MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU6164-08
April 2012

Operation and
Maintenance
Manual
3116 and 3126 Marine Engines
4KG1-Up (3116 Marine Engine)
1ZJ1-Up (3126 Marine Engine)
1SK1-Up (3116 Marine Engine)
6MK1-Up (3126 MarineEngine)
8NM1-Up (3126 MarineEngine)
6SR1-Up (3126 MarineEngine)
NSW1-Up (3126 MarineEngine)
4EZ1-Up (3126 MarineEngine)

SAFETY.CAT.COM
SEBU6164-08 51
Maintenance Section
Maintenance Interval Schedule

i04871889 Every 1500 L (400 US gal) of Fuel or 50

Service Hours
Maintenance Interval Schedule
Zinc Rods - Inspect/Replace ................................. 82
SMCS Code: 1000; 4450; 7500
First 7500 L (2000 US gal) of Fuel or 250
Ensure that all safety information, warnings, Service Hours
and instructions are read and understood before
any operation or any maintenance procedures Engine Valve Lash - Check ................................... 69
are performed. The user is responsible for the Fuel Injection Timing - Check ............................... 69
performance of all maintenance including the
following procedures: all adjustments, the use of Every 7500 L (2000 US gal) of Fuel or 250
proper lubricants, fluids, filters, and the installation Service Hours or 1 Year
of new components due to normal wear and aging .
The performance of this product may be diminished if Auxiliary Water Pump (Rubber Impeller) -
proper maintenance intervals and procedures are not Inspect ................................................................ 52
followed. Components may experience accelerated Battery Electrolyte Level - Check .......................... 53
wear if proper maintenance intervals and procedures Belts - Inspect/Adjust/Replace .............................. 53
are not followed. Coolant Sample (Level 1) - Obtain ....................... 58
Cooling System Supplemental Coolant Additive
Note: Use whichever of the following that occurs (SCA) - Test/Add ................................................. 60
first in order to determine the maintenance intervals: Engine Crankcase Breather - Clean ..................... 64
fuel consumption, service hours, and calendar time Engine Oil Sample - Obtain .................................. 66
. Before each consecutive interval is performed, all Engine Oil and Filter - Change ............................. 67
maintenance from the previous intervals must be Fuel System Primary Filter (Water Separator)
performed. Element - Replace .............................................. 71
Fuel System Secondary Filter - Replace .............. 72
Products that operate in severe operating conditions Fuel Tank Water and Sediment - Drain ................. 73
may require more frequent maintenance. Hoses and Clamps - Inspect/Replace .................. 74
Sea Water Strainer - Clean/Inspect ...................... 80
When Required Water Pump - Inspect ........................................... 81

Battery - Recycle .................................................. 52 Every 30 000 L (8000 US gal) of Fuel or 1000

Battery or Battery Cable - Disconnect .................. 53 Service Hours or 2 Years
Coolant - Change .................................................. 54
Coolant Extender (ELC) - Add .............................. 57 Aftercooler Core - Clean/Test ............................... 52
Engine Air Cleaner Element (Single Element) - Engine Protective Devices - Check ...................... 68
Inspect/Clean/Replace ........................................ 61 Engine Speed/Timing Sensor - Clean/Inspect ...... 69
Engine Oil Level Gauge - Calibrate ...................... 65 Turbocharger - Inspect .......................................... 80
Fuel System - Prime ............................................. 70
Every 60 000 L (16 000 US gal) of Fuel or
Daily 2000 Service Hours
Coolant Level - Check .......................................... 57 Engine Mounts - Inspect ....................................... 64
Engine Air Cleaner Service Indicator - Inspect ..... 63 Engine Valve Lash - Check ................................... 69
Engine Oil Level - Check ...................................... 64 Fuel Injection Timing - Check ............................... 69
Fuel System Water Separator - Check/Drain ........ 72 Heat Exchanger - Inspect ..................................... 74
Transmission Oil Level - Check ............................ 80
Walk-Around Inspection ........................................ 80 Every 91 000 L (24 000 US gal) of Fuel or
3000 Service Hours or 2 Years
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) Coolant Temperature Regulator - Replace ........... 59

Coolant Sample (Level 2) - Obtain ....................... 59 Overhaul

Every Year Overhaul Considerations ...................................... 77

Coolant Sample (Level 2) - Obtain ....................... 59

52 SEBU6164-08
Maintenance Section
Aftercooler Core - Clean/Test

i01089688 7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
Aftercooler Core - Clean/Test radiators are equipped to perform pressure tests.
If necessary, repair the core.
SMCS Code: 1064-070; 1064-081
8. Install the core. Refer to the Service Manual for
1. Remove the core. Refer to the Service Manual the procedure.
for the procedure.
For more information on cleaning the core, consult
2. Turn the aftercooler core upside-down in order to your Caterpillar dealer.
remove debris.

i04601721
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
Auxiliary Water Pump (Rubber
can attack the internal metals of the core and cause Impeller) - Inspect
leakage. Only use the recommended concentration of
cleaner. SMCS Code: 1371-040

Impellers and seals require periodic inspection.

3. Back flush the core with cleaner.
Impellers have a service life that is limited. The
service life depends on the engine operating
Caterpillar recommends the use of hot Hydrosolv
conditions.
100 liquid cleaner at a concentration of 30% and
at a temperature of 66° to 82°C (150° to 180°F).
Inspect the components more frequently when the
Table 11 lists the recommended Hydrosolv liquid
pump is exposed to debris, sand, or other abrasive
cleaners that are available from your Caterpillar
materials. Inspect the components if the pump is
dealer.
operating at a differential pressure of more than
Table 11 103 kPa (15 psi).
Hydrosolv Liquid Cleaners(1) Check the following components for wear or damage:
Description Container
• Bearings
1U-8804 Hydrosolv 100 4 L (1 US gal)
1U-5492 Hydrosolv 100 19 L (5 US gal) • Impeller
8T-7571 Hydrosolv 100 208 L (55 US gal) • Seals
(1) Refer to Application Guide, NEHS0526 or consult your
Caterpillar dealer for more information. • Wear plate
4. Steam clean the core in order to remove any • Key
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris. If wear or damage is found, replace the components
which are worn or damaged. Use the proper repair
5. Wash the core with hot, soapy water. Rinse the kit for the pump. Refer to the Disassembly and
core thoroughly with clean water. Assembly Manual for more information on servicing
the auxiliary water pump.

i00993589
Personal injury can result from air pressure.
Battery - Recycle
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro- SMCS Code: 1401-005; 1401-510; 1401-535;
tective face shield and protective clothing. 1401-561; 1401

Maximum air pressure at the nozzle must be less Always recycle a battery. Never discard a battery.
than 205 kPa (30 psi) for cleaning purposes.
Always return used batteries to one of the following
locations:
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow. • A battery supplier
SEBU6164-08 53
Maintenance Section
Battery Electrolyte Level - Check

• An authorized battery collection facility i01492654

• Recycling facility Battery or Battery Cable -

Disconnect
i02601752
SMCS Code: 1401; 1402-029
Battery Electrolyte Level -
Check
SMCS Code: 1401-535-FLV The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
When the engine is not run for long periods of time or tery cover should be removed before any servic-
when the engine is run for short periods, the batteries ing is attempted.
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.

All lead-acid batteries contain sulfuric acid which 1. Turn the start switch to the OFF position. Turn the
can burn the skin and clothing. Always wear a face ignition switch (if equipped) to the OFF position
shield and protective clothing when working on or and remove the key and all electrical loads.
near batteries.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
1. Remove the filler caps. Maintain the electrolyte the cable cannot contact the terminal. When four
level to the “FULL” mark on the battery. 12 volt batteries are involved, the negative side of
two batteries must be disconnected.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean 3. Tape the leads in order to help prevent accidental
water that is low in minerals. Do not use artificially starting.
softened water.
4. Proceed with necessary system repairs. Reverse
2. Check the condition of the electrolyte with the the steps in order to reconnect all of the cables.
245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean. i04745128

Clean the battery case with one of the following Belts - Inspect/Adjust/Replace
cleaning solutions:
SMCS Code: 1357-025; 1357-040; 1357-510
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water Inspection
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L Belt tension should be checked initially between
(1 qt) of clean water the first 20 to 40 hours of engine operation.

