Professional Documents
Culture Documents
September 2018
Operation and
Maintenance
Manual
C32 Marine Engine
SDN 1-UP (Engine)
ZP3 1-UP (Engine)
ZP2 1-UP (Engine)
PUBLICATIONS.CAT.COM
i06558969
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8773-07 3
Table of Contents
Refill Capacities............................................... 56
Foreword ........................................................... 4
Maintenance Recommendations .................... 64
Safety Section
Maintenance Interval Schedule....................... 66
Safety Messages............................................... 6
Operation Section
Engine Starting................................................ 42
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are accepted as proof of
maintenance or repair. Your authorized Cat dealer
can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.
6 SEBU8773-07
Safety Section
Safety Messages
Safety Section
i07275167
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Become familiar with all of the safety messages.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap for cleaning the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off the
engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Cat dealer
can provide new safety messages.
Illustration 1 g06283068
Illustration 2 g02897544
8 SEBU8773-07
Safety Section
Safety Messages
Illustration 3 g02897539
View of the right side of the engine and view of the air cleaner elements
Illustration 4 g01370904
Illustration 5 g01371640
Pressurized system! Hot coolant can cause seri- Explosion hazard! Do not use ether! This ma-
ous burns, injury or death. To open the cooling chine is equipped with an air inlet heater. Using
system filler cap, stop the engine and wait until ether can create explosions or fires that can
the cooling system components are cool. Loosen cause personal injury or death. Read and follow
the cooling system pressure cap slowly in order the starting procedure in the Operation and Main-
to relieve the pressure. Read and understand the tenance Manual.
Operation and Maintenance Manual before per-
forming any cooling system maintenance.
i06300340
Illustration 6 g01372254
One safety message is located on the top of each air Illustration 7 g03838041
cleaner.
Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
10 SEBU8773-07
Safety Section
General Hazard Information
Use caution when cover plates are removed. • When starting a new engine, make provisions to
Gradually loosen, but do not remove the last two stop the engine if an overspeed occurs. If an
bolts or nuts that are located at opposite ends of the engine has not been started since service has
cover plate or the device. Before removing the last been performed, make provisions to stop the
two bolts or nuts, pry the cover loose in order to engine if an overspeed occurs. Shutting down the
relieve any spring pressure or other pressure. engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
• Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
Illustration 9 g00687600
Avoid static electricity risk when fueling. Ultra-
Always use a board or cardboard when you check for low sulfur diesel fuel (ULSD fuel) poses a greater
a leak. Leaking fluid that is under pressure can static ignition hazard than earlier diesel formula-
penetrate body tissue. Fluid penetration can cause tions with a higher sulfur contents. Avoid death
serious injury and possible death. A pin hole leak can or serious injury from fire or explosion. Consult
cause severe injury. If fluid is injected into your skin, with your fuel or fuel system supplier to ensure
you must get treatment immediately. Seek treatment the delivery system is in compliance with fueling
from a doctor that is familiar with this type of injury. standards for proper grounding and bonding
practices.
Containing Fluid Spillage
NOTICE Lines, Tubes, and Hoses
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Do not bend or strike high-pressure lines. Do not
nance, testing, adjusting, and repair of the product. install lines, tubes, or hoses that are damaged.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Repair any fuel lines, oil lines, tubes, or hoses that
bling any component containing fluids. are loose or damaged. Leaks can cause fires.
Refer to Special Publication, NENG2500, “Cat Dealer Inspect all lines, tubes, and hoses carefully. Do not
Service Tool Catalog” or refer to Special Publication, use bare hands to check for leaks. Always use a
PECJ0003, “Cat Shop Supplies and Tools Catalog” board or cardboard for checking engine components
for tools and supplies suitable to collect and contain for leaks. Tighten all connections to the
fluids on Cat products. recommended torque.
Dispose of all fluids according to local regulations Check for the following conditions:
and mandates.
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
Ensure that all of the clamps, the guards, and the • A vacuum cleaner that is equipped with a high
heat shields are installed correctly. Correct efficiency particulate air filter (HEPA) can also be
installation of these components will help to prevent used.
these effects: vibration, rubbing against other parts
and excessive heat during operation. • Use exhaust ventilation on permanent machining
jobs.
Inhalation • Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
Softwrap
Illustration 10 g02159053
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
Exhaust approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
Use caution. Exhaust fumes can be hazardous to protective clothing in order to minimize direct contact.
your health. If you operate the equipment in an Use good hygiene practices and wash hands
enclosed area, adequate ventilation is necessary. thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Asbestos Information Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
Cat equipment and replacement parts that are up debris.
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
Reference: The applicable material safety data Check the coolant level after the engine has stopped
sheets can be found at the following web site by and the engine has been allowed to cool. Ensure that
searching using part number or the name: the filler cap is cool before removing the filler cap.
The filler cap must be cool enough to touch with a
https://catmsds.cat.com/MSDSSearch/servlet/ bare hand. Remove the filler cap slowly in order to
cat.cis.ecs. relieve pressure.
msdsSearch.controller.
UserIdentificationDisplayServlet Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Dispose of Waste Properly
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot
components to contact the skin.
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Illustration 11 g00706404
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
Improperly disposing of waste can threaten the explode.
environment. Potentially harmful fluids should be Always wear protective glasses when you work with
disposed of according to local regulations. batteries. Wash hands after touching batteries. The
Always use leakproof containers when you drain use of gloves is recommended.
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. i05326156
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Illustration 12 g00704000
All fuels, most lubricants, and some coolant mixtures Arcing or sparking could cause a fire. Secure
are flammable. connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
Always perform a Walk-Around Inspection, which or sparking.
may help you identify a fire hazard. Do not operate a
product when a fire hazard exists. Contact your Inspect all lines and hoses for wear or for
Caterpillar dealer for service. deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
Flammable fluids that are leaking or spilled onto hot clamps. Tighten all connections to the recommended
surfaces or onto electrical components can cause a torque. Leaks can cause fires.
fire. Fire may cause personal injury and property
damage. Properly install all oil filters and all fuel filters. The
filter housings must be tightened to the proper
A flash fire may result if the covers for the engine torque.
crankcase are removed within 15 minutes after an
emergency shutdown.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Caterpillar dealer for
additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
All fluids that are captured in the fluid spill
containment basin should be cleaned up
immediately. Failure to clean up spilled fluids can
cause a fire. Fire may cause personal injury and
property damage.
Store fuels and lubricants in properly marked Illustration 13 g00704059
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective Use caution when you are refueling an engine. Do
containers. Do not smoke in areas that are used for not smoke while you are refueling an engine. Do not
storing flammable materials. refuel an engine near open flames or sparks. Always
Do not expose the engine to any flame. stop the engine before refueling.
Exhaust shields (if equipped) protect hot exhaust Note: Avoid static electricity risk when fueling. Ultra-
components from oil or fuel spray from a failed line, low sulfur diesel fuel (ULSD fuel) poses a greater
tube, or seal. Exhaust shields must be installed static ignition hazard than earlier diesel formulations
correctly. with a higher sulfur content. Avoid death or serious
injury from fire or explosion. Consult your fuel or fuel
Do not weld on lines or tanks that contain flammable system supplier to ensure that the delivery system is
fluids. Do not flame cut lines or tanks that contain in compliance with fueling standards for proper
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to grounding and bonding practices.
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and securely attach all electrical wires. Check all
electrical wires daily. Repair any wires that are loose
or frayed before you operate the engine. Clean all
electrical connections and tighten all electrical
connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
SEBU8773-07 15
Safety Section
Crushing Prevention and Cutting Prevention
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Do not use ether as a starting aid. Refer to this
Operation and Maintenance Manual, “Starting the
Engine” for information about starting the engine.
i01359666
Chips or other debris may fly off objects when objects Do not start the engine or move any of the controls if
are struck. Before objects are struck, ensure that no there is a “DO NOT OPERATE” warning tag or similar
one will be injured by flying debris. warning tag attached to the start switch or to the
controls.
i01372247 Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
Mounting and Dismounting area is free of personnel.
SMCS Code: 1000; 4450; 7405 If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
Inspect the steps, the handholds, and the work area lights work properly, if equipped.
before mounting the engine. Keep these items clean
and keep these items in good repair. All protective guards and all protective covers must
be installed if the engine must be started in order to
Mount the engine and dismount the engine only at perform service procedures. To help prevent an
locations that have steps and/or handholds. Do not accident that is caused by parts in rotation, work
climb on the engine, and do not jump off the engine. around the parts carefully.
Face the engine in order to mount the engine or Do not bypass the automatic shutoff circuits. Do not
dismount the engine. Maintain a three-point contact disable the automatic shutoff circuits. The circuits are
with the steps and handholds. Use two feet and one provided in order to help prevent personal injury. The
hand or use one foot and two hands. Do not use any circuits are also provided in order to help prevent
controls as handholds. engine damage.
Do not stand on components which cannot support See the Service Manual for repairs and for
your weight. Use an adequate ladder or use a work adjustments.
platform. Secure the climbing equipment so that the
equipment will not move. i03941639
To ensure that the jacket water heater (if equipped) Grounding Practices
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the Properly ground the electrical system for the vessel
oil temperature gauge during the heater operation. and the engine. Proper grounding is necessary for
optimum engine performance and reliability. Improper
Engine exhaust contains products of combustion that grounding will result in uncontrolled or unreliable
can be harmful to your health. Always start the electrical circuit paths.
engine and operate the engine in a ventilated area. If
the engine is started in an enclosed area, vent the Uncontrolled or unreliable electrical circuit paths may
engine exhaust to the outside. result in damage to main bearings, crankshaft
bearing journal surfaces, and aluminum components.
i01462046 Uncontrolled electrical circuit paths may also cause
electrical noise. Electrical noise may degrade the
Engine Stopping performance of the vessel and of the radio.
SMCS Code: 1000 Connect the starting motor directly to the negative
battery terminal. Connect the alternator to the
Stop the engine according to the procedure in the negative battery or negative terminal for the starting
Operation and Maintenance Manual, “Engine motor. The alternator and the starting motor must
Stopping (Operation Section)” in order to avoid meet marine isolation requirements.
overheating of the engine and accelerated wear of
the engine components. Note: All electrical connections must meet or exceed
the American Boat and Yacht Council Standard E-11.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Use a bus bar with a direct path to the negative
Emergency Stop Button for normal engine stopping. battery terminal for low current components that
After an emergency stop, DO NOT start the engine require a negative battery connection. Connect the
until the problem that caused the emergency stop bus bar directly to the negative battery terminal.
has been corrected.
Note: All return paths to the negative battery must be
Stop the engine if an overspeed condition occurs able to carry fault currents.
during the initial start-up of a new engine or an
engine that has been overhauled. This may be The use of a bus bar ensures that the electronic
accomplished by shutting off the fuel supply to the control module (ECM) and the components
engine and/or shutting off the air supply to the connected to the ECM have a common reference
engine. point.
To stop an electronically controlled engine, cut the Refer to Special Instruction, REHS1187, “Marine
power to the engine. Engine Electronic Installation Guide” for additional
information on grounding procedures.
i06948165
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark may cause the combustible
gases that are produced by some batteries to ignite.
Connect the negative jump-start cable last from the
external power source to the negative terminal of the
starting motor. This connection sequence helps to
prevent sparks from igniting any combustible gasses
which batteries may produce. If the starting motor is
not equipped with a negative terminal, connect the
jump-start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started. See this
Operation and Maintenance Manual, “Engine
Starting” for specific starting instructions.
18 SEBU8773-07
Safety Section
Electrical System
Illustration 15 g03324810
(1) Engines (8) Direct current (DC) main negative bus (13) Immersed ground plate
(2) Parallel switch bar (14) Zinc bar
(3) Customer miscellaneous vessel loads (9) Alternating current (AC) grounding bus (15) Electronics ground plate
(4) Overcurrent protection bar (16) Chain plates
(5) Battery (10) Strainer (17) Grounding bus bar
(6) Battery disconnect switches (11) Cathodic protection bus bar (18) Engine negative terminal
(7) Battery (12) Lightening protection ground point (19) Battery
i05391510
Engine Electronics
SMCS Code: 1000; 1900
• Operating Altitude
• Engine Coolant Level
• Engine Coolant Temperature
• Fuel Temperature
• Intake Manifold Air Temperature
• System Voltage
• Turbocharger Inlet Temperature
The engine monitoring package may vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Product Information
Section
General Information
i04786506
Illustration 16 g02908117
View of the right side of a typical C32 Marine Engine
(1) Turbocharger (6) Filler cap for the expansion tank for the (11) Coolant sampling valve
(2) Crankcase breather jacket water cooling system (12) Engine oil filters
(3) Aftercooler (7) Fuel priming pump (13) Selector valve for the engine oil filter
(4) Electronic control module (ECM) (8) Selector valve for the fuel filter system system
(5) Expansion tank for the jacket water (9) Secondary fuel filters (14) Engine oil sampling valve
cooling system (10) Filler tube for the lubrication system (15) Flywheel
SEBU8773-07 21
Product Information Section
Model View Illustrations
Illustration 17 g02908118
View of the front of a typical C32 Marine Engine
(16) Heat exchanger for the jacket water (17) Heat exchanger for the separate circuit (18) Guard for the engine damper and for
cooling system aftercooling system (SCAC system) the alternator belt
Illustration 18 g02908119
View of the left side of a typical C32 Marine Engine
(19) Expansion tank for the SCAC cooling (20) Filler cap for the SCAC cooling system (22) Electric starting motor
system (21) Jacket water heater (23) Alternator
22 SEBU8773-07
Product Information Section
Product Description
Illustration 19 g03120676
View of the top of a typical C32 Marine Engine
(Some components removed for visibility)
(24) Lifting Eyes
Marine Transmissions
Several manufacturers of marine gears offer marine
transmissions through local distributors. Lubrication
oil for the marine transmission can be cooled by an
optional engine-mounted transmission oil cooler
(certain engine ratings).
Product Identification
Information
i07274971
Illustration 23 g06270736
Illustration 21 g06270731
Location of the Engine Identification Plate
Location of the Engine Serial Number Plate
26 SEBU8773-07
Product Information Section
Plate Locations and Film Locations
Illustration 24 g00102789
Typical information plate
Declaration of Conformity
SMCS Code: 1000
Illustration 25 g01231351
28 SEBU8773-07
Product Information Section
Emissions Certification Film
i04019095
i04602210
Reference Information
SMCS Code: 1000; 4450
Information for the following items may be needed to
order parts for your marine engine. Locate the
information for your engine. Record the information
on the appropriate space. Make a copy of this list for
a record. Keep this information for future reference.
Product Lifting
SMCS Code: 7000; 7002
Illustration 27 g00103228
NOTICE
Do not use the eyebolts that are on the marine trans-
mission housing to lift the engine.
Illustration 26 g00103219
To remove both the engine and the marine
NOTICE transmission, use the lifting eyes that are on the
Never bend the eyebolts and the brackets. Only load engine. Use an adjustable lifting beam to lift the
the eyebolts and the brackets under tension. Re- engine. All supporting members (chains and cables)
member that the capacity of an eyebolt is less as the should be parallel to each other. The chains and
angle between the supporting members and the ob- cables should be perpendicular to the top of the
ject becomes less than 90 degrees. object that is being lifted. Consult your Caterpillar
dealer or consult the OEM for information regarding
When it is necessary to remove a component at an fixtures for proper lifting of your complete package.
angle, only use a link bracket that is properly rated for
the weight. Marine Transmission Lifting
Use a hoist to remove heavy components. Use an
To remove the marine transmission ONLY, use the
adjustable lifting beam to lift the engine. All eyebolts that are on the marine transmission
supporting members (chains and cables) should be housing. Refer to the OEM for proper lifting
parallel to each other. The chains and cables should instructions (if equipped).
be perpendicular to the top of the object that is being
lifted. If a component resists removal, ensure that all of the
nuts and bolts have been removed. Ensure that no
Some removals require lifting fixtures in order to adjacent parts are interfering.
obtain proper balance. Lifting fixtures also help to
provide safety.
i07032177
To remove the engine ONLY, use the lifting eyes that
are on the engine. Product Storage
Lifting eyes are designed and installed for the SMCS Code: 7002
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and the Engine
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information Storage - Greater than 7 Days and less
regarding fixtures for proper engine lifting. than 30 Days
Caterpillar recommends maintaining the temperature
of the engine to a temperature of at least 5° C (9° F)
above ambient temperature to prevent corrosion. The
usage of jacket water heaters is an appropriate
method.
SEBU8773-07 31
Operation Section
Product Storage
Storage - Greater than 30 Days and less Note: VCI oil mixture is also to be added to the inlet
than 1 Year by removing a plug for checking boost pressure/
temperature at the cylinder head air inlet area. The
Note: If long-term storage for time exceeding 1 year sprayer should produce a fog to ensure it is drawn
is necessary, contact your local Caterpillar Dealer for into each cylinder. The minimum application rate is
the preferred procedure to use in your specific case. 5.5 mL per L (3 oz per 1000 cu in) of engine
displacement.
If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls, 8. Use a sprayer to apply a mixture of 50 percent VCI
piston rings, main bearings, connecting rod bearings, and 50 percent crankcase oil into the exhaust
crankshaft, and gears. openings. The minimum application rate for the oil
This lack of lubricant allows corrosion to begin to mixture is 5.5 mL per L (3 oz per 1000 cu in) of
appear on the metal. This condition is worse in areas engine displacement. Seal the exhaust pipe and
of high humidity. seal any drain holes in the muffler.
When the engine is started again, metal to metal 9. Remove the fuel from the secondary fuel filter
contact will cause wear before the surfaces receive housing. Alternately, empty and reinstall the spin-
oil. To minimize this wear, use the starter to turn the on fuel filter element to remove any dirt and water.
engine with the throttle in the FUEL OFF position.
Drain any sleeve metering fuel pump.
When oil pressure is shown on the pressure gauge,
start the engine. Clean the primary fuel filter. Fill with calibration
1. Clean the engine of any dirt, rust, grease, and oil. fluid or kerosene. Install the primary fuel filter and
Inspect the exterior. Paint areas that contain paint operate the priming pump to send clean oil to the
damage with a good quality paint. secondary filter and the engine.
