3116 Cat Die

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SAFETY.CAT.COM

3116 and 3126

MARINE ENGINESMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU6100-02-01)

2007 CaterpillarAll Rights Reserved

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61Maintenance Section

Maintenance Interval Schedule

i01005876

Maintenance Interval ScheduleSMCS Code: 1000; 7500

Note: Ensure that the Safety Information, Warnings,and Instructions are read and understoodbefore operation or maintenance procedures areperformed.

Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must also be performed.

When Required

Battery - Recycle .................................................. 62Battery or Battery Cable - Disconnect .................. 63Engine Oil Level Gauge - Calibrate ...................... 75Fuel System - Prime ............................................. 80

Daily

Cooling System Coolant Level - Check ................ 69Engine Air Cleaner Service Indicator - Inspect ..... 73Engine Oil Level - Check ...................................... 75Fuel System Water Separator - Drain ................... 82Marine Transmission Oil Level - Check ................. 86Walk-Around Inspection ........................................ 90

Every 1500 L (400 US gal) of Fuel or 50Service Hours

Zinc Rods - Inspect/Replace ................................. 91

First 7500 L (2000 US gal) of Fuel or 250Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 79Fuel Injection Timing - Check ............................... 79

Every 7500 L (2000 US gal) of Fuel or 250Service Hours or 1 Year

Auxiliary Water Pump - Inspect ............................. 62Battery Electrolyte Level - Check .......................... 63Belt - Inspect ......................................................... 63Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 70Engine Air Cleaner Element - Clean/Replace ....... 72Engine Crankcase Breather - Clean ..................... 74Engine Oil Sample - Obtain .................................. 76Engine Oil and Filter - Change ............................. 77Fuel Inlet Screen - Clean ...................................... 79Fuel System Primary Filter/Water Separator Element

- Replace ............................................................. 81Fuel System Secondary Filter - Replace .............. 82Fuel Tank Water and Sediment - Drain ................. 83Hoses and Clamps - Inspect/Replace .................. 84Sea Water Strainer - Clean/Inspect ...................... 89Water Pump - Inspect ........................................... 90

Every 30 000 L (8000 US gal) of Fuel or 1000Service Hours or 2 Years

Aftercooler Core - Clean/Test ............................... 62Cooling System Coolant (DEAC) - Change .......... 64Engine Protective Devices - Check ....................... 78

Magnetic Pickups - Clean/Inspect ........................ 86Turbocharger - Inspect .......................................... 89

Every 60 000 L (16 000 US gal) of Fuel or2000 Service Hours

Engine Mounts - Inspect ....................................... 74Engine Valve Lash - Inspect/Adjust ...................... 79Fuel Injection Timing - Check ............................... 79Governor Oil Supply Screen - Clean/Replace ...... 84Heat Exchanger - Inspect ..................................... 84

Every 91 000 L (24 000 US gal) of Fuel or3000 Service Hours or 2 Years

Cooling System Coolant Extender (ELC) - Add .... 69Cooling System Water Temperature Regulator -

Replace ............................................................... 72

Every 182 000 L (48 000 US gal) of Fuel or6000 Service Hours or 4 Years

Cooling System Coolant (ELC) - Change ............. 67

Overhaul

Overhaul Considerations ...................................... 86

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62Maintenance SectionAftercooler Core - Clean/Test

i01089688

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

1. Remove the core. Refer to the Service Manualfor the procedure.

2. Turn the aftercooler core upside-down in orderto remove debris.

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.

3. Back flush the core with cleaner.

Caterpillar recommends the use of hot Hydrosolv100 liquid cleaner at a concentration of 30% andat a temperature of 66 to 82 C (150 to 180 F).Table 35 lists the recommended Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 35

Hydrosolv Liquid Cleaners (1)

Description Container

1U-8804 Hydrosolv 100 4 L (1 US gal)

1U-5492 Hydrosolv 100 19 L (5 US gal)8T-7571 Hydrosolv 100 208 L (55 US gal)

(1) Refer to Application Guide, NEHS0526 or consult yourCaterpillar dealer for more information.

4. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

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

7. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

8. Install the core. Refer to the Service Manual for

the procedure.

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

i01059376

Auxiliary Water Pump - InspectSMCS Code: 1371-040

Impellers require periodic inspection and sealsrequire periodic inspection. Impellers have a servicelife that is limited. The service life depends on theengine operating conditions.

Inspect the components of the pump morefrequently when the pump is exposed to debris,sand, or other abrasive materials. Inspect thecomponents if the pump is operating at a differentialpressure of more than 103 kPa (15 psi).

Check the following components for wear andcheck the following components for damage:

Cam

Impeller

Seals

Wear plate

If wear is found or if damage is found, replacethe components which are worn or replace thecomponents which are damaged. Use the properrepair kit for the pump. Refer to the Disassemblyand Assembly for more information on servicing theauxiliary water pump.

i00037658

Battery - RecycleSMCS Code: 1401-561

1. Always recycle a battery. Never discard a battery.

2. Always return used batteries to one of thefollowing locations.

A battery supplier

An authorized battery collection facility

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Battery Electrolyte Level - Check

Recycling facility

i00914454

Battery Electrolyte Level -CheckSMCS Code: 1401-081

When the engine is not run for long periods oftime or when the engine is run for short periods,the batteries may not fully recharge. Ensure a fullcharge in order to help prevent the battery fromfreezing. If batteries are properly charged, ammeterreading should be very near zero.