Thoroughly rinse the battery case with clean water. Check the belt tension. Refer to the Operation
and Maintenance Manual, “Maintenance Interval
Use a fine grade of sandpaper to clean the Schedule” topic (Maintenance Section) for the proper
terminals and the cable clamps. Clean the items intervals.
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal To check the belt tension, apply 110 N (25 lb ft)
of material can cause the clamps to not fit properly. of force midway between the pulleys. A correctly
Coat the clamps and the terminals with 5N-5561 adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
Silicone Lubricant, petroleum jelly or MPGM. (0.59 inch).

To maximize the engine performance, inspect the

belts for wear and for cracking. Replace belts that are
worn or damaged.
54 SEBU6164-08
Maintenance Section
Coolant - Change

For applications that require multiple drive belts, 3. Tighten adjusting bolt (1) and mounting bolts (2).
replace the belts in matched sets. Replacing only For the proper torque, refer to the Specifications
one belt of a matched set will cause the new belt to Manual, SENR3130, “Torque Specifications”.
carry more load because the older belt is stretched.
The additional load on the new belt could cause the 4. Install the belt guard.
new belt to break.
If new belts are installed, check the belt tension again
If the belts are too loose, vibration causes after 30 minutes of engine operation at the rated rpm.
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating. Water Pump Belt
If the belts are too tight, unnecessary stresses are
placed on the pulley bearings and on the belts.
These stresses may shorten the service life of the
components.

Remove the belt guard. Inspect the condition and

adjustment of the alternator belts and accessory
drive belts (if equipped).

If the belt does not require replacement or adjustment,

install the belt guard. If the belt requires adjustment
or replacement, perform the following procedure to
adjust the belt tension.

• If the engine is equipped with a refrigerant Illustration 23

g01075753
compressor (air conditioner), the belts for the
Exploded view of the drive assembly for a water pump belt
following components will have automatic belt
tensioners: the alternator, the fan drive, and the (1) Mounting bolt
(2) Square hole
accessories (3) Adjusting bolt

• If the engine is not equipped with a refrigerant 1. Slightly loosen mounting bolts (1) and adjusting
compressor, the alternator is used to adjust the bolt (3).
belt tension.
2. Adjust the belt tension with a square drive in
Adjustment square hole (2).

Alternator Belt 3. Tighten adjusting bolt (3) and mounting bolt (1).
For the proper torque, refer to the Specifications
Manual, SENR3130, “Torque Specifications”.

4. Install the belt guard.

If new belts are installed, check the belt tension after

30 minutes of engine operation at the rated rpm.

i04538352

Coolant - Change
SMCS Code: 1350-044; 1352; 1395-044; 1395

g01075759
Refer to this Operation and Maintenance Manual,
Illustration 22 “Fluid Recommendations” for the correct intervals
(1) Adjusting bolt for changing the coolant.
(2) Mounting bolts
Clean the cooling system and flush the cooling
1. Slightly loosen mounting bolts (2) and adjusting system before the recommended maintenance
bolt (1). interval if the following conditions exist:
2. Move the pulley in order to adjust the belt tension. • The engine overheats frequently.
SEBU6164-08 55
Maintenance Section
Coolant - Change

• Foaming is observed.
NOTICE
• The oil has entered the cooling system and the Dispose of used engine coolant properly or recycle.
coolant is contaminated. Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
• The fuel has entered the cooling system and the distillation procedure is the only method acceptable by
coolant is contaminated. Caterpillar to reclaim the used coolant.

Drain the Cooling System For information regarding the disposal and the
recycling of used coolant, consult your Cat dealer or
consult Cat Dealer Service Tool Group:

Pressurized System: Hot coolant can cause seri- Inside USA: 1-800-542-TOOL
ous burns. To open the cooling system filler cap, Inside Illinois: 1-800-541-TOOL
stop the engine and wait until the cooling system Canada: 1-800-523-TOOL
components are cool. Loosen the cooling system International: 1-309-578-7372
pressure cap slowly in order to relieve the pres-
sure. Flush

NOTICE Systems Filled with Cat ELC, Cat ELI, or a

Care must be taken to ensure that fluids are contained Conventional Coolant that Meets the Cat
during performance of inspection, maintenance, test- EC-1 Requirements and the Standards
ing, adjusting, and repair of the product. Be prepared of ASTM D6210
to collect the fluid with suitable containers before
opening any compartment or disassembling any com- 1. Flush the cooling system with clean water in order
ponent containing fluids. to remove any debris.
Refer to Special Publication, NENG2500, “Cat Dealer 2. Close the drain valve (if equipped). Clean the
Service Tool Catalog” or refer to Special Publication, drain plugs. Install the drain plugs. Refer to
PECJ0003, “Cat Shop Supplies and Tools Catalog” for the Specifications Manual, SENR3130, “Torque
tools and supplies suitable to collect and contain fluids Specifications” for more information on the proper
on Cat products. torques.
Dispose of all fluids according to local regulations and
mandates. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained. 3. Fill the cooling system with clean water. Install the
cooling system filler cap.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling 4. Start and run the engine at low idle until the
system filler cap. temperature reaches 49 to 66 °C (120 to 150 °F).

3. Open the cooling system drain valve (if equipped). 5. Stop the engine and allow the engine to cool.
If the cooling system is not equipped with a drain Loosen the cooling system filler cap slowly
valve, remove one of the drain plugs. in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
Note: If equipped, be sure to drain the heater and (if equipped) or remove the cooling system drain
any related supply and return lines. plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve
Allow the coolant to drain. (if equipped). Clean the drain plugs. Install the
drain plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
information on the proper torques.
56 SEBU6164-08
Maintenance Section
Coolant - Change

Systems Filled with Cat DEAC, 9. Stop the engine and allow the engine to cool.
Conventional Coolant which does not Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
Meet the Cat EC-1 Requirements, or cooling system filler cap. Open the drain valve
Supplemental Coolant Additive (SCA) (if equipped) or remove the cooling system drain
and Water plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to
3. Flush the cooling system with clean water in order flush the heater and any related supply and return
to remove any debris. lines. Close the drain valve (if equipped). Clean
the drain plugs. Install the drain plugs. Refer to
4. Close the drain valve (if equipped). Clean the the Specifications Manual, SENR3130, “Torque
drain plugs. Install the drain plugs. Refer to Specifications” for more information on the proper
the Specifications Manual, SENR3130, “Torque torques.
Specifications” for more information on the proper
torques. Fill the Cooling System
NOTICE NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
per minute to avoid air locks.

