Professional Documents
Culture Documents
Copy of Caterpillar C18 Marine Engine Operation and Maintenance Manual (SEBU9023-09) (MANUAL-P - 4462028 - 1 - A) - 1
Copy of Caterpillar C18 Marine Engine Operation and Maintenance Manual (SEBU9023-09) (MANUAL-P - 4462028 - 1 - A) - 1
December 2019
Operation and
Maintenance
Manual
C18 Marine Engine
GEX 1-UP (Engine)
PHW 1-UP (Package)
PUBLICATIONS.CAT.COM
i07966018
NOTICE
When replacement parts are required for this product Caterpillar recommends using original Cater-
pillar® replacement parts.
Other parts may not meet certain original equipment specifications.
When replacement parts are installed, the machine owner/user should ensure that the machine re-
mains in compliance with all applicable requirements.
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.
SEBU9023-09 3
Table of Contents
Safety Messages............................................... 6
Reference Information Section
Electrical System............................................. 15
Engine Electronics........................................... 18
Operation Section
Engine Starting................................................ 37
Maintenance Section
4 SEBU9023-09
Foreword
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 SEBU9023-09
Safety Section
Safety Messages
Safety Section
i04930171
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 g03100237
View of the sides of a typical C18 Commercial Engine
SEBU9023-09 7
Safety Section
Safety Messages
Illustration 2 g03100241
View of the top of a typical C18 Commercial Engine
Illustration 3 g01370904
Illustration 4 g01371640
i06300340
Illustration 6 g00702020
Illustration 5 g03838041
• Ensure that all protective guards and all covers
are secured in place on the engine.
Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or • Never put maintenance fluids into glass
repaired. These warning tags (Special Instruction, containers. Glass containers can break.
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each • Use all cleaning solutions with care.
operator control station. When appropriate,
disconnect the starting controls. • Report all necessary repairs.
Do not allow unauthorized personnel on the engine, Unless other instructions are provided, perform
or around the engine when the engine is being the maintenance under the following conditions:
serviced.
• The engine is stopped. Ensure that the engine
Cautiously remove the following parts. To help cannot be started.
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed. • The protective locks or the controls are in the
applied position.
• Filler caps
• Disconnect the batteries when maintenance is
• Grease fittings performed or when the electrical system is
serviced. Disconnect the battery ground leads.
• Pressure taps Tape the leads in order to help prevent sparks.
• Breathers
• Drain plugs
SEBU9023-09 9
Safety Section
General Hazard Information
• When starting a new engine, make provisions to Avoid direct spraying of water on electrical
stop the engine if an overspeed occurs. If an connectors, connections, and components. When
engine has not been started since service has using air for cleaning, allow the machine to cool to
been performed, make provisions to stop the reduce the possibility of fine debris igniting when
engine if an overspeed occurs. Shutting down the redeposited on hot surfaces.
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine. Fluid Penetration
• 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.
Static Electricity Hazard when Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct
Fueling with Ultra-low Sulfur Diesel installation of these components will help to prevent
Fuel these effects: vibration, rubbing against other parts
and excessive heat during operation.
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the Inhalation
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
Illustration 8 g02159053
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater Exhaust
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death Use caution. Exhaust fumes can be hazardous to
or serious injury from fire or explosion. Consult your health. If you operate the equipment in an
with your fuel or fuel system supplier to ensure enclosed area, adequate ventilation is necessary.
the delivery system is in compliance with fueling
standards for proper grounding and bonding Asbestos Information
practices.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Lines, Tubes, and Hoses Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Do not bend or strike high-pressure lines. Do not you handle any replacement parts that contain
install lines, tubes, or hoses that are damaged. asbestos or when you handle asbestos debris.
Repair any fuel lines, oil lines, tubes, or hoses that Use caution. Avoid inhaling dust that might be
are loose or damaged. Leaks can cause fires. generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
Inspect all lines, tubes, and hoses carefully. Do not to your health. The components that may contain
use bare hands to check for leaks. Always use a asbestos fibers are brake pads, brake bands, lining
board or cardboard for checking engine components material, clutch plates, and some gaskets. The
for leaks. Tighten all connections to the asbestos that is used in these components is bound
recommended torque. in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
Check for the following conditions: asbestos is generated.
• End fittings that are damaged or leaking If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Outer covering that is chafed or cut
• Never use compressed air for cleaning.
• Wire that is exposed in reinforced hose
• Avoid brushing materials that contain asbestos.
• Outer covering that is ballooning locally
• Avoid grinding materials that contain asbestos.
• Flexible part of the hose that is kinked or crushed
• Use a wet method in order to clean up asbestos
• Armoring that is embedded in the outer covering materials.
SEBU9023-09 11
Safety Section
Burn Prevention
• A vacuum cleaner that is equipped with a high Reference: The applicable material safety data
efficiency particulate air filter (HEPA) can also be sheets can be found at the following web site by
used. searching using part number or the name:
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate Illustration 9 g00706404
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands Improperly disposing of waste can threaten the
thoroughly after handling Softwrap material. Do not environment. Potentially harmful fluids should be
smoke until washing hands thoroughly after handling disposed of according to local regulations.
Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean Always use leakproof containers when you drain
up debris. fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i02088921
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings or
related items are disconnected.
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.
12 SEBU9023-09
Safety Section
Fire Prevention and Explosion Prevention
Check the coolant level after the engine has stopped All fuels, most lubricants, and some coolant mixtures
and the engine has been allowed to cool. Ensure that are flammable.
the filler cap is cool before removing the filler cap.
The filler cap must be cool enough to touch with a Always perform a Walk-Around Inspection, which
bare hand. Remove the filler cap slowly in order to may help you identify a fire hazard. Do not operate a
relieve pressure. product when a fire hazard exists. Contact your
Caterpillar dealer for service.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact Flammable fluids that are leaking or spilled onto hot
the skin, the eyes, or the mouth. surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.
Oils
A flash fire may result if the covers for the engine
Hot oil and hot lubricating components can cause crankcase are removed within 15 minutes after an
personal injury. Do not allow hot oil or hot emergency shutdown.
components to contact the skin.
Determine whether the engine will be operated in an
If the application has a makeup tank, remove the cap environment that allows combustible gases to be
for the makeup tank after the engine has stopped. drawn into the air inlet system. These gases could
The filler cap must be cool to the touch. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Batteries If the application involves the presence of
The liquid in a battery is an electrolyte. Electrolyte is combustible gases, consult your Caterpillar dealer for
an acid that can cause personal injury. Do not allow additional information about suitable protection
electrolyte to contact the skin or the eyes. devices.
Remove all flammable materials such as fuel, oil, and
Do not smoke while checking the battery electrolyte debris from the engine. Do not allow any flammable
levels. Batteries give off flammable fumes which can materials to accumulate on the engine.
explode.
All fluids that are captured in the fluid spill
Always wear protective glasses when you work with containment basin should be cleaned up
batteries. Wash hands after touching batteries. The immediately. Failure to clean up spilled fluids can
use of gloves is recommended. cause a fire. Fire may cause personal injury and
property damage.
i05326156
Store fuels and lubricants in properly marked
Fire Prevention and Explosion containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Prevention containers. Do not smoke in areas that are used for
storing flammable materials.
SMCS Code: 1000; 4450; 7405
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray from a failed line,
tube, or seal. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
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
Illustration 10 g00704000 connections.
Use of personal protection equipment (PPE) may be Eliminate all wiring that is unattached or
needed. unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
SEBU9023-09 13
Safety Section
Fire Prevention and Explosion Prevention
Illustration 12 g02298225
Fire Extinguisher Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
Make sure that a fire extinguisher is available. Be performed. After the maintenance is performed,
familiar with the operation of the fire extinguisher. reinstall the guards.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations Keep objects away from moving fan blades. The fan
on the instruction plate. blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
Ether order to avoid injury to the eyes.
Do not use ether as a starting aid. Refer to this Chips or other debris may fly off objects when objects
Operation and Maintenance Manual, “Starting the are struck. Before objects are struck, ensure that no
Engine” for information about starting the engine. one will be injured by flying debris.
Do not bend high-pressure lines. Do not strike high- Mounting and Dismounting
pressure lines. Do not install any lines that are bent
or damaged. SMCS Code: 1000; 4450; 7405
Repair any lines that are loose or damaged. Leaks Inspect the steps, the handholds, and the work area
can cause fires. Consult your Caterpillar dealer for before mounting the engine. Keep these items clean
repair or for replacement parts. and keep these items in good repair.
Check lines, tubes, and hoses carefully. Do not use Mount the engine and dismount the engine only at
your bare hand to check for leaks. Use a board or locations that have steps and/or handholds. Do not
cardboard to check for leaks. Tighten all connections climb on the engine, and do not jump off the engine.
to the recommended torque.
Face the engine in order to mount the engine or
Replace the parts if any of the following conditions dismount the engine. Maintain a three-point contact
are present: with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• End fittings are damaged or leaking. controls as handholds.
• Outer coverings are chafed or cut. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Wires are exposed. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer coverings are ballooning.
Do not carry tools or supplies when you mount the
• Portions of the hoses are kinked. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
• Outer covers have embedded armoring.
i03560601
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
Before Starting Engine
are installed correctly in order to prevent vibration, SMCS Code: 1000
rubbing against other parts, and excessive heat.
NOTICE
i01359666 For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
Crushing Prevention and provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
Cutting Prevention air and/or fuel supply to the engine.
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
SEBU9023-09 15
Safety Section
Engine Starting
Grounding Practices
Properly ground the electrical system for the vessel
and the engine. Proper grounding is necessary for
optimum engine performance and reliability. Improper
grounding will result in uncontrolled or unreliable
electrical circuit paths.
Uncontrolled or unreliable electrical circuit paths may
result in damage to main bearings, crankshaft
bearing journal surfaces, and aluminum components.
Uncontrolled electrical circuit paths may also cause
electrical noise. Electrical noise may degrade the
performance of the vessel and of the radio.
Connect the starting motor directly to the negative
battery terminal. Connect the alternator to the
negative battery or negative terminal for the starting
motor. The alternator and the starting motor must
meet marine isolation requirements.
Note: All electrical connections must meet or exceed
the American Boat and Yacht Council Standard E-11.
Use a bus bar with a direct path to the negative
battery terminal for low current components that
require a negative battery connection. Connect the
bus bar directly to the negative battery terminal.
Illustration 13 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
i02784356
Engine Electronics
SMCS Code: 1000; 1900
• Operating Altitude
• Engine Coolant Level
• Engine Speed
• Fuel Temperature
• Intake Manifold Air Temperature
• System Voltage
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and
display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.