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 useclean water that is low in minerals. Do not useartificially softened water.

2. Check the condition of the electrolyte with the1U-7298 Coolant/Battery Tester ( C) or the1U-7297 Coolant/Battery Tester ( F).

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

A mixture of 0.1 L (.12 qt) of baking soda and1 L (1 qt) of clean water

A mixture of 0.1 L (.12 qt) of ammonia and 1 L(1 qt) of clean water

Thoroughly rinse the battery case with cleanwater.

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 fitproperly. Coat the clamps and the terminals with5N-5561 Lubrication Compound, petroleum jellyor MPGM grease.

i00095575

Battery or Battery Cable -Disconnect

SMCS Code: 1402-0291. Turn the start switch to the OFF position. Turn the

ignition 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 sideof two 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.

i00855842

Belt - InspectSMCS Code: 1357-040; 1357; 1397-040; 1397

Inspection

Belt tension should be checked initially between

the first 20 to 40 hours of engine operation.After the initial check, the belt tension should bechecked at Every 250 Service Hours or ThreeMonths.

To maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts thatare worn or damaged.

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.

The additional load on the new belt could cause thenew belt to break.

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

If the belts are too tight, unnecessary stresses areplaced on the pulley bearings and on the belts. Thismay shorten the service life of the components.

Remove the belt guard. Inspect the condition andadjustment of the alternator belts and accessorydrive belts (if equipped).

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64Maintenance SectionCooling System Coolant (DEAC) - Change

To check the belt tension, apply 110 N (25 lb ft)of force midway between the pulleys. A correctlyadjusted belt will deflect 9 mm (0.35 inch) to 15 mm(0.59 inch).

If the belt does not require replacement oradjustment, install the belt guard. If the belt requiresadjustment or replacement, perform the followingprocedure to adjust the belt tension.

If the engine is equipped with a freon compressor(air conditioner), the belt for the fan drive, thealternator, and the accessories will have anautomatic belt tensioner.

If the engine is not equipped with a freoncompressor, the alternator is used to adjust thebelt tension.

AdjustmentAlternator Belt

g00285332Illustration 16

(1) Adjusting bolt(2) Mounting bolts

1. Slightly loosen mounting bolts (2) and adjustingbolt (1).

2. Move the pulley in order to adjust the belttension.

3. Tighten adjusting bolt (1) and mounting bolts (2).Refer to the Operation and Maintenance Manual,Torque Specifications topic (MaintenanceSection).

4. Install the belt guard.

If new belts are installed, check the belt tensionagain after 30 minutes of engine operation at therated rpm.

Water Pump Belt


Exploded view of the drive assembly for a water pump belt

(1) Mounting bolt

(2) Square hole(3) Adjusting bolt

1. Slightly loosen mounting bolts (1) and adjustingbolt (3).

2. Adjust the belt tension with a square drive insquare hole (2).

3. Tighten adjusting bolt (3) and mounting bolt (1).Refer to the Operation and Maintenance Manual,Torque Specifications topic (MaintenanceSection).

4. Install the belt guard.

If new belts are installed, check the belt tensionagain after 30 minutes of engine operation at therated rpm.

i01081100

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 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.

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Cooling System Coolant (DEAC) - Change

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 regulatorand the hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling 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 slowlyin order to relieve any pressure. Remove thecooling system filler cap.

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equipped

with a drain valve, remove one of the 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 Caterpillar

dealer or consult Caterpillar Service TechnologyGroup:

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

Flush

1. Flush the cooling system with clean water inorder to remove any debris.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer tothe Specifications Manual for your particularengine for more specific information on theproper torques. Refer to the Specifications,SENR3130, Torque Specifications for moregeneral information on the 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 .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 lowidle for a minimum of 30 minutes. The coolanttemperature should 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 (ifequipped) 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 Plugging

Note: For the following procedure to be effective,there must be some active flow through the coolingsystem components.


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66Maintenance SectionCooling System Coolant (DEAC) - Change



3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting CoolingSystem Cleaner. Add .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 lowidle for a minimum of 90 minutes. The coolanttemperature should 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 (ifequipped) 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.

Fill

Refer to the Operation and Maintenance Manual,Coolant Specifications topic for informationregarding acceptable water, coolant/antifreeze, andsupplemental coolant additive requirements. Referto the Operation and Maintenance Manual, RefillCapacities topic for the capacity of the enginessystem.

Engines that are Equipped with a CoolantRecovery Tank


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start the engine and run the engine at low idle.Increase the engine rpm to 1500 rpm. Run theengine at high idle for one minute in order topurge the air from the cavities of the engine

block. Stop the engine.

