- Caterpillar Products: All
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.
Problem
This Memo is for INFORMATION ONLY and relates to questions arising from machines that have been submerged. The questions generally raised are in reference to reclamation of machines that were stored or operating in flooded areas.
Note: No dealer technician should begin work on anyCaterpillar machine until he or she is satisfied that it is safe to do so. The decision to proceed with such work is solely at the discretion of the dealer technician and Caterpillar accepts no responsibility or liability for any personal injury or property damage resulting therefrom.
Note: Good judgment and common sense, based on the broad machine experience of the CaterpillarDealers involved in this work should be exercised. This document is provided for GUIDANCE only and should not be considered the definitive work on flooded machine reclamation.
The process and inspection may vary from machine to machine, based on machine size, type, location and application. Some machines may only have seen heavy rain and wind and will likely be treated differently from those that have been immersed or submerged. Many of these machines will have experienced heavy exposure to salt water, which carries the additional penalty of rapid corrosion.
More damage may have occurred if the machine was submerged for a long period of time or if the machine sat for a long period of time without the contamination or salt being cleaned from the machine.
Solution
When performing service or repair procedures to any Caterpillar product that has been under water, please use the SIMS work order process. To identify Caterpillar product that has been under water in SIMS, use the SMoption in the Problem Description field. The SM designation should be used only once per serial number.
Before inspecting the machine or performing any type of maintenance steam clean the entire machine in order to remove any type of contaminated material or salt. Remove all guards and access covers in order to clean the entire machine. Do not attempt to move or operate the machine until all of the following procedures have been completed and a Dealer Checkout – Systems Test procedure has been completed:
Replace any damaged warning labels or manuals found on the machine.
Engine
Determine if the machine has been immersed or submerged in water by checking the engine oil level and inspecting the intake and exhaust for water. If the engine oil dipstick shows overfilling, it is more than likely waterlogged.
Any engine that has been immersed or submerged should be treated as a major overhaul project. This would consist of a complete disassembly with replacement of any rusted or corroded parts that could not be brought back to within reusability guidelines. All wiring harnesses, sensors, electrical, electro mechanical and electronic assemblies including the ECM(s) will need to be replaced. A complete engine replacement or a Remanreplacement can also be used if desired.
Cooling System
Pressure wash the radiator in order to remove any corrosion producing substance. Inspect all hoses and lines for deterioration. Check the level of the coolant. If the coolant is above the correct level, drain the system and flush. Refill the coolant with the amount specified in the machines OMM.
HVAC
Clean the entire system. Pressure wash the condenser and evaporator. Clean all ducts, controls, and drain lines thoroughly. Inspect the compressor for any internal water before using. Replace parts as necessary.
Power Train
Inspect all components for water. If water is found, drain the fluid and clean all surfaces. Replace the fluid with the proper amount found in the OMM. Inspect all bearing surfaces for corrosion. Clean as necessary. Grease all U-Joints thoroughly in order to remove moisture. Replace any maintenance free U-Joints or bearings.
Fuel System
Inspect the fuel tank and lines for any water. Drain the tank of any contaminated fuel. Flush the tank. If water was found in the tank, remove the fuel lines and remove any moisture. Remove the water separator from the engine and remove any water. Replace the fuel filter. Refill the tank with clean fuel
Hydraulic System
Most hydraulic systems are closed systems. Drain and flush the system. Replace all filters. Perform SOS after refill for water content. If the machine has been submerged for a significant amount of time, inspect the cylinders and the pumps/motors for leakage. Some seal materials degrade in water. If the oil level in the tank is overfull, drain and replace the oil with the amount specified in the machines OMM.
Cab
Inspect the ROPS, FOPS, or TOPS for any damage or corrosion. Clean and paint as required. Inspect the cab mounts for any type of deterioration. All sound suppression material and insulation will need to be replaced. Replace the seat cushions and seat belt(s). Clean and replace the compressor and control valve for the seat. Spray door hinges and other bare surfaces with silicon oil.
Electrical System
Disconnect all wire connectors. Remove any moisture from the pins. Inspect all wires and looms for any damage. Clean each wire and loom in order to remove any type of residue that would cause deterioration to the wire.
Note: Dielectric grease should NOT be used in electrical connectors on Caterpillar machines regardless of the connector family. The use of dielectric grease in connector assemblies can result in moisture and dirt contamination. Moisture and dirt contamination can lead to shorts and/or intermittent connections. Dielectric grease shall be restricted to use on bolted connections such as the following: ring terminals, cable assemblies, battery posts, and spark plug connections. Caterpillar part number 151-1340 Dielectric Grease should be used.
Attachments
Apply a large amount of grease to any fitting in order to flush the water out of any joint or connection.
Generator
Clean the entire unit. Remove the generator. Clean the generator. Refer to Special Instruction, SEHS9124,. The whole generator must be cleaned. Dry the generator until the Polarization Index (PI) of all of the windings is above 2.0. Operating the generator with a PI of less than 2.0 will likely result in winding failure. The drying process may take an extended amount of time (weeks are possible). If the PI will not rise above 2.0, replace the faulty winding or the entire generator. Replace the generator bearing(s). Allow the generator to dry.
Final Procedures
Complete the Dealer Checkout - System Testprocedures in order to determine if the machine is safe to operate. All repairs should be reported in SIMS.