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3116 and 3126 MARINE ENGINES

1. 4 Inspect the cooling system for leaks 100992487 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 A WARNING Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Note Test the concentration of the Supplemental Coolant Additive SCA or test the SCA concentration as part of an S O S Coolant Analysis Test for SCA Concentration Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration 71 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add Use the 8T 5296 Coolant Conditioner Test Kit or use the 4C 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to the Operation and Maintenance Manual for more information on conventional coolant antifreeze cooling system maintenance Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Refer to the Operation and Maintenance Manual Water Supplemental Coolant Additive SCA topic Maintenance Section Refer to the Operation and Maintenance Manual Conventional Coolant Antifreeze Cooling System Maintenance topic Maintenance Section
2. S 0 S Coolant Analysis S O S coolant samples can be analyzed at your Caterpillar dealer S O S Coolant Analysis is a program that is based on periodic samples Level 1 Level 1 is a basic analysis of the coolant The following items are tested e Glycol Concentration e Concentration of SCA e pH e Conductivity The results are reported and recommendations are made according to the results Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S O S Coolant Analysis Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recommended maximum A WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the e
3. 4 L 1 US gal Description 1U 8804 Hydrosolv 100 1U 5492 Hydrosolv 100 19 L 5 US gal 8T 7571 Hydrosolv 100 208 L 55 US gal 1 Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the core Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer 101059376 Auxiliary Water Pump Inspect SMCS Code 1371 040 Impellers require periodic inspection and seals require periodic inspection Impellers have a service life that is limited The service life depends on the engine operating conditions Inspect the c
4. Check the engine oil level If necessary use a marking pen in order to correct the FULL mark X Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine Obtain the Sample and the Analysis A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtain
5. on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil e f the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve knob clockwise in order to close the drain valve e f the engine is not equipped with a drain valve remove the oil drain plug in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating
6. procedure Note Refer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed 101007424 Zinc Rods Inspect Replace SMCS Code 1388 040 1388 510 Corrosion in sea water circuits can result in premature deterioration of cooling system components leaks and possible cooling system contamination The corrosion may be caused by the lack of zinc rods in the sea water system Zinc rods are inserted in the sea water cooling system of the engine in order to help prevent the corrosive oxidation that is caused by sea water The reaction of the zinc to the sea water causes the zinc rods to oxidize rather than the cooling system components Rapid deterioration of zinc rods may indicate the presence of uncontrolled electrical currents from improperly installed electrical attachments or improperly grounded electrical attachments The zinc rods must be inspected at the proper intervals The zinc rods must be replaced when deterioration occurs Inspect the Zinc Rods The zinc rods are red for easy identification Table 38 shows the locations of the zinc rods and the quantities of the zinc rod Table 38 Locations of the Zinc Rods Location Quantity Heat Exchanger 3 Transmission Oil Cooler 2 Exhaust Elbow 1 Aftercooler 5 1 Zinc rods will only be located in marine transmission oil coolers that are cooled with sea water 2 Exhaust elbows that a
7. Cooling System Cleaner Add 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling system filler cap 4 Start the engine and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques Cooling Systems with Heavy Deposits or Plugging Note For the following procedure to be effective there must be some active flow through the cooling system components 1 Flush the cooling system with clean water in order to remo
8. cleaner element with the recommended oil 7 The dry element should be oiled before installation Apply small amounts of oil across the top of each pleat Allow the oil to soak into the element for 20 minutes Oil any remaining white spots 8 Inspect the housing and the clamp for the element Replace the housing and the clamp if necessary 73 Maintenance Section Engine Air Cleaner Service Indicator Inspect 9 Remove the seal from the air inlet opening Install the clean oiled element Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section Single Element Air Cleaner Illustration 23 g00548847 1 Element 1 Remove the element 1 and discard the element 1 2 Install a new element 1 101061105 Engine Air Cleaner Service Indicator Inspect SMCS Code 7452 040 Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommen
9. e Replacement of the fuel filter Engines that are Equipped with a Fuel Priming Pump Illustration 30 g00516899 1 Select knob 2 Plunger 1 Turn select knob 1 counterclockwise until the indicator is in line with the body of the priming pump 2 Unlock the plunger and operate the plunger until a resistance is felt A considerable number of pump strokes may be required 3 Push in plunger 2 and tighten by hand 4 Turn select knob 1 clockwise until the indicator is in line with the fuel outlet NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 5 Promptly start the engine If the engine runs rough increase the engine rom to one half of the rated rpm Note If the engine will not start further priming may be necessary If the engine continues to misfire or smoke after starting further priming may be necessary Engines that are Not Equipped with a Fuel Priming Pump NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components 81 Maintenance Section Fuel System Primary Filter Water Separator Element Replace If the engine is not equipped with a fuel priming pump it may be necessary to fill the fuel filter with clean fuel The following procedure will only a
10. ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual for more information on lubricant specifications Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual for more information on refill capacities NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL m
11. electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 1U 7298 Coolant Battery Tester C or the 1U 7297 Coolant Battery Tester F 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 L 12 qt of baking soda and 1L 1 qt of clean water e A mixture of 0 1 L 12 gt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Lubrication Compound petroleum jelly or MPGM grease 63 Maintenance Section Battery Electrolyte Level Check 100095575 Battery or Battery Cable Disconnect SMCS Code 1402 029 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 v
12. filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap Illustration 19 g00103638 1 Recovery tank filler cap 2 COLD FULL mark 3 LOW ADD mark 5 Loosen the cap for the coolant recovery tank slowly in order to relieve any pressure Remove the cap for the coolant recovery tank 6 Pour Extended Life Coolant ELC into the coolant recovery tank until the coolant reaches the COLD FULL mark DO NOT fill the coolant recovery tank above the COLD FULL mark 7 Clean the cap for the coolant recovery tank Install the cap for the coolant recovery tank 8 Start the engine Inspect the cooling system for leaks and for proper operating temperature Engines that are NOT Equipped with a Coolant Recovery Tank NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Place the transmission in neutral Start the engine and operate the engine at low idle Increase the engine rom to 1500 rom Operate the engine at 1500 rpm for
13. for signs of wear and or for signs of fatigue Inspect the crankshaft for any of the following conditions e Deflection e Damage to the journals e Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the rod bearings and main bearings Note If the crankshaft or the camshaft are removed for any reason use the magnetic particle inspection process to check for cracks Replace the crankshaft vibration damper if any of the following conditions are found e Engine failure due to a broken crankshaft e Excessive wear of the front main bearing e Excessive wear of the gear train that is not caused by a lack of lubrication e Visconic damper that is dented cracked or leaking e Visconic damper that is discolored from heat e Rubber damper that is deteriorated and cracked e Rubber damper with slippage of the outer ring Inspect the gear train for the following conditions e Worn gear teeth e Unusual fit e Unusual wear Testing Test the following components during the overhaul e Fuel injection nozzles e Fuel injection pump e Governor Testing the fuel system during the overhaul will ensure that your engine operates at peak efficiency Your Caterpillar dealer can provide these services and components in order to ensure that your fuel system is operating within the appropriate specifications Clea
14. is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 Nem 18 Ib in 101007514 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage g00516808 Illustration 25 1 Hose clamp 2 Breather assembly 3 Seal 1 Loosen hose clamp 1 and remove the hose from breather assembly 2 2 Remove breather assembly 2 and seal 3 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Install a breather element that is clean and dry Install seal 3 and breather assembly 2 5 Install the hose Install hose clamp 1 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torque 100259257 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine e Deterioration of the engine mo
15. mm 2 76 inch 1 The angle indicates the number of degrees that the front of the engine is raised 76 Maintenance Section Engine Oil Sample Obtain 4degrees 46 mm 1 81 inch 20 mm 0 79 inch Table 37 Engine Oil Level Gauge 4KG05783 UP 1SK01725 UP 8NM01466 UP 6SR1 UP 1ZJ1 UP 6MK1 UP Angle FULL Mark X ADD Mark Y 10 degrees 125 mm 4 92 inch 114 mm 4 49 inch 9 degrees 124 mm 4 89 inch 106 mm 4 17 inch 8 degrees 122 mm 4 80 inch 102 mm 4 02 inch 7 degrees 120 mm 4 72 inch 96 mm 3 78 inch 6 degrees 115 mm 4 53 inch 89 mm 3 50 inch 5 degrees 110 mm 4 33 inch 81 mm 3 19 inch 4 degrees 101 mm 3 98 inch 71 mm 2 80 inch 3 degrees 94 mm 3 70 inch 66 mm 2 60 inch 2 degrees 90 mm 3 54 inch 59 mm 2 32 inch 1 degree 82 mm 3 23 inch 52 mm 2 05 inch 0 degrees 76 mm 2 99 inch 46 mm 1 81 inch 1 degree 65 mm 2 56 inch 39 mm 1 54 inch 2 degrees 59 mm 2 32 inch 33 mm 1 30 inch 3 degrees 53 mm 2 09 inch 26 mm 1 02 inch 5 degrees 39 mm 1 54 inch 12 mm 0 47 inch 1 The angle indicates the number of degrees that the front of the engine is raised A negative angle indicates the number of degrees that the front of the engine is lowered Verifying the Calibration of the Oil Level Gauge Caterpillar recommends verif
16. proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start the engine and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve
17. to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose Note For torques on hose clamps see this Operation and Maintenance Manual Torque Specifications Maintenance Section 7 Install the hose clamps with a torque wrench Note For the proper coolant to use see this Operation and Maintenance Manual Coolant Recommendations Maintenance Section 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 86 Maintenance Section Magnetic Pickups Clean Inspect i00906366 Magnetic Pickups Clean Inspect SMCS Code 1907 040 7400 040 7400 070 Illustration 35 g00293335 Typical example 1 Magnetic pickup 2 Flywheel housing Illustration 36 g00293337 Typical magnetic pickup 1 Remove magnetic pickup 1 from flywheel housing 2 Check the condition of the end of the magnetic pickup Check for signs of wear and contaminants 2 Clean the metal
18. 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming of the coolant e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain A WARNING Pressurized System Hot coolant can cause seri ous burns 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 pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs Allow the coolant to drain 68 Maintenance Section Cooling System Coolant ELC Change NOTICE Dispose of used engine coolant properly or recycle Various methods have been
