4 Exhaust System
1. Exhaust Backpressure __________ in-H2O (_________ mm-H2O) At Rated Load.
2. Exhaust Pipe I.D. __________ in (__________ mm), Connection at Engine Is: □Solid □Flex 3. Muffler Mfgr. ____________________ Model ____________________ □Single □Dual
4. Exhaust System Total Length __________ Ft (__________ M) Number of Elbows? ______________________________________________________ 5.□Yes □No Is Exhaust System Adequately Supported and Free to Expand When Hot?
6.□Yes □No Is Rain Protection Provided? If So, How? ____________________________________________________________________ 7. Location of Exhaust Outlet Relative to Air Inlet? ____________________________________________________________________________________
Remarks:
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 Attachedto 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 mostcases) 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 _______________21.0 Engine 14. Fan Speed at engine rated speed __________ rpm Fan LC to Crank LC __________ 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 2/3of 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).
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:
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?________________________________________________________ ____________________________________________________________________________________________________________________________ 8. Are Controls Adjustable for Field Maintenance? □Yes □No
Remarks:
8 Starting, Charging Systems
1. Starter Manufacturer ___________________ Model ____________________ Volts ____________________ Solenoid □Up □Down 2. Alternator Manufacturer ___________________ Model ____________________ Volts __________ Amps __________ Speed __________ X Engine RPM 3. Battery Volts ___________________ Total CCA Rating ___________________ Amps (0°F) Number of Batteries? ___________________
4. Battery Cable Size? ___________________ Total Length? __________ in (_________ mm) 5. Starting Aids: Glow Plugs □Yes □No, __________ Volts
Ether Aid □Yes □No, Sprays __________ cc per Injection. JW Heater □Yes □No, __________ Watts.
Air Heater □Yes □No, Mfgr. _________________________
6. What Portion of Load, if Any, Cannot be Disconnected from Engine During Starting? ________________________________________________________ ____________________________________________________________________________________________________________________________ 7. Does Equipment Manufacturer Provide Own Wiring on Engine? □Yes □No
8. What Devices Consume Electrical Power from Alternator/Battery? ______________________________________________________________________ __________________________________________________________________ Is Alternator Adequately Sized? □Yes □No
Remarks:
9 Monitoring System, Gauges
High JW Temp: □Gauge □Warning Light □Alarm □Shutdown at __________°F (__________) Low Oil Pressure: □Gauge □Warning Light □Alarm □Shutdown at __________PSI (__________) ______________ □Gauge □Warning Light □Alarm □Shutdown at __________ (__________) ______________ □Gauge □Warning Light □Alarm □Shutdown at __________ (__________) ______________ □Gauge □Warning Light □Alarm □Shutdown at __________ (__________)
Remarks:
10 Serviceability Checklist
1. Too 3. Remove, Repair Too
Daily Maintenance OK Difficult Replace OK Difficult
Check Oil Level □ □ Replace Belts □ □
Add Oil □ □ Replace Thermostat □ □
Check Coolant Level □ □ Repair Water Pump □ □
Fill Radiator □ □ Remove Oil Pan □ □
Check Water Separator □ □ Remove Rocker Arms □ □
Remove Cylinder Head □ □
Remove Starter □ □
2.Periodic Maintenance □ □ Remove Alternator □ □
Service Air Cleaners □ □ Replace Radiator □ □
Change Oil Filters □ □ Adjust Rack □ □
Drain Oil Pan □ □ In-Frame Overhaul □ □
Service Coolant Treatment □ □ Replace Engine □ □
Drain Cooling System □ □ Adjust All Belts □ □
Adjust Fuel System □ □ Describe Any Other Serviceability Points That Need Improvement.______________ Service Meter Visibility □ □ ____________________________________________________________________ Adjust Clutch □ □ ____________________________________________________________________ Adjust Valve Lash □ □ ____________________________________________________________________
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. Miscellaneous Remarks, Recommendations, Observations, Etc.
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
Manufacturer Witness Supplier Witness Caterpillar
_____________________________________ _____________________________________ _____________________________________
Signature Signature Signature
_____________________________________ _____________________________________ _____________________________________
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