c32 marine engine (rxb) - jimmy · pdf file70 sebu7908-09 maintenance section maintenance...

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C32 MARINE ENGINE(RXB)Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7908-09)

®© 2009 CaterpillarAll Rights Reserved

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SEBU7908-09 69Maintenance Section

Maintenance Interval Schedule

i03634432

Maintenance Interval Schedule(Engines Which Are Rated “B”and Engines Which Are Rated“C”)SMCS Code: 1000; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible forthe performance of maintenance, including alladjustments, the use of proper lubricants, fluids,filters, and the installation of new componentsdue to normal wear and aging. The performanceof this product may be diminished if propermaintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Replace .................................................. 74Battery or Battery Cable - Disconnect .................. 75Engine - Clean ...................................................... 87Engine Oil Level Gauge - Calibrate ...................... 91Engine Storage Procedure - Check ...................... 94Fuel System - Prime ............................................. 95Heat Exchanger - Inspect ..................................... 99Maintenance Recommendations ........................ 105Sea Water Strainer - Clean/Inspect ..................... 112Zinc Rods - Inspect/Replace ................................ 114

Daily

Cooling System Coolant Level - Check ................ 83Engine Air Cleaner Service Indicator - Inspect ..... 89Engine Oil Level - Check ...................................... 90Fuel System Primary Filter/Water Separator -Drain ................................................................... 97Walk-Around Inspection ....................................... 113

Initial 10 Service Hours

Belts - Inspect/Adjust/Replace .............................. 76

Every 50 Service Hours or Weekly

Sea Water Strainer - Clean/Inspect ..................... 112Zinc Rods - Inspect/Replace ................................ 114

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 84

Every Year


Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 82

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 80

First 22 700 L (6000 US gal) of Fuel or 250Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 95

Every 22 700 L (6000 US gal) of Fuel or 250Service Hours or 1 Year

Auxiliary Water Pump (Rubber Impeller) -Inspect ................................................................ 74Battery Electrolyte Level - Check .......................... 75Belts - Inspect/Adjust/Replace .............................. 76Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 83Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 85Engine - Clean ...................................................... 87Engine Air Cleaner Element - Clean/Replace ....... 87Engine Crankcase Breather - Clean ..................... 90Engine Oil Sample - Obtain .................................. 92Engine Oil and Filter - Change ............................. 92Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 96Fuel System Secondary Filter - Replace .............. 98Fuel Tank Water and Sediment - Drain ................. 98Hoses and Clamps - Inspect/Replace ................ 101

Every 90 850 L (24 000 US gal) of Fuel or1000 Service Hours

Aftercooler Core - Clean/Test ............................... 73Closed Crankcase Ventilation (CCV) Fumes DisposalFilter - Replace .................................................... 77Turbocharger - Inspect ......................................... 112

70 SEBU7908-09Maintenance SectionMaintenance Interval Schedule


Auxiliary Water Pump (Bronze Impeller) -Inspect ................................................................ 74Cooling System Coolant (DEAC) - Change .......... 77Cooling System Water Temperature Regulator -Replace ............................................................... 85Crankshaft Vibration Damper - Inspect ................. 86Engine Mounts - Inspect ....................................... 90Engine Speed/Timing Sensors - Check/Clean/Calibrate .............................................................. 94Engine Valve Lash - Inspect/Adjust ...................... 95Engine Valve Rotators - Inspect ........................... 95Heat Exchanger - Inspect ..................................... 99Starting Motor - Inspect ....................................... 112


Alternator - Inspect ............................................... 74Water Pump - Inspect .......................................... 114

Overhaul

Maintenance Recommendations ........................ 105Overhaul (Major) ................................................. 108


Maintenance Interval Schedule

i03753401

Maintenance Interval Schedule(Engines Which Are Rated “E”)SMCS Code: 1000; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible forthe performance of maintenance, including alladjustments, the use of proper lubricants, fluids,filters, and the installation of new componentsdue to normal wear and aging. The performanceof this product may be diminished if propermaintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Replace .................................................. 74Battery or Battery Cable - Disconnect .................. 75Engine - Clean ...................................................... 87Engine Oil Level Gauge - Calibrate ...................... 91Engine Storage Procedure - Check ...................... 94Fuel System - Prime ............................................. 95Heat Exchanger - Inspect ..................................... 99Maintenance Recommendations ........................ 102Sea Water Strainer - Clean/Inspect ..................... 112Zinc Rods - Inspect/Replace ................................ 114

Daily

Cooling System Coolant Level - Check ................ 83Engine Air Cleaner Service Indicator - Inspect ..... 89Engine Oil Level - Check ...................................... 90Fuel System Primary Filter/Water Separator -Drain ................................................................... 97Walk-Around Inspection ....................................... 113

Initial 10 Service Hours

Belts - Inspect/Adjust/Replace .............................. 76

Every 50 Service Hours or Weekly

Sea Water Strainer - Clean/Inspect ..................... 112Zinc Rods - Inspect/Replace ................................ 114

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)


Every Year


Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 82

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 80

First 22 700 L (6000 US gal) of Fuel or 250Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 95

Every 22 700 L (6000 US gal) of Fuel or 250Service Hours or 1 Year

Auxiliary Water Pump (Rubber Impeller) -Inspect ................................................................ 74Battery Electrolyte Level - Check .......................... 75Belts - Inspect/Adjust/Replace .............................. 76Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 83Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 85Engine - Clean ...................................................... 87Engine Air Cleaner Element - Clean/Replace ....... 87Engine Crankcase Breather - Clean ..................... 90Engine Oil Sample - Obtain .................................. 92Engine Oil and Filter - Change ............................. 92Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 96Fuel System Secondary Filter - Replace .............. 98Fuel Tank Water and Sediment - Drain ................. 98Hoses and Clamps - Inspect/Replace ................ 101


Aftercooler Core - Clean/Test ............................... 73Closed Crankcase Ventilation (CCV) Fumes DisposalFilter - Replace .................................................... 77Turbocharger - Inspect ......................................... 112


Auxiliary Water Pump (Bronze Impeller) -Inspect ................................................................ 74Cooling System Coolant (DEAC) - Change .......... 77Cooling System Water Temperature Regulator -Replace ............................................................... 85Crankshaft Vibration Damper - Inspect ................. 86

72 SEBU7908-09Maintenance SectionMaintenance Interval Schedule

Engine Mounts - Inspect ....................................... 90Engine Speed/Timing Sensors - Check/Clean/Calibrate .............................................................. 94Engine Valve Lash - Inspect/Adjust ...................... 95Engine Valve Rotators - Inspect ........................... 95Heat Exchanger - Inspect ..................................... 99Starting Motor - Inspect ....................................... 112


Alternator - Inspect ............................................... 74Maintenance Recommendations ........................ 102Oil Cooler Core - Check/Clean/Test .................... 108Overhaul (Top End) .............................................. 111Water Pump - Inspect .......................................... 114

Overhaul

Maintenance Recommendations ........................ 102Overhaul (Major) ................................................. 108


Aftercooler Core - Clean/Test

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Aftercooler Core - Clean/TestSMCS Code: 1064-070; 1064-081

Note: An aftercooler that circulates fresh wateror treated water may require cleaning less oftenthan an aftercooler which circulates salt water.The maintenance interval for an aftercooler whichcirculates fresh water or treated water should beevaluated when the aftercooler is cleaned and testedafter the first 1000 hours of engine operation. Theinterval will vary depending on operating conditions.

Clean the Aftercooler CoreRemove the core. Refer to the Disassembly andAssembly Manual, “Aftercooler - Remove” for theprocedure.

1. Turn the aftercooler core on one side in orderto remove debris. Remove the debris that isaccessible.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

2. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 20 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 20

Hydrosolv Liquid Cleaners(1)

PartNumber 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 cleanerat temperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

3. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris from the insideand from the outside of the core.

Note: Do not use high pressure when the fins arecleaned. High pressure can damage the fins.

4. Wash the core with hot, soapy water.

5. Flush the core thoroughly in order to removeresidue and remaining debris. Flush the core withclean, fresh water until the water that is exiting thecore is clear and free of debris.

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.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

6. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

Test the Aftercooler Core1. Inspect the core for trapped debris andcleanliness. If necessary, remove the debris andrepeat the cleaning procedure.

2. Inspect the core for damage and perform apressure test in order to detect leaks. Many shopsthat service radiators are equipped to performpressure tests.

