Operation & Maintenance Manual Sebu9100-01-00-All

SEBU9100-01
July 2013
Operation and
Maintenance
Manual
C32 Marine Engine
RSD 1-Up (Engine)
SAFETY.CAT.COM
i05296198
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
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.
SEBU9100 3
Table of Contents
Table of Contents Refill Capacities....................... ....................... 47
Foreword.............................. ............................. 4 Maintenance Recommendations.......... .......... 55
Maintenance Interval Schedule ........... ........... 57

Safety Section
Safety Messages....................... ....................... 5

Reference Information Section
Engine Ratings ....................... ...................... 105

General Hazard Information ............... .............. 8
Burn Prevention....................... ........................11 Engine Performance and Performance Analysis

Report (PAR)........................ ....................... 107
Fire Prevention and Explosion Prevention ... .. 12
Customer Service ..................... .................... 108
Crushing Prevention and Cutting Prevention . 14
Reference Materials ................... ...................111
Mounting and Dismounting............... .............. 14
Index Section
Before Starting Engine ................. .................. 14
Index............................... ...............................115
Engine Starting ........................ ....................... 15
Engine Stopping ....................... ...................... 15
Electrical System ...................... ...................... 15
Engine Electronics..................... ..................... 17
Product Information Section
General Information.................... .................... 19
Product Identification Information.......... ......... 24
Operation Section
Lifting and Storage..................... ..................... 26
Features and Controls .................. .................. 29
Engine Diagnostics..................... .................... 33
Engine Starting ........................ ....................... 35
Engine Operation...................... ...................... 40
Cold Weather Operation................. ................ 41
Engine Stopping ....................... ...................... 45
Maintenance Section
4 SEBU9100
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This manual frequent lubrication and maintenance than is
should be stored in or near the engine area in a specified in the Maintenance Interval Schedule may
literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing Maintenance Intervals
improvement and advancement of product design
may have caused changes to your engine which are Perform maintenance on items at multiples of the
not included in this manual. Whenever a question original requirement. Each level and/or individual
arises regarding your engine, or this manual, please items in each level should be shifted ahead or back
consult with your Cat dealer for the latest available depending upon your specific maintenance practices,
information. operation and application. We recommend that the
maintenance schedules be reproduced and displayed
Safety near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
This safety section lists basic safety precautions. In as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, “Maintenance Records” for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more Major engine overhaul details are not covered in the
efficiently and economically. Skill and techniques Operation and Maintenance Manual except for the
develop as the operator gains knowledge of the interval and the maintenance items in that interval.
engine and its capabilities. Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers a
The operation section is a reference for operators. variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.
Maintenance California Proposition 65 Warning
The maintenance section is a guide to engine care. Diesel engine exhaust and some of its constituents
The illustrated, step-by-step instructions are grouped are known to the State of California to cause cancer,
by fuel consumption, service hours and/or calendar birth defects, and other reproductive harm.
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that Battery posts, terminals and related accessories
follow. contain lead and lead compounds. Wash hands after
Use fuel consumption or service hours to determine handling.
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
SEBU9100 5
Safety Section
Safety Messages
Safety Section
i04786498
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 g02897544
View of the left side and of the top of the engine
6 SEBU9100
Safety Section
Safety Messages
View of the right side of the engine and view of the air cleaner elements
SEBU9100 7
Safety Section
Safety Messages
Universal Warning (1)

Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before per-
forming any cooling system maintenance.
Explosion Hazard (3)
One safety message is located on the valve cover

base towards the front of each side of the engine.
One safety message is located on top of the
instrument panel, if equipped.
Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed Illustration 5 g01372254
the warnings could result in injury or death. Con-
tact any Cat dealer for replacement manuals. One safety message is located on the top of each air
Proper care is your responsibility. cleaner.
Hot Fluid Under Pressure (2)

Explosion hazard! Do not use ether! This machine
is equipped with an air inlet heater. Using ether
can create explosions or fires that can cause per-
sonal injury or death. Read and follow the starting
procedure in the Operation and Maintenance
Manual.
One safety message is located on the top of each

expansion tank.
8 SEBU9100
Safety Section
General Hazard Information
i05334609

SMCS Code: 1000; 4450; 7405
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
• When work is performed around an engine that is
Illustration 6 g00104545 operating, wear protective devices for ears in order
to help prevent damage to hearing.
Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or • Do not wear loose clothing or jewelry that can snag
repaired. These warning tags (Special Instruction, on controls or on other parts of the engine.
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each • Ensure that all protective guards and all covers are
operator control station. When appropriate, secured in place on the engine.
disconnect the starting controls.
• Never put maintenance fluids into glass
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being containers. Glass containers can break.
serviced.
• Use all cleaning solutions with care.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids, • Report all necessary repairs.
hold a rag over the part that is being removed.
Unless other instructions are provided, perform
• Filler caps the maintenance under the following conditions:
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two bolts
or nuts that are located at opposite ends of the cover
plate or the device. Before removing the last two bolts
or nuts, pry the cover loose in order to relieve any
spring pressure or other pressure.
SEBU9100 9
Safety Section
• The engine is stopped. Ensure that the engine Fluid Penetration

cannot be started.
• The protective locks or the controls are in the

applied position.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• When starting a new engine, make provisions to

stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine. Illustration 8 g00687600
• Do not attempt any repairs that are not Always use a board or cardboard when you check for
understood. Use the proper tools. Replace any a leak. Leaking fluid that is under pressure can
equipment that is damaged or repair the penetrate body tissue. Fluid penetration can cause
equipment. serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
• Start the engine with the operator controls. Never you must get treatment immediately. Seek treatment
short across the starting motor terminals or the from a doctor that is familiar with this type of injury.
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the Containing Fluid Spillage
electrical system could be damaged.
NOTICE
Pressurized Air and Water Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Pressurized air and/or water can cause debris and/or nance, testing, adjusting, and repair of the product.
hot water to be blown out which could result in Be prepared to collect the fluid with suitable contain-
personal injury.
ers before opening any compartment or disassem-
The maximum air pressure for cleaning purposes bling any component containing fluids.
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip Refer to Special Publication, NENG2500, “Cat Dealer
guarding (if applicable) and personal protective Service Tool Catalog” or refer to Special Publication,
equipment. The maximum water pressure for PECJ0003, “Cat Shop Supplies and Tools Catalog”
cleaning purposes must be below 275 kPa (40 psi). for tools and supplies suitable to collect and contain
fluids on Cat products.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective Dispose of all fluids according to local regulations and
shoes, and eye protection. Eye protection includes mandates.
goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.
Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when
redeposited on hot surfaces.
10 SEBU9100
Safety Section
Static Electricity Hazard when Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct installation
Fueling with Ultra-low Sulfur Diesel of these components will help to prevent these
Fuel 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.
Avoid static electricity risk when fueling. Ultra-low

sulfur diesel fuel (ULSD fuel) poses a greater stat- Exhaust
ic ignition hazard than earlier diesel formulations
Use caution. Exhaust fumes can be hazardous to
with a higher sulfur contents. Avoid death or seri- your health. If you operate the equipment in an
ous injury from fire or explosion. Consult with enclosed area, adequate ventilation is necessary.
your fuel or fuel system supplier to ensure the de-
livery system is in compliance with fueling stand-
ards for proper grounding and bonding practices. Asbestos Information
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
Check for the following conditions: not hazardous unless airborne dust that contains
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
• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering
SEBU9100 11
Safety Section
Burn Prevention
• Never use compressed air for cleaning. Dispose of Waste Properly

• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other

way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States , use Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
Occupational Safety and Health Administration
disposed of according to local regulations.
(OSHA) requirements. These OSHA
requirements can be found in 29 CFR 1910.1001. Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
• Obey environmental regulations for the disposal of drain, or into any source of water.
asbestos.
• Stay away from areas that might have asbestos i02088921
particles in the air.
Burn Prevention
Softwrap SMCS Code: 1000; 4450; 7405
Keep the engine room ventilation operating at full Do not touch any part of an operating engine. Allow
capacity. Wear a particulate respirator that has been the engine to cool before any maintenance is
approved by the National Institute of Occupational performed on the engine. Relieve all pressure in the
Safety and Health (NIOSH) . Wear appropriate appropriate system before any lines, fittings or related
protective clothing in order to minimize direct contact. items are disconnected.
Use good hygiene practices and wash hands
thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling Coolant
Softwrap material. Clean up debris with a vacuum or When the engine is at operating temperature, the
by wet sweeping. Do not use pressurized air to clean engine coolant is hot. The coolant is also under
up debris. pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
Reference: The applicable material safety data hot coolant or with steam can cause severe burns.
sheets can be found at the following web site by Allow cooling system components to cool before the
searching using part number or the name: cooling system is drained.
http://dsf2ws.cat.com/msds/servlet/ Check the coolant level after the engine has stopped
cat.cis.ecs.msdsSearch.controller. and the engine has been allowed to cool. Ensure that
UserIdentificationDisplayServlet the filler cap is cool before removing the filler cap.
The filler cap must be cool enough to touch with a
bare hand. Remove the filler cap slowly in order to
relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot
components to contact the skin.
12 SEBU9100
Safety Section
Fire Prevention and Explosion Prevention
If the application has a makeup tank, remove the cap Determine whether the engine will be operated in an
for the makeup tank after the engine has stopped. environment that allows combustible gases to be
The filler cap must be cool to the touch. drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
Batteries property damage, or engine damage could result.
The liquid in a battery is an electrolyte. Electrolyte is If the application involves the presence of
an acid that can cause personal injury. Do not allow combustible gases, consult your Caterpillar dealer for
electrolyte to contact the skin or the eyes. additional information about suitable protection
devices.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can Remove all flammable materials such as fuel, oil, and
explode. debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The All fluids that are captured in the fluid spill
use of gloves is recommended. containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
may cause personal injury and property damage.
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
connections.
Use of personal protection equipment (PPE) may be Eliminate all wiring that is unattached or unnecessary.
needed. Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
All fuels, most lubricants, and some coolant mixtures and/or circuit breakers.
are flammable.
Always perform a Walk-Around Inspection, which Arcing or sparking could cause a fire. Secure
may help you identify a fire hazard. Do not operate a connections, recommended wiring, and properly
product when a fire hazard exists. Contact your maintained battery cables will help to prevent arcing
or sparking.
Caterpillar dealer for service.
Inspect all lines and hoses for wear or for
Flammable fluids that are leaking or spilled onto hot
deterioration. Properly route all hoses. The lines and
surfaces or onto electrical components can cause a hoses must have adequate support and secure
fire. Fire may cause personal injury and property clamps. Tighten all connections to the recommended
damage. torque. Leaks can cause fires.
A flash fire may result if the covers for the engine Properly install all oil filters and all fuel filters. The
crankcase are removed within 15 minutes after an filter housings must be tightened to the proper torque.
emergency shutdown.
SEBU9100 13
Safety Section
Fire Prevention and Explosion Prevention
Illustration 12 g00704059 Illustration 13 g02298225
Use caution when you are refueling an engine. Do not Gases from a battery can explode. Keep any open
smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery. Do
refuel an engine near open flames or sparks. Always not smoke in battery charging areas.
stop the engine before refueling.
Never check the battery charge by placing a metal
Note: Avoid static electricity risk when fueling. Ultra- object across the terminal posts. Use a voltmeter or a
low sulfur diesel fuel (ULSD fuel) poses a greater hydrometer.
static ignition hazard than earlier diesel formulations
with a higher sulfur content. Avoid death or serious Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
injury from fire or explosion. Consult your fuel or fuel Operation Section of this manual for specific
system supplier to ensure that the delivery system is instructions.
in compliance with fueling standards for proper
grounding and bonding practices. Do not charge a frozen battery. Charging a frozen
battery may cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations on
the instruction plate.
Ether
Do not use ether as a starting aid. Refer to this
Operation and Maintenance Manual, “Starting the
Engine” for information about starting the engine.
Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent or
damaged.
14 SEBU9100
Safety Section
Crushing Prevention and Cutting Prevention
Repair any lines that are loose or damaged. Leaks i01372247

can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts. Mounting and Dismounting
Check lines, tubes, and hoses carefully. Do not use SMCS Code: 1000; 4450; 7405
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections Inspect the steps, the handholds, and the work area
to the recommended torque. before mounting the engine. Keep these items clean
and keep these items in good repair.
Replace the parts if any of the following conditions
are present: Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
• End fittings are damaged or leaking. climb on the engine, and do not jump off the engine.
• Outer coverings are chafed or cut. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Wires are exposed. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• Outer coverings are ballooning. controls as handholds.
• Portions of the hoses are kinked. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Outer covers have embedded armoring. platform. Secure the climbing equipment so that the
equipment will not move.
• End fittings are displaced.
Do not carry tools or supplies when you mount the
Make sure that all clamps, guards, and heat shields engine or when you dismount the engine. Use a hand
are installed correctly in order to prevent vibration, line to raise and lower tools or supplies.
rubbing against other parts, and excessive heat.
i03560601
i01359666
Before Starting Engine
Crushing Prevention and SMCS Code: 1000
Cutting Prevention
SMCS Code: 1000; 4450; 7405 NOTICE
For initial start-up of a new or rebuilt engine, and for
Support the component properly when work beneath start-up of an engine that has been serviced, make
the component is performed. provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
Unless other maintenance instructions are provided, air and/or fuel supply to the engine.
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed, Engine exhaust contains products of combustion
reinstall the guards. which may be harmful to your health. Always start
Keep objects away from moving fan blades. The fan and operate the engine in a well ventilated area
blades will throw objects or cut objects. and, if in an enclosed area, vent the exhaust to the
outside.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Inspect the engine for potential hazards.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no Do not start the engine or move any of the controls if
one will be injured by flying debris. there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
SEBU9100 15
Safety Section
Engine Starting
If equipped, ensure that the lighting system for the i01462046

engine is suitable for the conditions. Ensure that all
lights work properly, if equipped. Engine Stopping
All protective guards and all protective covers must SMCS Code: 1000
be installed if the engine must be started in order to
perform service procedures. To help prevent an Stop the engine according to the procedure in the
accident that is caused by parts in rotation, work Operation and Maintenance Manual, “Engine
around the parts carefully. Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
Do not bypass the automatic shutoff circuits. Do not the engine components.
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The Use the Emergency Stop Button (if equipped) ONLY
circuits are also provided in order to help prevent in an emergency situation. Do not use the Emergency
engine damage. Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
See the Service Manual for repairs and for problem that caused the emergency stop has been
adjustments. corrected.
Stop the engine if an overspeed condition occurs
i03941639
during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
Engine Starting by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
SMCS Code: 1000
To stop an electronically controlled engine, cut the
If a warning tag is attached to the engine start switch power to the engine.
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started. i05187136
All protective guards and all protective covers must

be installed if the engine must be started in order to
Electrical System
perform service procedures. To help prevent an SMCS Code: 1000; 1400
accident that is caused by parts in rotation, work
around the parts carefully. Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit is
Start the engine with the engine start switch. operating. A spark may cause the combustible
gasses that are produced by some batteries to ignite.
Always start the engine according to the procedure
that is described in this Operation and Maintenance Connect the negative jump-start cable last from the
Manual, “Starting the Engine” for information about external power source to the negative terminal of the
starting the engine. Know the correct procedure to starting motor. This connection sequence helps to
prevent major damage to the engine components. prevent sparks from igniting any combustible gasses
Know the correct procedure to prevent personal which batteries may produce. If the starting motor is
injury. not equipped with a negative terminal, connect the
jump-start cable to the engine block.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working Check the electrical wires daily for wires that are
properly, check the water temperature gauge and the loose or frayed. Tighten all loose electrical wires
oil temperature gauge during the heater operation. before the engine is operated. Repair all frayed
electrical wires before the engine is started. See this
Engine exhaust contains products of combustion that Operation and Maintenance Manual, “Engine
can be harmful to your health. Always start the engine Starting” for specific starting instructions.
and operate the engine in a ventilated area. If the
engine is started in an enclosed area, vent the engine Grounding Practices
exhaust to the outside.
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.
16 SEBU9100
Safety Section
Electrical System
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.
Note: All return paths to the negative battery must be
able to carry any likely fault currents.
The use of a bus bar ensures that the electronic
control module (ECM) and the components
connected to the ECM have a common reference
point.
Refer to Special Instruction, REHS1187, Marine
Engine Electronic Installation Guide for additional
information on grounding procedures.
SEBU9100 17
Safety Section
Engine Electronics
Negative Battery Connection for Multiple Engines
(1) Engines (8) Direct current (DC) main negative bus bar (14) Zinc bar
(2) Parallel switch (9) Alternating current (AC) grounding bus (15) Electronics ground plate
(3) Customer miscellaneous vessel loads bar (16) Chain plates
(4) Overcurrent protection (10) Strainer (17) Grounding bus bar
(5) Battery (11) Cathodic protection bus bar (18) Engine negative terminal
(6) Battery disconnect switches (12) Lightening protection ground point (19) Battery
(7) Battery (13) Immersed ground plate
Install the battery disconnect switches as close as i05391510

possible to the battery positive (+) but outside of the
battery enclosure. Engine Electronics
Note: If multiple bus bars are used to connect SMCS Code: 1000; 1900
components to the negative battery, a common
reference should be provided. All bus bars must be
wired together for proper engine synchronization for
multiple engine operations.
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
18 SEBU9100
Safety Section
Engine Electronics
This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) may monitor the engine operating
conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an
immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes may
limit engine speed and/or the engine power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be monitored
as a part of the Engine Monitoring System:
• Operating Altitude
• Engine Coolant Level

• Engine Coolant Temperature
• Engine Oil Pressure

• Engine Speed
• Fuel Temperature
• Intake Manifold Air Temperature
• System Voltage
• Turbocharger Inlet Temperature

The engine monitoring package may vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: In a derated condition, the amount of derate
can be determined by monitoring “Actual Maximum
Available Engine Torque %” .
Refer to the Troubleshooting Manual for more
information.
SEBU9100 19
Product Information Section
Model View Illustrations
Product Information General Information

Section
i04786506

SMCS Code: 1000
View of the right side of a typical C32 Marine Engine
(1) Turbocharger (6) Filler cap for the expansion tank for the (11) Coolant sampling valve
(2) Crankcase breather jacket water cooling system (12) Engine oil filters
(3) Aftercooler (7) Fuel priming pump (13) Selector valve for the engine oil filter
(4) Electronic control module (ECM) (8) Selector valve for the fuel filter system system
(5) Expansion tank for the jacket water (9) Secondary fuel filters (14) Engine oil sampling valve
cooling system (10) Filler tube for the lubrication system (15) Flywheel
20 SEBU9100
General Information
View of the front of a typical C32 Marine Engine
(16) Heat exchanger for the jacket water (17) Heat exchanger for the separate circuit (18) Guard for the engine damper and for the
cooling system aftercooling system (SCAC system) alternator belt
View of the left side of a typical C32 Marine Engine
(19) Expansion tank for the SCAC cooling (20) Filler cap for the SCAC cooling system (22) Electric starting motor
system (21) Jacket water heater (23) Alternator
SEBU9100 21
General Information
Product Description
View of the top of a typical C32 Marine Engine
(Some components removed for visibility)
(24) Lifting Eyes
i05043609 The C32 Marine Engine uses a low emission system

which is integrated into the engine air cleaner. This
Product Description system eliminates the venting of oil vapors into the
engine room. The closed crankcase ventilation
SMCS Code: 1000; 4450; 4491 system is completely enclosed. This system requires
a minimum amount of maintenance.
The Cat C32 Marine Engine has the following
characteristics: Engine Specifications
• Four-stroke cycle Note: The front end of the engine is opposite the
flywheel end of the engine. The left side and the right
• Direct fuel injection
side of the engine are determined from the flywheel
• Mechanically actuated electronic unit injection end. The number 1 cylinder is the front cylinder.
• Turbocharging
• Separate circuit aftercooling (SCAC)

The Mechanical Electronic Unit Injector (MEUI) fuel
system eliminates many of the mechanical
components that are used in a pump-and-line
system. The electronic control and mechanical
actuation also provide increased control of the timing
and increased control of the fuel injection pressure.
The timing advance is achieved by precise control of
the unit injector timing. Engine speed is controlled by
adjusting the injection duration. A special speed-
timing wheel provides information to the Electronic
Control Module (ECM) for detection of cylinder
position and engine speed.
22 SEBU9100
General Information
Product Description
Cat C32Marine Engine • Engine monitoring

• Electronic engine speed governing
• Automatic air/fuel ratio control

• Torque rise shaping
• Injection timing control

• System diagnostics
The engine ECM will automatically provide the
correct amount of fuel in order to start the engine. Do
not hold the throttle down while the engine is
cranking. If the engine fails to start in 20 seconds,
release the starting switch. Allow the starting motor to
cool for 2 minutes before using the starting motor
again.
Cylinder and valve locations For more information on electronic engine features,
(A) Inlet valves refer to the Operation and Maintenance Manual,
(B) Exhaust valves “Features and Controls” topic (Operation Section).
(C) Front of the engine
Engine Cooling and Lubrication
Table 1
C32 Marine Engine Specifications The engines have water-cooled exhaust manifolds,
risers, and turbochargers. These components will
Cylinders and Arrangement 12 cylinder vee block minimize the heat that is radiated into the engine
room. Changes to the cooling system of these
Bore 145 mm (5.7 inch) engines minimize the weight and the size of the
Stroke 162 mm (6.4 inch)
engine. These changes also improve the engine
performance. The cooling system heat exchangers,
Compression Ratio 15:1 the expansion tanks, and the deaerator help to
prevent cavitation of the water pumps. Water pumps
Aspiration Twin Turbocharged Aftercooled that work properly help maintain the performance of
Aspiration the jacket water pump.
Displacement 32 L (1953 in3)
The cooling system consists of the following
Firing Order 1-10-9-6-5-12-11-4-3-8-7-2
components:
Rotation (flywheel end) Counterclockwise • Centrifugal jacket water pump that is driven by
gears
Electronic Engine Features • Two water temperature regulators which regulate

the engine coolant temperature
The engine has built-in diagnostics in order to ensure
that all of the components are operating properly. In • Oil cooler
the event of a system component failure, the operator
will be alerted to the condition via the diagnostic lamp • Auxiliary water pump and a SCAC water pump
located on the control panel. Cat Electronic
Technician (ET) can be used to read the numerical • Deaerators that remove air from the coolant
code of the faulty component or condition. Intermittent
faults are also logged and stored in memory. • Treated water aftercooling
These Cat Marine Engines are designed with The engine lubricating oil, which is supplied by a
electronic controls. The integral on board computer gear-type pump, is cooled. The engine lubricating oil
controls the operation of the engine. Current is also filtered. Bypass valves provide unrestricted
operating conditions are monitored. The Electronic flow of lubrication oil to the engine components during
Control Module (ECM) controls the response of the the following conditions:
engine to these conditions and to the demands of the
operator. These conditions and operator demands • High oil viscosity
determine the precise control of fuel injection by the
ECM. The electronic engine control system provides • Plugged oil cooler or plugged oil filter elements
the following features: (paper cartridge)
SEBU9100 23
General Information
Product Description
Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
application guidelines and operation and
maintenance recommendations. In addition, use
recommended fuels, coolants, and lubricants. Use
this Operation and Maintenance Manual as a guide
for required engine maintenance.
Expected engine life is generally predicted by the
average power that is demanded. The average power
that is demanded is based on fuel consumption of the
engine over time. Reduced hours of operation at full
throttle and/or operating at reduced throttle settings
result in a lower average power demand. Reduced
hours of operation will increase the length of
operating time before an engine overhaul is required.
For more information, refer to the Operation and
Maintenance Manual, “Overhaul Considerations”
topic.
24 SEBU9100
Product Identification Information
Plate Locations and Film Locations
Product Identification
Information
i05048259
Plate Locations and Film

Locations
SMCS Code: 1000; 4450
Cat engines are identified by serial numbers and by
arrangement numbers. These numbers are shown on
the Engine Serial Number Plate and on the Engine
Identification Plate. Cat dealers need these numbers
in order to determine the components that were Illustration 21 g00123229
included with the engine. This permits accurate Typical serial number plate
identification of replacement part numbers.
Engine Serial Number (1) Engine Identification Plate (2)

The Engine Serial Number Plate is located on the left The Engine Identification Plate is located on the
side of the engine block near the front at the bottom of exhaust manifold on the side of the engine that is
the water jacket. used for service.
Illustration 20 g03217620 Illustration 22 g03217622
Location of the Engine Serial Number Plate Location of the Engine Identification Plate
SEBU9100 25
Product Identification Information
Emissions Certification Film
Modification Number
Engine Low Idle rpm
Engine Full Load rpm
Performance Specification Number
Primary Fuel Filter Number
Water Separator Element Number
Secondary Fuel Filter Element Number
Lubrication Oil Filter Element Number
Auxiliary Oil Filter Element Number
Supplemental Coolant Additive Maintenance Element
Typical information plate Number (Optional)
The following information is stamped on the Engine Total Lubrication System Capacity
Identification Plate.
Total Cooling System Capacity
Engine Serial Number
Air Cleaner Element Number
Engine Arrangement Number
Alternator Belt Number
Engine Modification Number
The engine identification plate also contains other
important information about the engine.
i04019095
Emissions Certification Film

SMCS Code: 1000; 7405
Note: This information is pertinent in the United

States , in Canada and in Europe .
Consult your Cat dealer for an Emission Control
Warranty Statement.
This label is located on the engine.
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.
Record for Reference

Engine Model
Engine Serial Number
Engine Arrangement Number
26 SEBU9100
Operation Section
Product Lifting
Operation Section Use a hoist to remove heavy components. Use an

adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
Lifting and Storage be perpendicular to the top of the object that is being
lifted.
i05237729 Some removals require lifting fixtures in order to
obtain proper balance. Lifting fixtures also help to
Product Lifting provide safety.
SMCS Code: 7000; 7002 Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure that
proper lifting devices are provided. Consult your Cat
dealer for information regarding fixtures for proper
engine lifting.
i05237799
Product Storage
SMCS Code: 7002
Note: If the engine will be stored for more than 1 year,

contact your local Cat dealer for the preferred
procedure.
Engine
NOTICE Storage (Less Than One Year)
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem- If an engine is not used, oil can run off the following
ber that the capacity of an eyebolt is less as the angle parts that normally receive lubrication: cylinder walls,
between the supporting members and the object be- piston rings, main bearings, connecting rod bearings,
comes less than 90 degrees. crankshaft and gears.
When it is necessary to remove a component at an This lack of lubricant allows corrosion to begin to
angle, only use a link bracket that is properly rated for appear on the metal. This condition is worse in areas
the weight. of high humidity.
When the engine is started again, metal to metal
contact will cause wear before the surfaces receive
oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge,
start the engine.
1. Clean the engine of any dirt, rust, grease, and oil.

Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.
2. Remove any dirt from all air cleaners. Check all

seals, gaskets, and the filter element for damage.
3. Apply lubricant to all points in this Operation and

Maintenance Manual, “Maintenance Interval
Illustration 25 g03341634 Schedule”.
Lifting eyes
SEBU9100 27
Lifting and Storage
Product Storage
4. Drain the crankcase oil. Replace the crankcase oil 10. Remove the fuel nozzles or spark plugs. Apply
and change the oil filters. For the proper 30 mL (1 oz) of the mixture of oils (50 percent VCI
procedure, refer to this Operation and oil and 50 percent engine oil) into each cylinder.
Maintenance Manual, “Engine Oil and Filter -
Change”. Use a bar or a turning tool in order to turn over the
engine slowly. This action puts the oil on the
cylinder walls. Install all fuel nozzles or spark plugs
5. If the engine is equipped with an air starting motor, and tighten to the correct torque.
fill the reservoir with a mixture of 50 percent
volatile corrosion inhibitor (<nomen>VCI 11. Spray a thin amount of the mixture of oil (50
</nomen>) and 50 percent engine oil. percent VCI oil and 50 percent engine oil) onto the
flywheel, the ring gear teeth, and the starter pinion.
6. Add VCI to the crankcase oil. The volume of VCI in Install the covers in order to prevent evaporation of
the crankcase oil should be 3 to 4 percent. the vapors from the VCI oil.
Note: If the engine crankcase is full, drain enough
12. Apply a heavy amount of Cat Multipurpose
engine oil so the mixture can be added.
Grease (MPGM) to all outside parts that move,
7. Remove the air filter elements. Turn the engine at such as rod threads, ball joints, linkage and so on.
cranking speed with the throttle control in FUEL
Note: Install all covers. Ensure that tape has been
OFF position. Use a sprayer to add a mixture of 50 installed over all openings, air inlets, exhaust
percent VCI and 50 percent engine oil into the air openings, the flywheel housing, the crankcase
inlet or turbocharger inlet. breathers, the dipstick tubes and so on
Note: The mixture of VCI can be added to the inlet by Ensure that all covers are airtight and
removing the plug for checking turbocharger boost weatherproof. Use a waterproof weather resistant
pressure. The minimum rate of application is tape such as Kendall No. 231 or an equivalent.
5.5 mL per 1 L (3 oz per 1000 cu in) of engine Do not use duct tape. Duct tape will only seal for a
displacement. short time.
8. Use a sprayer to apply a mixture of 50 percent VCI 13. If possible, remove the batteries. As an
and 50 percent crankcase oil into the exhaust alternative, place the batteries in storage. As
openings. The minimum application rate for the oil needed, periodically charge the batteries while the
mixture is 5.5 mL per L (3 oz per 1000 cu in) of batteries are in storage.
engine displacement. Seal the exhaust pipe and If the batteries are not removed, wash the tops of
seal any drain holes in the muffler. the batteries until the tops are clean. Apply an
electrical charge to the batteries in order to obtain
9. Remove the fuel from the secondary fuel filter a specific gravity of 1.225.
housing. Alternately, empty and reinstall the spin-
on fuel filter element in order to remove any dirt Disconnect the battery terminals. Place a plastic
cover over the batteries.
and water. Drain any sleeve metering fuel pump.
Clean the primary fuel filter. Fill with calibration Note: For additional information, refer to Special
fluid or kerosene. Install the primary fuel filter and Instruction, SEHS7633, “Battery Test Procedure”.
operate the priming pump in order to send clean oil
to the secondary filter and the engine. 14. Loosen all belts.
Open the fuel tank drain valve in order to drain any 15. Place a waterproof cover over the engine. Ensure
water and dirt from the fuel tank. Apply a spray of that the engine cover is secure. The cover should
calibration fluid or kerosene at the rate of be loose enough to allow air to circulate around the
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank engine in order to prevent damage from
capacity in order to prevent rust in the fuel tank. condensation.
Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel. 16. Attach a tag with the date of storage to the
Apply a small amount of oil to the threads on the engine.
fuel tank filler neck and install the cap. Seal all
openings to the tank in order to prevent 17. Remove the waterproof cover at 2 month or 3
evaporation of the fuel and as a preservative. month intervals in order to check the engine for
corrosion. If the engine has signs of corrosion,
repeat the protection procedure.
28 SEBU9100
Lifting and Storage
Product Storage
Raw Water System Prime the engine with clean diesel fuel before
starting.
Completely drain the raw water system by removing
all the drain plugs from the raw water pump, the water 11. If the engine is equipped with a fresh water
shielded manifolds, the heat exchanger bonnets, and system, ensure that the system is clean. Ensure
the aftercooler. that the system is full. Ensure that the system has
the correct amount of supplemental cooling system
Note: To ensure complete drainage and evaporation
during storage, DO NOT install the drain plugs. Place conditioner.
all removed plugs in a cloth bag and fasten the bag to If the engine is equipped with a raw water system,
the engine for storage. install all of the drain plugs and zinc plugs. Fill the
system. Priming the raw water system pumps
Removal from Storage before operation may be necessary.
12. On the first day of operation, check the entire

1. Remove all outside protective covers. engine several times for leaks and correct
2. Change the oil and filters. operation.
13. Refer to Special Publication, SEBU5898, “Cold

3. Check the condition of the fan and alternator belts.
Weather Recommendations Operation and
Replace the belts, if necessary. Refer to this
Maintenance” when the temperature is less than
Operation and Maintenance Manual, “Belts -
−12° C (10° F) at the time of removal from storage.
Inspect/Adjust/Replace” or refer to this Operation
and Maintenance Manual, “Belts - Inspect/
Replace” for the correct procedure.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner

elements.
6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.
8. Pressure lubricate the engine before starting the

engine. Pressure lubrication of the engine ensures
immediate lubrication. Pressure lubrication of the
engine prevents damage to the engine which
might otherwise occur at start-up. If the engine is
not equipped with a prelube pump, contact your
Cat dealer for information about lubrication of the
engine before the engine is started.
9. Check the condition of all rubber hoses. Replace

any worn hoses. Replace any damaged hoses.
10. Before start-up, test the cooling system for a 3 to

6 percent concentration of coolant conditioner. Add
liquid coolant conditioner or a coolant conditioner
filter, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
SEBU9100 29
Features and Controls
Battery Disconnect Switch
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:
(If Equipped) • Coolant temperature reaches 18 °C (64 °F).
SMCS Code: 1411 • The engine has been running for fourteen minutes.
The battery disconnect switch and the engine start Cold mode operation varies the fuel injection amount
switch perform different functions. Turn off the battery for white smoke cleanup. Cold mode operation also
disconnect switch in order to disable the entire varies the timing for white smoke cleanup. The
electrical system. The battery remains connected to
engine operating temperature is usually reached
the electrical system when you turn off the engine
start switch. before the walk-around inspection is completed. The
engine will idle at the programmed low idle rpm in
Turn the battery disconnect switch to the OFF order to be put in gear.
position and remove the key when you service the
electrical system or any other components. NOTICE
A machine equipped with this electronically controlled
Also turn the battery disconnect switch to the OFF engine should not be moved until it is out of Cold
position and remove the key when the engine will not Mode operation.
be used for an extended period of a month or more.
This will prevent drainage of the battery. If the machine is operated while in Cold Mode opera-
tion power will be noticeably reduced.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam- After the cold mode is completed, the engine should
age to the electrical system could result. be operated at mid-speed to low speed until normal
operating temperature is reached. The engine will
reach normal operating temperature faster when the
To ensure that no damage to the engine occurs, verify engine is operated at low speed and low power
that the engine is fully operational before cranking the demand.
engine. Do not crank an engine that is not fully
operational. i05239848
Perform the following procedure in order to check the

battery disconnect switch for proper operation:
Control Panel
(Cat Marine Engine Control
1. With the battery disconnect switch in the ON
position, verify that electrical components are Panel III (MECP III ) (If
functioning. Verify that the hour meter is displaying Equipped))
information. Verify that the engine will crank.
SMCS Code: 7451
2. Turn the battery disconnect switch to the OFF Refer to Special Instruction, REHS4817, Overview
position. and Configuration of the Marine Classification Society
(MCS) Alarm and Protection (A&P), MCS Controller
3. Verify that the following items are not functioning: and Remote Equipment Interface (REI).
electrical components, hour meter and engine
cranking. If any of the items continue to function
with the battery disconnect switch in the OFF
position, consult your Caterpillar dealer.
i01491446
Cold Start Strategy

SMCS Code: 1450; 1456; 1900
The ECM will set the cold start strategy when the
coolant temperature is below 18 °C (64 °F).
30 SEBU9100
Control Panel
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
When the “OFF/MANUAL/REMOTE” switch is in the

OFF position, this control panel cannot be used to
start or to stop the engine. When the “OFF/MANUAL/
REMOTE” switch is in the REMOTE position, the
control panel can stop the engine but cannot be used
to start the engine.
Inside of the control panel
(8) “CRANK OVERRIDE” switch
(9) “SHUTDOWN OVERRIDE” switch
SEBU9100 31
Derating Strategy
i05391538
NOTICE
If no oil pressure is indicated, STOP the engine. If
Derating Strategy maximum coolant temperature is exceeded, STOP
SMCS Code: 1901 the engine. Engine damage can result.
The engine electronic control module (ECM) may limit

the amount of fuel flowing into the injectors in order to Engine Coolant Temperature – This
protect the engine. Any of the following factors could gauge indicates the engine coolant
initiate a derate: temperature. The temperature may vary
according to the load. Do not allow the
• The engine coolant level is high. temperature to exceed the boiling temperature of
• The engine coolant temperature is high. the pressurized cooling system.
The sensor for engine coolant temperature must be
• The engine oil pressure is low. fully submerged in order to detect the temperature
• The engine oil temperature is high. correctly. If the engine is operating above the normal
temperature range, perform the following procedure:
• The fuel pressure is high or the fuel pressure is
low. 1. Reduce the load and/or the engine rpm.
• The engine speed is high. 2. Inspect the cooling system for leaks.
• The temperature of the air entering the air cleaner 3. Determine if the engine must be shut down
is high. immediately or if the engine can be cooled by
reducing the load and/or rpm.
• The engine intake manifold temperature is high.
Engine Load – This gauge indicates a
Note: This fuel limiting strategy is in place to ensure percentage of the engine's full rated
the longevity and durability of the engine. torque. The calculation of the
percentage is based on these factors: flow of fuel,
The derate condition that may result will limit peak engine rpm, fuel energy content and fuel
power. In no case will the power loss exceed a 50%
reduction in total engine power. correction factor. This gauge flashes if the torque
exceeds the maximum limit that is programmed
Note: In a derated condition, the amount of derate into the control strategy.
can be determined by monitoring the “Actual
Maximum Available Engine Torque %” . Engine Oil Pressure – The oil pressure
should be greatest after a cold engine is
Contact your Cat dealer for more information about started. The pressure will decrease as
the derating procedure. the engine warms up. The pressure will increase
when the engine rpm is increased. The pressure
will stabilize when the engine rpm is stable.
i02004087
A lower oil pressure is normal at low idle. If the load is
Gauges and Indicators stable and the gauge reading changes, perform the
following procedure:
SMCS Code: 7450
Your engine may not have the same gauges or all of 1. Remove the load.
the gauges that are described.
2. Reduce engine speed to low idle.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order. 3. Check and maintain the oil level.
Determine the normal operating range by observing
the gauges over a period of time. Noticeable changes Engine Oil Temperature – This gauge
in gauge readings indicate potential gauge or engine indicates the engine oil temperature
problems. Problems may also be indicated by gauge after the oil has passed through the oil
readings that change even if the readings are within cooler. The oil cooler is thermostatically
specifications. Determine and correct the cause of controlled.
any significant change in the readings. Consult your
Caterpillar dealer for assistance. Exhaust Temperature – This gauge
indicates the exhaust temperature at the
exhaust inlets to the turbochargers. The
two exhaust temperatures may vary slightly.
32 SEBU9100
Overspeed
The exhaust temperatures at the exhaust inlets to the Tachometer – This gauge indicates
turbochargers provide a good indication of engine engine speed (rpm). When the throttle
performance. For engines with dry exhaust manifolds, control lever is moved to the full throttle
the temperatures are representative of the actual position without load, the engine is running at
temperatures of the valves. Monitor this parameter high idle. The engine is running at the full load
frequently. rpm when the throttle control lever is at the full
throttle position with maximum rated load.
NOTICE
Severe damage to the engine can result if the exhaust NOTICE
temperature at the inlet to the turbocharger exceeds To help prevent engine damage, never exceed the
the extreme limit. high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated at
high idle without damage, but should never be al-
Fuel Pressure – This gauge indicates
lowed to exceed high idle rpm.
fuel pressure to the fuel injection pump
from the fuel filter. A decrease in fuel
pressure usually indicates a dirty fuel filter or a Note: The high idle rpm and the full load rpm are
plugged fuel filter. As the fuel filter becomes stamped on the Information Plate.
plugged, there will be a noticeable reduction in
the engine's performance. Transmission Oil Pressure – This gauge
indicates the oil pressure in the marine
Fuel Temperature – This gauge indicates transmission. The measurement
the temperature of the fuel. A high fuel depends on the temperature of the oil and the
temperature can adversely affect quantity of the oil that circulates through the
performance. If the temperature of the fuel is too marine transmission lubrication system.
low, the fuel filter may begin to plug. See this
Operation and Maintenance Manual, “Fuel and the Transmission Oil Temperature – This
Effect from Cold Weather” for more information. gauge indicates the temperature of the
oil that is in the marine transmission.
Fuel Usage – This gauge indicates the The measurement depends on the temperature of
rate of fuel usage. the water and the quantity of the water that is
pumped through the marine transmission oil
Inlet Manifold Air Pressure – This gauge cooler.
indicates the air pressure (turbocharger
boost pressure) in the air inlet manifold i03648188
after the aftercooler. The inlet manifold air
pressure depends on the engine rating, the load, Overspeed
and the operating conditions. To establish the
normal inlet manifold air pressure, compare the SMCS Code: 1900; 1907; 1912; 7427
data from the gauge to the data from the engine
An overspeed condition is detected by the electronic
commissioning and look for trends.
control module (ECM). If the engine speed exceeds
Inlet Manifold Air Temperature – This 115 percent of the rated engine speed, the ECM will
shut off the electronic unit injectors. The electronic
gauge indicates the inlet manifold air unit injectors will be shut off until the engine speed
temperature after the aftercooler. As the drops below the high idle rpm for the engine. A
inlet air increases in temperature the following diagnostic fault code will be logged into the ECM
conditions occur: expansion of the air, less memory and the engine overspeed warning will be
oxygen in the cylinders and less power. If the annunciated on the display. “DIAGNOSTIC” lamp
temperature of the inlet air is too high during full will indicate a diagnostic fault code.
speed and load operation, the engine may
consume excessive fuel.
Service Hour Meter – This gauge

indicates the total number of clock hours
on the engine.
System Voltage – This gauge indicates

the voltage of the electrical system.
SEBU9100 33
Engine Diagnostics
Self-Diagnostics
Engine Diagnostics i03840813
i01563934
Fault Logging
SMCS Code: 1000; 1900; 1901; 1902
Self-Diagnostics The system provides the capability of Fault Logging.
SMCS Code: 1000; 1900; 1901; 1902 When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
Caterpillar Electronic Engines have the capability to logged in the memory of the ECM. The codes that
perform a self-diagnostics test. When the system have been logged in the memory of the ECM can be
detects an active problem, the “DIAGNOSTIC” lamp retrieved with Caterpillar electronic service tools.
is activated. Diagnostic codes will be stored in The codes that have been logged can be cleared with
permanent memory in the Electronic Control Module Caterpillar electronic service tools. The codes that
(ECM). The diagnostic codes can be retrieved by have been logged in the memory of the ECM will be
using the following components: automatically cleared from the memory after 100
hours. The following faults cannot be cleared from the
• Caterpillar electronic service tools memory of the ECM without using a factory
password: overspeed, low engine oil pressure and
• “DIAGNOSTIC” lamp high engine coolant temperature.
Note: The “DIAGNOSTIC” lamp must be installed by
i00864752
the OEM or by the customer.
Some installations have electronic displays that Engine Operation with Active
provide direct readouts of the engine diagnostic
codes. Refer to the manual that is provided by the Diagnostic Codes
OEM for more information on retrieving engine SMCS Code: 1000; 1900; 1901; 1902
diagnostic codes.
Engine performance can be limited as a result of an
Active codes represent problems that currently exist. active diagnostic code.
These problems should be investigated first. If a code
is active, the “DIAGNOSTIC” lamp will flash the flash An active diagnostic code represents a problem that
code at five second intervals. requires service as soon as possible. If a diagnostic
code is generated, check the following conditions:
Logged codes represent the following items:
• Engine oil pressure
• Intermittent problems
• Coolant temperature
• Recorded events
• Coolant level
• Performance history
If the oil pressure, coolant temperature, and coolant
The problems may have been repaired since the level are within the normal ranges, engine operation
logging of the code. These codes do not indicate that may continue. However, ensure that the engine is
a repair is needed. The codes are guides or signals serviced as soon as possible.
when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the
corresponding logged fault codes should be cleared.
34 SEBU9100
Engine Diagnostics
Engine Operation with Intermittent Diagnostic Codes
i05072873
Engine Operation with

Intermittent Diagnostic Codes
SMCS Code: 1000; 1900; 1901; 1902
The Electronic Control Module (ECM) can detect
abnormal operation of the electronic components that
are found on the engine. The ECM generates an
ACTIVE diagnostic code when an abnormal condition
is detected. The condition is also logged in ECM
memory. The logged information that is stored in ECM
memory is called a LOGGED diagnostic code. This
information may be useful to the technician for
troubleshooting the problem. A diagnostic code is
considered to be intermittent when the condition is
logged in ECM memory and the condition is not
currently active.
In most cases the engine does not need to be
stopped because of an intermittent code. However,
the operator should retrieve the codes and the
operator should reference the appropriate information
in order to identify the nature of the event. Take note
of the following characteristics of engine
performance:
• Low power
• Engine rpm limits

This information can be useful to help troubleshoot
the situation. If the nature of the problem persists, a
qualified service technician should be consulted. For
more information on diagnostic codes, refer to the
Troubleshooting Guide for this engine.
SEBU9100 35
Engine Starting
Before Starting Engine
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
periodic maintenance before the engine is started. damaged guards or for missing guards. Repair any
Inspect the engine compartment. This inspection can damaged guards. Replace damaged guards and/
help prevent major repairs at a later date. Refer to the or missing guards.
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information. • Disconnect any battery chargers that are not
protected against the high current drain that is
• For the maximum service life of the engine, make created when the electric starting motor (if
a thorough inspection before the engine is started. equipped) is engaged. Check electrical cables and
Look for the following items: oil leaks, coolant check the battery for poor connections and for
leaks, loose bolts and trash buildup. Remove trash corrosion.
buildup and arrange for repairs, as needed.
• Reset all of the shutoffs or alarm components.
• Inspect the cooling system hoses for cracks and
for loose clamps. • Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
• Inspect the alternator and accessory drive belts for mark on the oil level gauge.
cracks, breaks, and other damage.
• Check the coolant level. Observe the coolant level
• Inspect the wiring for loose connections and for in the coolant recovery tank (if equipped). Maintain
worn wires or frayed wires. the coolant level to the “FULL” mark on the
coolant recovery tank.
• Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply • If the engine is not equipped with a coolant
valve. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
NOTICE the engine is equipped with a sight glass, maintain
All valves in the fuel return line must be open before the coolant level in the sight glass.
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing • Observe the air cleaner service indicator (if
failure or other damage. equipped). Service the air cleaner when the yellow
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,
fuel may have drained from the fuel system. Air may • Ensure that any driven equipment has been
have entered the filter housing. Also, when fuel filters disengaged. Minimize electrical loads or remove
have been changed, some air pockets will be trapped any electrical loads.
in the engine. In these instances, prime the fuel
system. Refer to the Operation and Maintenance
i04409253
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Engine exhaust contains products of combustion

which may be harmful to your health. Always start
and operate the engine in a well ventilated area When using starting fluid (ether), follow the manu-
and, if in an enclosed area, vent the exhaust to the facturer's instructions carefully. Use the starting
outside. fluid sparingly and spray only while cranking the
engine. Failure to do so could result in an explo-
sion and/or fire and personal injury.
36 SEBU9100
Engine Starting
Starting the Engine
NOTICE NOTICE
The optional ether starting aid is the only starting fluid Oil pressure should rise within 15 seconds after the
system that is recommended on the engine. engine starts. Do not increase engine speed until the
oil pressure gauge indicates normal. If oil pressure is
not indicated on the gauge within 15 seconds, DO
The engine is designed to start without starting aids NOT operate the engine. STOP the engine, investi-
at temperatures greater than 13° C (55° F) gate and correct the cause.
When No. 2 diesel fuel is used, the following items
provide a means of minimizing starting problems and 3. Increase the engine rpm to approximately 1/4 of
fuel problems in cold weather: starting aids, engine oil
pan heaters, jacket water heaters, fuel heaters and the full load rpm.
fuel line insulation.
4. Allow the engine to idle for 3 to 5 minutes, or allow
For temperatures below −18° C (0° F), consult your the engine to idle until the water temperature
Cat dealer. indicator begins to rise. The engine should run at
Use the procedure that follows for cold weather low idle smoothly until speed is gradually
starting. increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation.
Note: If the engine has not been run for several 5. Operate the engine at low load until all systems
weeks, fuel may have drained. Air may have moved reach operating temperature. Check the gauges
into the filter housing. Also, when fuel filters have during the warm-up period.
been changed, some air will be left in the filter
housing. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information i05237813
on priming the fuel system.
Starting the Engine
NOTICE SMCS Code: 1000; 1450
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
Automatic Starting
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to al-
low the starting motor to cool before attempting to
start the engine again.
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid person-
1. Turn the ignition switch to the RUN position. al injury, always remain clear of the the engine
Advance the throttle in order to supply fuel to the when the engine is in the AUTOMATIC mode.
engine.
For automatic starting, the engine control switch must
NOTICE be in the AUTO position or in the REMOTE position.
Excessive ether can cause piston and piston ring The engine will automatically start when the remote
start/stop initiate contact closes.
damage. Use ether for cold starting purposes only.
Do not use excessive starting fluid while starting the
engine. Do not use starting fluid after the engine is
Manual Starting
running.
NOTICE
For initial start-up of a new or rebuilt engine, and for
2. If equipped, press the “STARTING AID” switch in start-up of an engine that has been serviced, make
order to improve cold weather starting. Release provision to shut the engine off should an overspeed
the “STARTING AID” switch when the engine occur. This may be accomplished by shutting off the
starts. Use the starting fluid sparingly. Carefully air and/or fuel supply to the engine.
follow the instructions of the OEM.
Do not start the engine if a “DO NOT OPERATE”
warning tag or a similar warning tag is attached to any
of the controls.
Ensure that no one will be endangered before the
engine is started and when the engine is started.
SEBU9100 37
Engine Starting
Starting the Engine
Perform all of the procedures that are described in Starting the Engine with the Cat Marine
this Operation and Maintenance Manual, “Before
Starting Engine” topic. Engine Control Panel III (MECP III) (If
Equipped)
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to al-
low the starting motor to cool before attempting to
start the engine again.
Note: If the optional prelube is used, the prelube

pump will operate before cranking begins. The ECM
will allow the engine to be operated at rated rpm
when the oil pressure sensors indicate that the oil
pressure is sufficient.
Starting the Engine with the Cat Marine

Engine Control Panel I (MECP I) (If
Equipped)
(3) “START” switch
(4) “ON/OFF” switch for the “LOCAL THROTTLE”
(5) “LOCAL THROTTLE” switch
(6) “OFF/MANUAL/REMOTE” switch
(1) “OFF/MANUAL/REMOTE” switch Illustration 30 g03200996
(2) “START” switch (7) “CRANK OVERRIDE” switch
(8) “SHUTDOWN OVERRIDE” switch
Note: The engine key switch and the start circuits are (9) “TORQUE LIMIT” switch
controlled by the “OFF/LOCAL/REMOTE” switch.
The position of the “OFF/LOCAL/REMOTE” switch When the “OFF/LOCAL/REMOTE” switch is in
does not affect the operation of the “STOP” switch. LOCAL mode, the engine cannot be started from the
remote control unit. The LOCALl position does not
1. Position the “OFF/LOCAL/REMOTE” switch to the energize the key switch (J906 circuit) beyond the
engine harness.
LOCAL position or to the REMOTE position.
1. Position the “OFF/LOCAL/REMOTE” switch to the
2. Activate the “START” switch to start the engine.
LOCAL position or to the REMOTE position.
2. Activate the “START” switch to start the engine.

38 SEBU9100
Engine Starting
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
Many batteries which are considered unusable are

still rechargeable. After jump starting, the alternator After Starting Engine
may not be able to fully recharge batteries that are SMCS Code: 1000
severely discharged. The batteries must be charged
to the proper voltage with a battery charger. For Note: In temperatures from 0 to 60 °C (32 to 140 °F),
information on testing and charging, refer to the
Special Instruction, SEHS7633, “Battery Test the warm-up time is approximately five minutes. In
Procedure”. temperatures below 0 °C (32 °F), additional warm-up
time may be required.
NOTICE Note: Ensure that the self-test for the monitoring
Use a battery that is sourced with the same voltage system is completed before you operate the engine
as the electric starting motor. Use ONLY equal voltage under load.
for jump starting. The use of higher voltage will dam-
age the electrical system. 1. Operate the engine at low idle rpm for five minutes.
Perform these checks during the warm-up:
Do not reverse the battery cables. The alternator can
be damaged. Attach the negative battery cable last • Check for any fluid leaks and for any air leaks.
and remove the negative battery cable first.
When an external electrical source is used to start the • Check all the gauges.
engine, turn the control switch on the generator set to
the “OFF” position. Turn all electrical accessories Observe the gauges and record the data frequently
OFF before attaching the jump start cables. while the engine is operating. Comparing the data
over time will help to determine normal readings for
Ensure that the main power switch is in the OFF posi- each gauge. This will also help detect abnormal
tion before jump start cables are attached to the en- operating developments. Investigate any
gine that is being started. significant changes in the readings.
2. After the engine has idled for five minutes and the
1. Turn the start switch on the stalled engine to the inspections have been made, increase the engine
OFF position. Turn off all accessories. speed to 1/2 rated rpm.
SEBU9100 39
Engine Starting
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.
3. Observe the water discharge at the sea water

outlet. If water discharge is not visible or the water
flow is restricted, perform the following procedure:
a. Stop the engine immediately.
b. Inspect the inlet screen and the sea water

strainer for debris. Remove any debris that is
found.
c. Inspect the cooling system and the auxiliary
water pumps for evidence of leaks.
4. Check for any fluid leaks and for any air leaks.
5. Perform any necessary repairs before you operate

the engine.
6. After the inspections have been made, move the

throttle control to the idle position and proceed with
operation.
40 SEBU9100
Engine Operation
Engine Operation
Engine Operation • Observe the service indicator frequently. Keep the

air cleaner elements clean.
i05392621 • Ensure that the turbochargers are operating
correctly so that the proper air/fuel ratio is
Engine Operation maintained. Clean exhaust indicates proper
functioning.
SMCS Code: 1000
• Maintain a good electrical system.
Proper operation and maintenance are key factors in
obtaining the maximum life and economy of the One defective battery cell will overwork the alternator.
engine. If the directions in the Operation and This will consume excess power and excess fuel.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. • Ensure that the belts are properly adjusted. The
The engine can reach normal operating temperature belt should be in good condition.
in less than the time for a walk-around inspection of
the engine. • Ensure that all of the connections of the hoses are
tight. The connections should not leak.
The engine can be operated at the rated rpm after the
engine reaches operating temperature. The engine • When possible, utilize the heat of the jacket water
will reach normal operating temperature sooner system and the energy from the heat of the
during a low engine speed (rpm) and during a low- exhaust system.
power demand. This procedure is more effective than
idling the engine at no load. The engine should reach • Keep keel coolers, heat exchangers, and water
operating temperature in a few minutes. pumps clean. Keep the components in good repair.
Gauge readings should be observed and the data • Ensure that all of the accessory pumps are
should be recorded frequently while the engine is repaired. The pumps should operate efficiently.
operating. Comparing the data over time will help to
determine normal readings for each gauge. • Do not exceed the maximum oil level.
Comparing data over time will also help detect
abnormal operating developments. Significant • Never operate without water temperature
changes in the readings should be investigated. regulators.
Water temperature regulators regulate the
i01060957
temperature of the coolant. Water temperature
regulators help to provide efficient operating
Fuel Conservation Practices temperatures. Cold engines consume excessive fuel.
Water temperature regulators also help prevent
SMCS Code: 1000; 1250 engine overheating.
The efficiency of the engine can affect the fuel
economy. Caterpillar's design and technology in Cruising Speed
manufacturing provides maximum fuel efficiency in all
applications. Follow the recommended procedures in The recommended cruising speed of the engine is
order to attain optimum performance for the life of the 300 to 400 rpm below the rated speed of the engine.
engine.
Operating at the recommended cruising speed will
• Avoid spilling fuel. help to provide the maximum engine service life and
the most economical operation.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. The fuel lines should be repaired if there is
evidence of failure.
• Be aware of the properties of the different fuels.
Use only the recommended fuels.
• Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of
time.
SEBU9100 41
Cold Weather Operation
Cold Weather Operation Hints for Cold Weather Operation