SEBU9023-09 19
Product Information Section
General Information
Product Information
Section
General Information
i04907986
Illustration 14 g03074657
View of the front of a typical C18 Commercial Marine Engine
(1) Expansion tank for the jacket water (6) Expansion tank for the separate circuit (11) Guard group for the belt and for the
system aftercooling system (SCAC system) alternator
(2) Engine oil filters (7) Housing for the temperature regulator (12) Engine oil level gauge
(3) Fuel filters (8) Fuel shutoff valve (13) Oil sampling valve
(4) Fuel selector valve (9) Sampling valve for the engine oil (14) Engine oil filter selector
(5) Fuel priming valve (10) Oil filler tube
20 SEBU9023-09
Product Information Section
Model View Illustrations
Illustration 15 g03078916
View of the right side of a typical C18 Commercial Marine Engine
(15) Turbocharger (20) Sight gauge for the jacket water (25) Drain for the engine oil pan
(16) Lifting eye expansion tank (26) Engine starting motor
(17) Engine oil fill cap (21) Alternator (27) Cooler for the marine transmission
(18) Exhaust manifold (22) Sampling valve for the SCAC system (28) Aftercooler
(12) Engine oil level gauge (23) Engine oil cooler
(19) Housing for the deaerator (24) Engine oil pan
SEBU9023-09 21
Product Information Section
Model View Illustrations
Illustration 16 g03078861
View of the left side of a typical C18 Commercial Marine Engine
(29) Sight gauge for the expansion tank for (32) Fumes disposal filter (36) Water pump for the SCAC system
the SCAC system (33) Air cleaner (37) Water pump for the jacket water system
(30) Aftercooler (34) Pump for engine oil pan (38) Drain valve for the aftercooler
(31) Electronic control module (ECM) (35) Fuel cooler
22 SEBU9023-09
Product Information Section
Product Description
The Cat C18 Marine Engine provides the following • Separate circuit aftercooler (SCAC)
features:
The engine lubricating oil, that is supplied by a gear
• Four-cycle pump, is cooled. The engine lubricating oil is also
filtered. Bypass valves provide unrestricted flow of
• Direct fuel injection lubrication oil to the engine components during the
following conditions:
• Electronic unit injection
• High oil viscosity
• Turbocharged
• Plugged oil cooler or plugged oil filter elements
• Heat exchanger cooled (paper cartridge)
• Separate circuit aftercooler (SCAC)
The electronic engine control system provides the Engine Service Life
following features:
• Engine monitoring Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
• Electronic governing operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and
• Automatic air/fuel ratio control lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
• Torque rise shaping
Engine Specifications
Illustration 18 g00904617
Cylinder and valve locations
(A) Exhaust valve
(B) Inlet valve
Table 1
C18 Marine Engine Specifications
Aspiration Turbocharged
Aftercooled
Displacement 18 L (1098 cubic inch)
Product Identification
Information
i04932015
Illustration 19 g03103159
(Some parts removed for visibility)
The serial number plate is located on the cylinder
block on the right side of the engine.
Illustration 21 g03103160
(Some parts removed for visibility)
The information plate is located on the exhaust
manifold on the right side of the engine.
SEBU9023-09 25
Product Information Section
Emissions Certification Film
Illustration 22 g00102789
Typical information plate
i07709181
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.
Operation Section
Product Lifting
SMCS Code: 7000; 7002
Illustration 24 g03105039
Lifting eyes
i07026640
Product Storage
SMCS Code: 7002
Engine
Storage - Greater than 7 Days and less
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.
SEBU9023-09 27
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 5. Remove the plastic covers from the air cleaner
weatherproof. Use a waterproof weather resistant elements.
tape such as Kendall No. 231 or an equivalent. Do
6. Use a bar or a turning tool to turn the engine in the
not use duct tape. Duct tape will only seal for a
normal direction of rotation. The procedure
short time.
ensures that no hydraulic locks or resistance exist.
13. If possible, remove the batteries. As an
7. Before starting the engine, remove the valve cover
alternative, place the batteries in storage. As
or covers. Put a large amount of engine oil on the
needed, periodically charge the batteries while the
camshaft, cam followers, and valve mechanism to
batteries are in storage.
prevent damage to the mechanism.
If the batteries are not removed, wash the tops of
8. Pressure lubricate the engine before starting the
the batteries until the tops are clean. Apply an
engine. Pressure lubrication of the engine ensures
electrical charge to the batteries to obtain a
immediate lubrication. Pressure lubrication of the
specific gravity of 1.225.
engine prevents damage to the engine which
Disconnect the battery terminals. Place a plastic might otherwise occur at start-up. If the engine is
cover over the batteries. not equipped with a prelube pump, contact your
Cat dealer for information about lubrication of the
Note: For additional information, refer to Special engine before the engine is started.
Instruction, SEHS7633, “Battery Test Procedure”.
9. Check the condition of all rubber hoses. Replace
14. Loosen all belts. any worn hoses. Replace any damaged hoses.
15. Place a waterproof cover over the engine. Ensure 10. Before start-up, test the cooling system for a 3 to
that the engine cover is secure. The cover should 6 percent concentration of coolant conditioner.
be loose enough to allow air to circulate around Add liquid coolant conditioner or a coolant
the engine to prevent damage from condensation. conditioner filter, if equipped.
16. Attach a tag with the date of storage to the Test the coolant mixture for proper nitrite level. If
engine. necessary, adjust the coolant mixture.
17. Remove the waterproof cover at 2 month or 3 Prime the engine with clean diesel fuel before
month intervals to check the engine for corrosion. starting.
If the engine has signs of corrosion, repeat the
protection procedure. 11. If the engine is equipped with a fresh water
system, ensure that the system is clean. Ensure
Raw Water System that the system is full. Ensure that the system has
the correct amount of supplemental cooling
Completely drain the raw water system by removing system conditioner.
all the drain plugs from the raw water pump, the
water shielded manifolds, the heat exchanger If the engine is equipped with a raw water system,
bonnets, and the aftercooler. install all the drain plugs and zinc plugs. Fill the
system. Priming the raw water system pumps
Note: To ensure complete drainage and evaporation
before operation may be necessary.
during storage, DO NOT install the drain plugs. Place
all removed plugs in a cloth bag and fasten the bag to 12. On the first day of operation, check the entire
the engine for storage. engine several times for leaks and correct
operation.
Removal from Storage
13. Refer to Special Publication, SEBU5898, “Cold
1. Remove all outside protective covers. Weather Recommendations Operation and
Maintenance” when the temperature is less than
2. Change the oil and filters. −12° C (10° F) at the time of removal from
3. Check the condition of the fan and alternator belts. storage.
Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts -
Inspect/Adjust/Replace” or refer to this Operation
and Maintenance Manual, “Belts - Inspect/
Replace” for the correct procedure.
4. Replace the fuel filter elements.
SEBU9023-09 29
Operation Section
Features and Controls
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
Illustration 25 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 26 g03342374
Inside of the control panel
(8) “CRANK OVERRIDE” switch
(9) “SHUTDOWN OVERRIDE” switch
SEBU9023-09 31
Operation Section
Gauges and Indicators
Your engine may not have the same gauges or all of Engine Oil Temperature – This gauge
the gauges that are described. indicates the engine oil temperature
after the oil has passed through the oil
Gauges provide indications of engine performance. cooler. The oil cooler is thermostatically
Ensure that the gauges are in good working order. controlled.
Determine the normal operating range by observing
the gauges over time. Noticeable changes in gauge Exhaust Temperature – This gauge
readings indicate potential gauge or engine indicates the exhaust temperature at the
problems. Problems may also be indicated by gauge exhaust inlets to the turbochargers. The
readings that change even if the readings are within two exhaust temperatures may vary slightly.
specifications. Determine and correct the cause of
any significant change in the readings. Consult your The exhaust temperatures at the exhaust inlets to the
Caterpillar dealer for assistance. turbochargers provide a good indication of engine
performance. For engines with dry exhaust
NOTICE manifolds, the temperatures are representative of the
If no oil pressure is indicated, STOP the engine. If actual temperatures of the valves. Monitor this
maximum coolant temperature is exceeded, STOP parameter frequently.
the engine. Engine damage can result.
NOTICE
Severe damage to the engine can result if the ex-
Engine Coolant Temperature – This haust temperature at the inlet to the turbocharger ex-
gauge indicates the engine coolant ceeds the extreme limit.
temperature. The temperature may vary
according to the load. Do not allow the
temperature to exceed the boiling temperature of Fuel Level – This gauge indicates the
the pressurized cooling system. fuel level in the fuel tank. Normally, the
fuel level gauge will register the fuel
Fully submerge the engine coolant temperature level only when the switch is in the ON position.
sensor to detect correctly the temperature. If the
engine is operating above the normal temperature Fuel Pressure – This gauge indicates
range, perform the following procedure: fuel pressure to the fuel injection pump
from the fuel filter. A decrease in fuel
1. Reduce the load and/or the engine rpm.
pressure usually indicates a dirty fuel filter or a
2. Inspect the cooling system for leaks. plugged fuel filter. As the fuel filter becomes
plugged, there will be a noticeable reduction in
3. Determine if the engine must be shut down the engine performance.
immediately or if the engine can be cooled by
reducing the load and/or rpm. Fuel Temperature – This gauge indicates
the temperature of the fuel. A high fuel
Engine Load – This gauge indicates a temperature can adversely affect
percentage of the full rated torque. The performance. If the temperature of the fuel is too
calculation of the percentage is based low, the fuel filter may begin to plug. See this
on these factors: flow of fuel, engine rpm, fuel Operation and Maintenance Manual, “Fuel and
energy content and fuel correction factor. This the Effect from Cold Weather” for more
gauge flashes if the torque exceeds the maximum information.
limit that is programmed into the control strategy.
Fuel Usage – This gauge indicates the
Engine Oil Pressure – The oil pressure rate of fuel usage.
should be greatest after a cold engine is
started. The pressure will decrease as
the engine warms up. The pressure will increase
when the engine rpm is increased. The pressure
will stabilize when the engine rpm is stable.
A lower oil pressure is normal at low idle. If the load is
stable and the gauge reading changes, perform the
following procedure:
32 SEBU9023-09
Operation Section
Overspeed
Inlet Manifold Air Pressure – This gauge For more information, refer to the following
indicates the air pressure (turbocharger resources.
boost pressure) in the air inlet manifold
after the aftercooler. The inlet manifold air • Troubleshooting Guide, SENR5002,
pressure depends on the engine rating, the load, “Troubleshooting for Marine Engine Electronic
and the operating conditions. To establish the Displays”
normal inlet manifold air pressure, compare the • Application and Installation Guide, LEGM0001,
data from the gauge to the data from the engine
“Marine Engine Electronic Displays Installation
commissioning and look for trends.
Guide”
Inlet Manifold Air Temperature – This
gauge indicates the inlet manifold air i03648188
temperature after the aftercooler. As the
inlet air increases in temperature the following Overspeed
conditions occur: expansion of the air, less SMCS Code: 1900; 1907; 1912; 7427
oxygen in the cylinders and less power. If the
temperature of the inlet air is too high during full An overspeed condition is detected by the electronic
speed and load operation, the engine may control module (ECM). If the engine speed exceeds
consume excessive fuel. 115 percent of the rated engine speed, the ECM will
shut off the electronic unit injectors. The electronic
Service Hour Meter – This gauge unit injectors will be shut off until the engine speed
indicates the total number of clock drops below the high idle rpm for the engine. A
hours on the engine. diagnostic fault code will be logged into the ECM
memory and the engine overspeed warning will be
System Voltage – This gauge indicates annunciated on the display. “DIAGNOSTIC” lamp will
the voltage of the electrical system. indicate a diagnostic fault code.
The minimum coolant temperature that will activate The failure of the coolant level sensor will not cause a
the alarm is 104° C (219° F). The switch opens as shutdown of the engine or any horsepower change.
the coolant cools. A procedure for resetting is not
required. Engine Oil Pressure Sensor
Failure of the Coolant Temperature The engine oil pressure sensor can detect engine oil
Sensor pressure for diagnostic purposes. The engine oil
pressure sensor sends a signal to the Electronic
If one of the following conditions exist, a failure of the Control Module (ECM).
coolant temperature sensor may have occurred:
Low Oil Pressure Warning
• Sensor output is open.
The setpoint is dependent upon the engine rpm. The
• Sensor output is shorted to ground or supply. fault will be active and logged only if the engine has
been running for more than 15 seconds.
• Measured reading of the coolant temperature is
out of the specification.