19. 1054 070 1054 510 If your air cleaner element becomes plugged the air can split the element filter material Unfiltered air will drastically accelerate internal engine wear Contact your Caterpillar dealer for the correct filter element Note The engine will be equipped with either an AIRSEP air cleaner or a single element air cleaner AIRSEP air cleaner elements may be cleaned The single element air cleaner must be replaced AIRSEP Air Cleaner Element NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine g00517117 Illustration 22 1 Vacuum regulator element 2 Air cleaner element Note Use the 102 9720 Cleaning Kit This product contains the detergent and oil that is made specifically for the maintenance of the AIRSEP elements 1 Remove the vacuum limiter element and the AIRSEP element 2 Cover the air inlet opening with a clean cloth or seal with tape in order to prevent dirt and debris from entering the engine 3 Tap the element in order to di
20. 3116 and 3126 MARINE ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU6100 02 01 2007 Caterpillar CATERPILLAR All Rights Reserved 101005876 Maintenance Interval Schedule SMCS Code 1000 7500 Note Ensure that the Safety Information Warnings and Instructions are read and understood before operation or maintenance procedures are performed Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Battery Recycle eeeseceeeeseeeeeeeeseeeeeeeeseeeeees 62 Battery or Battery Cable Disconnect 63 Engine Oil Level Gauge Calibrate 8 75 Fuel System Prime cccccseccceesseeeeeeeesteeeeeeeaes 80 Daily Cooling System Coolant Level Check 69 Engine Air Cleaner Service Indicator Inspect 73 Engine Oil Level Check cccccccseceeeeeesteeeeeenes 75 Fuel System Water Separator Drain 0 82 Marine Transmission Oil Level Check 86 Walk Around Inspection cccceeeeseeeeeeeeneeeeeeeneaes 90 Every 1500 L 400 US gal of Fuel or 50 Service Hours Zinc Rods Inspect Replace n se 91 First 7500 L 2000 US gal of Fuel or 250 Service Hours Engine Valve Lash Inspect Adjust ee 79 Fuel Injection Timing Check n se 79 Every 7500 L 2000 US gal of Fuel or 250 Service
21. Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques Fill Refer to the Operation and Maintenance Manual Coolant Specifications topic for information regarding acceptable water coolant antifreeze and supplemental coolant additive requirements Refer to the Operation and Maintenance Manual Refill Capacities topic for the capacity of the engine s system Engines that are Equipped with a Coolant Recovery Tank NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start the engine and run the engine at low idle Increase the engine rom to 1500 rpm Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Add coolant to the cooling system until the cooling system is full 4 Clean the cooling system filler cap Inspect the gasket that is on t
22. Fuel ratio control e Cam followers e Fuel Transfer pump e Timing advance If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be salvaged repaired or replaced Using out of spec parts can result in the following problems e Unscheduled downtime e Costly repairs e Damage to other engine parts e Reduced engine efficiency 88 Maintenance Section Overhaul Considerations e Increased fuel consumption Reduced engine efficiency and increased fuel consumption translates into higher operating costs Therefore Caterpillar Inc recommends repairing out of spec parts or replacing out of spec parts Component Replacement Replace the following components during the overhaul e Piston Rings e Thrust bearings e Main bearings e Connecting rod bearings e Gaskets and seals e Engine mounts e Hoses Inspection Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts e Camshaft e Camshaft bearings e Crankshaft e Crankshaft vibration damper e Gear train Inspect the camshaft for damage to the journals and the lobes Inspect the camshaft bearings
23. Governor Oil Supply Screen Clean Replace SMCS Code 1264 070 1264 510 Illustration 34 g00521118 1 Screen 2 Seal 3 Fitting 4 Seals 5 Oil supply tube 1 Remove oil supply tube 5 and seals 4 from the cylinder head 2 Remove fitting 8 and seal 2 from the governor housing 3 Remove screen 1 4 Wash screen 1 in solvent in order to remove any debris Inspect screen 1 for damage and inspect screen 1 for deterioration If necessary obtain a new screen Inspect all seals for damage and deterioration If necessary obtain new seals 5 Install screen 1 into the governor housing The screen must be far enough into the governor housing in order to allow clearance for seals 2 and fitting 3 6 Install seals 2 fitting 3 seal 4 and oil supply tube 5 101057362 Heat Exchanger Inspect SMCS Code 1379 040 The interval for the maintenance of the tube and fin heat exchanger depends on the operating environment of the vessel and on the operating time The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items e Cleanliness of the tubes of the heat exchanger e Effectiveness of the heat exchanger system Operating in water that contains silt sediment salt algae etc will adversely affect the heat exchanger system In addition intermittent use of the vessel will advers
24. Hours or 1 Year Auxiliary Water Pump Inspect 62 Battery Electrolyte Level Check ccceeseees 63 Belt INSP Ct E nonen a 63 Cooling System Supplemental Coolant Additive SCA Test Add cccceceeeceeeteeeeeeeeeeeteeeeeenaees 70 Engine Air Cleaner Element Clean Replace 72 Engine Crankcase Breather Clean 008 74 Engine Oil Sample Obtain cesses 76 Engine Oil and Filter Change ccceeeees 77 Fuel Inlet Screen Clean cecccceeesseeeeeesteeeeeeaes 79 Fuel System Primary Filter Water Separator Element REplaCe aA E 81 Fuel System Secondary Filter Replace 82 Fuel Tank Water and Sediment Drain 83 Hoses and Clamps Inspect Replace 84 Sea Water Strainer Clean Inspect c e 89 Water Pump Inspect eee eeeeeeeeteeeeeeeneeeeeeeaes 90 61 Maintenance Section Maintenance Interval Schedule Every 30 000 L 8000 US gal of Fuel or 1000 Service Hours or 2 Years Aftercooler Core Clean Test a se 62 Cooling System Coolant DEAC Change 64 Engine Protective Devices Check ccc0e 78 Magnetic Pickups Clean Inspect ccceee 86 Turbocharger Inspect oo eeeeeeeeeeteeeeeeenteeeeeenaaes 89 Every 60 000 L 16 000 US gal of Fuel or 2000 Service Hours Engine Mounts Inspect eceeeeeeeeteeeeeeeeeeeeeeeee 74 Engine Valve Lash Inspect Adju
