
Table 7
Coolant Type
Cat ELC
Coolant Service Life
Service Life
(1)(2)
12000 Service Hours or Six Years
(3)
Commercial coolant that meets the
Caterpillar EC-1 Specification
Cat DEAC
6000 Service Hours or Six Years
(4)(5)
3000 Service Hours or Three Years
Commercial Heavy-Duty
Coolant/Antifreeze that meets
“ASTM D6210”
Commercial Heavy-Duty
Coolant/Antifreeze that meets
“ASTM D4985”
Cat SCA
(6) and water
(7)
3000 Service Hours or Two Years
3000 Service Hours or One Year
3000 Service Hours or Two Years
Commercial supplemental coolant additive
(8) and water
(6)(7)
3000 Service Hours or One Year
(1)
Use the interval that occurs first.
(2)
Refer to the engine’s Operation and Maintenance Manuals, “Maintenance Interval
Schedule” for the correct interval for replacement of the cooling system water temperature regulator.
(3)
Cat ELC Extender must be added at 6000 service hours or one half of the service life of the Cat ELC.
(4) An extender must be added at 3000 service hours or one half of the service life of the coolant.
(5)
In order to be used in Cat diesel engines in accordance with the service interval for EC-1 coolants that is listed in this Special Publication, commercial EC-1 coolants must also pass/conform to the additional requirements for EC-1 specification coolants as stated in the coolant section of this Special Publication.
(6) The concentration of Cat SCA in a cooling system that uses Cat SCA and water should be from 6% to 8% by volume.
(7)
Refer to this Special Publication, “General Coolant Information” under the section that discusses the requirements for water.
(8) Consult the supplier for the commercial SCA for instructions on usage. Also, refer to this Special Publication, “Water/Supplemental Coolant Additive” topic for additional information.
Note: These coolant change intervals are only achievable with annual S·O·S Services Level 2 coolant sampling and analysis.
Cat ELC can be recycled into conventional coolants.
Cat S·O·S Coolant Analysis
Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and freezing. S·O·S coolant analysis can be done at your
Cat dealer. Caterpillar S·O·S coolant analysis is the best way to monitor the condition of your coolant and your cooling system. S·O·S coolant analysis is a program that is based on periodic samples.
Cat S·O·S Coolant Analysis (Level 1)
A coolant analysis (Level 1) is a test of the following properties of the coolant:
•
Glycol concentration for freeze protection and boil protection
•
Ability to protect from erosion and corrosion
• pH
•
Conductivity
•
Visual analysis
•
Odor analysis
For information about performing this maintenance, refer to this Operation and Maintenance Manual,
“Coolant System Coolant Sample (Level 1) — Obtain”.
For information about performing this maintenance, refer to this Operation and Maintenance Manual,
“Maintenance Interval Schedule”.
SEBU8013-01
Cat S·O·S Coolant Analysis (Level 2)
A coolant analysis ( Level 2) is a comprehensive chemical evaluation of the coolant. The S·O·S coolant analysis ( Level 2) has the following features:
•
Full coolant analysis (Level 1)
•
Identification of metal corrosion and of contaminants
•
Identification of buildup of the impurities that cause corrosion
•
Identification of buildup of the impurities that cause scaling
•
Determination of the possibility of electrolysis within the cooling system of the engine
Contact your local Cat dealer for additional information concerning the S·O·S Coolant Analysis program.
Refill Capacity (Coolant)
Table 8
Approximate Refill Capacities for Coolant
Compartment or System Liters Quarts
Engine and Expansion Tank
(1)
45 48
(1) The following capacities are for engines that have heat exchangers and expansion tanks that are installed in the factory. Cooling systems which are installed by the OEM for the vessel may differ. Refer to the OEM specifications.
Grease
NOTICE
These recommendations are subject to change without notice. Contact your local Cat dealer for the most up-to-date recommendations.
Caterpillar provides various greases that vary in performance from a moderate performance to an extremely high performance. Cat greases service the entire line of Cat products in the wide variety of climates throughout the world. From this variety of
Cat grease products, you can find a Cat grease that will meet or exceed the performance requirements of most on-highway trucks.
The performance requirements of your engine must be determined before you select any Cat grease.
Consult the recommendations for greases that are made by the OEM for the equipment. Then, consult with your Cat dealer for a list of greases that have the performance specifications and the available sizes of containers.
103
Maintenance Section
Refill Capacities
Note: Always choose grease that meets or exceeds the recommendations that are specified by the equipment manufacturer for the application.
104
Maintenance Section
Maintenance Recommendations
Maintenance
Recommendations
i01179728
General Maintenance
Information
SMCS Code: 4450; 7000
Note: Read the warnings and read the instructions that are contained in the Safety Section of this manual. These warnings and instructions must be understood before you perform any operation or any maintenance procedures.
Rotating electric machines are complex structures that are exposed to the following forms of stress:
• mechanical
• electrical
• thermal
• environmental
These stresses may be of varying magnitudes. The electrical insulation systems are very susceptible to damage that is caused by the stresses that are listed above. Exposure to these stresses may shorten the effective life of the electrical insulation system.
Therefore, the service life of an electric machine will largely depend on the serviceability of the electrical insulation systems. An inspection program and a testing procedure are recommended. An inspection program and a testing procedure will ensure that the equipment is maintained in satisfactory condition.
This will increase field reliability.
A regular maintenance and inspection program can provide an evaluation of the present condition of the equipment. A regular maintenance program and a regular inspection program can also reveal future problems. The frequency of this maintenance program will depend on the following factors:
• application
• environmental conditions
• operator’s experience
• operator’s philosophy
A regular maintenance program is strongly recommended. This program would involve the following steps:
• periodic disassembly
SEBU8013-01
• knowledgeable visual examination of the equipment
• the application of electrical tests
Never perform a test over the rated potential. These tests can damage insulation that is contaminated or insulation that is in marginal condition. For more information, refer to “I.E.E.E. Standard 432-1992” or consult a Caterpillar dealer.
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050 i02909163
Coolant System
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.
To relieve the pressure from the coolant system, turn off the engine. Allow the cooling system pressure cap to cool. Remove the cooling system pressure cap slowly in order to relieve pressure.
Fuel System
To relieve the pressure from the fuel system, turn off the engine.
High Pressure Fuel Lines (If Equipped)
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems.
This is because of the following differences:
•
The high pressure fuel lines are constantly charged with high pressure.
SEBU8013-01 105
Maintenance Section
Maintenance Recommendations
•
The internal pressures of the high pressure fuel lines are higher than other types of fuel system.
Before any service or repair is performed on the engine fuel lines, perform the following tasks:
1. Stop the engine.
2. Wait for ten minutes.
Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system.
Engine Oil
To relieve pressure from the lubricating system, turn off the engine.
Welding on Engines with
Electronic Controls
SMCS Code: 1000 i03642798
NOTICE
Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or your Caterpillar dealer regarding welding on a chassis frame or rail.
Proper welding procedures are necessary in order to avoid damage to the engine’s ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld on a unit that is equipped with a Caterpillar Electronic Engine. The following procedure is considered to be the safest procedure to weld on a component. This procedure should provide a minimum risk of damage to electronic components.
NOTICE
Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train, the bearings, hydraulic components, electrical components, and other components.
Do not ground the welder across the centerline of the package. Improper grounding could cause damage to the bearings, the crankshaft, the rotor shaft, and other components.
Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage.
Note: Perform the welding in areas that are free from explosive hazards.
1. Stop the engine. Turn the switched power to the
OFF position.
2. Disconnect the negative battery cable from the battery. If a battery disconnect switch is provided, open the switch.
3. Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins.
106
Maintenance Section
Maintenance Recommendations
SEBU8013-01
Illustration 59 g01075639
Use the example above. The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
4. Connect the welding ground cable directly to the part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings, hydraulic components, electrical components, and ground straps.
Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current flow from the welder could severely damage the component.
5. Protect the wiring harness from welding debris and spatter.
6. Use standard welding practices to weld the materials.
SEBU8013-01 107
Maintenance Section
Maintenance Recommendations i03860683
Generator Start-up Checklist
SMCS Code: 4450
Table 9
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________
Generator Serial Number: _________________________________
GENERATOR NAME PLATE INFORMATION
Voltage: ___________________
Amperage: _________________
Storage Location:
Arrangement Number: ___________________
Arrangement Number: ___________________
Package (prime, continuous, standby): _________________
Kilowatts: ________________________________________
Main Stator Megohmmeter Reading:
Generator dried for 24 hours prior to startup?
SPACE HEATERS
Before Storage:
Yes
(Y/N)
No
After Storage:
Drying method:
Comments
Space heaters operating properly?
Space heater operated 48 hours before startup?
MEGOHMMETER TEST Special
Instruction, SEHS9124
Beginning of Storage
Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
Start-up
PMG Stator
Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
30 sec.
reading
60 sec.
reading
30 sec.
corrected
60 sec.
corrected
Ambient temp.
Comments
108
Maintenance Section
Maintenance Recommendations
Table 10
Regulator
GENERATOR START-UP CHECKLIST (CONT.)
Voltage Amps
No Load
Full Load
All Frames
2400, 2500,
2800, and
2900 Frames
F1 to F2
E1 to E2
E1 to E3
E2 to E3
PM1 to PM4
2600 Frame
All Frames
2400, 2500,
2800, and
2900 Frames
PM1 to PM2
PM1 to PM3
PM2 to PM3
Generator Excitation
Name Plate
Information:
F1 to F2
E1 to E2
E1 to E3
E2 to E3
PM1 to PM4
2600 Frame
PM1 to PM2
PM1 to PM3
PM2 to PM3
AC
AC
AC
DC
AC
AC
AC
DC
AC
AC
AC
AC
DC
AC
AC
AC
AC
Table 11
ELECTRICAL
Unit properly grounded
Check diodes
GENERATOR START-UP CHECKLIST (CONT.)
Yes No
Over current protection
Over voltage protection
Check for loose wiring
Adjust voltage
Adjust frequency
SEBU8013-01
Comments
Compare with F1 to
F2
Comments
SEBU8013-01 109
Maintenance Section
Maintenance Recommendations
Table 12
GENERATOR START-UP CHECKLIST (CONT.)
MECHANICAL
Bearing temperature readings at full load
Data
Front __________ Rear
___________
Stator temperature readings at full load
Air gap on main stator
Air gap on exciter stator
A0 _______ B0 _______
C0 _______
Top __________ Bottom
__________
Top __________ Bottom
__________
Air gap of PMG
Ambient air to generator at full load
Supplier air opening to generator
Top __________ Bottom
__________
Temperature
____________________
Size of Opening
_________________
SWITCH GEAR/PARALLEL OPERATION
Manufacturer:
Setting 1 Setting 2 Setting 3
Type of Circuit breaker
Overload setting
Reverse power relay
VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system
Enclosure type
Motor:
— Total SKVA
— Total HP
UPS
— Size
Other loads:
— Lighting
— Computers
— Welding
— Non-linear
— Other
Comments
Comments
FULL LOAD DATA
Voltage Amps KW KVARS P.F.
110
Maintenance Section
Maintenance Interval Schedule i03634531
Maintenance Interval Schedule
SMCS Code: 1000; 7500
Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance including all adjustments. The user is responsible for the use of proper lubricants, fluids, and filters. The user is responsible for the installation of new components due to normal wear and aging. The performance of this product may be diminished if proper maintenance intervals and procedures are not followed. Components may experience accelerated wear if proper maintenance intervals and procedures are not followed.
Note: Use whichever of the following that occurs first in order to determine the maintenance intervals: fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all maintenance from the previous intervals must be performed.
Products that operate in severe operating conditions may require more frequent maintenance.
When Required
Battery — Recycle …………………………………………. 114
Battery — Replace …………………………………………. 114
Battery or Battery Cable — Disconnect …………….. 115
Engine — Clean ……………………………………………. 130
Engine Oil Level Gauge — Calibrate ……………….. 134
Engine Storage Procedure — Check ……………….. 140
Fuel System — Prime ……………………………………. 142
Generator — Dry …………………………………………… 151
Generator Set — Test ……………………………………. 156
Generator Set Alignment — Check ………………….. 157
Heat Exchanger — Inspect …………………………….. 158
Maintenance Recommendations …………………… 165
Sea Water Strainer — Clean/Inspect ……………….. 173
Varistor — Test ……………………………………………… 176
Winding — Test …………………………………………….. 178
Zinc Rods — Inspect/Replace …………………………. 179
Daily
Closed Crankcase Ventilation (CCV) Filter Service
Indicator — Inspect ………………………………………. 117
Cooling System Coolant Level — Check ………….. 125
Engine Air Cleaner Service Indicator — Inspect … 131
Engine Oil Level — Check ……………………………… 134
Fuel System Primary Filter/Water Separator —
Drain ……………………………………………………….. 145
Generator Load — Check ………………………………. 155
Power Factor — Check ………………………………….. 171
Walk-Around Inspection ……………………………….. 177
SEBU8013-01
Initial 20 to 40 Service Hours
Belts — Inspect/Adjust/Replace ……………………….. 116
Every Week
Electrical Connections — Check ……………………… 130
Generator Bearing Temperature — Measure/
Record …………………………………………………….. 155
Power Factor — Check ………………………………….. 171
Standby Generator Set Maintenance
Recommendations …………………………………….. 173
Stator Winding Temperature — Measure/Record .. 175
Voltage and Frequency — Check ……………………. 177
Every 50 Service Hours or Weekly
Aftercooler Condensate Drain Valve —
Inspect/Clean …………………………………………….. 112
Sea Water Strainer — Clean/Inspect ……………….. 173
Zinc Rods — Inspect/Replace …………………………. 179
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) —
Obtain ……………………………………………………… 127
Every 500 Service Hours
Cooling System Coolant Sample (Level 1) —
Obtain ……………………………………………………… 126
Every 1000 Service Hours
Insulation — Test …………………………………………… 162
Every 2000 Service Hours
Generator — Inspect ……………………………………… 153
Generator Set Vibration — Inspect ………………….. 157
Stator Lead — Check …………………………………….. 174
Every 2000 Service Hours or 1 Year
Generator Bearing — Lubricate ………………………. 155
Every Year
Cooling System Coolant Sample (Level 2) —
Obtain ……………………………………………………… 127
Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) — Add .. 124
Every 8000 Service Hours
Rotating Rectifier — Check …………………………….. 171
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) — Change ……….. 122
SEBU8013-01
First 14 400 L (3750 US gal) of Fuel or 250
Service Hours
Engine Valve Lash — Inspect/Adjust ……………….. 141
Engine Valve Rotators — Inspect ……………………. 141
Fuel Injector — Inspect/Adjust ………………………… 142
Every 14 400 L (3750 US gal) of Fuel or 250
Service Hours or 1 Year
Auxiliary Water Pump (Rubber Impeller) —
Inspect ……………………………………………………… 114
Battery Charger — Check ……………………………….. 115
Battery Electrolyte Level — Check ……………………. 115
Belts — Inspect/Adjust/Replace ……………………….. 116
Cooling System Supplemental Coolant Additive
(SCA) — Test/Add ……………………………………….. 127
Engine — Clean ……………………………………………. 130
Engine Air Cleaner Element — Clean/Replace ….. 130
Engine Crankcase Breather — Clean ………………. 133
Engine Oil Sample — Obtain ………………………….. 135
Fuel System Primary Filter (Water Separator)
Element — Replace …………………………………….. 144
Fuel System Secondary Filter — Replace ………… 146
Fuel Tank Water and Sediment — Drain …………… 150
Hoses and Clamps — Inspect/Replace ……………. 159
Every 28 500 L (7500 US gal) of Fuel or 500
Service Hours or 1 Year
Engine Oil and Filter — Change ……………………… 136
Every 57 000 L (15 000 US gal) of Fuel or
1000 Service Hours
Aftercooler Core — Clean/Test ………………………… 112
Closed Crankcase Ventilation (CCV) Fumes Disposal
Filter — Replace …………………………………………… 117
Heat Exchanger — Inspect …………………………….. 158
Turbocharger — Inspect …………………………………. 175
Every 170 400 L (45 000 US gal) of Fuel or
3000 Service Hours
Auxiliary Water Pump (Bronze Impeller) —
Inspect ……………………………………………………… 113
Cooling System Coolant (DEAC) — Change ……… 119
Cooling System Water Temperature Regulator —
Replace ……………………………………………………. 128
Crankshaft Vibration Damper — Inspect …………… 129
Engine Mounts — Inspect ………………………………. 133
Engine Speed/Timing Sensor — Clean/Inspect …. 139
Engine Valve Lash — Inspect/Adjust ……………….. 141
Engine Valve Rotators — Inspect ……………………. 141
Fuel Injector — Inspect/Adjust ………………………… 142
Starting Motor — Inspect ……………………………….. 174
Every 284 000 L (75 000 US gal) of Fuel or
5000 Service Hours
Alternator — Inspect ………………………………………. 113
Oil Cooler Core — Check/Clean/Test ……………….. 167
111
Maintenance Section
Maintenance Interval Schedule
Water Pump — Inspect ………………………………….. 178
Overhaul
Generator Bearing — Inspect/Replace …………….. 154
Maintenance Recommendations …………………… 165
Overhaul (Major) …………………………………………. 167
Overhaul (Top End) ……………………………………… 170
Commissioning
Generator Set Alignment — Check ………………….. 157
112
Maintenance Section
Aftercooler Condensate Drain Valve — Inspect/Clean
SMCS Code: 1063-042-DN, VL i02098179
Aftercooler Condensate Drain
Valve — Inspect/Clean
Illustration 60
(1) Adapter
(2) Valve
(3) Plunger
(4) Valve seat g01069660
The engine boost pressure forces the plunger to move down to the valve seat. The plunger must close against the seat at a pressure of 27.5 kPa
(4 psi). When the engine is stopped, the absence of boost pressure allows the plunger to rise to the open position, which allows condensation from the aftercooler to drain out.
The plunger must be able to move freely in order to close the system when the engine is running. The plunger must be able to move freely in order to allow condensation to drain from the aftercooler when the engine is stopped. Residue from normal engine operation could cause the plunger to stick.
1. Remove the valve from the adapter. Check the valve in order to determine if the plunger moves freely. If the plunger does not move easily, clean the valve with solvent.
2. Reassemble the aftercooler condensate drain valve. Refer to the Operation and Maintenance
Manual for more information on the proper torques.
SEBU8013-01 i03635591
Aftercooler Core — Clean/Test
SMCS Code: 1064-070; 1064-081
Note: An aftercooler that circulates fresh water or treated water may require cleaning less often than an aftercooler which circulates salt water.
The maintenance interval for an aftercooler which circulates fresh water or treated water should be evaluated when the aftercooler is cleaned and tested after the first 1000 hours of engine operation. The interval will vary depending on operating conditions.
Clean the Aftercooler Core
Remove the core. Refer to the Disassembly and
Assembly Manual, “Aftercooler — Remove” for the procedure.
1. Turn the aftercooler core on one side in order to remove debris. Remove the debris that is accessible.
NOTICE
Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.
2. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 13 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer.
Table 13
Hydrosolv Liquid Cleaners
(1)
Part
Number
Description
1U-5490 Hydrosolv 4165
174-6854
Hydrosolv 100
Size
19 L (5 US gallon)
19 L (5 US gallon)
(1)
Use a two to five percent concentration of the cleaner at temperatures up to 93°C (200°F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more information.
3. Steam clean the core in order to remove any residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside and from the outside of the core.
Note: Do not use high pressure when the fins are cleaned. High pressure can damage the fins.
4. Wash the core with hot, soapy water.
SEBU8013-01
5. Flush the core thoroughly in order to remove residue and remaining debris. Flush the core with clean, fresh water until the water that is exiting the core is clear and free of debris.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded.
6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.
Test the Aftercooler Core
1. Inspect the core for trapped debris and cleanliness. If necessary, remove the debris and repeat the cleaning procedure.
2. Inspect the core for damage and perform a pressure test in order to detect leaks. Many shops that service radiators are equipped to perform pressure tests.
3. Plug both ends of the aftercooler core and pressurize the core to 205 kPa (30 psi). Submerge the core in water. Look for bubbles which are being emitted from the core. The bubbles are evidence of leaks.
4. If any leaks are found, do not attempt to repair the core.
Install a core that is clean and a core that passes the pressure test in step 3. Refer to the Disassembly and Assembly Manual, “Aftercooler — Install” for the procedure.
For more information on cleaning the core, consult your Caterpillar dealer.
113
Maintenance Section
Alternator — Inspect i02676048
Alternator — Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required.
Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge.
i01042055
Auxiliary Water Pump (Bronze
Impeller) — Inspect
SMCS Code: 1371-040
Impellers and seals require periodic inspection.
Impellers have a service life that is limited. The service life depends on the engine operating conditions.
Inspect the components more frequently when the pump is exposed to debris, sand, or other abrasive materials. Inspect the components if the pump is operating at a differential pressure of more than
103 kPa (15 psi).
Check the following components for wear or damage:
•
Bearings
•
Impeller
•
Seals
•
Wear plate
If wear or damage is found, replace the components which are worn or damaged. Use the proper repair kit for the pump. Refer to the Disassembly and
Assembly for more information on servicing the auxiliary water pump.
114
Maintenance Section
Auxiliary Water Pump (Rubber Impeller) — Inspect i01041983
Auxiliary Water Pump (Rubber
Impeller) — Inspect
SMCS Code: 1371-040
Impellers and seals require periodic inspection.
Impellers have a service life that is limited. The service life depends on the engine operating conditions.
Inspect the components more frequently when the pump is exposed to debris, sand, or other abrasive materials. Inspect the components if the pump is operating at a differential pressure of more than
103 kPa (15 psi).
Check the following components for wear or damage:
•
Bearings
• Impeller
•
Seals
•
Wear plate
If wear or damage is found, replace the components which are worn or damaged. Use the proper repair kit for the pump. Refer to the Disassembly and
Assembly for more information on servicing the auxiliary water pump.
i02039199
Battery — Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Return used batteries to one of the following locations:
•
A battery supplier
•
An authorized battery collection facility
•
A recycling facility
Battery — Replace
SMCS Code: 1401-510
SEBU8013-01 i02156825
Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.
