Caterpillar C280 OM&M

SEBU7876-07 August 2013

Operation and Maintenance Manual C280 Marine, Marine Auxiliary, and Petroleum Engines PKA 1-Up (C280-8 Engine) NKB 1-Up (C280-16 Engine) SCB 1-Up (C280-6 Engine) A4F 1-Up (C280-16 Engine) TSJ 1-Up (C280-12 Engine) LDL 1-Up (C280-6 Engine) NDT 1-Up (C280-8 Engine) RDW 1-Up (C280-12 Engine) TDX 1-Up (C280-16 Engine)

SAFETY.CAT.COM

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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, including human factors that can affect safety. 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 verify that you are authorized to perform this work, and 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 you are authorized to perform this work, and 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. Failure to follow this warning may 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.

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3 Table of Contents

Table of Contents

Maintenance Interval Schedule (Standby)... ... 74

Foreword.............................. ............................. 4

Maintenance Interval Schedule (Prime) ..... .... 75

Safety Section

Warranty Section

Safety Messages....................... ....................... 5

Warranty Information .................. .................. 131

General Hazard Information ............... .............. 8

Reference Information Section

Burn Prevention....................... ........................11

Engine Ratings ....................... ...................... 132

Fire Prevention and Explosion Prevention ... .. 12

Engine Performance and Performance Analysis Report (PAR)........................ ....................... 134

Crushing Prevention and Cutting Prevention . 14 Mounting and Dismounting............... .............. 14 Before Starting Engine ................. .................. 14 Engine Starting ........................ ....................... 15 Engine Stopping ....................... ...................... 15 Electrical System ...................... ...................... 15

Product Information Section General Information.................... .................... 17 Product Identification Information.......... ......... 27

Operation Section Lifting and Storage..................... ..................... 29 Features and Controls .................. .................. 31 Engine Starting ........................ ....................... 50 Engine Operation...................... ...................... 57 Cold Weather Operation................. ................ 58 Engine Stopping ....................... ...................... 60

Maintenance Section Refill Capacities....................... ....................... 63 Maintenance Recommendations.......... .......... 72

Customer Service ..................... .................... 135 Reference Materials .................. ................... 137

Index Section Index............................... .............................. 148

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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 Cat 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 Cat 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.

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 Cat dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul

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.

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 Cat dealer. Your Cat 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 Cat dealer. Consult with your dealer for information regarding these options.

Maintenance

California Proposition 65 Warning

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.

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

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.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

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Safety Section Safety Messages

Safety Section i05202753

Safety Messages SMCS Code: 1000; 7405 There may be several specific safety messages on your engine. The exact location and a description of the safety messages are reviewed in this section. Become familiar with all safety messages. Ensure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the safety messages. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety messages. The safety messages that are loosened could drop off the engine. Replace any safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety message on the replacement part. Your Cat dealer can provide new safety messages.

Do not operate or work on this engine 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.

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Illustration 1

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Engine Lifting (1) The safety messages for engine lifting are located on the number three cylinder head and on the number four cylinder head.

If improper equipment is used to lift the engine, injury and damage can occur. Use cables that are properly rated for the weight. Use a spreader bar and attach the cables according to the information on the warning label.

Hot Pressurized Fluid (3) The safety message for hot pressurized fluid is located on the oil filter covers and on the fuel filter covers.

Illustration 4 Illustration 2

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Improper lift rigging can allow unit to tumble causing injury and damage. If improper equipment is used to lift the engine, injury and damage can occur. Use cables that are properly rated for the weight. Use a spreader bar and attach the cables according to the information on the warning label.

Engine Lifting (2)

Filter contains hot pressurized fluid when engine is running. To avoid personal injury, stop engine before removing filter cover.

Flash Fire (4) The safety message for flash fire is located on the crankcase covers.

The safety messages for engine lifting are located on the number one cylinder head and on the number two cylinder head.

Illustration 5

Illustration 3

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Improper lift rigging can allow unit to tumble causing injury and damage.

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Flash fire may result in personal injury, if crankcase covers are removed within fifteen minutes after emergency shut down. Do not restart engine until cause for shutdown has been corrected.

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Safety Section General Hazard Information

Centrifugal Oil Filters (5) The safety message for the centrifugal oil filters is located on the centrifugal oil filter covers.

Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced. 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

Illustration 6

Do not remove pressurized.

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cover

when

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.

centrifuge is

The centrifugal oil filter contains hot pressurized fluid when the centrifuge is pressurized. Do not remove the cover when the centrifuge is pressurized. i05334609

General Hazard Information SMCS Code: 1000; 4450; 7405 Illustration 8

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• 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. • 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. Illustration 7

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Attach a “Do Not Operate” warning tag to the start switch or controls before the engine is serviced or repaired. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer. Attach the warning tags to the engine and to each operator control station. When appropriate, disconnect the starting controls.

• 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:

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9 Safety Section General Hazard Information

• The engine is stopped. Ensure that the engine cannot be started.

Fluid Penetration

• 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. • When starting a new engine, make provisions to stop the engine if an overspeed occurs. If an engine has not been started since service has been performed, make provisions to stop the engine if an overspeed occurs. Shutting down the engine may be accomplished by shutting off the fuel supply and/or the air supply to the engine. • Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment. • Start the engine with the operator controls. Never short across the starting motor terminals or the batteries. This method of starting the engine 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 which could result in personal injury. The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded and used with effective chip guarding (if applicable) and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). 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. Always wear eye protection for cleaning the cooling system. Avoid direct spraying of water on electrical connectors, connections, and components. When using air for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when redeposited on hot surfaces.

Illustration 9

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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, “Cat Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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Safety Section General Hazard Information

Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel The removal of sulfur and other compounds in ultralow sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a static dissipating additive. Many factors can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion. Ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding.

Ensure that all of the clamps, the guards, and the heat shields are installed correctly. Correct installation of these components will help to prevent these effects: vibration, rubbing against other parts and excessive heat during operation.

Inhalation

Illustration 10

Avoid static electricity risk when fueling. Ultra-low sulfur diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur contents. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

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

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Exhaust Use caution. Exhaust fumes can be hazardous to your health. If you operate the equipment in an enclosed area, adequate ventilation is necessary.

Asbestos Information Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Cat 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 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:

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11 Safety Section Burn Prevention

• Never use compressed air for cleaning.

Dispose of Waste Properly

• 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. • 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.

Softwrap Keep the engine room ventilation operating at full capacity. Wear a particulate respirator that has been approved by the National Institute of Occupational Safety and Health (NIOSH) . Wear appropriate protective clothing in order to minimize direct contact. Use good hygiene practices and wash hands thoroughly after handling Softwrap material. Do not smoke until washing hands thoroughly after handling Softwrap material. Clean up debris with a vacuum or by wet sweeping. Do not use pressurized air to clean up debris. Reference: The applicable material safety data sheets can be found at the following web site by searching using part number or the name: http://dsf2ws.cat.com/msds/servlet/ cat.cis.ecs.msdsSearch.controller. UserIdentificationDisplayServlet

Illustration 11

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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. i00910250

Burn Prevention SMCS Code: 1000; 4450; 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 lubrication system, in the fuel system, or in the cooling 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. When pressure is relieved rapidly, the hot coolant can turn into steam. 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 only after the engine has been stopped. Do not step on the engine in order to remove the filler cap. Use a ladder, if necessary. Ensure that the filler cap is cool before removing the filler cap. 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.

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Safety Section Fire Prevention and Explosion Prevention

Oils Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Keep all of the exhaust manifold and turbocharger shields in place in order to protect components from oil spray if there is a failure of a line, a tube, or a seal.

Batteries Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. Batteries give off combustible gases which can explode. Ensure proper ventilation for batteries that are in an enclosure. 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 to ignite. Do not smoke when batteries are serviced. Always thaw a frozen battery before jump starting the battery. Frozen batteries can explode. i05374808

Fire Prevention and Explosion Prevention SMCS Code: 1000; 4450; 7405

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 Cat 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 in a line, a tube, or a seal failure. 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 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.

Illustration 12

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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 Cat dealer for service.

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.

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13 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 fuel filters. The filter housings must be tightened to the proper torque.

Illustration 14

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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.

Illustration 13

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Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.

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.

Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.

Avoid static electricity risk when fueling. Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations with a higher Sulfur content. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Do not charge a frozen battery. Charging a frozen battery may result in 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 Ether is flammable and poisonous. Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray.

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Safety Section Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 °F). Keep ether cylinders away from open flames or sparks. Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel. Do not spray ether into an engine if the engine is equipped with a thermal starting aid for cold weather starting.

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. 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.

Lines, Tubes, and Hoses Do not bend high-pressure lines. Do not strike highpressure 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 Cat 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.

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Mounting and Dismounting SMCS Code: 1000; 4450; 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.

• Wires are exposed. • Outer coverings are ballooning. • Flexible parts of the hoses are kinked.

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.

• Outer covers have embedded armoring. • End fittings are displaced.

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Make sure that all clamps, guards, and heat shields are installed correctly in order to prevent vibration, rubbing against other parts, and excessive heat.

Before Starting Engine SMCS Code: 1000

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Crushing Prevention and Cutting Prevention SMCS Code: 1000; 4450; 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.

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.

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15 Safety Section Engine Starting

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. 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.

Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help 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 and the oil temperature during heater operation. Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. i01032808

If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped.

Engine Stopping

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.

To avoid overheating of the engine and accelerated wear of the engine components, stop the engine according to this Operation and Maintenance Manual, “Engine Stopping” topic (Operation Section).

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.

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.

See the Service Manual for repairs and for adjustments. i02136012

Engine Starting

SMCS Code: 1000

On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop the engine if an overspeed condition occurs. This may be accomplished by shutting off the fuel supply and/or the air supply to the engine.

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. If there is a possibility that unburned gas remains in the exhaust system, refer to the purge procedure in this Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Start the engine from the operator's compartment or from the engine start switch.

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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. 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.

Grounding Practices 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.

16 Safety Section Electrical System

Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the engine electronics and communications. Ensure that all grounds are secure and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to carry the full charging current of the alternator. For the starting motor, do not attach the battery negative terminal to the engine block. Ground the engine block with a ground strap that is furnished by the customer. Connect this ground strap to the ground plane. Use a separate ground strap to ground the battery negative terminal for the control system to the ground plane. If rubber couplings connect the steel piping of the cooling system and the radiator, the piping and the radiator can be electrically isolated. Ensure that the piping and the radiator are continuously grounded to the engine. Use ground straps that bypass the rubber couplings.

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SEBU7876

17 Product Information Section Model View Illustrations

Product Information Section General Information i05377072

Model View Illustrations SMCS Code: 1000 The illustrations show various typical features of a C280 Series Engine. The illustrations do not show all of the engine configurations that are available.

Illustration 15

g03357869

View of the right side of the C280 Engine with Front Mounted Turbocharger (1) Shield for the exhaust manifold (2) Cover for the high performance aftercooler (3) Lifting eyes (4) Engine crankcase breathers (5) Air shutoff

(6) Exhaust bypass (7) Cover for the turbocharger (8) Engine oil filters (9) Drain valves for the oil filters (10) Engine oil level gauge (11) Engine oil filler tube

(12) Centrifugal engine oil filter (13) Circuit breaker box (14) Expansion relief valves for the crankcase (15) Engine control module (16) Fuel filters

18

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General Information Model View Illustrations

Illustration 16

g03345398

View of the left side of the C280 Engine with Front Mounted Turbocharger (17) Engine starting motors (air starting) (18) Drain valve for the engine oil pan (19) Integral relay valve for the air starting system

(20) Air pressure regulator for the engine starting motors (21) Screen for the air pressure system (22) Fuel priming pump

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19 General Information Model View Illustrations

Illustration 17

g03345635

View of the front of the C280 Engine (23) Turbochargers (24) Engine oil cooler (remote location)

(25) Water drains (26) Prelube pump for engine oil

(27) Guard for engine crankshaft damper

20

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General Information Model View Illustrations

Illustration 18

g03403385

Right Side View of a C280-16 Engine With Rear Mounted Turbochargers (1) Turbocharger (2) Exhaust (3) Air shutoff (4) Engine crankcase breathers

(5) Aftercooler cover (6) Exhaust manifold shield (7) Prelube pump (8) Crankcase explosion relief valves

(9) Prelube pump (10) Circuit breaker box (11) Engine control module (12) Engine oil drain

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21 General Information Product Description

Illustration 19

g03403386

Left Side View of a C280-16 Engine With Rear Mounted Turbochargers (13) Engine oil filters (14) Fuel filters (15) Air starting motors

(16) Centrifugal oil filters (17) Engine oil level gauge (18) Engine oil filler i05377092

Product Description SMCS Code: 1000; 4450; 4491 C280 Series Engines are intended for use in these applications: • Petroleum • Marine • Marine Auxiliary The engines are rated from 900 rpm to 1000 rpm.

(19) Fuel transfer pump

Engine Service Life Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. This adherence includes use of the recommended lubricants, fuels, and coolant/antifreezes. For the engine maintenance that is required, see this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

22

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General Information Product Description

Engine Specifications Table 1

C280 Series Engine Specifications Item

C280-06

C280-08

C280-12

C280-16

50 degree vee 12

50 degree vee 16

Operating rpm

900 to 1000

Low idle rpm

300 to 500

Cylinders and arrangement

In-line 6

In-line 8

Bore

280 mm (11 inch)

Stroke

300 mm (11.8 inch)

Displacement per cylinder

18.7 L (1127 cubic inches)

Total displacement



222 L (13,530 cubic inches)

296 L (18,036 cubic inches)

Compression ratio

13:1 12.6:1(1)

Aspiration

TA

Rotation (flywheel end)

Standard rotation is counterclockwise. Clockwise rotation is optional.

Fuel Delivery

Electronic Unit Injectors

Fuel

See this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

Method of starting

Air starting motors Electric starting motors

Maximum allowable exhaust back pressure

254 mm (10 inch of H2O)

Maximum allowable inlet air restriction

3.7 kPa (15 inches of H2O)

(1)

C280-16 Up-rate with front mounted turbocharger.

Engine Design C280-06Engine

Illustration 20

C280-06 Engine design (A) Exhaust valves (B) Inlet valves (C) Flywheel

g00486404

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C280-08Engine

Illustration 21

C280-16Engine

g00486405

Illustration 23

C280-08 Engine design

C280-16 Engine design

(A) Exhaust valves (B) Inlet valves (C) Flywheel

(A) Exhaust valves (B) Inlet valves (C) Flywheel

C280-12Engine

Illustration 22

C280-12 Engine design (A) Exhaust valves (B) Inlet valves (C) Flywheel

g00279793

g00279792

24

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Drives and Gear Trains

(Table 2, contd)

Front Drives For C280 Series Engines

Front Drives

Auxiliary water pump

2230

Optional scavenge oil pump

1524

(1)

The speed of the component is listed for an engine that is operating at 1000 rpm. For an engine that is operating at 900 rpm, multiply the speed of the component by .9. For an engine that is operating at 750 rpm, multiply the speed of the component by .75.

Illustration 25 shows the fluid flow of the Optional front drive.

Illustration 24

g02935577

Standard rotation Illustration 25

(A) Standard front drive (B) Optional front drive (1) Jacket water pump (2) Aftercooler and oil cooler pump (3) Auxiliary water pump (4) Engine oil pump (5) Optional scavenge oil pump (6) Fuel transfer pump (7) Scavenge oil pump

(1) Water outlet (2) Water inlet (3) Oil outlet (4) Oil inlet

Table 2 lists the speed of the components that are shown in Illustration 24 . Table 2

Front Drives For C280 Series Engines Component

Speed (1)

Jacket water pump

2522

Aftercooler and oil cooler pump

2522

Scavenge oil pump

1627

Engine oil pump

1524

Fuel transfer pump

1995

(continued)

g02935580

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Engine Front Gear Train

Illustration 27 Illustration 26

g00268306

C280 Series Engine front gear train (1) Crankshaft (2) Idler (3) Idler (4) Jacket water pump (5) Aftercooler and oil cooler pump (6) Scavenge oil pump or auxiliary pump (7) Engine oil pump

g00291364

(1) Crankshaft (2) Large cluster idler (3) Small cluster idler (4) Camshaft

Illustration 28 shows the relationship of the rear gear train for the C280-12 Engine and the C280-16 Engine.

Table 3 lists the number of teeth for the gears in Illustration 26 . Table 3

Front Gear Train For C280 Series Engines Gear

Number Of Teeth

(1) Crankshaft

96

(2) Idler

68

(3) Idler

67

(4) Jacket water pump

38

(5) Aftercooler and oil cooler pump

38

(6) Scavenge oil pump

59

(7) Engine oil pump

63

Engine Rear Gear Train

Illustration 28

g00268312

(1) Crankshaft (2) Large cluster idler (3) Small cluster idler (4) Camshaft (5) Idler

Table 4 lists the number of teeth for the gears in illustrations 27 and in 28 . Table 4

Rear Gear Train For C280 Series Engines

Illustration 27 shows the relationship of the rear gear train for the C280-06 Engine and the C280-08 Engine.

Gear

Number Of Teeth

(1) Crankshaft

81

(2) Large Cluster Idler

90

(3) Small Cluster Idler

45

(4) Camshaft

81

(5) Idler

81

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Reference Weights Table 5 Approximate Engine Weights Dry weight of the engine with attachments

C280-06 Engine

C280-08 Engine

C280-12 Engine

C280-16 Engine

15680 kg (34500 lb)

19000 kg (41800 lb)

25140 kg (55300 lb)

29950 kg (65900 lb)

Table 6

Approximate Weights Of Serviceable Parts Component Cylinder block

C280-06 Engine

C280-08 Engine

C280-12 Engine

C280-16 Engine

4180 kg (9200 lb)

5584 kg (12300 lb)

6646 kg (14620 lb)

8630 kg (18986 lb)

Bearing cap Crankshaft

65 kg (144 lb) 1782 kg (3920 lb)

Flywheel assembly Crankshaft vibration damper

2288 kg (5034 lb)

491 kg (1080 lb) 183 kg (405 lb)

267 kg (588 lb)

2091 kg (4600 lb)

2602 kg (5724 lb)

486 kg (1071 lb)

492 kg (1084 lb)

269 kg (588 lb)

486 kg (1071 lb)

Cylinder head assembly

235 kg (517 lb)

196 kg (433 lb)

Cylinder liner

128 kg (282 lb)

100 kg (221 lb)

Piston assembly

36 kg (77 lb)

Piston pin

19 kg (42 lb)

Piston rod assembly

57 kg (125 lb)

Turbocharger

401 kg (883 lb)

Aftercooler core (1)

36 kg (80 lb)

Unit injector

104 kg (229 lb)

12 kg (27 lb)

Front housing

258 kg (568 lb)

Rear housing Used air cleaner element (1)

73 kg (161 lb)

222 kg (488 lb)

456 kg (1003 lb)

35 kg (78 lb)

29 kg (64 lb)

The weight is listed for a single-stage aftercooler. A two-stage aftercooler and an aftercooler with a deep core are also available.

Table 7

Approximate Weights Of Package Generator Sets Item

C280-06 Engine

C280-08 Engine

C280-12 Engine

C280-16 Engine

Engine (1)

15680 kg (34500 lb)

19000 kg (41800 lb)

25140 kg (55300 lb)

29950 kg (65900 lb)

Generator (2)

8270 kg (18200 lb)

10640 kg (23400 lb)

13640 kg (30000 lb)

17820 kg (39200 lb)

Module

1360 kg (3000 lb)

1410 kg (3100 lb)

1480 kg (3260 lb)

1650 kg (3630 lb)

Mounting base

7820 kg (17200 lb)

8640 kg (19000 lb)

Mounting base (2)

8170 kg (17970 lb)

9750 kg (21450 lb)

Coupling (2)

590 kg (1300 lb)

Total

33160 kg (72960 lb)

38450 kg (84768 lb)

Total(2)

34070 kg (74970 lb)

41390 kg (91050 lb)

(1) (2)

n/a 10250 kg (22550 lb)

14070 kg (30950 lb)

720 kg (1580 lb)

980 kg (2160 lb) n/a

51230 kg (112690 lb)

64470 kg (141840 lb)

The weights of the engines that are listed includes attachments that are mounted on the engines. The engine weights are dry weights. Double bearing generator

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27 Product Identification Information Plate Locations and Film Locations

Product Identification Information i04812743

Plate Locations and Film Locations SMCS Code: 1000; 4450

Engine Identification Cat engines are identified with serial numbers, with performance specification numbers, and with arrangement numbers. In some of the cases, modification numbers are used. These numbers are shown on the Serial Number Plate and the Information Plate that are mounted on the engine. Cat dealers need these numbers in order to determine the components that were included with the engine. This information permits accurate identification of replacement part numbers.

Illustration 30

g02935876

The engine information plate is located between the last two crankcase covers on the right-hand side of the engine.

Serial Number Plate

Engine Information Plate

Illustration 31

(2) Engine serial number plate

Illustration 29

(1) Engine information plate

g02935657

g02935658

28

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Product Identification Information Reference Information

(Table 8, contd) Packaging Arrangement Engine Low Idle rpm Engine Power Rating Engine Full Load rpm Performance Specification Number Governor Group Number Turbocharger Primary Fuel Filter Illustration 32

g00123229

The serial number plate is located between the last two crankcase covers on the right-hand side of the engine.

Secondary Fuel Filter Engine Oil Filter Air Cleaner Capacity of the Lubrication System

i01419795

Capacity of the Cooling System

Reference Information SMCS Code: 1000; 4450 Identification of the items in Table 8 may be needed in order to obtain parts and service. Some of the numbers are on the engine Serial Number Plate and/ or Information Plate. Locate the information for your engine. Record the information on the appropriate space in Table 8 . Make a copy of this list for a record. Retain the information for future reference. The top level part numbers in the Parts Manual for the engine are listed with the engine arrangement number. Occasionally, an arrangement may be slightly modified before the product is shipped from the factory. In these cases, a modification number indicates that the arrangement has been modified. The packaging arrangement may also be called a pricing arrangement or a customer arrangement. This is the total package with attachments and options that are not included in the engine arrangement. The performance specification can be used by your Caterpillar dealer with the Technical Marketing Information system. Before the engine leaves the factory, the engine performance is tested. Detailed performance data is recorded. The performance specification number can be used for obtaining the data. Table 8 Reference Numbers Engine Model Engine Serial Number Engine Arrangement Number

(continued)

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29 Operation Section Product Lifting

Operation Section Lifting and Storage i05379025

Product Lifting SMCS Code: 7000; 7002

Illustration 34

g00902989

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.

Illustration 33

g03403864

Typical lifting eye locations on a C280-16 Engine. Use a hoist to remove heavy components. Some removals require lifting fixtures in order to obtain proper balance and safety.

To lift the engine ONLY, attach anchor shackles to the lifting eyes that are on the engine. The 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 Cat dealer for information regarding fixtures for proper engine lifting. Use an adjustable lifting beam to lift the entire 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. Follow the instructions that are on the engine lifting warning labels:

Illustration 35

1. Use proper spreader bar, as shown.

g01231066

30

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Lifting and Storage Product Storage

i02425915

2. Attach two proper rated cables to spreader bar from engine lift shackles.

Product Storage SMCS Code: 7002 If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder liner surface. Rust on the cylinder liner surface will cause increased engine wear and a reduction in engine service life. To help prevent excessive engine wear, use the following guidelines: • Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

Illustration 36

g01231042

The Do Not Lift films are applied to various locations on the product. Do NOT use these locations to lift the product.

Engine Lifting with a Generator NOTICE Do not use the engine lifting eyes to remove the engine and generator together. A lifting plate is provided with the package generator set. Instructions for lifting the package generator set are stamped on the lifting plate. Consult your Cat dealer for information regarding proper fixtures and lifting devices. Generator set packages will not be level if you lift the unit with a single lifting point. A counterweight can be added between the package frame rails whenever the application requires frequent relocation of the unit. For complete information about adding the counterweight, consult your Cat dealer. The single point lifting eye is secured from the factory before the enclosure is shipped. The correct orientation of the single point lifting eye will allow you to look through the eye when you stand at the side of the enclosure. The lifting eye may stretch when the package is lifted. This stretch may cause the locking nuts to loosen. Loosening could cause the lifting eye to swivel. Ensure that the lifting eye is correctly oriented on the packaged generator set. Ensure that the lifting eye is tightened to the correct torque before you lift the packaged generator set.

• If freezing temperatures are expected, check the cooling system for adequate protection against freezing. See this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section). If an engine is out of operation and if use of the engine is not planned, special precautions should be made. If the engine will be stored for more than one month, a complete protection procedure is recommended. For more detailed information on engine storage, see Special Instruction, SEHS9031, “Storage Procedure For Caterpillar Products”. Your Caterpillar dealer can assist in preparing the engine for extended storage periods.

SEBU7876

31 Features and Controls Alarms and Shutoffs

Features and Controls i05393709

Alarms and Shutoffs SMCS Code: 7400

Setpoints for Alarms and Shutoffs Alarms and shutoffs are activated by critical operating temperatures, pressures, levels, or speeds. Engines are equipped with alarms in order to alert the operator if undesirable operating conditions occur. When an alarm is activated, corrective measures must be made before damage to the engine can occur. Shutoffs are set at more critical operating setpoints than alarms. Any problem that causes the engine to shut off must be corrected before the engine is restarted. Table 9 lists the alarms and shutoffs that are available and the corresponding suggested setpoints. Some of the conditions that cause an alarm will also cause the engine to be derated. When the “SHUTDOWN PRTN OVERRIDE” switch is in the ON position, no shutoff or derate will occur unless one of the following conditions occurs: • An overspeed condition exists • The “EMERGENCY STOP” switch is activated. Note: Some of the items that are listed in Table 9 are optional. Table 9

Alarms and Shutoffs for C280 Engines (Distillate Fuel) Condition

Parameter

Application

Setpoint for Alarm

Setpoint for Shutoff

Temperature regulator 38° C (100° F)

45° C (113° F)

61° C (142° F)

Cooling System High Low

Aftercooler and oil cooler water pump pressure (outlet)

-

70 kPa (10 psi)(1)

-

Low

Auxiliary water pump pressure (outlet)

-

70 kPa (10 psi)(1)

-

Low

Coolant level

-

Level

-

Low

Jacket water pump pressure (outlet)

-

70 kPa (10 psi)(1)

-

High

Jacket water coolant temperature (outlet)

-

103 °C (217 °F)

109 °C (228 °F)

Jacket water coolant temperature (inlet) and engine oil temperature (inlet)

-

2 °C (4 °F)(2)

-

Minimum differential

Exhaust

(continued)

32

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Features and Controls Alarms and Shutoffs

(Table 9, contd)


Parameter

Application

Setpoint for Alarm

Setpoint for Shutoff

High

Exhaust port temperature deviation

-

50 °C (90 °F) difference from the average temperature of all of the cylinders

-

High

Turbocharger exhaust inlet (before turbine)

-

630 °C (1166 °F)

-

High

Turbocharger exhaust inlet (before turbine)

650 °C (1202 °F)

-

High

Exhaust port temperature

-

(3)

-

-

75 kPa (11 psi)

-

High Output rating

Fuel High

Fuel filter differential pressure

Low

Fuel pump pressure (outlet)

The engine speed is less than 650 rpm.

140 kPa (20 psi)(4)

Low

Fuel pump pressure (outlet)

The engine speed is greater than 650 rpm.

