CATERPILLAR C18 Parts Manual

SEBP3816-35 July 2009 VOLUME I Pages 1-628 Parts Manual See “General Information” for New Parts Manual Features. C18 Industrial Engine WJH1-Up (Engine) This Parts Manual is also Available in .PDF Format on Compact Disc (CD-ROM) - Caterpillar Form No. SERP3816 SAFETY.CAT.COM

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: D e a l e r C o n t a c t P h o n e N u m b e r H o u r s Sales: Parts: Service:

MEMORANDA MEMORANDA SEBP3816-35

TABLE OF CONTENTS Name Page Name Page GENERAL INFORMATION ......... ......... A4 REPAIR ALTERNATIVES .......... .......... A6 SUPPLEMENTAL COOLANT ADDITIVES ... ... A7 MAINTENANCE PARTS ........... ........... A8 INDEX ................... ................... A13 ENGINE ARRANGEMENT .......... .......... 1 ENGINE AR .............................. 1 ENGINE AR-COMPLETE ......... ......... 3 ENGINE AR-CORE ............ ............ 11 BASIC ENGINE ............... ............... 31 ACTUATOR GP-VALVE .......... .......... 31 ADAPTER GP-ENGINE TO TMSN ..... ..... 39 ADAPTER GP-FLYWHEEL ........ ........ 40 ADAPTER GP-OIL PAN DRAIN ...... ...... 42 ADAPTER GP-PUMP DRIVE ....... ....... 43 AIR COMPRESSOR GP .......... .......... 44 BASE GP-VALVE COVER & INJ HARN ... ... 69 BELT GP-SERPENTINE .......... .......... 77 BELT TENSIONER GP .......... .......... 79 BELT TIGHTENER GP .......... .......... 81 CAMSHAFT GP ............. ............. 83 CLUTCH GP ............... ............... 87 COMPRESSOR & MTG GP-REFRIG .... .... 94 COMPRESSOR GP-REFRIGERANT .... .... 97 COVER GP-CYLINDER BLOCK ...... ...... 98 COVER GP-FLYWHEEL HOUSING .... .... 105 COVER GP-FRONT HOUSING ...... ...... 110 COVER GP-VALVE MECHANISM ..... ..... 112 CRANKSHAFT GP ............ ............ 139 CYLINDER BLOCK AS .......... .......... 141 CYLINDER BLOCK GP .......... .......... 147 CYLINDER HEAD AS ........... ........... 155 CYLINDER HEAD GP ........... ........... 163 DAMPER & PULLEY GP ......... ......... 174 DAMPER GP ............... ............... 177 DRAIN GP-ENGINE OIL .......... .......... 180 DRIVE GP-ACCESSORY ......... ......... 181 DRIVE GP-FAN .............. .............. 189 DRIVE GP-POWER TAKE-OFF ...... ...... 211 DRIVE GP-PUMP ............. ............. 215 ENGINE BRAKE GP ........... ........... 216 FASTENER GP-ALTERNATOR ...... ...... 219 FASTENER GP-ENGINE ......... ......... 220 FASTENER GP-FLYWHEEL HOUSING ... ... 223 FASTENER GP-FRONT COVER ...... ...... 224 FASTENER GP-FRONT HOUSING .... .... 228 FASTENER GP-OIL PAN ......... ......... 234 FASTENER GP-SOUND SUPPRESSION ............. ............. 236 FASTENER GP-VALVE MECHANISM ... ... 237 FLYWHEEL GP .............. .............. 238 GEAR GP-CAMSHAFT .......... .......... 262 GEAR GP-FRONT ............ ............ 263 GEAR GP-REAR ............. ............. 266 GOVERNOR GP-AIR COMPRESSOR ... ... 270 GUARD GP-BELT ............ ............ 272 HOUSING GP-FLYWHEEL ........ ........ 275 HOUSING GP-FRONT .......... .......... 281 KIT-CRANKSHAFT BEARING ....... ....... 292 LIFTING GP-ENGINE ........... ........... 293 LINES GP-AIR COMPRESSOR ...... ...... 301 MECHANISM GP-FUEL PUMP & VALVE .................. .................. 304 MOUNTING GP-AIR COMPRESSOR .... .... 311 MOUNTING GP-ALTERNATOR ...... ...... 313 MOUNTING GP-ALTERNATOR & COMPR ................. ................. 331 PAN GP-OIL ............... ............... 335 PANEL GP-SOUND SUPPRESSION .... .... 359 PISTON & ROD GP ........................ 363 PLUG GP-CYLINDER BLOCK ....... ....... 369 PLUG GP-CYLINDER HEAD ....... ....... 378 PLUG GP-ENGINE ............ ............ 381 PLUG GP-FLYWHEEL HOUSING ..... ..... 385 PLUG GP-OIL PAN ............ ............ 386 POWER TAKE-OFF GP .......... .......... 390 PULLEY GP .............................. 394 PULLEY GP-AUXILIARY DRIVE ...... ...... 396 ROCKER ARM GP ............ ............ 398 SEAL GP-CRANKSHAFT ......... ......... 410 SUPPORT GP-ENGINE .......... .......... 413 SUPPORT GP-POWER TAKE-OFF .... .... 422 V-BELT SET ............... ............... 424 LUBRICATION SYSTEM .......... .......... 430 BASE GP-OIL FILTER .......... .......... 430 FASTENER GP-OIL PUMP MOUNTING ... ... 433 FILLER GP-ENGINE OIL ......... ......... 434 FILTER GP-ENGINE OIL ......... ......... 441 FUMES DISPOSAL GP .......... .......... 452 GAUGE GP-OIL LEVEL (DIPSTICK) .... .... 458 GUIDE GP-OIL LEVEL GAUGE ...... ...... 470 LINES GP-ENGINE OIL .......... .......... 476 LINES GP-OIL .............. .............. 489 LINES GP-TURBOCHARGER OIL ..... ..... 490 MOUNTING GP-OIL LEVEL GAUGE .... .... 502 PUMP GP-ENGINE OIL .......... .......... 503 VALVE GP-FLUID SAMPLING ....... ....... 505 COOLING SYSTEM .......................... 506 ADAPTER GP-FAN ............ ............ 506 COOLANT CONDITIONER GP ...... ...... 511 CORE GP-OIL COOLER ......... ......... 529 FAN GP-BLOWER ............ ............ 530 SEBP3816-35 TABLE OF CONTENTS A1