3. Plug both ends of the aftercooler core andpressurize the core to 205 kPa (30 psi). Submergethe core in water. Look for bubbles which arebeing emitted from the core. The bubbles areevidence of leaks.

4. If any leaks are found, do not attempt to repair thecore.

Install a core that is clean and a core that passes thepressure test in step 3. Refer to the Disassemblyand Assembly Manual, “Aftercooler - Install” for theprocedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

74 SEBU7908-09Maintenance SectionAlternator - Inspect

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Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspect theammeter (if equipped) during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system. Makerepairs, as required.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i01042055

Auxiliary Water Pump (BronzeImpeller) - InspectSMCS Code: 1371-040

Impellers and seals require periodic inspection.Impellers have a service life that is limited. Theservice life depends on the engine operatingconditions.

Inspect the components more frequently when thepump is exposed to debris, sand, or other abrasivematerials. Inspect the components if the pump isoperating at a differential pressure of more than103 kPa (15 psi).

Check the following components for wear or damage:

• Bearings

• Impeller

• Seals

• Wear plate

If wear or damage is found, replace the componentswhich are worn or damaged. Use the proper repairkit for the pump. Refer to the Disassembly andAssembly for more information on servicing theauxiliary water pump.

i01041983

Auxiliary Water Pump (RubberImpeller) - InspectSMCS Code: 1371-040

Impellers and seals require periodic inspection.Impellers have a service life that is limited. Theservice life depends on the engine operatingconditions.

Inspect the components more frequently when thepump is exposed to debris, sand, or other abrasivematerials. Inspect the components if the pump isoperating at a differential pressure of more than103 kPa (15 psi).

Check the following components for wear or damage:

• Bearings

• Impeller

• Seals

• Wear plate

If wear or damage is found, replace the componentswhich are worn or damaged. Use the proper repairkit for the pump. Refer to the Disassembly andAssembly for more information on servicing theauxiliary water pump.

i02153996

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. 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 inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.


Battery Electrolyte Level - Check

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting 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 thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe 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 abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE “-” battery terminal.

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

• 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 theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

76 SEBU7908-09Maintenance SectionBelts - Inspect/Adjust/Replace

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i02856850

Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

InspectionInspect the alternator belt and any accessory beltsfor wear and for cracking. Replace the belts if thebelts are not in good condition.

To check the belt tension, apply 110 N (25 lb) of forcemidway between the pulleys. A correctly adjustedbelt will deflect 13 to 19 mm (0.50 to 0.75 inch).

Slippage of loose belts can reduce the efficiencyof the driven components. Vibration of loose beltscan cause unnecessary wear on the followingcomponents:

• Belts

• Pulleys

• Bearings

If the belts are too tight, unnecessary stress is placedon the components. This reduces the service life ofthe components.

ReplacementFor applications that require multiple drive belts,replace the drive belts in matched sets. Replacingone drive belt of a matched set will cause the newdrive belt to carry more load because the older drivebelts are stretched. The additional load on the newdrive belt could cause the new drive belt to fail.

Alternator Belt Adjustment

g00960176Illustration 24(1) Adjusting nuts(2) Mounting bolt(3) Mounting bolt(4) Mounting bolt

1. Remove the drive belt guard.

2. Loosen mounting bolts (2), (3), and (4). Loosenadjusting nuts (1).

3. Turn adjusting nuts (1) in order to increase ordecrease the drive belt tension.

4. Tighten adjusting nuts (1). Tighten mounting bolts(2), (3), and (4).

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belttension again after 30 minutes of engine operation atthe rated rpm.


Closed Crankcase Ventilation (CCV) Fumes Disposal Filter - Replace

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Closed Crankcase Ventilation(CCV) Fumes Disposal Filter -ReplaceSMCS Code: 1317-510-FI

g00889933Illustration 25(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 bythe following items:

• Engine load

• Soot concentration

• Condition of the engine

Use the following steps in order to ensure the properreplacement 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).

i02571689

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse 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 watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe 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 systemcomponents are cool. Loosen the cooling systempressure 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 inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove one of the drain plugs.

Allow the coolant to drain.

78 SEBU7908-09Maintenance SectionCooling System Coolant (DEAC) - Change

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Dealer Service Tools:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theSpecifications Manual for your particular engine formore specific information on the proper torques.Refer to the Specifications, SENR3130, “TorqueSpecifications” for more general information onthe proper torques.

NOTICEFill 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 cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start the engine and run the engine at low idle for aminimum of 30 minutes. The coolant temperatureshould be at least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve (ifequipped). Clean the drain plugs. Install the drainplugs. Refer to the Specifications Manual for yourparticular engine for more specific information onthe proper torques. Refer to the Specifications,SENR3130, “Torque Specifications” for moregeneral information on the proper torques.

Cooling Systems with HeavyDeposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water in orderto remove any debris.



3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

4. Start the engine and run the engine at low idle for aminimum of 90 minutes. The coolant temperatureshould be at least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.


Cooling System Coolant (DEAC) - Change


FillRefer to Special Publication, SEBU6251,“Commercial Diesel Engine FluidsRecommendations” for information regardingacceptable water, antifreeze/coolant, andsupplemental coolant additive requirements.

Engines that are Equipped with a CoolantRecovery Tank


1. Fill the cooling system with antifreeze/coolant.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations”for additional information on cooling systemspecifications. Do not install the cooling systemfiller cap.

2. Start the engine and run the engine at low idle.Increase the engine rpm to high idle. Run theengine at high idle for one minute in order topurge 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 coolingsystem is full.

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system fillercap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the face ofthe cooling system filler cap. If the cooling systemfiller cap does not retain the correct pressure,install a new cooling system filler cap.

g01268104Illustration 26(1) Recovery tank filler cap(2) “COLD FULL” mark(3) “LOW ADD” mark

5. Loosen the cap for the coolant recovery tankslowly in order to relieve any pressure. Removethe cap for the coolant recovery tank.

6. Pour coolant into the coolant recovery tank untilthe 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 heatexchanger may require the coolant recovery tank tobe overfilled approximately 102 mm (4 inch) abovethe CODE FULL mark.

7. Clean the cap for the coolant recovery tank. Installthe cap for the coolant recovery tank.

8. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

9. Stop the engine and allow the engine to cool.Verify the coolant level in the coolant recoverytank.

Note: If necessary, refer to step8 through step 9 inorder to purge air from the cooling system.

Engines that are Not Equipped with aCoolant Recovery Tank


1. Fill the cooling system with antifreeze/coolant.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations”for additional information on cooling systemspecifications. Do not install the cooling systemfiller cap.

80 SEBU7908-09Maintenance SectionCooling System Coolant (ELC) - Change

2. Start the engine and run the engine at low idle.Increase the engine rpm to high idle. Run theengine at high idle for one minute in order topurge 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 levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system fillercap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the face ofthe cooling system filler cap. If the cooling systemfiller cap does not retain the correct pressure,install a new cooling system filler cap.


i02555261

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming of the coolant

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drained andreplaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove the cooling system drain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Dealer Service Tools:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.



3. Fill the cooling system with clean water. Install thecooling system filler cap.


Cooling System Coolant (ELC) - Change

4. Start the engine and run the engine at lowidle until the temperature reaches 49 to 66 °C(120 to 150 °F).


Fill

Engines that are Equipped with a CoolantRecovery Tank


1. Fill the cooling system with Extended Life Coolant(ELC). Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”topic (Maintenance Section) for more informationon cooling system specifications. Do not install thecooling system filler cap.

2. Start the engine and operate the engine at lowidle. Increase the engine rpm to high idle. Operatethe engine at high idle for one minute in order topurge 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 thecooling system is full.

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler cap isnot damaged, use a 9S-8140 Pressurizing Pumpin order to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.


5. Loosen the cap for the coolant recovery tankslowly in order to relieve any pressure. Removethe cap for the coolant recovery tank.

6. Pour Extended Life Coolant (ELC) into the coolantrecovery tank until the coolant reaches the “COLDFULL” mark. DO NOT fill the coolant recovery tankabove the “COLD FULL” mark.

Note: Pleasure craft that are cooled by a heatexchanger may require the coolant recovery tank tobe overfilled approximately 102 mm (4 inches) abovethe “COLD FULL” mark.

7. Clean the cap for the coolant recovery tank. Installthe cap for the coolant recovery tank.


9. Stop the engine and allow the engine to cool.Verify the coolant level in the coolant recoverytank.

Note: If necessary, refer to step 8 through step 9 inorder to purge air from the cooling system.