3. Add coolant to 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.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 the

cooling system filler cap is stamped on the faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.


(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.

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Cooling System Coolant (ELC) - Change

6. Pour coolant into the coolant recovery tank untilthe coolant reaches the COLD FULL mark. DONOT fill the coolant recovery tank above theCOLD FULL mark.

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

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

Engines that are Not Equipped with aCoolant Recovery Tank


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start the engine and run the engine at low idle.Increase the engine rpm to 1500 rpm. Run theengine at high idle for one minute in order topurge the air from the cavities of the engineblock. Stop the engine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (.5 inch) below the bottomof the pipe for filling. Maintain the coolant levelwithin 13 mm (.5 inch) to the proper level on thesight glass (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 faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.


i01083041

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-070; 1395-044Clean 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 drainedand replaced.

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 regulatorand the hoses, if necessary.

Drain


1. 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.

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equippedwith a drain valve, remove the cooling systemdrain plugs.

Allow the coolant to drain.

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68Maintenance SectionCooling System Coolant (ELC) - Change

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The full

distillation 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 Service TechnologyGroup:

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

Flush




3. Fill the cooling system with clean water. Installthe cooling system filler cap.

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

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap 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.

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, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Place the transmission in neutral. Start the engineand operate the engine at low idle. Increase theengine rpm to 1500 rpm. Operate the engine at1500 rpm for one minute in order to purge airfrom the cavities of the engine block. Stop theengine.

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 capis not damaged, use a 9S-8140 PressurizingPump in order to pressure test the coolingsystem filler cap. The correct pressure for thecooling system filler cap is stamped on the faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.


(1) Recovery tank filler cap(2) COLD FULL mark(3) LOW ADD mark

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Cooling System Coolant Extender (ELC) - Add

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 thecoolant recovery tank until the coolant reachesthe COLD FULL mark. DO NOT fill the coolantrecovery tank above the COLD FULL mark.

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


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, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Place the transmission in neutral. Start the engineand operate the engine at low idle. Increase theengine rpm to 1500 rpm. Operate the engine at1500 rpm for one minute in order to purge airfrom the cavities of the engine block. Stop theengine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (.5 inch) below the bottomof the pipe for filling. Maintain the coolant levelwithin 13 mm (.5 inch) to the proper level on thesight glass (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 capis not damaged, use a 9S-8140 PressurizingPump in order to pressure test the coolingsystem filler cap. The correct pressure for thecooling system filler cap is stamped on the faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.


i00259474

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-045; 1395-081Caterpillar Extended Life Coolant (ELC) does notrequire the frequent Supplemental Coolant Additive(SCA) additions associated with the presentconventional coolants. The Extender only needs tobe added once.

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

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 coolantfrom the cooling system in order to add theExtender.

3. Add Extender according to the requirements foryour engines cooling system capacity. Refer tothe Operation and Maintenance Manual, RefillCapacities in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to the Operation and Maintenance Manual,Cooling System Specifications information forthe Caterpillar ELC Extender additions.

4. Clean the cooling system filler cap. Inspect thecooling system filler cap gaskets. Replace thecooling system filler cap if the cooling systemfiller cap gaskets are damaged. Install thecooling system filler cap.

i00893001

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

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70Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

Engines That Are Equipped with aCoolant Recovery Tank


(1) Filler cap. (2) COLD FULL mark. (3) LOW ADD mark.

1. Observe the coolant level in the coolant recoverytank. Maintain the coolant level to COLD FULLmark (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 the coolant specifications in themaintenance information for your product. Donot fill the coolant recovery tank above COLDFULL 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 recoverytank during engine operation. When the engine isstopped and cool, the coolant will return to theengine.

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 (.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.


Typical filler cap gaskets

3. Clean the cooling system filler cap and inspectthe condition of the filler cap gaskets. Replacethe cooling system filler cap if the filler capgaskets are damaged. Reinstall the coolingsystem filler cap.

4. Inspect the cooling system for leaks.

i00992487

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

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

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an SOS Coolant Analysis.

Test for SCA Concentration

Coolant/Antifreeze and SCA

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

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

Use the 8T-5296 Coolant Conditioner Test Kitor use the 4C-9301 Coolant Conditioner Test Kitin order to check the concentration of the SCA.Refer to the Operation and Maintenance Manual formore information on conventional coolant/antifreezecooling system maintenance.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the Operationand Maintenance Manual, Water/SupplementalCoolant Additive (SCA) topic (MaintenanceSection). Refer to the Operation and Maintenance

Manual, Conventional Coolant/Antifreeze CoolingSystem Maintenance topic (Maintenance Section).

SOS Coolant Analysis

SOS coolant samples can be analyzed at yourCaterpillar dealer. SOS Coolant Analysis is aprogram that is based on periodic samples.

Level 1

Level 1 is a basic analysis of the coolant. Thefollowing items are tested:

Glycol Concentration

Concentration of SCA

pH

Conductivity

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an SOS CoolantAnalysis.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessive

supplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engines heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.


