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Application and Installation Guide: Industrial
Application and Installation Guide: Industrial
APPLICATION and
INSTALLATION GUIDE
TABLE OF CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1
2
INTRODUCTION
3
4
ENGINE SELECTION
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Comparison with Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Horsepower, Torque, and Machine Productivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Calculated Horsepower Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dynamometer Measured Horsepower Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Measured Horsepower Demand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Torque Rise Effect on Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Response Effect on Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adequate Machine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel Heating Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Auxiliary Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SAE Standard Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Determining Total Power Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Simulating Performance of a Smaller Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Life Related to Load Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Ratings and Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Capability Determines Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power Setting Determines Maximum Fuel Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Factors Involved in Establishing a Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Usage Determines Rating Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engines are Developed for Specific Rating Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rating Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Continuous Rating Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Intermittent Rating Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maximum Rating Discussed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Application Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Altitude Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Homologation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Actual Power Output Derives From Load Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Laboratory Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Configuration Variations Provide Rating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Aftercooling Variations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Aftercooling Configurations Versus Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mechanically Governed Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electronically Governed Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5
ENGINE SELECTION
6
Dynamometer Measured Torque Rise % =
Horsepower Demand (Peak Torque) – (Rated Torque)
__________________________ x 100
Rated Torque
Actual load demand measurement by
powered dynamometer is the most accu-
rate way to determine power demand of Cat Diesel Engines typically provide high
components or of a total machine. It is rec- torque rise to perform well in a wide variety
ommended that a manufacturer do this to of applications.
more accurately determine where power is
being consumed. This can identify a device
A torque curve is the graphical representa-
or system which is using more power than
tion of torque versus speed.
it should and is in need of redesign for
improved efficiency. For example, this occa-
sionally happens with hydraulic systems. Some modification to a torque curve is
However, a dynamometer normally mea- possible in those cases where this is
sures only the steady-state power demand. required to achieve satisfactory machine
More sophisticated instrumentation is performance. Consult your engine supplier
required to measure load demand under if this need exits.
dynamic, transient conditions. If this type of
measuring apparatus is available, the dyno- If torque rise is higher than necessary,
driven load must accurately simulate the real those parts of the machine driveline ahead
machine operation to yield accurate data. of the transmission may be subjected to
Estimated h.p. loss due to: 1) torque con- torque levels which may shorten the life of
verter, 2) transmissions, 3) generators, 4) gearing and bearings. For this reason it is
belt drives, 5) gear reducers. sometimes desirable to let the machine
operator shift to a lower gear to increase
Engine Measured Horsepower Demand engine speed, instead of always lugging
the engine without a gear change. So, the
Usually, the most practical way to assess decision to use an extra high torque rise
power demand, and capability of an engine engine must also consider driveline capa-
to perform adequately, is to make a logical bility. By contrast, an engine with insuffi-
selection based on calculation or compari- cient torque rise will seem weak and may
son with past experience and test it. There even stop running before the operator has
is no substitute for a rigorous evaluation of time to make a shift change. This is not
an engine in the machine or application. acceptable either. The best compromise is
This provides the final proof of machine to use enough torque rise to satisfy
performance acceptability, or it will identify machine performance requirements, but
shortcomings in need of correction. not so much that driveline life becomes
unacceptable.
Torque Rise Effect on Performance
Devices such as blowers, pumps, and pro-
For machines which are capable of lugging pellers cannot lug an engine because
the engine (i.e., applying sufficient load to power demand drops off much more quick-
pull the engine speed down below rated ly than engine capability as speed is
speed, at full throttle), it is important to con- reduced. The amount of torque rise avail-
sider two other characteristics of engine able in these applications is generally
performance. These are torque rise and meaningless because torque rise is not
response to sudden load change. required, except as it may contribute to the
ability to accelerate the load.
7
Response Effect on Performance Fuel Heating Value
A naturally aspirated engine has the fastest Heating value of the fuel affects power out-
response to sudden load increase because put because fuel is delivered to the engine
required combustion air is immediately on a volumetric basis. Allowance should
available. be made for a fuel with lower heat content
(higher API than standard) where the
A turbocharged engine will not respond power level is critical. Caterpillar Diesel
quite as fast because it takes a moment for ratings are based on use of 35 API fuel
the turbo to accelerate upon sudden load with HHV of 19,590 Btu/lb (45570 kJ/kg) or
increase. Steady progress in turbocharger 138,000 Btu/gal.
development has produced smaller, faster
responding turbochargers and, therefore, Auxiliary Loads
turbocharged engines which respond quick-
ly to sudden load increase. In a steady load In addition to the main load carried by the
and speed situation, turbo response is of engine, allowance must also be made for
no consequence. Air/fuel ratio controllers, all other engine-driven auxiliary loads. Extra
also called smoke limiters, momentarily loads imposed by a cooling fan, alternator,
limit fuel delivery until sufficient air is avail- steering pump, air compressor, and hydraulic
able for combustion. They respond to inlet pump may represent a significant propor-
manifold boost pressure. The air/fuel ratio tion of total engine power available.
setting is a compromise between machine
responsiveness and acceptable level of SAE Standard Conditions
transient smoke for a particular application.
Engine ratings express actual usable power
Adequate Machine Performance available under standard SAE (Society of
Automotive Engineers) specified condi-
Manufacturers and customers develop tions of 29.38 in Hg (99.2 kPa) barometer,
their own ideas of what constitutes ade- 85°F (30°C). Devices, such as the oil pump,
quate machine performance. Insufficient fuel pump, and jacket water pump, which
power causes low productivity and user are part of a runnable engine, do not sub-
dissatisfaction. Excessive power costs tract from rated power.
more to purchase, requires heavier drive-
line components, and may reduce Determining Total Power Needs
machine life if the operator is careless. The
ideal machine is responsive, productive, After establishing main load power demand
and durable, satisfying the owner’s need and adding all auxiliary power demands,
for performance and overall value. some additional power should be allowed
for peak loads (such as grades and rough
Tolerances terrain) and reserve for acceleration.
8
Simulating Performance Engine Capability Determines Ratings
of a Smaller Engine
Horsepower rating capability is determined
If a machine is thought to be overpowered by engine design. Combined capability and
and a change to a smaller engine is being durability of all engine components deter-
considered, it is possible to simulate a mine how much horsepower can be pro-
lower horsepower engine by resetting the duced successfully in a particular application.
fuel system on the larger engine to some
lower horsepower. Then, an experienced Power Setting Determines Maximum
operator can fully evaluate machine perfor- Fuel Rate
mance at the lower horsepower. Although
performance will not be exactly the same, The horsepower output of a basic engine
because of greater rotational inertia and model can be varied within its design range
displacement (which both improve ability by changing the engine fuel setting or speed
to handle sudden load changes), this will setting. Both of these settings affect the
roughly simulate performance to be expect- engine’s maximum fuel rate and, therefore,
ed with a smaller engine. This may demon- the power output capability. Thermal and
strate that a smaller engine is a viable pos- mechanical design limits will not be
sibility which should be tested further. Or, exceeded, if an appropriate engine and
such testing may show that the lower power rating is selected.
level cannot meet the peak demands sat-
isfactory; that the larger engine will deliver
sufficient performance advantage to justify Factors Involved in Establishing
its cost. a Rating
9
Engines are Developed for Specific range of applications characterized by the
Rating Levels fluctuating load and speed. The majority of
material handling and agricultural applica-
Engines are designed and developed to tions are in this category.
produce specific power levels for particular
applications. Subsequent lab and field Maximum Rating Discussed
experience confirms the validity of these
ratings. Increasing the engine horsepower Maximum rating developed when only nat-
beyond approved levels by increasing the urally aspirated engines were available.
fuel rate, to compensate for excessive load, Although this was never intended as a
is not an acceptable practice. Excessive usable rating, it was used by some as a
engine wear or damage can result and point of reference. The actual rating was
could invalidate the warranty. Published sometimes compared with the maximum,
ratings express engine power and speed and the difference was somewhat erro-
capability under specified loading condi- neously considered to be a power reserve
tions or for specific applications. or an indication of degree of conservatism
of the rating.
Rating Curves
Today, with turbocharged engines, a maxi-
Consult TMI for Industrial Engine rating mum rating has even less significance. An
curves which show available ratings at var- engine can often produce power levels
ious speeds for each model and configura- well beyond approved application ratings;
tion. Specification sheets also carry some but, unless the effect of these ratings on
of this information, for preliminary sizing engine life in a particular application is
purposes. known, there is no basis for judging conser-
vatism of ratings. Use of maximum ratings
Continuous Rating Defined was also encouraged, unfortunately, by
competitive pressures between manufac-
The CONTINUOUS rating is the power tures trying to extend the apparent capa-
and speed capability of the engine, which bility of their engines. Appropriate Caterpillar
can be used without interruption or load ratings are established for each application
cycling. Few industrial or agricultural appli- or type of duty. Rely upon these recom-
cations require a rating as low as the con- mendations rather than attempts at com-
tinuous rating because load and speed parison with almost meaningless maxi-
fluctuation is usually present. However, the mum ratings.
continuous rating will extend engine life
and reliability in any application. Application Ratings
10
Special Ratings Homologation
Most engine applications are well under- Machine manufacturers who plan to export
stood and utilize one of the above existing product to other countries should investigate
published ratings which have been con- the need for homologation (approval) in that
firmed by thousands of hours of successful country. This may affect acceptability of
experience. However, occasionally, a unique engines, ratings, and other machine features.
application merits special rating considera- Ultimately the end user is responsible to make
tion because of unusually low load factor sure his engine complies with all regulations.
or unusually short life requirements. In this
case, consult dealer. Factory application Actual Power Output Derives
engineers will require that a special rating from Load Demand
request data sheet be submitted for review
before a special rating can be considered
Regardless of engine rating (power and
for approval.
speed setting), the actual power devel-
oped by an engine derives from the load
Altitude Derating imposed by driven equipment. For exam-
ple, an engine set to produce 500 hp
Each model and rating has established (373 kW) will actually produce only 40 hp
maximum altitude capabilities for lug and (30 kW), if the driven load demands only
for nonlug applications. For higher altitude 40 hp (30 kW). For this reason, average fuel
operation, power settings must be reduced consumption is an indicator of average load
approximately 3% per 1000 ft (305 m) above demand. Average fuel consumption is also
the altitude limit for that rating. Diesel used as an indicator of load severity on the
engines do not self-derate enough so that engine by comparing it with maximum fuel
the fuel setting can be left unchanged. If rate associated with the approved rating for
they are not reset to appropriate power lev- that application. When this ratio is expressed
els, naturally aspirated engines may smoke as a percent, it is called load factor.
badly and turbocharged engines may suffer
excessive thermal and mechanical loading, Laboratory Testing
resulting in internal damage, without giving
external indication of distress.
Engine ratings are set at levels which pro-
vide both satisfactory performance and
Regulatory Requirements engine life. This requires consideration of
many operating variables used to assess
Regulatory requirements often dictate the severity of operation on internal engine
use of specific regulatory agency-approved parts. To provide data for this purpose, all
rating levels, as required in underground engine models are run in the laboratory to
mining and in mobile industrial equipment acquire part load data. It shows how each
designed to be self-propelled on-highway. of the significant operating parameters varies
Caterpillar works with certain of these agen- with load and speed. Measured parame-
cies (for example, Mine Safety and Health ters include turbo speed, exhaust temper-
Administration [MSHA] and Environmental ature before and after turbocharger, fuel
Protection Agency [EPA]) to provide preap- consumption, boost, smoke level, and fuel
proved ratings. Compliance with these regu- limit setting position. To assure good per-
lations can make it difficult to get special rat- formance and long life, limits on each of
ings or to derate the engine. these parameters are established. These
are run under controlled reference condi-
tions so that valid comparison with other
data and with other ambient conditions can
be made.
11
Engine Configuration Variations An aftercooler between the turbocharger and
Provide Rating Range the engine intake manifold cools the hot
compressed air. Cooling the air increases
On a given engine model, a horsepower its density and allows more air to be
range capability is created by providing packed into the cylinder and more fuel to
different engine configurations such as be burned. The rating is typically limited by
naturally aspirated, turbocharged, and tur- internal temperature limits, turbocharged
bocharged-aftercooled. Internally, these speed, and structural limits.
engines may differ significantly.
Because the effect of turbochargers and
Also, Caterpillar offers both direct injected aftercoolers is to provide more air to the
(DI) and prechamber injected (PC) engines engine, and fuel rate can usually be
to provide a more complete product offer- increased to use this extra combustion air,
ing. Each system has its own advantage. engine component loading or turbo speed
become the limit on rating. Caterpillar Diesel
Engines do not utilize turbos or aftercoolers
Increasing horsepower output by injecting as add-ons. Rather, engines are designed
more fuel requires additional air for com- and developed in all aspects for these
plete combustion and internal cooling. This higher loading levels. Then they are tested
requires additional mechanical strength of thoroughly to assure long life and satisfac-
internal components and additional design tory performance.
features, such as oil jet cooling for pistons.
In an engine, the mass flow of air supplied
Aftercooling Variations
to each cylinder determines the amount of Engine jacket water is usually used in the
fuel which can be efficiently burned. But, the aftercooler to cool the turbocharger-com-
entire engine must be designed for strength pressed air. This jacket water aftercooled
and durability at approved power levels. (JWAC) configuration includes the after-
cooler and piping required to flow engine
The limit on a naturally aspirated engine jacket water through the aftercooler. This
horsepower rating is usually the amount of is the most reliable aftercooling system
air available for combustion, because of because it is an integral part of the engine
exhaust temperature and smoke levels. jacket water circuit and a separate water
pump is not required.
Turbocharging, using energy from waste
exhaust gas, provides an efficient means Lower aftercooler water temperatures per-
to increase air flow. Compression of the air mit higher engine ratings because cooler,
by the turbocharger increases the air tem- denser air allows the burning of more fuel
perature. The horsepower rating of a tur- without exceeding exhaust temperature
bocharged engine is usually limited by the limits. The use of a separate circuit after-
internal temperatures, turbocharger speed, cooled (SCAC) engine configuration
and structural limits. requires a separate source of lower tem-
perature aftercooler water. This is not
practical in most material handling and ag
applications.
12
Battery Recommendations
13
4. Other battery positive and negative 12. J1587 (ATA) and CAT Data Link (CDL)
control wiring should be with AWG 14 positive and negative leads must be
wire. unshielded twisted pairs (1 twist per
25 mm) within each data link (not
5. All other engine, display, sensor, and combined). These leads must NOT be
data link wiring can be accommodated installed in a metal conduit, because
by AWG 16. the conduit acts as a shield.
6. All circuits for engine related power, 13. The J1939 (CAN) data link MUST be
control and displays must be dedicated shielded and its positive and negative
to engine functions (isolated from other leads must be twisted (1 twist per
machine electrical/electronic functions) 25 mm). Consult the engine’s wiring
to minimize the risk of introducing schematic for proper routing of the wire
electrical noise into engine related shield. Extended wire end Deutsch pins
circuits. For example do not operate a and sockets are available to facilitate
machine control solenoid from power shield routing through Deutsch con-
or ground wires also serving engine nectors (133-0967 & 133-0969).
electronics.
14. All wire bundles must be adequately
7. All wire insulation outside diameter protected from accidental damage
must be 2.2 to 3.4 mm to facilitate (stepping, dropping hard objects,
adequate environmental sealing when pinch points, or grabbing).
used with Deutsch connectors.
15. The only electrical connections (not
8. Any unused Deutsch connector wire considering the starter circuit) required
location MUST have an 8T-8737 seal- to allow an electronic engine to start
ing plug installed for environmental and achieve low idle are all positive
sealing. and negative battery connections to
the engine ECM. It may be advanta-
geous for the initial start-up of a new
9. Any wire bundle exiting a Deutsch machine powered by an electronic
connector must have at least twice engine to start with the basic positive
the bundle diameter as a bend radius and negative battery circuits for the
if a bend is necessary. This is to avoid initial start, then connect one circuit
excessive stress on the back-side at a time to the customer connector to
Deutsch connector environmental validate each circuit (one at a time).
seals. A minimum straight length of
25 mm is recommended for wires
exiting a Deutsch connector. 16. Caterpillar electronic engines leave the
factory with all customer programm-
able parameters/features programmed
10. Do not paint Deutsch connectors. to default values. Consult the most cur-
Paint will wick into the mating con- rent version of the Electronic Application
nector components and prevent easy and Installation Guide (SENR1025) for
future disassembly if required. default and parameter/feature ranges/
options. To change any customer
11. The recommended master disconnect parameter, an electronic engine ser-
switch is between the engine ECM vice tool is required. Currently the
power/start switch and the unswitched Electronic Technician (ET) and the
power connection to the engine ECM. Electronic Computer Analyzer Pro-
grammer (ECAP) are the only two
14
industrial electronic engine service tools 20. The most up-to-date indications of
supported by Caterpillar. All Caterpillar electronic features available can be
industrial engines have a service tool con- found by referring to the customer
nection as part of the on-engine wire har- connector (J3/P3) pin-out descrip-
ness. The service tool connector is located tions given on the industrial engine
on the customer interface connector wiring schematic. Please note that
(J3/P3) mounting bracket. customer connector pin-outs HAVE
minor differences between industrial
17. A Caterpillar electronic engine instal- inline six cylinder and vee engines,
lation audit checklist is included in and possibly major differences between
this manual on page 137. on-highway truck, marine, machine
and EPG applications. So, while an
electronic capability might be similar
18. Caterpillar also provides detailed to another non-industrial application,
electronic troubleshooting manuals. the capability probably will NOT be
Contact your servicing CAT dealer or identical (e.g. cruise control for on-
Factory contact for this appropriate highway vs. PTO mode for industrial
electronic engine manual. This manu- — cruise control operates on vehicle
al MUST be used in any electronic ground speed, PTO operates
diagnostic troubleshooting journey for on engine speed). Please refer
a comprehensive orderly diagnostic to the most current version of
journey. SENR1025 for the latest
industrial electronic descrip-
19. Caterpillar currently has an industrial tions.
electronic engine display attachment.
This display is referred to as an 21. Please be aware that the service tool
Electronic Monitoring System (EMS). will not allow anyone the capability of
The EMS consists of three separate damaging the engine by features acti-
units: a main unit (warning lamps and vated or operational limits selected.
scrollable parameter window), a tacho-
The OEM has the ability to select any
meter unit (engine speed), and a quad
gauge unit (oil pressure, water tem- rating available (A – E tier) contained
perature, battery voltage, and fuel within the personality flash file with-
transfer pump pressure). If any of the out factory passwords for any given
display units are used, the main unit family of industrial iron. It IS the respon-
must be used (it decodes the CDL sibility of the OEM or engine selling
data link information for itself and the dealer to make sure the appropriate
other two units). The tachometer and tier rating for the application is select-
quad gauge units are optional. Multiple ed. If an OEM or customer arbitrarily
display units can be used, and a max- selects a higher rating, drive train
imum total wire length of 33 meters is damage or reduced engine time to
suggested. Refer to the engine wiring overhaul could result. If drive train
schematics or EMS wiring schematic damage occurs because of misap-
(148-5625) for proper wiring and fea- plied rating, Caterpillar is NOT respon-
ture implementation. The EMS requires sible for drive train damage. OEM’s
24V for operation even though the have the option of locking out critical
engine ECM may operate on 12V parameters to prevent tampering —
power. A 12V to 24V converter is e.g. rating. If a parameter is locked
available (127-8853). Caterpillar has out, factory passwords are required
available an EMS interconnect har- to unlock the parameter.
ness (160-1050) if more than the
main unit is utilized.
15
Safety
Every machine manufacturer is concerned about the safety of those who will own,
operate, or be near any machine. The following suggestions/considerations
may help minimize the risk of injury: ✓ Acknowledge
2. Locate the fuel filler where it is convenient for service and will not allow ____
spilling of fuel on the engine, even by a careless operator. Make sure the
fuel tank is vented and contains enough expansion volume to allow fuel
expansion as it warms.
3. Route, enclose, and clip all electrical wires to avoid wearing through ____
the insulation and causing an electrical short. Also route wiring away
from hot components.
4. Guard hot parts (exhaust manifold, water lines, air lines from the turbocharger ____
(air-to-air aftercooling systems)) to help prevent contact by the operator unless
the component is adequately surrounded by machine features to prevent
accidental contact.
5. Route, clip, and guard hydraulic/fuel lines and hoses away from sharp ____
edges, hot engine components, and pinch points to avoid damage.
Supplementary shielding may be necessary.
6. Install a fire extinguisher on the machine for quick access in the case of ____
an emergency.
7. Provide instruction and warning labels where needed to inform the ____
operator against improper actions.
9. Consider means for locking open inspection doors, shields, and guards. ____
to avoid accidental closure.
10. Consider non-slip steps and grab handles for routine inspections, ____
especially for radiator coolant level/fill checks.
16
Application/Engine: Industrial — S/N Prefixes:
2AW1 — UP .....3176C 1DW1 — UP .....3196 6BR1 — UP .....3406E
3LW1 — UP ......3456 7PR1 — UP ......3408E 4CR1 — UP .....3412E
1. Caterpillar does not accept warranty responsibilities for customer wiring. ____
2. An AWG 4 wire must be installed between the ground lug on the J3/P3 ____
mounting bracket and the battery negative buss. Using a frame member
as a ground conductor is not acceptable for engine electronics.
3. A maximum of three terminal lugs per any single electrical lug recommended. ____
4. Wire insulation outside diameter is 2.2 — 3.4 mm when used with Deutsch ____
connectors. This assures proper environmental sealing.
5. Allen head bolt lock torque on Deutsch connectors = 2.26 N•m. ____
6. 8T-8737 sealing plugs must be installed in every unused Deutsch connector ____
pin location.
7. Every wire exiting a Deutsch connector must withstand a 45 N pull test. ____
8. Wire bundle exiting Deutsch connectors should have a minimum bend radius ____
of 2X bundle diameter, and 25 mm straight before bend starts.
9. Deutsch connector back seals are not stressed allowing moisture entry. ____
10. All wires — bundled, secured, and protected from accidental damage ____
(stepping, dropping hard objects, pinch points, grabbing).
11. All electronic features utilized by the customer have been demonstrated. ____
12. Deutsch connectors are not painted. Paint will wick and impair serviceability. ____
13. Logged faults caused by installation audit activity cleared, and any other logged ____
faults corrected and cleared.
14. Customer instructed on how operational and configuration checks can be ____
made before shipment to end user, so consistent engine operation is insured
for a given application.
16. Suggested battery master disconnect is between engine pwr/start switch and ____
ECM unswitched positive battery junction. If master disconnect is located in
the battery negative cable, the last hour of ECM job data will be lost (sw opened).
17. The J1587 data link (143-5018) must be unshielded twisted pair (1 twist/25 mm). ____
18. The CDL data link (143-5018) must be unshielded twisted pair (1 twist/25 mm). ____
19. The J1939 data link (153-2707) must be shielded twisted pair (1 twist/25 mm). ____
17
Application/Engine: Industrial — All Engines with Cat Data Link
2. If display option is utilized, EMS main unit must be used. Other two units of ____
EMS display (quad gauge, tach) are optional.
3. Caterpillar interconnect harness between EMS units is available (160-1050) – used? ____
4. If auxiliary temperature and pressure sensors are utilized, trip points must be ____
programmed via, ET for enunciation on the main EMS unit.
5. EMS requires 24V supply. If 12V electric’s are utilized, install a 127-8853 converter. ____
Is a jumper wire across the negative battery in and out terminals on the converter
in place?
7. Wire size for EMS = (+) & (–) BAT.14AWG; ALL OTHER 16AWG dedicated to ____
CAT electronics only (other machine functions not permitted).
8. Battery positive supply must be 5A circuit breaker protected (single unit). ____
9. Multiple EMS display stations are permitted. Ref. page 59 in SENR1025-03 or ____
LEXH6427 (Product News) for details (NON-shielded data link wire required).