260 kPa (38 psi)(4)

High

Fuel temperature (inlet)

-

66 °C (151 °F)

72 °C (162 °F)

Inlet Air High

Air filter differential pressure (restriction)

-

3.7 kPa (.54 psi)

-

High

Inlet manifold air pressure (boost pressure)

-

(5)

-

High

Inlet manifold air temperature

50 °C (122 °F) aftercooler and oil cooler water temperature regulator

92 °C (198 °F)

98 °C (208 °F)

High


50 °C (122 °F) aftercooler and oil cooler water temperature regulator (with a High Performance Aftercooler)

78 °C (172 °F)

98 °C (208 °F)

High


32 °C (90 °F) aftercooler and oil cooler water temperature regulator

75 °C (167 °F)

98 °C (208 °F)

High


32 °C (90 °F) aftercooler and oil cooler water temperature regulator (with a High Performance Aftercooler)

61 °C (142 °F)

98 °C (208 °F)

Lubrication High

Crankcase pressure

-

0.6 kPa (.09 psi)

1 kPa (.15 psi)

High

Engine oil temperature

-

92 °C (198 °F)

98 °C (208 °F)

Low

Engine oil level

-

50 mm (2 inch) above the inlet for the oil suction

-

Low

Engine oil pressure


120 kPa (17 psi)(6)

105 kPa (15 psi)

Low

Engine oil pressure


320 kPa (46 psi)(6)

260 kPa (38 psi)

(continued)

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(Table 9, contd)


Parameter

Application

Setpoint for Alarm

Setpoint for Shutoff 165 kPa (24 psi)

High

Engine oil filter differential pressure

-

70 kPa (10 psi)

High

Detection of oil mist

-

Presence of oil mist in the crankcase

N/A

Metal particle detection

-

Presence of metal particles in the oil lines

Miscellaneous High

Overspeed

Low

Air starting motor supply pressure

Low (1) (2) (3) (4) (5) (6)

-

-

113 % of rated rpm

Vane

750 kPa (109 psi)

-

Turbine

515 kPa (75 psi)

-

An optional setpoint is 0.07 kPa times the engine rpm. The minimum difference between the two temperatures must be greater than 2 °C (4 °F). For example, a jacket water coolant temperature inlet of 90 °C minus a lube oil temperature inlet of 85 °C is an acceptable difference of 5 °C. An alarm for the temperature of the exhaust port is specific to the particular project. The primary alarm for exhaust temperature is the exhaust inlet to the turbocharger. An optional setpoint is 0.4 kPa times the engine rpm. The setpoint is determined by adding 30 kPa to the maximum test specification from the dynamometer. An optional setpoint is 0.5 kPa times the engine rpm.

Table 10 Alarms and Shutoffs for C280-12/16 (5060bkw) and C280-16 (5600bkw) A4 Based Engines

Condition

Parameter

Application(1)

Setpoint for Alarm (Alarm Default State)

Setpoint for Derate (Derate Default State)

Setpoint for Shutoff (Shutdown Default State)

106° C (223° F) - ON

109° C (228° F) - ON

Cooling

High

Engine Coolant Temperature

C280-16 5600 bkw

103° C (217° F) - ALWAYS ON (2)

C280-12/16 5060 bkw

103° C (217° F) - ON

Low

Engine Coolant Temperature

80° C (176° F) - ON

-

-

Low

Engine Coolant Inlet Pressure

Map - ON

-

-

Low

Engine Coolant Level

Switch - ON

-

-

Aftercooler Coolant Temperature

C280-16 5600 bkw

45° C (113° F) - ON

48° C (118° F) - ON

61° C (142° F) - OFF

High

C280-12/16 5060 bkw

39° C (102° F) - ON

42° C (108° F) - ON

55° C (131° F) - OFF

Map - On

-

-

Low

Aftercooler Coolant Pressure

Exhaust High

Turbine Inlet Temperature

C280-16 5600 bkw

660° C (1220° F) - ON

661° C (1222° F) - ON

690° C (1274° F) - ON

C280-12/16 5060 bkw

630° C (1166° F) - ON

631° C (1168° F) - ON

660° C (1220° F) - ON

High

Turbine Inlet Temperature Differential

100° C (212° F) - ON

-

-

High

Exhaust Port Temperature (1-20)

580° C (1076° F) - ON

-

600° C (1112° F) - OFF

(continued)

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Features and Controls Alarms and Shutoffs

(Table 10, contd) High

Exhaust Port Temperature Deviation (1-20)

75° C (167° F) - ON

-

125° C (257° F) - OFF

Low

Exhaust Port Temperature Deviation (1-20)

125° C (257° F) - ON

-

200° C (392° F) - OFF

C280-16 5060 bkw/5600 30,000 RPM - ALWAYS - ON (2) bkw

30,100 RPM - ON

31,000 RPM - ON

34,000 RPM - ALWAYS - ON (2)

34,100 RPM - ON

35,500 RPM - ON

High

Turbine Shaft Speed C280-12 5060 bkw

High

Turbine Shaft Speed Differential

3 percent - ON (3) Fuel

High

Fuel Filter Restriction

75 kPa (11 psi) - ON

-

-

Low

Fuel Pressure

Map - ON

-

-

Inlet Air High

Intake Manifold Air Temperature

61° C (142° F) - ALWAYS ON (2)

62° C (144° F) - ON

71° C (160° F) - OFF

High

Crankcase Pressure

0.6 kPa (0.09 psi) - ON

-

1 kPa (0.15 psi) - ON

Lubrication High

Engine Oil Temperature

92° C (198° F) - ALWAYS ON (2)

92° C (198° F) - ON

98° C (208° F) - ON

Low

Engine Oil Pressure

Map - ALWAYS ON (2)

-

Map - ON

High

Engine Oil Filter Restriction

70 kPa (10 psi) - ON

-

-

-

1017 RPM - ALWAYS ON (2)

-

115 percent of Rated ALWAYS ON (2)

Miscellaneous C280-16 5600 bkw High

(1) (3)

(2)

Engine Overspeed C280-12/16 5060 bkw

(2)

990 RPM - ALWAYS ON 113 percent or Rated ALWAYS ON (2)

Empty cell implies setting is applicable to both engines Not Configurable Enabled at Turbo Speeds Greater than 15,000 RPM.

Shut down Procedure For the Oil Mist Detector If a shutdown occurs due to excessive oil mist, use the following procedure. Note: Instructions from the Service Manual, “Disassembly and Assembly” module will be necessary in order to perform this procedure. 1. After the shutdown, inspect the control system for other alarm conditions. Compare the timing of the shutdown to the activation of the alarm. Ensure that the shutdown was initiated by the oil mist detector. 2. Inform the master engineer that the engine is unavailable.

3. Inspect the display of the oil mist detector in order to ensure that the shutdown is genuine. The green “Ready” indicator is OFF and the red “Alarm” indicator is FLASHING. Inspect the display for other faults. 4. After verifying the cause of the shutdown, shut off the air supply to the starting motor. This procedure will prevent accidental starting. 5. Open the cylinder pressure valves (Keine valves) for all of the cylinders.

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Guards must be in place prior to operating barring device motor. Remove all hand tools prior to operating barring device motor. NOTICE Do not use an impact wrench to operate the barring device. The use of an impact wrench will cause gear tooth failure. 6. Operate the prelube pump and the barring device. If the flywheel will rotate freely, rotate the engine for two complete revolutions (720 degrees). Lock the barring device. 7. Deactivate the prelube pump.

Flash fire may result in personal injury, if crankcase covers are removed within fifteen minutes after emergency shut down. Do not restart engine until cause for shutdown has been corrected. 8. After the engine has been shut down for 15 minutes, remove all of the crankcase covers. The oil mist detector monitors each section of the crankcase. First investigate the section with the fault condition. Note: Measure the temperatures quickly before the bearings can cool is important. This procedure will provide the most accurate indication of the operating temperatures of the bearings. Step 9 can be efficiently performed by two people: one person measures the temperatures, and one person records the temperatures. 9. Use a 123-6700 Laser Infrared Thermometer. Record all three temperatures for the small end bearing and for the large end bearing of each connecting rod. Record the temperatures for the front, the center, and the rear of each bearing. Note: Lower temperatures can be expected for a shutdown during partial load operation. a. The temperature of any small end bearing should not exceed the average temperature of all of the small end bearings by more than 15 °C (60 °F). The temperature of any large end bearing should not exceed the average temperature of all of the large end bearings by more than 15 °C (60 °F).

b. The maximum temperature of any bearing after full load operation should not exceed 105 °C (221 °F). 10. Ensure that the large end bearings of the connecting rods can move freely. Normally, the rods can be moved slightly. Move the rods back and forth along the crankshaft journal. 11. If the following conditions occur, perform Steps 11.a. and 11.b.: • The temperatures are within the specifications that are listed in Steps 9.a. and 9.b.. • A closer visual inspection shows no damage to the following components: pistons, cylinder liners, piston pins, main bearings and gear trains. a. Remove the oil filters. For instructions, see this Operation and Maintenance Manual, “Engine Oil Filter - Change” topic (Maintenance Section). b. Cut the oil filters open with a utility knife. Inspect the pleats of the filter material for debris. The type of debris that is found will indicate components that require further inspection. 12. If the temperatures of the bearings exceed the specifications that are listed in Steps 9.a. and 9.b., remove the components that are affected. Perform a full inspection of the components. 13. When the engine is in satisfactory condition, perform a complete inspection of the oil mist detector. For instructions, see the literature that is provided by the OEM of the detector. NOTICE Do not operate the engine starting motor until the barring group pinion gear is fully disengaged from the flywheel ring gear. Serious damage to the engine could result. 14. Start the engine according to this Operation and Maintenance Manual, “Engine Starting” topic (Operation Section). Operate the engine at low idle rpm for 10 minutes. If the oil mist detector causes another shutdown, repeat this entire procedure.

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15. After the engine has operated with no problem for 10 minutes, stop the engine. Immediately remove all of the crankcase covers. Measure the temperatures of the connecting rod bearings. This procedure will verify the correct operation of the engine. 16. Resume normal operation. i05393433

Control Panel SMCS Code: 7451

Cat Alarm and Protection Control Panel Note: For additional information on Cat Alarm and Protection Control Panel refer to Systems Operation, UENR2430.

Illustration 37

g03402526

Cat Alarm and Protection Control Panel (1) Direct control unit panel (DCU) (2) “AUX 1 POWER” lamp

(3) “AUX 2 POWER” lamp (4) “COMMON SHUTDOWN” lamp

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37 Features and Controls Control Panel

(5) “GENERAL ALARM” lamp (6) “EMERGENCY” switch

(7) “SPEED CONTROL” switch (8) “GOVERNOR CONTROL” switch

(9) “ENGINE CONTROL” switch

Illustration 38

g03409900

Switches on the inside panel of the control panel (10) “LOCAL THROTTLE” switch (11) “CRANK OVERRIDE” switch (12) “MANUAL RUN/STOP” switch

(13) “LOW IDLE” switch (14) “ENGINE PRTN OVERRIDE” switch (15) “PRELUBE OVERRIDE” switch

(16) “MANUAL PRELUBE” switch

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Features and Controls Control Panel

Illustration 39

g03409723

DCU Panel (17) LCD screen (18) “POWER” indicator lamp (19) “ALARM” list (20) “START” switch

(21) “STOP” switch (22) Context-sensitive menu switches (soft switches) (23) “SCROLL DOWN” switch

Marine Monitoring System II Control Panel Note: For additional information on the Marine Monitoring System II Control Panel, refer to Systems Operation Troubleshooting Testing and Adjusting, RENR2490, “Marine Monitoring System II”.

(24) “SCROLL UP” switch (25) “MENU” switch

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39 Features and Controls Engine Speed Control

Illustration 40

g01167136

Marine Monitoring System II Control Panel (1) Monitor (2) Messenger display (3) “ENGINE SPEED” gauge (tachometer) (4) “SUMMARY SHUTDOWN” indicator (5) “SUMMARY ALARM” indicator (6) “STARTING AIR PRESSURE” gauge (7) “CONTROL FAILURE” indicator

(8) “SPEED SWITCH FAILURE” indicator (9) “ENGINE HOURS” meter (10) “ENGINE PRELUBE” indicator (11) “EMERGENCY STOP” button (12) “OFF/RESET, LOCAL, and REMOTE” switch (13) “FUEL CONTROL” switch i04812303

Engine Speed Control SMCS Code: 1915

Dual Dynamic Operation of Engine (Marine Propulsion) The ADEM governor is set up to provide a variable speed control (default). The ADEM governor is also set up to provide a constant speed control (selected through input to ADEM control). The variable speed control is the default configuration that is used to propel the vessel.

(14) “HORN SILENCE and LAMP TEST” switch (15) “PRELUBE, RUN, and START” switch (16) “GOVERNOR CONTROL” switch (17) “GOVERNOR” switch (18) “SPEED CONTROL” switch

A second group of governor gains are used with the constant speed control. The second group of governor gains are selected by the dual dynamic select switch. Constant speed control is desired when an electric propulsion system is used with dynamic positioning. To use constant speed control, set the following parameters for this feature to work properly:

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Features and Controls Gauges and Indicators

• Determine a known constant speed for the application. The constant speed value is then programmed in the ADEM . This value is entered with the Electronic Technician (ET) for the parameter “Engine Governor Desired Constant Speed” . The default value is set at the rated speed. • Tune the ADEM control for proper operation. The following governor gain parameters are used to tune the engine for proper operation: “Governor Gain Factor #2” , “Governor Minimum Stability Factor #2” and “Governor Maximum Stability Factor #2” . Caterpillar recommends a validation of the preset parameters during commissioning procedure. The parameters that have been set at the factory may need adjusting.

Global Throttle Select and Global Throttle PWM Input Features (Marine Propulsion) The global throttle is available with dual dynamics in order to allow a third throttle input. This feature allows the user to change the throttle input from variable speed control to a load share module. This feature also allows the user to synchronizer the module when constant speed is desired. The global throttle input is selected by grounding the “Global Throttle Select” input to the ADEM control. For more information on engine speed governing, refer to System Systems Operation/Testing And Adjusting and Adjusting, RENR5083, C280 Marine Engines. i05377111

Gauges and Indicators SMCS Code: 7450 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 time. Noticeable changes in gauge readings can 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 Cat dealer for assistance. Your engine may not have the same gauges or all of the gauges that are described.

NOTICE If no oil pressure is indicated, STOP the engine. The engine will be damaged from operating without oil pressure. Engine Oil Pressure – This gauge indicates the pressure of the engine oil. The pressure will be highest 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. Oil Filter Differential Pressure – This gauge indicates the difference in pressure between the inlet side and the outlet side of the engine oil filters. As the oil filter elements become plugged, the pressure will increase. Replace the engine oil filter elements when the oil filter differential pressure reaches 103 kPa (15 psi). 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. The oil temperature is controlled by an 85 °C (185 °F) temperature regulator that is in contact with the oil. The pump for the aftercooler and the oil cooler pumps coolant for the engine oil. Crankcase Pressure – This gauge indicates the pressure that is inside the crankcase. Changes in the pressure may indicate problems with the following components: crankcase breathers, pistons, piston rings and cylinder liners. Aftercooler and Oil Cooler Water Temperature – This gauge indicates the temperature of the coolant at the inlet to the aftercooler and oil cooler circuit. The water temperature is regulated by water temperature regulators. If the cooling system cannot remove enough heat from the water, then the engine cannot be cooled properly. An oil temperature that exceeds the normal oil temperature may indicate that a problem has occurred in the lubrication system and/or the cooling system. Those problems may involve the following components: water temperature regulators, oil coolers, cylinder heads, cylinder liners, pistons and bearings.

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41 Features and Controls Gauges and Indicators

Jacket Water Coolant Temperature – This gauge indicates the temperature of the engine coolant at the outlet for the jacket water. The temperature may vary according to the load. The temperature should never be allowed to exceed the boiling temperature of the pressurized cooling system. The jacket water coolant temperature is regulated to a temperature of 90 °C (194 °F) at the inlet for the jacket water. If the engine is operating above the normal temperature range, perform the following procedure:

Exhaust Port Temperature – This gauge indicates the temperature of the exhaust gas from each individual cylinder. The temperature is measured at the exhaust port of each cylinder head. The exhaust temperature will vary slightly between the cylinders. Individual cylinder exhaust temperatures should not vary by more than 50 °C (122 °F) from the average of all of the cylinder exhaust temperatures. Tachometer – This gauge indicates the engine rpm.

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 the rpm. 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. Inlet Manifold Air Pressure – This gauge indicates the air pressure (turbocharger boost pressure) in the air inlet manifold after the aftercooler. The 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. Air Restriction – This gauge indicates the difference in air pressure between the inlet side and the engine side of the air filter element. The air restriction is measured at the air inlet to the turbocharger. As the air filter element becomes plugged, the difference in pressure between the two sides of the air cleaner element will increase. For optimum engine performance, clean the elements or replace the elements when the air restriction reaches 2.5 kPa (10 inches of H2O). Maximum air restriction is 3.7 kPa (15 inches of H2O). Turbocharger Exhaust Inlet Temperature – This gauge indicates the temperature of the exhaust gas at the inlet of the turbocharger.

NOTICE To help prevent engine damage, never exceed the high idle rpm. An overspeed can result in serious damage to the engine. The engine can be operated at high idle without damage, but the engine should never be allowed to exceed the high idle rpm. Note: The high idle rpm and the full load rpm are stamped on the Information Plate. Engine Hours – This meter indicates the total number of clock hours of operation for the engine. Fuel Pressure – This gauge indicates the fuel pressure to the engine from the fuel filter. The fuel pressure will decrease as the fuel filter differential pressure increases. A decrease in fuel pressure usually indicates a plugged fuel filter. Fuel Filter Differential Pressure – This gauge indicates the difference in fuel pressure between the inlet side and the outlet side of the fuel filters. As the fuel filter elements become plugged, the difference in pressure between the two sides of the fuel filter increases. Replace the fuel filter elements when the fuel filter differential pressure reaches 69 kPa (10 psi). Note: The following gauges are optional. These gauges may be mounted on a gauge panel or in a remote location. Oil Scavenge Pump Outlet Pressure – This gauge indicates the oil pressure from the outlet of the oil scavenge pump. Oil scavenge pumps supply the engine with lube oil from a remote tank. These pumps are used in applications with limited space for the engine. For information about marine transmissions, refer to the literature that is provided by the OEM of the marine transmission or the vessel.

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Transmission Oil Temperature – This gauge indicates the temperature of the oil that is in the transmission. The measurement depends on the temperature of the water and the quantity of the water that is pumped through the transmission oil cooler.

information is sent to the Engine Control Module (ECM). An overspeed will cause an engine shutdown.

Transmission Oil Pressure – This gauge indicates the oil pressure in the marine transmission. The measurement depends on the temperature of the oil and the quantity of the oil that circulates through the transmission lubrication system. Note: An optional gauge can be provided in order to indicate the oil pressure of other driven equipment. For information about the driven equipment, refer to the literature that is provided by the OEM of the driven equipment. i05391355

Sensors and Electrical Components

Illustration 42

g00509590

(3) Oil temperature sensor (4) Unfiltered oil pressure sensor (5) Filtered oil pressure sensor (6) Jacket water pressure sensor (7) Oil pressure sensor

Oil temperature sensor (3) – A sensor in the oil temperature regulator housing helps to monitor the oil temperature. Excessive oil temperature can cause an alarm or a shutdown.

SMCS Code: 1900; 7400

Sensor Locations Different applications may have different sensors. Some of the sensors are optional. The following illustrations show the locations of sensors for C280 Engines. For both the in-line engines and the vee engines, most of the sensors have the same location. For sensors that are at different locations, the differences are shown.

Unfiltered oil pressure sensor (4) – This sensor is located before the oil filters. The pressure of the unfiltered oil is compared to the pressure of the filtered oil. Oil filter differential pressure is calculated from the difference between the pressure before the filters and the pressure after the filters. High differential pressure can cause an alarm or a shutdown. Filtered oil pressure sensor (5) – This sensor is located after the oil filters. The pressure of the filtered oil is compared to the pressure of the unfiltered oil. Oil filter differential pressure is calculated from the difference between the pressure before the filters and the pressure after the filters. High differential pressure can cause an alarm or a shutdown. Jacket water pressure sensor (6) – Jacket water pressure is detected by a pressure sensor that is located on the elbow at the outlet of the jacket water pump. Low jacket water pressure will activate an alarm.

Illustration 41

g00509557

(1) Turbine speed sensor (2) Magnetic pickups

Turbine speed sensor (1) – The rpm of the turbine wheel is detected by a speed sensor. The sensor is inside of the turbocharger housing. Magnetic pickups (2) – The rpm of the flywheel ring gear is detected by magnetic pickups. The

Oil pressure sensor (7) – The engine oil pressure is monitored by a pressure sensor. Low oil pressure can cause an alarm or a shutdown.

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43 Features and Controls Sensors and Electrical Components

Illustration 43

g00510011

Left side of view of the C280-16 Engine with rear mounted turbocharger. (8) Filtered fuel pressure sensor (9) Unfiltered fuel pressure sensor (10) Jacket water outlet temperature sensor

(11) Inlet manifold air pressure sensor (12) Fuel temperature sensor (13) Aftercooler water temperature sensor

(14) Exhaust temperature sensor (15) Metal particle detector (16) Starting air pressure sensor

Note: A vee engine is used to show the sensor locations in Illustrations 43 and 44 . The vee engines and the in-line engines have different locations for the sensors that detect these parameters: inlet manifold air pressure (11), inlet manifold air temperature (18) and aftercooler water temperature (13).

the engine (Illustration 44 ). High inlet manifold air pressure will activate an alarm.

Filtered fuel pressure sensor (8) – The sensor for detecting the fuel pressure of the filtered fuel is located after the fuel filters. Low fuel pressure will activate an alarm.

Aftercooler water temperature sensor (13) – The sensor for aftercooler water temperature is located before the aftercooler. For vee engines, see Illustration 43 . For in-line engines, see Illustration 44 . High aftercooler water temperature can cause an alarm or a shutdown.

Unfiltered fuel pressure sensor (9) – The sensor for detecting the fuel pressure of the unfiltered fuel is located after the fuel filters. Fuel filter differential pressure is calculated from the difference between the pressure before the filters and the pressure after the filters. High differential pressure will activate an alarm. Jacket water outlet temperature sensor (10) – Jacket water outlet temperature is measured before the water temperature regulators. A high temperature can cause an alarm or a shutdown. Inlet manifold air pressure sensor (11) – On vee engines, the sensor for inlet manifold air pressure is located behind a cylinder head (Illustration 43 ). On in-line engines, the sensor is located on the side of

Fuel temperature sensor (12) – A sensor for fuel temperature is located on the rear of the fuel filters. Excessive fuel temperature can activate an alarm or a shutoff.

Exhaust temperature sensor (14) – Exhaust temperatures are measured from the exhaust port of each cylinder (Illustration 43 ). An alarm is activated if the exhaust temperature from any cylinder deviates excessively from the average temperature of all of the cylinders. Metal particle detector (15) – A metal particle detector is mounted near the oil pump (Illustration 43 ). Excessive metal particles in the oil can cause an alarm or a shutdown. Starting air pressure sensor (16) – A sensor for measuring starting air pressure is located in the air

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line before the starting motor. Low starting air pressure activates an alarm.

Illustration 44

g01165731

Right side of view of the C280-16 Engine with rear mounted turbocharger. (17) Turbocharger turbine inlet temperature sensor (18) Inlet manifold air temperature sensor

(19) Crankcase pressure sensor (20) Oil level sensor

Turbocharger turbine inlet temperature sensor (17) – A temperature sensor is mounted at the inlet of the turbocharger turbine. A high turbocharger turbine inlet temperature will activate an alarm. Inlet manifold air temperature sensor (18) – On vee engines, the sensor for inlet manifold air temperature is located next to a cylinder head (Illustration 48 ). On in-line engines, the sensor is located on the side of the engine (Illustration 44 ). High inlet manifold air temperature can activate an alarm or a shutdown. Crankcase pressure sensor (19) – The crankcase pressure sensor is located near the oil level gauge. High crankcase pressure can activate an alarm or a shutdown. Oil level sensor (20) – The crankcase oil level is monitored by a float that is inside of the crankcase. Low oil level will activate an alarm.

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Illustration 45

g03361126

Right side view of a C280-16 Engine with front mounted turbocharger. (7) Engine oil filter inlet temperature sensor (8) Fuel filter outlet primary pressure sensor (9) Fuel filter outlet temperature sensor (10) Wastegate air pressure sensor (11) CRKC pressure sensor (lubrication system)

(12) Intake manifold air temperature primary sensor (13) Intake manifold air temperature secondary sensor (14) Fuel filter outlet pressure secondary sensor

(15) Fuel filter outlet pressure primary sensor (16) Fuel filter inlet pressure sensor

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Illustration 46

g03361130

Left side view of a C280-16Engine with a front mounted turbocharger (17) Block outlet cooler oil temperature sensor

(18) Air starting motor pressure sensor

(19) Prelube satisfied sensor

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Illustration 47

g01165866

Top view (21) Boost pressure sensor (22) Primary speed/timing sensor

(23) Secondary speed/timing sensor (24) Atmospheric pressure sensor

Boost pressure sensor (21) – The boost pressure sensor measures the boost pressure in the inlet air manifold. Primary speed/timing sensor (22) – The primary engine speed/timing sensor is located in the camshaft cover on the rear of the engine. The engine speed/ timing sensor provides accurate information to the ECM about the position of the crankshaft and the engine rpm. The ECM uses the position of the crankshaft in order to determine ignition timing.

Note: For the upgrade engine, the ECM uses the position of the crankshaft to determine primary speed/ timing. The upgrade engine also uses the position of the camshaft to determine secondary speed and timing.

Secondary speed/timing sensor (23) – The secondary engine speed/timing sensor is located in the camshaft cover on the rear of the engine. The engine speed/timing sensor provides accurate information to the ECM about the position of the crankshaft and the engine rpm. The ECM uses the position of the crankshaft in order to determine ignition timing. Atmospheric pressure sensor (24) – The sensor monitors the atmospheric pressure. The master ECM uses the signal to adjust the air/fuel ratio in order to maintain the level of emissions that is desired.

Illustration 48

g00510176

Sensor for auxiliary water pressure A sensor that monitors the auxiliary water pressure is located near the outlet of the auxiliary water pump. Low auxiliary water pressure will activate an alarm.

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A low level of coolant can cause an alarm or a shutdown. To correct the condition, add coolant to the cooling system. Investigate the cause of the coolant loss.

Illustration 49

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Oil mist detector The concentration of oil mist in the crankcase is monitored with an oil mist detector. A high concentration of oil mist can activate an alarm or a shutdown.

Illustration 52

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Sensor for air restriction Air restriction is measured between the air cleaner and the turbocharger. The pressure sensor detects the air filter differential pressure. A high differential pressure will cause an alarm. This alarm is typically caused by a dirty air filter.

Engine Protective Systems Illustration 50

g00510417

Top view of a liquid detector in the water temperature regulator housing A liquid detector may be installed in the water temperature regulator housing or in a remote water line. The detector helps to monitor the level of coolant in the cooling system.

Typically, engine protective systems include these components: control panel, gauge panel, junction box, contactor and transducer panel, wiring harness, relays, thermocouples and resistive temperature devices. Control panel – This panel contains the start/stop controls. This panel often contains the relay control or the programmable logic control that provides protection for the engine. This panel is not mounted on the engine. Gauge panel – Primarily, these three types of gauge panels are available: mechanical, electrical and computer display. Some gauge panels are a combination of all three types. The most common type is mechanical. Tubing from the engine sends the input to the mechanical pressure gauges. Traditional capillary tubes are used for the mechanical temperature gauges. Electrical gauges use a sending unit with variable resistance or a 4 to 20 mA signal. The computer display is used for systems with programmable logic controllers. The computer display uses thermocouples, resistance temperature detectors, and 4 to 20 mA transducers.