• If the engine is started, operate the engine until a
i04557066 minimum operating temperature of 71 °C (160 °F)
is achieved. Achieving operating temperature will
Cold Weather Operation help prevent the intake valves and exhaust valves
from sticking.
SMCS Code: 1000; 1250
• The cooling system and the lubrication system for
Cat Diesel Engines can operate effectively in cold
weather. The starting and the operation of the diesel the engine do not lose heat immediately upon
engine is dependent on the following items in cold shutdown. This means that an engine can be shut
weather: down for a few hours and the engine will start
readily. If the engine is shut down for at least
• The type of fuel that is used 8hours, the engine should be considered cooled to
outside temperature.
• The viscosity of the oil
• Install the correct lubricant in each compartment
• Optional starting aids before the beginning of cold weather.
• Optional warm-up aids • Check all rubber parts (hoses, fan drive belts, and
so on) weekly.
Refer to Special Publication, SEBU5898, Cold
Weather Recommendations for Cat Machines. • Check all electrical wiring and connections for any
The purpose of this section will cover the following fraying or damaged insulation.
information:
• Keep all batteries fully charged and warm.
• Explain potential problems that are caused by
• Fill the fuel tank at the end of each shift.
cold-weather operation.
• Check the air cleaners and the air intake daily.
• Suggest steps which can be taken in order to
Check the air intake more often when you operate
minimize starting problems and operating
in snow.
problems when the ambient air temperature is
colder than 0 to −55 °C (32 to −67 °F).
The operation and maintenance of an engine in
freezing temperatures is complex because of the Personal injury or property damage can result
following conditions: the unlimited differences in from alcohol or starting fluids.
weather conditions, engine applications and the
supplies that are available in your area. These Alcohol or starting fluids are highly flammable
factors, recommendations from your Cat dealer, past and toxic and if improperly stored could result in
proven practices, and the information that is injury or property damage.
contained in this section should be combined to
provide guidelines for cold-weather operation.
DO NOT USE ETHER (starting fluids) unless spe-

cifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.
NOTICE
The optional automatic ether injection system is the
only starting fluid system that is recommended. Ex-
cessive starting fluid can cause piston and ring dam-
age. Use starting fluid for cold starting purposes only.
42 SEBU9100
• Inject starting fluid only when the engine is Recommendations for the Coolant
cranking.
Provide cooling system protection for the lowest
• Dryers for the air system may be effective in expected outside temperature. Refer to the Operation
reducing moisture condensation and the formation and Maintenance Manual, “Fluid Recommendations”
for the recommended coolant mixture.
of ice in air systems.
In cold weather, check the coolant often for the proper
• The injection of alcohol may prevent moisture from glycol concentration in order to ensure adequate
freezing the air compressor governor and other freeze protection.
components of the air system.
• For jump starting with cables in cold weather, refer Jacket Water Heater
to the Operation and Maintenance Manual for jump A jacket water heater heats the coolant that
starting instructions. 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 Idling the Engine
recommended for heating the lube oil. To ensure the
compatibility of the components, only use equipment While the engine is idling, the application of a light
that is recommended by Caterpillar . 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 lu- an elevated low idle speed for extended periods will
bricating 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, follow
these recommendations: Recommendations for Coolant
The temperature of the heating surface must not ex- Warm Up
ceed 150 °C (300 °F). The maximum heat density of
the heating surface must not exceed 1.24 w/cm2 Warm up any system that has cooled below normal
(8W/in2). operating temperatures due to inactivity. The warm-
up should be performed before the engine is returned
to full operation. During operation in very cold
Engine oil pan heaters are useful devices that provide temperature conditions, damage to engine valve
the following functions: mechanisms can result from engine operation for
short intervals. This damage can happen if the engine
• Assist in reducing the cold cranking amperage that is started and the engine is stopped many times
is needed to start the engine. without being operated in order to warm up
completely.
• Improve the flow of oil at start-up.
When the engine is operated below normal operating
• The time that is needed to warm up the engine is temperatures, fuel and oil are not completely burned
reduced. in the combustion chamber. This fuel and oil causes
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and
• The service life of bearings is increased. the deposits are burned off during operation at normal
Engine oil pan heaters can reduce the minimum engine operating temperatures.
ambient temperatures that are normally When the engine is started and stopped without
recommended for multigrade oil. Consult your dealer operating long enough to warm up completely, the
for more information. carbon deposits become thicker. The carbon deposits
will cause the following problems:
SEBU9100 43
Fuel and the Effect from Cold Weather
• Free operation of the valves is prevented. Insulating the Air Inlet and Engine
• Valves become stuck. Compartment
• Pushrods are bent. When temperatures below −18 °C (−0 °F) will be
frequently encountered, an air cleaner inlet that is
• Other damage to valve train components can located in the engine compartment may be specified.
result. The special air cleaner inlet is sometimes referred to
as a snow valve. An air cleaner that is located in the
For this reason, when the engine is started, the engine compartment may also minimize the snow
engine must be operated until the coolant that is packed in the air cleaner. Heat that is rejected
temperature is 71 °C (160 °F) minimum. Carbon by the engine warms the inlet air.
deposits on the valve stems are kept at a minimum
and the free operation of the valves and the valve Additional heat can be retained around the engine by
components are maintained. insulating the engine compartment.
Warm the engine thoroughly to keep other engine i04408649

parts in better condition. The service life of the engine
will be extended. Lubrication will be improved. There
will be less acid and less sludge in the oil. The better Fuel and the Effect from Cold
condition of the oil will provide longer service life for
the engine bearings, the piston rings, and other parts.
Weather
However, limit unnecessary idle time to 10 minutes. SMCS Code: 1000; 1250; 1280
Engine wear is greatest at low idle and unnecessary
idling wastes fuel. The following fuels are the grades that are available
for Cat engines:
On/Off Fan Clutch • No. 1
Viscous fans continuously rotate in cold weather, • No. 2
which creates unnecessary movement of the air. For
better control of the operation of the fan, an ON/OFF • Blend of No. 1 and No. 2
fan clutch may be used. ON/OFF fan clutches can
help prevent excessive cooling in cold weather. In the No. 2 diesel fuel is the most commonly used fuel.
“OFF” position, the fan is kept stationary by the ON/ Either No. 1 diesel fuel or a blend of No. 1 and No. 2
OFF fan clutch. The unnecessary movement of the is best suited for cold-weather operation.
air is reduced in order to maintain adequate engine
operating temperatures in cold weather. Quantities of No. 1 diesel fuel are limited. No. 1 diesel
fuels are usually available during the months of the
winter in the colder climates. During cold-weather
Purge Valve and Insulated Heater Lines operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary.
During periods of operations with a light load, The
coolant must bypass the radiator in order to help There are three major differences between No. 1 and
prevent excessive cooling of the engine. Coolant that No. 2 diesel fuel. No. 1 diesel fuel has the following
passes through the radiator must be minimized in properties:
order to maintain the engine operating temperature in
cold weather. • Lower cloud point
Excessive cooling of the engine is prevented by a • Lower pour point
“jiggle” valve that performs two functions. The valve
allows the flow of air and the valve prevents the flow • Lower rating of kJ (BTU) per unit volume of fuel
of coolant. These valves prevent the unnecessary
coolant flow, which may be diverted around the water When No. 1 diesel fuel is used, a decrease in power
temperature regulator to the radiator. and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
Insulated cab heater lines for very cold weather are
also beneficial. These lines provide more available The cloud point is the temperature when a cloud of
heat from the coolant to the cab and less heat is lost wax crystals begins to form in the fuel. These crystals
to the outside air. can cause the fuel filters to plug. The pour point is the
temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
pumps and through fuel lines.
44 SEBU9100
Fuel Related Components in Cold Weather
Be aware of these values when diesel fuel is Fuel Filters

purchased. Anticipate the average ambient
temperature of the area. Engines that are fueled in NOTICE
one climate may not operate well if the engines are Do not fill the fuel filters with fuel before installing
moved to another climate. Problems can result due to
changes in temperature. them. The fuel would not be filtered and could be con-
taminated. Contaminated fuel will cause accelerated
Before troubleshooting for low power or for poor wear to fuel system parts.
performance in the winter, check the type of fuel that
is being used.
NOTICE
When No. 2 diesel fuel is used, the following Caterpillar requires the use of a 4 micron(c) secon-
components provide a means of minimizing problems
dary fuel filter for the following reasons: to maximize
in cold weather:
fuel system life and to prevent premature wear out
• Starting aids from abrasive particles in the fuel. Cat high efficiency
fuel filters meet these requirements. Consult your Cat
• Engine oil pan heaters dealer for the proper part numbers.
• Engine coolant heaters

When the engine is equipped with a primary filter/
• Fuel line insulation water separator, the primary filter/water separator
must use a 10 micron filter to a 15 micron filter. The
For more information on cold-weather operation, see filters are becoming more critical as fuel injection
Special Publication, SEBU5898, “Cold Weather pressures increase to 209 MPa (30000 psi) and
Recommendations”. higher psi. For more information on priming the fuel
system, see the Operation and Maintenance Manual,
i04369188
“Fuel System - Prime” topic.
Fuel Related Components in Fuel Heaters

Cold Weather Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
SMCS Code: 1000; 1250; 1280 be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Fuel Tanks Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
Condensation can form in partially filled fuel tanks. also help to prevent overheating of the fuel. High fuel
Top off the fuel tanks after operating the engine. temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater with
Fuel tanks should contain some provision for draining a large heating surface. The fuel heater should be
water and sediment from the bottom of the tanks. practical in size. Small heaters can be too hot due to
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel the limited surface area.
supply pipe. Disconnect the fuel heater in warm weather.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is Note: Only use fuel heaters that are controlled by the
equipped with this system, regular maintenance of water temperature regulator or fuel heaters that are
the fuel system filter is important. self-regulating. Fuel heaters that are not controlled by
the water temperature regulator can heat the fuel in
Draining the fuel tank will help prevent water and/or excess of 65° C (149° F). A loss of engine power can
sediment from being pumped from the fuel storage occur if the fuel supply temperature exceeds 37° C
tank and into the engine fuel tank. Drain the water (100° F).
and sediment from any fuel storage tank at the
following intervals: Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
• Weekly the fuel when the engine operates in warm weather.
• Oil changes For further information on fuel heaters, consult your
Cat dealer.
• Refueling of the fuel tank
SEBU9100 45
Engine Stopping
Emergency Stopping
Engine Stopping i05237815
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-
fore stopping the engine.
Ensure that any components for the external system
that support the engine operation are secured after Avoiding hot engine shutdowns will maximize turbo-
the engine is stopped. charger shaft and bearing life.
1. Reduce the engine rpm to low idle.
2. Increase the engine rpm to no more than 50

percent of the rated rpm for 3 to 5 minutes in order
to cool the engine. Reduce the engine rpm to low
idle.
3. Push the “STOP” switch.
i04137729
After Stopping Engine

SMCS Code: 1000
Typical emergency stop button Note: After operation, allow 10 minutes for the engine
oil to return to the oil pan before checking the engine
The emergency stop button is in the OUT position for oil level.
normal engine operation. For an emergency stop,
push the emergency stop button. This shuts off the • Check the crankcase oil level. Maintain the oil level
fuel to the engine. This also activates the air shutoff (if between the “ADD” mark and the “FULL” mark
equipped). on the oil level gauge.
NOTICE Note: Only use oil that is recommended in this
Do not start the engine until the problem necessitating Operation and Maintenance Manual, “Fluid
the emergency stop has been located and corrected. Recommendations” article. Failure to do so may
result in engine damage.
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
To reset the engine control switch, turn the switch to Schedule”.
the “OFF/RESET” position.
• Fill the fuel tank to prevent accumulation of
To reset the emergency stop button, turn the button moisture in the fuel. Do not overfill the fuel tank.
clockwise. The spring-loaded button will return to the
OUT position. The button may also be pulled to the • Allow the engine to cool. Check the coolant level.
OUT position. Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
46 SEBU9100
Engine Stopping
After Stopping Engine
Note: Only use coolant that is recommended in this

Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.
• If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU9100 47
Maintenance Section
Refill Capacities
Maintenance Section Note: The interval for changing the coolant varies
depending on the type of coolant being replaced.
Refer to this article, “Coolant Recommendations”for
the intervals.
Refill Capacities
Note: For more information, refer to Special
i04618990
Publication, SEBU6251, Cat Commercial Diesel
Engine Fluids Recommendations.
Refill Capacities Diesel Engine Oil
SMCS Code: 1000; 1348; 1395; 7560
Cat Diesel Engine Oil (Cat DEO )
Lubrication System
Cat oils have been developed and tested in order to
The refill capacities for the engine crankcase reflect provide the full performance and service life that has
the approximate capacity of the crankcase or sump been designed and built into Cat engines. Cat oils
plus standard oil filters. Auxiliary oil filter systems will are currently used to fill Cat Diesel Engines at the
require additional oil. Refer to the OEM specifications factory. These oils are offered by Cat dealers for
for the capacity of the auxiliary oil filter. continued use when the engine oil is changed.
Table 2 Consult your Cat dealer for more information on
these oils.
Approximate Refill Capacities
Due to significant variations in the quality and in the
Compartment or System Liters Quarts performance of commercially available oils,
Caterpillar makes the following recommendations:
Engine Crankcase(1) 138 146
(1) Deep sump oil pan (500 hr) Note: Cat DEO and Cat DEO-ULS multigrade oils
are the preferred oils for use in this Cat Diesel
Engine.
Cooling System Capacity Table 4
To maintain the cooling system properly, the total Commercial
capacity of the cooling system must be determined. Cat Lubricants Viscosity Grade
Lubricants
The capacity of the total cooling system will vary
between individual installations. The external system SAE 15W-40
Cat DEO-ULS
can include the following components: expansion Diesel Engine Oil-Ul- SAE 10W-30
tank, radiator and piping. Refer to the specifications tra Low Sulfur (API Cat DEO-ULS SYN
that are provided by the OEM. Record the total SAE 5W-40
CJ-4)
cooling system capacity in the appropriate Table. Cat DEO Cold
SAE 0W-40
Weather
For the recommended coolant, see this Operation
and Maintenance Manual, “Fluid Recommendations”. Diesel Engine Oil SAE 15W-40
Table 3 (API CI-4/CI-4 PLUS Cat DEO
and API CH-4) SAE 10W-30
C32 Separate Circuit Aftercooled (SCAC) Engines
Coolant System Refill Capacity

Engines which are Certified to US Marine
Jacket water system 128 L (135 qt)
Environmental Protection Agency (EPA)
SCAC system 26.5 L (28 qt)
Tier 3 Regulations
i05391578 NOTICE
An engine certified to US Environmental Protection
Fluid Recommendations Agency (US EPA) Marine Tier 3 regulations which is
SMCS Code: 1280; 1348; 1395; 7560 installed in a US flagged vessel must use ultra-low
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR
Note: Refer to the emissions label on the engine to part 80.510 (c). When an engine is not installed in a
determine to which emissions regulation the engine is US flagged vessel, refer to applicable local or Interna-
certified. tional Maritime Organization (IMO) regulations for fuel
requirements.
48 SEBU9100
Refill Capacities
Fluid Recommendations
Caterpillar recommends the use of Cat DEO-ULS (Table 5, contd)

for engines that use ultra-low sulfur diesel fuel (ULSD
fuel) or sulfur-free diesel fuel. Cat DEO-ULS has the
proper amount of lubricity for engines using ULSD.
The use of engine oil that meets Cat Engine API CH-4 Oil Category performance require-
Crankcase Fluid specifications (Cat ECF-3) ments and
specifications is acceptable. Refer to this article For oils that are between 1.30 percent and
“Commercial Oil” for more information. 1.50 percent sulfated ash, passing one addi-
Cat ECF-1-a
tional Cat 1P SCOTE test (ASTM D6681) is
Engines which are Not Certified to US required and
Oils of sulfated ash > 1.50 percent are not
Marine EPA Tier 3 Regulations allowed
Cat DEO is recommended for engines using fuels of

sulfur levels that exceed 0.2 percent (> 2000 ppm
(mg/kg) ). Cat DEO-ULS may be used in these
applications if an oil analysis program is followed. The
oil change interval may be affected by the fuel sulfur Engines which are Certified to US Marine
level. Refer to this Operation and Maintenance
Manual, “Engine Oil Sample - Obtain” for more Environmental Protection Agency (EPA)
information about the Cat S·O·S Oil Sampling Tier 3 Regulations
program.
If an engine which is certified to US Marine EPA Tier 3
Commercial Oil Regulations is installed on a US flagged vessel and is
not using Cat DEO-ULS, Caterpillar recommends
Note: Non-Cat commercial oils are, as a group, the use of an oil that meets the following standards:
second choice oils. Within this grouping of second Cat ECF-3 specification and API CJ-4 oil category.
choice oils there are tiered levels of performance.
Lubricant Viscosity
NOTICE
Caterpillar does not warrant the quality or perform- In selecting oil for any engine application, both of the
ance of non-Cat fluids. following must be satisfied: the oil viscosity and the
category of oil performance or the specification for oil
performance . Using only one of these parameters
The three current Caterpillar ECF specifications are: will not sufficiently define oil for an engine application.
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each
higher Cat ECF specification provides increased The proper SAE viscosity grade of oil is determined
performance over lower Cat ECF specifications. by the following temperatures: minimum ambient
temperature during cold engine start-up and
A commercial oil must meet the following standards maximum ambient temperature during engine
to be considered an equivalent of a Cat diesel engine operation.
oil:
Table 5 Refer to Table 6 (minimum temperature) in order to
Cat Engine Crankcase Fluids (ECF) Definitions
determine the required oil viscosity for starting a cold
engine.
Cat Performance
API Oil Category Refer to Table 6 (maximum temperature) in order to
Requirement
select the oil viscosity for engine operation at the
Cat ECF-3
API CJ-4 Oil Category performance highest ambient temperature that is anticipated.
requirements
Note: Generally, use the highest oil viscosity that is
API CI-4 / CI-4 PLUS Oil Category perform-
available to meet the requirement for the temperature
ance requirements and
Passing standard Cat C13 engine test per
at start-up.
Cat ECF-2 Table 6
API requirements and
Oils of sulfated ash > 1.50 percent are not
Lubricant Viscosities for Ambient Temperatures for
allowed
Cat Diesel Engines
Oil Type and Per- °C °F
Viscosity
(continued) formance
Grade Min Max Min Max
Requirements
(continued)
SEBU9100 49
Refill Capacities
(Table 6, contd) S·O·S Services Oil Analysis

Lubricant Viscosities for Ambient Temperatures for
Cat Diesel Engines Caterpillar has developed a maintenance tool that
evaluates oil degradation. the maintenance
Cat Cold Weather management also detects the early signs of wear on
SAE 0W-40 −40 40 −40 104
DEO-ULS internal components. The Cat tool for oil analysis is
called S·O·S oil analysis and the tool is part of the
Cat DEO-ULS SYN SAE 5W-40 −30 50 −22 122
S·O·S Services program. S·O·S oil analysis divides
Cat DEO-ULS SAE 10W-30 −18 40 0 104 oil analysis into four categories:
Cat DEO SAE 15W-40 −10 50 14 122 • Component wear rate
SAE 0W-30 −40 30 −40 86
Cat ECF-1-a, Cat • Oil condition
SAE 5W-30 −30 30 −22 86
ECF-2, Cat ECF-3
SAE 10W-40 −18 50 0 122
• Oil contamination
• Identification of oil
Note: A cold soaked start occurs when the engine
has not been operated recently, allowing the oil to These four types of analysis are used to monitor the
condition of your equipment. The four types of
become more viscous due to cooler ambient analysis will also help you identify potential problems.
temperatures. Supplemental heat is recommended A properly administered S·O·S oil analysis program
for cold soaked starts below the minimum ambient will reduce repair costs and the program will lessen
temperature. Supplemental heat may be necessary the impact of downtime.
for cold soaked starts that are above the minimum
temperature depending on factors such as parasitic The S·O·S Oil Analysis program uses a wide range of
load. tests to determine the condition of the oil and the
crankcase. Guidelines that are based on experience
and a correlation to failures have been established for
Total Base Number (TBN) and Fuel Sulfur these tests. Exceeding one or more of these
Levels guidelines could indicate serious fluid degradation or
a pending component failure. A trained person at your
The use of Cat S·O·S Services oil analysis is Cat dealership should make the final analysis.
recommended strongly for determining oil life.
NOTICE
The minimum required Total Base Number (TBN) for Always use a designated pump for oil sampling, and
oil depends on the fuel sulfur level. The TBN for new use a separate designated pump for coolant sam-
oil is typically determined by the ASTM D2896 pling. Using the same pump for both types of samples
procedure. For direct injection engines that use may contaminate the samples that are being drawn.
distillate fuel, the following guidelines apply: This contaminate may cause a false analysis and an
Table 7 incorrect interpretation that could lead to concerns by
TBN recommendations for applications in Cat engines both dealers and customers.
Fuel Sulfur Level per- TBN of Commercial
Cat Engine Oils (1)
cent (ppm) Engine Oils Refer to Special Publication, SEBU6251, Cat
Commercial Diesel Engine Fluids Recommendations
0.05 percent Cat DEO-ULS in order to obtain additional information about S·O·S
Min 7
(500ppm) Cat DEO Services oil analysis. You can also contact your local
Cat dealer.
>0.05-0.2 percent Cat DEO
Min 10
(>500- 2000 ppm) (2) Cat DEO-ULS
Fuel
Above 0.2 percent
Cat DEO (5) Min 10 Note: Caterpillar strongly recommends the filtration
(above 2000ppm) (3) (4)
(1)
of fuel through a fuel filter with a rating of four microns
Cat DEO-ULS applies to Cat DEO-ULS SAE 15W-40,
SAE10W-30, Cat DEO-ULS SYN SAE 5W-40, and Cat DEO
(c) absolute or less. This filtration should be located
Cold Weather SAE 0W-40. Cat DEO applies to Cat DEO SAE on the device that dispenses the fuel to the fuel tank
15W-40 and SAE 10W-30. for the engine. This filtration should also be located
(2) Use of an oil analysis program to determine oil drain intervals is on the device that dispenses fuel from the bulk
strongly recommended if fuel sulfur is between 0.05% (500 storage tank. Series filtration is recommended.
ppm) and 0.5% (5000 ppm).
(3) Use of an oil analysis program to determine oil drain intervals is
required if fuel sulfur is above 0.5% (5000 ppm).
(4) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
refer to TBN and engine oil guidelines given in this section.
(5) Cat DEO-ULS may be used if an oil analysis program is fol-
lowed. High fuel sulfur levels may reduce the oil drain intervals.
50 SEBU9100
Refill Capacities
The use of diesel fuel that contains >0.0050 percent

NOTICE (>50 ppm (mg/kg)) of sulfur may cause the aftercooler
In order to meet expected fuel system component life, to foul. Fouling of the aftercooler may result in engine
4 micron(c) absolute or less secondary fuel filtration is damage.
required for all Cat Diesel Engines that are equipped
with unit injected fuel systems. All current Cat Diesel Note: If the engine operates in an area outside of US
Engines are factory equipped with Cat Advanced Ef- EPA jurisdiction and where fuel quality is unknown,
ficiency 4 micron(c) absolute fuel filters. refer to EPA regulations for instructions on obtaining
a migratory exemption. In order to operate a Cat
Caterpillar does not warrant the quality or perform- Marine Diesel Engine which is certified to US EPA
ance of non-Cat fluids and filters. Marine Tier 3 Standards with fuel that contains >50
ppm (mg/kg) of sulfur, modifications to the crankcase
ventilation system (CCV system) must be made to
Fuel for Cat Marine Diesel Engines prevent fouling of the aftercooler. Crankcase fumes
which are certified to United States cannot be routed back into the engine air intake when
the engine is operating with fuel that contains >50
Environmental Protection Agency Tier 3 ppm (mg/kg) of sulfur. Contact your Cat dealer for
Standards (US EPA Tier 3 Standards) more information.
NOTICE
Specifications for Distillate Diesel Fuel
An engine certified to US Environmental Protection
Note: Diesel fuel used to operate a Cat Marine
Agency (US EPA) Marine Tier 3 regulations which is
Diesel Engine which is certified to US EPA Tier 3
installed in a US flagged vessel must use ultra-low
Standards must also meet the “Cat Specification for
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR
Distillate Diesel Fuel for Off-Highway Diesel
part 80.510 (c). When an engine is not installed in a
Engines”. The acceptability of these fuels for use is
US flagged vessel, refer to applicable local or Interna-
determined on a case by case basis. A complete fuel
tional Maritime Organization (IMO) regulations for fuel
analysis is required. Consult your Cat dealer for
requirements.
further information.
Cat Marine Diesel Engines which are certified to US NOTICE

EPA Tier 3 Standards are designed to operate with The footnotes are a key part of the “Caterpillar Speci-
the following types of fuel: fication for Distillate Diesel Fuel for Off-Highway Die-
sel Engines” Table. Read ALL of the footnotes.
Table 8
Caterpillar Specification for Distillate Fuel for Nonroad
Diesel Engines
Specifications Requirements ASTM ISO Test

Test
Aromatics 35% maximum D1319 ISO 3837
0.01% maximum
Ash D482 ISO 6245
(weight)
Carbon Residue on 0.35% maximum

D524 ISO 4262
10% Bottoms (weight)
Illustration 32 g02157153 40 minimum (DI

engines) D613
NACD Film Cetane Number (1) or ISO 5165
35 minimum (PC D6890
• Ultra-low Sulfur Diesel Fuel (ULSD fuel). ULSD engines)
fuel contains ≤0.0015 percent (≤15 ppm (mg/kg) of
sulfur. The cloud point
must not exceed
• Approved blends of biodiesel fuel. Refer to the Cloud Point the lowest ex- D2500 ISO 3015
pected ambient
“Biodiesel” topic in this article for more information.
temperature.
(continued)
SEBU9100 51
Refill Capacities
(Table 8, contd) (Table 8, contd)

(2) Via standards tables, the equivalent kg/m3 (kilograms per cubic
Caterpillar Specification for Distillate Fuel for Nonroad
meter) using the ASTM D287 test method temperature of
Diesel Engines 15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/
m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
Specifications Requirements ASTM ISO Test (3) Certain Cat fuel systems and engine components can operate
Test on fuel with a maximum sulfur content of 3%. Contact your Cat
dealer for guidance about appropriate maintenance intervals
Copper Strip
No. 3 maximum D130 ISO 2160 and fluids for engines operating on fuel with sulfur levels be-
Corrosion tween 0.1% and 3%.
(4) Follow the test conditions and procedures for gasoline (motor).
10% at 282 °C
(540 °F)
maximum
Distillation D86 ISO 3405 Biodiesel
90% at 360 °C
(680 °F) A biodiesel blend of up to 20 percent may be used in
maximum the engine when the fuel blend meets the
recommendations in table 9 and meets the
Flash Point legal limit D93 ISO 2719 recommendations in Special Publication, SEBU6251,
Minimum of 80%
“Biodiesel”. A blend of greater than 20 percent
reflectance after biodiesel may be acceptable in some cases. See
Thermal Stability aging for 180 mi- D6468
No equiva- your Cat dealer for more information.
lent test
nutes at 150 °C
(302 °F) Note: A complete Cat S·O·S Services oil analysis
program is recommended strongly when using
30 minimum No equiva- biodiesel blends above 5 percent.
API Gravity (2) D287
45 maximum lent test Table 9
6 °C (10 °F) mini- Biodiesel Blends for Cat Commercial Diesel Engines
Pour Point mum below ambi- D97 ISO 3016
Distillate diesel fuel
ent temperature Biodiesel blend stock Final blend
used for blend
D5453 ISO 20846 Caterpillar distillate
Sulfur (3) or or Caterpillar biodiesel B20: ASTM D7467
diesel fuel specifica-
D2622 ISO 20884 specification, ASTM and API gravity 30-
tion, ASTM D975 or
D6751 or EN14214 45
1.4 cSt minimum EN590
and 20.0 cSt maxi-
mum as delivered
to the fuel injection Cooling System
pumps
Kinematic Viscosity - -
1.4 cSt minimum
and 4.5 cSt maxi-
mum as delivered The cooling system operates under pressure
to the rotary fuel which is controlled by the pressure cap. Remov-
injection pumps
ing the cap while the system is hot may allow the
Water and D1796 or escape of hot coolant and steam, causing serious
0.05% maximum ISO 3734
Sediment D2709 burns.
No equiva- Before you remove the pressure cap, allow the
Water 0.05% maximum D6304
lent test system to cool. Use a thick cloth and turn the
0.05% maximum pressure cap slowly to the first stop to allow pres-
Sediment
(weight)
D473 ISO 3735 sure to escape before fully removing the cap.
Gums and Resins 10 mg per 100 mL Avoid contact with coolant.

