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3412E and C30 Marine Engines-Maintenance - Safety

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1. y7 I AU Illustration 45 g00396257 1 Fuel supply connections 2 Fuel filters 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 NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 1 It may be necessary to relieve residual fuel pressure from the fuel system before removing the fuel filter Loosen one of the fuel supply connections 1 in order to purge any residual pressure NOTICE Do not loosen fuel lines or fittings at the fuel manifold or ECM The engine components may be damaged 2 Remove the used fuel filter 3 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 4 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 98 Maintenance Section Fuel System Water Separator Drain SEBU7178 06 5 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for pro
2. Table 24 3412E and C30 Marine Engine Calibration of the Engine Oil Level Gauge Shallow Sump Left Hand Service Angle X ADD Mark Y FULL Mark 15 degrees 140 mm 5 5 inch 195 mm 7 7 inch 14 degrees 136 mm 5 4 inch 191 mm 7 5 inch 13 degrees 131 mm 5 2 inch 186 mm 7 3 inch 12 degrees 126mm 5 0 inch 182 mm 7 2 inch 11 degrees 122 mm 4 8 inch 179 mm 7 0 inch 10 degrees 118mm 4 6 inch 175 mm 6 9 inch 9 degrees 114 mm 4 5 inch 172 mm 6 8 inch 8 degrees 110 mm 4 3 inch 169 mm 6 7 inch 7 degrees 107 mm 4 2 inch 167 mm 6 6 inch 6 degrees 103 mm 4 1 inch 164 mm 6 5 inch 5 degrees 100 mm 3 9 inch 162 mm 6 4 inch 4 degrees 97 mm 3 8 inch 160 mm 6 3 inch 3 degrees 95 mm 3 7 inch 158 mm 6 2 inch 2 degrees 93 mm 3 7 inch 156 mm 6 1 inch 1 degree 91 mm 3 6 inch 154 mm 6 1 inch 0 degrees 87 mm 3 4 inch 150 mm 5 9 inch 1 degree 84 mm 3 3 inch 145 mm 5 7 inch 2 degrees 82 mm 3 2 inch 140 mm 5 5 inch 3 degrees 80 mm 3 1 inch 135 mm 5 3 inch 4 degrees 77 mm 3 0 inch 132 mm 5 2 inch 5 degrees 75 mm 3 0 inch 128 mm 5 0 inch 6 degrees 72 mm 2 8 inch 124 mm 4 9 inch 7 degrees 70 mm 2 8 inch 121 mm 4 8 inch 8 degrees 67 mm 2 6 inch 118 mm 4 6 inch 9 degrees 64 mm 2 5 inch 114 mm 4 5 inch 10 degrees 60 mm 2 4 inch 111 mm 4 4 inch 11 degrees 56 mm 2 2 inch 108 mm 4 3 inch 12 degrees
3. 73 Auxiliary Water Pump Rubber Impeller INSPEC rriar dade ete dae a iet aa daaa 73 Battery Electrolyte Level Check n 74 Cooling System Supplemental Coolant Additive SCA TestAdd wetecncy fecetetins cesShity tee nticeetecissiesets 83 Engine Air Cleaner Element Clean Replace 85 Engine Crankcase Breather Clean aaae 88 Engine Oil Sample Obtain a se 92 Engine Oil and Filter Change 0 ee 92 Fuel System Primary Filter Water Separator Element Replace cccccceeeeeeeeeeeeseeeaeees 95 Fuel System Secondary Filter Replace 97 Hoses and Clamps Inspect Replace 5 98 PM Level 1 Every 30 000 L 8000 US gal of Fuel or 400 Service Hours Deep Sump Alternator Belt Inspect Adjust Replace 73 Auxiliary Water Pump Rubber Impeller INSPEC inte i eaten alts 73 Battery Electrolyte Level Check 74 Cooling System Supplemental Coolant Additive SCA Test Add cic sececcnedectensieescteeteeedectiereedeet 83 Engine Air Cleaner Element Clean Replace 85 Engine Crankcase Breather Clean aaas 88 Engine Oil Sample Obtain ee 92 Engine Oil and Filter Change ceeeeeeeeee 92 Fuel System Primary Filter Water Separator Element Replace ccccceceeeeeeeeeeeeseeeeees 95 Fuel System Secondary Filter Replace 97 Hoses and Clamps Inspect Replace 9
4. 1 This is the recommended interval for coolant samples for all conventional heavy duty coolant antifreeze This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC 1 specification for engine coolant 2 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags SEBU7 178 06 83 Maintenance Section Cooling System Coolant Sample Level 2 Obta
5. 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 marks on the oil level gauge i01061121 Engine Speed Timing Sensors Check Clean Calibrate SMCS Code 1912 040 1912 070 1912 524 Hy we s RO Illustration 41 g00372612 Top view 1 Secondary speed timing sensor 2 Primary speed timing sensor 1 Remove the speed timing sensors from the front housing Check the condition of the plastic end of the speed timing sensors for wear and or contaminants 2 Clean the metal shavings and other debris from the face of the speed timing sensors Use the procedure in the Service Manual in order to calibrate the speed timing sensors Refer to the Service Manual for more information on the speed timing sensors 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 the valve train components This maintenance is recommended by Caterpillar as part of a lubric
6. 76 Maintenance Section Cooling System Coolant DEAC Change SEBU7178 06 102535540 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 is observed 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 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 wit
7. 84 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU7178 06 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 Level 2 This level coolant analysis is recommended when the engine is overhauled Refer to this Operations and Maintenance Manual Overhaul Considerations for further information 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 Pressurized System Hot coolant can cause seri ous burns To open the cooling system f
8. 53 mm 2 1 inch 105 mm 4 1 inch 13 degrees 49 mm 1 9 inch 102 mm 4 0 inch 14 degrees 46 mm 1 8 inch 99 mm 3 9 inch 15 degrees 42 mm 1 7 inch 96 mm 3 8 inch 1 A positive angle indicates that the front of the engine is raised A negative angle indicates that the front of the engine is lowered Table 25 3412E and C30 Marine Engine Calibration of the Engine Oil Level Gauge Shallow Sump Right Hand Service Angle X ADD Mark Y FULL Mark 15 degrees 144 mm 5 7 inch 197 mm 7 8 inch 14 degrees 140 mm 5 5 inch 193 mm 7 6 inch 13 degrees 136 mm 5 4 inch 189 mm 7 4 inch 12 degrees 130 mm 5 1 inch 185 mm 7 3 inch 11 degrees 125 mm 4 9 inch 182 mm 7 2 inch 10 degrees 120 mm 4 7 inch 178 mm 7 0 inch 9 degrees 116 mm 4 6 inch 175 mm 6 9 inch 8 degrees 113 mm 4 4 inch 172 mm 6 8 inch 7 degrees 109 mm 4 3 inch 170 mm 6 7 inch 6 degrees 105 mm 4 1 inch 167 mm 6 6 inch 5 degrees 102 mm 4 0 inch 165 mm 6 5 inch 4 degrees 99 mm 3 9 inch 163 mm 6 4 inch 3 degrees 96 mm 3 8 inch 161 mm 6 3 inch 2 degrees 93 mm 3 7 inch 158 mm 6 2 inch 1 degree 91 mm 3 6 inch 155 mm 6 1 inch 0 degrees 88 mm 3 5 inch 152 mm 6 0 inch 1 degree 85 mm 3 3 inch 148 mm 5 8 inch 2 degrees 82 mm 3 2 inch 144 mm 5
9. 102529444 Cooling System Coolant ELC 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 The engine overheats frequently Foaming of the coolant The oil has entered the cooling system and the coolant is contaminated 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 SEBU7178 06 79 Maintenance Section Cooling System Coolant ELC Change Drain 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 NO
10. 1054 510 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 Type 1 Note Use the 102 9720 Cleaning Kit This product contains the detergent and oil that is made specifically for the maintenance of the air cleaner elements 86 Maintenance Section Engine Air Cleaner Element Clean Replace SEBU7178 06 OTTO ToToyoyToyTol a Illustration 32 g00887344 Note This type of air cleaner element should be replaced after three cleanings 1 Remove the air cleaner element 1 Tap the air cleaner element in order to dislodge dirt particles Gently brush the air cleaner 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 2 Spray the air cleaner element with the cleaning solution Allow the air cleaner element to stand for 10 minutes 3 Rinse the air cleaner element with low water pressure The maxi
11. Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 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 Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations article for more information 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 102538100 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool Engines That Are Equipped with a Coolant R
12. Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases SEBU7 178 06 101 Maintenance Section Overhaul Considerations The oil consumption rate brake specific oil consumption is measured in grams per kW h lb per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons e Costly unplanned downtime can be avoided e Many original parts can be reused according to the standards for reusable parts e The engine service life can be extended without the risk of a major catastrophe due to en
13. for additional specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for additional 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 0 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 fora 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 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 additional specific
14. 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 additional specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for additional 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 this Operation and Maintenance Manual Refill Capacities and Recommendations for additional 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 rpm to 1500 rpm Operate the engine at 1500 rpm for one minute in order to purge air from the cavities of the engine block Return the engine to low idle 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 t
15. 1 Fill the cooling system with antifreeze coolant Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for additional 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 Return the engine to low idle Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 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
16. 7 inch 3 degrees 80 mm 3 1 inch 140 mm 5 5 inch 4 degrees 77 mm 3 0 inch 136 mm 5 4 inch 5 degrees 74 mm 2 9 inch 132 mm 5 2 inch 6 degrees 71 mm 2 8 inch 128 mm 5 0 inch 7 degrees 68 mm 2 7 inch 124 mm 4 9 inch 8 degrees 64 mm 2 5 inch 120 mm 4 7 inch 9 degrees 60 mm 2 4 inch 116 mm 4 6 inch 10 degrees 56 mm 2 2 inch 112 mm 4 4 inch 11 degrees 52 mm 2 0 inch 109 mm 4 3 inch 12 degrees 49 mm 1 9 inch 106 mm 4 2 inch 13 degrees 46 mm 1 8 inch 103 mm 4 1 inch 14 degrees 42 mm 1 7 inch 100 mm 3 9 inch 15 degrees 38 mm 1 5 inch 97 mm 3 8 inch 1 A positive angle indicates that the front of the engine is raised A negative angle indicates that the front of the engine is lowered SEBU7 178 06 91 Maintenance Section Engine Oil Level Gauge Calibrate Table 26 Table 27 3412E Marine Engine 3412E Marine Engine Calibration of the Engine Oil Level Gauge Calibration of the Engine Oil Level Gauge Deep Sump Deep Sump Left Hand Service Right Hand Service Angle X ADD Mark Y FULL Mark Angle X ADD Mark Y FULL Mark 15 degrees 202 mm 8 0 inch 263 mm 10 4 inch 15 degrees 223 mm 8 8 inch 278 mm 10 9 inch 14 degrees 200 mm 7 9
17. 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 78 Maintenance Section Cooling System Coolant ELC Change SEBU7178 06 Illustration 27 g01268104 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 Note Pleasure craft that are cooled by a heat exchanger may require the coolant recovery tank to be overfilled approximately 102 mm 4 inch 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 9 Stop the engine and allow the engine to cool Verify the coolant level in the coolant recovery tank Note If necessary refer to step 8 through step 9 in order to purge air from the cooling system 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
18. can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor whe
19. core thoroughly with clean water 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 100997205 Alternator Inspect SMCS Code 1405 040 Note This engine is equipped with an alternator circuit breaker Note the location of the alternator circuit breaker for your particular application If the alternator circuit breaker trips you will need to reset the breaker in order for the charging system to operate Refer to the information that is provided by the OEM for more information Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make
20. covers are installed 1 Start the engine according to Operation and Maintenance Manual Engine Starting Operation Section for the procedure SEBU7 178 06 95 Maintenance Section Fuel System Prime 2 Operate the engine at low idle 3 Observe the top surface of each valve rotator The valve rotators should turn slightly when the valves close NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life If a damaged rotator is not replaced valve face guttering could result and cause pieces of the valve to fall into the cylinder This can cause piston and cylinder head damage If a valve fails to rotate consult your Caterpillar dealer 102553422 Fuel System Prime SMCS Code 1258 548 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 2 BEN a ETAT PRES g00395938 Illustration 42 Fuel supply connections The fuel system should be primed after a unit injector is changed or when the fuel system is totally dry Note The fuel system does not typically need to be primed when the primary fuel filters or secondary fuel filters are changed or when an Electronic Control Module ECM is replaced When the engine is started under
21. 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 is required if the engine is overheating For information on maintenance of the heat exchanger and cleaning of the heat exchanger refer to Disassembly and Assembly Heat Exchanger Disassemble Your Caterpillar dealer has the equipment and the personnel in order to measure the pressure drop across the heat exchanger Consult your Caterpillar dealer or refer to the Service Manual for service information for the heat exchanger 102121526 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 SEBU7 178 06 99 Maintenance Section Marine Transmission Oil Level Check 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 carefully Tighten all connecti
22. inch 259 mm 10 2 inch 14 degrees 219mm 8 6 inch 272 mm 10 7 inch 13 degrees 197 mm 7 8 inch 253 mm 10 0 inch 13 degrees 217 mm 8 5 inch 269 mm 10 6 inch 12 degrees 193 mm 7 6 inch 246 mm 9 7 inch 12 degrees 213mm 8 4 inch 261 mm 10 3 inch 11 degrees 191 mm 7 5 inch 240 mm 9 4 inch 11 degrees 210mm 8 3 inch 256 mm 10 1 inch 10 degrees 187 mm 7 4 inch 235 mm 9 3 inch 10 degrees 208 mm 8 2 inch 250 mm 9 8 inch 9 degrees 183 mm 7 2 inch 230 mm 9 1 inch 9 degrees 204 mm 8 0 inch 246 mm 9 7 inch 8 degrees 178 mm 7 0 inch 223 mm 8 8 inch 8 degrees 199 mm 7 8 inch 241 mm 9 5 inch 7 degrees 173 mm 6 8 inch 219 mm 8 6 inch 7 degrees 194 mm 7 6 inch 236 mm 9 3 inch 6 degrees 168 mm 6 6 inch 213 mm 8 4 inch 6 degrees 190 mm 7 5 inch 233 mm 9 2 inch 5 degrees 164 mm 6 5 inch 208 mm 8 2 inch 5 degrees 185 mm 7 3 inch 227 mm 8 9 inch 4 degrees 159 mm 6 3 inch 203 mm 8 0 inch 4 degrees 181 mm 7 1 inch 223 mm 8 8 inch 3 degrees 155 mm 6 1 inch 195 mm 7 7 inch 3 degrees 176 mm 6 9 inch 217 mm 8 5 inch 2 degrees 151 mm 5 9 inch 192 mm 7 6 inch 2 degrees 174 mm 6 9 inch 214 mm 8 4 inch 1 degree 145 mm 5 7 inch 186 mm 7 3 inch 1 degree 168 mm 6 6 inch 210 mm 8 3 inch 0 degrees 139 mm 5 5 inch 183 mm 7 2 inch 0 degrees 165 mm 6 5 inch 205 mm 8 1 inch 1 degree 132 mm 5 2 inch 179 mm