2. Remove any dirt from all air cleaners. Check all Open the fuel tank drain valve to drain any water
seals, gaskets, and the filter element for damage. and dirt from the fuel tank. Apply a spray of
calibration fluid or kerosene at the rate of
3. Apply lubricant to all points in this Operation and 30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
Maintenance Manual, “Maintenance Interval capacity to prevent rust in the fuel tank. Add
Schedule”. 0.15 mL per L (.02 oz per 1 gal US) of commercial
4. Drain the crankcase oil. Replace the crankcase oil biocide such as Biobor JF to the fuel.
and change the oil filters. For the proper Apply a small amount of oil to the threads on the
procedure, refer to this Operation and fuel tank filler neck and install the cap. Seal all
Maintenance Manual, “Engine Oil and Filter - openings to the tank to prevent evaporation of the
Change”. fuel and as a preservative.
5. If the engine is equipped with an air starting motor, 10. Remove the fuel nozzles or spark plugs. Apply
fill the reservoir with a mixture of 50 percent 30 mL (1 oz) of the mixture of oils (50 percent VCI
volatile corrosion inhibitor (VCI) and 50 percent oil and 50 percent engine oil) into each cylinder.
engine oil.
Use a bar or a turning tool to turn over the engine
6. Add VCI to the crankcase oil. The volume of VCI in slowly. This action puts the oil on the cylinder
the crankcase oil should be 3 to 4 percent. walls. Install all fuel nozzles or spark plugs and
tighten to the correct torque.
Note: If the engine crankcase is full, drain enough
engine oil so the mixture can be added. 11. Spray a thin amount of the mixture of oil (50
percent VCI oil and 50 percent engine oil) onto the
7. Remove the air filter elements. Turn the engine at flywheel, the ring gear teeth, and the starter
cranking speed with the throttle control in FUEL pinion. Install the covers to prevent evaporation of
OFF position. Use a sprayer to add a mixture of 50 the vapors from the VCI oil.
percent VCI and 50 percent engine oil into the air
inlet or turbocharger inlet. 12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move,
such as rod threads, ball joints, linkage, etc.
Ensure that all covers are airtight and After the system has been drained, inspect all zinc
weatherproof. Use a waterproof weather resistant plugs (normally painted red) for damage from
tape such as Kendall No. 231 or an equivalent. Do corrosion.
not use duct tape. Duct tape will only seal for a Note: To ensure complete drainage and evaporation
short time. during storage, DO NOT install the drain plugs and
13. Under most conditions, it is best to remove the zinc plugs. Place all removed plugs in a cloth bag
batteries. As an alternative, place the batteries in and fasten the bag to the engine for storage.
storage. As needed, periodically charge the
batteries while the batteries are in storage.
Removal from Storage
If the batteries are not removed, wash the tops of 1. Remove all outside protective covers.
the batteries until the tops are clean. Apply an
2. Change the oil and filters.
electrical charge to the batteries to obtain a
specific gravity of 1.225. 3. Check the condition of the fan and alternator belts.
Replace the belts, if necessary. Refer to this
Disconnect the battery terminals. Place a plastic
Operation and Maintenance Manual, “Belts -
cover over the batteries.
Inspect/Adjust/Replace” or refer to this Operation
Note: For additional information, refer to Special and Maintenance Manual, “Belts - Inspect/
Instruction, SEHS7633, “Battery Test Procedure”. Replace” for the correct procedure.
15. Place a waterproof cover over the engine. Ensure 5. Remove the plastic covers from the air cleaner
that the engine cover is secure. The cover should elements.
be loose enough to allow air to circulate around 6. Use a bar or a turning tool to turn the engine in the
the engine to prevent damage from condensation. normal direction of rotation. The procedure
16. Attach a tag with the date of storage to the ensures that no hydraulic locks or resistance exist.
engine. 7. Before starting the engine, remove the valve cover
17. Remove the waterproof cover at 2 month or 3 or covers. Put a large amount of engine oil on the
month intervals to check the engine for corrosion. camshaft, cam followers, and valve mechanism to
If the engine has signs of corrosion, repeat the prevent damage to the mechanism.
protection procedure. 8. Pressure lubricate the engine before starting the
engine. Pressure lubrication of the engine ensures
Conventional Coolant System
immediate lubrication. Pressure lubrication of the
Completely fill the cooling system before storage. engine prevents damage to the engine which
might otherwise occur at start-up. If the engine is
Water or water which is mixed with supplemental not equipped with a prelube pump, contact your
coolant additive (SCA) is not an approved coolant for Cat dealer for information about lubrication of the
use with Cat C7-C32 Marine Engines which are engine before the engine is started.
cooled with heat exchangers. Cat C7-C32 Marine
Engines which are cooled with heat exchangers 9. Check the condition of all rubber hoses. Replace
require a minimum of 30 percent glycol to prevent any worn hoses. Replace any damaged hoses.
cavitation of cooling system components. A minimum
of 50 percent glycol is verystronglyrecommended. 10. Before start-up, test the cooling system for a 3 to
6 percent concentration of coolant conditioner.
Refer to this Operation and Maintenance Manual,
Add liquid coolant conditioner or a coolant
“Refill Capacities and Recommendations” or refer to
this Operation and Maintenance Manual, “Fluids conditioner filter, if equipped.
Recommendations” for more information about Test the coolant mixture for proper nitrite level. If
coolants.
necessary, adjust the coolant mixture.
Raw Water System
Prime the engine with clean diesel fuel before
Completely drain the raw water system by removing starting.
all the drain plugs from the raw water pump, the
water shielded manifolds, the heat exchanger
bonnets, and the aftercooler.
SEBU8773-07 33
Operation Section
Product Storage
Features and Controls When the cold start strategy is activated, low idle rpm
will be increased to 1000 rpm and the engine's power
will be limited.
i03646563
Cold mode operation will be deactivated when any of
Battery Disconnect Switch the following conditions have been met:
i01491446
i04997470
Control Panel
(Cat Marine Engine Control
Panel I (MECP I) (If Equipped))
SMCS Code: 7451
Illustration 28 g03174556
Illustration 29 g03196177
Cat Marine Engine Control Panel III (MECP III)
(1) Display control unit (DCU) (4) “ON/OFF” switch for the “LOCAL (6) “EMERGENCY STOP” switch
(2) “STOP” switch THROTTLE” (7) “OFF/MANUAL/REMOTE” switch
(3) “START” switch (5) “LOCAL THROTTLE” switch
Illustration 30 g03342374
Inside of the control panel
(8) “CRANK OVERRIDE” switch
(9) “SHUTDOWN OVERRIDE” switch
SEBU8773-07 37
Operation Section
Control Panel
i07275580
Control Panel
(CatMarine Engine Control Panel
II (MECP II) (If Equipped))
SMCS Code: 7451
Illustration 32 g06089081
View of Engine control switch selections.
(2) Engine control switch (ECS)
(9) Off
(10) Local
(11) Remote
Note: For further information regarding the MECP II Gauges provide indications of engine performance.
control panel refer to LEBM0070, “Cat Marine Control Ensure that the gauges are in good working order.
Panel (MECP II)”Operation and Maintenance Manual Determine the normal operating range by observing
the gauges over time. Noticeable changes in gauge
For further more information concerning the MECP II readings indicate potential gauge or engine
use the following web address: problems. Problems may also be indicated by gauge
readings that change even if the readings are within
https://engines.cat.com/en/marine/products/ specifications. Determine and correct the cause of
control-systems/a-p-panels.html any significant change in the readings. Consult your
Caterpillar dealer for assistance.
Select Cat Marine Panel MECP II Operation and
Maintenance Manual link found under Service NOTICE
Information. If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
i05391538 the engine. Engine damage can result.
Derating Strategy
Engine Coolant Temperature – This
SMCS Code: 1901 gauge indicates the engine coolant
temperature. The temperature may vary
The engine electronic control module (ECM) may
limit the amount of fuel flowing into the injectors in according to the load. Do not allow the
order to protect the engine. Any of the following temperature to exceed the boiling temperature of
factors could initiate a derate: the pressurized cooling system.
• The engine coolant level is high. Fully submerge the engine coolant temperature
sensor to detect correctly the temperature. If the
• The engine coolant temperature is high. engine is operating above the normal temperature
range, perform the following procedure:
• The engine oil pressure is low.
1. Reduce the load and/or the engine rpm.
• The engine oil temperature is high. 2. Inspect the cooling system for leaks.
• The fuel pressure is high or the fuel pressure is 3. Determine if the engine must be shut down
low. immediately or if the engine can be cooled by
reducing the load and/or rpm.
• The engine speed is high.
Engine Load – This gauge indicates a
• The temperature of the air entering the air cleaner percentage of the full rated torque. The
is high. calculation of the percentage is based
• The engine intake manifold temperature is high. on these factors: flow of fuel, engine rpm, fuel
energy content and fuel correction factor. This
Note: This fuel limiting strategy is in place to ensure gauge flashes if the torque exceeds the maximum
the longevity and durability of the engine. limit that is programmed into the control strategy.
The derate condition that may result will limit peak Engine Oil Pressure – The oil pressure
power. In no case will the power loss exceed a 50% should be greatest after a cold engine is
reduction in total engine power. started. The pressure will decrease as
the engine warms up. The pressure will increase
Note: In a derated condition, the amount of derate when the engine rpm is increased. The pressure
can be determined by monitoring the “Actual will stabilize when the engine rpm is stable.
Maximum Available Engine Torque %” .
A lower oil pressure is normal at low idle. If the load is
Contact your Cat dealer for more information about stable and the gauge reading changes, perform the
the derating procedure. following procedure:
i03947882
1. Remove the load.
2. Reduce engine speed to low idle.
Gauges and Indicators
3. Check and maintain the oil level.
SMCS Code: 7450
Your engine may not have the same gauges or all of
the gauges that are described.
SEBU8773-07 39
Operation Section
Gauges and Indicators
Engine Oil Temperature – This gauge Inlet Manifold Air Temperature – This
indicates the engine oil temperature gauge indicates the inlet manifold air
after the oil has passed through the oil temperature after the aftercooler. As the
cooler. The oil cooler is thermostatically inlet air increases in temperature the following
controlled. conditions occur: expansion of the air, less
oxygen in the cylinders and less power. If the
Exhaust Temperature – This gauge temperature of the inlet air is too high during full
indicates the exhaust temperature at the speed and load operation, the engine may
exhaust inlets to the turbochargers. The consume excessive fuel.
two exhaust temperatures may vary slightly.
Service Hour Meter – This gauge
The exhaust temperatures at the exhaust inlets to the indicates the total number of clock
turbochargers provide a good indication of engine hours on the engine.
performance. For engines with dry exhaust
manifolds, the temperatures are representative of the System Voltage – This gauge indicates
actual temperatures of the valves. Monitor this the voltage of the electrical system.
parameter frequently.
i01563934
Fault Logging
SMCS Code: 1000; 1900; 1901; 1902
Self-Diagnostics The system provides the capability of Fault Logging.
SMCS Code: 1000; 1900; 1901; 1902 When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
Caterpillar Electronic Engines have the capability to logged in the memory of the ECM. The codes that
perform a self-diagnostics test. When the system have been logged in the memory of the ECM can be
detects an active problem, the “DIAGNOSTIC” lamp retrieved with Caterpillar electronic service tools. The
is activated. Diagnostic codes will be stored in codes that have been logged can be cleared with
permanent memory in the Electronic Control Module Caterpillar electronic service tools. The codes that
(ECM). The diagnostic codes can be retrieved by have been logged in the memory of the ECM will be
using the following components: automatically cleared from the memory after 100
hours. The following faults cannot be cleared from
• Caterpillar electronic service tools the memory of the ECM without using a factory
password: overspeed, low engine oil pressure and
• “DIAGNOSTIC” lamp high engine coolant temperature.
Note: The “DIAGNOSTIC” lamp must be installed by
i00864752
the OEM or by the customer.
Some installations have electronic displays that Engine Operation with Active
provide direct readouts of the engine diagnostic Diagnostic Codes
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine SMCS Code: 1000; 1900; 1901; 1902
diagnostic codes.
Engine performance can be limited as a result of an
Active codes represent problems that currently exist. active diagnostic code.
These problems should be investigated first. If a code
is active, the “DIAGNOSTIC” lamp will flash the flash An active diagnostic code represents a problem that
code at five second intervals. requires service as soon as possible. If a diagnostic
code is generated, check the following conditions:
Logged codes represent the following items:
• Engine oil pressure
• Intermittent problems
• Coolant temperature
• Recorded events
• Coolant level
• Performance history
If the oil pressure, coolant temperature, and coolant
The problems may have been repaired since the level are within the normal ranges, engine operation
logging of the code. These codes do not indicate that may continue. However, ensure that the engine is
a repair is needed. The codes are guides or signals serviced as soon as possible.
when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the
corresponding logged fault codes should be cleared.
SEBU8773-07 41
Operation Section
Engine Operation with Intermittent Diagnostic Codes
i05072873
Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i01486758 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
• All of the guards must be put in place. Check for
Perform the required daily maintenance and other
damaged guards or for missing guards. Repair
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can any damaged guards. Replace damaged guards
help prevent major repairs at a later date. Refer to and/or missing guards.
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more • Disconnect any battery chargers that are not
information. protected against the high current drain that is
created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables and
a thorough inspection before the engine is started. check the battery for poor connections and for
Look for the following items: oil leaks, coolant corrosion.
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.
• Inspect the cooling system hoses for cracks and • Check the engine lubrication oil level. Maintain the
for loose clamps. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the wiring for loose connections and for the coolant level to the “FULL” mark on the coolant
worn wires or frayed wires. recovery tank.
• Check the fuel supply. Drain water from the water • If the engine is not equipped with a coolant
separator (if equipped). Open the fuel supply recovery tank maintain the coolant level within
valve. 13 mm (0.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain
NOTICE the coolant level in the sight glass.
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel • Observe the air cleaner service indicator (if
pressure. High fuel pressure may cause filter housing equipped). Service the air cleaner when the yellow
failure or other damage. diaphragm enters the red zone, or when the red
piston locks in the visible position.
If the engine has not been started for several weeks, • Ensure that any driven equipment has been
fuel may have drained from the fuel system. Air may disengaged. Minimize electrical loads or remove
have entered the filter housing. Also, when fuel filters any electrical loads.
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel i04409253
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system. Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
If the engine fails to start within 30 seconds, release For automatic starting, the engine control switch must
the starter switch or button and wait two minutes to be in the AUTO position or in the REMOTE position.
allow the starting motor to cool before attempting to The engine will automatically start when the remote
start the engine again. start/stop initiate contact closes.
NOTICE
Starting the Engine with the Cat Marine
Do not engage the starting motor when flywheel is Engine Control Panel III (MECP III) (If
turning. Do not start the engine under load. Equipped)
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
Illustration 34 g03199057
(3) “START” switch
(4) “ON/OFF” switch for the “LOCAL THROTTLE”
(5) “LOCAL THROTTLE” switch
(6) “OFF/MANUAL/REMOTE” switch
Illustration 33 g03199056
(1) “OFF/MANUAL/REMOTE” switch
(2) “START” switch Illustration 35 g03200996
(7) “CRANK OVERRIDE” switch
Note: The engine key switch and the start circuits are (8) “SHUTDOWN OVERRIDE” switch
controlled by the “OFF/LOCAL/REMOTE” switch. (9) “TORQUE LIMIT” switch
The position of the “OFF/LOCAL/REMOTE” switch
does not affect the operation of the “STOP” switch. When the “OFF/LOCAL/REMOTE” switch is in
LOCAL mode, the engine cannot be started from the
1. Position the “OFF/LOCAL/REMOTE” switch to the remote control unit. The LOCALl position does not
LOCAL position or to the REMOTE position. energize the key switch (J906 circuit) beyond the
engine harness.
2. Activate the “START” switch to start the engine.
1. Position the “OFF/LOCAL/REMOTE” switch to the
LOCAL position or to the REMOTE position.
2. Activate the “START” switch to start the engine.
SEBU8773-07 45
Operation Section
Starting with Jump Start Cables
Note: If the “START” switch does not start the 2. Connect one positive end of the jump start cable to
engine, start the engine with the “CRANK/ the positive cable terminal of the discharged
OVERRIDE” switch on the inside of the control box. battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
i03640789 charging or starting source.
Starting with Jump Start 3. Connect one negative end of the jump start cable
to the negative cable terminal of the charging or
Cables starting source. Connect the other negative end of
SMCS Code: 1000; 1401; 1402; 1900 the jump start cable to the stalled engine block or
to the chassis ground. This procedure helps to
prevent potential sparks from igniting combustible
gases that are produced by some batteries.
Improper jump start cable connections can cause
an explosion resulting in personal injury. 4. Charge the batteries. The engine will not continue
to run after starting if the batteries have not been
Prevent sparks near the batteries. Sparks could charged.
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine. 5. Start the engine.
If the installation is not equipped with a backup 6. Immediately after the stalled engine is started,
battery system, it may be necessary to start the disconnect the jump start cables in reverse order.
engine from an external electrical source.
Refer to the Electrical Schematic for your engine.
For information on troubleshooting the charging Consult your Caterpillar dealer for more information.
system, refer to Special Instruction, REHS0354,
“Charging System Troubleshooting”. i01042616
When an external electrical source is used to start • Check all the gauges.
the engine, turn the control switch on the generator
set to the “OFF” position. Turn all electrical accesso- Observe the gauges and record the data
ries OFF before attaching the jump start cables. frequently while the engine is operating.
Comparing the data over time will help to
Ensure that the main power switch is in the OFF posi-
tion before jump start cables are attached to the en- determine normal readings for each gauge. This
gine that is being started. will also help detect abnormal operating
developments. Investigate any significant changes
in the readings.
1. Turn the start switch on the stalled engine to the
OFF position. Turn off all accessories. 2. After the engine has idled for five minutes and the
inspections have been made, increase the engine
speed to 1/2 rated rpm.
46 SEBU8773-07
Operation Section
After Starting Engine
NOTICE
To avoid engine overheating and possible engine
damage, ensure that water discharge is visible at the
sea water outlet and/or the water flow is not
restricted.
If the water flow is restricted and/or water discharge
is not visible at the sea water outlet, follow the recom-
mended procedure.
Interrupted starts put excessive stress on the drive • Ensure that the turbochargers are operating
train. Interrupted starts also waste fuel. To get the correctly so that the proper air/fuel ratio is
driven equipment in motion, engage the clutch maintained. Clean exhaust indicates proper
smoothly with no load on the equipment. This functioning.
method should produce a start that is smooth and
• Maintain a good electrical system.
easy. The engine rpm should not increase and the
clutch should not slip. One defective battery cell will overwork the alternator.
This will consume excess power and excess fuel.