5. Fill the cooling system with a mixture of clean 1. Fill the cooling system. Refer to this Operation and
water and Cat Fast Acting Cooling System Maintenance Manual, “Fluid Recommendations”
Cleaner. for more information on cooling system
specifications Refer to this Operation and
6. Choose 1 of the following options. Maintenance Manual, “Refill Capacities” for
information about the capacity of the cooling
• Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal) system. Do not install the cooling system filler cap.
of the cooling system capacity.
2. Start and run the engine at low idle. Increase the
• For cooling systems with heavy deposits or engine rpm to high idle. Run the engine at high
plugging, add 0.5 L (1 pint) of cleaner per idle for 1 minute in order to purge the air from the
3.8 to 7.6 L (1 to 2 US gal) of the cooling system cavities of the engine block. Stop the engine.
capacity.
3. Check the coolant level. Maintain the coolant level
7. Install the cooling system filler cap. within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
8. Start and run the engine at low idle for a minimum 13 mm (0.5 inch) to the proper level on the sight
of 30 minutes. For cooling systems with heavy glass (if equipped).
deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at 4. Clean the cooling system filler cap. Inspect the
least 82 °C (180 °F). gasket that is on the cooling system filler cap.
Only install the used filler cap if the gasket is not
NOTICE damaged. Use a 9S-8140 Pressurizing Pump to
Improper or incomplete rinsing of the cooling system pressure test a reinstalled cooling system filler
can result in damage to copper and other metal com- cap. The correct pressure for the cooling system
ponents. filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
To avoid damage to the cooling system, make sure does not retain the correct pressure, install a new
to completely flush the cooling system with clear wa- cooling system filler cap.
ter. Continue to flush the system until all signs of the
cleaning agent are gone. 5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
SEBU6164-08 57
Maintenance Section
Coolant Extender (ELC) - Add

i04862631 1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling
Coolant Extender (ELC) - Add system filler cap.
SMCS Code: 1352-544-NL 2. If necessary, drain enough coolant from the
cooling system in order to add the Cat ELC
Note: Refer to this Operation and Maintenance Extender.
Manual, “Fluid Recommendations” (Cooling System)
for the maintenance interval for the addition of the 3. Add Cat ELC Extender according to the
coolant extender. requirements for the cooling system capacity.
Refer to this Operation and Maintenance Manual,
Cat ELC (Extended Life Coolant) and Cat ELI “Refill Capacities” for the coolant capacity.
(Extended Life Inhibitor) do not require the frequent
additions of any supplemental cooling additives. The 4. Clean the cooling system filler cap. Inspect the
Cat ELC Extender will only be added one time. gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
Note: Do not use conventional supplemental coolant damaged. Install the cooling system filler cap.
additive (SCA) with Cat ELC or with Cat ELI.
For further information, refer to this Operation and
Check the cooling system only when the engine is Maintenance Manual, , “Fluid Recommendations”.
stopped and cool.

i04550124

Coolant Level - Check

Personal injury can result from hot coolant, steam
and alkali. SMCS Code: 1395-082

At operating temperature, engine coolant is hot Check the coolant level when the engine is stopped
and under pressure. The radiator and all lines and cool.
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Engines That Are Equipped with a
Remove cooling system pressure cap slowly to Coolant Recovery Tank
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.

Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared Illustration 24
g00103638
to collect the fluid with suitable containers before (1) Filler cap
opening any compartment or disassembling any com- (2) “COLD FULL” mark
ponent containing fluids. (3) “LOW ADD” mark

Refer to Special Publication, NENG2500, “Cat Dealer 1. Observe the coolant level in the coolant recovery
Service Tool Catalog” or refer to Special Publication, tank. Maintain the coolant level to “COLD FULL”
PECJ0003, “Cat Shop Supplies and Tools Catalog” for mark (2) on the coolant recovery tank.
tools and supplies suitable to collect and contain fluids
on Cat products. 2. Loosen filler cap (1) slowly in order to relieve any
pressure. Remove the filler cap.
Dispose of all fluids according to local regulations and
mandates.
58 SEBU6164-08
Maintenance Section
Coolant Sample (Level 1) - Obtain

3. Pour the proper coolant mixture into the tank. i04333559

Refer to this Operation and Maintenance Manual,
“Refill Capacities” for information about coolants. Coolant Sample (Level 1) -
Do not fill the coolant recovery tank above “COLD
FULL” mark (2).
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
4. Clean filler cap (1) and the receptacle. Reinstall
the filler cap and inspect the cooling system for Testing the engine coolant is important to ensure
leaks. that the engine is protected from internal cavitation
and corrosion. The analysis also tests the ability of
Note: The coolant will expand as the coolant heats the coolant to protect the engine from boiling and
up during normal engine operation. The additional freezing. S·O·S Systems Coolant Analysis can be
volume will be forced into the coolant recovery tank done at your Cat dealer. Cat S·O·S coolant analysis is
during engine operation. When the engine is stopped the best way to monitor the condition of your coolant
and cool, the coolant will return to the engine. and your cooling system. S·O·S coolant analysis is a
program that is based on periodic samples.
Engines That Are Not Equipped
Note: Obtaining a Coolant Sample (Level 1) is
with a Coolant Recovery Tank optional if the cooling system is filled with one of
the following coolants: Cat ELC (Extended Life
Coolant)., Cat ELI (Extended Life Inhibitor), and
Conventional Heavy-Duty Coolant.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Note: Obtain a Coolant Sample (Level 1) if the
stop the engine and wait until the cooling system cooling system is filled with any of the following
components are cool. Loosen the cooling system coolants: Cat DEAC, Cat SCA, and Conventional
pressure cap slowly in order to relieve the pres- Heavy-Duty Coolants.
sure.
For additional information about coolant analysis
and about other coolants, see this Operation and
1. Remove the cooling system filler cap slowly in Maintenance Manual, “Fluid Recommendations” or
order to relieve pressure. consult your Cat dealer.

2. Maintain the coolant level within 13 mm (0.5 inch)

of the bottom of the filler pipe. If the engine is Sampling Conditions
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass. If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.

If the engine is not equipped with a sampling port, the

coolant should be warm.

Use the following guidelines for proper sampling of

the coolant:

• Complete the information on the label for the

sampling bottle before you begin to take the
samples.

• Keep the unused sampling bottles stored in plastic

bags.
g00103639
Illustration 25
Typical filler cap gaskets
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
3. Clean the cooling system filler cap and inspect
the condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are • Keep the lids on empty sampling bottles until you
are ready to collect the sample.
damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

SEBU6164-08 59
Maintenance Section
Coolant Sample (Level 2) - Obtain

• Place the sample in the mailing tube immediately i04638756

after obtaining the sample in order to avoid
contamination. Coolant Sample (Level 2) -
Obtain
• Never collect samples from expansion bottles.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
• Never collect samples from the drain for a system.
An S·O·S Coolant Analysis (Level 2) is a
Timing of the Sampling comprehensive chemical evaluation of the coolant.
This analysis is also a check of the overall condition
Table 12 of the cooling system. The S·O·S Coolant Analysis
Recommended Interval (Level 2) has the following features:

Type of Coolant Level 1 Level 2 • Full coolant analysis (Level 1)

Cat DEAC
Cat SCA • Identification of metal corrosion and contaminants
Conventional Every 250 hours Yearly(1)
Heavy-Duty • Identification of buildup of the impurities that cause
Coolants corrosion and scaling
Cat ELC
Cat ELI • Determination of the possibility of electrolysis
Commercial
Optional(1) Yearly(1) within the cooling system of the engine
EC-1 Coolants
The results are reported and appropriate
(1) The Level 2 Coolant Analysis should be performed sooner if a recommendations are made.
problem is suspected or identified.

Note: Check the SCA (Supplemental Coolant Obtaining the Sample

Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at Refer to Operation and Maintenance Manual,
the interval that occurs first. “Coolant Sample (Level 1) - Obtain” for the guidelines
for proper sampling of the coolant.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to Submit the sample for Level 2 analysis.
receive the full effect of S·O·S analysis, establish
a consistent trend of data. In order to establish For further information, refer to this Operation and
a pertinent history of data, perform consistent Maintenance Manual, “Fluid Recommendations”.
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your Cat
i04240223
dealer.
Coolant Temperature
NOTICE
Always use a designated pump for oil sampling, and Regulator - Replace
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may SMCS Code: 1355-510
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- Replace the water temperature regulator before the
rect interpretation that could lead to concerns by both water temperature regulator fails. Replacing the
dealers and customers. water temperature regulator reduces the chances for
unscheduled downtime.
Submit the sample for Level 1 analysis. A water temperature regulator that fails in a
partially opened position can cause overheating or
Note: Level 1 results may indicate a need for Level overcooling of the engine.
2 Analysis.
60 SEBU6164-08
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

A water temperature regulator that fails in the open i02456600

position will cause the engine operating temperature
to be too low during partial load operation. Low Cooling System Supplemental
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
Coolant Additive (SCA) -
cylinders. This excessive carbon buildup could result Test/Add
in an accelerated wear of the piston rings and wear
of the cylinder liner. SMCS Code: 1352-045; 1395-081