10. Total length of CAT data link cable should not exceed 33 m. ____
11. Cat data link cable must be a twisted pair (1/25 mm) non-shielded. ____
REF. SENR1025 (change level 03 dated June 98) Electronic A&I Guide
SENR1073 (change level 01 dated February 98) 6 Cyl Troubleshooting
SENR1065 (change level 01 dated March 98) 8 & 12 Cyl Troubleshooting
LEXH7530 (change level 00 dated 1997) EMS Operators Guide
LEXH6427 (dated Nov. 1996) Engine Monitoring System (EMS) for Caterpillar
Industrial Engines
18
POWER TRANSMISSIONS
Page
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General Description and Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine-Mounted Enclosed Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Light-Duty (LD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Normal-Duty (ND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Heavy-Duty (HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Extra Heavy-Duty (EHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Typical Light-Duty (LD) Clutch Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Typical Normal-Duty (ND) Clutch Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Typical Heavy-Duty (HD) Clutch Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Typical Extra Heavy-Duty (EHD) Clutch Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Automotive-Type Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Centrifugal Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Mechanical Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Automatic, Semiautomatic, and Preselector-Type Transmissions . . . . . . . . . . . . . . . . . . . . . 26
Speed Increasers/Reducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Stub Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fluid (Hydraulic) Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Torque Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single-Stage Torque Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Multistage Torque Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Side Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overhung Power Transmission Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wet Flywheel Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Misalignment Capability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Stiffness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Coupling Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auxiliary Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Gear Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Crankshaft Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Gear Drive Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
19
POWER TRANSMISSIONS
When selecting the power transmission Numerous devices are available for con-
system, the possible need for a com- nection or engagement of the engine to
plete torsional analysis must be consid- the driven machine. The device selection
ered. System incompatibility will result in will depend on the desired engagement
premature and/or avoidable failures. function; however, several general consid-
(Refer to Mounting and Alignment sec- erations must be made regardless of the
tion, Page 33, Torsional.) device selected.
20
Engine-Mounted Enclosed Clutches Light-Duty (LD)
Caterpillar offers, as price list attachments, A light-duty clutch is used primarily to dis-
a wide selection of “power takeoff” -type connect and pick up light inertia loads, but
enclosed clutches suitable for most indus- does more work during engagement than
trial-type applications. “cut-off” duty.
These clutches (power takeoffs) will be cov- A light-duty clutch should engage within
ered in greater detail under the following two seconds, start the load less than six
classifications (clutch rating definitions), as times per hour, and never heat the pres-
well as the specific selection considerations sure plate outer surface above hand hold-
for the type of clutch and application. ing temperature.
Normal-Duty (ND)
21
Heavy-duty applications may raise the Typical Normal-Duty (ND)
clutch outer surface temperature to a max- Clutch Applications
imum of 150°F (65.6°C ) rise above ambi-
ent air temperature. A. Agitators — solid or semisolids.
B. Batchers — textile.
Example: Power takeoff starting average C. Blowers and fans — centrifugal
inertia loads whose starting load is 80% of and lobe.
the running load. Also, rock crusher appli- D. Bottling machines.
cations where the clutch is not used to E. Compressors — all centrifugal
“break loose” jammed loads. and lobe-type.
F. Elevators, bucket — uniformly
Extra Heavy-Duty (EHD) loaded or fed.
G. Feeders — apron, belt, screw, or vane.
H. Filling machine — can type.
An extra heavy-duty clutch is used to start
I. Mixers — continuous.
inertia loads requiring over four seconds to
J. Pumps — three or more cylinders;
start the heaviest load, with longest slip peri-
gear- or rotary-type.
od per engagement not exceeding 10 sec-
K. Conveyor — uniform load.
onds. Also, when the product of seconds of
clutch slip per engagement times number of
engagements per hour exceeds 180, it is Typical Heavy-Duty (HD)
beyond extra heavy-duty. Contact your Clutch Applications
Caterpillar dealer for application approval
of extra heavy-duty-type service. A. Cranes and hoist — working clutch.
B. Crushers — ore and stone.
Example: Power takeoff starting inertia C. Drums — braking.
loads whose starting load approaches or D. Compressors — lobe rotary plus three
exceeds the running load. or more cylinder reciprocating-type.
E. Haulers — car puller and barge-type.
F. Mills — ball-type.
Typical Light-Duty (LD) G. Paper mill machinery — except
Clutch Applications calenders and driers.
H. Presses — brick and clay.
A. Agitators — pure liquids. I. Pumps — one- and two-cylinder
B. Cookers — cereal. reciprocating-type.
C. Elevators, bucket — uniform loads, J. Mud pumps — one- and two-cylinder
all types. reciprocating-type.
D. Feeders — disc-type.
E. Kettle — brew. Typical Extra Heavy-Duty (EHD)
F. Line shafts — light-duty. Clutch Applications
G. Machines, general — all types with
uniform loads, nonreversing.
H. Pumps — centrifugal. A. Compressors — one- and two-cylin-
der reciprocating-type.
B. Calenders and driers — paper mill.
C. Mills — hammer-type.
D. Shaker — reciprocating-type.
22
Once all machine parameters have been Although this type of clutch is not a
established, contact your Caterpillar dealer Caterpillar price list attachment, on the
for selection assistance. smaller engine families, there is offered a
selection of flywheels to accommodate the
Automotive-Type Clutches more common commercial models offered
by a number of manufacturers.
Also known as diaphram or spring-loaded-
type clutches, this category is generally a If the machine design requires this type of
light-duty classification; it is normally used clutch, the package designer and installer
in strictly mobile applications, such as on- should work very closely with the clutch
highway trucks or higher speed mobile manufacturer to ensure proper selection.
machines, which utilize a multispeed trans-
mission. The automotive-type clutch is CAUTION: THIS TYPE OF CLUTCH, DUE
normally foot-operated for disengagement TO ITS INHERENT TORQUE CAPACITY
or is engaged with the friction being gener- LIMITATIONS, SHOULD NOT BE USED
ated by spring force acting on an engine- WITH THE LARGER 3500 FAMILY
driven plate. CATERPILLAR ENGINES.
Figure 2
SPRING-LOADED AUTOMOTIVE TYPE CLUTCH
23
Air Clutches the output shaft must be supported by two
support bearings. These bearings must be
Air-type clutches are commercially avail- mounted on a common base with the engine
able in sizes to fit the entire Caterpillar package. Air pressure to operate the clutch
Diesel Engine line. Basically, engagement is supplied by an air connection through the
friction is maintained by air pressure. This drilled passage in the output shaft. Clutch
feature is particularly advantageous when alignment tolerances are reduced as air
remote control of the engagement/disen- pressure to the clutch increases.
gagement functions is required.
Caterpillar does not offer air clutches on an
Air clutches utilize an expanding air blad- attachment basis. When selecting an air
der for the clutch element. (See Figure 3.) clutch, the package designer/installer must
work closely with the clutch manufacturer.
Air clutches do not normally have side load
capability, so if such capability is required,
Figure 3
AIR CLUTCH
24
Centrifugal Clutches TRANSMISSIONS
Centrifugal clutches are commercially avail- Over the years rapid technological ad-
able in sizes to fit the entire Caterpillar vances have enabled numerous commercial
Diesel Engine line. The centrifugal clutch manufacturers to offer a broad range of
accomplishes the engagement/disengage- transmissions with nearly unlimited fea-
ment functions by centrifugal force which is tures and options.
generated by the engine operating speed. It
provides a power engagement/disengage- For this discussion transmissions will be
ment function controlled strictly by the divided into three broad classifications all
engine governor speed control (throttle). of which transmit power through sets of
mechanical gears, either spur or helical
Centrifugal clutches offer smooth automat- types, or planetary designs. Where multi-
ic engagement of load without complicated speed capability is provided, it is accom-
controls. Typically, a diesel engine with a plished either mechanically or automatical-
full load operating speed of 1800 rpm will ly (hydraulically, pneumatically, etc.).
be fitted with a centrifugal clutch which
effects engagement at a speed of about Due to the large number of transmissions
1000 engine rpm. Once engaged, most commercially available and the fact that
clutches of this type will remain engaged Caterpillar does not offer transmissions (with
even if the engine speed is pulled down the exception of marine transmissions —
due to load — as low as the engagement single speed — forward/reverse functions)
speed (i.e., 1000 rpm) or lower (e.g., dis- as price list attachments, the transmission
engagement at 800 rpm). If the load is discussion will be restricted to general oper-
such that engine stall speed is ating principles and considerations.
approached, the clutch will disengage.
When selecting a transmission, the pack-
Centrifugal clutches are not offered by age designer must work closely with the
Caterpillar as standard price list attach- transmission manufacturer.
ments. As with the air-type clutches, they
have limited or no side load capability and
for other than in-line drive loads, a sepa- CAUTION: REGARDLESS OF THE TYPE
rately supported output shaft with two sup- OR BRAND OF TRANSMISSION SELECT-
port bearings must be provided and must ED, THE DESIGNER MUST ENSURE
be mounted on a common base with the THAT IT HAS THE CORRECT HORSE-
engine package. POWER, TORQUE, AND SPEED CAPA-
BILITY TO MATCH THE DIESEL ENGINE
PERFORMANCE CHARACTERISTICS.
When selecting a centrifugal clutch, the pack-
age designer/installer must work closely with
the clutch manufacturer.
25
Mechanical Transmission Automatic, Semiautomatic, and
Preselector-Type Transmissions
The mechanical transmission provides the
lowest cost method of providing multiple As the names imply, these transmission
output speeds when the driven equipment types effect the gear changes either com-
input speed range or torque requirements pletely automatically or as predetermined
exceed the operating capability of the diesel by the machine operator.
engine. Mechanical transmissions are usu-
ally equipped with some type of clutch
Engine power engagement/disengagement
assembly to facilitate not only engine start-
clutching is normally fully automatic and
ing but also to change gear ratios.
does not require the machine operator to
physically move a clutch pedal or lever. For
disengagement the operator need only
move the selector lever to a neutral position.
26
Figure 5 AUTOMATIC TRANSMISSIONS
27
Speed Increasers/Reducers Compounds
These power transmission devices resem- Although infrequently found in material han-
ble a mechanical transmission in that dling/agriculture applications, specific de-
power is normally transmitted through a signs may require an engine compound.
mechanical gear set of spur or helical
gears. They are used when the engine Basically, a compound is an enclosed gear or
speed range is not compatible with the dri- chain device which permits several engines
ven equipment input speed requirements to provide input power with the power out-
and when the installation is best suited to put coming from one or more shafts.
an in-line drive arrangement rather than
the offset belt of chain drive systems.
Compounds providing a single engine input
and multiple outputs is most common. An
example would be a hydrostatic machine
where a single engine provides power to
multiple hydraulic pumps when separate
pumps are used for the various functional
drives of the machine.
28
Caterpillar does not offer compounds as The package designer/installer must work
standard price list attachments, however, a closely with the compound manufacturer
number of commercial manufacturers offer to ensure proper selection and installation.
a variety of different compounds.
29
Hydraulic Drives The primary advantage of a hydraulic cou-
pling is the total lack of a mechanical con-
Hydraulic drive devices generally fall into nection between the driving engine and the
two major classifications: fluid or hydraulic driven equipment.
couplings and torque converters.
This isolates or greatly reduces the transfer
The theory involved is similar in all types of of mechanical shocks, vibration, and unde-
hydraulic drives although the internal sirable torsional effects between the driven
design may vary. Basically, the engine out- load and the engine.
put is absorbed by a turbine-type pump.
The oil or fluid in the pump housing is accel- A hydraulic coupling will prevent engine stall
erated outward, and the engine power is under load; however, the engine can be
transmitted to the outer edge of the pump pulled down in speed by varying degrees
as kinetic energy in the form of high veloc- depending on the hydraulic coupling fluid
ity fluid. This energy is then transferred cooling capacity. It also permits starting high
back towards the center of the output inertia-driven loads without the use of a cut-
shaft. This is where the differences occur off clutch.
between a hydraulic or fluid coupling and a
torque converter.
The main disadvantages of a hydraulic cou-
pling are the reduced efficiency over a
Fluid (Hydraulic) Couplings mechanically coupled drive and its inability
to generate a torque multiplication as is
In the fluid couplings, the high velocity fluid possible with a torque converter.
is directed into a matching turbine located
very close to the turbine-type pump which
is engine driven. The matching turbine Normally, hydraulic couplings are best suit-
absorbs the energy as the fluid is directed ed to applications which are constant speed
back toward the center of the coupling and applications where the slip capability is
the energy is delivered to the output shaft. desirable to compensate for shock loads,
overloads, high inertia load startups, and
assist in torsional vibration reduction.
Torque Converters
30
in such a manner as to produce a multipli- The necessity of matching a torque con-
cation of the input torque to the output shaft verter to the engine cannot be overempha-
at reduced output speeds (rpm). sized. An improperly sized converter, one
with the wrong blading or one which oper-
ates in a highly inefficient speed range, will
prove unsatisfactory. An improperly matched
torque converter can result in engine over-
load, high inefficiency, high fuel consump-
tion, poor engine response, and other
undesirable results.
31
Additionally, cooling of the torque convert- Multistage Torque Converters
er fluid is required. Torque converter cool-
ing must be provided for the equivalent of Most applications will utilize a multistage
at least 30% of the total engine heat rejec- converter. They provide a broader usable
tion when using a precombustion cham- range and higher torque multiplication value
ber-type engine. When using a direct injec- than single-stage converters.
tion-type engine, torque converter cooling
must be provided for the equivalent of at
least 50% of the total engine heat rejection. Torque converter manufacturers provide
excellent manuals and assistance in the
selection of the correct converter for a spe-
Caterpillar offers, as price list attachments, cific application. Consequently, rather than
either jacket water connections for heat elaborating on selection guidelines in this
exchanger-type coolers or, on the 3200, publication, it is suggested that the pack-
3300, and 3400 Series Engines, complete age designer/installer counsel with the con-
heat exchanger cooling packages. verter manufacturer for expert advice.
It is imperative that the cooling package be In addition to offering the same benefits as
of adequate capacity. The capacity of a hydraulic drive, the torque converter also
Caterpillar-supplied cooling systems can offers a torque multiplication benefit as
be obtained from your Caterpillar dealer. well as, if properly matched, higher power
transmission efficiency. The multistage
Most commercially available converters converter is particularly preferred for vari-
are also offered with attachment cooling able output speed applications.
packages.
As standard price list attachments,
If the engine cooling system is used to cool Caterpillar offers flywheels to couple to
the torque converter, adequate reserve most commercial torque converters and
radiator capacity must be provided. (Refer hydraulic drives.
to Cooling section.)
Special Considerations
Single-Stage Torque Converters
With the selection of any of the above
This type of converter is normally selected methods of power transmission, several
for light-duty applications. It has a decreas- general areas must also be given special
ing torque absorption curve as the output consideration to ensure a successful
speed approaches stall condition and will installation.
not pull down the engine input speed (lug
the engine). Side Loading
32
For Caterpillar-supplied attachment power CAUTION: CERTAIN APPLICATIONS,
takeoffs, the Caterpillar Industrial Engine SUCH AS AGRICULTURE MACHINES,
Price List LEKI8162 provides complete DRILLS, OFF-HIGHWAY TRUCK, ETC.,
instructions and capacity data for side load REQUIRE CONSIDERATION OF THE
evaluation. EFFECTS OF THE DYNAMIC BENDING
MOMENT IMPOSED DURING NORMAL
For power transmission devices supplied by MACHINE MOVEMENT OR ABRUPT
others, the manufacturer must be consulted STARTING AND STOPPING.
for a capability analysis of his equipment.
The dynamic load limits and the maximum
Overhung Power Transmission bending moment that can be tolerated by
Equipment the flywheel housing can be obtained from
your Caterpillar dealer.
Power transmission equipment, which is
directly mounted to the engine flywheel For determination of the bending moment
housing, must be evaluated to ensure that of overhung power transmission equipment
the overhung weight is within the tolerable installations, see Figure 13.
limits of the engine. If not, adequate addi-
tional support must be provided to avoid
damage.
33
To compensate for power transmission B. Have the capability of evacuating the
systems which create a high bending transmission fluid from the flywheel
moment due to overhung load, a third housing back to the transmission
mount is required. Proper design of the reservoir to prevent engine crank-
support is essential. Forces and deflec- shaft seal flooding.
tions of all components of the mounting
system must be resolved. If the third These provisions can be provided on
mount is in the form of a spring, with a ver- Caterpillar Engines but additional cost will
tical rate considerably lower than vertical normally be incurred.
rate of the rear engine support, the effect
of the mount is in a proper direction to
reduce bending forces on the flywheel COUPLINGS
housing due to downward gravity forces,
but the overall effect may be minor at high Unless a belt, chain, or universal joint-type
gravity force levels. The use of supports drive is taken directly from the output shaft
with a vertical rate higher than the engine of the engine-driven power transmission
rear mount is not recommended since device, the use of some type of mechani-
frame bending deflections can subject the cal coupling device is recommended.
engine power transmission equipment
structure to high forces. Another precau-
tion is to design the support so that it pro- The coupling must be installed between
vides as little resistance as possible to the power transmission output shaft and
engine roll. This also helps to isolate the the input drive shaft of the driven machine.
engine/transmission structure from mount- On close-coupled driven equipment, the use
ing frame or base deflection. of a coupling can be avoided if two basic
criteria are met:
Wet Flywheel Housings
A. Is the torsional compatibility of the
Certain types of power transmission equip- driven machine compatible with the
ment require a “wet” flywheel housing. engine to the point that lack of a cou-
pling will not cause either engine or
driven machine problems?
Wet housing equipment requires that the B. Is the package base sufficiently rigid to
flywheel housing be able to accommodate a avoid any distortion during operation?
degree of flooding by the fluid medium of the Does it contain sufficient alignment
power transmission equipment. The stan- control features to successfully retain
dard Caterpillar Diesel Engine does not: alignment during operation to preclude
the need for the misalignment toler-
A. Contain sufficient provisions for seal- ance capability of a coupling?
ing in the area of the rear crankshaft
seal to prevent the transfer of the Seldom can both of these questions be
power transmission fluid into the answered affirmatively.
engine lubricating oil reservoir (pan).
A large number of commercial coupling
designs, are available to the package
designer/installer.
34
Commercial couplings make use of resilient If single bearing equipment is used,
materials ranging from rubber and tough the coupling must be torsionally and
fabrics to springs and air-filled tubes and radially rigid to transmit the load and
drums in order to absorb minor mechani- support the weight of the driven equip-
cal misalignment and relative movement ment input shaft. It must be flexible to
between engine and load. It is important to compensate for angular misalignment
have the best possible alignment and put a due to:
minimum load and reliance on the flexible 1. Thermal growth differences be-
coupling. Air clutches are not flexible cou- tween the diesel engine and driven
plings and imposing misalignment on them equipment.
will cause damage. 2. Dimensional tolerances between
the two units and dynamic condi-
tions, such as torque reaction.
3. Momentary misalignment due to
shock or other transient conditions.
B. Stiffness
35
When selecting a coupling, ensure Belt Drives
that the design can withstand reason-
able misalignment without materially Several options exist for belt driving various
decreasing the service life of the flex- auxiliary attachments. Both of the following
ible elements. methods are available from Caterpillar:
AUXILIARY DRIVES
36
MOUNTING AND ALIGNMENT
Page
General Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fixed Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Semimobile Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Mobile Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Out-of-Balance Driven Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Bases ................................................................. 41
Purpose and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Thermal Growth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Types of Engine Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rigid Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Subbase Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Skid Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Semi-flexible Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Flexible Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Collision Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Isolation — Antivibration/Noise Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flexible Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bulk Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Checking Face Run Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking Outside Diameter Run Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking Parallel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking Angular Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Torque Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Belt and Chain Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Alignment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Single-Bearing Driven Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Flexible-Type Couplings — Flywheel Housing-Mounted Driven Equipment. . . . . . . . . . . . 56
Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Flywheel Concentricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Flywheel Face Run Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Flywheel Housing Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine Mounting Face Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Driven Equipment Mounting Face Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Flexible-Type Coupling — Remote-Mounted Driven Equipment . . . . . . . . . . . . . . . . . . . . 60
Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Flywheel Concentricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Flywheel Face Run Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Angular Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Linear Relationship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Tolerances and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Vibration and Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Linear Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Torsional Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
37
MOUNTING AND ALIGNMENT
GENERAL DISCUSSION Fixed installations offer positive bene-
fits in that they involve fewer mounting
The correct mounting and coupling to the and design problems than the other
load are essential to the success of any categories; but conditions may dictate
engine installation. (See Power Transmission isolation against vibration or sound,
section.) which will complicate the engine
mounting.
Agriculture and material handling installa-
tions may incorporate all types of mounting B. Semimobile Installations
methods; consequently, no single system
will be universally successful. It is just as In these installations, although part of
possible to encounter problems from an a machine is occasionally moved, the
extremely rigid constrained mounting sys- engine is not generally used as
tem if improperly applied as it is with a flex- motive power to move the machine,
ible mounting if incorrectly applied to the nor is it normally operated while the
installation or machine to be powered. machine is in motion. Examples of
semimobile installations would be
All installations will fall into three basic cat- rock crushers, batch plants, concrete
egories: mixers, airport support vehicles, port-
able air compressors, conveyors, and
portable irrigation engine drives. With-
A. Fixed Installations in this category are several examples
of machines which do move while the
Where usable, fixed installations offer engine is in operation, but only at a
positive benefits. Some examples are slow, steady pace. Examples of these
more permanent plant installations machines are continuous pavers or
such as mine ventilation blowers, cot- overlayers, paving finishers, certain soil
ton gins, pumps, standby power sys-
tems, etc.
38
shredders, and continuous mining Although similar to the fixed installa-
machines, as well as certain types of tion, semimobile installations involve
cranes, shovels, and draglines. other considerations in the area of
power transmission components.
Mounting considerations are impera-
tive to minimize machinery stress and
maintain proper alignment.
C. Mobile Installations
39
GENERAL CONSIDERATIONS Out-of-Balance Driven Equipment
The Caterpillar Diesel Engine is a rigid, The engine itself is designed and built to run
self-contained structure which will operate very smoothly. Objectionable vibration gen-
and maintain its inherent alignment unless erally arises from either poor driveline com-
subjected to extreme external stresses. ponent match to the engine or unbalance of
the driven equipment. Reciprocating com-
Due to the diversity of types of installations, pressors, for example, can cause prema-
no one mounting system or method is ture failure of the mounting structure or
universally acceptable. If the engine is not undesirable vibration even though the unit
mounted in a manner suited to the specific is properly mounted and isolated from the
application, taking into account the charac- engine.
teristics of the engine, the driven loads, and
the operating cycle of the machine, one or Even though the engine and the driven
more of the following results will occur. load are in balance, it is also possible to
encounter undesirable and damaging vibra-
Vibration tion as a result of the driving or connecting
equipment having a misalignment or out-
Transmission of undesirable vibration to of-balance condition. Long shafts, drives,
driven equipment or to the machine struc- gear assemblies, clutches, or any type of
ture may occur. In certain types of heavy coupling where misalignment, out of bal-
mobile installations such as rock crushers, ance, or mass shifting may occur are prob-
the engine vibration is insignificant com- able sources of vibration.
pared to the drive equipment vibration of
the operating machine. In this case the Alignment
machine vibration could be detrimental to
the engine and its mounting and could An unsatisfactory engine mounting nearly
possibly result in cracking of fatigue of a always results in alignment problems
structural member which happened to between the engine and the driven machin-
vibrate in natural harmony with the engine. ery. Assuming that failure of the driven
equipment does not occur first, the forces
The same amplitude and frequency of or loads transmitted to the engine in the
vibration generated by the engine could form of pounding, twisting, flexing, or thrust
result in structural damage if a fixed instal- could result in engine crankshaft and bear-
lation were housed in a building or close to ing failure. Costly failures of this nature can
sensitive instruments or equipment such be avoided if, at the design and installation
as computers. (For a more complete dis- stage, the importance of proper alignment
cussion of vibrations, refer to Isolation between the engine and driven load and
Antivibration/Noise Mounting, Page 44.) providing an adequate mounting to main-
tain alignment is considered.