3. Ensure that the ranges of the gauges are normal
when the engine is operating at one-half of the • Ensure that the belts are properly adjusted. The
rated rpm. Ensure that all gauges operate belt should be in good condition.
properly.
• Ensure that all of the connections of the hoses are
4. Increase the engine rpm to the rated rpm. Always tight. The connections should not leak.
increase the engine rpm to the rated rpm before
the load is applied. • When possible, utilize the heat of the jacket water
system and the energy from the heat of the
5. Apply the load. Begin operating the engine at low exhaust system.
load. Check the gauges and equipment for proper
operation. After normal oil pressure is reached and • Keep keel coolers, heat exchangers, and water
the temperature gauge begins to move, the engine pumps clean. Keep the components in good
repair.
may be operated at full load. Check the gauges
and equipment frequently when the engine is • Ensure that all of the accessory pumps are
operated under load. repaired. The pumps should operate efficiently.
Extended operation at low idle or at reduced load • Do not exceed the maximum oil level.
may cause increased oil consumption and carbon
buildup in the cylinders. This carbon buildup • Never operate without water temperature
results in a loss of power and/or poor regulators.
performance.
Water temperature regulators regulate the
temperature of the coolant. Water temperature
i01060957 regulators help to provide efficient operating
temperatures. Cold engines consume excessive fuel.
Fuel Conservation Practices Water temperature regulators also help prevent
engine overheating.
SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel Cruising Speed
economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency in The recommended cruising speed of the engine is
all applications. Follow the recommended procedures 300 to 400 rpm below the rated speed of the engine.
in order to attain optimum performance for the life of
the engine. Operating at the recommended cruising speed will
help to provide the maximum engine service life and
• Avoid spilling fuel. the most economical operation.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. The fuel lines should be repaired if there is
evidence of failure.
• Be aware of the properties of the different fuels.
Use only the recommended fuels.
• Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of
time.
• Observe the service indicator frequently. Keep the
air cleaner elements clean.
50 SEBU8773-07
Operation Section
Cold Weather Operation
Cold Weather Operation • Check all rubber parts (hoses, fan drive belts, and
so on) weekly.
i04557066 • Check all electrical wiring and connections for any
fraying or damaged insulation.
Cold Weather Operation
• Keep all batteries fully charged and warm.
SMCS Code: 1000; 1250
• Fill the fuel tank at the end of each shift.
Cat Diesel Engines can operate effectively in cold
weather. The starting and the operation of the diesel • Check the air cleaners and the air intake daily.
engine is dependent on the following items in cold Check the air intake more often when you operate
weather: in snow.
• The type of fuel that is used
• The viscosity of the oil
Personal injury or property damage can result
• Optional starting aids from alcohol or starting fluids.
Hints for Cold Weather Operation • Dryers for the air system may be effective in
reducing moisture condensation and the formation
• If the engine is started, operate the engine until a of ice in air systems.
minimum operating temperature of 71 °C (160 °F)
• The injection of alcohol may prevent moisture from
is achieved. Achieving operating temperature will
freezing the air compressor governor and other
help prevent the intake valves and exhaust valves
components of the air system.
from sticking.
• The cooling system and the lubrication system for
the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
down for a few hours and the engine will start
readily. If the engine is shut down for at least
8hours, the engine should be considered cooled to
outside temperature.
• For jump starting with cables in cold weather, refer Jacket Water Heater
to the Operation and Maintenance Manual for
jump starting instructions. A jacket water heater heats the coolant that
surrounds the combustion chamber providing the
following functions:
Viscosity of the Engine Lubrication
Oil • Startability is improved.
Proper engine oil viscosity is essential. Oil viscosity • Warm up time is reduced.
affects the amount of torque that is needed to crank
the engine. Refer to the Operation and Maintenance • The required temperature for ether is reduced.
Manual, “Fluid Recommendations” for the
recommended viscosity of oil. An electric jacket water heater can be activated once
the engine is stopped. An effective jacket water
heater is typically a 1500 W unit. Consult your marine
Lubricating Oil Heaters dealer for more information.
Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure the Idling the Engine
compatibility of the components, only use equipment
that is recommended by Caterpillar. While the engine is idling, the application of a light
load (parasitic load) will assist in maintaining the
minimum operating temperature. The minimum
NOTICE operating temperature is 71 °C (160 °F). Maintaining
Heating elements that are in direct contact with the an elevated low idle speed for extended periods will
lubricating oil can cause coking of the oil. be easier with the installation of a hand throttle. An
idle speed of 1200 rpm is preferred for all engines.
To aviod coking of the oil when the oil is heated, fol-
low these recommendations:
Recommendations for Coolant
The temperature of the heating surface must not ex-
ceed 150 °C (300 °F). The maximum heat density of Warm Up
the heating surface must not exceed 1.24 w/cm2
(8W/in2). Warm up any system that has cooled below normal
operating temperatures due to inactivity. The warm-
Engine oil pan heaters are useful devices that up should be performed before the engine is returned
provide the following functions: to full operation. During operation in very cold
temperature conditions, damage to engine valve
• Assist in reducing the cold cranking amperage mechanisms can result from engine operation for
that is needed to start the engine. short intervals. This damage can happen if the
engine is started and the engine is stopped many
• Improve the flow of oil at start-up. times without being operated in order to warm up
completely.
• The time that is needed to warm up the engine is
reduced. When the engine is operated below normal operating
temperatures, fuel and oil are not completely burned
• The service life of bearings is increased. in the combustion chamber. This fuel and oil causes
soft carbon deposits to form on the valve stems.
Engine oil pan heaters can reduce the minimum Generally, the deposits do not cause problems and
ambient temperatures that are normally the deposits are burned off during operation at
recommended for multigrade oil. Consult your dealer normal engine operating temperatures.
for more information.
When the engine is started and stopped without
operating long enough to warm up completely, the
Recommendations for the Coolant carbon deposits become thicker. The carbon
deposits will cause the following problems:
Provide cooling system protection for the lowest
expected outside temperature. Refer to the • Free operation of the valves is prevented.
Operation and Maintenance Manual, “Fluid
Recommendations” for the recommended coolant • Valves become stuck.
mixture.
• Pushrods are bent.
In cold weather, check the coolant often for the
proper glycol concentration in order to ensure • Other damage to valve train components can
adequate freeze protection.
result.
52 SEBU8773-07
Operation Section
Fuel and the Effect from Cold Weather
For this reason, when the engine is started, the Additional heat can be retained around the engine by
engine must be operated until the coolant insulating the engine compartment.
temperature is 71 °C (160 °F) minimum. Carbon
deposits on the valve stems are kept at a minimum i04408649
and the free operation of the valves and the valve
components are maintained.
Fuel and the Effect from Cold
Warm the engine thoroughly to keep other engine
parts in better condition. The service life of the engine
Weather
will be extended. Lubrication will be improved. There SMCS Code: 1000; 1250; 1280
will be less acid and less sludge in the oil. The better
condition of the oil will provide longer service life for The following fuels are the grades that are available
the engine bearings, the piston rings, and other parts. for Cat engines:
However, limit unnecessary idle time to 10 minutes.
Engine wear is greatest at low idle and unnecessary • No. 1
idling wastes fuel.
• No. 2
On/Off Fan Clutch • Blend of No. 1 and No. 2
Viscous fans continuously rotate in cold weather, No. 2 diesel fuel is the most commonly used fuel.
which creates unnecessary movement of the air. For Either No. 1 diesel fuel or a blend of No. 1 and No. 2
better control of the operation of the fan, an ON/OFF is best suited for cold-weather operation.
fan clutch may be used. ON/OFF fan clutches can
help prevent excessive cooling in cold weather. In the Quantities of No. 1 diesel fuel are limited. No. 1
“OFF” position, the fan is kept stationary by the ON/ diesel fuels are usually available during the months
OFF fan clutch. The unnecessary movement of the of the winter in the colder climates. During cold-
air is reduced in order to maintain adequate engine weather operation, if No. 1 diesel fuel is not available,
operating temperatures in cold weather. use No. 2 diesel fuel, if necessary.
Purge Valve and Insulated Heater Lines There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
During periods of operations with a light load, The
coolant must bypass the radiator in order to help • Lower cloud point
prevent excessive cooling of the engine. Coolant that
passes through the radiator must be minimized in • Lower pour point
order to maintain the engine operating temperature in
cold weather. • Lower rating of kJ (BTU) per unit volume of fuel
Excessive cooling of the engine is prevented by a When No. 1 diesel fuel is used, a decrease in power
“jiggle” valve that performs two functions. The valve and in fuel efficiency may be noticed. Other operating
allows the flow of air and the valve prevents the flow effects should not be experienced.
of coolant. These valves prevent the unnecessary
coolant flow, which may be diverted around the water The cloud point is the temperature when a cloud of
temperature regulator to the radiator. wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
Insulated cab heater lines for very cold weather are temperature when diesel fuel will thicken. The diesel
also beneficial. These lines provide more available fuel becomes more resistant to flow through fuel
heat from the coolant to the cab and less heat is lost pumps and through fuel lines.
to the outside air.
Be aware of these values when diesel fuel is
Insulating the Air Inlet and Engine purchased. Anticipate the average ambient
Compartment temperature of the area. Engines that are fueled in
one climate may not operate well if the engines are
When temperatures below −18 °C (−0 °F) will be moved to another climate. Problems can result due to
changes in temperature.
frequently encountered, an air cleaner inlet that is
located in the engine compartment may be specified. Before troubleshooting for low power or for poor
The special air cleaner inlet is sometimes referred to performance in the winter, check the type of fuel that
as a snow valve. An air cleaner that is located in the is being used.
engine compartment may also minimize the snow
that is packed in the air cleaner. Heat that is rejected When No. 2 diesel fuel is used, the following
by the engine warms the inlet air. components provide a means of minimizing problems
in cold weather:
• Starting aids
SEBU8773-07 53
Operation Section
Fuel Related Components in Cold Weather
• Engine oil pan heaters When the engine is equipped with a primary filter/
water separator, the primary filter/water separator
• Engine coolant heaters must use a 10 micron filter to a 15 micron filter. The
filters are becoming more critical as fuel injection
• Fuel line insulation pressures increase to 209 MPa (30000 psi) and
higher psi. For more information on priming the fuel
For more information on cold-weather operation, see system, see the Operation and Maintenance Manual,
Special Publication, SEBU5898, “Cold Weather “Fuel System - Prime” topic.
Recommendations”.
i04369188
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
Fuel Related Components in in cold weather due to waxing. A fuel heater should
Cold Weather be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
SMCS Code: 1000; 1250; 1280
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
Fuel Tanks also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
Condensation can form in partially filled fuel tanks. availability of engine power. Choose a fuel heater
Top off the fuel tanks after operating the engine. with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
Fuel tanks should contain some provision for draining to the limited surface area.
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water Disconnect the fuel heater in warm weather.
and sediment to settle below the end of the fuel
supply pipe. Note: Only use fuel heaters that are controlled by the
water temperature regulator or fuel heaters that are
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is self-regulating. Fuel heaters that are not controlled by
equipped with this system, regular maintenance of the water temperature regulator can heat the fuel in
the fuel system filter is important. excess of 65° C (149° F). A loss of engine power can
occur if the fuel supply temperature exceeds 37° C
Draining the fuel tank will help prevent water and/or (100° F).
sediment from being pumped from the fuel storage
tank and into the engine fuel tank. Drain the water Note: Heat exchanger type fuel heaters should have
and sediment from any fuel storage tank at the a bypass provision in order to prevent overheating of
following intervals: the fuel when the engine operates in warm weather.
Fuel Filters
NOTICE
Do not fill the fuel filters with fuel before installing
them. The fuel would not be filtered and could be con-
taminated. Contaminated fuel will cause accelerated
wear to fuel system parts.
NOTICE
Caterpillar requires the use of a 4 micron (c) secon-
dary fuel filter for the following reasons: to maximize
fuel system life and to prevent premature wear out
from abrasive particles in the fuel. Cat high efficiency
fuel filters meet these requirements. Consult your Cat
dealer for the proper part numbers.
54 SEBU8773-07
Operation Section
Engine Stopping
i03893229
Manual Stop Procedure
SMCS Code: 1000; 7418
Emergency Stopping
SMCS Code: 1000; 7418 NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
NOTICE celerated wear of the engine components.
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices If the engine has been operating at high rpm and/or
or controls for normal stopping procedure. high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
Ensure that any components for the external system fore stopping the engine.
that support the engine operation are secured after
the engine is stopped. Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.
Deep sump
Approximate Refill Capacities
138 146
Compartment or System Liters Quarts
Note: HEX cooled engine JW and SCAC system C32 HEX Cooled SCAC Engines
volumes represent the fill volumes up to the cold full Coolant System Coolant Capacity
mark.
JW system 117.8 L (124.5 qt)
Cat oils have been developed and tested in order to Cat DEO is recommended for engines using fuels of
provide the full performance and service life that has sulfur levels that exceed 0.2 percent (> 2000 ppm
been designed and built into Cat engines. Cat oils (mg/kg) ). Cat DEO-ULS may be used in these
are currently used to fill Cat Diesel Engines at the applications if an oil analysis program is followed.
factory. These oils are offered by Cat dealers for The oil change interval may be affected by the fuel
continued use when the engine oil is changed. sulfur level. Refer to this Operation and Maintenance
Consult your Cat dealer for more information on Manual, “Engine Oil Sample - Obtain” for more
these oils. information about the Cat S·O·S Oil Sampling
program.
Due to significant variations in the quality and in the
performance of commercially available oils, Commercial Oil
Caterpillar makes the following recommendations:
Note: Non-Cat commercial oils are, as a group,
Note: Cat DEO and Cat DEO-ULS multigrade oils
second choice oils. Within this grouping of second
are the preferred oils for use in this Cat Diesel
choice oils there are tiered levels of performance.
Engine.
NOTICE
Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids.
58 SEBU8773-07
Maintenance Section
Fluid Recommendations
The three current Caterpillar ECF specifications are: Note: Generally, use the highest oil viscosity that is
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each available to meet the requirement for the temperature
higher Cat ECF specification provides increased at start-up.
performance over lower Cat ECF specifications.
Table 11
A commercial oil must meet the following standards
to be considered an equivalent of a Cat diesel engine Lubricant Viscosities for Ambient Temperatures for
oil: Cat Diesel Engines
Table 10 °C °F
Oil Type and Per-
Cat Engine Crankcase Fluids (ECF) Definitions Viscosity
formance
Grade Min Max Min Max
Requirements
Cat Performance
API Oil Category
Requirement
Cat Cold Weather
SAE 0W-40 −40 40 −40 104
API CJ-4 Oil Category performance DEO-ULS
Cat ECF-3
requirements Cat DEO-ULS SYN SAE 5W-40 −30 50 −22 122
API CI-4 / CI-4 PLUS Oil Category perform- SAE 10W-30 −18 40 0 104
Cat DEO-ULS
ance requirements and
Cat DEO SAE 15W-40 −10 50 14 122
Passing standard Cat C13 engine test per
Cat ECF-2
API requirements and SAE 0W-30 −40 30 −40 86
Oils of sulfated ash > 1.50 percent are not
Cat ECF-1-a, Cat
allowed SAE 5W-30 −30 30 −22 86
ECF-2, Cat ECF-3
API CH-4 Oil Category performance require- SAE 10W-40 −18 50 0 122
ments and
For oils that are between 1.30 percent and
1.50 percent sulfated ash, passing one addi- Note: A cold soaked start occurs when the engine
Cat ECF-1-a has not been operated recently, allowing the oil to
tional Cat 1P SCOTE test (“ASTM D6681”) is
required and become more viscous due to cooler ambient
Oils of sulfated ash > 1.50 percent are not temperatures. Supplemental heat is recommended
allowed for cold soaked starts below the minimum ambient
temperature. Supplemental heat may be necessary
Engines which are Certified to US Marine for cold soaked starts that are above the minimum
Environmental Protection Agency (EPA) Tier 3 temperature depending on factors such as parasitic
Regulations load.
If an engine which is certified to US Marine EPA Tier Total Base Number (TBN) and Fuel Sulfur
3 Regulations is installed on a US flagged vessel and Levels
is not using Cat DEO-ULS, Caterpillar recommends
the use of an oil that meets the following standards: The use of Cat S·O·S Services oil analysis is
Cat ECF-3 specification and API CJ-4 oil category. recommended strongly for determining oil life.
Lubricant Viscosity The minimum required Total Base Number (TBN) for
oil depends on the fuel sulfur level. The TBN for new
In selecting oil for any engine application, both of the oil is typically determined by the “ASTM D2896”
following must be satisfied: the oil viscosity and the procedure. For direct injection engines that use
category of oil performance or the specification for oil distillate fuel, the following guidelines apply:
performance . Using only one of these parameters Table 12
will not sufficiently define oil for an engine
application. TBN recommendations for applications in Cat engines
Fuel Sulfur Level per- TBN of Commercial
The proper SAE viscosity grade of oil is determined Cat Engine Oils (1)
cent (ppm) Engine Oils
by the following temperatures: minimum ambient
temperature during cold engine start-up and 0.05 percent Cat DEO-ULS
maximum ambient temperature during engine Min 7
(500ppm) Cat DEO
operation.
>0.05-0.2 percent Cat DEO
Min 10
Refer to Table 11 (minimum temperature) in order to (>500- 2000 ppm) (2) Cat DEO-ULS
determine the required oil viscosity for starting a cold
engine. Above 0.2 percent
Cat DEO (5) Min 10
(above 2000ppm) (3)(4)
Refer to Table 11 (maximum temperature) in order to
select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated. (continued)
SEBU8773-07 59
Maintenance Section
Fluid Recommendations
Table 13
Caterpillar Specification for Distillate Fuel for Nonroad
Diesel Engines
ASTM
Specifications Requirements Test ISO Test
Aromatics 35% maximum “D1319” “ISO 3837”
0.01% maximum
Ash “D482” “ISO 6245”
(weight)
40 minimum (DI
engines) “D613”
Illustration 37 g02157153 Cetane Number (1) or “ISO 5165”
35 minimum (PC “D6890”
NACD Film engines)
• Ultra-low Sulfur Diesel Fuel (ULSD fuel). ULSD The cloud point
fuel contains ≤0.0015 percent (≤15 ppm (mg/kg) of must not exceed
Cloud Point the lowest ex- “D2500” “ISO 3015”
sulfur.
pected ambient
temperature.
