CAT + Caterpillar C30 Marine Engine Operation & Maintenance Manual by Heavy Equipment Manual

Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

Foreword

LiteratureInformation

Thismanualcontainssafety,operationinstructions,lubricationandmaintenanceinformation.Thismanual shouldbestoredinorneartheengineareainaliteratureholderorliteraturestoragearea.Read,studyand keepitwiththeliteratureandengineinformation.

EnglishistheprimarylanguageforallCatpublications.TheEnglishusedfacilitatestranslationand consistencyinelectronicmediadelivery.

Somephotographsorillustrationsinthismanualshowdetailsorattachmentsthatmaybedifferentfromyour engine.Guardsandcoversmayhavebeenremovedforillustrativepurposes.Continuingimprovementand advancementofproductdesignmayhavecausedchangestoyourenginewhicharenotincludedinthis manual.Wheneveraquestionarisesregardingyourengine,orthismanual,pleaseconsultwithyourCat dealerforthelatestavailableinformation.

Safety

Thissafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifieshazardous,warning situations.Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingor performinglubrication,maintenanceandrepaironthisproduct.

Operation

Operatingtechniquesoutlinedinthismanualarebasic.Theyassistwithdevelopingtheskillsandtechniques requiredtooperatetheenginemoreefficientlyandeconomically.Skillandtechniquesdevelopasthe operatorgainsknowledgeoftheengineanditscapabilities.

Theoperationsectionisareferenceforoperators.Photographsandillustrationsguidetheoperatorthrough proceduresofinspecting,starting,operatingandstoppingtheengine.Thissectionalsoincludesadiscussion ofelectronicdiagnosticinformation.

Maintenance

Themaintenancesectionisaguidetoenginecare.Theillustrated,step-by-stepinstructionsaregroupedby fuelconsumption,servicehoursand/orcalendartimemaintenanceintervals.Itemsinthemaintenance schedulearereferencedtodetailedinstructionsthatfollow.

Usefuelconsumptionorservicehourstodetermineintervals.Calendarintervalsshown(daily,annually,etc.) maybeusedinsteadofservicemeterintervalsiftheyprovidemoreconvenientschedulesandapproximate theindicatedservicemeterreading.

RecommendedserviceshouldbeperformedattheappropriateintervalsasindicatedintheMaintenance IntervalSchedule.TheactualoperatingenvironmentoftheenginealsogovernstheMaintenanceInterval Schedule.Therefore,underextremelysevere,dusty,wetorfreezingcoldoperatingconditions,morefrequent lubricationandmaintenancethanisspecifiedintheMaintenanceIntervalSchedulemaybenecessary.

Themaintenancescheduleitemsareorganizedforapreventivemaintenancemanagementprogram.Ifthe preventivemaintenanceprogramisfollowed,aperiodictune-upisnotrequired.Theimplementationofa preventivemaintenancemanagementprogramshouldminimizeoperatingcoststhroughcostavoidances resultingfromreductionsinunscheduleddowntimeandfailures.

MaintenanceIntervals

Performmaintenanceonitemsatmultiplesoftheoriginalrequirement.Eachleveland/orindividualitemsin eachlevelshouldbeshiftedaheadorbackdependinguponyourspecificmaintenancepractices,operation andapplication.Werecommendthatthemaintenanceschedulesbereproducedanddisplayedneartheengine asaconvenientreminder.Wealsorecommendthatamaintenancerecordbemaintainedaspartofthe engine'spermanentrecord.

SeethesectionintheOperationandMaintenanceManual,"MaintenanceRecords"forinformationregarding documentsthataregenerallyacceptedasproofofmaintenanceorrepair.YourauthorizedCatdealercan assistyouinadjustingyourmaintenancescheduletomeettheneedsofyouroperatingenvironment.

Overhaul

MajorengineoverhauldetailsarenotcoveredintheOperationandMaintenanceManualexceptforthe intervalandthemaintenanceitemsinthatinterval.Majorrepairsarebestlefttotrainedpersonneloran authorizedCatdealer.YourCatdealeroffersavarietyofoptionsregardingoverhaulprograms.Ifyou experienceamajorenginefailure,therearealsonumerousafterfailureoverhauloptionsavailablefromyour Catdealer.Consultwithyourdealerforinformationregardingtheseoptions.

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocausecancer,birth defects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

ZincRods-Inspect/Replace

SMCS-1388-040;1388-510

i05198936

Corrosioninseawatercircuitscanresultinprematuredeteriorationofsystemcomponents,leaks,and possiblecoolingsystemcontamination.Alackofzincrodsintheseawatersystemcancause corrosionintheseawatercoolingsystem.