40
Engine Construction BASES
41
Thermal Growth equipment, locomotives, etc., this type
of mounting is generally not desir-
Design consideration must also be given able. It is suitable only on machines
to compensate for the change in distance where the frame is so rigid that no
between the mounting bolts, which secure operating-induced stresses or distor-
the diesel engine to the base, occurring tions are transmitted to the engine.
when engine temperature changes from This is normally possible only in
cold to operating temperature level. As machines where weight is desirable;
engine temperature increases to operating hence, the use of extremely heavy
level, the entire engine grows in length due frames will impose no operating or
to thermal expansion. cost problems. Rigid mounting is suit-
able for all fixed installations; however,
engine vibration and driven equipment
Cast iron has a coefficient of expansion of vibration will be transmitted to any
0.0000055, and that of steel is 0.0000063. adjoining areas unless the foundation
This means that the block of an engine 94 in is isolated. (See Isolation, Page 44.)
(238.8 cm) in length will grow 0.083 in
(0.212 cm) if its temperature is increased
from 50°F (10°C) to 200°F (98.8°C). Using In normal service most semimobile
0.0000063 as the plate steel coefficient of and mobile installations will undergo
expansion, a steel weldment of 94 in some frame twisting and distortion,
(238.8 cm) will grow 0.089 in (0.226 cm) although it may be limited to a few
through the same temperature range. The thousands of an inch (several mm).
small difference in growth between the Rigid mounting in this type of installa-
block and the lubricating oil pan is com- tion may result in broken engine
pensated for in the design of the engine by mounting lugs or cracked flywheel
making the holes in the flange of the housing, mount and base failures,
attached component (rails) larger than the and possible crankcase and cylinder
attaching bolts. block cracks. Heavy inertia shock
loads can also be experienced, as
any machine shock such as moving
Due to the growth resulting from thermal heavy material, or emergency stop,
expansion, the engine must not be dowel or accident imposes impact loads on
located in more than one location. It is the engine mounting. (See Collision
recommended that a dowel locator be used Stops, Page 43.)
only on one engine mounting rail located at
the flywheel housing. Clearance between
the mounting bolts and the mounting brack- B. Subbase Mounting
ets to the base will then allow slip to com-
pensate for thermal growth. This is the most common method of
engine mounting in semimobile appli-
Type of Engine Mountings cations and is frequently used in fixed
installations and occasionally in mobile
There are five basic types of engine applications.
mounting, with variations possible within
each of the basic categories. The subbase method allows the pack-
age designer/installer to properly sup-
A. Rigid Mounting port the engine and support and align
the driven equipment on a common
rigid base which can also be isolated
Although frequently utilized in heavy-
duty applications such as earthmoving
42
from the main machine structure. Its or spring supports to isolate vibration
single disadvantage is additional without imposing external forces.
weight.
The value of mounting the engine
The subbase mounting may use vari- and driven equipment on a common
ous designs ranging from a rein- base is immeasurable in maintaining
forced concrete slab isolated by cork, proper alignment, particularly if an
rubber, sand, etc., to a rigid steel outboard bearing is utilized.
weldment isolated by rubber mounts
43
D. Semi-flexible Mounting Caution: The industrial-type front sup-
ports must not be used for semi-flexible
This type of mounting is occasionally mounting. They lack the flexibility of a
used in semimobile types of machines three-point mounting and will allow
and nearly always used for mobile frame distortion to cause engine
applications. Rare exceptions to the mounting component failure.
above statement are where a rigid
mounting is used in heavy machines A semi-flexible engine mounting will
where the weight of frame rigidity is always require the use of a flexible
not a problem. coupling or universal joint-type drive
unless the drive load is directly
The semi-flexible mounting concept mounted to the engine flywheel hous-
is not applicable to the 3500 Family ing. An example of this is a hydraulic
Engines and should be considered pump where hose connections pro-
only for mobile equipment diesel vide the flexibility to completely iso-
engine arrangements. The mobile late the engine pump system.
equipment engine arrangements uti-
lize a front mount which has the flexi-
bility to effect a three-point mounting.
44
The semi-flexible mounting benefits E. Flexible Mounting
can be summarized as isolating the
engine vibration from the vehicle Full flexible mounting systems are
while preventing distortion of the rarely required or suitable for most
vehicle structure and vehicle vibration material handling applications, how-
from being transmitted to the engine ever, there may be specific installa-
structure. tions where the characteristics of this
concept are desirable.
This type of mounting requires a
knowledge of the frequency, ampli- Probably the most common usage of
tude, and planes of vibration to select flexible mounting is in the propeller-
the proper isolation mounts. (See driven airplane. The engine and pro-
Vibration and Isolation, Page 59.) peller are directly and positively con-
nected, and the power package is
Consideration must also be given to nearly completely isolated vibration
a suitable means of maintaining a wise from the machine structure. No
smooth working drive between the external shafts, belts, chains, or other
engine and the driven unit. Each is types of drives are connected —
normally free to move; however, their hence, the power package has great
movement is not necessarily related in freedom of movement.
an orderly fashion. An example would
be a material hauling unit such as a The degree of expertise and complica-
mechanical drive off-highway truck. tions involved in developing a suc-
The engine may move in response to cessful flexible mounting, coupled with
inertia loads, ground surface dis- the fact that such mounting is seldom
placements, and torque reactions; yet required or desirable in agriculture/
it must be connected to provide a material handling applications, deems
smooth positive drive to an axle which it inappropriate to devote further dis-
is subjected to surface displacement cussion in this publication.
and angularity as well as inertia and
driving torque.
It is strongly recommended that if you
or your customer finds it necessary to
A successful semi-flexible mounting, utilize a flexible-type mounting that
in addition to requiring a high level of your Caterpillar dealer be contacted
technical expertise, will normally for consultation before any significant
require lab and field testing for ulti- effort is invested in design develop-
mate qualification of suitability. ment. Should all concur that such a
system is desirable, a team effort of
the involved parties is necessary to
develop a suitable system.
45
FOUNDATIONS To calculate the necessary foundation
depth, use:
For fixed installations it is frequently pre-
ferred to install a permanent foundation of W
reinforced concrete. Foundation Depth (ft) = ___________
150 2 B 2 L
Historically, concrete foundations have been W
massive structures. The Caterpillar multi- Foundation Depth (m) = _____________
cylinder modern speed engine does not 2402.8 2 B 2 L
require the enormous traditional structure.
W = Total wet weight of engine-
driven equipment pounds —
If a concrete foundation is required, some (kg).
minimum design guidelines to consider are:
150 = Density of concrete (pounds
— The foundation length and width per cubic foot).
should exceed the length and width
of the engine-driven equipment a 2402.8 = Density of concrete (kilo-
minimum of 1 ft (0.305 m) on all sides. grams per cubic meter).
46
Suggested concrete mixture by volume is separated from the foundation by expan
1:2:3 of cement, sand, and aggregate with sive joint material. This prohibits the vibra-
a maximum 4 in (101.8 mm) slump with a tion from traveling from the block to the
28-day compressive strength of 3000 psi floor and also eliminates the possibility of
(27,000 N•m2). losing tools in the pit during servicing.
The foundation should be reinforced with Cork is normally not effective with vibration
No. 8 gauge steel wire fabric or equivalent, frequencies below 1800 cps and, if not
horizontally placed on 6 in (152 mm) cen- kept dry, will rot. For these reasons it is sel-
ters. An alternate method of reinforcing is dom used with fixed installations. It can be
to place No. 6 reinforcing bars on 12 in used as a separator between the unit foun-
(304 mm) centers horizontally. Bars should dation and surrounding floor due to its
clear the foundation surface a minimum of resistance to oils, acids, or temperatures
3 in (76.3 mm). between 0°F (–18°C) and 200°F (93°C).
47
Isolation — Antivibration/Noise the lower the natural frequency of the iso-
Mounting lator (soft), the greater the deflection and
the more effective the isolation. However,
Caterpillar Engines are capable of with- the loading limit of the isolator must not be
standing all self-induced vibrations and no exceeded.
isolation is required to prolong service life.
However, vibrations from surrounding equip- No matter what type of isolation is used, it
ment, if severe, can harm an engine which should be sized to have its natural fre-
is inoperative for long periods of time. If quency as far removed from the exciting
these vibrations are not isolated, the lubri- frequencies of the engine as possible. If
cating oil film between bearings and shafts these two frequencies were similar, the
can be reduced to the point where damage entire unit would be in resonance.
could result.
The static weight of the machinery must
For a fixed installation where a reinforced load a resilient mount close to the center of
concrete foundation is utilized, a separate its deflection range. Therefore, the weight
method of isolation is possible. The system that will rest on each isolator must be known
is covered under Bulk Isolation, Page 45. and the isolators properly matched in
respect to the load and its center of gravity.
For all other types of installations, flexible-
type isolators are used. The most effective isolators are of the steel
spring design. They are capable of isolat-
CAUTION: MOST COMMERCIAL ISOLA- ing up to 96% of all vibrations, provide
TION DESIGN HAS LIMITED SIDE LOAD overall economy, and permit mounting the
CAPABILITY. FLEXIBLE-TYPE ISOLA- power unit on a surface which need only
TORS ARE ONLY GENERALLY ACCEPT- be capable of supporting the static load.
ABLE FOR DRIVES NOT IMPOSING No allowance for torque or vibratory loads
HIGH SIDE LOADS. is required. Spring isolators are also avail-
able with rubber side thrust isolation for
use when the engine is side loaded or
Flexible Isolation
located on a moving surface.
Several commercial isolators are available
which will provide varying degrees of iso-
lation. Care must be taken to select the
best isolator for the application. Generally,
Figure 23
48
By the addition of a rubber plate beneath The foundation pit should be made slightly
the spring isolator, the high frequency longer and wider than the foundation block
vibrations which are transmitted through base. A wooden form the size and shape
the spring are also blocked. These high of the foundation is then placed on the
frequency vibrations are not harmful but gravel or sand bed for pouring the con-
can result in annoying noise. crete. After the wooden form is removed,
the isolating material is placed around the
CAUTION: THIS SYSTEM REQUIRES foundation sides, completely isolating the
THAT ALL CONNECTIONS TO THE foundation from the surrounding earth.
BASE-MOUNTED EQUIPMENT HAVE
SUITABLE FLEXIBLE CONNECTORS.
THIS WOULD INCLUDE SUCH CON-
NECTIONS AS EXHAUST, WATER, AIR,
FUEL, ELECTRICAL, CRANKCASE
BREATHER, ETC.
Bulk Isolation
Isolation of block foundations may also The modern diesel engine, as well as most
be accomplished by using 8 in to 10 in driven equipment, must be mounted on a
(203.2 mm to 254 mm) of wet gravel or surface which is true to prevent prestressing
sand in the bed of the foundation pit. Sand the engine or driven equipment frame when
and gravel are capable of reducing the torquing it to the mounting structure, when
amount of engine vibration transmitted by as more than three support points are used.
much as one-third to one-half. The isolating
value of gravel is somewhat greater than Large Caterpillar Diesel Engines such as
sand. To minimize settling of the foundation, 3500 Family are fastened to the mounting
the gravel or sand should be thoroughly structure at four or more points. All mounting
tamped before pouring the concrete block. points must bear equally on the mounting
49
structure. To determine if shims are required, Shim packs should be of nonrusting mate-
set the engine on the mounting structure rial. Handle shims carefully. After align-
but do not attempt to secure it by bolting it ment, each mounting surface must carry its
in place. Using a feeler gauge, check all portion of the load.
mounting points for clearance between the
mounting point and the base. If clearance Before the engine and driven equipment
exists which exceeds 0.005 in (0.127 mm) can be aligned, each foot must carry its
compensation must be provided. portion of the load. Failure to do this can
result not only in misalignment, but also in
If the mounting base is a rigid steel struc- springing of the substructure causing res-
ture, the areas where the engine mounts onant vibrations, high stress in welds or
make contact may be machined to bring base metal, and high twisting forces in the
them all into a true plane. If this is imprac- engine or generator.
tical, shims should be used.
This same requirement for a true plane
Shim packs under all equipment should be (flat) mounting is also necessary for most
0.200 in (5 mm) minimum thickness to per- driven equipment. If specific instructions
mit later corrections requiring the removal are not provided by the driven equipment
of shims, if necessary. manufacturer, the same principles as rec-
ommended for the engine can be applied.
Figure 25
50
ALIGNMENT Common mistakes include failure to detect
“run out” of rotating assemblies and paral-
Principles lel or angular misalignment of the engine
and driven machine.
To provide the necessary alignment between
the diesel engine and all mechanically dri- The run out of a hub or flywheel can be
ven components, an understanding of the measured by turning the part in question
types of misalignment and the methods of while measuring from any stationary point
measurement is required. to the surface being checked. This can be
done with a dial indicator. Note: Measure
Many crankshaft and bearing failures are to the pilot surface being used, not to an
the result of improper alignment of drive adjacent surface, because surfaces not
systems at the time of initial engine instal- used for pilots normally are not machined
lation. Misalignment always results in as closely.
some type of vibration or stress loading.
This check should be made first on the
CAUTION: BEFORE MAKING ANY face of the wheel or hub, as illustrated in
ATTEMPTS TO MEASURE RUN OUT OR Figure 26. Whenever making a face check,
ALIGNMENT, IT IS IMPORTANT THAT make sure the shaft end play does not
ALL SURFACES TO BE MEASURED OR change as you rotate it. The crankshaft
MATED BE COMPLETELY CLEAN AND must be moved within the diesel engine to
FREE FROM GREASE, PAINT, OXIDA- remove all end play and that position must
TION, OR RUST AND DIRT — ALL OF be maintained throughout the alignment
WHICH CAN CAUSE INACCURATE MEA- procedures.
SUREMENTS.
Figure 26
51
Checking Face Run Out run out in addition to face run out. For this
reason the face run out is checked first.
While turning the wheel 360°, note any
change in the dial indicator reading. After the face run out has been eliminated,
Any change is caused by face run out. outside diameter run out can be checked.
Face run out may be caused by foreign This must also be done with a dial indicator.
material between a crankshaft flange and (See Figure 27.)
flywheel, uneven torquing or from machin-
ing variations.
Figure 27
52
Checking Outside Diameter Run Out should be followed on the driven side of
the coupling.
While turning the hub through 360° of rota-
tion, check for any change in indicator After the run out of both the driving and dri-
reading. The indicator is held stationary ven sides of the coupling have been found
and, if the reading changes, the outside within limits, the engine and load align-
diameter is off center. ment can be checked. There are two kinds
of misalignment: parallel and angular (bore
After the flywheel or driving hub has been and face). (See Figures 28.)
checked for run out, the same procedure
Figure 28
Figure 29
53
C. The vertical thermal growth of the Note: the face and bore alignment affect
engine is usually more than that of the each other. Thus, the face alignment should
driven equipment. Engine main bear- be rechecked after the bore alignment and
ing clearance should be considered vice versa.
when adjusting for parallel alignment.
After determining that the engine and load
Note: Both parts can be rotated together if are in alignment, the crankshaft end play
desired. This would eliminate any out-of- should be checked to see that bolting and
roundness of the parts from showing up in coupling together does not cause end thrust.
the dial indicator reading. In most cases
rubber driving elements must be removed Torque Reaction
or disconnected on one end during align-
ment since they can give false parallel The tendency of the engine to twist in the
readings. opposite direction of shaft rotation and the
tendency of the driven machine to turn in
Checking Angular Alignment the direction of shaft rotation is torque
reaction. It naturally increases with load
Angular misalignment can be determined and may cause a torque vibration. This
by measuring between the two parts to be type of vibration will not be noticeable at
joined. The measurement can be easily idle but will be felt with load. This usually is
made with a feeler gauge, and it should be caused by a change in alignment due to
the same at four points around the hubs insufficient base strength allowing exces-
Figure 30. sive base deflection under torque reaction
load. This has the effect of introducing a
If the coupling is installed, a dial indicator from side to side centerline offset which disap-
one face to the other will indicate any angular pears when the engine is idled (unloaded)
misalignment. In either case, the readings will or stopped.
be influenced by how far from the center of
rotation the measurement is made.
Figure 30
54
Belt and Chain Drives Couplings
Belt and chain drives may also cause the A coupling must be torsionally compatible
engine or driven machine to shift or change with engine and driven load so that tor-
position when a heavy load is applied. sional vibration amplitudes are kept within
Belts and chains may also cause PTO acceptable limits. A mathematical study
shaft or crankshaft deflection, which can called a torsional vibration analysis should
cause bearing failures and shaft bending be done on any combination of engine-drive-
failures. The driving sprocket or pulley line-load for which successful experience
must always be mounted as close to the doesn’t already exist. A coupling with the
supporting bearing as possible. Side load wrong torsional stiffness can cause serious
limits must not be exceeded. Sometimes, damage to engine or driven equipment.
due to heavy side load, it is necessary to
provide additional support for the driving All couplings have certain operating ranges
pulley or sprocket. This can be done by of misalignment, and the manufacturers
providing a separate shaft which is sup- should be contacted for this information.
ported by a pillow block bearing on each
side of the pulley or sprocket. This shaft
can then be driven by the engine or clutch Some drives, such as U-joint couplings,
through an appropriate coupling. The size have different operating angle limits for dif-
of the driving and driven sprockets or pul- ferent speeds.
leys is also important. A larger pulley or
sprocket will give a higher chain or belt As a general rule, the angle should be the
speed. This allows more horsepower to be same on each end of the shaft. (See
transmitted with less chain or belt tension. Figure 31.) The yokes must be properly
If it is suspected that the engine or the dri- aligned and sliding spline connections
ven machine is shifting under load, it can should move freely. If there is no angle at
be checked by measuring from a fixed all, the bearings will brinell due to lack of
point with a dial indicator while loading and movement.
unloading the engine. Torque reactive
vibrations or torque reactive misalignment
will always occur under load.
55
ALIGNMENT INSTRUCTIONS which results from engine bearing
clearances and natural droop as a
General Considerations result of the overhung weight of the
flywheel. The flywheel should be
Alignment methods will vary depending on raised several times to get a “feel”
the coupling method selected. On Caterpillar for the bearing clearance to prevent
Diesel Engines either a flexible-type or rigid- excessive lift which means reverse
type coupling is acceptable, depending on bending of the crankshaft.
the specific installation characteristics and
the results of the Torsional Analysis.
Alignment Instructions —
Single-Bearing Driven Equipment
56
4. Flywheel Face Run Out the indicator readings at positions (A),
(B), (C), and (D). Subtract the droop
Set the tip of the indicator on the face dimension (Step 1) from the reading
of the flywheel Figure 33. Position the indicated at position (C) and subtract
crankshaft to the front of its end play one-half the droop dimension from
and zero the indicator. Shift the crank- the reading indicated at positions (B)
shaft to the rear of its end play, and and (D) on the flywheel housing to
record the TIR. With the crankshaft determine the true concentricity.
to the rear of its end play, zero the
indicator. Rotate the crankshaft and
record the TIR when the flywheel
positions (A), (B), (C), and (D) are at
the top. Be sure to remove the crank-
shaft end play before recording these
readings. Remove the flywheel hous-
ing access cover and place a pry bar
between the rear face of the flywheel
housing and the front face of the fly-
wheel assembly. Move the crankshaft-
flywheel assembly to the rear of the
engine to remove all end play.
Figure 34
Mount the dial indicator on the fly- Repeat the same measurement with
wheel assembly with the tip located the straight edge located on positions
on the pilot bore of the flywheel hous- (B) and (D).
ing and set the reading to zero.
Rotate the crankshaft in the direction
Steps 1 through 6 establish the engine
of normal engine rotation and record
tolerances. The following Steps, 7 and
8, determine the driven equipment
57
tolerances or refer to manufacturers This dimension must equal the engine
specifications. mounting face depth Step 6 less one-
half of the crankshaft end play as
7. Support the driven equipment input described in Step 4. If not, it must be
shaft until it is centered (all droop is corrected by changing the adapting
removed). parts, or by shimming if the required
correction is small. Shimming is usu-
ally the less desirable approach.
8. Driven Equipment Mounting
Face Depth
With the engine and driven equip-
ment tolerances known, proceed to
With the driven equipment mounting mount the driven equipment to the
and driving flange or face centered, engine.
as described in Step 7, and the flex-
ible coupling attached to the input
shaft, the face depth can be mea- 9. Support the driven machine on a hoist
sured. Place a straight edge across and bring it into position with the engine.
the surface of the front face of the
coupling which mates to the flywheel 10. Align the driven equipment housing
assembly. With a scale measure the mounting flange with the flywheel
distance from the coupling mounting housing, using locating dowels if
face to the mounting face of the dri- required. Install connecting bolts with
ven equipment housing as shown in sufficient torque to compress the
Figure 35. lockwashers, but not to final torque.
Figure 35
58
11. Install the bolts which secure the cou- readjust the driven equipment hous-
pling to the flywheel and torque as ing position by changing the shims.
recommended. There must be clearance at all points
when making this check.
12. Check crankshaft end play to ensure
that the proper relationship exists 15. With the proper number of shims
between the engine mounting face installed to align the driven equip-
depth Step 6 and the driven equip- ment housing parallel to the flywheel
ment mounting face depth Step 8. housing, tighten the bolts securing
Place a pry bar between the flywheel the driven equipment housing to the
assembly and the flywheel housing. flywheel housing sufficiently to com-
The crankshaft should move both for- press the lockwashers.
ward and backward within the engine
and, in both positions, remain fixed 16. Torque the bolts holding the driven
when pressure on the pry bar is equipment frame to the base assembly
relaxed. Any tendency of the crank- to one-half the recommended value.
shaft to move when pry bar pressure
is released indicates that the driven
equipment and coupling assembly 17. Repeat Step 14. If the feeler gauge
are imposing a horizontal force on the measurements indicate that misalign-
crankshaft, which will result in thrust ment is still present, repeat operation
bearing failure. If this condition exists, described in Steps 14 through 17
readjust the thickness of shims used until proper alignment is obtained.
between the driven equipment input
shaft and the coupling as described 18. Retorque all coupling and mounting
in Step 8. bolts to the specified torque value.
59
B. Flexible-Type Couplings — 2. Flywheel Concentricity
Remote-Mounted Driven Equipment
Remove the pry bar and check to
1. Droop ensure that the dial indicator has re-
turned to zero; if it is not, reset. Rotate
Mount a dial indicator on the engine the crankshaft, in the normal direc-
flywheel housing. Mark the flywheel tion only, and record the TIR when
at points A, B, C, and D in 90° incre- the flywheel positions (A), (B), (C),
ments as shown in Figure 36. The and (D) are at the top. (Refer to Page
indicator tip must contact the pilot 58 for proper tolerances.)
diameter of the flywheel assembly.
With the dial indicator in position (A), 3. Crankshaft End Play
set the reading to zero. Place a pry
bar under the flywheel assembly at Ensure the crankshaft-flywheel assem-
position (C) and, by prying against a bly is completely to the rearmost posi-
floor mounted support, raise the fly- tion of the engine assembly. Reset
wheel until it is stopped by the main the dial indicator to zero. Relocate the
bearings. (Caution: Do not pry against pry bar and move crankshaft-fly-
the flywheel housing.) Record the wheel assembly forward in the engine
reading of the dial indicator. This is assembly. The dial indicator reading in
the amount of droop in the crankshaft this position is the crankshaft end play.
which results from engine bearing
clearances and natural droop as a
result of the overhung weight of the 4. Flywheel Face Run out
flywheel.
Set the tip of the indicator on the face
The flywheel should be raised sever- of the flywheel Figure 36. Position the
al times to get a “feel” for the bearing crankshaft to the front of its end play
clearance to prevent excessive lift and zero the indicator. Shift the crank-
which means reverse bending of the shaft to the rear of its end play and
crankshaft. record the TIR. With the crankshaft at
the rear of its end play, zero the indi-
cator. Rotate the crankshaft and
record the TIR when the flywheel posi-
tions (A), (B), (C), and (D) are at the
top. Remove all end play before
recording each reading. Remove the
flywheel housing access cover. Then
place a pry bar between the rear face
of the flywheel housing and the front of
the flywheel assembly. Move the crank-
shaft-flywheel assembly to the rear of
the engine, removing all end play.
Figure 36
60
5. Mounting are stiff enough to affect the bore align-
ment and give a false reading.