• Approved blends of biodiesel fuel. Refer to the
“Biodiesel” topic in this article for more Copper Strip
No. 3 maximum “D130” “ISO 2160”
information. Corrosion
The use of diesel fuel that contains >0.0050 percent 10% at 282 °C
(>50 ppm (mg/kg)) of sulfur may cause the (540 °F)
aftercooler to foul. Fouling of the aftercooler may maximum
Distillation “D86” “ISO 3405”
result in engine damage. 90% at 360 °C
(680 °F)
Note: If the engine operates in an area outside of US maximum
EPA jurisdiction and where fuel quality is unknown,
refer to EPA regulations for instructions on obtaining Flash Point legal limit “D93” “ISO 2719”
a migratory exemption. In order to operate a Cat Minimum of 80%
Marine Diesel Engine which is certified to US EPA reflectance after
Marine Tier 3 Standards with fuel that contains >50 No equiva-
Thermal Stability aging for 180 mi- “D6468”
lent test
ppm (mg/kg) of sulfur, modifications to the crankcase nutes at 150 °C
ventilation system (CCV system) must be made to (302 °F)
prevent fouling of the aftercooler. Crankcase fumes
30 minimum No equiva-
cannot be routed back into the engine air intake API Gravity (2) “D287”
when the engine is operating with fuel that contains 45 maximum lent test
>50 ppm (mg/kg) of sulfur. Contact your Cat dealer 6 °C (10 °F) mini-
for more information. Pour Point mum below ambi- “D97” “ISO 3016”
ent temperature
Specifications for Distillate Diesel Fuel
“D5453” ISO 20846
Sulfur (3) or or
Note: Diesel fuel used to operate a Cat Marine
“D2622” ISO 20884
Diesel Engine which is certified to US EPA Tier 3
Standards must also meet the “Cat Specification for 1.4 cSt minimum
Distillate Diesel Fuel for Off-Highway Diesel and 20.0 cSt max-
Engines”. The acceptability of these fuels for use is imum as delivered
determined on a case by case basis. A complete fuel to the fuel injec-
tion pumps
analysis is required. Consult your Cat dealer for Kinematic
- -
further information. Viscosity 1.4 cSt minimum
and 4.5 cSt maxi-
mum as delivered
NOTICE
The footnotes are a key part of the “Caterpillar Speci- to the rotary fuel
fication for Distillate Diesel Fuel for Off-Highway Die- injection pumps
sel Engines” Table. Read ALL of the footnotes.
(continued)
SEBU8773-07 61
Maintenance Section
Fluid Recommendations
No equiva-
Water 0.05% maximum “D6304”
lent test
Cooling System
0.05% maximum
Sediment “D473” “ISO 3735”
(weight)
Coolant Recommendations
Table 15
Coolant Recommendations for use in Cat Diesel Engines
Service Required
Recommendations Product
Hours(1)(2)(3) Maintenance
Table 16
Special Requirements for Cat C7 through C32 Separate Circuit Aftercooled (SCAC) Marine Engines(1)(2)
Maximum of 20% glycol is allowed in the aftercooler circuit (not applicable to the jacket water circuit which is capable of 50% glycol).
Water mixed with ELI or water mixed with SCA are not recommended for use in applications that require freeze protection.(3)(4)(5)
(1) Heat exchanger cooled and keel cooled configurations
(2) For freezing protection of −5° C (23° F) temperatures and lower, consult your Cat dealer for guidance.
(3) For applications that allow the use of Cat ELI and water, a minimum of 7.5% of Cat ELI is recommended.
(4) For applications that allow the use of SCA and water, a minimum of 6% to a maximum of 8% concentration of Cat SCA is recommended.
(5) Refer to Operation and Maintenance Manual, “Cat Commercial Diesel Engine Fluids Recommendations” SEBU6251 for an example of the
amount of ELI to add when diluting ELC.
SEBU8773-07 63
Maintenance Section
Fluid Recommendations
Conventional coolants require the maintenance addi- • Ability to protect from erosion and corrosion
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless • pH
approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring • Conductivity
compatibility and acceptable performance.
• Visual analysis
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- • Odor analysis
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been The results are reported, and appropriate
approved specifically for use by the coolant manufac- recommendations are made.
turer. The coolant manufacturer is responsible for en-
suring compatibility and acceptable performance. S·O·S Services Coolant Analysis (Level 2)
Failure to follow these recommendations can result in A coolant analysis (Level 2) is a comprehensive
shortened cooling system component life. chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
Cat ELC can be recycled into conventional coolants. system.
S·O·S Services Coolant Analysis The S·O·S coolant analysis (Level 2) has the
following features:
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and • Full coolant analysis (Level 1)
corrosion. The analysis also tests the ability of the
• Identification of metal corrosion and of
coolant to protect the engine from boiling and
freezing. S·O·S coolant analysis can be done at your contaminants
Cat dealer. Cat S·O·S coolant analysis is the best
• Identification of buildup of the impurities that
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program cause corrosion
that is based on periodic samples.
• Identification of buildup of the impurities that
Table 17 cause scaling
Recommended Interval • Determination of the possibility of electrolysis
within the cooling system of the engine
Type of Level 1 Level 2
Coolant The results are reported, and appropriate
recommendations are made.
Cat DEAC
Conventional Heavy- Every 250 hours Yearly(1) For more information on S·O·S coolant analysis,
Duty Coolants consult your Cat dealer.
Cat ELC
Cat ELI
Optional Yearly(1)
Greases
Commercial EC-1
Coolants If it is necessary to choose a single grease, always
(1) The Level 2 Coolant Analysis should be performed sooner if a
choose a grease that meets or exceeds the
problem is suspected or identified. requirements of the most demanding application.
Remember that the products which barely meet the
Note: Check the SCA (Supplemental Coolant minimum performance requirements can be
expected to barely produce the minimum lives of your
Additive) of the conventional coolant at every oil
parts. False economy is being used if a grease is
change or at every 250 hours. Perform this check at purchased with the lowest cost as the only
the interval that occurs first. consideration. Instead, use the grease that yields the
lowest total operating cost. The cost should be based
S·O·S Services Coolant Analysis (Level 1) on an analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
A coolant analysis (Level 1) is a test of the properties is required.
of the coolant.
The following properties of the coolant are tested:
64 SEBU8773-07
Maintenance Section
Maintenance Recommendations
NOTICE
Do not ground the welder to electrical components
Contact with high pressure fuel may cause fluid such as the ECM or sensors. Improper grounding
penetration and burn hazards. High pressure fuel can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
spray may cause a fire hazard. Failure to follow
other components.
these inspection, maintenance and service in-
structions may cause personal injury or death. Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
The high pressure fuel lines are the fuel lines that are to the bearings, the crankshaft, the rotor shaft, and
between the high pressure fuel pump and the high other components.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These Clamp the ground cable from the welder to the com-
fuel lines are different from fuel lines on other fuel ponent that will be welded. Place the clamp as close
systems. as possible to the weld. This will help reduce the pos-
This is because of the following differences: sibility of damage.
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
• Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
• Product Link
from the welder could also severely damage
electrical/electronic components that are located
• Cell/Sat Radio
between the welder ground and the weld.
• DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.
Illustration 38 g01075639
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
66 SEBU8773-07
Maintenance Section
Maintenance Interval Schedule
Note: Do not use high pressure when the fins are For more information on cleaning the core, consult
cleaned. High pressure can damage the fins. your Cat dealer.
NOTICE
Test the Aftercooler Core Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic
1. Inspect the core for trapped debris and cleaner can attack the internal metals of the core and
cleanliness. If necessary, remove the debris and cause leakage. Only use the recommended concen-
repeat the cleaning procedure. tration of cleaner.
Rating
Interval
A B C D
(continued)
70 SEBU8773-07
Maintenance Section
Maintenance Recommendations
• Environmental qualities • Operating the engine at loads that are greater than
the rated load
• Installation
• Operating the engine at speeds that are greater
Refer to the standards for your engine or consult your than the rated speed
Caterpillar dealer to determine if your engine is
operating within the defined parameters. • Use of the engine for an application that is not
approved
Because of individual applications, identification all
the factors which can contribute to severe operation Improper Maintenance Practices
is not possible. Consult your Caterpillar dealer about
the maintenance that is needed for your specific • Extension of maintenance intervals
engine.
The following factors can contribute to severe
operation: environment, improper operating
procedures, and improper maintenance practices.
SEBU8773-07 71
Maintenance Section
Maintenance Recommendations
• Not using recommended fuel, lubricants, and Note: The driven equipment may also require service
coolant when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Overhaul Considerations
Overhaul Intervals Which are Based on
Some factors that are important for determining the Fuel Consumption
overhaul intervals include the following
considerations: Experience has shown that the interval for an
overhaul is most accurately based on fuel
• Performance of preventive maintenance consumption. Fuel consumption corresponds more
accurately to the engine load.
• Use of recommended lubricants
Table 21
• Use of recommended coolants Overhaul Intervals(1)
• The engine service life can be extended without S·O·S Coolant Analysis (Level 2) provides a report of
the risk of a major catastrophe due to engine the results of both the analysis and the maintenance
failure. recommendations.
• The best cost/value relationship per hour of For more information, refer to Special Publication,
extended life can be attained. SEBU6251, “Caterpillar Commercial Diesel Engine
Fluids Recommendations” or contact your Caterpillar
After Failure Overhaul dealer.
If a major engine failure occurs and the engine must Engine Components
be removed, many options are available. An overhaul
should be performed if the engine block or the Refer to this Operation and Maintenance Manual,
crankshaft needs to be repaired. “Overhaul (Top End)” for a list of components which
are affected by a top end overhaul. Refer to this
If the engine block and/or the crankshaft is Operation and Maintenance Manual, “Overhaul
repairable, the overhaul cost should be between 40 (Major)” for a list of components which are affected
percent and 50 percent of the cost of a new engine by a major overhaul.
with a similar exchange core.
This lower cost can be attributed to three aspects: i05239037
• Caterpillar Inc. remanufactured exchange Refer to this Operation and Maintenance Manual,
“Maintenance Recommendations” in order to
components determine the maintenance interval for a major
overhaul.
Coolant Analysis
The need for a major overhaul is determined by
The concentration of supplemental coolant additive several factors.
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further • An increase of oil consumption
coolant analysis is recommended when the engine is
overhauled. • An increase of crankcase blowby
A coolant analysis can be conducted to verify the • The total amount of fuel consumption
condition of the water that is being used in the
cooling system. A full water analysis can be obtained • The service hours of the engine
by consulting your local water utility company or an
agricultural agent. Private laboratories are also • The wear metal analysis of the lube oil
available for water analysis.
• An increase in the levels of noise and vibration
Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2). An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
need service. An increase in the levels of noise and
S·O·S Coolant Analysis (Level 2) vibration indicates that rotating parts require service.
An S·O·S Coolant Analysis (Level 2) is a Note: An oil analysis may indicate a decrease of
comprehensive coolant analysis which completely wear metals in the lube oil. The cylinder liners may
analyzes the coolant and the effects on the cooling be worn so that polishing of the bore occurs. Also,
system. An S·O·S Coolant Analysis (Level 2) the increased use of lube oil will dilute the wear
provides the following information: metals.
• Complete S·O·S Coolant Analysis (Level 2) Monitor the engine as the engine accumulates
service hours. Consult your Cat dealer about
• Visual inspection of properties scheduling a major overhaul.
• Identification of metal corrosion Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
• Identification of contaminants
that is provided by the OEM of the driven equipment.
• Identification of built up impurities (corrosion and
scale)
SEBU8773-07 73
Maintenance Section
Overhaul (Major)
A major overhaul includes all of the work that is done • All marine certification society approved tapes are
for the top end overhaul. A major overhaul includes installed in order to cover up fuel line connections
additional parts and labor. Additional parts and labor and oil line connections according to the SOLAS
are required in order to completely rebuild the regulations.
engine.
For the major overhaul, all of the bearings, seals, Inspection, Reconditioning, or
gaskets, and components that wear are Exchanging of Components
disassembled. The parts are cleaned and inspected.
If necessary, the parts are replaced. The crankshaft
Inspect the following components according to the
is measured for wear. The crankshaft may require
instructions that are in Caterpillar reusability
regrinding. Alternatively, the crankshaft may be
publications. Refer to Guidelines for Reusable Parts
replaced with a Cat replacement part. and Salvage Operations, SEBF8029, “Index of
Your Cat dealer can provide these services and Publications on Reusability or Salvage of Used
components. Your Cat dealer can ensure that the Parts”.
components are operating within the appropriate Recondition the worn components or exchange the
specifications. components, if necessary. Your Cat dealer can
provide these services and components.
Replacement of Components
• Camshaft followers
Replace the following components during the major
overhaul: • Camshaft thrust washers
• Mounting bolts for the secondary fuel filter base • Exhaust manifold bellows
• All shields that have been installed to cover up fuel • Inlet manifold seals
and oil line connections per (SOLAS) regulations
• Oil cooler core
• Oil pump
• Pistons
• Piston pins
• Prelube pump
• Pushrods
• Rocker arms
74 SEBU8773-07
Maintenance Section
Overhaul (Major)
• Spacer plate • Excessive wear of the gear train that is not caused
by a lack of lubrication
• Software update
Inspect the gears of the gear train and inspect the
• Turbocharger gear train bushings for the following conditions:
• Independent laboratory
Caterpillar recommends an S·O·S coolant analysis
(Level II) which is a comprehensive chemical
evaluation of the coolant. This analysis is also a
check of the overall condition of the inside of the
cooling system. The following services are provided:
i04363377
3. Steam clean the core in order to remove any For more information on cleaning the core, consult
residue. Flush the fins of the aftercooler core. your Cat dealer.
Remove any other trapped debris from the inside
and from the outside of the core. i05194761
Note: Do not use high pressure when the fins are Aftercooler Core - Inspect
cleaned. High pressure can damage the fins.
SMCS Code: 1064-040
4. Wash the core with hot, soapy water.
The interval for the maintenance of the aftercooler
5. Flush the core thoroughly in order to remove depends on the operating environment of the vessel
and on the operating time. The sea water that is
residue and remaining debris. Flush the core with
circulated through the aftercooler and the amount of
clean, fresh water until the water that is exiting the operating time of the vessel affects the following
core is clear and free of debris. items:
• Cleanliness of the tubes of the aftercooler
Personal injury can result from air pressure. • Effectiveness of the aftercooler
Operating in water that contains silt, sediment, salt,
Personal injury can result without following prop-
algae, and so on, will adversely affect the aftercooler
er procedure. When using pressure air, wear a
system. In addition, intermittent use of the vessel will
protective face shield and protective clothing.
adversely affect the aftercooler.
The maximum air pressure for cleaning purposes
The following items indicate that the aftercooler may
must be reduced to 205 kPa (30 psi) when the air
require cleaning:
nozzle is deadheaded.
• Increased coolant temperature
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow. • Engine overheating
• Excessive pressure drop between the water inlet
Test the Aftercooler Core and the water outlet
1. Inspect the core for trapped debris and An operator that is familiar with the normal operating
cleanliness. If necessary, remove the debris and temperature of the coolant can determine when the
repeat the cleaning procedure. coolant temperature is out of the normal range.
Inspection and maintenance of the aftercooler are
2. Inspect the core for damage and perform a required if the engine is overheating.
pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform Your Cat dealer has the equipment and the trained
personnel that are needed in order to measure the
pressure tests. pressure drop across the aftercooler.
3. Plug both ends of the aftercooler core and
Refer to the Operation and Maintenance Manual,
pressurize the core to 205 kPa (30 psi). “Aftercooler Core - Clean/Test”. For more information
Submerge the core in water. Look for bubbles on servicing the aftercooler, consult your Cat dealer.
which are being emitted from the core. The
bubbles are evidence of leaks. i03091745
Refer to Disassembly and Assembly, “Auxiliary Water 1. Turn the key start switch to the OFF position.
Pump - Remove” in order to remove the auxiliary Remove the key and all electrical loads.
water pump. Refer to Disassembly and Assembly ,
“Auxiliary Water Pump - Disassemble” in order to 2. Turn OFF the battery charger. Disconnect the
disassemble the auxiliary water pump. charger.
Inspect the following components for wear or 3. Turn battery isolator switch to OFF position.
damage:
4. The NEGATIVE “-” cable connects the NEGATIVE
• Bearings “-” battery terminal to the ground plane.
Disconnect the cable from the NEGATIVE “-”
• Impeller battery terminal.
• Seals 5. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
• Wear plate Disconnect the cable from the POSITIVE “+”
If wear or damage is found, replace the components battery terminal.
which are worn or damaged. Use the proper repair kit
for the pump. Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
Refer to Disassembly and Assembly, “Auxiliary Water recycling facility.
Pump - Assemble” in order to assemble the auxiliary
water pump. Refer to Disassembly and Assembly , 6. Remove the used battery.
“Auxiliary Water Pump - Install” in order to install the
auxiliary water pump. 7. Install the new battery.
Thoroughly rinse the battery case with clean 1. Turn the start switch to the OFF position. Turn the
water. ignition switch (if equipped) to the OFF position
Use the 1U-9921 Battery Service Tool to clean and remove the key and all electrical loads.
the battery terminals. Use a wire brush to clean 2. Disconnect the negative battery terminal at the
the cable clamps. Clean the items until the battery that goes to the start switch. Ensure that
surfaces are bright or shiny. DO NOT remove the cable cannot contact the terminal. When four
material excessively. Excessive removal of 12 volt batteries are involved, the negative side of
material can cause the clamps to fit improperly. two batteries must be disconnected.
Coat the clamps and the terminals with the Loctite
®
product listed below, petroleum jelly or MPGM. 3. Tape the leads in order to help prevent accidental
starting.
• For Americas North - Loctite LB8632
4. Proceed with necessary system repairs. Reverse
• For Europe and Africa, Middle East, CIS the steps in order to reconnect all of the cables.
(AMEC) - Loctite LB8104
Replace
1. Remove the front cover.
2. Insert a ratchet with a square drive into the square
hole that is located in the tensioner for the fan
drive belt. Rotate the tensioner clockwise in order
to relieve tension on the fan drive belt. Remove
the fan drive belt.
3. Then insert a ratchet with a square drive into the
square hole that is located in the tensioner for the
alternator belt.
4. Rotate the tensioner counterclockwise in order to
relieve tension on the alternator belt. Remove the
alternator belt.
5. Install the new belt correctly, as shown. Be sure
Illustration 40 g03338555 that the belt is fully seated on the pulleys. The
(1) Belt tensioner correct tension will automatically be applied when
(2) Square drive used for belt replacement the ratchet is removed.
Inspect
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry
more load because the older belt is stretched. The
additional load on the new belt could cause the new
belt to break.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
If the belts are too tight, unnecessary stresses are
placed on the pulley bearings and on the belts.