The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the charger.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Disconnect the cable from the NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+” battery terminal.
Note: Always recycle a battery. Never discard a battery. Return used batteries to an appropriate recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that the key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
SEBU8013-01
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
i01942625
Battery Charger — Check
SMCS Code: 1401-535
Check the battery charger for proper operation. If the batteries are properly charged, the needle of the ammeter will register near “0” (zero).
The batteries should be kept warm, when possible.
The temperature of the battery will affect cranking power. A battery that is too cold will not crank the engine, even if the engine is warm.
The batteries may not fully recharge when the engine is not run for long periods of time. The batteries may not fully recharge if the engine only runs for short periods. Ensure a full charge in order to help prevent the battery from freezing.
Battery Electrolyte Level —
Check
i02601752
SMCS Code: 1401-535
When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing.
115
Maintenance Section
Battery Charger — Check
•
A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
•
A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
Battery or Battery Cable —
Disconnect
i01492654
SMCS Code: 1402-029
All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.
1. Remove the filler caps. Maintain the electrolyte level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following cleaning solutions:
The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the battery that goes to the start switch. Ensure that the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental starting.
4. Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the cables.
116
Maintenance Section
Belts — Inspect/Adjust/Replace i02229322
Belts — Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspection
Inspect the alternator belt and any accessory belts for wear and for cracking. Replace the belts if the belts are not in good condition.
Check the belt tension according to the information in the Service Manual, “Specifications”.
Slippage of loose belts can reduce the efficiency of the driven components. Vibration of loose belts can cause unnecessary wear on the following components:
•
Belts
•
Pulleys
•
Bearings
If the belts are too tight, unnecessary stress is placed on the components. This reduces the service life of the components.
Replacement
For applications that require multiple drive belts, replace the drive belts in matched sets. Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched. The additional load on the new drive belt could cause the new drive belt to fail.
SEBU8013-01
Alternator Belt Adjustment
Illustration 61
(1) Adjusting nuts
(2) Mounting bolt
(3) Mounting bolt
(4) Mounting bolt g00960176
1. Remove the drive belt guard.
2. Loosen mounting bolts (2), (3), and (4). Loosen adjusting nuts (1).
3. Turn adjusting nuts (1) in order to increase or decrease the drive belt tension.
4. Tighten adjusting nuts (1). Tighten mounting bolts
(2), (3), and (4).
5. Reinstall the drive belt guard.
If new drive belts are installed, check the drive belt tension again after 30 minutes of engine operation at the rated rpm.
SEBU8013-01 117
Maintenance Section
Closed Crankcase Ventilation (CCV) Filter Service Indicator — Inspect i01852860
Closed Crankcase Ventilation
(CCV) Filter Service Indicator
— Inspect
SMCS Code: 1317-040-FI g01637464
Illustration 63
Illustration 62
(1) Plastic cover
(2) Service indicator g00744250
The Closed Crankcase Ventilation system (CCV) is equipped with a service indicator. If the fumes disposal filter becomes plugged prior to the normal service interval, increased restriction of the filter will cause the crankcase pressure to become positive.
When the pressure continues to rise, the service indicator will show through the plastic cover. The service indicator indicates the need for the fumes disposal filter to be changed. Refer to the Operation and Maintenance Manual, “Closed Crankcase
Ventilation (CCV) Fumes Disposal Filter — Replace” topic for more information.
Note: Check the service indicator when the engine is running at low idle.
i03615046
Closed Crankcase Ventilation
(CCV) Fumes Disposal Filter —
Replace
SMCS Code: 1317-510-FI
The engine may look like one of the engines which are pictured below.
g01637466
Illustration 64
(1) Crankcase breather
(2) Filter base and filter for fumes disposal
(3) Air cleaner
The Closed Crankcase Ventilation system (CCV) requires the replacement of the fumes disposal filter.
The service interval of the CCV will be affected by the following items:
•
Engine load
•
Soot concentration
•
Condition of the engine
118
Maintenance Section
Closed Crankcase Ventilation (CCV) Fumes Disposal Filter — Replace
The CCV is equipped with a service indicator. If the fumes disposal filter becomes plugged prior to the normal service interval, increased restriction of the filter will cause the vacuum to become positive. When the pressure continues to rise, the service indicator will show through the cap. The service indicator indicates the need for the fumes disposal filter to be changed. Reset the service indicator by using the following procedure:
Resetting the Service Indicator
g01292899
Illustration 65
(4) Plastic cover
(5) Service indicator
1. Remove the plastic cover.
2. Push down on the service indicator.
3. Replace the cover.
Replacing the Fumes Disposal
Filter
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Note: When possible, perform the maintenance while the engine is off.
SEBU8013-01
Illustration 66
(6) Filter base assembly
(7) Latches
(8) Canister g01938796
1. Release the latches that hold the canister to the filter base assembly .
Note: Removal of the canister may be difficult while the engine is operating. The canister has negative air pressure while the engine is operating. This creates a vacuum.
2. Lower the canister in order to expose the element.
There may be oil in the bottom of the canister.
Avoid spilling the oil.
3. Remove the filter element by pulling down.
Dispose of the used element properly.
4. Remove the O-ring assembly on the top end cap of the used element.
5. Replace the O-ring seal on the bottom of the filter base assembly.
6. Install the new O-ring on the top end cap of the element. Install the element into the correct place.
7. Replace the canister and align the canister with the boss on the filter base assembly.
8. Clamp the latches in the closed position.
SEBU8013-01
Cooling System Coolant
(DEAC) — Change
SMCS Code: 1350-070; 1395-044 i03211768
119
Maintenance Section
Cooling System Coolant (DEAC) — Change
Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary.
Drain
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The heat exchanger and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:
•
The engine overheats frequently.
• Foaming of the coolant
•
The oil has entered the cooling system and the coolant is contaminated.
•
The fuel has entered the cooling system and the coolant is contaminated.
Illustration 67 g01355994
1. Stop the engine and allow the engine to cool.
Loosen expansion tank filler cap (1) slowly in order to relieve any pressure. Remove the expansion tank filler cap.
2. Open the cooling system drain valve (if equipped).
3. In order to fully drain the coolant, remove the following plugs:
a. Remove plug (2) in order to vent the water near the water temperature regulator.
g01355995
Illustration 68
Commercial application
120
Maintenance Section
Cooling System Coolant (DEAC) — Change
SEBU8013-01
Illustration 69
Pleasure craft g01637916
b. Remove drain plug (3) from the bottom heat exchanger.
Illustration 70 g01355996
c. Remove drain plug (4) from the bottom of the water cooled exhaust manifold.
d. Remove drain plugs (5) from the bottom of the jacket water pump inlet.
e. Remove drain plug (6) from the bottom of the oil cooler.
4. Allow coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
NOTICE
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.
1. Flush the cooling system with clean water in order to remove any debris.
2. Close the drain valve (if equipped). Clean the drain plugs. Reinstall the drain plugs. Refer to the Operation and Maintenance Manual for more information on the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install the expansion tank filler cap.
4. Start the engine and run the engine for a minimum of 30 minutes with a coolant temperature of at least 82°C (180°F).
5. Stop the engine and allow the engine to cool.
Loosen the expansion tank filler cap slowly in order to relieve any pressure. Remove the expansion tank filler cap. Open the drain valve
(if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Reinstall the drain plugs. Refer to the Specifications Manual for more information on the proper torques.
SEBU8013-01
Cooling Systems with Heavy
Deposits or Plugging
Note: For the following procedure to be effective, there must be some active flow through the cooling system components.
1. Flush the cooling system with clean water in order to remove any debris.
2. Close the drain valve (if equipped). Clean the drain plugs. Reinstall the drain plugs. Refer to the Operation and Maintenance Manual for more information on the proper torques.
3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the expansion tank filler cap.
4. Start and run the engine at low idle for a minimum of 90 minutes. The coolant temperature should be at least 82°C (180°F).
5. Stop the engine and allow the engine to cool.
Loosen the expansion tank filler cap slowly in order to relieve any pressure. Remove the expansion tank filler cap. Open the drain valve (if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped).
Clean the drain plugs. Reinstall the drain plugs.
Refer to the Operation and Maintenance Manual for more information on the proper torques.
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
Engines That Are Equipped with a
Coolant Recovery Tank
1. Fill the system to the top with the mixture of coolant/antifreeze that is recommended. Refer to the Operation and Maintenance Manual for more information on cooling system specifications.
2. Reinstall the filler cap on the coolant recovery tank.
3. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Stop the engine.
4. Remove filler cap from the coolant recovery tank.
121
Maintenance Section
Cooling System Coolant (DEAC) — Change
5. Pour the coolant/antifreeze into the tank until the coolant reaches the “COLD FULL” mark. Do not fill the tank above the “COLD FULL” mark.
6. Clean the filler cap. Install the filler cap onto the recovery tank. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.
Engines That Are Not Equipped with a
Coolant Recovery Tank
1. Fill the expansion tank with the coolant/antifreeze.
Do not install the expansion tank filler cap.
2. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight glass (if equipped).
4. Clean the expansion tank filler cap. Inspect the gasket on the filler cap for the expansion tank.
If the gasket for the filler cap for the expansion tank is damaged, discard the old filler cap and install a new filler cap for the expansion tank. If the gasket for the filler cap for the expansion tank is not damaged, use a
9S-8140 Pressurized
Pump Group in order to pressure test the filler cap for the expansion tank. The correct pressure for the filler cap of the expansion tank is stamped on the face of the filler cap for the expansion tank. If the expansion tank filler cap does not retain the correct pressure, install a new expansion tank filler cap.
5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.
122
Maintenance Section
Cooling System Coolant (ELC) — Change
SMCS Code: 1350-070; 1395-044 i03211792
Cooling System Coolant (ELC)
— Change
SEBU8013-01
Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary.
Drain
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The heat exchanger and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:
•
The engine overheats frequently.
• Foaming of the coolant
•
The oil has entered the cooling system and the coolant is contaminated.
•
The fuel has entered the cooling system and the coolant is contaminated.
Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.
Illustration 71 g01355994
1. Stop the engine and allow the engine to cool.
Loosen expansion tank filler cap (1) slowly in order to relieve any pressure. Remove the expansion tank filler cap.
2. Open the cooling system drain valve (if equipped).
3. In order to fully drain the coolant, remove the following plugs:
a. Remove plug (2) in order to vent the water near the water temperature regulator.
Illustration 72
Commercial application g01355995
SEBU8013-01 123
Maintenance Section
Cooling System Coolant (ELC) — Change
Illustration 73
Pleasure craft g01637916
b. Remove drain plug (3) from the bottom heat exchanger.
Illustration 74 g01355996
c. Remove drain plug (4) from the bottom of the water cooled exhaust manifold.
d. Remove drain plugs (5) from the bottom of the jacket water pump inlet.
e. Remove drain plug (6) from the bottom of the oil cooler.
4. Allow coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order to remove any debris.
2. Close the drain valve (if equipped). Clean the drain plugs. Reinstall the drain plugs. Refer to the Operation and Maintenance Manual for more information on the proper torques.
3. Fill the cooling system with clean water. Reinstall the expansion tank filler cap. Operate the engine until the temperature reaches 49 to 66°C
(120 to 150°F).
4. Stop the engine and allow the engine to cool.
Loosen the expansion tank filler cap slowly in order to relieve any pressure. Remove the expansion tank filler cap. Open the drain valve
(if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water.
5. If necessary, repeat step 2 through step 4.
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
Engines That Are Equipped with a
Coolant Recovery Tank
1. Fill the expansion tank to the top with the
ELC. Refer to the Operation and Maintenance
Manual for more information on cooling system specifications.
2. Reinstall the filler cap for the recovery tank.
124
Maintenance Section
Cooling System Coolant Extender (ELC) — Add
3. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Stop the engine.
4. Loosen the filler cap of the recovery tank slowly in order to relieve any pressure. Remove the filler cap from the recovery tank.
5. Pour the ELC into the tank until the coolant reaches the “COLD FULL” mark. Do not fill the tank above the “COLD FULL” mark.
6. Clean the filler cap of the recovery tank. Reinstall the filler cap onto the recovery tank. Start the engine. Inspect the coolant recovery tank for coolant leaks and for proper operating temperature.
Engines That Are Not Equipped with a
Coolant Recovery Tank
1. Fill the expansion tank with the ELC. Do not reinstall the expansion tank filler cap.
2. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight glass (if equipped).
4. Clean the expansion tank filler cap. Inspect the gasket of the filler cap for the expansion tank. If the gasket is damaged, discard the old expansion tank filler cap and install a new expansion tank filler cap. If the gasket is not damaged, use a
9S-8140 Pressurized Pump Group in order to pressure test the expansion tank filler cap. The correct pressure for the filler cap of the expansion tank is stamped on the face of the filler cap for the expansion tank. If the expansion tank filler cap does not retain the correct pressure, install a new expansion tank filler cap.
5. Start the engine. Inspect the engine for coolant leaks and for proper operating temperature.
SEBU8013-01 i02482066
Cooling System Coolant
Extender (ELC) — Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants. The Cat ELC Extender only needs to be added once.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender with Cat ELC.
Do NOT use conventional supplemental coolant additive (SCA) with Cat ELC. Mixing Cat ELC with conventional coolants and/or conventional SCA reduces the
Cat ELC service life.
Check the cooling system only when the engine is stopped and cool.
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.
Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
SEBU8013-01 125
Maintenance Section
Cooling System Coolant Level — Check
Engines That Are Equipped with a
Coolant Recovery Tank
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Loosen the cooling system filler cap slowly in order to relieve pressure. Remove the cooling system filler cap.
2. It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the requirements for your engine’s cooling system capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations” article for more information.
4. Clean the cooling system filler cap. Inspect the gaskets on the cooling system filler cap. Replace the cooling system filler cap if the gaskets are damaged. Install the cooling system filler cap.
i02456586
Cooling System Coolant Level
— Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped and cool.
Illustration 75
(1) Filler cap
(2) “COLD FULL” mark
(3) “LOW ADD” mark g00103638
1. Observe the coolant level in the coolant recovery tank. Maintain the coolant level to “COLD FULL” mark (2) on the coolant recovery tank.
2. Loosen filler cap (1) slowly in order to relieve any pressure. Remove the filler cap.
3. Pour the proper coolant mixture into the tank.
Refer to this Operation and Maintenance Manual,
“Refill Capacities and Recommendations” for information about coolants. Do not fill the coolant recovery tank above “COLD FULL” mark (2).
4. Clean filler cap (1) and the receptacle. Reinstall the filler cap and inspect the cooling system for leaks.
Note: The coolant will expand as the coolant heats up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool, the coolant will return to the engine.
Engines That Are Not Equipped with a Coolant Recovery Tank
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system filler cap slowly in order to relieve pressure.
126
Maintenance Section
Cooling System Coolant Sample (Level 1) — Obtain
2. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant level to the proper level in the sight glass.
Illustration 76
Typical filler cap gaskets g00103639
3. Clean the cooling system filler cap and inspect the condition of the filler cap gaskets. Replace the cooling system filler cap if the filler cap gaskets are damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.
i03619060
Cooling System Coolant
Sample (Level 1) — Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems that are filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule.
Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant
instead of Cat ELC. This includes the following types of coolants:
•
Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
•
Cat DEAC (Diesel Engine Antifreeze/Coolant)
•
Commercial heavy-duty coolant/antifreeze
SEBU8013-01
Table 14
Recommended Interval
Type of Coolant Level 1
Cat DEAC
Every 500
Hours
(1)
Level 2
Initial 500 Hours and Yearly
(1)(2)
Cat ELC Optional
(2)
Initial 500 Hours and Yearly
(2)
(1) This is the recommended interval for coolant samples for all conventional heavy-duty coolant/antifreeze. This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC-1 specification for engine coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified.
NOTICE
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
Illustration 77 g01942100
Coolant sampling valve on bottom of the inlet bonnet for the oil cooler
The coolant sampling valve for the engine coolant is located on the right side of the engine on the inlet bonnet for the oil cooler.
SEBU8013-01
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from your Caterpillar dealer.
Use the following guidelines for proper sampling of the coolant:
•
Complete the information on the label for the sampling bottle before you begin to take the samples.
•
Keep the unused sampling bottles stored in plastic bags.
• Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.
• Keep the lids on empty sampling bottles until you are ready to collect the sample.
•
Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.
•
Never collect samples from expansion bottles.
•
Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” or consult your
Caterpillar dealer.
127
Maintenance Section
Cooling System Coolant Sample (Level 2) — Obtain i01987714
Cooling System Coolant
Sample (Level 2) — Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) — Obtain” for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For additional information about coolant analysis, see Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar dealer.
i03509177
Cooling System Supplemental
Coolant Additive (SCA) —
Test/Add
SMCS Code: 1352-045; 1395-081
Note: This maintenance is NOT required for cooling systems that are filled with Extended Life
Coolant.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with the skin and eyes. Do not drink cooling system coolant additive.
128
Maintenance Section
Cooling System Water Temperature Regulator — Replace
SEBU8013-01
Add the SCA, If Necessary
NOTICE
Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine’s heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components.
Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal.
Do not exceed the recommended amount of supplemental coolant additive concentration.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” and to Special Publication, GECJ0003, “Cat Shop Supplies and Tools” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to applicable regulations and mandates.
Note: Caterpillar recommends an S·O·S coolant analysis (Level 1).
Cooling Systems that Use
Conventional Coolant
Test the Concentration of the SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration.
Test the concentration of the SCA with the
4C-9301
Coolant Conditioner Test Kit.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system filler cap slowly.
2. If necessary, drain some coolant in order to allow space for the addition of the SCA.
3. Add the proper amount of SCA. For the proper amount of SCA, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic. The proper concentration of SCA depends on the type of coolant that is used. For the proper concentration of SCA, refer to Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluids
Recommendations”.
4. Clean the cooling system filler cap. Install the cooling system filler cap.
i03645060
Cooling System Water
Temperature Regulator —
Replace
SMCS Code: 1355-510
Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice.
Replacing the water temperature regulator reduces the chances for unscheduled downtime. Refer to this
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for the proper maintenance interval.
A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine.
A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in cracking of the cylinder head or piston seizure problems.
SEBU8013-01 129
Maintenance Section
Crankshaft Vibration Damper — Inspect
A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage.
Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or cylinder head surface.
Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulators
— Remove and Water Temperature Regulators —
Install” for the replacement procedure of the water temperature regulator, or consult your Caterpillar dealer.
Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing.
i03175962
Crankshaft Vibration Damper
— Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. This can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range.
The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine.
g01134779
Illustration 78
Viscous vibration damper
Typical example
(1) Crankshaft pulley
(2) Weight
(3) Case
Inspection
Inspect the damper for the following conditions:
•
The damper is dented, cracked, or fluid is leaking from the damper.
• The paint on the damper is discolored from excessive heat.
•
The damper is bent.
•
The bolt holes are worn or there is a loose fit for the bolts.
•
The engine has had a crankshaft failure due to torsional forces.
Replace the damper if any of these conditions exist.
Removal and Installation
Refer to this Operation and Maintenance Manual,
“Belts — Inspect/Adjust/Replace” for information on removing and on installing the belt. Refer to the Disassembly and Assembly Manual, “Vibration
Damper and Pulley — Remove and Install” for information on removing and installing the damper.
130
Maintenance Section
Electrical Connections — Check i01595880
Electrical Connections — Check
SMCS Code: 4459-535
Check all exposed electrical connections for tightness.
Check the following devices for loose mounting or for physical damage:
• transformers
• fuses
• capacitors
• lightning arrestors
Check all lead wires and electrical connections for proper clearance.
Engine — Clean
SMCS Code: 1000-070 i01646701
SEBU8013-01
Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when you clean the engine. Avoid electrical components such as the alternator, the starter, and the ECM.
i01756656
Engine Air Cleaner Element —
Clean/Replace
SMCS Code: 1054-070; 1054-510
NOTICE
Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
Type 1
Note: Use the
102-9720 Cleaning Kit. This product contains the detergent and oil that is made specifically for the maintenance of the air cleaner elements.
Personal injury or death can result from high voltage.
Moisture can create paths of electrical conductivity.
Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO
NOT OPERATE”.
NOTICE
Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following benefits:
•
Easy detection of fluid leaks
•
Maximum heat transfer characteristics
•
Ease of maintenance
Illustration 79
(1) Air cleaner element g00898593
Note: This type of air cleaner element should be replaced after three cleanings.
1. Remove the air cleaner element (1). Tap the air cleaner element in order to dislodge dirt particles.
Gently brush the air cleaner element with a soft bristle brush.
SEBU8013-01 131
Maintenance Section
Engine Air Cleaner Service Indicator — Inspect
Type 2
NOTICE
Do not use gasoline, steam, caustic or unapproved detergents, or parts cleaning solvents. Do not use high pressure water or air to clean the air cleaner element.
Any of those liquids or methods can cause air cleaner element damage.
2. Spray the air cleaner element with the cleaning solution. Allow the air cleaner element to stand for 10 minutes.
3. Rinse the air cleaner element with low water pressure. The maximum water pressure for this procedure is 275 kPa (40 psi). Tap water is acceptable. Start to rinse the air cleaner element from the clean side (inside). Next, clean the dirty side (outside) in order to flush out dirt. Inspect the air cleaner element for tears and/or holes after the air cleaner element is cleaned. Do not reuse damaged air cleaner elements.
NOTICE
Do not use compressed air, open flame, or hot air to dry the air cleaner element. Excess heat shrinks cotton fiber, and compressed air may blow holes in the material. Allow the air cleaner element to air dry.
4. Shake excess water off the air cleaner element , and allow the air cleaner element to air dry. Drying the air cleaner element in the sun speeds the process.
NOTICE
Do not use transmission fluid, engine oil, diesel fuel, or other lubricant to oil the air cleaner element. The air cleaner element can not function correctly if improper oil is used. Never operate an engine with a dry air cleaner element. The air cleaner element can not function correctly without oil. Always saturate the clean air cleaner element with the recommended oil.