Zincrodsareinsertedintheseawatercoolingsystemoftheengineinordertohelppreventthe corrosiveactionofsaltwater.Thereactionofthezinctotheseawatercausesthezincrodsto deteriorate.Thezincrodsdeteriorateinsteadofenginepartsforthecoolingsystemthataremore critical.Rapiddeteriorationofzincrodsmayindicatethepresenceofuncontrolledelectricalcurrents fromimproperlyinstalledelectricalattachmentsorimproperlygroundedelectricalattachments.

Thezincrodsmustbeinspectedattheproperintervals.Thezincrodsmustbereplacedwhen deteriorationoccurs.

InspecttheZincRods

Thezincrodsareredforeasyidentification.Table1showsthelocationsofthezincrodsandthe quantitiesofthezincrods.

InletElbowforSeaWaterOntheHeatExchanger1

OutletElbowforSeaWaterOntheHeatExchanger1

1.Removethezincrod.

Illustration1g00104048

2.Tapthezincrodlightlywithahammer.Ifthezincrodhasdeteriorated,orifthezincrodflakes, installanewzincrod.

ReplacetheZincRods

Illustration2g00104049

This is the sample of the manual if you need complete manual Click Here to download

1.Unscrewtheoldzincrodordrilltheoldzincrodfromtheplug.Cleantheplug.

2.Apply9S-3263Compoundtotheshoulderofanewzincrod.Applythecompoundonlytothe shoulderofthezincrod.Installthezincrodintotheplug.

3.Coattheexternalthreadsoftheplugwith5P-3413PipeSealant.Installthezincrod.Referto OperationandMaintenanceManualformoreinformationontorquespecifications.

FriJun2509:52:43UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

WaterPump-Inspect

SMCS-1361-040;1361

Afailedwaterpumpmightcausesevereengineoverheatingproblemsthatcouldresultinthe followingconditions:

•Cracksinthecylinderhead

•Apistonseizure

•Otherpotentialdamagetotheengine

i05264233

Afailedwaterpumpmightcausesevereengineoverheatingproblems.Overheatingcouldresultin cracksinthecylinderhead,apistonseizure,orotherpotentialdamagetotheengine.

Visuallyinspectthewaterpumpforleaks.Ifleakingofthewaterpumpsealsisobserved,replaceall ofthewaterpumpseals.RefertotwoarticlesintheDisassemblyandAssemblyManual,"Water Pump-DisassembleandWaterPump-Assemble"forthedisassemblyandassemblyprocedure.If necessarytoremovethewaterpump,refertotwoarticlesintheDisassemblyandAssemblyManual, "WaterPump-RemoveandWaterPump-Install".

Inspectthewaterpumpforwear,cracks,pinholes,andproperoperation.RefertothePartsManual forthecorrectpartnumbersforyourengineorconsultyourCatdealerifrepairisneededor replacementisneeded.

FriJun2509:52:33UTC+05302021

Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

Walk-AroundInspection

SMCS-1000-040

InspecttheEngineforLeaksandforLooseConnections

i05867447

Awalk-aroundinspectionshouldonlyrequireafewminutes.Whenthetimeisusedtoperformthese checks,costlyrepairsandaccidentscanbeavoided.

Formaximumengineservicelife,makeathoroughinspectionoftheenginecompartmentbeforeyou starttheengine.Lookforitemssuchas:oilleaks,coolantleaks,loosebolts,wornbeltsandloose connections.Makerepairs,asneeded:

•Theguardsmustbeintheproperplace.Repairdamagedguardsorreplacemissingguards.

•Wipeallcapsandplugsbeforetheengineisservicedinordertoreducethechanceofsystem contamination.

NOTICE

Foranytypeofleak(coolant,lube,orfuel)cleanupthefluid.If leakingisobserved,findthesourceandcorrecttheleak.Ifleakingis suspected,checkthefluidlevelsmoreoftenthanrecommendeduntil theleakisfoundorfixed,oruntilthesuspicionofaleakisprovedtobe unwarranted.

Accumulatedgreaseand/oroilonanengineordeckisafirehazard. Removethisdebriswithsteamcleaningorhighpressurewater.

•Ensurethatthecoolinglinesareproperlyclamped.Checkforleaks.Checktheconditionofall pipes.

•Checkthemarinetransmissionoillevel.RefertotheOEMspecificationforthemarine transmissionorrefertotheOEMspecificationforthevessel.

•Inspectthewaterpumpsforcoolantleaks.

Note:Thewaterpumpsealislubricatedbycoolantinthecoolingsystem.Asmallamountofleakage tooccurastheenginecoolsdownisnormal.

Excessivecoolantleakagemayindicatetheneedtoreplacethewaterpumpseal.Fortheremovalof waterpumpsandtheinstallationofwaterpumpsand/orseals,refertotheServiceManualforthe engineorconsultyourCatdealer.

•Inspectthelubricationsystemforleaksatthefrontcrankshaftseal,therearcrankshaftseal,the oilpan,theoilfilters,andthevalvecover.

