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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Safety Section Safety Messages

Illustration 1

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Safety Section Safety Messages

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.

SEBU7876

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

SEBU7876

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

SEBU7876

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

SEBU7876

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

SEBU7876

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

SEBU7876

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

110.8 L (6764 cubic inches)

147.8 L (9018 cubic inches)

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

SEBU7876

23 General Information Product Description

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

SEBU7876

General Information Product Description

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

SEBU7876

25 General Information Product Description

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

26

SEBU7876

General Information Product Description

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

SEBU7876

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)

SEBU7876

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)

Alarms and Shutoffs for C280 Engines (Distillate Fuel) Condition

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

Inlet manifold air temperature

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

Inlet manifold air temperature

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

75 °C (167 °F)

98 °C (208 °F)

High

Inlet manifold air temperature

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

The engine speed is less than 650 rpm.

120 kPa (17 psi)(6)

105 kPa (15 psi)

Low

Engine oil pressure

The engine speed is less than 650 rpm.

320 kPa (46 psi)(6)

260 kPa (38 psi)

(continued)

SEBU7876

33 Features and Controls Alarms and Shutoffs

(Table 9, contd)

Alarms and Shutoffs for C280 Engines (Distillate Fuel) Condition

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)

34

SEBU7876

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.

SEBU7876

35 Features and Controls Alarms and Shutoffs

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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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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• 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

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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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).

SEBU7876

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.

SEBU7876

55

SEBU7876

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.

56

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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.

57

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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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67 Refill Capacities Fluid Recommendations

(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% (