23. 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 102417406 Overhaul Top End SMCS Code 7595 020 TE A top end overhaul involves the removal the inspection and the rework of the cylinder head components A few additional components are replaced and serviced Your Caterpillar dealer can provide these services and components Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications The following definitions explain the terminology for the services that are performed during an overhaul Inspect Inspect the 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 The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures New parts are not required if the existing parts can still be used reconditioned or repaired If the components are not in the reusability guidelines refer to the Service Manual Specifications module Rebuild The component is reconditioned in order to comply with reusability guidelines Replace The service life of the part is exhausted The part may fail before the next maintenance inte
24. positive angle indicates that the front of the engine is raised A negative angle indicates that the front of the engine is lowered 1 A positive angle indicates that the front of the engine is raised A negative angle indicates that the front of the engine is lowered 92 Maintenance Section Engine Oil Sample Obtain SEBU7178 06 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 S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis 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
25. the auxiliary water pump with water 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 104 Maintenance Section Turbocharger Inspect SEBU7178 06 101539769 Turbocharger Inspect SMCS Code 1052 040 1052 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant
26. 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 the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap 101741595 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 the installation and the location of the engine oil level gauge can be different for each engine The angle of the installation and the location of the engine oil level gauge will affect ADD mark X and FULL mark Y These marks are engraved on the engine oil level gauge The engine oil level gauge must be calibrated after the engine is installed in the vessel Tables 24 through 27 list the installation angles front to rear and the corresponding oil level marks Use a marking pen in order to engrave ADD mark X and FULL mark Y on the engine oil level gauge according to the information in Tables 24 through 27 XE FULL ADD p i uae Illustration 39 g00539533 Oil level gauge X ADD mark Y FULL mark 90 Maintenance Section Engine Oil Level Gauge Calibrate SEBU7178 06
27. 2 040 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 recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location Illustration 36 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 88 Maintenance Section Engine Crankcase Breather Clean SEBU7178 06 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 re
28. 3412E and C30 MARINE ENGINES Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU7178 06 2009 Caterpillar CATERPILLAR All Rights Reserved 66 Maintenance Section Maintenance Recommendations SEBU7178 06 Maintenance Recommendations 103126761 System Pressure Release SMCS Code 1250 1300 1350 5050 Personal injury or death can result from sudden machine movement Sudden movement of the machine can cause in jury to persons on or near the machine To prevent injury or death make sure that the area around the machine is clear of personnel and ob structions before operating the machine Coolant System Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure To relieve the pressure from the coolant system turn off the machine Allow the cooling system system pressure cap to cool Remove the cooling system pressure cap slowly in order to relieve pressure 103642798 Welding on Engines with Electronic Controls SMCS Code 1000 NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult the OEM of the equip ment or your Caterpillar dealer regarding welding on a chassis frame or rail Proper welding procedures are necessary in order to avoid damage to the engine s ECM sensors an
29. 7 0 inch 1 degree 158 mm 6 2 inch 199 mm 7 8 inch 2 degrees 129mm 5 1 inch 175 mm 6 9 inch 2 degrees 155 mm 6 1 inch 195 mm 7 7 inch 3 degrees 124mm 4 9 inch 170 mm 6 7 inch 3 degrees 150mm 5 9 inch 190 mm 7 5 inch 4 degrees 120 mm 4 7 inch 166 mm 6 5 inch 4 degrees 144mm 5 7 inch 186 mm 7 3 inch 5 degrees 116mm 4 6 inch 161 mm 6 3 inch 5 degrees 140mm 5 5 inch 182 mm 7 2 inch 6 degrees 110mm 4 3 inch 157 mm 6 2 inch 6 degrees 135mm 5 3 inch 176 mm 6 9 inch 7 degrees 105mm 4 1 inch 153 mm 6 0 inch 7 degrees 131 mm 5 2 inch 174 mm 6 9 inch 8 degrees 101 mm 4 0 inch 148 mm 5 8 inch 8 degrees 126mm 5 0 inch 169 mm 6 7 inch 9 degrees 97 mm 3 8 inch 143 mm 5 6 inch 9 degrees 124mm 4 9 inch 166 mm 6 5 inch 10 degrees 92 mm 3 6 inch 139 mm 5 5 inch 10 degrees 116 mm 4 6 inch 162 mm 6 4 inch 11 degrees 87 mm 3 4 inch 136 mm 5 4 inch 11 degrees 113 mm 4 4 inch 160 mm 6 3 inch 12 degrees 84 mm 3 3 inch 133 mm 5 2 inch 12 degrees 109 mm 4 3 inch 159 mm 6 3 inch 13 degrees 78mm 3 1 inch 130 mm 5 1 inch 13 degrees 105 mm 4 1 inch 154 mm 6 1 inch 14 degrees 76 mm 3 0 inch 127 mm 5 0 inch 14 degrees 101 mm 4 0 inch 151 mm 5 9 inch 15 degrees 71 mm 2 8 inch 124 mm 4 9 inch 15 degrees 98 mm 3 9 inch 148 mm 5 8 inch 1 A
30. 8 PM Level 2 Every76 000 L 20 000 US gal of Fuel or 1000 Service Hours Heat Exchanger Inspect ieee 98 SEBU7178 06 69 Maintenance Section Maintenance Interval Schedule PM Level 2 Every 76 000 L 20 000 US gal of Fuel or 1000 Service Hours Engines Equipped with Crankcase Fumes Recirculation System Aftercooler Core Clean Test i e 72 Closed Crankcase Ventilation CCV Fumes Disposal Filter Replace eccccceceeceeeeeeeeeeeeeeesnneaees 75 Turbocharger Inspect s es 104 PM Level 3 Every 174 000 L 46 200 US gal of Fuel or 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 76 PM Level 3 Every 228 000 L 60 000 US gal of Fuel or 3000 Service Hours Alternator Inspect cececeeeeeeceeeeeeeeeeeeeteeeeeees 72 Auxiliary Water Pump Bronze Impeller oL O E A E AE dtd 73 Cooling System Coolant DEAC Change 76 Cooling System Water Temperature Regulator Replace iets ecclesia otic a E es 84 Crankshaft Vibration Damper Inspect 85 Engine Mounts Inspect 0 eee 88 Engine Speed Timing Sensors Check Clean CADIE Se iesnc se eect tech ees ca woth arae 94 Engine Valve Lash Inspect Adjust cee 94 Engine Valve Rotators Inspect i e 94 Starting Motor Inspect cece eeeteeeeeenees 103 Turbocharger Inspect n se 104 Water Pump Inspect cecceeeeeeeeeeeeetteeees 105 Overhaul Ov
31. Mounts Inspect ee ceeeeeeeeeeeeeeeenneeees 88 Overhaul Overhaul Considerations ccccccccceeeee esses eeeees 100 72 Maintenance Section Aftercooler Core Clean Test SEBU7178 06 Aftercooler Core Clean Test Engines That Are Equipped with Crankcase Fumes Recirculation System 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 Hydrosolv liquid cleaner Table 22 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 22 Hydrosolv Liquid Cleaners Container 19 L 5 US gal 19 L 5 US gal 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information Description 1U 5490 Hydrosolv 4165 174 6854 Hydrosolv 100 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
32. TICE 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 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 additional specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for additional 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