A water temperature regulator that fails in the closed

position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder Cooling system coolant additive contains alkali.
head or piston seizure problems. To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
NOTICE coolant additive.
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
Note: Test the concentration of the Supplemental
engine damage.
Coolant Additive (SCA) or test the SCA concentration
as part of an S·O·S Coolant Analysis.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed. Test for SCA Concentration
If the water temperature regulator is installed incor- Coolant and SCA
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
NOTICE
ulator is installed in the original position. Ensure that
Do not exceed the recommended six percent supple-
the water temperature regulator vent hole is open.
mental coolant additive concentration.
Do not use liquid gasket material on the gasket or
cylinder head surface. Use the 8T-5296 Coolant Conditioner Test Kit
or use the 4C-9301 Coolant Conditioner Test Kit
in order to check the concentration of the SCA.
NOTICE Refer to this Operation and Maintenance Manual,
Care must be taken to ensure that fluids are contained “Refill Capacities and Recommendations” for more
during performance of inspection, maintenance, test- information.
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before Water and SCA
opening any compartment or disassembling any com-
ponent containing fluids.
NOTICE
Refer to Special Publication, NENG2500, “Cat Dealer Do not exceed the recommended eight percent sup-
Service Tool Catalog” or refer to Special Publication, plemental coolant additive concentration.
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
tools and supplies suitable to collect and contain fluids Test the concentration of the SCA with the 8T-5296
on Cat products. Coolant Conditioner Test Kit. Refer to the Special
Publication, SEBU6251, “Caterpillar Commercial
Dispose of all fluids according to local regulations and Diesel Engine Fluids Recommendations” for more
mandates. information.

Note: If replacing only the water temperature S·O·S Coolant Analysis

regulator, only drain the coolant to a level that is
below the water temperature regulator housing. S·O·S coolant samples can be analyzed at your
Caterpillar dealer. S·O·S Coolant Analysis is a
Refer to two articles in the Disassembly and program that is based on periodic samples.
Assembly Manual, “Water Temperature Regulator -
Remove and Water Temperature Regulator - Install”
Level 1
for the replacement procedure or consult your Cat
dealer.
Level 1 is a basic analysis of the coolant. The
following items are tested:
SEBU6164-08 61
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace

• Glycol Concentration 3. Add the proper amount of SCA. Refer

to the Special Publication, SEBU6251,
• Concentration of SCA “Caterpillar Commercial Diesel Engines Fluids
Recommendations” for more information on SCA
• pH requirements.

• Conductivity 4. Clean the cooling system filler cap. Inspect the

gaskets of the cooling system filler cap. If the
The results are reported, and recommendations gaskets are damaged, replace the old cooling
are made according to the results. Consult your system filler cap with a new cooling system filler
Caterpillar dealer for information on the benefits of cap. Install the cooling system filler cap.
managing your equipment with an S·O·S Coolant
Analysis.
i04441631

Level 2 Engine Air Cleaner

This level coolant analysis is recommended when the Element (Single Element) -
engine is overhauled. Refer to this Operations and Inspect/Clean/Replace
Maintenance Manual, “Overhaul Considerations” for
further information. SMCS Code: 1051; 1054-040; 1054-070; 1054-510

Add the SCA, If Necessary NOTICE

Never run the engine without an air cleaner element
NOTICE installed. Never run the engine with a damaged air
Do not exceed the recommended amount of sup- cleaner element. Do not use air cleaner elements with
plemental coolant additive concentration. Excessive damaged pleats, gaskets or seals. Dirt entering the
supplemental coolant additive concentration can form engine causes premature wear and damage to engine
deposits on the higher temperature surfaces of the components. Air cleaner elements help to prevent air-
cooling system, reducing the engine's heat transfer borne debris from entering the air inlet.
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temper- If the air cleaner element becomes plugged, the air
ature components. Excessive supplemental coolant can split the material of the air cleaner element.
additive concentration could also result in radiator Unfiltered air will drastically accelerate internal
tube blockage, overheating, and/or accelerated water engine wear. Your Cat dealer has the proper air
pump seal wear. Never use both liquid supplemental cleaner elements for your application. Consult your
coolant additive and the spin-on element (if equipped) Cat dealer for the correct air cleaner element.
at the same time. The use of those additives together
could result in supplemental coolant additive concen- • Check the precleaner (if equipped) daily for
tration exceeding the recommended maximum. accumulation of dirt and debris. Remove any dirt
and debris, as needed.

• Operating conditions (dust, dirt, and debris) may

require more frequent service of the air cleaner
Pressurized System: Hot coolant can cause seri- element.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system • The air cleaner element should be replaced at least
components are cool. Loosen the cooling system one time per year. This replacement should be
pressure cap slowly in order to relieve the pres- performed regardless of the number of cleanings.
sure.
Cleaning the Air Cleaner Element
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling Use a clean air cleaner element while dirty elements
system filler cap. are being cleaned.

Note: Always discard drained fluids according to

local regulations.

2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow
space for the extra SCA.
62 SEBU6164-08
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace

Aim the hose towards the inside of the element along

NOTICE the length of the filter to help prevent damage to the
Do not clean the air cleaner elements by bumping or paper pleats. Do not aim the stream of air directly at
tapping. This could damage the seals. Do not use el- the air cleaner element. Dirt could be forced further
ements with damaged pleats, gaskets or seals. Dam- into the pleats.
aged elements will allow dirt to pass through. Engine
damage could result. Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
Visually inspect the air cleaner elements before
air cleaner elements which require daily cleaning
cleaning. Inspect the air cleaner elements for damage
because of a dry, dusty environment. Cleaning with
to the seal, the gaskets, and the outer cover. Inspect
pressurized air is recommended prior to vacuum
the filter material for rips and for tears. Discard any
cleaning. Vacuum cleaning will not remove deposits
damaged air cleaner elements.
of carbon and oil.
There are two common methods that are used to
clean air cleaner elements: Inspecting the Air Cleaner Element
• Pressurized air
• Vacuum cleaning
Pressurized Air

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.
g02633320
Illustration 27
The maximum air pressure for cleaning purposes Typical air cleaner element
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded. Inspect the clean, dry air cleaner element. Use a 60
W blue light in a dark room or in a similar facility.
Place the blue light in the air cleaner element. Rotate
the air cleaner element. Inspect the air cleaner
element for tears and/or holes. Inspect the air cleaner
element for light that may show through the filter
material. , Compare the air cleaner element to a new
air cleaner element that has the same part number to
determine if the filter is clean.

Do not use an air cleaner element that has any tears

and/or holes in the filter material. Do not use an air
cleaner element with damaged pleats, gaskets, or
seals. Discard damaged air cleaner elements.

Illustration 26
g02633318 Replacing the Air Cleaner Element
Typical air cleaner element
Note: Replace an old air cleaner element with a new
air cleaner element after the old element has been
Note: When the air cleaner elements are cleaned, cleaned six times.
always begin with the clean side (inside) in order to
force dirt particles toward the dirty side (outside).
Storing the Air Cleaner Elements
If an air cleaner element that passes inspection will
not be used, the air cleaner element can be stored
for future use.
SEBU6164-08 63
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

g02633322 g00103777
Illustration 28 Illustration 29
Typical service indicator
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An air flow restriction Observe the service indicator. The air cleaner
may result. To protect against dirt and damage, element should be cleaned or the air cleaner element
wrap the air cleaner elements in Volatile Corrosion should be replaced when one of the following
Inhibited (VCI) paper. conditions occur:

Place the air cleaner element into a box for storage. • The yellow diaphragm enters the red zone.
For identification, mark the outside of the box and
mark the air cleaner element. Include the following • The red piston locks in the visible position.
information:

• Date of cleaning Test the Service Indicator

Service indicators are important instruments.
• Number of cleanings
Store the box in a dry location. • Check for ease of resetting. The service indicator
should reset in less than three pushes.

i01900118 • Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
Engine Air Cleaner Service The yellow core should latch approximately at the
Indicator - Inspect greatest vacuum that is attained.