Engines that are NOT Equipped with aCoolant Recovery Tank


1. Fill the cooling system with Extended Life Coolant(ELC). Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”topic (Maintenance Section) for more informationon cooling system specifications. Do not install thecooling system filler cap.

82 SEBU7908-09Maintenance SectionCooling System Coolant Extender (ELC) - Add

2. Start the engine and operate the engine at lowidle. Increase the engine rpm to high idle. Operatethe engine at high idle for one minute in order topurge 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 levelwithin 13 mm (.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler cap isnot damaged, use a 9S-8140 Pressurizing Pumpin order to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.


i02482066

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-045; 1395-081

Cat ELC (Extended Life Coolant) does not requirethe frequent additions of any supplemental coolingadditives which are associated with the presentconventional coolants. The Cat ELC Extender onlyneeds to be added once.

NOTICEUse only Cat Extended Life Coolant (ELC) Extenderwith 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 theCat ELC service life.

Check the cooling system only when the engine isstopped and cool.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolant fromthe cooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to therequirements for your engine's cooling systemcapacity. Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”article for more information.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.


Cooling System Coolant Level - Check

i02538100

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

Engines That Are Equipped with aCoolant Recovery Tank


1. Observe the coolant level in the coolant recoverytank. Maintain the coolant level to “COLD FULL”mark (2) on the coolant recovery tank.

2. Loosen filler cap (1) slowly in order to relieve anypressure. Remove the filler cap.

3. Pour the proper coolant mixture into the tank.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” forinformation about coolants. Do not fill the coolantrecovery tank above “COLD FULL” mark (2).

4. Clean filler cap (1) and the receptacle. Reinstallthe filler cap and inspect the cooling system forleaks.

Note: The coolant will expand as the coolant heatsup during normal engine operation. The additionalvolume will be forced into the coolant recovery tankduring engine operation. When the engine is stoppedand cool, the coolant will return to the engine.

Engines That Are Not Equippedwith a Coolant Recovery Tank


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.

g00103639Illustration 29

Typical filler cap gaskets

3. Clean the cooling system filler cap and inspectthe condition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i02837191

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems thatare filled with Cat ELC should have a Coolant Sample(Level 2) that is obtained at the recommended intervalthat is stated in the Maintenance Interval Schedule.

84 SEBU7908-09Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants:

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 21

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC Every 250Hours(1) Yearly(1)(2)

Cat ELC Optional(2) Yearly(2)

(1) This is the recommended interval for coolant samples for allconventional heavy-duty coolant/antifreeze. This is also therecommended interval for coolant samples of commercialcoolants that meet the Cat EC-1 specification for enginecoolant.

(2) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• 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, “RefillCapacities and Recommendations” or consult yourCaterpillar dealer.

i01987714

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542


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 coolantanalysis, see Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” or consult your Caterpillar dealer.


Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i03509177

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Note: This maintenance is NOT required forcooling systems that are filled with Extended LifeCoolant.

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

NOTICEExcessive supplemental coolant additive concentra-tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine'sheat transfer characteristics. Reduced heat transfercould cause cracking of the cylinder head and otherhigh temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the waterpump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” and to Special Publica-tion, GECJ0003, “Cat Shop Supplies and Tools” fortools and supplies suitable to collect and contain flu-ids on Caterpillar products.

Dispose of all fluids according to applicable regula-tions and mandates.

Note: Caterpillar recommends an S·O·S coolantanalysis (Level 1).

Cooling Systems that UseConventional Coolant

Test the Concentration of the SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Test the concentration of the SCA with the 4C-9301Coolant Conditioner Test Kit.

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

3. Add the proper amount of SCA. For theproper amount of SCA, refer to this Operationand Maintenance Manual, “Refill Capacitiesand Recommendations” topic. The properconcentration of SCA depends on the type ofcoolant that is used. For the proper concentrationof SCA, refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations”.

4. Clean the cooling system filler cap. Install thecooling system filler cap.

i03645060

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime. Refer to thisOperation and Maintenance Manual, “MaintenanceInterval Schedule” for the proper maintenanceinterval.

86 SEBU7908-09Maintenance SectionCrankshaft Vibration Damper - Inspect

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in the closedposition can cause excessive overheating. Excessiveoverheating could result in cracking of the cylinderhead or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup inside thecylinders. This excessive carbon buildup could resultin an accelerated wear of the piston rings and wearof the cylinder liner.

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the enginemay overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to two articles in the Disassembly andAssembly Manual, “Water Temperature Regulators- Remove and Water Temperature Regulators -Install” for the replacement procedure of the watertemperature regulator, or consult your Caterpillardealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling system toa level that is below the water temperature regulatorhousing.

i03175962

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the crankshaft vibration damper or failureof the crankshaft vibration damper can increasetorsional vibrations. This can result in damage tothe crankshaft and to other engine components. Adeteriorating damper can cause excessive gear trainnoise at variable points in the speed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

g01134779Illustration 30Viscous vibration damper

Typical example(1) Crankshaft pulley(2) Weight(3) Case

InspectionInspect the damper for the following conditions:

• The damper is dented, cracked, or fluid is leakingfrom the damper.

• The paint on the damper is discolored fromexcessive heat.

• The damper is bent.

• The bolt holes are worn or there is a loose fit forthe bolts.


Engine - Clean

• The engine has had a crankshaft failure due totorsional forces.

Replace the damper if any of these conditions exist.

Removal and InstallationRefer to this Operation and Maintenance Manual,“Belts - Inspect/Adjust/Replace” for informationon removing and on installing the belt. Refer tothe Disassembly and Assembly Manual, “VibrationDamper and Pulley - Remove and Install” forinformation on removing and installing the damper.

i01646701

Engine - CleanSMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when you clean the engine. Avoidelectrical components such as the alternator, thestarter, and the ECM.

i01727320

Engine Air Cleaner Element -Clean/ReplaceSMCS Code: 1054-070; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

Type 1Note: Use the 102-9720 Cleaning Kit. This productcontains the detergent and oil that is made specificallyfor the maintenance of the air cleaner elements.


Note: This type of air cleaner element should bereplaced after three cleanings.

1. Remove the air cleaner element (1). Tap the aircleaner element in order to dislodge dirt particles.Gently brush the air cleaner element with a softbristle brush.

NOTICEDo not use gasoline, steam, caustic or unapproveddetergents, or parts cleaning solvents. Do not use highpressure water or air to clean the air cleaner element.Any of those liquids or methods can cause air cleanerelement damage.

88 SEBU7908-09Maintenance SectionEngine Air Cleaner Element - Clean/Replace

2. Spray the air cleaner element with the cleaningsolution. Allow the air cleaner element to standfor 10 minutes.

3. Rinse the air cleaner element with low waterpressure. The maximum water pressure for thisprocedure is 275 kPa (40 psi). Tap water isacceptable. Start to rinse the air cleaner elementfrom the clean side (inside). Next, clean the dirtyside (outside) in order to flush out dirt. Inspect theair cleaner element for tears and/or holes afterthe air cleaner element is cleaned. Do not reusedamaged air cleaner elements.

NOTICEDo not use compressed air, open flame, or hot air todry the air cleaner element. Excess heat shrinks cot-ton fiber, and compressed air may blow holes in thematerial. 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. Dryingthe air cleaner element in the sun speeds theprocess.

NOTICEDo not use transmission fluid, engine oil, diesel fuel,or other lubricant to oil the air cleaner element. Theair cleaner element can not function correctly if im-proper oil is used. Never operate an engine with adry air cleaner element. The air cleaner element cannot function correctly without oil. Always saturate theclean air cleaner element with the recommended oil.

5. The dry air cleaner element should be oiled beforeinstallation. Apply small amounts of oil across thetop of each pleat. Allow the oil to soak into the aircleaner element for 20 minutes. Oil any remaining“white” spots.

6. Inspect the housing and the clamp for air cleanerelement (1). Install the clean, oiled air cleanerelement. Replace the housing and the clamp, ifnecessary. Refer to Specifications, SENR3130,“Torque Specifications” for the proper torque ofthe clamp.

Type 2


1. Disconnect latches (1).

2. Remove cover (2).


Note: This type of air cleaner element may becleaned up to six times.

4. Refer to Guideline for Reusable Parts and SalvageOperations, SEBF8062 for cleaning instructions orreplace the air cleaner element.