Illustration 51

Coolant level switch on an expansion tank A coolant level switch may be installed on an expansion tank.

g00510420

Junction box – The junction box provides a common location for all of the wiring connections. The junction box is mounted on the engine or on an accessory module. Contactor and Transducer Panel – This panel contains some sensors that primarily detect the different engine pressures such as oil pressure, boost pressure, and other sensors. The sensors are

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49 Features and Controls Sensors and Electrical Components

connected to contactors or transducers. This panel is sometimes mounted on the engine. Contactor – A contactor is a switch that is controlled by temperature or pressure. The temperature or pressure that triggers the switch is set to a critical setpoint. If the setpoint is reached, an alarm or a shutdown will be activated. Transducer – A transducer converts a mechanical stimulus into an electrical signal. An external power source is required. Relay – A relay is an electromechanical device which uses a relatively small current to control an electromagnet. The electromagnet activates electrical contacts. The contacts open and the contacts close in order to switch larger electrical currents. Thermocouple – This device is used for monitoring temperature. A thermocouple has two different metals that are connected. A small voltage is generated when the two metals are heated. The voltage is interpreted by an electronic device in order to determine the temperature. Resistive temperature detector (RTD) – This device is used for monitoring temperature. Temperature effects the electrical resistance of wiring. When the wire is heated, the resistance of the RTD increases. When the wire is cooled, the resistance of the RTD decreases. A device measures the resistance in order to help determine the temperature. Wiring harness – The wiring harness connects the engine sensors to the junction box. Setpoint – A setpoint is a critical limit of an operating parameter. A setpoint can be a temperature, a pressure, a level, a speed, and others. An alarm or a shutdown is activated if an operating parameter reaches a setpoint.

Illustration 53

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Contactor and transducer panel For C280 Series Engines, the following two types of controls for protective systems are available:

• Programmable logic • Relay control An example of a system with programmable logic is the Marine Monitoring System. Programmable systems are often designed for specific installations. All of the systems that have relay control are designed for specific installations. Refer to this Operation and Maintenance Manual, “Control Panel” section for additional information.

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Engine Starting Before Starting Engine

Engine Starting

Engine Protective System Perform a lamp test for the alarm system. i05389585

Before Starting Engine

Reset all of the devices that may prevent the engine from starting:

SMCS Code: 1000; 1400; 1450

• Air shutoff

Perform the required daily maintenance and other periodic maintenance before starting the engine. This maintenance can prevent major repairs at a later date. See this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

• Control panel

Walk-Around Inspection

Fuel System

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 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.

To obtain maximum service life for your engine, make a thorough inspection before starting the engine. Make a walk-around inspection of the installation. Look for items such as oil or coolant leaks, loose bolts, and trash buildup. Remove any trash. Make repairs, if necessary.

• Inspect the fuel lines for loose fittings and leaks. Ensure that the fuel lines are properly clamped.

• The guards must be in the proper place. Repair damaged guards or replace missing guards.

• Overspeed switch Pumping air into the pneumatic linkage of the fuel rack shutoff may be necessary.

• Open all fuel supply lines and fuel return lines.

• Check the fuel supply. Keep fuel tanks nearly full. Partially filled tanks will collect moisture. Do not overfill the fuel tank. When fuel is warm, fuel expands and the fuel may overflow. • Drain water and sediment from the fuel tank.

• Ensure that the areas around the rotating parts are clear.

• Drain water and sediment from the primary filter/ water separators.

Air Inlet System

Lubrication System

Ensure the following conditions: • The air inlet piping and the air filters are in place. • All clamps and connections are secure.

Cooling System • Inspect the cooling system for leaks or loose connections. Inspect the condition of all the pipes for the cooling system. Ensure that the connections are properly clamped. • Inspect the water pumps for evidence of leaks. • Check the coolant level. Add coolant, if necessary. For information on the proper coolant to use, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

Illustration 54

Oil level gauge (1) “ADD” mark (2) (FULL) “mark”

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51 Engine Starting Before Starting Engine

• Check the engine crankcase oil level. Maintain the oil level between the “ADD” and “FULL ” marks on the “ENGINE STOPPED WITH OIL COLD” side of the oil level gauge. For information on the proper oil to use, see the Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

Fluids may escape from the cylinder pressure valves at high velocity during this procedure and cause personal injury. Always stay clear and keep personnel away from the cylinder pressure valves during this procedure.

• Check for leaks at the following components: crankshaft seals, crankcase, oil filters, oil gallery plugs, sensors and valve covers. • Inspect the tubes, tee pieces, and clamps on the crankcase breathers.

Starting System • Ensure that the engine control system allows the engine to be started from the local position. • Ensure that the engine will be started at low idle rpm. • Ensure that the barring device is fully disengaged. • Drain moisture and sediment from the air tank and from any other air piping. • Check the air pressure for starting. Open the air supply valve. Note: If the engine is equipped with a system for external support, prepare the system before starting the engine. Ensure that all of the systems for engine support are enabled. Perform all prestart checks for the control system.

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. 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. Do not start the engine or move any controls while a “DO NOT OPERATE” warning tag is attached to the start switch or other controls. Do not start the engine or move any controls if a similar warning tag is attached to the start switch or controls. Ensure that no one will be endangered before the engine is started and when the engine is started. Perform the procedures that are described in this Operation and Maintenance Manual, “Before Starting Engine” topic (Operation Section).

Purge the Cylinders

1. Ensure that the driven equipment is disengaged. Note: Two typical control panels are illustrated. If the engine is equipped with a different control panel, follow the instructions that are provided by the OEM of the control panel.

Illustration 55

Cylinder pressure valve (Keine valve) (1) Cap nut (2) Valve cock

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Engine Starting Before Starting Engine

Illustration 56

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Illustration 58

g00275016

Fuel priming pump

(1) “ENGINE CONTROL” switch

4. Turn the handle of the fuel priming pump clockwise in order to prime the fuel system. Turn the handle until a resistance to the fuel flow is felt. If the engine is equipped with an electric fuel priming pump, activate the electric fuel priming pump. Operate the electric fuel priming pump until fuel pressure is indicated on the fuel pressure gauge.

Illustration 57

g03404149

(2) “LOCAL THROTTLE” switch (3) “STARTING MOTOR” switch (4) “CRANK OVERRIDE” switch (5) “RUN/STOP” switch (6) “LOW IDLE” switch (7) “ENGINE PROTECTION OVERRIDE” switch (8) “RAPID START/STOP” switch (9) “MANUAL PRELUBE” switch (10) “OIL MIST OVERRIDE” switch

2. Turn “OFF/RESET, LOCAL, and REMOTE” switch (1) to the “LOCAL” position. NOTICE The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing surfaces. 3. Turn “MANUAL PRELUBE” switch (9) to the “ON (I)” position. Allow the prelube pump to operate. When the prelube indicator illuminates, the engine has sufficient prelube to start.

5. Immediately after engine start-up, ensure that oil pressure and fuel pressure are indicated on the gauges. Allow the engine to idle for 3 to 5 minutes. The engine speed should stabilize at low idle rpm. Check all of the pressure gauges. Inspect the engine for leaks and listen for unusual noises. When all systems are normal, the rpm may be increased. Ensure that the oil pressure and the fuel pressure are in the normal ranges. After the engine has started and the warm-up is complete, the engine can be operated at low rpm and low load. The engine will reach normal operating temperature faster if the engine is operated at low rpm and with a low-power demand. This procedure is more effective than idling the engine with no load. The engine should reach normal operating temperature in a few minutes.

Starting the Engine After an Overhaul or Major Repair Use the following guidelines for operation and maintenance after an overhaul or a major repair. This procedure will ensure that the engine is functioning correctly. The procedure for start-up requires approximately1hour and 45 minutes. 1. Perform the procedures that are described in this Operation and Maintenance Manual, “Before Starting Engine” topic (Operation Section).

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53 Engine Starting Cold Weather Starting

2. Operate the jacket water heaters and the prelube pump. Allow the lubricating oil to circulate for 1/2 hour. 3. During prelube pump operation, use the barring device to rotate the crankshaft for a minimum of four revolutions. 4. Start the engine. Operate the engine at low idle rpm for 15 minutes. Allow the engine temperature to rise. Check for the correct temperatures and pressures. Inspect the installation for leaks. 5. Do not apply the load. Increase the engine rpm to high idle rpm for 5 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks. 6. Shut off the engine. Remove the side covers. Measure the temperature of the bearings with a 123-6700 Laser Infrared Thermometer. Ensure that the large ends of the connecting rod bearings move freely. Visually inspect the piston skirts, cylinder liners, and bearings for any abnormal signs such as flaking and/or scuffing. If the appearance of the components is satisfactory, install the side covers. 7. Start the engine. Operate the engine at low idle rpm for 5 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks. 8. The temperatures will not stabilize for some time because the engine will be operating without a load. To warm the engine up to “normal” operating temperature, increase the engine rpm to high idle rpm for 5 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

11. Increase the load to the full rated load. Operate the engine with this load for 15 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks. If all of the temperatures and the pressures are acceptable, the engine can be returned service.

Maintenance Procedures After an Overhaul or Major Repair After the initial start-up, See the maintenance procedures that are in this Operation and Maintenance Manual (Maintenance Section). Table 11 Maintenance Procedures After an Overhaul or Major Repair Interval After the start-up procedure

Maintenance Procedure Obtain an oil sample and analysis. Remove at least one oil filter element from each oil filter housing. Cut the element open. Inspect the filter material for debris.

100 operating hours

Obtain an oil sample and analysis.

500 operating hours

Replace all of the oil filter elements. Cut the used elements open. Inspect the filter material for debris. Perform the procedures that are described in this Operation and Maintenance Manual, “Engine Valve Lash - Check/Adjust” topic (Maintenance Section).

i00972001

Cold Weather Starting

Note: Monitor the cooling system temperatures in order to ensure that the water to the engine is being properly cooled. Observe the water temperature of the aftercooler and oil cooler system. The temperature should not exceed 50 °C (122 °F). 9. Apply 25 percent of the rated load. Operate the engine with this load for 15 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

10. Increase the load to 50 percent of the rated load. Operate the engine with this load for 15 minutes. Check for the correct temperatures and pressures. Inspect the installation for leaks.

For temperatures below 0 °C (32 °F), a jacket water heater and a lube oil heater are necessary. Also, a fuel heater will maintain the temperature of the fuel above the cloud point.

The engine can be started normally at temperatures above 0 °C (32 °F). Heating aids are required in order to start the engine in lower temperatures. 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 .

54 Engine Starting Cold Weather Starting

Jacket water heaters are available as optional equipment. Jacket water heaters are recommended for improving startability in cold temperatures. These heaters are recommended for all installations that have automatic starting. Oil viscosity affects the amount of torque that is needed to crank the engine. Oil temperatures below 10 °C (50 °F) require cranking torque that is excessive. For applications that require rapid start-up and loading, oil heaters are recommended for heating the lube oil to 10 °C (50 °F) when the ambient conditions are below this temperature. To start the engine at colder temperatures, a larger volume of starting air and/or a higher air pressure is necessary. Ensure a sufficient supply of air pressure for cold weather starting. Do not exceed the maximum air pressure for the starting motor. See the engine's Application and Installation Guide for information on cranking torque and air starting motors at various temperatures. Condensation of vapor in the air supply can freeze in cold weather. Ice that forms in the supply lines will restrict the air supply. If particles of ice enter the inlet of the starting motor, the starting motor can be damaged. Dry air is required for cold weather in order to help prevent ice from forming in the supply lines. A water separator is recommended in order to remove vapor from compressed air prior to the air storage tank. If the engine operates in a humid environment with temperatures that are below 0 °C (32 °F), an air dryer is needed in order to prevent condensation from freezing in the piping. If the starting air is also used for pneumatic controls, an air dryer is essential. Consult your Caterpillar dealer for more information on the starting aids that are available for cold weather starting.

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55

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Engine Starting Starting the Engine

i05315572

Starting the Engine SMCS Code: 1000; 1450

Illustration 59

g02176581

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:

NOTICE If pressurized air is not supplied to the air shutoff, the shutoff will not operate in an emergency situation. Do not shut off the air supply to the air shutoff. Ensure that the air shutoff has a supply of pressurized air.

• 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.

Note: Some air starting motors are connected to the same source of compressed air that activates the air shutoff. 1. Turn the air supply to the starting motor OFF.

• If the “START” button is configured as HOLD, press and hold the “START” button until the engine starts. i00972993

After Starting Engine SMCS Code: 1000

DO NOT apply a load to the engine or increase the rpm until the oil pressure gauge indicates a minimum of 160 kPa (23 psi) at low idle rpm. Check the gauges during the warm-up. Complete a walk-around inspection. Check for leaks and unusual noises. 2. Ensure that the gauges indicate normal ranges for the engine rpm. After verifying that the engine systems are normal, engage the driven equipment.

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Engine Starting After Starting Engine

Begin operating the engine at low load. Continue to check the gauges and the driven equipment. Operate the engine at a low load until the engine reaches normal operating temperatures. 3. After normal oil pressure is reached and the jacket water temperature reaches 65 °C (149 °F), the engine may be operated at full load. Increase the load, as needed.

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Engine Operation Engine Operation

Engine Operation

i00531763

i05292546

Engine Operation SMCS Code: 1000 Proper operation and maintenance are key factors in attaining the maximum service life and economy for the engine. Follow the instructions in this Operation and Maintenance Manual in order to minimize operating costs and maximize the service life of the engine. Observe the gauges frequently while the engine is operating. Record the data from the gauges in a log regularly. Compare the data to the specifications for normal engine operation. Comparing the data over time will help to detect changes in engine performance. Investigate any significant change in the gauge readings.

Operating the Engine and the Driven Equipment Check the gauges and the driven equipment frequently while the engine is operating under a load. The engine can be operated for extended periods of time at full load.

Partial Load Operation Extended operation at reduced load (less than 30%) may cause problems with the engine: • Increased oil consumption and carbon buildup in the cylinders • Fuel slobber through the exhaust system which may result in a loss of power and/or poor performance Apply a full load to the engine on an hourly basis or operate the engine at a load level that is greater than 30%. These actions will maintain engine efficiency and performance by burning excess carbon from the cylinders. When possible, before shutting down the engine after running the engine for extended periods at low load, apply a full load for approximately 30 minutes. Running the engine at full load allows excess carbon to burn from the following components: cylinders, pistons and valves.

Partial Load Operation In Cold Weather Operation of the jacket water heater is recommended if the engine is operating at a low load in extreme cold.

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. • When possible, utilize the heat of the jacket water system and the heat from the exhaust system. • Keep keel coolers, 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.

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Cold Weather Operation Fuel and the Effect from Cold Weather

Cold Weather Operation

• Starting aids • Engine oil pan heaters

i05264084

Fuel and the Effect from Cold Weather SMCS Code: 1000; 1250; 1280 The following fuels are the grades that are available for Cat engines:

• Engine coolant heaters • Fuel heaters • Fuel line insulation For more information on cold-weather operation, see Special Publication, SEBU5898, “Cold Weather Recommendations”.

• No. 1 • No. 2

i00932529

• Blend of No. 1 and No. 2

Fuel Related Components in Cold Weather

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.

SMCS Code: 1000; 1250; 1280

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. 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:

Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after operating the engine. Fuel tanks should have a 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. Drain the water and sediment in order to help prevent freezing.

Fuel Filters A primary fuel filter and/or a water separator is recommended between the fuel tank and the secondary fuel filter. The micron rating and the location of a primary fuel filter is important in cold weather operation. The primary fuel filter and the fuel supply line are the most common components that are affected by cold fuel. The micron rating of the primary fuel filter should only be low enough to protect the fuel transfer pump. A primary filter with a low micron rating can be plugged by wax crystals in cold weather. Note: Refer to the Parts Manual for the engine in order to determine the part numbers of the fuel filters.

Fuel Heaters Fuel heaters help prevent plugging of the fuel filters due to waxing in cold weather. Install fuel heaters so that the fuel is heated before the fuel enters the primary fuel filters.

SEBU7876

59 Cold Weather Operation Fuel Related Components in Cold Weather

Use a fuel heater that is mechanically simple but adequate for the application. The fuel heater should also prevent the fuel from overheating. High fuel temperatures reduce the performance of the engine. Choose a fuel heater with a surface for heating that is as large as possible but also practical. Small heaters can be too hot because of a limited surface area. For warm weather, disconnect the fuel heater or deactivate the fuel heater. Heat exchanger type fuel heaters should have a bypass provision in order to prevent the fuel from overheating in warm weather. Only use thermostatically controlled fuel heaters or self-regulated fuel heaters with this engine. A fuel heater that is not thermostatically controlled can heat the fuel above 65 °C (149 °F). A loss of engine power can occur if the fuel supply temperature exceeds 29 °C (85 °F). For further information on fuel heaters, consult your Caterpillar dealer.

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Engine Stopping Emergency Stopping

Engine Stopping i01373213

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 system that provides external support to the engine is secured after the engine is stopped. NOTICE Do not start the engine until the problem necessitating the emergency stop has been located and corrected.

Emergency Stop Button

Illustration 60

g00104303

Typical emergency stop button The emergency stop button is in the OUT position for normal engine operation. For an emergency stop, press the emergency stop button. The button will lock in place. The engine will not start when the button is locked. To reset the button, turn the button clockwise. The spring-loaded button will return to the OUT position. Use of the emergency stop button will shut off the fuel. Note: Some marine engines are equipped with an emergency stop button that must be pulled in order to stop the engine.

SEBU7876

61 Engine Stopping Manual Stop Procedure

i05315574

Manual Stop Procedure SMCS Code: 1000; 7418

Illustration 61

g02176599

62

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Engine Stopping After Stopping Engine

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. i02508920

After Stopping Engine SMCS Code: 1000 • Check the engine crankcase oil level. Maintain the oil level between the “ADD” and “FULL” marks on the “ENGINE STOPPED” side of the oil level gauge. • If necessary, perform minor adjustments. Repair any leaks and tighten loose bolts. • Note the service hour reading. Perform the maintenance that is scheduled in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). NOTICE Only use antifreeze/coolant mixtures recommended in the Refill Capacities and Recommendations section of this manual. Failure to do so can cause engine damage. • Allow the engine to cool. Check the coolant level. • If freezing temperatures are expected, check the coolant for protection against freezing. The cooling system must be protected against freezing to the lowest expected outside temperature. Add the proper coolant/water mixture, if necessary. • Perform all required periodic maintenance on all driven equipment. Refer to the instructions that are provided by the OEM of the driven equipment.

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63 Maintenance Section Refill Capacities

Maintenance Section Refill Capacities i04810854

Refill Capacities SMCS Code: 1000; 1348; 1395; 7560

Lubricant Capacities The capacity of the engine lubrication system includes the capacity of the oil filters that are installed at the factory. Auxiliary oil filter systems (if equipped) will require additional oil. Refer to the specifications that are provided by the OEM of the auxiliary oil filter system. Table 12 Approximate Refill Capacities for C280 Series Engine Lubrication Systems Compartment or System

C280-06 Engines

C280-08 Engines

C280-12 Engines

C280-16 Engines

Industrial Engines and Generator Set Engines Standard oil pan

880 L (229 US gal)

1112 L (289 US gal)

1302 L (339 US gal)

1677 L (443 US gal)

943 L (245 US gal)

1091 L (284 US gal)

Marine Engines Engine crankcase (1) (1)

731 L (190 US gal)

795 L (207 US gal)

Zero degree installation

Cooling System Capacities To maintain the cooling system, the total cooling system capacity must be determined. The total cooling system capacity will vary between individual installations. The total cooling system capacity can include the following components: engine, expansion tank, heat exchanger, radiator, keel cooler and piping. Refer to the specifications that are provided by Caterpillar or the OEM of the installation. Record the total cooling system capacity in the appropriate Table. Table 13 Approximate Refill Capacities for C280 Series Engine Cooling Systems Compartment or System

C280-06 Engine

C280-08 Engine

C280-12 Engine

C280-16 Engine

Engine

400 L (105 US gal)

530 L (140 US gal)

800 L (210 US gal)

1060 L (280 US gal)

Standard expansion tank

300 L (80 US gal)

300 L (80 US gal)

300 L (80 US gal)

300 L (80 US gal)

Optional expansion tank

475 L (125 US gal)

475 L (125 US gal)

475 L (125 US gal)

475 L (125 US gal)

Piping (expansion tank) (1)

150 L (40 US gal)

150 L (40 US gal)

200 L (55 US gal)

200 L (55 US gal)

Heat exchanger

50 L (15 US gal)

50 L (15 US gal)

100 L (30 US gal)

100 L (30 US gal)

Total cooling system (1)

The capacity of the piping is typical for generator set applications.

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Refill Capacities Fluid Recommendations

i05377305

Fluid Recommendations

NOTICE Caterpillar does not warrant the quality or performance of non-Cat fluids.

SMCS Code: 1280; 1348; 1395; 7560 Refer to this Operation and Maintenance Manual, “Severe Service Application” for information about operating an engine in a severe service application.

The three current Caterpillar 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 interval for changing the coolant varies depending on the type of coolant being replaced. Refer to this article, “Coolant Recommendations”, for the intervals for changing the coolant.

A commercial oil must meet the following standards to be considered an equivalent of a Cat Diesel Engine Oil :

Diesel Engine Oil

Table 15 Cat Engine Crankcase Fluids (ECF) Definitions

For more information, refer to Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations.

Cat Performance Requirement

Cat ECF Specifications Requirements

Cat ECF-3

API CJ-4 Oil Category performance requirements

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 Cat 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. Due to significant variations in the quality and in the performance of commercially available oils, Caterpillar makes the following recommendations: Table 14

Cat Lubricants

Viscosity Grade SAE 15W-40

API CI-4 / CI-4 PLUS Oil Category performance requirements Cat ECF-2

Passing standard Cat C13 engine test per API requirements Oils of sulfated ash > 1.50 percent are not allowed API CH-4 Oil Category performance requirements

Cat ECF-1-a

For oils that are between 1.30 percent and 1.50 percent sulfated ash, passing one additional Cat 1P SCOTE test (ASTM D6681) is required Oils of sulfated ash > 1.50 percent are not allowed

Cat DEO-ULS Diesel Engine Oil-Ultra Low Sulfur

SAE 10W-30 Cat DEO-ULS SYN

SAE 5W-40

Cat Cold Weather DEO-ULS

SAE 0W-40 SAE 15W-40

Cat DEO

Diesel Engine Oil

SAE 10W-30 Cat DEO SYN

SAE 5W-40

Note: Cat DEO and Cat DEO-ULS multigrade oils are the preferred oils for use in this Cat Diesel Engine.

Commercial Oil Note: Non-Cat commercial oils are second choice oils for your engine.

In selecting oil for any engine application, both of the following must be satisfied: the oil viscosity and the category of oil performance or the specification for oil performance . 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 following temperatures: minimum ambient temperature during cold engine start-up and maximum ambient temperature during engine operation. Refer to Table 16 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine. Refer to Table 16 (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.

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65 Refill Capacities Fluid Recommendations

Table 16

Table 17

Lubricant Viscosities for Ambient Temperatures for Cat Diesel Engines Oil Type and Performance Requirements

Viscosity Grade

Min

Max

Min

Max

Cat ECF-1-a Cat ECF-2 Cat ECF-3

SAE 0W-30

−40

30

−40

86

Cat Cold Weather DEO-ULS Cat ECF-1-a Cat ECF-2 Cat ECF-3

SAE 0W-40

Cat DEO-ULS Cat ECF-1-a Cat ECF-2 Cat ECF-3

SAE 5W-30

Cat DEO-ULS SYN Cat DEO Cat ECF-1-a Cat ECF-2 Cat ECF-3

SAE 5W-40

Cat ECF-1-a Cat ECF-2 Cat ECF-3 Cat DEO-ULS Cat DEO

°C

−40

°F

40

−40

TBN recommendations for applications in Cat engines (1)

Fuel Sulfur Level percent (ppm)

Cat Engine Oils

TBN of Commercial Engine Oils

≤0.05 percent (≤500 ppm)

Cat DEO-ULS Cat DEO

Min 7

0. 1- 0.05 percent (1000-500 ppm)

Cat DEO-ULS Cat DEO

Min 7

Above 0.1 percent (above 1000 ppm)(2)

Cat DEO(3)

Min 10

104 (1)

−30

30

−22

86

(2) (3)

−30

50

−22

122

SAE 10W-30 −18

40

0

104

SAE 10W-40 −18

50

0

122

SAE 15W-40 −9.5

50

15

122

When using fuel with 0.10% sulfur (1000 ppm) or higher, refer to this Operation and Maintenance Manual, “Severe Service Application” for more information. For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm), refer to TBN and engine oil guidelines given in this section. Cat DEO-ULS may be used if an oil analysis program is followed. Base the oil change interval on the analysis.

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

Note: A cold soaked start occurs when the engine has not been operated recently, allowing the oil to become more viscous due to cooler ambient temperatures. 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 depending on factors such as parasitic load.

Total Base Number (TBN) and Fuel Sulfur Levels The use of Cat S·O·S Services oil analysis is recommended strongly for determining oil life. The minimum required Total Base Number (TBN) for oil depends on the fuel sulfur level. The TBN for new oil is typically determined by the ASTM D2896 procedure. For direct injection engines that use distillate fuel, the following guidelines apply:

• 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 the crankcase. 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.

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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, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations in order to obtain additional information about S·O·S Services oil analysis. You can also contact your local Cat dealer.

Fuel Note: Caterpillar strongly recommends the filtration of fuel through a fuel filter with a rating of four microns (c) absolute or less. This filtration should be located on the device that dispenses the fuel to the fuel tank for the engine. This filtration should also be located on the device that dispenses fuel from the bulk storage tank. Series filtration is recommended. NOTICE In order to meet expected fuel system component life, 4 micron(c) absolute or less secondary fuel filtration is required for all Cat Diesel Engines that are equipped with unit injected fuel systems. All current Cat Diesel Engines are factory equipped with Cat Advanced Efficiency 4 micron(c) absolute fuel filters. Caterpillar does not warrant the quality or performance of non-Cat fluids and filters.

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 “Cat Specification for Distillate Diesel Fuel for Off-Highway Diesel Engines” found in this Special Publication, “Distillate Diesel Fuel” article. 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 a case by case basis. A complete fuel analysis is required. Consult your Cat dealer for further information. NOTICE The footnotes are a key part of the “Caterpillar Specification for Distillate Diesel Fuel for Off-Highway Diesel Engines” Table. Read ALL of the footnotes. Table 18

Caterpillar Specification for Distillate Fuel for Nonroad Diesel Engines Specifications

Requirements

ASTM Test

ISO Test

Aromatics

35% maximum

D1319

ISO 3837

Ash

0.01% maximum (weight)

D482

ISO 6245

Carbon Residue on 0.35% maximum (weight) 10% Bottoms

D524

ISO 4262

D613 or D6890

ISO 5165

D2500

ISO 3015

D130

ISO 2160

D86

ISO 3405

D93

ISO 2719

40 minimum (DI engines) Cetane Number (1) 35 minimum (PC engines)

Diesel engines can 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. 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.

Cloud Point

The cloud point must not exceed the lowest expected ambient temperature.

Copper Strip Corrosion

No. 3 maximum

For more information, refer to Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations or consult your Cat dealer for further information.

Distillation

10% at 282 °C (540 °F) maximum

Flash Point

90% at 360 °C (680 °F) maximum legal limit

Diesel Distillate Fuel 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.

(continued)

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(Table 18, contd)

Caterpillar Specification for Distillate Fuel for Nonroad Diesel Engines Specifications

Thermal Stability

API Gravity (2)

Requirements Minimum of 80% reflectance after aging for 180 minutes at 150 °C (302 °F)

ASTM Test

D6468

No equivalent test

D287

No equivalent test

30 minimum 45 maximum

Pour Point

Sulfur

ISO Test

6 °C (10 °F) minimum below ambient temperature

D97

ISO 3016

(3) (4) (5)

D5453 or D2622

ISO 20846 or ISO 20884

1.4 cSt minimum and 20.0 cSt maximum as delivered to the fuel injection pumps Kinematic Viscosity

Biodiesel blend stock Caterpillar biodiesel specification, ASTM D6751 or EN14214 D1796 or D2709

ISO 3734

Water

0.05% maximum

D6304

No equivalent test

Sediment

0.05% maximum (weight)

D473

ISO 3735

10 mg per 100 mL maximum

D381

ISO 6246

0.52 mm (0.0205 inch) maximum at 60 °C (140 °F)

D6079

No equivalent test

(1)

(2)

(3)

Note: A complete Cat S·O·S Services oil analysis program is recommended strongly when using biodiesel blends above 5 percent.