1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Refer to theOperation and Maintenance Manual for moreinformation on SCA requirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If the

gaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

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72Maintenance SectionCooling System Water Temperature Regulator - Replace

i00912898

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.

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

A water temperature regulator that fails in theclosed position can cause excessive overheating.Excessive overheating could result in cracking ofthe cylinder head 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 insidethe cylinders. This excessive carbon buildup couldresult in an accelerated wear of the piston rings andwear of 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 engine may 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 the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling systemto a level that is below the water temperatureregulator housing.

i01008141

Engine Air Cleaner Element -Clean/Replace

SMCS Code: 1054-070; 1054-510If your air cleaner element becomes plugged, the aircan split the element filter material. Unfiltered air willdrastically accelerate internal engine wear. Contactyour Caterpillar dealer for the correct filter element.

Note: The engine will be equipped with either anAIRSEP air cleaner or a single element air cleaner.AIRSEP air cleaner elements may be cleaned. Thesingle element air cleaner must be replaced.

AIRSEP Air Cleaner Element

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.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.


(1) Vacuum regulator element(2) Air cleaner element

Note: Use the 102-9720 Cleaning Kit. Thisproduct contains the detergent and oil that is madespecifically for the maintenance of the AIRSEP elements.

1. Remove the vacuum limiter element and theAIRSEP element.

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Engine Air Cleaner Service Indicator - Inspect

2. Cover the air inlet opening with a clean cloth, orseal with tape in order to prevent dirt and debrisfrom entering the engine.

3. Tap the element in order to dislodge dirtparticles. Gently brush the 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.

4. Spray the element with the cleaning solution.Allow the element to stand for 20 minutes.

5. Rinse the element with low water pressure. Themaximum water pressure for this procedure is275 kPa (40 psi). Tap water is acceptable. Startto rinse the element from the clean side (inside).Next, clean the dirty side (outside) in order toflush out dirt. Inspect the element for tears and/orholes after the element is cleaned. Do not reusedamaged 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.

6. Shake excess water off the element, and allowthe element to air dry. Drying the element in thesun speeds the process.

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.

7. The dry element should be oiled beforeinstallation. Apply small amounts of oil acrossthe top of each pleat. Allow the oil to soak intothe element for 20 minutes. Oil any remainingwhite spots.

8. Inspect the housing and the clamp for theelement. Replace the housing and the clamp,if necessary.

9. Remove the seal from the air inlet opening.Install the clean, oiled element. Refer to theOperation and Maintenance Manual, TorqueSpecifications topic (Maintenance Section).

Single Element Air Cleaner


(1) Element

1. Remove the element (1) and discard the element(1).

2. Install a new element (1).

i01061105

Engine Air Cleaner ServiceIndicator - InspectSMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differentialgauge for inlet air pressure. The differential gaugefor inlet air pressure displays the difference in thepressure that is measured before the air cleanerelement and the pressure that is measured afterthe air cleaner element. As the air cleaner elementbecomes dirty, the pressure differential rises. If yourengine is equipped with a different type of serviceindicator, follow the OEM recommendations in orderto service the air cleaner element.

A service indicator may be mounted on the aircleaner element or in a remote location.

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76Maintenance SectionEngine Oil Sample - Obtain

Table 37

Engine Oil Level Gauge4KG05783-UP1SK01725-UP8NM01466-UP

6SR1-UP1ZJ1-UP6MK1-UP

Angle (1) FULL Mark (X) ADD Mark (Y)

10 degrees 125 mm (4.92 inch) 114 mm (4.49 inch)









1 degree 82 mm (3.23 inch) 52 mm (2.05 inch)


-1 degree 65 mm (2.56 inch) 39 mm (1.54 inch)

-2 degrees 59 mm (2.32 inch) 33 mm (1.30 inch)



-5 degrees 39 mm (1.54 inch) 12 mm (0.47 inch)(1) The angle indicates the number of degrees that the front of

the engine is raised. A negative angle indicates the number ofdegrees that the front of the engine is lowered.

Verifying the Calibration of the OilLevel GaugeCaterpillar recommends verifying the calibration ofthe oil level gauge at the first oil change. Use thefollowing procedure to verify the FULL mark onthe oil level gauge:

Note: The vessel must be level in order to performthis procedure.

1. Operate the engine until normal operatingtemperature is achieved. Stop the engine.Remove one of the drain plugs for the enginecrankcase. Allow the engine oil to drain.

2. Remove the used engine oil filter. Install the newengine oil filter. Install the crankcase drain plugand tighten the crankcase drain plug.

3. Add 25 L (26.5 qt) of the recommended oil gradeand weight of engine oil to the crankcase.

Note: The engine may be equipped with auxiliaryengine oil filters which require additional oil. Referto the OEM specifications.

NOTICE

To help prevent crankshaft or bearing damage, crankengine to fill all filters before starting. Do not crankengine for more than 30 seconds.

NOTICEDo not crank the engine for more than 30 seconds.Allow the starting motor to cool for two minutes beforecranking again.