5. The dry air cleaner element should be oiled before installation. Apply small amounts of oil across the top of each pleat. Allow the oil to soak into the air cleaner element for 20 minutes. Oil any remaining
“white” spots.
6. Inspect the housing and the clamp for air cleaner element (1). Install the clean, oiled air cleaner element. Replace the housing and the clamp, if necessary. Refer to Specifications, SENR3130,
“Torque Specifications” for the proper torque of the clamp.
Illustration 80 g00898590
1. Disconnect latches (1).
2. Remove cover (2).
3. Remove the air cleaner element.
Note: This type of air cleaner element may be cleaned up to six times.
4. Refer to Guideline for Reusable Parts and Salvage
Operations, SEBF8062 for cleaning instructions or replace the air cleaner element.
5. Install the air cleaner element.
6. Install cover (2).
7. Fasten cover (2) with latches (1).
Engine Air Cleaner Service
Indicator — Inspect
i00641711
SMCS Code: 7452-040
Illustration 81 g00291942
Typical air cleaner service indicator that is mounted on the air cleaner housing
132
Maintenance Section
Engine Air Cleaner Service Indicator — Inspect
An air cleaner service indicator may be mounted on the air cleaner element or in a remote location.
Some vessels are equipped with a low air pressure indicator that monitors the inlet air pressure. This indicator measures air pressure before the air is drawn through the air cleaner element. Then, the indicator monitors the pressure level after the air has passed through the air cleaner element. As the air cleaner element becomes dirty, this air cleaner pressure differential rises.
Some vessels may be equipped with a different air cleaner indicator.
If your vessel is equipped with a different type of air cleaner indicator, follow the recommendations for the vessel. You can also follow the recommendations in the air cleaner OEM in order to service the air cleaner element.
g00103777
Illustration 82
Typical Air Cleaner Service Indicator
Observe the air cleaner service indicator. You should clean the air cleaner element, or you should replace the air cleaner element under two conditions:
•
The yellow diaphragm enters the red zone.
•
The service indicator displays the red color at any time.
•
The red piston locks in the visible position.
Test the Air Cleaner Service
Indicator
Air cleaner service indicators are important, inexpensive instruments. Two methods can be used to test the service indicator.
•
Check for ease of resetting. The service indicator should reset in less than three pushes.
SEBU8013-01
•
Check the movement of the yellow core when the engine is accelerated to the engine rated rpm.
The yellow core should latch at the approximate greatest vacuum that is attained.
The air cleaner service indicator should be replaced under certain conditions and at certain times:
•
The service indicator does not reset easily.
•
The yellow core does not latch at the greatest vacuum.
• The engine is used for a year.
•
The engine is overhauled.
•
Major engine components are replaced.
Note: Replace the air cleaner service indicator often whenever you operate in a severely dusty environment.
If the new service indicator will not reset, the hole for the service indicator may be plugged.
Note: When a new service indicator is installed, excessive force may crack the top of the service indicator. Tighten the service indicator to a torque of 2 N·m (18 lb in).
Service the Air Cleaner Service
Indicator
NOTICE
Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.
If the air cleaner element becomes plugged, the air can split the filter material. Unfiltered air will drastically accelerate internal engine wear. Your
Caterpillar dealer has air filter elements for this unit.
Consult your Caterpillar dealer for the correct air cleaner element.
If the air cleaner service indicator appears red at any time, clean the air cleaner element or install a new air cleaner element. At 250 hour intervals, clean the air cleaner element or replace the air cleaner element .
SEBU8013-01 133
Maintenance Section
Engine Crankcase Breather — Clean
Refer to the Operation and Maintenance Manual
(Maintenance Section) for more information on servicing the air cleaner element.
i02751871
Engine Crankcase Breather —
Clean
SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a regular basis, the crankcase breather will become plugged. A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage.
Illustration 83 g01377732
1. Loosen hose clamp (1) and remove breather hose
(2) from valve cover (3).
2. Remove valve cover (3). Refer to the Disassembly and Assembly Manual.
Illustration 84 g01377736
3. Wash breather (4) in solvent that is clean and nonflammable. Allow the breather to dry before installation.
4. Install the valve cover. Refer to the Disassembly and Assembly Manual.
5. Install the breather hose on the valve cover. Install the hose clamp.
i02456872
Engine Mounts — Inspect
SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for proper bolt torque. Engine vibration can be caused by the following conditions:
• Improper mounting of the engine
• Deterioration of the engine mounts
Any engine mount that shows deterioration should be replaced. Refer to Special Publication, SENR3130,
“Torque Specifications” for the recommended torques. Refer to the OEM recommendations for more information.
134
Maintenance Section
Engine Oil Level — Check
Engine Oil Level — Check
SMCS Code: 1348-535-FLV i02703852
Illustration 85
Right hand service shown g01356472
1. Stop the engine and allow the engine oil to drain into the crankcase for approximately ten minutes.
Illustration 86
Oil level gauge
(Y) “ADD” mark
(X) “FULL” mark g00110310
2. Check the engine oil. Maintain the engine oil level between “ADD” mark (Y) and “FULL” mark (X) on engine oil level gauge (2). Do not fill the crankcase above “FULL” mark (X).
NOTICE
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil’s lubricating characteristics and could result in the loss of power.
3. Remove engine oil filler cap (1) and add oil, if necessary. Clean the engine oil filler cap. Reinstall the engine oil filler cap.
SEBU8013-01 i02703804
Engine Oil Level Gauge —
Calibrate
SMCS Code: 1326-524
The engine is shipped with an engine oil level gauge that is not marked. The engine oil level gauge is not marked because the following features can be different for each engine:
•
Angle of the installation
•
Side for service
The engine oil level gauge must be calibrated after the engine is installed in the vessel.
Note: The engine may be equipped with auxiliary engine oil filters. The extra filters require more engine oil than the standard amounts. Refer to the OEM specifications.
Use the following procedure in order to calibrate and mark the engine oil level gauge.
1. Ensure that the engine is properly aligned and that the engine is in the design trim. The engine must be installed properly in the vessel.
Note: If the engine has oil in the crankcase, skip step
2 and proceed to step 3.
2. If there is no oil in the engine, use information in this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” in order to select the correct oil for the engine. Add engine oil to the crankcase by using the procedure in this
Operation and Maintenance Manual, “Engine Oil and Filter — Change ”. Choose the appropriate amount of oil from the following types of sumps:
•
Standard Oil Sump: Fill the crankcase with
45.4 L (48 qt) of the recommended oil.
• Deep Oil Sump: Fill the crankcase with 64.3 L
(68 qt) of the recommended oil.
Clean the engine oil level gauge and install the engine oil level gauge.
Note: If the engine contains oil, perform steps 3 through 7. Skip steps 3 through 7 if you are filling the engine with oil for the first time.
3. Operate the engine until normal operating temperature is achieved. Stop the engine. Drain the engine oil by using the procedure in this
Operation and Maintenance Manual, “Engine Oil and Filter — Change ”.
SEBU8013-01
4. Replace the engine oil filter by using the procedure in this Operation and Maintenance Manual,
“Engine Oil and Filter — Change ”.
5. Clean the engine oil level gauge and install the engine oil level gauge.
6. Use the information in Operation and Maintenance
Manual, “Refill Capacities and Recommendations” in order to select the correct oil for the engine.
7. Add engine oil to the crankcase by using the procedure in this Operation and Maintenance
Manual, “Engine Oil and Filter — Change ”. Choose the appropriate amount of oil from the following two sumps:
•
Standard Oil Sump: Fill the crankcase with
45.4 L (48 qt) of the recommended oil.
•
Deep Oil Sump: Fill the crankcase with 64.3 L
(68 qt) of the recommended oil.
8. Start the engine. Ensure that the lubrication system and the new engine oil filter are filled.
Inspect the lubrication system for leaks.
9. Stop the engine and allow the engine oil to drain into the engine crankcase for approximately ten minutes.
10. Check the engine oil level. Use a marking tool in order to engrave the “ADD” mark (Y) to the correct location on the gauge assembly.
11. Add 3.8 L (4 qt) of the recommended oil grade and weight of engine oil to the crankcase. Add this amount for both standard sumps and deep sumps.
12. Check the engine oil level. Use a marking tool in order to engrave “FULL” mark (X) onto the correct location on the gauge assembly.
Illustration 87
Oil Level Gauge “ADD” mark (Y) and “FULL” mark (X) g00110310
135
Maintenance Section
Engine Oil Sample — Obtain
Engine Oil Sample — Obtain
SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM i03542996
In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, provide the following information:
•
Engine model
•
Service hours on the engine
•
The number of hours that have accumulated since the last oil change
•
The amount of oil that has been added since the last oil change
To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample.
To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.
Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.
The
169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The fluid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided.
136
Maintenance Section
Engine Oil and Filter — Change
SEBU8013-01
NOTICE
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump.
For instructions, see Special Publication, PEgj0047,
“How To Take A Good S·O·S Oil Sample”. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your engine.
i02683617
Engine Oil and Filter — Change
SMCS Code: 1318-510; 1348-044
The S·O·S oil analysis program analyzes used oil in order to determine if the oil change interval is suitable for your specific engine.
Drain the Oil
Do not drain the oil when the engine is cold. As the oil cools, waste particles settle on the bottom of the oil pan. The waste particles are not removed when the cold oil is drained. Drain the crankcase when the oil is warm. This method allows proper draining of the waste particles that are suspended in the oil.
Failure to follow this recommended procedure will allow the waste particles to be recirculated through the engine lubrication system with the new oil.
1. After the engine has been operated at normal operating temperature, STOP the engine.
2. Drain the oil according to the equipment on the engine.
Note: Drain the oil into a suitable container. DO NOT drain the oil into the bilge sump. Dispose of the oil according to local regulations.
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact skin.
If the engine is equipped with duplex oil filters, the engine oil filter elements can be changed while the engine is in operation. This is useful if the oil filter elements require more frequent replacement than the engine oil. Refer to “Replacing the Engine Oil Filters
During Engine Operation”.
The oil change interval can be affected by several factors:
•
Air/fuel ratio
•
Ambient air conditions
•
Engine application
•
Fuel type
•
Oil type
•
Size of the oil sump
Illustration 88
Oil drain plug g01348195
Note: If a suction device is used in order to remove the oil from the oil pan, ensure that the suction device is clean. This will prevent dirt from entering into the oil pan. Be careful not to strike the engine oil suction tubes or the piston cooling jets.
a. If the engine does not have a drain valve or a pump, remove an oil drain plug. Allow the oil to drain. After the oil has drained, clean the drain plug and clean the fitting for the drain plug.
Install the drain plug. Tighten the drain plug to
70 ± 15 N·m (52 ± 11 lb ft).
b. If the engine has an oil drain valve, open the valve. After the oil has drained, close the valve.
SEBU8013-01 137
Maintenance Section
Engine Oil and Filter — Change
Replacing the Engine Oil Filters With the
Engine Stopped (Standard Oil Filters)
c. If the engine has a pump for removing dirty oil, connect a hose to the outlet of the pump. Place the hose in a suitable container. Open the valve for the drain line. The two marks on the valve must be turned so that one mark points to the pump and the second mark points to the drain line. Operate the pump until the crankcase is empty. Close the valve to the drain line.
Disconnect the hose.
d. If the oil drain valve has a “quick connect” coupling, attach the coupling. Open the drain valve in order to drain the crankcase. After the oil has drained, close the drain valve.
Disconnect the coupling.
3. Replace the engine oil filter elements before filling the crankcase with new oil.
Replace the Oil Filter Elements
Replace the engine oil filters when any of the following conditions occur:
• Every oil change
•
The engine oil filter differential pressure reaches
103 kPa (15 psi).
•
The oil filter elements have been used for 1000 service hours.
Note: Do not attempt to clean the used oil filters.
Used oil filters will retain waste particles. The used oil filters would not filter the oil properly.
Service tools are available to aid in the service of oil filters. Consult your Caterpillar dealer for the part names and the part numbers. Follow the instructions that are supplied with the service tools. If the service tools are not used, perform the following appropriate procedure.
Illustration 89
Standard Oil Filters
Right hand service g01356351
Perform the following procedure after the oil has been drained.
1. Remove used oil filters and properly discard the used oil filters.
Illustration 90
Typical filter mounting base and filter gasket g00103713
2. Clean the sealing surface of the filter mounting base. Make sure that the former oil filter gaskets are removed.
3. Apply a thin film of clean engine oil to the seal of each new filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to engine components.
138
Maintenance Section
Engine Oil and Filter — Change
4. Install the filters by hand. Tighten each filter until the sealing surface contacts the base. Note the position of the index marks on each filter in relation to a fixed point on the filter base.
Note: Caterpillar filters have rotation index marks that are spaced 90° or 1/4 of a turn away from each other. When you tighten the filters, use the rotation index marks as a guide.
5. Tighten each filter according to the instructions that are printed on the filter.
Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the filters to the amount that is required for final installation. Make sure that the installation tool does not damage the filters. Do not overtighten the oil filter.
Replacing the Engine Oil Filters During
Engine Operation (Duplex Oil Filter
System Only)
SEBU8013-01
This filter contains hot, pressurized oil that can cause burns and fire hazards, which may result in bodily injury or death. Follow the instructions given in this Operation and Maintenance Manual and stop the engine if rapid air movement exists to blow the oil.
Illustration 91
Duplex Oil Filter System
Left hand service g01356340
If the engine is equipped with duplex oil filters, the engine oil filter elements can be changed while the engine is in operation. This is useful if the oil filter elements require more frequent replacement than the engine oil.
Illustration 92 g01034883
1. Open the “FILL” valve for a minimum of five minutes in order to fill the oil filter elements that will not be serviced. The oil filters that will not be serviced must be full of engine oil. Close the FILL valve.
2. Move the control valve to the “AUX RUN” position in order to change the main oil filter elements.
Move the selector valve to the “MAIN RUN” position in order to change the auxiliary oil filter elements.
3. Allow the oil pressure gauge for the oil filter that is being changed to reach a “ZERO” pressure reading.
4. Perform Step 1 through Step 5 of “Replacing the
Engine Oil Filters With the Engine Stopped”.
5. Open the “FILL” valve for a minimum of five minutes in order to fill the new oil filter elements.
6. Close the “FILL” valve. Rotate the control valve to the “RUN” position for the oil filter that was serviced.
7. Inspect the oil filters for oil leaks. If any leaks exist, stop the engine and make any necessary repairs.
8. If the engine oil filters were replaced without changing the crankcase oil, maintain the oil level between the “FULL” mark and the “ADD” mark on the oil level gauge. If necessary, add oil.
SEBU8013-01
Fill the Crankcase
NOTICE
Only use oils that are recommended by Caterpillar.
For the proper oil to use, refer to this Operation and
Maintenance Manual, “Engine Oil” topic (Maintenance
Section).
NOTICE
If the engine is equipped with an auxiliary oil filter system, extra oil must be added when filling the crankcase. If equipped with an auxiliary oil filter system that is not supplied by Caterpillar, follow the recommendations of the OEM.
NOTICE
Engine damage can occur if the crankcase is filled above the “FULL” mark on the oil level gauge (dipstick).
An overfull crankcase can cause the crankshaft to dip into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These bubbles (foam) can cause the following problems: reduction of the oil’s ability to lubricate, reduction of oil pressure, inadequate cooling, oil blowing out of the crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following problems: guttering of the valves, packing of carbon under the piston rings, and wear of the cylinder liner.
If the oil level is above the “FULL” mark on the oil level gauge, drain some of the oil immediately.
1. Remove the oil filler cap. Fill the crankcase through the oil filler tube only. For the amount of oil and type of oil to use, refer to Operation and Maintenance Manual, “Refill Capacities and
Recommendations” (Maintenance Section). Clean the oil filler cap. Install the oil filler cap.
NOTICE
To prevent crankshaft or bearing damage, crank engine with fuel off to fill all filters before starting.
Do Not crank engine for more than 30 seconds.
2. Close the fuel supply line and crank the engine until the oil pressure gauge indicates 70 kPa
(10 psi). Open the fuel supply line. Allow the starting motor to cool for two minutes before cranking again.
139
Maintenance Section
Engine Speed/Timing Sensor — Clean/Inspect
3. Ensure that the oil level is to the “FULL” mark on the oil level gauge. Start the engine and operate the engine at low idle for two minutes. This will ensure that the lubrication system has oil and that the oil filters are filled with oil. Inspect the engine and the oil filters for oil leaks. If any leaks exist, stop the engine and make any necessary repairs.
4. Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes.
5. Remove the oil level gauge and check the oil level. Maintain the oil level between the “FULL” mark and the “ADD” mark on the oil level gauge. If necessary, add oil.
Inspect the Used Oil Filter Elements
Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the oil filter for metal debris. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure.
Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the element. Ferrous metals may indicate wear on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the aluminum parts, the brass parts, or the bronze parts of the engine. Parts that may be affected include the following components: main bearings, rod bearings, turbocharger bearings, and cylinder heads.
Aluminum debris may indicate problems with the bearings of the front gears. If you find aluminum debris, inspect the crankshaft vibration damper and the idler gear bearings.
Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter element.
If an excessive amount of debris is found in the oil filter element, consult your Caterpillar dealer in order to arrange for further oil analysis.
i03572058
Engine Speed/Timing Sensor —
Clean/Inspect
SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
140
Maintenance Section
Engine Storage Procedure — Check
SEBU8013-01
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Camshaft Speed/Timing Sensor
3. Connect the harness assembly.
Crankshaft Speed/Timing Sensor
Illustration 93
(1) Bolt
(2) Sensor
(3) Harness assembly g01368433
Removal Procedure
1. Disconnect the harness assembly.
2. Remove the bolt and the sensor.
3. Remove the O-ring seal from the sensor.
Procedure for Cleaning and Inspecting
Check the condition of the plastic end of the sensor for wear and for contaminants. Clean the metal shavings and other debris from the face of the sensor.
Installation Procedure
1. Install a new O-ring seal on the sensor. Lubricate the O-ring seal with clean engine oil.
2. Position the sensor in the housing and install the bolt.
Illustration 94
(4) Bolt
(5) Sensor
(6) Harness g01900805
Removal Procedure
1. Disconnect the harness assembly.
2. Remove the bolt and the sensor.
3. Remove the O-ring seal from the sensor.
Procedure for Cleaning and Inspecting
Check the condition of the plastic end of the sensor for wear and for contaminants. Clean the metal shavings and other debris from the face of the sensor.
Installation Procedure
1. Install a new O-ring seal on the sensor. Lubricate the O-ring seal with clean engine oil.
2. Install the position sensor in the front housing and install the bolt.
3. Connect the harness assembly.
i03585580
Engine Storage Procedure —
Check
SMCS Code: 1000-535
See your Caterpillar dealer for the storage procedure if the engine will be stored for more than one year.
SEBU8013-01
Refer to this Operation and Maintenance Manual,
“Product Storage” if the engine will be stored for less than one year.
i03126876
Engine Valve Lash —
Inspect/Adjust
SMCS Code: 1102-025
The initial valve lash adjustment on new engines, rebuilt engines, or remanufactured engines is recommended at the first scheduled oil change. The initial adjustment is necessary due to initial wear of the valve train components and seating of the valve train components.
This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life.
Adjustment of the Electronic Unit
Injector
Adjust the electronic unit injector (preload) at the same interval as the valve lash adjustment. The operation of Caterpillar engines with improper valve adjustments and with improper adjustments of the electronic unit injector can reduce engine efficiency.
This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.
NOTICE
Only qualified service personnel should perform this maintenance. Refer to the Systems Operation/Testing and Adjusting Manual, “Valve Lash and Valve Bridge
Adjustment” article or consult your Caterpillar dealer for the complete valve lash adjustment procedure.
141
Maintenance Section
Engine Valve Lash — Inspect/Adjust i01597115
Engine Valve Rotators — Inspect
SMCS Code: 1109-040
When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to help prevent being burned by hot oil or spray.
Engine valve rotators rotate the valves when the engine runs. This helps to prevent deposits from building up on the valves and the valve seats.
Perform the following steps after the engine valve lash is set, but before the valve covers are installed:
1. Start the engine according to Operation and
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
2. Operate the engine at low idle.
3. Observe the top surface of each valve rotator. The valve rotators should turn slightly when the valves close.
NOTICE
A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life. If a damaged rotator is not replaced, valve face guttering could result and cause pieces of the valve to fall into the cylinder. This can cause piston and cylinder head damage.
If a valve fails to rotate, consult your Caterpillar dealer.
Ensure that the engine can not be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance.
142
Maintenance Section
Fuel Injector — Inspect/Adjust
SMCS Code: 1290-025 i03534881
Fuel Injector — Inspect/Adjust
Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting the unit injectors.
The electronic unit injectors use high voltage. Disconnect the unit injector enable circuit connector in order to prevent personal injury. Do not come in contact with the injector terminals while the engine is running.
The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.
Only qualified service personnel should perform this maintenance. Refer to the Systems Operation,
Testing and Adjusting, “Electronic Unit Injector —
Test” for the test procedure, and Systems Operation,
Testing and Adjusting, “Electronic Unit Injector —
Adjust” for the adjustment procedure for the injectors.
i03570039
Fuel System — Prime
SMCS Code: 1258-548
SEBU8013-01
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Note: Refer to this Operation and Maintenance
Manual, “Fuel System Secondary Filter — Replace” for information on replacing the filter.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
Clean up fuel spills immediately.
g01096972
Illustration 95
Hand priming pump
(1) Air purge screw
(2) Fuel pressure regulating valve
The Secondary Fuel Filter Has
Been Replaced
1. Turn the ignition switch to the “OFF” position.
2. Open the air purge screw for the fuel filter by three full turns. Do not remove the air purge screw.
SEBU8013-01
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
3. Start the engine. The engine should start and the engine should run smoothly. If the engine does not start after 30 seconds, allow the starting motor to cool for two minutes before attempting to start the engine again.
Note: You may use the hand priming pump for the fuel filter (if equipped) instead of starting the engine and running the engine.