33. Water Strainer Clean Inspect 5 Wash the oil cooler core and the aftercooler core with hot soapy water Rinse the oil cooler core and the aftercooler core thoroughly with clean water 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 oil cooler core and the aftercooler core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the components in order to ensure cleanliness The oil cooler core and the aftercooler core should be pressure tested Repair the oil cooler core and the aftercooler core if necessary Install the oil cooler core and the aftercooler core For more information about cleaning the cores consult your Caterpillar dealer 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 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
34. all a breather element that is clean and dry Install the seal the breather assembly and the clamp Refer to the Specifications SENR3130 in order to locate the proper torques 5 Install the hose Install the hose clamp Refer to the Specifications SENR3130 in order to locate the proper torques 102456872 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 mounts Any engine mount that shows deterioration should be replaced Refer to Special Publication SENR3130 Torque Specifications for the recommended torques Refer to the OEM recommendations for more information SEBU7 178 06 89 Maintenance Section Engine Oil Level Check 100623423 Engine Oil Level Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin e l lt ADD FULL 5 g00110310 Illustration 38 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause
35. an attack the internal metals of the core and cause leakage Note Use this cleaning procedure to clean the oil cooler core and the aftercooler core 1 Remove the oil cooler core and the aftercooler core 2 Remove any debris from the oil cooler core and the aftercooler core To remove debris from the oil cooler core turn the oil cooler core onto one end To remove debris from the aftercooler core turn the aftercooler core upside down 3 Flush the oil cooler core and the aftercooler core internally with cleaner in order to loosen foreign substances This will also help to remove oil from the oil cooler core and the aftercooler core Note The use of Hydrosolv Liquid Cleaners is recommended Table 29 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 29 Hydrosolv Liquid Cleaners Part er s Number Description Size 1U 5490 Hydrosolv 4165 19 L 5 US gallon 174 6854 Hydrosolv 100 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Use steam to clean the oil cooler core and the aftercooler core This removes any remaining residue from the cleaner Flush the fins of the oil cooler core and the aftercooler core Remove any other trapped debris SEBU7 178 06 103 Maintenance Section Sea
36. ance Section Maintenance Interval Schedule Fuel System Secondary Filter Replace 97 Hoses and Clamps Inspect Replace 98 PM Level 2 Every 76 000 L 20 000 US gal of Fuel or 800 Service Hours Heat Exchanger Inspect ieee 98 PM Level 2 Every 76 000 L 20 000 US gal of Fuel or 800 Service Hours Engines Equipped with Crankcase Fumes Recirculation System Aftercooler Core Clean Test iesene 72 Closed Crankcase Ventilation CCV Fumes Disposal Filter Replace erriren ere 75 Turbocharger Inspect neseser 104 PM Level 3 Every 228 000 L 60 000 US gal of Fuel or 2400 Service Hours Alternator Inspect ceceeeeeeeeceeceeeeeeeeeeteeeeeees 72 Auxiliary Water Pump Bronze Impeller Ao A E E E EE 73 Cooling System Coolant DEAC Change 76 Cooling System Water Temperature Regulator Replace ese air as adane A AERA 84 Crankshaft Vibration Damper Inspect 85 Engine Mounts Inspect eeeeeeeeeeeeeeeeeeeeenteeees 88 Engine Speed Timing Sensors Check Clean Cal FAL assalto e a aA rA R TR 94 Engine Valve Lash Inspect Adjust c eee 94 Engine Valve Rotators Inspect 94 Overhaul Top End sieisen ninii 100 Starting Motor Inspect aeeie 103 Turbocharger Inspect n se 104 Water Pump Inspect ccecceeeeeeeeeeeeeteeeeees 105 PM Level 3 Every 228 000 L 60 000 US gal of Fuel or 3000 Service Hours Engine
37. and Assembly for more information on servicing the auxiliary water pump 101041983 Auxiliary Water Pump Rubber Impeller Inspect SMCS Code 1371 040 Impellers and seals require periodic inspection Impellers have a service life that is limited The service life depends on the engine operating conditions 74 Maintenance Section Battery Replace SEBU7178 06 Inspect the components 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 or damage e Bearings e Impeller e Seals e Wear plate If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump Refer to the Disassembly and Assembly for more information on servicing the auxiliary water pump 102153996 Battery Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cove
38. ation 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 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 101597115 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to help prevent being burned by hot oil or spray Engine valve rotators rotate the valves when the engine runs This helps to prevent deposits from building up on the valves and the valve seats Perform the following steps after the engine valve lash is set but before the valve
39. auge Calibrate 89 Fuel System Prime cccceecceeeeeeeeeeeeeeeeeeeeeneees 95 Heat Exchanger Inspect iseenesesse 98 Sea Water Strainer Clean Inspect 2 103 Zinc Rods Inspect Replace 2 00eeeee 106 Daily Cooling System Coolant Level Check 81 Engine Air Cleaner Service Indicator Inspect 87 Engine Oil Level Check ecceeeeeeeeeteeeeeeenneeees 89 Fuel System Primary Filter Water Separator Drain aa atsteae MAM taste eacte nants Al 97 Fuel System Water Separator Drain 06 98 Marine Transmission Oil Level Check 99 Walk Around Inspection cceeceeeeeeeeereeeees 105 Every 250 Service Hours Cooling System Coolant Sample Level 1 OBTAIN oeie eae aaa aa aa a 82 Every Year Cooling System Coolant Sample Level 2 Obtain sii an een anid ee eee ASL 83 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 80 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 78 Every 3800 L 1000 US gal of Fuel or 50 Service Hours Sea Water Strainer Clean Inspect 2 103 Zinc Rods Inspect Replace 00eee 106 Initial Oil Change Engine Valve Lash Inspect Adjust 0 0 0 eee 94 PM Level 1 Every 15 000 L 4000 US gal of Fuel or 200 Service Hours Shallow Sump Alternator Belt Inspect Adjust Replace
40. 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 Coolant Analysis Level 2 e Visual inspection of properties e Identification of metal corrosion e Identification of contaminants e Identification of built up impurities corrosion and scale S 0 S Coolant Analysis Level 2 provides a report of the results of both the analysis and the maintenance recommendations For more information about coolant analysis consult your Caterpillar dealer 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
41. ble 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 7 Install the hose clamps with a torque wrench Note Refer to the Specifications SENR3130 Torque Specifications in order to locate the proper torques 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 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 100 Maintenance Section Overhaul Top End SEBU7178 06 All support for the warranty of the transmission will be the responsibility of the OEM All