(4) D381 ISO 6246
maximum
(1) Alternatively, to ensure a minimum cetane number of 35 (PC en-
gines), and 40 (DI engines), distillate diesel fuel should have a NOTICE
minimum cetane index of 37.5 (PC engines), and 44.2 (DI en- Never add coolant to an overheated engine. Engine
gines) when the ASTM D4737-96a test method is used. A fuel damage could result. Allow the engine to cool first.
with a higher cetane number may be required for operation at a
higher altitude or in cold weather.
(continued)
52 SEBU9100
Refill Capacities
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 temper-
ature or drained completely in order to prevent dam-
age caused by freezing coolant.
Never operate an engine without water temperature

regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system
problems can develop without water temperature
regulators. Removing the regulators allows some
coolant to bypass the radiator, potentially causing
overheating.
SEBU9100 53
Refill Capacities
Coolant Recommendations
Table 10
Coolant Recommendations for use in Cat Diesel Engines
Service Required
Recommendations Product
Hours(1) (2) (3) Maintenance
Add Cat ELC Extend-

12000 hours er at 6000 service
Cat ELC (Cat Extended Life Coolant)
or 6 years hours or one half of
service life
Preferred
Add Cat ELC Extend-
12000 hours er at 6000 service
Cat ELI (Cat Extended Life Inhibitor)
or 6 years hours or one half of
service life
Cat EC-1 specification and ASTM D6210 and
Organic Additive Technology (OAT) based on a combination of a mono-
Add Extender at 3000
carboxylic acid and a dicarboxylic acid 6000 hours
Min requirements service hours or one
Phosphate, borate, and silicate free or 6 years
half of service life
Tolyltriazole: minimum typical concentration of 900 ppm (mg/kg)
Nitrite: minimum typical concentration of 500 ppm (mg/kg) in new coolants
SCA (Supplemental
3000 hours
Acceptable Cat DEAC (Cat Diesel Engine Antifreeze/Coolant) coolant additive) at
or 3 years
maintenance intervals
ASTM D6210 and
Min requirements for fully for- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US gal)
3000 hours SCA at maintenance
mulated Heavy Duty Com- and maximum of 2400 ppm (140 grains/US gal)
or 2 years intervals
mercial coolants Silicon concentration: minimum of 100 ppm (mg/kg) and maximum of 275
ppm (mg/kg)
ASTM D4985 and(1)

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US gal) SCA at initial fill and
3000 hours
mercial coolants requiring and maximum of 2400 ppm (140 grains/US gal) SCA at maintenance
or 1 year
SCA precharge Silicon concentration: minimum of 100 ppm (mg/kg) and maximum of 275 intervals
ppm (mg/kg)
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets Re-
agent 4 ASTM D1193 requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.
Table 11
Special Requirements for Cat C7 through C32Separate 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)
(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.
54 SEBU9100
Refill Capacities
The following properties of the coolant are tested:

NOTICE
Use Only Approved SCAs and Extenders • Glycol concentration for freeze protection and boil
protection
Conventional coolants require the maintenance addi-
tion of SCA throughout the expected life of the cool- • Ability to protect from erosion and corrosion
ants. Do NOT use an SCA with a coolant unless
approved specifically by the coolant supplier. The
• pH
coolant manufacturer is responsible for ensuring com-
patibility and acceptable performance. • Conductivity
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- • Visual analysis
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been • Odor analysis
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en- The results are reported, and appropriate
suring compatibility and acceptable performance. recommendations are made.
Failure to follow these recommendations can result in S·O·S Services Coolant Analysis (Level
shortened cooling system component life.
2)
Cat ELC can be recycled into conventional coolants. A coolant analysis (Level 2) is a comprehensive
chemical evaluation of the coolant. This analysis is
S·O·S Services Coolant Analysis also a check of the overall condition of the cooling
system.
Testing the engine coolant is important to ensure that The S·O·S coolant analysis (Level 2) has the
the engine is protected from internal cavitation and following features:
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and • Full coolant analysis (Level 1)
freezing. S·O·S coolant analysis can be done at your
Cat dealer. Cat S·O·S coolant analysis is the best • Identification of metal corrosion and of
way to monitor the condition of your coolant and your contaminants
cooling system. S·O·S coolant analysis is a program
that is based on periodic samples. • Identification of buildup of the impurities that cause
Table 12 corrosion
Recommended Interval • Identification of buildup of the impurities that cause
scaling
Type of Level 1 Level 2
Coolant • Determination of the possibility of electrolysis
within the cooling system of the engine
Cat DEAC
Conventional Heavy- Every 250 hours Yearly(1) The results are reported, and appropriate
Duty Coolants recommendations are made.
Cat ELC
For more information on S·O·S coolant analysis,
Cat ELI
Optional Yearly(1) consult your Cat dealer.
Commercial EC-1
Coolants
(1)
Greases
The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified. If it is necessary to choose a single grease, always
choose a grease that meets or exceeds the
Note: Check the SCA (Supplemental Coolant requirements of the most demanding application.
Additive) of the conventional coolant at every oil Remember that the products which barely meet the
change or at every 250 hours. Perform this check at minimum performance requirements can be expected
the interval that occurs first. to barely produce the minimum lives of your parts.
False economy is being used if a grease is purchased
with the lowest cost as the only consideration.
S·O·S Services Coolant Analysis (Level Instead, use the grease that yields the lowest total
1) operating cost. The cost should be based on an
analysis that includes the costs of parts, labor,
A coolant analysis (Level 1) is a test of the properties downtime, and the cost of the amount of grease that
of the coolant. is required.
SEBU9100 55
Maintenance Recommendations
System Pressure Release
Maintenance Do not loosen the high pressure fuel lines in order to

remove air pressure from the fuel system.
Recommendations
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
off the engine.
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050 i05264113
Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Cat dealer regarding welding on a chas-
To relieve the pressure from the coolant system, turn sis frame or rail.
off the engine. Allow the cooling system pressure cap
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure. Proper welding procedures are necessary in order to
avoid damage to the engine ECM, sensors, and
Fuel System associated components. When possible, remove the
component from the unit and then weld the
To relieve the pressure from the fuel system, turn off component. If removal of the component is not
the engine. possible, the following procedure must be followed
when you weld on a unit that is equipped with a Cat
Electronic Engine. The following procedure is
High Pressure Fuel Lines (If Equipped) considered to be the safest procedure to weld on a
component. This procedure should provide a
minimum risk of damage to electronic components.
Contact with high pressure fuel may cause fluid NOTICE

penetration and burn hazards. High pressure fuel Do not ground the welder to electrical components
spray may cause a fire hazard. Failure to follow such as the ECM or sensors. Improper grounding can
these inspection, maintenance and service in- cause damage to the drive train, the bearings, hy-
structions may cause personal injury or death. draulic components, electrical components, and other
components.
The high pressure fuel lines are the fuel lines that are Do not ground the welder across the centerline of the
between the high pressure fuel pump and the high package. Improper grounding could cause damage to
pressure fuel manifold and the fuel lines that are the bearings, the crankshaft, the rotor shaft, and other
between the fuel manifold and cylinder head. These components.
fuel lines are different from fuel lines on other fuel
systems. Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
This is because of the following differences: as possible to the weld. This will help reduce the pos-
sibility of damage.
• The high pressure fuel lines are constantly
charged with high pressure.
Note: Perform the welding in areas that are free from
• The internal pressures of the high pressure fuel explosive hazards.
lines are higher than other types of fuel system.
1. Stop the engine. Turn the switched power to the
Before any service or repair is performed on the OFF position.
engine fuel lines, perform the following tasks:
2. Disconnect the negative battery cable from the
1. Stop the engine. battery. If a battery disconnect switch is provided,
open the switch.
2. Wait for ten minutes.
56 SEBU9100
Welding on Engines with Electronic Controls
Note: If electrical/electronic components are used as

3. Disconnect the J1/P1 and J2/P2 connectors from a ground for the welder, or electrical/electronic
the ECM. Move the harness to a position that will components are located between the welder ground
not allow the harness to move back accidentally, and the weld, current flow from the welder could
and contact any of the ECM pins. severely damage the component.
5. Protect the wiring harness from welding debris and

spatter.
6. Use standard welding practices to weld the

materials.
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
4. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.
SEBU9100 57
Maintenance Interval Schedule
i05392076 “Engine Oil Level - Check”.......................................74
Maintenance Interval Schedule “Fuel System Primary Filter/Water Separator -

Drain” .......................................................................83
SMCS Code: 1000; 4450; 7500
“Walk-Around Inspection” ..................................... 103
Ensure that all safety information, warnings, and
instructions are read and understood before any Every 50 Service Hours or Weekly
operation or any maintenance procedures are
performed. The user is responsible for the “Aftercooler Condensate Drain Valve - Inspect/
performance of all maintenance including the Clean” ......................................................................58
following procedures: all adjustments, the use of
proper lubricants, fluids, filters and the installation of “Engine Cooling System Corrosion Protection System
new components due to normal wear and aging . The - Inspect”..................................................................72
performance of this product may be diminished if
proper maintenance intervals and procedures are not “Sea Water Strainer - Clean/Inspect” ................... 101
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures Every 250 Service Hours
are not followed.
“Belts - Inspect/Adjust/Replace”..............................62
Note: Use whichever of the following that occurs first
in order to determine the maintenance intervals: fuel “Coolant Sample (Level 1) - Obtain”........................67
consumption, service hours and calendar time . “Cooling System Supplemental Coolant Additive
Before each consecutive interval is performed, all (SCA) - Test/Add”.....................................................69
maintenance from the previous intervals must be
performed. “Engine Oil Sample - Obtain”...................................75
Products that operate in severe operating conditions “Fuel Tank Water and Sediment - Drain” .................88
may require more frequent maintenance.
“Hoses and Clamps - Inspect/Replace”...................91
When Required
Every 250 Service Hours or 1 Year
“Aftercooler Core - Clean/Test”................................59
“Battery Electrolyte Level - Check” ..........................61
“Aftercooler Core - Inspect” .....................................60
“Battery - Replace”...................................................60
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
“Battery or Battery Cable - Disconnect”...................61
Systems)
“Coolant - Change” ..................................................63
“Coolant Sample (Level 2) - Obtain”........................68
“Coolant Extender (ELC) - Add” ..............................65
“Engine Valve Lash - Check” ...................................81
“Engine - Clean”.......................................................71
“Engine Valve Rotators - Inspect”............................81
“Engine Oil Level Gauge - Calibrate”.......................75
“Fuel Injector - Check” .............................................81
“Engine Oil and Filter - Change”..............................76
Every 500 Service Hours
“Engine Storage Procedure - Check” ......................80
“Engine Crankcase Breather - Clean” .....................73
“Fuel System - Prime”..............................................82
“Fuel System Primary Filter (Water Separator)
“Heat Exchanger - Clean/Test” ................................89 Element - Replace”..................................................83
“Heat Exchanger - Inspect”......................................90 “Fuel System Secondary Filter - Replace” ..............84
“Maintenance Recommendations” ..........................93 Initial 1000 Service Hours
“Sea Water Strainer - Clean/Inspect” ................... 101 “Aftercooler Core - Inspect” .....................................60
Daily “Heat Exchanger - Inspect”......................................90
“Coolant Level - Check”...........................................66
“Engine Air Cleaner Service Indicator - Inspect” .....72
58 SEBU9100
Aftercooler Condensate Drain Valve - Inspect/Clean
Every 1000 Service Hours “Overhaul (Top End)” ............................................100
“Engine Air Cleaner Element (Single Element) -

i05215845
Inspect/Replace”......................................................71
“Turbocharger - Inspect” ....................................... 102 Aftercooler Condensate Drain
Every 2000 Service Hours Valve - Inspect/Clean
SMCS Code: 1063-042-DN
“Fumes Disposal Filter Element - Replace”.............88
Every Year
“Coolant Sample (Level 2) - Obtain”........................68
Every 3000 Service Hours

“Auxiliary Water Pump (Bronze Impeller) - Inspect/
Replace” ..................................................................60
“Bolts (Fuel Filter Base) - Inspect/Replace” ............63
“Coolant Temperature Regulator - Replace” ...........68
“Crankshaft Vibration Damper - Inspect”.................70
“Engine Mounts - Inspect” .......................................74
“Engine Speed/Timing Sensor - Clean/Inspect”......80 Aftercooler condensate drain valves
(1) Drain valves
“Engine Valve Lash - Check” ...................................81 (2) Valve seats
(3) Plungers
“Engine Valve Rotators - Inspect”............................81
The engine boost pressure forces the plunger to
“Fuel Injector - Check” .............................................81 move down to the valve seat. The plunger must close
against the seat at a pressure of 27.5 kPa (4 psi).
“Starting Motor - Inspect” ...................................... 101 When the engine stops, the absence of boost
pressure allows the plunger to rise to the open
Every 5000 Service Hours position, allowing condensation from the aftercooler
to drain.
“Water Pump - Inspect”......................................... 104
The plunger must be able to move freely in order to
Every 170 400 L (45 000 US gal) of close the system when the engine is running. The
plunger must be able to move freely in order to allow
Fuel or 3000 Service Hours condensation to drain from the aftercooler when the
engine is stopped. Residue from normal engine
“Auxiliary Water Pump (Bronze Impeller) - Inspect/ operation could cause the plunger to stick.
Replace” ..................................................................60
Overhaul NOTICE
Care must be taken to ensure that fluids are con-
“Aftercooler Core - Clean/Test”................................59 tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
“Heat Exchanger - Clean/Test” ................................89 Be prepared to collect the fluid with suitable contain-
“Maintenance Recommendations” ..........................93
bling any component containing fluids.
“Overhaul (Major)” ...................................................97
Refer to Special Publication, NENG2500, “Cat Dealer
Overhaul (Top End) Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
“Aftercooler Core - Inspect” .....................................60 for tools and supplies suitable to collect and contain
“Heat Exchanger - Inspect”......................................90
Dispose of all fluids according to local regulations and
“Maintenance Recommendations” ..........................93 mandates.
“Oil Cooler Core - Check/Clean/Test”......................97

SEBU9100 59
Aftercooler Core - Clean/Test
1. Remove the valve from the adapter. Check the 3. Steam clean the core in order to remove any
valve in order to determine if the plunger moves residue. Flush the fins of the aftercooler core.
freely. If the plunger does not move easily, clean Remove any other trapped debris from the inside
the valve with solvent. and from the outside of the core.
2. Reassemble the aftercooler condensate drain Note: Do not use high pressure when the fins are
valve. Refer to the Specifications Manual, cleaned. High pressure can damage the fins.
SENR3130, Torque Specifications for more
information on the proper torques. 4. Wash the core with hot, soapy water.
5. Flush the core thoroughly in order to remove

i04363377
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
Aftercooler Core - Clean/Test core is clear and free of debris.
SMCS Code: 1064-070; 1064-081
Note: An aftercooler that circulates fresh water or

treated water may require cleaning less often than an
aftercooler which circulates salt water. The Personal injury can result from air pressure.
maintenance interval for an aftercooler which
circulates fresh water or treated water should be Personal injury can result without following prop-
evaluated when the aftercooler is cleaned and tested er procedure. When using pressure air, wear a
after the first 1000 hours of engine operation. The protective face shield and protective clothing.
interval will vary depending on operating conditions. The maximum air pressure for cleaning purposes
Clean the Aftercooler Core nozzle is deadheaded.
Remove the core. Refer to the Disassembly and
Assembly Manual, “Aftercooler - Remove” for the 6. Dry the core with compressed air. Direct the air in
procedure. the reverse direction of the normal flow.
1. Turn the aftercooler core on one side in order to Test the Aftercooler Core
remove debris. Remove the debris that is
1. Inspect the core for trapped debris and cleanliness.
accessible.
If necessary, remove the debris and repeat the
cleaning procedure.
NOTICE
Do not use a high concentration of caustic cleaner to 2. Inspect the core for damage and perform a
clean the core. A high concentration of caustic pressure test in order to detect leaks. Many shops
cleaner can attack the internal metals of the core and that service radiators are equipped to perform
cause leakage. Only use the recommended concen- pressure tests.
tration of cleaner.
3. Plug both ends of the aftercooler core and
pressurize the core to 205 kPa (30 psi). Submerge
2. Back flush the core with cleaner.
the core in water. Look for bubbles which are being
Caterpillar recommends the use of Hydrosolv emitted from the core. The bubbles are evidence of
liquid cleaner. Table 13 lists Hydrosolv liquid leaks.
cleaners that are available from your Cat dealer.
Table 13 4. If any leaks are found, do not attempt to repair the
core.
Hydrosolv Liquid Cleaners(1)
Part Number Description

Install a core that is clean and a core that passes the
Size
pressure test in step 3. Refer to the Disassembly and
1U-5490 Hydrosolv 4165 19 L (5 US gallon) Assembly Manual, “Aftercooler - Install” for the
procedure.
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner at temper-
For more information on cleaning the core, consult
atures up to 93°C (200°F). Consult your Cat dealer for more your Cat dealer.
information.
60 SEBU9100
Aftercooler Core - Inspect
i05194761 Refer to Disassembly and Assembly, “Auxiliary Water

Pump - Remove” in order to remove the auxiliary
Aftercooler Core - Inspect water pump. Refer to Disassembly and Assembly,
“Auxiliary Water Pump - Disassemble” in order to
SMCS Code: 1064-040 disassemble the auxiliary water pump.
The interval for the maintenance of the aftercooler Inspect the following components for wear or
depends on the operating environment of the vessel damage:
and on the operating time. The sea water that is
circulated through the aftercooler and the amount of • Bearings
operating time of the vessel affects the following
items: • Impeller
• Cleanliness of the tubes of the aftercooler • Seals
• Effectiveness of the aftercooler • Wear plate
Operating in water that contains silt, sediment, salt, If wear or damage is found, replace the components
algae, and so on, will adversely affect the aftercooler which are worn or damaged. Use the proper repair kit
system. In addition, intermittent use of the vessel will for the pump.
adversely affect the aftercooler.
Refer to Disassembly and Assembly, “Auxiliary Water
The following items indicate that the aftercooler may Pump - Assemble” in order to assemble the auxiliary
require cleaning: water pump. Refer to Disassembly and Assembly,
“Auxiliary Water Pump - Install” in order to install the
• Increased coolant temperature auxiliary water pump.
• Engine overheating
i02153996
• Excessive pressure drop between the water inlet
and the water outlet Battery - Replace
An operator that is familiar with the normal operating SMCS Code: 1401-510
temperature of the coolant can determine when the
coolant temperature is out of the normal range.
Inspection and maintenance of the aftercooler are
required if the engine is overheating.
Batteries give off combustible gases which can
Your Cat dealer has the equipment and the trained explode. A spark can cause the combustible
personnel that are needed in order to measure the gases to ignite. This can result in severe personal
pressure drop across the aftercooler. injury or death.
Refer to the Operation and Maintenance Manual, Ensure proper ventilation for batteries that are in
“Aftercooler Core - Clean/Test”. For more information an enclosure. Follow the proper procedures in or-
on servicing the aftercooler, consult your Cat dealer. der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
i03091745
Auxiliary Water Pump (Bronze

Impeller) - Inspect/Replace
The battery cables or the batteries should not be
SMCS Code: 1371-510
removed with the battery cover in place. The bat-
Impellers and seals require periodic inspection. tery cover should be removed before any servic-
Impellers have a service life that is limited. The ing is attempted.
service life depends on the engine operating
conditions. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
Inspect the components more frequently when the resulting in personal injury.
pump is exposed to debris, sand, or other abrasive
materials. Inspect the components if the pump is
operating at a differential pressure of more than 1. Turn the key start switch to the OFF position.
103 kPa (15 psi). Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the

charger.
SEBU9100 61
Battery Electrolyte Level - Check
Clean the battery case with one of the following

3. The NEGATIVE “-” cable connects the NEGATIVE cleaning solutions:
“-” battery terminal to the ground plane.
Disconnect the cable from the NEGATIVE “-” • A mixture of 0.1 kg (0.2 lb) of baking soda and
battery terminal. 1 L (1 qt) of clean water
4. The POSITIVE “+” cable connects the POSITIVE • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
“+” battery terminal to the starting motor. (1 qt) of clean water
Disconnect the cable from the POSITIVE “+” Thoroughly rinse the battery case with clean water.
battery terminal.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
Note: Always recycle a battery. Never discard a until the surfaces are bright or shiny. DO NOT
battery. Return used batteries to an appropriate remove material excessively. Excessive removal of
recycling facility. material can cause the clamps to not fit properly.
5. Remove the used battery. Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
6. Install the new battery.
i01492654
Note: Before the cables are connected, ensure that

the key start switch is OFF. Battery or Battery Cable -
7. Connect the cable from the starting motor to the Disconnect
POSITIVE “+” battery terminal.
SMCS Code: 1401; 1402-029
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
i02601752
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
Battery Electrolyte Level - tery cover should be removed before any servic-
ing is attempted.
Check
Removing the battery cables or the batteries with
SMCS Code: 1401-535-FLV the cover in place may cause a battery explosion
resulting in personal injury.
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order 1. Turn the start switch to the OFF position. Turn the
to help prevent the battery from freezing. ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the

All lead-acid batteries contain sulfuric acid which battery that goes to the start switch. Ensure that
can burn the skin and clothing. Always wear a the cable cannot contact the terminal. When four
face shield and protective clothing when working 12 volt batteries are involved, the negative side of
on or near batteries. two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
1. Remove the filler caps. Maintain the electrolyte starting.
level to the “FULL” mark on the battery.
4. Proceed with necessary system repairs. Reverse
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean the steps in order to reconnect all of the cables.
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.

62 SEBU9100
Belts - Inspect/Adjust/Replace
i05224104 Adjust
Belts - Inspect/Adjust/Replace The belt tension does not require adjustment.
SMCS Code: 1357-025; 1357-040; 1357-510 Replace

1. Remove the front cover.
2. Insert a ratchet with a square drive into the square
hole that is located in the tensioner for the fan drive
belt. Rotate the tensioner clockwise in order to
relieve tension on the fan drive belt. Remove the
fan drive belt.
3. Then insert a ratchet with a square drive into the
square hole that is located in the tensioner for the
alternator belt.
4. Rotate the tensioner counterclockwise in order to
relieve tension on the alternator belt. Remove the
alternator belt.
5. Install the new belt correctly, as shown. Be sure
that the belt is fully seated on the pulleys. The
correct tension will automatically be applied when
the ratchet is removed.
6. Replace the front cover.
(1) Belt tensioner
(2) Square drive used for belt replacement
Inspect
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry
more load because the older belt is stretched. The
additional load on the new belt could cause the new
belt to break.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
If the belts are too tight, unnecessary stresses are
placed on the pulley bearings and on the belts. These
stresses may shorten the service life of the
components.
Remove the belt guard, if equipped. Inspect the
condition and adjustment of the alternator belts and
accessory drive belts (if equipped).
If the belt does not require replacement, install the
belt guard. If the belt requires adjustment or
replacement, follow the procedure below.
SEBU9100 63
Bolts (Fuel Filter Base) - Inspect/Replace
i05238809 i04538352
Bolts (Fuel Filter Base) - Coolant - Change

Inspect/Replace SMCS Code: 1350-044; 1352; 1395-044; 1395
SMCS Code: 1262-040-BC; 1262-510-BC; 7553- Refer to this Operation and Maintenance Manual,
040; 7553-510 “Fluid Recommendations” for the correct intervals for
changing the coolant.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
Drain the Cooling System
Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
NOTICE
Mounting bolts for the secondary fuel filter base nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Three bolts are used to mount the base for the ers before opening any compartment or disassem-
secondary fuel filter to the mounting bracket. Inspect
the bolts for the following conditions: bling any component containing fluids.
• Wear
Service Tool Catalog” or refer to Special Publication,
• Corrosion PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
• Cracking fluids on Cat products.
• Sagging
mandates.
• Crushing
1. Stop the engine and allow the engine to cool.
Replace any damaged bolts. Refer to Disassembly
and Assembly, UENR3257, “Fuel Filter Base - Ensure that the engine will not start when the
Remove and Install” for the procedure. cooling system is drained.
2. Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling
system filler cap.
64 SEBU9100
Coolant - Change
3. Open the cooling system drain valve (if equipped). 5. Stop the engine and allow the engine to cool.
If the cooling system is not equipped with a drain Loosen the cooling system filler cap slowly in order
valve, remove one of the drain plugs. to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
Note: If equipped, be sure to drain the heater and any equipped) or remove the cooling system drain
related supply and return lines.
plugs. Allow the water to drain. Flush the cooling
Allow the coolant to drain. system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
NOTICE plugs. Refer to the Specifications Manual,
Dispose of used engine coolant properly or recycle. SENR3130, Torque Specifications for more
Various methods have been proposed to reclaim used information on the proper torques.
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable Systems Filled with Cat DEAC ,
by Caterpillar to reclaim the used coolant.
Conventional Coolant which does not
For information regarding the disposal and the Meet the Cat EC-1 Requirements, or
recycling of used coolant, consult your Cat dealer or Supplemental Coolant Additive (SCA)
consult Cat Dealer Service Tool Group :
and Water
Inside USA 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL 3. Flush the cooling system with clean water in order
Canada 1-800-523-TOOL to remove any debris.
International 1-309-578-7372
4. Close the drain valve (if equipped). Clean the drain
Flush plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, Torque
Systems Filled with Cat ELC, Cat ELI, or a Specifications for more information on the proper
Conventional Coolant that Meets the Cat torques.
EC-1 Requirements and the Standards of
ASTM D6210 NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Flush the cooling system with clean water in order
to remove any debris.
5. Fill the cooling system with a mixture of clean water
2. Close the drain valve (if equipped). Clean the drain and Cat Fast Acting Cooling System Cleaner.
plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, Torque 6. Choose 1 of the following options.
Specifications for more information on the proper
torques. • Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity.
NOTICE • For cooling systems with heavy deposits or

Fill the cooling system no faster than 19 L (5 US gal) plugging, add 0.5 L (1 pint) of cleaner per
per minute to avoid air locks. 3.8 to 7.6 L (1 to 2 US gal) of the cooling
system capacity.
3. Fill the cooling system with clean water. Install the 7. Install the cooling system filler cap.
cooling system filler cap.
8. Start and run the engine at low idle for a minimum
4. Start and run the engine at low idle until the of 30 minutes. For cooling systems with heavy
temperature reaches 49 to 66 °C (120 to 150 °F). deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at
least 82 °C (180 °F).
SEBU9100 65
Coolant Extender (ELC) - Add
4. Clean the cooling system filler cap. Inspect the