5. Install the air cleaner element (3).


Sequence for latches

6. Install cover (2). Fasten cover (2) with latches(1)in the sequence that is shown in Illustration 33.


Engine Air Cleaner Service Indicator - Inspect

Type 3


1. Disconnect latches (1).

2. Remove cover (2).


Note: This type of air cleaner element may becleaned up to six times.

4. Refer to Guideline for Reusable Parts and SalvageOperations, SEBF8062 for cleaning instructions orreplace 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 ServiceIndicator - Inspect(If Equipped)SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the aircleaner housing or in a remote location.

g00103777Illustration 35Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.

90 SEBU7908-09Maintenance SectionEngine Crankcase Breather - Clean

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

i02263740

Engine Crankcase Breather -CleanSMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.


Typical example(1) Hose clamp(2) Breather assembly(3) Retaining clamp(4) Seal

1. Loosen hose clamp (1) and remove the hose frombreather assembly (2).

2. Loosen retaining clamp (3). Remove the breatherassembly and seal (4).

3. Wash the breather element in solvent that is cleanand nonflammable. Allow the breather element todry before installation.

4. Install a breather element that is clean and dry.Install the seal, the breather assembly, and theclamp. Refer to the Specifications, SENR3130 inorder to locate the proper torques.

5. Install the hose. Install the hose clamp. Refer tothe Specifications, SENR3130 in order to locatethe proper torques.

i02456872

Engine Mounts - InspectSMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration should bereplaced. Refer to Special Publication, SENR3130,“Torque Specifications” for the recommendedtorques. Refer to the OEM recommendations formore information.

i03709060

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

g01996258Illustration 37Typical C32 Marine Engine

1. Stop the engine and allow the engine oil to draininto the crankcase for approximately ten minutes.


Engine Oil Level Gauge - Calibrate


Oil level gauge(Y) “ADD” mark(X) “FULL” mark

2. Check the engine oil. Maintain the engine oil levelbetween “ADD” mark (Y) and “FULL” mark (X) onengine oil level gauge (2). Do not fill the crankcaseabove “FULL” mark (X).

NOTICEOperating your engine when the oil level is above the“FULL” mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil's lubricating char-acteristics and could result in the loss of power.

3. Remove engine oil filler cap (1) and add oil, ifnecessary. Clean the engine oil filler cap. Reinstallthe engine oil filler cap.

i02776578

Engine Oil Level Gauge -CalibrateSMCS Code: 1326-524

The engine is shipped with an engine oil level gaugethat is not marked. The engine oil level gauge isnot marked because the following features can bedifferent for each engine:

• Angle of the installation

• Side for service

The engine oil level gauge must be calibrated afterthe engine is installed in the vessel.

Note: The engine may be equipped with auxiliaryengine oil filters. The extra filters require more engineoil than the standard amounts. Refer to the OEMspecifications.

Use the following procedure in order to calibrate andmark the engine oil level gauge.

1. Ensure that the engine is properly aligned and thatthe engine is in the design trim. The engine mustbe installed properly in the vessel.

Note: If the engine has oil in the crankcase, skip step2 and proceed to step 3.

2. If there is no oil in the engine, use information inthis Operation and Maintenance Manual, “RefillCapacities and Recommendations” in order toselect the correct oil for the engine. Add engine oilto the crankcase by using the procedure in thisOperation and Maintenance Manual, “Engine Oiland Filter - Change ”. Choose the appropriateamount of oil from the following type of sump:

• Standard Oil Sump: Fill the crankcase with75.7 L (80 qt) of the recommended oil.

Clean the engine oil level gauge and install theengine oil level gauge.

Note: If the engine contains oil, perform steps 3through 7. Skip steps 3 through 7 if you are filling theengine with oil for the first time.

3. Operate the engine until normal operatingtemperature is achieved. Stop the engine. Drainthe engine oil by using the procedure in thisOperation and Maintenance Manual, “Engine Oiland Filter - Change ”.

4. Replace the engine oil filter by using the procedurein this Operation and Maintenance Manual,“Engine Oil and Filter - Change ”.

5. Clean the engine oil level gauge and install theengine oil level gauge.

6. Use the information in Operation and MaintenanceManual, “Refill Capacities and Recommendations”in order to select the correct oil for the engine.

7. Add engine oil to the crankcase by using theprocedure in this Operation and MaintenanceManual, “Engine Oil and Filter - Change ”. Choosethe appropriate amount of oil from the followingsump:

• Standard Oil Sump: Fill the crankcase with75.7 L (80 qt) of the recommended oil.

8. Start the engine. Ensure that the lubricationsystem and the new engine oil filter are filled.Inspect the lubrication system for leaks.

9. Stop the engine and allow the engine oil to draininto the engine crankcase for approximatelytwenty minutes.

10.Check the engine oil level. Use a marking tool inorder to engrave the “ADD” mark (Y) to the correctlocation on the gauge assembly.

92 SEBU7908-09Maintenance SectionEngine Oil Sample - Obtain

11.Add 9.5 L (10 qt) of the recommended oil gradeand weight of engine oil to the crankcase with astandard sump. Allow the oil to drain into the sumpfor approximately 20 minutes.

12.Check the engine oil level. Use a marking tool inorder to engrave “FULL” mark (X) onto the correctlocation on the gauge assembly.


Oil Level Gauge “ADD” mark (Y) and “FULL” mark (X)

i03542996

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEgj0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Caterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02107152

Engine Oil and Filter - ChangeSMCS Code: 1318-510; 1348-044

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.


Engine Oil and Filter - Change

Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles settle on the bottomof the oil pan. The waste particles are not removedwith the draining cold oil. Drain the crankcase withthe engine stopped. Drain the crankcase with theoil warm. This draining method allows the wasteparticles that are suspended in the oil to be drainedproperly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Use one of thefollowing methods to drain the engine crankcase oil:

• If the engine is equipped with a drain valve, turn thedrain valve knob counterclockwise in order to drainthe oil. After the oil has drained, turn the drain valveknob clockwise in order to close the drain valve.

• If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oilto drain. If the engine is equipped with a shallowsump, remove the bottom oil drain plugs from bothends of the oil pan.

After the oil has drained, the oil drain plugs shouldbe cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter Gp. Break apart the pleats and inspect theoil filter for metal debris. An excessive amountof metal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.

g00103713Illustration 40Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasket isremoved.

4. Apply clean engine oil to the new oil filter gasket.

NOTICEDo 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 toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that areshown on the oil filter. Do not overtighten the oilfilter.

Fill the Engine Crankcase1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual, “Refill Capacities andRecommendations” for more information.

NOTICEIf 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 overfillingthe crankcase with oil can cause engine damage.

94 SEBU7908-09Maintenance SectionEngine Speed/Timing Sensors - Check/Clean/Calibrate

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the oil level gauge.

i03709240

Engine Speed/Timing Sensors- Check/Clean/CalibrateSMCS Code: 1912-040; 1912-070; 1912-524


Top view(1) Secondary speed/timing sensor(2) Primary speed/timing sensor

1. Remove the speed/timing sensors from the fronthousing. Check the condition of the plastic endof the speed/timing sensors for wear and/orcontaminants.

2. Clean the metal shavings and other debrisfrom the face of the speed/timing sensors. Usethe procedure in the Troubleshooting Manual,“Speed/Timing Sensor - Calibrate” in order tocalibrate the speed/timing sensors.

i01458399

Engine Storage Procedure -CheckSMCS Code: 1000-535

The oil change interval may be extended to 12months for a vehicle that is operated seasonallyand placed in storage for the remainder of the yearby using the required storage procedures and therequired start-up procedures. This extension ispermitted if the following categories for oil changeintervals in the Operation and Maintenance Manual,“Maintenance Interval Schedule” have not beenreached:

• Mileage

• Operating hours

• Fuel consumption

If an engine is out of operation and if use of theengine is not planned, special precautions shouldbe made. If the engine will be stored for more thanthree months, a complete protection procedure isrecommended. For more detailed information onengine storage, see Special Instruction, SEHS9031,“Storage Procedure For Caterpillar Products”.

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderliner surface. Rust on the cylinder liner surface willcause increased engine wear and a reduction inengine service life. Caterpillar recommends theuse of volatile corrosion inhibitor (VCI) oil in orderto prevent internal engine damage due to moistureduring storage. These inhibitors in the VCI oil act byevaporating inside the engine. The inhibitors thencondense over the inside surfaces of the engine. Theevaporation process and the condensing processoffers full protection to surfaces that cannot bereached with preservatives. 0.9 L (1.0 qt) of 4C-6792VCI oil will treat 28.4 L (30.0 qt) of engine oil. Thiswill give a 3 percent concentration of VCI oil. Theengine must be completely sealed when the engineis stored in order for the VCI oil to function properly.The VCI oil is easily cleaned from the engine whenyou remove the engine from storage. The volatilevapors are removed by simply running the engineto operating temperature. A mineral oil base is leftbehind after the volatile vapors are removed.