(If Equipped) If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
SMCS Code: 7452-040 the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Some engines may be equipped with a different indicator may be plugged.
service indicator.
The service indicator may need to be replaced
Some engines are equipped with a differential gauge frequently in environments that are severely dusty, if
for inlet air pressure. The differential gauge for inlet necessary. Replace the service indicator annually
air pressure displays the difference in the pressure regardless of the operating conditions. Replace the
that is measured before the air cleaner element and service indicator when the engine is overhauled, and
the pressure that is measured after the air cleaner whenever major engine components are replaced.
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is Note: When a new service indicator is installed,
equipped with a different type of service indicator, excessive force may crack the top of the service
follow the OEM recommendations in order to service indicator. Tighten the service indicator to a torque
the air cleaner service indicator. of 2 N·m (18 lb in).

The service indicator may be mounted on the air

cleaner housing or in a remote location.
64 SEBU6164-08
Maintenance Section
Engine Crankcase Breather - Clean

i01007514 i02456872

Engine Crankcase Breather - Engine Mounts - Inspect

Clean SMCS Code: 1152-040; 1152
SMCS Code: 1317-070
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
NOTICE by the following conditions:
Perform this maintenance with the engine stopped.
• Improper mounting of the engine
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become • Deterioration of the engine mounts
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause Any engine mount that shows deterioration should be
crankshaft seal leakage. replaced. Refer to Special Publication, SENR3130,
“Torque Specifications” for the recommended
torques. Refer to the OEM recommendations for
more information.

i01007363

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Check the oil level after the engine has stopped.

This maintenance procedure must be performed on
a level surface.

g00516808
Illustration 30
(1) Hose clamp
(2) Breather assembly
(3) Seal

1. Loosen hose clamp (1) and remove the hose from

breather assembly (2). Illustration 31
g00110310

(Y) “ADD” mark

2. Remove breather assembly (2) and seal (3). (X) “FULL” mark

3. Wash the breather element in solvent that is clean 1. Maintain the oil level between the “ADD” mark (Y)
and nonflammable. Allow the breather element to and the “FULL” mark (X) on the oil level gauge.
dry before installation. Do not fill the crankcase above “FULL” mark (X).
4. Install a breather element that is clean and dry.
Install seal (3) and breather assembly (2). NOTICE
Operating your engine when the oil level is above the
5. Install the hose. Install hose clamp (1). Refer to “FULL” mark could cause your crankshaft to dip into
the Operation and Maintenance Manual, “Torque the oil. The air bubbles created from the crankshaft
Specifications” topic (Maintenance Section) for dipping into the oil reduces the oil's lubricating char-
the proper torque. acteristics and could result in the loss of power.

2. Remove oil filler cap and add oil, if necessary.

Clean the oil filler cap. Reinstall the oil filler cap.
SEBU6164-08 65
Maintenance Section
Engine Oil Level Gauge - Calibrate

i01139872 Calibration of Oil Level Gauge

Engine Oil Level Gauge - Table 13

Calibrate Engine Oil Level Gauge

4KG1-05782
SMCS Code: 1326-524; 1326 1SK1-01724
8NM1-01465
The engine is shipped with an engine oil level gauge Angle(1) “FULL” Mark (X) “ADD” Mark (Y)
that is not marked. The engine oil level gauge is
not marked because the angle of installation can be 15 degrees 156 mm (6.14 inch) 137 mm (5.39 inch)
different for each engine. The angle of installation will 14 degrees 151 mm (5.95 inch) 133 mm (5.24 inch)
affect the “ADD” mark (Y) and the “FULL” mark (X)
that is engraved on the engine oil level gauge. 13 degrees 148 mm (5.83 inch) 129 mm (5.08 inch)
12 degrees 144 mm (5.67 inch) 125 mm (4.92 inch)
The engine oil level gauge must be calibrated after
the engine is installed in the vessel. Table 13 and 11 degrees 139 mm (5.47 inch) 119 mm (4.69 inch)
Table 14 list the corresponding “ADD” mark, “FULL” 10 degrees 136 mm (5.35 inch) 115 mm (4.53 inch)
mark and the angle of installation. Use a marking pen
in order to engrave “ADD” mark (Y) and “FULL” mark 9 degrees 130 mm (5.12 inch) 114 mm (4.49 inch)
(X) on the engine oil level gauge according to the 8 degrees 128 mm (5.04 inch) 113 mm (4.45 inch)
information in Table 13 or Table 14.
7 degrees 121 mm (4.76 inch) 114 mm (4.49 inch)
6 degrees 117 mm (4.61 inch) 107 mm (4.21 inch)
5 degrees 113 mm (4.45 inch) 100 mm (3.94 inch)
4 degrees 112 mm (4.41 inch) 93 mm (3.66 inch)
3 degrees 111 mm (4.37 inch) 88 mm (3.47 inch)
2 degrees 109 mm (4.29 inch) 81 mm (3.19 inch)
g00110310
Illustration 32
1 degree 102 mm (4.02 inch) 76 mm (2.99 inch)
Oil Level Gauge
(Y) “ADD” mark 0 degrees 96 mm (3.78 inch) 70 mm (2.76 inch)
(X) “FULL” mark (1) The angle indicates the number of degrees that the front of the
engine is raised.
66 SEBU6164-08
Maintenance Section
Engine Oil Sample - Obtain

Table 14 Note: The engine may be equipped with auxiliary

Engine Oil Level Gauge
engine oil filters which require additional oil. Refer to
4KG05783-UP the OEM specifications.
1SK01725-UP
8NM01466-UP NOTICE
6SR1-UP To help prevent crankshaft or bearing damage, crank
1ZJ1-UP
engine to fill all filters before starting. Do not crank
6MK1-UP
engine for more than 30 seconds.
Angle(1) “FULL” Mark (X) “ADD” Mark (Y)
10 degrees 125 mm (4.92 inch) 114 mm (4.49 inch) NOTICE
9 degrees 124 mm (4.89 inch) 106 mm (4.17 inch) Do not crank the engine for more than 30 seconds.
Allow the starting motor to cool for two minutes before
8 degrees 122 mm (4.80 inch) 102 mm (4.02 inch) cranking again.
7 degrees 120 mm (4.72 inch) 96 mm (3.78 inch)
Turbocharger (if equipped) damage can result, if the
6 degrees 115 mm (4.53 inch) 89 mm (3.50 inch) engine rpm is not kept low until the engine oil light/
5 degrees 110 mm (4.33 inch) 81 mm (3.19 inch) gauge verifies the oil pressure is sufficient.
4 degrees 101 mm (3.98 inch) 71 mm (2.80 inch)
4. Start the engine. Ensure that the lubrication
3 degrees 94 mm (3.70 inch) 66 mm (2.60 inch)
system and the new engine oil filter is filled.
2 degrees 90 mm (3.54 inch) 59 mm (2.32 inch) Inspect the lubrication system for leaks.
1 degree 82 mm (3.23 inch) 52 mm (2.05 inch) 5. Stop the engine and allow the engine oil to drain
0 degrees 76 mm (2.99 inch) 46 mm (1.81 inch) into the engine crankcase for approximately ten
minutes.
-1 degree 65 mm (2.56 inch) 39 mm (1.54 inch)
-2 degrees 59 mm (2.32 inch) 33 mm (1.30 inch) 6. Check the engine oil level. If necessary, use a
marking pen in order to correct the “FULL” mark
-3 degrees 53 mm (2.09 inch) 26 mm (1.02 inch) (X).
-4 degrees 46 mm (1.81 inch) 20 mm (0.79 inch)
-5 degrees 39 mm (1.54 inch) 12 mm (0.47 inch) i04237495
(1) The angle indicates the number of degrees that the front of
the engine is raised. A negative angle indicates the number of
Engine Oil Sample - Obtain
degrees that the front of the engine is lowered.
SMCS Code: 1348-554-SM
Verifying the Calibration of the Oil In addition to a good preventive maintenance
Level Gauge program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
Caterpillar recommends verifying the calibration of analysis provides infrared analysis, which is required
the oil level gauge at the first oil change. Use the for determining nitration and oxidation levels.
following procedure to verify the “FULL” mark on the
oil level gauge: Obtain the Sample and the Analysis
Note: The vessel must be level in order to perform
this procedure.