Turbocharger (if equipped) damage can result, if theengine rpm is not kept low until the engine oil light/ gauge verifies the oil pressure is sufficient.

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

5. Stop the engine and allow the engine oil to draininto the engine crankcase for approximately tenminutes.

6. Check the engine oil level. If necessary, use amarking pen in order to correct the FULL mark(X).

i01070756

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

7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using SOS oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

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

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Engine Oil and Filter - Change

Service hours on the engine

The number of hours that have accumulatedsince the 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 8T-9190 Fluid Sampling Bottle Group isrecommended for use with the sampling valve. Thebottle group includes the parts that are neededfor obtaining oil samples. Instructions are alsoprovided.

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.

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, PEHP6001,How To Take A Good Oil Sample. Consult yourCaterpillar dealer for complete information andassistance in establishing an SOS program foryour engine.

i00652130

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.

Do not drain the oil when the engine is cold. Asthe oil cools, suspended waste particles settleon the bottom of the oil pan. The waste particlesare not removed with the draining cold oil. Drainthe crankcase with the engine stopped. Drain thecrankcase with the oil warm. This draining methodallows the waste particles that are suspended in theoil to be drained properly.

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 normaloperating temperature, stop the engine. Use one ofthe following methods to drain the engine crankcaseoil:

If the engine is equipped with a drain valve, turnthe drain valve knob counterclockwise in order todrain the oil. After the oil has drained, turn thedrain valve knob clockwise in order to close thedrain 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 fromboth ends 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.

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78Maintenance SectionEngine Protective Devices - Check

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

2. Cut the oil filter open with a 4C-5084 Oil FilterCutter. Break apart the pleats and inspect the oilfilter for metal debris. An excessive amount ofmetal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between theferrous metals and the nonferrous metals thatare found in the oil filter element. Ferrous metalsmay indicate wear on the steel and cast ironparts 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.


Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasketis removed.

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 thatare shown on the oil filter. Do not overtighten the

oil filter.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual for more information onlubricant specifications. Fill the crankcase withthe proper amount of oil. Refer to the Operationand Maintenance Manual for more informationon refill capacities.

NOTICEIf equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturers recommendations. Under filling or overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters before

starting the engine. Do not crank the engine for 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 backto the 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 ADDand FULL marks on the oil level gauge.

i00626013

Engine Protective Devices -CheckSMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.

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Engine Valve Lash - Inspect/Adjust

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual InspectionVisually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replaced

immediately.

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.The adjustment is necessary due to the initial wear

of the valve train components and to the seating ofthe valve 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 motor

to 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 maintenanceis performed.

Refer to the Service Manual for more information.

i00850658

Fuel Injection Timing - CheckSMCS Code: 1251-036-TM; 1290-036-TM

Note: The correct fuel timing specification isfound on the Engine Information Plate. Fueltiming specifications may vary for different engineapplications and/or for different power ratings.

A qualified mechanic should adjust the fuel injectortiming because special tools and training arerequired.

Refer to your Caterpillar dealer for the completeadjustment procedure for the fuel injector timing.

i01015310

Fuel Inlet Screen - CleanSMCS Code: 1256-070

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.

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.

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80Maintenance SectionFuel System - Prime


Location of fuel inlet screen

1. Disconnect the fuel supply line.

2. Remove the fuel inlet screen.

3. Clean the fuel inlet screen with a nonflammablesolvent.

4. Install the fuel inlet screen.

5. Connect the fuel supply line.

i01007661

Fuel System - Prime

SMCS Code: 1258-548

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

Prime the fuel system in order to fill the fuel filter.Prime the fuel system in order to purge trappedair. The fuel system should be primed under the

following conditions:

Running out of fuel

Storage

Replacement of the fuel filter

Engines that are Equipped with aFuel Priming Pump


(1) Select knob

(2) Plunger

1. Turn select knob (1) counterclockwise until theindicator is in line with the body of the primingpump.

2. Unlock the plunger and operate the plunger untila resistance is felt. A considerable number ofpump strokes may be required.

3. Push in plunger (2) and tighten by hand.

4. Turn select knob (1) clockwise until the indicatoris in line with the fuel outlet.

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

5. Promptly start the engine. If the engine runsrough, increase the engine rpm to one half ofthe rated rpm.

Note: If the engine will not start, further priming maybe necessary. If the engine continues to misfireor smoke after starting, further priming may be

necessary.

Engines that are Not Equipped witha Fuel Priming Pump

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.

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Fuel System Primary Filter/Water Separator Element - Replace

If the engine is not equipped with a fuel primingpump, it may be necessary to fill the fuel filter withclean fuel. The following procedure will only allowfiltered fuel to enter the fuel system.


(1) Plug(2) Fuel filter

1. Remove plug (1) in order to fill fuel filter (2).Ensure that air is able to vent from the fitting ofthe plug while the fuel filter is being filled. Cleanup any spilled fuel immediately. Clean plug (1).Install plug (1).