TABLE OF CONTENTS Name Page Name Page FAN GP-SUCTION ............ ............ 533 FASTENER GP-OIL COOLER ....... ....... 537 FASTENER GP-WATER LINES ...... ...... 538 FASTENER GP-WATER PUMP ...... ...... 539 FILTER AS-COOLANT CONDITIONER ... ... 541 FITTING GP-RADIATOR VENT ...... ...... 543 FITTING GP-WATER LINES ........ ........ 544 FLANGE GP-TMSN OIL COOLER ..... ..... 546 LINES GP-TURBOCHARGER WATER ... ... 547 LINES GP-WATER ............ ............ 550 PLUG GP-WATER LINES ......... ......... 572 PUMP GP-WATER ............ ............ 581 RADIATOR GP ............................ 591 VALVE-MANUAL .......................... 628 AIR INLET AND EXHAUST SYSTEM ..... ..... 629 ADAPTER GP-AIR CLEANER ....... ....... 629 ADAPTER GP-AIR INLET ......... ......... 630 AIR CLEANER GP ............ ............ 631 CAP AS-RAIN .............. .............. 648 CONNECTION GP-EXHAUST ....... ....... 652 COVER GP-AIR INLET .......... .......... 657 ELBOW GP-AIR INLET .......... .......... 658 ELBOW GP-EXHAUST .......... .......... 662 ELBOW-EXHAUST ............ ............ 666 FITTING GP-EXHAUST .......... .......... 670 FLANGE GP-EXHAUST .......... .......... 674 KIT-EXHAUST PARTS .......... .......... 679 LINES GP-AIR .............. .............. 680 LINES GP-TURBOCHARGER ....... ....... 714 MANIFOLD GP-EXHAUST ........ ........ 716 MUFFLER ................ ................ 720 MUFFLER GP .............. .............. 721 MUFFLER GP-SPARK ARRESTOR .... .... 724 PIPE GP-EXHAUST ........... ........... 726 PRECLEANER GP ............ ............ 730 SHIELD GP-HEAT ............ ............ 734 SHIELD GP-MANIFOLD .......... .......... 736 SHUTOFF GP-AIR ............ ............ 738 TURBOCHARGER GP .......... .......... 751 FUEL SYSTEM ............... ............... 785 BASE GP-FUEL FILTER .......... .......... 785 COOLER GP-FUEL ........................ 786 FASTENER GP-FUEL LINES ....... ....... 790 FILTER GP-FUEL ............. ............. 792 FILTER GP-WATER SEP & FUEL ..... ..... 795 FITTING GP-FUEL LINES ......... ......... 798 FITTING GP-QUICK DISCONNECT .... .... 800 INJECTOR GP-FUEL ........... ........... 801 LINES GP-FLEXIBLE FUEL ........ ........ 802 LINES GP-FUEL ............. ............. 803 LINES GP-FUEL FILTER ......... ......... 811 MANIFOLD GP-FUEL ........... ........... 863 PUMP & MTG GP-FUEL TRANSFER .... .... 865 PUMP GP-FUEL INJECTION ....... ....... 867 PUMP GP-FUEL PRM & PRIM FILTER ... ... 873 PUMP GP-FUEL PRM & SEC FILTER ... ... 875 PUMP GP-FUEL PRM & WATER SEP ... ... 884 PUMP GP-FUEL TRANSFER ....... ....... 885 VALVE GP-CHECK ............ ............ 886 VALVE GP-FUEL BYPASS ........ ........ 890 ELECTRICAL AND STARTING SYSTEM ... ... 891 ALTERNATOR GP-CHARGING ...... ...... 891 BATTERY GP .............. .............. 925 CABLE GP-BATTERY ...................... 928 CONNECTION GP-ELECTRICAL ..... ..... 930 CONTROL & MTG GP-ENGINE ELEK ... ... 933 CONTROL GP-AUTO START/STOP .... .... 938 CONTROL GP-ENGINE SPEED ...... ...... 942 CONTROL GP-REMOTE SPEED ..... ..... 944 CONVERTER GP-ELECTRICAL ...... ...... 945 FASTENER GP-WIRING HARNESS .... .... 947 FASTENER GP-ENGINE WIRING ..... ..... 948 HARNESS AS-PANEL .......... .......... 951 HARNESS AS-SENSOR ......... ......... 952 HEATER GP-JACKET WATER ....... ....... 954 LUBRICATOR GP-AIR MOTOR ...... ...... 956 MODULE GP-INTERFACE ........ ........ 957 MOUNTING GP-CIRCUIT BREAKER .... .... 958 MOUNTING GP-JACKET WTR HEATER .................................. 965 MOUNTING GP-SENSOR ......... ......... 969 SENSOR GP-COOLANT LEVEL ...... ...... 971 SENSOR GP-ENGINE .......... .......... 972 SENSOR GP-LIQUID LEVEL ....... ....... 976 SENSOR GP-POSITION ......... ......... 978 SENSOR GP-PRESSURE ......... ......... 979 SENSOR GP-SPEED ........... ........... 986 SENSOR GP-TEMPERATURE ....... ....... 994 SILENCER-AIR STARTING ........ ........ 1002 SOFTWARE GP-ENG RATINGS ELEK ... ... 1003 STARTING AID GP-ETHER ........ ........ 1003 STARTING MOTOR GP-AIR ........ ........ 1006 STARTING MOTOR GP-ELECTRIC .... .... 1018 SUPPORT GP-BATTERY ......... ......... 1046 SWITCH GP-MAGNETIC ......... ......... 1047 SWITCH GP-REMOTE STARTING ..... ..... 1049 SWITCH GP-START ........... ........... 1050 SWITCH GP-TOGGLE .......... .......... 1051 VALVE GP-AIR STARTING ........ ........ 1052 VALVE GP-ETHER STARTING ....... ....... 1054 WIRING GP-ELECTRONIC CONTROL ... ... 1056 WIRING GP-ENGINE ........... ........... 1058 WIRING GP-ENGINE ELECTRONIC .... .... 1077 WIRING GP-SENSOR .......... .......... 1082 WIRING GP-UNIT INJECTOR ....... ....... 1083 A2 TABLE OF CONTENTS SEBP3816-35