•Inspectthefuelsystemforleaks.

•Inspectthepipingfortheairinletsystemandtheelbowsforcracksandforlooseclamps.

•Inspectthealternatorbeltandtheaccessorydrivebeltsforcracks,breaks,orotherdamage.

Beltsformultiplegroovepulleysmustbereplacedasmatchedsets.Ifonlyonebeltisreplaced,the beltwillcarrymoreloadthanthebeltsthatarenotreplaced.Theolderbeltsarestretched.The additionalloadonthenewbeltcouldcausethebelttobreak.

•Drainthewaterandthesedimentfromfueltanksonadailybasisinordertoensurethatonly cleanfuelentersthefuelsystem.

•Inspectthewiringandthewiringharnessesforlooseconnectionsandforwornwiresorfrayed wires.

•Inspectthealternatorconnections.

•Inspectthegroundstrapforagoodconnectionandforgoodcondition.

•Inspectthestarterconnections.

•InspecttheECMgroundstrapforagoodconnectionandforgoodcondition.

•Disconnectanybatterychargersthatarenotprotectedagainstthecurrentdrainofthestarting motor.Checktheconditionandtheelectrolytelevelofthebatteries,unlesstheengineis equippedwithamaintenancefreebattery.

•Checktheconditionofthegauges.Replaceanygaugeswhicharecracked.Replaceanygauges thatcannotbecalibrated.

FriJun2509:51:46UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

Turbocharger-Inspect

SMCS-1052-040;1052

i05965726

Periodicinspectionandcleaningarerecommendedfortheturbochargercompressorhousing(inlet side).Anyfumesfromthecrankcasearefilteredthroughtheairinletsystem.Therefore,by-products fromoilandfromcombustioncancollectintheturbochargercompressorhousing.Overtime,this buildupcancontributetolossofenginepower,increasedblacksmokeandoveralllossofengine efficiency.

Iftheturbochargerfailsduringengineoperation,damagetotheturbochargercompressorwheel and/ortotheenginemayoccur.Damagetotheturbochargercompressorwheelcancauseadditional damagetothepistons,thevalves,andthecylinderhead.

NOTICE

Turbochargerbearingfailurescancauselargequantitiesofoiltoenter theairinletandexhaustsystems.Lossofenginelubricantcanresultin seriousenginedamage.

Minorleakageofaturbochargerhousingunderextendedlowidle operationshouldnotcauseproblemsaslongasaturbochargerbearing failurehasnotoccurred.

Whenaturbochargerbearingfailureisaccompaniedbyasignificant engineperformanceloss(exhaustsmokeorenginerpmupatnoload), donotcontinueengineoperationuntiltheturbochargerisrepairedor replaced.

Aninspectionoftheturbochargercanminimizeunscheduleddowntime.Aninspectionofthe turbochargercanalsoreducethechanceforpotentialdamagetootherengineparts.

Note:Turbochargercomponentsrequireprecisionclearances.Theturbochargercartridgemustbe balancedduetohighrpm.SevereServiceApplicationscanacceleratecomponentwear.Severe ServiceApplicationsrequiremorefrequentinspectionsofthecartridge.

RemovalandInstallation

Foroptionsregardingtheremoval,installation,repair,andreplacement,consultyourCatdealer. RefertotheServiceManualforthisenginefortheprocedureandspecifications.

CleaningandInspecting

1.Removetheexhaustoutletpipingandremovetheairinletpipingfromtheturbocharger. Visuallyinspectthepipingforthepresenceofoil.Cleantheinteriorofthepipesinorderto preventdirtfromenteringduringreassembly.

2.Turnthecompressorwheelandtheturbinewheelbyhand.Theassemblyshouldturnfreely. Inspectthecompressorwheelandtheturbinewheelforcontactwiththeturbochargerhousing. Thereshouldnotbeanyvisiblesignsofcontactbetweentheturbinewheelorcompressorwheel andtheturbochargerhousing.Ifthereisanyindicationofcontactbetweentherotatingturbine wheelorthecompressorwheelandtheturbochargerhousing,theturbochargermustbe reconditioned.

3.Checkthecompressorwheelforcleanliness.Ifonlythebladesideofthewheelisdirty,dirt and/ormoistureispassingthroughtheairfilteringsystem.Ifoilisfoundonlyonthebackside ofthewheel,thereisapossibilityofafailedturbochargeroilseal.

Thepresenceofoilmaybetheresultofextendedengineoperationatlowidle.Thepresenceof oilmayalsobetheresultofarestrictionofthelinefortheinletair(pluggedairfilters),which causestheturbochargertoslobber.

4.Inspecttheboreoftheturbinehousingforcorrosion.

5.Cleantheturbochargerhousingwithstandardshopsolventsandasoftbristlebrush.

6.Fastentheairinletpipingandtheexhaustoutletpipingtotheturbochargerhousing.