1. Operate the engine until normal operating Hot oil and hot components can cause personal
temperature is achieved. Stop the engine. injury. Do not allow hot oil or hot components to
Remove one of the drain plugs for the engine contact the skin.
crankcase. Allow the engine oil to drain.
Before you take the oil sample, complete the Label,
2. Remove the used engine oil filter. Install the new
PEEP5031 for identification of the sample. In order
engine oil filter. Install the crankcase drain plug
to help obtain the most accurate analysis, provide
and tighten the crankcase drain plug.
the following information:
3. Add 25 L (26.5 qt) of the recommended oil grade
and weight of engine oil to the crankcase. • Engine model
• Service hours on the engine
SEBU6164-08 67
Maintenance Section
Engine Oil and Filter - Change

• The number of hours that have accumulated since Do not drain the oil when the engine is cold. As the oil
the last oil change cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
• The amount of oil that has been added since the with the draining cold oil. Drain the crankcase with
last oil change the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
To ensure that the sample is representative of the oil particles that are suspended in the oil to be drained
in the crankcase, obtain a warm, mixed oil sample. properly.

To avoid contamination of the oil samples, the tools Failure to follow this recommended procedure will
and the supplies that are used for obtaining oil cause the waste particles to be recirculated through
samples must be clean. the engine lubrication system with the new oil.

Caterpillar recommends using the sampling valve

in order to obtain oil samples. The quality and the
Drain the Engine Oil
consistency of the samples are better when the After the engine has been run at the normal operating
sampling valve is used. The location of the sampling
temperature, stop the engine. Use one of the
valve allows oil that is flowing under pressure to be
following methods to drain the engine crankcase oil:
obtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle is • If the engine is equipped with a drain valve, turn the
drain valve knob counterclockwise in order to drain
recommended for use with the sampling valve. The the oil. After the oil has drained, turn the drain valve
fluid sampling bottle includes the parts that are
knob clockwise in order to close the drain valve.
needed for obtaining oil samples. Instructions are
also provided.
• If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
NOTICE to drain. If the engine is equipped with a shallow
Always use a designated pump for oil sampling, and sump, remove the bottom oil drain plugs from both
use a separate designated pump for coolant sampling. ends of the oil pan.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This After the oil has drained, the oil drain plugs should
contaminate may cause a false analysis and an incor- be cleaned and installed.
rect interpretation that could lead to concerns by both
dealers and customers.
Replace the Oil Filter
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is NOTICE
designed to accept sampling bottles. Disposable Caterpillar oil filters are built to Caterpillar speci-
tubing must be attached to the pump for insertion fications. Use of an oil filter not recommended by
into the sump. Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
For instructions, see Special Publication, PEGJ0047, the larger waste particles from unfiltered oil entering
“How To Take A Good S·O·S Oil Sample”. Consult the engine lubricating system. Only use oil filters
your Cat dealer for complete information and recommended by Caterpillar.
assistance in establishing an S·O·S program for your
engine. 1. Remove the oil filter with a 1U-8760 Chain
Wrench.
i02107152
2. Cut the oil filter open with a 175-7546 Oil Filter
Engine Oil and Filter - Change Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
SMCS Code: 1318-510 of metal debris in the oil filter may indicate early
wear or a pending failure.

Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found in
Hot oil and hot components can cause personal the oil filter element. Ferrous metals may indicate
injury. Do not allow hot oil or hot components to wear on the steel and cast iron parts of the engine.
contact the skin.
68 SEBU6164-08
Maintenance Section
Engine Protective Devices - Check

Nonferrous metals may indicate wear on the

aluminum parts, brass parts or bronze parts of NOTICE
the engine. Parts that may be affected include To prevent crankshaft bearing damage, crank the en-
the following items: main bearings, rod bearings, gine with the fuel OFF. This will fill the oil filters before
turbocharger bearings, and cylinder heads. starting the engine. Do not crank the engine for more
than 30 seconds.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order 2. Start the engine and run the engine at “LOW
to arrange for a further analysis if an excessive IDLE” for two minutes. Perform this procedure in
amount of debris is found in the oil filter. order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.

3. Stop the engine and allow the oil to drain back to

the sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the oil level gauge.

i00626013

Engine Protective Devices -

Check
g00103713
Illustration 33
Typical filter mounting base and filter gasket
SMCS Code: 7400-535

3. Clean the sealing surface of the filter mounting Alarms and shutoffs must function properly. Alarms
base. Ensure that all of the old oil filter gasket is provide timely warning to the operator. Shutoffs help
removed. to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
4. Apply clean engine oil to the new oil filter gasket. in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
NOTICE
Do not fill the oil filters with oil before installing them. A calibration check of the engine protective devices
This oil would not be filtered and could be contaminat- will ensure that the alarms and shutoffs activate
ed. Contaminated oil can cause accelerated wear to at the setpoints. Ensure that the engine protective
engine components. devices are functioning properly.

5. Install the oil filter. Tighten the oil filter until the NOTICE
oil filter gasket contacts the base. Tighten the oil During testing, abnormal operating conditions must be
filter by hand according to the instructions that are simulated.
shown on the oil filter. Do not overtighten the oil
filter. The tests must be performed correctly in order to pre-
vent possible damage to the engine.
Fill the Engine Crankcase
To prevent damage to the engine, only authorized
1. Remove the oil filler cap. Refer to the Operation service personnel or your Caterpillar dealer should
and Maintenance Manual, “Refill Capacities and perform the tests.
Recommendations” for more information.

NOTICE
Visual Inspection
If equipped with an auxiliary oil filter system or a re- Visually check the condition of all gauges, sensors
mote oil filter system, follow the OEM or filter manu- and wiring. Look for wiring and components that
facturer's recommendations. Under filling or overfilling are loose, broken, or damaged. Damaged wiring
the crankcase with oil can cause engine damage. or components should be repaired or replaced
immediately.
SEBU6164-08 69
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect

i04748255 i04242309

Engine Speed/Timing Sensor - Engine Valve Lash - Check

Clean/Inspect SMCS Code: 1105-535
(Magnetic Pick-ups)
The initial valve lash adjustment on new engines,
SMCS Code: 1905-040; 1905-070; 1907-040; rebuilt engines, or remanufactured engines is
1907-070 recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
valve train components.

The maintenance is recommended by Caterpillar as

part of a lubrication and preventive maintenance
schedule to help provide maximum engine life.

Note: Only qualified service personnel should

perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve
bridge, see System Systems Operation/Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
Consult your Cat dealer for assistance.
g00293335
Illustration 34
Typical example
(1) Magnetic pickup
(2) Flywheel housing
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.

i00850658

Fuel Injection Timing - Check

SMCS Code: 1251-036-TM; 1290-036-TM

Illustration 35
g00293337 Note: The correct fuel timing specification is
found on the Engine Information Plate. Fuel
Typical magnetic pickup
timing specifications may vary for different engine
applications and/or for different power ratings.
1. Remove magnetic pickup from flywheel housing.
Check the condition of the end of the magnetic A qualified mechanic should adjust the fuel injector
pickup. Check for signs of wear and contaminants. timing because special tools and training are
required.
2. Clean the metal shavings and other debris from
the face of the magnet. Refer to your Caterpillar dealer for the complete
adjustment procedure for the fuel injector timing.
3. Install the magnetic pickup and adjust the
magnetic pickup. Contact your Cat dealer for
further information.
70 SEBU6164-08
Maintenance Section
Fuel System - Prime

i01007661
NOTICE
Fuel System - Prime Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
SMCS Code: 1250-548; 1258-548
minutes before cranking the engine again.