TABLE OF CONTENTS Name Page Name Page HYDRAULIC SYSTEM ........... ........... 1084 MOUNTING GP-PUMP .......... .......... 1084 PUMP & MTG GP-HYDRAULIC ...... ...... 1086 PUMP GP-HYDRAULIC .......... .......... 1099 PUMP GP-PISTON ............ ............ 1115 ROTATING GP-PUMP ........... ........... 1121 VALVE GP-RELIEF ............ ............ 1122 ENCLOSURES, GUARDS AND BASES ... ... 1123 BASE GP-ENGINE ........................ 1123 PRIME PACKAGE ............. ............. 1124 MOUNTING GP-PUMP .......... .......... 1124 PUMP GP-GEAR .......................... 1126 ROTATING GP-PUMP ........... ........... 1129 VALVE GP-PUMP CONTROL ....... ....... 1133 TRANSMISSION .............. .............. 1135 PUMP GP-CHARGE ........... ........... 1135 OPERATOR STATION ........................ 1136 AMMETER GP .............. .............. 1136 BOX GP-INSTRUMENT PANEL ...... ...... 1137 CONTROL GP-ENGINE MONITORING ... ... 1139 CONTROL GP-UNPRGMED MONITOR ... ... 1140 GAUGE GP-COOLANT TEMPERATURE ............. ............. 1141 GAUGE GP-ENGINE OIL PRESSURE ... ... 1142 GAUGE GP-FUEL PRESSURE ...... ...... 1143 MODULE GP-DISPLAY .......... .......... 1144 MOUNTING GP-INSTRUMENT PANEL ... ... 1145 MOUNTING GP-TACHOMETER ...... ...... 1154 PANEL GP-INSTRUMENT ......... ......... 1155 PLUG GP-INSTRUMENT PANEL ..... ..... 1178 TACHOMETER GP-ELECTRIC ...... ...... 1181 VOLTMETER GP ............. ............. 1183 SERVICE EQUIPMENT AND SUPPLIES ... ... 1187 ACTUATOR GP-PUMP .......... .......... 1187 CHART-PLATE & FILM .......... .......... 1188 KIT-GASKET .............................. 1189 PLATE GP-ENGINE IDENTIFICATION ... ... 1190 PLATE GP-IDENTIFICATION ....... ....... 1191 PART NUMBER INDEX ........... ........... B1 SEBP3816-35 TABLE OF CONTENTS A3