Very Low Oil Pressure Warning
The ECM will detect the failure of the coolant
temperature sensor. The diagnostic lamp will warn The very low oil pressure setpoint is dependent upon
the operator about the status of the coolant the engine rpm. If Derate mode is selected, the ECM
temperature sensor. Strategies that are related to the will derate the engine power. The engine horsepower
coolant temperature will be disabled if a failure will be limited.
occurs. The failure of the coolant temperature sensor
will not cause a shutdown of the engine or any Failure of the Engine Oil Pressure Sensor
horsepower change.
If one of the following conditions exist, a failure of the
Coolant Level Sensor engine oil pressure sensor may have occurred:
The coolant level sensor monitors the engine coolant • The engine oil pressure sensor is open.
level. The sensor will detect coolant level. The
coolant level sensor provides information to the ECM. • The engine oil pressure sensor is shorted to
The output from the ECM can indicate a low coolant ground or supply.
level through a relay or a lamp. Coolant must be
added to the cooling system in order to correct the • Measured reading of the oil pressure is out of the
condition. See the Operation and Maintenance specification.
Manual for more information.
The ECM will detect the failure of the engine oil
The system can be programmed with one of the pressure sensor. The diagnostic lamp warns the user
following options: about the status of the engine oil pressure sensor.
The strategies related to oil pressure will be disabled.
Enabled – The system will monitor the input from the The failure of the engine oil pressure sensor will not
coolant level sensor. The system is programmed with cause a shutdown of the engine or any horsepower
this value when the engine is shipped by Caterpillar. change.
Disabled – The system will monitor the input from
the coolant level sensor. All of the diagnostics that Fuel Pressure Sensor
are associated with the coolant level sensor will be
disabled. The fuel pressure sensor monitors the fuel filter
pressure. Low fuel pressure or high fuel pressure will
not cause a shutdown of the engine or any
Failure of the Coolant Level Sensor horsepower change. Fuel pressure that is outside of
the normal range will affect the engine performance.
A failure of the coolant level sensor may occur under If the fuel filter outlet pressure is low, the fuel filter
the following conditions: may need to be replaced.
Table 2
Fuel Pressure Sensor Note: The air pressure sensor for the inlet manifold is
Minimum allowable pressure of the fuel trans- located on the top right side of the engine.
415 kPa (60 psi)
fer pump at full load speed
The boost pressure is determined from the difference
Minimum allowable pressure in the fuel mani-
276 kPa (40 psi)
in pressure between the air pressure sensor for the
fold at full load speed inlet manifold and the atmospheric pressure sensor
(crankcase pressure).
Fuel Temperature Sensor Failure of the Air Pressure Sensor for the
Inlet Manifold
The fuel temperature sensor monitors the fuel
temperature. Fuel temperature is monitored in order A failure of the air pressure sensor for the inlet
to adjust the fuel rate so that the engine will deliver manifold may have occurred if any of the following
consistent power. The fuel temperature sensor can conditions are present:
also be used to warn the operator of excessive fuel
temperature. A high fuel temperature can adversely • The output of the air pressure sensor for the inlet
affect the engine performance. manifold is open.
Table 3
• The output of the air pressure sensor for the inlet
Fuel Temperature Sensor
manifold is shorted to ground or to supply.
Operating range of the fuel temperature sen- 30 to 70°C
sor for activation of the power correction by • The reading of the air pressure sensor for the inlet
(86 to 158°F)
the ECM manifold is out of the specification.
The ECM will detect the failure of the air pressure
Air Temperature Sensor for the sensor for the inlet manifold. The operator will be
warned of the problem through the diagnostic lamp.
Inlet Manifold The strategies that are related to the boost will be
disabled. The failure of the air pressure sensor for the
The air temperature sensor for the inlet manifold inlet manifold will not cause a shutdown of the engine
measures the inlet manifold air temperature. The or any horsepower change.
Electronic Control Module (ECM) monitors the signal
from the air temperature sensor for the inlet manifold.
The output of the ECM can indicate high inlet Speed/Timing Sensor
manifold air temperature through a relay or a lamp.
The air temperature sensor for the inlet manifold will If the ECM cannot receive a signal from the primary
not cause a shutdown of the engine or any speed/timing sensor, the “DIAGNOSTIC” lamp will
horsepower change. indicate a diagnostic fault code which will be logged
in the ECM memory.
Note: The air temperature sensor for the inlet
manifold will be affected by the heat that is conducted The backup speed/timing sensor is used when the
ECM does not receive a signal from the primary
from the inlet manifold. This is true when the engine
speed/timing sensor. The backup speed/timing
is idling and after the engine is shut off. This warm-up sensor will be used until the primary speed/timing
is due to the lack of coolant circulation through the sensor is replaced.
engine. The reading from the air temperature sensor
for the inlet manifold may be significantly higher than Failure of the Speed/Timing Sensor
the actual temperature of the air inside the inlet
manifold until the inlet manifold cools. A failure of the speed/timing sensor may have
occurred if one of the following conditions occur:
Air Pressure Sensor for the Inlet
• The output of the speed/timing sensor has
Manifold opened.
The air/fuel ratio control utilizes actual engine speed
• The speed/timing sensor is shorted to ground.
and actual boost pressure (inlet manifold air
pressure) in order to control the transient smoke • The speed/timing sensor is shorted to supply.
level. When the throttle is increased and the engine
demands more fuel, the fuel limit is controlled in or to • The speed/timing sensor is missing pulses.
reduce overall smoke levels of the engine exhaust.
The Electronic Control Module (ECM) controls • The speed/timing sensor has extra pulses.
injection timing and the amount of fuel that is
injected.
SEBU9023-09 35
Operation Section
Sensors and Electrical Components
i00864752
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 28 g03199057
(3) “START” switch
(4) “ON/OFF” switch for the “LOCAL THROTTLE”
(5) “LOCAL THROTTLE” switch
(6) “OFF/MANUAL/REMOTE” switch
Illustration 27 g03199056
(1) “OFF/MANUAL/REMOTE” switch
(2) “START” switch
Note: The engine key switch and the start circuits are
controlled by the “OFF/LOCAL/REMOTE” switch. Illustration 29 g03200996
The position of the “OFF/LOCAL/REMOTE” switch (7) “CRANK OVERRIDE” switch
does not affect the operation of the “STOP” switch. (8) “SHUTDOWN OVERRIDE” switch
(9) “TORQUE LIMIT” switch
1. Position the “OFF/LOCAL/REMOTE” switch to the
LOCAL position or to the REMOTE position. When the “OFF/LOCAL/REMOTE” switch is in
LOCAL mode, the engine cannot be started from the
2. Activate the “START” switch to start the engine. remote control unit. The LOCALl position does not
energize the key switch (J906 circuit) beyond the
engine harness.
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.
40 SEBU9023-09
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.
SEBU9023-09 41
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.
The engine can be operated at the rated rpm after If successful, the machine will continue to run
indefinitely at the current rpm until taken out of non-
the engine is started and after the engine reaches work mode.
operating temperature. The engine will reach normal
operating temperature sooner during a low engine
speed (rpm) and during a low-power demand. This Exhaust Temperature Low Code Actions
procedure is more effective than idling the engine at
no load. The engine should reach operating Once the 173-18 Engine Exhaust Manifold #1
temperature in a few minutes. Temperature #1: Low - Moderate Severity (2)
warning message is shown, there are two actions the
Gauge readings should be observed and the data can be taken to remove them:
should be recorded frequently while the engine is
operating. Comparing the data over time will help to Non-Work Mode
determine normal readings for each gauge.
Comparing data over time will also help detect Put the machine in Non-Work mode.
abnormal operating developments. Significant
changes in the readings should be investigated. • This will allow Hydrocarbon Mitigation to start
automatically and attempt to achieve the target
temperatures for the intake and exhaust.
Hydrocarbon Mitigation
• If the strategy does not achieve target
The hydrocarbon mitigation is a feature to protect the temperatures, the engine will return to low idle for
DOC against temperatures below 325° C (617° F). 60 minutes and then Hydrocarbon Mitigation
Temperatures below this range can damage the begins.
aftertreatment of the machine. The initial occurrence
displays as a warning and then if temperatures do not • If the strategy continues to fail, the next action will
increase by the operator or strategy, the machine will
go into shutdown. Messages appear sequentially as need to be taken to clear the codes.
follows: Non-Work Mode Failure
• First : Key cycle to warning If the machine is being used at the time of the
• Secondary : Warning to shut down warning message and cannot be put into Non-Work
mode, then raise the intake and exhaust temperature
If the warning messages are not acknowledged, then for their time thresholds.
the shutdown counter begins. Once the engine has
shutdown for low exhaust temperatures, the 173-18 • Intake air manifold temperature is greater than
Engine Exhaust Manifold #1 Temperature #1: Low - 10° C (50° F) for 10 minutes continuously
Moderate Severity (2) will return until the engine has
successfully reached target temperatures. • Exhaust manifold temperature is greater than
325° C (617° F) for 30 minutes continuously
Once exhaust temperatures below 325° C (617° F)
are observed for an hour, the Hydrocarbon Mitigation • Blender - Ideal time to perform this is during the 60
feature begins and the following conditions below minute low time after a Hydrocarbon Mitigation
become active. failure.
SEBU9023-09 43
Operation Section
Fuel Conservation Practices
Note: Hydrocarbon Mitigation will always start • When possible, utilize the heat of the jacket water
mitigation. system and the energy from the heat of the
exhaust system.
Partial Load Operation • Keep keel coolers, heat exchangers, and water
pumps clean. Keep the components in good
Extended operation at reduced load (less than 30%)
may cause increased oil consumption and carbon repair.
buildup in the cylinders. Extended operation at
reduced load may also cause fuel to slobber through • Ensure that all of the accessory pumps are
the exhaust system. A loss of power and/or poor repaired. The pumps should operate efficiently.
performance may result.
• Do not exceed the maximum oil level.
To maintain engine efficiency and performance, apply
70% load to the engine on an hourly basis. Operating • Never operate without water temperature
the engine at a load level that is greater than 30% will regulators.
also maintain engine efficiency and performance.
Water temperature regulators regulate the
This action will burn excess carbon from the temperature of the coolant. Water temperature
cylinders.
regulators help to provide efficient operating
temperatures. Cold engines consume excessive fuel.
i01060957 Water temperature regulators also help prevent
engine overheating.
Fuel Conservation Practices
SMCS Code: 1000; 1250 Cruising Speed
The efficiency of the engine can affect the fuel The recommended cruising speed of the engine is
economy. Caterpillar's design and technology in 300 to 400 rpm below the rated speed of the engine.
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures Operating at the recommended cruising speed will
in order to attain optimum performance for the life of help to provide the maximum engine service life and
the engine. the most economical operation.
• Avoid spilling fuel.
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.
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.
46 SEBU9023-09
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
SEBU9023-09 47
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.
48 SEBU9023-09
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.
i04137729
The engine control switch and the emergency stop • If necessary, perform minor adjustments. Repair
button must be reset before the engine can be any leaks and tighten any loose bolts.
restarted. The air shutoff (if equipped) must be reset
before the engine can be restarted. Reset the engine • Note the service hour meter reading. Perform the
control switch before resetting the emergency stop maintenance that is in the Operation and
button. Maintenance Manual, “Maintenance Interval
Schedule”.
To reset the engine control switch, turn the switch to
the “OFF/RESET” position. • Fill the fuel tank to prevent accumulation of
moisture in the fuel. Do not overfill the fuel tank.
To reset the emergency stop button, turn the button
clockwise. The spring-loaded button will return to the • Allow the engine to cool. Check the coolant level.
OUT position. The button may also be pulled to the Maintain the cooling system at 13 mm (0.5 inch)
OUT position. from the bottom of the pipe for filling.