4. While the engine is running, observe the air purge screw. When a small drop of fuel appears at the threads of the air purge screw, close and tighten air purge screw.
Note: There may be a noticeable change in the sound of the running engine when the air purge screw is tightened. The change in the sound of the engine is normal.
Note: Failure to tighten all fittings could result in serious fuel leaks.
5. Clean any residual fuel from the engine components.
The Engine Has Been Run Out of
Fuel
1. Turn the ignition switch to the “OFF” position.
2. Fill the fuel tank(s) with clean diesel fuel.
3. Open the fuel pressure regulating valve by two and one half turns. The regulating valve is located in the integral fuel filter base.
Note: Do not remove the regulating valve completely.
Open the valve enough to allow the air that is trapped in the cylinder head to be purged from the fuel system.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
4. Crank the engine for 30 seconds. Use a suitable container to catch the fuel while you crank the engine. Allow the starting motor to cool for two minutes.
143
Maintenance Section
Fuel System — Prime
Note: You may use the hand priming pump for the fuel filter (if equipped) instead of cranking the engine.
5. Crank the engine for 30 seconds. Allow the starting motor to cool for two minutes.
6. Close and tighten the fuel pressure regulating valve.
7. Crank the engine for 30 seconds. Allow the starting motor to cool for two minutes.
8. Repeat Step 7 until the engine starts and the engine runs.
Note: Failure to tighten all fittings could result in serious fuel leaks.
9. Clean any residual fuel from the engine components.
The Engine Has Been Rebuilt
1. Turn the ignition switch to the “OFF” position.
2. Fill the fuel tank (s) with clean diesel fuel.
3. Open the the air purge screw for the fuel filter by three full turns. Do not remove the air purge screw.
4. Open the fuel pressure regulating valve by two and one half turns. The regulating valve is located in the integral fuel filter base.
Note: Do not remove the regulating valve completely.
Open the valve enough to allow the air that is trapped in the cylinder head to be purged from the fuel system.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
5. Crank the engine for 30 seconds. Use a suitable container to catch the fuel while you crank the engine. Allow the starting motor to cool for two minutes.
Note: You may use the hand priming pump for the fuel filter (if equipped) instead of cranking the engine.
6. Crank the engine for 30 seconds. Allow the starting motor to cool for two minutes.
7. Close and tighten the air purge screw.
8. Crank the engine for 30 seconds. Allow the starting motor to cool for two minutes.
144
Maintenance Section
Fuel System Primary Filter (Water Separator) Element — Replace
9. Close and tighten the fuel pressure regulating valve.
Note: Failure to tighten all fittings could result in serious fuel leaks.
10. Crank the engine for 30 seconds. Allow the starting motor to cool for two minutes.
11. Repeat Step 10 until the engine starts and runs.
12. Clean any residual fuel from the engine components.
i02049797
Fuel System Primary Filter
(Water Separator) Element —
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector to fail. If the fuel has been contaminated with water, the element should be changed before the regularly scheduled interval.
The primary filter/water separator also provides filtration in order to help extend the life of the secondary fuel filter. The element should be changed regularly. Install a vacuum gauge. Change the element for the primary filter/water separator if the pressure is at 50 to 70 kPa (15 to 20 inches Hg).
Replace the Element
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SEBU8013-01
Illustration 96
(1) Bowl
(2) Element
(3) Drain g00668636
1. Stop the engine.
2. Turn the start switch to the “OFF” position.
3. Shut off the fuel tank supply valve to the engine.
4. If the primary fuel filter is equipped with a drain valve (3), open the drain valve in order to drain any fuel from the filter case. Close the drain valve (3).
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
5. Remove the fuel filter bowl (1) and wash the fuel filter bowl with clean diesel fuel.
6. Remove the fuel filter (2).
7. Clean the gasket sealing surface of the fuel filter base. Ensure that all of the old gasket is removed.
8. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
In order to maximize fuel system life and prevent premature wear out from abrasive particles in the fuel, use Caterpillar fuel filters.
Consult your Caterpillar dealer for proper part numbers.
9. Install the new fuel filter (2). Spin the fuel filter onto the fuel filter base until the gasket contacts the base. Use the rotation index marks on the filters as a guide for proper tightening. Tighten the filter for an additional 3/4 turn by hand. Do not overtighten the filter.
SEBU8013-01 145
Maintenance Section
Fuel System Primary Filter/Water Separator — Drain
NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
10. Install the clean fuel filter bowl (1) on the new fuel filter.
NOTICE
The water separator is under suction during normal engine operation. Ensure that the vent plug is tightened securely to help prevent air from entering the fuel system.
11. Open the fuel tank supply valve.
12. Start the engine and check for leaks. Run the engine for one minute. Stop the engine and check the engine for leaks again.
Detection of leaks is very difficult especially if the engine is running. The primary filter/water separator is under suction. A leak will allow air to enter the fuel. The air in the fuel can cause low power due to aeration of the fuel. If air enters the fuel, check the components for overtightening or undertightening.
i02927285
Fuel System Primary
Filter/Water Separator — Drain
SMCS Code: 1260-543; 1263-543
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
Clean up fuel spills immediately.
Illustration 97
(1) Element
(2) Bowl
(3) Drain g01453091
Bowl (2) should be monitored daily for signs of water.
If water is present, drain the water from the bowl.
1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Dispose of the water properly.
2. Close drain (3).
NOTICE
The water separator is under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system.
146
Maintenance Section
Fuel System Secondary Filter — Replace i03572801
Fuel System Secondary Filter —
Replace
SMCS Code: 1261-510-SE
SEBU8013-01
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel spills immediately.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: If the engine is equipped with duplex fuel filters, the fuel filter elements can be replaced while the engine is in operation. Refer to “Replacing the
Fuel Filter Elements During Engine Operation For
Engines That Are Equipped With Duplex Fuel Filters”.
Replacing the Fuel Filter Elements with the Engine Stopped
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Illustration 98
Right hand service
(1) Fuel priming pump
(2) Fuel filter g01902879
1. Stop the engine.
2. Turn off the start switch or disconnect the battery
(starting motor) when maintenance is performed on fuel filters.
3. Shut off the fuel tank supply valve to the engine.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
4. Unlock the fuel priming pump in order to relieve residual pressure in the fuel system.
5. Remove the used fuel filter. Use a cloth or use a container in order to catch excess fuel.
6. Clean the gasket sealing surface of the fuel filter base. Ensure that all of the old gasket is removed.
7. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before installing. The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
8. Install the new fuel filter. Tighten the fuel filter until the gasket contacts the base. Tighten the fuel filter by hand according to the instructions that are shown on the fuel filter. Do not overtighten the fuel filter.
Note: DO NOT remove the plug in the fuel filter base in order to release the air from the fuel system during periodic service of the fuel filter. Periodic removal of the plug will result in increased wear of the threads in the fuel filter base.
SEBU8013-01 147
Maintenance Section
Fuel System Secondary Filter — Replace
Replacing the Main Fuel Filter
9. Operate the fuel priming pump plunger until a strong resistance is felt and until the check valve clicks. This procedure will require considerable strokes. Lock the fuel priming pump.
10. Open the fuel tank supply valve.
11. Start the engine according to the normal operating procedures. Immediately increase the engine rpm between 1000 to 1200 rpm with no load. The engine will begin to misfire briefly until air from the fuel filter is purged. No damage to the engine will occur.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
12. If the engine stalls during the purging of the air, refer to the Operation and Maintenance Manual,
“Fuel System — Prime” for more information.
Replacing the Fuel Filter Elements
During Engine Operation For
Engines That Are Equipped With
Duplex Fuel Filters
If the engine is equipped with duplex fuel filters, the fuel filters can be replaced while the engine is in operation.
Illustration 99
Duplex fuel filters g01902892
Engines are shipped from the factory with the control valve in the
MAIN RUN position.
(3) Fuel pressure gauge for the main fuel filter
(4) Plate that shows the position of the valve
(5) Fuel pressure gauge for the auxiliary fuel filter
(6) Control valve
(7) Auxiliary fuel filter
(8) Main fuel filter
Use the following procedure in order to replace the main fuel filter while the engine is in operation.
This filter contains pressurized fuel that can cause a fire hazard, which may result in bodily injury or death. Follow the instructions given in this Operation and Maintenance Manual and stop the engine if rapid air movement exists to blow the fuel.
Illustration 100 g01902917
1. Move the control valve to the LH FLOW — RH FILL position as marked on plate. The fuel pressure gauge for the main fuel filter should indicate full pressure. The fuel pressure gauge for the auxiliary fuel filter should indicate slight pressure.
Five minutes may be required in order to fill the auxiliary fuel filter. The auxiliary fuel filter must become full of fuel.
148
Maintenance Section
Fuel System Secondary Filter — Replace
SEBU8013-01
Illustration 101 g01902918
2. Move the control valve to the AUX RUN position.
The fuel pressure gauge for the auxiliary fuel filter should indicate full pressure. The fuel pressure gauge for the main fuel filter should indicate no pressure.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
3. Remove the used main fuel filter. Use a cloth or use a container in order to catch excess fuel.
4. Clean the gasket sealing surface of the main fuel filter base. Ensure that all of the old gasket is removed.
5. Apply clean diesel fuel to the new main fuel filter gasket.
6. Install a new main fuel filter. Tighten the fuel filter until the gasket contacts the base. Tighten the fuel filter by hand according to the instructions that are shown on the fuel filter. Do not overtighten the fuel filter.
Illustration 102 g01902918
7. Move the control valve to the RH FLOW — LH
FILL position. The fuel pressure gauge for the auxiliary fuel filter should indicate full pressure.
The fuel pressure gauge for the main fuel filter should indicate slight pressure. Five minutes may be required in order to fill the main fuel filter. The main filter must become full of fuel.
Illustration 103 g01902917
8. Move the control valve to the MAIN RUN position.
The fuel pressure gauge for the main fuel filter should indicate full pressure. The fuel pressure gauge for the auxiliary fuel filter should indicate no pressure.
replacing the Auxiliary Fuel Filter
The procedure for replacing the auxiliary fuel filter is similar to the procedure for replacing the main fuel filter.
SEBU8013-01 149
Maintenance Section
Fuel System Secondary Filter — Replace
Illustration 104
Duplex fuel filters g01902892
The engine is operating with the control valve in the AUX RUN position.
(3) Fuel pressure gauge for the main fuel filter
(4) Plate that shows the position of the valve
(5) Fuel pressure gauge for the auxiliary fuel filter
(6) Control valve
(7) Auxiliary fuel filter
(8) Main fuel filter
Use the following procedure in order to replace the auxiliary fuel filter while the engine is in operation.
Illustration 105 g01902918
1. Move the control valve to the RH FLOW — LH FILL position. The fuel pressure gauge for the auxiliary fuel filter should indicate full pressure. The fuel gauge for the main fuel filter should indicate slight pressure. Five minutes may be required for filling the main fuel filter. The main fuel filter must become full of fuel.
Illustration 106 g01902917
2. Move the control valve to the MAIN RUN position.
The fuel pressure gauge for the main fuel filter should indicate full pressure. The fuel pressure gauge for the auxiliary fuel filter should indicate no pressure.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
3. Remove the used auxiliary fuel filter. Use a cloth or use a container in order to catch excess fuel.
4. Clean the gasket sealing surface of the auxiliary fuel filter base. Ensure that all of the old gasket is removed.
5. Apply clean diesel fuel to the new auxiliary fuel filter gasket.
6. Install a new auxiliary fuel filter. Tighten the fuel filter until the gasket contacts the base. Tighten the fuel filter by hand according to the instructions that are shown on the fuel filter. Do not overtighten the fuel filter.
150
Maintenance Section
Fuel Tank Water and Sediment — Drain
SEBU8013-01
Illustration 107 g01902917
7. Move the control valve to the LH FLOW — RH FILL position. The fuel pressure gauge for the main fuel filter should indicate full pressure. The fuel pressure gauge for the auxiliary fuel filter should indicate slight pressure. Allow five minutes in order to fill the auxiliary fuel filter. The auxiliary fuel filter must become full of fuel.
Illustration 108 g01902918
8. Move the control valve to the AUX RUN position.
The fuel pressure gauge for the auxiliary fuel filter should indicate full pressure. The fuel pressure gauge for the main fuel filter should indicate no pressure.
Move the control valve to the FLOW BOTH position after both fuel filters are replaced.
i03645042
Fuel Tank Water and Sediment
— Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Fuel Tank
Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks.
Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve.
Note: Failure to properly close the drain can allow air into the system, which could have detrimental results to performance.
Check the fuel daily. Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled. Allow five to ten minutes before performing this procedure.
SEBU8013-01
Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank may overflow.
Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important.
Fuel Storage Tanks
Drain the water and the sediment from the fuel storage tank during the following conditions:
• Weekly
•
Oil change
•
Refill of the tank
This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. A four micron(c) absolute filter for the breather vent on the fuel tank is also recommended. Refer to Special Publication, SENR9620, “Improving Fuel
System Durablity”.
If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to settle before filling the engine fuel tank. Internal baffles in the bulk storage tank will also help trap sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i03997990
Generator — Dry
SMCS Code: 4450-569
151
Maintenance Section
Generator — Dry
Refer to Special Instruction, REHS9124, “Cleaning and Drying of the Generator” for further necessary information.
Of the following methods for drying the generator, the use of external heat is preferred.
• External heat
•
Internal heat
•
Combination of external and internal heat
• Circulating current
External heat is the most preferable method.
Insulation drying time can vary from a few hours to several days. The drying time depends on the moisture content and the process for drying that is used.
Note: Drying sometimes does not produce the required results. The use of a qualified rebuild shop may be necessary for dipping and drying the generator.
Personal injury or death can result from improper troubleshooting and repair procedures.
The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.
Refer to this Operation and Maintenance Manual,
“Generator Isolating for Maintenance” for information regarding the procedure to isolate the generator in a safe manner.
Illustration 109 g02175752
Typical curves of the resistance in the insulation that is drying
(1) Curve of the temperature in the windings
(2) Heat turned off.
(3) Drying time in hours
(4) Temperature in degrees celsius
(5) Curve of insulation resistance during drying process
(6) Insulation resistance in megohms
152
Maintenance Section
Generator — Dry
Note: When new insulation or very damp insulation is being dried, the resistance will probably fall rapidly. The rapid fall in resistance is the result of the temperature being raised to a value for drying. After reaching a minimum for a given temperature, the resistance will again rise as moisture is driven out of the insulation. The actual values will vary with each situation. Refer to Illustration 110.
If the windings or insulation are wet during the resistance measurement, use a 5 megohm resistor for protection in series with red positive lead. This procedure limits the voltage across the circuit under the test. Use this method until drying is well in progress and the resistance has reached an acceptable level.
Check the windings after every 4 hours when either external or internal heat is used to dry the generator.
Check the windings very hour when circulating current is used to dry the generator. Refer to Special
Instruction, REHS9124, “Cleaning and Drying of the
Generator” for more information.
Drying is complete when the tests show no increase in resistance and the resistance is above the minimum. Record these readings and compare these readings. Keep these records for future reference.
Illustration 110 g01696934
Curve of insulation resistance for windings in good condition
(1) Resistance after 30 seconds
(2) Resistance after 60 seconds
Illustration 110 indicates the curve of the resistance of a normal high resistance in the windings over a period of 60 seconds. The resistance after 60 seconds will be greater than the resistance or equal to the resistance after 30 seconds .
Note: If the insulation resistance after 60 seconds is not higher than the resistance after 30 seconds , the insulation may be weak.
SEBU8013-01
Illustration 111 g01697074
Curve of insulation resistance for windings that are wet or dirty
(1) Resistance after 30 seconds
(2) Resistance after 60 seconds
Illustration 111 indicates the curve of the resistance that is decaying over a period of 60 seconds. If the insulation resistance after 60 seconds is not higher than the resistance after 30 seconds , clean the windings and thoroughly dry the windings. Refer to Special Instruction, REHS9124, “Cleaning and
Drying of the Generator” for more information.
Note: Caterpillar recommends a minimum acceptable insulation resistance of 1 megohm for generators which operate with less than 1000 V of operating or rated voltage. Generators which operate at 1000 V of operating or rated voltage should have a minimum insulation resistance as determined by the following equation:
R = (V/1000) + M
“R” is the minimum insulation resistance.
“V” is the rated voltage.
“M” is 1 megohm.
These values are approximate. It may be possible to operate a generator with less resistance.
External Heat
Ovens
The best oven is a forced air drying oven for drying electrical equipment. Radiant ovens sometimes cause localized overheating.
NOTICE
Do not heat the generator too quickly. Try to limit the rise in temperature of the insulation and windings to
11.11° C (20° F) per hour. Failure to do so may cause equipment damage.
SEBU8013-01 153
Maintenance Section
Generator — Inspect
Note: Many electrical shops are equipped with baking ovens.
Heat the generator to approximately 75° C (167° F).
Never exceed 75° C (167° F) until the insulation tester tests correctly for insulation resistance (at least
4 hours).
Alternate Method
A tent formed by a tarp or a canvas with heated lamps or a portable space heater may be used as an alternate method.
A hole should be left in the top of the tarp for ensuring proper circulation through the generator and for permitting the moisture to exhaust. Heat the generator to approximately 75° C (167° F). Never exceed 75° C (167° F) until the insulation tester tests correctly for insulation resistance (at least 4 hours).
Internal Heating
If generators operate under one of the following conditions, the electric space heaters should be installed as part of the generator:
• Generators are in damp environments and go for long periods of time without operation.
•
Generators operate regularly in an environment with moisture laden air.
Circulating Current
Drying can be accomplished by circulating low voltage current through the windings. Since the voltage is low, the breakdown of the insulation will not occur as the breakdown might have occurred with normal operation and wet insulation. Refer to Special
Instruction, REHS9124, “Cleaning and Drying of the
Generator” for this procedure.
Generator — Inspect
SMCS Code: 4450-040 i01880220
Personal injury or death can result from improper troubleshooting and repair procedures.
The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.
The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure to safely isolate the generator.
Proper maintenance of electrical equipment requires periodic visual examination of the generator and periodic visual examination of the windings. Proper maintenance of electrical equipment also requires appropriate electrical checks and appropriate thermal checks. Insulation material should be examined for cracks. The insulation material should be examined for accumulations of dirt and dust. If there is an insulation resistance value that is below normal, a conductive path may be present. This conductive path may be made of one of the following materials:
•
Carbon
• Salt
•
Metal dust
•
Dirt that is saturated with moisture
These contaminants will develop a conductive path which may produce shorts. Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen. If excess dirt is the cause of a restriction in the ventilation, cleaning is also advisable. Restricted ventilation will cause excessive heating.
NOTICE
To avoid the possibility of deterioration to the generator windings, do not clean the generator unless there is visual, electrical, or thermal evidence that dirt is present.
If harmful dirt accumulations are present, a variety of cleaning techniques are available. The cleaning procedure that is used may be determined by one of the items on the following list:
• The extent of the cleaning procedure that is being attempted
154
Maintenance Section
Generator Bearing — Inspect/Replace
•
The type of enclosure of the generator
•
The voltage rating of the generator
•
The type of dirt that is being removed
Cleaning (Assembled Generators)
Cleaning may be required at the point of installation.
At this point, complete disassembly of the generator may not be necessary or feasible. In this case, a vacuum cleaner should be used to pick up the following items: dry dirt, dust, and carbon. This will prevent the spreading of these contaminants.
A small nonconductive tube may need to be connected to the vacuum cleaner. This will allow the vacuum cleaner to clean the surfaces that are not exposed. After most of the dust has been removed, a small brush may be attached to the vacuum hose in order to loosen dirt that is more firmly attached to the surface.
After the initial cleaning with a vacuum, compressed air may be used to remove the remaining dust and dirt. Compressed air that is used for cleaning should be free of moisture and free of oil. Air pressure should be a maximum of 210 kPa (30 psi) in order to prevent mechanical damage to the insulation. If the above cleaning procedures are not effective, consult a Caterpillar dealer.
Cleaning (Disassembled
Generators)
An initial insulation resistance check should be made on the generator in order to confirm electrical integrity. A minimum reading of one megohm would be expected with severely contaminated generators.
A zero megohm reading may indicate an insulation breakdown. An insulation breakdown requires more than cleaning. An insulation breakdown requires repair.
A high pressure wash is normally an effective way to clean windings. This includes windings that have been exposed to flooding or windings that have been contaminated by salt. A solution of hot water and detergent is used for this method of cleaning.
A high pressure wash sprays a high velocity fluid stream of this solution over the generator that is being cleaned. This detergent washing is followed by multiple sprays of clean water. The clean water is used in order to remove the detergent or the clean water is used in order to dilute the detergent.
SEBU8013-01
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation resistance should now be normal. If the insulation resistance is not normal, repeat the procedure. It may be necessary to use solvents if the generator is contaminated with oil or if the generator is contaminated with grease.
Note: For more information on drying methods, refer to Special Instructions, SEHS9124, “Cleaning and
Drying of Electric Set Generators”.
i03099722
Generator Bearing —
Inspect/Replace
(SR4 Generator)
SMCS Code: 4471-040; 4471-510
The following maintenance procedure for generator bearings should be followed at every major engine overhaul:
Inspect
1. Remove the bearing bracket. Inspect the following items: bracket bore, bearing outer race, and rolling elements. On standby power units, the bearing must be inspected and the grease must be replaced at three year intervals. The sleeve in the bearing bracket should be inspected for out of roundness, excessive wear, and a bracket step that is less than 0.0762 mm (0.0030 inch). If there is no sleeve in the bearing bracket, inspect the bore of the bearing bracket. The bearing should be inspected for damage to the outer race, severe fretting, and smoothness of operation.
When possible, the bearing elements should be inspected. Some double shielded ball bearings prevent visual inspection of the elements of the bearing. Other double shielded ball bearings have a retaining ring. This retaining ring can be removed in order to allow access for a visual inspection of the elements of the bearing.
On two-bearing generators, the front bearing can only be removed after the drive coupling is removed. Refer to the Systems Operation
Testing and Adjusting Disassembly and Assembly,
“Coupling — Remove” for the generator for instructions for removing the drive coupling.