42. brate ee 89 Fuel System Prime ccceecceeeeeeeeeeeeneeeeeeeeneeees 95 Heat Exchanger Inspect iseenese 98 Sea Water Strainer Clean Inspect 5 103 Zinc Rods Inspect Replace 2 0seeeee 106 Daily Cooling System Coolant Level Check 81 Engine Air Cleaner Service Indicator Inspect 87 Engine Oil Level Check eeceeeeeceeeeteeeeeerneeees 89 Fuel System Primary Filter Water Separator Drains teres cca ea e aa A eaaa SA 97 Fuel System Water Separator Drain 98 Marine Transmission Oil Level Check 99 Walk Around Inspection cceeeeeteeeeeeeeeeeees 105 Every 250 Service Hours Cooling System Coolant Sample Level 1 OD AIIM EEE oui caeisdintideN insti dctedihs aden 82 Every Year Cooling System Coolant Sample Level 2 ODtAIN a esd eaaa eaa aeaa ern at 83 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 80 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 78 Every 3800 L 1000 US gal of Fuel or 50 Service Hours Sea Water Strainer Clean Inspect 4 103 Every 4700 L 1250 US gal of Fuel or 50 Service Hours Zinc Rods Inspect Replace 00se 106 Initial Oil Change Engine Valve Lash Inspect Adjust eee 94 PM Level 1 Every 15 000 L 4000 US gal of Fuel or 150 Se
43. d associated components When possible remove the component from the unit and then weld the component If removal of the component is not possible the following procedure must be followed when you weld on a unit that is equipped with a Caterpillar Electronic Engine The following procedure is considered to be the safest procedure to weld on a component This procedure should provide a minimum risk of damage to electronic components NOTICE Do not ground the welder to electrical components such as the ECM or sensors Improper grounding can cause damage to the drive train the bearings hy draulic components electrical components and other components Do not ground the welder across the centerline of the package Improper grounding could cause damage to the bearings the crankshaft the rotor shaft and other components Clamp the ground cable from the welder to the com ponent that will be welded Place the clamp as close as possible to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 1 Stop the engine Turn the switched power to the OFF position 2 Disconnect the negative battery cable from the battery If a battery disconnect switch is provided open the switch 3 Disconnect the J1 P1 and J2 P2 connectors from the ECM Move the harness to a position that will not allow the harness to accidentally move back and make contact with a
44. d 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 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 If 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 SEBU7 178 06 93 Maintenance Section Engine Oil and Filter Change e If 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 Caterpil
45. e and check for leaks again Detecting leaks is difficult 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 check the components for overtightening or undertightening SEBU7 178 06 97 Maintenance Section Fuel System Primary Filter Water Separator Drain 101463757 Fuel System Primary Filter Water Separator Drain SMCS Code 1260 543 1263 543 2 g g00668636 Illustration 44 1 Bowl 2 Element 3 Drain Bowl 1 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close drain 3 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 100823807 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE 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
46. e the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed 101040881 Zinc Rods Inspect Replace SMCS Code 1388 040 1388 510 Corrosion in sea water circuits can result in premature deterioration of system components leaks and possible cooling system contamination A lack of zinc rods in the sea water system can cause corrosion in the sea water cooling system Zinc rods are inserted in the sea water cooling system of the engine in order to help prevent the corrosive action of salt water The reaction of the zinc to the sea water causes the zinc rods to deteriorate The zinc rods deteriorate instead of engine parts for the cooling system that are more critical 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 30 shows the locations of the zinc rods and the quantities of the zinc rods Table 30 Locat
47. ease the belt tension 4 Tighten adjusting nuts 1 Tighten mounting bolt 2 Refer to the Specifications SENR3130 Torque Specifications for the proper torques 5 Reinstall the belt guard If new belts are installed check the belt adjustment again after 30 minutes of engine operation at the rated rom Replacement 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 belts are stretched The additional load on the new belt could cause the new belt to break Refer to the Service Manual for more information on the procedures for the following topics belt removal and installation of the belt 101042055 Auxiliary Water Pump Bronze Impeller Inspect SMCS Code 1371 040 Impellers and seals require periodic inspection Impellers have a service life that is limited The service life depends on the engine operating conditions Inspect the components 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 or damage e Bearings e Impeller e Seals e Wear plate If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump Refer to the Disassembly
48. ecovery Tank Illustration 29 g01268104 1 Recovery tank 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 filler cap 3 Pour the proper coolant mixture into the tank Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for information about coolants 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 82 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU7178 06 Engines That Are Not Equipped with a Coolant Recovery Tank 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 press
49. el and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing with standard shop sol
50. ement 2 Bowl 3 Drain 2 Remove element 1 from the element mounting base while bowl 2 is attached 3 Dispose of the contents of the filter Remove bowl 2 from element 1 The bowl is reusable Do not discard the bowl Dispose of the used element 4 Remove the O ring from the gland of the bowl Clean the following components e Bowl e O ring e Mounting base Inspect the O ring for damage and for deterioration Replace the O ring if necessary 5 Lubricate the O ring with clean diesel fuel 6 Install bowl 2 on a new element Tighten the bowl by hand Do not use tools in order to tighten the bowl 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 7 Lubricate the top seal of element 1 with clean diesel fuel The element may be filled with fuel at this time Install the new element on the mounting base Tighten the element by hand 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 8 Open the main fuel supply valve 9 Start the engine and check for leaks Run the engine for one minute Stop the engin
51. erhaul Considerations s c 100 70 Maintenance Section Maintenance Interval Schedule SEBU7178 06 103651154 Maintenance Interval Schedule Fast Craft Rated Engine SMCS Code 1000 7500 Contact your Caterpillar dealer in order to determine whether your engine is a fast craft rated engine Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Aftercooler Core Clean Test ieee 72 Battery Replace ooo eee eeeeeeceeeeeeeeeeeeneeeeeeeneaeees 74 Battery or Battery Cable Disconnect 75 Engine Oil Level Gauge Cali
52. gine failure e The best cost value relationship per hour of extended life can be attained After Failure Overhaul If a major engine failure occurs and the engine must be removed many options are available An overhaul should be performed if the engine block or the 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 Overhaul Recommendation To minimize downtime a scheduled engine overhaul by your Caterpillar dealer is recommended 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 Unit Fuel Injector Clean the fuel injector body and replace the O rings Replace the O rings and the gasket on the injector sleeve Clean the area around the injecto
53. h 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 CaterpillaService Technology Groupr 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 additional specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for additional 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 0 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
