13/08/2016

C7IndustrialEngineJTF00001UP(SEBP443660)Documentation

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Welcome:john_lyons
Product:INDUSTRIALENGINE
Model:C7INDUSTRIALENGINEJTF19336
Configuration:C7IndustrialEngineJTF00001UP

OperationandMaintenanceManual
C7IndustrialEngine
MediaNumberSEBU808904

PublicationDate01/03/2014

DateUpdated12/03/2014

i02436705

OverhaulConsiderations
SMCS7595043

Reducedhoursofoperationatfullloadwillresultinaloweraveragepowerdemandandreducedfuel
consumption.Adecreasedaveragepowerdemandshouldincreaseboththeengineservicelifeandthe
overhaulinterval.
Theneedforanoverhaulisgenerallyindicatedbyincreasedfuelconsumption,increasedoilconsumption,
excessiveengineblowby,andreducedpower.Arctictemperatures,extremelyhightemperatures,corrosive
environments,orextremelydustyconditionscontributetoprematurewearandtheneedforanoverhaul.
Thefollowingfactorsareimportantwhenadecisionisbeingmadeonthepropertimeforanengine
overhaul:
Theneedforpreventivemaintenance
Thequalityofthefuelthatisbeingused
Theoperatingconditions
TheresultsoftheSOSanalysis

OilConsumptionasanOverhaulIndicator
Oilconsumption,fuelconsumption,andmaintenanceinformationcanbeusedtoestimatethetotaloperating
costforyourCaterpillarengine.Oilconsumptioncanalsobeusedtoestimatetherequiredcapacityofa
makeupoiltankthatissuitableforthemaintenanceintervals.
Oilconsumptionisinproportiontothepercentageoftheratedengineload.Asthepercentageoftheengine
loadisincreased,theamountofoilthatisconsumedperhouralsoincreases.
Theoilconsumptionrate(brakespecificoilconsumption)ismeasuredingramsperkW/h(lbperbhp).The
brakespecificoilconsumption(BSOC)dependsontheengineload.ConsultyourCaterpillardealerfor
assistanceindeterminingthetypicaloilconsumptionrateforyourengine.
Whenanengine'soilconsumptionhasrisentothreetimestheoriginaloilconsumptionrateduetonormal
wear,anengineoverhaulshouldbescheduled.Theremaybeacorrespondingincreaseinblowbyandaslight
increaseinfuelconsumption.

OverhaulOptions
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BeforeFailureOverhaul
Aplannedoverhaulbeforefailuremaybethebestvalueforthefollowingreasons:
Costlyunplanneddowntimecanbeavoided.
Manyoriginalpartscanbereusedaccordingtothestandardsforreusableparts.
Theengine'sservicelifecanbeextendedwithouttheriskofamajorcatastropheduetoenginefailure.
Thebestcost/valuerelationshipperhourofextendedlifecanbeattained.
AfterFailureOverhaul
Ifamajorenginefailureoccursandtheenginemustberemoved,manyoptionsareavailable.Anoverhaul
shouldbeperformediftheengineblockorthecrankshaftneedstoberepaired.
Iftheengineblockisrepairableand/orthecrankshaftisrepairable,theoverhaulcostshouldbebetween40
percentand50percentofthecostofanewenginewithasimilarexchangecore.
Thislowercostcanbeattributedtothreeaspects:
SpeciallydesignedCaterpillarenginefeatures
Caterpillardealerexchangecomponents
CaterpillarInc.remanufacturedexchangecomponents

OverhaulRecommendation
Tominimizedowntime,CaterpillarInc.recommendsascheduledengineoverhaulbyyourCaterpillardealer
beforetheenginefails.Thiswillprovideyouwiththebestcost/valuerelationship.
Note:Overhaulprogramsvaryaccordingtotheengineapplicationandaccordingtothedealerthatperforms
theoverhaul.ConsultyourCaterpillardealerforspecificinformationabouttheavailableoverhaulprograms
andaboutoverhaulservicesforextendingtheenginelife.
IfanoverhaulisperformedwithoutoverhaulservicefromyourCaterpillardealer,beawareofthefollowing
maintenancerecommendations.

RebuildorExchange
CylinderHeadAssembly,CylinderPacks,OilPump,andFuelTransferPump
ThesecomponentsshouldbeinspectedaccordingtotheinstructionsthatarefoundinvariousCaterpillar
reusabilitypublications.TheSpecialPublication,SEBF8029liststhereusabilitypublicationsthatareneeded
forinspectingtheengineparts.
Ifthepartscomplywiththeestablishedinspectionspecificationsthatareexpressedinthereusableparts
guideline,thepartsshouldbereused.
Partsthatarenotwithintheestablishedinspectionspecificationsshouldbedealtwithinoneofthefollowing
manners:
Salvaging
Repairing
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Replacing
Usingoutofspecpartscanresultinthefollowingproblems:
Unscheduleddowntime
Costlyrepairs
Damagetootherengineparts
Reducedengineefficiency
Increasedfuelconsumption
Reducedengineefficiencyandincreasedfuelconsumptiontranslatesintohigheroperatingcosts.Therefore,
CaterpillarInc.recommendsrepairingoutofspecpartsorreplacingoutofspecparts.