NOTICE
gasket that is on the cooling system filler cap. Only
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal install the used filler cap if the gasket is not
components. damaged. Use a 9S-8140 Pressurizing Pump to
pressure test a reinstalled cooling system filler cap.
To avoid damage to the cooling system, make sure to The correct pressure for the cooling system filler
completely flush the cooling system with clear water. cap is stamped on the face of the cooling system
Continue to flush the system until all signs of the
cleaning agent are gone. filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling
system filler cap.
9. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in order 5. Start the engine. Inspect the cooling system for
to relieve any pressure. Remove the cooling leaks and for proper operating temperature.
system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain i04862631
plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to Coolant Extender (ELC) - Add
flush the heater and any related supply and return
SMCS Code: 1352-544-NL
lines. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the Note: Refer to this Operation and Maintenance
Specifications Manual, SENR3130, Torque Manual, “Fluid Recommendations” (Cooling System)
Specifications for more information on the proper for the maintenance interval for the addition of the
torques. coolant extender.
Fill the Cooling System Cat ELC (Extended Life Coolant) and Cat ELI
(Extended Life Inhibitor) do not require the frequent
additions of any supplemental cooling additives. The
Cat ELC Extender will only be added one time.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Note: Do not use conventional supplemental coolant
per minute to avoid air locks. additive (SCA) with Cat ELC or with Cat ELI.
Check the cooling system only when the engine is
1. Fill the cooling system. Refer to this Operation and stopped and cool.
Maintenance Manual, “Fluid Recommendations”
for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for Personal injury can result from hot coolant, steam
information about the capacity of the cooling and alkali.
system. Do not install the cooling system filler cap.
At operating temperature, engine coolant is hot
2. Start and run the engine at low idle. Increase the and under pressure. The radiator and all lines to
engine rpm to high idle. Run the engine at high idle heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
for 1 minute in order to purge the air from the
cavities of the engine block. Stop the engine. Remove cooling system pressure cap slowly to
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
within 13 mm (0.5 inch) below the bottom of the touch with your bare hand.
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.
66 SEBU9100
Coolant Level - Check
NOTICE
mandates.
(1) Filler cap
1. Loosen the cooling system filler cap slowly in order (2) “COLD FULL” mark
(3) “LOW ADD” mark
to relieve pressure. Remove the cooling system
filler cap.
1. Observe the coolant level in the coolant recovery
2. If necessary, drain enough coolant from the cooling tank. Maintain the coolant level to “COLD FULL”
system in order to add the Cat ELC Extender . mark (2) on the coolant recovery tank.
3. Add Cat ELC Extender according to the 2. Loosen filler cap (1) slowly in order to relieve any
requirements for the cooling system capacity. pressure. Remove the filler cap.
Refer to this Operation and Maintenance Manual,
3. Pour the proper coolant mixture into the tank. Refer
“Refill Capacities” for the coolant capacity.
to this Operation and Maintenance Manual, “Refill
4. Clean the cooling system filler cap. Inspect the Capacities” for information about coolants. Do not
gaskets on the cooling system filler cap. Replace fill the coolant recovery tank above “COLD FULL”
the cooling system filler cap if the gaskets are mark (2).
damaged. Install the cooling system filler cap.
4. Clean filler cap (1) and the receptacle. Reinstall the
For further information, refer to this Operation and filler cap and inspect the cooling system for leaks.
Maintenance Manual, , Fluid Recommendations.
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
i04550124
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
Coolant Level - Check and cool, the coolant will return to the engine.
SMCS Code: 1395-082
Engines That Are Not Equipped
Check the coolant level when the engine is stopped
and cool. with a Coolant Recovery Tank
Engines That Are Equipped with a
Coolant Recovery Tank
pressure.
1. Remove the cooling system filler cap slowly in

order to relieve pressure.
SEBU9100 67
Coolant Sample (Level 1) - Obtain
2. Maintain the coolant level within 13 mm (0.5 inch) For additional information about coolant analysis and
of the bottom of the filler pipe. If the engine is about other coolants, see this Operation and
equipped with a sight glass, maintain the coolant Maintenance Manual, “Fluid Recommendations” or
consult your Cat dealer.
level to the proper level in the sight glass.
Sampling Conditions
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.
If the engine is not equipped with a sampling port, the
coolant should be warm.
Use the following guidelines for proper sampling of
the coolant:
• Complete the information on the label for the

sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic

Illustration 38 g00103639 bags.
Typical filler cap gaskets
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
3. Clean the cooling system filler cap and inspect the from any other location.
condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are • Keep the lids on empty sampling bottles until you
damaged. Reinstall the cooling system filler cap. are ready to collect the sample.
4. Inspect the cooling system for leaks. • Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
i04333559
• Never collect samples from expansion bottles.

Coolant Sample (Level 1) -
• Never collect samples from the drain for a system.
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Timing of the Sampling
Testing the engine coolant is important to ensure that Table 14
the engine is protected from internal cavitation and
corrosion. The analysis also tests the ability of the Recommended Interval
coolant to protect the engine from boiling and
freezing. S·O·S Systems Coolant Analysis can be
Type of Level 1 Level 2
done at your Cat dealer. Cat S·O·S coolant analysis Coolant
is the best way to monitor the condition of your Cat DEAC
coolant and your cooling system. S·O·S coolant Cat SCA
analysis is a program that is based on periodic Conventional Heavy-
Every 250 hours Yearly(1)
samples. Duty Coolants
Note: Obtaining a Coolant Sample (Level 1) is Cat ELC

optional if the cooling system is filled with one of Cat ELI
Optional(1) Yearly(1)
the following coolants: Cat ELC (Extended Life Commercial EC-1
Coolant)., Cat ELI (Extended Life Inhibitor) and Coolants
Conventional Heavy-Duty Coolant. (1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any of the following Note: Check the SCA (Supplemental Coolant
coolants: Cat DEAC, Cat SCA and Conventional Additive) of the conventional coolant at every oil
Heavy-Duty Coolants. change or at every 250 hours. Perform this check at
the interval that occurs first.
68 SEBU9100
Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible i04240223

to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish a
consistent trend of data. In order to establish a
Coolant Temperature
pertinent history of data, perform consistent Regulator - Replace
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your Cat SMCS Code: 1355-510
dealer.
Replace the water temperature regulator before the
water temperature regulator fails. Replacing the water
NOTICE temperature regulator reduces the chances for
Always use a designated pump for oil sampling, and unscheduled downtime.
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of samples A water temperature regulator that fails in a partially
may contaminate the samples that are being drawn. opened position can cause overheating or
This contaminate may cause a false analysis and an overcooling of the engine.
incorrect interpretation that could lead to concerns by
A water temperature regulator that fails in the open
both dealers and customers. position will cause the engine operating temperature
to be too low during partial load operation. Low
Submit the sample for Level 1 analysis. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
Note: Level 1 results may indicate a need for Level 2 cylinders. This excessive carbon buildup could result
Analysis. in an accelerated wear of the piston rings and wear of
the cylinder liner.
i04638756 A water temperature regulator that fails in the closed

position can cause excessive overheating. Excessive
Coolant Sample (Level 2) - overheating could result in cracking of the cylinder
head or piston seizure problems.
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 NOTICE
Failure to replace your water temperature regulator
An S·O·S Coolant Analysis (Level 2) is a on a regularly scheduled basis could cause severe
comprehensive chemical evaluation of the coolant. engine damage.
This analysis is also a check of the overall condition
of the cooling system. The S·O·S Coolant Analysis Caterpillar engines incorporate a shunt design cool-
(Level 2) has the following features: ing system and require operating the engine with a
water temperature regulator installed.
• Full coolant analysis (Level 1)
If the water temperature regulator is installed incor-
• Identification of metal corrosion and contaminants rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera-
• Identification of buildup of the impurities that cause ture regulator is installed in the original position. En-
corrosion and scaling sure that the water temperature regulator vent hole is
open.
• Determination of the possibility of electrolysis Do not use liquid gasket material on the gasket or cyl-
within the cooling system of the engine inder head surface.
The results are reported and appropriate
recommendations are made.
Obtaining the Sample

Refer to Operation and Maintenance Manual,
“Coolant Sample (Level 1) - Obtain” for the guidelines
for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For further information, refer to this Operation and
Maintenance Manual, “Fluid Recommendations”.
SEBU9100 69
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
NOTICE NOTICE
Care must be taken to ensure that fluids are con- Excessive supplemental coolant additive concentra-
tained during performance of inspection, mainte- tion can form deposits on the higher temperature sur-
nance, testing, adjusting, and repair of the product. faces of the cooling system, reducing the engine's
Be prepared to collect the fluid with suitable contain- heat transfer characteristics. Reduced heat transfer
ers before opening any compartment or disassem- could cause cracking of the cylinder head and other
bling any component containing fluids. high temperature components.
Refer to Special Publication, NENG2500, “Cat Dealer Excessive supplemental coolant additive concentra-
Service Tool Catalog” or refer to Special Publication, tion could also result in blockage of the heat exchang-
PECJ0003, “Cat Shop Supplies and Tools Catalog” er, overheating, and/or accelerated wear of the water
for tools and supplies suitable to collect and contain pump seal.
Do not exceed the recommended amount of supple-
Dispose of all fluids according to local regulations and mental coolant additive concentration.
mandates.
NOTICE
Note: If replacing only the water temperature Care must be taken to ensure that fluids are con-
regulator, only drain the coolant to a level that is tained during performance of inspection, mainte-
below the water temperature regulator housing. nance, testing, adjusting, and repair of the product.
Refer to two articles in the Disassembly and Be prepared to collect the fluid with suitable contain-
Assembly Manual, “Water Temperature Regulator - ers before opening any compartment or disassem-
Remove and Water Temperature Regulator - Install” bling any component containing fluids.
for the replacement procedure or consult your Cat
dealer. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” and to Special Publica-
tion, GECJ0003, “Cat Shop Supplies and Tools” for
i05053052 tools and supplies suitable to collect and contain flu-
ids on Caterpillar products.
Cooling System Supplemental Dispose of all fluids according to applicable regula-
Coolant Additive (SCA) - Test/ tions and mandates.
Add
SMCS Code: 1352-045; 1395-081 Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1).
Note: This maintenance is NOT required for
cooling systems that are filled with Extended Life Cooling Systems that Use
Coolant. Conventional Coolant
Test the Concentration of the SCA
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact NOTICE
with the skin and eyes. Do not drink cooling sys- Do not exceed the recommended six percent supple-
tem coolant additive. mental coolant additive concentration.
Test the concentration of the SCA with the 4C-9301

Coolant Conditioner Test Kit.
70 SEBU9100
Crankshaft Vibration Damper - Inspect
Add the SCA, If Necessary

pressure.
1. Remove the cooling system filler cap slowly.
2. If necessary, drain some coolant in order to allow

space for the addition of the SCA.
3. Add the proper amount of SCA. For the proper

amount of SCA, refer to this Operation and
Maintenance Manual, “Refill Capacities and
Recommendations” or refer to this Operation and
Maintenance Manual, “Fluid Recommendations”. Illustration 39 g01134779
The proper concentration of SCA depends on the Viscous vibration damper

type of coolant that is used. For the proper Typical example
concentration of SCA, refer to Special Publication, (1) Crankshaft pulley
SEBU6251, Caterpillar Commercial Diesel Engine (2) Weight
(3) Case
Fluids Recommendations.
4. Clean the cooling system filler cap. Install the Inspection
cooling system filler cap.
Inspect the damper for the following conditions:
i03175962
• The damper is dented, cracked, or fluid is leaking
from the damper.
Crankshaft Vibration Damper -
Inspect • The paint on the damper is discolored from
excessive heat.
SMCS Code: 1205-040
• The damper is bent.
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase • The bolt holes are worn or there is a loose fit for
torsional vibrations. This can result in damage to the the bolts.
crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train • The engine has had a crankshaft failure due to
noise at variable points in the speed range. torsional forces.
The damper is mounted to the crankshaft which is Replace the damper if any of these conditions exist.
located behind the belt guard on the front of the
engine. Removal and Installation
“Belts - Inspect/Adjust/Replace” for information on
removing and on installing the belt. Refer to the
Disassembly and Assembly Manual, “Vibration
Damper and Pulley - Remove and Install” for
information on removing and installing the damper.
SEBU9100 71
Engine - Clean
i01646701 i05024170
Engine - Clean Engine Air Cleaner Element

SMCS Code: 1000-070 (Single Element) - Inspect/
Replace
SMCS Code: 1051; 1054-040; 1054-510
Personal injury or death can result from high
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.
Periodic cleaning of the engine is recommended. Typical air cleaner installation

Steam cleaning the engine will remove accumulated (1) Cover for the air cleaner cannister
oil and grease. A clean engine provides the following (2) Latches for the air cleaner
benefits: (3) Air cleaner cannister
• Easy detection of fluid leaks

NOTICE
• Maximum heat transfer characteristics Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
• Ease of maintenance cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets, or seals. Dirt entering the
Note: Caution must be used in order to prevent engine causes premature wear and damage to en-
electrical components from being damaged by gine components. Air cleaner elements help to pre-
excessive water when you clean the engine. Avoid vent airborne debris from entering the air inlet.
electrical components such as the alternator, the
starter, and the ECM.
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Cat dealer has the proper air cleaner
elements for your application. Consult your Cat
dealer for the correct air cleaner element.
NOTICE
Never service the air cleaner element with the engine
running. Operating the engine without an air cleaner
allows dirt to enter the engine.
Replacing the Air Cleaner Element

1. Open the four latches on the air cleaner.
2. Remove the used air cleaner. Properly dispose of

the air cleaner according to local standards. Wipe
the inside of the air cleaner canister to remove any
accumulated dirt and debris.
72 SEBU9100
Engine Air Cleaner Service Indicator - Inspect
3. Install a new air cleaner. • Check for ease of resetting. The service indicator
should reset in less than three pushes.
4. Close the four latches.
• Check the movement of the yellow core when the
5. Reset the service indicator. engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
i01900118 greatest vacuum that is attained.
Engine Air Cleaner Service If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
Indicator - Inspect the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
(If Equipped) indicator may be plugged.
SMCS Code: 7452-040 The service indicator may need to be replaced
Some engines may be equipped with a different frequently in environments that are severely dusty, if
service indicator. necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
Some engines are equipped with a differential gauge service indicator when the engine is overhauled, and
for inlet air pressure. The differential gauge for inlet whenever major engine components are replaced.
air pressure displays the difference in the pressure
that is measured before the air cleaner element and Note: When a new service indicator is installed,
the pressure that is measured after the air cleaner excessive force may crack the top of the service
element. As the air cleaner element becomes dirty, indicator. Tighten the service indicator to a torque of
the pressure differential rises. If your engine is 2 N·m (18 lb in).
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator. i05303334
The service indicator may be mounted on the air

cleaner housing or in a remote location.
Engine Cooling System
Corrosion Protection System -
Inspect
SMCS Code: 1388-040
Galvanic corrosion may harm components that cool
the engine. Corrosion is caused when dissimilar
metals are in contact and the dissimilar metals are
immersed in salt water. The voltage potential from
salt water to the engine must be tested on a regular
basis to protect the cooling components.
Typical service indicator
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
SEBU9100 73
Engine Crankcase Breather - Clean
Location of the Corrosion Testing the Voltage Potential

Protection Post Operate the engine for at least 30 minutes, then stop
the engine. Disconnect the engine from the shore
C18SCACMarine Engine power connection. Use a 257-9140 Multimeter and
a 244-1536 Cable Group to test the voltage
potential from the salt water to the engine. A silver-
silver chloride half cell probe is widely available if the
Cat tools are not available.
1. Connect a #8 American Wire Gauge (AWG) cable
from the sacrificial anode to the bonding system of
the vessel.
2. Test the voltage at the bonding stud.
3. Test the voltage at the bonding connector.
Results of the Test

The voltage potential must be between -0.500 mV
and -0.800 mV.
Note: A value near or greater than 0.0 mV is
extremely corrosive.
Measure the galvanic potential of the system and
apply zinc or other less noble metal to divert
corrosion. Contact your Cat dealer for more
information.
(1) Bonding connector
(2) Bonding stud i02263740
(3) Vessel zinc
Engine Crankcase Breather -
C32SCACMarine Engine Clean
SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a

regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
(4) Bonding connector
(5) Vessel zinc
(6) Bonding stud
74 SEBU9100
Engine Mounts - Inspect
i04948069
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Illustration 44 g01136454 (Y) “ADD” mark
Typical example (X) “FULL” mark
(1) Hose clamp
(2) Breather assembly
(3) Retaining clamp
NOTICE
(4) Seal Perform this maintenance with the engine stopped.
1. Loosen hose clamp (1) and remove the hose from 1. Maintain the oil level between the “ADD” mark (Y)
breather assembly (2). and the “FULL” mark (X) on the oil level gauge .
Do not fill the crankcase above the “FULL” mark
2. Loosen retaining clamp (3). Remove the breather (X).
assembly and seal (4).
3. Wash the breather element in solvent that is clean NOTICE

and nonflammable. Allow the breather element to Engine damage can occur if the crankcase is filled
dry before installation. above the “FULL” mark on the oil level gauge
(dipstick).
4. Install a breather element that is clean and dry.
Install the seal, the breather assembly, and the An overfull crankcase can cause the crankshaft to dip
clamp. Refer to the Specifications, SENR3130 in into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
order to locate the proper torques. bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
5. Install the hose. Install the hose clamp. Refer to the pressure, inadequate cooling, oil blowing out of the
Specifications, SENR3130 in order to locate the crankcase breathers and excessive oil consumption.
proper torques.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
i02456872
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of
Engine Mounts - Inspect carbon under the piston rings and wear of the cylinder
liner.
SMCS Code: 1152-040; 1152
If the oil level is above the “FULL” mark on the oil lev-
Inspect the engine mounts for deterioration and for el gauge, drain some of the oil immediately.
proper bolt torque. Engine vibration can be caused by
the following conditions:
2. Remove the oil filler cap and add oil, if necessary.
• Improper mounting of the engine For the correct oil to use, see this Operation and
Maintenance Manual, “Fluid Recommendations”
• Deterioration of the engine mounts
topic. Do not fill the crankcase above the “FULL”
Any engine mount that shows deterioration should be mark (X) on the oil level gauge. Clean the oil filler
replaced. Refer to Special Publication, SENR3130, cap. Install the oil filler cap.
Torque Specifications for the recommended torques.
Refer to the OEM recommendations for more 3. Record the amount of oil that is added. For the next
information.
oil sample and analysis, include the total amount of
oil that has been added since the previous sample.
SEBU9100 75
Engine Oil Level Gauge - Calibrate
i04548759 7. Add engine oil to the crankcase using the

procedure in this Operation and Maintenance
Engine Oil Level Gauge - Manual, “Engine Oil and Filter - Change”. Add
Calibrate 110 L (116 qt) of the recommended oil if the oil
filters were changed. If the filters were not
SMCS Code: 1326-524; 1326 changed, subtract 2 L (2.1 qt) of oil from the total
The engine is shipped with an engine oil level gauge for each filter.
that is marked with “ADD” and “FULL” marks. This 8. Start the engine. Ensure that the lubrication system
procedure should only be performed when the
generator set is not installed in a perfectly horizontal and the new engine oil filters are filled. Inspect the
plane. lubrication system for leaks.
The engine oil level gauge may only be calibrated 9. Stop the engine and allow the engine oil to drain
after the generator set is installed in the vessel. into the engine crankcase for approximately 20
Note: The engine may be equipped with auxiliary minutes.
engine oil filters. The extra filters require more engine 10. Check the engine oil level. Use a marking tool in
oil than the standard amounts. Refer to the order to engrave the new “ADD” mark (Y) to the
specifications of the original equipment manufacturer
correct location on the gauge assembly.
(OEM).
Use the following procedure in order to calibrate and 11. Add 28 L (30 qt) of the recommended oil grade
mark the engine oil level gauge. and weight of engine oil to the crankcase. Allow
the oil to drain into the sump for approximately 20
1. Ensure that the generator set is properly aligned minutes.
and that the vessel is in the design trim. The
generator set must be installed properly in the 12. Check the engine oil level. Use a marking tool in
vessel. order to engrave the new “FULL” mark (X) onto
the correct location on the gauge assembly.
Note: If the engine is being filled with oil for the first
time, perform Step 2. If the engine contained oil
before this calibration procedure, skip Step 2 and
proceed to Step 3.
2. Use the information in this Operation and

Maintenance Manual, “Fluid Recommendations” in
order to select the correct oil for the engine. Add
engine oil to the crankcase by using the procedure
in this Operation and Maintenance Manual,
“Engine Oil and Filter - Change”. Fill the crankcase Oil Level Gauge “ADD” mark (Y) and “FULL” mark
(X)
with 138 L (146 qt) of the recommended oil.
3. Operate the engine until normal operating i04237495
temperature is achieved. Stop the engine. Drain

the engine oil by using the procedure in this Engine Oil Sample - Obtain
Operation and Maintenance Manual, “Engine Oil SMCS Code: 1348-554-SM
and Filter - Change”.
In addition to a good preventive maintenance
4. If needed, replace the engine oil filters using the program, Caterpillar recommends using S·O·S oil
procedure in this Operation and Maintenance analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
Manual, “Engine Oil and Filter - Change”. for determining nitration and oxidation levels.
5. Clean the engine oil level gauge and install the
engine oil level gauge.
6. Use the information in Operation and Maintenance

Manual, “Fluid Recommendations” in order to
select the correct oil for the engine.
76 SEBU9100
Engine Oil and Filter - Change
Obtain the Sample and the Analysis For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
i05036729
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order to SMCS Code: 1318-510
help obtain the most accurate analysis, provide the
following information:
• Engine model Hot oil and hot components can cause personal
• Service hours on the engine
contact the skin.
• The number of hours that have accumulated since
the last oil change
NOTICE
• The amount of oil that has been added since the Care must be taken to ensure that fluids are con-
last oil change tained during performance of inspection, mainte-
To ensure that the sample is representative of the oil Be prepared to collect the fluid with suitable contain-
in the crankcase, obtain a warm, mixed oil sample. ers before opening any compartment or disassem-
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil Refer to Special Publication, NENG2500, “Cat Dealer
samples must be clean. Service Tool Catalog” or refer to Special Publication,
Caterpillar recommends using the sampling valve in PECJ0003, “Cat Shop Supplies and Tools Catalog”
order to obtain oil samples. The quality and the for tools and supplies suitable to collect and contain
consistency of the samples are better when the fluids on Cat products.
sampling valve is used. The location of the sampling Dispose of all fluids according to local regulations and
valve allows oil that is flowing under pressure to be mandates.
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The Interval for Engine Oil and Filter
fluid sampling bottle includes the parts that are Change
needed for obtaining oil samples. Instructions are
also provided. The interval for changing the engine oil and filters is
dependent on the power rating of the engine. Refer to
NOTICE this Operation and Maintenance Manual, “Engine
Always use a designated pump for oil sampling, and Rating Definitions” to determine the rating of the
use a separate designated pump for coolant sam- engine.
pling. Using the same pump for both types of samples Table 15
may contaminate the samples that are being drawn. Engine Oil and Filter Change Intervals
This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by Engine Rating Service Hours
both dealers and customers.
A Every 1000 SH
Auxiliary Engine
If the engine is not equipped with a sampling valve, B
Every 750 SH
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable C Every 500 SH
tubing must be attached to the pump for insertion into
the sump.
SEBU9100 77
Drain the Engine Oil Nonferrous metals may indicate wear on the
aluminum parts, brass parts, or bronze parts of the
Do not drain the oil when the engine is cold. As the oil engine. Parts that may be affected include the
cools, suspended waste particles settle on the bottom following items: main bearings, rod bearings,
of the oil pan. The waste particles are not removed turbocharger bearings and cylinder heads.
with the draining cold oil. Drain the crankcase with the
engine stopped. Drain the crankcase with the oil Due to normal wear and friction, small amounts of
warm. This draining method allows the waste debris may be found in the oil filter. Consult your
particles that are suspended in the oil to be drained Cat dealer in order to arrange for a further
properly. analysis if an excessive amount of debris is found
in the oil filter.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
• If the engine is equipped with a drain valve, turn

the drain valve knob counterclockwise in order to
drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the
drain valve.
• If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil to
drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both Illustration 47 g00103713
ends of the oil pan. Typical filter mounting base and filter gasket
After the oil has drained, the oil drain plugs should be 3. Clean the sealing surface of the filter mounting
cleaned and installed.
base. Ensure that all of the old oil filter gasket is
Replace the Oil Filter With the removed.
Engine Stopped (Standard Oil 4. Apply clean engine oil to the new oil filter gasket.
Filters)
NOTICE
NOTICE Do not fill the oil filters with oil before installing them.
Caterpillar oil filters are built to Caterpillar specifica- This oil would not be filtered and could be contami-
tions. Use of an oil filter not recommended by Cater- nated. Contaminated oil can cause accelerated wear
pillar could result in severe engine damage to the to engine components.
engine bearings, crankshaft, etc., as a result of the
larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom- 5. Install the oil filter. Tighten the oil filter until the oil
mended by Caterpillar . filter gasket contacts the base. Tighten the oil filter
by hand according to the instructions that are
1. Remove the oil filter with a 1U-8760 Chain shown on the oil filter. Do not overtighten the oil
Wrench. filter.
2. Cut the oil filter open with a 175-7546 Oil Filter

Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear
or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
78 SEBU9100
Replacing the Engine Oil Filters 1. Open the “FILL” valve for a minimum of 5 minutes
During Engine Operation (Duplex in order to fill the oil filter elements that will not be
serviced. The oil filters that will not be serviced
Oil Filters) must be full of engine oil. Close the FILL valve.
2. Move the control valve to the “AUX RUN” position

in order to change the main oil filter elements.
This filter contains hot, pressurized oil that can Move the selector valve to the “MAIN RUN”
cause burns and fire hazards, which may result in position in order to change the auxiliary oil filter
bodily injury or death. Follow the instructions giv- elements.
en in this Operation and Maintenance Manual and
stop the engine if rapid air movement exists to 3. Allow the oil pressure gauge for the oil filter that is
blow the oil. being changed to reach a “ZERO” pressure
reading.
4. Perform Step 1 through Step 5 of “Replace the Oil

Filter With the Engine Stopped (Standard Oil
Filters)”.
5. Open the “FILL” valve for a minimum of 5 minutes

in order to fill the new oil filter elements.
6. Close the “FILL” valve. Rotate the control valve to
the “RUN” position for the oil filter that was
serviced.
Fill the Engine Crankcase

NOTICE
Illustration 48 g01426431 If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
If the engine is equipped with duplex oil filters, the facturer's recommendations. Under filling or overfilling
engine oil filter elements can be changed while the the crankcase with oil can cause engine damage.
engine is in operation.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
SEBU9100 79
3. Start the engine according to this Operation and