FriJun2509:51:32UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

StartingMotor-Inspect

SMCS-1451-040;1453-040

i00651416

CaterpillarInc.recommendsascheduledinspectionofthestartingmotor.Ifthestartingmotorfails, theenginemaynotstartinanemergencysituation.

Checkthestartingmotorforproperoperation.Checktheelectricalconnectionsandcleanthe electricalconnections.RefertotheServiceManualformoreinformationonthecheckingprocedure andforspecificationsorconsultyourCaterpillardealerforassistance.

FriJun2509:51:22UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

SeaWaterStrainer-Clean/Inspect

SMCS-1371-040;1371-070

i06104394

Theseawaterstrainermustbecleaninordertoallowproperenginecooling.Checktheseawater strainerforplugging.Inspecttheseawaterstrainermorefrequentlyifthevesselisbeingoperatedin waterwhichisshallowordirty.RefertotheOEMrecommendationsformoreinformationabout inspectingandcleaningtheseawaterstrainer.

Ensurethattheauxiliarywaterpumpisprimedandthatthesuctionlineisopen.

1.Shutoffseawatervalve.

2.Removetheseawaterstrainerandcleanthescreen.Removeanydirtanddebris.

3.Installtheseawaterstrainer.Filltheseawaterstrainerandthesuctionlinefortheauxiliary waterpumpwithwater.

4.Openseawatervalve.

FriJun2509:51:09UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

OverhaulConsiderations

SMCS-7595-043

i02018788

Reducedhoursofoperationatfullloadwillresultinaloweraveragepowerdemand.Adecreased averagepowerdemandshouldincreaseboththeengineservicelifeandtheoverhaulinterval.

Theneedforanoverhaulisgenerallyindicatedbyincreasedfuelconsumptionandbyreducedpower.

Thefollowingfactorsareimportantwhenadecisionisbeingmadeonthepropertimeforanengine overhaul:

•Theneedforpreventivemaintenance

•Thequalityofthefuelthatisbeingused

•Theoperatingconditions

•TheresultsoftheS·O·Sanalysis

OilConsumptionasanOverhaulIndicator

Oilconsumption,fuelconsumption,andmaintenanceinformationcanbeusedtoestimatethetotal operatingcostforyourCaterpillarengine.Oilconsumptioncanalsobeusedtoestimatetherequired capacityofamakeupoiltankthatissuitableforthemaintenanceintervals.

Oilconsumptionisinproportiontothepercentageoftheratedengineload.Asthepercentageofthe engineloadisincreased,theamountofoilthatisconsumedperhouralsoincreases.

Theoilconsumptionrate(brakespecificoilconsumption)ismeasuredingramsperkW/h(lbper bhp).Thebrakespecificoilconsumption(BSOC)dependsontheengineload.Consultyour Caterpillardealerforassistanceindeterminingthetypicaloilconsumptionrateforyourengine.

Whenanengine'soilconsumptionhasrisentothreetimestheoriginaloilconsumptionratedueto normalwear,anengineoverhaulshouldbescheduled.Theremaybeacorrespondingincreasein blowbyandaslightincreaseinfuelconsumption.

OverhaulOptions

BeforeFailureOverhaul

Aplannedoverhaulbeforefailuremaybethebestvalueforthefollowingreasons:

•Costlyunplanneddowntimecanbeavoided.

•Manyoriginalpartscanbereusedaccordingtothestandardsforreusableparts.

•Theengineservicelifecanbeextendedwithouttheriskofamajorcatastropheduetoengine failure.

•Thebestcost/valuerelationshipperhourofextendedlifecanbeattained.

AfterFailureOverhaul

Ifamajorenginefailureoccursandtheenginemustberemoved,manyoptionsareavailable.An overhaulshouldbeperformediftheengineblockorthecrankshaftneedstoberepaired.

Iftheengineblockisrepairableand/orthecrankshaftisrepairable,theoverhaulcostshouldbe between40percentand50percentofthecostofanewenginewithasimilarexchangecore.

Thislowercostcanbeattributedtothreeaspects:

•SpeciallydesignedCaterpillarenginefeatures

•Caterpillardealerexchangecomponents

•CaterpillarInc.remanufacturedexchangecomponents

OverhaulRecommendation

Tominimizedowntime,ascheduledengineoverhaulbyyourCaterpillardealerisrecommended.This willprovideyouwiththebestcost/valuerelationship.

Note:Overhaulprogramsvaryaccordingtotheengineapplicationandaccordingtothedealerthat performstheoverhaul.ConsultyourCaterpillardealerforspecificinformationabouttheavailable overhaulprogramsandaboutoverhaulservicesforextendingtheenginelife.

IfanoverhaulisperformedwithoutoverhaulservicefromyourCaterpillardealer,beawareofthe followingmaintenancerecommendations.