GENERAL INFORMATION 1. ENGINE IDENTIFICATION Caterpillar engines are identified with Serial Numbers and Arrangement Numbers. In some cases, Modification Numbers are also used. The serial number plate which shows these numbers is mounted on the engine. Caterpillar dealers need this information to determine which components were included on the engine when it was assembled at the factory. This permits accurate identification of replacement part numbers. 2. ORDERING PARTS Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Their parts inventories are up to date and include all parts normally required to protect your investment in Caterpillar Engines. Dealers may offer repair kits or remanufactured parts to allow selection of the most effective repair alternative for a particular situation. When ordering parts, your order should specify the quantity, part number, part name, and the serial number/product identification number of the engine for which the parts are needed. 3. PARTS MANUAL ORGANIZATION Product information in this manual is presented as "information elements" that represent all of the components for the specific model. An Engine Arrangement is an example of an information element. The information elements are organized alphabetically by part name and secondarily by part number within each major section of the manual. 4. TABLE OF CONTENTS A table of contents (TOC) is found at the beginning of the manual. The TOC lists each section of the manual with a complete list of all information elements organized as they appear in the manual. Page numbers are provided for quick reference to detailed parts identification illustrations and serviceable consist lists. 5. MAINTENANCE PARTS INDEX The Maintenance Parts Index, located near the beginning of the manual, references most frequently used maintenance part numbers, providing description, quantity, usage and page number. This information is organized alphabetically by part description. 6. INDEX The index located near the front of the manual is an alphabetical listing of all information elements included in the manual. Page numbers are provided for quick reference to detailed parts identification illustrations and serviceable consist lists. 7. PART NUMBER INDEX A numerical index listing all part numbers and the corresponding page number(s) appears at the back of the manual. 8. CAPTIONS Captions located at the beginning each information element identify the part number and part name along with additional descriptive information. S/N information found in each caption should be used to select correct information for a specific engine. Field replacement options, identification of optional attachment components, and where used ("part of") information is also provided. The first line of a caption is shown in larger type font to indicate the beginning of an information element. Captions for additional pages that may be required to illustrate an information element will be shown in standard type font and will include the term (contd.) . 9. NON-SERVICED PARTS In some instances it is necessary to display non-serviced parts that are a link to lower level serviceable consist lists. These non-serviced part numbers are shown in italic type indicating that they are not available. All consist lists have not been converted to reflect this enhancement. A4 GENERAL INFORMATION SEBP3816-35