These stresses may shorten the service life of the
components.
Remove the belt guard, if equipped. Inspect the
condition and adjustment of the alternator belts and
accessory drive belts (if equipped).
SEBU8773-07 81
Maintenance Section
Bolts (Fuel Filter Base) - Inspect/Replace
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Illustration 41 g03320213 Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
Mounting bolts for the secondary fuel filter base bling any component containing fluids.
Three bolts are used to mount the base for the Refer to Special Publication, NENG2500, “Cat Dealer
secondary fuel filter to the mounting bracket. Inspect Service Tool Catalog” or refer to Special Publication,
the bolts for the following conditions: PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
• Wear fluids on Cat products.
• Corrosion Dispose of all fluids according to local regulations
and mandates.
• Cracking
• Sagging 1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
• Crushing
cooling system is drained.
Replace any damaged bolts. Refer to Disassembly
2. Loosen the cooling system filler cap slowly in order
and Assembly, UENR3257, “Fuel Filter Base -
Remove and Install” for the procedure. to relieve any pressure. Remove the cooling
system filler cap.
82 SEBU8773-07
Maintenance Section
Coolant - Change
3. Open the cooling system drain valve (if equipped). 5. Stop the engine and allow the engine to cool.
If the cooling system is not equipped with a drain Loosen the cooling system filler cap slowly in
valve, remove one of the drain plugs. order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
Note: If equipped, be sure to drain the heater and equipped) or remove the cooling system drain
any related supply and return lines.
plugs. Allow the water to drain. Flush the cooling
Allow the coolant to drain. system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
NOTICE plugs. Refer to the Specifications Manual,
Dispose of used engine coolant properly or recycle. SENR3130, “Torque Specifications” for more
Various methods have been proposed to reclaim information on the proper torques.
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac- Systems Filled with Cat DEAC,
ceptable by Caterpillar to reclaim the used coolant.
Conventional Coolant which does not
Meet the Cat EC-1 Requirements, or
For information regarding the disposal and the
recycling of used coolant, consult your Cat dealer or Supplemental Coolant Additive (SCA)
consult Cat Dealer Service Tool Group: and Water
Inside USA 1-800-542-TOOL 3. Flush the cooling system with clean water in order
Inside Illinois 1-800-541-TOOL to remove any debris.
Canada 1-800-523-TOOL
International 1-309-578-7372 4. Close the drain valve (if equipped). Clean the drain
plugs. Install the drain plugs. Refer to the
Flush Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
Systems Filled with Cat ELC, Cat ELI, or torques.
a Conventional Coolant that Meets the
NOTICE
Cat EC-1 Requirements and the Fill the cooling system no faster than 19 L (5 US gal)
Standards of ASTM D6210 per minute to avoid air locks.
1. Flush the cooling system with clean water in order 5. Fill the cooling system with a mixture of clean
to remove any debris. water and Cat Fast Acting Cooling System
2. Close the drain valve (if equipped). Clean the drain Cleaner.
plugs. Install the drain plugs. Refer to the 6. Choose 1 of the following options.
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper • Add 0.5 L (1 pint) of cleaner per 15 L
torques. (4 US gal) of the cooling system capacity.
4. Start and run the engine at low idle until the 8. Start and run the engine at low idle for a minimum
temperature reaches 49 to 66 °C (120 to 150 °F). of 30 minutes. For cooling systems with heavy
deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at
least 82 °C (180 °F).
SEBU8773-07 83
Maintenance Section
Coolant Extender (ELC) - Add
1. Fill the cooling system. Refer to this Operation and Check the cooling system only when the engine is
stopped and cool.
Maintenance Manual, “Fluid Recommendations”
for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
Personal injury can result from hot coolant,
information about the capacity of the cooling steam and alkali.
system. Do not install the cooling system filler cap.
At operating temperature, engine coolant is hot
2. Start and run the engine at low idle. Increase the and under pressure. The radiator and all lines to
engine rpm to high idle. Run the engine at high heaters or the engine contain hot coolant or
idle for 1 minute in order to purge the air from the steam. Any contact can cause severe burns.
cavities of the engine block. Stop the engine.
Remove cooling system pressure cap slowly to
3. Check the coolant level. Maintain the coolant level relieve pressure only when engine is stopped and
within 13 mm (0.5 inch) below the bottom of the cooling system pressure cap is cool enough to
touch with your bare hand.
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight Do not attempt to tighten hose connections when
glass (if equipped). the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
84 SEBU8773-07
Maintenance Section
Coolant Level - Check
NOTICE
Engines That Are Equipped with a
Care must be taken to ensure that fluids are con- Coolant Recovery Tank
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
1. Remove the cooling system filler cap slowly in For additional information about coolant analysis and
order to relieve pressure. about other coolants, see this Operation and
Maintenance Manual, “Fluid Recommendations” or
2. Maintain the coolant level within 13 mm (0.5 inch) consult your Cat dealer.
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant Sampling Conditions
level to the proper level in the sight glass.
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.
If the engine is not equipped with a sampling port, the
coolant should be warm.
Use the following guidelines for proper sampling of
the coolant:
Coolant Sample (Level 1) - • Never collect samples from the drain for a system.
Note: Obtain a Coolant Sample (Level 1) if the Note: Check the SCA (Supplemental Coolant
cooling system is filled with any of the following Additive) of the conventional coolant at every oil
coolants: Cat DEAC, Cat SCA and Conventional change or at every 250 hours. Perform this check at
Heavy-Duty Coolants. the interval that occurs first.
86 SEBU8773-07
Maintenance Section
Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible For further information, refer to this Operation and
to the recommended sampling interval. In order to Maintenance Manual, “Fluid Recommendations”.
receive the full effect of S·O·S analysis, establish a
consistent trend of data. In order to establish a i04240223
pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your Cat Coolant Temperature
dealer. Regulator - Replace
NOTICE SMCS Code: 1355-510
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam- Replace the water temperature regulator before the
pling. Using the same pump for both types of sam- water temperature regulator fails. Replacing the
ples may contaminate the samples that are being water temperature regulator reduces the chances for
drawn. This contaminate may cause a false analysis unscheduled downtime.
and an incorrect interpretation that could lead to con- A water temperature regulator that fails in a partially
cerns by both dealers and customers. opened position can cause overheating or
overcooling of the engine.
Submit the sample for Level 1 analysis. A water temperature regulator that fails in the open
position will cause the engine operating temperature
Note: Level 1 results may indicate a need for Level 2
to be too low during partial load operation. Low
Analysis. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
i04638756 cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
Coolant Sample (Level 2) - the cylinder liner.
Obtain A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
SMCS Code: 1350-008; 1395-554; 1395-008; 7542 overheating could result in cracking of the cylinder
An S·O·S Coolant Analysis (Level 2) is a head or piston seizure problems.
comprehensive chemical evaluation of the coolant.
This analysis is also a check of the overall condition NOTICE
of the cooling system. The S·O·S Coolant Analysis Failure to replace your water temperature regulator
(Level 2) has the following features: on a regularly scheduled basis could cause severe
engine damage.
• Full coolant analysis (Level 1)
Caterpillar engines incorporate a shunt design cool-
• Identification of metal corrosion and contaminants ing system and require operating the engine with a
water temperature regulator installed.
• Identification of buildup of the impurities that
If the water temperature regulator is installed incor-
cause corrosion and scaling
rectly, the engine may overheat, causing cylinder
• Determination of the possibility of electrolysis head damage. Ensure that the new water tempera-
ture regulator is installed in the original position. En-
within the cooling system of the engine
sure that the water temperature regulator vent hole is
open.
The results are reported and appropriate
recommendations are made. Do not use liquid gasket material on the gasket or cyl-
inder head surface.
Obtaining the Sample
Refer to Operation and Maintenance Manual,
“Coolant Sample (Level 1) - Obtain” for the guidelines
for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
SEBU8773-07 87
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
NOTICE NOTICE
Care must be taken to ensure that fluids are con- Excessive supplemental coolant additive concentra-
tained during performance of inspection, mainte- tion can form deposits on the higher temperature sur-
nance, testing, adjusting, and repair of the product. faces of the cooling system, reducing the engine's
Be prepared to collect the fluid with suitable contain- heat transfer characteristics. Reduced heat transfer
ers before opening any compartment or disassem- could cause cracking of the cylinder head and other
bling any component containing fluids. high temperature components.
Refer to Special Publication, NENG2500, “Cat Dealer Excessive supplemental coolant additive concentra-
Service Tool Catalog” or refer to Special Publication, tion could also result in blockage of the heat ex-
PECJ0003, “Cat Shop Supplies and Tools Catalog” changer, overheating, and/or accelerated wear of the
for tools and supplies suitable to collect and contain water pump seal.
fluids on Cat products.
Do not exceed the recommended amount of supple-
Dispose of all fluids according to local regulations mental coolant additive concentration.
and mandates.
NOTICE
Note: If replacing only the water temperature Care must be taken to ensure that fluids are con-
regulator, only drain the coolant to a level that is tained during performance of inspection, mainte-
below the water temperature regulator housing. nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Refer to two articles in the Disassembly and ers before opening any compartment or disassem-
Assembly Manual, “Water Temperature Regulator - bling any component containing fluids.
Remove and Water Temperature Regulator - Install”
for the replacement procedure or consult your Cat Refer to Special Publication, NENG2500, “Caterpillar
dealer. Dealer Service Tool Catalog” and to Special Publica-
tion, GECJ0003, “Cat Shop Supplies and Tools” for
i05053052
tools and supplies suitable to collect and contain flu-
ids on Caterpillar products.
Cooling System Supplemental Dispose of all fluids according to applicable regula-
Coolant Additive (SCA) - Test/ tions and mandates.
Add
Note: Caterpillar recommends an S·O·S coolant
SMCS Code: 1352-045; 1395-081 analysis (Level 1).
Note: This maintenance is NOT required for
cooling systems that are filled with Extended Life Cooling Systems that Use
Coolant. Conventional Coolant
Test the Concentration of the SCA
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact NOTICE
with the skin and eyes. Do not drink cooling sys- Do not exceed the recommended six percent supple-
tem coolant additive. mental coolant additive concentration.
i06103521
i06103535
Engine - Clean
SMCS Code: 1000-070
NOTICE
Accumulated grease and oil on an engine is a fire NOTICE
hazard. Keep the engine clean. Remove debris and Never run the engine without an air cleaner element
fluid spills whenever a significant quantity accumu- installed. Never run the engine with a damaged air
lates on the engine. cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets, or seals. Dirt entering
Periodic cleaning of the engine is recommended. the engine causes premature wear and damage to
Steam cleaning the engine will remove accumulated engine components. Air cleaner elements help to pre-
oil and grease. A clean engine provides the following vent airborne debris from entering the air inlet.
benefits:
If the air cleaner element becomes plugged, the air
• Easy detection of fluid leaks can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
• Maximum heat transfer characteristics engine wear. Your Cat dealer has the proper air
cleaner elements for your application. Consult your
• Ease of maintenance Cat dealer for the correct air cleaner element.
Note: Caution must be used in order to prevent NOTICE
electrical components from being damaged by Never service the air cleaner element with the engine
excessive water when you clean the engine. Avoid running. Operating the engine without an air cleaner
electrical components such as the alternator, the allows dirt to enter the engine.
starter, and the ECM.
4. Close the four latches. • Check the movement of the service indicator core
when the engine is run at full load speed. The core
5. Reset the service indicator. should latch approximately at the greatest vacuum
that is attained.
i06103548
If the service indicator does not reset easily, or if the
Engine Air Cleaner Service core does not latch at the greatest vacuum, the
service indicator should be replaced. If the new
Indicator - Inspect service indicator will not reset, the hole for the service
indicator may be plugged.
(If Equipped)
If necessary, replace the service indicator more
SMCS Code: 7452-040 frequently in environments that are severely dusty.
Some engines may be equipped with a different Replace the service indicator annually regardless of
service indicator. the operating conditions. Replace the service
indicator when the engine is overhauled, and
Some engines are equipped with a differential gauge whenever major engine components are replaced.
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure Note: When a new service indicator is installed,
that is measured before and after the air cleaner excessive force may crack the top of the service
element. As the air cleaner element becomes dirty, indicator. Tighten the service indicator to a torque of
the pressure differential rises. If your engine is 2 N·m (18 lb in).
equipped with a different type of service indicator,
follow the OEM recommendations in order to service i07047562
the air cleaner service indicator.
The service indicator may be mounted on the clean Engine Cooling System
side of the air cleaner housing or in a remote
location. Corrosion Protection System -
Inspect
SMCS Code: 1388-040
Galvanic corrosion may harm components that cool
the engine. Corrosion is caused when dissimilar
metals are in contact and the dissimilar metals are
immersed in salt water. The voltage potential from
salt water to the engine must be tested regularly to
protect the cooling components.
Note: These engines are not shipped from the
factory with sacrificial zinc anodes installed in the
seawater system, therefore special attention must be
given to bonding. On insulated-earth engines
(battery negative isolated from cylinder block),
Illustration 46 g00103777 bonding is defined as the electrical interconnection of
Typical service indicator metal objects in common contact with water, and to
the sacrificial anodes or impressed current system.
Observe the service indicator. The air cleaner On negative-earth engines (battery negative is
element should be cleaned or the air cleaner element connected directly to cylinder block), bonding may be
should be replaced when one of the following defined as connecting to the engine negative
conditions occur: terminal, or the engines bus, which is, in turn,
connected to the vessel anode. Caterpillar engines
• The yellow diaphragm enters the red zone. are designed as insulated-earth engines.
• The red piston locks in the visible position. Note: Without a bonding system in place to protect
the engine cooling system, the engine may
Test the Service Indicator experience corrosion.
Service indicators are important instruments. There are two basic types of corrosion in any marine
installation:
• Check for ease of resetting. The service indicator
should reset in less than three pushes. • Stray Current Corrosion – an aggressive type of
corrosion that occurs anytime electric current is
supplied unintentionally or accidentally
SEBU8773-07 91
Maintenance Section
Engine Cooling System Corrosion Protection System - Inspect
• Galvanic Corrosion – this type of corrosion occurs 3. Test the voltage at the bonding connector.
as the least noble anodes (dissimilar metals in the
same electrolyte (sea water)) Use the following for voltage potential testing.
Table 24
Galvanic corrosion is a slower type of corrosion,
Corrosion probe
usually occurring over a longer period. Caterpillar
engines are designed with a maximum 0.2 V Freely Protected Over
potential across seawater components. Most Eroding Protected
corrosion seen on vessels today occurs from stray
currents. Bronze
0–600 600–700 700–1200
Location of the Corrosion Readings in
Millivolts Steel
Protection Post 0–750 750–950 950–1200
To investigate stray current corrosion, turn on-board • Completed circuit between any metal component
electrical components “ON” one-by-one. As in contact with sea water and vessel anode (for
components are turned “ON”, watch for changes in example, each component and vessel anode
voltage. With any voltage change on any component, connected in circuit). It's recommended each
this is a sign of stray current and should be corrected component be connected via a low voltage
immediately. connection, rather than running each component
to a common bus. If a connection to the common
Results of the Test bus fails, that component will not be protected.
Connected in series, if a connection fails, that
The voltage potential must be between 600 mV and component would still be protected due to its
700 mV. second connection
Note: A value near or greater than 0.0 mV is • Electrically isolated metal components in contact
extremely corrosive. with sea water (for example, each component is
protected with its own anode)
Measure the galvanic potential of the system and
apply zinc or other less noble metal to divert • Impressed current cathodic protection (ICCP).
corrosion. Contact your Cat dealer for more
Manufacturer recommendations should be
information.
followed on all ICCP systems
Bonding the Marine Engine Note: All marine engines must be bonded using one
of these three aforementioned methods. Caterpillar
recommends bonding these engines with method
#1. Regarding the engine portion of this bonding
circuit, the engine bonding stud locations should be
used.
Note: Bonding is not only for engines. All
components in contact with sea water must be
bonded and tested! For example, if the propeller
shaft is not connected within the same circuit as the
other components, the shaft will have a different
voltage potential and could draw metal away from the
engine. Everything in contact with sea water has to
be included in the bonding circuit. The anodes have
to be able to sufficiently raise the potential of all
components.
Illustration 48 g06219255
(1) Engine
(2) Propeller shaft
(3) Sea cock
(4) Vessel anode
(5) Engine bonding conductor
(6) Common bonding conductor (wire)
(7) Hull Through-bolts
Illustration 50 g06218826
C32 marine engine bonding stud
An insulated conductor should be used on all On aluminum hulls, incorporating the engine
bonding systems. The bonding wire should be a bonding systems within the vessels system is
minimum size of #8 American Wire Gauge (AWG) suggested. Since aluminum hulls are a specialized
and should be multi-stranded. As the bonding circuit subject for the vessel and the engine is just attaching
may be exposed to sea water, soldered or brazed to the vessels system, seek professional advice on
connections are recommended. Each bonding circuit the vessel bonding/anode system. The principles are
or connection to sacrificial anode should have a good the same as fiberglass/wooden hulled vessel where
electrical connection (typical resistance of <0.2 ohm). the anodes and through bolts are isolated from the
hull. If the bonding is incorrect on an aluminum hull,
On steel boats with anodes bolted or welded to the damage can quickly occur. Many aluminum hulls use
outside of the hull, bonding the engines bonding stud impressed current cathodic protection (ICCP).
directly to the hull is recommended. The
aforementioned bonding of the stud to the hull Note: After making the bonding connection from the
ensures that you have a direct connection to the engine, it is imperative voltage potential be measured
vessel anodes.
on all components in contact with seawater.
On fiberglass and wooden hulls, you are able to
bond to a through-bolt used to attach the anode to C32 engines and generator sets built in Griffin are
the outside of the hull. On fiberglass and wooden shipped with both a neutral cable connection on the
hulls, it is important to isolate the anode and the generator end and an engine bonding stud. For these
through-bolt from the hull. engines and generator sets, both
Illustration 52 g00110310
(Y) “ADD” mark
(X) “FULL” mark
Illustration 51 g01136454
NOTICE
Typical example Perform this maintenance with the engine stopped.
(1) Hose clamp
(2) Breather assembly
(3) Retaining clamp 1. Maintain the oil level between the “ADD” mark (Y)
(4) Seal and the “FULL” mark (X) on the oil level gauge .
Do not fill the crankcase above the “FULL” mark
1. Loosen hose clamp (1) and remove the hose from (X).
breather assembly (2).