5. Promptly start the engine. If the engine runs

rough, increase the engine rpm to one half of the
Fuel leaked or spilled onto hot surfaces or elec-
rated rpm.
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
Note: If the engine will not start, further priming
changing fuel filters or water separator elements.
may be necessary. If the engine continues to misfire
Clean up fuel spills immediately.
or smoke after starting, further priming may be
necessary.
Prime the fuel system in order to fill the fuel filter.
Prime the fuel system in order to purge trapped air. Engines that are Not Equipped with
The fuel system should be primed under the following
conditions: a Fuel Priming Pump
• Running out of fuel NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
• Storage clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
• Replacement of the fuel filter connected fuel system components.

Engines that are Equipped with a If the engine is not equipped with a fuel priming
Fuel Priming Pump pump, it may be necessary to fill the fuel filter with
clean fuel. The following procedure will only allow
filtered fuel to enter the fuel system.

g00516899
Illustration 36
(1) Select knob
g00516900
(2) Plunger Illustration 37
(1) Plug
1. Turn select knob (1) counterclockwise until the (2) Fuel filter
indicator is in line with the body of the priming
pump. 1. Remove plug (1) in order to fill fuel filter (2).
Ensure that air is able to vent from the fitting of
2. Unlock the plunger and operate the plunger until a the plug while the fuel filter is being filled. Clean
resistance is felt. A considerable number of pump up any spilled fuel immediately. Clean plug (1).
strokes may be required. Install plug (1).

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

Do not crank the engine continuously for more than
4. Turn select knob (1) clockwise until the indicator is 30 seconds. Allow the starting motor to cool for two
in line with the fuel outlet. minutes before cranking the engine again.
SEBU6164-08 71
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

2. Start the engine and immediately increase the

engine rpm to one half of the rated rpm. NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
3. Maintain the engine rpm until the engine operates clean the area around a fuel system component that
smoothly. will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
4. Reduce the engine rpm to low idle.
1. Close the main fuel supply valve.
i02927282

Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.

Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.

The primary filter/water separator also provides Illustration 38

g01453091
filtration in order to help extend the life of the (1) Element
secondary fuel filter. The element should be changed (2) Bowl
regularly. If a vacuum gauge is installed, the (3) Drain
primary filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg). 2. Remove element (1) from the element mounting
base while bowl (2) is attached.
Replace the Element 3. Dispose of the contents of the filter. Remove bowl
(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.

Fuel leaked or spilled onto hot surfaces or elec- 4. Remove the O-ring from the gland of the bowl.
trical components can cause a fire. To help pre- Clean the following components:
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. • Bowl
Clean up fuel spills immediately.
• O-ring
NOTICE • Mounting base
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Inspect the O-ring for damage and for
ing, adjusting and repair of the product. Be prepared to deterioration. Replace the O-ring, if necessary.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 5. Lubricate the O-ring with clean diesel fuel.
nent containing fluids.
6. Install bowl (2) on a new element. Tighten the
Refer to Special Publication, NENG2500, “Caterpillar bowl by hand. Do not use tools in order to tighten
Dealer Service Tool Catalog” for tools and supplies the bowl.
suitable to collect and contain fluids on Caterpillar
products. NOTICE
The primary filter/water separator may be prefilled with
Dispose of all fluids according to local regulations and fuel to avoid rough running/stalling of the engine due
mandates. to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts.
72 SEBU6164-08
Maintenance Section
Fuel System Secondary Filter - Replace

7. Lubricate the top seal of element (1) with clean 6. Clean the gasket sealing surface of the fuel filter
diesel fuel. The element may be filled with fuel at base. Ensure that all of the old gasket is removed.
this time. Install the new element on the mounting
base. Tighten the element by hand. 7. Apply clean diesel fuel to the new fuel filter gasket.

NOTICE NOTICE
The water separator is under suction during normal Do not fill the secondary fuel filter with fuel before in-
engine operation. Ensure that the vent plug is tight- stalling. The fuel would not be filtered and could be
ened securely to help prevent air from entering the fu- contaminated. Contaminated fuel will cause acceler-
el system. ated wear to fuel system parts.

8. Open the main fuel supply valve. 8. Install a new fuel filter, and tighten the fuel filter
until the gasket contacts the base.
9. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and check 9. Tighten the fuel filter by hand according to the
for leaks again. instructions that are shown on the fuel filter.

Detecting leaks is difficult while the engine is Do not overtighten the fuel filter.
running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel. 10. Lock the fuel priming pump (if equipped). Open
The air in the fuel can cause low power due to the fuel tank supply valve.
aeration of the fuel. If air enters the fuel, check the
components for overtightening or undertightening. 11. If the engine stalls, refer to the Operation and
Maintenance Manual, “Fuel System - Prime” topic
(Maintenance Section) for more information.
i01007602

Fuel System Secondary Filter - i04170131

Replace Fuel System Water Separator

SMCS Code: 1261-510-SE - Check/Drain
SMCS Code: 1263-535; 1263-543

Fuel leaked or spilled onto hot surfaces or elec-

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

2. Turn off the start switch, or disconnect the battery NOTICE

(starting motor) when maintenance is performed The water separator is not a filter. It separates water
on fuel filters. from the fuel.
3. Shut off the fuel tank supply valve to the engine. The engine should never be allowed to run with the
water level in the separator more than 1/2 full or en-
NOTICE gine damage may result.
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
A water separator is recommended. The water
separator should be installed between the fuel
4. Unlock the fuel priming pump (if equipped). This tank and the engine fuel inlet. Drain the water and
relieves any residual pressure in the fuel system. sediment from the water separator on a daily basis.

5. Remove the used fuel filter. Use a cloth, or use a

container to catch excess fuel.
SEBU6164-08 73
Maintenance Section
Fuel Tank Water and Sediment - Drain

i04363480

Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g01076474
Illustration 39
(1) Drain Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
NOTICE tools and supplies suitable to collect and contain fluids
Care must be taken to ensure that fluids are contained on Cat products.
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared Dispose of all fluids according to local regulations and
to collect the fluid with suitable containers before mandates.
opening any compartment or disassembling any com-
ponent containing fluids.
Fuel Tank
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication, Fuel quality is critical to the performance and to the
PECJ0003, “Cat Shop Supplies and Tools Catalog” for service life of the engine. Water in the fuel can cause
tools and supplies suitable to collect and contain fluids excessive wear to the fuel system. Condensation
on Cat products. occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
Dispose of all fluids according to local regulations and fuel system and the fuel returns to the fuel tank. This
mandates. causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
1. Open drain (1). Catch the draining water in a sources can help to eliminate water in the fuel.
suitable container. Dispose of the water properly.
Drain the Water and the Sediment
NOTICE
The water separator is under suction during normal Fuel tanks should contain some provision for draining
engine operation. Ensure that the drain valve is tight- water and draining sediment from the bottom of the
ened securely to help prevent air from entering the fuel fuel tanks.
system.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
2. Close drain (1). the drain valve.

Note: Failure to properly close the drain can allow air

into the system, which could have detrimental results
to performance.

Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
74 SEBU6164-08
Maintenance Section
Heat Exchanger - Inspect

Fill the fuel tank after operating the engine in • Increased coolant temperature
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The • Engine overheating
fuel expands as the fuel gets warm. The tank may
overflow. • Excessive pressure drop between the water inlet
and the water outlet
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel An operator that is familiar with the normal operating
supply pipe. Some fuel tanks use supply lines that temperature of the coolant can determine when
take fuel directly from the bottom of the tank. If the coolant temperature is out of the normal range.
the engine is equipped with this system, regular Inspection and maintenance of the heat exchanger
maintenance of the fuel system filter is important. are required if the engine is overheating.