54. hat 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 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 Refill Capacities and Recommendations for more information 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 94 Maintenance Section Engine Speed Timing Sensors Check Clean Calibrate SEBU7178 06
55. hat 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 80 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7178 06 Illustration 28 g01268104 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 Note Pleasure craft that are cooled by a heat exchanger may require the coolant recovery tank to be overfilled approximately 102 mm 4 inch 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 9 Stop the engine and allow the engine to cool Verify the coolant level in the coolant recovery tank Note If necessary refer to step 8 through 9 in order to purge air from the cooling s
56. iller 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 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 Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations 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 101061981 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 overheat
57. in e Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see this Operation and Maintenance Manual Refill Capacities and Recommendations or consult your Caterpillar dealer 101987714 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6251 Caterpillar Commercial Diesel Engines Fluids Recommendations
58. information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for additional general information on the proper torques Fill Refer to the Special Publication SEBU6251 Commercial Diesel Engine Fluids Recommendations for information regarding acceptable water antifreeze coolant and supplemental coolant additive requirements 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 antifreeze coolant Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for additional 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 Return the engine to low idle 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 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
59. ing Excessive 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 the temperature regulators on a regularly scheduled basis could cause severe engine damage Never operate the engine without the temperature reg ulators installed If the temperature regulator is installed incorrectly the engine may overheat causing cylinder head damage Ensure that the new temperature regulator is installed in the original position SEBU7 178 06 85 Maintenance Section Crankshaft Vibration Damper Inspect 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 Fill the engine with coolant to the correct level once the new water temperature regulators have been installed Be sure to use the correct type of coolant The coolant should always be maintained a
60. ions of the Zinc Rods Location Quantity Inlet Elbow for Sea Water On the Heat Exchanger Outlet Elbow for Sea Water On the Heat Exchanger 1 1 Remove the zinc rod Illustration 47 g00104048 2 Tap the zinc rod lightly with a hammer If the zinc rod has deteriorated or if the zinc rod flakes install a new zinc rod Replace the Zinc Rods Illustration 48 g00104049 1 Unscrew the old zinc rod or drill the old zinc rod from the plug Clean the plug 2 Apply 9S 3263 Compound to the shoulder of a new zinc rod Apply the compound only to the shoulder of the zinc rod Install the zinc rod into the plug SEBU7178 06 107 Maintenance Section Zinc Rods Inspect Replace 3 Coat the external threads of the plug with 5P 3413 Pipe Sealant Install the zinc rod Refer to Operation and Maintenance Manual for more information on torque specifications
61. lar 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 system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Gp 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 40 g00103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure t
62. 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 SEBU7 178 06 77 Maintenance Section Cooling System Coolant DEAC Change 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 additional specific information on the proper torques Refer to the Specifications SENR3130 Torque Specifications for additional 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 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
63. ltration in order to help extend the life of the secondary fuel filter The element should be changed regularly If a vacuum gauge is installed the primary filter water separator should be changed at 50 to 70 kPa 15 to 20 inches Hg 96 Maintenance Section SEBU7178 06 Fuel System Primary Filter Water Separator Element Replace Replace the Element 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 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 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 1 Close the main fuel supply valve OO Illustration 43 g01453091 1 El
64. mum water pressure for this procedure is 275 kPa 40 psi Tap water is acceptable Start to rinse the air cleaner element from the clean side inside Next clean the dirty side outside in order to flush out dirt Inspect the air cleaner element for tears and or holes after the air cleaner element is cleaned Do not reuse damaged air cleaner 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 4 Shake excess water off the air cleaner element and allow the air cleaner element to air dry Drying the air cleaner 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 cleaner element with the recommended oil 5 The dry air cleaner element should be oiled before installation Apply small amounts of oil across the top of each pleat Allow the oil to soak into the air cleaner element for 20 minutes Oil any remaining white spots 6 Inspect the housing and the clamp for air cleaner element 1 Install the clean oiled air cleane
65. ny of the ECM pins SEBU7178 06 67 Maintenance Section Maintenance Recommendations Illustration 24 g01075639 Use the example above The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components 1 Engine 2 Welding electrode 3 Keyswitch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electrical Electronic component 8 Minimum distance between the component that is being welded and any electrical electronic component 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 4 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Note If electrical electronic components are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow from the welder could seve
66. ons 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 Replace the Hoses and the Clamps 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 to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suita
67. or consult your Caterpillar dealer 102456600 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 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 and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration 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 this Operation and Maintenance Manual Refill Capacities and Recommendations for more information 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 Special Publication SEBU6251 Caterpillar Commercial Diesel Engine Fluids Recommendations for more information S O 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