25. are recommended for the engine Repair of Piston Ring And Bore As An Indicator Investigate the piston the ring and the bore or repair the piston the ring and the bore if one of the following conditions occurs e Oil consumption is in excess of 1 quart of oil per 60 gallons of fuel that is consumed The oil consumption must not be caused by leakage e Crankcase blowby is in excess of 2 cubic feet per hour per horsepower Measure the crankcase blowby with an 8T 2700 Blowby Indicator e Fuel consumption has increased e Loss of power has occurred The cylinder head must be removed in order to repair the piston the ring and the bore After removing the cylinder head inspect the valves and the valve seats Repair the valve and the valve seats if necessary Determine if any other components of the engine should be inspected Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons e Avoid costly unplanned downtime e Reuse many original parts according to the standards for reusable parts e Extend the engine s service life without the risk of a major catastrophe due to engine failure e Attain the best cost value relationship per hour of extended life After Failure Overhaul If a major engine failure occurs and the engine must be removed from the hull many options are available An overhaul should be performed if the engine block or the
26. arks on the oil level gauge 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately i00869628 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of t
27. ations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start the engine and run the engine at low idle Increase the engine rom to 1500 rpm Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a pressure test A 9S 8140 Pressurizing Pump is used to perform the pressure test The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 67 Maintenance Section Cooling System Coolant ELC Change 101083041 Cooling System Coolant ELC Change SMCS Code 1350 070 1395
28. c should adjust the fuel injector timing because special tools and training are required Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injector timing 101015310 Fuel Inlet Screen Clean SMCS Code 1256 070 A WARNING Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 80 Maintenance Section Fuel System Prime Eo A Illustration 29 g00521058 Location of fuel inlet screen 1 Disconnect the fuel supply line 2 Remove the fuel inlet screen 3 Clean the fuel inlet screen with a nonflammable solvent 4 Install the fuel inlet screen 5 Connect the fuel supply line i01007661 Fuel System Prime SMCS Code 1258 548 A WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Prime the fuel system in order to fill the fuel filter Prime the fuel system in order to purge trapped air The fuel system should be primed under the following conditions e Running out of fuel e Storage
29. crankshaft needs to be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features e Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchange components 87 Maintenance Section Overhaul Considerations Overhaul Recommendation To minimize downtime Caterpillar Inc recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails This will provide you with the best cost value relationship Note Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life If an overhaul is performed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations Rebuild or Exchange Inspect the following components according to the instructions that are found in various Caterpillar reusability publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts e Cylinder head assembly e Connecting rods e Pistons e Turbocharger e Oil pump e
30. daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly e Oil change e Refill of the tank 84 Maintenance Section Governor Oil Supply Screen Clean Replace This will helo prevent water or sediment from being pumped from the storage tank into the engine fuel tank If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 101015388
31. dations in order to service the air cleaner element A service indicator may be mounted on the air cleaner element or in a remote location 74 Maintenance Section Engine Crankcase Breather Clean Illustration 24 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator
32. e overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface Refer to the Service Manual for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 101008141 Engine Air Cleaner Element Clean Replace SMCS Code
33. ed during normal engine operation The 8T 9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve The bottle group includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEHP6001 How To Take A Good Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 77 Maintenance Section Engine Oil and Filter Change 100652130 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle
34. efully Tighten all connections to the rec ommended torque Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings 85 Maintenance Section Hoses and Clamps Inspect Replace Replace the Hoses and the Clamps A WARNING Pressurized System Hot coolant can cause seri ous burns 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 pres sure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order
35. ely affect the heat exchanger system The following items indicate that the heat exchanger may require cleaning e Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range Inspection and maintenance of the heat exchanger are required if the engine is overheating Your Caterpillar dealer has the equipment and the trained personnel that are needed in order to measure the pressure drop across the heat exchanger The procedure for cleaning the heat exchanger is similar to the procedure that is used for cleaning the aftercooler core Refer to the Operation and Maintenance Manual Aftercooler Core Clean Test topic Maintenance Section For more information on servicing the heat exchanger consult your Caterpillar dealer i00907072 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses car
36. engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities in the Maintenance Section for the capacity of the cooling system for your engine Refer to the Operation and Maintenance Manual Cooling System Specifications information for the Caterpillar ELC Extender additions 4 Clean the cooling system filler cap Inspect the cooling system filler cap gaskets Replace the cooling system filler cap if the cooling system filler cap gaskets are damaged Install the cooling system filler cap 100893001 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool 70 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add Engines That Are Equipped with a Coolant Recovery Tank Illustration 20 g00103638 1 Filler cap 2 COLD FULL mark 3 LOW ADD mark 1 Observe the coolant level in the coolant recovery tank Maintain the coolant level to COLD FULL mark 2 on the coolant recovery tank 2 Loosen filler cap 1 slowly in order to relieve any pressure Remove the fi
