Caterpillar C280 OM&M
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(2) i05296198. 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..
(3) SEBU7876. 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.
(4) 4. SEBU7876. 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..
(5) 5. SEBU7876. 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..
(6) 6. SEBU7876. Safety Section Safety Messages. Illustration 1. g03332860.
(7) 7. SEBU7876. 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. g00296929. g00299841. 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. g00299818. Improper lift rigging can allow unit to tumble causing injury and damage.. g00123185. 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) 8. SEBU7876. 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.. g00123191. 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. g00702020. • 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. g00104545. 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:.
(9) SEBU7876. 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. g00687600. Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.. Containing Fluid Spillage NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “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..
(10) 10. SEBU7876. 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. g02159053. 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:.
(11) SEBU7876. 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. g00706404. Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water. 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..
(12) 12. SEBU7876. 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. g00704000. Use of personal protection equipment (PPE) may be needed. All fuels, most lubricants, and some coolant mixtures are flammable. Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a product when a fire hazard exists. Contact your 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..
(13) SEBU7876. 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. g02298225. 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. g00704059. 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..
(14) 14. SEBU7876. 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.. i01372247. 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.. i03560601. 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. i01359666. 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..
(15) SEBU7876. 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.. i01032810. 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) 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.
(17) 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) 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.
(19) 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) 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.
(21) 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) 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.
(23) 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) 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.
(25) 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) 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.
(27) 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) 28. SEBU7876. 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).
(29) 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) 30. SEBU7876. 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..
(31) 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) 32. SEBU7876. 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).
(33) 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) 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..
(35) 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..
(36) 36. SEBU7876. Features and Controls Control Panel. 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.
(37) SEBU7876. 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.
(38) 38. SEBU7876. Features and Controls Control Panel. Illustration 39. g03409723. DCU Panel (17) LCD screen (18) “POWER” indicator lamp (19) “ALARM” list (20) “START” switch. (21) “STOP” switch (22) Context-sensitive menu switches (soft switches) (23) “SCROLL DOWN” switch. Marine Monitoring System II Control Panel Note: For additional information on the Marine Monitoring System II Control Panel, refer to Systems Operation Troubleshooting Testing and Adjusting, RENR2490, “Marine Monitoring System II”.. (24) “SCROLL UP” switch (25) “MENU” switch.
(39) SEBU7876. 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:.
(40) 40. SEBU7876. Features and Controls Gauges and Indicators. • Determine a known constant speed for the application. The constant speed value is then programmed in the ADEM . This value is entered with the Electronic Technician (ET) for the parameter “Engine Governor Desired Constant Speed” . The default value is set at the rated speed. • Tune the ADEM control for proper operation. The following governor gain parameters are used to tune the engine for proper operation: “Governor Gain Factor #2” , “Governor Minimum Stability Factor #2” and “Governor Maximum Stability Factor #2” . Caterpillar recommends a validation of the preset parameters during commissioning procedure. The parameters that have been set at the factory may need adjusting.. Global Throttle Select and Global Throttle PWM Input Features (Marine Propulsion) The global throttle is available with dual dynamics in order to allow a third throttle input. This feature allows the user to change the throttle input from variable speed control to a load share module. This feature also allows the user to synchronizer the module when constant speed is desired. The global throttle input is selected by grounding the “Global Throttle Select” input to the ADEM control. For more information on engine speed governing, refer to System Systems Operation/Testing And Adjusting and Adjusting, RENR5083, C280 Marine Engines. i05377111. Gauges and Indicators SMCS Code: 7450 Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a time. Noticeable changes in gauge readings can indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your Cat dealer for assistance. Your engine may not have the same gauges or all of the gauges that are described.. NOTICE If no oil pressure is indicated, STOP the engine. The engine will be damaged from operating without oil pressure. Engine Oil Pressure – This gauge indicates the pressure of the engine oil. The pressure will be highest after a cold engine is started. The pressure will decrease as the engine warms up. The pressure will increase when the engine rpm is increased. The pressure will stabilize when the engine rpm is stable. Oil Filter Differential Pressure – This gauge indicates the difference in pressure between the inlet side and the outlet side of the engine oil filters. As the oil filter elements become plugged, the pressure will increase. Replace the engine oil filter elements when the oil filter differential pressure reaches 103 kPa (15 psi). Engine Oil Temperature – This gauge indicates the engine oil temperature after the oil has passed through the oil cooler. The oil cooler is thermostatically controlled. The oil temperature is controlled by an 85 °C (185 °F) temperature regulator that is in contact with the oil. The pump for the aftercooler and the oil cooler pumps coolant for the engine oil. Crankcase Pressure – This gauge indicates the pressure that is inside the crankcase. Changes in the pressure may indicate problems with the following components: crankcase breathers, pistons, piston rings and cylinder liners. Aftercooler and Oil Cooler Water Temperature – This gauge indicates the temperature of the coolant at the inlet to the aftercooler and oil cooler circuit. The water temperature is regulated by water temperature regulators. If the cooling system cannot remove enough heat from the water, then the engine cannot be cooled properly. An oil temperature that exceeds the normal oil temperature may indicate that a problem has occurred in the lubrication system and/or the cooling system. Those problems may involve the following components: water temperature regulators, oil coolers, cylinder heads, cylinder liners, pistons and bearings..
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