Replace
1. All ball bearings should be cleaned. The cavity in the bracket should be repacked with
2S-3230
Grease. Pack the ball bearings (one-third to one-half of the volume of the cavity).
SEBU8013-01
2. Use an induction heater to heat the ball bearings to
107 °C (224.6 °F) for ten minutes in order to install either of the following bearings: ball bearings that are new and ball bearings that have been inspected. Mount the bearings on the shaft. To reinstall the hub, heat the hub to 400 °C (752.0 °F) for three hours. Mount the hub to the shaft.
3. Ensure that the tube of the grease gun is filled with grease.
4. Remove the bracket drain plug and operate the generator for one hour. This will allow the grease to expand. The expanding grease will force the excess grease from the cavity. When the excess grease is forced from the cavity, the internal pressure will be reduced. The generator should continue to operate until the grease stops purging.
5. Stop the engine. Install the bracket drain plug.
Wipe off the excess grease.
6. For greasing intervals, follow the recommendations on the lubrication plate (if equipped) or refer to
Maintenance Schedule, “Generator Bearing —
Lubricate”. Whenever the bearings are greased, repeat Step 1. DO NOT MIX GREASES.
i04011489
Generator Bearing — Lubricate
SMCS Code: 4471-086
Lubricating Process (If Applicable)
Note: If the generator already has a visible grease point, go to Step 4.
1. Remove either the louver assembly or the rear plate from the rear of the generator housing.
2. Remove the top grease pipe plug and remove the lower grease pipe plug.
3. Install a grease fitting in the grease pipe.
4. Grease the bearings with
2S-3230 Bearing
Lubricant.
5. Wipe off the excess grease. Remove the top grease fitting. Install the plug.
6. Operate the generator for 1 hour. This process will allow the grease to expand. The expanding grease will force the excess grease from the cavity. When the excess grease is forced from the cavity, the internal pressure will be reduced.
The generator should continue to operate until the grease stops purging.
155
Maintenance Section
Generator Bearing — Lubricate
7. Stop the engine. Install the plug in the bottom grease pipe. Wipe off the excess grease.
8. Install the louver assembly or install the rear plate.
Additional Information
Refer to Special Instruction, REHS4892, “Generator
Bearing Service” for further information.
i04011510
Generator Bearing
Temperature — Measure/Record
SMCS Code: 4471-082-TA
If a Marine Classification Society system (MCS system) is not available, bearing temperature detectors are used with equipment that has been provided by the customer. Bearing temperature detectors may help to prevent premature bearing failure.
A bearing temperature that is 50 °C (122 °F) above the ambient temperature may require a change in operation. The unit should be shut down in order to prevent damage if the bearing temperature is 50 °C
(122 °F) above the ambient temperature.
Generator Load — Check
SMCS Code: 4450-535-LA i01878834
Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
During normal operation, monitor the power factor and monitor generator loading.
156
Maintenance Section
Generator Set — Test
When a three-phase generator is installed or when a three-phase generator is reconnected, ensure that the total current in any one phase does not exceed the nameplate rating. Each phase should carry the same load. This allows the three-phase generator to work at the rated capacity. If one phase current exceeds the nameplate amperage, an electrical imbalance will occur. An electrical imbalance can result in an electrical overload and an electrical imbalance can result in overheating on three-phase generators. This is not applicable to single-phase generators.
The power factor can be referred to as the efficiency of the load. This can be expressed as the ratio of kVA to actual kW. The power factor can be calculated by dividing kW by kVA. Power factor is expressed as a decimal. Power factor is used to mean the portion of current that is supplied to a system that is doing useful work. The portion of the current that is not doing useful work is absorbed in maintaining the magnetic field in motors. This current (reactive load) can be maintained without engine power.
i02377583
Generator Set — Test
SMCS Code: 4450-081
DANGER: Shock/Electrocution Hazard-Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.
SEBU8013-01
Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock hazard to its user.
Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.
When servicing or repairing electric power generation equipment:
•
Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO
NOT OPERATE.
•
Make sure the generator engine is stopped.
•
Make sure all batteries are disconnected.
•
Make sure all capacitors are discharged.
Table 15
Part Number
237-5130
Tools Needed
Part
Digital
Multimeter
12 VDC battery
Potential
Transformer
Quantity
1
1
1
The generator set functional test is a simplified test that can be performed in order to determine if the generator is functional. The generator set functional test should be performed on a generator set that is under load.
The generator set functional test determines if the following statements happen:
•
A phase voltage is being generated.
•
The phase voltages are balanced.
•
The phase voltages change relative to engine speed.
The generator set functional test consists of the following steps:
SEBU8013-01
1. Stop the generator. Connect the potential transformer’s high voltage winding to the generator terminals (T1) and (T2). Connect the voltmeter to the low voltage winding. If two transformers are available, connect the high voltage winding of the second transformer to the generator terminals (T1) and (T3). Connect the secondary terminals that correspond to generator terminal (T2) of both transformers together.
2. Disconnect wires “E+” and “E-” from the voltage regulator. Disconnect the generator from the load.
3. Connect a 12 VDC automotive battery to wires
“E+” and “E-”.
4. Measure the AC voltage across the low voltage terminals of the transformer that correspond to the following generator terminals: “T1” and “T2”, “T2” and “T3”, and “T3” and “T1”. Record the voltages.
Generator Set Alignment —
Check
(Generator Sets)
i03956450
SMCS Code: 7002-024
The genset must be aligned when the genset is installed or moved into a different position. If the generator set is run at the full continuous rating, the alignment of the generator to the engine must be checked annually.
Properly maintain the alignment between the engine and the driven equipment in order to minimize the following problems:
•
Bearing problems
•
Vibration of the engine crankshaft
•
Vibration of the driven equipment
Refer to the following information for more information about the alignment of the generator set:
•
Special Instruction, SEHS7654, “Alignment —
General Instructions”
•
Special Instruction, SEHS7259, “Alignment of
Single Bearing Generators”
•
Special Instruction, REHS0177, “Alignment of the
Close Coupled Two Bearing Generators”
157
Maintenance Section
Generator Set Alignment — Check
Keep a record of the measurement of the alignment.
The record may be used to check the trend of the alignment. The record may be used to analyze the trend of the alignment.
i03112463
Generator Set Vibration —
Inspect
SMCS Code: 4450-040-VI
Check for vibration damage. Vibration may cause the following problems:
•
Loose fittings
•
Loose belts
•
Excessive noise
•
Cracked insulation
The following areas are susceptible to vibration damage:
•
Stator output leads
•
Protective sleeving
•
Insulation
•
Exposed electrical connections
•
Transformers
•
Fuses
•
Capacitors
•
Lightning arresters
When a generator set is installed a vibration plot should be recorded in order to assist in diagnosing potential problems. This vibration plot should be updated yearly. The vibration plot should also be updated when the generator set is moved. Refer to
Data Sheet, LEKQ4023, “Linear Vibration” for the allowable limits of vibration.
Contact the Caterpillar Dealer Service Tools group for information on ordering a vibration analyzer that will meet your needs.
158
Maintenance Section
Heat Exchanger — Inspect
Heat Exchanger — Inspect
SMCS Code: 1379-040 i03712080
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The heat exchanger and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
The interval for the maintenance of the plate type heat exchanger depends on the operating environment of the vessel and on the operating time. The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items:
•
Cleanliness of the heat exchanger plates
•
Effectiveness of the heat exchanger system
SEBU8013-01
Operating in water that contains the following will adversely affect the heat exchanger system: silt, sediment, salt, and algae. In addition, intermittent use of the vessel will adversely affect the heat exchanger system.
The following items indicate that the heat exchanger may require cleaning:
•
Increased coolant temperature
•
Engine overheating
• Excessive pressure drop between the water inlet and the water outlet
An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range.
Inspection of the heat exchanger and maintenance of the heat exchanger are required if the engine is overheating.
Your Caterpillar dealer has the equipment and the personnel in order to measure the pressure drop across the heat exchanger.
Cleaning Procedure
Removal and Disassembly of the Heat
Exchanger
Drain the heat exchanger. Refer to the Disassembly and Assembly Manual, “Heat Exchanger — Remove” for the removal procedure.
Refer to the Disassembly and Assembly Manual,
“Heat Exchanger — Disassemble” for the disassembly procedure. Keep the plates in order..
Cleaning the Heat Exchanger
Refer to “Choosing the Correct Cleaning Fluid” for the correct cleaning fluid for your heat exchanger.
Clean the plates with a cleaning solution and a soft brush. Pressurized water may also be used. Do not use steel wool or a wire brush, which may scratch the plate. Any iron scratches on the plates can lead to corrosion of the plates. Rinse the plates with water.
Choosing the Correct Cleaning Fluid
Refer to 16 for the correct cleaning fluid for the heat exchanger.
SEBU8013-01
Table 16
Problem
Scaling
Sediment
(5)
Gross fouling
Biological growth
Source
Calcium carbonate
Calcium sulfate
Silicates
Corrosion products
Metal oxides
Silt
Diatomic organisms
Seaweed
Chips of wood and fibers
Mussels
Barnacles
Bacteria
Nematodes
Protozoa
Cleaners
(1)(2)(3)(4)
Nitric acid
Sulfamic acid
Citric acid
Phosphoric acid
Complexing agents
Sodium polyphosphates
Residue
Oily films
Asphalt
Fats
Paraffinic or
Naphtha based solvent such as
Kerosene.
(6)(7)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Cleaners should be mixed at a maximum concentration of 4 percent by weight. The temperature of the cleaning solution should be less than 60 °C (140 °F).
Do not use water that contains more than 300 ppm of chlorine in the preparation of cleaning solutions.
Do not use hydrochloric acid to clean stainless steel plates. Do not use hydrofluoric acid to clean titanium plates.
Do not use a type of ketone such as acetone and methyletyketone. Do not use aromatics such as benzene and toluene. Do not use esters such as ethylacetate and butylacetate. Do not use halogenated hydrocarbons such as chlorothene and carbon tetrachloride.
The addition of surfactants to the cleaning solution may ease cleaning.
Do not mix the solvent with water for cleaning. Dry the plates with a cloth or rinse the plates with water.
Gaskets that are made from natural rubber, butyl rubber and
EPDM rubber will swell in these solvents. Do not allow the solvent to contact the gasket more than half an hour.
Assembly and Installation of the Heat
Exchanger
Refer to the Disassembly and Assembly Manual,
“Heat Exchanger — Assemble” for the assembly procedure.
Refer to the Disassembly and Assembly Manual,
“Heat Exchanger — Install” for the installation procedure.
159
Maintenance Section
Hoses and Clamps — Inspect/Replace i03847809
Hoses and Clamps —
Inspect/Replace
SMCS Code: 7554-040; 7554-510
Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine. Take proper safety precautions before inspecting or replacing hoses and clamps.
Note: Always use a board or cardboard when the engine components are checked for leaks. Leaking fluid that is under pressure can cause serious injury or possible death. This includes leaks that are the size of a pin hole. Refer to Operation and
Maintenance Manual, “General Hazard Information” for more information.
Inspect the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the following conditions. Replace any hose which exhibits any of the following conditions. Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation.
•
Hoses which are cracked
•
Hoses which are soft
• Outer covering that is chafed or cut
•
Exposed wire that is used for reinforcement
•
Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
•
Armoring that is embedded in the outer covering
•
Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps
Inspect all clamps for the following conditions.
Replace any clamp which exhibits signs of any of the following conditions.
•
Cracking
•
Looseness
•
Damage
Inspect all couplings for leaks. Replace any coupling which exhibits signs of leaks.
Each installation application can be different. The differences depend on the following factors:
160
Maintenance Section
Hoses and Clamps — Inspect/Replace
•
Type of hose
•
Type of fitting material
•
Anticipated expansion and contraction of the hose
•
Anticipated expansion and contraction of the fittings
Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.
Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace hose clamps which are loose.
Replace the Hoses and the Clamps
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Cooling System
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
SEBU8013-01
Personal injury can result from removing hoses or fittings in a pressure system.
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
1. Stop the engine.
2. Allow the engine to cool.
3. Before servicing a coolant hose, slowly loosen the filler cap for the cooling system in order to relieve any pressure.
4. Remove the filler cap for the cooling system.
5. Drain the coolant from the cooling system to a level that is below the hose that is being replaced.
Drain the coolant into a suitable clean container.
The coolant can be reused.
6. Remove the hose clamps.
7. Disconnect the old hose.
8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and installing the proper hose clamps.
10. Refill the cooling system.
11. Clean the filler cap for the cooling system. Inspect the gaskets on the filler cap. Replace the filler cap if the gaskets are damaged. Install the filler cap.
12. Start the engine. Inspect the cooling system for leaks.
Fuel System
Personal injury can result from removing hoses or fittings in a pressure system.
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
SEBU8013-01 161
Maintenance Section
Hoses and Clamps — Inspect/Replace
Lubrication System
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components.
Note: High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors. High pressure fuel lines are constantly charged with high pressure. Do not check the high pressure fuel lines with the engine or the starting motor in operation. Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure fuel lines in order to allow pressure to be purged.
1. Drain the fuel from the fuel system to a level that is below the hose that is being replaced.
2. Remove the hose clamps.
3. Disconnect the old hose.
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and installing the proper hose clamps.
6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the engine.
Note: Fuel must be added to the fuel system ahead of the fuel filter.
7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System — Prime” for information about priming the engine with fuel.
8. Start the engine. Inspect the fuel system for leaks.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
1. Drain the oil from the lubrication system to a level that is below the hose that is being replaced.
2. Remove the hose clamps.
3. Disconnect the old hose.
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and installing the proper hose clamps.
6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, “Engine
Oil Level — Check” in order to ensure that the lubrication system is filled with the proper amount of engine oil.
7. Start the engine. Inspect the lubrication system for leaks.
Air System
1. Remove the hose clamps.
2. Disconnect the old hose.
3. Replace the old hose with a new hose.
4. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and installing the proper hose clamps.
5. Start the engine. Inspect the air lines for leaks.
162
Maintenance Section
Insulation — Test
Insulation — Test
i03642858
SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081
Recommended Periodic Insulation
Tests
The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
Table 17
Part Number
300-8648
Tools Needed
Part Name
Insulation
Testing Gp
Quantity
1
Periodically, use an insulation tester to check the insulation resistance of the generator’s main stator winding. The frequency of this test is determined by the generator’s environment. Previous insulation tester readings will also determine the frequency of this test.
Test the main stator windings with an insulation tester in the following situations:
•
The generator set is started for the first time.
•
The generator set is removed from storage.
•
The generator set is operating in a humid environment. Test every three months.
•
The generator set is not protected from the elements in an enclosed area. Test every three months.
• The generator set is installed in an enclosed area.
This area needs to be low in humidity and this area needs to have steady temperatures. Test every twelve months (minimum).
SEBU8013-01
•
The generator set has not been run under load for three months. Test the generator set weekly.
Use space heaters around the generator set if the generator is exposed to a sea water environment or if the humidity is above 75 percent. Also use space heaters if a test result was below 3 megohms.
Space heaters must be used whenever the generator set is not under load. Space heaters must also be used whenever salt is present or whenever high humidity is present. Using a space heater in this fashion is the only way to maintain insulation tester readings above one megohm. Use space heaters only when the generator is not running.
For additional information, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
Recommended Procedure for the
Insulation Test
Personal injury or death can result from electrocution.
The megohmmeter is applying a high voltage to the circuit.
To avoid electrocution, do not touch the instrument leads without first discharging them. When finished testing also discharge the generator windings.
1. Take the generator out of service.
2. Visually inspect the generator for moisture. If moisture exists, do not perform this insulation test. Dry the unit first. Refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
3. Inspect the installation. Determine the equipment that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Disconnect “T0” from ground.
6. Disconnect the sensing lead wires for the regulator. This may be accomplished by unplugging the harness connectors.
7. Disconnect the PT leads of the load share module.
8. Connect the insulation tester’s Black lead to ground.
9. Connect the insulation tester’s RED lead to “T0”.
SEBU8013-01
10. Set the voltage to the rated voltage of the generator.
11. Use the 30/60 Time Resistance Method:
a. Apply voltage.
b. Observe the readings at 30 seconds. Observe the readings at 60 seconds.
c. Record the 60 second reading. This reading must be corrected for temperature.
d. Record temperature.
e. Record humidity.
f. Remove voltage.
12. Evaluate the readings. The actual value of the resistance may vary greatly between generators.
For this reason, the insulation’s condition must be evaluated. Base this evaluation on the comparison between the 60 second resistance readings and the readings that were taken on previous dates.
These two readings must be taken under similar conditions. If a 60 second resistance reading has a 50 percent reduction from the previous reading, the insulation may have absorbed too much moisture.
Switch the insulation tester to the “OFF” position.
This will discharge the insulation tester’s leads.
Disconnect the insulation tester’s leads.
Note: The results from the insulation resistance checks indicate when cleaning and/or repairing is becoming critical. Generally, insulation resistance will vary greatly with temperature. Therefore, always test at the same temperature and humidity. Refer to
Illustration 112.
Engine Serial Number
_____________________________________
Serial Number for the Generator
________________________
163
Maintenance Section
Insulation — Test
164
Maintenance Section
Insulation — Test
SEBU8013-01
Illustration 112 g00633226
SEBU8013-01 i03958771
Maintenance
Recommendations
SMCS Code: 1000
Maintenance Information
The operating conditions of an engine affect the maintenance intervals and the time between overhauls for the engine. The following conditions affect the maintenance intervals and the expected overhaul interval for the engine.
Severe Operation
Severe operation is the use of an engine that exceeds current published standards for the engine.
Caterpillar maintains standards for the following engine parameters:
•
Horsepower
• Range of rpm
•
Fuel consumption
•
Fuel quality
• Altitude
•
Maintenance intervals
•
Selection of oil
• Selection of coolant
•
Environmental qualities
•
Installation
Refer to the standards for your engine or consult your
Caterpillar dealer in order to determine if your engine is operating within the defined parameters.
Severe operation can accelerate component wear.
Engines that are operating under severe conditions may need more frequent maintenance intervals for the following reasons:
•
Maximum reliability
•
Retention of full service life
Because of individual applications, it is not possible to identify all of the factors which can contribute to severe operation. Consult your Caterpillar dealer about the maintenance that is needed for your specific engine.
165
Maintenance Section
Maintenance Recommendations
The following factors can contribute to severe operation: environment, improper operating procedures, and improper maintenance practices.
Environmental Factors
Extreme Ambient Temperatures
Extended operation in environments that are extremely cold or hot can damage components. Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures. Extremely hot inlet air reduces the performance capabilities of the engine.
Note: See this Operation and Maintenance Manual,
“Cold Weather Operation” topic (Operation Section), or see Supplement, SEBU5898, “Cold Weather
Recommendations”.
Cleanliness
Unless the equipment is cleaned regularly, extended operation in a dirty environment and in a dusty environment can damage components. Built up mud, dirt, and dust can encase components. This operating environment can make maintenance difficult. The buildup can contain corrosive chemicals. Corrosive chemicals and salt can damage some components.
Improper Operating Procedures
•
Extended operation at low idle
•
Minimum cool down periods after high load factor operation
• Operating the engine beyond the guidelines for the engine rating
•
Operating the engine at loads that are greater than the rated load
• Operating the engine at speeds that are greater than the rated speed
•
Use of the engine for an application that is not approved
Improper Maintenance Practices
•
Extension of maintenance intervals
•
Not using recommended fuel, lubricants, and antifreeze/coolant solutions
166
Maintenance Section
Maintenance Recommendations
Overhaul Information
Caterpillar makes the following recommendations for the timing of the overhaul procedures for your engine.
The intervals may be extended based on individual application and load factors. Contact your Caterpillar dealer for further information about the optimal maintenance interval for the overhaul procedures.
Table 18
Overhaul
Procedure
Top End
Overhaul
Major Overhaul
Recommended Interval
Every 284000 L (750000 US gal) or 5000 SH
Every 570000 L (150000 US gal) or 10000 SH
Note: Refer to this Operation and Maintenance
Manual, “Overhaul (Top)” for further information about the top overhaul.
Note: Refer to this Operation and Maintenance
Manual, “Overhaul (Major)” for further information about the major overhaul.
Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval.
The need for an overhaul is generally indicated by increased fuel consumption and by reduced power.
The following factors are important when a decision is being made on the proper time for an engine overhaul:
• The need for preventive maintenance
• The quality of the fuel that is being used
• The operating conditions
• The results of the S·O·S analysis
Oil Consumption as an Overhaul
Indicator
Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.
Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.
SEBU8013-01
The oil consumption rate (brake-specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake-specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.
When te engine oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. The scheduled overhaul will provide you with the best cost/value relationship.
Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life.
A planned overhaul before failure may be the best value for the following reasons:
•
Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the standards for reusable parts.
•
The service life of the engine can be extended without the risk of a major catastrophe due to engine failure.
•
The best cost/value relationship per hour of extended life can be attained.
After Failure Overhaul
If a major engine failure occurs and the engine must be removed from the hull, many options are available.
An overhaul should be performed if the engine block or the crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft is repairable, the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core.
This lower cost can be attributed to three aspects:
• Specially designed Caterpillar engine features
•
Caterpillar dealer exchange components
SEBU8013-01 167
Maintenance Section
Oil Cooler Core — Check/Clean/Test
•
Caterpillar Inc. remanufactured exchange components
Oil Cooler Core —
Check/Clean/Test
(If Equipped)
SMCS Code: 1378-070; 1378-081; 1378-535 i03634803
Clean the Oil Cooler Core
Remove the core. Refer to the Disassembly and
Assembly Manual, “Oil Cooler — Remove” for the procedure.
1. Turn the oil cooler core on one side in order to remove debris. Remove the debris that is accessible.
NOTICE
Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.
2. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 19 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer.
Table 19
Hydrosolv Liquid Cleaners
(1)
Part
Number
Description Size
1U-5490
Hydrosolv 4165
174-6854
Hydrosolv 100
19 L (5 US gallon)
19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner at temperatures up to 93°C (200°F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more information.