-

0.05% maximum

Lubricity

A biodiesel blend of up to 20 percent may be used in the engine when the fuel blend meets the recommendations in table 19 and meets the recommendations in Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations.

Biodiesel Blends for Cat Commercial Engines -

Water and Sediment

(6)

Biodiesel

Table 19

1.4 cSt minimum and 4.5 cSt maximum as delivered to the rotary fuel injection pumps

Gums and Resins

(Table 18, contd) (4) Certain Cat fuel systems and engine components can operate on fuel with a maximum sulfur content of 3%. Contact your Cat dealer for guidance about appropriate maintenance intervals and fluids for engines operating on fuel with sulfur levels between 0.1% and 3%. (5) An engine which operates on fuel with 0.1% (1000 ppm) of sulfur or more is operating in a severe service application. Refer to this Operation and Maintenance Manual, “Severe Service Application” for information about operating an engine in a severe service application. (6) Follow the test conditions and procedures for gasoline (motor).

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/m3 (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/ m3, and for the maximum API gravity of 45 is 801.3 kg/m3. ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 engines and engines with aftertreatment devices.

(continued)

Final blend

Distillate diesel fuel used for blend

Caterpillar distillate B20: ASTM D7467 diesel fuel specificaand API gravity 30tion, ASTM D975 or 45 EN590

Fuel Additives Cat Diesel Fuel Conditioner Cat Diesel Fuel Conditioner is a proprietary formulation that has been extensively tested for use with distillate diesel fuels for use in Cat Diesel Engines. Cat Diesel Fuel Conditioner is a high performance diesel fuel conditioner. Cat Diesel Fuel Conditioner is for use with lower quality fuels that do not meet the minimum requirements of any of the following: • “Caterpillar Specification for Distillate Diesel Fuel” • National Conference on Weights and Measures (NCWM) Premium Diesel definition (refer to the 2004 or newer National Institute of Standards & Technology (NIST) Handbook). • EN590 (non-arctic) • ASTM D975 Cat Diesel Fuel Conditioner is the only fuel conditioner/additive available to the end user that is tested and approved by Caterpillar for use in Cat Diesel Engines.

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Refer to Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations for information about the use of Cat Diesel Fuel Conditioner.

Note: For best results, your fuel supplier should treat the fuel when additives are needed.

Cat Diesel Fuel System Cleaner

Note: Refer to Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations for complete information about the proper fluids for use in the cooling system.

Note: Cat Diesel Fuel System Cleaner is the only fuel system cleaner available to the end user that is tested and approved by Caterpillar for use in Cat Diesel Engines. Cat Diesel Fuel System Cleaner is a proven high performance detergent product designed specifically for cleaning deposits that form in the fuel system. Deposits in the fuel system reduce system performance and can increase fuel consumption. Cat Diesel Fuel System Cleaner addresses the deposits formed due to the use of degraded diesel fuel, poor quality diesel fuel, and diesel fuel containing high quantities of high molecular weight compounds. Cat Diesel Fuel System Cleaner addresses deposits formed due to the use of biodiesel, biodiesel blends, and biodiesel that does not meet the appropriate quality specifications. Continued use of Cat Diesel Fuel System Cleaner is proven to inhibit the growth of new deposits. Caterpillar strongly recommends that Cat Diesel Fuel System Cleaner be used with biodiesel and biodiesel blends. Cat Diesel Fuel System Cleaner is suitable for use with biodiesel/biodiesel blends that meet Caterpillar biodiesel recommendations and requirements. Not all fuel cleaners are suitable for use with biodiesel/biodiesel blends. Read and follow all applicable label usage instructions. Also, refer to Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations, article and also refer to the “Biodiesel” article, which includes Caterpillar biodiesel recommendations and requirements.

Aftermarket Fuel Additives There are many different types of fuel additives that are available to use. Caterpillar does not generally recommend the use of fuel additives. In special circumstances, Caterpillar recognizes the need for fuel additives. Use fuel additives with caution. The additive may not be compatible with the fuel. Some additives may precipitate. This action causes deposits in the fuel system. The deposits may cause seizure. Some additives may plug fuel filters. Some additives may be corrosive, and some additives may be harmful to the elastomers in the fuel system. Some additives may damage emission control systems. Some additives may raise fuel sulfur levels above the maximum levels that are allowed by the following agencies: EPA and other regulatory agencies. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can make recommendations for additives to use and for the proper level of treatment.

Cooling System

The cooling system operates under pressure which is controlled by the radiator pressure cap. Removing the cap while the system is hot may allow the escape of hot coolant and steam, causing serious burns. Before you remove the radiator cap, allow the system to cool. Use a thick cloth and turn the radiator cap slowly to the first stop to allow pressure to escape before fully removing the cap. Avoid contact with coolant. NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first. NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely in order to prevent damage caused by freezing coolant. 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.

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Coolant Recommendations A Cat Diesel Engine equipped with air-to-air aftercooling (ATAAC) requires a minimum of 30 percent glycol to help prevent water pump cavitation. Table 20

Coolant Recommendations for Cat Diesel Engines Recommendations

Product

Service Hours(1) (2) (3)

Required Maintenance

Preferred

Cat ELC and Cat ELI

12000 hours or 6 years

Add Cat ELC Extender at 6000 service hours or one half of service life

Min requirements

Cat EC-1 specification and ASTM D6210 and Organic Additive Technology (OAT) based on a combination of a monocarboxylic acid and a dicarboxylic acid Phosphate, borate, and silicate free Tolyltriazole: minimum typical concnetration of 900 ppm Nitrite: minimum typical concentration of 500 ppm in new coolants


Add Extender at 3000 service hours or one half of service life

Cat DEAC


SCA at maintenance intervals

Cat SCA in water



ASTM D6210 and Nitrite (as NO2) concentration: Minimum of 1200 Min requirements for fully forppm (70 grains/US gal) and maximum of 2400 ppm mulated Heavy Duty Commer(140 grains/US gal) cial coolants Silicon concentration: minimum of 100 ppm and maximum of 275 ppm



ASTM D4985 and(1) Nitrite (as NO2) concentration: Minimum of 1200 Min requirements for Commerppm (70 grains/US gal) and maximum of 2400 ppm cial coolants requiring SCA (140 grains/US gal) precharge Silicon concentration: minimum of 100 ppm and maximum of 275 ppm

3000 hours or 1 year

SCA at initial fill and SCA at maintenance intervals

Min requirements for SCA and water

3000 hours or 1 year

Per manufacturer recommendations

Acceptable

(1) (2) (3)

Commercial supplemental coolant additive and water

New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets Reagent 4 ASTM D1193 requirements. Maintain the in-service coolant at the given limits. When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S Services Level 2 coolant sampling analysis.

Table 21

Special Requirements Cat C7-C32 Marine Engines with heat exchangers Cat diesel engines equipped with air-to-air aftercooling (ATAAC)

Minimum of 30% glycol is required. 50% Glycol is recommended. Water alone or water with SCA or with ELI is NOT allowed.

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NOTICE Use Only Approved SCAs and Extenders Conventional coolants require the maintenance addition of SCA throughout the expected life of the coolants. Do NOT use an SCA with a coolant unless approved specifically by the coolant supplier. The coolant manufacturer is responsible for ensuring compatibility and acceptable performance. To help ensure expected performance, EC-1 coolants require the one time maintenance addition of an extender at coolant service mid-life. Do not use an extender with a coolant unless the extender has been approved specifically for use by the coolant manufacturer. The coolant manufacturer is responsible for ensuring compatibility and acceptable performance. Failure to follow these recommendations can result in shortened cooling system component life. Cat ELC can be recycled into conventional coolants. For more information, refer to Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations.

S·O·S Services 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. Cat 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. Table 22

Recommended Interval Type of Level 1 Level 2 Coolant Cat DEAC Cat SCA Conventional HeavyDuty Coolants Cat ELC Cat ELI Commercial EC-1 Coolants (1)

Every 250 hours

Yearly(1)

S·O·S Services Coolant Analysis (Level 1) A coolant analysis (Level 1) is a test of the properties of the coolant. The following properties of the coolant are tested: • Glycol concentration for freeze protection and boil protection • Ability to protect from erosion and corrosion • pH • Conductivity • Visual analysis • Odor analysis The results are reported, and appropriate recommendations are made.

S·O·S Services Coolant Analysis (Level 2) A coolant analysis (Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the cooling system. 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 The results are reported, and appropriate recommendations are made.

Optional(1)

Yearly(1)

The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified.

Note: Check the SCA (Supplemental Coolant Additive) of the conventional coolant at every oil change or at every 250 hours. Perform this check at the interval that occurs first.

For more information on S·O·S coolant analysis, consult your Cat dealer.

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Greases If necessary, choose a single grease, always choose a grease that meets or exceeds the requirements of the most demanding application. Remember that the products which barely meet the minimum performance requirements can be expected to produce the minimum lives of your parts. False economy is being used if a grease is purchased with the lowest cost as the only consideration. Instead, use the grease that yields the lowest total operating cost. The cost should be based on an analysis that includes the costs of parts, labor, downtime, and the cost of the amount of grease that is required. For more information, refer to Special Publication, SEBU7003, Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations.

72 Maintenance Recommendations System Pressure Release

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Maintenance Recommendations

Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system.

Engine Oil i02909163

System Pressure Release

To relieve pressure from the lubricating system, turn off the engine.

SMCS Code: 1250; 1300; 1350; 5050

Coolant System

i05264113

Welding on Engines with Electronic Controls SMCS Code: 1000

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)

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 Cat dealer regarding welding on a chassis frame or rail. Proper welding procedures are necessary in order to avoid damage to the engine 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 Cat 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.

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 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.

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.

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.

This is because of the following differences: • The high pressure fuel lines are constantly charged with high pressure. • 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.

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.

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73 Maintenance Recommendations Welding on Engines with Electronic Controls

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 move back accidentally, and contact any of the ECM pins.

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.

Illustration 62

g01075639

Use the example above. The current flow from the welder to the ground clamp of the welder will not damage 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.

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Maintenance Recommendations Maintenance Interval Schedule

i05378851

When Required

Maintenance Interval Schedule (Standby)

“Centrifugal Oil Filter - Inspect”................................82

SMCS Code: 1000; 4450; 7500

“Engine Air Cleaner Element (Single Element) Inspect/Replace”......................................................94

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. An authorized operator may perform the maintenance items with daily intervals. An authorized operator may perform the maintenance items with intervals of every week. The maintenance that is recommended for all other maintenance intervals must be performed by an authorized service technician or by your Cat dealer. The user is responsible for the performance of all maintenance which includes the following items: performing all adjustments, using proper lubricants, fluids, and filters and replacing old components with new components due to normal wear and aging . Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

“Coolant Extender (ELC) - Add” ..............................87

“Engine Crankcase Breather - Clean” .....................97 “Engine Oil - Change” ..............................................99 “Engine Oil Filter - Change” .................................. 101 “Fuel Analysis - Obtain” ........................................ 109 “Fuel System - Prime”............................................110 “Fuel System Primary Filter (Water Separator) Element - Replace”................................................ 111 “Fuel System Secondary Filter - Replace” ............112 “Metal Particle Detector - Inspect/Clean” ..............115 “Zinc Rods - Inspect/Replace”.............................. 129

Daily

Before each consecutive interval is performed, all maintenance from the previous intervals must be performed.

“Coolant Level - Check”...........................................88

Choose the interval that occurs first in order to determine the correct maintenance interval: fuel consumption, service hours and calendar time . Products that operate in severe operating conditions may require more frequent maintenance.

“Air Starting Motor Lubricator Oil Level - Check”.....80

All of the following will affect the oil change interval: operating conditions, fuel type, oil type and size of the oil sump . Scheduled oil sampling analyzes used oil in order to determine if the oil change interval is suitable for your specific engine. Refer to this Operation and Maintenance Manual, “Engine Oil and Filter - Change” in order to determine the oil change interval that is suitable for your specific engine. To determine the maintenance intervals for the overhauls, refer to this Operation and Maintenance Manual, “Maintenance Recommendations” . Unless other instructions are provided, perform maintenance and perform repairs under the following conditions:

Every Week “Air Tank Moisture and Sediment - Drain” ...............80 “Control Panel - Inspect/Test” ..................................83 “Engine Air Cleaner Service Indicator - Inspect” .....96 “Engine Air Precleaner - Check/Clean” ...................97 “Engine Oil Level - Check”.................................... 104 “Fuel System Primary Filter/Water Separator Drain” .....................................................................112 “Fuel Tank Water and Sediment - Drain” ...............115 “Jacket Water Heater - Check” ..............................115 “Walk-Around Inspection” ..................................... 128

Every 6 Months “Coolant Sample (Level 1) - Obtain”........................89

The starting system is disabled.

Every Year

The engine is stopped.

“Aftercooler Condensation - Drain”..........................77

The generator does not pose an electrical shock hazard.

“Aftercooler Core - Clean/Test”................................78

The generator is disconnected from the load.

“Air Shutoff - Test” ....................................................78 “Air Starting Motor Lubricator Bowl - Clean”............79

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Maintenance Recommendations Maintenance Interval Schedule

“Barring Device - Lubricate”.....................................81 “Coolant Sample (Level 2) - Obtain”........................90 “Coolant Temperature Regulator - Replace” ...........90 “Cooling System Supplemental Coolant Additive (SCA) - Test/Add”.....................................................91 “Engine Mounts - Inspect” .......................................98 “Engine Oil Filter - Change” .................................. 101 “Engine Oil Sample - Obtain”................................ 104 “Engine Protective Devices - Check”.................... 105 “Engine Valve Lash and Bridge - Check”.............. 108 “Engine Valve Rotators - Inspect”......................... 109 “Exhaust Piping - Check”...................................... 109 “Fuel System Primary Filter (Water Separator) Element - Replace”................................................111 “Fuel System Secondary Filter - Replace” ............112 “Oil Mist Detector - Check” ....................................116 “Prelube Pump - Lubricate” .................................. 123 “Speed Sensor - Clean/Inspect” ........................... 123 “Starting Motor - Inspect” ...................................... 123

Every 3 Years “Camshaft Roller Followers - Inspect” .....................82 “Coolant (DEAC) - Change”.....................................83 “Crankshaft Vibration Damper - Inspect”.................92 “Driven Equipment - Check” ....................................93 “Engine Oil Temperature Regulator - Replace” .... 105 “Turbocharger - Inspect” ....................................... 127 “Water Pump - Inspect”......................................... 128

Every 6 Years “Coolant (ELC) - Change”........................................86

An authorized operator may perform the maintenance items with daily intervals. An authorized operator may perform the maintenance items with intervals of every week. The maintenance that is recommended for all other maintenance intervals must be performed by an authorized service technician or by your Cat dealer. The user is responsible for the performance of all maintenance which includes the following items: performing all adjustments, using proper lubricants, fluids, and filters and replacing old components with new components due to normal wear and aging . Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Before each consecutive interval is performed, all maintenance from the previous intervals must be performed. Choose the interval that occurs first in order to determine the correct maintenance interval: fuel consumption, service hours and calendar time . Products that operate in severe operating conditions may require more frequent maintenance. All of the following will affect the oil change interval: operating conditions, fuel type, oil type and size of the oil sump . Scheduled oil sampling analyzes used oil in order to determine if the oil change interval is suitable for your specific engine. Refer to this Operation and Maintenance Manual, “Engine Oil and Filter - Change” in order to determine the oil change interval that is suitable for your specific engine. To determine the maintenance intervals for the overhauls, refer to this Operation and Maintenance Manual, “Maintenance Recommendations” . Unless other instructions are provided, perform maintenance and perform repairs under the following conditions: The starting system is disabled. The engine is stopped. The generator does not pose an electrical shock hazard. The generator is disconnected from the load.

When Required i05370297

Maintenance Interval Schedule (Prime) SMCS Code: 1000; 4450; 7500 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

“Centrifugal Oil Filter - Inspect”................................82 “Coolant Extender (ELC) - Add” ..............................87 “Engine Air Cleaner Element (Single Element) Inspect/Replace”......................................................94 “Engine Crankcase Breather - Clean” .....................97 “Engine Oil - Change” ..............................................99

76 Maintenance Recommendations Maintenance Interval Schedule

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“Engine Oil Filter - Change” .................................. 101

“Engine Protective Devices - Check”.................... 105

“Fuel Analysis - Obtain” ........................................ 109

Initial 1000 Service Hours or 6 Months

“Fuel System - Prime”............................................110 “Fuel System Primary Filter (Water Separator) Element - Replace”................................................111 “Fuel System Secondary Filter - Replace” ............112 “Metal Particle Detector - Inspect/Clean” ..............115 “Zinc Rods - Inspect/Replace”.............................. 129

“Engine Valve Rotators - Inspect”......................... 109

Every 1000 Service Hours or 6 Months “Barring Device - Lubricate”.....................................81 “Coolant Sample (Level 2) - Obtain”........................90

Every Service Hour

“Engine Oil Filter - Change” .................................. 101

“Trend Data - Record”........................................... 124

“Exhaust Piping - Check”...................................... 109

Daily

“Fuel System Primary Filter (Water Separator) Element - Replace”................................................ 111

“Air Starting Motor Lubricator Oil Level - Check”.....80 “Air Tank Moisture and Sediment - Drain” ...............80

“Fuel System Secondary Filter - Replace” ............112 “Prelube Pump - Lubricate” .................................. 123

“Control Panel - Inspect/Test” ..................................83 “Coolant Level - Check”...........................................88

“Speed Sensor - Clean/Inspect” ........................... 123

“Engine Air Cleaner Service Indicator - Inspect” .....96

Every 2000 Service Hours

“Engine Air Precleaner - Check/Clean” ...................97

“Air Starting Motor Lubricator Bowl - Clean”............79

“Engine Oil Level - Check”.................................... 104

“Engine Valve Lash and Bridge - Check”.............. 108

“Fuel System Primary Filter/Water Separator Drain” .....................................................................112

Every 2000 Service Hours or 1 Year

“Fuel Tank Water and Sediment - Drain” ...............115 “Walk-Around Inspection”..................................... 128

Every Week “Jacket Water Heater - Check” ..............................115

“Aftercooler Condensation - Drain”..........................77 “Engine Valve Lash and Bridge - Check”.............. 108 “Engine Valve Rotators - Inspect”......................... 109

Every 4000 Service Hours or 1 Year “Aftercooler Core - Clean/Test”................................78

Every 250 Service Hours

“Coolant Temperature Regulator - Replace” ...........90

“Coolant Sample (Level 1) - Obtain”........................89

“Starting Motor - Inspect” ...................................... 123

“Cooling System Supplemental Coolant Additive (SCA) - Test/Add”.....................................................91

Every 8000 Service Hours or 3 Years

Every 250 Service Hours or 6 Weeks “Air Shutoff - Test” ....................................................78

“Camshaft Roller Followers - Inspect” .....................82 “Coolant (DEAC) - Change”.....................................83

“Engine Oil Sample - Obtain”................................ 104

“Crankshaft Vibration Damper - Inspect”.................92

“Oil Mist Detector - Check” ....................................116

“Driven Equipment - Check” ....................................93

Every 500 Service Hours or 3 Months

“Engine Oil Temperature Regulator - Replace” .... 105

“Engine Mounts - Inspect” .......................................98

“Water Pump - Inspect”......................................... 128

“Turbocharger - Inspect” .......................................127

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Maintenance Recommendations Aftercooler Condensation - Drain

Between 16 000 and 24 000 Service Hours “Overhaul (Top End)” .............................................119 “Overhaul Considerations” ................................... 120

Every 16 000 Service Hours or 6 Years

1. Remove plug (1). 2. Drain the moisture into a suitable container. 3. Install the plug.

12 and 16 Cylinder Engines 12 and 16 cylinder engines have two drain plugs for draining moisture from the aftercooling system.

“Coolant (ELC) - Change”........................................86

Between 36 000 and 44 000 Service Hours “Overhaul (Major)” .................................................116 “Overhaul Considerations” ................................... 120 i02348942

Aftercooler Condensation Drain SMCS Code: 1063

Illustration 64

The aftercooler is similar to a radiator. Coolant passes through the tubes in the aftercooler core. Inlet air that is warmed by the turbocharger compressor is directed through the aftercooler core. The air is cooled in the aftercooler.

g00297165

For 12 and 16 cylinder engines, one drain plug is located on the right side near the rear of the engine. (1) Plug

Condensation can form in the passages of the aftercooler system. Drain plugs are provided for draining the moisture.

6 and 8 Cylinder Engines 6 and 8 cylinder engines have one drain plug for draining moisture from the aftercooling system.

Illustration 65

g00297166

For 12 and 16 cylinder engines, one drain plug is located on the left side near the front of the engine. (2) Plug

Note: Prepare a suitable container for the moisture. 1. Remove plugs (1) and (2). Illustration 63

g00475925

For 6 and 8 cylinder engines, one drain plug is located on the left side near the rear of the engine. (1) Plug

Note: Prepare a suitable container for the moisture.

2. Drain the moisture into a suitable container. 3. Install the plugs.

78 Maintenance Recommendations Aftercooler Core - Clean/Test

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i05253323

Aftercooler Core - Clean/Test SMCS Code: 1064-070; 1064-081 Before cleaning the aftercooler core, determine if the aftercooler requires cleaning. Use the 152-2067 Differential Pressure Gauge to measure the differential pressure of the air side of the aftercooler. When the air side differential pressure reaches 7 kPa (1.0 psi) at full rated power, clean the aftercooler core.

Cleaning the Aftercooler See the Service Manual, “Disassembly and Assembly” module for instructions on removal, disassembly, assembly, and installation. Note: The following procedure may be used for cleaning both the aftercooler core and the oil cooler core. 1. Remove the core. Disassemble the core.

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. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. 6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow. 7. Inspect the core in order to ensure cleanliness. Pressure-test the core. Many shops that service radiators are equipped to perform pressure tests. If necessary, repair the core. 8. Install the core. For more information on cleaning the core, consult your Cat dealer.

2. Turn the core upside-down in order to remove debris. NOTICE Do not use a high pressure spray for cleaning the fins of the core. A high pressure spray can damage the surface of the fins and reduce the flow of air through the core.

i01052568

Air Shutoff - Test SMCS Code: 1078-081 The air shutoff must operate properly in case an emergency shutdown is needed. Test the operation of the air shutoff. It is not necessary for the engine to be operating in order to test the shutoff.

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. 3. Back flush the core with cleaner. Caterpillar recommends the use of Hydrosolv liquid cleaner. Consult your Cat dealer for the part numbers and quantities that are available. Use a 2 to 5 percent concentration of the cleaner at temperatures up to 93 °C (200 °F). 4. Steam-clean the core in order to remove any residue. Flush the fins of the aftercooler core. Remove any other trapped debris. 5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

Illustration 66

Air shutoff for in-line engines (1) Knob (2) Reset lever

g00545921

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79 Maintenance Recommendations Air Starting Motor Lubricator Bowl - Clean

1. Ensure that the air supply to the lubricator is OFF.

Illustration 67

g00545922

Air shutoff for vee engines Illustration 68

(1) Knob (2) Reset lever

g01333332

(1) Filler plug (2) Bowl (3) Drain valve

1. To activate the air shutoff, pull knob (1). A plate that is inside of the apparatus will cover the air inlet. This prevents air from entering the inlet manifold.

2. Slowly loosen filler plug (1) in order to release the pressure from the lubricator.

Reset lever (2) should move to the “CLOSED” position. If this fails to occur, investigate the problem. See the Service Manual, “Disassembly and Assembly” topic.

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.

DO NOT operate the engine if the air shutoff will not activate. Note: The air shutoff must be reset before the engine can be started. 2. To reset the air shutoff, move reset lever (2) to the “OPEN” position. i02654935

Air Starting Motor Lubricator Bowl - Clean SMCS Code: 1451-070 If the engine is equipped with an air starting motor, use the following procedure:

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.

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. 3. Place a suitable container under bowl (2) and open drain valve (3) in order to drain the oil from the bowl. 4. Remove bowl (2). Clean the bowl with warm water. 5. Dry the bowl. Inspect the bowl for cracks. If the bowl is cracked, replace the damaged bowl with a new bowl. Inspect the gasket. If the gasket is damaged, replace the gasket. 6. Install the bowl. 7. Make sure that drain valve (3) is closed. 8. For instructions on filling the lubricator, see this Operation and Maintenance Manual, “Air Starting Motor Lubricator Oil Level - Check” topic.

80 Maintenance Recommendations Air Starting Motor Lubricator Oil Level - Check

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i02654969

Air Starting Motor Lubricator Oil Level - Check SMCS Code: 1451-535

Adjust the Lubricator Note: Adjust the lubricator with a constant rate of air flow. After the adjustment, the lubricator will release oil in proportion to variations of the air flow. 1. Ensure that the fuel supply to the engine is OFF.

NOTICE Never allow the lubricator bowl to become empty. The air starting motor will be damaged by a lack of lubrication. Ensure that sufficient oil is in the lubricator bowl.

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. 2. Operate the air starting motor. Observe the drops of oil that are released in dome (1). Note: Some lubricators have an adjustment screw rather than a knob. 3. If necessary, adjust the lubricator in order to release from one to three drops of oil per second. To increase the rate, turn knob (2) counterclockwise. To decrease the rate, turn the knob clockwise. i04534752

Illustration 69

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1. Observe the oil level in sight gauge (3). If the oil level is less than 1/2, add oil to the lubricator bowl.

Air Tank Moisture and Sediment - Drain SMCS Code: 1466-543-M&S Moisture and sediment in the air starting system can cause the following conditions:

Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury.

• Freezing • Corrosion of internal parts • Malfunction of the air starting system

Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. 2. Ensure that the air supply to the lubricator is OFF. Slowly loosen filler plug (4) in order to release pressure from the lubricator bowl. 3. Remove filler plug (4). Pour oil into the lubricator bowl. Use nondetergent SAE 10W oil for temperatures that are greater than 0 °C (32 °F). Use air tool oil for temperatures that are below 0 °C (32 °F). 4. Install filler plug (4).

When opening the drain valve, wear protective gloves, a protective face shield, protective clothing, and protective shoes. Pressurized air could cause debris to be blown and result in personal injury.

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81 Maintenance Recommendations Barring Device - Lubricate

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, “Cat Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products.

NOTICE Do not operate the engine starting motor until the barring group pinion gear is fully disengaged from the flywheel ring gear. Serious damage to the engine could result.

Electric Barring Device Note: This type of barring device may be electrically driven or manually driven.

Dispose of all fluids according to local regulations and mandates. 1. Open the drain valve that is on the bottom of the air tank. Allow the moisture and sediment to drain. 2. Close the drain valve. i02601741

Barring Device - Lubricate SMCS Code: 1235-086

Illustration 70

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Rear view of an electrically driven barring device NOTICE Do not use an impact wrench to operate the barring device. The use of an impact wrench will cause gear tooth failure.

Lubricating the Pinion

Guards must be in place prior to operating barring device motor. Remove all hand tools prior to operating barring device motor. Note: Prelube of the engine is required before the crankshaft is rotated for normal maintenance. The barring device provides a means for slowly turning the flywheel in order to service the engine. When the barring device is in the engaged position, the engine starting system is disabled. When the barring device is not used, the barring device must be fully disengaged from the flywheel and secured in the disengaged position. Refer to the Service Manual for information on operation of the barring device.

Illustration 71

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Section view of a barring device without the electric motor (1) Grease fitting (2) Vent

1. Ensure that the barring device is locked in the disengaged position. 2. Lubricate grease fitting (1) with Cat Advanced 3Moly Grease until the grease is visible at vent (2).

82 Maintenance Recommendations Camshaft Roller Followers - Inspect

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Lubricating the Reducer

i01904185

Camshaft Roller Followers Inspect SMCS Code: 1209-040 For instructions on disassembly and assembly of the valve lifter group, see the Service Manual, “Disassembly and Assembly” module. Inspect the following components for wear at each metal to metal contact point: • Rollers for the valve lifters • Camshaft Illustration 72

g00991445

1. Ensure that the barring device is locked in the disengaged position.

Inspect each roller for wear, excessive movement, and end play. If excessive wear or other signs of deterioration are found, replace the damaged components.