UnitFuelInjector

CleanthefuelinjectorbodyandreplacetheO-rings.ReplacetheO-ringsandthegasketonthe injectorsleeve.Cleantheareaaroundtheinjectorseatingintheinjectorsleeve.RefertotheService Manualforthecompleteprocedure,orconsultwithyourCaterpillardealerforassistance.

RebuildorExchange

CylinderHeadAssembly,ConnectingRods,Pistons,CylinderLiners,Turbocharger,Cylinder Packs,OilPump,andFuelTransferPump

Thesecomponentsshouldbeinspectedaccordingtotheinstructionsthatarefoundinvarious Caterpillarreusabilitypublications.TheSpecialPublication,SEBF8029liststhereusability publicationsthatareneededforinspectingtheengineparts.

Ifthepartscomplywiththeestablishedinspectionspecificationsthatareexpressedinthereusable partsguideline,thepartsshouldbereused.

Partsthatarenotwithintheestablishedinspectionspecificationsshouldbedealtwithinoneofthe followingmanners:

•Salvaging

•Repairing

•Replacing

Usingout-of-specpartscanresultinthefollowingproblems:

•Unscheduleddowntime

•Costlyrepairs

•Damagetootherengineparts

•Reducedengineefficiency

•Increasedfuelconsumption

Reducedengineefficiencyandincreasedfuelconsumptiontranslatesintohigheroperatingcosts. Therefore,CaterpillarInc.recommendsrepairingout-of-specpartsorreplacingout-of-specparts.

Inspectionand/orReplacement

PistonRings,CrankshaftBearings,ValveRotators,andCrankshaftSeals

Thefollowingcomponentsmaynotlastuntilthesecondoverhaul.

•Thrustbearings

•Mainbearings

•Rodbearings

•Valverotators

•Crankshaftseals

CaterpillarInc.recommendstheinstallationofnewpartsateachoverhaulperiod.

Inspectthesepartswhiletheengineisdisassembledforanoverhaul.

Inspectthecrankshaftforanyofthefollowingconditions:

•Deflection

•Damagetothejournals

•Bearingmaterialthathasseizedtothejournals

Checkthejournaltaperandtheprofileofthecrankshaftjournals.Checkthesecomponentsby interpretingthewearpatternsonthefollowingcomponents:

•Rodbearing

•Mainbearings

Note:Ifthecrankshaftisremovedforanyreason,usethemagneticparticleinspectionprocessto checkforcracksinthecrankshaft.

Inspectthecamshaftfordamagetothejournalsandtothelobes.

Note:Ifthecamshaftisremovedforanyreason,usethemagneticparticleinspectionprocesstocheck forcracksinthecamshaft.

Inspectthefollowingcomponentsforsignsofwearorforsignsofscuffing:

•Camshaftbearings

•Camshaftfollowers

CaterpillarInc.recommendsreplacingthecrankshaftvibrationdamper.

OilCoolerCoreandAftercoolerCore

Duringanoverhaul,theremovaloftheoilcoolercoreandtheaftercoolercoreisrecommended.The oilcoolercoreandtheaftercoolercoreshouldbecleanedandpressuretested. NOTICE

Donotusecausticcleanerstocleanthecore.

Causticcleanerscanattacktheinternalmetalsofthecoreandcause leakage.

Note:Usethiscleaningproceduretocleantheoilcoolercoreandtheaftercoolercore.

1.Removetheoilcoolercoreandtheaftercoolercore.

2.Removeanydebrisfromtheoilcoolercoreandtheaftercoolercore.Toremovedebrisfromthe oilcoolercore,turntheoilcoolercoreontooneend.Toremovedebrisfromtheaftercooler core,turntheaftercoolercoreupside-down.

3.Flushtheoilcoolercoreandtheaftercoolercoreinternallywithcleanerinordertoloosen foreignsubstances.Thiswillalsohelptoremoveoilfromtheoilcoolercoreandtheaftercooler core.

Note:TheuseofHydrosolvLiquidCleanersisrecommended.Table1liststheHydrosolv LiquidCleanersthatareavailablefromyourCaterpillardealer.

Table1

HydrosolvLiquidCleaners(1)

PartNumberDescriptionSize

1U-5490Hydrosolv416519L(5USgallon)

174-6854Hydrosolv10019L(5USgallon)

(1)Useatwotofivepercentconcentrationofthecleanerattemperaturesupto93°C(200°F).RefertoApplication Guide,NEHS0526orconsultyourCaterpillardealerformoreinformation.

4.Usesteamtocleantheoilcoolercoreandtheaftercoolercore.Thisremovesanyremaining residuefromthecleaner.Flushthefinsoftheoilcoolercoreandtheaftercoolercore.Remove anyothertrappeddebris.

5.Washtheoilcoolercoreandtheaftercoolercorewithhot,soapywater.Rinsetheoilcooler coreandtheaftercoolercorethoroughlywithcleanwater.