2. Loosen retaining clamp (3). Remove the breather
assembly and seal (4).
3. Wash the breather element in solvent that is clean
and nonflammable. Allow the breather element to
dry before installation.
4. Install a breather element that is clean and dry.
Install the seal, the breather assembly, and the
clamp. Refer to the Specifications, SENR3130 in
order to locate the proper torques.
5. Install the hose. Install the hose clamp. Refer to
the Specifications, SENR3130 in order to locate
the proper torques.
SEBU8773-07 95
Maintenance Section
Engine Oil Level Gauge - Calibrate
9. Check the engine oil level. Use a marking tool to To ensure that the sample is representative of the oil
engrave the “ADD” mark (Y) to the correct location in the crankcase, obtain a warm, mixed oil sample.
on the gauge assembly.
To avoid contamination of the oil samples, the tools
10. Add 28 L (30 qt) of the recommended oil grade and the supplies that are used for obtaining oil
and weight of engine oil to the crankcase with a samples must be clean.
shallow sump. Add this amount for both shallow Caterpillar recommends using the sampling valve in
sumps and deep sumps. Allow the oil to drain into order to obtain oil samples. The quality and the
the sump for approximately 20 minutes. consistency of the samples are better when the
sampling valve is used. The location of the sampling
11. Check the engine oil level. Use a marking tool to valve allows oil that is flowing under pressure to be
engrave “FULL” mark (X) onto the correct location obtained during normal engine operation.
on the gauge assembly.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
Illustration 53 g00110310 ples may contaminate the samples that are being
Oil Level Gauge “ADD” mark (Y) and “FULL” mark (X) drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
i04237495 cerns by both dealers and customers.
Engine Oil Sample - Obtain If the engine is not equipped with a sampling valve,
SMCS Code: 1348-554-SM use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
In addition to a good preventive maintenance tubing must be attached to the pump for insertion into
program, Caterpillar recommends using S·O·S oil the sump.
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required For instructions, see Special Publication, PEGJ0047,
for determining nitration and oxidation levels. “How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
Obtain the Sample and the engine.
Analysis
i05036729
• Engine model
• Service hours on the engine
Drain the Engine Oil Nonferrous metals may indicate wear on the
aluminum parts, brass parts, or bronze parts of the
Do not drain the oil when the engine is cold. As the oil engine. Parts that may be affected include the
cools, suspended waste particles settle on the following items: main bearings, rod bearings,
bottom of the oil pan. The waste particles are not turbocharger bearings and cylinder heads.
removed with the draining cold oil. Drain the
crankcase with the engine stopped. Drain the Due to normal wear and friction, small amounts of
crankcase with the oil warm. This draining method debris may be found in the oil filter. Consult your
allows the waste particles that are suspended in the Cat dealer in order to arrange for a further analysis
oil to be drained properly.
if an excessive amount of debris is found in the oil
Failure to follow this recommended procedure will filter.
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
After the engine has been run at the normal
operating temperature, stop the engine. Use one of
the following methods to drain the engine crankcase
oil:
Typical filter mounting base and filter gasket If the engine is equipped with duplex oil filters, the
engine oil filter elements can be changed while the
3. Clean the sealing surface of the filter mounting engine is in operation.
base. Ensure that all of the old oil filter gasket is
removed.
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components.
5. Install the oil filter. Tighten the oil filter until the oil
filter gasket contacts the base. Tighten the oil filter
by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
filter.
5. Open the “FILL” valve for a minimum of 5 minutes 1. Remove the oil filler cap. Fill the crankcase
in order to fill the new oil filter elements. through the oil filler tube only. Clean the oil filler
cap. Install the oil filler cap.
6. Close the “FILL” valve. Rotate the control valve to
the “RUN” position for the oil filter that was
NOTICE
serviced. To prevent crankshaft or bearing damage, crank en-
gine with fuel off to fill all filters before starting.
Fill the Engine Crankcase Do Not crank engine for more than 30 seconds.
NOTICE
If equipped with an auxiliary oil filter system or a re- 2. Close the fuel supply line and crank the engine
mote oil filter system, follow the OEM or filter manu- until the oil pressure gauge indicates 70 kPa
facturer's recommendations. Under filling or (10 psi). Open the fuel supply line. Allow the
overfilling the crankcase with oil can cause engine starting motor to cool for 2 minutes before
damage.
cranking again.
3. Start the engine according to this Operation and
NOTICE Maintenance Manual, “Starting The Engine”
To prevent crankshaft bearing damage, crank the en- procedure (Operation Section). Operate the
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more engine at low idle for 2 minutes. in order to ensure
than 30 seconds. that the lubrication system has oil and that the oil
filters are filled with oil. Inspect the engine for oil
leaks. Ensure that the oil level is at the “FULL”
NOTICE mark on the “LOW IDLE” side of the oil level
Engine damage can occur if the crankcase is filled gauge.
above the “FULL” mark on the oil level gauge
(dipstick). 4. Stop the engine and allow the oil to drain back into
the sump for a minimum of 10 minutes.
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel- 5. Remove the oil level gauge and check the oil level.
oped and also force air bubbles into the oil. These Maintain the oil level to the “FULL” mark on the
bubbles (foam) can cause the following problems: re- “ENGINE STOPPED” side of the oil level gauge.
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption. Inspect the Used Oil Filter
Excessive oil consumption will cause deposits to form
Elements
on the pistons and in the combustion chamber. De- Cut the used oil filter element open with a utility knife.
posits in the combustion chamber lead to the follow- Remove the metal wrap. Cut the filter element free
ing problems: guttering of the valves, packing of from the end caps. Spread apart the pleats and
carbon under the piston rings and wear of the cylin- inspect the element for metal debris. An excessive
der liner. amount of debris in the element may indicate early
If the oil level is above the “FULL” mark on the oil lev- wear or a pending failure.
el gauge, drain some of the oil immediately.
Use a magnet to differentiate between the ferrous
Use the following procedure in order to fill the metals and the nonferrous metals that are found in
crankcase if the engine oil filters were replaced the element. Ferrous metals may indicate wear on
during engine operation. the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
1. If the engine oil filters were replaced during engine aluminum parts, the brass parts, or the bronze parts
operation, operate the engine at low idle. Ensure of the engine. Parts that may be affected include the
that the oil level is at the “FULL” mark on the “LOW following components: main bearings, rod bearings,
turbocharger bearings and cylinder heads.
IDLE” side of the oil level gauge.
Aluminum debris may indicate problems with the
2. Add oil, if necessary. Remove the oil filler cap. Fill
bearings of the front gears. If you find aluminum
the crankcase through the oil filler tube only. debris, inspect the crankshaft vibration damper and
the idler gear bearings.
Use the following procedure in order to fill the
crankcase if the engine oil filters were replaced with
the engine stopped. Refer to this Operation and
Maintenance Manual, “Fluid Recommendations” for
information about choosing the oil for the engine.
100 SEBU8773-07
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect
• Fuel consumption
If an engine is out of operation and if use of the
engine is not planned, special precautions should be
made. If the engine will be stored for more than three
months, a complete protection procedure is
recommended. For more detailed information on
engine storage, see Special Instruction, SEHS9031,
“Storage Procedure For Caterpillar Products”.
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the use
of volatile corrosion inhibitor (VCI) oil in order to
Illustration 57 g01137086 prevent internal engine damage due to moisture
Front view during storage. These inhibitors in the VCI oil act by
evaporating inside the engine. The inhibitors then
(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor condense over the inside surfaces of the engine. The
evaporation process and the condensing process
offers full protection to surfaces that cannot be
1. Remove the speed/timing sensors from the front reached with preservatives. 0.9 L (1.0 qt) of
housing. Check the condition of the plastic end of 4C-6792 VCI oil will treat 28.4 L (30.0 qt) of engine
the speed/timing sensors for wear and/or oil. This will give a 3 percent concentration of VCI oil.
contaminants. The engine must be completely sealed when the
engine is stored in order for the VCI oil to function
2. Clean the metal shavings and other debris from properly. The VCI oil is easily cleaned from the
the face of the speed/timing sensors. Use the engine when you remove the engine from storage.
procedure in the Troubleshooting Manual, “Speed/ The volatile vapors are removed by simply running
Timing Sensor - Calibrate” in order to calibrate the the engine to operating temperature. A mineral oil
speed/timing sensors. base is left behind after the volatile vapors are
removed.
SEBU8773-07 101
Maintenance Section
Engine Valve Lash - Check
Ensure that the engine cannot be started while Be sure the engine cannot be started while this
this maintenance is being performed. To help pre- maintenance is being performed. To prevent pos-
vent possible injury, do not use the starting motor sible injury, do not use the starting motor to turn
to turn the flywheel. the flywheel.
Hot engine components can cause burns. Allow Hot engine components can cause burns. Allow
additional time for the engine to cool before additional time for the engine to cool before
measuring/adjusting valve lash clearance. measuring/adjusting the unit injectors.
The electronic unit injectors use high voltage.
i01597115
Disconnect the unit injector enable circuit con-
nector in order to prevent personal injury. Do not
come in contact with the injector terminals while
Engine Valve Rotators - the engine is running.
Inspect The operation of Cat engines with improper
SMCS Code: 1109-040 adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.
When inspecting the valve rotators, protective Only qualified service personnel should perform this
glasses or face shield and protective clothing maintenance. Refer to the following topics for your
must be worn, to help prevent being burned by engine for the correct procedure: Refer to the
hot oil or spray. Systems Operation, Testing and Adjusting, “Fuel
System” for the maintenance procedure.
Engine valve rotators rotate the valves when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats. NOTICE
The camshafts must be correctly timed with the
Perform the following steps after the engine valve crankshaft before an adjustment of the lash for the
lash is set, but before the valve covers are installed: fuel injector is made. The timing pins must be re-
moved from the camshafts before the crankshaft is
turned or damage to the cylinder block will be the
result.
102 SEBU8773-07
Maintenance Section
Fuel System - Prime
i02728734
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.
Illustration 59 g01368408
(1) Fuel priming pump
(2) Fuel filter base
(3) Secondary fuel filter
Fuel leaked or spilled onto hot surfaces or electri- 2. Remove element (1) from the element mounting
cal components can cause a fire. To help prevent base while bowl (2) is attached.
possible injury, turn the start switch off when
changing fuel filters or water separator elements. 3. Dispose of the contents of the filter. Remove bowl
Clean up fuel spills immediately. (2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
4. Remove the O-ring from the gland of the bowl.
Clean the following components:
• Bowl
104 SEBU8773-07
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the
fuel system.
Illustration 61 g00668636
(1) Bowl
(2) Element
(3) Drain
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.
SEBU8773-07 105
Maintenance Section
Fuel System Secondary Filter - Replace
i05303381
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates. Illustration 62 g03140296
Typical secondary fuel filter
(1) Priming pump
NOTICE (2) Fuel shutoff
Keep all parts clean from contaminants. (3) Drain valve
(4) Fuel indicators
Contaminants may cause rapid wear and shortened (5) Auxiliary secondary fuel filter
component life. (6) Main secondary fuel filter
(7) Fuel selector valve
Note: If the engine is equipped with duplex fuel Replacing the Fuel Filter Elements
filters, the fuel filter elements can be replaced while
the engine is in operation. Refer to “Replacing the with the Engine Stopped
Fuel Filter Elements During Engine Operation For
Engines That Are Equipped With Duplex Fuel NOTICE
Filters”. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
106 SEBU8773-07
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE NOTICE
Do not fill the secondary fuel filter with fuel before in- Do not allow dirt to enter the fuel system. Thoroughly
stalling. The fuel would not be filtered and could be clean the area around a fuel system component that
contaminated. Contaminated fuel will cause acceler- will be disconnected. Fit a suitable cover over discon-
ated wear to fuel system parts. nected fuel system component.
8. Install the new fuel filter. Tighten the fuel filter until NOTICE
the gasket contacts the base. Tighten the fuel filter Care must be taken to ensure that fluids are con-
by hand according to the instructions that are tained during performance of inspection, mainte-
shown on the fuel filter. Do not overtighten the fuel nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
filter. ers before opening any compartment or disassem-
bling any component containing fluids.
Note: Do not remove the plug in the fuel filter base to
release the air from the fuel system during periodic Refer to Special Publication, NENG2500, “Cat Dealer
service of the fuel filter. Periodic removal of the plug Service Tool Catalog” or refer to Special Publication,
will result in increased wear of the threads in the fuel PECJ0003, “Cat Shop Supplies and Tools Catalog”
filter base. for tools and supplies suitable to collect and contain
fluids on Cat products.
9. Operate the fuel priming pump plunger until a
strong resistance is felt and until the check valve Dispose of all fluids according to local regulations
clicks. This procedure will require considerable and mandates.
strokes. Lock the fuel priming pump.
10. Open the fuel tank supply valve. Replacing the Main Fuel Filter
11. Start the engine according to the normal Use the following procedure to replace the main fuel
operating procedures. Immediately increase the filter while the engine is in operation.
engine rpm between 1000 to 1200 rpm with no
load. The engine will begin to misfire briefly until
air from the fuel filter is purged. No damage to the
engine will occur.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Once the lever has been moved to the AUX RUN 1. Move the fuel selector valve to the MAIN RUN
position, the fuel gauge for the auxiliary filter position as marked on the indicator plate.
should indicate full pressure and the fuel gauge for
the main filter should indicate no pressure.
3. Slowly open the drain valve and purge any
remaining pressure from the main filter. Some fuel
may also drain from the fuel drain. The fuel
indicator for the auxiliary filter should indicate full
pressure and the fuel indicator for the main filter
should indicate no pressure.
4. Remove the used main fuel filter.
5. Clean the gasket sealing surface of the main fuel
filter base. Ensure that all of the old gasket is
removed.
6. Apply clean diesel fuel to the new main fuel filter Illustration 66 g03410043
gasket.
7. Install a new main fuel filter. Tighten the fuel filter 2. Once the lever has been moved to the MAIN RUN
until the gasket contacts the base. Tighten the fuel position, the fuel gauge for the main filter should
filter by hand according to the instructions that are indicate full pressure and the fuel gauge for the
shown on the fuel filter. Do not overtighten the fuel auxiliary filter should indicate no pressure.
filter. 3. Slowly open the drain valve and purge any
8. Move the lever to the RH FLOW - LH FILL position. remaining pressure from the auxiliary filter. Some
The indicator for the main filter should indicate fuel may also drain from the fuel drain. The fuel
slight pressure. Purge the air from lines for the indicator for the main filter should indicate full
main filter through the drain valve. Close the drain pressure and the fuel indicator for the auxiliary
valve when the fuel starts flowing through the filter should indicate no pressure.
drain valve. 4. Remove the used auxiliary filter.
9. Move the fuel selection lever to the FLOW BOTH 5. Clean the gasket sealing surface of the auxiliary
position and monitor the main filter for leaks. fuel filter base. Ensure that all of the old gasket is
Uninstall and reinstall the main filter if necessary. removed.
Replacing the Auxiliary Fuel Filter 6. Apply clean diesel fuel to the new auxiliary fuel
filter gasket.
Use the following procedure to replace the auxiliary
fuel filter while the engine is in operation.
108 SEBU8773-07
Maintenance Section
Fuel Tank Water and Sediment - Drain
7. Install a new auxiliary fuel filter. Tighten the fuel Fuel Tank
filter until the gasket contacts the base. Tighten
the fuel filter by hand according to the instructions Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
that are shown on the fuel filter. Do not overtighten excessive wear to the fuel system. Condensation
the fuel filter. occurs during the heating and cooling of fuel. The
8. Move the fuel selection lever to the “LH FLOW - condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
RH FILL” position. The indicator for the auxiliary causes water to accumulate in fuel tanks. Draining
filter should indicate slight pressure. Purge the air the fuel tank regularly and obtaining fuel from reliable
from the lines for the auxiliary filter through the sources can help to eliminate water in the fuel. The
drain valve. Close the drain valve when the fuel fuel tank utilizes a fuel tank vent to prevent an air lock
starts to flow through the valve. or vacuum. Ensure that the vent is free of debris and
not damaged.
9. Move the fuel selection lever to the FLOW BOTH
position and monitor the auxiliary filter for leaks. Drain the Water and the Sediment
Uninstall and reinstall the auxiliary filter if
necessary. Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
i06104305
Prepare to catch water and sediment in an
Fuel Tank Water and Sediment appropriate container. Connect a hose (if necessary)
to the valve prior to opening the valve.
- Drain
SMCS Code: 1273-543-M&S Open the drain valve on the bottom of the fuel tank in
order to drain the water and the sediment. Close the
drain valve.
NOTICE
Care must be taken to ensure that fluids are con- Note: Failure to close the drain properly could result
tained during performance of inspection, mainte- in fuel leakage, which could have detrimental results
nance, testing, adjusting, and repair of the product. to performance.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Check the fuel daily. Drain the water and sediment
bling any component containing fluids. from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
Refer to Special Publication, NENG2500, “Cat Dealer fuel tank has been filled. Allow 5 to 10 minutes before
Service Tool Catalog” or refer to Special Publication, performing this procedure.
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain Fill the fuel tank after operating the engine in order to
fluids on Cat products. drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
Dispose of all fluids according to local regulations expands as the fuel gets warm. The tank may
and mandates. overflow.
Some fuel tanks use stand pipes that allow water and
sediment to settle below the end of the fuel stand
pipe. Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
• Weekly
• Refill of the tank
This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
the breather vent on the fuel tank is also
recommended.
SEBU8773-07 109
Maintenance Section
Fumes Disposal Filter Element - Replace
If a bulk storage tank has been refilled or moved Note: When possible, perform the maintenance while
recently, allow adequate time for the sediment to the engine is off.
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap 1. Release the latches that hold the canister to the
sediment. Filtering fuel that is pumped from the cap.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. Note: Removal of the canister may be difficult while
the engine is operating. The canister has negative air
i05019230 pressure while the engine is operating which creates
a vacuum.
Fumes Disposal Filter Element
2. Lower the canister in order to expose the element.
- Replace There may be oil in the bottom of the canister.
SMCS Code: 1074 Avoid spilling the oil.
Replacement of the fumes disposal filter is affected 3. Remove the filter element by pulling down.
by the following items: Dispose of the used element properly.
• Engine load 4. Replace the canister and align the canister with the
boss on the filter base assembly.