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

2. Start the engine and immediately increase theengine rpm to one half of the rated rpm.

3. Maintain the engine rpm until the engine operatessmoothly.

4. Reduce the engine rpm to low idle.

i00914347

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 fuel system componentsto 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 bechanged regularly. The primary filter/water separatorshould be changed when the vacuum gauge (ifequipped) registers 50 to 70 kPa (15 to 20 In Hg).

Replace the Element



(1) Vent valve(2) Base(3) Can(4) Element(5) Drain plug

1. Close the main fuel supply valve.

2. Remove drain plug (5). Depress vent valve (1)in order to start the flow of fuel. Allow the fuel todrain into a suitable container. Dispose of thefuel properly.

3. Install the drain plug.

4. Remove can (3) from base (2).

5. Remove element (4) from the can. Dispose ofthe used element.

6. Remove the gasket. Clean the followingcomponents:

Can

Gasket

Base

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82Maintenance SectionFuel System Secondary Filter - Replace

Inspect the gasket for damage and fordeterioration. Replace the gasket, if necessary.

7. Install the gasket. Lubricate the gasket withclean diesel fuel.

NOTICEThe primary filter/water separatormay 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.

8. Install a new element in the can. The can maybe filled with fuel at this time.

9. Install the can on the base. Tighten the can byhand. Do not use tools in order to tighten the can.

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.

10. Open the main fuel supply valve.

11. Start the engine and check for leaks. Run theengine for one minute. Stop the engine andcheck for leaks again.

Leaks are difficult to detect while the engine isrunning. The primary filter/water separator isunder suction. A leak will allow air to enter thefuel. The air in the fuel can cause low power dueto aeration of the fuel. If air enters the fuel, ensurethat all components are properly tightened.

i01007602

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


1. Stop the engine.

2. Turn off the start switch, or disconnect the battery(starting motor) when maintenance is performedon fuel filters.

3. Shut off the fuel tank supply valve to the engine.

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

4. Unlock the fuel priming pump (if equipped). Thisrelieves any residual pressure in the fuel system.

5. Remove the used fuel filter. Use a cloth, or use acontainer to catch excess fuel.

6. Clean the gasket sealing surface of the fuelfilter base. Ensure that all of the old gasket isremoved.

7. Apply clean diesel fuel to the new fuel filtergasket.

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.

8. Install a new fuel filter, and tighten the fuel filteruntil the gasket contacts the base.

9. Tighten the fuel filter by hand according to theinstructions that are shown on the fuel filter.

Do not overtighten the fuel filter.

10. Lock the fuel priming pump (if equipped). Openthe fuel tank supply valve.

11. If the engine stalls, refer to the Operation andMaintenance Manual, Fuel System - Prime topic(Maintenance Section) for more information.

i00909035

Fuel System Water Separator- DrainSMCS Code: 1263-543

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

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Fuel Tank Water and Sediment - Drain


(1) Vent valve(2) Base(3) Can(4) Element

(5) Drain plug

Water in the fuel can cause fuel system componentsto fail. Drain the water separator daily. Drain thewater separator more frequently when a largeconcentration of water is present in the fuel system.

1. Close the fuel supply valve.

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

2. Remove drain plug (5). Depress vent valve (1) inorder to start the flow. Allow the water to draininto a suitable container. Allow the water to flowuntil fuel flows from the drain.

3. Install the drain plug. Dispose of the liquidproperly.

4. Open the fuel supply valve.

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.

i00073301

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

Fuel Tank

Fuel quality is critical to the performance and tothe service life of the engine. Water in the fuel cancause excessive fuel system wear. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes throughthe fuel system and the fuel returns to the fuel tank.This causes water to accumulate in fuel tanks.Draining the fuel tank regularly and obtaining fuelfrom reliable sources can help to eliminate waterin the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision fordraining water and draining sediment from thebottom of the fuel tanks.

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

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drain

the 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. If

the 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

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84Maintenance SectionGovernor Oil Supply Screen - Clean/Replace

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank.

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.

i01015388

Governor Oil Supply Screen -Clean/ReplaceSMCS Code: 1264-070; 1264-510


(1) Screen(2) Seal(3) Fitting(4) Seals(5) Oil supply tube

1. Remove oil supply tube (5) and seals (4) fromthe cylinder head.

2. Remove fitting (3) and seal (2) from the governorhousing.

3. Remove screen (1).

4. Wash screen (1) in solvent in order to removeany debris. Inspect screen (1) for damage andinspect screen (1) for deterioration. If necessary,obtain a new screen. Inspect all seals fordamage and deterioration. If necessary, obtainnew seals.

5. Install screen (1) into the governor housing. Thescreen must be far enough into the governorhousing in order to allow clearance for seals (2)and fitting (3).

6. Install seals (2), fitting (3), seal (4) and oil supply

tube (5).

i01057362

Heat Exchanger - InspectSMCS Code: 1379-040

The interval for the maintenance of the tube andfin heat exchanger depends on the operatingenvironment of the vessel and on the operatingtime. The sea water that is circulated through theheat exchanger and the amount of operating timeof the vessel affects the following items:

Cleanliness of the tubes of the heat exchanger

Effectiveness of the heat exchanger system

Operating in water that contains silt, sediment, salt,algae, etc will adversely affect the heat exchangersystem. In addition, intermittent use of the vesselwill adversely affect the heat exchanger system.