Engine Valve Lash - Inspect/Adjust

i00869628

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change. Theadjustment is necessary due to the initial wear ofthe valve train components and to the seating of thevalve train components.

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenance isperformed.

Refer to the Service Manual for more information.

i01597115

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to help prevent being burned byhot oil or spray.

Engine valve rotators rotate the valves when theengine runs. This helps to prevent deposits frombuilding up on the valves and the valve seats.

Perform the following steps after the engine valvelash is set, but before the valve covers are installed:

1. Start the engine according to Operation andMaintenance Manual, “Engine Starting” (OperationSection) for the procedure.

2. Operate the engine at low idle.

3. Observe the top surface of each valve rotator. Thevalve rotators should turn slightly when the valvesclose.

NOTICEA valve rotator which does not operate properly willaccelerate valve face wear and valve seat wear andshorten valve life. If a damaged rotator is not replaced,valve face guttering could result and cause pieces ofthe valve to fall into the cylinder. This can cause pistonand cylinder head damage.

If a valve fails to rotate, consult your Caterpillardealer.

i02553422

Fuel System - PrimeSMCS 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 whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

96 SEBU7908-09Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace

g00395938Illustration 42Fuel supply connections

The fuel system should be primed after a unit injectoris changed or when the fuel system is totally dry.

Note: The fuel system does not typically need to beprimed when the primary fuel filters or secondary fuelfilters are changed or when an Electronic ControlModule (ECM) is replaced. When the engine isstarted under these circumstances, the engine maymomentarily run rough until the air is purged fromthe system.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.

1. Loosen a fuel supply connection to the regulatingvalve, as shown.

Note: The fuel priming pump is located on thesecondary fuel filter. Operating the fuel priming pumpwithout loosening a fuel connection upstream ofthe regulating valve can cause a failure of the fueltransfer pump seal.

2. Open the fuel priming pump and operate the pumpuntil air is purged and the fuel appears at the fuelconnection. Tighten the fuel connection.

3. Crank the engine after pressurizing the system.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

4. If the engine does not start, repeat Steps 1through 3 in order to start the engine.

i02927282

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS 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 injectorto fail. If the fuel has been contaminated with water,the element should be changed before the regularlyscheduled interval.

The primary filter/water separator also providesfiltration in order to help extend the life of thesecondary fuel filter. The element should be changedregularly. If a vacuum gauge is installed, theprimary filter/water separator should be changed at50 to 70 kPa (15 to 20 inches Hg).

Replace the Element



Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.


NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

1. Close the main fuel supply valve.


Fuel System Primary Filter/Water Separator - Drain

g01453091Illustration 43(1) Element(2) Bowl(3) Drain

2. Remove element (1) from the element mountingbase while bowl (2) is attached.

3. Dispose of the contents of the filter. Remove bowl(2) from element (1). The bowl is reusable. Do notdiscard the bowl. Dispose of the used element.

4. Remove the O-ring from the gland of the bowl.Clean the following components:

• Bowl

• O-ring

• Mounting base

Inspect the O-ring for damage and fordeterioration. Replace the O-ring, if necessary.

5. Lubricate the O-ring with clean diesel fuel.

6. Install bowl (2) on a new element. Tighten thebowl by hand. Do not use tools in order to tightenthe bowl.

NOTICEThe primary filter/water separator may be prefilled withfuel to avoid rough running/stalling of the engine dueto air. Do not fill the secondary filter with fuel beforeinstallation. The fuel would not be filtered and couldbe contaminated. Contaminated fuel will cause accel-erated wear to fuel system parts.

7. Lubricate the top seal of element (1) with cleandiesel fuel. The element may be filled with fuel atthis time. Install the new element on the mountingbase. Tighten the element by hand.

NOTICEThe water separator is under suction during normalengine 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 theengine for one minute. Stop the engine and checkfor leaks again.

Detecting leaks is difficult while the engine isrunning. The primary filter/water separator isunder suction. A leak will allow air to enter the fuel.The air in the fuel can cause low power due toaeration of the fuel. If air enters the fuel, check thecomponents for overtightening or undertightening.

i01463757

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543

g00668636Illustration 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).

98 SEBU7908-09Maintenance SectionFuel System Secondary Filter - Replace

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i00823807

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE



(1) Fuel supply connections(2) Fuel filters

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.

NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

1. It may be necessary to relieve residual fuelpressure from the fuel system before removingthe fuel filter.

Loosen one of the fuel supply connections (1) inorder to purge any residual pressure.

NOTICEDo not loosen fuel lines or fittings at the fuel manifoldor ECM. The engine components may be damaged.

2. Remove the used fuel filter.

3. Clean the gasket sealing surface of the fuel filterbase. Ensure that all of the old gasket is removed.

4. Apply clean diesel fuel to the new fuel filter gasket.

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

5. Install the new fuel filter. Spin the fuel filter ontothe fuel filter base until the gasket contacts thebase. Use the rotation index marks on the filtersas a guide for proper tightening. Tighten thefilter for an additional 3/4 turn by hand. Do notovertighten the filter.

i03645042

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.



Heat Exchanger - Inspect

Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Note: Failure to properly close the drain can allow airinto the system, which could have detrimental resultsto performance.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A four micron(c) absolute filter for the breathervent on the fuel tank is also recommended. Referto Special Publication, SENR9620, “Improving FuelSystem Durablity”.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i03712080

Heat Exchanger - InspectSMCS Code: 1379-040

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The heat exchanger and alllines to heaters or the engine contain hot coolantor steam. Any contact can cause severe burns.

Remove the filler cap slowly to relieve pressureonly when the engine is stopped and the filler capfor the heat exchanger is cool enough to touchwith your bare hand.

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

100 SEBU7908-09Maintenance SectionHeat Exchanger - Inspect


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.


The interval for the maintenance of the plate type heatexchanger depends on the operating environment ofthe vessel and on the operating time. The sea waterthat is circulated through the heat exchanger and theamount of operating time of the vessel affects thefollowing items:

• Cleanliness of the heat exchanger plates

• Effectiveness of the heat exchanger system

Operating in water that contains the following willadversely affect the heat exchanger system: silt,sediment, salt, and algae. In addition, intermittent useof the vessel will adversely affect the heat exchangersystem.

The following items indicate that the heat exchangermay require cleaning:

• Increased coolant temperature

• Engine overheating

• Excessive pressure drop between the water inletand the water outlet

An operator that is familiar with the normal operatingtemperature of the coolant can determine whenthe coolant temperature is out of the normal range.Inspection of the heat exchanger and maintenanceof the heat exchanger are required if the engine isoverheating.

Your Caterpillar dealer has the equipment and thepersonnel in order to measure the pressure dropacross the heat exchanger.

Cleaning Procedure

Removal and Disassembly of the HeatExchanger

Drain the heat exchanger. Refer to the Disassemblyand Assembly Manual, “Heat Exchanger - Remove”for the removal procedure.

Refer to the Disassembly and Assembly Manual,“Heat Exchanger - Disassemble” for the disassemblyprocedure. Keep the plates in order..

Cleaning the Heat Exchanger

Refer to “Choosing the Correct Cleaning Fluid” forthe correct cleaning fluid for your heat exchanger.Clean the plates with a cleaning solution and a softbrush. Pressurized water may also be used. Do notuse steel wool or a wire brush, which may scratch theplate. Any iron scratches on the plates can lead tocorrosion of the plates. Rinse the plates with water.

Choosing the Correct Cleaning Fluid

Refer to 22 for the correct cleaning fluid for the heatexchanger.


Hoses and Clamps - Inspect/Replace

Table 22

Problem Source Cleaners(1)(2)(3)(4)

Scaling

Calciumcarbonate

Calcium sulfateSilicates

Sediment(5)

Corrosionproducts

Metal oxidesSilt

Diatomicorganisms

Gross fouling

SeaweedChips of woodand fibersMusselsBarnacles

Biological growthBacteriaNematodesProtozoa

Nitric acidSulfamic acidCitric acid

Phosphoric acidComplexingagentsSodium

polyphosphates

ResidueOily filmsAsphaltFats

Paraffinic orNaphtha basedsolvent such asKerosene.(6)(7)

(1) Cleaners should be mixed at a maximum concentration of 4percent by weight. The temperature of the cleaning solutionshould be less than 60 °C (140 °F).