37. fuel filter Use a cloth or use a container to catch excess fuel 6 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 7 Apply clean diesel fuel to the new fuel filter gasket NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 8 Install a new fuel filter and tighten the fuel filter until the gasket contacts the base 9 Tighten the fuel filter by hand according to the instructions that are shown on the fuel filter Do not overtighten the fuel filter 10 Lock the fuel priming pump if equipped Open the fuel tank supply valve 11 If the engine stalls refer to the Operation and Maintenance Manual Fuel System Prime topic Maintenance Section for more information i00909035 Fuel System Water Separator Drain SMCS Code 1263 543 A WARNING Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Illustration 33 g00467033 1 Vent valve Base Can Element 5 Drain plug ARUN Water in the fuel can cause fuel system components to fail Drain the water separator daily Drain the water separator more frequently when a large concentration of water is present in the fuel system 1 Close the fuel supply valve NOTICE Use a suitable conta
38. he can by hand Do not use tools in order to tighten the can NOTICE The water separator is under suction during normal engine operation Ensure that the vent plug is tight ened securely to help prevent air from entering the fu el system 10 Open the main fuel supply valve 11 Start the engine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Leaks are difficult to detect while the engine is running The primary filter water separator is under suction A leak will allow air to enter the fuel The air in the fuel can cause low power due to aeration of the fuel If air enters the fuel ensure that all components are properly tightened i01007602 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE A WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 1 Stop the engine 2 Turn off the start switch or disconnect the battery starting motor when maintenance is performed on fuel filters 3 Shut off the fuel tank supply valve to the engine NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 4 Unlock the fuel priming pump if equipped This relieves any residual pressure in the fuel system 5 Remove the used
39. he cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a pressure test A 9S 8140 Pressurizing Pump is used to perform the pressure test The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap Illustration 18 g00103638 1 Recovery tank filler cap 2 COLD FULL mark 3 LOW ADD mark 5 Loosen the cap for the coolant recovery tank slowly in order to relieve any pressure Remove the cap for the coolant recovery tank 6 Pour coolant into the coolant recovery tank until the coolant reaches the COLD FULL mark DO NOT fill the coolant recovery tank above the COLD FULL mark 7 Clean the cap for the coolant recovery tank Install the cap for the coolant recovery tank 8 Start the engine Inspect the cooling system for leaks and for proper operating temperature Engines that are Not Equipped with a Coolant Recovery Tank NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Cooling System Specific
40. he valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life 79 Maintenance Section Engine Valve Lash Inspect Adjust A WARNING Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information i00850658 Fuel Injection Timing Check SMCS Code 1251 036 TM 1290 036 TM Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechani
41. if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques Fill Engines that are Equipped with a Coolant Recovery Tank NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Place the transmission in neutral Start the engine and operate the engine at low idle Increase the engine rom to 1500 rom Operate the engine at 1500 rpm for one minute in order to purge air from the cavities of the engine block Stop the engine 3 Pour more ELC into the cooling system until the cooling system is full 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system
42. iner to catch any fuel that might spill Clean up any spilled fuel immediately 2 Remove drain plug 5 Depress vent valve 1 in order to start the flow Allow the water to drain into a suitable container Allow the water to flow until fuel flows from the drain 3 Install the drain plug Dispose of the liquid properly 4 Open the fuel supply valve NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system 83 Maintenance Section Fuel Tank Water and Sediment Drain i00073301 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive fuel system wear Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel
43. l through the inlet air oil by products from oil and by products from combustion The buildup reduces boost and air flow The buildup also contributes to loss of engine power increased black smoke and overall loss of engine efficiency Cleaning and Inspecting 1 Remove the air inlet piping from the turbocharger and remove the compressor housing from the turbocharger 2 Clean the turbocharger compressor housing with Hydrosolv Liquid Cleaners and a hard bristle brush 3 Clean the turbocharger compressor wheel and clean the backplate assembly with 4C 4079 Brake and Electric Cleaner 90 Maintenance Section Walk Around Inspection 100893389 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaki
44. l gauge must be calibrated after the engine is installed in the vessel Table 36 and Table 37 list the corresponding ADD mark FULL mark and the angle of installation Use a marking pen in order to engrave ADD mark Y and FULL mark X on the engine oil level gauge according to the information in Table 36 or Table 37 FULL Illustration 27 g00110310 Oil Level Gauge Y ADD mark X FULL mark Calibration of Oil Level Gauge Table 36 Engine Oil Level Gauge 4KG1 05782 1SK1 01724 8NM1 01465 Angle FULL Mark X ADD Mark Y 15 degrees 156 mm 6 14 inch 137 mm 5 39 inch 14 degrees 151 mm 5 95 inch 133 mm 5 24 inch 13 degrees 148 mm 5 83 inch 129 mm 5 08 inch 12 degrees 144 mm 5 67 inch 125 mm 4 92 inch 11 degrees 139 mm 5 47 inch 119 mm 4 69 inch 10 degrees 136 mm 5 35 inch 115 mm 4 53 inch 9 degrees 130 mm 5 12 inch 114 mm 4 49 inch 8 degrees 128 mm 5 04 inch 113 mm 4 45 inch 7 degrees 121 mm 4 76 inch 114 mm 4 49 inch 6 degrees 117 mm 4 61 inch 107 mm 4 21 inch 5 degrees 113 mm 4 45 inch 100 mm 3 94 inch 4 degrees 112 mm 4 41 inch 93 mm 3 66 inch 3 degrees 111 mm 4 37 inch 88 mm 3 47 inch 2 degrees 109 mm 4 29 inch 81 mm 3 19 inch 1 degree 102 mm 4 02 inch 76 mm 2 99 inch 0 degrees 96 mm 3 78 inch 70