3. Steam clean the core in order to remove any residue. Flush the fins of the oil cooler core.
Remove any other trapped debris from the inside and from the outside of the core.
4. Wash the core with hot, soapy water.
5. Flush the core thoroughly in order to remove residue and remaining debris. Flush the core with clean, fresh water until the water that is exiting the core is clear and free of debris.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded.
6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.
Test the Oil Cooler Core
1. Inspect the core for trapped debris and cleanliness. If necessary, remove the debris and repeat the cleaning procedure.
2. Inspect the core for damage and perform a pressure test in order to detect leaks. Many shops that service radiators are equipped to perform pressure tests.
3. Plug both ends of the oil cooler core and pressurize the core to 205 kPa (30 psi). Submerge the core in water. Look for bubbles which are being emitted from the core. The bubbles are evidence of leaks.
4. If any leaks are found, do not attempt to repair the core.
Install a core that is clean and a core that passes the pressure test in step 3. Refer to the Disassembly and Assembly Manual, “Oil Cooler — Install” for the procedure.
For more information on cleaning the core, consult your Caterpillar dealer.
i03962492
Overhaul (Major)
SMCS Code: 7595-020-MJ
Note: Refer to this Operation and Maintenance
Manual, “Maintenance Recommendations” for information about the optimal maintenance interval for the major overhaul.
The need for a major overhaul is determined by several factors.
•
An increase of oil consumption
•
An increase of crankcase blowby
168
Maintenance Section
Overhaul (Major)
•
The total amount of fuel consumption
•
The service hours of the engine
•
The wear metal analysis of the lube oil
•
An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need service. An increase in the levels of noise and vibration indicates that rotating parts require service.
Note: An oil analysis may indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals.
Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about scheduling a major overhaul.
Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment.
For the major overhaul, all of the bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned and inspected.
If necessary, the parts are replaced. The crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft may be replaced with a Caterpillar replacement part.
Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.
Replacement of Components
Replace the following components during the major overhaul:
•
Camshaft bearings
•
Connecting rod bearings
• Crankshaft seals
•
Crankshaft thrust washers
•
Electronic unit injectors
• Gear train bushings
•
Gear train bearings
•
Main bearings
• Piston rings
SEBU8013-01
•
Aftercooler core
International Convention for Safety of
Life at Sea (SOLAS)
Caterpillar recommends replacing the following:
• All shields that have been installed to cover up fuel and oil line connections per (SOLAS) regulations
•
All marine certification society approved tapes are installed in order to cover up fuel line connections and oil line connections according to the SOLAS regulations.
Inspection, Reconditioning, or
Exchanging of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used
Parts”.
Recondition the worn components or exchange the components, if necessary. Your Caterpillar dealer can provide these services and components.
• Camshaft followers
•
Camshaft thrust washers
•
Connecting rods
• Crankshaft vibration damper
•
Cylinder head assembly
•
Cylinder liners
• Engine mounts
•
Scavenge oil pump
•
Engine wiring harness
• Exhaust manifold seals
•
Exhaust manifold bellows
•
Fuel pressure regulating valve
• Fuel priming pump
•
Fuel transfer pump
•
Inlet manifold gaskets
• Inlet manifold seals
SEBU8013-01
•
Oil cooler core
•
Oil pump
•
Pistons
•
Piston pins
•
Prelube pump
•
Pushrods
•
Rocker arms
•
Spacer plate
•
Software update
•
Turbocharger
Inspection of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used
Parts”.
•
Camshaft
•
Crankshaft
•
Driven equipment (alignment)
•
Engine cylinder block
•
Engine control module
•
Flywheel
•
Front gear train (gears)
•
Oil suction screen
•
Rear gear train
Inspect the camshaft for damage to the journals and the lobes.
Inspect the crankshaft for any of the following conditions:
•
Deflection
•
Damage to the journals
•
Bearing material that has seized to the journals
169
Maintenance Section
Overhaul (Major)
Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:
• rod bearing
• main bearings
Note: If the crankshaft or the camshaft are removed for any reason, use the magnetic particle inspection process to check for cracks.
Replace the crankshaft vibration damper if any of the following conditions occur:
•
Engine failure due to a broken crankshaft
•
Excessive wear of the front bearing for the crankshaft
•
Excessive wear of the gear train that is not caused by a lack of lubrication
Inspect the gears of the gear train and inspect the gear train bushings for the following conditions:
•
Worn gear teeth
•
Unusual fit
• Unusual wear
In addition to the inspection of components, inspect the alignment of the driven equipment. See the
Application and Installation Guide for the engine or see the literature that is provided by the OEM of the driven equipment.
Cleaning of Components
Clean the oil suction screen. Also, remove side covers in order to clean the oil sump. For instructions on removal and installation of components, see the Service Manual, “Disassembly and Assembly” module.
Obtain a Coolant Analysis
For conventional heavy-duty coolant or antifreeze, check the concentration of supplemental coolant additive (SCA) regularly. The concentration of SCA can be checked with an S·O·S coolant analysis (Level
1). A more detailed coolant analysis is recommended periodically.
170
Maintenance Section
Overhaul (Top End)
For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals which were deposited on the engine over time.
A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis may be obtained from the following sources:
•
Caterpillar dealer
•
Local water utility company
•
Agricultural agent
•
Independent laboratory
Caterpillar recommends an S·O·S coolant analysis
(Level II). This analysis is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system. The following services are provided:
•
Full Level 1 analysis
•
Identification of the source of metal corrosion and of contaminants
• Identification of buildup of the impurities that cause corrosion
•
Identification of buildup of the impurities that cause scaling
• Determination of possible electrolysis within the engine cooling system
A report of the results of the analysis is provided.
Maintenance recommendations are based on the results.
For more information about S·O·S coolant analysis, consult your Caterpillar dealer.
i03962489
Overhaul (Top End)
SMCS Code: 7595-020-TE
Note: Refer to this Operation and Maintenance
Manual, “Maintenance Recommendations” for information about the optimal maintenance interval for the top overhaul.
SEBU8013-01
A top end overhaul involves the removal, the inspection, and the rework of the cylinder head components. A few additional components are replaced and serviced.
Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.
The following definitions explain the terminology for the services that are performed during an overhaul:
Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired. If the components are not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Rebuild – The component is reconditioned in order to comply with reusability guidelines.
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part. Some worn components may be exchanged with your Caterpillar dealer for a credit on replacement parts. Consult your Caterpillar dealer about repair options for your engine.
If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the recommendations in Table 20.
SEBU8013-01
Table 20
Recommendations for Top End Overhauls
(1)
Service Top End Overhaul
Inspect
Rebuild
Replace
Cylinder head assemblies
Valves
Inspect
Replace
Rocker arms
Valve bridges
Fuel Injectors
Clean/Test Oil cooler core
(2)
Aftercooler core (Fresh water or treated water system)
(3)
Replace Cylinder head gaskets
Aftercooler core (salt water system)
(1)
(2)
(3)
For instructions on removal and installation of components, see the Service Manual, “Disassembly and Assembly” module.
Refer to this Operation and Maintenance Manual, “Oil Cooler
Core — Check/Clean/Test” for the procedure.
Refer to this Operation and Maintenance Manual, “Aftercooler
Core — Clean/Test” for the procedure.
i01216962
Power Factor — Check
SMCS Code: 4450-535-PWR
The power factor of a system can be determined by a power factor meter or by calculations. The power factor can be calculated by dividing kW by kVA.
Power factor is expressed as a decimal.
Rotating Rectifier — Check
i02331392
SMCS Code: 4465-535
Check the exciter armature. Ensure that the rotating rectifier is tight. If a failure of a rectifier is suspected, refer to “Testing A Brushless Exciter Rotating
Rectifier With An Ohmmeter”.
171
Maintenance Section
Power Factor — Check
Testing A Brushless Exciter
Rotating Rectifier With An
Ohmmeter
Table 21
Part Number
6V-7070
9U-7330
146-4080
7X-1710
Tools Needed
Part Name
Digital
Multimeter
Multimeter
Digital
Multimeter
(RS-232)
Multimeter Probe
Group
Quantity
1
1
1
1
Illustration 113 g00555106
If the failure of a rectifier is suspected, use the following procedure.
1. Remove the cover from the exciter.
2. Remove the nut that secures the rectifier to the heat sink.
3. Remove the diode lead.
4. Lift the rectifier from the heat sink.
5. Refer to Illustration 113. Connect the ohmmeter’s leads across the rectifier. Note the meter reading.
6. Reverse the ohmmeter leads. Note the meter reading.
The ohmmeter should indicate a low resistance when the ohmmeter leads are across the rectifier in one direction. The ohmmeter should indicate a high resistance when the leads are reversed.
If the ohmmeter indicates a low resistance in both directions, the rectifier is shorted. A high resistance in both directions indicates an open rectifier.
172
Maintenance Section
Rotating Rectifier — Check
Replace any faulty rectifiers with rectifiers that have comparable operating characteristics. Include the following information when a rectifier is being ordered for replacement:
•
Part Number of the rectifier
• Model number of the exciter
•
Type of the exciter
•
Serial number of the generator
Rectifier Block Test
Illustration 114
Rectifier Block
(1) “AC1” terminal
(2) “AC2” terminal
(3) “AC3” terminal
(4) Negative terminal
(5) Positive terminal g00775020
Perform the following steps in order to test the rectifier block. When possible, use the diode test scale. If there is no diode test scale, use the resistance scale.
1. Touch the red ohmmeter lead to the rectifier terminal that is marked “+”.
SEBU8013-01
2. Touch the black ohmmeter lead to the rectifier terminals that have the following labels: “AC1”,
“AC2”, and “AC3”. The meter should indicate an open circuit or high resistance for each rectifier terminal. If the meter does not indicate an open circuit or high resistance, the rectifier is bad.
Replace the rectifier.
3. Touch the black ohmmeter lead to the rectifier terminal that is marked “+”.
4. Touch the red ohmmeter lead to the rectifier terminals that have the following labels: “AC1”,
“AC2”, and “AC3”. The meter should indicate a good diode or low resistance. If the meter does not indicate a good diode or low resistance, the rectifier is bad. Replace the rectifier.
5. Touch the black ohmmeter lead to the rectifier terminal that is marked “−”.
6. Touch the red ohmmeter lead to the rectifier terminals that have the following labels: “AC1”,
“AC2”, and “AC3”. The meter should indicate an open circuit or high resistance for each rectifier terminal. If the meter does not indicate an open circuit or high resistance, the rectifier is bad.
Replace the rectifier.
7. Touch the red ohmmeter lead to the rectifier terminal that is marked “−”.
8. Touch the black ohmmeter lead to the rectifier terminals that have the following labels: “AC1”,
“AC2”, and “AC3”. The meter should indicate a good diode or low resistance. If the meter does not indicate a good diode or low resistance, the rectifier is bad. Replace the rectifier.
Replace any faulty rectifiers with rectifiers that have comparable operating characteristics. Include the following information when a rectifier is being ordered for replacement:
•
Part Number of the rectifier
•
Model number of the exciter
•
Type of the exciter
•
Serial number of the generator
SEBU8013-01 173
Maintenance Section
Sea Water Strainer — Clean/Inspect
Maintenance and Operation
Procedures
i00905687
Sea Water Strainer —
Clean/Inspect
SMCS Code: 1371-040; 1371-070
The sea water strainer must be clean in order to allow proper engine cooling. Check the sea water strainer for plugging. Inspect the sea water strainer more frequently if the vessel is being operated in water which is shallow or dirty. Refer to the
OEM recommendations for more information about inspecting and cleaning the sea water strainer.
Ensure that the auxiliary water pump is primed and that the suction line is open.
1. Remove the sea water strainer and clean the screen. Remove any dirt and debris.
2. Install the sea water strainer. Fill the sea water strainer and the suction line for the auxiliary water pump with water.
i03108463
Standby Generator
Set Maintenance
Recommendations
SMCS Code: 4450-041
A standby generator set may not need to be used very often. However, the generator set is usually needed for operation in an emergency situation.
Maintenance of the standby generator set is very important for the following reasons:
•
The generator set must always be in excellent operating condition.
•
The generator set must be ready to work under load at any time.
Establishing a Preventive Maintenance Program will provide these benefits:
•
Maximum availability of the standby generator set
•
Longer service life for the generator set
•
Minimum of expensive repairs
Your Caterpillar dealer can help you to establish an effective Preventive Maintenance Program for your generator set. Consult your Caterpillar dealer for details.
The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
The recommended maintenance for the generator set is listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule (Standby Generator
Sets)” (Maintenance Section).
Maintenance and Repair
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the subsequent maintenance intervals must be performed by an authorized service technician or by your Caterpillar dealer.
Unless other instructions are provided, perform maintenance and repairs under the following conditions:
•
The engine is stopped.
•
The starting system is disabled.
•
The generator does not pose an electrical shock hazard.
• The generator is disconnected from the load.
Operation
To ensure proper operation, the generator set must be exercised regularly. For instructions on operating the generator set, see the Operation and Maintenance
Manual for the generator set control panel.
For these operation procedures, follow the instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting the engine, engine operation, and stopping the engine.
174
Maintenance Section
Starting Motor — Inspect
Record Keeping
Maintain a record in order to document these items: gauge readings, maintenance that is performed, problems, and repairs.
Space Heaters
Moisture causes damage to generators and other electrical equipment. Make every effort to keep the generator set as dry as possible.
Generators can operate without problems in humid environments. However, problems can occur when the generator is inactive. Moisture can condense on the windings. This can result in poor performance.
Also, damage to the windings can occur.
Use space heaters in order to help keep the windings dry. When the generator is not active, ensure that the space heaters are operating. When the generator is operating, turn OFF the space heaters.
i01113939
Starting Motor — Inspect
SMCS Code: 1451-040; 1453-040
If the starting motor fails, the engine may not start in an emergency situation. A scheduled inspection of the starting motor is recommended.
The starting motor pinion and the flywheel ring gear must be in good condition in order for the engine to start properly. The engine will not start if the starting motor pinion does not engage the flywheel ring gear. The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement.
Inspect the starting motor for proper operation. Listen for grinding when the engine is started. Inspect the teeth of the starting motor pinion and the flywheel ring gear. Look for patterns of wear on the teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starting motor pinion and the flywheel ring gear must be replaced.
Electric Starting Motor
Note: Problems with the electric starting motor can be caused by the following conditions: malfunction of the solenoid and malfunction of the electric starting system.
Inspect the electrical system for the following conditions:
•
Loose connections
•
Corrosion
•
Wires that are worn or frayed
•
Cleanliness
Make repairs, if necessary.
Air Starting Motor
SEBU8013-01
Personal injury or death can result from improperly checking for a leak.
Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.
Inspect all of the components in the air circuit for the starting motor. Inspect all of the air lines and connections for leaks.
If the teeth of the starting motor pinion and/or the flywheel ring gear are damaged, the air circuit for the starting motor must be examined in order to determine the cause of the problem.
Removal and Installation of the
Starting Motor
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the starting motor and installing the starting motor.
Consult your Caterpillar dealer for assistance.
i03230840
Stator Lead — Check
SMCS Code: 4459-535
Ensure that the stator output leads are routed out of the generator in a manner that prevents the leads from rubbing against metal objects.
Visually inspect the following areas for cracking and physical damage:
• stator output leads
• protective sleeving
SEBU8013-01 175
Maintenance Section
Stator Winding Temperature — Measure/Record
• insulation i04011511
Stator Winding Temperature —
Measure/Record
SMCS Code: 4453-082-TA
SR4B generators are provided with embedded temperature detectors. The detectors are installed in the slots of the main armature (stator) and in the bearing housing. If the Marine Classification Society system (MCS system) is not installed, the detectors are used with equipment that is provided by the customer. This equipment is used in order to measure the winding temperature of the main armature. This equipment is also used in order to monitor the main winding temperature of the armature.
Note: If the main stator winding temperature is
150° C (302° F), the alarm fault will appear.
i01539769
Turbocharger — Inspect
SMCS Code: 1052-040; 1052
Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through the air inlet system. Therefore, by-products from oil and from combustion can collect in the turbocharger compressor housing. Over time, this buildup can contribute to loss of engine power, increased black smoke and overall loss of engine efficiency.
If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine damage.
Minor leakage of a turbocharger housing under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred.
When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is repaired or replaced.
An inspection of the turbocharger can minimize unscheduled downtime. An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts.
Note: Turbocharger components require precision clearances. The turbocharger cartridge must be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent inspections of the cartridge.
Removal and Installation
For options regarding the removal, installation, repair and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the procedure and specifications.
Cleaning and Inspecting
1. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. Visually inspect the piping for the presence of oil. Clean the interior of the pipes in order to prevent dirt from entering during reassembly.
2. Turn the compressor wheel and the turbine wheel by hand. The assembly should turn freely. Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing. If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing, the turbocharger must be reconditioned.
176
Maintenance Section
Varistor — Test
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt and/or moisture is passing through the air filtering system. If oil is found only on the back side of the wheel, there is a possibility of a failed turbocharger oil seal.
The presence of oil may be the result of extended engine operation at low idle. The presence of oil may also be the result of a restriction of the line for the inlet air (plugged air filters), which causes the turbocharger to slobber.
4. Use a dial indicator to check the end clearance on the shaft. If the measured end play is greater than the Service Manual specifications, the turbocharger should be repaired or replaced.
An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel. The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications.
5. Inspect the bore of the turbine housing for corrosion.
6. Clean the turbocharger housing with standard shop solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.
Varistor — Test
SMCS Code: 4466-081
SEBU8013-01 i01494879 g00677004
Illustration 115
PMPE Generator Wiring Diagram
(CR1-CR6) Diodes
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer
Ohmmeter
An ohmmeter can be used to check a varistor
(CR7). Place an ohmmeter across the varistor. The resistance should be a minimum of 15000 ohms. If the resistance is less than 15000 ohms, the varistor is faulty.
SEBU8013-01
Test Light
g00555113
Illustration 116
Test Light
Refer to the test light that is shown in Illustration 116.
Follow these steps in order to test the varistor:
1. Disconnect either lead of the varistor (CR7).
2. Place the test light across the varistor.
3. Observe the results. The lamp should not light.
4. Reverse the test light.
5. Observe the results. The lamp should not light.
If the test light illuminates in either direction, there is a short in the varistor. Replace any faulty varistors with varistors that have comparable operating characteristics. Include the following information when a varistor is being ordered for replacement:
•
Part number of the varistor
•
Serial number of the generator
After the varistor has been replaced, verify that the strapping of the field winding lead is securely wound on the shaft. Also, verify that the strapping of the field winding lead is securely tied.
i01491868
Voltage and Frequency — Check
SMCS Code: 4450-535-EL
Check for the proper voltage setting and check for the proper frequency setting. Check for stability.
For the correct voltage and frequency, refer to the generator set’s Serial Plate.
177
Maintenance Section
Voltage and Frequency — Check i02706582
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and for Loose Connections
A walk-around inspection should only require a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:
•
The guards must be in the proper place. Repair damaged guards or replace missing guards.
•
Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is a fire hazard. Remove this debris with steam cleaning or high pressure water.
•
Ensure that the cooling lines are tight and ensure that the cooling lines are properly clamped. Check for leaks. Check the condition of all pipes.
• Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract.
Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of water pumps and the installation of water pumps and/or seals, refer to the Service Manual for the engine or consult your Caterpillar dealer.
•
Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve cover.
178
Maintenance Section
Water Pump — Inspect
•
Inspect the fuel system for leaks. Look for loose fuel line clamps.
•
Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps.
•
Inspect the alternator belt and the accessory drive belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on the new belt could cause the belt to break.
•
Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires.
•
Inspect the ground strap for a good connection and for good condition.
•
Inspect the ECM to the cylinder head ground strap for a good connection and for good condition.
•
Disconnect any battery chargers that are not protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery.
•
Check the condition of the gauges. Replace any gauges which are cracked and replace any gauges that can not be calibrated.
i03543200
Water Pump — Inspect
SMCS Code: 1361-040; 1361
A failed water pump might cause severe engine overheating problems that could result in the following conditions:
•
Cracks in the cylinder head
•
A piston seizure
• Other potential damage to the engine
A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head, a piston seizure or other potential damage to the engine.
Illustration 117
PMPE Generator Wiring Diagram
(CR1-CR6) Diodes
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer
SEBU8013-01
Visually inspect the water pump for leaks. If leaking of the water pump seals is observed, replace all of the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump
— Disassemble and Water Pump — Assemble” for the disassembly and assembly procedure. If it is necessary to remove the water pump, refer to two articles in the Disassembly and Assembly Manual,
“Water Pump — Remove and Water Pump — Install”.
Inspect the water pump for wear, cracks, pin holes and proper operation. Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed.
Winding — Test
SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081 i01787397 g00677004
SEBU8013-01
Table 22
Part Number
6V-7070
Tools Needed
Part
(1)
Digital
Multimeter
Quantity
1
146-4080
Digital
Multimeter
(RS232)
1
(1) Only one multimeter is necessary for this test. Either of the multimeters that are shown will work.
The high voltage that is produced by an operating generator set can cause severe injury or death.
Before performing any maintenance or repairs, ensure that the generator will not start.
Place the engine control switch in the “OFF” position. Attach “DO NOT OPERATE” tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
Measure the resistance of the following windings:
(L1), (L2), (L3), (L4), and (L5). The winding that is being tested must be disconnected from the other components before the resistance can be measured. The following resistance measurements are approximations. If the measured value is not near the listed approximation, the winding is probably damaged. For a more precise resistance value, consult the Technical Marketing Information
(TMI). Refer to the generator arrangement that is in question.
Note: The winding temperature affects the resistance. When the winding temperature increases, the winding resistance also increases. When the winding temperature decreases, the winding resistance also decreases. Therefore, a correct measurement can be performed only when the winding is at room temperature.
The following armature windings have very little resistance: (L2), (L4), and (L5). The resistance of these windings will measure near 0 ohms. Use a milliohmmeter to measure the resistance of the armature windings.