(2) Do not use water that contains more than 300 ppm of chlorinein the preparation of cleaning solutions.

(3) Do not use hydrochloric acid to clean stainless steel plates. Donot use hydrofluoric acid to clean titanium plates.

(4) Do not use a type of ketone such as acetone andmethyletyketone. Do not use aromatics such as benzeneand toluene. Do not use esters such as ethylacetate andbutylacetate. Do not use halogenated hydrocarbons such aschlorothene and carbon tetrachloride.

(5) The addition of surfactants to the cleaning solution may easecleaning.

(6) Do not mix the solvent with water for cleaning. Dry the plateswith a cloth or rinse the plates with water.

(7) Gaskets that are made from natural rubber, butyl rubber andEPDM rubber will swell in these solvents. Do not allow thesolvent to contact the gasket more than half an hour.

Assembly and Installation of the HeatExchanger

Refer to the Disassembly and Assembly Manual,“Heat Exchanger - Assemble” for the assemblyprocedure.

Refer to the Disassembly and Assembly Manual,“Heat Exchanger - Install” for the installationprocedure.

i02121526

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardclamp.

Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosen.This can result in leaks. A constant torque hoseclamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

102 SEBU7908-09Maintenance SectionMaintenance Recommendations

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel 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 propertorques.

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap's gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10.Start the engine. Inspect the cooling system forleaks.

i03753503

MaintenanceRecommendations(Engines Which Have “E”Ratings)SMCS Code: 1000

Overhaul ConsiderationsSome factors that are important for determiningthe overhaul intervals include the followingconsiderations:

• Performance of preventive maintenance

• Use of recommended lubricants

• Use of recommended coolants

• Use of recommended fuels

• Proper installation

• Operating conditions

• Operation within acceptable limits

• Engine load

• Engine speed

• Use of S·O·S Services Fluids Analyses

Generally, engines that are operated at a reducedload and/or speed achieve more service life beforean overhaul. However, this is for engines that areproperly operated and maintained.

Other factors must also be considered for determininga major overhaul:

• The total amount of fuel consumption

• The service hours of the engine

• An increase of oil consumption

• An increase of crankcase blowby

• The wear metal analysis of the lube oil

• An increase in the levels of noise and vibration

An increase of wear metals in the lube oil indicatesthat the bearings and the surfaces that wear mayneed to be serviced. An increase in the levels ofnoise and vibration indicates that rotating partsrequire service.


Maintenance Recommendations

Note: It is possible for oil analysis to indicate adecrease of wear metals in the lube oil. The cylinderliners may be worn so that polishing of the boreoccurs. Also, the increased use of lube oil will dilutethe wear metals.

Monitor the engine as the engine accumulatesservice hours. Consult your Caterpillar dealer aboutscheduling a major overhaul.

Note: The driven equipment may also require servicewhen the engine is overhauled. Refer to the literaturethat is provided by the OEM of the driven equipment.

Overhaul Intervals Which are Based onFuel Consumption

Experience has shown that the interval foran overhaul is most accurately based on fuelconsumption. Fuel consumption corresponds moreaccurately to the engine load.

Table 23

Overhaul Intervals

Top End Overhaul Fuel Consumption 454250 L (120000 US gal)

Major Overhaul Fuel Consumption 757100 L (200000 US gal)

Overhaul Intervals Which are Based onOil Consumption

Oil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h (lb perbhp). The brake specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillardealer for assistance in determining the typical oilconsumption rate for your engine.

When an engine's oil consumption has risen tothree times the original oil consumption rate dueto normal wear, an engine overhaul should bescheduled. There may be a corresponding increasein blowby and a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The engine service life can be extended without therisk of a major catastrophe due to engine failure.

• The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine block orthe crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost should be between 40percent and 50 percent of the cost of a new enginewith a similar exchange core.

This lower cost can be attributed to three aspects:


• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level 1). Furthercoolant analysis is recommended when the engineis overhauled.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company oran agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar Inc. recommends an S·O·S CoolantAnalysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level 2) providesthe following information:

• Complete S·O·S Coolant Analysis (Level 2)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level 2) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information, refer to Special Publication,SEBU6251, “Caterpillar Commercial Diesel EngineFluids Recommendations” or contact your Caterpillardealer.

Engine Components

Refer to this Operation and Maintenance Manual,“Overhaul (Top End)” for a list of components whichare affected by a top end overhaul. Refer to thisOperation and Maintenance Manual, “Overhaul(Major)” for a list of components which are affectedby a major overhaul.

Severe Service ApplicationsSevere service operation can accelerate componentwear. An engine which operates in a severe serviceapplication may need more frequent maintenanceintervals for the following reasons:

• Maximum reliability

• Retention of full service life

A severe service application is an application whichexceeds the current published standards for thatengine. Caterpillar maintains standards for thefollowing engine parameters:

• Horsepower

• Range of rpm


• Fuel quality

• Altitude

• Maintenance intervals

• Selection of oil

• Selection of coolant

• Environmental qualities

• Installation

Refer to the standards for your engine or consult yourCaterpillar dealer in order to determine if your engineis operating within the defined parameters.

Because of individual applications, it is not possibleto identify all of the factors which can contribute tosevere operation. Consult your Caterpillar dealerabout the maintenance that is needed for yourspecific engine.

The following factors can contribute to severeoperation: environment, improper operatingprocedures, and improper maintenance practices.

Extreme Ambient Temperatures

Extended operation in environments that areextremely cold or hot can damage components. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesthe performance capabilities of the engine.



Note: See this Operation and Maintenance Manual,“Cold Weather Operation” topic (Operation Section),or see Supplement, SEBU5898, “Cold WeatherRecommendations”.

Cleanliness

Unless the equipment is cleaned regularly, extendedoperation in a dirty environment and in a dustyenvironment can damage components. Built up mud,dirt, and dust can encase components. This canmake maintenance difficult. The buildup can containcorrosive chemicals. Corrosive chemicals and saltcan damage some components.

Improper Operating Procedures

• Extended operation at low idle

• Minimum cool down periods after high load factoroperation

• Operating the engine beyond the guidelines for theengine rating

• Operating the engine at loads that are greater thanthe rated load

• Operating the engine at speeds that are greaterthan the rated speed

• Use of the engine for an application that is notapproved

Improper Maintenance Practices

• Extension of maintenance intervals

• Not using recommended fuel, lubricants, andcoolant

i03718161

MaintenanceRecommendations(Engines Which Are Rated “B”and Engines Which Are Rated“C”)SMCS Code: 1000

Overhaul ConsiderationsSome factors that are important for determiningthe overhaul intervals include the followingconsiderations:

• Performance of preventive maintenance

• Use of recommended lubricants

• Use of recommended coolants

• Use of recommended fuels

• Proper installation

• Operating conditions

• Operation within acceptable limits

• Engine load

• Engine speed

• Use of S·O·S Services Fluids Analyses

Generally, engines that are operated at a reducedload and/or speed achieve more service life beforean overhaul. However, this is for engines that areproperly operated and maintained.

Other factors must also be considered for determininga major overhaul:












Overhaul Intervals Which are Based onFuel Consumption

Experience has shown that the interval foran overhaul is most accurately based on fuelconsumption. Fuel consumption corresponds moreaccurately to the engine load.

Table 24

Maintenance Interval for Overhauls

Engine Rating B C

Major Overhaul 1400600 L(370000 US gal)

757100 L(200000 US gal)

Overhaul Intervals Which are Based onOil Consumption

Oil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h (lb perbhp). The brake specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillardealer for assistance in determining the typical oilconsumption rate for your engine.

When an engine's oil consumption has risen tothree times the original oil consumption rate dueto normal wear, an engine overhaul should bescheduled. There may be a corresponding increasein blowby and a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The engine service life can be extended without therisk of a major catastrophe due to engine failure.

• The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine block orthe crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost should be between 40percent and 50 percent of the cost of a new enginewith a similar exchange core.

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level 1). Furthercoolant analysis is recommended when the engineis overhauled.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company oran agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar Inc. recommends an S·O·S CoolantAnalysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level 2) providesthe following information:

• Complete S·O·S Coolant Analysis (Level 2)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level 2) provides a report ofthe results of both the analysis and the maintenancerecommendations.