• Soot concentration
5. Clamp the latches in the closed position.
• Condition of the engine
Resetting the Service Indicator (If
Replacing the Fumes Disposal Equipped)
Filter
Illustration 68 g01292899
(4) Plastic cover
(5) Service indicator
Illustration 67 g03123321
Typical installation
(1) Latches for the canister
(2) Service indicator
(3) Cap for the canister
(4) Engine air cleaner
(5) Canister
110 SEBU8773-07
Maintenance Section
Heat Exchanger - Clean/Test
Heat Exchanger - Clean/Test Personal injury can result without following prop-
er procedure. When using pressure air, wear a
SMCS Code: 1379-070; 1379-081 protective face shield and protective clothing.
The maximum air pressure for cleaning purposes
Clean the Heat Exchanger must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
1. Remove the heat exchanger from the engine.
Refer to the Disassembly and Assembly Manual, 8. Dry the heat exchanger core with compressed air.
“Heat Exchanger - Remove” for the procedure. Direct the air in the reverse direction of the normal
2. Remove the heat exchanger core from the heat flow.
exchanger. Refer to the Disassembly and
Assembly Manual, “Heat Exchanger - Test the Heat Exchanger Core
Disassemble” for the procedure.
1. Inspect the heat exchanger core for trapped debris
3. Turn the heat exchanger core onto one side in and cleanliness. If necessary, remove the debris
order to remove debris. Remove the debris that is and repeat the cleaning procedure.
accessible.
2. Inspect the heat exchanger core for damage and
NOTICE perform a pressure test in order to detect leaks.
Do not use a high concentration of caustic cleaner to Many shops that service radiators are equipped to
clean the core. A high concentration of caustic perform pressure tests.
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen- 3. Plug both ends of the heat exchanger core and
tration of cleaner. pressurize the core to 100 kPa (14.5 psi).
Submerge the core in water. Look for bubbles
4. Back flush the heat exchanger core with cleaner. which are being emitted from the core. The
bubbles are evidence of leaks.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 26 lists Hydrosolv liquid 4. If any leaks are found, do not attempt to repair the
cleaners that are available from your Cat dealer. core.
Table 26 5. Install a core that is clean and that passes the
Hydrosolv Liquid Cleaners(1) pressure test in step 3. Refer to the Disassembly
and Assembly Manual, “Heat Exchanger -
Part Number Description Size
Assemble” for the procedure.
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
6. Install the heat exchanger onto the engine. Refer
174-6854 Hydrosolv 100 19 L (5 US gallon) to the Disassembly and Assembly Manual, “Heat
(1) Use a 2 to 5 percent concentration of the cleaner at tempera- Exchanger - Install” for the procedure.
tures up to 93°C (200°F). Consult your Cat dealer for more
information.
For more information on cleaning the core, consult Operating in water that contains the following will
your Cat dealer. adversely affect the heat exchanger system: silt,
sediment, salt and algae. In addition, intermittent use
i03712080 of the vessel will adversely affect the heat exchanger
system.
Heat Exchanger - Inspect The following items indicate that the heat exchanger
SMCS Code: 1379-040 may require cleaning:
• Increased coolant temperature
• Engine overheating
Personal injury can result from hot coolant,
steam and alkali. • Excessive pressure drop between the water inlet
and the water outlet
At operating temperature, engine coolant is hot
and under pressure. The heat exchanger and all An operator that is familiar with the normal operating
lines to heaters or the engine contain hot coolant temperature of the coolant can determine when the
or steam. Any contact can cause severe burns. coolant temperature is out of the normal range.
Inspection of the heat exchanger and maintenance of
Remove the filler cap slowly to relieve pressure the heat exchanger are required if the engine is
only when the engine is stopped and the filler cap overheating.
for the heat exchanger is cool enough to touch
with your bare hand. Your Caterpillar dealer has the equipment and the
personnel in order to measure the pressure drop
Cooling System Conditioner contains alkali. across the heat exchanger.
Avoid contact with skin and eyes.
Cleaning Procedure
NOTICE
Keep all parts clean from contaminants. Removal and Disassembly of the Heat
Exchanger
Contaminants may cause rapid wear and shortened
component life. Drain the heat exchanger. Refer to the Disassembly
and Assembly Manual, “Heat Exchanger - Remove”
for the removal procedure.
NOTICE
Care must be taken to ensure that fluids are con- Refer to the Disassembly and Assembly Manual,
tained during performance of inspection, mainte- “Heat Exchanger - Disassemble” for the disassembly
nance, testing, adjusting, and repair of the product. procedure. Keep the plates in order..
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Cleaning the Heat Exchanger
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer Refer to “Choosing the Correct Cleaning Fluid” for
Service Tool Catalog” or refer to Special Publication, the correct cleaning fluid for your heat exchanger.
PECJ0003, “Cat Shop Supplies and Tools Catalog” Clean the plates with a cleaning solution and a soft
for tools and supplies suitable to collect and contain brush. Pressurized water may also be used. Do not
fluids on Cat products. use steel wool or a wire brush, which may scratch the
plate. Any iron scratches on the plates can lead to
Dispose of all fluids according to local regulations corrosion of the plates. Rinse the plates with water.
and mandates.
Choosing the Correct Cleaning Fluid
The interval for the maintenance of the plate type
heat exchanger depends on the operating Refer to 27 for the correct cleaning fluid for the heat
environment of the vessel and on the operating time. exchanger.
The sea water that is circulated through the heat
exchanger and the amount of operating time of the
vessel affects the following items:
• Cleanliness of the heat exchanger plates
Table 27
Refer to the Disassembly and Assembly Manual, • Hoses which are soft
“Heat Exchanger - Assemble” for the assembly
procedure. • Outer covering that is chafed or cut
• Anticipated expansion and contraction of the Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
fittings
Due to extreme temperature changes, the hose will 1. Stop the engine.
heat set. Heat setting causes hose clamps to loosen
which can result in leaks. A constant torque hose 2. Allow the engine to cool.
clamp will help to prevent loose hose clamps.
3. Before servicing a coolant hose, slowly loosen the
Replace hoses that are cracked or soft. Replace filler cap for the cooling system to relieve any
hoses that show signs of leakage. Replace hoses pressure.
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace 4. Remove the filler cap for the cooling system.
hose clamps which are loose.
5. Drain the coolant from the cooling system to a
Replace the Hoses and the Clamps level that is below the hose that is being replaced.
Drain the coolant into a suitable clean container.
The coolant can be reused.
NOTICE
Care must be taken to ensure that fluids are con- 6. Remove the hose clamps.
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. 7. Disconnect the old hose.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- 8. Replace the old hose with a new hose.
bling any component containing fluids.
9. Install hose clamps which have been inspected or
Refer to Special Publication, NENG2500, “Cat Dealer install new hose clamps. Refer to Specifications,
Service Tool Catalog” or refer to Special Publication, SENR3130, “Torque Specifications” “Hose
PECJ0003, “Cat Shop Supplies and Tools Catalog” Clamps” for information about selecting and
for tools and supplies suitable to collect and contain installing the proper hose clamps.
fluids on Cat products.
10. Refill the cooling system.
Dispose of all fluids according to local regulations
and mandates. 11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect
the vacuum valve and seat for debris or damage.
Replace the filler cap if the gaskets are damaged.
Install the filler cap.
12. Start the engine. Inspect the cooling system for
leaks.
114 SEBU8773-07
Maintenance Section
Hoses and Clamps - Inspect/Replace
NOTICE
Do not bend or strike high pressure lines. Do not in- Hot oil and hot components can cause personal
stall bent or damaged lines, tubes or hoses. Repair injury. Do not allow hot oil or hot components to
any loose or damaged fuel and oil lines, tubes and contact the skin.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
1. Drain the oil from the lubrication system to a level
recommended torque.
that is below the hose that is being replaced.
2. Remove the hose clamps.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly 3. Disconnect the old hose.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any 4. Replace the old hose with a new hose.
disconnected fuel system components. 5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
Note: High-pressure fuel lines may be installed SENR3130, “Torque Specifications” “Hose
between the high-pressure fuel pump and the fuel Clamps” for information about selecting and
injectors. High-pressure fuel lines are constantly installing the proper hose clamps.
charged with high pressure. Do not check the high-
pressure fuel lines with the engine or the starting 6. Refill the lubrication system. Refer to this
motor in operation. Wait for 10 minutes after the Operation and Maintenance Manual, “Engine Oil
engine stops before you perform any service or Level - Check” to ensure that the lubrication
repair on high-pressure fuel lines. Waiting for 10 system is filled with the proper amount of engine
minutes will allow the pressure to be purged. oil.
1. Drain the fuel from the fuel system to a level that is 7. Start the engine. Inspect the lubrication system for
below the hose that is being replaced. leaks.
i06548288
Maintenance
Recommendations
SMCS Code: 1000
Rating
Interval
A B C D
• Fuel consumption • Operating the engine at loads that are greater than
the rated load
• Fuel quality
• Operating the engine at speeds that are greater
• Altitude than the rated speed
• Maintenance intervals • Use of the engine for an application that is not
approved
• Selection of oil
Improper Maintenance Practices
• Selection of coolant
• Extension of maintenance intervals
• Environmental qualities
• Not using recommended fuel, lubricants, and
• Installation
coolant
Refer to the standards for your engine or consult your
Caterpillar dealer to determine if your engine is Overhaul Considerations
operating within the defined parameters.
Some factors that are important for determining the
Because of individual applications, identification all overhaul intervals include the following
the factors which can contribute to severe operation considerations:
is not possible. Consult your Caterpillar dealer about
the maintenance that is needed for your specific • Performance of preventive maintenance
engine.
• Use of recommended lubricants
The following factors can contribute to severe
operation: environment, improper operating • Use of recommended coolants
procedures, and improper maintenance practices.
• Use of recommended fuels
Extreme Ambient Temperatures
• Proper installation
Extended operation in environments known for
extreme cold or hot can damage components. Valve • Operating conditions
components can be damaged by carbon buildup if
the engine is frequently started and stopped • Operation within acceptable limits
environments known for extreme cold temperatures.
Extremely hot inlet air reduces the performance • Engine load
capabilities of the engine.
• Engine speed
Note: See this Operation and Maintenance Manual,
“Cold-Weather Operation” topic (Operation Section), • Use of S·O·S Services Fluids Analyses
or see Supplement, SEBU5898, “Cold-Weather
Recommendations”. Generally, engines that are operated at a reduced
load and/or speed achieve more service life before
Cleanliness an overhaul. Achieving more service life prior to an
overhaul is for engines that are properly operated
Unless the equipment is cleaned regularly, extended and maintained.
operation in a dirty environment and in a dusty Other factors must also be considered for
environment can damage components. Built up mud, determining a major overhaul:
dirt, and dust can encase components. The
aforementioned elements can make maintenance • The total amount of fuel consumption
difficult. The buildup can contain corrosive chemicals.
Corrosive chemicals and salt can damage some • The service hours of the engine
components.
• An increase of oil consumption
Improper Operating Procedures
• An increase of crankcase blowby
• Extended operation at low idle
• The wear metal analysis of the lube oil
• Minimum cool down periods after high load factor
operation • An increase in the levels of noise and vibration
• Operating the engine beyond the guidelines for
the engine rating
SEBU8773-07 117
Maintenance Section
Maintenance Recommendations
Interval Fuel Consumption Service Hours This lower cost can be attributed to three aspects:
Top End 1000000 L (264000 US gal) 10000 • Specially designed Caterpillar engine features
Major 2000000 L (528000 US gal) 20000 • Caterpillar dealer exchange components
(1) Use the interval that occurs first.
• Caterpillar Inc. remanufactured exchange
components
Overhaul Intervals Which are Based on
Oil Consumption Coolant Analysis
Oil consumption, fuel consumption, and maintenance The concentration of supplemental coolant additive
information can be used to estimate the total (SCA) should be checked regularly with test kits or
operating cost for your Caterpillar engine. Oil with S·O·S Coolant Analysis (Level 1). Further
consumption can also be used to estimate the coolant analysis is recommended when the engine is
required capacity of a makeup oil tank that is suitable overhauled.
for the maintenance intervals.
A coolant analysis can be conducted to verify the
Oil consumption is in proportion to the percentage of condition of the water that is being used in the
the rated engine load. As the percentage of the cooling system. A full water analysis can be obtained
engine load is increased, the amount of oil that is by consulting your local water utility company or an
consumed per hour also increases. agricultural agent. Private laboratories are also
The oil consumption rate (brake-specific oil available for water analysis.
consumption) is measured in grams per kW/h (lb per Caterpillar Inc. recommends an S·O·S Coolant
bhp). The brake-specific oil consumption (BSOC) Analysis (Level 2).
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil S·O·S Coolant Analysis (Level 2)
consumption rate for your engine.
When an engines oil consumption has risen to An S·O·S Coolant Analysis (Level 2) is a
three times the original oil consumption rate due comprehensive coolant analysis which completely
to normal wear, an engine overhaul should be analyzes the coolant and the effects on the cooling
scheduled. There may be a corresponding increase system. An S·O·S Coolant Analysis (Level 2)
in blowby and a slight increase in fuel consumption. provides the following information:
118 SEBU8773-07
Maintenance Section
Oil Cooler Core - Check/Clean/Test
• Complete S·O·S Coolant Analysis (Level 2) Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 30 lists Hydrosolv liquid
• Visual inspection of properties cleaners that are available from your Caterpillar
• Identification of metal corrosion dealer.
Table 30
• Identification of contaminants Hydrosolv Liquid Cleaners(1)
Clean the Oil Cooler Core 6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Remove the core. Refer to the Disassembly and
Assembly Manual, “Oil Cooler - Remove” for the Test the Oil Cooler Core
procedure.
1. Turn the oil cooler core on one side in order to 1. Inspect the core for trapped debris and
remove debris. Remove the debris that is cleanliness. If necessary, remove the debris and
accessible. repeat the cleaning procedure.
2. Inspect the core for damage and perform a
NOTICE pressure test in order to detect leaks. Many shops
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic that service radiators are equipped to perform
cleaner can attack the internal metals of the core and pressure tests.
cause leakage. Only use the recommended concen-
tration of cleaner. 3. Plug both ends of the oil cooler core and
pressurize the core to 205 kPa (30 psi).
Submerge the core in water. Look for bubbles
2. Back flush the core with cleaner. which are being emitted from the core. The
bubbles are evidence of leaks.
SEBU8773-07 119
Maintenance Section
Overhaul (Major)
4. If any leaks are found, do not attempt to repair the For the major overhaul, all of the bearings, seals,
core. gaskets, and components that wear are
disassembled. The parts are cleaned and inspected.
Install a core that is clean and a core that passes the If necessary, the parts are replaced. The crankshaft
pressure test in step 3. Refer to the Disassembly and is measured for wear. The crankshaft may require
Assembly Manual, “Oil Cooler - Install” for the regrinding. Alternatively, the crankshaft may be
procedure. replaced with a Cat replacement part.
For more information on cleaning the core, consult Your Cat dealer can provide these services and
your Caterpillar dealer. components. Your Cat dealer can ensure that the
components are operating within the appropriate
i05239037 specifications.
• An increase in the levels of noise and vibration • Mounting bolts for the secondary fuel filter base
Monitor the engine as the engine accumulates • All marine certification society approved tapes are
service hours. Consult your Cat dealer about installed in order to cover up fuel line connections
scheduling a major overhaul. and oil line connections according to the SOLAS
regulations.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Inspection, Reconditioning, or
Exchanging of Components
A major overhaul includes all of the work that is done
for the top end overhaul. A major overhaul includes Inspect the following components according to the
additional parts and labor. Additional parts and labor instructions that are in Caterpillar reusability
are required in order to completely rebuild the publications. Refer to Guidelines for Reusable Parts
engine. and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
Parts”.
120 SEBU8773-07
Maintenance Section
Overhaul (Major)
• Engine mounts Inspect the camshaft for damage to the journals and
the lobes.
• Scavenge oil pump
Inspect the crankshaft for any of the following
• Engine wiring harness conditions:
• Fuel pressure regulating valve • Bearing material that has seized to the journals
• Fuel priming pump Check the journal taper and the profile of the
crankshaft journals. Check these components by
• Fuel transfer pump interpreting the wear patterns on the following
components:
• Inlet manifold gaskets
• Rod bearing
• Inlet manifold seals
• Main bearings
• Oil cooler core
Note: If the crankshaft or the camshaft are removed
• Oil pump for any reason, use the magnetic particle inspection
process to check for cracks.
• Pistons
Replace the crankshaft vibration damper if any of the
• Piston pins following conditions occur:
In addition to the inspection of components, inspect • Identification of buildup of the impurities that
the alignment of the driven equipment. See the cause corrosion
Application and Installation Guide for the engine or
see the literature that is provided by the OEM of the • Identification of buildup of the impurities that
driven equipment. cause scaling
If you elect to perform an overhaul without the The starting motor pinion and the flywheel ring gear
services of a Cat dealer, be aware of the must be in good condition in order for the engine to
recommendations in Table 31 . start properly. The engine will not start if the starting
Table 31 motor pinion does not engage the flywheel ring gear.
Recommendations for Top End Overhauls (1)
The teeth of the starting motor pinion and the
flywheel ring gear can be damaged because of
Service Top End Overhaul irregular engagement.
Inspect Cylinder head assemblies Inspect the starting motor for proper operation. Listen
Rebuild for grinding when the engine is started. Inspect the
Replace Valves teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth.
Aftercooler core(2)
Inspect
Heat exchanger(3)
Look for teeth that are broken or chipped. If damaged
teeth are found, the starting motor pinion and the
Inspect Rocker arms flywheel ring gear must be replaced.
Replace Valve bridges
Cylinder head gaskets Personal injury or death can result from improp-
Replace
Fuel Injectors erly checking for a leak.
(1) For instructions on removal and installation of components, see
the Service Manual, “Disassembly and Assembly” module. Always use a board or cardboard when checking
(2) Refer to this Operation and Maintenance Manual, “Aftercooler for a leak. Escaping air or fluid under pressure,
Core - Inspect” for the procedure. even a pin-hole size leak, can penetrate body tis-
(3) Refer to this Operation and Maintenance Manual, “Heat Ex- sue causing serious injury, and possible death.
changer - Inspect” for the procedure.
(4) Refer to this Operation and Maintenance Manual, “Oil Cooler If fluid is injected into your skin, it must be
Core - Check/Clean/Test” for the procedure. treated immediately by a doctor familiar with this
type of injury.
i04277901
Sea Water Strainer - Clean/ Inspect all of the components in the air circuit for the
starting motor. Inspect all of the air lines and
Inspect connections for leaks.