NOTICE
Maintenance Manual, “Starting The Engine”
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge procedure (Operation Section). Operate the engine
(dipstick). at low idle for 2 minutes. in order to ensure that the
lubrication system has oil and that the oil filters are
An overfull crankcase can cause the crankshaft to dip filled with oil. Inspect the engine for oil leaks.
into the oil. This will reduce the power that is devel- Ensure that the oil level is at the “FULL” mark on
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- the “LOW IDLE” side of the oil level gauge.
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the 4. Stop the engine and allow the oil to drain back into
crankcase breathers and excessive oil consumption. the sump for a minimum of 10 minutes.
Excessive oil consumption will cause deposits to form 5. Remove the oil level gauge and check the oil level.
on the pistons and in the combustion chamber. De- Maintain the oil level to the “FULL” mark on the
posits in the combustion chamber lead to the follow- “ENGINE STOPPED” side of the oil level gauge.
ing problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylinder Inspect the Used Oil Filter Elements
liner.
If the oil level is above the “FULL” mark on the oil lev- Cut the used oil filter element open with a utility knife.
el gauge, drain some of the oil immediately. Remove the metal wrap. Cut the filter element free
from the end caps. Spread apart the pleats and
inspect the element for metal debris. An excessive
Use the following procedure in order to fill the amount of debris in the element may indicate early
crankcase if the engine oil filters were replaced during wear or a pending failure.
engine operation.
Use a magnet to differentiate between the ferrous
1. If the engine oil filters were replaced during engine metals and the nonferrous metals that are found in
the element. Ferrous metals may indicate wear on the
operation, operate the engine at low idle. Ensure steel and the cast iron parts of the engine. Nonferrous
that the oil level is at the “FULL” mark on the metals may indicate wear on the aluminum parts, the
“LOW IDLE” side of the oil level gauge. brass parts, or the bronze parts of the engine. Parts
that may be affected include the following
2. Add oil, if necessary. Remove the oil filler cap. Fill components: main bearings, rod bearings,
the crankcase through the oil filler tube only. turbocharger bearings and cylinder heads.
Use the following procedure in order to fill the Aluminum debris may indicate problems with the
crankcase if the engine oil filters were replaced with bearings of the front gears. If you find aluminum
the engine stopped. Refer to this Operation and debris, inspect the crankshaft vibration damper and
Maintenance Manual, “Fluid Recommendations” for the idler gear bearings.
information about choosing the oil for the engine.
, Small amounts of debris may be found in the oil filter
1. Remove the oil filler cap. Fill the crankcase through element due to normal wear and friction. If an
excessive amount of debris is found in the oil filter
the oil filler tube only. Clean the oil filler cap. Install element, consult your Caterpillar dealer in order to
the oil filler cap. arrange for further oil analysis.
NOTICE
To prevent crankshaft or bearing damage, crank en-
gine with fuel off to fill all filters before starting.
Do Not crank engine for more than 30 seconds.
2. Close the fuel supply line and crank the engine

until the oil pressure gauge indicates 70 kPa
(10 psi). Open the fuel supply line. Allow the
starting motor to cool for 2 minutes before cranking
again.
80 SEBU9100
Engine Speed/Timing Sensor - Clean/Inspect
i04602232 i01458399
Engine Speed/Timing Sensor - Engine Storage Procedure -

Clean/Inspect Check
SMCS Code: 1905-040; 1905-070; 1907-040; 1907- SMCS Code: 1000-535
070
The oil change interval may be extended to 12
months for a vehicle that is operated seasonally and
placed in storage for the remainder of the year by
using the required storage procedures and the
required start-up procedures. This extension is
permitted if the following categories for oil change
intervals in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” have not been
reached:
• Mileage
• Operating hours
• Fuel consumption
If an engine is out of operation and if use of the
engine is not planned, special precautions should be
made. If the engine will be stored for more than three
months, a complete protection procedure is
recommended. For more detailed information on
engine storage, see Special Instruction, SEHS9031,
“Storage Procedure For Caterpillar Products”.
If the engine will not be started for several weeks, the
Illustration 50 g01137086 lubricating oil will drain from the cylinder walls and
Front view from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the use
of volatile corrosion inhibitor (VCI) oil in order to
1. Remove the speed/timing sensors from the front prevent internal engine damage due to moisture
housing. Check the condition of the plastic end of during storage. These inhibitors in the VCI oil act by
the speed/timing sensors for wear and/or evaporating inside the engine. The inhibitors then
condense over the inside surfaces of the engine. The
contaminants. evaporation process and the condensing process
2. Clean the metal shavings and other debris from the offers full protection to surfaces that cannot be
reached with preservatives. 0.9 L (1.0 qt) of
face of the speed/timing sensors. Use the 4C-6792 VCI oil will treat 28.4 L (30.0 qt) of engine
procedure in the Troubleshooting Manual, “Speed/ oil. This will give a 3 percent concentration of VCI oil.
Timing Sensor - Calibrate” in order to calibrate the The engine must be completely sealed when the
speed/timing sensors. engine is stored in order for the VCI oil to function
properly. The VCI oil is easily cleaned from the engine
when you remove the engine from storage. The
volatile vapors are removed by simply running the
engine to operating temperature. A mineral oil base is
left behind after the volatile vapors are removed.
SEBU9100 81
Engine Valve Lash - Check
i04242309 3. Observe the top surface of each valve rotator. The

valve rotators should turn slightly when the valves
Engine Valve Lash - Check close.
SMCS Code: 1105-535
NOTICE
The initial valve lash adjustment on new engines, A valve rotator which does not operate properly will
rebuilt engines, or remanufactured engines is accelerate valve face wear and valve seat wear and
recommended at the first scheduled oil change. The shorten valve life. If a damaged rotator is not re-
adjustment is necessary due to the initial wear of the placed, valve face guttering could result and cause
valve train components and to the seating of the pieces of the valve to fall into the cylinder. This can
valve train components. cause piston and cylinder head damage.
The maintenance is recommended by Caterpillar as
part of a lubrication and preventive maintenance If a valve fails to rotate, consult your Caterpillar
schedule to help provide maximum engine life. dealer.
Note: Only qualified service personnel should
i04841177
perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve
bridge, see System Systems Operation/Testing and Fuel Injector - Check
Adjusting, “Engine Valve Lash - Inspect/Adjust”. SMCS Code: 1290-535
Consult your Cat dealer for assistance.
Be sure the engine cannot be started while this

Ensure that the engine can not be started while maintenance is being performed. To prevent pos-
this maintenance is being performed. To help pre- sible injury, do not use the starting motor to turn
vent possible injury, do not use the starting motor the flywheel.
to turn the flywheel.
Hot engine components can cause burns. Allow
Hot engine components can cause burns. Allow additional time for the engine to cool before meas-
additional time for the engine to cool before meas- uring/adjusting the unit injectors.
uring/adjusting valve lash clearance.
The electronic unit injectors use high voltage. Dis-
connect the unit injector enable circuit connector
in order to prevent personal injury. Do not come
i01597115
in contact with the injector terminals while the en-
gine is running.
Engine Valve Rotators - Inspect
SMCS Code: 1109-040 The operation of Cat engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
When inspecting the valve rotators, protective component life.
glasses or face shield and protective clothing Only qualified service personnel should perform this
must be worn, to help prevent being burned by maintenance. Refer to the following topics for your
hot oil or spray. engine for the correct procedure: Refer to the
Systems Operation, Testing and Adjusting, “Fuel
System” for the maintenance procedure.
Engine valve rotators rotate the valves when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats. NOTICE
The camshafts must be correctly timed with the crank-
Perform the following steps after the engine valve shaft before an adjustment of the lash for the fuel in-
lash is set, but before the valve covers are installed: jector is made. The timing pins must be removed from
the camshafts before the crankshaft is turned or dam-
1. Start the engine according to Operation and age to the cylinder block will be the result.
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
2. Operate the engine at low idle.

82 SEBU9100
Fuel System - Prime
i02728734
Fuel System - Prime

SMCS Code: 1250-548; 1258-548
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
The fuel system should be primed after a unit injector

is changed or when the fuel system is totally dry.
Note: The fuel system does not typically need to be

primed when the primary fuel filters or secondary fuel
filters are changed or when an Electronic Control
Module (ECM) is replaced. When the engine is
started under these circumstances, the engine may Illustration 51 g01373601
momentarily run rough until the air is purged from the
system.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
(1) Fuel priming pump
(2) Fuel filter base
(3) Secondary fuel filter
Follow the procedure below in order to prime the

engine with fuel.
SEBU9100 83
Fuel System Primary Filter/Water Separator - Drain
1. Turn the priming pump plunger (4) 2. Close drain (3).

counterclockwise in order to unlock the plunger.
Manually pump the plunger in order to fill the fuel NOTICE
lines and the fuel filters with fuel. The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
2. As the air is purged from the fuel system, fuel ened securely to help prevent air from entering the
pressure will increase. This will create resistance fuel system.
in the plunger. Continue to pump the plunger until a
strong resistance is felt. The number of strokes will
vary with the amount of air in the fuel lines. i05354209
3. After resistance is felt in the plunger, push in the Fuel System Primary Filter
plunger. Lock the plunger by turning the plunger
clockwise.
(Water Separator) Element -
4. Start the engine at low idle.
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
5. If the engine runs rough, continue to run the engine
at low idle until the engine runs smoothly. Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
NOTICE the element should be changed before the regularly
Do not crank the engine continuously for more than scheduled interval.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. If a vacuum gauge is installed, the primary
i01463757 filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).
Fuel System Primary Filter/
Water Separator - Drain Replace the Element
SMCS Code: 1260-543; 1263-543

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Refer to Special Publication, NENG2500, “Dealer
(1) Bowl Service Tool Catalog” for tools and supplies suitable
(2) Element to collect and contain fluids on Cat products.
(3) Drain
Bowl (1) should be monitored daily for signs of water. mandates.
If water is present, drain the water from the bowl.
1. Open drain (3). The drain is a self-ventilated drain.

Catch the draining water in a suitable container.
Dispose of the water properly.
84 SEBU9100
Fuel System Secondary Filter - Replace
NOTICE
7. Lubricate the top seal of element (1) with clean
clean the area around a fuel system component that diesel fuel. Install the new element on the
will be disconnected. Fit a suitable cover over discon- mounting base. Tighten the element by hand.
nected fuel system component.
NOTICE
NOTICE The water separator is under suction during normal
Do not fill fuel filters with fuel before installing engine operation. Ensure that the vent plug is tight-
them. The fuel will not be filtered and could be ened securely to help prevent air from entering the
contaminated. Contaminated fuel will cause accel- fuel system.
erated wear to fuel system parts. The fuel system
should be primed prior to starting the engine. 8. Open the main fuel supply valve.
9. Start the engine and check for leaks. Run the

1. Close the main fuel supply valve.
engine for 1 minute. Stop the engine and check for
leaks again.
Detecting leaks is difficult while the engine is
running. The primary filter/water separator is under
suction. A leak will allow air to enter the fuel. The
air in the fuel can cause low power due to aeration
of the fuel. Ensure that the components are
correctly installed to prevent air from entering the
fuel system.
i05303381
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE
(1) Element
(2) Bowl
(3) Drain
2. Remove element (1) from the element mounting cal components can cause a fire. Clean up fuel
base while bowl (2) is attached. spills immediately.
3. Dispose of the contents of the filter. Remove bowl

(2) from element (1). The bowl is reusable. Do not NOTICE
discard the bowl. Dispose of the used element. Care must be taken to ensure that fluids are con-
4. Remove the O-ring from the gland of the bowl. nance, testing, adjusting, and repair of the product.
Clean the following components: Be prepared to collect the fluid with suitable contain-
• Bowl bling any component containing fluids.
• O-ring Refer to Special Publication, NENG2500, “Cat Dealer

• Mounting base PECJ0003, “Cat Shop Supplies and Tools Catalog”
Inspect the O-ring for damage and for fluids on Cat products.
deterioration. Replace the O-ring, if necessary.
5. Lubricate the O-ring with clean diesel fuel. mandates.
6. Install bowl (2) on a new element. Tighten the bowl

by hand. Do not use tools in order to tighten the
bowl.
SEBU9100 85
NOTICE
2. Turn off the start switch or disconnect the battery
Keep all parts clean from contaminants.
(starting motor) when maintenance is performed
Contaminants may cause rapid wear and shortened on fuel filters.
component life.
3. Shut off the fuel tank supply valve to the engine.
Note: If the engine is equipped with duplex fuel filters,

the fuel filter elements can be replaced while the NOTICE
engine is in operation. Refer to “Replacing the Fuel Use a suitable container to catch any fuel that might
Filter Elements During Engine Operation For Engines spill. Clean up any spilled fuel immediately.
That Are Equipped With Duplex Fuel Filters”.
4. Unlock the fuel priming pump in order to relieve
residual pressure in the fuel system.
5. Remove the used fuel filter. Use a cloth or use a

container in order to catch excess fuel.
6. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
7. Apply clean diesel fuel to the new fuel filter gasket.
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
Typical secondary fuel filter
filter base.
(1) Priming pump
(2) Fuel shutoff
9. Operate the fuel priming pump plunger until a
(3) Drain valve strong resistance is felt and until the check valve
(4) Fuel indicators clicks. This procedure will require considerable
(5) Auxiliary secondary fuel filter
(6) Main secondary fuel filter
strokes. Lock the fuel priming pump.
(7) Fuel selector valve
10. Open the fuel tank supply valve.
Replacing the Fuel Filter Elements 11. Start the engine according to the normal operating
with the Engine Stopped procedures. Immediately increase the engine rpm
between 1000 to 1200 rpm with no load. The
NOTICE engine will begin to misfire briefly until air from the
Do not allow dirt to enter the fuel system. Thoroughly fuel filter is purged. No damage to the engine will
clean the area around a fuel system component that occur.
will be disconnected. Fit a suitable cover over discon-
1. Stop the engine.

86 SEBU9100
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
12. If the engine stalls during the purging of the air,

refer to the Operation and Maintenance Manual,
“Fuel System - Prime” for more information.
Replacing the Fuel Filter Elements

During Engine Operation For
Engines That Are Equipped With
Duplex Fuel Filters Illustration 56 g03409950
Note: The engine must be at IDLE in order to replace

the fuel filter elements during engine operation. 1. Move the fuel selector valve to the AUX RUN
position as marked on the indicator plate.
This filter contains pressurized fuel that can

cause a fire hazard, which may result in bodily in-
jury or death. Follow the instructions given in this
Operation and Maintenance Manual and stop the
engine if rapid air movement exists to blow the
fuel.
NOTICE
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
NOTICE 2. Once the lever has been moved to the AUX RUN
Care must be taken to ensure that fluids are con- position, the fuel gauge for the auxiliary filter
tained during performance of inspection, mainte- should indicate full pressure and the fuel gauge for
the main filter should indicate no pressure.
ers before opening any compartment or disassem- 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, indicator for the auxiliary filter should indicate full
PECJ0003, “Cat Shop Supplies and Tools Catalog” pressure and the fuel indicator for the main filter
for tools and supplies suitable to collect and contain should indicate no pressure.
Dispose of all fluids according to local regulations and 4. Remove the used main fuel filter.
mandates. 5. Clean the gasket sealing surface of the main fuel
filter base. Ensure that all of the old gasket is
removed.
Replacing the Main Fuel Filter
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.
SEBU9100 87
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.
Uninstall and reinstall the main filter if necessary.
2. Once the lever has been moved to the MAIN RUN
Replacing the Auxiliary Fuel Filter
position, the fuel gauge for the main filter should
Use the following procedure to replace the auxiliary indicate full pressure and the fuel gauge for the
fuel filter while the engine is in operation. 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.
7. Install a new auxiliary fuel filter. Tighten the fuel
1. Move the fuel selector valve to the MAIN RUN filter until the gasket contacts the base. Tighten the
position as marked on the indicator plate. fuel filter by hand according to the instructions that
are shown on the fuel filter. Do not overtighten the
fuel filter.
8. Move the fuel selection lever to the “LH FLOW -
RH FILL” position. The indicator for the auxiliary
filter should indicate slight pressure. Purge the air
from the lines for the auxiliary filter through the
drain valve. Close the drain valve when the fuel
starts to flow through the valve.
9. Move the fuel selection lever to the FLOW BOTH

position and monitor the auxiliary filter for leaks.
Uninstall and reinstall the auxiliary filter if
necessary.
88 SEBU9100
Fuel Tank Water and Sediment - Drain
i05111531 Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the
- Drain engine is equipped with this system, regular
maintenance of the fuel system filter is important.
SMCS Code: 1273-543-M&S
Fuel Storage Tanks
NOTICE
Care must be taken to ensure that fluids are con- Drain the water and the sediment from the fuel
tained during performance of inspection, mainte- storage tank during the following conditions:
nance, testing, adjusting, and repair of the product. • Weekly
ers before opening any compartment or disassem- • Oil change
• Refill of the tank
Service Tool Catalog” or refer to Special Publication, This procedure will help prevent water or sediment
PECJ0003, “Cat Shop Supplies and Tools Catalog” from being pumped from the storage tank into the
for tools and supplies suitable to collect and contain engine fuel tank. A four micron(c) absolute filter for
fluids on Cat products. the breather vent on the fuel tank is also
recommended.
mandates. If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
Fuel Tank baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
Fuel quality is critical to the performance and to the storage tank helps to ensure the quality of the fuel.
service life of the engine. Water in the fuel can cause When possible, water separators should be used.
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The i05019230
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining Fumes Disposal Filter Element
the fuel tank regularly and obtaining fuel from reliable - Replace
sources can help to eliminate water in the fuel.
SMCS Code: 1074
Drain the Water and the Sediment Replacement of the fumes disposal filter is affected
Fuel tanks should contain some provision for draining by the following items:
water and draining sediment from the bottom of the
fuel tanks. • Engine load
Open the drain valve on the bottom of the fuel tank in • Soot concentration
order to drain the water and the sediment. Close the
drain valve. • Condition of the engine
Note: Failure to close the drain can allow air into the Replacing the Fumes Disposal
system, which could have detrimental results to
performance. Filter
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the Hot oil and hot components can cause personal
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure. injury. Do not allow hot oil or hot components to
contact the skin.
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.
SEBU9100 89
Heat Exchanger - Clean/Test
(4) Plastic cover
(5) Service indicator
1. Remove the plastic cover.
Illustration 60 g03123321 2. Push down on the service indicator.

Typical installation 3. Replace the cover.
(1) Latches for the canister
(2) Service indicator
(3) Cap for the canister i05194829
(4) Engine air cleaner
(5) Canister Heat Exchanger - Clean/Test
Note: When possible, perform the maintenance while SMCS Code: 1379-070; 1379-081
the engine is off.
Clean the Heat Exchanger
1. Release the latches that hold the canister to the
cap. 1. Remove the heat exchanger from the engine.
Refer to the Disassembly and Assembly Manual,
Note: Removal of the canister may be difficult while “Heat Exchanger - Remove” for the procedure.
the engine is operating. The canister has negative air
pressure while the engine is operating which creates 2. Remove the heat exchanger core from the heat
a vacuum. exchanger. Refer to the Disassembly and
2. Lower the canister in order to expose the element. Assembly Manual, “Heat Exchanger -
There may be oil in the bottom of the canister. Disassemble” for the procedure.
Avoid spilling the oil.
3. Turn the heat exchanger core onto one side in
3. Remove the filter element by pulling down. Dispose order to remove debris. Remove the debris that is
of the used element properly. accessible.
4. Replace the canister and align the canister with the

NOTICE
boss on the filter base assembly. Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic
5. Clamp the latches in the closed position.
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen-
Resetting the Service Indicator (If tration of cleaner.
Equipped)
4. Back flush the heat exchanger core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 16 lists Hydrosolv liquid
cleaners that are available from your Cat dealer.
90 SEBU9100
Heat Exchanger - Inspect
Table 16 4. If any leaks are found, do not attempt to repair the

Hydrosolv Liquid Cleaners(1) core.
Part Number Description Size 5. Install a core that is clean and that passes the
pressure test in step 3. Refer to the Disassembly
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
and Assembly Manual, “Heat Exchanger -
174-6854 Hydrosolv 100 19 L (5 US gallon) Assemble” for the procedure.
(1) Use a 2 to 5 percent concentration of the cleaner at tempera-
tures up to 93°C (200°F). Consult your Cat dealer for more 6. Install the heat exchanger onto the engine. Refer to
information. the Disassembly and Assembly Manual, “Heat
Exchanger - Install” for the procedure.
5. Clean the heat exchanger core with steam to
remove any residue. Flush the fins of the heat
your Cat dealer.
exchanger. Remove any other trapped debris from
the inside and from the outside of the core.
i05194157
6. Wash the heat exchanger core with hot, soapy
water. Heat Exchanger - Inspect
7. Flush the heat exchanger core thoroughly in order SMCS Code: 1379-040
to remove residue and remaining debris. Flush the The interval for the maintenance of the heat
heat exchanger core with clean, fresh water until exchanger depends on the operating environment of
the water that is exiting the core is clear and free of the vessel and on the operating time. The sea water
debris. that is circulated through the heat exchanger and the
amount of operating time of the vessel affects the
following items:
• Cleanliness of the tubes of the heat exchanger

Personal injury can result from air pressure. • Effectiveness of the heat exchanger system
Personal injury can result without following prop- Operating in water that contains silt, sediment, salt,
er procedure. When using pressure air, wear a algae, and so on, will adversely affect the heat
protective face shield and protective clothing. exchanger system. In addition, intermittent use of the
vessel will adversely affect the heat exchanger
The maximum air pressure for cleaning purposes system.
nozzle is deadheaded. The following items indicate that the heat exchanger
may require cleaning:
8. Dry the heat exchanger core with compressed air.
Direct the air in the reverse direction of the normal • Increased coolant temperature
flow.
• Engine overheating
Test the Heat Exchanger Core • Excessive pressure drop between the water inlet
and the water outlet
1. Inspect the heat exchanger core for trapped debris
and cleanliness. If necessary, remove the debris An operator that is familiar with the normal operating
and repeat the cleaning procedure. temperature of the coolant can determine when the
coolant temperature is out of the normal range.
2. Inspect the heat exchanger core for damage and Inspection and maintenance of the heat exchanger
perform a pressure test in order to detect leaks. are required if the engine is overheating.
Many shops that service radiators are equipped to Your Cat dealer has the equipment and the trained
perform pressure tests. personnel that are needed in order to measure the
pressure drop across the heat exchanger.
3. Plug both ends of the heat exchanger core and
pressurize the core to 100 kPa (14.5 psi). Refer to this Operation and Maintenance Manual,
Submerge the core in water. Look for bubbles “Heat Exchanger - Clean/Test”. For more information
on servicing the heat exchanger, consult your Cat
which are being emitted from the core. The dealer.
bubbles are evidence of leaks.
SEBU9100 91
Hoses and Clamps - Inspect/Replace
i05373687 • Type of hose
Hoses and Clamps - Inspect/ • Type of fitting material
Replace • Anticipated expansion and contraction of the hose

SMCS Code: 7554-040; 7554-510 • Anticipated expansion and contraction of the
fittings
Hoses and clamps must be inspected periodically
and replaced at the recommended interval to ensure Due to extreme temperature changes, the hose will
safe and continuous operation of the engine. Failure heat set. Heat setting causes hose clamps to loosen
to replace a fuel hose at the recommended change which can result in leaks. A constant torque hose
interval may result in a hazardous situation. Take clamp will help to prevent loose hose clamps.
proper safety precautions before inspecting or
replacing hoses and clamps. Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses
Note: Always use a board or cardboard when the that show signs of damage. Replace hose clamps
engine components are checked for leaks. Leaking that are cracked or damaged. Tighten or replace hose
fluid that is under pressure can cause serious injury clamps which are loose.
or possible death. Leaks that are the size of a pin
hole are included. Refer to Operation and Replace the Hoses and the Clamps
Maintenance Manual, “General Hazard Information”
for more information. NOTICE
Inspect the Hoses and the Clamps tained during performance of inspection, mainte-
Inspect all hoses for leaks that are caused by the Be prepared to collect the fluid with suitable contain-
following conditions. Replace any hose which exhibits
any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions bling any component containing fluids.
may result in a hazardous situation. Refer to Special Publication, NENG2500, “Cat Dealer
• Hoses which are cracked
• Hoses which are soft for tools and supplies suitable to collect and contain
• Outer covering that is chafed or cut Dispose of all fluids according to local regulations and
mandates.
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally

Cooling System
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering

• Hoses which exhibit signs of leakage which are not Pressurized System: Hot coolant can cause seri-
the result of loose couplings or clamps ous burns. To open the cooling system filler cap,
Inspect all clamps for the following conditions.
Replace any clamp which exhibits signs of any of the components are cool. Loosen the cooling system
following conditions. pressure cap slowly in order to relieve the
pressure.
• Cracking
• Looseness
• Damage
Personal injury can result from removing hoses
Inspect all couplings for leaks. Replace any coupling or fittings in a pressure system.
which exhibits signs of leaks.
Failure to relieve pressure can cause personal
Each installation application can be different. The injury.
differences depend on the following factors:
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
92 SEBU9100
Hoses and Clamps - Inspect/Replace
NOTICE
1. Stop the engine.
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
2. Allow the engine to cool.
any loose or damaged fuel and oil lines, tubes and
3. Before servicing a coolant hose, slowly loosen the hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
filler cap for the cooling system in order to relieve
recommended torque.
any pressure.
4. Remove the filler cap for the cooling system.

NOTICE
5. Drain the coolant from the cooling system to a level Do not allow dirt to enter the fuel system. Thoroughly
that is below the hose that is being replaced. Drain clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
the coolant into a suitable clean container. The
connected fuel system components.
coolant can be reused.
6. Remove the hose clamps.
Note: High-pressure fuel lines may be installed
7. Disconnect the old hose. between the high-pressure fuel pump and the fuel
injectors. High-pressure fuel lines are constantly
8. Replace the old hose with a new hose. charged with high pressure. Do not check the high-
pressure fuel lines with the engine or the starting
9. Install hose clamps which have been inspected or
motor in operation. Wait for 10 minutes after the
install new hose clamps. Refer to Specifications, engine stops before you perform any service or repair
SENR3130, Torque Specifications, “Hose Clamps” on high-pressure fuel lines. Waiting for 10 minutes will
for information about selecting and installing the to allow the pressure to be purged.
proper hose clamps. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
10. Refill the cooling system.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap 3. Disconnect the old hose.
if the gaskets are damaged. Install the filler cap.
4. Replace the old hose with a new hose.
12. Start the engine. Inspect the cooling system for
leaks. 5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
Fuel System SENR3130, Torque Specifications, “Hose Clamps”
for information about selecting and installing the
proper hose clamps.
6. Carefully inspect the engine for any spilled fuel.

Personal injury can result from removing hoses Make sure that no fuel remains on or close to the
or fittings in a pressure system. engine.
Failure to relieve pressure can cause personal
injury. Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved. 7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel.
8. Start the engine. Inspect the fuel system for leaks.

Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
SEBU9100 93
Lubrication System i03658149
Maintenance
Recommendations
Hot oil and hot components can cause personal
SMCS Code: 1000
contact the skin.
Relationship of Fuel Consumption
1. Drain the oil from the lubrication system to a level to Service Hours
that is below the hose that is being replaced. Experience has shown that maintenance intervals are
most accurately based on fuel consumption. Fuel
2. Remove the hose clamps. consumption corresponds more accurately to the
engine load. Table 17 lists average ranges of fuel
3. Disconnect the old hose. consumption and service hours for the C32 engine.

SENR3130, Torque Specifications, “Hose Clamps”
proper hose clamps.
6. Refill the lubrication system. Refer to this

Operation and Maintenance Manual, “Engine Oil
Level - Check” in order to ensure that the
lubrication system is filled with the proper amount
of engine oil.
7. Start the engine. Inspect the lubrication system for

leaks.
Air System
2. Disconnect the old hose.