68. ot last until the second overhaul e Thrust bearings e Main bearings e Rod bearings e Valve rotators e Crankshaft seals Caterpillar Inc recommends the installation of new parts at each overhaul period Inspect these parts while the engine is disassembled for an overhaul 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 following components e Rod bearing e Main bearings Note If the crankshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the crankshaft Inspect the camshaft for damage to the journals and to the lobes Note If the camshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the camshaft Inspect the following components for signs of wear or for signs of scuffing e Camshaft bearings e Camshaft followers Caterpillar Inc recommends replacing the crankshaft vibration damper Oil Cooler Core and Aftercooler Core During an overhaul the removal of the oil cooler core and the aftercooler core is recommended The oil cooler core and the aftercooler core should be cleaned and pressure tested NOTICE Do not use caustic cleaners to clean the core Caustic cleaners c
69. othing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the 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 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean SEBU7 178 06 75 Maintenance Section Battery or Battery Cable Disconnect Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt 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 Silicone Lubricant petroleum jelly or MPGM 101492654 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the batter
70. p 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 102482066 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Cat ELC Extended Life Coolant does not require the frequent additions of any supplemental cooling additives which are associated with the present conventional coolants The Cat ELC Extender only needs to be added once NOTICE Use only Cat Extended Life Coolant ELC Extender with Cat ELC Do NOT use conventional supplemental coolant addi tive SCA with Cat ELC Mixing Cat ELC with conven tional coolants and or conventional SCA reduces the Cat ELC service life Check the cooling system only when the engine is stopped and cool SEBU7 178 06 81 Maintenance Section Cooling System Coolant Level Check Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns
71. per tightening Tighten the filter for an additional 3 4 turn by hand Do not overtighten the filter 102379747 Fuel System Water Separator Drain SMCS Code 1263 543 a J g00668636 Illustration 46 1 Bowl 2 Element 3 Drain Bowl 1 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close drain 3 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 101065537 Heat Exchanger Inspect SMCS Code 1379 040 The interval for the maintenance of the plate type heat exchanger depends on the operating environment of the vessel and on the operating time The raw 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 heat exchanger plates e Effectiveness of the heat exchanger system Operating the engine in water that contains silt sediment salt algae or other significant contaminants will have an adverse effect on the heat exchanger system In addition intermittent use of the vessel will adversely affect the heat exchanger system The
72. r element Replace the housing and the clamp if necessary Refer to Specifications SENR3130 Torque Specifications for the proper torque of the clamp Type 2 Illustration 33 g00888130 1 Disconnect latches 1 2 Remove cover 2 3 Remove air cleaner element 3 Note This type of air cleaner element may be cleaned up to six times SEBU7 178 06 87 Maintenance Section Engine Air Cleaner Service Indicator Inspect 4 Refer to Guideline for Reusable Parts and Salvage Operations SEBF8062 for cleaning instructions or replace the air cleaner element 5 Install the air cleaner element 3 1 3 6 5 4 2 Illustration 34 g00888209 Sequence for latches 6 Install cover 2 Fasten cover 2 with latches 1 in the sequence that is shown in Illustration 34 Type 3 Illustration 35 g00888128 1 Disconnect latches 1 2 Remove cover 2 3 Remove air cleaner element 3 Note This type of air cleaner element may be cleaned up to six times 4 Refer to Guideline for Reusable Parts and Salvage Operations SEBF8062 for cleaning instructions or replace the air cleaner element 5 Install the air cleaner element 3 6 Install cover 2 7 Fasten cover 2 with latches 1 i01900118 Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 745
73. r seating in the injector sleeve Refer to the Service Manual for the complete procedure or consult with your Caterpillar dealer for assistance Rebuild or Exchange Cylinder Head Assembly Connecting Rods Pistons Cylinder Liners Turbocharger Cylinder Packs Oil Pump and Fuel Transfer Pump These components should be inspected 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 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 dealt with in one of the following manners e Salvaging e Repairing e Replacing 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 e Increased fuel consumption 102 Maintenance Section Overhaul Considerations SEBU7178 06 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 Inspection and or Replacement Piston Rings Crankshaft Bearings Valve Rotators and Crankshaft Seals The following components may n
74. r should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the key start switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnect the charger 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the key start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the ground plane to the NEGATIVE battery terminal 102601752 Battery Electrolyte Level Check SMCS Code 1401 535 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 All lead acid batteries contain sulfuric acid which can burn the skin and cl
75. rely damage the component 5 Protect the wiring harness from welding debris and spatter 6 Use standard welding practices to weld the materials 68 Maintenance Section Maintenance Interval Schedule SEBU7178 06 103651158 Maintenance Interval Schedule Standard Rated Engine SMCS Code 1000 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Aftercooler Core Clean Test i e 72 Battery Replace 0 cccceccsecceeeeneeeeeeeeeneeeeeee 74 Battery or Battery Cable Disconnect 75 Engine Oil Level G
76. repairs as required Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge SEBU7 178 06 73 Maintenance Section Alternator Belt Inspect Adjust Replace 102456322 Alternator Belt Inspect Adjust Replace SMCS Code 1357 036 1357 510 Inspection To maximize the engine performance inspect the belt for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the life of the belt To check the belt tension apply 110 N 25 Ib of force midway between the pulleys A correctly adjusted belt will deflect 13 to 19 mm 0 50 to 0 75 inch Adjustment Illustration 25 g00122875 1 Adjusting nuts 2 Mounting bolt 1 Remove the belt guard 2 Loosen mounting bolt 2 and adjusting nuts 1 3 Turn adjusting nuts 1 in order to increase or decr
77. rval The part must be replaced with a part that meets functional specifications The replacement part may be a new part a CAT remanufactured part a rebuilt part or a used part Some worn components may be exchanged with your Caterpillar dealer for a credit on replacement parts Consult your Caterpillar dealer about repair options for your engine If you elect to perform an overhaul without the services of a Caterpillar dealer be aware of the recommendations in Table 28 Table 28 Recommendations for Top End Overhauls 1 Service Top End Overhaul Inspect Cylinder head assemblies Rebuild Replace Valves Inspect Rocker arms Replees Valve bridges Replace Cylinder head gaskets 1 For instructions on removal and installation of components see the Service Manual Disassembly and Assembly module 102018788 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand A decreased average power demand should increase both the engine service life and the overhaul interval The need for an overhaul is generally indicated by increased fuel consumption and by reduced power The following factors are important when a decision is being made on the proper time for an engine overhaul e The need for preventive maintenance e The quality of the fuel that is being used e The operating conditions e The results of the S O S analysis