The engine and the driven equipment
should be mounted so that any neces- 7. Angular Alignment
sary shimming is applied to the driven
equipment. The centerline of the engine Mount a dial indicator to read between
crankshaft should be lower than the the driven equipment input flange and
centerline of the driven equipment by the flywheel face and measure angular
approximately 0.0065 in (0.165 mm) to misalignment. Adjust position of driven
allow for thermal expansion of the equipment until TIR is within 0.008 in
engine. The value 0.0065 in (0.165 mm) (0.20 mm).
allowed for thermal expansion is for the
engine only. If it is anticipated that ther-
mal expansion will also affect the dri- 8. Linear Relationship
ven equipment centerline to mounting
plane distance, that value must be sub- Mount dial indicator to the driven
tracted from the engine thermal expan- equipment side of the flexible coupling
sion value in order to establish the total and indicate on the outside diameter of
engine centerline to driven equipment the flywheel side of the coupling. Zero
centerline distance. When measuring the indicator at 12 o’clock and rotate
this value, the TIR will be 0.013 in the engine in its normal direction of
(0.330 mm) plus the droop as estab- rotation and check the total indicator
lished in Step 1. reading at every 90°. Subtract the full
“droop” from the bottom reading to give
Shim packs under all equipment the corrected alignment reading.
should be 0.200 in (5 mm) minimum
thickness to provide for later correc- The value of the top-to-bottom reading
tions which might require the removal should be 0.008 in (0.20 mm) or less
of shims. under operating temperature condi-
tions, with the engine indicating low.
6. Coupling Adjust all shims under the feet of the
driven equipment the same amount
to obtain this limit.
Attach the driven member of the cou-
pling to the flywheel and tighten all
bolts to the specified torque value. The final value of the top-to-bottom
alignment should include a factor for
vertical thermal growth.
Gear-type couplings, double sets of
plate-type rubber block drives, and Cat
viscous-damped couplings are the only
ones that can be installed prior to making
the alignment check. Most couplings
61
Subtract one-half the “droop” from the 10. Crankshaft End Play
3 o’clock and 9 o’clock reading. This
should be 0.008 in (0.20 mm) or less. The crankshaft end play must be
Shift the driven equipment on the rechecked to ensure that the driven
mounts until this limit is obtained. equipment is not positioned in a man-
ner which imposes a preload on the
Note: the sum of the side “raw” reading crankshaft thrust washers. (Refer to
should equal the bottom reading within Step 4.) Place a pry bar between the
0.002 in (0.051 mm). Otherwise the flywheel assembly and the flywheel
mounting of the dial indicator is too housing. The crankshaft should move
weak to support the indicator weight. both forward and backward within the
engine and, in both positions, remain
fixed when pressure on the pry bar is
relaxed. Any tendency of the crank-
shaft to move when pry bar pressure
is released indicates that the driven
equipment assembly must be moved
rearward on the base assembly or, if
used, the number of shims between
the input flange and the flexible cou-
pling must be reduced.
62
VIBRATION AND ISOLATION frequency of the system coincides with the
frequency of the vibrations. The total
Vibration engine-driven equipment system must be
designed to avoid critical linear or torsion-
Any mechanical system which possesses al vibrations.
mass and elasticity is capable of relative
motion. If this motion repeats itself after a Linear Vibration
given time period, it is known as vibration.
An engine produces many vibrations as it Linear vibration is usually identified by a
operates due to combustion forces, torque noisy or shaking machine. Its exact nature
reactions, structural mass and stiffness is difficult to define without instrumenta-
combinations, and manufacturing toler- tion. The human senses are not adequate
ances on rotating components. These to detect relationships between the magni-
forces require that mounting and driveline tude of displacement of a vibration and its
design be correct, or they can create a wide period of occurrence. For instance, a first
range of undesirable conditions, ranging order (1 2 rpm) vibration of 0.010 in
from unwanted noise to high stress levels (0.254 mm) displacement may feel about
and ultimate failure of engine or driven the same as third order measurement of
equipment components. 0.002 in (0.051 mm).
Figure 38 FREQUENCY
CYCLES PER MINUTE (CPM)
63
However, as depicted in Figure 38, the
severity of vibration does correlate reason-
ably well with levels of perception and
annoyance.
Figure 41
64
Vibration amplitude can be expressed as Vibration acceleration is another important
either a peak-to-peak average value or a characteristic of vibration. It is the rate of
root-mean-square (rms) value which is change of velocity. In the example, note that
0.707 times the peak amplitude. These peak acceleration is at the extreme limit of
readings are referred to in theoretical dis- travel where velocity is “0.” As the velocity
cussions. increases, the acceleration decreases until
it reaches “0” at the neutral point.
Another popular method used to deter-
mine the magnitude of vibration is to mea- Acceleration peak is normally referred to in
sure that vibration velocity. Note that the units of “g”, where “g” equals the force of
weight is not only moving, but also chang- gravity at the earth’s surface. (980 2
ing direction. This means that the speed of 655 cm/s2 = 386 in/s2 = 32.2 ft/s2.)
the weight is also constantly changing. At
its limit of motion, the speed of the weight The vibration acceleration can be calculat-
is “0.” As it passes through the neutral ed as:
position, its speed or velocity is greatest.
g Peak = 1.42 D F2 2 10–8
The velocity is an extremely important
characteristic of vibration but because of
its changing nature, a single point has Most machinery vibration is complex and
been chosen for measurement. This is the consists of many frequencies. Displace-
peak velocity and is normally expressed in ment, velocity, and acceleration are all
inches per second peak. used to diagnose particular problems.
Displacement measurements tend to be a
better indication of vibration under condi-
Velocity is a direct measure of vibration and, tions of dynamic stress and are, therefore,
as such, provides the best overall indicator most commonly used. Note that the overall
of machinery condition. It does not, how- or total peak-to-peak displacement described
ever, reflect the effect of vibration on brittle in Figure 42 is approximately the sum of all
material which fractures or cracks more the individual vibrations.
readily than ductile or softer materials.
D = Peak-to-peak
Figure 42
displacement in mils
(1 mil = 0.001 in).
F = Frequency in
cycles per minute
(cpm).
65
Torsional Vibration result in extensive and costly damage to
components in the drive train, or engine
Torsional vibration occurs as an engine failure. Conducted at the design stage of a
crankshaft twists and returns. project, the mathematical torsional analy-
sis may reveal torsional vibration problems
which can be avoided by modification of
Torsional vibration originates with the driven equipment shafts, masses or cou-
power stroke of the piston. The simplified plings. The torsional report will show the
drive train in Figure 43 illustrates the rela- natural frequencies, the significant reso-
tionship of shaft diameter, length, and iner- nant speeds, and either the relative ampli-
tia on the natural frequency of the system. tudes or a theoretical determination of
whether the maximum permissible stress
To ensure the compatibility of an engine level is exceeded. Also shown are the
and the driven equipment, a theoretical approximate nodal locations in the mass
torsional vibration analysis is necessary. elastic system for each significant natural
Disregarding the torsional compatibility of frequency.
the engine and driven equipment can
Figure 43
The following technical data is required to C. With driven equipment on both ends of
perform a torsional analysis: the engine, the horsepower require-
ment of each set of equipment is
A. Operating speed ranges, lowest speed required and whether operation at the
to highest speed, and whether it is vari- same time will occur.
able or constant speed operation.
D. A general sketch of the complete sys-
B. Load curve on some types of installa- tem showing the relative location of
tions for application with a load depen- each piece of equipment and type of
dent variable stiffness coupling. connection.
66
F. WR2 or principal dimensions of each Since compatibility of the installation is the
rotating mass and location of mass on system designer’s responsibility; it is also
attached shaft. his responsibility to obtain the theoretical
torsional vibration analysis. Upon request
G. Torsional rigidity and minimum shaft mass elastic systems of items furnished by
diameter, or detailed dimensions of all Caterpillar will be supplied to the customer
shafting in the driven system whether without charge so that he can calculate the
separately mounted or installed in a theoretical torsional vibration analysis.
housing.
Mass elastic data for the Caterpillar Diesel
H. If a reciprocating compressor is uti- Engine is covered in the Technical
lized, a harmonic analysis of the com- Information File, as well as a complete list
pressor torque curve under various of the required data should you wish
load conditions is required. If this is not Caterpillar to perform a torsional analysis.
available, then a torque curve of the There is a nominal charge for this service
compressor under each load condition from Caterpillar.
is required. The WR2 of the available
flywheels for the compressor should be
submitted.
67
68
AIR INTAKE
Page
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Restriction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Service Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Air Cleaner Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Dust Particle Size Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Two-Stage Air Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Oil Bath Air Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Exhaust Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Flexibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Pipe Ends and Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Breakaway Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Piping Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Straight Section Before Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
69
AIR INTAKE
The function of the air intake system is to Caterpillar offers an air cleaner package
furnish an adequate supply of clean, dry, as optional equipment for all engines. The
low temperature air to the engine. Failing Caterpillar air cleaner is matched to the
this, increased maintenance costs and/or engine to meet its requirements; however,
performance problems are certain to result. vehicle requirements often result in the
The following recommendations must be choice of an alternate package. The follow-
observed in order to obtain a satisfactory ing information will be helpful where modi-
installation: fications are made to the Caterpillar sys-
tem or where an alternate system is used.
A. Every installation must include an effi-
cient provision for removing dirt parti- A. Service Life
cles from the intake air.
The air cleaner must be sized so that
B. The air inlet location and piping routing initial restriction is low enough to give
must be chosen to best obtain cool air. acceptable life within the maximum allow-
All joints should be air tight and all able restriction of the air inlet system.
pipes properly supported. The air inlet
must be designed to minimize the Air Flow
ingestion of water from rain storms,
road splash, or during the engine
washing process. Refer to the Industrial Engine Data Sheet.
The value given as combustion air flow
is for full load bhp at SAE conditions.
C. The system maximum restriction rec-
ommended values must be adhered to.
THE DIRTY AIR CLEANER MAXIMUM Restriction
IS –25 IN. H2O (–6.2 kPa) FOR NATU-
RALLY ASPIRATED ENGINES AND Pressure drop across a typical air cleaner
–30 IN. H2O (–7.5 kPa) FOR TURBO- will be 6.0 in. H2O (1.5 kPa) when clean.
CHARGED ENGINES. For specific the piping system might typically add
engine limits refer to the TMI. another 3.0 in. H2O (0.75 kPa) pressure
drop. For maximum permissible air restric-
tion for a dirty air cleaner element refer to
AIR CLEANER the Industrial Engine Data Sheet. To pro-
vide for satisfactory engine performance
Dirt is the basic source of engine wear. and adequate filter element service life,
Most dirt enters the engine via the inlet air. the element should be sized as large as
Cylinder walls or liners, pistons, piston practical. The 9.0 in. H2O (2.2 kPa) initial
rings, valves, valve guides and, in fact, any pressure drop is an important measure
engine moving part is subjected to accel- of the expected element service life.
erated wear when undue amounts of dirt Generally, the maximum initial (clean dry)
are contained in the inlet air. Therefore, restriction recommendation is 15 in. H2O
careful air cleaner selection is vital to a (3.7 kPa). See the Industrial Engine Data
good engine installation. Sheet for specific engine limits.
70
Service Indicator b. Use sonic dust feeder.
71
10 micron (0.001 mm to 0.01 mm) size dust E. Exhaust Ejector
has a measurable effect on engine life; how-
ever, ONE TEASPOONFUL PER HOUR OF In extremely dusty environments where
125 MICRON (0.125 mm) SIZE DUST WILL dust and other particles cause air clean-
WEAR OUT AN ENGINE IN 24 HOURS. ers to plug up quickly, precleaners are
Put another way, inlet air dust particle sizes often used to extend the service life of air
larger than bearing oil film thicknesses will cleaner elements. However, at the same
seriously affect bearing and piston ring life. time, precleaners can often become an
added maintenance problem.
C. Two-Stage Air Cleaners
An improved precleaner has been
For conditions where dust concentrations designed as an integral part of any
are higher or where increased service exhaust aspirated air cleaner system.
life is desired air cleaners are available
with a precleaning stage. This precleaner Using a louvered body design, the pre-
imparts a swirl to the air, centrifuging out cleaner has a very high separator effi-
a major percentage of the dirt particles ciency. It will separate and remove over
which may be collected in a reservoir or 90% of the dirt and chaff from the incom-
exhausted out on either a continuous or ing air stream.
an intermittent basis.
The system provides a good solution to
D. Oil Bath Air Cleaners a difficult problem.
— Lower efficiency
— Low ambient temperatures, low oil
level, low air flow (such as at low
idle), and installed tilt angle
lessens efficiency further.
— Oil carry-over, whether resulting
from overfilling or increased air
flow, can seriously affect turbo-
charger and engine life.
72
SYSTEM B. System Design
73
Pipe Ends and Hose Connections Piping Support
Beaded pipe ends at hose joints are rec- Bracing and supports are required for the
ommended. Sealing surfaces should be piping. The turbocharger inlet pipe must be
round, smooth, and free of burrs or sharp supported when its weight exceeds 25 lb
edges that could cut the hose. The tubing (11.3 kg). Unsupported weight on clamp-
should have sufficient strength to with- type joints should not exceed 3 lb (1.4 kg).
stand the hose clamping forces. Avoid the
use of plastic tubing since it can lose much Straight Section Before Turbocharger
of its strength when subjected to tempera-
tures of 300°F (149°C) or above. Either “T” When possible, the piping to the tur-
bolt-type or SAE-type F hose clamps pro- bocharger inlet should be designed to
viding 360° seal should be used. They ensure that air is flowing in a straight, uni-
should be top quality clamps. Double form direction into the turbocharger com-
clamps are recommended on connections pressor. A straight section of at least two
downstream of the air cleaner. or three times pipe diameter is recom-
mended because air striking the compres-
Breakaway Joints sor wheel at an angle can create pulsa-
tions which can cause premature com-
A breakaway joint allows the cab or hood to pressor wheel failure.
tilt away from the engine compartment for
accessibility and servicing of the engine.
Half of the rubber seal flange remains on the
engine air intake and the other half of the
flange is secured to the enclosure or hood.
74
EXHAUST
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Exhaust Silencer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Exhaust Backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Piping ................................................................. 77
Exhaust Pyrometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
75
EXHAUST
Silencer design is a highly specialized art. Q = Exhaust gas flow in cubic feet per
The silencer manufacturer must be given minute.
responsibility for the details of construction. D = Inside diameter of pipe in inches.
For exhaust gas flow see the Industrial
Engine Data Sheet. T = Exhaust temperature in °F.
76
To determine values of straight equivalent PIPING
length for smooth elbows use:
When routing the exhaust system, each of
Standard 90° Elbow = the following factors should be considered:
33 2 Pipe Diameter
1. Flexible joints are needed to isolate
Long Sweep 90° Elbow = engine movement and vibration and to
20 2 Pipe Diameter offset piping expansion and contrac-
tion. From its cold state, a steel pipe will
expand 0.0076 in per foot per 100°F
Standard 45° Elbow = (0.63 mm per meter per 37.8°C) tem-
15 2 Pipe Diameter perature rise. For example, the expan-
sion of 10 ft (3.05 m) of pipe with a tem-
To determine values of straight pipe equiv- perature rise of 50°F to 850°F (10°C to
alent length for flexible tubing use: 400°C) is 0.61 in (15.49 mm). If not
accounted for, the piping movement
L = Lf 2 2 can exert undue stress on the tur-
bocharger structure and the pipe sup-
ports.
Exhaust backpressure is measured as the
engine is operating under rated conditions.
Either a water manometer or a gauge mea- The maximum allowable load that the
suring inches of water can be used. If not turbocharger is permitted to support is
equipped, install a pressure tap on a 25 lb (11.3 kg). This usually requires that
straight length of exhaust pipe. This tap a support be located within 4 ft (1.2 m)
should be located as close as possible to of the turbocharger, with a flexible con-
the turbocharger or exhaust manifold on a nection located between the turbo-
naturally aspirated engine, but at least charger and the support. Manifolds for
12 in (305 mm) downstream of a bend. If naturally aspirated engines can sup-
an uninterrupted straight length of at least port up to 50 lb (22.7 kg).
18 in (457 mm) is not available (12 in
[305 mm] preceeding and 6 in [152 mm] Flexible joints should be located in a
following the tap) care should be taken to longitudinal run of pipe rather than on a
locate the probe as close as possible to the transverse section. This allows flexibility
neutral axis of the exhaust gas flow. For for engine side motion.
example, a measurement taken on the out-
side of a 90° bend at the pipe surface will 2. Water must not be permitted to enter
be higher than a similar measurement taken the engine through the exhaust piping.
on the inside of the pipe bend. The pressure
tap can be made by using a 1/8 NPT “half
coupling” welded or brazed to the desired On mobile machine installations, a low
location on the exhaust pipe. After the cou- horizontal exhaust pipe mounting is
pling is attached, drill a 0.12 in (3.05 mm) sometimes used, but it is difficult to find
diameter hole through the exhaust pipe a place under the chassis where the
wall. If possible, remove burrs on the exhaust gas can be discharged without
inside of the pipe so that the gas flow is not adversely affecting some aspect of
disturbed. The gauge or gauge hose can machine design. The tailpipe should be
then be attached to the “half coupling.” tipped to the side and inboard to avoid
noise bouncing off the road and exces-
sive heat on the tires.
77
A vertical silencer mounting is more com- C. Drain holes near a low point in the pip-
mon. The exhaust outlet should be located ing are used. Holes smaller than 1/8 in
so that fumes do not enter the air cleaner (3.17 mm) have a tendency to become
or the cab under any operating condition of plugged, and unfortunately holes of that
the machine. Water protection for vertical size or larger are likely to be a source
systems can involve these items: of noise and focus for corrosion.
78
COOLING
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Radiator Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Cooling Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Filling Ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Pump Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Cooling Level Sensitivity (Drawdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Air/Gas Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Shunt-Type Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Other Radiator Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Radiator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Antifreeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Coolant Conditioners and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Fan Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Fan Diameter and Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Fan Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Fan Shrouds and Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Air Flow Losses and Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Obstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Gauges and Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Water Temperature Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Block Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
79
COOLING
80
Caterpillar provides a radiator or heat ex- partly because the large majority of mobile
changer and expansion tank system equipment applications cannot be ade-
designed to perform satisfactorily with each quately served by Caterpillar industrial
engine manufactured and to be compatible radiators.
with various power levels selected. Modifi-
cations to the cooling packages are not
acceptable without approval because of RADIATOR STRUCTURE
possible disturbance to coolant flow paths.
Caterpillar industrial radiators such as the
3200 and 3300 Series unit construction
The expansion tank and heat exchanger
type and the 3400 Series bolted core are
perform the same function as the radiator.
not designed for mobile equipment appli-
Whereas a radiator fan provides air flow
cations. Applications of these radiators
through the cooling fins of the radiator to
require isolation from machine vibration,
transfer coolant heat to the air, an external
and large impact loads. The maximum
coolant supply passes through the tubes
total amplitude of vibration allowed at any
of the heat exchanger to accomplish heat
point on the radiator core is 10 mil (±5 mil).
transfer.
Core isolation is provided by rubber mounts
from the radiator frame sufficient to limit
On 3400 and 300 Series Engines the ther- core vibration amplitude for relatively high
mostats in the heat exchanger systems frequency vibration; but low frequency
sense coolant temperature supplied to the vibration in the order of 15 Hz may amplify
engine jacket water circulating pump rather radiator core motion beyond 10 mil. In these
than the coolant discharged from the cases special machine frame or radiator
engine cylinder heads, as in radiator and support modifications must be made.
heat exchanger systems of Models 3208,
3304, 3306, and D353. The pump inlet
Mobile equipment applications require
temperature-controlled heat exchanger
radiator construction which incorporates
system provides less variation in tempera-
bolted top and bottom tanks with side
ture because bypass coolant and heat
channel support. Reinforcing strips should
exchanger flow mix at the thermostat sens-
be used on both sides of the core header-
ing bulb and in the expansion tank before
to-tank bolted joint to limit distortion.
passing to the pump. Water pump inlet pres-
Compressed rubber is often incorporated
sure is greater because the external cooling
between the core and the inboard side of
restriction is eliminated from the flow path.
the channel members to provide additional
core support.
The material handling and agricultural
business includes many different applica-
Since many of the radiators used by equip-
tions of industrial engines. But, for the most
ment manufacturers will not be Caterpillar
part, the cooling system requirements are
designed, a complete evaluation of the
not unique. With the exception of pumping
cooling system is required to prove the
applications and some permanent on-site
capability of the system. Reference material
compressor applications, radiators are used
for such an evaluation is provided by Engine
for engine cooling. Although Caterpillar-
Data Sheet EDS 50.5. Another useful ref-
designed cooling packages are recom-
erence for evaluating radiator top tank
mended for many applications, there are
design is provided by EDS 52.1.
occasions where equipment manufactur-
ers prefer to supply their own radiators,
81
COOLING CAPABILITY Cooling capability of a radiator and torque
converter cooler are referenced to a 70%
Caterpillar requires the maximum coolant efficiency operating level as a general
discharge temperature to the radiator to be design consideration. Normally, the perfor-
210°F (98°C) for sea level operation and mance characteristics of speed and torque
recommends a minimum ambient capability ratio, input and output power, and the heat
of 110°F (42.9°C) during full load opera- generated by lost power is provided by the
tion at all operating speeds. This includes torque converter manufacturer. The effi-
all additional heat loads which might be ciency characteristic will be associated with
imposed on the cooling system such as an engine speed, and cooling system oper-
torque converter coolers or air-to-oil coolers ating characteristics should be observed at
which might be added in front of the radiator. this engine speed whenever possible.
As indicated in EDS 50.5, certain measur- Equipment manufacturers often find that
ing devices are required to evaluate cool- imposing a load on the engine is difficult to
ing capability. A suitable method for mea- accomplish during cooling test operations.
suring engine power could be a fuel meter, Direct drive machines are the most difficult
fuel setting indicator (rack position), or and usually require that some type of
dynamometer. Additional measured data dynamometer or other load absorbing
are engine speed, coolant temperatures in device be fastened to the output shaft.
and out of radiator, air temperature to the Torque converters can be used as load
radiator (several locations), and ambient absorbing devices if a separate cooling
air temperature which is sampled far method (such as cold plant water) is pro-
enough from the machine to eliminate vided to the cooler. Extended operation at
effects of heat generated by the operating converter stall can be accomplished allow-
machine. ing all coolant temperatures to stabilize
without excessive torque converter oil tem-
perature. Note, however, that the cooling
Location of the test site should be such capability established in this manner does
that heated air which has passed through not include the equivalent of 30% flywheel
the radiator is not forced back through the horsepower which would normally be
radiator in an unrealistic manner by walls cooled by the engine cooling system. This
or other adjacent structures (recirculation must be included by calculation in the
of air). Recirculation of air can also be an same manner as the calculation shown in
inherent characteristic of the cooling sys- EDS 50.5 for extrapolating observed tem-
tem, but should be avoided. Locating nar- perature data to 210°F (90°C) radiator top
row strips of cloth on small pieces of wire tank conditions. The additional heat load
fastened at various locations around the which must be added is 30% of flywheel
outside surface of the radiator provides an horsepower multiplied times 42.4 Btu/
excellent flow path indicator. Another use- min/hp.
ful tool for indicating air flow path can be
made by attaching a narrow strip of cloth
to the end of a long piece of wire which Some correction factors to the observed
can be used as a probe around the engine ambient air temperature capability for the
or radiator periphery. Baffling of the radia- machine must not be overlooked. Altitude
tor or air flow directors are often necessary above sea level reduces the density of air
to ensure that unheated ambient air is and its ability to cool the radiator. A good
directed to the radiator for most effective correction factor is 2.5°F (1.38°C) deducted
cooling. This is an insidious problem which
should not be overlooked.