SEBU9023-09 49
Operation Section
After Stopping Engine
i07277454
Fluid Recommendations
SMCS Code: 1280; 1348; 1395; 7560
The minimum required Total Base Number (TBN) for The S·O·S Oil Analysis program uses a wide range
oil depends on the fuel sulfur level. The TBN for new of tests to determine the condition of the oil and the
crankcase. Guidelines that are based on experience
oil is typically determined by the “ASTM D2896” and a correlation to failures have been established
procedure. For direct injection engines that use for these tests. Exceeding one or more of these
distillate fuel, the following guidelines apply: guidelines could indicate serious fluid degradation or
Table 10 a pending component failure. A trained person at
your Cat dealership should make the final analysis.
TBN recommendations for applications in Cat engines
Fuel Sulfur Level per-
Cat Engine Oils (1)
TBN of Commercial NOTICE
cent (ppm) Engine Oils Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
0.05 percent Cat DEO-ULS pling. Using the same pump for both types of sam-
Min 7
(500ppm) Cat DEO ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
(continued) cerns by both dealers and customers.
SEBU9023-09 53
Maintenance Section
Fluid Recommendations
Fuel
Note: Caterpillar strongly recommends the filtration
of fuel through a fuel filter with a rating of four
microns(c) absolute or less. This filtration should be
on the device that dispenses the fuel to the fuel tank
for the engine. This filtration should also be on the
device that dispenses fuel from the bulk storage tank.
Series filtration is recommended.
Illustration 32 g02157153
NOTICE
The footnotes are a key part of the “Caterpillar Speci-
fication for Distillate Diesel Fuel for Off-Highway Die-
sel Engines” Table. Read ALL of the footnotes.
54 SEBU9023-09
Maintenance Section
Fluid Recommendations
Table 11
Caterpillar Specification for Distillate Fuel for Nonroad (Table 11, contd)
Diesel Engines
Caterpillar Specification for Distillate Fuel for Nonroad
ASTM Diesel Engines
Specifications Requirements Test ISO Test
ASTM
Aromatics 35% maximum “D1319” “ISO 3837” Specifications Requirements Test ISO Test
0.01% maximum “D1796”
Ash “D482” “ISO 6245” Water and
(weight) 0.05% maximum or “ISO 3734”
Sediment
“D2709”
Carbon Residue 0.35% maximum
“D524” “ISO 4262”
on 10% Bottoms (weight) No equiva-
Water 0.05% maximum “D6304”
lent test
40 minimum (DI
engines) “D613” 0.05% maximum
Sediment “D473” “ISO 3735”
Cetane Number (1) or “ISO 5165” (weight)
35 minimum (PC “D6890”
engines) Gums and Resins 10 mg per 100 mL
(4) “D381” “ISO 6246”
maximum
The cloud point
(1) Alternatively, to ensure a minimum cetane number of 35 (PC
must not exceed
engines), and 40 (DI engines), distillate diesel fuel should have
Cloud Point the lowest ex- “D2500” “ISO 3015” a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en-
pected ambient gines) when the “ASTM D4737-96a” test method is used. A fuel
temperature. with a higher cetane number may be required for operation at a
higher altitude or in cold weather.
Copper Strip (2) Via standards tables, the equivalent kg/m3 (kilograms per cubic
No. 3 maximum “D130” “ISO 2160”
Corrosion meter) using the “ASTM D287” test method temperature of
15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/
10% at 282 °C
m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
(540 °F) (3) Certain Cat fuel systems and engine components can operate
maximum on fuel with a maximum sulfur content of 3%. Contact your Cat
Distillation “D86” “ISO 3405” dealer for guidance about appropriate maintenance intervals
90% at 360 °C
and fluids for engines operating on fuel with sulfur levels be-
(680 °F)
tween 0.1% and 3%.
maximum (4) Follow the test conditions and procedures for gasoline (motor).
Flash Point legal limit “D93” “ISO 2719”
Note: Vessels that are traveling internationally and
Minimum of 80% that have on/off NOx controls must enable these
reflectance after controls prior to entering a NECA. For US flagged
No equiva-
Thermal Stability aging for 180 mi- “D6468”
lent test vessels, on/off controls are not allowed without an
nutes at 150 °C
(302 °F)
exemption during international travel. The controls
must always be on. Foreign destinations should be
30 minimum No equiva- reviewed for supply of ULSD fuel and DEF prior to
API Gravity (2) “D287”
45 maximum lent test departure. Exemptions for ULSD or DEF use by US
flagged vessels may be requested from the US
6 °C (10 °F) mini- Environmental Protection Agency (EPA). The EPA
Pour Point mum below ambi- “D97” “ISO 3016” can be contacted at the following address:
ent temperature
(continued)
SEBU9023-09 55
Maintenance Section
Fluid Recommendations
Biodiesel
A biodiesel blend of up to 20 percent may be used in
the engine when the fuel blend meets the
recommendations in table 12 and meets the
recommendations in Special Publication, SEBU6251,
“Biodiesel”. A blend of greater than 20 percent
biodiesel may be acceptable sometimes. See your
Cat dealer for more information.
Cooling System
NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.
NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem-
perature or drained completely in order to prevent
damage caused by freezing coolant.
Coolant Recommendations
Table 13
Coolant Recommendations for use in Cat Diesel Engines
Service Required
Recommendations Product
Hours(1)(2)(3) Maintenance
Table 14
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.
SEBU9023-09 57
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 15 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. Cost analysis should also include the cost
A coolant analysis (Level 1) is a test of the properties of the amount of grease that is required.
of the coolant.
The following properties of the coolant are tested:
58 SEBU9023-09
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 33 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
60 SEBU9023-09
Maintenance Section
Maintenance Interval Schedule
Note: Before each consecutive interval is performed, Initial 500 Hours (for New Systems,
all maintenance from the previous interval must be
performed. Refilled Systems, and Converted
Systems)
When Required
“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 71
“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 62
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 64 Initial 1000 Service Hours
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 65 “ Heat Exchanger - Inspect”. . . . . . . . . . . . . . . . . . . 97
Every 14 400 L (3750 US gal) of Every 284 000 L (75 000 US gal) of
Fuel or 250 Service Hours or 1 Year Fuel or 5000 Service Hours
“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 64 “ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . 108
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Overhaul
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 82
“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 62
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 83 “ Heat Exchanger - Clean/Test”. . . . . . . . . . . . . . . . 96
“ Fuel System Primary Filter (Water Separator) “Maintenance Recommendations” . . . . . . . . . . . . 100
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 90
“ Oil Cooler Core - Check/Clean/Test” . . . . . . . . . 102
“ Fuel System Secondary Filter - Replace”. . . . . . . 91
“Overhaul (Major)” . . . . . . . . . . . . . . . . . . . . . . . . . 103
“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 94
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 98
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen-
tration of cleaner.
Illustration 34 g03161198
(1) Valve
(2) Plunger 2. Back flush the core with cleaner.
(3) Valve seat
Caterpillar recommends the use of Hydrosolv
The engine boost pressure forces the plunger to liquid cleaner. Table 16 lists Hydrosolv liquid
move down to the valve seat. The plunger must close cleaners that are available from your Cat dealer.
against the seat at a pressure of 2.8 kPa (0.4 psi). Table 16
The absence of boost pressure when the engine is
stopped allows the plunger to rise to the open Hydrosolv Liquid Cleaners(1)
position. The open position allows condensation from
Part Number Description Size
the aftercooler to drain out.
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
The plunger must be able to move freely in order to
close the system when the engine is running. The 174-6854 Hydrosolv 100 19 L (5 US gallon)
plunger must be able to move freely in order to allow
(1) Use a two to five percent concentration of the cleaner at tem-
condensation to drain from the aftercooler when the
engine is stopped. Residue from normal engine peratures up to 93°C (200°F). Consult your Cat dealer for more
information.
operation could cause the plunger to stick.
SEBU9023-09 63
Maintenance Section
Auxiliary Water Pump (Bronze Impeller) - Inspect/Replace
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. i03091745
Note: Do not use high pressure when the fins are Auxiliary Water Pump (Bronze
cleaned. High pressure can damage the fins.
Impeller) - Inspect/Replace
4. Wash the core with hot, soapy water. SMCS Code: 1371-510
5. Flush the core thoroughly in order to remove Impellers and seals require periodic inspection.
residue and remaining debris. Flush the core with Impellers have a service life that is limited. The
clean, fresh water until the water that is exiting the service life depends on the engine operating
core is clear and free of debris. conditions.
Inspect the components more frequently when the
pump is exposed to debris, sand, or other abrasive
materials. Inspect the components if the pump is
Personal injury can result from air pressure. operating at a differential pressure of more than
103 kPa (15 psi).
Personal injury can result without following prop-
er procedure. When using pressure air, wear a Refer to Disassembly and Assembly, “Auxiliary Water
protective face shield and protective clothing. Pump - Remove” in order to remove the auxiliary
water pump. Refer to Disassembly and Assembly ,
The maximum air pressure for cleaning purposes “Auxiliary Water Pump - Disassemble” in order to
must be reduced to 205 kPa (30 psi) when the air disassemble the auxiliary water pump.
nozzle is deadheaded.
Inspect the following components for wear or
6. Dry the core with compressed air. Direct the air in damage:
the reverse direction of the normal flow.
• Bearings
Test the Aftercooler Core • Impeller
1. Inspect the core for trapped debris and • Seals
cleanliness. If necessary, remove the debris and
repeat the cleaning procedure. • Wear plate
2. Inspect the core for damage and perform a If wear or damage is found, replace the components
pressure test in order to detect leaks. Many shops which are worn or damaged. Use the proper repair kit
for the pump.
that service radiators are equipped to perform
pressure tests. Refer to Disassembly and Assembly, “Auxiliary Water
Pump - Assemble” in order to assemble the auxiliary
3. Plug both ends of the aftercooler core and water pump. Refer to Disassembly and Assembly ,
pressurize the core to 205 kPa (30 psi). “Auxiliary Water Pump - Install” in order to install the
Submerge the core in water. Look for bubbles auxiliary water pump.
which are being emitted from the core. The
bubbles are evidence of leaks.
4. If any leaks are found, do not attempt to repair the
core.
Install a core that is clean and a core that passes the
pressure test in step 3. Refer to the Disassembly and
Assembly Manual, “Aftercooler - Install” for the
procedure.
64 SEBU9023-09
Maintenance Section
Battery - Replace
i07419560
http://www.loctite.com/en/meta/meta-nav/
location-selector.html
i06738663
The battery cables or the batteries should not be Intervals for Maintenance
removed with the battery cover in place. The bat-
tery cover should be removed before any servic- Inspect the belt 20 to 40 hours after the initial start-
ing is attempted. up. Replace the belt every 3000 service hours.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion Inspection
resulting in personal injury.
Inspect the belt for wear and for cracking. Replace
the belt if the belt is not in good condition.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position Check the belt tension according to the information in
and remove the key and all electrical loads. the Specifications Manual, “Belt Tension Chart”.
2. Disconnect the negative battery terminal at the Slippage of loose belts can reduce the efficiency of
battery that goes to the start switch. Ensure that the driven components. Vibration of loose belts can
the cable cannot contact the terminal. When four cause unnecessary wear on the following
components:
12 volt batteries are involved, the negative side of
two batteries must be disconnected. • Belts
3. Tape the leads in order to help prevent accidental • Pulleys
starting.
• Bearings
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
Replacement
1. Remove the belt guard.
66 SEBU9023-09
Maintenance Section
Coolant - Change
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Illustration 36 g03123244
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Typical belt tensioner installation ers before opening any compartment or disassem-
(2) Square hole for ratchet bling any component containing fluids.