2. Remove level plugs (2) and check the lubricant level. 3. If necessary, remove cap (1) and add Caterpillar 4C-6767 Synthetic Oil until the oil is visible at the level plugs.

i00449365

Centrifugal Oil Filter - Inspect SMCS Code: 1328-040

4. Reinstall the level plugs and reinstall the cap. Hot oil and components can cause personal injury.

Manual Barring Device

Do not allow hot oil or components to contact skin.

Illustration 73

g01098833

(1) Grease fitting (2) Gear end

1. Ensure that the barring device is locked in the disengaged position. 2. Lubricate grease fitting (1) with Cat Advanced 3Moly Grease until the grease is visible at gear end (2).

Illustration 74

g00270570

(1) Valve. (2) Base.

Note: If the engine is operating, close valve (1) to the centrifugal oil filter that will be cleaned. Prepare a cover for base (2). The cover will prevent the oil mist from flowing through the orifice in the base.

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83 Maintenance Recommendations Control Panel - Inspect/Test

1. Disassemble the centrifugal oil filter according to the instructions in the Service Manual. 2. Thoroughly clean all of the parts of the centrifugal oil filter. Carefully inspect all of the parts. 3. Measure the clearance between the bearing and the base and measure the clearance between the bearing and the spindle. Follow the instructions that are in the Service Manual. Replace any part that does not meet the specifications that are in the Service Manual. NOTICE Ensure that all of the rotor components are thoroughly clean before assembling the rotor. Failure to do so can cause an out of balance condition that can cause rapid wear to the bearings and the spindle.

• The engine overheats frequently. • The coolant is foaming. • Oil or fuel has entered the cooling system and the coolant is contaminated.

Drain the Cooling System 1. Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained. 2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

Note: Install a new paper liner when the centrifugal oil filter is assembled. 4. Assemble the centrifugal oil filter according to the instructions in the Service Manual. i04232973

Control Panel - Inspect/Test SMCS Code: 4490-040; 4490-081; 7451-040; 7451081 Inspect the instrument panel for good condition. Perform the self-test. All of the warning lamps should illuminate. If a warning lamp does not illuminate, replace the bulb immediately. If the alarm does not sound, investigate the problem and correct the problem.

Illustration 75

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Location of the cooling system drain valves or drain plugs on the water pumps (1) Jacket water pump (2) Aftercooler and oil cooler pump

Check the condition of all of the gauges. If a gauge is broken, repair the gauge or replace the gauge immediately. Frequently monitor the gauges during normal operation. Record the data in a log. Compare the new data to the data that was previously recorded. Comparing the new data to the recorded data will help to establish the trends of engine performance. A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge. i04810864

Coolant (DEAC) - Change SMCS Code: 1350-070; 1395-044 Clean the cooling system before the recommended maintenance interval if the following conditions exist:

Illustration 76

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Location of the drain plug (jacket water) for 3606 and 3608 Engines

84 Maintenance Recommendations Coolant (DEAC) - Change

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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 Cat Fast Acting Cooling System Cleaner. Add .5 L (1 pt) of cleaner per 15 L (4 US gal) of the cooling system capacity. Install the cooling system filler cap. 4. Start the engine. Operate the engine for a minimum of 30 minutes with a coolant temperature of at least 82 °C (180 °F). Illustration 77

g00475850

Location of the drain plugs (jacket water) for 3612 and 3616 Engines 3. Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the 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 Cat dealer or consult Caterpillar Dealer Service Tools Group : Outside U.S.A. (309) 675-6277 Inside U.S.A. 1-800-542-TOOL Inside Illinois 1-800-541-TOOL Canada 1-800-523-TOOL CSTG COSA Geneva, Switzerland 41-22-849 40 56

Clean the Cooling System 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. After the cooling system has been drained, flush the cooling system with clean water in order to remove any debris. 2. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs.

5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the water to drain. NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone. 6. Flush the cooling system with clean water until the water that drains is clean. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs.

Cleaning a Cooling System that has Heavy Deposits or Plugging Note: For the following procedure to be effective, there must be an active flow through the cooling system components. 1. After the cooling system has been drained, flush the cooling system with clean water in order to remove any debris. 2. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs. 3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pt) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the cooling system filler cap.

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85 Maintenance Recommendations Coolant (DEAC) - Change

4. Start the engine. Operate the engine for a minimum of 90 minutes with a coolant temperature of at least 82 °C (180 °F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the water to drain. NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone. 6. Flush the cooling system with clean water until the water that drains is clean. Close the cooling system drain valves (if equipped). Clean the cooling system drain plugs and install the cooling system drain plugs.

Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Note: For information about the proper coolant to use, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section). For the capacity of the cooling system, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” (Maintenance Section).

Illustration 78

g00546449

(1) Plug

1. Fill the cooling system with coolant/antifreeze. The water lines for the turbochargers must be vented when the cooling system is filled. Remove plug (1). Press a small screwdriver into the check valve in order to vent the line. After filling the cooling system, do not install the cooling system filler cap. 2. Start the engine. Operate the engine in order to purge the air from the cavities of the engine block. Allow the coolant to warm and allow the coolant level to stabilize. Stop the engine. 3. Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant to the level that is specified by the OEM of the cooling system. 4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets of the cooling system filler cap are damaged, discard the old cooling system filler cap. Install a new cooling system filler cap. If the gaskets of the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump to pressure test the filler cap. The correct pressure is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not maintain the correct pressure, install a new cooling system filler cap. 5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

86 Maintenance Recommendations Coolant (ELC) - Change

SEBU7876

i04810872

Coolant (ELC) - Change SMCS Code: 1350-070; 1395-044 Use only clean water to flush the cooling system when Extended Life Coolant (ELC) is drained and replaced.

Drain the Cooling System 1. Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained. 2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

Illustration 81

g00475850

Location of the drain plugs (jacket water) for 3612 and 3616 Engines 3. Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the 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 Cat dealer or consult Cat Dealer Service Tools Group :

Illustration 79

g00130652

Location of the cooling system drain valves or drain plugs on the water pumps (1) Jacket water pump (2) Aftercooler and oil cooler pump

Outside U.S.A. (309) 675-6277 Inside U.S.A. 1-800-542-TOOL Inside Illinois 1-800-541-TOOL Canada 1-800-523-TOOL CSTG COSA Geneva, Switzerland 41-22-849 40 56

Clean the Cooling System 1. After the cooling system has been drained, flush the cooling system with clean water in order to remove any debris. 2. Close the cooling system drain valves (if equipped). Clean the drain plugs and install the drain plugs. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Illustration 80

g00475784

Location of the drain plug (jacket water) for 3606 and 3608 Engines

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87 Maintenance Recommendations Coolant Extender (ELC) - Add

3. Fill the cooling system with clean water. Install the cooling system filler cap. Install the vent plug (4). Operate the engine until the temperature reaches 49 °C (120 °F) to 66 °C (150 °F). 4. Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. 5. Open the cooling system drain valves (if equipped). Remove the drain plugs. See Illustration 79 . Allow the coolant to drain. Flush the cooling system with clean water. Close the cooling system drain valves (if equipped). Install the drain plugs. 6. Repeat Steps 3, 4, and 5.

Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.

3. Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant within 13 mm (.5 inch) below the bottom of the filler pipe. 4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets of the cooling system filler cap are damaged, discard the old cooling system filler cap. Install a new cooling system filler cap. If the gaskets of the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump to pressure test the filler cap. The correct pressure is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not maintain the correct pressure, install a new cooling system filler cap. 5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature. i04862631

Coolant Extender (ELC) - Add SMCS Code: 1352-544-NL Note: Refer to this Operation and Maintenance Manual, “Fluid Recommendations” (Cooling System) for the maintenance interval for the addition of the coolant extender. Cat ELC (Extended Life Coolant) and Cat ELI (Extended Life Inhibitor) do not require the frequent additions of any supplemental cooling additives. The Cat ELC Extender will only be added one time. Note: Do not use conventional supplemental coolant additive (SCA) with Cat ELC or with Cat ELI. Illustration 82

g00546449

1. Fill the cooling system with Extended Life Coolant (ELC). The water lines for the turbochargers must be vented when the cooling system is filled. Remove plug (1). Press a small screwdriver into the check valve in order to vent the line. After filling the cooling system, do not install the cooling system filler cap. 2. Start the engine. Operate the engine in order to purge the air from the cavities of the engine block. Allow the ELC to warm and allow the coolant level to stabilize. Stop the engine.

Check the cooling system only when the engine is stopped and cool.

88 Maintenance Recommendations Coolant Level - Check

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i04810912

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.

Coolant Level - Check SMCS Code: 1395-082

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual“Mounting and Dismounting” topic for safety information.

Engines That Are Equipped With a Sight Gauge

Cooling System Coolant Additive 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, “Cat Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat 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. If necessary, 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 the cooling system capacity. Refer to this Operation and Maintenance Manual, “Refill Capacities” for the coolant capacity. 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. For further information, refer to this Operation and Maintenance Manual, , Fluid Recommendations.

Illustration 83

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(1) Filler cap (2) Sight gauge

If the engine is equipped with a sight gauge, observe the position of the coolant in the sight gauge. At normal operating temperature, the proper coolant level is in the upper half of the sight gauge. If the coolant level is low, add the proper coolant mixture.

Engines That Are Not Equipped With a Sight Gauge

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.

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89 Maintenance Recommendations Coolant Sample (Level 1) - Obtain

Check the coolant level when the engine is stopped and cool. Check the coolant level only after the engine has been stopped. Ensure that the cooling system filler cap is cool enough to touch with your bare hand. Remove the cooling system filler cap slowly in order to relieve any pressure. Maintain the coolant within 13 mm (0.5 inch) below the bottom of the filler pipe.

Add Coolant Note: For the proper coolant mixture to use, see this Operation and Maintenance Manual“Refill Capacities and Recommendations” ........ (Maintenance Section). 1. Stop the engine. Allow the engine to cool. 2. Remove the cooling system filler cap slowly in order to relieve any pressure. Pour the proper coolant mixture into the filler pipe.

i04810997

Coolant Sample (Level 1) 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. 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, 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 Cat dealer. Use the following guidelines for proper sampling of the coolant: • Never collect samples from expansion bottles. • Never collect samples from the drain for a system. • Keep the unused sampling bottles stored in plastic bags.

Illustration 84

g00103639

Gaskets 3. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling system filler cap with a new cooling system filler cap. Install the cooling system filler cap. 4. Start the engine. Inspect the cooling system for leaks.

• Keep the lids on empty sampling bottles until you are ready to collect the sample. • Complete the information on the label for the sampling bottle before you begin to take the samples. • Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location. •

In order to avoid contamination, immediately place the sample in the tube that is provided for mailing.

Submit the sample for Level 1 analysis. Note: Level 1 results may indicate a need for Level 2 Analysis. For additional information about coolant analysis, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations”.

90 Maintenance Recommendations Coolant Sample (Level 2) - Obtain

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Testing the Concentration of SCA in a Cooling System that Uses Conventional Coolant For the conventional heavy-duty antifreeze/coolant solution, 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).

Testing the Concentration of SCA in a Cooling System that Uses SCA and Water Two methods may be used to check the concentration of SCA:

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, “Cat Dealer Service Tool Catalog” or refer to Special Publication, PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

• Check the concentration of SCA with a 298-5311 Coolant Nitrite Test Kit or a 294-7420 Test Kit.

Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” for the guidelines for a proper sampling of the coolant.

• Check the concentration of SCA with an S·O·S coolant analysis (Level 1).

Submit the sample for Level 2 analysis.

See this Operation and Maintenance Manual, “Cooling System Supplemental Cooling Additives (SCA) - Test/Add” for more information about testing the SCA.

For additional information about coolant analysis, see Special Publication, SEBU7003, “Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations” or consult your Cat dealer. i04210326

i05378157

Coolant Sample (Level 2) Obtain

Coolant Temperature Regulator - Replace

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

SMCS Code: 1355-510

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.

Replace the Jacket Water Temperature Regulators and the Oil Cooler Water Temperature Regulators Replace the water temperature regulators before the water temperature regulators fail. Replacing the water temperature regulator is a recommended preventive maintenance practice. Replacing the water temperature regulators reduces the chances for unscheduled downtime. 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 a seizure of the pistons.

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91 Maintenance Recommendations Cooling System Supplemental Coolant Additive (SCA) - Test/Add

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 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.

NOTICE Failure to replace the water temperature regulators on a regularly scheduled basis could cause severe engine damage.

Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water pump seal.

Never operate the engine without the water temperature regulators 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. Refer to the Service Manual for the procedure to replace the water temperature regulators, or consult your Cat dealer. Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the regulator housing. i02832607

Cooling System Supplemental Coolant Additive (SCA) - Test/ Add SMCS Code: 1352-045; 1395-081

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.

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 This maintenance procedure is required for conventional coolants such as DEAC.This maintenance is NOT required for cooling systems that are filled with Extended Life 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 8T-5296 Coolant Conditioner Test Kit.

92 Maintenance Recommendations Crankshaft Vibration Damper - Inspect

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Add the SCA, If Necessary

Add the SCA, If Necessary



1. Remove the cooling system filler cap slowly.

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.

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, SEBU7003, 3600 Series and C280 Series Diesel Engine Fluids Recommendations.

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. For the proper concentration of SCA, refer to Special Publication, SEBU7003, 3600 Series and C280 Series Diesel Engine Fluids Recommendations. 4. Clean the cooling system filler cap. Install the cooling system filler cap.

4. Clean the cooling system filler cap. Install the cooling system filler cap.

i04397909

Cooling Systems that Use Water and SCA

Crankshaft Vibration Damper Inspect

Test the Concentration of the SCA

SMCS Code: 1205-040

Test the concentration of the SCA with a 298-5311 Coolant Nitrite Test Kit for SCA or perform an S·O·S Coolant Analysis. The test kit includes the following items: a tool for the testing, 30 ampoules for testing nitrite, instructions and a case. 294-7420 Test Kit contains the refill ampoules for the 298-5311 Coolant Nitrite Test Kit. Use the instructions that are included with the test kit in order to properly conduct the testing.

The crankshaft vibration damper limits the torsional vibration of the crankshaft. The visconic damper has a weight that is located inside a fluid filled case.

Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the times at which the procedures should be conducted. Test the concentration of the SCA more frequently if more frequent testing is indicated by the results of the S·O·S Coolant Analysis.

A damper that is hot may be the result of excessive torsional vibration, worn bearings, or damage to the damper. Use an infrared thermometer to monitor the temperature of the damper during operation. Follow the instructions that are included with the infrared thermometer. If the temperature reaches 100°C (212 °F), consult your Cat dealer.

NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration.

Inspect the damper for evidence of dents, cracks, and leaks of the fluid.

Damage to the crankshaft vibration damper or failure of the damper can increase torsional vibrations. This vibration can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive torsional vibrations.

If a fluid leak is found, determine the type of fluid. The fluid in the damper is silicone. Silicone has the following characteristics: transparent, viscous and smooth. If the fluid leak is oil, inspect the crankshaft seals for leaks. If a leak is observed, replace all of the seals.

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93 Maintenance Recommendations Driven Equipment - Check

Inspect the damper and repair or replace the damper for any of the following reasons. • The damper is dented, cracked, or leaking. • The paint on the damper is discolored from heat. • The engine has had a failure because of a broken crankshaft. • The crankshaft bearings are showing excessive wear. • There is a large amount of gear train wear that is not caused by a lack of oil.

Dampers With Sampling Ports

The typical limit for the degradation of the damper fluid viscosity that is used by Hasse & Wrede GmbH is 20 percent for most applications. The reports from Hasse & Wrede should indicate that the fluid samples meet this viscosity limit.

Dampers Without Sampling Ports Some dampers do not have a port for a fluid sample. These dampers must be rebuilt or the dampers must be replaced when one of the following criteria has been met: • The damper has been operated for 20000 hours. • The engine is undergoing a major overhaul.

Removal and Installation Refer to the Disassembly and Assembly Manual, “Vibration Damper - Remove and Install” article or consult your Cat dealer for information about damper replacement. i00934883

Driven Equipment - Check SMCS Code: 3279-535

Check the Alignment To minimize bearing problems and vibration of the engine crankshaft and the driven equipment, the alignment between the engine and driven equipment must be properly maintained. Check the alignment according to the instructions that are provided by the following manufacturers: Illustration 85

g00819045

Some dampers have ports for fluid samples. If the damper has no external damage, collect a sample of the damper fluid. The fluid should be analyzed in order to check for a loss of viscosity. Use the results of the analysis to determine if the damper should be rebuilt or replaced. Kits for fluid samples are available from the address that follows. Return the kits to the same address for analysis. Hasse & Wrede GmbH Georg-Knorr-Straße 4 12681 Berlin Germany Phone +49 30 9392-3135 Fax +49 30 9392-7-3135 Alternate phone +49 30 9392-3156 Alternate fax +49 30 9392-7-3156

• Caterpillar • OEM of the drive coupling • OEM of the driven equipment Torque all of the fasteners to the proper specifications.

Inspect the Drive Coupling Inspect the drive coupling according to the instructions that are provided by the OEM of the coupling. For the following service information, see the literature that is provided by the OEM of the coupling: • Lubrication requirements • Specifications for the end play • Reusability Guidelines • Replacement instructions

94 Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Replace

Inspect the Rear Gear Train Inspect the crankshaft gear. If excessive wear is found, replace the crankshaft gear and the large cluster idler. If any gear causes damage to other gears through failure, replace the entire rear gear train. For the correct parts, see the Parts Manual for the engine. For removal and replacement instructions, see the Service Manual, “Disassembly and Assembly” module. Consult your Caterpillar dealer for assistance. i04811089

Engine Air Cleaner Element (Single Element) - Inspect/ Replace SMCS Code: 1051; 1054-040; 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.

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• Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirt and debris, as needed. • Operating conditions (dust, dirt, and debris) may require more frequent service of the air cleaner element. • Replace the element when the air restriction reaches 3.75 kPa (15 inches of H2O). • Replace the element when the red piston of the service indicator locks in the visible position. • The air cleaner element may be cleaned up to six times. • Replace the element at least one time per year. Perform this replacement regardless of the number of cleanings. Replace the dirty paper elements with clean elements. Before installation, thoroughly inspect the element for tears and/or holes in the filter material. Inspect the gasket or the seal of the element for damage. Maintain a supply of suitable elements for replacement purposes.

NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements If the air cleaner element becomes plugged, the air pressure can split the filter material of the element. Unfiltered air will drastically accelerate internal engine wear. Your Cat dealer has the proper air cleaner elements for your application.

Illustration 86

g02935196

(1) Access door (2) Element (3) Clips (4) Cup (5) Screen

1. Open access door (1). Remove element (2). 2. Seal the air inlet to the turbocharger with a cover or tape. This cover will help to prevent dirt from entering the turbocharger when the body of the air cleaner is cleaned.

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95 Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Replace

3. Loosen clips (3). Remove cup (4). Clean the inside of the cup.

• Pressurized air • Vacuum cleaning

4. Clean screen (5) with pressurized air. 5. Use a cloth to clean the inside of the access door and the body of the air cleaner. 6. Install cup (4). Fasten clips (3). 7. Inspect a clean, dry air cleaner element for good condition.

Pressurized Air Pressurized air can be used to clean elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi).

8. Remove the tape or the cover from the air inlet to the turbocharger. Install the air cleaner element. 9. Secure the access door. 10. If necessary, reset the air cleaner service indicator.

Replace the Soot Filter Some applications use an air silencer that is wrapped in a washable soot filter. The soot filter helps prevent airborne dust and debris from entering the air inlet. As the soot filter becomes dirty, the air restriction increases. Replace the soot filter when the air restriction reaches 3.75 kPa (15 inches of H2O). 1. Remove the dirty soot filter from the air silencer. 2. Inspect the air silencer. Clean the air silencer, if necessary.

Illustration 87

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Note: When the elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside).

3. Inspect a clean, dry soot filter for good condition. Install the soot filter.

Aim the hose so that the air flows inside the element along the length of the filter to help prevent damage to the paper pleats. Do not aim the stream of air directly at the element. Dirt could be forced into the pleats.

Cleaning the Air Cleaner Elements

Note: Refer to “Inspecting the Air Cleaner Elements”.

The air cleaner element can be used up to six times. When the element is cleaned, check the filter material for rips or tears. Replace the element at least one time per year regardless of the number of cleanings.

Vacuum Cleaning

Use clean elements while dirty elements are being cleaned. NOTICE Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the elements before cleaning. Inspect the elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged elements. Two methods are used to clean air cleaner elements:

Vacuum cleaning is a good method for cleaning elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil. Note: Refer to “Inspecting the Air Cleaner Elements”.

96 Maintenance Recommendations Engine Air Cleaner Service Indicator - Inspect

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Inspecting the Air Cleaner Elements

• Date of cleaning • Number of cleanings Store the container in a dry location. For detailed information on cleaning the air cleaner element, refer to Special Publication, SEBF8062, Procedure to Inspect and Clean Air Filters. i00935673

Engine Air Cleaner Service Indicator - Inspect SMCS Code: 7452-040 Illustration 88

g00281693

A service indicator may be mounted on the air cleaner or in a remote location.

Inspect the clean, dry element. Use a 60 W blue light in a dark room or in a similar facility. Place the blue light in the element. Rotate the element. Inspect the element for tears and/or holes. Inspect the element for light that may show through the filter material. If necessary to confirm the result, compare the element to a new element that has the same part number. Do not use an element that has any tears and/or holes in the filter material. Do not use an element with damaged pleats, gaskets, or seals. Discard damaged elements.

Storing Air Cleaner Elements If an element that passes inspection will not be used immediately, store the element for future use.

Illustration 90

g00476444

Service indicator Some engines may be equipped with a different service indicator. Observe the service indicator. Clean the air cleaner element or replace the element when the following conditions occur: • The yellow diaphragm enters the red zone. • The red piston locks in the visible position. • The air restriction reaches 3.75 kPa (15 inches of H2O).

Illustration 89

g00281694

Do not use paint, a waterproof cover, or plastic as a protective covering for storage. Restricted air flow may result. To protect against dirt and damage, wrap the elements in Volatile Corrosion Inhibiter (VCI) paper. Place the element into a cardboard box for storage. For identification, mark the outside of the container and mark the element. Include the following information:

Inspect the service indicator daily for cracks, holes, or loose fittings. If any of these conditions are present, repair the service indicator or replace the service indicator.

Test the Service Indicator After Every 1000 Service Hours Service indicators are important instruments. Use the following procedure to verify that the service indicator is operating properly.

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Illustration 91

97 Maintenance Recommendations Engine Air Precleaner - Check/Clean

g00476445

(1) Fitting () Reset button

1. Unscrew the service indicator from fitting (1). A porous filter is part of the fitting.

Illustration 92

2. Inspect the porous filter for cleanliness. Clean the filter, if necessary. Use compressed air or a clean, nonflammable solvent.

g02935338

(1) Clip (2) Cup

1. Loosen clips (1). Remove cup (2).

3. Apply vacuum (suction) to the service indicator. 2. Clean the inside of the cup. The yellow diaphragm should enter the red zone and the piston should lock into position. If this does not occur, obtain a new service indicator. 4. Reset the service indicator by pressing reset button (2). If the service indicator does not reset easily, obtain a new service indicator.

3. Install the cup. Fasten the clips. i01421692

Engine Crankcase Breather Clean SMCS Code: 1317-070

Note: Excessive force may crack the top of the service indicator. 5. Install the service indicator. Tighten the service indicator to a torque of 2 N·m (18 lb in). The service indicator may need to be replaced frequently in environments that are severely dusty. Replace the service indicator annually regardless of the operating conditions. Replace the service indicator when the engine is overhauled, and whenever major engine components are replaced. i04811213

Engine Air Precleaner - Check/ Clean SMCS Code: 1055-070; 1055-535 Note: More frequent cleaning may be required in dusty environments.

Clean the crankcase breather elements and replace the O-ring seals at every oil change. Perform this maintenance when the engine is 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.

98 Maintenance Recommendations Engine Mounts - Inspect

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Resilient Isolators

Illustration 93

g00745657

(1) Breather assembly (2) Tee (3) Hose clamp (4) O-ring seal (5) Retaining clamp

Illustration 94

g00745665

(1) Rubber element

1. Loosen hose clamps (3). Remove tee (2). 2. Loosen retaining clamps (5). Remove breather assemblies (1) and O-ring seals (4). 3. Wash the breather elements in clean nonflammable solvent. Inspect tee (2) for cracks that can be caused by vibration. Replace the old tee with a new tee if cracking is found. 4. Install new O-ring seals (4). 5. Allow the breather elements to dry before installation. Install the breather assemblies in the original position. Coat the rubber parts with clean engine oil or petroleum jelly in order to make installation easier. 6. Install the retaining clamps and the hose clamps. See the Service Manual, “Specifications” module for the proper torque. i01421709

Engine Mounts - Inspect SMCS Code: 1152-040; 1152 Inspect the condition of the isolators. The isolators must be kept clean and dry. Ensure that the isolators are free of oil and contamination.

Each isolator has four rubber elements. The most usual cause for failure of the isolator is oil contamination of the rubber elements. Inspect the rubber elements of each isolator for the following conditions. • Swelling • Blistering • Cracking Perform the following procedures when deterioration of the rubber elements is initially observed: • Record the observation in a log. • Check the alignment of the driven equipment. After deterioration of the rubber elements is initially observed, the rubber elements must be carefully inspected. Any further deterioration of the rubber elements must be recorded. The isolator must be repaired or replaced if rapid deterioration of the rubber elements is observed. Deterioration of the rubber elements is usually accompanied by settling of the isolator. Settling of the isolator will result in misalignment between the engine and the driven equipment.

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99 Maintenance Recommendations Engine Oil - Change

Check the Center Bolt

Table 23 Oil Change Intervals For C280 Engines Engine

Lube Oil Capacity(1) Oil Change Interval (2)

Petroleum Engines C280-06

880 L (229 US gal)

1400 Service Hours

C280-08

1112 L (289 US gal)

1350 Service Hours

C280-12

1302 L (339 US gal) 1000 Service Hours

C280-16

1073 L (443 US gal) 1000 Service Hours Marine Engines (Zero Degree Tilt)

Illustration 95

g00745664

(2) Locknut (3) Adjustable assembly (A) Clearance above the adjustable assembly

Check the tightness of locknut (2) on the center bolt. Use a minimum torque of 100 N·m (75 lb ft).

C280-06

731 L (190 US gal)

1000 Service Hours

C280-08

795 L (207 US gal)

900 Service Hours

C280-12

943 L (245 US gal)

900 Service Hours

C280-16

1091 L (284 US gal)

600 Service Hours

(1)

If locknut (2) is loose, perform the following Steps:

The capacity includes the oil sump plus oil filters that are installed at the factory. Engines with auxiliary oil filters will require additional oil. The capacity is approximate. The actual capacity may vary by five percent. Caterpillar recommends using the capacity that is listed and then adjusting the oil level according to the oil level gauge (dipstick). Use this oil change interval in the absence of oil analysis.

1. Tighten locknut (2) to 140 N·m (105 lb ft).

(2)

2. Measure clearance (A) above adjustable assembly (3).

Change the Engine Oil

3. Compare the clearance to the specification from the engine commissioning. The clearance and the specification from the engine commissioning must be equal. Any difference in the dimension indicates that the height of the isolator has changed. A change in the height of the isolator will result in misalignment between the engine and the driven equipment. i02349007

Engine Oil - Change SMCS Code: 1348-044; 1348

Oil Change Interval Considerations for the oil change interval include the type of fuel and the engine application. The establishment of an S·O·S oil analysis program will enable an evaluation of the used oil. The evaluation can be used to determine the oil change interval that is suitable for your specific engine. Change the engine oil when oil analysis determines that the oil has reached the condemning limit. In the absence of oil analysis, change the engine oil according to the interval that is listed in Table 23 .