SENR3130, Torque Specifications, “Hose Clamps”
proper hose clamps.
Note: The bellows and the V-clamps that are used on
the bellows should never be reused.
5. Start the engine. Inspect the air lines for leaks.
Table 17
Maintenance Interval Schedule
Fuel Consumption for C32 ACERT Commercial Diesel Engines(1)
Interval Rating
(continued)
94 SEBU9100
(Table 17, contd)

A B C D
25,000 L 33,000 L 40,000 L 50,000 L
250 Service Hours (6,600 US gal) (8,800 US gal) (10,500 US gal) (13,200 US gal)
50,000 L 66,000 L 80,000 L 100,000 L

500 Service Hours (13,200 US gal) (17,600 US gal) (21,000 US gal) (26,400 US gal)
100,000 L 132,000 L 160,000 L 200,000 L

1,000 Service Hours
(26,400 US gal) (35,200 US gal) (42,000 US gal) (52,800 US gal)
200,000 L 264,000 L 320,000 L 400,000 L

2,000 Service Hours
300,000 L 396,000 L 480,000 L 600,000 L

3,000 Service Hours
(1) Fuel consumption is based on a load factor of approximately 60 percent.
Maintenance intervals must be reduced for engines Because of individual applications, it is not possible to
that operate in a severe service application and for identify all of the factors which can contribute to
engines that operate in a different engine rating severe operation. Consult your Caterpillar dealer
definition. about the maintenance that is needed for your
specific engine.
Severe Service Application The following factors can contribute to severe
operation: environment, improper operating
Severe service operation can accelerate component procedures and improper maintenance practices.
wear. An engine which operates in a severe service
application may need more frequent maintenance
intervals for the following reasons: Extreme Ambient Temperatures
• Maximum reliability Extended operation in environments that are
extremely cold or hot can damage components. Valve
• Retention of full service life components can be damaged by carbon buildup if the
engine is frequently started and stopped in very cold
A severe service application is an application which temperatures. Extremely hot inlet air reduces the
exceeds the current published standards for that performance capabilities of the engine.
engine. Caterpillar maintains standards for the
following engine parameters: Note: See this Operation and Maintenance Manual,
“Cold Weather Operation” topic (Operation Section),
• Horsepower or see Supplement, SEBU5898, “Cold Weather
Recommendations”.
• Range of rpm
• Fuel consumption Cleanliness
• Fuel quality Unless the equipment is cleaned regularly, extended
operation in a dirty environment and in a dusty
• Altitude environment can damage components. Built up mud,
dirt, and dust can encase components. This can
• Maintenance intervals make maintenance difficult. The buildup can contain
corrosive chemicals. Corrosive chemicals and salt
• Selection of oil can damage some components.
• Selection of coolant
• Environmental qualities
• Installation
Refer to the standards for your engine or consult your
Caterpillar dealer in order to determine if your engine
is operating within the defined parameters.
SEBU9100 95
Improper Operating Procedures • The total amount of fuel consumption
• Extended operation at low idle • The service hours of the engine
• Minimum cool down periods after high load factor • An increase of oil consumption
operation
• An increase of crankcase blowby
• Operating the engine beyond the guidelines for the
engine rating • The wear metal analysis of the lube oil
• Operating the engine at loads that are greater than • An increase in the levels of noise and vibration
the rated load An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
• Operating the engine at speeds that are greater need to be serviced. An increase in the levels of
than the rated speed noise and vibration indicates that rotating parts
require service.
• Use of the engine for an application that is not
approved Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
Improper Maintenance Practices liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
• Extension of maintenance intervals the wear metals.
Monitor the engine as the engine accumulates
• Not using recommended fuel, lubricants, and service hours. Consult your Caterpillar dealer about
coolant scheduling a major overhaul.
Overhaul Considerations Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
Some factors that are important for determining the
overhaul intervals include the following that is provided by the OEM of the driven equipment.
considerations:
Overhaul Intervals Which are Based on
• Performance of preventive maintenance
Fuel Consumption
• Use of recommended lubricants
Experience has shown that the interval for an
• Use of recommended coolants overhaul is most accurately based on fuel
consumption. Fuel consumption corresponds more
• Use of recommended fuels accurately to the engine load.
• Proper installation
• Operating conditions
• Operation within acceptable limits
• Engine load
• Engine speed
• Use of S·O·S Services Fluids Analyses
Generally, engines that are operated at a reduced
load and/or speed achieve more service life before an
overhaul. However, this is for engines that are
properly operated and maintained.
Other factors must also be considered for determining
a major overhaul:
Table 18
Overhaul Intervals
Top End Overhaul Fuel Consumption 1000000 L (264000 US gal)
Major Overhaul Fuel Consumption 2000000 L (528000 US gal)

96 SEBU9100
Overhaul Intervals Which are Based on • Specially designed Caterpillar engine features
Oil Consumption • Caterpillar dealer exchange components
Oil consumption, fuel consumption, and maintenance • Caterpillar Inc. remanufactured exchange
information can be used to estimate the total components
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable Coolant Analysis
for the maintenance intervals.
The concentration of supplemental coolant additive
Oil consumption is in proportion to the percentage of (SCA) should be checked regularly with test kits or
the rated engine load. As the percentage of the with S·O·S Coolant Analysis (Level 1). Further
engine load is increased, the amount of oil that is coolant analysis is recommended when the engine is
consumed per hour also increases. overhauled.
The oil consumption rate (brake specific oil A coolant analysis can be conducted in order to verify
consumption) is measured in grams per kW/h (lb per the condition of the water that is being used in the
bhp). The brake specific oil consumption (BSOC) cooling system. A full water analysis can be obtained
depends on the engine load. Consult your Caterpillar by consulting your local water utility company or an
dealer for assistance in determining the typical oil agricultural agent. Private laboratories are also
consumption rate for your engine. available for water analysis.
When an engine's oil consumption has risen to Caterpillar Inc. recommends an S·O·S Coolant
three times the original oil consumption rate due Analysis (Level 2).
to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption. S·O·S Coolant Analysis (Level 2)
An S·O·S Coolant Analysis (Level 2) is a
Overhaul Options comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
Before Failure Overhaul system. An S·O·S Coolant Analysis (Level 2)
provides the following information:
A planned overhaul before failure may be the best
value for the following reasons: • Complete S·O·S Coolant Analysis (Level 2)
• Costly unplanned downtime can be avoided. • Visual inspection of properties
• Many original parts can be reused according to the • Identification of metal corrosion
standards for reusable parts.
• Identification of contaminants
• The engine service life can be extended without
• Identification of built up impurities (corrosion and
the risk of a major catastrophe due to engine
scale)
failure.
S·O·S Coolant Analysis (Level 2) provides a report of
• The best cost/value relationship per hour of the results of both the analysis and the maintenance
extended life can be attained. recommendations.
After Failure Overhaul For more information, refer to Special Publication,

SEBU6251, Caterpillar Commercial Diesel Engine
If a major engine failure occurs and the engine must Fluids Recommendations or contact your Caterpillar
be removed, many options are available. An overhaul dealer.
should be performed if the engine block or the
crankshaft needs to be repaired. Engine Components
If the engine block is repairable and/or the crankshaft Refer to this Operation and Maintenance Manual,
is repairable, the overhaul cost should be between 40 “Overhaul (Top End)” for a list of components which
percent and 50 percent of the cost of a new engine are affected by a top end overhaul. Refer to this
with a similar exchange core. Operation and Maintenance Manual, “Overhaul
(Major)” for a list of components which are affected by
This lower cost can be attributed to three aspects: a major overhaul.
SEBU9100 97
Oil Cooler Core - Check/Clean/Test
i03751386
Oil Cooler Core - Check/Clean/ Personal injury can result from air pressure.
Test Personal injury can result without following prop-
SMCS Code: 1378-070; 1378-081; 1378-535 er procedure. When using pressure air, wear a
protective face shield and protective clothing.
This maintenance procedure shall be performed
when the top end overhaul is performed. Refer to this The maximum air pressure for cleaning purposes
Operation and Maintenance Manual, “Maintenance must be reduced to 205 kPa (30 psi) when the air
Recommendations” article for information about the nozzle is deadheaded.
maintenance interval for the top end overhaul.
6. Dry the core with compressed air. Direct the air in
Clean the Oil Cooler Core the reverse direction of the normal flow.
Remove the core. Refer to the Disassembly and
Assembly Manual, “Oil Cooler - Remove” for the Test the Oil Cooler Core
procedure.
1. Inspect the core for trapped debris and cleanliness.
1. Turn the oil cooler core on one side in order to If necessary, remove the debris and repeat the
remove debris. Remove the debris that is cleaning procedure.
accessible.
2. Inspect the core for damage and perform a
pressure test in order to detect leaks. Many shops
NOTICE that service radiators are equipped to perform
Do not use a high concentration of caustic cleaner to pressure tests.
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and 3. Plug both ends of the oil cooler core and pressurize
cause leakage. Only use the recommended concen- the core to 205 kPa (30 psi). Submerge the core in
tration of cleaner. water. Look for bubbles which are being emitted
from the core. The bubbles are evidence of leaks.
2. Back flush the core with cleaner.
4. If any leaks are found, do not attempt to repair the
Caterpillar recommends the use of Hydrosolv core.
liquid cleaner. Table 19 lists Hydrosolv liquid
cleaners that are available from your Caterpillar Install a core that is clean and a core that passes the
dealer. pressure test in step 3. Refer to the Disassembly and
Table 19
Assembly Manual, “Oil Cooler - Install” for the
procedure.
Hydrosolv Liquid Cleaners(1)
Part Number Description Size your Caterpillar dealer.
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
i05239037
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner at temper-
atures up to 93°C (200°F). Refer to Application Guide,
Overhaul (Major)
NEHS0526 or consult your Caterpillar dealer for more SMCS Code: 7595-020-MJ
information.
3. Steam clean the core in order to remove any “Maintenance Recommendations” in order to
determine the maintenance interval for a major
residue. Flush the fins of the oil cooler core. overhaul.
Remove any other trapped debris from the inside
and from the outside of the core. The need for a major overhaul is determined by
several factors.
4. Wash the core with hot, soapy water.
5. Flush the core thoroughly in order to remove

residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear and free of debris.
98 SEBU9100
Overhaul (Major)
• An increase of oil consumption • Camshaft bearings

• An increase of crankcase blowby • Connecting rod bearings
• The total amount of fuel consumption • Crankshaft seals

• The service hours of the engine • Crankshaft thrust washers
• The wear metal analysis of the lube oil • Electronic unit injectors
• An increase in the levels of noise and vibration • Gear train bushings
An increase of wear metals in the lube oil indicates • Gear train bearings
that the bearings and the surfaces that wear may
need service. An increase in the levels of noise and • Main bearings
vibration indicates that rotating parts require service.
• Mounting bolts for the secondary fuel filter base
Note: An oil analysis may indicate a decrease of
wear metals in the lube oil. The cylinder liners may be • Piston rings
worn so that polishing of the bore occurs. Also, the
increased use of lube oil will dilute the wear metals.
International Convention for Safety of Life
Monitor the engine as the engine accumulates at Sea (SOLAS)
service hours. Consult your Cat dealer about
scheduling a major overhaul. Caterpillar recommends replacing the following:
Note: The driven equipment may also require service
• All shields that have been installed to cover up fuel
when the engine is overhauled. Refer to the literature and oil line connections per (SOLAS) regulations
that is provided by the OEM of the driven equipment.
• All marine certification society approved tapes are
A major overhaul includes all of the work that is done
for the top end overhaul. A major overhaul includes installed in order to cover up fuel line connections
additional parts and labor. Additional parts and labor and oil line connections according to the SOLAS
are required in order to completely rebuild the engine. regulations.
For the major overhaul, all of the bearings, seals, Inspection, Reconditioning, or
gaskets, and components that wear are
disassembled. The parts are cleaned and inspected. Exchanging of Components
If necessary, the parts are replaced. The crankshaft is
measured for wear. The crankshaft may require Inspect the following components according to the
regrinding. Alternatively, the crankshaft may be instructions that are in Caterpillar reusability
replaced with a Cat replacement part. publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, Index of
Your Cat dealer can provide these services and Publications on Reusability or Salvage of Used Parts.
components. Your Cat dealer can ensure that the
components are operating within the appropriate Recondition the worn components or exchange the
specifications. components, if necessary. Your Cat dealer can
provide these services and components.
Replacement of Components
Replace the following components during the major
overhaul:
SEBU9100 99
Overhaul (Major)
• Camshaft followers • Camshaft

• Camshaft thrust washers • Crankshaft
• Connecting rods • Driven equipment (alignment)

• Crankshaft vibration damper • Engine cylinder block
• Cylinder head assembly • Engine control module

• Cylinder liners • Flywheel
• Engine mounts • Front gear train (gears)

• Scavenge oil pump • Oil suction screen
• Engine wiring harness • Rear gear train
• Exhaust manifold seals Inspect the camshaft for damage to the journals and
the lobes.
• Exhaust manifold bellows
Inspect the crankshaft for any of the following
• Fuel pressure regulating valve conditions:
• Fuel priming pump • Deflection
• Fuel transfer pump • Damage to the journals
• Inlet manifold gaskets • Bearing material that has seized to the journals
• Inlet manifold seals Check the journal taper and the profile of the
crankshaft journals. Check these components by
• Oil cooler core interpreting the wear patterns on the following
components:
• Oil pump
• Rod bearing
• Pistons
• Main bearings
• Piston pins
Note: If the crankshaft or the camshaft are removed
• Prelube pump for any reason, use the magnetic particle inspection
process to check for cracks.
• Pushrods
Replace the crankshaft vibration damper if any of the
• Rocker arms following conditions occur:
• Spacer plate • Engine failure due to a broken crankshaft
• Software update • Excessive wear of the front bearing for the

crankshaft
• Turbocharger
• Excessive wear of the gear train that is not caused
Inspection of Components by a lack of lubrication
Inspect the following components according to the Inspect the gears of the gear train and inspect the
instructions that are in Caterpillar reusability gear train bushings for the following conditions:
publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, Index of • Worn gear teeth
Publications on Reusability or Salvage of Used Parts.
• Unusual fit
• Unusual wear
100 SEBU9100
Overhaul (Top End)
In addition to the inspection of components, inspect • Full Level I analysis

the alignment of the driven equipment. See the
Application and Installation Guide for the engine or • Identification of the source of metal corrosion and
see the literature that is provided by the OEM of the of contaminants
driven equipment.
• Identification of buildup of the impurities that cause
Cleaning of Components corrosion
Clean the oil suction screen. Also, remove side • Identification of buildup of the impurities that cause
covers in order to clean the oil sump. For instructions scaling
on removal and installation of components, see the
Service Manual, “Disassembly and Assembly” • Determination of possible electrolysis within the
module. engine cooling system
Cleaning and Pressure Testing of A report of the results of the analysis is provided.
Maintenance recommendations are based on the
Components results.
Clean and pressure test the aftercooler core. Refer to For more information about S·O·S coolant analysis,
this Operation and Maintenance Manual, “Aftercooler consult your Cat dealer.
Core - Clean/Test” for the procedure.
Clean and pressure test the heat exchanger. Refer to i05195216
this Operation and Maintenance Manual, “Heat
Exchanger - Clean/Test” for the procedure. Overhaul (Top End)
SMCS Code: 7595-020-TE
Obtain a Coolant Analysis
For conventional heavy-duty coolant or antifreeze, “Maintenance Recommendations” article for
check the concentration of supplemental coolant information about the maintenance interval for the top
additive (SCA) regularly. The concentration of SCA end overhaul.
can be checked with an S·O·S coolant analysis
(Level I). A more detailed coolant analysis is A top end overhaul involves the removal, the
recommended periodically. inspection, and the rework of the cylinder head
components. A few additional components are
For example, considerable deposits are found in the replaced and serviced.
water jacket areas on the external cooling system, but
the concentrations of coolant additives were carefully Your Cat dealer can provide these services and
maintained. The coolant water probably contained components. Your Cat dealer can ensure that the
minerals which were deposited on the engine over components are operating within the appropriate
time. specifications.
A coolant analysis can be conducted in order to verify The following definitions explain the terminology for
the condition of the water that is being used in the the services that are performed during an overhaul:
cooling system. A full water analysis may be obtained
from the following sources: Inspect – Inspect the components according to the
instructions that are in Cat reusability publications.
• Cat dealer Refer to Guidelines for Reusable Parts and Salvage
Operations, SEBF8029, Index of Publications on
• Local water utility company Reusability or Salvage of Used Parts. The guidelines
were developed in order to help Cat dealers and
• Agricultural agent customers to avoid unnecessary expenditures. New
parts are not required if the existing parts can still be
• Independent laboratory used, reconditioned, or repaired. If the components
are not in the reusability guidelines, refer to the
Caterpillar recommends an S·O·S coolant analysis Service Manual, “Specifications” module.
(Level II) which is a comprehensive chemical
evaluation of the coolant. This analysis is also a Rebuild – The component is reconditioned in order to
check of the overall condition of the inside of the comply with reusability guidelines.
cooling system. The following services are provided:
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement part
may be a new part, a CAT remanufactured part, a
rebuilt part, or a used part. Some worn components
may be exchanged with your Cat dealer for a credit
SEBU9100 101
Sea Water Strainer - Clean/Inspect
on replacement parts. Consult your Cat dealer about SMCS Code: 1451-040; 1453-040
repair options for your engine.
Air Starting Motor
If you elect to perform an overhaul without the
services of a Cat dealer, be aware of the If the starting motor fails, the engine may not start in
recommendations in Table 20 . an emergency situation. A scheduled inspection of
Table 20 the starting motor is recommended.
Recommendations for Top End Overhauls (1) The starting motor pinion and the flywheel ring gear
Service Top End Overhaul must be in good condition in order for the engine to
start properly. The engine will not start if the starting
Inspect Cylinder head assemblies motor pinion does not engage the flywheel ring gear.
Rebuild The teeth of the starting motor pinion and the flywheel
Replace Valves ring gear can be damaged because of irregular
engagement.
Aftercooler core(2)
Inspect
Heat exchanger(3) Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
Inspect Rocker arms
Replace Valve bridges
teeth of the starting motor pinion and the flywheel ring
gear. Look for patterns of wear on the teeth. Look for
teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
Clean/Test Oil cooler core(4) ring gear must be replaced.
Cylinder head gaskets
Replace
Fuel Injectors
(1) For instructions on removal and installation of components, see

Personal injury or death can result from improp-
the Service Manual, “Disassembly and Assembly” module. erly checking for a leak.
(2) Refer to this Operation and Maintenance Manual, “Aftercooler
Core - Inspect” for the procedure. Always use a board or cardboard when checking
(3) Refer to this Operation and Maintenance Manual, “Heat Ex- for a leak. Escaping air or fluid under pressure,
changer - Inspect” for the procedure. even a pin-hole size leak, can penetrate body tis-
(4) Refer to this Operation and Maintenance Manual, “Oil Cooler sue causing serious injury, and possible death.
Core - Check/Clean/Test” for the procedure.
If fluid is injected into your skin, it must be treated
i04277901 immediately by a doctor familiar with this type of
injury.
Sea Water Strainer - Clean/
Inspect Inspect all of the components in the air circuit for the
starting motor. Inspect all of the air lines and
SMCS Code: 1371-040; 1371-070 connections for leaks.
The sea water strainer must be clean in order to allow If damaged teeth are found, the air circuit for the
proper engine cooling and component life. The sea starting motor must be examined in order to
water strainer is located before the sea water pump determine the cause of the problem.
impeller and filters out debris. Check the sea water
strainer for plugging. Inspect the sea water strainer Electric Starting Motor
more frequently if the vessel is being operated in
water which is shallow or dirty. Refer to the OEM If the starting motor fails, the engine may not start in
recommendations for more information about an emergency situation. A scheduled inspection of
inspecting and cleaning the sea water strainer. the starting motor is recommended.
i05264216
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine to
start properly. The engine will not start if the starting
Starting Motor - Inspect motor pinion does not engage the flywheel ring gear.
(If equipped) The teeth of the starting motor pinion and the flywheel
ring gear can be damaged because of irregular
engagement.
102 SEBU9100
Turbocharger - Inspect
Inspect the starting motor for proper operation. Listen

for grinding when the engine is started. Inspect the NOTICE
teeth of the starting motor pinion and the flywheel ring Turbocharger bearing failures can cause large quanti-
gear. Look for patterns of wear on the teeth. Look for ties of oil to enter the air inlet and exhaust systems.
teeth that are broken or chipped. If damaged teeth Loss of engine lubricant can result in serious engine
are found, the starting motor pinion and the flywheel damage.
ring gear must be replaced.
Minor leakage of a turbocharger housing under ex-
Problems with the electric starting motor can be tended low idle operation should not cause problems
caused by the following conditions: malfunction of the as long as a turbocharger bearing failure has not
solenoid and malfunction of the electric starting occurred.
system.
When a turbocharger bearing failure is accompanied
Inspect the electrical system for the following by a significant engine performance loss (exhaust
conditions: smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
• Loose connections replaced.
• Corrosion
An inspection of the turbocharger can minimize
• Wires that are worn or frayed unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
• Cleanliness damage to other engine parts.
Removal and Installation of the Note: Turbocharger components require precision

clearances. The turbocharger cartridge must be
Starting Motor balanced due to high rpm. Severe Service
Applications can accelerate component wear. Severe
Refer to the Service Manual, “Disassembly and Service Applications require more frequent
Assembly” module for information on removing the inspections of the cartridge.
starting motor and installing the starting motor.
Consult your Cat dealer for assistance and/or for Removal and Installation
options on replacement of the starting motor. For options regarding the removal, installation, repair
and replacement, consult your Cat dealer. Refer to
i05264219 the Service Manual for this engine for the procedure
and specifications.
Turbocharger - Inspect
Cleaning and Inspecting
SMCS Code: 1052-040
1. Remove the exhaust outlet piping and remove the
Periodic inspection and cleaning is recommended for
the turbocharger compressor housing (inlet side). Any air inlet piping from the turbocharger. Visually
fumes from the crankcase are filtered through the air inspect the piping for the presence of oil. Clean the
inlet system. Therefore, by-products from oil and from interior of the pipes in order to prevent dirt from
combustion can collect in the turbocharger entering during reassembly.
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black 2. Turn the compressor wheel and the turbine wheel
smoke and overall loss of engine efficiency. by hand. The assembly should turn freely. Inspect
If the turbocharger fails during engine operation, the compressor wheel and the turbine wheel for
damage to the turbocharger compressor wheel and/ contact with the turbocharger housing. There
or to the engine may occur. Damage to the should not be any visible signs of contact between
turbocharger compressor wheel can cause additional the turbine wheel or compressor wheel and the
damage to the pistons, the valves, and the cylinder turbocharger housing. If there is any indication of
head.
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned.
SEBU9100 103
Walk-Around Inspection
3. Check the compressor wheel for cleanliness. If

NOTICE
only the blade side of the wheel is dirty, dirt and/or
For any type of leak (coolant, lube, or fuel) clean up
moisture is passing through the air filtering system. the fluid. If leaking is observed, find the source and
If oil is found only on the back side of the wheel, correct the leak. If leaking is suspected, check the flu-
there is a possibility of a failed turbocharger oil id levels more often than recommended until the leak
seal. is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the NOTICE
turbocharger to slobber. Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean-
4. Use a dial indicator to check the end clearance on ing or high pressure water.
the shaft. If the measured end play is greater than
the Service Manual specifications, the
• Ensure that the cooling lines are properly clamped.
turbocharger should be repaired or replaced. An Check for leaks. Check the condition of all pipes.
end play measurement that is less than the
minimum Service Manual specifications could • Check the marine transmission oil level. Refer to
indicate carbon buildup on the turbine wheel. The the OEM specification for the marine transmission
turbocharger should be disassembled for cleaning or refer to the OEM specification for the vessel.
and for inspection if the measured end play is less
• Inspect the water pumps for coolant leaks.
than the minimum Service Manual specifications.
Note: The water pump seal is lubricated by coolant in
5. Inspect the bore of the turbine housing for
the cooling system. A small amount of leakage to
corrosion. occur as the engine cools down is normal.
6. Clean the turbocharger housing with standard shop Excessive coolant leakage may indicate the need to
solvents and a soft bristle brush. replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
7. Fasten the air inlet piping and the exhaust outlet or seals, refer to the Service Manual for the engine or
piping to the turbocharger housing. consult your Cat dealer.
i05193156
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters, and the valve cover.
Walk-Around Inspection
SMCS Code: 1000-040 • Inspect the fuel system for leaks.
• Inspect the piping for the air inlet system and the
Inspect the Engine for Leaks and elbows for cracks and for loose clamps.
for Loose Connections • Inspect the alternator belt and the accessory drive
A walk-around inspection should only require a few belts for cracks, breaks, or other damage.
minutes. When the time is used to perform these
checks, costly repairs and accidents can be avoided. Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
For maximum engine service life, make a thorough carry more load than the belts that are not replaced.
inspection of the engine compartment before you The older belts are stretched. The additional load on
start the engine. Look for items such as: oil leaks, the new belt could cause the belt to break.
coolant leaks, loose bolts, worn belts and loose
connections. Make repairs, as needed:
• The guards must be in the proper place. Repair

damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
104 SEBU9100
Water Pump - Inspect
• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection

and for good condition.
• Inspect the ECM ground strap for a good

connection and for good condition.
• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges which are cracked. Replace any gauges
that cannot be calibrated.
i05264233
Water Pump - Inspect

SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in the following
conditions:
• Cracks in the cylinder head
• A piston seizure
• Other potential damage to the engine
A failed water pump might cause severe engine
overheating problems. Overheating could result in
cracks in the cylinder head, a piston seizure, or other
potential damage to the engine.
Visually inspect the water pump for leaks. If leaking of
the water pump seals is observed, replace all of the
water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Disassemble and Water Pump - Assemble” for the
disassembly and assembly procedure. If necessary
to remove the water pump, refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Remove and Water Pump - Install”.
Inspect the water pump for wear, cracks, pin holes,
and proper operation. Refer to the Parts Manual for
the correct part numbers for your engine or consult
your Cat dealer if repair is needed or replacement is
needed.
SEBU9100 105
Reference Information Section
Engine Rating Conditions
Reference Information vessels: cold-water trawlers, purse seiners, crew

boats, supply boats, ferries and towboats.
Section
C(Maximum Continuous) – Vessels operating at
rated load and rated speed up to 50% of the time with
Engine Ratings cyclical load and speed (20% to 80% load factor).
Typical operation is from 2000 service hours to 4000
service hours per year. Typical applications may
i05037610 include the following vessels: ferries, harbor tugs,
fishing boats, offshore service boats, displacement
Engine Rating Conditions hull yachts and short trip coastal freighters.
SMCS Code: 1000
D(Intermittent Duty) – Vessels operating at rated
Ratings are based on SAE J1128/ISO 8665 standard load and rated speed up to 16% of the time (up to
ambient conditions of 100 kPa (29.5 inch mercury) 50% load factor). Typical operation is from 1000
and 25° C (77° F). Ratings also apply at AS1501, service hours to 3000 service hours per year. Typical
BS5514, DIN 6271 and ISO 3046/1 standard applications may include the following vessels:
conditions of 100 kPa (29.5 inch mercury), 27° C offshore patrol boats, customs boats, police boats,
(81° F), and 60% relative humidity. fishing boats, fire boats and harbor tugs.
Power is based on a 35° (16° C (61° F) fuel which
has Low heat value (LHV) of 42780 kJ/kg E(High Performance) – Vessels operating at rated
(18390 B/lb) used at 29° C (84° F) with a density of load and speed up to 8% of the time (up to 30% load
838.9 g/L (7.001 lb/US gal). factor). Typical operation is from 250 service hours to
1000 service hours per year. Typical applications may
Engine ratings may be defined as gross output include the following vessels: pleasure craft, harbor
ratings or as the total output capability of the engine patrol boats, harbor master boats, fishing boats and
when equipped with lubrication oil, fuel, and jacket patrol boats.
water pumps. The power to drive auxiliary
applications must be deducted from the gross output
to arrive at the net power available for the external NOTICE
(flywheel) load. Typical auxiliary applications include Operating engines above the rating definitions can re-
cooling fans, air compressors, charging alternators, sult in shorter service life before overhaul.
marine gears, and seawater pumps.
For more information about the engine rating, refer to

i05037211
your Application and Installation Guide or contact
your Cat dealer.
Engine Rating Definitions
SMCS Code: 1000 i00899220
The use of the vessel must be known for the rating to Marine Classification Society
match the operating profile.
In selecting a rating for a specific application, the
Certification Requirements
most important consideration is the time that is spent SMCS Code: 1000
at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also The major seafaring nations have established
identify the corresponding times below rated rpm. technical groups called marine classification
societies. Caterpillar Inc. has maintained standards
A(Unrestricted Continuous) – Vessels operating at and quality under the guidelines that are set forth by
rated load and rated speed up to 100% of the time the 14 major marine classification societies that are
without interruption or load cycling (80% to 100% load listed. For more information, refer to Engine Data
factor). Typical operation is 5000 service hours to Sheet, 103.1 and Engine Data Sheet, 103.1.1 in the
8000 service hours per year. Typical applications may Caterpillar Technical Manual.
include the following vessels: freighters, tugboats and
bottom drag trawlers. ABS – American Bureau of Shipping (USA)
BV – Bureau Veritas (France)
B(Heavy Duty) – Vessels operating at rated load and
speed up to 80% of the time with some load cycling CCG – Canadian Coast Guard (Canada)
(40% to 80% load factor). Typical operation is from CCRS – China Corporation Register of Shipping
1000 service hours to 3000 service hours per year. (Taiwan)
Typical applications may include the following
106 SEBU9100
Engine Ratings
Marine Classification Society Certification Requirements
CCS – China Classification Society (China)