2. Insert a ratchet with a square drive into the square Refer to Special Publication, NENG2500, “Cat Dealer
hole that is located in the tensioner for the belt. Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
3. Rotate the tensioner counterclockwise to relieve for tools and supplies suitable to collect and contain
tension on the belt. Remove the belt. fluids on Cat products.
4. Install the new belt correctly, as shown. Be sure Dispose of all fluids according to local regulations
that the belt is fully seated on the pulleys. The and mandates.
correct tension will automatically be applied when
the ratchet is removed. 1. Stop the engine and allow the engine to cool.
5. Install the belt guard. Ensure that the engine will not start when the
cooling system is drained.
i04982933 2. Loosen the cooling system filler caps slowly in
order to relieve any pressure. Remove the cooling
Coolant - Change system filler caps.
SMCS Code: 1350-044; 1352; 1395; 1395-044 3. Open the cooling system drains. Refer to the
“Jacket Water System” and “SCAC System” for the
Note: The engine has two separate cooling systems,
the jacket water system, and the separate circuit drain locations.
aftercooler system (SCAC system). Change the Note: If equipped, be sure to drain the heater and
coolant in both systems whenever the coolant is any related supply and return lines.
changed.
Refer to this Operation and Maintenance Manual, Allow the coolant to drain.
“Fluid Recommendations” for the correct intervals for
changing the coolant. NOTICE
Dispose of used engine coolant properly or recycle.
Clean the cooling system and flush the cooling Various methods have been proposed to reclaim
system before the recommended maintenance used coolant for reuse in engine cooling systems.
interval if the following conditions exist: The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant.
• The engine overheats frequently.
• Foaming is observed. For information regarding the disposal and the
recycling of used coolant, consult your Cat dealer or
• The oil has entered the cooling system and the consult Cat Dealer Service Tool Group:
coolant is contaminated.
Inside USA 1-800-542-TOOL
• The fuel has entered the cooling system and the Inside Illinois 1-800-541-TOOL
coolant is contaminated. Canada 1-800-523-TOOL
International 1-309-578-7372
SEBU9023-09 67
Maintenance Section
Coolant - Change
Illustration 38 g03163459
Jacket water heat exchanger drain (Some parts
removed for visibility)
68 SEBU9023-09
Maintenance Section
Coolant - Change
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).
SEBU9023-09 69
Maintenance Section
Coolant Extender (ELC) - Add
1. Fill the cooling systems. Refer to this Operation Check the cooling system only when the engine is
stopped and cool.
and Maintenance Manual, “Fluid
Recommendations” for more information on
cooling system specifications Refer to this
Operation and Maintenance Manual, “Refill
Personal injury can result from hot coolant,
Capacities” for information about the capacity of steam and alkali.
the cooling systems. Do not install the cooling
system filler caps. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
2. Start and run the engine at low idle. Increase the heaters or the engine contain hot coolant or
engine rpm to high idle. Run the engine at high steam. Any contact can cause severe burns.
idle for 1 minute in order to purge the air from the
Remove cooling system pressure cap slowly to
cavities of the engine block. Stop the engine. relieve pressure only when engine is stopped and
3. Check the coolant level. Maintain the coolant level cooling system pressure cap is cool enough to
touch with your bare hand.
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within Do not attempt to tighten hose connections when
13 mm (0.5 inch) to the proper level on the sight the coolant is hot, the hose can come off causing
glass (if equipped). burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
70 SEBU9023-09
Maintenance Section
Coolant Level - Check
• Keep the lids on empty sampling bottles until you Note: Level 1 results may indicate a need for Level 2
are ready to collect the sample. Analysis.
i04240223
Dispose of all fluids according to local regulations
and mandates.
Coolant Temperature
Regulator - Replace Note: If replacing only the water temperature
regulator, only drain the coolant to a level that is
SMCS Code: 1355-510 below the water temperature regulator housing.
Replace the water temperature regulator before the Refer to two articles in the Disassembly and
water temperature regulator fails. Replacing the Assembly Manual, “Water Temperature Regulator -
water temperature regulator reduces the chances for Remove and Water Temperature Regulator - Install”
unscheduled downtime. for the replacement procedure or consult your Cat
dealer.
A water temperature regulator that fails in a partially
opened position can cause overheating or
overcooling of the engine. i05053052
A water temperature regulator that fails in the open Cooling System Supplemental
position will cause the engine operating temperature
to be too low during partial load operation. Low Coolant Additive (SCA) - Test/
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
Add
cylinders. This excessive carbon buildup could result SMCS Code: 1352-045; 1395-081
in an accelerated wear of the piston rings and wear of
the cylinder liner. Note: This maintenance is NOT required for
cooling systems that are filled with Extended Life
A water temperature regulator that fails in the closed Coolant.
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
Cooling system coolant additive contains alkali.
NOTICE To help prevent personal injury, avoid contact
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe with the skin and eyes. Do not drink cooling sys-
engine damage. tem coolant additive.
Note: Caterpillar recommends an S·O·S coolant The damper is mounted to the crankshaft which is
analysis (Level 1). located behind the belt guard on the front of the
engine. The damper on your engine may look like
one of the following dampers.
Cooling Systems that Use
Conventional Coolant
Test the Concentration of the SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
i06103535
Engine - Clean
SMCS Code: 1000-070
Illustration 42 g01134779
Single viscous vibration damper
(1) Crankshaft pulley
(2) Weight Personal injury or death can result from high
(3) Case voltage.
Moisture can create paths of electrical
conductivity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
NOT OPERATE”” .
NOTICE
Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
lates on the engine.
Illustration 44 g03195697
Typical air cleaner installation
(1) Cover for the air cleaner cannister
(2) Latches for the air cleaner
(3) Air cleaner cannister Illustration 45 g01640336
Typical air cleaner service indicator
NOTICE
Never run the engine without an air cleaner element Some engines may be equipped with a different
installed. Never run the engine with a damaged air service indicator.
cleaner element. Do not use air cleaner elements Observe the service indicator. Clean the air cleaner
with damaged pleats, gaskets, or seals. Dirt entering element or replace the air cleaner element when the
the engine causes premature wear and damage to following conditions occur:
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet. • The yellow diaphragm enters the red zone.
If the air cleaner element becomes plugged, the air • The red piston locks in the visible position.
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal • The air restriction reaches 6 kPa
engine wear. Your Cat dealer has the proper air (25 inches of H2O).
cleaner elements for your application. Consult your
Cat dealer for the correct air cleaner element.
Test the Service Indicator
NOTICE Service indicators are important instruments.
Never service the air cleaner element with the engine
running. Operating the engine without an air cleaner
allows dirt to enter the engine. • Check for ease of resetting. The service indicator
should reset in less than three pushes.
Readings in Steel
Millivolts 0–750 750–950 950–1200
Aluminum
0–800 800–1050 1050–1200
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 g06498949
(4) Engine
(5) Propeller shaft
(6) Sea cock
(7) Vessel anode
(8) Engine bonding conductor
(9) Common bonding conductor (wire)
(10) Hull Through-bolts
Illustration 50 g06498953
C18 SCAC marine engine bonding stud (2)
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 the anodes and through bolts are isolated from the
ohm). hull. If the bonding is incorrect on an aluminum hull,
damage can quickly occur. Many aluminum hulls use
On steel boats with anodes bolted or welded to the impressed current cathodic protection (ICCP).
outside of the hull, bonding the engines bonding stud
directly to the hull is recommended. The Note: After making the bonding connection from the
aforementioned bonding of the stud to the hull engine, it is imperative voltage potential be measured
ensures that you have a direct connection to the
on all components in contact with seawater.
vessel anodes.
On fiberglass and wooden hulls, you are able to C18 engines and generator sets built in Griffin are
bond to a through-bolt used to attach the anode to shipped with both a neutral cable connection on the
the outside of the hull. On fiberglass and wooden generator end and an engine bonding stud. For these
hulls, it is important to isolate the anode and the engines and generator sets,
through-bolt from the hull.
• A connection must be made from the neutral cable
connection to ground on the generator end.
i02751871
NOTICE
Perform this maintenance with the engine stopped.
i02456872
i04948069 i07945717
10. Check the engine oil level. Use a marking tool to In addition to a good preventive maintenance
engrave the “ADD” mark (Y) to the correct location program, Caterpillar recommends using S·O·S oil
on the gauge assembly. analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
11. Add 3.8 L (4 qt) of the recommended oil grade for determining nitration and oxidation levels.
and weight of engine oil to the crankcase.
12. Check the engine oil level. Use a marking tool to
Obtain the Sample and the
engrave “FULL” mark (X) onto the correct location Analysis
on the gauge assembly.
To ensure that the sample is representative of the oil Do not drain the oil when the engine is cold. As the oil
in the crankcase, obtain a warm, mixed oil sample. cools, waste particles settle on the bottom of the oil
pan. The waste particles are not removed when the
To avoid contamination of the oil samples, the tools cold oil is drained. Drain the crankcase when the oil
and the supplies that are used for obtaining oil is warm. This method allows proper draining of the
samples must be clean. waste particles that are suspended in the oil.
Caterpillar recommends using the sampling valve in Failure to follow this recommended procedure will
order to obtain oil samples. The quality and the allow the waste particles to be recirculated through
consistency of the samples are better when the the engine lubrication system with the new oil.
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be 1. After the engine has been operated at normal
obtained during normal engine operation. operating temperature, STOP the engine.
The 169-8373 Fluid Sampling Bottle is Note: Drain the oil into a suitable container. DO NOT
recommended for use with the sampling valve. The drain the oil into the bilge sump. Dispose of the oil
fluid sampling bottle includes the parts that are according to local regulations.
needed for obtaining oil samples. Instructions are
also provided. Note: If a suction device is used in order to remove
the oil from the oil pan, ensure that the suction device
NOTICE is clean. Using a clean suction device prevents dirt
Always use a designated pump for oil sampling, and from entering into the oil pan. Be careful not to strike
use a separate designated pump for coolant sam- the engine oil suction tubes or the piston cooling jets.
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being 2. Open the oil drain valve. After the oil has drained,
drawn. This contaminate may cause a false analysis close the valve
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers. 3. Drain the oil according to the equipment on the
engine. If the engine has a pump for removing
For instructions, see Special Publication, PEGJ0047, dirty oil, connect a hose to the outlet of the pump.
“How To Take A Good S·O·S Oil Sample”. Consult Place the hose in a suitable container. Open the
your Cat dealer for complete information and valve for the drain line. The two marks on the
assistance in establishing an S·O·S program for your valve must be turned so that one mark points to
engine. the pump and the second mark points to the drain
line. Operate the pump until the crankcase is
i05007775 empty. Close the valve to the drain line.
Disconnect the hose.
Engine Oil and Filter - Change
4. Replace the engine oil filter elements before filling
SMCS Code: 1318-510 the crankcase with new oil.
Illustration 56 g00103713
Typical filter mounting base and filter gasket
Aluminum debris may indicate problems with the 2. Close the fuel supply line and crank the engine
bearings of the front gears. If you find aluminum until the oil pressure gauge indicates 70 kPa
debris, inspect the crankshaft vibration damper and (10 psi). Open the fuel supply line. Allow the
the idler gear bearings.
starting motor to cool for 2 minutes before
Due to normal wear and friction, it is not uncommon cranking again.
to find small amounts of debris in the oil filter
element. If an excessive amount of debris is found in 3. Ensure that the oil level is to the “FULL” mark on
the oil filter element, consult your Caterpillar dealer in the oil level gauge. Start the engine and operate
order to arrange for further oil analysis. the engine at low idle for 2 minutes. This will
ensure that the lubrication system has oil and that
Fill the Crankcase the oil filters are filled with oil. Inspect the engine
and the oil filters for oil leaks. If any leaks exist,
NOTICE stop the engine and make any necessary repairs.