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 and maintenance of the heat exchangerare required if the engine is overheating.

Your Caterpillar dealer has the equipment andthe trained personnel that are needed in orderto measure the pressure drop across the heatexchanger.

The procedure for cleaning the heat exchanger issimilar to the procedure that is used for cleaningthe aftercooler core. Refer to the Operation andMaintenance Manual, Aftercooler Core - Clean/Testtopic (Maintenance Section). For more informationon servicing the heat exchanger, consult yourCaterpillar dealer.

i00907072

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

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

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Hoses and Clamps - Inspect/Replace

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

place of any standard hose clamp. Ensure that theconstant torque hose clamp is the same size asthe standard clamp.

Due to extreme temperature changes, the hosewill heat set. Heat setting causes hose clamps toloosen. This can result in leaks. A constant torquehose clamp 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

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 slowlyin order to relieve any pressure. Remove thecooling system filler cap.

Note: Drain the coolant into a suitable, clean

container. The coolant can be reused.3. Drain the coolant from the cooling system to

a level that is below the hose that is beingreplaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

Note: For torques on hose clamps, see thisOperation and Maintenance Manual, Torque

Specifications (Maintenance Section).7. Install the hose clamps with a torque wrench.

Note: For the proper coolant to use, see thisOperation and Maintenance Manual, CoolantRecommendations (Maintenance Section).

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler caps 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.

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86Maintenance SectionMagnetic Pickups - Clean/Inspect

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Magnetic Pickups -Clean/Inspect

SMCS Code: 1907-040; 7400-040; 7400-070


Typical example

(1) Magnetic pickup(2) Flywheel housing


Typical magnetic pickup

1. Remove magnetic pickup (1) from flywheelhousing (2). Check the condition of the end ofthe magnetic pickup. Check for signs of wearand contaminants.

2. Clean the metal shavings and other debris fromthe face of the magnet.

3. Install the magnetic pickup and adjust themagnetic pickup. Refer to the Service Manual forthe installation procedure.

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Marine Transmission Oil Level- Check

SMCS Code: 3081-535Check the marine transmission oil level accordingto the instructions that are provided by the OEM ofthe transmission or the OEM of the vessel.

For the lubrication requirements of the transmission,refer to the recommendations on the nameplate orthe Owners Manual for the transmission.

Marine Transmission Operation,Maintenance, Warranty, and PartsSupport

For information on maintenance and operation ofthe marine transmission, consult your Caterpillardealer and/or the OEM dealer of the transmission.

All support for the warranty of the transmission willbe the responsibility of the OEM. All parts supportfor the transmission will be the responsibility ofthe OEM. This parts support includes both theinstallation of parts and the resolution of any serviceproblems.

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Overhaul ConsiderationsSMCS Code: 7595-043

The following items can increase the engine servicelife before an overhaul is required:

Use only lubricants that are recommended byCaterpillar.

Follow the recommended guidelines formaintenance.

Use an SOS Oil Analysis to determine themaximum interval for changing the oil filter andthe oil.

Follow the rating definitions that are recommendedfor the engine.

Repair of Piston, Ring, And BoreAs An Indicator

Investigate the piston, the ring, and the bore orrepair the piston, the ring, and the bore if one of thefollowing conditions occurs:

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Overhaul Considerations

Oil consumption is in excess of 1 quart of oilper 60 gallons of fuel that is consumed. The oilconsumption must not be caused by leakage.

Crankcase blowby is in excess of 2 cubic feetper hour per horsepower. Measure the crankcaseblowby with an 8T-2700 Blowby Indicator .

Fuel consumption has increased.

Loss of power has occurred.

The cylinder head must be removed in order torepair the piston, the ring, and the bore. Afterremoving the cylinder head, inspect the valvesand the valve seats. Repair the valve and thevalve seats, if necessary. Determine if any othercomponents of the engine should be inspected.

Overhaul OptionsBefore Failure Overhaul

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

Avoid costly unplanned downtime.

Reuse many original parts according to thestandards for reusable parts.

Extend the engines service life without the risk ofa major catastrophe due to engine failure.

Attain the best cost/value relationship per hour ofextended life.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed from the hull, many options areavailable. An overhaul should be performed if theengine block or the crankshaft needs to be repaired.

If the engine block is repairable and/or thecrankshaft is repairable, the overhaul cost shouldbe between 40 percent and 50 percent of the cost

of a new engine with a similar exchange core.

This lower cost can be attributed to three aspects:

Specially designed Caterpillar engine features

Caterpillar dealer exchange components

Caterpillar Inc. remanufactured exchangecomponents

Overhaul Recommendation

To minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealerthat performs the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of thefollowing maintenance recommendations.

Rebuild or Exchange

Inspect the following components according to theinstructions that are found in various Caterpillarreusability publications. The Special Publication,SEBF8029 lists the reusability publications that areneeded for inspecting the engine parts.