CR – Croatian Register of Shipping (Croatia)
DnV – Det norske Veritas (Norway)
GL – Germanischer Lloyd (Germany)
KR – Korean Register of Shipping (Korea)
LR – Lloyd's Register of Shipping (Great Britain)
NK – Nippon Kaiji Kyokai (Japan)
PR – Polish Register (Poland)
RINa – Registro Italiano Navale (Italy)
RS – Maritime Register of Shipping (Russia)
SEBU9100 107
Engine Performance and Performance Analysis Report (PAR)
Engine Performance
Engine Performance and If the engine is covered by a warranty, the Cat

warranty will cover the cost in order to solve a valid
Performance Analysis deficiency of the engine's performance. However, if
the engine is not at fault, all costs that are incurred
Report (PAR) will be the responsibility of the owner.
Note: Adjustment of the fuel system outside
i04537530 Caterpillar specified limits will not improve fuel
efficiency. Adjustment of the fuel system outside
Engine Performance Caterpillar specified limits could also result in
damage to the engine.
SMCS Code: 1000
Cat engines are manufactured with state-of-the-art
Today's marine operator is concerned with
technology. Cat engines are designed to help
performance, cost of operation and satisfactory
provide two characteristics in all applications:
engine life. Traditionally, poor performance of the
vessel is believed to result from a lack of engine • Maximum performance
performance or from a loss of engine performance. In
fact, the engine is only one of numerous factors that • Fuel efficiency
influence the overall performance of a vessel.
To ensure optimum performance for the service life of
Several factors determine the power demand on an the engine, follow the recommended operation
engine. The engine does not have control over the procedures that are described in this manual. Also,
demand that is caused by the vessel design. The follow the preventive maintenance procedures that
vessel design includes the following features: are described in this manual.
• Hull
Performance Analysis Report (PAR)
• Propeller
To verify the condition of the propulsion system,
• Drive train Caterpillar has developed the Performance Analysis
Report (PAR) for marine engines.
Those features also affect the amount of power that is
available to perform additional work. For example, A PAR is an in-vessel test procedure that is
those features affect the power that is used to drive performed by a Caterpillar analyst under operating
an auxiliary pump. conditions. The test compares the performance of all
marine engine systems to the original testing
If a problem with the performance of the vessel specifications.
occurs, consider the following effects on power
demand: When a PAR is conducted at Sea Trial, an installation
of high quality can be ensured. The PAR will confirm
• Loads the matching of the following components for
optimum performance and for fuel efficiency: hull,
• Condition of the vessel rudders, propeller, marine transmission, ventilation
and cooling systems.
• Vessel design
Caterpillar recommends scheduling a PAR in order to
• Condition of the drive train maintain optimum performance.
• Condition of the propeller A periodic PAR can define deterioration of the

propulsion system. A PAR can assist in repairs, in
Deterioration of the engine systems decreases the overhauls, and in maintenance schedules. This will
ability of the engine to produce power and vessel help to provide the most economical, efficient cost of
speed. Engine systems include the cooling system, operation.
the lubrication system, the fuel system, etc. The
engine is not likely to be the cause of poor fuel
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.
108 SEBU9100
Customer Service
Customer Assistance
Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i03910803
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000; 4450 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
When a problem arises concerning the operation or Caterpillar Asia Pte. Ltd.
the service of an engine, the problem will normally be 7 Tractor Road
managed by the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level, use the phone number that is listed below to Hong Kong
talk with a Field Service Coordinator: Phone: 852-2848-0333
Fax: 852-2848-0440
1-800-447-4986
Japan
The normal hours are from 8:00 to 4:30 Monday Shin Caterpillar Mitsubishi Ltd.
through Friday Central Standard Time. SBS Tower
10-1, Yoga 4-Chome
3. If your needs have not been met still, submit the
Setagaya-Ku, Tokyo 158-8530
matter in writing to the following address: Japan
Caterpillar Inc. Phone: 81-3-5717-1150
Marine Center of Excellence Fax: 81-3-5717-1177
Manager, Customer Service Japan
111 Southchase Blvd Caterpillar Power Systems, Inc.
Fountain Inn, SC 29644 SBS Tower (14th floor)
Please keep in mind: probably, your problem will 4-10-1, Yoga
ultimately be solved at the dealership, using the Setagaya-Ku, Tokyo 158-0097
dealership facilities, equipment, and personnel. Phone: 81-3-5797-4300
Therefore, follow the steps in sequence when a Fax: 81-3-5797-4359
problem is experienced.
Australia and New Zealand
Outside of the USA and of Canada Caterpillar of Australia Ltd.
1 Caterpillar Drive
If a problem arises outside the USA and outside Private Mail Bag 4
Canada , and if the problem cannot be resolved at the Tullamarine, Victoria 3043
dealer level, consult the appropriate Caterpillar Australia
office.
Phone: 03-9953-9333
Latin America, Mexico, Carribean Fax: 03-9335-3366
Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
SEBU9100 109
Customer Service
Ordering Replacement Parts
i01028392 i04760831
Ordering Replacement Parts On-Board Replacement Parts

SMCS Code: 4450; 7567 SMCS Code: 7567
The various Marine Classification Societies require a
supply of replacement parts on vessels that are
primarily powered by diesel engines. The
When replacement parts are required for this replacement parts may be needed for making repairs
product Caterpillar recommends using Caterpil- offshore or at remote ports. The types of replacement
lar replacement parts or parts with equivalent parts and the numbers of parts depends on the range
specifications including, but not limited to, physi- of the vessel. The following two categories of vessels
cal dimensions, type, strength and material. are considered:
Failure to heed this warning can lead to premature Category 1 – This category includes vessels that
failures, product damage, personal injury or make short trips between ports.
death. Category 2 – This category includes vessels in
ocean service that is unrestricted. The vessels may
travel far from ports that provide service. The list of
Quality Caterpillar replacement parts are available replacement parts for this category is more extensive.
from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are Table 21 lists the parts that are recommended by
normally needed to protect your Caterpillar engine Caterpillar for vessels in both categories.
investment.
The requirements of individual Marine Classification
When you order parts, please specify the following Societies may differ. Table 22 lists the requirements
information: of all the Marine Classification Societies. Additionally,
some items that are recommended by Caterpillar are
• Part number listed. All of the parts that are listed in Table 21 and
22 are recommended for vessels in Category 2. To
• Part name customize this list for your specific engine application,
consult your Cat dealer.
• Quantity
Table 21
If there is a question concerning the part number, Replacement Parts for Vessels in Category 1 and Cate-
please provide your dealer with a complete gory 2
description of the needed item.
Quantity Item
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the 4 Air cleaner element
information that is stamped on the Information Plate.
1 Alternator belt
This information is described in this Operation and
Maintenance Manual (Product Information Section). 1 Electronic control module (ECM)
Discuss the problem with the dealer. Inform the 1 Electronic unit injector
dealer about the conditions of the problem and the
- Engine oil
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in - Extended Life Coolant (ELC) and Extender
troubleshooting the problem and solving the problem or
faster. Diesel Engine Antifreeze/Coolant (DEAC) and Sup-
plemental Coolant Additive (SCA)
4 Fuel filter elements

1 Fluid sampling bottles
- Liquid gasket material
4 Engine oil filters
1 Service kit (electronic connector)
4 Water temperature regulator
4 Zinc rods
110 SEBU9100
Customer Service
On-Board Replacement Parts
Table 22 (Table 22, contd)

Replacement Parts for Vessels in Category 2 Replacement Parts for Vessels in Category 2
System Quantity Item System Quantity Item

Camshaft and 1 Bolt (crankshaft to flywheel) 2 Piston pin retainer
crankshaft
1 Camshaft gear 1 Piston rings (complete set)
1 Crankshaft gear 3 Seals (cylinder liner)
1 Idler gear and balance weight Starting 1 Starting motor

gear assembly (water pump)
Turbocharger 1 Complete turbocharger
1 Shaft and thrust washer (idler
gear and balance weight gear - Gasket
assembly) 4 Locknut
Cooling 1 Aftercooler core and gasket 4 Stud (mounting)
1 Auxiliary water pump Valves 6 Exhaust valves
1 Jacket water pump 4 Inlet valves
4 Water temperature regulator 10 Valve guides
Cylinder head 6 Bolt and washer 24 Valve locks
1 Bolt and nut (exhaust manifold) 10 Valve rotators
1 Cylinder head assembly 10 Valve springs
4 Gasket (cylinder)
- Water seals for one cylinder
Fuel 3 Electronic unit injector
1 Fuel transfer pump
3 Seal (electronic unit injector)
Inlet air 2 Air cleaner element

Lubrication 1 Bypass valve (oil cooler)
1 Bypass valve (oil filter)
1 Gasket (oil pan)
1 Oil cooler core (engine)
1 Oil cooler core (marine gear)
Miscellaneous 1 Gasket kit (engine)
Piston 1 Connecting rod assembly
1 Connecting rod bearing
1 Cylinder liner
1 Filler band (cylinder liner)
1 Main bearing
2 Cap bolt and washer (main

bearing)
1 Piston assembly
1 Piston pin
(continued)
SEBU9100 111
Reference Materials
Maintenance Records
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.

• Establish maintenance schedules for other
engines that are operated in the same
environment.
• Show compliance with the required maintenance
practices and maintenance intervals.
Maintenance records can be used for various other
business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is managed. Accurate
maintenance records can help your Cat dealer to
fine-tune the recommended maintenance intervals in
order to meet the specific operating situation. This
should result in a lower engine operating cost.
Records should be kept for the following items:
Fuel Consumption – A record of fuel consumption is
essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
Service Hours – A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents – These items should be easy to obtain,
and these items should be kept in the engine history
file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:
Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills
• Owner repair costs

• Owner receipts
• Maintenance log
112 SEBU9100
Reference Materials
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 23
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU9100 113
Reference Materials
Reference Material
i05045310 • Special Publication, PEHJ0191, “S·O·S Coolant

Analysis”
Reference Material
• Special Publication, PEGJ0047, “How To Take A
SMCS Code: 1000; 4450 Good Oil Sample”
The following literature can be obtained through any • Special Publications, PEDP7036, “S·O·S Fluids
Cat dealer. Analysis Cornerstone”
Engine Oil • Special Publications, PEHP7076, “Understanding
S·O·S Services Tests”
• Datasheet, PEHJ0159, “Cat DEO-ULS (SAE 15W-
40)” (North America - Canada, Mexico, and United • Special Publication, PEHP7052, “Making the Most
States) of S·O·S Services”
• Datasheet, PEHJ0059, “Cat DEO (SAE 10W-30 • Special Publication, PEGJ0045, “Reporting
and SAE 15W-40)” (North America - Canada, Particle Count by ISO Code”
Mexico, and United States)
• Special Publication, PEGJ0046, “Understanding
• Datasheet, PEHJ0021, “Cat DEO (SAE 10W-30 Your S·O·S Services Results”
and SAE 15W-40)” (Worldwide - except North
America, Egypt , Saudi Arabia , and Brazil) Miscellaneous
• Datasheet, PEHJ0072, “Cat DEO (SAE 10W-30 • Special Publication, SEBU6251, Cat Commercial
and SAE 15W-40)” (Brazil) Diesel Engine Fluids Recommendations
• Datasheet, PEHJ0091, “Cat DEO (SAE 10W-30 • Special Publication, PECP9067, “One Safe
and SAE 15W-40)” (Egypt and Saudi Arabia ) Source”
• Datasheet, PEHJ0008, “Cat Arctic DEO (SAE 0W- • Special Instruction, REHS0354, Charging System
30)” (Canada and United States) Troubleshooting
Coolants • Installation Guide, REHS1187, Marine Engine

Electronic Installation Guide
• Special Publication, PMEP5027, “Label - Cat
ELC Radiator Label” • Specifications, SENR3130, “Torque
Specifications”
• Datasheet, PEHJ0067, “Cat ELC (Extended Life
Coolant)” (Worldwide) • Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
• Datasheet, PEHP9554, “Cat DEAC (Diesel Engine Operations”
Antifreeze/Coolant) (Concentrate)”
• Special Publication, SEBF8062, “Guideline for
Fuels Reusable Parts - Cleaning and Inspection of Air
Filters”
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine” • Special Publication, SEBU5898, Cold Weather
Recommendations for all Cat Machines
S·O·S Services
• Special Instruction, SEHS9031, “Storage
• Procedure for Cat Products”
• Special Instruction, SEHS8622, “Using the FT-
1984 Air-To-Air Aftercooler Leak Test Group”
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Special Instruction, SEHS7332, “Do Not Operate

Tag”
114 SEBU9100
Reference Materials
Decommissioning and Disposal
i03989612
Decommissioning and
Disposal
SMCS Code: 1000
When the product is removed from service, local
regulations for the product decommissioning will vary.
Disposal of the product will vary with local
regulations. Consult the nearest Cat dealer for
additional information.
SEBU9100 115
Index Section
Index
A Engines That Are Equipped with a Coolant
Recovery Tank ........................................... 66
After Starting Engine........................................ 38
Engines That Are Not Equipped with a Coolant
After Stopping Engine...................................... 45
Recovery Tank ........................................... 66
Aftercooler Condensate Drain Valve -
Coolant Sample (Level 1) - Obtain .................. 67
Inspect/Clean................................................. 58
Sampling Conditions.................................... 67
Aftercooler Core - Clean/Test .......................... 59
Timing of the Sampling ................................ 67
Clean the Aftercooler Core .......................... 59
Coolant Sample (Level 2) - Obtain .................. 68
Test the Aftercooler Core ............................. 59
Obtaining the Sample .................................. 68
Aftercooler Core - Inspect................................ 60
Coolant Temperature Regulator - Replace ...... 68
Auxiliary Water Pump (Bronze Impeller) -
Cooling System Supplemental Coolant
Inspect/Replace............................................. 60
Additive (SCA) - Test/Add .............................. 69
Cooling Systems that Use Conventional
B Coolant....................................................... 69
Crankshaft Vibration Damper - Inspect............ 70
Battery - Replace............................................. 60
Inspection..................................................... 70
Battery Disconnect Switch (If Equipped) ......... 29
Removal and Installation.............................. 70
Battery Electrolyte Level - Check .................... 61
Crushing Prevention and Cutting Prevention .. 14
Battery or Battery Cable - Disconnect ............. 61
Customer Assistance..................................... 108
Before Starting Engine ...............................14, 35
Outside of the USA and of Canada ........... 108
Belts - Inspect/Adjust/Replace......................... 62
USA and Canada ...................................... 108
Adjust ........................................................... 62
Customer Service .......................................... 108
Inspect ......................................................... 62
Replace........................................................ 62
Bolts (Fuel Filter Base) - Inspect/Replace ....... 63 D
Burn Prevention................................................11
Decommissioning and Disposal .....................114
Batteries....................................................... 12
Derating Strategy............................................. 31
Coolant..........................................................11
Oils................................................................11
E
C Electrical System ............................................. 15
Grounding Practices .................................... 15
Cold Start Strategy .......................................... 29
Negative Battery Connection for Multiple
Cold Weather Operation.................................. 41
Engines ...................................................... 17
Hints for Cold Weather Operation................ 41
Emergency Stopping ....................................... 45
Idling the Engine .......................................... 42
Emissions Certification Film ............................ 25
Recommendations for Coolant Warm Up .... 42
Engine - Clean ................................................. 71
Recommendations for the Coolant .............. 42
Engine Air Cleaner Element (Single
Viscosity of the Engine Lubrication Oil......... 42
Element) - Inspect/Replace ........................... 71
Cold Weather Starting ..................................... 35
Replacing the Air Cleaner Element.............. 71
Control Panel (Cat Marine Engine Control
Engine Air Cleaner Service Indicator -
Panel III (MECP III ) (If Equipped)) ................ 29
Inspect (If Equipped)...................................... 72
Coolant - Change............................................. 63
Test the Service Indicator............................. 72
Drain the Cooling System ............................ 63
Engine Cooling System Corrosion
Fill the Cooling System ................................ 65
Protection System - Inspect........................... 72
Flush ............................................................ 64
Location of the Corrosion Protection Post ... 73
Coolant Extender (ELC) - Add ......................... 65
Results of the Test........................................ 73
Coolant Level - Check ..................................... 66
Testing the Voltage Potential........................ 73
116 SEBU9100
Index Section
Engine Crankcase Breather - Clean................ 73 California Proposition 65 Warning ................. 4

Engine Diagnostics.......................................... 33 Literature Information..................................... 4
Engine Electronics........................................... 17 Maintenance .................................................. 4
Engine Mounts - Inspect.................................. 74 Maintenance Intervals.................................... 4
Engine Oil and Filter - Change ........................ 76 Operation ....................................................... 4
Drain the Engine Oil ..................................... 77 Overhaul ........................................................ 4
Fill the Engine Crankcase ............................ 78 Safety............................................................. 4
Inspect the Used Oil Filter Elements............ 79 Fuel and the Effect from Cold Weather............ 43
Interval for Engine Oil and Filter Change ..... 76 Fuel Conservation Practices............................ 40
Replace the Oil Filter With the Engine Stopped Cruising Speed ............................................ 40
(Standard Oil Filters) .................................. 77 Fuel Injector - Check........................................ 81
Replacing the Engine Oil Filters During Engine Fuel Related Components in Cold Weather .... 44
Operation (Duplex Oil Filters)..................... 78 Fuel Filters ................................................... 44
Engine Oil Level - Check ................................. 74 Fuel Heaters ................................................ 44
Engine Oil Level Gauge - Calibrate ................. 75 Fuel Tanks.................................................... 44
Engine Oil Sample - Obtain ............................. 75 Fuel System - Prime ........................................ 82
Obtain the Sample and the Analysis............ 76 Fuel System Primary Filter (Water
Engine Operation............................................. 40 Separator) Element - Replace ....................... 83
Engine Operation with Active Diagnostic Replace the Element.................................... 83
Codes ............................................................ 33 Fuel System Primary Filter/Water Separator
Engine Operation with Intermittent - Drain ............................................................ 83
Diagnostic Codes........................................... 34 Fuel System Secondary Filter - Replace ......... 84
Engine Performance...................................... 107 Replacing the Fuel Filter Elements During
Performance Analysis Report (PAR).......... 107 Engine Operation For Engines That Are
Engine Performance and Performance Equipped With Duplex Fuel Filters............. 86
Analysis Report (PAR) ................................. 107 Replacing the Fuel Filter Elements with the
Engine Rating Conditions.............................. 105 Engine Stopped.......................................... 85
Engine Rating Definitions .............................. 105 Fuel Tank Water and Sediment - Drain............ 88
Engine Ratings .............................................. 105 Drain the Water and the Sediment............... 88
Engine Speed/Timing Sensor - Clean/ Fuel Storage Tanks ...................................... 88
Inspect ........................................................... 80 Fuel Tank ..................................................... 88
Engine Starting ...........................................15, 35 Fumes Disposal Filter Element - Replace ....... 88
Engine Stopping .........................................15, 45 Replacing the Fumes Disposal Filter ........... 88
Engine Storage Procedure - Check................. 80 Resetting the Service Indicator (If Equipped)
Engine Valve Lash - Check.............................. 81 ................................................................... 89
Engine Valve Rotators - Inspect ...................... 81
G
F Gauges and Indicators .................................... 31
Fault Logging................................................... 33 General Hazard Information .............................. 8
Features and Controls ..................................... 29 Containing Fluid Spillage ............................... 9
Fire Prevention and Explosion Prevention ...... 12 Dispose of Waste Properly............................11
Ether ............................................................ 13 Fluid Penetration............................................ 9
Fire Extinguisher.......................................... 13 Inhalation ..................................................... 10
Lines, Tubes, and Hoses ............................. 13 Lines, Tubes, and Hoses ............................. 10
Fluid Recommendations.................................. 47 Pressurized Air and Water ............................. 9
Cooling System............................................ 51 Softwrap........................................................11
Diesel Engine Oil ......................................... 47 Static Electricity Hazard when Fueling with
Fuel .............................................................. 49 Ultra-low Sulfur Diesel Fuel........................ 10
Greases ....................................................... 54 General Information......................................... 19
Foreword............................................................ 4
SEBU9100 117
Index Section
H O
Heat Exchanger - Clean/Test........................... 89 Oil Cooler Core - Check/Clean/Test ................ 97
Clean the Heat Exchanger........................... 89 Clean the Oil Cooler Core ............................ 97
Test the Heat Exchanger Core..................... 90 Test the Oil Cooler Core............................... 97
Heat Exchanger - Inspect ................................ 90 On-Board Replacement Parts ....................... 109
Hoses and Clamps - Inspect/Replace ............. 91 Operation Section............................................ 26
Inspect the Hoses and the Clamps .............. 91 Ordering Replacement Parts ......................... 109
Replace the Hoses and the Clamps ............ 91 Overhaul (Major).............................................. 97
Cleaning and Pressure Testing of
Components............................................. 100
I Cleaning of Components ........................... 100
Important Safety Information ............................. 2 Inspection of Components ........................... 99
Inspection, Reconditioning, or Exchanging of
Components............................................... 98
L Obtain a Coolant Analysis.......................... 100
Lifting and Storage........................................... 26 Replacement of Components ...................... 98
Overhaul (Top End)........................................ 100
Overspeed ....................................................... 32
M
Maintenance Interval Schedule ....................... 57 P
Daily ............................................................. 57
Every 1000 Service Hours ........................... 58 Plate Locations and Film Locations................. 24
Every 170 400 L (45 000 US gal) of Fuel or Engine Identification Plate (2) ...................... 24
3000 Service Hours.................................... 58 Engine Serial Number (1)............................. 24
Every 2000 Service Hours ........................... 58 Product Description ......................................... 21
Every 250 Service Hours ............................. 57 Electronic Engine Features.......................... 22
Every 250 Service Hours or 1 Year.............. 57 Engine Cooling and Lubrication................... 22
Every 3000 Service Hours ........................... 58 Engine Service Life ...................................... 23
Every 50 Service Hours or Weekly .............. 57 Engine Specifications .................................. 21
Every 500 Service Hours ............................. 57 Product Identification Information.................... 24
Every 5000 Service Hours ........................... 58 Product Information Section ............................ 19
Every Year.................................................... 58 Product Lifting.................................................. 26
Initial 1000 Service Hours ............................ 57 Product Storage............................................... 26
Initial 500 Hours (for New Systems, Refilled Engine.......................................................... 26
Systems, and Converted Systems)............ 57
Overhaul ...................................................... 58
R
Overhaul (Top End)...................................... 58
When Required............................................ 57 Reference Information..................................... 25
Maintenance Log ............................................112 Record for Reference................................... 25
Maintenance Recommendations................55, 93 Reference Information Section ...................... 105
Overhaul Considerations ............................. 95 Reference Material .........................................113
Relationship of Fuel Consumption to Service Coolants......................................................113
Hours.......................................................... 93 Engine Oil ...................................................113
Maintenance Records..................................... 111 Fuels ...........................................................113
Maintenance Section....................................... 47 Miscellaneous .............................................113
Manual Stop Procedure................................... 45 S·O·S Services ...........................................113
Marine Classification Society Certification Reference Materials ....................................... 111
Requirements .............................................. 105 Refill Capacities............................................... 47
Model View Illustrations................................... 19 Cooling System Capacity............................. 47
Mounting and Dismounting.............................. 14 Lubrication System ...................................... 47
118 SEBU9100
Index Section
S
Safety Messages............................................... 5
Explosion Hazard (3) ..................................... 7
Hot Fluid Under Pressure (2) ......................... 7
Universal Warning (1) .................................... 7
Safety Section ................................................... 5
Sea Water Strainer - Clean/Inspect............... 101
Self-Diagnostics............................................... 33
Starting Motor - Inspect (If equipped) ............ 101
Air Starting Motor ....................................... 101
Electric Starting Motor................................ 101
Removal and Installation of the Starting Motor
................................................................. 102
Starting the Engine .......................................... 36
Automatic Starting........................................ 36
Manual Starting............................................ 36
Starting with Jump Start Cables ...................... 38
System Pressure Release............................... 55
Coolant System............................................ 55
Engine Oil .................................................... 55
Fuel System ................................................. 55
T
Table of Contents............................................... 3
Turbocharger - Inspect .................................. 102
Cleaning and Inspecting ............................ 102
Removal and Installation............................ 102
W
Walk-Around Inspection ................................ 103
Inspect the Engine for Leaks and for Loose
Connections ............................................. 103
Water Pump - Inspect .................................... 104
Welding on Engines with Electronic Controls .. 55
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:
Product Identification Number:
Engine Serial Number:
Transmission
Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment
Number:
Dealer Information
Name: Branch:
Address:
Dealer Phone Hours

Contact Number
Sales:
Parts:
Service:
©2013 Caterpillar CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

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SEBU9100-01

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Refill Capacities....................... ....................... 47

Foreword.............................. ............................. 4 Maintenance Recommendations.......... .......... 55

Maintenance Interval Schedule ........... ........... 57

Safety Messages....................... ....................... 5

Engine Ratings ....................... ...................... 105

Burn Prevention....................... ........................11 Engine Performance and Performance Analysis

Engine Stopping ....................... ...................... 15

Electrical System ...................... ...................... 15

Engine Electronics..................... ..................... 17

Product Information Section

General Information.................... .................... 19

Product Identification Information.......... ......... 24

Lifting and Storage..................... ..................... 26

Features and Controls .................. .................. 29

Engine Diagnostics..................... .................... 33

Engine Starting ........................ ....................... 35

Engine Operation...................... ...................... 40

Cold Weather Operation................. ................ 41

Engine Stopping ....................... ...................... 45

Foreword Recommended service should be performed at the

Universal Warning (1)

Explosion Hazard (3)

One safety message is located on the valve cover

Do not operate or work on this equipment unless

Hot Fluid Under Pressure (2)

One safety message is located on the top of each

General Hazard Information

• Wear a hard hat, protective glasses, and other

• The engine is stopped. Ensure that the engine Fluid Penetration

• The protective locks or the controls are in the

• When starting a new engine, make provisions to

Avoid static electricity risk when fueling. Ultra-low

• Wire that is exposed in reinforced hose

• Flexible part of the hose that is kinked or crushed

• Never use compressed air for cleaning. Dispose of Waste Properly

• Avoid grinding materials that contain asbestos.

• A vacuum cleaner that is equipped with a high

• Wear an approved respirator if there is no other

Illustration 12 g00704059 Illustration 13 g02298225

Lines, Tubes, and Hoses

Repair any lines that are loose or damaged. Leaks i01372247

If equipped, ensure that the lighting system for the i01462046

All protective guards and all protective covers must

Uncontrolled or unreliable electrical circuit paths may

Note: All electrical connections must meet or exceed

Negative Battery Connection for Multiple Engines

Install the battery disconnect switches as close as i05391510

This engine has a comprehensive, programmable

• Engine Coolant Level

• Engine Oil Pressure

• Turbocharger Inlet Temperature

Product Information General Information

Model View Illustrations

i05043609 The C32 Marine Engine uses a low emission system

• Separate circuit aftercooling (SCAC)