45. lement A WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Illustration 32 g00467033 1 Vent valve Base Can Element 5 Drain plug AUN 1 Close the main fuel supply valve 2 Remove drain plug 5 Depress vent valve 1 in order to start the flow of fuel Allow the fuel to drain into a suitable container Dispose of the fuel properly 3 Install the drain plug 4 Remove can 3 from base 2 5 Remove element 4 from the can Dispose of the used element 6 Remove the gasket Clean the following components e Can e Gasket e Base 82 Maintenance Section Fuel System Secondary Filter Replace Inspect the gasket for damage and for deterioration Replace the gasket if necessary 7 Install the gasket Lubricate the gasket with clean diesel fuel NOTICE The primary filter water separator may be prefilled with fuel to avoid rough running stalling of the engine due to air Do not fill the secondary filter with fuel before installation The fuel would not be filtered and could be contaminated Contaminated fuel will cause accel erated wear to fuel system parts 8 Install a new element in the can The can may be filled with fuel at this time 9 Install the can on the base Tighten t
46. ller cap 3 Pour the proper coolant mixture into the tank Refer to the coolant specifications in the maintenance information for your product Do not fill the coolant recovery tank above COLD FULL mark 2 4 Clean filler cap 1 and the receptacle Reinstall the filler cap and inspect the cooling system for leaks Note The coolant will expand as the coolant heats up during normal engine operation The additional volume will be forced into the coolant recovery tank during engine operation When the engine is stopped and cool the coolant will return to the engine Engines That Are Not Equipped with a Coolant Recovery Tank A WARNING Pressurized System Hot coolant can cause seri ous burns 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 pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration 21 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and inspect the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap
47. llow filtered fuel to enter the fuel system g00516900 Illustration 31 1 Plug 2 Fuel filter 1 Remove plug 1 in order to fill fuel filter 2 Ensure that air is able to vent from the fitting of the plug while the fuel filter is being filled Clean up any spilled fuel immediately Clean plug 1 Install plug 1 NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 Start the engine and immediately increase the engine rom to one half of the rated rom 3 Maintain the engine rpm until the engine operates smoothly 4 Reduce the engine rom to low idle 100914347 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Water in the fuel can cause the engine to run rough Water in the fuel may cause fuel system components to fail If the fuel has been contaminated with water the element should be changed before the regularly scheduled interval The primary filter water separator also provides filtration in order to help extend the life of the secondary fuel filter The element should be changed regularly The primary filterAwater separator should be changed when the vacuum gauge if equipped registers 50 to 70 kPa 15 to 20 In Hg Replace the E
48. ly 110 N 25 Ib ft of force midway between the pulleys A correctly adjusted belt will deflect 9 mm 0 35 inch to 15 mm 0 59 inch If the belt does not require replacement or adjustment install the belt guard If the belt requires adjustment or replacement perform the following procedure to adjust the belt tension e f the engine is equipped with a freon compressor air conditioner the belt for the fan drive the alternator and the accessories will have an automatic belt tensioner e f the engine is not equipped with a freon compressor the alternator is used to adjust the belt tension Adjustment Alternator Belt Illustration 16 g00285332 1 Adjusting bolt 2 Mounting bolts 1 Slightly loosen mounting bolts 2 and adjusting bolt 1 2 Move the pulley in order to adjust the belt tension 3 Tighten adjusting bolt 1 and mounting bolts 2 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section 4 Install the belt guard If new belts are installed check the belt tension again after 30 minutes of engine operation at the rated rpm Water Pump Belt Illustration 17 g00426869 Exploded view of the drive assembly for a water pump belt 1 Mounting bolt 2 Square hole 3 Adjusting bolt 1 Slightly loosen mounting bolts 1 and adjusting bolt 8 2 Adjust the belt tension with a square drive in square hole 2 3 Tighte
49. n adjusting bolt 8 and mounting bolt 1 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section 4 Install the belt guard If new belts are installed check the belt tension again after 30 minutes of engine operation at the rated rpm 101081100 Cooling System Coolant DEAC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming of the coolant e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain A WARNING Pressurized System Hot coolant can cause seri ous burns 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 pres sure 1 Stop the engine and allow the engine to co
50. ng is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water e Ensure that cooling lines are properly clamped and that cooling lines are tight Check for leaks Check the condition of all pipes e Check the marine transmission oil level Refer to the OEM specification for the marine transmission or refer to the OEM specification for the vessel e Inspect the water pumps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover e Inspect the fuel system for leaks Look for loose fuel line clamps e Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps e Inspect the al
51. ngine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to the Operation and Maintenance Manual for more information on SCA requirements 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 72 Maintenance Section Cooling System Water Temperature Regulator Replace 100912898 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessiv
52. ning The following components should be cleaned and pressure tested during the overhaul e Engine oil cooler e Marine gear oil cooler e Aftercooler e Heat exchanger Refer to the Operation and Maintenance Manual Aftercooler Core Clean Test topic Maintenance Section for the cleaning procedure Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits or with S O S Coolant Analysis Level 1 Further coolant analysis is recommended when the engine is overhauled For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals that were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis can be obtained by consulting your local water utility Company or an agricultural agent Private laboratories are also available for water analysis Caterpillar Inc recommends an S O S Coolant Analysis Level 2 S O S Coolant Analysis Level 2 An S O S Coolant Analysis Level 2 is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level 2 provides the following information e Complete S O S Co