78. rvice Hours or 1 Year Shallow Sump Alternator Belt Inspect Adjust Replace 73 Auxiliary Water Pump Rubber Impeller INSPOCt nega aa ae aa aTa au a a aani 73 Battery Electrolyte Level Check seses 74 Cooling System Supplemental Coolant Additive SCA Test Add 0 eeccecceececeeeeeeseeeeeeseeeeteteeeeeaees 83 Engine Air Cleaner Element Clean Replace 85 Engine Crankcase Breather Clean aaeain 88 Engine Oil Sample Obtain n 92 Engine Oil and Filter Change 0 ee 92 Fuel System Primary Filter Water Separator Element Replace cecceeeeeeeeeeeeeeeeeeeees 95 Fuel System Secondary Filter Replace 97 Hoses and Clamps Inspect Replace 5 98 PM Level 1 Every 30 000 L 8000 US gal of Fuel or 300 Service Hours or 1 Year Deep Sump Alternator Belt Inspect Adjust Replace 73 Auxiliary Water Pump Rubber Impeller INSPOCl cosas Ade Ae ee oie ater ae 73 Battery Electrolyte Level Check 74 Cooling System Supplemental Coolant Additive SCA Test Add oo eccceceeeeeeeeeeeeeenteeeeeeeenaeees 83 Engine Air Cleaner Element Clean Replace 85 Engine Crankcase Breather Clean aaisen 88 Engine Oil Sample Obtain asasinen 92 Engine Oil and Filter Change n se 92 Fuel System Primary Filter Water Separator Element Replace ceccceeceeeeeeeeeeseeneees 95 SEBU7 178 06 71 Mainten
79. s 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 Inspect the ECM 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 Check the condition of the gauges Replace any gauges which are cracked Replace any gauges that can not be calibrated 103543200 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 106 Maintenance Section Zinc Rods Inspect Replace SEBU7178 06 A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary to remov
80. 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 obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers 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 PEgj0047 How To Take A Good S 0 S Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 102107152 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 Hot oil an
81. set 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 is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 102263740 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 Illustration 37 g01136454 Typical example 1 Hose clamp 2 Breather assembly 3 Retaining clamp 4 Seal 1 Loosen hose clamp 1 and remove the hose from breather assembly 2 2 Loosen retaining clamp 3 Remove the breather assembly and seal 4 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Inst
82. t the correct concentration 103175962 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine 1 Te Illustration 31 g01134779 Viscous vibration damper Typical example 1 Crankshaft pulley 2 Weight 3 Case Inspection Inspect the damper for the following conditions The damper is dented cracked or fluid is leaking from the damper The paint on the damper is discolored from excessive heat The damper is bent The bolt holes are worn or there is a loose fit for the bolts The engine has had a crankshaft failure due to torsional forces Replace the damper if any of these conditions exist Removal and Installation Refer to this Operation and Maintenance Manual Belts Inspect Adjust Replace for information on removing and on installing the belt Refer to the Disassembly and Assembly Manual Vibration Damper and Pulley Remove and Install for information on removing and installing the damper 101727320 Engine Air Cleaner Element Clean Replace SMCS Code 1054 070
83. these circumstances the engine may momentarily run rough until the air is purged from the system 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 1 Loosen a fuel supply connection to the regulating valve as shown Note The fuel priming pump is located on the secondary fuel filter Operating the fuel priming pump without loosening a fuel connection upstream of the regulating valve can cause a failure of the fuel transfer pump seal 2 Open the fuel priming pump and operate the pump until air is purged and the fuel appears at the fuel connection Tighten the fuel connection 3 Crank the engine after pressurizing the system 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 4 If the engine does not start repeat Steps 1 through 3 in order to start the engine 102927282 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 an electronic unit injector 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 fi
84. tion 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 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 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 Inspect the fuel system for leaks Inspect the hose that goes from the unit injector hydraulic pump to the left side fluid manifold Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Inspect the alternator 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 Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enter
85. ure 2 Maintain the coolant level within 13 mm 0 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 30 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 4 Inspect the cooling system for leaks 102837191 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat DEAC Diesel Engine Antifreeze Coolant e Commercial heavy duty coolant antifreeze Table 23 Recommended Interval Type of Coolant Level 1 Level 2 Every 250 Cat DEAC Hours Yearly Cat ELC Optional Yearly
86. vents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing SEBU7 178 06 105 Maintenance Section Walk Around Inspection 101063972 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only require a few minutes When the time is used 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 you start 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 leaking 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 Ensure that the cooling lines are properly clamped Check for leaks Check the condi
87. y cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 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 volt 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 101735844 Closed Crankcase Ventilation CCV Fumes Disposal Filter Replace SMCS Code 1317 510 FI OTTO ToToyoyToyTol a 0 Illustration 26 g00889933 1 Air cleaner element 2 Fumes disposal filter The Closed Crankcase Ventilation system CCV requires the replacement of the fumes disposal filter The service interval of the CCV will be affected by the following items e Engine load e Soot concentration e Condition of the engine Use the following steps in order to ensure the proper replacement of the fumes disposal filter 1 Remove air cleaner element 1 2 Remove fumes disposal filter 2 3 Install a new fumes disposal filter 2 4 Install air cleaner element 1
88. ystem 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 this Operation and Maintenance Manual Refill Capacitites and Recommendations for additional 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 rpm to 1500 rpm Operate the engine at 1500 rpm for one minute in order to purge air from the cavities of the engine block Return the engine to low idle 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 ca

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