Cylinder head assembly

Connecting rods

Pistons

Turbocharger

Oil pump

Fuel ratio control

Cam followers

Fuel Transfer pump

Timing advance

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be salvaged, repaired, orreplaced.

Using out-of-spec parts can result in the followingproblems:

Unscheduled downtime

Costly repairs

Damage to other engine parts

Reduced engine efficiency

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88Maintenance SectionOverhaul Considerations

Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Component Replacement

Replace the following components during theoverhaul:

Piston Rings

Thrust bearings

Main bearings

Connecting rod bearings

Gaskets and seals

Engine mounts

Hoses

Inspection

Inspect 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

Camshaft bearings

Crankshaft

Crankshaft vibration damper

Gear train

Inspect the camshaft for damage to the journalsand the lobes. Inspect the camshaft bearings forsigns of wear and/or for signs of fatigue.

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 rod bearingsand 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 ofthe following conditions are found:

Engine failure due to a broken crankshaft

Excessive wear of the front main bearing

Excessive wear of the gear train that is notcaused by a lack of lubrication

Visconic damper that is dented, cracked, orleaking

Visconic damper that is discolored from heat

Rubber damper that is deteriorated and cracked

Rubber damper with slippage of the outer ring

Inspect the gear train for the following conditions:

Worn gear teeth

Unusual fit

Unusual wear

Testing

Test the following components during the overhaul:

Fuel injection nozzles

Fuel injection pump

Governor

Testing the fuel system during the overhaul will

ensure that your engine operates at peak efficiency.Your Caterpillar dealer can provide these servicesand components in order to ensure that yourfuel system is operating within the appropriatespecifications.

Cleaning

The following components should be cleaned andpressure tested during the overhaul:

Engine oil cooler

Marine gear oil cooler

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90Maintenance SectionWalk-Around Inspection

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Walk-Around InspectionSMCS Code: 1000-040

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

For maximum engine service life, make a thoroughinspection of the engine compartment beforestarting 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 cooling lines are properly clampedand that cooling lines are tight. 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 andthe parts contract.

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.

Inspect the lubrication system for leaks at thefront crankshaft seal, the rear crankshaft seal, theoil pan, the oil filters and the valve cover.

Inspect the fuel system for leaks. Look for loosefuel line clamps.

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

Inspect the alternator belt and the accessorydrive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replacedas matched sets. If only one belt is replaced, thebelt will carry more load than the belts that arenot replaced. The older belts are stretched. Theadditional load on the new belt could cause thebelt 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 connectionand for good condition.

Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolytelevel of the batteries, unless the engine isequipped with a maintenance free battery.

Check the condition of the gauges. Replace anygauges which are cracked or any gauges thatcan not be calibrated.

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Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in thefollowing conditions:

Cracks in the cylinder head

A piston seizure

Other potential damage to the engine

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Zinc Rods - Inspect/Replace

Visually inspect the water pump for leaks. If anyleaking is observed, replace the water pumpseal or the water pump assembly. Refer to theService Manual for the disassembly and assemblyprocedure.

Note: Refer to the Service Manual or consult yourCaterpillar dealer if any repair is needed or anyreplacement is needed.

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

Corrosion in sea water circuits can result inpremature deterioration of cooling systemcomponents, leaks, and possible cooling system

contamination. The corrosion may be caused by thelack of zinc rods in the sea water system.

Zinc rods are inserted in the sea water coolingsystem of the engine in order to help prevent thecorrosive oxidation that is caused by sea water. Thereaction of the zinc to the sea water causes thezinc rods to oxidize rather than the cooling systemcomponents. Rapid deterioration of zinc rods mayindicate the presence of uncontrolled electricalcurrents from improperly installed electricalattachments or improperly grounded electricalattachments.

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

Inspect the Zinc Rods

The zinc rods are red for easy identification. Table38 shows the locations of the zinc rods and thequantities of the zinc rod:

Table 38

Locations of the Zinc Rods

Location Quantity

Heat Exchanger 3

Transmission Oil Cooler (1) 2

Exhaust Elbow (2) 1

Aftercooler (3) 5(1) Zinc rods will only be located in marine transmission oil coolers

that are cooled with sea water.(2) Exhaust elbows that are aftermarket may or may not be

equipped with zinc rods.(3) 3126 Engine Only

1. Remove the zinc rod.

2. Inspect the zinc rod.

Ensure that the zinc rod will remain effective untilthe next scheduled inspection.

a. If the zinc rod has deteriorated excessively,install a new zinc rod.


b. Tap the zinc rod lightly with a hammer. If thezinc rod flakes, install a new zinc rod.

3. If the zinc rod will be reused, scrape the layer ofoxidation from the zinc rod before installation.The layer of oxidation reduces the effectivenessof the zinc rod.

Replace the Zinc Rods

1. Unscrew the old zinc rod from the plug.

If not enough material remains or the zinc rod hasbroken off, drill the old zinc rod from the plug.

2. Clean the plug.


(1) Shoulder

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