For more information, refer to Special Publication,SEBU6251, “Caterpillar Commercial Diesel EngineFluids Recommendations” or contact your Caterpillardealer.

Engine Components

Refer to this Operation and Maintenance Manual,“Overhaul (Top End)” for a list of components whichare affected by a top end overhaul. Refer to thisOperation and Maintenance Manual, “Overhaul(Major)” for a list of components which are affectedby a major overhaul.

Severe Service ApplicationSevere service operation can accelerate componentwear. An engine which operates in a severe serviceapplication may need more frequent maintenanceintervals for the following reasons:

• Maximum reliability

• Retention of full service life

A severe service application is an application whichexceeds the current published standards for thatengine. Caterpillar maintains standards for thefollowing engine parameters:

• Horsepower

• Range of rpm


• Fuel quality

• Altitude

• Maintenance intervals

• Selection of oil

• Selection of coolant

• Environmental qualities

• Installation

Refer to the standards for your engine or consult yourCaterpillar dealer in order to determine if your engineis operating within the defined parameters.

Because of individual applications, it is not possibleto identify all of the factors which can contribute tosevere operation. Consult your Caterpillar dealerabout the maintenance that is needed for yourspecific engine.

The following factors can contribute to severeoperation: environment, improper operatingprocedures, and improper maintenance practices.

Extreme Ambient Temperatures

Extended operation in environments that areextremely cold or hot can damage components. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesthe performance capabilities of the engine.

Note: See this Operation and Maintenance Manual,“Cold Weather Operation” topic (Operation Section),or see Supplement, SEBU5898, “Cold WeatherRecommendations”.

Cleanliness

Unless the equipment is cleaned regularly, extendedoperation in a dirty environment and in a dustyenvironment can damage components. Built up mud,dirt, and dust can encase components. This canmake maintenance difficult. The buildup can containcorrosive chemicals. Corrosive chemicals and saltcan damage some components.

Improper Operating Procedures

• Extended operation at low idle

• Minimum cool down periods after high load factoroperation

• Operating the engine beyond the guidelines for theengine rating

• Operating the engine at loads that are greater thanthe rated load

• Operating the engine at speeds that are greaterthan the rated speed

• Use of the engine for an application that is notapproved

Improper Maintenance Practices

• Extension of maintenance intervals

• Not using recommended fuel, lubricants, andcoolant

108 SEBU7908-09Maintenance SectionOil Cooler Core - Check/Clean/Test

i03756788

Oil Cooler Core -Check/Clean/Test(Engines Which Are Rated “E”)SMCS Code: 1378-070; 1378-081; 1378-535

This procedure should only be performed on engineswhich are rated “E”. Perform this maintenanceprocedure together with the top end overhaul.

Clean the Oil Cooler CoreRemove the core. Refer to the Disassembly andAssembly Manual, “Oil Cooler - Remove” for theprocedure.

1. Turn the oil cooler core on one side in orderto remove debris. Remove the debris that isaccessible.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

2. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 25 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 25

Hydrosolv Liquid Cleaners(1)

PartNumber 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 cleanerat temperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

3. Steam clean the core in order to remove anyresidue. Flush the fins of the oil cooler core.Remove any other trapped debris from the insideand from the outside of the core.

4. Wash the core with hot, soapy water.

5. Flush the core thoroughly in order to removeresidue and remaining debris. Flush the core withclean, fresh water until the water that is exiting thecore is clear and free of debris.

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.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

6. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

Test the Oil Cooler Core1. Inspect the core for trapped debris andcleanliness. If necessary, remove the debris andrepeat the cleaning procedure.

2. Inspect the core for damage and perform apressure test in order to detect leaks. Many shopsthat service radiators are equipped to performpressure tests.

3. Plug both ends of the oil cooler core andpressurize the core to 205 kPa (30 psi). Submergethe core in water. Look for bubbles which arebeing emitted from the core. The bubbles areevidence of leaks.

4. If any leaks are found, do not attempt to repair thecore.

Install a core that is clean and a core that passes thepressure test in step 3. Refer to the Disassemblyand Assembly Manual, “Oil Cooler - Install” for theprocedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

i03753448

Overhaul (Major)SMCS Code: 7595-020-MJ

Refer to this Operation and Maintenance Manual,“Maintenance Recommendations” in order todetermine the maintenance interval for a majoroverhaul.

The need for a major overhaul is determined byseveral factors.




Overhaul (Major)









A major overhaul includes all of the work that is donefor the top end overhaul. A major overhaul includesadditional parts and labor. Additional parts and laborare required in order to completely rebuild the engine.

For the major overhaul, all of the bearings,seals, gaskets, and components that wear aredisassembled. The parts are cleaned and inspected.If necessary, the parts are replaced. The crankshaftis measured for wear. The crankshaft may requireregrinding. Alternatively, the crankshaft may bereplaced with a Caterpillar replacement part.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

Replacement of ComponentsReplace the following components during the majoroverhaul:

• Aftercooler core

• Camshaft bearings

• Connecting rod bearings

• Crankshaft seals

• Crankshaft thrust washers

• Electronic unit injectors

• Gear train bushings

• Gear train bearings

• Main bearings

• Piston rings

International Convention for Safety ofLife at Sea (SOLAS)

Caterpillar recommends replacing the following:

• All shields that have been installed to cover up fueland oil line connections per (SOLAS) regulations

• All marine certification society approved tapes areinstalled in order to cover up fuel line connectionsand oil line connections according to the SOLASregulations.

Inspection, Reconditioning orExchanging of ComponentsInspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

Recondition the worn components or exchange thecomponents, if necessary. Your Caterpillar dealer canprovide these services and components.

• Camshaft followers

• Camshaft thrust washers

• Connecting rods

• Crankshaft vibration damper

• Cylinder head assembly

• Cylinder liners

• Engine mounts

• Scavenge oil pump

• Engine wiring harness

• Exhaust manifold seals

• Exhaust manifold bellows

• Fuel pressure regulating valve

110 SEBU7908-09Maintenance SectionOverhaul (Major)

• Fuel priming pump

• Fuel transfer pump

• Inlet manifold gaskets

• Inlet manifold seals

• Oil cooler core

• Oil pump

• Pistons

• Piston pins

• Prelube pump

• Pushrods

• Rocker arms

• Spacer plate

• Software update

• Turbocharger

Inspection of ComponentsInspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

• Camshaft

• Crankshaft

• Driven equipment (alignment)

• Engine cylinder block

• Engine control module

• Flywheel

• Front gear train (gears)

• Oil suction screen

• Rear gear train

Inspect the camshaft for damage to the journals andthe lobes.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

• rod bearing

• main bearings

Note: If the crankshaft or the camshaft are removedfor any reason, use the magnetic particle inspectionprocess to check for cracks.

Replace the crankshaft vibration damper if any of thefollowing conditions occur:

• Engine failure due to a broken crankshaft

• Excessive wear of the front bearing for thecrankshaft

• Excessive wear of the gear train that is not causedby a lack of lubrication

Inspect the gears of the gear train and inspect thegear train bushings for the following conditions:

• Worn gear teeth

• Unusual fit

• Unusual wear

In addition to the inspection of components, inspectthe alignment of the driven equipment. See theApplication and Installation Guide for the engine orsee the literature that is provided by the OEM of thedriven equipment.

Cleaning of ComponentsClean the oil suction screen. Also, remove sidecovers in order to clean the oil sump. For instructionson removal and installation of components, seethe Service Manual, “Disassembly and Assembly”module.

Obtain a Coolant AnalysisFor conventional heavy-duty coolant or antifreeze,check the concentration of supplemental coolantadditive (SCA) regularly. The concentration of SCAcan be checked with an S·O·S coolant analysis (LevelI). A more detailed coolant analysis is recommendedperiodically.

SEBU7908-09 111Maintenance SectionOverhaul (Top End)

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant water probablycontained minerals which were deposited on theengine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis may be obtainedfrom the following sources:

• Caterpillar dealer

• Local water utility company

• Agricultural agent

• Independent laboratory

Caterpillar recommends an S·O·S coolant analysis(Level II). This is a comprehensive chemicalevaluation of the coolant. This analysis is also acheck of the overall condition of the inside of thecooling system. The following services are provided:

• Full Level I analysis

• Identification of the source of metal corrosion andof contaminants

• Identification of buildup of the impurities that causecorrosion

• Identification of buildup of the impurities that causescaling

• Determination of possible electrolysis within theengines' cooling system

A report of the results of the analysis is provided.Maintenance recommendations are based on theresults.