If the engine is equipped with an auxiliary oil filter sys-
tem, extra oil must be added when filling the crank- 4. Stop the engine and allow the oil to drain back into
case. If equipped with an auxiliary oil filter system the sump for a minimum of 10 minutes.
that is not supplied by Caterpillar, follow the recom-
5. Remove the oil level gauge and check the oil level.
mendations of the OEM.
Maintain the oil level between the “FULL” mark
and the “ADD” mark on the oil level gauge. If
NOTICE necessary, add oil.
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge i02703023
(dipstick).
An overfull crankcase can cause the crankshaft to dip
Engine Storage Procedure -
into the oil. This will reduce the power that is devel- Check
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- SMCS Code: 1000-535
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the Caterpillar recommends storage procedures and
crankcase breathers and excessive oil consumption. start-up procedures for all engines that are stored for
more than 1 month. These procedures provide
Excessive oil consumption will cause deposits to form maximum protection to internal engine components.
on the pistons and in the combustion chamber. De- Refer to Special Instruction, SEHS9031, “Storage
posits in the combustion chamber lead to the follow- Procedure For Caterpillar Products” for information
ing problems: guttering of the valves, packing of on these procedures.
carbon under the piston rings and wear of the cylin-
der liner. An extension of the oil change interval to 12 months
is permitted if you follow the required procedures for
If the oil level is above the “FULL” mark on the oil lev- storage and start-up. This extension is permitted if
el gauge, drain some of the oil immediately. the following intervals in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule” have not been reached:
1. Remove the oil filler cap. Fill the crankcase
through the oil filler tube only. For the correct • Operating hours
amount of oil , refer to this Operation and
• Fuel consumption
Maintenance Manual, “Refill Capacities”. Refer to
this Operation and Maintenance Manual, “Fluid
i07139300
Recommendations” for the correct type of oil.
Clean the oil filler cap. Install the oil filler cap.
Engine Valve Lash - Check
NOTICE SMCS Code: 1105-535
To prevent crankshaft or bearing damage, crank en-
gine with fuel off to fill all filters before starting. The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
Do Not crank engine for more than 30 seconds. recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of the
valve train components and to the seating of the
valve train components.
SEBU9023-09 87
Maintenance Section
Engine Valve Rotators - Inspect
NOTICE
Illustration 59 g01096972
Do not crank the engine continuously for more than
Hand priming pump 30 seconds. Allow the starting motor to cool for two
(1) Air purge screw minutes before cranking the engine again.
(2) Fuel pressure regulating valve
SEBU9023-09 89
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
4. Crank the engine for 30 seconds. Use a suitable 8. Crank the engine for 30 seconds. Allow the starting
container to catch the fuel while you crank the motor to cool for two minutes.
engine. Allow the starting motor to cool for two
9. Close and tighten the fuel pressure regulating
minutes.
valve.
Note: You may use the hand priming pump for the
Note: Failure to tighten all fittings could result in
fuel filter (if equipped) instead of cranking the engine.
serious fuel leaks.
5. Crank the engine for 30 seconds. Allow the starting
10. Crank the engine for 30 seconds. Allow the
motor to cool for two minutes.
starting motor to cool for two minutes.
6. Close and tighten the fuel pressure regulating
11. Repeat Step 10 until the engine starts and runs.
valve.
12. Clean any residual fuel from the engine
7. Crank the engine for 30 seconds. Allow the starting
components.
motor to cool for two minutes.
8. Repeat Step 7 until the engine starts and the i02927285
engine runs.
Fuel System Primary Filter/
Note: Failure to tighten all fittings could result in
serious fuel leaks. Water Separator - Drain
SMCS Code: 1260-543; 1263-543
9. Clean any residual fuel from the engine
components.
The Engine Has Been Rebuilt Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
1. Turn the ignition switch to the “OFF” position. possible injury, turn the start switch off when
changing fuel filters or water separator elements.
2. Fill the fuel tank (s) with clean diesel fuel. Clean up fuel spills immediately.
3. Open the the air purge screw for the fuel filter by
three full turns. Do not remove the air purge screw.
NOTICE
4. Open the fuel pressure regulating valve by two and Care must be taken to ensure that fluids are con-
one half turns. The regulating valve is located in tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
the integral fuel filter base. Be prepared to collect the fluid with suitable contain-
Note: Do not remove the regulating valve completely. ers before opening any compartment or disassem-
bling any component containing fluids.
Open the valve enough to allow the air that is trapped
in the cylinder head to be purged from the fuel Refer to Special Publication, NENG2500, “Caterpillar
system. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
NOTICE products.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two Dispose of all fluids according to local regulations
minutes before cranking the engine again. and mandates.
Illustration 60 g01453091
(1) Element
(2) Bowl
(3) Drain
i07945372
3. Shut off the fuel tank supply valve to the engine.
4. Open the drain valve (3) to drain any fuel from the
Fuel System Primary Filter filter case. Close the drain valve.
(Water Separator) Element -
NOTICE
Replace Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
SMCS Code: 1260-510-FQ; 1263-510-FQ nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Water in the fuel can cause the engine to run rough. ers before opening any compartment or disassem-
Water in the fuel may cause an electronic unit injector bling any component containing fluids.
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly Refer to Special Publication, NENG2500, “Cat Dealer
scheduled interval. Service Tool Catalog” or refer to Special Publication,
The primary filter/water separator also provides PECJ0003, “Cat Shop Supplies and Tools Catalog”
filtration to help extend the life of the secondary fuel for tools and supplies suitable to collect and contain
filter. The element should be changed regularly. fluids on Cat products.
Install a vacuum gauge. Change the element for the
Dispose of all fluids according to local regulations
primary filter/water separator if the pressure is at
and mandates.
50 kPa (14.7 inch mercury) to 70 kPa
(20.6 inch mercury).
5. Remove the fuel filter bowl (1) and wash the fuel
filter bowl with clean diesel fuel.
6. Remove the fuel filter (2).
SEBU9023-09 91
Maintenance Section
Fuel System Secondary Filter - Replace
i05303381
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
8. Install the new fuel filter. Tighten the fuel filter until
the gasket contacts the base. Tighten the fuel filter
by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.
Note: Do not remove the plug in the fuel filter base to
release the air from the fuel system during periodic
service of the fuel filter. Periodic removal of the plug
will result in increased wear of the threads in the fuel
filter base.
Illustration 62 g03140296
9. Operate the fuel priming pump plunger until a
Typical secondary fuel filter strong resistance is felt and until the check valve
(1) Priming pump clicks. This procedure will require considerable
(2) Fuel shutoff
(3) Drain valve strokes. Lock the fuel priming pump.
(4) Fuel indicators
(5) Auxiliary secondary fuel filter 10. Open the fuel tank supply valve.
(6) Main secondary fuel filter
(7) Fuel selector valve 11. Start the engine according to the normal
operating procedures. Immediately increase the
engine rpm between 1000 to 1200 rpm with no
Replacing the Fuel Filter Elements load. The engine will begin to misfire briefly until
with the Engine Stopped air from the fuel filter is purged. No damage to the
engine will occur.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly NOTICE
clean the area around a fuel system component that Do not crank the engine continuously for more than
will be disconnected. Fit a suitable cover over discon- 30 seconds. Allow the starting motor to cool for two
nected fuel system component. minutes before cranking the engine again.
1. Stop the engine. 12. If the engine stalls during the purging of the air,
refer to the Operation and Maintenance Manual,
2. Turn off the start switch or disconnect the battery
“Fuel System - Prime” for more information.
(starting motor) when maintenance is performed
on fuel filters.
Replacing the Fuel Filter Elements
3. Shut off the fuel tank supply valve to the engine.
During Engine Operation For
NOTICE Engines That Are Equipped With
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately. Duplex Fuel Filters
Note: The engine must be at IDLE in order to replace
the fuel filter elements during engine operation.
SEBU9023-09 93
Maintenance Section
Fuel System Secondary Filter - Replace
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 discon-
nected fuel system component.
Illustration 64 g03329518
NOTICE
Care must be taken to ensure that fluids are con- 2. Once the lever has been moved to the AUX RUN
tained during performance of inspection, mainte- position, the fuel gauge for the auxiliary filter
nance, testing, adjusting, and repair of the product. should indicate full pressure and the fuel gauge for
Be prepared to collect the fluid with suitable contain- the main filter should indicate no pressure.
ers before opening any compartment or disassem-
bling any component containing fluids. 3. Slowly open the drain valve and purge any
remaining pressure from the main filter. Some fuel
Refer to Special Publication, NENG2500, “Cat Dealer
may also drain from the fuel drain. The fuel
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” indicator for the auxiliary filter should indicate full
for tools and supplies suitable to collect and contain pressure and the fuel indicator for the main filter
fluids on Cat products. should indicate no pressure.
Dispose of all fluids according to local regulations 4. Remove the used main fuel filter.
and mandates.
5. Clean the gasket sealing surface of the main fuel
filter base. Ensure that all of the old gasket is
Replacing the Main Fuel Filter removed.
6. Apply clean diesel fuel to the new main fuel filter
Use the following procedure to replace the main fuel gasket.
filter while the engine is in operation.
7. Install a new main fuel filter. Tighten the fuel filter
until the gasket contacts the base. Tighten the fuel
filter by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.
8. Move the lever to the RH FLOW - LH FILL position.
The indicator for the main filter should indicate
slight pressure. Purge the air from lines for the
main filter through the drain valve. Close the drain
valve when the fuel starts flowing through the
drain valve.
9. Move the fuel selection lever to the FLOW BOTH
position and monitor the main filter for leaks.
Illustration 63 g03409950
Uninstall and reinstall the main filter if necessary.
1. Move the fuel selector valve to the AUX RUN Replacing the Auxiliary Fuel Filter
position as marked on the indicator plate.
Use the following procedure to replace the auxiliary
fuel filter while the engine is in operation.
94 SEBU9023-09
Maintenance Section
Fuel Tank Water and Sediment - Drain
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,
Illustration 66 g03410043 PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
2. Once the lever has been moved to the MAIN RUN fluids on Cat products.
position, the fuel gauge for the main filter should
Dispose of all fluids according to local regulations
indicate full pressure and the fuel gauge for the and mandates.
auxiliary filter should indicate no pressure.
3. Slowly open the drain valve and purge any
remaining pressure from the auxiliary filter. Some
fuel may also drain from the fuel drain. The fuel
indicator for the main filter should indicate full
pressure and the fuel indicator for the auxiliary
filter should indicate no pressure.
4. Remove the used auxiliary filter.
5. Clean the gasket sealing surface of the auxiliary
fuel filter base. Ensure that all of the old gasket is
removed.
6. Apply clean diesel fuel to the new auxiliary fuel
filter gasket.
SEBU9023-09 95
Maintenance Section
Fumes Disposal Filter Element - Replace
Open the drain valve on the bottom of the fuel tank in Replacing the Fumes Disposal
order to drain the water and the sediment. Close the
drain valve. Filter
Note: Failure to close the drain properly could result
in fuel leakage, which could have detrimental results
to performance. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
Check the fuel daily. Drain the water and sediment contact the skin.
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.