53. ol Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 65 Maintenance Section Cooling System Coolant DEAC Change 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting
54. olant Analysis Level 1 e Visual inspection of properties e Identification of metal corrosion e identification of contaminants e Identification of built up impurities corrosion and scale S O S Coolant Analysis Level 2 provides a report of the results of both the analysis and the maintenance recommendations that are based on the analysis For more information about coolant analysis consult your Caterpillar dealer 89 Maintenance Section Sea Water Strainer Clean Inspect i00905687 Sea Water Strainer Clean Inspect SMCS Code 1371 040 1371 070 The sea water strainer must be clean in order to allow proper engine cooling Check the sea water strainer for plugging Inspect the sea water strainer more frequently if the vessel is being operated in water which is shallow or dirty Refer to the OEM recommendations for more information about inspecting and cleaning the sea water strainer Ensure that the auxiliary water pump is primed and that the suction line is open 1 Remove the sea water strainer and clean the screen Remove any dirt and debris 2 Install the sea water strainer Fill the sea water strainer and the suction line for the auxiliary water pump with water 101057899 Turbocharger Inspect SMCS Code 1052 040 Periodic cleaning is recommended for the turbocharger compressor inlet side The following items collect in the turbocharger compressor housing since the fumes from the crankcase trave
55. olt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables 100855842 Belt Inspect SMCS Code 1357 040 1357 1397 040 1397 Inspection Belt tension should be checked initially between the first 20 to 40 hours of engine operation After the initial check the belt tension should be checked at Every 250 Service Hours or Three Months To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating If the belts are too tight unnecessary stresses are placed on the pulley bearings and on the belts This may shorten the service life of the components Remove the belt guard Inspect the condition and adjustment of the alternator belts and accessory drive belts if equipped 64 Maintenance Section Cooling System Coolant DEAC Change To check the belt tension app
56. omponents of the pump more frequently when the pump is exposed to debris sand or other abrasive materials Inspect the components if the pump is operating at a differential pressure of more than 103 kPa 15 psi Check the following components for wear and check the following components for damage e Cam e Impeller e Seals e Wear plate If wear is found or if damage is found replace the components which are worn or replace the components which are damaged Use the proper repair kit for the pump Refer to the Disassembly and Assembly for more information on servicing the auxiliary water pump i00037658 Battery Recycle SMCS Code 1401 561 1 Always recycle a battery Never discard a battery 2 Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 100914454 Battery Electrolyte Level Check SMCS Code 1401 081 When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing If batteries are properly charged ammeter reading should be very near zero A WARNING All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the
57. one minute in order to purge air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 69 Maintenance Section Cooling System Coolant Extender ELC Add 100259474 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Caterpillar Extended Life Coolant ELC does not require the frequent Supplemental Coolant Additive SCA additions associated with the present conventional coolants The Extender only needs to be added once Check the cooling system only when the
58. re aftermarket may or may not be equipped with zinc rods 3 3126 Engine Only 1 Remove the zinc rod 91 Maintenance Section Zinc Rods Inspect Replace 2 Inspect the zinc rod Ensure that the zinc rod will remain effective until the next scheduled inspection a If the zinc rod has deteriorated excessively install a new zinc rod Illustration 37 g00481100 b Tap the zinc rod lightly with a hammer If the zinc rod flakes install a new zinc rod 3 If the zinc rod will be reused scrape the layer of oxidation from the zinc rod before installation The layer of oxidation reduces the effectiveness of the zinc rod Replace the Zinc Rods 1 Unscrew the old zinc rod from the plug If not enough material remains or the zinc rod has broken off drill the old zinc rod from the plug 2 Clean the plug g00480345 Illustration 38 1 Shoulder of the zinc rod 2 Threads of the zinc rod 3 External threads of the plug Note DO NOT apply adhesive or sealant to threads 2 of the zinc rod 92 Maintenance Section Zinc Rods Inspect Replace 3 Apply 9S 3263 Thread Lock Compound to shoulder 1 of a new zinc rod Apply the compound ONLY to the shoulder of the zinc rod Install the zinc rod onto the plug 4 Coat external threads 3 of the plug with 5P 3413 Pipe Sealant Install the zinc rod Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section
59. shavings and other debris from the face of the magnet 3 Install the magnetic pickup and adjust the magnetic pickup Refer to the Service Manual for the installation procedure 101089872 Marine Transmission Oil Level Check SMCS Code 3081 535 Check the marine transmission oil level according to the instructions that are provided by the OEM of the transmission or the OEM of the vessel For the lubrication requirements of the transmission refer to the recommendations on the nameplate or the Owner s Manual for the transmission Marine Transmission Operation Maintenance Warranty and Parts Support For information on maintenance and operation of the marine transmission consult your Caterpillar dealer and or the OEM dealer of the transmission All support for the warranty of the transmission will be the responsibility of the OEM All parts support for the transmission will be the responsibility of the OEM This parts support includes both the installation of parts and the resolution of any service problems 101081132 Overhaul Considerations SMCS Code 7595 043 The following items can increase the engine service life before an overhaul is required e Use only lubricants that are recommended by Caterpillar e Follow the recommended guidelines for maintenance e Use an S O S Oil Analysis to determine the maximum interval for changing the oil filter and the oil e Follow the rating definitions that