Exciter Armature (Rotor) (L2) – less than 0.1 ohm
Main armature (Stator) (L4) – less than 0.1 ohm
Pilot Exciter Armature (L5) – less than 0.1 ohm
Use a multimeter in order to measure the resistance of field windings (L1) and (L3).
179
Maintenance Section
Zinc Rods — Inspect/Replace
Exciter Field (Stator) (L1) – approximately 3.0
ohms to 6.0 ohms
Main Field (Rotor) (L3) – approximately 0.75 ohms to 2.0 ohms
Note: There should be no continuity between any winding and ground. There should be no continuity between any winding and another winding.
i03996033
Zinc Rods — Inspect/Replace
SMCS Code: 1388-040; 1388-510
Caterpillar requires the inspection of the zinc rods every 50 service hours until a wear rate is established.
Corrosion in sea water circuits can result in premature deterioration of system components, leaks, and possible cooling system contamination.
Zinc rods are inserted in the sea water cooling system of the engine in order to help prevent the corrosive action of salt water. The reaction of the zinc to the sea water causes the zinc rods to deteriorate.
The zinc rods deteriorate instead of engine parts for the cooling system that are more critical. Rapid deterioration of zinc rods may indicate the presence of uncontrolled electrical currents from improperly installed electrical attachments or improperly grounded electrical attachments.
The zinc rods must be inspected at the proper intervals. The zinc rods must be replaced when deterioration occurs.
Inspect the zinc rods within 24 hours of initially filling the plumbing with sea water. If no significant corrosion is noted, inspect the zinc rods weekly or inspect the zinc rods after each 50 hours of engine operation. If no significant deterioration is noted, inspect the zinc rods weekly or inspect the zinc rods after each 50 hours of engine operation.
Locations of the Zinc Rods
The number and the location of the zinc rods may vary between engines.
180
Maintenance Section
Zinc Rods — Inspect/Replace
Illustration 118 g01937139
One or two zinc rods may be located in the transmission oil cooler.
Illustration 119
One zinc rods may be located in the fuel cooler.
g02182894
Illustration 120 g01937142
One zinc rod may be located on top of the auxiliary water pump.
SEBU8013-01
SEBU8013-01 181
Maintenance Section
Zinc Rods — Inspect/Replace
Illustration 121
One zinc rod may be located in the intake for the heat exchanger. One zinc rod may be located in the outlet for the heat exchanger.
g01937141
Replace the Zinc Rods
Illustration 122
View of the top of the engine
One zinc rod may be located in the lines group.
Inspect the Zinc Rods
1. Remove the zinc rod.
g01958134
Illustration 124 g00104049
1. Unscrew the old zinc rod or drill the old zinc rod from the plug. Clean the plug.
2. Apply
9S-3263 Compound to the shoulder of a new zinc rod. Apply the compound only to the shoulder of the zinc rod. Install the zinc rod into the plug.
3. Coat the external threads of the plug with
5P-3413 Pipe Sealant. Install the zinc rod. Refer to the Specifications Manual for more information on torque specifications.
Illustration 123 g00104048
2. Tap the zinc rod lightly with a hammer. If the zinc rod has deteriorated, or if the zinc rod flakes, install a new zinc rod.
182
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i04011911
Emissions Warranty
Information
SMCS Code: 1000
Caterpillar Inc. (Caterpillar) warrants to the ultimate purchaser and each subsequent purchaser that:
1. New non-road diesel engines and stationary diesel engines less than 10 liters per cylinder operated and serviced in the United States and Canada, including all parts of their emission control systems
(“emission related components”), are:
a. Designed, built, and equipped so as to conform, at the time of sale, with applicable emission standards prescribed by the United States
Environmental Protection Agency (EPA) by way of regulation.
b. Free from defects in materials and workmanship in emission-related components that can cause the engine to fail to conform to applicable emission standards for the warranty period.
2. New non-road diesel engines operated and serviced in the state of California, including all parts of their emission control systems (“emission related components”), are:
a. Designed, built, and equipped so as to conform, at the time of sale, to all applicable regulations adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and workmanship which cause the failure of an emission-related component to be identical in all material respects to the component as described in the
Caterpillar application for certification for the warranty period.
A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and stationary diesel engines, including the components covered and the warranty period, is found in supplement Special Publication, SELF9001, “Federal
Emission Control Warranty” and “Emission Control
Warranty for California”. Consult your authorized Cat dealer to determine if your engine is subject to an
Emission Control Warranty.
SEBU8013-01
SEBU8013-01
Reference Information
Section
Engine Ratings
Engine Rating Conditions
SMCS Code: 1000 i00727327
All engine ratings are in compliance with the following standard ambient air conditions of “SAE J1349”:
•
99 kPa (29.3 inches of Hg)
•
30 percent relative humidity
•
A temperature of 25 °C (77 °F)
Ratings relate to the standard conditions of
“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of
“BS5514”.
The engine ratings are based on the following fuel specifications:
• Low heat value (LHV) of the fuel of 42 780 kJ/kg
(18,390 Btu/lb) at 29 °C (84 °F)
•
Gravity (API) of 35 degrees at 15 °C (60 °F)
•
Specific gravity of .849 at 15 °C (60 °F)
•
Density of 850 kg/m
3
(7.085 lb/US gal)
The engine ratings are gross output ratings.
Gross Output Ratings – The total output capability of the engine that is equipped with standard accessories.
Standard accessories include the following components:
• Oil pumps
• Fuel pumps
•
Water pumps
Subtract the power that is required to drive auxiliary components from the gross output. This will produce the net power that is available for the external load
(flywheel).
183
Reference Information Section
Engine Ratings i03570771
Engine Rating Definitions
SMCS Code: 1000
Power rating definitions are in accordance with
ISO8528.
Prime Power
Output is available with varying load for an unlimited time. The average power output is 70% of the prime power rating. Typical peak demand of 100% of prime rated ekW with 10% of overload capability is for emergency use for a maximum of one hour in 12.
The engine cannot be operated at overload for more than 25 hours per year.
Continuous Power
Output is available with varying load for an unlimited time. The average power output is between 70% and
100% of the continuous power rating. Typical peak demand is 100% of continuous rated ekW for 100% of operating hours.
Standby Power
Output is available with varying load for the duration of the interruption of the normal power source. The average power output is 70% of the standby power rating. The typical operation is 200 hours per year.
The maximum expected usage is 500 hours per year.
Emergency Standby Power
Output is available with varying load for the duration of an emergency outage. The average power output is 70% of the standby power rating. The typical operation is 50 hours per year. The maximum expected usage is 200 hours per year.
i00899220
Marine Classification Society
Certification Requirements
SMCS Code: 1000
The major seafaring nations have established technical groups called marine classification societies. Caterpillar Inc. has maintained standards and quality under the guidelines that are set forth by the 14 major marine classification societies that are listed. For more information, refer to Engine Data
Sheet, 103.1 and Engine Data Sheet, 103.1.1 in the
Caterpillar Technical Manual.
184
Reference Information Section
Engine Ratings
ABS – American Bureau of Shipping (USA)
BV – Bureau Veritas (France)
CCG – Canadian Coast Guard (Canada)
CCRS – China Corporation Register of Shipping
(Taiwan)
CCS – China Classification Society (China)
CR – Croatian Register of Shipping (Croatia)
DnV – Det norske Veritas (Norway)
GL – Germanischer Lloyd (Germany)
KR – Korean Register of Shipping (Korea)
LR – Lloyd’s Register of Shipping (Great Britain)
NK – Nippon Kaiji Kyokai (Japan)
PR – Polish Register (Poland)
RINa – Registro Italiano Navale (Italy)
RS – Maritime Register of Shipping (Russia)
SEBU8013-01
SEBU8013-01
Engine Performance and
Performance Analysis
Report (PAR)
i01044073
Engine Performance
SMCS Code: 1000
Today’s marine operator is concerned with performance, cost of operation and satisfactory engine life. Traditionally, poor performance of the vessel is believed to result from a lack of engine performance or from a loss of engine performance. In fact, the engine is only one of numerous factors that influence the overall performance of a vessel.
Several factors determine the power demand on an engine. The engine does not have control over the demand that is caused by the vessel design. The vessel design includes the following features:
•
Hull
•
Propeller
•
Drive train
Those features also affect the amount of power that is available to perform additional work. For example, those features affect the power that is used to drive an auxiliary pump.
If a problem with the performance of the vessel occurs, consider the following effects on power demand:
•
Loads
• Condition of the vessel
• Vessel design
•
Condition of the drive train
• Condition of the propeller
Deterioration of the engine systems decreases the ability of the engine to produce power and vessel speed. Engine systems include the cooling system, the lubrication system, the fuel system, etc. The engine is not likely to be the cause of poor fuel economy without excessive exhaust smoke and/or the loss of power.
If you have a valid problem with the engine’s performance, consult an authorized Caterpillar dealer for assistance.
185
Reference Information Section
Engine Performance and Performance Analysis Report (PAR)
If the engine is covered by a warranty, the Caterpillar warranty will cover the cost in order to solve a valid deficiency of the engine’s performance. However, if the engine is not at fault, all costs that are incurred will be the responsibility of the owner.
Note: Adjustment of the fuel system outside
Caterpillar specified limits will not improve fuel efficiency. Adjustment of the fuel system outside
Caterpillar specified limits could also result in damage to the engine.
Caterpillar engines are manufactured with state-of-the-art technology. Caterpillar engines are designed to help provide two characteristics in all applications:
•
Maximum performance
• Fuel efficiency
To ensure optimum performance for the service life of the engine, follow the recommended operation procedures that are described in this manual. Also, follow the preventive maintenance procedures that are described in this manual.
Performance Analysis Report
(PAR)
To verify the condition of the propulsion system,
Caterpillar has developed the Performance Analysis
Report (PAR) for marine engines.
A PAR is an in-vessel test procedure that is performed by a Caterpillar analyst under operating conditions.
The test compares the performance of all marine engine systems to the original testing specifications.
When a PAR is conducted at Sea Trial, an installation of high quality can be ensured. The PAR will confirm the matching of the following components for optimum performance and for fuel efficiency: hull, rudders, propeller, marine transmission, ventilation, and cooling systems.
Caterpillar recommends scheduling a PAR in order to maintain optimum performance.
A periodic PAR can define deterioration of the propulsion system. A PAR can assist in repairs, in overhauls, and in maintenance schedules. This will help to provide the most economical, efficient cost of operation.
186
Reference Information Section
Customer Service
Customer Service
i03910803
Customer Assistance
SMCS Code: 1000
USA and Canada
When a problem arises concerning the operation or the service of an engine, the problem will normally be managed by the dealer in your area.
Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. If you have a problem that has not been handled to your complete satisfaction, follow these steps:
1. Discuss your problem with a manager from the dealership.
2. If your problem cannot be resolved at the dealer level, use the phone number that is listed below to talk with a Field Service Coordinator:
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday through Friday Central Standard Time.
3. If your needs have not been met still, submit the matter in writing to the following address:
Caterpillar Inc.
Marine Center of Excellence
Manager, Customer Service
111 Southchase Blvd
Fountain Inn, SC 29644
Please keep in mind: probably, your problem will ultimately be solved at the dealership, using the dealership facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a problem is experienced.
Outside of the USA and of Canada
If a problem arises outside the USA and outside
Canada, and if the problem cannot be resolved at the dealer level, consult the appropriate Caterpillar office.
Latin America, Mexico, Carribean
Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
Europe, Africa, and Middle East
Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
Fax: 22-849-4544
Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: 65-662-8333
Fax: 65-662-8302
China
Caterpillar China Ltd.
37/F., The Lee Gardens
33 Hysan Avenue
Causeway Bay
G.P.O. Box 3069
Hong Kong
Phone: 852-2848-0333
Fax: 852-2848-0440
Japan
Shin Caterpillar Mitsubishi Ltd.
SBS Tower
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Japan
Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Japan
Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Fax: 81-3-5797-4359
Australia and New Zealand
Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
SEBU8013-01
SEBU8013-01 i01028392
Ordering Replacement Parts
SMCS Code: 7567
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are normally needed to protect your Caterpillar engine investment.
When you order parts, please specify the following information:
•
Part number
• Part name
• Quantity
If there is a question concerning the part number, please provide your dealer with a complete description of the needed item.
When a Caterpillar engine requires maintenance and/or repair, provide the dealer with all the information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the dealer about the conditions of the problem and the nature of the problem. Inform the dealer about when the problem occurs. This will help the dealer in troubleshooting the problem and solving the problem faster.
187
Reference Information Section
Customer Service i01880104
On-Board Replacement Parts
SMCS Code: 7567
The various Marine Classification Societies require a supply of replacement parts on vessels that are primarily powered by diesel engines. The replacement parts may be needed for making repairs offshore or at remote ports. The types of replacement parts and the numbers of parts depends on the range of the vessel. The following two categories of vessels are considered:
Category 1 – This category includes vessels that make short trips between ports.
Category 2 – This category includes vessels in ocean service that is unrestricted. The vessels may travel far from ports that provide service. The list of replacement parts for this category is more extensive.
Table 23 lists the parts that are recommended by
Caterpillar for vessels in both categories.
The requirements of individual Marine Classification
Societies may differ. Table 24 lists the requirements of all the Marine Classification Societies. Additionally, some items that are recommended by Caterpillar are listed. All of the parts that are listed in Table 23 and
24 are recommended for vessels in Category 2. To customize this list for your specific engine application, consult your Caterpillar dealer.
Table 23
Replacement Parts for Vessels in Category
1 and Category 2
Quantity Item
4
1
1
1
—
—
Air cleaner element
Alternator belt
Electronic control module (ECM)
Electronic unit injector
Engine oil
Extended Life Coolant (ELC) and Extender or
Diesel Engine Antifreeze/Coolant (DEAC) and Supplemental Coolant Additive (SCA)
4
1
—
Fuel filter elements
Fluid sampling bottles
Liquid gasket material
Engine oil filters 4
1
4
Service kit (electronic connector)
Water temperature regulators
(continued)
188
Reference Information Section
Customer Service
(Table 23, contd)
Replacement Parts for Vessels in Category
1 and Category 2
Quantity
4 Zinc rods
Item
Table 24
Replacement Parts for Vessels in Category 2
System
Camshaft and crankshaft
Quantity
1 Bolt (crankshaft to flywheel)
Item
1
1
1
Camshaft gear
Crankshaft gear
Cooling
1
1
1
1
Idler gear and balance weight gear assembly
(water pump)
Shaft and thrust washer
(idler gear and balance weight gear assembly)
Aftercooler core and gasket
Auxiliary water pump
Cylinder head
4
6
1
Jacket water pump
Water temperature regulator
Bolt and washer
Bolt and nut (exhaust manifold)
1
4
—
Fuel
Inlet air
Lubrication
3
1
3
2
1
1
1
Cylinder head assembly
Gasket (cylinder)
Water seals for one cylinder
Electronic unit injector
Fuel transfer pump
Seal (electronic unit injector)
Air cleaner element
Bypass valve (oil cooler)
Miscellaneous
1
1
1
Bypass valve (oil filter)
Gasket (oil pan)
Oil cooler core (engine)
Oil cooler core (marine gear)
Gasket kit (engine)
(continued)
SEBU8013-01
(Table 24, contd)
Replacement Parts for Vessels in Category 2
System
Piston
Quantity
1
Item
Connecting rod assembly
1
1
1
1
2
Connecting rod bearing
Cylinder liner
Filler band (cylinder liner)
Main bearing
Cap bolt and washer (main bearing)
Piston assembly
Starting
Turbocharger
1
1
2
1
3
1
1
4
4
4
Piston pin
Piston pin retainer
Piston rings (complete set)
Seals (cylinder liner)
Starting motor
Complete turbocharger
Gasket
Locknut
Valves 6
4
10
24
10
10
Stud (mounting)
Exhaust valves
Inlet valves
Valve guides
Valve locks
Valve rotators
Valve springs
SEBU8013-01
Reference Materials
i04011530
Reference Material
SMCS Code: 1000
The following literature can be obtained through any
Caterpillar dealer.
Diesel Engine Oils
•
Data Sheet, PEHJ0021, “Cat DEO (Diesel Engine
Oil) APD, EAME, LACD Only”
•
Data Sheet, PEHJ0059, “Cat DEO (for North
America)”
•
Data Sheet, PEHJ0091, “Cat DEO (Egypt and
Saudi Arabia)”
•
Data Sheet, PEHJ0159, “Cat DEO-ULS (Ultra Low
Sulfur)”
•
Special Publication, PEHJ0192, “Optimizing Oil
Change Intervals”
•
Special Publication, PEGJ0047, “How To Take A
Good S·O·S Oil Sample”
•
Data Sheet, PEHP7062, “Cat DEO SYN”
•
Special Publication, PELJ0179, “Caterpillar Engine
Crankcase Fluid-1 Specification (Cat ECF-1)”
•
Special Publication, SEBD0640, “Oil and Your
Engine”
•
Special Publication, SEBU5898, “Cold Weather
Recommendations”
Greases
•
Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease”
•
Data Sheet, NEHP6011, “Cat Arctic Platinum
Grease”
•
Data Sheet, NEHP6012, “Cat Desert Gold Grease”
•
Data Sheet, NEHP6015, “Cat Special Purpose
Grease”
•
Data Sheet, PEGJ0035, “Grease Selection Guide”
•
Data Sheet, PEHJ0088, “Cat Multipurpose Grease”
•
Data Sheet, PEHP0002, “Cat Advanced 3Moly
Grease”
189
Reference Information Section
Reference Materials
Fuels
•
CD-ROM, PEXT9044, “Improving Fuel System
Durability”
•
Special Publication, SEBD0717, “Diesel Fuels and
Your Engine”
•
Special Publication, SENR9620, “Improving Fuel
System Component Durability”
Coolants
•
Special Publication, PEEP5032, “Engine Coolant
Label”
•
Data Sheet, PEHP9554, “Cat DEAC (Diesel
Engine Antifreeze/Coolant) ”
•
Data Sheet, PEHJ0067, “Cat ELC (Extended Life
Coolant)”
•
Labels, PMEP5027, “Label — ELC Label”
•
Special Publication, SEBD0518, “Know Your
Cooling System”
S·O·S Services
•
Labels, SEBU5031, “S·O·S Oil Analysis Label”
•
Special Publication, PEGJ0046, “Cat S·O·S
Services: Understanding Your Results”
•
Special Publication, PEGJ0047, “How To Take A
Good S·O·S Oil Sample”
•
Data Sheet, NEHP6013, “S·O·S Fluids Analysis
Products”
•
Special Publication, PEHJ0191, “Cat S·O·S Fluid
Analysis”
•
Special Publication, PEHP7052, “Cat S·O·S
Services Management Guide”
Miscellaneous
•
Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Recommendations”
•
Special Instruction, REHS4817, “Overview,
Installation, and Configuration of the Marine
Classification Society Alarm and Protection (MCS
A&P), MCS Controller and Remote Panel”
•
Service Manual, RENR2385, “C18 Marine and
Marine Auxiliary Generator Set Engines”
190
Reference Information Section
Reference Materials
•
Special Publication, LEBM0189, “Marine Power
Display Operator’s Guide”
•
Special Publication, LEDM5615, “Caterpillar
Marine Parts and Service Locations Directory U.S.,
Canada, Mexico, and Caribbean”
• Special Publication, NEHS0526, “Service
Technician Application Guide”
•
Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog”
• Special Publication, PECJ0003, “Cat Shop Tools and Supplies”
•
Special Publication, PECP9067, “One Safe Source
2008 — 2009 Parts Catalog”
• Special Instruction, REHS0354, “Charging System
Troubleshooting for All Engines”
•
Special Instruction, REHS1187, “Marine Engine
Electronic Installation Guide”
• Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
Operations”
•
Special Publication, SEBU5898, “Cold Weather
Recommendations”
•
Special Instruction, SEHS7332, “Do Not Operate
Tag”
•
Special Instruction, SEHS7633, “Battery Test
Procedure”
•
Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
•
Specifications, SENR3130, “Torque Specifications”
• Special Publication, SENR5002, “Installation Guide for Marine Engine Electronic Displays”
Additional Reference Material
The “Engine Fluids Data Book” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult
EMA at the following address:
Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
E-mail: [email protected]
(312) 827-8700
Facsimile: (312) 827-8737
SEBU8013-01
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook.
This publication can also be obtained from the following locations: local technological society, local library, and local college. If necessary, consult SAE at the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
The “American Petroleum Institute Publication No.
1509” can be obtained from the following locations: local technological society, local library, and local college. If necessary, consult API at the following address:
American Petroleum Institute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service regarding international standards and standardizing activities. ISO can also supply information on the following subjects that are not controlled by ISO: national standards, regional standards, regulations, certification, and related activities. Consult the member of ISO in your country.
International Organization for Standardization
(ISO)
1, rue de Varembé
Case postale 56
CH-1211 Genève 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
E-mail: [email protected]
Web site: http://www.iso.ch
European classifications are established by the
Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
CIMAC Central Secretariat
Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
SEBU8013-01 i03623818
Decommissioning and
Disposal
SMCS Code: 1000
When the generator set is removed from service, local regulations for the generator set decommissioning will vary. Disposal of the generator set will vary with local regulations. Consult the nearest Caterpillar dealer for additional information.
i00912149
Maintenance Records
SMCS Code: 1000
Caterpillar Inc. recommends the retention of accurate maintenance records. Accurate maintenance records can be used for the following purposes:
•
Determine operating costs.
•
Establish maintenance schedules for other engines that are operated in the same environment.
•
Show compliance with the required maintenance practices and maintenance intervals.
Maintenance records can be used for a variety of other business decisions that are related to engine maintenance.
Maintenance records are a key element of a maintenance program that is well managed. Accurate maintenance records can help your Caterpillar dealer to fine tune the recommended maintenance intervals in order to meet the specific operating situation. This should result in a lower engine operating cost.
Records should be kept for the following items:
Fuel Consumption – A record of fuel consumption is essential in order to determine when the load sensitive components should be inspected or repaired. Fuel consumption also determines overhaul intervals.