Fill the fuel tank after operating the engine in order to
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
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 Illustration 67 g03123321
Typical installation
This procedure will help prevent water or sediment
from being pumped from the storage tank into the (1) Latches for the canister
(2) Service indicator
engine fuel tank. A four micron(c) absolute filter for (3) Cap for the canister
the breather vent on the fuel tank is also (4) Engine air cleaner
recommended. (5) Canister
96 SEBU9023-09
Maintenance Section
Fumes Disposal Filter Service Indicator - Check
Note: When possible, perform the maintenance while 3. Replace the cover.
the engine is off.
i04434870
1. Release the latches that hold the canister to the
cap. Fumes Disposal Filter Service
Note: Removal of the canister may be difficult while Indicator - Check
the engine is operating. The canister has negative air
pressure while the engine is operating which creates SMCS Code: 1074-535-IND; 1317-535-IND
a vacuum.
3. Turn the heat exchanger core onto one side in 8. Dry the heat exchanger core with compressed air.
order to remove debris. Remove the debris that is Direct the air in the reverse direction of the normal
accessible. flow.
NOTICE
Do not use a high concentration of caustic cleaner to
Test the Heat Exchanger Core
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and 1. Inspect the heat exchanger core for trapped debris
cause leakage. Only use the recommended concen- and cleanliness. If necessary, remove the debris
tration of cleaner. and repeat the cleaning procedure.
2. Inspect the heat exchanger core for damage and
4. Back flush the heat exchanger core with cleaner. perform a pressure test in order to detect leaks.
Many shops that service radiators are equipped to
Caterpillar recommends the use of Hydrosolv
perform pressure tests.
liquid cleaner. Table 19 lists Hydrosolv liquid
cleaners that are available from your Cat dealer. 3. Plug both ends of the heat exchanger core and
Table 19 pressurize the core to 100 kPa (14.5 psi).
Hydrosolv Liquid Cleaners(1) Submerge the core in water. Look for bubbles
which are being emitted from the core. The
Part Number Description Size bubbles are evidence of leaks.
1U-5490 Hydrosolv 4165 19 L (5 US gallon) 4. If any leaks are found, do not attempt to repair the
174-6854 Hydrosolv 100 19 L (5 US gallon) core.
(1) Use a 2 to 5 percent concentration of the cleaner at tempera- 5. Install a core that is clean and that passes the
tures up to 93°C (200°F). Consult your Cat dealer for more pressure test in step 3. Refer to the Disassembly
information.
and Assembly Manual, “Heat Exchanger -
5. Clean the heat exchanger core with steam to Assemble” for the procedure.
remove any residue. Flush the fins of the heat 6. Install the heat exchanger onto the engine. Refer
exchanger. Remove any other trapped debris from to the Disassembly and Assembly Manual, “Heat
the inside and from the outside of the core. Exchanger - Install” for the procedure.
6. Wash the heat exchanger core with hot, soapy For more information on cleaning the core, consult
water. your Cat dealer.
7. Flush the heat exchanger core thoroughly in order
i06521408
to remove residue and remaining debris. Flush the
heat exchanger core with clean, fresh water until
the water that is exiting the core is clear and free
Heat Exchanger - Inspect
of debris. (If Equipped)
SMCS Code: 1379-040
The interval for the maintenance of the heat
Personal injury can result from air pressure. exchanger depends on the operating environment of
the vessel and on the operating time. The sea water
Personal injury can result without following prop- that is circulated through the heat exchanger and the
er procedure. When using pressure air, wear a amount of operating time of the vessel affects the
protective face shield and protective clothing. following items:
The maximum air pressure for cleaning purposes • Cleanliness of the tubes of the heat exchanger
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded. • Effectiveness of the heat exchanger system
Operating in water that contains silt, sediment, salt,
algae, and so on, will adversely affect the heat
exchanger system. In addition, intermittent use of the
vessel will adversely affect the heat exchanger
system.
The following items indicate that the heat exchanger
may require cleaning:
98 SEBU9023-09
Maintenance Section
Hoses and Clamps - Inspect/Replace
• Excessive pressure drop between the water inlet • Flexible part of the hose that is kinked or crushed
and the water outlet
• Armoring that is embedded in the outer covering
An operator that is familiar with the normal operating
temperature of the coolant can determine when the • Exhaust bellows for leaks or damage
coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger • Hoses which exhibit signs of leakage which are
are required if the engine is overheating. not the result of loose couplings or clamps
Your Cat dealer has the equipment and the trained Inspect all clamps for the following conditions.
personnel that are needed to measure the pressure Replace any clamp which exhibits signs of any of the
drop across the heat exchanger. following conditions.
Refer to this Operation and Maintenance Manual, • Cracking
“Heat Exchanger - Clean/Test”. For more information
on servicing the heat exchanger, consult your Cat • Looseness
dealer.
• Damage
i06825542
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
Hoses and Clamps - Inspect/
Replace Each installation application can be different. The
differences depend on the following factors:
SMCS Code: 7554-040; 7554-510
• Type of hose
Hoses and clamps must be inspected periodically
and replaced at the recommended interval to ensure • Type of fitting material
safe and continuous operation of the engine. Failure
to replace a fuel hose at the recommended change • Anticipated expansion and contraction of the hose
interval may result in a hazardous situation. Take
proper safety precautions before inspecting or • Anticipated expansion and contraction of the
replacing hoses and clamps. fittings
Note: Always use a board or cardboard when the Due to extreme temperature changes, the hose will
engine components are checked for leaks. Leaking heat set. Heat setting causes hose clamps to loosen
fluid that is under pressure can cause serious injury which can result in leaks. A constant torque hose
or possible death. Leaks that are the size of a pin clamp will help to prevent loose hose clamps.
hole are included. Refer to Operation and
Maintenance Manual, “General Hazard Information”
for more information.
Note: Ensure that the hose is compatible with the
application.
Replace hoses that are cracked or soft. Replace 5. Drain the coolant from the cooling system to a
hoses that show signs of leakage. Replace hoses level that is below the hose that is being replaced.
that show signs of damage. Replace hose clamps Drain the coolant into a suitable clean container.
that are cracked or damaged. Tighten or replace
The coolant can be reused.
hose clamps which are loose.
6. Remove the hose clamps.
Replace the Hoses and the Clamps 7. Disconnect the old hose.
6. Carefully inspect the engine for any spilled fuel. 5. Start the engine. Inspect the air lines for leaks.
Make sure that no fuel remains on or close to the
engine. i07196018
Hot oil and hot components can cause personal Severe Operation
injury. Do not allow hot oil or hot components to
contact the skin. Severe operation is the use of an engine that
exceeds current published standards for the engine.
Caterpillar maintains standards for the following
1. Drain the oil from the lubrication system to a level engine parameters:
that is below the hose that is being replaced.
• Horsepower
2. Remove the hose clamps.
SEBU9023-09 101
Maintenance Section
Maintenance Recommendations
• Selection of coolant
Improper Operating Procedures
The following factors are important when a decision • The service life of the engine can be extended
is being made on the proper time for an engine without the risk of a major catastrophe due to
overhaul: engine failure.
• The need for preventive maintenance • The best cost/value relationship per hour of
extended life can be attained.
• The quality of the fuel that is being used
After Failure Overhaul
• The operating conditions
If a major engine failure occurs and the engine must
• The results of the S·O·S analysis be removed from the hull, many options are
available. An overhaul should be performed if the
Oil Consumption as an Overhaul engine block or the crankshaft needs to be repaired.
Indicator If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
Oil consumption, fuel consumption, and maintenance percent and 50 percent of the cost of a new engine
information can be used to estimate the total with a similar exchange core.
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the This lower cost can be attributed to three aspects:
required capacity of a makeup oil tank that is suitable
for the maintenance intervals. • Specially designed Caterpillar engine features
Oil consumption is in proportion to the percentage of • Caterpillar dealer exchange components
the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is • Caterpillar Inc. remanufactured exchange
consumed per hour also increases. components
The oil consumption rate (brake-specific oil
consumption) is measured in grams per kW/h (lb per i07186224
bhp). The brake-specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar Oil Cooler Core - Check/Clean/
dealer for assistance in determining the typical oil
consumption rate for your engine. Test
SMCS Code: 1378-535; 1378-081; 1378-070
When the engine oil consumption has risen to three
times the original oil consumption rate due to normal This maintenance procedure shall be performed
wear, an engine overhaul should be scheduled. when the major overhaul is performed. Refer to this
There may be a corresponding increase in blowby Operation and Maintenance Manual, “Maintenance
and a slight increase in fuel consumption. Recommendations” article for information about the
maintenance interval for the major overhaul.
Overhaul Options
Clean the Oil Cooler Core
Before Failure Overhaul
Remove the core. Refer to the Disassembly and
To minimize downtime, Caterpillar Inc. recommends Assembly Manual, “Oil Cooler - Remove” for the
a scheduled engine overhaul by your Caterpillar procedure.
dealer before the engine fails. The scheduled
overhaul will provide you with the best cost/value 1. Turn the oil cooler core on one side to remove
relationship. debris. Remove the debris that is accessible.
Note: Overhaul programs vary according to the NOTICE
engine application and according to the dealer that Do not use a high concentration of caustic cleaner to
performs the overhaul. Consult your Caterpillar clean the core. A high concentration of caustic
dealer for specific information about the available cleaner can attack the internal metals of the core and
overhaul programs and about overhaul services for cause leakage. Only use the recommended concen-
extending the engine life. tration of cleaner.
• Costly unplanned downtime can be avoided. Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 21 lists Hydrosolv liquid
• Many original parts can be reused according to the cleaners that are available from your Caterpillar
standards for reusable parts. dealer.
SEBU9023-09 103
Maintenance Section
Overhaul (Major)
Table 21
Hydrosolv Liquid Cleaners(1) Install a core that is clean and a core that passes the
Part Number Description Size
pressure test in step 3. Refer to the Disassembly and
Assembly Manual, “Oil Cooler - Install” for the
1U-5490 Hydrosolv 4165 19 L (5 US gal) procedure.
174-6854 Hydrosolv 100 19 L (5 US gal) For more information on cleaning the core, consult
(1) Use a two to five percent concentration of the cleaner at tem-
your Caterpillar dealer.
peratures up to 93°C (200°F). Refer to Application Guide,
NEHS0526 or consult your Caterpillar dealer for more i07186240
information.
Your Cat dealer can provide these services and • Cylinder head assembly
components. Your Cat dealer can ensure that the
components are operating within the appropriate • Cylinder liners
specifications.
• Engine mounts
Replacement of Components • Scavenge oil pump
Replace the following components during the major • Engine wiring harness
overhaul:
• Exhaust manifold seals
• Camshaft bearings
• Exhaust manifold bellows
• Connecting rod bearings
• Fuel pressure regulating valve
• Crankshaft seals
• Fuel priming pump
• Crankshaft thrust washers
• Fuel transfer pump
• Electronic unit injectors
• Inlet manifold gaskets
• Gear train bushings
• Inlet manifold seals
• Gear train bearings
• Oil cooler core
• Main bearings
• Oil pump
• Piston rings
• Pistons
International Convention for Safety of
• Piston pins
Life at Sea (SOLAS)
• Prelube pump
Caterpillar recommends replacing the following:
• Pushrods
• All shields that have been installed to cover up fuel
and oil line connections per (SOLAS) regulations • Rocker arms
• All marine certification society approved tapes are • Spacer plate
installed to cover up fuel line connections and oil
line connections according to the SOLAS • Software update
regulations.
• Turbocharger
Inspection, Reconditioning, or
Exchanging of Components Inspection of Components
Inspect the following components according to the
Inspect the following components according to the instructions that are in Caterpillar reusability
instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts
publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of
and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used
Publications on Reusability or Salvage of Used Parts”.
Parts”.
• Camshaft
Recondition the worn components or exchange the
components, if necessary. Your Cat dealer can • Crankshaft
provide these services and components.