60. slodge dirt particles Gently brush the element with a soft bristle brush NOTICE Do not use gasoline steam caustic or unapproved detergents or parts cleaning solvents Do not use high pressure water or air to clean the air cleaner element Any of those liquids or methods can cause air cleaner element damage 4 Spray the element with the cleaning solution Allow the element to stand for 20 minutes 5 Rinse the element with low water pressure The maximum water pressure for this procedure is 275 kPa 40 psi Tap water is acceptable Start to rinse the element from the clean side inside Next clean the dirty side outside in order to flush out dirt Inspect the element for tears and or holes after the element is cleaned Do not reuse damaged elements NOTICE Do not use compressed air open flame or hot air to dry the air cleaner element Excess heat shrinks cot ton fiber and compressed air may blow holes in the material Allow the air cleaner element to air dry 6 Shake excess water off the element and allow the element to air dry Drying the element in the sun speeds the process NOTICE Do not use transmission fluid engine oil diesel fuel or other lubricant to oil the air cleaner element The air cleaner element can not function correctly if im proper oil is used Never operate an engine with a dry air cleaner element The air cleaner element can not function correctly without oil Always saturate the clean air
61. st eee 79 Fuel Injection Timing Check n se 79 Governor Oil Supply Screen Clean Replace 84 Heat Exchanger Inspect eee eeeeteeeeeeeeeeeeeeeeees 84 Every 91 000 L 24 000 US gal of Fuel or 3000 Service Hours or 2 Years Cooling System Coolant Extender ELC Add 69 Cooling System Water Temperature Regulator Replace a etee tah eke OG eats eee 72 Every 182 000 L 48 000 US gal of Fuel or 6000 Service Hours or 4 Years Cooling System Coolant ELC Change 67 Overhaul Overhaul Considerations c0ccccceeeeeeeeeeeeeees 86 62 Maintenance Section Aftercooler Core Clean Test i01089688 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1 Remove the core Refer to the Service Manual for the procedure 2 Turn the aftercooler core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of hot Hydrosolv 100 liquid cleaner at a concentration of 30 and at a temperature of 66 to 82 C 150 to 180 F Table 35 lists the recommended Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 35 Hydrosolv Liquid Cleaners Container
62. system Only use oil filters recommended by Caterpillar 78 Maintenance Section Engine Protective Devices Check 1 Remove the oil filter with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 40 5084 Oil Filter Cutter Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 28 g00103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat
63. ternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break e Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery e Check the condition of the gauges Replace any gauges which are cracked or any gauges that can not be calibrated 101057943 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine Visually inspect the water pump for leaks If any leaking is observed replace the water pump seal or the water pump assembly Refer to the Service Manual for the disassembly and assembly
64. unts Any engine mount that shows deterioration should be replaced Refer to the Service Manual for the recommended torques Refer to the OEM recommendations for more information 101007363 Engine Oil Level Check SMCS Code 1348 535 FLV Check the oil level after the engine has stopped This maintenance procedure must be performed on a level surface FULL Illustration 26 g00110310 Y ADD mark X FULL mark 1 Maintain the oil level between the ADD mark Y and the FULL mark X on the oil level gauge Do not fill the crankcase above FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 Remove oil filler cap and add oil if necessary Clean the oil filler cap Reinstall the oil filler cap 101139872 Engine Oil Level Gauge Calibrate SMCS Code 1326 524 The engine is shipped with an engine oil level gauge that is not marked The engine oil level gauge is not marked because the angle of installation can be different for each engine The angle of installation will affect the ADD mark Y and the FULL mark X that is engraved on the engine oil level gauge 75 Maintenance Section Engine Oil Level Check The engine oil leve
65. ve any debris 66 Maintenance Section Cooling System Coolant DEAC Change 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual for your particular engine for more specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for more general information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start the engine and run the engine at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain
66. ying the calibration of the oil level gauge at the first oil change Use the following procedure to verify the FULL mark on the oil level gauge Note The vessel must be level in order to perform this procedure 1 Operate the engine until normal operating temperature is achieved Stop the engine Remove one of the drain plugs for the engine crankcase Allow the engine oil to drain 2 Remove the used engine oil filter Install the new engine oil filter Install the crankcase drain plug and tighten the crankcase drain plug 3 Add 25 L 26 5 qt of the recommended oil grade and weight of engine oil to the crankcase Note The engine may be equipped with auxiliary engine oil filters which require additional oil Refer to the OEM specifications NOTICE To help prevent crankshaft or bearing damage crank engine to fill all filters before starting Do not crank engine for more than 30 seconds NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again Turbocharger if equipped damage can result if the engine rpm is not kept low until the engine oil light gauge verifies the oil pressure is sufficient 4 Start the engine Ensure that the lubrication system and the new engine oil filter is filled Inspect the lubrication system for leaks 5 Stop the engine and allow the engine oil to drain into the engine crankcase for approximately ten minutes 6

3116 and 3126 MARINE ENGINES

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