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Do not drain the oil when the engine is cold. As the oil cools, suspended 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 with the oil warm. This method allows the waste particles that are suspended in the oil to properly drain. 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. NOTICE Ensure that the engine is stopped before performing this procedure. Attach a DO NOT OPERATE tag to the starting controls. Note: Drain the oil into a suitable container. Dispose of fluids according to local regulations.

100 Maintenance Recommendations Engine Oil - Change

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b. Wash the screen assembly in clean nonflammable solvent. Allow the screen assembly to dry before installation. 4. Clean the bottom of the sump. Remove side covers in order to gain access to the sump. When the bottom of the sump is clean, install the side covers. 5. Install the oil suction screen. Install the cover and a new seal. 6. Change the engine oil filters. See this Operation and Maintenance Manual, “Engine Oil Filter Change” topic (Maintenance Section). Illustration 96

g00130760

7. Clean the centrifugal oil filters.

(1) Drain valve

2. Open drain valve (1) in order to drain used oil. After the oil has drained, close drain valve (1).

a. Disassemble the centrifugal oil filters according to the instructions in the Service Manual.

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 the oil pan. Be careful not to strike the engine oil suction tubes or the piston cooling jets.

b. Thoroughly clean all of the parts of the centrifugal oil filter. Carefully inspect all of the parts.

3. Clean the oil suction screen. Note: Approximately 1 L (1 qt) of oil will remain in the housing after the sump has been completely drained. This oil will pour out of the housing when the cover for the oil suction screen is removed. Prepare to catch the oil in a suitable container. Clean up any spilled oil with absorbent towels or pillows. DO NOT use absorbent particles to clean up the oil.

NOTICE Ensure that all of the rotor components are thoroughly clean before assembling the rotor. Failure to do so can cause an out of balance condition that can cause rapid wear to the bearings and the spindle. Note: Install a new paper liner when the centrifugal oil filter is assembled. c. Assemble the centrifugal oil filters according to the instructions in the Service Manual. NOTICE Only use oils that are recommended by Caterpillar. For the proper oil to use, refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section).

Illustration 97

g00540945

(2) Cover (3) Seal (4) Screen

a. Remove cover (2) and seal (3). Discard the used seal. Slide screen assembly (4) from the tube.

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101 Maintenance Recommendations Engine Oil Filter - Change

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.

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.

Replacing the Engine Oil Filters With the Engine Stopped

Hot oil and components can cause personal injury.

If the oil level is above the “FULL” mark on the oil level gauge, drain some of the oil immediately.

Do not allow hot oil or components to contact skin.

8. Remove the oil filler cap. Fill the crankcase through the oil filler tube only. Clean the oil filler cap. Install the oil filler cap.

Perform the following procedure after the oil has been drained.

9. Start the engine according to this Operation and Maintenance Manual, “Engine Starting” topic (Operation Section).

Note: Use this procedure if the engine oil filters do not have a control valve.

a. Operate the engine at low idle for two minutes. Inspect the engine for oil leaks. b. Ensure that the oil level is at the “FULL” mark on the “LOW IDLE” side of the oil level gauge. 10. Stop the engine and allow the oil to drain back into the sump for a minimum of ten minutes. 11. Remove the oil level gauge and check the oil level. Maintain the oil level to the “FULL” mark on the “ENGINE STOPPED” side of the oil level gauge. i00936346

Engine Oil Filter - Change

Illustration 98

g00296711

(1) Pressure gauge (2) Drain (3) Cover (4) Control valve

SMCS Code: 1308-510; 1308

1. Connect a hose from each drain valve (2) to a suitable container in order to catch the oil.

Replace the engine oil filters when the following conditions are met:

2. Open both drain valves (2). Allow the oil to drain.

• Every oil change • The engine oil filter differential pressure reaches 100 kPa (15 psi). • The oil filters have been used for 1000 service hours or six months.

Note: Some oil will remain in the housing after the oil has been drained. This oil will pour out of the housing when cover (3) is removed. Prepare to catch the oil in a suitable container. Clean up any spilled oil with rags. DO NOT use absorbent particles to clean up the oil.


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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 3. Be alert to the spring force. The cover has a spring force up to 240 N (54 lb). Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of covers (3). Before removing the last two bolts or nuts, pry the covers loose or tap the covers with a rubber mallet in order to relieve any spring pressure.

6. Ensure that the surfaces for O-ring seals (6) are clean. Inspect the O-ring seals. If the old O-ring seals are damaged or deteriorated, replace the old O-ring seals with new O-ring seals. Install the Oring seals. 7. Install covers (3). Ensure that the spring is seated properly between elements (7) and covers (3). Close drain valves (2). 8. Ensure that the crankcase is filled with oil. Operate the prelube pump and rotate the control valve (if equipped) to the “FILL” position for each housing. After both of the housings are full of oil, turn the control valve (if equipped) to the “RUN” position. 9. Start the engine. Check for oil leaks.

Replacing the Engine Oil Filters During Engine Operation

Filter contains hot pressurized fluid when engine is running. Follow instructions on control valve to avoid personal injury. If rapid air movement exists to blow fluid, Stop the engine to avoid fire.

Illustration 99

g00215989

If it is necessary to replace the oil filters during engine operation, perform the following procedure.

(5) Wire rack (6) O-ring seal (7) Element

4. Elements (7) are mounted on wire racks (5) inside the housing. Use a pan to catch the oil that drips when wire racks (5) are removed. Remove wire racks (5). Remove used elements (7). Clean up any oil that is spilled. NOTICE Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Caterpillar . 5. Ensure that the new oil filter elements are in good condition. Place the elements on wire rack (5). Install the wire rack and the elements.

Illustration 100

g00296711

(1) Pressure gauge (2) Drain (3) Cover (4) Control valve

1. Connect a hose from drain valve (2) to a suitable container in order to catch the oil.

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2. Rotate control valve (4) to the “LOWER SERVICE” position. 3. Open drain valve (2) and drain the lower oil filter housing. Observe pressure gauge (1) until the pressure is “0” . Note: Some oil will remain in the housing after the oil has been drained. This oil will pour out of the housing when cover (3) is removed. Prepare to catch the oil in a suitable container. Clean up any spilled oil with rags. DO NOT use absorbent particles to clean up the oil.

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 4. After zero pressure has been reached, remove cover (3). Be alert to the spring force. The cover has a spring force up to 240 N (54 lb). Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of cover (3). Before removing the last two bolts or nuts, pry the cover loose or tap the cover with a rubber mallet in order to relieve any spring pressure.

NOTICE Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Caterpillar . 6. Ensure that the new oil filter elements are in good condition. Place the elements on wire rack (5). Install the wire rack and the elements. 7. Ensure that the surfaces for O-ring seal (6) are clean. Inspect the O-ring seal. If the old O-ring seal is damaged or deteriorated, replace the old O-ring seal with a new O-ring seal. Install the O-ring seal. 8. Install cover (3). Ensure that the spring is seated properly between element (8) and cover (3). Close drain valve (2). 9. Rotate control valve (4) to the “LOWER FILL” position. Observe pressure gauge (1). Check cover (3) for leaks. Note: A hydraulic stop will limit the rotation of the control valve until the oil filter housing is full of oil. 10. After the pressure of the lower oil filter and the upper oil filter is equal, rotate control valve (4) to the “UPPER SERVICE” position. Repeat Step 1 through Step 9 for the upper oil filter. 11. After the oil filters have been serviced and after the pressure of the lower oil filter and the upper oil filter is equal, rotate control valve (4) to the “RUN” position.

Inspect the Used Oil Filter Elements Cut the used oil filter element open with a utility knife. Remove the metal wrap. Cut the filter element free from the end caps. Spread apart the pleats and inspect the element for metal debris. An excessive amount of debris in the element may indicate early wear or a pending failure.

Illustration 101

g00215989

(5) Wire rack (6) O-ring seal (7) Element

5. Elements (7) are mounted on wire rack (5) inside the housing. Use a pan to catch the oil that drips when wire rack (5) is removed. Remove wire rack (5). Remove used elements (7). Clean up any oil that is spilled.

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.

104 Maintenance Recommendations Engine Oil Level - Check

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Aluminum debris may indicate problems with the bearings of the front gears. If aluminum debris is found, inspect the crankshaft vibration damper and the bearings of the front idler gear. 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. i02050563

a. If the engine is stopped, remove oil level gauge (1). Observe the oil level on “ENGINE STOPPED WITH OIL COLD” side (3). b. If the engine is operating, reduce the engine speed to low idle. Remove oil level gauge (1) and observe the oil level on “ENGINE AT LOW IDLE WITH WARM OIL” side (4). The oil level should be between “ADD” mark (5) and “FULL” mark (6).

Engine Oil Level - Check SMCS Code: 1348-535-FLV The most accurate check of the oil level is performed when the engine is stopped. Perform this maintenance on a surface that is as level as possible.

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.

Illustration 102

g00748492

2. If necessary, remove oil filler cap (2) and add oil. For the correct oil to use, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section). Do not fill the crankcase above “FULL” mark (6). Clean the oil filler cap. Install the oil filler cap.

(1) Oil level gauge (dipstick) (2) Oil filler

3. Record the amount of oil that is added. For the next oil sample and analysis, include the total amount of oil that has been added since the previous oil change. This will help to provide the most accurate oil analysis. i00976229

Engine Oil Sample - Obtain Illustration 103

(3) (4) (5) (6)

“ENGINE STOPPED WITH OIL COLD” side “ENGINE AT LOW IDLE WITH WARM OIL” side “ADD” mark “FULL” mark

1. Ensure that oil level gauge (1) is seated.

g00748491

SMCS Code: 1348-554-SM 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.

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105 Maintenance Recommendations Engine Oil Temperature Regulator - Replace

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 taking the sample, complete the Label, PEEP5031 for identification of the sample. To help obtain the most accurate analysis, provide the following information:

NOTICE Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples. A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken. Always use a designated pump for oil sampling and a designated pump for coolant sampling. Failure to do so may cause a false analysis which could lead to customer and dealer concerns.

• Engine model • Service hours on the engine • The oil's hours of use • 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.

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, PEHP6001, “How To Take A Good Oil Sample”. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your engine.

To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.

i00839584

Engine Oil Temperature Regulator - Replace SMCS Code: 1330-510 The oil temperature regulators divert the engine oil to the oil cooler in order to maintain engine oil temperature. For instructions on replacing the oil temperature regulators, see the Service Manual, “Disassembly and Assembly” module. i02349308 Illustration 104

g00496859

Particle Sensor (1) Oil sampling valve

Engine Protective Devices Check SMCS Code: 7400-535

Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples is 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 8T-9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve. The bottle group includes the parts that are needed for obtaining oil samples. Instructions are also provided.

Alarms and shutoffs must function properly. Alarms provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation. Malfunctions must be simulated in order to test the engine protective devices.

106 Maintenance Recommendations Engine Protective Devices - Check

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NOTICE During testing, abnormal operating conditions must be simulated. The tests must be performed correctly in order to prevent possible damage to the engine.

Perform a Static Test Inspect the components of the alarm and shutoff systems for good condition. Test the operation of the alarms and shutoffs. A static test of the engine protective devices will ensure that the alarms and shutoffs are functioning properly. To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests. Consult your Caterpillar dealer or refer to the Service Manual for more information.

Inspect the Connections of the Engine Protective Devices Inspect the wiring and the electrical connections for these components: Illustration 105

• Connectors

g01173779

(1) Terminal strips on the back plate of the enclosure (2) Terminal strips on the rear of the panel

• Control panel • Junction box • Sensors

3. Check the wiring for secure connections at these points of the junction box and the control panel: • Connectors

1. Turn the engine control switch to the “OFF/ RESET” position. Open the circuit breaker or circuit breakers of the main power supply.

• Relays

2. Inspect all of the wiring for the following conditions:

• Terminal strips

• Fraying • Damaged insulation • Corrosion Make repairs, as needed.

• Switches

Perform a pull test for each wire. This test will ensure that the wiring is properly attached. Test each wire individually. a. Pull each wire with approximately 45 N (10 lb) of force. Pull the wire firmly. If a wire is loose, repair the connection. 4. Inspect the wiring at the relays and terminal strips for these conditions: • Corrosion • Fraying

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107 Maintenance Recommendations Engine Protective Devices - Check

a. If corrosion is found, scrape large deposits. Use cotton swabs with denatured alcohol to clean any corrosion that remains. Investigate the source of the corrosion. Correct the condition. If damage is found, replace the part. b. Remove frayed strands of wire or tin the wire. c. Perform Steps 6 and 7 for the connectors of the control panel and the junction box.

Perform a pull test for each wire. This test will ensure that the wiring is properly attached. Test each wire individually. a. For wiring that is attached to a connector, hold the body of the connector with one hand. Pull each wire with approximately 45 N (10 lb) of force. Pull the wire firmly. b. Before testing the wiring of the sensors, ensure that the sensors are securely installed. Then pull each wire with approximately 45 N (10 lb) of force. If a wire is loose, repair the connection. 6. Disconnect the connectors at the following locations. Inspect the connectors. • Engine sensors • Junction box • Modules of the control panel a. Inspect each pin and each socket for corrosion and damage.

Illustration 106

g01230500

Note: The wiring is crimped into the pins and sockets of Deutsch DT connectors.

If corrosion is found, scrape large deposits. Use cotton swabs with denatured alcohol to clean any corrosion that remains. Investigate the source of the corrosion. Correct the condition. If damage is found, replace the part. 7. Reconnect the connectors. a. For Military Standard and Jaeger connectors, ensure the following conditions: • The connection is threaded properly. • The connection is threaded completely. Very little thread or no thread is visible. b. For Deutsch DT connectors, ensure that the plug and the receptacle are securely connected.

Illustration 107

g01230207

Deutsch DT connectors 5. Check the wiring for secure connections at these points: • Connectors • Sensors

8. Close the circuit breaker or circuit breakers of the main power supply.

108 Maintenance Recommendations Engine Valve Lash and Bridge - Check

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i04811397

Engine Valve Lash and Bridge Check SMCS Code: 1102-535; 1121-535

The barring device provides a means for slowly turning the flywheel in order to service the engine. The barring device can also be used to prevent rotation of the crankshaft.

Fuel Injector Timing (Fuel Timing)

For instructions on the following procedures, see the Service Manual, “Systems Operation/Testing and Adjusting”. Consult your Cat dealer for assistance.

Correctly time the camshafts with the crankshaft before adjusting the fuel timing. The fuel timing dimension is stamped on the engine Information Plate.

Check the Timing of the Crankshaft and Camshaft

Fuel Injector Clamp

The timing of the crankshaft and camshaft must be checked, and the valve bridge must be adjusted before the valve lash is adjusted. Correctly time the camshafts with the crankshaft before adjusting the fuel timing.

The clamp must be used to draw the injector into the bore. Do not tap on the top of the injector. Be sure to protect the spray tip from dirt and damage.

NOTICE If the camshaft is rotated with the timing pin installed, the timing pin will break. This can result in further damage. Make sure to remove the timing pin before the camshaft is rotated.

NOTICE Do NOT attempt to adjust the valves if the crankshaft and camshaft are not synchronized. Disregard for this can result in engine damage such as bent valves.

NOTICE DO NOT use the starting motor to rotate the crankshaft. The lubrication oil can drain out from between the crankshaft and the engine bearings if the engine has not been operated for a period of time. Damage can result if the crankshaft is rotated on dry bearing surfaces. To prevent damage to the crankshaft bearings, DO NOT crank the engine before prelube, especially after this maintenance procedure. NOTICE The prelube pump should not be operated continuously for extended periods of time. If, during repairs, the prelube pump has run continuously for a period of three hours or more, it will be necessary to remove any oil that may have collected in the cylinders and/or above the valves. Prelube of the engine is required before the crankshaft is rotated for normal maintenance. Activate the prelube pump for rotating the engine crankshaft. NOTICE Do not use an impact wrench to operate the barring device. The use of an impact wrench will cause gear tooth failure.

Valve Bridge

Check the valve bridge and adjust the valve bridge, if necessary. Perform the procedure for both valve bridges for each cylinder. After the valve bridge is satisfactory, check the valve lash.

Engine Valve Lash If the valve lash is within the tolerance, an adjustment of the valve lash is NOT necessary. The crankshaft and camshaft timing must be checked, and valve bridge adjustment must be performed before making a valve lash adjustment. Perform the valve lash setting when the engine is cold. After the engine has been shut down and the valve covers are removed, the engine is considered cold. Before performing maintenance, prevent the entry of foreign matter into the top of the cylinder head and the valve mechanism. Thoroughly clean the area around the valve mechanism covers.

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109 Maintenance Recommendations Engine Valve Rotators - Inspect

i04399601

i04811563

Engine Valve Rotators - Inspect

Exhaust Piping - Check

SMCS Code: 1109-040

SMCS Code: 1061-535

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. Note: Use of a platform may be necessary to reach the engine valve rotators. Perform this procedure after the valve lash has been set. Note: Ensure that the engine cannot be started except by the person performing the maintenance procedure. Install a “DO NOT OPERATE” tag near the starting mechanism. 1. Remove the covers for the valve mechanisms. Refer to the Disassembly and Assembly Manual, “Valve Cover - Remove and Install” for the procedure.

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. Inspect the components of the exhaust system. Repair the components or replace the components for any of the following conditions: • Damage • Cracks • Leaks • Loose connections For information on removal and installation, see the Service Manual, “Disassembly and Assembly” module. Consult your Cat dealer for assistance. i02355562

2. Mark the tops of the valve rotators with a permanent marker. Note the position of the marks.

Fuel Analysis - Obtain

3. Install the covers for the valve mechanisms. Refer to the Disassembly and Assembly Manual, “Valve Cover - Remove and Install” for the procedure.

To ensure optimum performance of the engine, obtain a complete fuel analysis when fuel is delivered. Obtain the analysis before using the fuel.

4. Start the engine. Operate the engine for 5 minutes. Stop the engine.

1. Ask the supplier of the fuel for the fuel specifications.

5. Remove the covers for the valve mechanisms. Refer to the Disassembly and Assembly Manual, “Valve Cover - Remove and Install” for the procedure.

2. Obtain samples of the fuel.

6. Observe the position of the marks that are on the valve rotators. 7. If any valve fails to rotate, consult your Cat dealer. 8. Install the covers for the valve mechanisms. Refer to the Disassembly and Assembly Manual, “Valve Cover - Remove and Install” for the procedure.

SMCS Code: 1280-554

Note: If a fuel supply is delivered to the site by trucks, obtain samples from approximately five percent of the supply tanks. a. Submit a sample of the fuel immediately to an independent laboratory for analysis. The fuel analysis must include all of the properties that are listed in Special Publication, SEBU7003, “3600 Series and C280 Series Diesel Engine Fluids Recommendations”. b. Retain samples of the fuel in case future analysis is needed. Label the samples accurately for future identification. The samples may be needed for future analysis if questions about quality, stability, or compatibility arise.

110 Maintenance Recommendations Fuel System - Prime

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3. Compare the supplier's report to the report from the analysis. The reports may indicate variations within the fuel. If the reports are inconsistent, obtain another analysis of the fuel. This will eliminate the possibility of testing error. 4. Compare the reports to Special Publication, SEBU7003, “3600 Series and C280 Series Diesel Engine Fluids Recommendations”. If the fuel does not meet the minimum requirements, deposits and/or corrosion could cause excessive wear on the fuel system and/or failure of the fuel system. Clean fuel that meets the fuel recommendations will help ensure rated engine performance and maximum engine service life. i02349701

Fuel System - Prime SMCS Code: 1250-548; 1258-548

Illustration 108

g00748507

Typical example (1) Priming pump (2) Connector

2. Operate priming pump (1). Turn the handle clockwise until fuel appears at the openings of the vent plugs. Operate the priming pump until the fuel flows free of air bubbles. Clean up any spilled fuel immediately. 3. Tighten the vent plugs.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. 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. Prime the fuel system in order to fill dry fuel filters and purge air from the fuel system. Prime the fuel system after the following occurrences: • The fuel filter elements are replaced. • The engine is run dry. • The fuel lines have been disconnected. • The engine has been overhauled. • The engine is removed from storage. 1. Loosen the vent plugs that are on the top of the fuel filter covers.

Priming the Fuel System After Disconnecting Fuel Lines or After an Overhaul 1. Loosen connector (2). The connector is above the fuel pressure regulator valve. Use a cloth to catch any fuel and clean up any fuel that overflows. 2. Operate priming pump (1). Turn the handle clockwise until fuel appears at the opening of the connector. Operate the priming pump until the fuel flows free of air bubbles. Clean up any spilled fuel immediately. 3. Tighten connector (2).

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111 Maintenance Recommendations Fuel System Primary Filter (Water Separator) Element - Replace

i02046822

3. Remove nut (4). Remove the filter case.

Fuel System Primary Filter (Water Separator) Element Replace SMCS Code: 1260-510-FQ; 1263-510-FQ

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 110

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.

g00477788

(5) Element (6) Seals

4. Remove element (5) and seals (6).

Primary Filter

5. Clean the filter case, the element, and the seals with clean, nonflammable solvent. Allow the parts to dry.

Servicing the Primary Filters During Engine Operation

6. Inspect the element and the seals for good condition. Obtain new parts, if necessary. See the Parts Manual for the engine. 7. Assemble the clean, dry element, seals, and filter case. Use clean diesel fuel on the seals to make installation easier. Tighten nut (4). Close drain valve (3). 8. Lift lock (1) and move lever (2) to the “BOTH RUN” position for one minute. 9. To service “FILTER 1” , lift lock (1) and turn lever (2) to the “FILTER 2 RUN” position. Release the lock. 10. Repeat Steps 2 through 8 for “FILTER 1” .

Illustration 109

g00477786

Primary filters in the “FILTER 1 RUN” position (1) Lock (2) Lever (3) Drain valve (4) Nut

1. To service “FILTER 2” , lift lock (1) and turn lever (2) to the “FILTER 1 RUN” position. Release the lock. 2. Hold a suitable container under drain valve (3). Open the drain valve. Allow the moisture to drain. Close the drain valve.

Servicing the Primary Filters With the Engine Stopped 1. Ensure that the fuel to the engine is OFF. 2. Refer to “Servicing the Primary Filters During Engine Operation”. Perform Steps 2 through 7 for both filters. It may be necessary to prime the fuel system before the engine will start. See this Operation and Maintenance Manual, “Fuel System - Prime” topic (Maintenance Section).

112 Maintenance Recommendations Fuel System Primary Filter/Water Separator - Drain

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Water Separator

5. Repeat Steps 2 and 3 for filter (2).

Replace the water separator element according to the instructions that are provided by the OEM of the water separator.

Water Separator

i00938031

Fuel System Primary Filter/ Water Separator - Drain SMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

For specific instructions on draining the water separator, see the service information that is provided by the OEM of the water separator. 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.

i05361070

Fuel System Secondary Filter Replace

NOTICE Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.

SMCS Code: 1261-510-SE

Primary Filter

• The engine is operating at rated speed and at operating temperature and the fuel filter differential pressure reaches 69 kPa (10 psi).

Replace the secondary fuel filter elements when either of the following conditions occur:

• The fuel filter elements have been used for 1000 hours of operation. Service tools are available to aid in the service of oil filters and fuel filters. Consult your Cat 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.

Replacing the Secondary Filters With the Engine Stopped Illustration 111

g00477706

(1) Filter (2) Filter (3) Lock (4) Lever (5) Drain valve

1. To drain filter (1), lift lock (3) and turn lever (4) to the “FILTER 2 RUN” position. Release the lock. 2. Hold a suitable container under drain valve (5). Open the drain valve. Allow the moisture to drain. Close the drain valve. 3. Lift lock (3) and move lever (4) to the “BOTH RUN” position for one minute. 4. To drain filter (2), lift lock (3) and turn lever (4) to the “FILTER 1 RUN” position. Release the lock.

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.

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Illustration 112

113 Maintenance Recommendations Fuel System Secondary Filter - Replace

g00335918

(1) Control valve (2) Drain valve (3) Vent plug (4) Cover

1. Stop the engine. Connect one end of a hose to each drain valve (2). Insert the other end of the hoses into a suitable container in order to catch the fuel. 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. 2. Remove both vent plugs (3). Open both drain valves (2) in order to drain the secondary fuel filters.

Illustration 113

g00274418

Section view of the secondary fuel filter (4) Cover (5) O-ring seal (6) Wire rack (7) Element

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 3. Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of cover (4). Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure. Remove covers (4) from both fuel filter housings. 4. Four elements (7) are installed on wire rack (6). Remove wire racks (6). Discard the used elements. Remove O-ring seals (5). Discard the used O-ring seals. 5. Clean covers (4). Clean wire racks (6). Install new O-ring seals (5). 6. Inspect new elements (7) for good condition. Install elements (7) and wire racks (6). 7. Install covers (4). Ensure that the spring is seated properly between covers (4) and elements (7). 8. Close drain valves (2). Clean vent plugs (3). Install the vent plugs loosely. Prime the fuel system. See this Operation and Maintenance Manual, “Fuel System - Prime” topic (Maintenance Section). 9. Start the engine and check for fuel leaks.

114 Maintenance Recommendations Fuel System Secondary Filter - Replace

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Replacing the Secondary Filters During Engine Operation

3. Remove vent plug (3). Open drain valve (2) in order to drain the lower secondary fuel filter.

Filter contains hot pressurized fluid when engine is running. Follow instructions on control valve to avoid personal injury. If rapid air movement exists to blow fluid, Stop the engine to avoid fire.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Illustration 115

g00274418

Section view of the secondary fuel filter (4) Cover (5) O-ring seal (6) Wire rack (7) Element

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. Illustration 114

g00335918

(1) Control valve (2) Drain valve (3) Vent plug (4) Cover

1. To service the lower secondary fuel filter, turn control valve (1) to the “UPPER RUN” position. 2. Connect one end of a hose to drain valve (2). Insert the other end of the hose into a suitable container in order to catch the fuel. 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.

4. Gradually loosen but do not remove the last two bolts or nuts that are located at opposite ends of cover (4). Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure. Remove cover (4). 5. Four elements (7) are installed on wire rack (6). Remove wire rack (6). Discard the used elements. Remove O-ring seal (5). Discard the used O-ring seal. 6. Clean covers (4). Clean wire racks (6). Install new O-ring seals (5). 7. Inspect new elements (7) for good condition. Install elements (7) and wire rack (6). 8. Install cover (4). Ensure that the spring is seated properly between cover (4) and elements (7).

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115 Maintenance Recommendations Fuel Tank Water and Sediment - Drain

9. Close drain valve (2). Clean vent plug (3). Install the vent plug loosely. Slowly turn control valve (1) to the “LOWER FILL” position. After 5 minutes, turn control valve (1) to the “BOTH RUN” position. Tighten vent plug (3).

Some day tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some day 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.

10. To service the upper secondary fuel filter, turn control valve (1) to the “LOWER RUN” position. Perform Steps 1 through 9 for the upper secondary fuel filter.

Settling Tank

11. After both of the secondary fuel filters have been serviced, turn control valve (1) to the “BOTH RUN” position. The control valve Must Be Placed in the “BOTH RUN” position during normal operation after the fuel filters have been serviced. Never operate the engine on one bank of filters during normal operation. Failure to do so will result in fuel aeration that could cause premature injector wear and/or failures. i00939327

Fuel Tank Water and Sediment - Drain SMCS Code: 1273-543-M&S

Day 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 day tank. This causes water to accumulate in the day tank. Draining the day tank regularly and obtaining fuel from reliable sources can help to eliminate water from the fuel. Day tanks should have a provision for draining water and sediment. Open the drain valve on the bottom of the day tank in order to drain the water and the sediment. Close the drain valve. Drain the water and sediment from the day tank daily. The quality of the fuel and/or the operating conditions may require more frequent draining of the water and sediment. Fill the day 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.

Drain the water and the sediment from the settling tank daily. Ensure that the temperature of the settling tank is proper for the viscosity of the fuel oil.

Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank daily. Ensure that the water and sediment is drained from the fuel storage tank when the tank is refilled. This will help prevent water and/or sediment from being pumped from the fuel storage tank into the settling tank. i03230758

Jacket Water Heater - Check SMCS Code: 1383-535 Jacket water heaters help to improve startability in ambient temperatures that are below 21 °C (70 °F). All installations that require automatic starting should have jacket water heaters. Check the operation of the jacket water heater. Check the operation of the circulation pump, if equipped. For an ambient temperature of 0 °C (32 °F), the heater should maintain the jacket water coolant temperature at approximately 32 °C (90 °F). i04811657

Metal Particle Detector Inspect/Clean SMCS Code: 7400-040; 7400-070 If the metal particle detector causes a shutdown, inspect the detector.

116 Maintenance Recommendations Oil Mist Detector - Check

Illustration 116

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Metal particle detector

Illustration 117

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Oil mist detector

1. Remove the grid from the inside of the detector. 2. If metal particles are found, determine the source of the particles. NOTICE Metal particles in the lube oil may indicate a serious condition that requires immediate attention. If metal particles are found in the grid of the detector, do not start the engine until the source of the particles is found and the condition is corrected. Failure to do so could cause severe damage to the engine. 3. Clean the grid with nonflammable solvent. Install the clean, dry grid.

(1) Vent line (2) Drain

Inspect vent line (1) for proper ventilation. Open drain (2) in order to drain the condensation trap. Drain the condensation into a suitable container. Close the drain.

Check the Vacuum in the Measuring Track Check the vacuum in the measuring track according to the service instructions that are provided by the OEM of the oil mist detector. Adjust the driving air pressure, if necessary. Refer to the Testing and Adjusting, RENR2225 for additional information about the oil mist detector or the literature that is provided by the OEM of the oil mist detector. i02349423

i01979490

Oil Mist Detector - Check

Overhaul (Major)

SMCS Code: 1336-535; 7400-535

SMCS Code: 7595-020-MJ

Drain the Condensation

The need for a major overhaul is determined by several factors.

Note: More frequent draining may be required in humid environments.

• An increase of oil consumption • An increase of crankcase blowby • A decrease and variation of cylinder compression Other factors must also be considered for determining a major overhaul: • 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

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117 Maintenance Recommendations Overhaul (Major)

An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service.

Remanufacturing or Rebuilding of Components

Note: It is possible for oil analysis to 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.

• Air shutoff valve

Monitor the engine as the engine accumulates service hours. Consult your Caterpillar dealer about scheduling a major overhaul.

• Starting motor

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.

Replace the following components.

A major overhaul includes all of the work that is done for top end overhauls. A major overhaul includes additional parts and labor. Additional parts and labor are required in order to completely rebuild the engine.

• Connecting rod bearings

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.

Rework the following components.

• Centrifugal oil filter bearings • Cylinder heads

Replacement of Components • Accessory group bearings

• Cylinder head gaskets • Cylinder head valves and valve guides • Cylinder head valve spring guides • Exhaust manifold gaskets • Exhaust manifold seals and bellows • Exhaust shields • Front gear train bearings • Inlet air line seals

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations.

• Oil temperature regulators and seals

Fuel Consumption Before A Major Overhaul

• Water pump bearings and seals

The overhaul interval that is listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” is expressed in service hours. A more accurate figure to use is fuel consumption. Fuel consumption corresponds more accurately to the engine load. Table 24 lists an average range of fuel consumption for a reasonable load factor before a major overhaul.

Inspection and/or Replacement of Components

Table 24 Approximate Fuel Consumption Before A Major Overhaul Engine Model

Fuel Consumption

C280-06

11 370 000 L (3,000,000 US gal)

C280-08

15 160 000 L (4,000,000 US gal)

C280-12

22 740 000 L (6,000,000 US gal)

C280-16

30 320 000 L (8,000,000 US gal)

• Unit injectors

• Water temperature regulators and seals

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. Replace the components, if necessary.

118 Maintenance Recommendations Overhaul (Major)

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• Aftercooler core

• deflection

• Alarm and shutoff controls

• damage to the journals

• Camshafts

• bearing material that has seized to the journals

• Camshaft bearings

Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:

• Connecting rod bearings • Crankshaft

• rod bearing • Cylinder liners • main bearings • Cylinder sleeves • Exhaust manifolds • Front gear group

Note: If the crankshaft or the camshaft are removed for any reason, use the magnetic particle inspection process to check for cracks.

• Fuel transfer pump seals

Replace the crankshaft vibration damper if any of the following conditions occur:

• Main bearings

• Engine failure due to a broken crankshaft

• Oil cooler seals

• Excessive wear of the front bearing for the crankshaft

• Oil pump bushings and seals • O-Ring seals and plugs • Pistons and piston rings • Priority valve • Rear gear group • Rear gear train bearings and seals • Rocker arm bearings • Thermocouples • Thrust bearings • Turbocharger bearings, bushings, and seals • Valve lubricator pump, gaskets, and seals

• 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

Cleaning and Inspection of Components Clean the following components. Inspect the components for good condition. Replace the components, if necessary. Replace the gaskets and seals for the components.

• Valve mechanism group • Water pump bearing and seals Inspect the camshaft for damage to the journals and the lobes. Inspect the following components for signs of wear and/or for signs of scuffing: • camshaft bearings • camshaft followers Inspect the crankshaft for any of the following conditions:

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119 Maintenance Recommendations Overhaul (Top End)

Fuel Consumption Before A Top End Overhaul

• Air inlet lines • Camshaft front covers

The overhaul interval that is listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” is expressed in service hours. A more accurate figure to use is fuel consumption. Fuel consumption corresponds more accurately to the engine load. Table 25 lists an average range of fuel consumption for a reasonable load factor before a top end overhaul.

• Camshaft drive gear covers • Central structure covers • Crankcase side covers • Crankshaft

Table 25

• Crankshaft vibration damper

Approximate Fuel Consumption Before A Top End Overhaul

• Front housing group

Engine Model

• Fuel lines

Fuel Consumption

C280-06

5 685 000 L (1,500,000 US gal)

• Fuel transfer pump

C280-08

7 580 000 L (2,000,000 US gal)

• Gear inspection group

C280-12

11 370 000 L (3,000,000 US gal)

• Oil cooler core

C280-16

15 160 000 L (4,000,000 US gal)

• Oil lines

Remanufacturing or Rebuilding of Components

• Oil suction screen • Power take-off covers

Rework the following components:

• Priority valve group

• Air shutoff valve

• Rear housing group

• Cylinder heads

• Rear structure covers

• Cylinder dowels

• Valve covers

• Exhaust valves

• Water lines

• Exhaust valve seat inserts i02349437

• Inlet valves

Overhaul (Top End)

• Inlet valve seat inserts

SMCS Code: 7595-020-TE

• Inner valve springs

A top end overhaul involves the removal, the inspection, and the rework of the cylinder head components. Some additional components are replaced and serviced.

• Outer valve springs

Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.

• Unit injectors • Valve spring guides • Valve spring locks • Valve rotators

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.

Note: The angles of the valves and seats are different.

If you elect to perform an overhaul without the services of a Caterpillar dealer, be aware of the following recommendations.

If the valves and seats are not replaced, lap the valves and seats. The valve and the outer diameter of the seat must have 360 degrees of contact. If the valves and the seats require regrinding, see the Service Manual, “Specifications” module for the angles.

120 Maintenance Recommendations Overhaul Considerations

Inspection and/or Replacement 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. Replace the components, if necessary.

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Oil Suction Screen For cleaning the oil suction screen, see this Operation and Maintenance Manual, “Engine Oil - Change” procedure. i02301217

Overhaul Considerations

• Cylinder sleeves

SMCS Code: 7595-043

• Exhaust shields

Overhaul Information

• Starting motor

Replacement of Components

An overhaul is replacing the major worn components of the engine. An overhaul interval is a maintenance interval that is planned. The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts.

Replace the following components.

An overhaul also includes the following maintenance:

• Connecting rod bearings

• Inspection of all the parts that are visible during the disassembly

• Thermocouples

• Cylinder head gaskets and seals • Exhaust manifold gaskets • Fuel transfer pump seals • Inlet air line seals • Oil cooler seals • Oil pump bearings and seals

• Replacement of the seals and gaskets that are removed • Cleaning of the internal passages of the engine and the engine block Most owners will save money by overhauling the engine at the intervals that are recommended in this Operation and Maintenance Manual. Consider the graph in Illustration 118 .

• Oil temperature regulators and seals • Turbocharger bearings, bushings, and seals • Valve lubricator pump (if equipped) • Water pump bearings and seals • Water temperature regulators and seals

Cleaning and Inspection of Components Clean the following components. Inspect the components for good condition. Replace the components, if necessary. • Oil cooler core • Oil suction screen

Oil Cooler Core For cleaning the oil cooler core, see this Operation and Maintenance Manual, “Aftercooler Core - Clean/ Test” procedure. The procedure may be used for cleaning both the aftercooler core and the oil cooler core.

Illustration 118

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(Y) Cost (X) Time (1) Cost of maintenance and repair that is planned (2) Cost of maintenance and repair that is not planned

In Illustration 118 , line (1) represents the maintenance and repair costs for an owner that followed the recommendations for inspection, maintenance, and repair. The peaks represent overhauls.

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Line (2) represents the maintenance and repair costs for an owner that chose to operate beyond the recommended intervals. The initial cost of the “repairafter-failure” philosophy is lower. Also, the first overhaul was delayed. However, the peaks are significantly higher than the peaks for the customer that used the “repair-before-failure” philosophy .

Other factors must also be considered for determining a major overhaul:

The higher peaks result from two key factors:

• The total amount of fuel consumption

• Delaying an overhaul until a breakdown increases the chance of a catastrophic failure. This type of failure requires more parts, labor, and cleanup.

• The service hours of the engine

Generally, engines that are operated at a reduced load and/or speed achieve more service life before an overhaul. However, this is for engines that are properly operated and maintained.

• An increase of oil consumption

• Excessive wear means that fewer components will be reusable. More labor may be required for salvage or repair of the components.

• An increase of crankcase blowby

When all of the costs are considered, “repair-beforefailure” is the least expensive alternative for most components and engines.

• An increase in the levels of noise and vibration

It is not practical to wait until the engine exhibits symptoms of excessive wear or failure. It is not less costly to wait. 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 guidelines for reusable parts. • The service life of the engine can be extended without the risk of a major catastrophe due to engine failure. • Achieve the best cost/value relationship per hour of extended service life.

Overhaul Intervals Some factors that are important for determining the overhaul intervals include the following considerations: • Performance of preventive maintenance • Use of recommended lubricants • Use of recommended coolants • Use of recommended fuels • Proper installation • Operating conditions

• The wear metal analysis of the lube oil

An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service. Note: It is possible for oil analysis to 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.

Using Fuel Consumption For Calculating the Overhaul Intervals The total fuel consumption is the most important factor for estimating the overhaul interval. Fuel consumption compensates for the application and for the engine load. If the total fuel consumption has not been recorded, use the equation in Table 26 in order to estimate the hours until the overhaul. The equation may also be used to estimate overhaul intervals for new engines. Table 26 Equation For Calculating Overhaul Intervals H = F/R

• Operation within acceptable limits

“H” is the number of estimated hours until the overhaul interval.

• Engine load

“F” is the estimated total amount of fuel consumption of the engine.

• Engine speed

“R” is the rate of fuel consumption in liters per hour or gallons per hour.


Use the actual records of fuel consumption, when possible. If the actual records are not available, use the following procedure in order to estimate the fuel consumption. 1. Estimate the average percent of the load for the operation of the engine. 2. Refer to the engine's Caterpillar , “Engine Specifications” (“spec” sheet). This will determine the fuel consumption for the percent of the load that was estimated in Step 1. Use this figure for the equation in Table 26 .

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. 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.

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The use of out-of-spec parts could result in unscheduled downtime and/or costly repairs. The use of out-of-spec parts can also contribute to increased fuel consumption and reduction of engine efficiency. New parts are not necessary if the old parts can be reused, repaired, or salvaged. Otherwise, the old parts can be replaced or exchanged. Your Caterpillar dealer can provide the parts that are needed to rebuild the engine at the least possible cost.

Overhaul Programs An economical way to obtain most of the parts that are needed for overhauls is to use Caterpillar remanufactured parts. Caterpillar remanufactured parts are available at a fraction of the cost of new parts. These parts have been rebuilt by Caterpillar and certified for use. The following components are examples of the remanufactured parts: • Cylinder heads • Oil Pumps • Turbochargers • Water pumps Consult your Caterpillar dealer for details and for a list of the remanufactured parts that are available. Your Caterpillar dealer may be offering a variety of overhaul options.

When an engine's 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.

A Flat Rate Overhaul guarantees the maximum price that you will pay for an overhaul. Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar Engines. Consult your Caterpillar dealer in order to schedule a before failure overhaul.

Overhaul Inspection

Overhaul Recommendation

Refer to the Service Manual for the disassembly and assembly procedures that are necessary in order to perform the required maintenance on the items that are listed. Consult your Caterpillar dealer for assistance. To determine the reusability publications that are needed to inspect the engine, refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, Index of Publications on Reusability or Salvage of Used Parts. The Guidelines For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program. These guidelines were developed in order to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts. If the engine parts comply with the established inspection specifications, the parts can be reused.

Caterpillar recommends a scheduled overhaul in order to minimize downtime. A scheduled overhaul will provide the lowest cost and the greatest value. Schedule an overhaul with your Caterpillar dealer. Overhaul programs vary between dealers. To obtain specific information about the types of overhaul programs and services, consult your Caterpillar dealer.

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123 Maintenance Recommendations Prelube Pump - Lubricate

i00939520

Prelube Pump - Lubricate

3. Install the speed sensor according to the information in the Service Manual, “Specifications”.

SMCS Code: 1319-086

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Starting Motor - Inspect SMCS Code: 1451-040; 1453-040 More frequent inspection and replacement of the starting motor may be required for the following conditions: • Operation in harsh environments • Applications that require frequent stops and starts If the starting motor fails, the engine may not start in an emergency situation. A scheduled inspection of the starting motor is recommended. Illustration 119

g00478820

Grease fittings Lubricate the two motor bearings. Apply one pump of MPGM to each fitting with a hand operated grease gun. i01472973

Speed Sensor - Clean/Inspect SMCS Code: 1907-040; 1907-070

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. If damaged teeth are found, the air circuit for the starting motor must be examined in order to determine the cause of the problem.

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.

Illustration 120

g00293337

Typical speed sensor 1. Remove the speed sensor from the flywheel housing. Check the condition of the end of the speed sensor. Check for signs of wear and contaminants. 2. Clean the metal shavings and other debris from the face of the magnet.

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 repairs are needed, see the Service Manual or consult your Caterpillar dealer.

124 Maintenance Recommendations Trend Data - Record

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i01980670

Trend Data - Record SMCS Code: 1000-043 Records of engine performance are an important element of a maintenance program. The data on engine performance can help to predict problems with operation. Also, the data can provide information that is useful for achieving optimum operation. Traditionally, data on engine performance might be recorded regularly. However, the data might not be reviewed until the occurrence of a problem. This method of monitoring engine operation has several disadvantages: • The engine may not be providing optimum performance. This may not be noticed because the engine does not exhibit excessive changes in performance. • Because a problem occurs, the engine may be in an alarm condition that requires a quick response. • Repairs may cause more downtime. • The cost of downtime is compounded by the cost of parts and labor for repairs.

• Record the data regularly when the engine is operating at similar loads and speeds. • Obtain accurate data. • At regular intervals, review the data in a graphic format. • Perform corrections before damage and/or downtime occurs. Accurate data is provided by accurate instruments and proper use of the instruments. The gauges and the sensing devices must be in good condition. This is especially true for thermocouples. Establish a program for calibrating the instruments periodically. Avoid using infrared thermometers for obtaining data. Be sure to read the gauges properly. Accurate recording of the data is also important. Use the following Steps to establish a program. 1. Establish a baseline for the engine parameters. The baseline is necessary in order to know the normal gauge readings. The new data will be compared to the baseline. • Use the data from the engine commissioning. The data is recorded for various loads. The data is recorded before any wear or deterioration takes place.

The absence of an alarm condition does NOT guarantee normal operation. Not all parameters have alarms and/or shutdowns. Setpoints for alarms are outside of the normal ranges in order to avoid occasional nuisance warnings. An alarm indicates a serious condition that requires immediate attention. Service or repair is a reaction to an alarm condition.

• If there is no data from the engine commissioning, use data from the engine test cell. Understand that the data will not be specific to the site.

A different approach is necessary in order to schedule service before an alarm condition occurs. Monitor the trends of the engine's performance. The following benefits can be realized:

• If data is not available from the engine commissioning or the engine test cell, calculate an average of the existing data.

• Reduction of engine performance will be noticed sooner.

• Establish a new baseline after an overhaul.

• Problems can be predicted. This enables prevention of the problems. Service can be planned before an alarm condition occurs.

2. Frequently record the new data during engine operation. For an example of a log to use, see this Operation and Maintenance Manual, “Hourly Performance Log” (Reference Information Section).

• Planning for downtime will also reduce downtime. • The cost of parts and labor for service that is planned will be less than the cost of repairs that are not anticipated.

Monitoring the Trends of Engine Performance To maintain a program that is successful, several factors are important:

Be aware that the readings of some parameters depend on the engine load. Record the data when the engine is operating at a high load. This increases the accuracy of the data. Also, any reduction in performance will be revealed sooner. A load of 75 to 100 percent is recommended. • For operations with a consistent load cycle, record the data at the same time for each day. • If the load can be controlled, set the load to the same amount for each reading.

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Some parameters that are NOT affected by the load ARE affected by the engine rpm. Obtain the readings for these parameters when the engine is operating at the same rpm. Some parameters are not affected by either the load or the rpm. See Table 27 . Table 27 Parameters of Engine Operation Parameters That Depend On the Load Aftercooler and oil cooler water temperature (outlet) Exhaust manifold pressure Exhaust manifold temperature Illustration 121

Exhaust port temperature

Example of a graph of engine oil pressure

Generator stator temperature

(Y) Pressure in kPa (X) Calendar days (1) Baseline (2) Operating pressure (3) Setpoint (alarm)

Inlet air restriction Inlet manifold air pressure (boost pressure) Inlet manifold air temperature Jacket water coolant temperature (outlet) Parameters That Depend On the RPM Fuel filter differential pressure Jacket water pressure Lube oil pressure Oil filter differential pressure Parameters That Are Independent of the Load and RPM Aftercooler and oil cooler water temperature (inlet) Jacket water coolant temperature (inlet) Lube oil temperature

Note: A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge.

g00543927

3. Average the data for each day. Use a computer or graph paper in order to produce a graph of the data. Compare the new data to the baseline. This will help to reveal the trends of the engine performance. Illustration 121 shows that the engine oil pressure was near baseline (1). Later, the operating pressure was approaching setpoint (3). The trend of operating pressure (2) indicated that the condition required investigation before activation of the alarm. 4. Compare the new data to the data from previous months. This comparison will be useful for scheduling reconditioning for the engine.

Monitoring the Trends of Fuel Consumption Fuel consumption depends on the following factors: • Engine load • The fuel efficiency of the engine • The service hours of the engine Use these two methods in order to obtain accurate data on fuel consumption:


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• Calculate the Specific Fuel Consumption. For this calculation, the weight of the fuel that was burned is divided by the electrical energy that was produced. • Calculate the Heat Rate. This calculation compensates for the fuel energy content of different fuels. For this calculation, the low heat value (LHV) of the fuel is divided by the electrical energy that was produced.

(Table 30, contd) SFC is the specific fuel consumption. LHV is the low heat value of the fuel. HR is the heat rate.

Table 31 is an example for using the equation that is in Table 30 . The data in the example assumes the following conditions: • The specific fuel consumption is 205 grams per ekW-hr.

Calculating the Specific Fuel Consumption Use the equation that is in Table 28 to calculate the Specific Fuel Consumption. Table 28

• The LHV of the fuel is 42 000 kilojoules per kilogram. Table 31 Example of the Equation for Calculating the Heat Rate

Equation For Calculating the Specific Fuel Consumption

205 g

×

ekW-hr

= SFC

kg

42 000 kJ ×

F×D

kg

8608 kJ =

1000 g

ekW-hr

ekW-hr F is the liters of fuel that have been burned. D is the density of the fuel. The density is expressed in grams per liter. ekW-hr is the electrical kilowatt hours that were produced with the fuel.

The equation in Table 32 includes a conversion factor for calculating BTU from kJ. The data is from the example in Table 31 . Table 32 Conversion of kJ From the Heat Rate to BTU 8608 kJ

SFC is the specific fuel consumption.

1 BTU ×

ekW-hr

Table 29 is an example for using the equation that is in Table 28 . The data in the example assumes the following conditions: • During this operation, the engine used 18 440 liters of fuel. • The density of the fuel was 987 grams per liter.

8159 BTU =

1.055 kJ

ekW-hr

Monitoring the Trends of Oil Consumption The consumption of lube oil depends on the following factors: • Engine load

• The operation generated 88 800 ekW.

• Hours of operation

Table 29 Example of the Equation for Calculating the Specific Fuel Consumption 18 440 × 987 g/L × 88 800 ekW-hr

1 L

205g = ekW-hr

• Type of oil Monitor the engine's oil consumption by calculating the Specific Oil Consumption on a daily basis. Be aware that the following conditions can produce misleading data on oil consumption:

Calculating the Heat Rate

• Improper operation of the lube oil centrifuge

The specific fuel consumption must be determined before the heat rate can be calculated. Use the equation that is in Table 30 to calculate the heat rate.

• Inaccurate measurement of additions of oil

Table 30

• Overfilling of the oil sump Equation For Calculating the Heat Rate

• Leaking of lube oil

To measure additions of oil accurately, use a meter to monitor additions of oil at the engine. Also, check the total oil consumption against the delivery of oil.

SFC × LHV = HR

(continued)

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127 Maintenance Recommendations Turbocharger - Inspect

Calculating Specific Oil Consumption Use the equation that is in Table 33 in order to calculate the Specific Oil Consumption. Table 33

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.

Equation For Calculating the Specific Oil Consumption

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.

O×D = SOC ekW-hr O is the liters of oil that have been consumed. D is the density of the oil. The density is expressed in grams per liter. ekW-hr is the electrical kilowatt hours that have been produced during consumption of the oil.

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.

SOC is the specific oil consumption.

Table 34 is an example for using the equation that is in Table 33 . The data in the example assumes the following conditions: • The engine consumed 66 liters of oil during the operation. • The operation generated 88 800 ekW. Table 34 Example of the Equation for Calculating the Specific Oil Consumption 66 L 1

910 g ×

× L

1 88 800 ekW-hr

0.676 g = ekW-hr

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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 clearances that are precise. The turbocharger cartridge must be balanced due to high rpm. Severe service applications can accelerate the wear of the components. Severe service applications may require more frequent inspections of the turbocharger.

Removal and Installation For options regarding the removal, installation, repair and replacement, consult your Caterpillar dealer. Refer to the Service Manual for this engine or consult your Caterpillar dealer for the procedure and specifications.

Turbocharger - Inspect

Cleaning and Inspecting

SMCS Code: 1052-040

1. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. Visually inspect the piping for the presence of oil.

Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet side). Fouling of the compressor 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 could allow parts from the compressor wheel to enter an engine cylinder. This can cause additional damage to the pistons, the valves, and the cylinder head.

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 turbocharger wheel and the turbocharger housing, the turbocharger should be reconditioned or replaced.

128 Maintenance Recommendations Walk-Around Inspection

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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. Inspect the bore of the turbine housing for corrosion. 5. Clean the turbocharger housing with standard shop solvents and a soft bristle brush. 6. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing. i00528664

Walk-Around Inspection SMCS Code: 1000-040

Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. For maximum engine service life, thoroughly inspect the engine compartment before starting the engine. Look for items such as leaks, loose bolts, 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 cooling lines are properly clamped and tight. 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 when the engine cools 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. • 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. • 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. • Check the condition of the gauges. Replace any gauge that is damaged. Replace any gauge that can not be calibrated. • Inspect the exhaust system for leaks. Inspect the gaskets and the exhaust bellows joint. If a leak is found, make repairs. i04342954

Water Pump - Inspect SMCS Code: 1361-040 A failed water pump might cause severe engine overheating problems. Severe overheating problems could result in cracks in the cylinder head, a piston seizure, or other potential damage to the engine.

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129 Maintenance Recommendations Zinc Rods - Inspect/Replace

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 procedure. If removal of the water pump is necessary, 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 Cat dealer if repair is needed or replacement is needed. i03028045

Zinc Rods - Inspect/Replace SMCS Code: 1388-040; 1388-510 Corrosion in sea water circuits can result in the following issues: premature deterioration of cooling system components, leaks and possible cooling system contamination. The corrosion may be caused by the lack of zinc rods in the sea water system. Zinc rods are installed in the sea water cooling system of the engine in order to help prevent the corrosive oxidation that is caused by sea water. Electrical current is conducted through the contact of the zinc rods with the cooling system components. The zinc rods oxidize rather than the cooling system components. Rapid deterioration of zinc rods may indicate the presence of uncontrolled electrical currents from improperly installed electrical attachments or improperly grounded electrical attachments.

Illustration 122

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b. Tap the zinc rod lightly with a hammer. If the zinc rod breaks, install a new zinc rod. 3. If the zinc rod will be reused, scrape the layer of oxidation from the zinc rod before installation. The layer of oxidation reduces the effectiveness of the zinc rod.

Replace the Zinc Rods 1. Use pliers to unscrew the old zinc rod from the plug. If not enough material remains or the zinc rod has broken off, drill the zinc from the plug. 2. Clean the plug.

The engineer for the operation must determine the interval for inspecting the zinc rods. The interval for inspecting the zinc rods will depend on the size of the zinc rods and the number of zinc rods that are installed. Table 35 Locations of the Zinc Rods Location

Quantity

Elbow of the Auxiliary Water Pump

1

Elbow of the Aftercooler

1

Inspect the Zinc Rods

Illustration 123

1. Remove the zinc rod.

(1) Shoulder (2) Threads (3) External threads of the plug

2. Inspect the zinc rod. Ensure that the zinc rod will remain effective until the next scheduled inspection. a. If the zinc rod has deteriorated excessively, install a new zinc rod.

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Note: Do not apply adhesive or sealant to the threads of the zinc rod (2). 3. Apply 9S-3263 Thread Lock Compound to the shoulder (1) of a new zinc rod. Apply the compound only to the shoulder of the zinc rod. Install the zinc rod onto the plug.

130 Maintenance Recommendations Zinc Rods - Inspect/Replace

4. Coat the external threads of the plug (3) with 5P-3413 Pipe Sealant. Install the zinc rod. See Specifications, SENR3130, Torque Specifications for the torque for the plug.

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131 Warranty Section Warranty Information

Warranty Section Warranty Information i02355614

Warranty Information SMCS Code: 1000 All C280 Series Diesel Engines are covered by a standard one year warranty. The coverage of individual warranties may be different due to the engine application and the geographic location. C280 Series Diesel Engines are covered by the following warranties: • Caterpillar Warranty, SELF5202, New and Remanufactured Engines and New and Remanufactured Parts and Assembled Components for the Commonwealth of Independent States • Caterpillar Warranty, SELF5255, Marine Products Worldwide • Caterpillar Warranty, SELF5260, Industrial Engine Products and Electric Power Generation Products Worldwide When the engine is shipped, the warranty is included with parts that are shipped loose or with the Parts Manual.

Engine Protection Plans Extended Warranties and Service Contracts A wide variety of protection plans are available for Caterpillar Engines. Consult your Caterpillar dealer for detailed information on the specific programs and coverages that are available. Consult your Caterpillar dealer for information on a plan that is tailored in order to fit your requirements.

132

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Reference Information Section Engine Power Ratings

Reference Information Section

NOTICE Operating an engine above the engine's rating will reduce the service life of the engine before overhaul.