SMCS Code: 1371-070; 1371-040 If damaged teeth are found, the air circuit for the
starting motor must be examined in order to
The sea water strainer must be clean in order to determine the cause of the problem.
allow proper engine cooling and component life. The
sea water strainer is located before the sea water
pump impeller and filters out debris. Check the sea Electric Starting Motor
water strainer for plugging. Inspect the sea water
strainer more frequently if the vessel is being If the starting motor fails, the engine may not start in
operated in water which is shallow or dirty. Refer to an emergency situation. A scheduled inspection of
the OEM recommendations for more information the starting motor is recommended.
about inspecting and cleaning the sea water strainer.
The starting motor pinion and the flywheel ring gear
i05264216 must be in good condition in order for the engine to
start properly. The engine will not start if the starting
Starting Motor - Inspect motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the
(If equipped) flywheel ring gear can be damaged because of
irregular engagement.
SMCS Code: 1451-040; 1453-040
Inspect the starting motor for proper operation. Listen
Air Starting Motor for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth.
If the starting motor fails, the engine may not start in Look for teeth that are broken or chipped. If damaged
an emergency situation. A scheduled inspection of teeth are found, the starting motor pinion and the
the starting motor is recommended. flywheel ring gear must be replaced.
Problems with the electric starting motor can be
caused by the following conditions: malfunction of the
solenoid and malfunction of the electric starting
system.
SEBU8773-07 123
Maintenance Section
Turbocharger - Inspect
Inspect the electrical system for the following An inspection of the turbocharger can minimize
conditions: unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
• Loose connections damage to other engine parts.
• Corrosion Note: Turbocharger components require precision
clearances. The turbocharger cartridge must be
• Wires that are worn or frayed balanced due to high rpm. Severe Service
Applications can accelerate component wear. Severe
• Cleanliness Service Applications require more frequent
inspections of the cartridge.
Removal and Installation of the
Starting Motor Removal and Installation
Refer to the Service Manual, “Disassembly and For options regarding the removal, installation, repair,
Assembly” module for information on removing the and replacement, consult your Cat dealer. Refer to
starting motor and installing the starting motor. the Service Manual for this engine for the procedure
and specifications.
Consult your Cat dealer for assistance and/or for
options on replacement of the starting motor. Cleaning and Inspecting
i05965726 1. Remove the exhaust outlet piping and remove the
air inlet piping from the turbocharger. Visually
Turbocharger - Inspect inspect the piping for the presence of oil. Clean the
SMCS Code: 1052-040 interior of the pipes in order to prevent dirt from
entering during reassembly.
Periodic inspection and cleaning are recommended
for the turbocharger compressor housing (inlet side). 2. Turn the compressor wheel and the turbine wheel
Any fumes from the crankcase are filtered through by hand. The assembly should turn freely. Inspect
the air inlet system. Therefore, by-products from oil the compressor wheel and the turbine wheel for
and from combustion can collect in the turbocharger contact with the turbocharger housing. There
compressor housing. Over time, this buildup can
should not be any visible signs of contact between
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency. the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
If the turbocharger fails during engine operation, contact between the rotating turbine wheel or the
damage to the turbocharger compressor wheel and/ compressor wheel and the turbocharger housing,
or to the engine may occur. Damage to the the turbocharger must be reconditioned.
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder 3. Check the compressor wheel for cleanliness. If
head. only the blade side of the wheel is dirty, dirt and/or
moisture is passing through the air filtering
NOTICE system. If oil is found only on the back side of the
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems. wheel, there is a possibility of a failed turbocharger
Loss of engine lubricant can result in serious engine oil seal.
damage.
The presence of oil may be the result of extended
Minor leakage of a turbocharger housing under ex- engine operation at low idle. The presence of oil
tended low idle operation should not cause problems may also be the result of a restriction of the line for
as long as a turbocharger bearing failure has not the inlet air (plugged air filters), which causes the
occurred. turbocharger to slobber.
When a turbocharger bearing failure is accompanied 4. Inspect the bore of the turbine housing for
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue corrosion.
engine operation until the turbocharger is repaired or 5. Clean the turbocharger housing with standard
replaced.
shop solvents and a soft bristle brush.
124 SEBU8773-07
Maintenance Section
Walk-Around Inspection
6. Fasten the air inlet piping and the exhaust outlet • Inspect the lubrication system for leaks at the front
piping to the turbocharger housing. crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters, and the valve cover.
i05867447
• Inspect the fuel system for leaks.
Walk-Around Inspection • Inspect the piping for the air inlet system and the
SMCS Code: 1000-040 elbows for cracks and for loose clamps.
• Inspect the alternator belt and the accessory drive
Inspect the Engine for Leaks and belts for cracks, breaks, or other damage.
for Loose Connections Belts for multiple groove pulleys must be replaced as
A walk-around inspection should only require a few matched sets. If only one belt is replaced, the belt will
minutes. When the time is used to perform these carry more load than the belts that are not replaced.
checks, costly repairs and accidents can be avoided. The older belts are stretched. The additional load on
the new belt could cause the belt to break.
For maximum engine service life, make a thorough
• Drain the water and the sediment from fuel tanks
inspection of the engine compartment before you
start the engine. Look for items such as: oil leaks, on a daily basis in order to ensure that only clean
coolant leaks, loose bolts, worn belts and loose fuel enters the fuel system.
connections. Make repairs, as needed:
• Inspect the wiring and the wiring harnesses for
• The guards must be in the proper place. Repair loose connections and for worn wires or frayed
damaged guards or replace missing guards. wires.
• Wipe all caps and plugs before the engine is • Inspect the alternator connections.
serviced in order to reduce the chance of system
contamination. • Inspect the ground strap for a good connection
and for good condition.
NOTICE • Inspect the starter connections.
For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and • Inspect the ECM ground strap for a good
correct the leak. If leaking is suspected, check the flu- connection and for good condition.
id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is • Disconnect any battery chargers that are not
proved to be unwarranted. protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
NOTICE equipped with a maintenance free battery.
Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean- • Check the condition of the gauges. Replace any
ing or high pressure water.
gauges which are cracked. Replace any gauges
that cannot be calibrated.
• Ensure that the cooling lines are properly
clamped. Check for leaks. Check the condition of i05264233
all pipes.
Water Pump - Inspect
• Check the marine transmission oil level. Refer to
the OEM specification for the marine transmission SMCS Code: 1361-040
or refer to the OEM specification for the vessel. A failed water pump might cause severe engine
overheating problems that could result in the
• Inspect the water pumps for coolant leaks. following conditions:
Note: The water pump seal is lubricated by coolant in • Cracks in the cylinder head
the cooling system. A small amount of leakage to
occur as the engine cools down is normal. • A piston seizure
Excessive coolant leakage may indicate the need to • Other potential damage to the engine
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
or seals, refer to the Service Manual for the engine or
consult your Cat dealer.
SEBU8773-07 125
Maintenance Section
Water Pump - Inspect
Warranty Section
Warranty Information
i04769870
Emissions Warranty
Information
SMCS Code: 1000
Caterpillar warrants to the ultimate purchaser and
each subsequent purchaser that new Marine Diesel
Engines up to 18.5 liters per cylinder (excluding Tier
1 and Tier 2 Marine Engines less than 50 kW)
operated and serviced in the United States, including
all parts of their emission control systems (emission-
related components), are:
• Designed, built, and equipped so as to conform, at
the time of sale, with applicable emission
standards prescribed by the United States
Enviromental Protection Agency (EPA) by way of
regulation.
The use of the vessel must be known for the rating to Marine Classification Society
match the operating profile.
Certification Requirements
In selecting a rating for a specific application, the
most important consideration is the time that is spent SMCS Code: 1000
at full throttle. These rating definitions identify the
The major seafaring nations have established
percent of time at full throttle. The definitions also
technical groups called marine classification
identify the corresponding times below rated rpm.
societies. Caterpillar has maintained standards and
A (Unrestricted Continuous) – Vessels operating at quality under the guidelines that are set forth by the
rated load and rated speed up to 100% of the time 14 major marine classification societies that are
without interruption or load cycling (80% to 100% listed. For more information, refer to Engine Data
load factor). Typical operation is 5000 service hours Sheet, 103.1 and Engine Data Sheet, 103.1.1 in the
to 8000 service hours per year. Typical applications Caterpillar Technical Manual.
may include the following vessels: freighters,
ABS – American Bureau of Shipping (USA)
tugboats and bottom drag trawlers.
BV – Bureau Veritas (France)
B (Heavy Duty) – Vessels operating at rated load CCG – Canadian Coast Guard (Canada)
and speed up to 80% of the time with some load
cycling (40% to 80% load factor). Typical operation is CCRS – China Corporation Register of Shipping
from 1000 service hours to 3000 service hours per (Taiwan)
year. Typical applications may include the following
128 SEBU8773-07
Reference Information Section
Marine Classification Society Certification Requirements
Deterioration of the engine systems decreases the A periodic PAR can define deterioration of the
ability of the engine to produce power and vessel propulsion system. A PAR can assist in repairs, in
speed. Engine systems include the cooling system, overhauls, and in maintenance schedules. This will
the lubrication system, the fuel system, etc. The help to provide the most economical, efficient cost of
engine is not likely to be the cause of poor fuel operation.
economy without excessive exhaust smoke and/or
the loss of power.
If you have a valid problem with the engine's
performance, consult an authorized Cat dealer for
assistance.
130 SEBU8773-07
Reference Information Section
Customer Service
(continued)
132 SEBU8773-07
Reference Information Section
On-Board Replacement Parts
(continued)
SEBU8773-07 133
Reference Information Section
Reference Materials
Reference Materials
i05264255
Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Owner receipts
• Maintenance log
134 SEBU8773-07
Reference Information Section
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 34
Engine Model Customer Identifier
Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU8773-07 135
Reference Information Section
Reference Material
• Datasheet, PEHJ0067, “Cat ELC (Extended Life • Special Publication, SEBU5898, “Cold Weather
Coolant)” (Worldwide) Recommendations for all Cat Machines”
S·O·S Services
•
• Special Publication, PEHJ0191, “S·O·S Coolant
Analysis”
• Special Publication, PEGJ0047, “How To Take A
Good Oil Sample”
• Special Publications, PEDP7036, “S·O·S Fluids
Analysis Cornerstone”
136 SEBU8773-07
Reference Information Section
Decommissioning and Disposal
i03989612
Decommissioning and
Disposal
SMCS Code: 1000
When the product is removed from service, local
regulations for the product decommissioning will
vary. Disposal of the product will vary with local
regulations. Consult the nearest Cat dealer for
additional information.
SEBU8773-07 137
Index Section
Index
A Coolant Extender (ELC) - Add ........................ 83
Coolant Level - Check ..................................... 84
After Starting Engine ....................................... 45
Engines That Are Equipped with a Coolant
After Stopping Engine ..................................... 54
Recovery Tank ........................................... 84
Aftercooler Condensate Drain Valve -
Engines That Are Not Equipped with a
Inspect/Clean................................................. 76
Coolant Recovery Tank.............................. 84
Aftercooler Core - Clean/Test.................... 67, 76
Coolant Sample (Level 1) - Obtain.................. 85
Clean the Aftercooler Core .................... 67, 76
Sampling Conditions.................................... 85
Test the Aftercooler Core....................... 68, 77
Timing of the Sampling ................................ 85
Aftercooler Core - Inspect ............................... 77
Coolant Sample (Level 2) - Obtain.................. 86
Auxiliary Water Pump (Bronze Impeller) -
Obtaining the Sample .................................. 86
Inspect/Replace............................................. 77
Coolant Temperature Regulator - Replace ..... 86
Cooling System Supplemental Coolant
B Additive (SCA) - Test/Add.............................. 87
Battery - Replace............................................. 78 Cooling Systems that Use Conventional
Battery Disconnect Switch (If Equipped)......... 34 Coolant....................................................... 87
Battery Electrolyte Level - Check .................... 78 Crankshaft Vibration Damper - Inspect........... 88
Battery or Battery Cable - Disconnect............. 79 Inspection .................................................... 88
Before Starting Engine .............................. 16, 42 Removal and Installation ............................. 89
Belts - Inspect/Adjust/Replace ........................ 80 Crushing Prevention and Cutting Prevention.. 15
Adjust ........................................................... 80 Customer Assistance .................................... 130
Inspect ......................................................... 80 Outside of the USA and of Canada ........... 130
Replace........................................................ 80 USA and Canada....................................... 130
Bolts (Fuel Filter Base) - Inspect/Replace ...... 81 Customer Service.......................................... 130
Burn Prevention............................................... 13
Batteries....................................................... 13 D
Coolant ........................................................ 13
Declaration of Conformity................................ 27
Oils............................................................... 13
Decommissioning and Disposal.................... 136
Derating Strategy ............................................ 38
C
Cold Start Strategy .......................................... 34 E
Cold Weather Operation ................................. 50
Electrical System............................................. 17
Hints for Cold Weather Operation ............... 50
Grounding Practices .................................... 17
Idling the Engine .......................................... 51
Negative Battery Connection for Multiple
Recommendations for Coolant Warm Up.... 51
Engines ...................................................... 18
Recommendations for the Coolant.............. 51
Emergency Stopping....................................... 54
Viscosity of the Engine Lubrication Oil ........ 51
Emissions Certification Film ............................ 28
Cold Weather Starting ..................................... 42
Emissions Warranty Information ................... 126
Control Panel (Cat Marine Engine Control
Engaging the Driven Equipment ..................... 48
Panel I (MECP I) (If Equipped))..................... 35
Engine - Clean................................................. 89
Control Panel (Cat Marine Engine Control
Engine Air Cleaner Element (Single
Panel III (MECP III )(If Equipped))................. 35
Element) - Inspect/Replace ........................... 89
Control Panel (CatMarine Engine Control
Replacing the Air Cleaner Element ............. 89
Panel II (MECP II) (If Equipped))................... 37
Engine Air Cleaner Service Indicator -
Coolant - Change ............................................ 81
Inspect (If Equipped) ..................................... 90
Drain the Cooling System............................ 81
Test the Service Indicator ............................ 90
Fill the Cooling System ................................ 83
Flush ............................................................ 82
138 SEBU8773-07
Index Section
G When Required............................................ 66
Maintenance Log........................................... 134
Gauges and Indicators .................................... 38
Maintenance Recommendations .......64, 69, 115
General Hazard Information.............................. 9
Overhaul Considerations......................71, 116
Containing Fluid Spillage..............................11
Relationship of Fuel Consumption to Service
Dispose of Waste Properly .......................... 13
Hours ..................................................69, 115
Fluid Penetration ..........................................11
Maintenance Records ................................... 133
Inhalation ..................................................... 12
Maintenance Section....................................... 56
Lines, Tubes, and Hoses ..............................11
Manual Stop Procedure .................................. 54
Pressurized Air and Water........................... 10
Marine Classification Society Certification
Softwrap....................................................... 12
Requirements .............................................. 127
Static Electricity Hazard when Fueling with
Marine Towing ................................................. 29
Ultra-low Sulfur Diesel Fuel ........................11
Securing the Propeller ................................. 29
General Information ........................................ 20
Towing Procedure........................................ 29
Model View Illustrations .................................. 20
H Mounting and Dismounting ............................. 16
Heat Exchanger - Clean/Test ...................68, 110
Clean the Heat Exchanger ...................68, 110 O
Test the Heat Exchanger Core .............69, 110
Oil Cooler Core - Check/Clean/Test ...............118
Heat Exchanger - Inspect............................... 111
Clean the Oil Cooler Core...........................118
Cleaning Procedure.................................... 111
Test the Oil Cooler Core .............................118
Hoses and Clamps - Inspect/Replace............112
On-Board Replacement Parts ....................... 131
Inspect Tubes, Hoses, Bellows, and
Operation Section............................................ 29
Clamps......................................................112
Ordering Replacement Parts......................... 131
Replace the Hoses and the Clamps ...........113
Overhaul (Major) ......................................72, 119
Cleaning and Pressure Testing of
I Components ...................................... 74, 121
Important Safety Information............................. 2 Cleaning of Components ..................... 74, 121
Inspection of Components................... 74, 120
Inspection, Reconditioning, or Exchanging of
L
Components .......................................73, 119
Lifting and Storage .......................................... 30 Obtain a Coolant Analysis ................... 74, 121
Replacement of Components...............73, 119
M Overhaul (Top End) ....................................... 121
Maintenance Interval Schedule....................... 66
Daily ............................................................. 66 P
Every 1000 Service Hours........................... 66 Plate Locations and Film Locations ................ 25
Every 170 400 L (45 000 US gal) of Fuel or Engine Identification Plate (2)...................... 25
3000 Service Hours ................................... 67 Engine Serial Number (1) ............................ 25
Every 2000 Service Hours........................... 67 Product Description......................................... 22
Every 250 Service Hours ............................. 66 Electronic Engine Features ......................... 23
Every 3000 Service Hours........................... 67 Engine Cooling and Lubrication .................. 23
Every 50 Service Hours or Weekly.............. 66 Engine Service Life...................................... 24
Every 500 Service Hours ............................. 66 Engine Specifications .................................. 22
Every 5000 Service Hours........................... 67 Marine Transmissions ................................. 24
Every Year ................................................... 67 Product Identification Information ................... 25
Initial 1000 Service Hours............................ 66 Product Information Section............................ 20
Initial 500 Hours (for New Systems, Refilled Product Lifting ................................................. 30
Systems, and Converted Systems) ........... 66 Engine and Marine Transmission Lifting ..... 30
Overhaul (Top End) ..................................... 67 Marine Transmission Lifting......................... 30
140 SEBU8773-07
Index Section
S
Safety Messages............................................... 6
Explosion Hazard (3) ..................................... 9
Hot Fluid Under Pressure (2)......................... 8
Universal Warning (1) .................................... 8
Safety Section ................................................... 6
Sea Water Strainer - Clean/Inspect .............. 122
Self-Diagnostics .............................................. 40
Starting Motor - Inspect (If equipped)............ 122
Air Starting Motor....................................... 122
Electric Starting Motor ............................... 122
Removal and Installation of the Starting
Motor ........................................................ 123
Starting the Engine.......................................... 43
Automatic Starting ....................................... 43
Manual Starting............................................ 43
Starting with Jump Start Cables...................... 45
System Pressure Release............................... 64
Coolant System ........................................... 64
Engine Oil .................................................... 64
Fuel System................................................. 64
T
Table of Contents .............................................. 3
Towing Information .......................................... 29
Turbocharger - Inspect .................................. 123
Cleaning and Inspecting ............................ 123
Removal and Installation ........................... 123
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
SEBU8773 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2018 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.