Caterpillar 3500B Series II and 3500C Marine Propulsion Engines Operation and Maintenance Manual

SEBU7844-11 June 2008 Operation and Maintenance Manual 3500B Series II and 3500C Marine Propulsion Engines TTA1-Up (Engine) TTB1-Up (Engine) TTC1-Up (Engine) S2D1-Up (Engine) TTD1-Up (Engine) S2E1-Up (Engine) TTE1-Up (Engine) S2F1-Up (Engine) TTF1-Up (Engine) B5G1-Up (Engine) MRG1-Up (Engine) PAG1-Up (Engine) TTG1-Up (Engine) MKH1-Up (Engine) TTH1-Up (Engine) S2J1-Up (Engine) TTJ1-Up (Engine) S2K1-Up (Engine) S2L1-Up (Engine) S2M1-Up (Engine) S2N1-Up (Engine) S2S1-Up (Engine) S2T1-Up (Engine) E3W1-Up (Engine) S2W1-Up (Engine) E3X1-Up (Engine) S2X1-Up (Engine) S2Y1-Up (Engine) SAFETY.CAT.COM

i01658146 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. 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 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. 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. 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 the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. 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. Caterpillar dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.

SEBU7844-11 3 Table of Contents Table of Contents Foreword ................................................................. 4 Safety Section Safety Messages .................................................... 6 General Hazard Information ................................... 9 Burn Prevention ..................................................... 11 Fire Prevention and Explosion Prevention ............ 12 Crushing Prevention and Cutting Prevention ........ 14 Mounting and Dismounting ................................... 14 Before Starting Engine .......................................... 14 Engine Starting ..................................................... 15 Engine Stopping ................................................... 15 Electrical System .................................................. 15 Engine Electronics ................................................ 16 Product Information Section Model Views and Specifications ........................... 18 Product Identification Information ........................ 21 Operation Section Lifting and Storage ................................................ 23 Gauges and Indicators .......................................... 27 Features and Controls .......................................... 30 Engine Starting ..................................................... 41 Engine Operation .................................................. 46 Engine Stopping ................................................... 48 Cold Weather Operation ....................................... 50 Maintenance Section Refill Capacities .................................................... 52 Maintenance Recommendations .......................... 56 Maintenance Interval Schedule ............................ 58 Reference Information Section Engine Ratings ................................................... 126 Engine Performance and Performance Analysis Report (PAR) ..................................................... 129 Customer Service ............................................... 130 Reference Materials ............................................ 134 Index Section Index ................................................................... 139

4 SEBU7844-11 Foreword Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Caterpillar publications. The English used facilitates translation and consistency in electronic media delivery. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Caterpillar dealer for the latest available information. Safety This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product. Operation Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities. The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information. Maintenance The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow. Use fuel consumption or service hours to determine 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. Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary. The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures. Maintenance Intervals Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine’s permanent record. See the section in the Operation and Maintenance Manual, “Maintenance Records” for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Caterpillar dealer can assist you in adjusting your maintenance schedule to meet the needs of your operating environment. Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs are best left to trained personnel or an authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available from your Caterpillar dealer. Consult with your dealer for information regarding these options.

SEBU7844-11 5 Foreword California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

6 SEBU7844-11 Safety Section Safety Messages Safety Section i03110569 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. Please 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 of 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 Caterpillar dealer can provide new safety messages. g01589927 Illustration 1

SEBU7844-11 7 Safety Section Safety Messages g01589928 Illustration 2 (1) Universal Warning g01370904 Illustration 3 Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death. This warning label is located on the lower right hand face of the ECM panel. This warning label is located on the ﬁrst cylinder on each side of 8, 12, and 16 cylinder engines. This warning label is located on the last cylinder on each side of 12 and 16 cylinder engines. (2) Hot Surface g01372256 Illustration 4 Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.

8 SEBU7844-11 Safety Section Safety Messages This warning label is located on the valve cover for cylinder 5 and on the valve cover for cylinder 6 on 8 cylinder engines. This warning label is located on the valve cover for cylinder 9 and on the valve cover for cylinder 10 on 12 cylinder engines. This warning label is located on the valve cover for cylinder 13 and on the valve cover for cylinder 14 on 16 cylinder engines. (3) Pressurized System g01371640 Illustration 5 Pressurized system! Hot coolant can cause serious 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 Op- eration and Maintenance Manual before performing any cooling system maintenance. This warning is located on the top of the pressurized coolant tank. (4) Pressurized System g01371640 Illustration 6 Hot Fluid Under Pressure Do Not Remove Pressure Cap When Hot Failure to Follow Instructions Could Result in In- jury or Death This warning label is located on both sides of the duplex fuel filter housing. This warning label is located on both sides of the duplex oil filter housing. (5) Hot Fluid Under Pressure g01061488 Illustration 7

SEBU7844-11 9 Safety Section General Hazard Information Filter contains hot pressurized fluid when engine is running. Follow instructions on control valve to avoid injury if rapid air movement exists to blow fluid. Stop engine to avoid fire. This warning label is located on both sides of the duplex fuel filter housing. This warning label is located on both sides of the duplex oil filter housing. (6) Shock Hazard g01372247 Illustration 8 WARNING! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. This warning label is located on the lower left hand face of the ECM panel. i02566298 General Hazard Information SMCS Code: 1000; 4450; 7405 g00104545 Illustration 9 Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls. Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced. Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside. Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed. • Filler caps • Grease fittings • Pressure taps • Breathers • Drain plugs 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.

10 SEBU7844-11 Safety Section General Hazard Information g00702020 Illustration 10 • Wear a hard hat, protective glasses, and other protective equipment, as required. • When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing. • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. • Ensure that all protective guards and all covers are secured in place on the engine. • Never put maintenance fluids into glass containers. Glass containers can break. • Use all cleaning solutions with care. • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions: • The engine is stopped. Ensure that the engine cannot be started. • 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. • Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment. Pressurized Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury. When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi) when the air nozzle is deadheaded. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Fluid Penetration g00687600 Illustration 11 Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tools Catalog” for the following items: • Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids • Tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids.

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Caterpillar 3500B Series II and 3500C Marine Propulsion Engines Operation and Maintenance Manual

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