82
from the observed ambient temperature state (boiling point). In the cooling system
capability for each 1,000 ft (304.9 m) above pump inlet, a gas or vapor bubble will dis-
sea level. place liquid and reduce the amount of liquid
that can be pumped. This loss of pumping
Another correction which must be included volume can be observed as a loss in water
is the effect of antifreeze. The ability to pump pressure rise. The maximum pump
transfer heat diminishes when water is rise loss that is acceptable at the cavitation
mixed with ethylene glycol. Antifreeze solu- temperature is 10% of the pressure rise
tions of 50% will reduce ambient tempera- observed at 120°F coolant temperature to
ture capability approximately 6°F (3.3°C). the pump while operating at rated speed.
The acceptable cavitation temperature for
a given engine is 210°F (98°C) minus the
FILLING ABILITY (Reference EDS 50.5) temperature rise across the engine when
fully loaded. EDS 50.5 shows a method for
The cooling system must accept a bucket calculating temperature rise. As a general
fill method (interrupted) and continuous fill rule, the temperature rise will be in the
method at a minimum rate of 5 gpm range of 10°F to 15°F (5.5°C to 8.3°C). The
(18.9 L/min) without air lock (false fill). The TIF provides heat rejection to jacket water
coolant should not be below the qualified and pump flow which allows temperature
low operating level after engine start and rise calculations.
warm-up. The low coolant level is estab-
lished during drawdown tests. False fill is a
potential problem with all types of radiators Cavitation characteristics observed during
but especially with shunt-type radiators on an evaluation can be affected by the sys-
low profile machines. tem air venting capability. If air venting
problems are present, the cavitation tem-
perature should be rechecked after a solu-
Several items regarding filling problems tion to the venting problem is found.
are worthy of special mention. The engine
outlet hose (to radiator) should slope
COOLING LEVEL SENSITIVITY
upward continuously as should all air vent
lines from the engine to the radiator top (DRAWDOWN)
tank. Vent lines should enter as near to the (Reference EDS 50.5)
top of the tank as possible. The shunt line
on a shunt-type radiator should be as large The drawdown capability from full level
as possible, should slope downward con- with 180°F (82°C) pump inlet temperature
tinuously toward the water pump, and and engine operating at rated speed must
should be connected as close as possible be 12% of the total system volume with no
to the inlet of the engine cooling water more than a 10% loss in pump pressure
pump. The shunt hose opening in the radi- rise. This level, so established, is the low
ator should be as low as possible in the level reference position and should be
upper chamber of the baffled tank. Do not marked in such a manner that it can be
overlook the effect of filling characteristics accurately detected by visual inspection. A
when the machine is resting on a slope or metal plate or sight glass should be pro-
uneven ground. vided. The 12% value is appropriate for a
system which uses a 7 psi pressure cap,
PUMP CAVITATION (Reference EDS 50.5) but lower pressure systems should provide
16% drawdown capability.
Given the proper conditions of pressure and
temperature, all liquids will form a gaseous
83
An open volume above the cold full level 200 changes per minute. For example, if the
should be 10% of the total system volume volume of water above the core is 1 gal and
to allow for expansion of the coolant during the engine coolant flow rate is 1.10 gpm,
warm-up and for additional expansion due the 1 gal volume would be changed
to afterboil, during shutdown of a hot engine. 110 times per minute. In the case of the
The cold full level should be established shunt-type radiator, the volume between
with a fill tube which extends into the top tank the baffle and core should receive the same
below the top surface enough to establish maximum volume change rate.
the correct volume. See EDS 52.1. A small
air bleed hole (0.12 in. diameter [3.0 mm
diameter]) in filler tube, just below top of SHUNT-TYPE RADIATORS
radiator top tank is required to render this
expansion volume usable. A shunt cooling system helps prevent
pump cavitation by maintaining a positive
pressure head of coolant at the pump inlet
Shunt-type radiators, and especially those
at all times. The radiator top tank is divid-
which are used in low profile machines,
ed into two compartments (upper and
are occasionally marginal for expansion
lower) with a small air/coolant bleed or baf-
and afterboil volume. This may cause dis-
fle vent tube connecting them. A shunt line
charge of liquid sufficient to lower the cold
located as low as possible in the upper
level near the shunt tube opening. This, in
chamber directs coolant to the circulating
combination with start and warm-up of the
pump inlet. When the coolant reaches the
machine on a side slope, may allow induc-
temperature required to open the thermo-
tion of air into the cooling system. Large
stat, the coolant is directed to the lower
quantities of air induction may cause an
chamber of the radiator top tank, across
additional discharge of liquid. Such a con-
the top of the radiator core, and down
dition, if not detected, may cause over-
through the core to the circulating pump
heating. Location of a shunt tube on the
inlet. The small baffle vent connecting the
side of a top tank accentuates the sensi-
lower compartment to the upper should be
tivity to tilted operation.
located remote from the primary entry of
coolant into the lower chamber. Air or gas
AIR/GAS VENTING which is entrained in the coolant tends to
(Reference EDS 50.5) separate from the coolant, if a low velocity is
provided, and it collects above the core on
A certain amount of combustion gas leak- the bottom of the baffle, to be carried up
age and entrained air must be vented from through the small baffle tube where it col-
the cooling liquid. The venting requirement lects at the top of the upper chamber and
for each engine is shown in EDS 50.5. is eventually discharged through the pres-
Separation of gas from a liquid medium sure cap. The deaerated coolant in the upper
requires a low coolant velocity at the top of compartment flows slowly down the shunt
the radiator and a relatively quiescent flow. tube to the pump inlet and provides a near-
The coolant velocity across the top of a ly static pressure. The shunt tube should
radiator core should be approximately pro-gress downward continuously with-
2 fps (9.4 cm/s). Another way of stating out air locks. Use as large an inside diam-
this limit is based on the rate of change of eter as possible with one inch minimum
the fluid volume above the core. The max- preferred. (See Figure 46.) Any vent tube
imum rate of change of volume should be provided from the engine should be con-
nected near
84
Figure 46 SHUNT COOLING SYSTEM
85
Water Treatment Antifreeze Protection
Of prime consideration in any closed cool- Installations which expose the engine
ing system is the proper treatment of the coolant to subfreezing temperatures neces-
cooling water. The water should be treated sitate the addition of antifreeze to the water
to ensure that neither corrosion nor scale system. Ethylene glycol or Dowtherm 209
forms at any point in the system. Usually are recommended to protect against freez-
water hardness is expressed in grains per ing and to inhibit corrosion. Borate-nitrite
gallon; one grain being equal to 17.1 parts solutions such as Caterpillar corrosion
per million (ppm) expressed as calcium inhibitor or NALCO 2000 are compatible
carbonate. Water containing up to 3.5 grains only with ethylene glycol and can be used
per gallon is considered soft and causes to replenish the original corrosion inhibitors
few deposits. in the antifreeze.
pH 6.5 to 8
Chloride and Sulfate 100 ppm
Total Dissolved Solids 500 ppm
Total Hardness 200 ppm
86
Coolant Conditioners and Filters PLUMBING
All 3400 Series direct injection Engines Piping between the engine and radiator
require the use of a chemical coolant condi- should be flexible enough to provide for
tioner. The conditioner reduces potential relative motion between the two. Hoses
cylinder block and liner pitting and corrosion. less than 6 in (15.24 cm) in length provide
little flexibility and are difficult to install. If
A. Consult the factory for suitable coolant the hose is more than 18 in (45.7 cm) in
conditioners which should be applied length, it is susceptible to failure from
and maintained in accordance with vibration or coming loose at the connec-
published instructions. tions. Support the piping with brackets,
when necessary, to take weight off a verti-
cal joint. High quality hose, clamps, and fit-
B. If a dry charged additive water filter is tings are a prerequisite for long life and are
selected, the following plumbing rec- necessary to avoid premature failure. It is
ommendations should be followed. also necessary to “bead” pipe ends to
reduce the possibility of a hose blowing off.
1. The filter inlet and outlet are ordinary Double clamps are desirable for all hose
0.375 in (9.5 mm) inside diameter connections under pressure. Vent lines
rubber hoses. Connect the hoses to and shunt lines must slope downward
obtain the highest possible coolant without high or low areas that may trap air
pressure differential across the unit. and cause an air lock. In order to maintain
Heater hose connecting points at the correct flow relationship in a baffled
the coolant pump inlet and the tem- radiator top tank, it is recommended that
perature regulator housing are rec- no lines tee into the shunt or vent lines.
ommended. If uncertain, plumb the
inlet to a point on the discharge side
of the water pump and the outlet to FAN RECOMMENDATIONS
a point near the water pump inlet.
A. Fan Diameter and Speed
2. The outlet should be orificed with a
0.125 in (3.2 mm) internal diameter As a general rule, the most desirable
orifice. This will prevent excessive fan is one having the largest diameter
coolant flow through the filter which and turning at the lowest speed to deliv-
can bypass the radiator core and er the required air flow. This also results
reduce effectiveness of the cooling in lower fan noise and lowest fan horse-
system. Inlet and outlet lines should power draw from the engine. Blade tip
include shutoff valves so the filter speed, while being only one of the ele-
can be serviced without draining the ments of cooling fan design, is an item
cooling system. easily changed with choice of fan drive
pulley diameter. An optimum fan tip
velocity of 14,000 fpm (7112 cm/s) is a
good compromise for meeting noise leg-
islation requirements and cooling system
performance requirements. Maximum
acceptable tip speed is 16,000 fpm
(9144 cm/s) for Caterpillar fans.
87
B. Fan Performance not practical, and tip clearance is
increased; a 0.5 in (12.7 mm) clear-
Proper selection and placement of the ance is generally recommended.
fan is critical to the efficiency of the When a fan speed different from
cooling system. It requires careful those shown in the curves is needed,
matching of the fan and radiator by the additional performance data can
determining air flow needed and static be calculated using these fan rules:
air pressure which the fan must over-
come. This must be done since most For Speed Changes
discrepancies between cooling system
calculated performance and test results cfm2 = cfm1 rpm 2
____
are traceable to the “air side” and direct- rpm1
ly related to items affecting fan air flow.
( )
2
Ps2 = Ps1 rpm 2
____
There are two major considerations for rpm1
proper fan selection:
( )
3
hp2 = hp1 rpm 2
____
1. Air flow needed to provide the
rpm1
required cooling.
For Diameter Changes
2. Select a fan that provides the
required air flow, and one that is rela-
( )
3
cfm2 = cfm1 Dia 2
____
tively insensitive to small changes in
Dia1
static pressure. This desired design
point is where a small change in sta-
( )
2
tic pressure does not cause a large Ps2 = Ps1 Dia 2
____
change in air flow. Selecting a lower Dia1
pressure point is not recommended
( )
5
as it could be in the unstable “stall” hp2 = hp1 Dia 2
____
area where a small change in static Dia1
pressure causes a large change in
air flow. Performance curves for
For Air Density Changes
available Caterpillar fans are shown
as air flow (cfm), static pressure Ps2 = Ps1 r2
___
head, (inches of water, gauge) and r1
horsepower in TMI. The Caterpillar
curves are based on standard air hp2 = hp1 r2
density, an efficient fan shroud, and ___
no obstructions. r1
88
Ambient Capability Adjustments The fan tip clearance should be 0.5 in
(Air Flow or Fan rpm Changes) (12.7 mm) or less. A properly designed
shroud will:
nT2 = nT1
( )cfm1 0.7
____ 0.
cfm 2 . 1. Increase air flow.
C. Fan Shrouds and Fan Location D. Air Flow Losses and Efficiency
89
GAUGES AND DEVICES block and heads when the heater is
operating and to avoid overheating
A. Water Temperature Gauges caused when coolant recirculates
through the heater during normal engine
operation. The principle involved in
The size and location of the water tem- operation is called thermosyphoning.
perature gauge connection is shown on The heated coolant rises in the tank or
the Engine General Dimension Drawing block. Since the coolant system is a
available in the Industrial Drawing closed loop, the rising hot coolant will
Book. Be certain the temperature bulb be replaced by cold coolant and circu-
is located in the water flow. Use of a pipe lation results. Some heater systems
fitting reducer may remove the bulb incorporate coolant pumps. To prevent
from the coolant stream and cause an coolant bypassing the cylinder heads
erroneous reading. The gauge should during engine operation, a check valve
be marked with a red band or warning must be included in the block heater
at 210°F (98°C) and above. circuit. Many external heaters have
built-in check valves, but test the heater
B. Warning Devices first before installing it to be sure. Pour
water in the outlet of the heater; the
A large number of warning devices are check valve should prevent the water
available to indicate high coolant tem- from flowing through the heater. If the
perature, low radiator top tank level, block heater chosen does not contain
loss of coolant flow, and air in the water. an integral check valve, one must be
These should be installed in accor- installed. The check valve should be
dance with the manufacturer’s recom- installed on the inlet side of the tank.
mendations. A temperature sensing unit
should be set so that warning is given The inlet to the heater should be taken
at 210°F (98°C) engine outlet (top tank) near the oil cooler outlet for optimum
temperature, or lower. Caterpillar rec- flow. The outlet should be directed
ommends this device be part of every upward to the engine connection with-
installation and should be of high quality out loops or downward turns to as high
with accuracy of ±2°F (±1.1°C). Depend- a point in the cylinder heads as possible.
ing on engine model, this unit should be The greatest mixing and flow should
mounted on the cylinder head or coolant occur by connecting to the rear of the
regulator housing to monitor the coolant engine cylinder head. Vee engines
temperature as it leaves the engine to often require two heaters to provide
the radiator top tank. adequate circulation of coolant through
both banks.
C. Block Heaters
The outlet from the heater tank should
Devices which heat engine coolant to be directed upward to the engine con-
provide faster engine warm-up are com- nection with no loops or downward
monly called engine block heaters. turns. If the engine connection is made
They fall into two categories: internal or at the normal block drain, a tee fitting
immersion type and external or tank type. and drain plug in this line is recom-
mended.
Correct installation of the external type
is very important to ensure adequate
coolant circulation through the cylinder
90
HEAT EXCHANGER For a given jacket water flow rate, the per-
formance of a heat exchanger depends on
Most shell and tube heat exchangers are both the cold water flow rate and differen-
of either the single-pass or the two-pass tial temperature. To reduce tube erosion,
type. This designation refers to the flow in the flow rate of the cold water through the
the cold water circuit of the exchanger. In tubes should not exceed 6 fps (183 cm/s).
the two-pass type, the cold water flows The heat exchanger should be selected to
twice through the compartment where accommodate the cold water temperature
jacket water is circulated; in the single- and flow rate needed to keep the tempera-
pass type only once. See Figure 48. When ture differential of the jacket water below
using a single-pass exchanger, the cold about 15°F (8.3°C) at maximum engine heat
water should flow through the exchanger rejection. Thermostats must be retained in
in a direction opposite to the flow of jack- the jacket system to assure that the temper-
et coolant to provide maximum differential ature of the jacket water coolant returned to
temperature and heat transfer. This results the engine is approximately 175°F (79°C).
in improved heat exchanger performance.
In a two-pass exchanger, cooling will be Heat exchangers should be sized to accom-
equally effective using either of the jacket modate a heat rejection rate approximately
water connection points for the input and 10 percent greater than the tabulated engine
the other for return. heat rejection. The additional capacity is
91
intended to compensate for possible varia- Provision is made in all Caterpillar expan-
tions from published or calculated heat sion tanks to deaerate the jacket water to
rejection rates, overloads, or engine mal- prevent the formation of air pockets within
functions which might increase the heat the system and minimize pump cavitation.
rejection rate momentarily. It is not intended Entrained air encourages both corrosion
to replace all factors which affect heat tran- and erosion in the engine. Coolant may be
sfer, such as fouling factor, shell velocity, etc. lost because air will expand more than
water when it is heated. Entrained air is
Occasionally, special applications exist caused by air trapped during a fill oper-
which require an inboard heat exchanger ation, combustion gases leaking into the
size not available as a Caterpillar unit. cooling system, leaks in piping (particular-
When these conditions exist, it is necessary ly on inlet side of pump), or low water level
to obtain a heat exchanger from a supplier in the expansion tank. A low velocity area
other than Caterpillar. Heat exchanger is provided where deaeration can occur.
suppliers will provide information and aid Entrained air separates from the water
in selecting the proper size and material because the tanks are sized and baffled to
for the application. slow the full water flow to less than 2 fps
(60 cm/s).
Since heat exchanger tubes can be cleaned
more easily than the surrounding jacket; the The expansion tank is the highest point in
cold water usually is routed through tubes the jacket water circuit. The heat exchang-
and the engine coolant through the shell. er must be mounted at a level lower than
the coolant in the expansion tank, prefer-
ably several feet. The system should be
EXPANSION TANK designed so the total jacket water flows
from the engine outlet to the heat exchang-
Unlike radiators, heat exchangers have no er, to the expansion tank, and back to the
built-in provision for jacket water expan- jacket water pump inlet. This facilitates
sion. A surge (expansion) tank or tanks purging of air and also creates a positive
must be included in a heat exchanger sys- pressure at the jacket water pump inlet.
tem. A factory-designed tank is normally
specified to assure proper performance of Caterpillar expansion tanks should be
the total system. used on all installations with heat exchang-
er cooling, unless customer-supplied tank
Water expands about 5% of its volume has successfully met all Caterpillar cooling
between 32°F and 212°F (0°C and 100°C). system test criteria.
The expansion tank should have a capacity
of at least 20% of the system water volume
for this expansion and coolant reserve. It
must be vented to the atmosphere or inco-
porate a pressure cap to assure system
pressure. It must be located after the heat
exchanger to prevent the formation of a
vacuum, a primary cause of cavitation on
the suction side of the pump.
92
LUBRICATION
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Prelubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Duplex Oil Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Scheduled Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Lubricating Oil Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
High Sulfur Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Remote Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Tilt Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Supplemental Bypass Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
93
LUBRICATION
GENERAL PRELUBRICATION
The lubricating system of a modern diesel All 3500 Family engines have the capability
engine accomplishes three purposes. First, to prelubricate all critical bearing journals
it lubricates surfaces to minimize friction before energizing the starting motors. This
losses. Second, it cools internal engine feature is available regardless of starter
parts which cannot be directly cooled by motor type (i.e., pneumatic or electric).
the engine’s watercooling system. Third, it
cleans the engine by flushing away wear The automatic system utilizes an electric
particles. motor powered pump which fills the engine
oil galleries from the engine oil sump until
Proper lubrication requires clean oil, free the presence of oil is sensed at the upper
from abrasive particles and corrosive com- portion of the lubrication system. The
pounds. It also requires a lubricant with starter motors are automatically energized
sufficient film strength to withstand bearing only after the engine has been adequately
pressures, low enough viscosity index to prelubricated.
flow properly when cold, and high enough
to retain film strength when subjected to The manual system uses the engine’s
heat exposure on cylinder and piston walls. manually operated sump pump and allows
The lubricant must also be capable of neu- the engine operator to fill all engine oil pas-
tralizing harmful combustion products and sages after oil changes, filter changes,
holding them in suspension for the dura- periods of idleness, and before activating
tion of the oil change period. Your local the starter motors.
Caterpillar Dealer should be consulted to
determine the best lubricant for local fuels.
Either prelube system will allow the engine
operator to fill all engine oil passages after
Solid particles are removed from the oil by oil changes, filter changes, and before
mechanical filtration. The size of the mesh activating the starter motors. Either system
is determined by the maximum particle will allow the engine user to reduce the
size that can be circulated without notice- sometimes severe engine wear associated
able abrasive action. The standard oil filter with starting an engine after periods of
systems on Caterpillar Engines meet idleness.
these requirements and are sized to pro-
vide reasonable time intervals between
element changes. The filter change inter-
vals relate to oil change periods.
94
DUPLEX OIL FILTER SYSTEM the main filter elements. A vent valve
allows purging of air trapped in either the
The optional Caterpillar duplex oil filter main or auxiliary system when installing
system meets the requirements of the new elements. AIR MUST BE PURGED
standard filter system plus an auxiliary fil- FROM THE CHANGED SECTION TO ELIM-
ter system with the necessary valves and INATE POSSIBLE TURBOCHARGER AND
piping, Figure 49. The system provides the BEARING DAMAGE. The auxiliary system
means for changing either the main or aux- is capable of providing adequate oil filtra-
iliary filter elements with the engine run- tion for at least 100 hours under full load
ning at any load or speed. A filter change and speed operation. The same filter ele-
indicator is included to tell when to change ments are used in both systems.
SCHEDULED OIL SAMPLING This program will not indicate the condition
of the lube oil nor predict a fatigue or sud-
Many Caterpillar Dealers offer Scheduled den failure. Caterpillar recommendations
Oil Sampling as a means of determining for oil and oil change periods are published
engine condition by analyzing lubricating oil in service literature. Caterpillar does not
for wear particles. This program will ana- recommend exceeding the published oil
lyze the condition of your engines, indicate change recommendations.
shortcomings in engine maintenance,
show first signs of excessive wear which
would mean an upcoming failure, and help
reduce repair costs.
95
LUBRICATING OIL HEATERS periods reduce the corrosive effect of the
sulfuric acid that is formed by the sulfur
Heating elements in direct contact with and other byproducts of combustion. (See
lubricating oil are usually not recommend- Figure 50.)
ed due to the danger of oil coking. To avoid
this condition, heater skin temperatures The properties of the specific lube oil
should not exceed 300°F (150°C) and used, load factor, and other variables may
have a maximum heat density of 8 W/in2 affect the rate of wear due to sulfur. The
(12.5 W/1000 mm2). lube oil supplier should be consulted for
the analysis parameters and limits which
will assure satisfactory engine perfor-
HIGH SULFUR FUELS
mance with his products.
Caterpillar lube oil change period recom-
mendations are based on the use of diesel The alkaline reserve level of the lube oil
fuels containing 0.4% or less of sulfur by is important when high sulfur fuel is
weight. Fuel sulfur can produce rapid used. Caterpillar limits have not yet been
engine wear. Fuels of higher sulfur content established.
than 0.4% will require reducing the oil
change interval. Shortened oil change
Figure 50
96
REMOTE FILTERS TILT ANGLES
Some Caterpillar Engines have the capa- Installations at a permanent tilt or slant
bility for remote mounting the oil filter when angle should be reviewed by Caterpillar
space limitation or serviceability is a prob- Tractor Co. to ensure the lubrication sys-
lem. However, authorization from Caterpillar tem will function properly.
Tractor Co. must be obtained before mak-
ing any modification to the engine lubrica- Transient tilt angle limits are shown for all
tion system. engines in the TIF.
B. Use medium pressure, high tempera- Caterpillar Engines do not require a sup-
ture (250°F [120°C]) hose equivalent to plemental bypass oil filter system, but one
or exceeding SAE 100R5 specification. can be installed if requested by the user. If
used, system must have a non-drainback
C. Keep oil lines as short as possible. feature when the engine is shut down and
a 0.125 in maximum diameter orifice limit-
ing flow to 2 gpm (7.57 L/min). Refer to the
D. Support hose as necessary to keep from engine general dimension drawings for the
chafing or cutting on sharp corners. recommended bypass filter supply location
and oil return to the crankcase.
E. Use care in connecting oil lines so the
direction of oil flow is correct. (CAUTION: Supplemental bypass filters increase the
ENGINE DAMAGE WILL OCCUR IF oil capacity and may allow the oil and filter
OIL FILTER IS IMPROPERLY CON- change periods to be extended. Refer to
NECTED.) the Caterpillar Operation Guide for recom-
mended change periods.
97
98
FUEL GOVERNING AND CONTROL
Page
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Component Description and Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Water Separator and Primary Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Secondary Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Priming Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Governor and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Speed Droop Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Isochronous Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Electric Load Sharing Governors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Governor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Governor Capabilities and Recommended Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Governor Force and Motion Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Use of Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Design for Linkage Over-Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Shutdown Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fuel Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Cetane Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Distillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Flash Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Pour Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Water and Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Carbon Residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Ash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
99
FUEL GOVERNING AND CONTROL
100
replacing, the gauge will read low when the the tank enough to create the required
engine is operating at load. The governor expansion volume. A small vent hole (about
(11) controls the stroke of the individual 0.19 in [4.81 mm] diameter) in filler tube,
fuel pumps from shutoff to full delivery in just below top of tank, is required to make
order to achieve desired engine speed, this volume usable.
regardless of load.
Venting to atmospheric pressure is neces-
COMPONENT DESCRIPTION AND sary to prevent pressure or vacuum buildup.