Service Hours – A record of service hours is essential to determine when the speed sensitive components should be inspected or repaired.
Documents – These items should be easy to obtain, and these items should be kept in the engine history file. All of the documents should show this information: date, service hours, fuel consumption, unit number, and engine serial number. The following types of documents should be kept as proof of maintenance or repair for warranty:
191
Reference Information Section
Reference Materials
Keep the following types of documents as proof of maintenance for warranty. Also, keep these types of documents as proof of repair for warranty:
•
Dealer work orders and itemized bills
•
Owner’s repair costs
•
Owner’s receipts
•
Maintenance log
192
Reference Information Section
Reference Materials
Maintenance Log
SMCS Code: 1000
Table 25
Engine Model
Serial Number
Service
Hours
Quantity
Of Fuel
i01176304
SEBU8013-01
Customer Identifier
Arrangement Number
Service Item Date Authorization
SEBU8013-01 193
Index Section
Index
A
After Starting Engine ……………………………………… 80
After Stopping Engine…………………………………….. 84
Aftercooler Condensate Drain Valve —
Inspect/Clean……………………………………………… 112
Aftercooler Core — Clean/Test …………………………. 112
Clean the Aftercooler Core …………………………. 112
Test the Aftercooler Core ……………………………. 113
Air Starting……………………………………………………. 81
Alternator — Inspect ……………………………………….. 113
Auxiliary Water Pump (Bronze Impeller) —
Inspect ………………………………………………………. 113
Auxiliary Water Pump (Rubber Impeller) —
Inspect ………………………………………………………. 114
B
Battery — Recycle ………………………………………….. 114
Battery — Replace………………………………………….. 114
Battery Charger — Check………………………………… 115
Battery Disconnect Switch (If Equipped) …………… 71
Battery Electrolyte Level — Check ……………………. 115
Battery or Battery Cable — Disconnect ……………… 115
Before Starting Engine ……………………………… 17, 78
Belts — Inspect/Adjust/Replace………………………… 116
Alternator Belt Adjustment ………………………….. 116
Inspection…………………………………………………. 116
Replacement…………………………………………….. 116
Burn Prevention…………………………………………….. 14
Batteries……………………………………………………. 14
Coolant……………………………………………………… 14
Oils…………………………………………………………… 14
C
Closed Crankcase Ventilation (CCV) Filter Service
Indicator — Inspect ……………………………………….. 117
Closed Crankcase Ventilation (CCV) Fumes Disposal
Filter — Replace …………………………………………… 117
Replacing the Fumes Disposal Filter ……………. 118
Resetting the Service Indicator ……………………. 118
Cold Weather Operation…………………………………. 85
Hints for Cold Weather Operation…………………. 85
Idling the Engine ………………………………………… 86
Recommendations for Coolant Warm Up ………. 86
Recommendations for the Coolant ……………….. 86
Viscosity of the Engine Lubrication Oil…………… 86
Cold Weather Starting ……………………………………. 79
Configuration Parameters……………………………….. 74
Parameter Descriptions ………………………………. 75
Control Panel (Marine Classification Society Control
Panel (MCS Control Panel) (Standard Panel, if
Equipped)) ………………………………………………….. 42
General Information ……………………………………. 42
Help………………………………………………………….. 55
List of Alarms …………………………………………….. 47
Menu ………………………………………………………… 48
Start Engine and Stop Engine………………………. 45
Control Panel (Marine Classification Society Remote
Control Panel (MCS Remote Control Panel) (If
Equipped)) ………………………………………………….. 58
Alarms List ………………………………………………… 60
Home Button ……………………………………………… 61
Menu ………………………………………………………… 61
Start and Stop Engines ……………………………….. 60
Symbols and Indication Icons ………………………. 59
Cooling System Coolant (DEAC) — Change………. 119
Cooling Systems with Heavy Deposits or
Plugging ………………………………………………… 121
Drain ……………………………………………………….. 119
Fill ………………………………………………………….. 121
Flush ………………………………………………………. 120
Cooling System Coolant (ELC) — Change………… 122
Drain ………………………………………………………. 122
Fill ………………………………………………………….. 123
Flush ………………………………………………………. 123
Cooling System Coolant Extender (ELC) — Add… 124
Cooling System Coolant Level — Check …………… 125
Engines That Are Equipped with a Coolant
Recovery Tank ……………………………………….. 125
Engines That Are Not Equipped with a Coolant
Recovery Tank ……………………………………….. 125
Cooling System Coolant Sample (Level 1) —
Obtain ………………………………………………………. 126
Cooling System Coolant Sample (Level 2) —
Obtain ………………………………………………………. 127
Cooling System Supplemental Coolant Additive
(SCA) — Test/Add………………………………………… 127
Cooling Systems that Use Conventional
Coolant………………………………………………….. 128
Cooling System Water Temperature Regulator —
Replace…………………………………………………….. 128
Crankshaft Vibration Damper — Inspect …………… 129
Inspection………………………………………………… 129
Removal and Installation……………………………. 129
Crushing Prevention and Cutting Prevention …….. 16
Customer Assistance……………………………………. 186
Outside of the USA and of Canada……………… 186
USA and Canada ……………………………………… 186
Customer Service ………………………………………… 186
D
Declaration of Conformity ……………………………….. 29
Decommissioning and Disposal …………………….. 191
194
Index Section
SEBU8013-01
E
Electrical Connections — Check………………………. 130
Electrical System …………………………………………… 18
Grounding Practices …………………………………… 18
Electronic Modular Control Panel 3 (EMCP 3) (If
Equipped) …………………………………………………… 64
Annunciator Module ……………………………………. 66
Electronic Control Module 3 (ECMP3) …………… 64
Emergency Stopping ……………………………………… 83
Emergency Stop Button (If Equipped) …………… 83
Emissions Certification Film ……………………………. 30
Emissions Warranty Information…………………….. 182
Engine — Clean…………………………………………….. 130
Engine Air Cleaner Element — Clean/Replace ….. 130
Type 1 …………………………………………………….. 130
Type 2 …………………………………………………….. 131
Engine Air Cleaner Service Indicator — Inspect…. 131
Service the Air Cleaner Service Indicator …….. 132
Test the Air Cleaner Service Indicator………….. 132
Engine Crankcase Breather — Clean……………….. 133
Engine Diagnostics………………………………………… 74
Engine Electronics…………………………………………. 18
Engine Mounts — Inspect……………………………….. 133
Engine Oil and Filter — Change ………………………. 136
Drain the Oil …………………………………………….. 136
Fill the Crankcase …………………………………….. 139
Inspect the Used Oil Filter Elements……………. 139
Replace the Oil Filter Elements ………………….. 137
Engine Oil Level — Check ………………………………. 134
Engine Oil Level Gauge — Calibrate ………………… 134
Engine Oil Sample — Obtain …………………………… 135
Obtain the Sample and the Analysis……………. 135
Engine Operation…………………………………………… 82
Engine Performance…………………………………….. 185
Performance Analysis Report (PAR)……………. 185
Engine Performance and Performance Analysis
Report (PAR) …………………………………………….. 185
Engine Rating Conditions ……………………………… 183
Engine Rating Definitions ……………………………… 183
Continuous Power…………………………………….. 183
Emergency Standby Power ……………………….. 183
Prime Power ……………………………………………. 183
Standby Power…………………………………………. 183
Engine Ratings ……………………………………………. 183
Engine Shutoffs and Engine Alarms…………………. 71
Alarms………………………………………………………. 71
Shutoffs…………………………………………………….. 71
Testing the Shutoff and Alarm System…………… 72
Engine Speed/Timing Sensor — Clean/Inspect….. 139
Camshaft Speed/Timing Sensor …………………. 140
Crankshaft Speed/Timing Sensor ……………….. 140
Engine Starting ………………………………………… 17, 78
Engine Stopping ………………………………………. 18, 83
Engine Storage Procedure — Check………………… 140
Engine Valve Lash — Inspect/Adjust ………………… 141
Adjustment of the Electronic Unit Injector …….. 141
Engine Valve Rotators — Inspect …………………….. 141
F
Features and Controls ……………………………………. 42
Fire Prevention and Explosion Prevention ………… 14
Ether ………………………………………………………… 16
Fire Extinguisher ………………………………………… 16
Lines, Tubes, and Hoses …………………………….. 16
Foreword ……………………………………………………….. 5
California Proposition 65 Warning ………………….. 5
Literature Information……………………………………. 4
Maintenance ……………………………………………….. 4
Maintenance Intervals…………………………………… 4
Operation ……………………………………………………. 4
Overhaul …………………………………………………….. 4
Safety…………………………………………………………. 4
Fuel and the Effect from Cold Weather …………….. 87
Fuel Conservation Practices……………………………. 82
Fuel Injector — Inspect/Adjust…………………………. 142
Fuel Related Components in Cold Weather ………. 88
Fuel Filters ………………………………………………… 88
Fuel Heaters ……………………………………………… 88
Fuel Tanks…………………………………………………. 88
Fuel System — Prime …………………………………….. 142
The Engine Has Been Rebuilt…………………….. 143
The Engine Has Been Run Out of Fuel ……….. 143
The Secondary Fuel Filter Has Been
Replaced ……………………………………………….. 142
Fuel System Primary Filter (Water Separator)
Element — Replace ……………………………………… 144
Replace the Element…………………………………. 144
Fuel System Primary Filter/Water Separator —
Drain ………………………………………………………… 145
Fuel System Secondary Filter — Replace …………. 146
Replacing the Fuel Filter Elements During Engine
Operation For Engines That Are Equipped With
Duplex Fuel Filters ………………………………….. 147
Replacing the Fuel Filter Elements with the Engine
Stopped…………………………………………………. 146
Fuel Tank Water and Sediment — Drain …………… 150
Drain the Water and the Sediment………………. 150
Fuel Storage Tanks …………………………………… 151
Fuel Tank ………………………………………………… 150
G
Gauges and Indicators …………………………………… 40
General Hazard Information …………………………….. 11
Asbestos Information ………………………………….. 13
Containing Fluid Spillage …………………………….. 12
Dispose of Waste Properly ………………………….. 14
Fluid Penetration………………………………………… 12
Lines, Tubes, and Hoses …………………………….. 13
Pressurized Air and Water …………………………… 12
General Maintenance Information ………………….. 104
Generator — Dry……………………………………………. 151
Circulating Current……………………………………. 153
External Heat …………………………………………… 152
Internal Heating………………………………………… 153
SEBU8013-01 195
Index Section
Generator — Inspect………………………………………. 153
Cleaning (Assembled Generators)………………. 154
Cleaning (Disassembled Generators)………….. 154
Generator Bearing — Inspect/Replace (SR4
Generator) ………………………………………………… 154
Inspect ……………………………………………………. 154
Replace…………………………………………………… 154
Generator Bearing — Lubricate ……………………….. 155
Additional Information ……………………………….. 155
Lubricating Process (If Applicable) ……………… 155
Generator Bearing Temperature — Measure/
Record ……………………………………………………… 155
Generator Isolating for Maintenance ………………… 19
Generator Lead Connections ………………………….. 30
Grounding the Frame………………………………….. 31
Lead Numbering ………………………………………… 30
Multiple Units …………………………………………….. 31
Neutral Connections …………………………………… 31
Parallel to a Utility ………………………………………. 31
Single Units……………………………………………….. 31
Generator Load — Check ……………………………….. 155
Generator Operation………………………………………. 90
Block Loading ……………………………………………. 90
Excitation System ………………………………………. 91
Generator Options ……………………………………… 92
Loading of the Generator …………………………….. 90
Low Idle Adjustment……………………………………. 91
Power Factor……………………………………………… 91
Standby Generator Sets ……………………………… 91
Generator Set — Test …………………………………….. 156
Generator Set Alignment — Check (Generator
Sets) ………………………………………………………… 157
Generator Set Installation……………………………….. 38
Alignment ………………………………………………….. 39
Bearing Inspection ……………………………………… 38
Electrical Measurements……………………………… 39
Location ……………………………………………………. 38
Protective Devices ……………………………………… 39
Receiving Inspection…………………………………… 38
Storage …………………………………………………….. 38
Unpacking and Storage ………………………………. 38
Generator Set Vibration — Inspect …………………… 157
Generator Start-up Checklist …………………………. 107
H
Heat Exchanger — Inspect ……………………………… 158
Cleaning Procedure ………………………………….. 158
Hoses and Clamps — Inspect/Replace …………….. 159
Inspect the Hoses and the Clamps ……………… 159
Replace the Hoses and the Clamps ……………. 160
I
Important Safety Information …………………………….. 2
Installation ……………………………………………………. 38
Insulation — Test …………………………………………… 162
Recommended Periodic Insulation Tests……… 162
Recommended Procedure for the Insulation
Test……………………………………………………….. 162
L
Lifting and Storage ………………………………………… 34
M
Maintenance Interval Schedule ………………………. 110
Maintenance Log…………………………………………. 192
Maintenance Recommendations …………….. 104, 165
Maintenance Information …………………………… 165
Oil Consumption as an Overhaul Indicator …… 166
Overhaul Information ………………………………… 166
Maintenance Records…………………………………… 191
Maintenance Section……………………………………… 96
Manual Stop Procedure………………………………….. 84
Automatic Stopping…………………………………….. 84
Manual Stop Procedure (If Equipped with Marine
Classification Society Control Unit (MCS Control
Unit)) ………………………………………………………….. 83
Marine Classification Society Certification
Requirements ……………………………………………. 183
Model View Illustrations…………………………….. 20, 22
Model Views …………………………………………………. 20
Mounting and Dismounting……………………………… 17
O
Oil Cooler Core — Check/Clean/Test (If
Equipped) …………………………………………………. 167
Clean the Oil Cooler Core………………………….. 167
Test the Oil Cooler Core…………………………….. 167
On-Board Replacement Parts ……………………….. 187
Operation Section………………………………………….. 34
Ordering Replacement Parts …………………………. 187
Overhaul (Major)………………………………………….. 167
Cleaning of Components …………………………… 169
Inspection of Components …………………………. 169
Inspection, Reconditioning, or Exchanging of
Components…………………………………………… 168
Obtain a Coolant Analysis………………………….. 169
Replacement of Components …………………….. 168
Overhaul (Top End) ……………………………………… 170
196
Index Section
SEBU8013-01
P
Parallel Operation………………………………………….. 92
Circulating Currents ……………………………………. 95
Initial Start-Up ……………………………………………. 92
Load Division and Speed Droop (If Equipped)… 94
Parallel Operation Of Governors…………………… 94
Paralleling Multiple Units……………………………… 93
Starting Multiple Units …………………………………. 93
Stopping……………………………………………………. 95
Plate Locations and Film Locations………………….. 27
Engine Information (3) ………………………………… 27
Engine Serial Number (2) ……………………………. 27
Serial Number Plate for the Generator (1) ……… 27
Power Factor — Check…………………………………… 171
Product Description ……………………………………….. 24
Description of the Generator………………………… 26
Engine Description……………………………………… 24
Product Identification Information …………………….. 27
Product Information Section ……………………………. 20
Product Lifting……………………………………………….. 34
Lifting the Engine Only………………………………… 34
Lifting the Entire Package ……………………………. 34
Lifting the Generator Only……………………………. 34
Product Storage…………………………………………….. 34
Additional Information …………………………………. 37
Engine………………………………………………………. 34
Generator………………………………………………….. 36
R
Reference Information Section ………………………. 183
Reference Material ………………………………………. 189
Additional Reference Material…………………….. 190
Coolants………………………………………………….. 189
Diesel Engine Oils…………………………………….. 189
Fuels ………………………………………………………. 189
Greases ………………………………………………….. 189
Miscellaneous ………………………………………….. 189
S·O·S Services…………………………………………. 189
Reference Materials …………………………………….. 189
Reference Numbers ………………………………………. 28
Record for Reference………………………………….. 28
Refill Capacities…………………………………………….. 96
Refill Capacities and Recommendations…………… 96
Cooling System………………………………………… 101
Diesel Engine Oil ……………………………………….. 96
Fuel ………………………………………………………….. 98
Grease ……………………………………………………. 103
Rotating Rectifier — Check……………………………… 171
Rectifier Block Test …………………………………… 172
Testing A Brushless Exciter Rotating Rectifier With
An Ohmmeter…………………………………………. 171
S
Safety Messages …………………………………………….. 6
Safety Section ………………………………………………… 6
Sea Water Strainer — Clean/Inspect………………… 173
Sensors and Electrical Components (Engines
Equipped with MCS Control Unit) …………………… 68
Single Unit Operation …………………………………….. 92
Initial Start-Up ……………………………………………. 92
Starting……………………………………………………… 92
Stopping……………………………………………………. 92
Standby Generator Set Maintenance
Recommendations……………………………………… 173
Maintenance and Operation Procedures ……… 173
Starting Motor — Inspect ………………………………… 174
Air Starting Motor ……………………………………… 174
Electric Starting Motor……………………………….. 174
Removal and Installation of the Starting
Motor …………………………………………………….. 174
Starting the Engine (EMCP 3 (If Equipped))………. 79
Starting the Engine (If Equipped with Marine
Classification Society Control Unit (MCS Control
Unit)) ………………………………………………………….. 79
Stator Lead — Check……………………………………… 174
Stator Winding Temperature — Measure/Record .. 175
System Pressure Release …………………………….. 104
Coolant System………………………………………… 104
Engine Oil ……………………………………………….. 105
Fuel System …………………………………………….. 104
T
Table of Contents…………………………………………….. 3
Turbocharger — Inspect …………………………………. 175
Cleaning and Inspecting ……………………………. 175
Removal and Installation……………………………. 175
V
Varistor — Test………………………………………………. 176
Ohmmeter ……………………………………………….. 176
Test Light…………………………………………………. 177
Voltage and Frequency — Check …………………….. 177
Voltage Connections………………………………………. 31
Single-Phase Current From a Three-Phase
Generator ………………………………………………… 32
Three-Phase Voltage Connections ……………….. 31
Voltage Regulators ………………………………………… 72
Cat Digital Voltage Regulator (Cat DVR) ……….. 72
W
Walk-Around Inspection ……………………………….. 177
Inspect the Engine for Leaks and for Loose
Connections …………………………………………… 177
Warranty Information ……………………………………. 182
Warranty Section …………………………………………. 182
Water Pump — Inspect…………………………………… 178
Welding on Engines with Electronic Controls …… 105
Winding — Test……………………………………………… 178
SEBU8013-01
Z
Zinc Rods — Inspect/Replace …………………………. 179
Inspect the Zinc Rods ……………………………….. 181
Locations of the Zinc Rods ………………………… 179
Replace the Zinc Rods………………………………. 181
197
Index Section
198
Index Section
SEBU8013-01
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name:
Address:
Branch:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
©2010 Caterpillar
All Rights Reserved
Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
Printed in U.S.A.
Поиск товаров
Группа компании “RICHTONE” всегда готова предложить Вам запасные части для техники CATERPILLAR в нашем каталоге.
Для того что бы СКАЧАТЬ данную инструкцию напишите нам на электронную почту rceshopmanuals@gmail.com
подождите загрузки книги
Часть 1
Caterpillar Cat C18 Marine Engine Parts Catalog Manual Download
Buy and Download this COMPLETE Caterpillar Service and Repair Manual. It covers every single detail on your Caterpillar Cat C18 Marine Engine Parts .This is the authentic factory service manual from Caterpillar which covers every repair and service procedure.
Engine:- All engines included
Years:- All years included
Filesize:- 22 MB
Model Specific
Model Year: All
LANGUAGE: English
FORMAT: PDF
ZOOM IN/OUT: YES Instant Download: YES
COMPATIBLE: All Versions of Windows & Mac
==============
This is not generic repair information! It is vehicle specific. This is the exact same manual used by technicians at the dealership to maintain, service, diagnose and repair your Caterpillar.
Complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications to completely repair your vehicle with ease!
You get everything you will ever need in one easy-to-use pdf manual. No more flipping through books to find what you need. Print only the pages and diagrams you require. No more greasy pages or torn/lost paper manuals again.
All pages are printable, so print off what you need and take it with you to your vehicle or workshop. You can blow-up images and then print off enlarged copies!
This is the factory specific, highly detailed repair manual, with complete instructions and illustrations, wiring schematics and diagrams to completely service and repair your Caterpillar.
All Manuals Are Windows and Mac compatible!
YOU WILL BE GIVEN THE DOWNLOAD IMMEDIATELY UPON RECEIPT OF YOUR PAYMENT.. NO WAITING!
FIND IT…PRINT IT…USE IT…then Trash it.
Tons of pictures and diagrams at your fingertips!!
Save Money $$ By doing your own repairs! These manuals make it easy for any skill level WITH THESE VERY EASY TO FOLLOW, STEP-BY-STEP INSTRUCTIONS!
INSTANT DOWNLOAD means NO SHIPPING COST or WAITING FOR A BOOK OR CD TO ARRIVE IN THE MAIL…YOU WILL RECEIVE THIS MANUAL TODAY VIA DOWNLOAD ON COMPLETION OF PAYMENT VIA OUR SECURE PAYMENT PROCESSOR. WE ACCEPT ALL MAJOR CREDIT/DEBIT CARDS
The post Caterpillar Cat C18 Marine Engine Parts Catalog Manual Download appeared first on Caterpillar Service Manual Download.
Source: CAT MANUAL
Caterpillar Cat C18 Marine Engine Parts Catalog Manual Download
Description
Caterpillar CAT C18 Engine Service Repair Manual (EJG00001 and up)
Engine Model: C18
Serial Applicable: EJG00001 and up
Language English
Format: PDF
- Caterpillar CAT C18 Engine Service Repair Manual – 1037 Pages
Caterpillar C18 Manual Table of Content:
- Disassembly and Assembly
- Testing and Adjusting
- Troubleshooting
- Systems Operation
- Torque Specifications
- Specifications
- Schematic
This service manual is a guide to servicing and repairing of the Catapillar C18 Engine. The instructions are grouped by systems to serve the convenience of your ready reference.
Long productive life of your Engine depends to a great extent on correct servicing. The servicing consistent with what you will learn from this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job.
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.