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CAT 32 Aftercooler removal and test..why?

Discussion in 'Engines' started by mallorcaxx, Apr 20, 2020.

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  1. mallorcaxx

    mallorcaxx New Member

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    Hi all.
    I am a yacht captain aboard a yacht with Cat 32 engines.We last removed the intercoolers and had them pressure tested in 2016/17 @hours 527 hours at a cost of approx 7000 Euros each engine. Service and removal and pressure test was 10,000 per engine.

    The yacht is 9 years old and now has 750 hours only. Engines from 2010, yacht was launched in 2011.I asked Cat for a quote to service the engines this year and I was informed that the intercoolers need to removed and tested again after 225 hours again they are asking 10000 each engine for service and removal of the intercoolers.

    I know Cat has issues with previous models but i simply can not understand why they are asking us to do this again at such low hours. When i ask them to explain why.. i am told that Cat ask us to remove and test every 2 years or replace every 6. When my engine Operation and Maintenance manual quotes ....every 1000 service hours> aftercooler core clean/test. nothing is mentioned about removal and test every 2 years or replace every 6.

    I simply cant understand how Cat expect us to pay 14000 every 2 years ..7000x 2

    The engines are not under warranty but i still use Cat as i want the best service possible. Every year they are serviced, oil and coolant samples taken etc.

    I simply cannot understand these costs..!!! I need facts before i inform my boss he needs to spend another 20000 on the engines. I have asked Cat to explain why but nothing fore coming.. would anyone have any info? or have a contact number so i can speak to someone who can explain why? I have been a captain for 15 years and have never had to spend so much on engines!!!

    Thanks all.!!
    Last edited by a moderator: Apr 20, 2020
  2. mallorcaxx

    mallorcaxx New Member

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    Manual is dated November 2009

    Attached Files:

  3. Pascal

    Pascal Senior Member

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    Cat had an issue on the original C32 aftercooler design and came up with a redesign. I ve been running a 2009 84 Lazzara with C32s for almost 4 years now. I found the boat for the owners and the first thing my local cat guy mentioned when I asked him to survey the engines was that the AC would have to be upgraded. We did it after closing the deal (about $16k per engine) and haven’t touched them since. That was over 1500 hours ago.

    it seems to me that your local dealer is looking additional business. :)

    before the current boat I was running a boat with 3412Es. Put 4000 hours on her in 8 years, I think we cleaned the ACs once
  4. mallorcaxx

    mallorcaxx New Member

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    I spoke with another dealer in the uk who just mentioned ...that you should test or service every 2 years or replace every 6. But not at no where near the cost at which i am being asked to pay. Just a note..if the Intercoolers do fail is game over for the engines or at the very least engine rebuild..awesome design CAT!!!!!
  5. Pascal

    Pascal Senior Member

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    I was aware of the 6 year replacement recommendation but not testing every two years. Sound a bit extreme... hard to believe Cat can’t make aftercoolers (not intercooler BTW) last more than 6 years...
  6. bayoubud

    bayoubud Senior Member

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    A lot of Cat owners are questioning the maintenance schedule. My manual for 3406E and C15 engines updated 4/15/2015 states aftercooler clean and test at 15,000 gallons, or 1,000 service hours, or 2 years calendar time. Replace every 6000hrs or 6 years. Not sure if the same as the C32. I question this because of what you stated, low hours over the 2 year clean and test period. Average time for recreational use is way less than 1000hrs. in 2 years. Was told by a Cat mechanic the warranty program was the reason for the schedule. Adds a lot of expense when you amortize cost for cleaning and replacement over 6 years. You need to check for updates on your Cat maintenance schedule, it maybe different than original.
  7. Kapn

    Kapn Member

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    I find a lot of engine shops, all brands not just Cat, will get into a routine of recommending bundling services together that may not exactly match each engines requirements. The most common I've heard is a 2yr/1000 hr service that cleans and/or replaces everything that salt water runs through. Getting the service manual and reading it along with having good notes on past service is a good way to stay on top. Often times mechanics are dealing with customers who are very behind on service and they do indeed need everything done at once to catch up.
    It's a hard job to go to the owner and lay this out. I remember one time getting out all the books and having them turned to the maintenance pages as I was making notes. The owner asked what I was up to and then we started looking at it all together. Our discussions went smoother once he started to realized the scope and requirements of keeping a boat in good condition.
    I also remember getting a major service done on generators while we were in Mallorca. The invoice was staggering. A replacement generic plastic coolant overflow tank was over $150 (after converting from euros). In the US I could have bought it for under $10 at the auto parts store.
  8. Capt J

    Capt J Senior Member

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    If your aftercoolers are original, have them pulled and CHANGE them with new ones. CAT recommends changing them every 6 years. I've seen them fail, once even on a 3 year old yacht with the new style C32 aftercoolers and causing a rebuild. I don't think I'd inspect/pressure test them every 2 years, I WOULD just pull them every 6 years and replace them with new ones.
  9. Capt Ralph

    Capt Ralph Senior Member

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    Who ever told anybody C32s were cheap. Even when dust collecting.
  10. wdrzal

    wdrzal Senior Member

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    I would never let salt water in any engine,genny , again. I would use a interstage heat exchanger . I been thinking how to incorporate a Stainless steel hull bottom also to reject all the heat . IMO The only salt water running into the boat is for the water maker or too interstate heat exchangers.
  11. Capt Ralph

    Capt Ralph Senior Member

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    Keel coolers?
  12. mallorcaxx

    mallorcaxx New Member

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    Exactly my thoughts!!!
  13. mallorcaxx

    mallorcaxx New Member

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    Yep!!! Crazy!!
  14. wdrzal

    wdrzal Senior Member

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    You would need more surface area than that. Essentially the entire bottom of the boat. I'm thinking 50 to 90 foot luxury planning boats with high horsepower engines, duel generators, and enough AC cooling capacity to keep your ice cubes from melting on the hottest day.
    While I believe retro fitting is possible, every one would be a one off build to match the total btu load. It would be much better to be fitted into new hulls already sized correctly for the btu load of production boats.

    Interstage heat exchangers are another option.

    Sucking in Salt water and pumping it through a engine then out is the KISS way.

    Refrigerants are another possible solution as they absorb heat , move it , then reject it easily.
  15. Pascal

    Pascal Senior Member

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    not my experience. In 3 years and 8 months, and 1700hours, besides oil changes this is the extent of our costs

    port engine ECU replacement $3900
    Raw water system descale $400
    2 impellers $1000
    Valve cover seals stbd $200
    IAP sensors $400
    Remove clean and seal ZF coolers $1200

    I ll go over further needs this fall with the Cat tech, we ll do another set of impellers (I do them every two years /1000 hours or so) and are what else may be needed

    not bad for 10 year sold 1650 HP engines. I can tell you that we spent at least twice as much keeping the Cruisair chiller system going...
  16. mallorcaxx

    mallorcaxx New Member

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    I wish the owner used his yacht more to be honest...i could then justify some of these costs!!
  17. NYCAP123

    NYCAP123 Senior Member

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    Using it too little is as bad if not worse than using it too much. At 83 hours per year it would be cheaper to charter.
  18. Capt J

    Capt J Senior Member

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    That's all well and good if you're interested in an 8 knot boat. Most people aren't and a keel cooled system will not work on a yacht or sportfish.
  19. mallorcaxx

    mallorcaxx New Member

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    No it would not be.. but i see your point!!
  20. mapism

    mapism Senior Member

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    Are they, practically?
    If you are aware of any pleasure boat built with that setup, I'd be very curious to have a look at her specs.
    I'm always interested to learn something totally new - to me, anyway.