Engine Ratings

Ratings for Marine Propulsion Engines i02349607

Table 36 Rated Power Output for C280 Series Marine Propulsion Engines

Engine Power Ratings SMCS Code: 1000

Engine Model

Rating Conditions The engine ratings are based in compliance with the following standard ambient air conditions of SAE J1995 January 1990 and ISO3046: C280-06

• Dry barometric pressure of 99 kPa • Temperature of 25 °C Engine performance and fuel consumption are based on the following fuel specifications: • The low heat value (LHV) of the fuel is 42780 kJ/kg at 29 °C. • The density of the fuel is 838.9 g/L.

C280-08

The following tolerances are included: • ± five percent for specific fuel consumption • ± three percent for brake kilowatts at the flywheel The power at the flywheel is demonstrated at a Caterpillar Engine test cell. Before engine power is derated, the maximum temperature of the inlet air to the turbocharger is 45 ° C.

C280-12

The engine ratings represent net power. The power that is required for the following parameters has been subtracted from the net power: • Air filter restriction • Exhaust restriction • Fuel pump

C280-16

• Pumps that circulate lube oil • Water pumps

Rating Definitions and Power Output For information on power curves for engine rpm, see the Application and Installation Guide.

(1) (2)

Power (bkW)

Speed (RPM)

Marine CSR(1)

1730

900

Marine CSR

1850

1000

Marine MCR(2)

1900

900

Marine MCR

2030

1000

Marine Auxiliary Prime

1900

900


2030

1000

Marine CSR

2300

900

Marine CSR

2460

1000

Marine MCR

2530

900

Marine MCR

2710

1000


2530

900


2710

1000

Marine CSR

3460

900

Marine CSR

3700

1000

Marine MCR

3800

900

Marine MCR

4060

1000


3800

900


4060

1000

Marine CSR

4600

900

Marine CSR

4920

1000

Marine MCR

5060

900

Marine MCR

5420

1000


5060

900


5420

1000

Engine Rating

Continuous Service Rating Maximum Continuous Rating

SEBU7876

133 Engine Ratings Marine Classification Society Certification Requirements

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. 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)

134

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Engine Performance and Performance Analysis Report (PAR) Engine Performance

Engine Performance and Performance Analysis Report (PAR) i04537530

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.

If the engine is covered by a warranty, the Cat 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. Cat engines are manufactured with state-of-the-art technology. Cat engines are designed to help provide two characteristics in all applications: • Maximum performance • Fuel efficiency

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:

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.

• Hull

Performance Analysis Report (PAR)

• 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 Cat dealer for assistance.

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.

SEBU7876

135 Customer Service Customer Assistance

Customer Service i03910803

Customer Assistance SMCS Code: 1000; 4450

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:

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

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

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

136

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Customer Service Ordering Replacement Parts

i01028392

Ordering Replacement Parts SMCS Code: 4450; 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.

SEBU7876

137 Reference Materials Maintenance Records

Reference Materials i01053481

Maintenance Records SMCS Code: 1000; 4450 Caterpillar Inc. recommends the retention of accurate maintenance records. Accurate maintenance records can be used for the following purposes: • Demonstration of compliance with the required maintenance practices and maintenance intervals • Determination of operating costs • Establishment of maintenance schedules for other engines that are operated in the same environment 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. Keep records 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. Keep the following documents as proof of maintenance or repair for warranty: • Dealer work orders and itemized bills • Logs of engine performance • Maintenance logs • Owner's repair costs • Owner's receipts • Trend charts

138

SEBU7876

Reference Materials Hourly Performance Log

i01980649

Hourly Performance Log SMCS Code: 1000 Table 37 Engine Performance (First Shift) Engine Serial Number Hour Percent load Engine rpm Service hour meter Inlet manifold air temperature Inlet manifold air pressure Air restriction (left and right) Jacket water coolant temperature (inlet and outlet) Jacket water pressure Fuel pressure Fuel temperature Fuel filter differential pressure Oil pressure Oil temperature Oil filter differential pressure Exhaust manifold temperature (left and right) Cylinder exhaust temperature (1) Cylinder exhaust temperature (2) Cylinder exhaust temperature (3) Cylinder exhaust temperature (4) Cylinder exhaust temperature (5) Cylinder exhaust temperature (6) Cylinder exhaust temperature (7) Cylinder exhaust temperature (8) Cylinder exhaust temperature (9) Cylinder exhaust temperature (10) Cylinder exhaust temperature (11) Cylinder exhaust temperature (12) Cylinder exhaust temperature (13) Cylinder exhaust temperature (14) Cylinder exhaust temperature (15) Cylinder exhaust temperature (16)

Operator 00

Date 00

00

00

00

00

00

00

SEBU7876

139 Reference Materials Hourly Performance Log

Table 38 Engine Performance (Second Shift) Engine Serial Number Hour Percent load Engine rpm Service hour meter Inlet manifold air temperature Inlet manifold air pressure Air restriction (left and right) Jacket water coolant temperature (inlet and outlet) Jacket water pressure Fuel pressure Fuel temperature Fuel filter differential pressure Oil pressure Oil temperature Oil filter differential pressure Exhaust manifold temperature (left and right) Cylinder exhaust temperature (1) Cylinder exhaust temperature (2) Cylinder exhaust temperature (3) Cylinder exhaust temperature (4) Cylinder exhaust temperature (5) Cylinder exhaust temperature (6) Cylinder exhaust temperature (7) Cylinder exhaust temperature (8) Cylinder exhaust temperature (9) Cylinder exhaust temperature (10) Cylinder exhaust temperature (11) Cylinder exhaust temperature (12) Cylinder exhaust temperature (13) Cylinder exhaust temperature (14) Cylinder exhaust temperature (15) Cylinder exhaust temperature (16)

Operator 00

Date 00

00

00

00

00

00

00

140

SEBU7876

Reference Materials Hourly Performance Log

Table 39 Engine Performance (Third Shift) Engine Serial Number Hour Percent load Engine rpm Service hour meter Inlet manifold air temperature Inlet manifold air pressure Air restriction (left and right) Jacket water coolant temperature (inlet and outlet) Jacket water pressure Fuel pressure Fuel temperature Fuel filter differential pressure Oil pressure Oil temperature Oil filter differential pressure Exhaust manifold temperature (left and right) Cylinder exhaust temperature (1) Cylinder exhaust temperature (2) Cylinder exhaust temperature (3) Cylinder exhaust temperature (4) Cylinder exhaust temperature (5) Cylinder exhaust temperature (6) Cylinder exhaust temperature (7) Cylinder exhaust temperature (8) Cylinder exhaust temperature (9) Cylinder exhaust temperature (10) Cylinder exhaust temperature (11) Cylinder exhaust temperature (12) Cylinder exhaust temperature (13) Cylinder exhaust temperature (14) Cylinder exhaust temperature (15) Cylinder exhaust temperature (16)

Operator 00

Date 00

00

00

00

00

00

00

SEBU7876

141 Reference Materials Daily Performance Log

i00973555

Daily Performance Log SMCS Code: 1000

142

SEBU7876

Reference Materials Daily Performance Log

Table 40 Engine Performance Operator

Date

Time

Site name

Engine no.

Serial no.

Engine hours

Engine rpm

% Load

% Availability

Air Inlet

Nominal

Actual

Exhaust

Manifold pressure

Manifold temperature (left)

Manifold temperature

Manifold temperature (right)

Air restriction (left)

Stack temperature (left)

Air restriction (right)

Stack temperature (right)

Turbocharger rpm (left)

Turbocharger rpm (right)

Cylinder Exhaust

Nominal

Actual

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

Nominal

Actual

Nominal

Actual

Nominal temperature Actual temperature Cylinder Exhaust Nominal temperature Actual temperature Jacket Water

ACOC

Inlet temperature

Inlet temperature

Outlet temperature

Pressure

Pressure

Lubrication Oil Generator

Pressure

Output (kW)

Temperature

Bearing temperature (front)

Filter differential pressure

Bearing temperature (rear)

Fuel

Generator Windings

Pressure

Temperature (phase A)

Temperature

Temperature (phase B)

Filter differential pressure

Temperature (phase C)

% Actuator travel

Fluid Level Check

Amount Added

Fluid Level Check

Crankcase

Generator bearing (front)

Cooling system

Generator bearing (rear)

Day tank

Starting motor lubricator

Amount Added

Governor Operator

Date Findings and Observations

Time

Site name Status

Engine no. Recommendations

(continued)

SEBU7876

143 Reference Materials Daily Performance Log

(Table 40, contd) Engine Performance

Required Parts Part No.

Description

Parts Availability

Repair Time

144

SEBU7876

Reference Materials Maintenance Log

i01176304

Maintenance Log SMCS Code: 1000; 4450 Table 41 Engine Model

Customer Identifier

Serial Number

Arrangement Number

Service Hours

Quantity Of Fuel

Service Item

Date

Authorization

SEBU7876

145 Reference Materials Reference Material

i04230510

Reference Material

Coolants

SMCS Code: 1000; 4450

• Supplement, SEBU7003, “Caterpillar 3600 Series and C280 Series Diesel Engine Fluids Recommendations”

The following literature can be obtained through any Caterpillar dealer.

• Data Sheet, PEHP9554, “Cat DEAC (Diesel Engine Antifreeze/Coolant) (Concentrate)”

Lubricants

• Data Sheet, PEHJ0067, “Cat ELC (Extended Life Coolant)” (Worldwide)

• Operation and Maintenance Manual, SEBU5898, “Cold Weather Recommendations” • Data Sheet, PEHJ0093, “Cat DEO (SAE 30 and SAE 40)” • Special Publication, PEHJ0191, “Cat S·O·S Fluid Analysis”

• Special Publication, PEHJ0191, “Cat S·O·S Fluid Analysis” • Special Publication, SEBD0518, “Knowing Your Cooling System”

Miscellaneous

• Data Sheet, PEHP0002, “Cat Advanced 3Moly Grease”

• Special Publication, PECP9067, “One Safe Source”

• Data Sheet, PEHJ0088, “Cat Multipurpose Grease”

• Disassembly and Assembly, RENR5085, “C280 Engines”

• Data Sheet, NEHP6015, “Cat High Speed Ball Bearing Grease”

• Owners Manual, SEBU7134, “Marine Monitoring System”

• Special Publication, PEDP1129, “Listen To Your Oil”

• Service Manual, RENR5080, “C280 Engines”

• Special Publication, PEHP6001, “How To Take A Good Oil Sample” • Supplement, SEBU7003, “Caterpillar 3600 Series and C280 Series Diesel Engine Fluids Recommendations”

Fuels • Application and Installation Guide, LEBW5119, “Petroleum Engines Application and Installation Guide” • Supplement, SEBU7003, “Caterpillar 3600 Series and C280 Series Diesel Engine Fluids Recommendations”

• Service Manual, SENR4619, “Emergency Repair Procedures” • Specifications, SENR3130, “Torque Specifications” • Specifications, RENR5082, “C280 Engines” • Special Publication, LEDM5615, “Caterpillar Marine Parts and Service Locations” • Systems Operation/Testing and Adjusting, RENR5083, “C280 Engines”

146

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Reference Materials Reference Material

Guidelines for Reusable Parts and Salvage Operations • Special Publication, SEBF8029, “Index to Guidelines for Reusable Parts and Salvage Operations” • Guidelines for Reusable Parts and Salvage Operations, SEBF8092, “Specifications for Reusable Turbocharger Components” • Guidelines for Reusable Parts and Salvage Operations, SEBF8100, “Components for 3600 Family of Engines” • Guidelines for Reusable Parts and Salvage Operations, SEBF8101, “Specifications for Cylinder Blocks” • Guidelines for Reusable Parts and Salvage Operations, SEBF8102, “Specifications for Crankshaft Measurement” • Guidelines for Reusable Parts and Salvage Operations, SEBF8103, “Specifications for Grinding Crankshafts” • Guidelines for Reusable Parts and Salvage Operations, SEBF8104, “Specifications for Camshaft Measurement” • Guidelines for Reusable Parts and Salvage Operations, SEBF8105, “Injector and Valve Lifter Group” • Guidelines for Reusable Parts and Salvage Operations, SEBF8106, “Specifications for Cylinder Head Assemblies” • Guidelines for Reusable Parts and Salvage Operations, SEBF8107, “Specifications for Pistons and Rings” • Guidelines for Reusable Parts and Salvage Operations, SEBF8108, “Specifications for Connecting Rods and Bearings” • Guidelines for Reusable Parts and Salvage Operations, SEBF8109, “Specifications for Measuring Cylinder Liners” • Guidelines for Reusable Parts and Salvage Operations, SEBF8110, “Specifications for Water Pumps” • Guidelines for Reusable Parts and Salvage Operations, SEBF8129, “Procedure to Salvage Cylinder Head Assemblies” • Guidelines for Reusable Parts and Salvage Operations, SEBF8150, “Procedure to Inspect, Clean, and Flush Pistons”

• Guidelines for Reusable Parts and Salvage Operations, SEBF8151, “Procedure to Salvage Cylinder Blocks With Damaged Cylinder Head Stud Threads” • Guidelines for Reusable Parts and Salvage Operations, SEBF8152, “Procedure to Rebuild Vibration Dampers” • Guidelines for Reusable Parts and Salvage Operations, SEBF8160, “Procedure to Salvage Oil Pan Assemblies” • Guidelines for Reusable Parts and Salvage Operations, SEBF8171, “Recommendations for Cleaning and Inspecting 3600 Family of Engines Components”

Special Instructions • Special Instruction, SEHS8704, “Removal of Damaged Turbocharger and Operation of Marine Engines Without Turbocharging” • Special Instruction, SEHS8841, “Using the Ironstitch® Procedure for Casting Salvage” • Special Instruction, SEHS8857, “Installation of Service Replacement Woodward Governor Group” • Special Instruction, SEHS8919, “Cast Iron Welding Procedures” • Special Instruction, SEHS9156, “Installation and Use of 4C-5818 Collar and Retainer Group” • Special Instruction, SEHS9162, “Spring Isolator Group Installation and Adjustment Procedure” • Special Instruction, SEHS9182, “Procedure for Handling, Cleaning, Assembly, Installation and Protection of Service Replacement Crankshafts” • Special Instruction, SEHS8622, “Using the FT1984 Air-To-Air Aftercooler Leak Test Group” • Special Instruction, SEHS9031, “Storage Procedure for Caterpillar Products” • Special Instruction, SEHS9827, “Calibration of Pressure Contactors” • Special Instruction, SEHS9828, “Calibration of Temperature Contactors” • Special Instruction, REHS9031, “Alignment Procedure for Resilient Mounts on 3612 and 3616 Engines” • Special Instruction, SEHS7332, “Do Not Operate Tag”

SEBU7876

147 Reference Materials Decommissioning and Disposal

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 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 i03989612

Decommissioning and Disposal SMCS Code: 1000 When the product is removed from service, local regulations for the product decommissioning will vary. Disposal of the product will vary with local regulations. Consult the nearest Cat dealer for additional information.

148

SEBU7876

Index Section

Index A After Starting Engine........................................ 55 After Stopping Engine...................................... 62 Aftercooler Condensation - Drain .................... 77 12 and 16 Cylinder Engines......................... 77 6 and 8 Cylinder Engines............................. 77 Aftercooler Core - Clean/Test .......................... 78 Cleaning the Aftercooler .............................. 78 Air Shutoff - Test .............................................. 78 Air Starting Motor Lubricator Bowl - Clean ...... 79 Air Starting Motor Lubricator Oil Level Check............................................................. 80 Adjust the Lubricator.................................... 80 Air Tank Moisture and Sediment - Drain .......... 80 Alarms and Shutoffs ........................................ 31 Setpoints for Alarms and Shutoffs ............... 31 Shut down Procedure For the Oil Mist Detector ................................................................... 34

B Barring Device - Lubricate ............................... 81 Electric Barring Device................................. 81 Manual Barring Device................................. 82 Before Starting Engine ...............................14, 50 Air Inlet System............................................ 50 Cooling System............................................ 50 Engine Protective System............................ 50 Fuel System ................................................. 50 Lubrication System ...................................... 50 Purge the Cylinders ..................................... 51 Starting System............................................ 51 Starting the Engine After an Overhaul or Major Repair......................................................... 52 Walk-Around Inspection............................... 50 Burn Prevention................................................11 Batteries....................................................... 12 Coolant..........................................................11 Oils............................................................... 12

C Camshaft Roller Followers - Inspect................ 82 Centrifugal Oil Filter - Inspect .......................... 82 Cold Weather Operation.................................. 58 Cold Weather Starting ..................................... 53 Control Panel................................................... 36 Cat Alarm and Protection Control Panel ..... 36

Marine Monitoring System II Control Panel . 38 Control Panel - Inspect/Test............................. 83 Coolant (DEAC) - Change ............................... 83 Clean the Cooling System ........................... 84 Cleaning a Cooling System that has Heavy Deposits or Plugging.................................. 84 Drain the Cooling System ............................ 83 Fill the Cooling System ................................ 85 Coolant (ELC) - Change .................................. 86 Clean the Cooling System ........................... 86 Drain the Cooling System ............................ 86 Fill the Cooling System ................................ 87 Coolant Extender (ELC) - Add ......................... 87 Coolant Level - Check ..................................... 88 Add Coolant ................................................. 89 Engines That Are Equipped With a Sight Gauge ........................................................ 88 Engines That Are Not Equipped With a Sight Gauge ........................................................ 88 Coolant Sample (Level 1) - Obtain .................. 89 Testing the Concentration of SCA in a Cooling System that Uses Conventional Coolant ... 90 Testing the Concentration of SCA in a Cooling System that Uses SCA and Water ............. 90 Coolant Sample (Level 2) - Obtain .................. 90 Coolant Temperature Regulator - Replace ...... 90 Replace the Jacket Water Temperature Regulators and the Oil Cooler Water Temperature Regulators............................. 90 Cooling System Supplemental Coolant Additive (SCA) - Test/Add .............................. 91 Cooling Systems that Use Conventional Coolant....................................................... 91 Cooling Systems that Use Water and SCA.. 92 Crankshaft Vibration Damper - Inspect............ 92 Dampers With Sampling Ports..................... 93 Dampers Without Sampling Ports................ 93 Removal and Installation.............................. 93 Crushing Prevention and Cutting Prevention .. 14 Customer Assistance..................................... 135 Outside of the USA and of Canada ........... 135 USA and Canada ...................................... 135 Customer Service .......................................... 135

D Daily Performance Log .................................. 141 Decommissioning and Disposal .................... 147

SEBU7876

149 Index Section

Driven Equipment - Check............................... 93 Check the Alignment.................................... 93 Inspect the Drive Coupling........................... 93 Inspect the Rear Gear Train......................... 94

E Electrical System ............................................. 15 Grounding Practices .................................... 15 Emergency Stopping ....................................... 60 Emergency Stop Button............................... 60 Engine Air Cleaner Element (Single Element) - Inspect/Replace ........................... 94 Cleaning the Air Cleaner Elements.............. 95 Replace the Soot Filter................................. 95 Servicing the Air Cleaner Elements ............. 94 Engine Air Cleaner Service Indicator Inspect ........................................................... 96 Test the Service Indicator After Every 1000 Service Hours............................................. 96 Engine Air Precleaner - Check/Clean.............. 97 Engine Crankcase Breather - Clean................ 97 Engine Mounts - Inspect.................................. 98 Resilient Isolators......................................... 98 Engine Oil - Change ........................................ 99 Change the Engine Oil................................. 99 Oil Change Interval ...................................... 99 Engine Oil Filter - Change ............................. 101 Inspect the Used Oil Filter Elements.......... 103 Replacing the Engine Oil Filters During Engine Operation ................................................. 102 Replacing the Engine Oil Filters With the Engine Stopped........................................ 101 Engine Oil Level - Check ............................... 104 Engine Oil Sample - Obtain ........................... 104 Obtain the Sample and the Analysis.......... 105 Engine Oil Temperature Regulator Replace........................................................ 105 Engine Operation............................................. 57 Operating the Engine and the Driven Equipment.................................................. 57 Partial Load Operation................................. 57 Engine Performance...................................... 134 Performance Analysis Report (PAR).......... 134 Engine Performance and Performance Analysis Report (PAR) ................................. 134 Engine Power Ratings ................................... 132 Rating Conditions....................................... 132 Rating Definitions and Power Output......... 132 Engine Protective Devices - Check ............... 105

Inspect the Connections of the Engine Protective Devices ................................... 106 Perform a Static Test.................................. 106 Engine Ratings .............................................. 132 Engine Speed Control ..................................... 39 Dual Dynamic Operation of Engine (Marine Propulsion)................................................. 39 Global Throttle Select and Global Throttle PWM Input Features (Marine Propulsion).. 40 Engine Starting ...........................................15, 50 Engine Stopping .........................................15, 60 Engine Valve Lash and Bridge - Check ......... 108 Check the Timing of the Crankshaft and Camshaft.................................................. 108 Engine Valve Lash ..................................... 108 Fuel Injector Timing (Fuel Timing).............. 108 Valve Bridge............................................... 108 Engine Valve Rotators - Inspect .................... 109 Exhaust Piping - Check ................................. 109

F Features and Controls ..................................... 31 Fire Prevention and Explosion Prevention ...... 12 Ether ............................................................ 13 Fire Extinguisher.......................................... 13 Lines, Tubes, and Hoses ............................. 14 Fluid Recommendations.................................. 64 Cooling System............................................ 68 Diesel Engine Oil ......................................... 64 Fuel .............................................................. 66 Greases ....................................................... 71 Foreword............................................................ 4 California Proposition 65 Warning ................. 4 Literature Information..................................... 4 Maintenance .................................................. 4 Maintenance Intervals.................................... 4 Operation ....................................................... 4 Overhaul ........................................................ 4 Safety............................................................. 4 Fuel Analysis - Obtain.................................... 109 Fuel and the Effect from Cold Weather............ 58 Fuel Conservation Practices............................ 57 Fuel Related Components in Cold Weather .... 58 Fuel Filters ................................................... 58 Fuel Heaters ................................................ 58 Fuel Tanks.................................................... 58 Fuel System - Prime .......................................110 Priming the Fuel System After Disconnecting Fuel Lines or After an Overhaul ................110

150

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Index Section

Fuel System Primary Filter (Water Separator) Element - Replace ......................111 Primary Filter............................................... 111 Water Separator..........................................112 Fuel System Primary Filter/Water Separator - Drain ...........................................................112 Primary Filter...............................................112 Water Separator..........................................112 Fuel System Secondary Filter - Replace ........112 Replacing the Secondary Filters During Engine Operation ......................................114 Replacing the Secondary Filters With the Engine Stopped.........................................112 Fuel Tank Water and Sediment - Drain...........115 Day Tank .....................................................115 Fuel Storage Tanks .....................................115 Settling Tank ...............................................115

G Gauges and Indicators .................................... 40 General Hazard Information .............................. 8 Containing Fluid Spillage ............................... 9 Dispose of Waste Properly............................11 Fluid Penetration............................................ 9 Inhalation ..................................................... 10 Lines, Tubes, and Hoses ............................. 10 Pressurized Air and Water ............................. 9 Softwrap........................................................11 Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel........................ 10 General Information......................................... 17

H Hourly Performance Log................................ 138

I Important Safety Information ............................. 2

J Jacket Water Heater - Check..........................115

L Lifting and Storage........................................... 29

M Maintenance Interval Schedule (Prime) .......... 75 Between 16 000 and 24 000 Service Hours ................................................................... 77 Between 36 000 and 44 000 Service Hours ................................................................... 77 Daily ............................................................. 76 Every 1000 Service Hours or 6 Months ....... 76 Every 16 000 Service Hours or 6 Years ....... 77 Every 2000 Service Hours ........................... 76 Every 2000 Service Hours or 1 Year............ 76 Every 250 Service Hours ............................. 76 Every 250 Service Hours or 6 Weeks .......... 76 Every 4000 Service Hours or 1 Year............ 76 Every 500 Service Hours or 3 Months ......... 76 Every 8000 Service Hours or 3 Years .......... 76 Every Service Hour ...................................... 76 Every Week.................................................. 76 Initial 1000 Service Hours or 6 Months ........ 76 When Required............................................ 75 Maintenance Interval Schedule (Standby)....... 74 Daily ............................................................. 74 Every 3 Years............................................... 75 Every 6 Months ............................................ 74 Every 6 Years............................................... 75 Every Week.................................................. 74 Every Year.................................................... 74 When Required............................................ 74 Maintenance Log ........................................... 144 Maintenance Recommendations..................... 72 Maintenance Records.................................... 137 Maintenance Section....................................... 63 Manual Stop Procedure................................... 61 Marine Classification Society Certification Requirements .............................................. 133 Metal Particle Detector - Inspect/Clean ..........115 Model View Illustrations................................... 17 Mounting and Dismounting.............................. 14

O Oil Mist Detector - Check................................116 Check the Vacuum in the Measuring Track ..................................................................116 Drain the Condensation ..............................116 Operation Section............................................ 29 Ordering Replacement Parts ......................... 136 Overhaul (Major).............................................116 Cleaning and Inspection of Components....118

SEBU7876

151 Index Section

Fuel Consumption Before A Major Overhaul ..................................................................117 Inspection and/or Replacement of Components..............................................117 Remanufacturing or Rebuilding of Components..............................................117 Replacement of Components .....................117 Overhaul (Top End).........................................119 Cleaning and Inspection of Components... 120 Fuel Consumption Before A Top End Overhaul ..................................................................119 Inspection and/or Replacement of Components............................................. 120 Remanufacturing or Rebuilding of Components..............................................119 Replacement of Components .................... 120 Overhaul Considerations............................... 120 Overhaul Information ................................. 120

P Plate Locations and Film Locations................. 27 Engine Identification..................................... 27 Engine Information Plate.............................. 27 Serial Number Plate..................................... 27 Prelube Pump - Lubricate.............................. 123 Product Description ......................................... 21 Drives and Gear Trains ................................ 24 Engine Design.............................................. 22 Engine Service Life ...................................... 21 Engine Specifications .................................. 22 Reference Weights ...................................... 26 Product Identification Information.................... 27 Product Information Section ............................ 17 Product Lifting.................................................. 29 Engine Lifting with a Generator.................... 30 Product Storage............................................... 30

R Reference Information..................................... 28 Reference Information Section ...................... 132 Reference Material ........................................ 145 Additional Reference Material.................... 147 Coolants..................................................... 145 Fuels .......................................................... 145 Guidelines for Reusable Parts and Salvage Operations................................................ 146 Lubricants .................................................. 145 Miscellaneous ............................................ 145

Special Instructions.................................... 146 Reference Materials ...................................... 137 Refill Capacities............................................... 63 Cooling System Capacities.......................... 63 Lubricant Capacities .................................... 63

S Safety Messages ............................................... 5 Centrifugal Oil Filters (5) ................................ 8 Engine Lifting (1)............................................ 7 Engine Lifting (2)............................................ 7 Flash Fire (4).................................................. 7 Hot Pressurized Fluid (3) ............................... 7 Safety Section ................................................... 5 Sensors and Electrical Components ............... 42 Engine Protective Systems.......................... 48 Sensor Locations ......................................... 42 Speed Sensor - Clean/Inspect....................... 123 Starting Motor - Inspect ................................. 123 Starting the Engine .......................................... 55 System Pressure Release............................... 72 Coolant System............................................ 72 Engine Oil .................................................... 72 Fuel System ................................................. 72

T Table of Contents............................................... 3 Trend Data - Record ...................................... 124 Monitoring the Trends of Engine Performance ................................................................. 124 Turbocharger - Inspect .................................. 127 Cleaning and Inspecting ............................ 127 Removal and Installation............................ 127

W Walk-Around Inspection ................................ 128 Inspect the Engine for Leaks and for Loose Connections ............................................. 128 Warranty Information ..................................... 131 Engine Protection Plans............................. 131 Warranty Section ........................................... 131 Water Pump - Inspect .................................... 128 Welding on Engines with Electronic Controls .. 72

Z Zinc Rods - Inspect/Replace ......................... 129

152 Index Section

Inspect the Zinc Rods ................................ 129 Replace the Zinc Rods............................... 129

SEBU7876

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:

Branch:

Address:

Dealer Contact Sales: Parts: Service:

Phone Number

Hours

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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.

Caterpillar C280 OM&M

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