Inspectionand/orReplacement
CrankshaftBearings,ValveRotators,andCrankshaftSeals
Thefollowingcomponentsmaynotlastuntilthesecondoverhaul.
Thrustbearings
Mainbearings
Rodbearings
Valverotators
Crankshaftseals
CaterpillarInc.recommendstheinstallationofnewpartsateachoverhaulperiod.
Inspectthesepartswhiletheengineisdisassembledforanoverhaul.
Inspectthecrankshaftforanyofthefollowingconditions:
Deflection
Damagetothejournals
Bearingmaterialthathasseizedtothejournals
Checkthejournaltaperandtheprofileofthecrankshaftjournals.Checkthesecomponentsbyinterpreting
thewearpatternsonthefollowingcomponents:
Rodbearing
Mainbearings
Inspectthecamshaftfordamagetothejournalsandtothelobes.
Note:Ifthecamshaftisremovedforanyreason,usethemagneticparticleinspectionprocesstocheckfor
cracksinthecamshaft.
Inspectthefollowingcomponentsforsignsofwearorforsignsofscuffing:
Camshaftbearings
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Camshaftfollowers
CaterpillarInc.recommendsreplacingthecrankshaftvibrationdamper.
OilCoolerCore
Duringanoverhaul,CaterpillarInc.recommendstheremovaloftheoilcoolercore.Cleantheoilcoolercore.
Then,pressuretesttheoilcoolercore.

NOTICE
Donotusecausticcleanerstocleanthecore.
Causticcleanerscanattacktheinternalmetalsofthecoreandcause
leakage.

Note:Usethiscleaningproceduretocleantheoilcoolercore.
1.Removetheoilcoolercore.
2.Removeanydebrisfromtheoilcoolercore.Toremovedebrisfromtheoilcoolercore,turntheoil
coolercoreontooneend.
3.Flushtheoilcoolercoreinternallywithcleanerinordertoloosenforeignsubstances.Thiswillalso
helptoremoveoilfromtheoilcoolercore.
Note:CaterpillarInc.recommendstheuseofHydrosolvLiquidCleaners.Table1liststheHydrosolv
LiquidCleanersthatareavailablefromyourCaterpillardealer.
Table1
HydrosolvLiquidCleaners
PartNumber

Description

1U8812
1U5490

4L(1USgallon)
Hydrosolv4165

8T7570

8T5571

19L(5USgallon)
208L(55USgallon)

1U8804
1U5492

Size

4L(1USgallon)
Hydrosolv100

19L(5USgallon)
208L(55USgallon)

4.Usesteamtocleantheoilcoolercore.Thisremovesanyremainingresiduefromthecleaner.Flushthe
finsoftheoilcoolercore.Removeanyothertrappeddebris.
5.Washtheoilcoolercorewithhot,soapywater.Rinsetheoilcoolercorethoroughlywithcleanwater.
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Personalinjurycanresultfromairpressure.
Personalinjurycanresultwithoutfollowingproperprocedure.When
usingpressureair,wearaprotectivefaceshieldandprotectiveclothing.
Maximumairpressureatthenozzlemustbelessthan205kPa(30psi)
forcleaningpurposes.
6.Drytheoilcoolercorewithcompressedair.Directtheairinthereversedirectionofthenormalflow.
7.Inspectthecomponentsinordertoensurecleanliness.Theoilcoolercoreshouldbepressuretested.
Repairtheoilcoolercore,ifnecessary.Installtheoilcoolercore.
Formoreinformationaboutcleaningthecores,consultyourCaterpillardealer.

ObtainCoolantAnalysis
Theconcentrationofsupplementalcoolantadditive(SCA)shouldbecheckedregularlywithtestkitsorwith
SOSCoolantAnalysis(Level1).Furthercoolantanalysisisrecommendedwhentheengineisoverhauled.
Forexample,considerabledepositsarefoundinthewaterjacketareasontheexternalcoolingsystem,butthe
concentrationsofcoolantadditiveswerecarefullymaintained.Thecoolantwaterprobablycontained
mineralsthatweredepositedontheengineovertime.
Acoolantanalysiscanbeconductedinordertoverifytheconditionofthewaterthatisbeingusedinthe
coolingsystem.Afullwateranalysiscanbeobtainedbyconsultingyourlocalwaterutilitycompanyoran
agriculturalagent.Privatelaboratoriesarealsoavailableforwateranalysis.
CaterpillarInc.recommendsanSOSCoolantAnalysis(Level2).
SOSCoolantAnalysis(Level2)
AnSOSCoolantAnalysis(Level2)isacomprehensivecoolantanalysiswhichcompletelyanalyzesthe
coolantandtheeffectsonthecoolingsystem.AnSOSCoolantAnalysis(Level2)providesthefollowing
information:
CompleteSOSCoolantAnalysis(Level1)
Visualinspectionofproperties
Identificationofmetalcorrosion
Identificationofcontaminants
Identificationofbuiltupimpurities(corrosionandscale)
SOSCoolantAnalysis(Level2)providesareportoftheresultsofboththeanalysisandthemaintenance
recommendations.
Formoreinformationaboutcoolantanalysis,seeyourCaterpillardealer.
Copyright19932016CaterpillarInc.
AllRightsReserved.
PrivateNetworkForSISLicensees.

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