For more information about S·O·S coolant analysis,consult your Caterpillar dealer.

i03714880

Overhaul (Top End)(Engines Which are Rated “E”)SMCS Code: 7595-020-TE

A top end overhaul involves the removal, theinspection, and the rework of the cylinder headcomponents. A few additional components arereplaced and serviced.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

The following definitions explain the terminology forthe services that are performed during an overhaul:

Inspect – Inspect the components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”. The guidelines were developed in order tohelp Caterpillar dealers and customers to avoidunnecessary expenditures. New parts are notrequired if the existing parts can still be used,reconditioned, or repaired. If the components arenot in the reusability guidelines, refer to the ServiceManual, “Specifications” module.

Rebuild – The component is reconditioned in orderto comply with reusability guidelines.

Replace – The service life of the part is exhausted.The part may fail before the next maintenanceinterval. The part must be replaced with a part thatmeets functional specifications. The replacementpart may be a new part, a CAT remanufactured part,a rebuilt part, or a used part. Some worn componentsmay be exchanged with your Caterpillar dealer for acredit on replacement parts. Consult your Caterpillardealer about repair options for your engine.

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of therecommendations in Table 26.

Table 26

Recommendations for Top End Overhauls (1)

Service Top End Overhaul

Cylinder head assembliesInspectRebuildReplace Valves

Rocker arms

Valve bridgesInspectReplace

Fuel Injectors

Clean/Test Oil cooler core(2)Aftercooler core (Fresh water or

treated water system)(3)

Replace Cylinder head gasketsAftercooler core (salt water system)

(1) For instructions on removal and installation of components,see the Service Manual, “Disassembly and Assembly” module.

(2) Refer to this Operation and Maintenance Manual, “Oil CoolerCore - Check/Clean/Test” for the procedure.

(3) Refer to this Operation and Maintenance Manual, “AftercoolerCore - Clean/Test” for the procedure.

112 SEBU7908-09Maintenance SectionSea Water Strainer - Clean/Inspect

i01556871

Sea Water Strainer -Clean/InspectSMCS Code: 1371-040; 1371-070

The sea water strainer must be clean in order toallow proper engine cooling. Check the sea waterstrainer for plugging. Inspect the sea water strainermore frequently if the vessel is being operated inwater which is shallow or dirty. The sea water strainerprotects the aftercooler from debris. The sea waterstrainer will catch pieces of the rubber impeller fromthe raw water pump due to a failure from debris.

1. Close the valve for the sea water. The locationof the valve and the type of the valve may varywith each vessel.


2. Remove the hose clamp (2) on each side of thesea water strainer. Remove the sea water strainer(1).

3. Use clean water to clean the sea water strainer(1). Remove any dirt and debris. If there is debrisfrom the impeller, the impeller may need to bereplaced. Refer to Operation and MaintenanceManual, “Auxiliary Water Pump (Rubber Impeller)- Inspect” for replacement information.

4. Install the sea water strainer (1). Install the hoseand each hose clamp (2).

5. Open the valve for the sea water.

i00651416

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation. Checkthe electrical connections and clean the electricalconnections. Refer to the Service Manual for moreinformation on the checking procedure and forspecifications or consult your Caterpillar dealer forassistance.

i01539769

Turbocharger - InspectSMCS Code: 1052-040; 1052

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inlet side).Any fumes from the crankcase are filtered throughthe air inlet system. Therefore, by-products from oiland from combustion can collect in the turbochargercompressor housing. Over time, this buildup cancontribute to loss of engine power, increased blacksmoke and overall loss of engine efficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinderhead.

NOTICETurbocharger bearing failures can cause large quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.

An inspection of the turbocharger can minimizeunscheduled downtime. An inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts.

Note: Turbocharger components require precisionclearances. The turbocharger cartridge mustbe balanced due to high rpm. Severe ServiceApplications can accelerate component wear.Severe Service Applications require more frequentinspections of the cartridge.


Walk-Around Inspection

Removal and InstallationFor options regarding the removal, installation, repairand replacement, consult your Caterpillar dealer.Refer to the Service Manual for this engine for theprocedure and specifications.

Cleaning and Inspecting1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil. Cleanthe interior of the pipes in order to prevent dirtfrom entering during reassembly.

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel forcontact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and theturbocharger housing. If there is any indication ofcontact between the rotating turbine wheel or thecompressor 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, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbochargeroil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the line forthe inlet air (plugged air filters), which causes theturbocharger to slobber.

4. Use a dial indicator to check the end clearanceon the shaft. If the measured end play is greaterthan the Service Manual specifications, theturbocharger should be repaired or replaced.An end play measurement that is less than theminimum Service Manual specifications couldindicate carbon buildup on the turbine wheel. Theturbocharger should be disassembled for cleaningand for inspection if the measured end play is lessthan the minimum Service Manual specifications.

5. Inspect the bore of the turbine housing forcorrosion.

6. Clean the turbocharger housing with standardshop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.

i01063972

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only require a fewminutes. When the time is used to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before youstart the engine. Look for items such as oil leaksor coolant leaks, loose bolts, worn belts, looseconnections and trash buildup. Make repairs, asneeded:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that the cooling lines are properly clamped.Check for leaks. Check the condition of all pipes.

• Check the marine transmission oil level. Refer tothe OEM specification for the marine transmissionor refer to the OEM specification for the vessel.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pumps and the installation of water pumpsand/or seals, refer to the Service Manual for theengine or consult your Caterpillar dealer.

114 SEBU7908-09Maintenance SectionWater Pump - Inspect

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Inspect the hosethat goes from the unit injector hydraulic pump tothe left side fluid manifold.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the ECM ground strap for a goodconnection and for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges which are cracked. Replace any gaugesthat can not be calibrated.

i03543200

Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in the followingconditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

A failed water pump might cause severe engineoverheating problems that could result in cracks inthe cylinder head, a piston seizure or other potentialdamage to the engine.

Visually inspect the water pump for leaks. If leakingof the water pump seals is observed, replace all ofthe water pump seals. Refer to two articles in theDisassembly and Assembly Manual, “Water Pump- Disassemble and Water Pump - Assemble” forthe disassembly and assembly procedure. If it isnecessary to remove the water pump, refer to twoarticles in the Disassembly and Assembly Manual,“Water Pump - Remove and Water Pump - Install”.

Inspect the water pump for wear, cracks, pin holesand proper operation. Refer to the Parts Manualfor the correct part numbers for your engine orconsult your Caterpillar dealer if repair is needed orreplacement is needed.

i01040881

Zinc Rods - Inspect/ReplaceSMCS Code: 1388-040; 1388-510

Corrosion in sea water circuits can result in prematuredeterioration of system components, leaks, andpossible cooling system contamination. A lack of zincrods in the sea water system can cause corrosion inthe sea water cooling system.

Zinc rods are inserted in the sea water coolingsystem of the engine in order to help prevent thecorrosive action of salt water. The reaction of the zincto the sea water causes the zinc rods to deteriorate.The zinc rods deteriorate instead of engine partsfor the cooling system that are more critical. Rapiddeterioration of zinc rods may indicate the presenceof uncontrolled electrical currents from improperlyinstalled electrical attachments or improperlygrounded electrical attachments.

The zinc rods must be inspected at the properintervals. The zinc rods must be replaced whendeterioration occurs.

Inspect the Zinc RodsThe zinc rods are red for easy identification. Table27 shows the locations of the zinc rods and thequantities of the zinc rods.


Zinc Rods - Inspect/Replace

Table 27

Locations of the Zinc Rods

Location Quantity

Inlet Elbow for Sea Water On theHeat Exchanger 1

Outlet Elbow for Sea Water On theHeat Exchanger 1

1. Remove the zinc rod.


2. Tap the zinc rod lightly with a hammer. If the zincrod has deteriorated, or if the zinc rod flakes,install a new zinc rod.

Replace the Zinc Rods


1. Unscrew the old zinc rod or drill the old zinc rodfrom the plug. Clean the plug.

2. Apply 9S-3263 Compound to the shoulder ofa new zinc rod. Apply the compound only to theshoulder of the zinc rod. Install the zinc rod intothe plug.

3. Coat the external threads of the plug with5P-3413 Pipe Sealant. Install the zinc rod. Referto Operation and Maintenance Manual for moreinformation on torque specifications.

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