• Driven equipment (alignment)
• Camshaft followers
• Engine cylinder block
• Camshaft thrust washers
• Engine control module
• Connecting rods
• Flywheel
• Crankshaft vibration damper
• Front gear train (gears)
SEBU9023-09 105
Maintenance Section
Overhaul (Major)
• Excessive wear of the gear train that is not caused For example, considerable deposits are found in the
by a lack of lubrication water jacket areas on the external cooling system,
but the concentrations of coolant additives were
Inspect the gears of the gear train and inspect the carefully maintained. The coolant water probably
gear train bushings for the following conditions: contained minerals which were deposited on the
engine over time.
• Worn gear teeth
A coolant analysis can be conducted to verify the
• Unusual fit condition of the water that is being used in the
cooling system. A full water analysis may be obtained
• Unusual wear from the following sources:
• Cat dealer
• 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 inside the cooling
system. The following services are provided:
3. Check the compressor wheel for cleanliness. If • Ensure that the cooling lines are tight and ensure
only the blade side of the wheel is dirty, dirt and/or that the cooling lines are properly clamped. Check
moisture is passing through the air filtering for leaks. Check the condition of all pipes.
system. If oil is found only on the back side of the
• Inspect the water pumps for coolant leaks.
wheel, there is a possibility of a failed turbocharger
oil seal. Note: The water pump seal is lubricated by coolant in
The presence of oil may be the result of extended the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
engine operation at low idle. The presence of oil
parts contract.
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the Excessive coolant leakage may indicate the need to
turbocharger to slobber. replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
4. Inspect the bore of the turbine housing for or seals, refer to the Service Manual for the engine or
corrosion. consult your Caterpillar dealer.
5. Clean the turbocharger housing with standard • Inspect the lubrication system for leaks at the front
shop solvents and a soft bristle brush. crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
6. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing. • Inspect the fuel system for leaks. Look for loose
fuel line clamps.
i02706582
• Inspect the piping for the air inlet system and the
Walk-Around Inspection elbows for cracks and for loose clamps.
SMCS Code: 1000-040 • Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Inspect the Engine for Leaks and Belts for multiple groove pulleys must be replaced as
for Loose Connections matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
A walk-around inspection should only require a few The older belts are stretched. The additional load on
minutes. When the time is taken to perform these the new belt could cause the belt to break.
checks, costly repairs and accidents can be avoided.
• Drain the water and the sediment from fuel tanks
For maximum engine service life, make a thorough on a daily basis in order to ensure that only clean
inspection of the engine compartment before starting fuel enters the fuel system.
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose • Inspect the wiring and the wiring harnesses for
connections and trash buildup. Make repairs, as loose connections and for worn wires or frayed
needed: wires.
• The guards must be in the proper place. Repair • Inspect the ground strap for a good connection
damaged guards or replace missing guards. and for good condition.
• Wipe all caps and plugs before the engine is • Inspect the ECM to the cylinder head ground strap
serviced in order to reduce the chance of system for a good connection and for good condition.
contamination.
• Disconnect any battery chargers that are not
NOTICE protected against the current drain of the starting
For any type of leak (coolant, lube, or fuel) clean up motor. Check the condition and the electrolyte
the fluid. If leaking is observed, find the source and level of the batteries, unless the engine is
correct the leak. If leaking is suspected, check the flu- equipped with a maintenance free battery.
id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
108 SEBU9023-09
Maintenance Section
Water Pump - Inspect
i05264233
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
110 SEBU9023-09
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.
112 SEBU9023-09
Reference Information Section
Customer Service
(continued)
114 SEBU9023-09
Reference Information Section
On-Board Replacement Parts
(continued)
SEBU9023-09 115
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
116 SEBU9023-09
Reference Information Section
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 24
Engine Model Customer Identifier
Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU9023-09 117
Reference Information Section
Reference Material
i07422648
Reference Material
SMCS Code: 1000; 4450
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
publications.cat.com. Use the product name, sales
model, and serial number to obtain the correct
information for your product.
publications.cat.com
i04945953
Decommissioning and
Disposal
SMCS Code: 1000
When the engine is removed from service, local
regulations will vary for the engine decommissioning.
Disposal of the engine will vary with local regulations.
Consult the nearest Cat dealer for additional
information.
118 SEBU9023-09
Index Section
Index
A Timing of the Sampling ................................ 71
Coolant Sample (Level 2) - Obtain.................. 71
After Starting Engine ....................................... 40
Obtaining the Sample .................................. 72
After Stopping Engine ..................................... 48
Coolant Temperature Regulator - Replace ..... 72
Aftercooler Condensate Drain Valve -
Cooling System Supplemental Coolant
Inspect/Clean................................................. 62
Additive (SCA) - Test/Add.............................. 72
Aftercooler Core - Clean/Test.......................... 62
Cooling Systems that Use Conventional
Clean the Aftercooler Core .......................... 62
Coolant....................................................... 73
Test the Aftercooler Core............................. 63
Crankshaft Vibration Damper - Inspect........... 73
Auxiliary Water Pump (Bronze Impeller) -
Inspection .................................................... 74
Inspect/Replace............................................. 63
Removal and Installation ............................. 74
Crushing Prevention and Cutting Prevention.. 14
B Customer Assistance .....................................112
Battery - Replace............................................. 64 Outside of the USA and of Canada ............112
Battery Disconnect Switch (If Equipped)......... 29 USA and Canada........................................112
Battery Electrolyte Level - Check .................... 64 Customer Service...........................................112
Battery or Battery Cable - Disconnect............. 65
Before Starting Engine .............................. 14, 37 D
Belts - Inspect/Replace ................................... 65
Decommissioning and Disposal.....................117
Inspection .................................................... 65
Intervals for Maintenance ............................ 65
Replacement................................................ 65 E
Burn Prevention................................................11 Electrical System............................................. 15
Batteries....................................................... 12 Grounding Practices .................................... 16
Coolant .........................................................11 Negative Battery Connection for Multiple
Oils............................................................... 12 Engines ...................................................... 17
Emergency Stopping....................................... 48
C Emissions Certification Film ............................ 25
Engine - Clean................................................. 74
Cold Start Strategy .......................................... 29
Engine Air Cleaner Element (Single
Cold Weather Operation ................................. 44
Element) - Inspect/Replace ........................... 75
Hints for Cold Weather Operation ............... 44
Replacing the Air Cleaner Element ............. 75
Idling the Engine .......................................... 45
Engine Air Cleaner Service Indicator -
Recommendations for Coolant Warm Up.... 45
Inspect ........................................................... 75
Recommendations for the Coolant.............. 45
Test the Service Indicator ............................ 75
Viscosity of the Engine Lubrication Oil ........ 45
Engine Cooling System Corrosion
Cold Weather Starting ..................................... 37
Protection System - Inspect .......................... 76
Control Panel (Cat Marine Engine Control
Bonding the Marine Engine ......................... 78
Panel III (MECP III )(If Equipped))................. 29
Engine Specific Bonding.............................. 78
Coolant - Change ............................................ 66
Location of the Corrosion Protection Post... 77
Drain the coolant systems ........................... 66
Results of the Test ....................................... 78
Fill the Cooling System ................................ 69
Testing the Voltage Potential ....................... 77
Flush ............................................................ 68
Engine Crankcase Breather - Clean ............... 80
Coolant Extender (ELC) - Add ........................ 69
Engine Diagnostics ......................................... 36
Coolant Level - Check ..................................... 70
Engine Electronics........................................... 18
Add Coolant ................................................. 70
Engine Mounts - Inspect.................................. 80
Check the Coolant Level ............................. 70
Engine Oil and Filter - Change ........................ 83
Coolant Sample (Level 1) - Obtain.................. 70
Drain the Oil ................................................. 83
Sampling Conditions.................................... 71
SEBU9023-09 119
Index Section
Heat Exchanger - Inspect (If Equipped) .......... 97 Model View Illustrations .................................. 19
Hoses and Clamps - Inspect/Replace............. 98 Mounting and Dismounting ............................. 14
Inspect Tubes, Hoses, Bellows, and
Clamps....................................................... 98 O
Replace the Hoses and the Clamps ............ 99
Oil Cooler Core - Check/Clean/Test .............. 102
Clean the Oil Cooler Core.......................... 102
I
Test the Oil Cooler Core ............................ 103
Important Safety Information............................. 2 On-Board Replacement Parts ........................113
Operation Section............................................ 26
L Ordering Replacement Parts..........................113
Overhaul (Major) ........................................... 103
Lifting and Storage .......................................... 26 Cleaning and Pressure Testing of
Components ............................................ 105
M Cleaning of Components ........................... 105
Inspection of Components......................... 104
Maintenance Interval Schedule....................... 60
Inspection, Reconditioning, or Exchanging of
Daily ............................................................. 60
Components ............................................ 104
Every 1000 Service Hours........................... 60
Obtain a Coolant Analysis ......................... 105
Every 14 400 L (3750 US gal) of Fuel or 250
Replacement of Components.................... 104
Service Hours or 1 Year ............................. 61
Overspeed....................................................... 32
Every 170 400 L (45 000 US gal) of Fuel or
3000 Service Hours ................................... 61
Every 2000 Service Hours........................... 60 P
Every 250 Service Hours ............................. 60 Plate Locations and Film Locations ................ 24
Every 28 500 L (7500 US gal) of Fuel or 500 Information Plate ......................................... 24
Service Hours or 1 Year (Deep Sump) ...... 61 Serial Number Plate..................................... 24
Every 284 000 L (75 000 US gal) of Fuel or Product Description......................................... 22
5000 Service Hours ................................... 61 Engine Service Life...................................... 22
Every 50 Service Hours or Weekly.............. 60 Engine Specifications .................................. 23
Every 57 000 L (15 000 US gal) of Fuel or Product Identification Information ................... 24
1000 Service Hours ................................... 61 Product Information Section............................ 19
Every Year ................................................... 60 Product Lifting ................................................. 26
First 14 400 L (3750 US gal) of Fuel or 250 Product Storage .............................................. 26
Service Hours ............................................ 60 Engine.......................................................... 26
Initial 1000 Service Hours............................ 60
Initial 20 to 40 Service Hours....................... 60
R
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) ........... 60 Reference Information..................................... 25
Overhaul ...................................................... 61 Record for Reference .................................. 25
When Required............................................ 60 Reference Information Section ..................... 109
Maintenance Log............................................116 Reference Material .........................................117
Maintenance Recommendations ............ 58, 100 Reference Materials .......................................115
Maintenance Information........................... 100 Refill Capacities............................................... 50
Oil Consumption as an Overhaul Cooling System Capacity ............................ 50
Indicator ................................................... 102 Lubrication System Capacity....................... 50
Overhaul Information ................................. 101
Maintenance Records ....................................115 S
Maintenance Section....................................... 50
Manual Stop Procedure .................................. 48 Safety Messages............................................... 6
Marine Classification Society Certification Hot Fluid Under Pressure (2)......................... 7
Requirements .............................................. 109 Universal Warning (1) .................................... 7
SEBU9023-09 121
Index Section
T
Table of Contents .............................................. 3
Turbocharger - Inspect .................................. 106
Cleaning and Inspecting ............................ 106
Removal and Installation ........................... 106
W
Walk-Around Inspection ................................ 107
Inspect the Engine for Leaks and for Loose
Connections ............................................. 107
Water Pump - Inspect.................................... 108
Welding on Engines with Electronic
Controls ......................................................... 58
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:
SEBU9023 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow”, the
©2019 Caterpillar “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used
All Rights Reserved herein, are trademarks of Caterpillar and may not be used without permission.