GENERAL INFORMATION 10. PARTS LIST REFERENCE NUMBERS Numbers shown in the Ref No column correspond to numbers used in the associated graphic(s). An alphabetic suffix may be added to a reference number to identify lower level consist items. Numbers shown in the Graphic Ref column refer to the graphic number identifier displayed in the lower left corner of each illustration. The Graphic Ref number may be used in combination with the item Ref No to determine the correct part number. There may be intentional omission of a Ref No in a consist list as information is updated to reflect the latest serviceable part numbers. 11. INDENTED PART NAMES When a part name is indented in a parts list, it is part of (included in) the group or assembly under which it is indented. 12. ILLUSTRATION REFERENCE LETTERS When necessary, illustrations contain reference letters (A, B, C etc.) that are intended to track lines and harnesses from one point to another. They are also used to show where to reconnect illustrations that have been separated. 13. ABBREVIATIONS AND SYMBOLS O.D. – Outside Diameter I.D. – Inside Diameter A – Not Part Of This Group B – Use As Required C – Change From Previous Type D – Order By The Meter E – Order By The Centimeter F – Not Shown G – Order By The Inch I – Refer To Hydraulic Information System M – Metric Part R – Remfg Part May Be Available Y – Separate Illustration Z – Not Serviced Separately 14. DESCRIPTION OF TYPE CHANGES Type - A type is defined as any configuration change that requires an additional Information Element for an Arrangement, Group, or Assembly. If serial number breaks for types are not available, a type # ( Type 1, Type 2, etc.) will be displayed in the caption. These "type" changes are identified with a "C" note (change from previous type) in the Parts List. Only the "types" that apply to this Parts Manual will be included. Additional types may exist causing "C" notes to appear on an Information Element when no other types are shown. 15. <END> This symbol indicates the end of an information element. NOTE: Continuing improvement and advancement of product design may cause changes to your engine which may not be included in this publication. Whenever a question arises regarding your Caterpillar product or this publication, please consult your Caterpillar dealer for the latest available information. SEBP3816-35 GENERAL INFORMATION A5

REPAIR ALTERNATIVES REMANUFACTURED COMPONENTS As an option when making repairs consider Caterpillar Remanufactured Components. Components that are available through the Caterpillar Remanufactured Program are identified three ways in the parts book: • with the letter R in the note field of the parts list • with an R* at the beginning of the first line of the caption • with an *R at the end of the first line of the caption Typical components included in the Remanufacturing Program include: ALTERNATORS CONNECTING RODS CRANKSHAFTS - UNDERSIZE CRANKSHAFTS - UPGRADE TO NEW CYLINDER HEADS ELECTRONIC CONTROL MODULES (ECM) ELECTRONIC SENSORS FUEL INJECTORS FUEL NOZZLES FUEL PUMPS GOVERNORS OIL PUMPS PISTONS SHORT BLOCKS STARTERS TURBOCHARGERS - COMPLETE TURBOCHARGER CARTRIDGES WATER PUMPS Caterpillar Remanufactured engines for many engine arrangements are also available. A6 REPAIR ALTERNATIVES SEBP3816-35

CATERPILLAR C18 Parts Manual

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