INSTALLATION REQUIREMENTS A large tank can be collapsed by vacuum or
burst by pressure if not vented properly.
Individual components of the fuel system
are described here more completely as to Filler must be adequately sized and locat-
purpose, recommended features, and instal- ed for convenient filling. It should also be
lation requirements to achieve satisfactory lockable. Fuel spillage must not reach hot
performance and life. parts. Also, fuel spillage should not reach
items which can soak up or entrap fuel or
Fuel Tank be damaged by fuel.
It provides fuel storage and should have the Filler should be located near center of tank
following features: so that parking a mobile machine on a side
tilt will not cause expanding fuel to back up
into filler pipe and overflow. This will also
Adequate size for the intended applica- help avoid spilling fuel from a full tank
tion. Rule of thumb for tank size with 25% when operating on a grade.
reserve is:
Fuel tanks should be shielded or located
0.056 2 _____ hp (average) away from major heat radiating sources
2 _____ hours (between refills) such as hot exhaust manifolds and tur-
2 1.25 = _____ gal (U.S.) bochargers. Also, the cooling fan blast picks
0.27 2 _____ kW (average) up enough heat from the radiator to raise
2 _____ hours (between refills) fuel temperatures significantly if the air is
2 1.25 = _____ liters directed at the fuel tank. This will result in
some power loss because of the heated,
Adequate structural strength to avoid fail- expanded fuel. Fuel level should not be
ure under application conditions which may above the fuel injectors on the engine to
include shock loading and steady vibration. avoid possible seepage of fuel through a
leaky injector into the cylinder (and then to
Appropriate material. Zinc (galvanized or the oil pan) during engine shutdown. Also,
zinc-bearing materials such as brass) react to avoid hard starting, the fuel level should
with sulphur in fuel oil to form a sludge which not cause total suction lift of more than 12 ft
is harmful to the engine’s fuel injection sys- (3.7 m). Much less is better.
tem. Steel, aluminum, stainless steel, or
copper clad steel is used successfully. A sloping bottom helps collect sediment
and any major amounts of water, and a
Expansion volume must be adequate to bottom drain is necessary to permit peri-
allow for expansion of stored fuel during odic removal of these contaminants.
temperature change. Allowance of 5% of
tank volume is adequate. This can be pro-
vided by extending the filler neck down into
101
Fuel supply pickup should be off of the However, any system can be damaged by
bottom enough to leave 3% to 5% of the water in the fuel; so the water should be
fuel in the tank. This should leave sediment removed. Fuel system damage by water is
and water in the tank until drained off peri- always the responsibility of the user.
odically. The pickup line must rise upward
through the top of the tank so that the con- The water separator should be sized ade-
nection to fuel lines is above the full level quately to separate and store enough
in the tank. water between periodic drainings to pre-
vent overfilling and water carryover into the
Fuel return line should normally enter the engine’s fuel system.
tank at the top and extend downward, exiting
above the fuel level. Inlet and return lines The water separator should be mounted in
should be separated in the tank by at least a visible location. If the operator sees water,
12 in (304.8 mm) to avoid air pickup in the he is more likely to drain it out periodically.
inlet line. If the device is hard to see or difficult to ser-
vice, it may not receive regular attention.
Baffles reduce sloshing and resulting air
entrainment. They also prevent sudden A primary filter is not needed when a water
shifts in the tank’s center of gravity, when separator is used as on the 3200 and 3300
in motion, as on a mobile machine. Engines.
Strong fastening of the fuel tank to the The installation should include valves which
machine is essential. This is especially can isolate the separator and primary filter
important on a mobile application where when the elements are changed.
motion of a full tank generates sizeable
forces. It is good practice to use some non-
metallic cushioning material between the Lines and Fittings
tank and support members to avoid fretting
and wear on the tank. Pipes, hoses, and fittings must be mechan-
ically strong, leak-tight, and resistant to
deterioration due to age or environmental
Water Separator and Primary Filter
conditions. Sizing must be adequate to
minimize flow loss. Routing must be cor-
Fuel system components can be damaged rect, and flex connections, such as hose
by water-caused corrosion or by the poor assemblies, must isolate engine motion
lubricating quality of water. For this reason from the stationary members in the system.
separation and removal of water from the
fuel is essential. Also, because water can
collect and freeze at low points in fuel lines, The fuel supply and return lines should be
filters, or other components that contain no smaller in size than the fittings on the
fuel, a water separator should be placed as engine. Fuel line pressure measured in the
close to the fuel tank as practical in a visi- return line should be kept below 5 psi
ble, serviceable location. Usually, the sep- (34.5 kPa). A check valve can be used in
arator has a see-through feature that the fuel return line. A shutoff valve should
allows a quick visual check for presence of not be used, because damaging pressure
water and a quick-drain valve to let the would result if the valve were left closed
water out. Because the compact sleeve when engine was started.
metering injection pump on the 3208,
3304, and 3306 Engines uses fuel as a
lubricant, it can be damaged more quickly
by water than the scroll-type system.
102
Black iron pipe is suitable for diesel fuel Transfer Pump
lines. Copper pipe or tubing may be sub-
stituted in sizes of 0.5 in (12.7 mm) nomi- This pump delivers low pressure (15 psi to
nal pipe size or less. Valves and fittings 30 psi [103 kPa to 207 kPa]) fuel from the
may be cast iron or bronze (not brass). tank to the injection pump housing reser-
Zinc plating or zinc as a major alloy should voir. It is a gear-type pump with some lim-
not be used with diesel fuel because of ited priming capability when the pumping
instability in presence of sulphur. The sludge gears are full of fuel. This pump should be
formed by chemical action is extremely protected from abrasive wear and corrosion
harmful to an engine’s internal components. by a water separator or primary fuel filter.
103
Priming Pump Governor and Controls
When a fuel system has air in it, the hand The purpose of the governor is to control
priming pump is used to fill the system with engine speed by regulating the amount of
fuel and purge the air. Once this has been fuel injected. It does this by controlling the
done, the priming pump will not likely be rack or sleeve shaft position. The speed
used again until the fuel system is emptied control lever on the governor is positioned
for adjustment or repair. by the operator using some type of control
lever, cable, or remote actuator (air, elec-
Injection Pump tric, etc.).
Fuel is pumped at a very high pressure to Devices such as fuel-air ratio controls,
each cylinder injector by individual injection shutdown solenoids, and manual shutoffs
pumps. For example, a six-cylinder engine also operate on the governor which, in
has six separate injection pumps within the turn, operates on the rack or sleeve shaft.
injection pump group. The fuel volume
pumped on each stroke is controlled by the
rack (scroll system) or sleeve shaft (sleeve- GOVERNORS
metered fuel system) which determines
the effective pumping stroke. The governor All engine models have hydra-mechanical
controls the rack or sleeve shaft position, speed droop governors standard on indus-
thereby controlling fuel delivery to produce trial models, except 3208 and 3300 Engines
a governed speed, regardless of load. which have mechanical speed droop gov-
ernors as standard. Both types contain
Injection Lines mechanical ball-head-type speed govern-
ing devices, but the hydra-mechanical gov-
ernors use a pilot valve and servo system
Individual fuel lines carry fuel at the very controlling flow of engine oil to provide the
high pressure required for injection, from working force to move the rack.
individual injection pumps to each cylinder
injector. These lines are heavy-walled,
strong, specially extruded tubing made only Types of governors available for use on all
for this purpose. Because the injection Caterpillar Engines, except the 3208, are
lines carry such high pressure, they should speed droop, isochronous, and electric
not be bent or damaged during installation load sharing. Only the speed droop-type is
or operation. available on the 3208. The engine applica-
tion determines which one should be used.
Injectors Close regulation governors are required
for some types of processing operations.
For example, a forage harvester cutter head
The purpose of the injector valve is to or a rock crusher must operate in a narrow
spray the correct pattern of atomized fuel speed bank for best results.
into the combustion chamber (DI) or into
the precombustion chamber (PC). It has a
spring-loaded valve which requires that
the pressure rise to some elevated level
before valve opens at start of injection.
This is necessary for precision-timed fuel
delivery and assures a sharp cutoff of fuel
at the end of each injection period.
104
Sped Droop Governors When operated at less than rated full load
speed, the governor speed droop percent-
A speed droop governor’s full load speed is age increases. Governor springs can be
less than its no-load speed. This difference changed to restore proper droop.
is called speed droop and is expressed as a
percentage of full-load speed. For example, Isochronous Governors
a governor with 10% regulation, or speed
droop, with a full-load speed of 2000 rpm Isochronous governors, usually referred to
would have a no-load speed (high idle) of as “constant speed or zero percent speed
2200 rpm. droop,” are available on all Cat Engines
except the 3208. Their no-load and full-
The speed droop governors available on Cat load speeds are the same.
Engines are not all the same in construc-
tion, but their speed droop characteristics The isochronous governors used by
are similar. They are generally available in Caterpillar are the Woodward PSG, UG8D
nominal 3% and 10% versions. (dial-type) and UG8L (lever-type), and
EG3P-2301. These governors are serviced
Engines equipped with speed droop gov- by Caterpillar.
ernors can be shut down by moving the
hand throttle beyond a detent into a fuel-off Although these governors are isochronous,
position. A manual shutoff shaft and provi- they can be adjusted to provide speed
sions for mounting an optional DC shutoff droop. The speed droop adjustment is exter-
solenoid are standard on most Cat Engines. nal on the UG8D and newer PSG gover-
nors. It is internal on the UG8L.
The manual shutoff shaft can have a lever
installed on it to provide a mechanical or The PSG governor has its own oil pump
pneumatic method of stopping the engine, but operates on engine oil. It is available
whereas the solenoid option provides for for the smaller engines and can be sup-
remote electric shut down of the engine. plied with an electric speed-changing
motor for remote control.
Speed droop governors are recommended
for most mechanical and torque converter The UG8D and UG8L governors, which
drives where operation is characterized by have a self-contained oil pump and oil sup-
varying speeds. If output shaft speed on ply, are available on the larger engines.
a torque converter must be controlled or
limited, an output shaft governor must be
installed. The UG8D is available with a 24-32 Vdc,
100 VAC-50 Hz, 115 VAC-60 Hz, speed-
changing motor and a 24-32 Vdc shut-
Constant speed applications, such as down solenoid. The UG8L is available with
pumps and various processing operations, a 10 psi to 60 psi (69 kPa to 414 kPa) air
also use speed droop governors success- actuator. The PSG and UG8D are normally
fully if the effect of speed variation due to used for generator set applications. These
load change is not significant. governors and their applications are dis-
cussed more fully, with pictures, in the Oil
Field Application and Installation Guide.
105
Electric Load Sharing Governors An EG3P actuator is mounted on the engine,
and the control box is mounted remotely.
A Woodward 2301 electric load-sharing
governor system is available on most Refer to Generator Set Selection and
Caterpillar Engines except the 3208s and Installation Guide for more complete infor-
3300s. This governor is isochronous. It mation concerning electric governors.
also has the ability to provide automatic
and proportional load division between
Governor Selection
paralleled AC generators, even with differ-
ent sized units, and still maintain isochro-
nous speed. The following two charts summarize gov-
ernor configurations and their capabilities:
Governor Selection
Governor With
Speed Speed Droop 2301 2301
Droop Capability Load-Sharing Standby
Governor* PSG UG8D UG8L Governor Governor
D399 X X X X X**
G399 X X X X X**
D398 X X X X X
G398 X X X X X**
D379 X X X X X
G379 X X X X X**
D353 X X X X X
D349 X X X X**
D348 X X X X**
G342 X X
3412 X X X X
3408 X X X X
3406 X X X X
3306 X X
3304 X X
3208 X
**Speed droop available is dependent upon the specific engine. Contact your Caterpillar
Engine supplier for specifics.
**Standard equipment for standby automatic start-stop applications.
106
Governor Capabilities and Recommended Usage
2301 2301
Speed Isochronous Load- Speed
Droop Governor Sharing Control
Governor PSG UG8D UG8L Governor Governor
Load X
Sharing At
Isochronous
Speed
Isochronous X X X X X
Speed Droop X X X X X X
Rheostat X X
Speed
Adjustment
Electric X X X
Motor Speed
Adjustment
(AC-DC)
Air X X
Throttle
Speed
Adjustment
Shutdown by X
Governor
Throttle-
Diesel
Manual X X X X X
Shutoff
Plunger-
Diesel
DC Shutoff X X X X
Solenoid-
Diesel
Variable X X X
Speed
Operation
Constant X X X X X X
Speed
Operation
Parallel X X X X
Operation
(DC or AC)
107
CONTROLS is reached. This causes power complaints
because the engine is prevented from
Purpose — To input the governor with a operating at rated power, because the link-
correct speed signal, usually a mechanical age did not allow the engine to develop
motion, to result in desired engine speed. rated speed.
Description — Typically, the control sys- The best approach is to use a springloaded
tem will consist of a single lever-linkage break-over governor lever which accepts
arrangement, or a push-pull cable which motion of the control linkage beyond the
translates operator’s action to the governor travel of the governor shaft. Then it is easy
speed control lever. Sometimes the speed to adjust correctly and visually check that
control can also move the governor to the governor speed control lever will travel
shut-off position, but more typically, a sep- its full range.
arate shut-off device (solenoid or mechan-
ical linkage) is attached to the governor for Engine Shutdown Control
this purpose.
Engine shutdown is done by shutting off
Controls should be easy to use by the fuel supply in some manner. Usually this is
machine operator. They control engine done with a direct mechanical connection
speed and shut off fuel to stop the engine. which pulls the rack to shutoff, or with a
solenoid which does the same thing.
Governor Force and Motion Data Safety shutoffs are discussed more com-
pletely in another chapter.
The TIF contains information on (1) arc of
motion and (2) force level required to oper- FUELS
ate the governor speed control on each
engine model. This allows the designer to
select or design an appropriate cable con- Use clean fuel meeting Caterpillar’s recom-
trol, or some lever-link arrangement. mendations for best service life and perfor-
mance. Anything less is a compromise, and
the risk is the user’s responsibility. Dirty
Use of Control Cable fuel not meeting Caterpillar’s minimum fuel
specifications will adversely affect com-
When there is relative motion between the bustion, filter life, startability, and life of inter-
engine and the machine, a cable control nal components.
may be used to avoid transmitting unwant-
ed motion to the governor control lever
Clean fuel is of utmost importance to fuel
causing unacceptable speed fluctuation
injection system components if long, trou-
which can be confused with governor surge.
ble-free service life is expected. All
Caterpillar Engines are equipped with a fil-
Design for Linkage Over-Travel tering system that protects the fuel injec-
tion pumps and valves. These filters are
Control mechanisms must be designed not designed to cope with great quantities
with a stop which prevents overloading the of sediment and water. Both should be
governor lever when it reaches its limit of removed by a primary filtering system or
travel. But this causes a problem when the water separator.
stop on the control linkage is reached
before full speed position of governor lever
108
Fuel Selection The following additional information de-
scribes certain characteristics and their
Caterpillar Diesel Engines have the capac- relation to engine performance.
ity to burn a wide variety of fuels. In gener-
al, the engine can use the lowest-priced Cetane Number
distillate fuel which meets the following
requirements. This index of ignition quality is determined
in a special engine test by comparison
(Fuel condition as delivered to engine with fuels used as standard for high and
fuel filters.) low cetane numbers.
Cetane No. (direct injected engines) — Since the advent of high detergent oils,
40 minimum. sulfur content has become somewhat
less critical. A limit of 0.4% maximum is
Viscosity — 100 SUS at 100°F used for Caterpillar Engines without
(37.8°C) maximum. reducing oil change periods. However,
the worldwide fuel shortage has caused
Pour Point — 10°F (5.5°C) below this problem to resurface more often
ambient temperature. now because of very high sulfur levels in
some fuels. Oil change periods must be
Cloud Point — not higher than ambient reduced with higher sulfur fuel.
temperature.
Gravity
Sulfur — Shorten oil change period for
higher than 0.4% sulfur in fuel.
This measurement is an index of the
Water and Sediment — 0.1% maximum. weight of a measured volume of fuel.
Lower API ratings indicate heavier fuels
which contain more heat value by volume.
Some fuel specifications that meet the above
requirements:
Viscosity
ASTM D396 — No. 1 and No. 2 fuels
(burner fuels). This factor is a time measure of flow resis-
tance of a fuel. Some low viscosity fuels
ASTM D975 — No. 1-D and No. 2-D are not good lubricants; a viscosity which
diesel fuel oil. is too high makes for poor fuel atomiza-
tion, decreasing combustion efficiency.
BS2869 — Class A1, A2, B1, and B2
engine fuels. Distillation
BS2869 — Class C, C1, C2, and
This involves the heating of crude to rela-
Class D burner fuels.
tively high temperatures. The vapor which
DIN51601 — diesel fuel. results is drawn off at various tempera-
ture ranges producing fuel of different
DIN51603 — EL heating oil. types. The lighter fuel, such as gasoline,
comes off first, and the heavier fuel last.
109
Flash Point Corrosion
The lowest temperature at which the fuel To determine corrosion a polished cop-
will give off sufficient vapor to ignite per strip is immersed in the fuel for three
momentarily when a flame is applied to hours at 122°F (50°C). Any fuel impart-
the vapor. ing more than slight discoloration should
be rejected.
Pour Point
The customer should order as heavy a
This denotes the lowest temperature at fuel as his diesel engine and tempera-
which fuel will flow or pour. ture conditions permit. Fuel costs repre-
sent approximately 80% of total operat-
ing costs for an engine, so it is good
Water and Sediment economy to look closely at the largest
cost first.
The percentage by volume of water and
foreign material which may be removed NOTE: Caterpillar Diesel Engine fuel rack
from fuel by centrifuging. No more than settings are based on 35° API (specific
a trace should be present. gravity) fuel. The use of fuel oil with a higher
API (lower specific gravity) number will result
Carbon Residue in some reduction of power output. When
using heavier fuels, a corrected rack setting
should be used to prevent power levels
Percentage by weight of dry carbon above the approved rating. Your Caterpillar
remaining when fuel is ignited and Engine supplier should be contacted to
allowed to burn until no liquid remains. obtain the correct rack setting for fuels which
do not comply with the recommendations.
Ash Operation above the approved engine horse-
power rating level will result in reduced
This is percentage by weight of dirt, dust, engine life, increased owning and operating
and other foreign matter remaining after costs, and customer dissatisfaction.
combustion.
110
STARTING
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Electric Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Temperature Versus Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Battery Performance — Specific Gravity Versus Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Maximum Recommended Total Battery Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Caterpillar Engine Battery Recommendtions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Charging Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Starting System Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Air Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Air Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Tank Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cranking Time Required per Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Rate of Free Air Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Free Air Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Hydraulic Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Driven Load Reduction Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
111
STARTING
An engine starting system must be able to Electric starting is the most convenient to
crank the engine at sufficient speed for fuel use. Storage of energy is compact, however,
combustion to begin normal firing and keep charging the system is slow and difficult in
the engine running. case of emergency. Electric starting be-
comes less effective as the temperature
There are three common types of engine drops due to loss of battery discharge
starting systems: capacity and an increase in an engine’s
resistance to cranking under those condi-
tions. It is the least expensive system and
A. Electric is most adaptable to remote control and
automation.
B. Air
Damage can result if water enters and is
C. Hydraulic retained in the starting motor solenoid. To
prevent this, engines stored outside should
be provided with a flywheel housing cover.
The choice of systems depends upon avail- If possible, the starting motor should be
ability of the source of energy, availability mounted with the solenoid in an up position
of space for storage of energy, and ease of which would provide drainage and prevent
recharging the energy banks. water from collecting in the solenoid.
Startability of a diesel engine is affected Engines which are subject to heavy driven
primarily by ambient temperature, lubricat- load during cold start-up should be provided
ing oil viscosity, and the size of the cranking with a heavy-duty starting motor. See sec-
system. The diesel relies on the heat of tion on Driven Load Reduction Devices.
compression to ignite the fuel. This heat is
a result of both the cranking speed and the
length of time for cranking. When the engine
is cold, a longer period of cranking is re-
quired to develop this ignition temperature.
On precombustion chamber-type engines,
additional heat can be provided by using
glow plugs.
112
BATTERIES Batteries should be kept warm, if possible,
but not over 125°F (52°C) to ensure maxi-
Lead-acid storage batteries are the most mum engine cranking speed. The impact
common energy source for engine electric of colder temperatures is described below:
starting systems.
Temperature Versus Output
Two considerations in selecting proper bat-
tery capacity are: Percent of 80°F (27°C)
°F °C Ampere Hours Output Rating
A. The lowest temperature at which the 80 27 100
engine might be cranked. 32 0 65
0 –18 40
B. The parasitic load imposed on the
engine. The cranking batteries should always be
securely mounted where it is easy to check
A good rule of thumb is to select a battery water level, charge condition, and cleanli-
package which will provide at least four ness. They should be located as close to the
30-second cranking periods (total of two starting motors as is practical to minimize
minutes cranking) without dropping below voltage drop through the battery cables. All
60% of the nominal battery voltage. An battery connections must be kept tight and
engine should not be cranked continuously coated with grease to prevent corrosion.
for more than 30 seconds or starter motors
may overheat.
Battery Performance
Freezes
Specific Gravity % Charge Voltage per Cell °F °C
1.260 100 2.10 –70 –94
1.230 75 2.07 –39 –56
1.200 50 2.04 –16 –27
1.170 25 2.01 –02 –19
1.110 Discharged 1.95 +17 –08
113
Caterpillar Engine Battery Recommendations
114
Figure 53 TYPICAL WIRING DIAGRAMS
CHARGING SYSTEMS
Normally, engine-driven alternators are used Engine-driven alternators have the disad-
for battery charging. When selecting an vantage of charging batteries only while
alternator, consideration should be given to the engine is running. Trickle chargers are
the current draw of the electrical acces- available but require an A/C power source.
sories to be used and to the conditions in Battery chargers using AC power sources
which the alternator will be operating. An must be capable of limiting peak currents
alternator must be chosen which has ade- during the cranking cycle or must have a
quate capacity to power the accessories relay to disconnect the battery charger
and charge the battery. If the alternator will during the cranking cycle. In applications
be operating in a dusty, dirty environment; a where an engine-driven alternator and a
heavy-duty alternator should be selected. battery trickle charger are both used, the
disconnect relay must be controlled to dis-
Consideration should also be given to the connect the trickle charger during cranking
speed at which the engine will operate and running periods of the engine.
most of the time. An alternator drive ratio
should be selected so that the alternator
charges the system over the entire engine
speed range.
115
STARTING SYSTEM WIRING AIR STARTING
Power carrying capability and serviceability Air starting usually offers higher cranking
are the primary concerns of the wiring speeds than electric starting. This will usu-
system. ally result in faster starts with less cranking
time; however, remote controls and auto-
Select starter and battery cable size from the mation are more complex. On the other
size/length table on Page 109. For correct hand, the air system can be quickly
size and correct circuit for starting system recharged; but air storage tanks are prone
components, see typical wiring diagrams. to condensation problems and must be
The wiring should be protected by fuses or protected against internal corrosion and
a manual reset circuit breaker (not shown freezing.
on the wiring diagrams). Fuses and circuit
breakers should have sufficient capacity The air starting system includes: air starting
and be readily accessible for service. motor, air storage tank, starting valve, pres-
sure regulator, and oiler. A starting motor
Other preferred wiring practices are: discharge air silencer/vapor arrestor is an
optional accessory to the air starting sys-
tem. The pressure regulator is designed to
— Minimum number of connections, reduce inlet line pressure from a maximum
especially with battery cables. of 250 psi to 110 psi (1725 kPa to 759 kPa)
regulated air pressure to the motor. Higher
— Positive mechanical connections. supply air pressures may be used by utiliz-
ing additional regulators plumbed in series.
Unregulated systems must not exceed
— Permanently labeled or color-coded 150 psi (1034 kPa) to the starting motor.
wires.
Compressor
— Short cables to minimize voltage drop.
