Alarm and Protection Field Test Procedure for Certain Marine Engines {0374, 0599, 0706, 0708, 0709, 0769, 0781, 1000, 1408, 1439} Caterpillar

Electric Power Generation

C18 MAR GENSET (S/N: SSM1-UP; SSW1-UP)

C4.4 GEN SET (S/N: NRP1-UP)

Engine

3508C (S/N: PXA1-UP; TTA1-UP; PXB1-UP; TTB1-UP; TTM1-UP; TTP1-UP)

3512B (S/N: ED21-UP; SRH1-UP)

3512C (S/N: BG21-UP; BM21-UP; DE21-UP; MB21-UP; RL21-UP; SB21-UP; 2A21-UP; MB31-UP; TT41-UP; TT51-UP; DPB1-UP; DPC1-UP; PXC1-UP; TTC1-UP; PXE1-UP; TTE1-UP; PXF1-UP; TTF1-UP; PXG1-UP; TTG1-UP; EWJ1-UP; SLM1-UP; MXN1-UP; MXP1-UP; T3P1-UP; TKP1-UP; T3R1-UP; T3S1-UP; E3W1-UP; MNW1-UP; PXW1-UP; T3W1-UP; TTW1-UP; E3X1-UP; PXX1-UP; TTX1-UP; E3Y1-UP; T3Y1-UP)

3512E (S/N: MR21-UP; MD31-UP; MR31-UP; MR41-UP; MR71-UP; MR81-UP)

3516C (S/N: BS21-UP; ML21-UP; BG31-UP; ML31-UP; FT61-UP; TT61-UP; TT71-UP; DPD1-UP; PXD1-UP; TTD1-UP; PXH1-UP; TTH1-UP; PXJ1-UP; TTJ1-UP; TKR1-UP; JTS1-UP; TKS1-UP; MXT1-UP; TKT1-UP; FLW1-UP; TKX1-UP; TKY1-UP; TTY1-UP; E3Z1-UP; PXZ1-UP; TTZ1-UP)

3516E (S/N: MD51-UP; MR91-UP; MRC1-UP; MRN1-UP; MRY1-UP)

3606 (S/N: 8RB1-UP)

3608 (S/N: 6MC1-UP)

3612 (S/N: 9RC1-UP)

3616 (S/N: 1PD1-UP)

C175-16 (S/N: M6A1-UP; M6B1-UP)

C18 (S/N: TNA1-UP; GTB1-UP; T2R1-UP; GEX1-UP)

C280-08 (S/N: J4R1-UP)

C280-16 (S/N: NKB1-UP; A4F1-UP; S4M1-UP; TDX1-UP)

Industrial Engine

C9.3 (S/N: C931-UP; CA91-UP; CP91-UP)

Marine Engine

C18 MARINE (S/N: JHL1-UP; DTP1-UP)

C280-12 (S/N: TSJ1-UP; RML1-UP; RDW1-UP)

C280-6 (S/N: SCB1-UP; LDL1-UP)

C280-8 (S/N: PKA1-UP; NDT1-UP)

C32 MARINE (S/N: RSD1-UP; SDN1-UP)

C32 MARINE GS (S/N: DSJ1-UP; RTK1-UP)

C7.1 MARINE (S/N: JME1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Method to demonstrate Marine Alarm and Protection System to customers and Marine Certification Society surveyors using the validation Test Kit.

Caterpillar recommends that the tests are performed while the engine runs at a low idle as most alarm and shutdown set points are only active while the engine is running. See the appropriate Operation and Maintenance Guide for default set points, alarm set points, and shutdown set points.

This document only applies to marine engines equipped with thermowells and isolation valves.

Reference Section

Reference: Tool Operating Manual, NEHS1199, Using the 453-3204 Pressure and Temperature Test Group

Reference: Caterpillar Channel 1 to show how to use this tool with Wimborne Marine Classification Society (MCS) controls.

1. Go to https://channel1.videonitch.com.

2. Sign in.

3. Search "Alarm, Protection System Testing, & Adjusting".

4. Click the "Alarm, Protection System Testing, & Adjusting" title.

Required Tools

The 453-3204 Tool Gp (Pressure and Temperature Test Group) generates pressures up to 3447 kPa (500 psi) and temperatures from ambient to 350° C (662° F).

The tool group contains the following:

• Thermo well unit (requires external power)

• Pressure hand pump (battery powered)

• Connection hose

• Adaptor fittings: 12 mm JIC Male, 14 mm JIC Male, 9/16 JIC Male, 7/16 JIC Male, 7/16 JIC Female, and 16 mm sample port

• Some tools for sensor removal

• O-rings for sensor replacement

Sensor Testing

Pressure Test Procedure

Setup

1. While the engine is off, remove the desired pressure sensor from the engine, leaving its respective check valve in place to prevent fluid from leaking.