Personalinjurycanresultfromairpressure.

Personalinjurycanresultwithoutfollowingproperprocedure.When usingpressureair,wearaprotectivefaceshieldandprotectiveclothing.

Maximumairpressureatthenozzlemustbelessthan205kPa(30psi) forcleaningpurposes.

6.Drytheoilcoolercoreandtheaftercoolercorewithcompressedair.Directtheairinthereverse directionofthenormalflow.

7.Inspectthecomponentsinordertoensurecleanliness.Theoilcoolercoreandtheaftercooler coreshouldbepressuretested.Repairtheoilcoolercoreandtheaftercoolercore,ifnecessary. Installtheoilcoolercoreandtheaftercoolercore.

Formoreinformationaboutcleaningthecores,consultyourCaterpillardealer.

ObtainCoolantAnalysis

Theconcentrationofsupplementalcoolantadditive(SCA)shouldbecheckedregularlywithtestkits orwithS·O·SCoolantAnalysis(Level1).Furthercoolantanalysisisrecommendedwhentheengine isoverhauled.

Acoolantanalysiscanbeconductedinordertoverifytheconditionofthewaterthatisbeingusedin thecoolingsystem.Afullwateranalysiscanbeobtainedbyconsultingyourlocalwaterutility companyoranagriculturalagent.Privatelaboratoriesarealsoavailableforwateranalysis.

CaterpillarInc.recommendsanS·O·SCoolantAnalysis(Level2).

S·O·SCoolantAnalysis(Level2)

AnS·O·SCoolantAnalysis(Level2)isacomprehensivecoolantanalysiswhichcompletelyanalyzes thecoolantandtheeffectsonthecoolingsystem.AnS·O·SCoolantAnalysis(Level2)providesthe followinginformation:

•CompleteS·O·SCoolantAnalysis(Level2)

•Visualinspectionofproperties

•Identificationofmetalcorrosion

•Identificationofcontaminants

•Identificationofbuiltupimpurities(corrosionandscale)

S·O·SCoolantAnalysis(Level2)providesareportoftheresultsofboththeanalysisandthe maintenancerecommendations.

Formoreinformationaboutcoolantanalysis,consultyourCaterpillardealer.

FriJun2509:50:55UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

Overhaul(TopEnd)

SMCS-7595-020-TE

Atopendoverhaulinvolvestheremoval,theinspection,andthereworkofthecylinderhead components.Afewadditionalcomponentsarereplacedandserviced.

i02417406

YourCaterpillardealercanprovidetheseservicesandcomponents.YourCaterpillardealercan ensurethatthecomponentsareoperatingwithintheappropriatespecifications.

Thefollowingdefinitionsexplaintheterminologyfortheservicesthatareperformedduringan overhaul:

Inspect-InspectthecomponentsaccordingtotheinstructionsthatareinCaterpillarreusability publications.RefertoGuidelinesforReusablePartsandSalvageOperations,SEBF8029,"Indexof PublicationsonReusabilityorSalvageofUsedParts".Theguidelinesweredevelopedinordertohelp Caterpillardealersandcustomerstoavoidunnecessaryexpenditures.Newpartsarenotrequiredifthe existingpartscanstillbeused,reconditioned,orrepaired.Ifthecomponentsarenotinthereusability guidelines,refertotheServiceManual,"Specifications"module.

Rebuild-Thecomponentisreconditionedinordertocomplywithreusabilityguidelines.

Replace-Theservicelifeofthepartisexhausted.Thepartmayfailbeforethenextmaintenance interval.Thepartmustbereplacedwithapartthatmeetsfunctionalspecifications.Thereplacement partmaybeanewpart,aCATremanufacturedpart,arebuiltpart,orausedpart.Someworn componentsmaybeexchangedwithyourCaterpillardealerforacreditonreplacementparts.Consult yourCaterpillardealeraboutrepairoptionsforyourengine.

IfyouelecttoperformanoverhaulwithouttheservicesofaCaterpillardealer,beawareofthe recommendationsinTable1.

Table1

RecommendationsforTopEndOverhauls(1)

Inspect Rebuild

Replace Cylinderheadassemblies Valves

Inspect Replace Rockerarms Valvebridges

ReplaceCylinderheadgaskets

(1)Forinstructionsonremovalandinstallationofcomponents,seetheServiceManual,"DisassemblyandAssembly" module.

FriJun2509:50:45UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

HosesandClamps-Inspect/Replace

SMCS-7554-040;7554-510

i06825542

Hosesandclampsmustbeinspectedperiodicallyandreplacedattherecommendedintervaltoensure safeandcontinuousoperationoftheengine.Failuretoreplaceafuelhoseattherecommendedchange intervalmayresultinahazardoussituation.Takepropersafetyprecautionsbeforeinspectingor replacinghosesandclamps.