The compressor can be operated by either
— Ground cable from battery to starter an electric motor or an internal combustion
is preferred. If frame connections are engine. Space should be provided for ser-
used, tin the contact surface. Current vice accessibility, inspection, and for manual
path should not include high resis- starting of the internal combustion engine.
tance points such as painted, bolted,
or riveted joints. Supply Line
— Protect battery cables from rubbing The air supply line between the storage
against sharp or abrasive surfaces. tank and the air motor should be short and
direct and of a size equal to the discharge
opening of the air receiver. Black iron pipe
is preferable and must be properly sup-
ported to avoid vibration damage to the
compressor. Flexible connections between
the compressor outlet and the piping are
required.
116
Air Storage Tank The volume of free air required per start
(Vs) depends on three factors:
Air storage tank should meet American
Society of Mechanical Engineers (ASME) A. Cranking Time Required per Start
pressure vessel specifications and should
be equipped with a safety valve and a The cranking time per start depends
pressure gauge. Safety valves should be upon the engine model, engine condi-
regularly checked to guard against possi- tion, ambient air temperature, oil vis-
ble malfunction. A drain cock must be pro- cosity, fuel type, and design cranking
vided in the lowest part of the air receiver speed. Five to seven seconds is typical
tank for draining condensation. for an engine at 80°F (26.7°C). Restarts
of hot engines usually take less than
Tank Sizing two seconds.
117
The following formula may be used to esti- Pa = Atmospheric pressure (psia or
mate the time required for an air compressor kPa).
to raise the pressure in an air receiver to a
specified limit: Vr = Volume of air receiver (cubic
feet or cubic meters).
Pt 2 Vr
T = _______ N = Net free air delivery of compres-
Pa 2 N
sor (cubic feet per minute or
cubic meters per minute).
T = Time in minutes.
HYDRAULIC STARTING
Hydraulic starting provides highest cranking replaced, but recharging the pressurized
speeds and fastest starts. It is relatively gas, if lost, requires special equipment.
compact. Recharging time is fast, and the
system can be recharged by a hand pump Repair to the system usually requires spe-
provided for this purpose. The high pres- cial tools. The complete system is supplied
sure of the system requires special pipes by the starter manufacturer. Due to system
and fittings and extremely tight connec- complexity, hydraulic starting is not recom-
tions. Oil lost through leakage can easily be mended except where the use of electrical
connections could pose a safety hazard.
118
STARTING AIDS Ether
Starting aids are recommended when tem- Ether facilitates starting since it is a highly
peratures fall below certain levels, as shown volatile fluid which has a low ignition tem-
in the Operation and Maintenance Guides. perature. Many types of ether starting aids
Glow plugs and/or ether starting aids are are commercially available. The high pres-
sufficient for most conditions, with oil and sure metallic capsule-type is recommend-
coolant heating necessary in extremely ed. When placed in an injection device and
low ambients (refer to Operations and pierced, the ether passes into the intake
maintenance Guides for further data on manifold. This has proven to be the best
cold weather procedures). system since few special precautions are
required for handling, shipping, or storage.
Glow Plugs
CAUTION: WHEN OTHER THAN FULLY
Glow plugs are available for all precom- SEALED ETHER SYSTEMS ARE USED,
bustion chamber Caterpillar Engines. ENSURE ADEQUATE VENTILATION FOR
These glow plugs mount in each cylinder’s VENTING THE FUMES TO THE ATMOS-
precombustion chamber. Depending on PHERE TO PREVENT ACCIDENTAL
the size of the engine, they alone are ade- EXPLOSION AND DANGER TO OPERAT-
quate for temperatures as low as 0°F ING PERSONNEL.
(–15°C) before ether or other starting aids
are needed. Glow plugs function by sup- Ether must be used only as directed by the
plying a source, other than compression, manufacturer of the starting aid device.
to raise the air-fuel mixture to combustion The ether system must be such that a
temperature. maximum of 3.0 cc of ether will be
released, each time the button is pushed.
Glow plugs are simple to use and easy to Caterpillar ether systems are designed to
install. An ample wiring circuit is the only release 2.25 cc of ether each time the sys-
requirement. Each glow plug, regardless tem is activated. Excessive injection of
of voltage, is rated at 150 watts. Current ether can damage an engine.
draw for a 12-volt glow plug is 12.5 amps
and 6.25 amps for a 24-volt glow plug.
119
Heaters typically demand more horsepower when
they are extremely cold at start-up. The
When operating in areas which experience effect of this horsepower demand may be
long winter seasons or temperatures con- overcome by providing a means of
sistently in the 0°F (–18°C) range, it may declutching driven loads until the engine
be desirable to use an engine coolant has been started and warmed up for a few
heating system. minutes. This is not always easy or practi-
cal, so other means of relieving the load at
cold start-up may be required if the
This system should maintain the engine engine-load combination cannot be start-
coolant at a temperature of approximately ed with sufficient ease using the engine
90°F (32°C) to ensure quick starting, provide starting aids described earlier.
faster warm-up, save fuel during starting,
reduce engine wear, and extend battery life.
Some air compressors provide for shutoff
of the air compressor air inlet during cold
The coolant heaters are normally supplied starting. This greatly decreases drag on
to operate on single-phase alternating cur- the engine and improves cold startability.
rent, and an outside electrical source is This approach can only be used when the
required. For additional information see air compressor manufacturer provides this
Block Heaters in Cooling section. system and fully approves of its use. Other-
wise, air compressor damage could result.
Driven Load Reduction Devices
120
INSTRUMENTATION, MONITORING, AND SHUTOFF
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Jacket Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Intake Manifold Air Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Exhaust Temperature Gauge (Pyrometer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Engine Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Fuel Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Air Restriction Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Oil Filter Differential Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Alarm Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Solenoid Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Manual Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Shutoff Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Mechanical Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Hydra-Mechanical Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
121
INSTRUMENTATION, MONITORING, AND SHUTOFF
Note: Electric gauges must be on a sepa- 6. Electronic engines provide data link(s)
rate circuit to avoid voltage pulses which that broadcast engine operating para-
could give false readings. meters for Caterpillar or after market
display modules. Utilizing these features
INSTRUMENTATION minimizes duplication of features and
could provide the operator state-of-the-
art engine status display information.
Instrumentation enables the operator to
monitor engine systems and make correc-
tions BEFORE failure or damage occurs. TACHOMETER
Consider the following:
The tachometer indicates engine rpm. It is
1. Minimum recommended mechanically a self-powered electric tachometer that is
gov-erned engine instrumentation adjustable. The tachometer drive can also
includes: be used to drive mechanical tachometers.
Water temperature
JACKET WATER TEMPERATURE GAUGE
Oil pressure
This gauge indicates the temperature of the
Ammeter/Voltmeter jacket water as it leaves the engine. Jacket
water temperature must be maintained
Air cleaner restriction between minimum and maximum limits.
122
water aftercooled engines operate at a sig- FUEL PRESSURE GAUGE
nificantly higher inlet manifold air tempera-
ture than do the engines rated for 85°F The fuel pressure gauge indicates the pres-
(29.9°C) or 110°F (43.3°C) aftercooler water sure of the filtered fuel. A power reduction
temperatures. will occur if the fuel pressure drops too low.
Plugged fuel filters decrease fuel pressure
EXHAUST TEMPERATURE GAUGE High fuel pressure can burst fuel filter
(Pyrometer) housings, damage gaskets, and cause
erratic speed control because of increased
The pyrometer measures exhaust gas tem- friction drag in injection pumps.
peratures, normally after the turbocharger.
On Vee engines with two turbochargers, a
single instrument is supplied with dual AIR RESTRICTION GAUGE
temperature read-out for both banks. On
engines with single turbochargers, one The air restriction gauge measures the
instrument with a single read-out is provid- vacuum caused by the air filter restriction.
ed. DO NOT USE EXHAUST TEMPERA- Clogged air cleaners will result in reduced
TURE AS A LOAD SETTING INDICATOR
WITH TURBOCHARGED AND TURBO- air flow causing high exhaust temperature
CHARGED/AFTERCOOLED ENGINES. and sometimes excessive smoke. The air
The pyrometer should be used only to restriction gauge should be checked regu-
monitor changes in the combustion sys- larly, and air filters should be changed
tem and to warn of required maintenance. when restriction limits are reached.
This gauge indicates oil temperature after This gauge measures the difference in
the lube oil cooler. On most engines, the pressure between the filtered and unfil-
oil is cooled by engine jacket water. A high tered sides of the oil filter; a high reading
jacket water temperature or a clogged oil will indicate plugged oil filters. This gauge
cooler will prevent the engine lube oil from should be checked regularly.
being properly cooled.
AMMETER
ENGINE OIL PRESSURE GAUGE
An ammeter measures electrical current to
This gauge indicates the pressure of the or from the battery.
filtered oil. Oil pressure will be greatest after
starting a cold engine and will decrease
slightly as the oil warms up. Oil pressure is ALARM CONTACTORS
greater at operating speeds than at low
idle rpm. The specified minimum oil pres-
sure is for an engine running at continuous Low oil pressure and high water tempera-
rated speed. Plugged oil filter elements will ture alarms are recommended for every
decrease engine oil pressure. The oil filter engine installation. These are preset tem-
service indicator (where provided) should be perature and pressure switches that will
checked regularly for premature filter plug- activate a customer-supplied alarm, or light,
ging. STOP THE ENGINE IMMEDIATELY when temperature or pressure limits of the
IF OIL PRESSURE DROPS RAPIDLY. switch are exceeded. In addition, a low
water level alarm switch can be provided to
warn of a low water level condition. It may
123
be installed in the radiator top tank or the Shutoff Detent
heat exchanger expansion tank depending
on the type of cooling system provided. This shutoff can be activated by pushing
the governor speed control lever from
Any engine function involving speed, tem- the high position to the low idle position,
perature, and pressure control may be then snapping through the low idle posi-
sensed with an appropriate alarm or shut- tion into the shutoff position. To use this
off system. feature, the linkage must be designed
and sized to tolerate full loading reversal
Alarm switches available from Caterpillar will without undue stress or deflection.
operate on AC or DC voltage, from 6 volts
to 240 volts. These switches (single-pole Mechanical Shutoff
double-throw) may be used to activate
alarm horns or lights up to 5 amp rating. This attachment provides a mechanical
shutoff system that will automatically
SHUTOFF shut down the engine in case of low oil
pressure or high coolant temperature.
The system is hydraulically operated and
The following engine shutoff’s are available
contains a shutoff control group which
on Caterpillar Engines. Consult the Indus-
forces the engine governor rack to shut
trial Engines Price List for shutoff availability
off if a malfunction occurs.
on a particular engine model. In some
cases multiple shutoffs may be provided.
Hydra-Mechanical Shutoff
Solenoid Shutoff
This system includes provisions to shut
down an engine when either oil pres-
The shutoff solenoid is mounted on the
sure, coolant temperature, or speed are
governor shutoff housing and can be
outside normal limits. If engine oil pres-
activated either by an instrument panel-
sure or coolant temperature exceeds safe
mounted switch or by switches which
limits, the protective system will move
sense critical engine or driven-equipment
the fuel rack to the shutoff position. If the
functions. Shutoff solenoids are available
engine speed exceeds a predetermined
in either energized-to-shutoff or energized-
limit, the air supply will be shut off, in
to-run versions.
addition to moving the fuel rack to the
shutoff position. In an emergency situa-
Manual Shutoff tion, the system can be manually oper-
ated to close off the air supply and move
The manual shutoff shaft extends from the rack to the shutoff position.
the engine governor shutoff housing. To
utilize this shaft, a separate linkage sys- Caution: Sensing devices must not trigger
tem (usually a push-pull cable) must be engine shutdown in applications where
provided. The shaft must be held in shut- engine provides equipment mobility.
off position until the engine stops. Con-
sult the Industrial Engine Drawing Book
for manual shutoff shaft rotation range.
124
APPLICATION AND INSTALLATION AUDIT FORMS
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Application Approval Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Installation Audit Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Power Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Mounting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Fuel System, Governing, and Engine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Starting and Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Monitoring System and Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Serviceability Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Photos Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
125
APPLICATION AND INSTALLATION AUDIT FORMS
126
Caterpillar OEM Pilot Model Application Approval
Truck-Industrial Engines
8. Describe application as completely as possible:________________ 24. HP required at flywheel end of engine ______________________
______________________________________________________ *25. Describe, or provide sketch of rear driven equipment __________
______________________________________________________ ______________________________________________________
______________________________________________________ ______________________________________________________
______________________________________________________ ______________________________________________________
9. Transmission make _____________________ Model __________ 26. Distance from centerline of PTO drive to front face of crankshaft
10. Clutch make _____________Model__________ Size __________ pulley (in/cm) ________________ _____________(overhung load)
11. Torque converter make ______________ Model ______________ Diameter of driver pulley __________________________ (in/cm)
12. PTO equipment make ____________ Model __________________ Diameter of driven pulley __________________________ (in/cm)
13. Front power takeoff HP required____________________________ 27. Maximum angle of engine operation ________________________
How driven: in-line ________________ side load ______________ 28. Accessories not furnished by CTCo. driven by engine. How and
*Describe, or provide sketch of front driven equipment __________ where driven, HP required ________________________________
______________________________________________________ ______________________________________________________
______________________________________________________ ______________________________________________________
______________________________________________________ 29. Operating hours per day _______________ per year __________
14. Air compressor make ________________ Model ______________ ______________________________________________________
HP required _________________ ______________________________________________________
15. Alternator make ____________________ Model ______________ 30. Anticipated number hours to major overhaul __________________
Volts ________________ Amps ____________
16. Muffler make _______________________ Model ______________ Automotive Data
17. Radiator make ______________________ Model ______________ 24. Vehicle or body frontal area ______________________________
*If radiator to be used is not a Caterpillar furnished radiator, supply a 25. Type of trailer or body ____________________________________
radiator blueprint with this application. 26. Rear axle ratio(s)________________________________________
How are torque converter or auxiliary heat loads cooled? ________ 27. Overall gear reduction____________________________________
______________________________________________________ 28. Single or tandem drive axle ______________________________
______________________________________________________ 29. Tire size ______________________________________________
18. Radiator sized to _____________ btu full load cooling requirements. 30. Maximum GCW or GVW __________________________________
19. Angle of engine installation ________________________________ 31. Average GCW or GVW __________________________________
20. Percentage of time engine is operating at full load: ____________ 32. Top geared speed ______________________________ (mph/kph)
21. Percentage of time engine is idling to total daily operating time 33. Normal top speed when fully loaded ________________ (mph/kph)
______________________________________________________ empty ________________ (mph/kph)
22. Expected maximum altitude of operation ____________________ 34. Anticipated miles (km) per day ____________________________
feet (meters) Per year ______________________________________________
23. Expected maximum ambient air temperature for this application 35. Air conditioning make ____________________________________
______________ °F (°C) Model ____________ HP required __________________________
36. Power steering make _________________ Model ____________
HP required ________________
Printed in U.S.A.
FORM NO. 40-083187-02 (05.00)
127
If this application is currently being performed by another make gasoline or diesel engine, provide the following information, if possible. Engine make ____________
model _______________ gas _______________ diesel _______________ hp _______________ rpm ____________________________________fuel consumption
rate _______________ mpg (Km/Liter) or gallons (liters) per hour _______________. Typical top engine overhaul miles/Km/hours __________________________.
Other appropriate operation information ____________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________
Preliminary approval for a Pilot Model installation engine is requested for the application described. Final approval for multiple production of identical units will be based on
an acceptable Pilot Model Installation Audit (Form 40-681-83188).
This information is correct to the best of my knowledge. Caterpillar approves/disapproves this application as described.
Remarks: __________________________________________________
__________________________________________________________ __________________________________________________________
Company Name __________________________________________________________
__________________________________________________________
__________________________________________________________ __________________________________________________________
Individual’s Name __________________________________________________________
__________________________________________________________
__________________________________________________________ __________________________________________________________
Title
__________________________________________________________
__________________________________________________________ Signed
Telephone ________________________________________________
___________________________________________ ____________
Title Date
128
CATERPILLAR ENGINE INSTALLATION INFORMATION INDUSTRIAL AND TRUCK ENGINES
Installation
Audit No. ____________
Equipment Mfgr. ________________________________________ Address ________________________________________________________________
Cat Dealer ______________________________________________ Location ________________________________________________________________
Cat Dealer Contact ____________________________________________ Position _____________________________________ Phone ________________
Rating: __________ kW, __________ Volts, __________ Hz, __________ Phase, Wired: □Y □
Generator Manufacturer ______________________________________________ □ Single Bearing □ Two Bearing
Voltage Regulator Manufacturer ________________________________________ □ Volts/Hz □ Constant Voltage
Series Boost: □ Yes □ No
Remarks:
2 Mounting System
129
4 Exhaust System
5 Cooling System
Refer to Engine Data Sheets 50.5 for test instructions. Engine failure may result from inadequate cooling system design or installation. The CAT specified cooling
system test should be run on a pilot model machine to find and correct deficiencies before production. Cooling Test Results Must Be Attached to this report,
Unless System is Supplied By CAT.
Part 1:
1. System Type is: □ Radiator, □ Heat Exch., □ Cooling Tower, □ Other______________________________________
2. Shutters: □ Yes □ No Mfgr. _______________ Model _______________ Open at _______________ °F (_______________ °C)
3. JW Coolant Out Temp Stabilizes at _______________ °F (_______________ °C) After 20 minutes of most severe expected load cycle
Operation (full load in most cases) with _______________ °F (_______________ °C) ambient air.
4. Is JW Heater Used? □ Yes □ No
Where connected to Engine? ________________________________________________ From Engine? ____________________________________
5. Are Auxiliary Cooler Cores, or Devices Which Restrict Air Flow Used in Front or Behind Radiator? ____________________________________________
____________________________________________________________________________________________________________________________
6. List cooling system components supplied by CAT with group numbers ____________________________________________________________________
____________________________________________________________________________________________________________________________
Part II (not Required with Cat Supplied Cooling Package)
7. Is this a Shunt-Type System? □ Yes □ No. Is Auxiliary Expansion Tank Used? □ Yes □ No.
8. Capacity __________ Qt. (__________ Liter). Shunt Line I.D.? __________ in (__________ mm).
9. Does Shunt Line slope continuously downward from radiator to engine? □ Yes □ No.
10. Radiator Supplied* _____________________________ Part Number _____________________________ Model ________________________________
11. □ Vertical Flow □ Cross Flow Fins per inch __________ Tube Rows __________ Core Size _____________ 2 ______________
12. Fan Dia. __________ in (__________ mm) Number of Blades __________, □ Suction □ Blower
13. Fan Mfgr. _____________________________ Part No. _____________________________ Fan Drive Ratio _______________ 2 1.0 Engine
14. Fan Speed at engine rated speed __________ rpm Fan CL to Crank CL __________ in (__________ mm)
15. Drive Pulley Diameter? __________ in; Driven Pulley Diameter?__________ in.
16. Is Fan nearly centered in Radiator Core? □ Yes □ No. Position? __________________________________________________________
17. Fan to Core, clearance is __________ in (__________ mm). Fan to Shroud distance is __________ in (__________ mm).
18. Fan position within Shroud: (Recommend 2/3 of Fan Projection Upstream).
19. Describe position. ____________________________________________________________________________________________________________
20. Pressure Cap used? □ Yes □ No Setting __________ PSI (__________kPa)
21. □ Yes □ No System Meets Filling Requirements?
22. □ Yes □ No System Meets Cavitation Requirement, As Tested.
23. □ Yes □ No System Meets Drawdown Requirement, As Tested.
24. □ Yes □ No System Meets Venting Requirement, As Tested.
25. □ Yes □ No Cooling System Test Results are Attached (Not Required for Cat Supplied System).
*Radiator Drawing Must be Submitted for Review, Unless Sent Earlier with Application Approval.
Remarks:
6 Lube System
1. Oil Pan Sump: □ Front □ Center □ Rear. Dipstick Shows Full at ____________________________________________ Quarts.
2. Engine Oil Filter is: □ Engine Mounted □ Remote Mounted.
3. Tilt Requirement: Front Up __________; Front Down __________; Tilt Right __________; Tilt Left __________.
4. Is Auxiliary Filter Used? □ Yes □ No Mfgr. __________ Model __________.
Remarks:
130
7 Fuel System, Governing, Engine Control
1. Fuel Tank Capacity __________ gal (__________ liter) Number of Tanks? __________
2. Fuel Supply Line I.D. _________ in (__________ mm)
3. Fuel Return Line I.D. _________ in (__________ mm)
4. Is Water Separator Used? □ Yes □ No Manufacturer ____________________ Model ____________________
5. Does Tank Have Drain? □ Yes □ No Vent? □ Yes □ No
6. Governor Type? ________________________________________ Control Device: □ Cable, □ Linkage, or □ Actuator,
Powered by __________________________________________.
7. Does Machine Operate As Intended? □ Yes □ No If Not, Why Not?________________________________________________________
____________________________________________________________________________________________________________________________
□ Yes
8. Are Controls Adjustable for Field Maintenance? □ No
Remarks:
10 Serviceability Checklist
131
11 Photos Required
Photos Attached? Photos Required Showing:
□ Yes □ No 1. Main and Auxiliary Driven Equipment.
□ Yes □ No 2. Front and Rear Supports for Engine and Driven Equipment.
□ Yes □ No 3. Air Intake Ducting, Support, and Connection to Engine.
□ Yes □ No 4. Exhaust System, Support, and Connection to Engine.
□ Yes □ No 5. Radiator, Fan, Shroud & Coolant Lines (Not Required On Caterpillar Supplied System).
□ Yes □ No 6. Remote Oil Filter Mounting & Lines, If Applicable.
□ Yes □ No 7. Governor Control Device Including Actuator, If Any.
□ Yes □ No 8. Overall Views (LH and RH) of Engine Installation.
Note: 1. Attach Cooling System Test Results (Not Required with Cat Cooling System).
2. Attach Radiator Drawing (Not Required with Cat Cooling System).
3. Attach Photos.
4. Use Additional Sheets, If Necessary.
Approvals
Upon Factory Acceptance of This Pilot Model Engine Installation Audit, Supplier Will Receive a Copy of This Form with Installation Approval Reference Number.
40-682-83188-02
132
START-UP CHECKLIST
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Power Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Mounting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Fuel System, Governing, and Engine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Starting and Charging Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Monitoring Systems and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Bolt, Nut, and Taperlock Stud Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Electrical Audit Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Power Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Mounting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Jacket Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Fuel, Governing, & Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Starting & Charging Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Monitoring System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Electrical For Electronic Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Photographs Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
133
START-UP CHECKLIST
The purpose of this section is to provide a Are engine mounts tightly fastened?
quick reference checklist of items to be
reviewed before engine start-up. This list is AIR INTAKE SYSTEM
not necessarily complete for all types of
installations but should be considered a Are air cleaner and air piping in place and
minimum list of the most basic items for tightly connected?
most installations.
Is shipping covering removed from air
Each engine is fully tested at the factory, prior cleaner element?
to painting. But damage during shipping and
storage, incomplete installation, or deficien- Are shipping caps and tape removed so air
cies in the installation can prevent the engine inlet is unrestricted?
from starting or running right. A thorough
start-up checkout is recommended.
EXHAUST SYSTEM
The following checklist is arranged by sys-
tem in the same sequence as on the Check fastening of exhaust piping and
Installation Audit form and throughout this muffler.
Application and Installation Guide.
Are hoses or wires touching exhaust system?
Reroute and clip in place, if necessary.
POWER TRANSMISSION SYSTEM
Will exhaust gas be discharged to a safe
Are driveline elements all assembled, place?
tightened, and ready to run?
Are exhaust parts safely away from con-
Are driveline devices filled with oil, if required? tact with operator?
Are hydraulic circuits connected?
COOLING SYSTEM
Can load be disengaged for start-up?
Are hoses and pipes properly fastened?
Are rotating parts safely guarded?
If unit has a shunt system, does shunt line
If electrical power generation is involved, is slope continuously downward, without
engine-generator frame properly ground- loops or traps?
ed? (WARNING: IF UNIT IS ELECTRI-
CALLY INSULATED FROM GROUND, AS Is system filled with coolant?
COULD HAPPEN ON SOFT RUBBER
MOUNTS, AN INTERNAL SHORT-CIR- Check fan belts for correct tension.