2. Connect the test kit hose to the pressure sensor.

3. Thread the correct adaptor fitting onto the sensor. Turn the adaptor until the seal is covered and the adaptor is firmly seated.

   Note: To change the units displayed, enter Menu mode and select and scroll through UNITS until the desired units are displayed. Further gauge instructions can be found in the gauge manual included in the test kit.

Operation and Testing

Note: Caterpillar recommends running the engine at low idle while operating this test.

1. Loosen the pressure release on the pump.

2. Turn on the pressure gauge using the On/Off button.

3. Zero the gauge by pressing the Zero/Clear button.

4. Close the pressure release on the pump.

5. Press the adjustment pin to the right to generate pressure, or to the left to generate vacuum as labeled on the pump

6. Squeeze the handles of the pump until just above the desired alarm pressure, using the fine adjustment knob as necessary when in close range to the desired pressure. Rotate the adjustment knob clockwise to increase pressure and counterclockwise to decrease pressure.

7. Decrease pressure to the alarm point and verify that the alarm is present on the local display and in the engine room or control station. Increase the pressure to verify that the alarm then correctly deactivates.

8. Turn off the engine.

9. After testing, slowly open the pressure release knob to release pressure from the system. After the pressure gauge indicates zero, disconnect the hose and fittings in reverse order of connection.

10. Power off the gauge using the On/Off button.

11. Replace the sensor on the engine, using new O-rings as needed.

Temperature Test Procedure

Setup

Note: Setup while the engine is OFF.

1. The unit must have at least 6 inches of free space around it in all directions. Plug the power cord into a grounded main outlet and verify that the nominal voltage corresponds to that indicated on the back of the unit.

2. Select the probe sleeve of smallest hole size possible while allowing the probe to slide in and out easily. Check the well for any foreign objects, dirt, or grit before inserting the sleeve. Gently insert the probe sleeve into the well.

3. Power on the unit by toggling the switch at the rear of the instrument to the “I” (on) position. After a brief self-test, the controller will begin displaying the well temperature and will heat or cool until reaching the programmed set point.

Changing from 115 VAC to 230 VAC:

1. Unplug the unit.

2. Remove the fuse holder on the rear panel with a small straight slot screwdriver.

3. Replace the two 6 amp fuses with 3 amp 250 V fuses.

4. Replace the fuse holder with the 230 V in the display window.

5. Using the same screwdriver, move the heater switch to display 230 V.

   Note: If the heater switch and the fuse holder do not both read 230 V when complete, the unit either will not heat or only heat marginally.

The four keypad buttons are used to set the temperature set point, access and set other operating parameters, and access and set calibration parameters. The functions of the buttons are as follows:

• SET - Used to display the next parameter in the menu and to store parameters to the displayed value.

• DOWN - Used to decrement the displayed value of parameters.

• UP - Used to increment the displayed value.

• EXIT - Used to exit a function and to skip to the next function. Any changes made to the displayed value are ignored.

• Units are displayed in Celsius or Fahrenheit. There are two methods to change units.

• Press the SET and UP buttons simultaneously.

• Press the SET key three times from the temperature display to show Un = C. Press UP or DOWN to change units.

• The thermal insert has 6 smaller holes on one end and one large hole on the other. Verify that the correct end of the thermal insert is exposed and clear of contaminants.

• Disconnect the unit from the power supply when removing the insert. Use the insert removal tool to pull the insert straight and reinsert the opposite direction if needed.

Operation and Testing

While the engine is still off, remove the desired temperature sensor from the engine, leaving its respective thermo well in place to protect against fluid leaks.

• Press SET twice to access the set point value.

• Press UP or DOWN to change the set point value to a temperature just below the alarm set point.

• Press SET to program the new set point.

• Press EXIT to return to the temperature display.

• When the set point temperature is changed, the controller will switch the well heater on or off to raise or lower the temperature.

• The well may require 5 to 20 minutes to reach the set point and another 5 to 10 for temperature stabilization.

Note: Caterpillar recommends running the engine at low idle.

1. Insert the sensor probe into the thermal generator well to the full depth of the sensor. The probe fit should be snug.

2. Allow the temperature sensor probe to stabilize.

3. Raise the well temperature above the alarm temperature setpoint to activate the alarm.

4. Verify that the alarm is present on the local display and in the engine room or control station.

5. Reduce the temperature below alarm to verify that the alarm shuts off correctly.

   Note: When testing shutdown, reducing the temperature will have no effect and this step may be disregarded during testing.

1. With the engine off, lower the set point to below the ambient temperature and allow the unit to cool to ambient. This could take up to 15 minutes depending on test temperature.

2. Turn off and unplug the unit.

3. Remove the sensor from the well and replace the O-rings.

4. Fill thermowell cavity 50% full with 5P-8937 Joint Compound (Heat Sink Compound).

5. Install the sensor in the thermowell.

   Tighten sensor ... 20 ± 3 N·m (177 ± 27 lb in)