Note:Alwaysuseaboardorcardboardwhentheenginecomponentsarecheckedforleaks.Leaking fluidthatisunderpressurecancauseseriousinjuryorpossibledeath.Leaksthatarethesizeofapin holeareincluded.RefertoOperationandMaintenanceManual,"GeneralHazardInformation"for moreinformation.

Note:Ensurethatthehoseiscompatiblewiththeapplication.

InspectTubes,Hoses,Bellows,andClamps

Inspectalltubesandhosesforleaksthatarecausedbythefollowingconditions.Replaceanytubeor hosewhichexhibitsanyofthefollowingconditions.Failuretoreplaceatubeorhosewhichexhibits anyofthefollowingconditionsmayresultinahazardoussituation.

•Hoseswhicharecracked

•Hoseswhicharesoft

•Outercoveringthatischafedorcut

•Exposedwirethatisusedforreinforcement

•Outercoveringthatisballooninglocally

•Flexiblepartofthehosethatiskinkedorcrushed

•Armoringthatisembeddedintheoutercovering

•Exhaustbellowsforleaksordamage

•Hoseswhichexhibitsignsofleakagewhicharenottheresultofloosecouplingsorclamps

Inspectallclampsforthefollowingconditions.Replaceanyclampwhichexhibitssignsofanyofthe followingconditions.

•Cracking

•Looseness

•Damage

Inspectallcouplingsforleaks.Replaceanycouplingwhichexhibitssignsofleaks.

Eachinstallationapplicationcanbedifferent.Thedifferencesdependonthefollowingfactors:

•Typeofhose

•Typeoffittingmaterial

•Anticipatedexpansionandcontractionofthehose

•Anticipatedexpansionandcontractionofthefittings

Duetoextremetemperaturechanges,thehosewillheatset.Heatsettingcauseshoseclampstoloosen whichcanresultinleaks.Aconstanttorquehoseclampwillhelptopreventloosehoseclamps.

Replacehosesthatarecrackedorsoft.Replacehosesthatshowsignsofleakage.Replacehosesthat showsignsofdamage.Replacehoseclampsthatarecrackedordamaged.Tightenorreplacehose clampswhichareloose.

ReplacetheHosesandtheClamps NOTICE

Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjusting,andrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.

RefertoSpecialPublication,NENG2500,"CatDealerServiceTool Catalog"orrefertoSpecialPublication,PECJ0003,"CatShop SuppliesandToolsCatalog"fortoolsandsuppliessuitabletocollect andcontainfluidsonCatproducts.

Disposeofallfluidsaccordingtolocalregulationsandmandates.

CoolingSystem

PressurizedSystem:Hotcoolantcancauseseriousburns.Toopenthe coolingsystemfillercap,stoptheengineandwaituntilthecooling systemcomponentsarecool.Loosenthecoolingsystempressurecap slowlyinordertorelievethepressure.

Personalinjurycanresultfromremovinghosesorfittingsinapressure system.

Failuretorelievepressurecancausepersonalinjury.

Donotdisconnectorremovehosesorfittingsuntilallpressureinthe systemhasbeenrelieved.

1.Stoptheengine.

2.Allowtheenginetocool.

3.Beforeservicingacoolanthose,slowlyloosenthefillercapforthecoolingsystemtorelieve anypressure.

4.Removethefillercapforthecoolingsystem.

5.Drainthecoolantfromthecoolingsystemtoalevelthatisbelowthehosethatisbeing replaced.Drainthecoolantintoasuitablecleancontainer.Thecoolantcanbereused.

6.Removethehoseclamps.

7.Disconnecttheoldhose.

8.Replacetheoldhosewithanewhose.

9.Installhoseclampswhichhavebeeninspectedorinstallnewhoseclamps.Referto Specifications,SENR3130,"TorqueSpecifications","HoseClamps"forinformationabout selectingandinstallingtheproperhoseclamps.

10.Refillthecoolingsystem.

11.Cleanthecoolantfillercap.Inspectthegasketsonthefillercap.Inspectthegasketseat.Inspect thevacuumvalveandseatfordebrisordamage.Replacethefillercapifthegasketsare damaged.Installthefillercap.

12.Starttheengine.Inspectthecoolingsystemforleaks.

FuelSystem

Personalinjurycanresultfromremovinghosesorfittingsinapressure system.

Failuretorelievepressurecancausepersonalinjury.

Donotdisconnectorremovehosesorfittingsuntilallpressureinthe systemhasbeenrelieved.

Contactwithhighpressurefuelmaycausefluidpenetrationandburn hazards.Highpressurefuelspraymaycauseafirehazard.Failureto followtheseinspection,maintenanceandserviceinstructionsmaycause personalinjuryordeath.