CUIT TO GROUND COULD IMPOSE A
DANGEROUS HIGH VOLTAGE ON ENTIRE Will fan clear the shroud and guards safely?
MACHINE, CREATING A SERIOUS HAZ-
ARD FOR THE OPERATOR.) Are fan and drive safely guarded as
installed in the final installation?
Are generator leads connected?
LUBE SYSTEM
Are phases correctly connected?
Check engine oil level, using marking for
stopped engine.
134
FUEL SYSTEM, GOVERNING, MISCELLANEOUS
AND ENGINE CONTROL
Remove shipping covers and tape. Remove
Is fuel in tank? loose tools used during setup.
Are supply and return lines connected and Immediately after engine has been started,
routed safely? (They must not come in con- several other operating checks should be
tact with moving or hot parts.) made.
Is fuel system bled of air? (Use priming pump Check oil pressure and dipstick, if calibrat-
to allow air to escape by slightly loosening ed for checking while engine is running. Oil
each injection line while fuel is pressurized.) should be at “running” full mark.
Is there a reliable way to shut the engine Note any unusual vibrations or noise when
down, when necessary? accelerating slowly to high idle.
135
are used. Tighten Caterpillar-supplied bolts are used, chart shows how to identi-
bolts to the values given in the table of bolt, fy their grade. (See Figure 55.)
nut, and stud torques Figure 54. If other
BOLT, NUT AND TAPERLOCK STUD TORQUE
The torque values in the following tables apply to SAE
Grade 5 and higher grade bolts, nuts and taperlock studs
unless otherwise indicated in the Specifications.
GENERAL TIGHTENING TORQUE
Figure 54
General tightening torque. Caterpillar supplied bolts, nuts, and studs.
Figure 55
136
Caterpillar Electronic Engine Electrical Audit Checklist
137
Application/Engines: Industrial — S/N Prefixes:
7PR — UP .....3408E 4CR1 — UP .....3412E
138
Customer/System Parameters
OEM:________________________ Date: __________ Eng: __________ Eng S/N: __________
Application: ________________________________________________________________________
139
Date Of Audit: ________________________ Installation Audit No. __________________________
Equipment/Type: ________________________________________________________________________________________________________________
Application: ____________________________________________________________________________________________________________________
Engine Model: ________________________ S/N: ________________________ Core Arr: ________________________ PA/PL: __________________
Rating: ______________ Bhp/Bkw Speed: ______________ rpm Hi Idle: ______________ rpm Lo Idle: ______________ rpm
2. Flywheel Housing is SAE #:________ □ Dry □ Wet Adapter from SAE#: ____ to ____ P/N: __________________________
Item: ______________________ Max. HP: ________________________ Driven By: __________________ At: ______________X Engine Speed
Item: ______________________ Max. HP: ________________________ Driven By: __________________ At: ______________X Engine Speed
Item: ______________________ Max. HP: ________________________ Driven By: __________________ At: ______________X Engine Speed
Item: ______________________ Max. HP: ________________________ Driven By: __________________ At: ______________X Engine Speed
□ Yes □ No Flywheel thrust load within limits? Clutch Pulley Diameter: ____________________________________ mm
□ Yes □ No Flywheel side load with limits? Distance from Centerline of Side Load to
□ Yes □ No Auxiliary drives within torque limits? Clutch Output Shaft Shoulder: ______________________________ mm
5. If Equipment Mobile:
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
2 — MOUNTING SYSTEM
2. Rear: □ F/W Hsg □ F/W Hsg + Transmission Cradle □ Transmission □ Solid □ Resilient
3. Static Bending Moment @ Rear Face of Flywheel Housing: __________ N•M Within limits? □ Yes □ No
4. Overhung transmission/other equipment externally supported other than F/W housing? □ Yes □ No
5. Installed Tilt Angle Relative to Machine: __________deg. Front: □ Down □ Up Left Side: □ Down □ Up
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
140
3 — AIR INTAKE SYSTEM
3. Line Air Cleaner to Turbo/Manifold: Dia: _______ mm Ln: _______ mm Mtr’l:______________________ Beaded Connect? □ Yes □ No
4. Restriction Gauge Used: □ Yes □ No Location: ______________ Setting: ______________ Res. @Full Load: ______________
5. Line Turbo Comp to CAC: Dia: _______ mm Ln: _______ mm Mtr’l:____________________ Beaded Connections:? □ Yes □ No
6. Line CAC to Inlet Manifold: Dia: _______ mm Ln: _______ mm Mtr’l:____________________ Beaded Connections:? □ Yes □ No
7. Is pressure drop between turbo comp outlet and intake manifold less than 13.5 kPa @ rated? □ Yes □ No
8. At Rated, Max Design Intake Manifold Temp @ 25°C Ambient Temp = ____________________ °C (spec. value)
9. Corrected Intake Manifold Air Temp @ rated = __________ °C (test) Corrected value <= to spec. value? □ Yes □ No
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
4 — EXHAUST SYSTEM
2. Line Turbo to Muffler: Dia: _______ mm Ln: _______ mm Number of Elbows: ____________________________________________
3. Est Weight/Torque @ Engine Interface: ____________________________ Exh Back Pressure Measured Near Turbo @ Rated: __________________
5. Is adequate rain protection provided? □ Yes □ No Type of Rain Protection: □ Cap □ Bend □ Drain □ Shield
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
Refer to EDS 50.5 for specific instructions. Cooling test results must be attached to this report.
3. Jacket Water Heater Used? □ Yes □ No________________ Type: ______________________________ I/O Eng Location: ______________
4. Fan: Dia: _______ mm No. of Blades: __________________ □ Sucker □ Blower rpm/Dr. Ratio @ Rated: ________________
Part No.: ____________ Blade Pitch Angle: ____________deg Blade Tip to Shroud Clearance: __________mm
Fan Posit. Relative to Shroud (2/3 upstream recommended):________________________________________ Fan LE to Core Clearance: ________mm
5. Coolant Flow @ Rated: __________ L/min System Capacity (brim full): __________ liters Max Heat Rej to JW: __________________________kW
6. Describe and aux. Coolers “stacked” over the radiator and cooling air flow considerations:
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
141
6 — LUBE SYSTEM
1. Oil Pan Sump: □ Front □ Center □ Rear Dipstick: Full at _____________ Liters
4. Oil Filter: □ Left □ Right □ On Engine □ Remote: If Remote, Line Ln: ____________ mm
5. Auxiliary Filter: □ Yes □ No □ Left □ Right: Mfg: _____________ Add Oil Capacity: ________________Liters
6. OEM Required Continuous Tilt Operation: _______ deg Front: □ Up □ Dwn ________deg Left Side: □ Up □ Dwn
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
1. Fuel Tank Volume: _____ Liters _____ No. of Fuel Tanks: Vented Cap: □ Yes □ No Drain: □ Yes □ No
2. Location of Eng. Supply Tank Inlet: ____________________________ Location of Eng. Return Tank Outlet: __________________________________
3. Water separator used? □ Yes □ No Secondary Filter: Make: __________ Part No.: __________ Micron: __________
4. Eng. Supply Line ID: _______________ mm Eng. Return Line ID: __________ mm Fuel Cooler Installed: □ Yes □ No
5. Stabilized Fuel Temp to Eng. at Rated = _____ °C Supply Line Press Rest: ________ kPa Return Line Press Rest: __________kPa
7. Eng Spd Control: □ Cable □ Linkage □ Actuator □ TPS □ Pneumatic □ Hydraulic □ Motor □ Switch
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
1. Starter: □ Electric □ Volts: ____ Solenoid: □ UP □ Down □ Pneumatic Press:_____ kPa □ Hydraulic
2. Alternator: Make: __________________ Volts: __________________ Amps: __________________ Drive Ratio: ______________: 1
3. Battery: No.:______________________ Volts: __________________ CCA: __________________ Amp Hr. Cap @ 20 hrs: ______
6. Starting Aids:
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
142
9 — MONITORING SYSTEM
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
3. Describe Battery Neg Patch and Wire Size from Gnd Stud on J3/P3 Mounting Bracket to Battery Negative Bus: __________________________________
____________________________________________________________________________________________________________________________
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
11 — SERVICEABILITY
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
143
12 — PHOTOGRAPHS REQUIRED
__________________________________________________________________________________________________________________________
4. Maximum Expected Engine Tilt Angle During Operation: ____________deg What Orientation? __________________________________________
6. OEM Desired Time to Overhaul: ______________________________Hours Is this the “first” life of the machine? □ Yes □ No
7. If a repower/redesign, what engine was replaced? ____________________ bkW: _______________________ Rpm: ______________________
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
NOTE:
The engine installer must assure a safe installation in which moving or hot components are guarded or warning placards in place to avoid risk of personal
injury. This must include consideration of fuel, oil, water, air and electrical line routing to avoid pinch points, sharp edges, climbing step, and grab points.
NOTE:
Remarks: __________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
ACKNOWLEDGEMENTS:
OEM CATERPILLAR
144
MAINTENANCE AND RECORDS
Page
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Filter Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Fluid Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
145
MAINTENANCE AND RECORDS
146
Component Replacement 3. Successful experience can also
be identified from these records,
In some situations owners have found to provide a basis for future busi-
that unscheduled downtime is so ness decisions.
inconvenient and costly that it is better
economy to replace certain items, 4. Preventive maintenance prac-
which typically wear out after a some- tices can likely be modified to be
what predictable service period, before more economical based on
they fail. Factory Service Department recorded experience.
recommendations aided by user expe-
rience with a particular model, applica- In summary, there are numerous
tion, and job environment should be the examples to show that engine life
guide to timely component replacement before major overhaul may be
on a preventive maintenance (PM) basis. increased by 200% to 400%, and
more — be adhering to sound main-
B. RECORDS tenance practices. Good mainte-
nance practices will result in lower
An accurate, complete log of all main- overall cost of ownership, operation,
tenance and repair activities, by engine and increased machine availability.
serial number and date, should be
kept. This should include complete
information on amount of coolant and
lube oil added, adjustments made, and
parts replaced.
147
148
CONVERSION TABLES AND RULES OF THUMB
Page
English to Metric Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Area Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Volume and Capacity Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Length Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Temperature Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Units of Pressure and Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Units of Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Miscellaneous Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Brake Mean Effective Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Barometric Pressures and Boiling Points of Water at Various Altitudes. . . . . . . . . . . . . . . . . . . 153
Geometric Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Mathematical Expressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Heat Rejection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Gas Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Electricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Electric Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
On Site Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Air Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Oil Field Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Sawmill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Torque Converters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Velocity Versus Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Pipe Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Typical Friction Losses of Water in Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
149
CONVERSION TABLES AND RULES OF THUMB
AREA EQUIVALENTS
150
VOLUME AND CAPACITY EQUIVALENTS
LENGTH EQUIVALENTS
UNIT cm in ft yd m km mile
cm 1 0.3937 0.032 81 0.010 94 0.01 0.000 01 —
in 2.54 1 0.083 33 0.027 78 0.0254 0.000 03 —
ft 30.48 12 1 0.333 33 0.3048 0.000 30 —
yd 91.44 36 3 1 0.9144 0.000 91 —
m 100 39.3701 3.280 84 1.093 61 1 0.001 0.000 62
km 100 000 39 370.1 3280.84 1093.61 1000 1 0.621 37
mile 160 934 63 360 5280 1760 1609.34 1.609 34 1
151
UNITS OF PRESSURE AND HEAD
mm Hg in Hg in H2O ft H2O
UNIT (0° C) (0° C) (39° F) (39° F)
mm Hg 1 0.039 37 0.535 25 0.0446
in Hg 25.4 1 13.5954 1.132 96
in H2O 1.868 27 0.073 55 1 0.083 33
ft H2O 22.4193 0.882 65 12 1
psi 51.7151 2.036 03 27.6807 2.306 73
kg/cm2 735.561 28.9591 393.712 32.8094
bar 750.064 29.5301 401.474 33.4562
atm 760 29.9213 406.794 33.8995
kPa 7.500 64 0.295 30 4.014 74 0.334 56
UNITS OF FLOW
Cubic foot per second, also written second-foot, is the unit of flow in the English system used to express rate of flow in large pumps,
ditches, and canals. Flow in pipe lines, from pumps and wells is commonly measured in gallons per minute.
Rates of water consumption and measurement of municipal water supply are ordinarily made in million gallons per day. The Miner’s
Inch is still used in some localities for irrigation and hydraulic mining, but is not suitable for general use.
152
UNITS OF POWER
MISCELLANEOUS EQUIVALENTS
150.8 2 Torque
BMEP psi = _____________
Displacement
BAROMETRIC PRESSURE
153
GEOMETRIC FORMULAS HEAT REJECTION:
Jacket Water
Turbocharged Engines
Btu/min = 42 2 BHP
Naturally-Aspirated, Roots Blown and Spark-lgnited
Engines
Circumference: Circle 2πr Btu/min = 45 2 BHP
Area: Circle πr2 Oil Cooler Btu/min = 5 2 BHP
Ellipse πab Watercooled Manifold Btu/min = 7 2 BHP
Sphere 4πr2 Torque Converter Btu/min = 42.4 2 BHP input 2
(100 — conv. eff.)
Cylinder 2πr (r + l)
100
Triangle 1
/2 ab
Volume: Ellipsoid of revolution 4/3πb2a
Laws of Exponents Laws of Logarithms
Sphere 4/3πr3
Cylinder πr2l 1 x
ax 2 ay = ax – y –x
In (y ) = 2 In y
Cone πb2a ax = a
ax 2 ay = ax — y
12
ax
2
x__ 2
+ y__ (ab)x = ax 2 bx ay = ax – y In (ab) = In a + In b
Analytical: Circle + =1
r2 + r2
Ellipse
2
x__
+
2
+ y__
=1 (ax)y = axy a° = 1 In ( ab ) = In a – In b
a + b2
2
2 2
x__ + y__
Hyperbola + =1
a2 + b2
FUEL CONSUMPTION — BHP:
Parabola y2 = ± 2px
Line y = mx + b
BHP = GPH fuel 2 15 Diesel 1/15 gal. per
BHP-h
MATHEMATICAL EXPRESSIONS BHP = GPH fuel 2 9.5 Gasoline 1/10 gal. per
Trigonmetric Relations BHP-h
BHP = cu ft/h fuel 2 1/8 Natural Gas* 7 to 8
y
sin O = __ cu ft/BHP-h
r
kW = GPH fuel 2 10 Diesel 1/10
gal/kW-h
x *100 Btu gas.
cos O = __
r
y GAS COMPRESSOR:
tan O = __
x
BHP = 22 RcVS
Sin2 O + cos2 O = 1 Where: Rc = Stage Compression Ratio
V = Million cu ft/day
S = Number of Stages
Law of Cosines
a2 + b2 – 2ab cos O = c2
154
COOLING: CONVEYORS: 15 to 20° Incline.
Heat Exchanger Flow Rate Vertical lift in feet 2 tons per hour
BHP = ____________________________
Raw water to jacket water 1:1 to 2:1 500
Submerged Pipe Cooling
1
/2 sq. ft. surface area per HP PUMPS:
With 85° F flowing water
Feet of lift per 1000 GPM
Deep Well BHP = ______________________
ELECTRICITY: 3
Generator Capacity Required Pipe Line BHP = Barrels per hour 2 psi 2 0.00053
Motors:
1 kW per nameplate hp (motor running cool or warm GPM 2 lb/gal (Liquid) 2 feet of head
to touch) Any Liquid BHP = ______________________________
33,000 2 pump efficiency*
11/4 kW per nameplate hp (motor running hot to touch)
Horsepower Requirements *Efficiency: Centrigugal
kW
11/2 BHP per kW of load or ________________ Single impeller, double suction 65-80%
0.746 2 Gen. Eff. Single impeller, side suction 55-75%
65-80%
ELECTRIC SETS: Deep well turbine 75%
Reciprocating
Motor Starting Requirements
Inrush kV•A (Code F motor) = 5.5 2 BHP
OIL FIELD DRILLING:
Inrush Current (Code F motor) = 6.2 2 Full load rated
current Hoisting
1 kV•A per HP at full load Weight 2 FPM (assume 100 is unknown)
BHP = ____________________________________
Generator full load rated current capacity 33,000 2 0.85 (eff.)
Voltage Rated Current
120 6.01 2 kW Mud Pumps
GPM 2 lb/gal 2 (feet of head)
208 3.47 2 kW BHP = ____________________________________
240 3.01 2 kW 33,000 2 pump efficiency (see pumps)
480 1.50 2 kW
2400 0.30 2 kW Dry Table
4160 0.17 2 kW Depth in Feet BHP Required
Generator Cooling Requirements 12000 - 4000 75
Air Flow = 20 CFM per kW 4000 - 8000 100
Circuit Breaker Trip Selection 8000 - 12000 150
1.15 to 1.25 2 full load generator amp rating 12000 - 16000 200
Single Phase Rating of 3-Phase Generator
60% of 3-phase rating SAWMILL:
Generator Temperature Rise 11/2 BHP per inch of saw diameter at 500 RPM
Increase 1° C for each 330 feet above 3300 feet Increase or decrease in proportion to RPM
Swing Cut-Off Saw
ON SITE POWER REQUIREMENTS: 24-inch 3 BHP
Based on 100,000 sq. ft. of office bldg., etc., and 40° N. 36-inch 71/2 BHP
latitudes 42-inch 10 BHP
Electric Requirements: Table Trimmer 71/2 to 10 BHP
600 kW continuous load Blower Fan, 12-foot sawdust 3 to 5 BHP
(Air conditioning is absorption) Planer Mill 2 to 4 BHP per 100 board feet per hour
Use three – 300 kW units 24 to 30-inch planers 15 to 25 BHP
(2 prime and 1 standby) Edgers
Air Conditioning Compressor: 2 saws 12 to 15 BHP
400 tons prime load 3 saws 15 to 25 BHP
Use two – 200 hp engines Slab Saw 10 BHP
(No standby) Jack Ladder 10 BHP
Approximate fuel consumption
REFRIGERATION: Softwood 1 gal. per 1000 board feet
Hardwood 1 gal. per 750 board feet
One ton refrigeration = 200 Btu/min = 12,000 Btu/h
One boiler HP = 33,475 Btu/h
TORQUE CONVERTERS:
One ton compressor rating = One Engine hp
Auxiliary air conditioning equipment requires Peak output shaft horsepower:
1
/4 hp per ton of compressor rating Normally 80% of input horsepower for either single
Ice Plant: or three-stage converter.
Complete power requires 4-5 hp per daily ton capacity Output shaft speed at peak output horsepower:
Single-stage — 0.7 to 0.85 engine full load speed
AIR COMPRESSORS: Three-stage — 0.5 to 0.6 engine full load speed
Torque multiplication at or near stall:
hp = 1/4 2 cu ft per minute at 100 psi Single-stage — 2.2 to 3.4 times engine torque
Increase BHP 10% for 125 psi Three-stage — 3.6 to 5.4 times engine torque
Decrease BHP 10% for 80 psi
155
156
PIPE DIMENSIONS
Standard Iron Pipe
157
TYPICAL FRICTION LOSSES OF WATER IN PIPE
(OLD PIPE)
gpm (l/s) 3/4" (19.05 mm) 1" (25.4 mm) 1-1/4" 31.75 mm) 1-1/2" (38.1 mm) 2" (50.8 mm) 2-1/2" (63.5 mm) gpm (l/s)
5 .34 10.5 3.25 0.84 0.40 0.16 0.05 3" (76.2 mm) 5 .34
10 .63 38.0 11.7 3.05 1.43 0.50 0.17 0.07 10 .63
15 .95 80.0 25.0 6.50 3.05 1.07 0.37 0.15 15 .95
20 1.26 136.0 42.0 11.1 5.20 1.82 0.61 0.25 20 1.26
25 1.58 4" (101.6 mm) 64.0 16.6 7.85 2.73 0.92 0.38 25 1.58
30 1.9 0.13 89.0 23.0 11.0 3.84 1.29 0.54 30 1.9
35 2.21 0.17 119.0 31.2 14.7 5.10 1.72 0.71 35 2.21
40 2.52 0.22 152.0 40.0 18.8 6.60 2.20 0.91 40 2.52
45 2.84 0.28 5" (127 mm) 50.0 23.2 8.20 2.76 1.16 45 2.84
50 3.15 0.34 0.11 60.0 28.4 9.90 3.32 1.38 50 3.15
60 3.79 0.47 0.16 85.0 39.6 13.9 4.65 1.92 60 3.79
70 4.42 0.63 0.21 113.0 53.0 18.4 6.20 2.57 70 4.42
75 4.73 0.72 0.24 129.0 60.0 20.9 7.05 2.93 75 4.73
80 5.05 0.81 0.27 145.0 68.0 23.7 7.90 3.28 80 5.05
90 5.68 1.00 0.34 6" (152.4 mm) 84.0 29.4 9.80 4.08 90 5.68
100 6.31 1.22 0.41 0.17 102.0 35.8 12.0 4.96 100 6.31
125 7.89 1.85 0.63 0.26 7" (177.8 mm) 54.0 17.6 7.55 125 7.89
150 9.46 2.60 0.87 0.36 0.17 76.0 25.7 10.5 150 9.46
175 11.05 3.44 1.16 0.48 0.22 8" (203.2 mm) 34.0 14.1 175 11.05
200 12.62 4.40 1.48 0.61 0.28 0.15 43.1 17.8 200 12.62
225 14.20 5.45 1.85 0.77 0.35 0.19 54.3 22.3 225 14.20
250 15.77 6.70 2.25 0.94 0.43 0.24 65.5 27.1 250 15.77
275 17.35 7.95 2.70 1.10 0.51 0.27 9" (228.6 mm) 32.3 275 17.35
300 18.93 9.30 3.14 1.30 0.60 0.32 0.18 38.0 300 18.93
325 20.5 10.8 3.65 1.51 0.68 0.37 0.21 44.1 325 20.5
350 22.08 12.4 4.19 1.70 0.77 0.43 0.24 50.5 350 22.08
375 23.66 14.2 4.80 1.95 0.89 0.48 0.28 10" 254 mm) 375 23.66
400 25.24 16.0 5.40 2.20 1.01 0.55 0.31 0.19 400 25.24
425 26.81 17.9 6.10 2.47 1.14 0.61 0.35 0.21 425 26.81
450 28.39 19.8 6.70 2.74 1.26 0.68 0.38 0.23 450 28.39
475 29.97 7.40 2.82 1.46 0.75 0.42 0.26 475 29.97
500 31.55 8.10 2.90 1.54 0.82 0.46 0.28 500 31.55
750 47.32 7.09 3.23 1.76 0.98 0.59 750 47.32
1000 63.09 12.0 5.59 2.97 1.67 1.23 1000 63.09
1250 78.86 8.39 4.48 2.55 1.51 1250 78.86
1500 94.64 11.7 6.24 3.52 2.13 1500 94.64
1750 110.41 7.45 4.70 2.80 1750 110.41
2000 126.18 10.71 6.02 3.59 2000 126.18
Size of Fiting 2" 2-1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16"
90 Ell 5.5 6.5 8. 11. 14. 16. 21. 26. 32. 37 42
46 Ell 2.5 3. 3.8 5. 6.3 7.5 10. 13. 15. 17 19
Long Sweep Ell 3.5 4.2 5.2 7. 9. 11. 14. 17. 20. 24 27
Close Return Bend 13. 15. 18. 24. 31. 37. 51. 61. 74. 85 100
Tee — Straight Run 3.5 4.2 5.2 7. 9. 11. 14. 17. 20. 24 27
Tee — Side Inlet or Outlet 12. 14. 17. 22. 27. 33. 43. 53. 68. 78 88
Globe Valve Open 55. 67. 82. 110. 140.
Angle Valve Open 27. 33. 41. 53. 70.
Gate Valve Fully Open 1.2 1.4 1.7 2.3 2.9 3.5 4.5 5.8 6.8 8 9
Gate Valve Half Open 27. 33. 41. 53. 70. 100. 130. 160. 200. 230 260
Check Valve 19. 23. 32. 43. 53.
158
LEBH0504 © 2000 Caterpillar Inc. Printed in the U.S.A.