a. A failed water pump might cause severe engine overheating problems that could result in the following conditions:
• Cracks in the cylinder head • A piston seizure
• Other potential damage to the engine
b. To test the Water Pump Pressure, proceed as follows (Refer to Figure 13.4.2.2-1 callouts): c. The water pump outlet pressure can be checked on the water manifold assembly (4). This check
will determine if the water pump is operating correctly.
d. Remove 1/2 “ square plug (1) from the water manifold assembly (2). Install the pressure gauge 9S-8138 Pressure Gauge in the port and measure the pump pressure. The pressure of the water pump should be 16 + 2 PSI (112+ 12kPa).
e. A change of pressure can be measured between the plug (1) on the water manifold assembly (2) and the plug (3) on the inlet side of the water pump (4).
1
2
3
13.4.2.3 REMOVE WATER PUMP
ALWAYS WEAR EYE PROTECTION WHEN YOU PERFORM ANY SERVICE WORK ON A COOLING SYSTEM
RELEASE THE PRESSURE IN THE COOLING SYSTEM BEFORE PERFORMING ANY SERVICE WORK. IF THE PRESSURE IN THE COOLING SYSTEM IS NOT RELEASED OR THE TEMPERATURE OF THE SYSTEM IS NOT PERMITTED TO COOL, STEAM OR HOT WATER MAY BE RELEASED WHEN YOU REMOVE THE FILLER CAP. THIS MAY CAUSE PERSONAL INJURY.
TO RELEASE THE PRESSURE IN A COOLING SYSTEM, LET THE SYSTEM COOL, PUT A HEAVY CLOTH OVER THE CAP AND LOOSEN IT SLOWLY.
DO NOT ALLOW UNDILUTED CORROSION INHIBITORS OR DILUTED/UNDILUTED RADIATOR CLEANERS TO COME IN CONTACT WITH THE SKIN OR EYES.
ALWAYS FOLLOW THE MANUFACTURER’S INSTRUCTIONS WHEN HANDLING CORROSION INHIBITORS, RADIATOR CLEANERS OR ANTIFREEZE BE ESPECIALLY SURE TO FOLLOW THE MANUFACTURER’S RECOMMENDATIONS CONCERNING TOXICITY.
ETHYLENE GLYCOL MAY CATCH FIRE WHEN IT IS HOT OR EXPOSED TO AN OPEN FLAME. DO NOT WELD, CUT OR USE AN OPEN FLAME NEAR LEAKING COOLANT THAT CONTAINS ANTIFREEZE.
DO NOT REMOVE FILLER CAP AFTER OPERATION UNTIL SYSTEM HAS COOLED DOWN. FAILURE TO ALLOW ENGINE COOLANT TO COOL DOWN COULD RESULT IN SECOND AND THIRD DEGREE BURNS. CAP MAY BE HALF-TURNED TO RELIEVE PRESSURE AND THEN REMOVED TO INSPECT COOLANT LEVEL.
WARNING WARNING WARNING WARNING WARNING WARNING WARNING
PERSONAL INJURY CAN RESULT FROM HOT COOLANT, STEAM AND ALKALI.
AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE. THE RADIATOR AND ALL LINES TO THE ENGINE CONTAIN HOT COOLANT OR STEAM. ANY CONTACT CAN CAUSE SEVERE BURNS.
CAUTION
CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING, ADJUSTING AND REPAIR OF THE PU. BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEMBLY ANY COMPONENT CONTAINING FLUIDS. DISPOSE OF FLUIDS ACCORDING TO LOCAL REGULATIONS AND MANDATES.
CAUTION
THE WATER TEMPERATURE REGULATORS (2 EA) ARE AN IMPORTANT PART OF THE COOLING SYSTEM. THE WATER TEMPERATURE REGULATORS DIVIDE THE COOLANT FLOW BETWEEN THE RADIATOR AND THE BYPASS ELBOW. THIS WILL MAINTAIN THE CORRECT ENGINE TEMPERATURE. IF THE WATER TEMPERATURE REGULATORS ARE NOT INSTALLED IN THE SYSTEM, THERE IS NO MECHANICAL TEMPERATURE CONTROL. MOST OF THE COOLANT WILL GO THROUGH THE BYPASS. THIS WILL CAUSE THE ENGINE TO OVERHEAT IN HOT WEATHER. IF A HIGHER VOLUME OF COOLANT GOES THROUGH THE RADIATOR, THE ENGINE WILL NOT REACH NORMAL OPERATING TEMPERATURES. THIS OCCURS DURING COLD WEATHER.
To remove the Water Pump, proceed as follows:
a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. This is accomplished by performing the following:
WARNING
(1) Shutdown the PU in accordance with Section 5.1.6.1 Shutdown Generators. (2) Isolate the PU from any power plant control system in accordance with Note 1. (3) Pull to open the PU DC Power Control Breaker.
(4) Push to open both Emergency Stop Switches.
(5) Place both Engine Control Switches (ECS) in the OFF position. (6) Place a DO NOT OPERATE tag on both generator control panels. (7) Turn the Battery Bank Parallel Switch to the OFF position.
(8) De-energize both Battery Chargers.
(9) Disconnect the negative and positive cables from both Battery Banks. (10) Place a DO NOT OPERATE tag on both Battery Banks.
(11) Place all Circuit Breakers in the LOCK OUT position.
(12) Disconnect both 7P1 and 7P2 Connectors located on the inside panel of the PDC. (13) Close and Lock both generator set control panels.
NOTE 1: When the DC Control Power Circuit Breaker is in the (OFF) position (Pulled – Out), all control power is turned off to the PU. This will cause the HUB to stop functioning. This causes the network to not see the equipment shutdown and all PU’s after it. When pulling major maintenance the (A) (B) Communication Cable must be routed to the next PU in order to reestablish the communication network.
b. Drain the coolant from the engine into a suitable container for storage or disposal. c. Remove the Water Temperature Regulators and manifold.
d. Remove the Oil Cooler Front Bonnet. Be prepared to use Fluid Spillage Containment.
NOTE: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of fluids according to local regulations and mandates.
e. Remove the coolant coupling from the line at the base of the Water Pump. f. Remove mounting bolts from the timing gear cover and remove the Water Pump.
g. Check the condition of 0-ring seal. Use a new part for replacement if 0-ring seal is worn or damaged.
13.4.2.4 INSTALL WATER PUMP
To install the Water Pump, proceed as follows:
a. This maintenance requires that the PU MUST be shutdown, rendered unable to start, cool enough for the maintenance to be performed, and Communication Cable (A) and (B) rerouted to the next PU. See procedures and warnings in paragraph 13.4.2.3.
b. Check the condition of 0-ring seal. Use a new part for replacement if 0-ring seal is worn or damaged.
c. Reinstall the water pump and timing gear cover with the mounting bolts. d. Reconnect the coolant coupling at the inlet of the water pump.
g. Refill the coolant system using Section 13.4.5.5 and Annex G as reference.
NOTE: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of fluids according to local regulations and mandates.
13.4.3 FILLER CAP
The following maintenance procedures are provided for the Filler Cap: Inspect
Test Remove Install