NOTICE

Donotbendorstrikehighpressurelines.Donotinstallbentor damagedlines,tubesorhoses.Repairanylooseordamagedfueland oillines,tubesandhoses.Leakscancausefires.Inspectalllines,tubes andhosescarefully.Tightenallconnectionstotherecommended torque.

NOTICE

Donotallowdirttoenterthefuelsystem.Thoroughlycleanthearea aroundafuelsystemcomponentthatwillbedisconnected.Fita suitablecoveroveranydisconnectedfuelsystemcomponents.

Note:High-pressurefuellinesmaybeinstalledbetweenthehigh-pressurefuelpumpandthe fuelinjectors.High-pressurefuellinesareconstantlychargedwithhighpressure.Donotcheck thehigh-pressurefuellineswiththeengineorthestartingmotorinoperation.Waitfor10 minutesaftertheenginestopsbeforeyouperformanyserviceorrepaironhigh-pressurefuel lines.Waitingfor10minuteswillallowthepressuretobepurged.

1.Drainthefuelfromthefuelsystemtoalevelthatisbelowthehosethatisbeingreplaced.

2.Removethehoseclamps.

3.Disconnecttheoldhose.

Note:Whenservicingfuelsystem,usecap/sorcover/sasrequiredtoprotectthesystemand maintainfuelsystemcleanliness.

4.Replacetheoldhosewithanewhose.

5.Installhoseclampswhichhavebeeninspectedorinstallnewhoseclamps.Referto Specifications,SENR3130,"TorqueSpecifications","HoseClamps"forinformationabout selectingandinstallingtheproperhoseclamps.

6.Carefullyinspecttheengineforanyspilledfuel.Makesurethatnofuelremainsonorcloseto theengine.

Note:Fuelmustbeaddedtothefuelsystemaheadofthefuelfilter.

7.Refillthefuelsystem.RefertothisOperationandMaintenanceManual,"FuelSystem-Prime" forinformationaboutprimingtheenginewithfuel.

8.Starttheengine.Inspectthefuelsystemforleaks.

LubricationSystem

Hotoilandhotcomponentscancausepersonalinjury.Donotallowhot oilorhotcomponentstocontacttheskin.

1.Draintheoilfromthelubricationsystemtoalevelthatisbelowthehosethatisbeingreplaced.

2.Removethehoseclamps.

3.Disconnecttheoldhose.

4.Replacetheoldhosewithanewhose.

5.Installhoseclampswhichhavebeeninspectedorinstallnewhoseclamps.Referto Specifications,SENR3130,"TorqueSpecifications","HoseClamps"forinformationabout selectingandinstallingtheproperhoseclamps.

6.Refillthelubricationsystem.RefertothisOperationandMaintenanceManual,"EngineOil Level-Check"toensurethatthelubricationsystemisfilledwiththeproperamountofengine oil.

7.Starttheengine.Inspectthelubricationsystemforleaks.

AirSystem

1.Removethehoseclamps.

2.Disconnecttheoldhose.

3.Replacetheoldhosewithanewhose.

4.Installhoseclampswhichhavebeeninspectedorinstallnewhoseclamps.Referto Specifications,SENR3130,"TorqueSpecifications","HoseClamps"forinformationabout selectingandinstallingtheproperhoseclamps.

Note:ThebellowsandtheV-clampsthatareusedontheexhaustbellowsshouldneverbe reused.

5.Starttheengine.Inspecttheairlinesforleaks.

FriJun2509:50:35UTC+05302021

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Product:MARINEENGINE

Model:C30MARINEENGINECLX

Configuration:C30MarineEngineCLX00001-UP

OperationandMaintenanceManual

3412EandC30MarineEngines

MediaNumber-SEBU7178-08PublicationDate-01/12/2009DateUpdated-17/02/2016

HeatExchanger-Inspect

SMCS-1379-040

i05162232

Note:Themaintenanceintervalfortheheatexchangerwillvarydependingonoperatingconditions andenvironment.Themaintenanceintervalshouldbeevaluatedatthefollowingintervals:

•AttheintervalstatedinthisOperationandMaintenanceManual,"MaintenanceInterval Schedule"

•Afterthefirst1000hoursofengineoperation.

•Atleastonceevery2years

Theraw/seawaterthatiscirculatedthroughtheheatexchangerandtheamountofoperatingtimeof thevesselaffectsthefollowingitems:

•Cleanlinessoftheheatexchangerplates

•Effectivenessoftheheatexchangersystem

Operatingtheengineinwaterthatcontainssilt,sediment,salt,algae,orothersignificantcontaminants willhaveanadverseeffectontheheatexchangersystem.Inaddition,intermittentuseofthevessel willadverselyaffecttheheatexchangersystem.

Thefollowingitemsindicatethattheheatexchangermayrequirecleaning:

•Increasedcoolanttemperature

•Engineoverheating

•Excessivepressuredropbetweenthewaterinletandthewateroutlet

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