Your Caterpillar dealer has the equipment and the

Fuel Storage Tanks trained personnel that are needed in order to measure
Drain the water and the sediment from the fuel the pressure drop across the heat exchanger.
storage tank during the following conditions:
The procedure for cleaning the heat exchanger is
similar to the procedure that is used for cleaning
• Weekly the aftercooler core. Refer to the Operation and
Maintenance Manual, “Aftercooler Core - Clean/Test”
• Oil change topic (Maintenance Section). For more information on
servicing the heat exchanger, consult your Caterpillar
• Refill of the tank dealer.
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel i04301694
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended. Hoses and Clamps -
If a bulk storage tank has been refilled or moved
Inspect/Replace
recently, allow adequate time for the sediment to
SMCS Code: 7554-040; 7554-510
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap Hoses and clamps must be inspected periodically
sediment. Filtering fuel that is pumped from the
in order to ensure safe operation and continuous
storage tank helps to ensure the quality of the fuel.
operation of the engine. Take proper safety
When possible, water separators should be used. precautions before inspecting or replacing hoses and
clamps.
i01057362
Note: Always use a board or cardboard when the
Heat Exchanger - Inspect engine components are checked for leaks. Leaking
fluid that is under pressure can cause serious
SMCS Code: 1379-040 injury or possible death. Leaks that are the size
of a pin hole are included. Refer to Operation and
The interval for the maintenance of the tube and Maintenance Manual, “General Hazard Information”
fin heat exchanger depends on the operating for more information.
environment of the vessel and on the operating time.
The sea water that is circulated through the heat
exchanger and the amount of operating time of the
Inspect the Hoses and the Clamps
vessel affects the following items:
Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which exhibits
• Cleanliness of the tubes of the heat exchanger any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
• Effectiveness of the heat exchanger system may result in a hazardous situation.
Operating in water that contains silt, sediment, salt,
algae, etc will adversely affect the heat exchanger • Hoses which are cracked
system. In addition, intermittent use of the vessel will
adversely affect the heat exchanger system. • Hoses which are soft

The following items indicate that the heat exchanger • Outer covering that is chafed or cut
may require cleaning:
SEBU6164-08 75
Maintenance Section
Hoses and Clamps - Inspect/Replace

• Exposed wire that is used for reinforcement Replace the Hoses and the Clamps
• Outer covering that is ballooning locally NOTICE
Care must be taken to ensure that fluids are contained
• Flexible part of the hose that is kinked or crushed during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
• Armoring that is embedded in the outer covering to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
• Hoses which exhibit signs of leakage which are not ponent containing fluids.
the result of loose couplings or clamps
Refer to Special Publication, NENG2500, “Cat Dealer
Inspect all clamps for the following conditions.
Service Tool Catalog” or refer to Special Publication,
Replace any clamp which exhibits signs of any of the
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
following conditions.
tools and supplies suitable to collect and contain fluids
on Cat products.
• Cracking
Dispose of all fluids according to local regulations and
• Looseness mandates.
• Damage
Cooling System
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.

Each installation application can be different. The

differences depend on the following factors: Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
• Type of hose stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Type of fitting material pressure cap slowly in order to relieve the pres-
sure.
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Personal injury can result from removing hoses or
Due to extreme temperature changes, the hose will fittings in a pressure system.
heat set. Heat setting causes hose clamps to loosen
which can result in leaks. A constant torque hose Failure to relieve pressure can cause personal in-
clamp will help to prevent loose hose clamps. jury.

Replace hoses that are cracked or soft. Replace Do not disconnect or remove hoses or fittings un-
hoses that show signs of leakage. Replace hoses til all pressure in the system has been relieved.
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace 1. Stop the engine.
hose clamps which are loose.
2. Allow the engine to cool.

3. Before servicing a coolant hose, slowly loosen the

filler cap for the cooling system in order to relieve
any pressure.

4. Remove the filler cap for the cooling system.

5. Drain the coolant from the cooling system to a

level that is below the hose that is being replaced.
Drain the coolant into a suitable clean container.
The coolant can be reused.

6. Remove the hose clamps.

76 SEBU6164-08
Maintenance Section
Hoses and Clamps - Inspect/Replace

7. Disconnect the old hose. Note: High-pressure fuel lines may be installed
between the high-pressure fuel pump and the fuel
8. Replace the old hose with a new hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the
9. Install hose clamps which have been inspected or high-pressure fuel lines with the engine or the starting
install new hose clamps. Refer to Specifications, motor in operation. Wait for 10 minutes after the
SENR3130, “Torque Specifications”, “Hose engine stops before you perform any service or repair
Clamps” for information about selecting and on high-pressure fuel lines. Waiting for 10 minutes
installing the proper hose clamps. will to allow the pressure to be purged.

10. Refill the cooling system. 1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap 2. Remove the hose clamps.
if the gaskets are damaged. Install the filler cap.
3. Disconnect the old hose.
12. Start the engine. Inspect the cooling system for
leaks. 4. Replace the old hose with a new hose.

Fuel System 5. Install hose clamps which have been inspected or

install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
Personal injury can result from removing hoses or
fittings in a pressure system. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Failure to relieve pressure can cause personal in- engine.
jury.
Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved.
7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel.

Contact with high pressure fuel may cause fluid 8. Start the engine. Inspect the fuel system for leaks.
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol- Lubrication System
low these inspection, maintenance and service in-
structions may cause personal injury or death.

NOTICE Hot oil and hot components can cause personal

Do not bend or strike high pressure lines. Do not in- injury. Do not allow hot oil or hot components to
stall bent or damaged lines, tubes or hoses. Repair contact the skin.
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 1. Drain the oil from the lubrication system to a level
ommended torque. that is below the hose that is being replaced.

2. Remove the hose clamps.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly 3. Disconnect the old hose.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis- 4. Replace the old hose with a new hose.
connected fuel system components.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
SEBU6164-08 77
Maintenance Section
Overhaul Considerations

6. Refill the lubrication system. Refer to this • Crankcase blowby is in excess of 2 cubic feet
Operation and Maintenance Manual, “Engine per hour per horsepower. Measure the crankcase
Oil Level - Check” in order to ensure that the blowby with an 8T-2700 Blowby Indicator .
lubrication system is filled with the proper amount
of engine oil. • Fuel consumption has increased.
7. Start the engine. Inspect the lubrication system • Loss of power has occurred.
for leaks.
The cylinder head must be removed in order to repair
Air System the piston, the ring, and the bore. After removing the
cylinder head, inspect the valves and the valve seats.
1. Remove the hose clamps. Repair the valve and the valve seats, if necessary.
Determine if any other components of the engine
2. Disconnect the old hose. should be inspected.

3. Replace the old hose with a new hose. Overhaul Options

4. Install hose clamps which have been inspected or Before Failure Overhaul
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose A planned overhaul before failure may be the best
Clamps” for information about selecting and value for the following reasons:
installing the proper hose clamps.
• Avoid costly unplanned downtime.
Note: The bellows and the V-clamps that are used
on the bellows should never be reused. • Reuse many original parts according to the
standards for reusable parts.
5. Start the engine. Inspect the air lines for leaks.
• Extend the engine's service life without the risk of
a major catastrophe due to engine failure.
i01081132

Overhaul Considerations • Attain the best cost/value relationship per hour of

extended life.
SMCS Code: 7595-043
After Failure Overhaul
The following items can increase the engine service
life before an overhaul is required: If a major engine failure occurs and the engine must
be removed from the hull, many options are available.
An overhaul should be performed if the engine block
• Use only lubricants that are recommended by or the crankshaft needs to be repaired.
Caterpillar.
If the engine block is repairable and/or the crankshaft
• Follow the recommended guidelines for is repairable, the overhaul cost should be between 40
maintenance.
percent and 50 percent of the cost of a new engine
with a similar exchange core.
• Use an S·O·S Oil Analysis to determine the
maximum interval for changing the oil filter and the
oil. This lower cost can be attributed to three aspects:

• Follow the rating definitions that are recommended • Specially designed Caterpillar engine features
for the engine.
• Caterpillar dealer exchange components
Repair of Piston, Ring, And Bore • Caterpillar Inc. remanufactured exchange
As An Indicator components

Investigate the piston, the ring, and the bore or Overhaul Recommendation
repair the piston, the ring, and the bore if one of the
following conditions occurs: To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar
• Oil consumption is in excess of 1 quart of oil dealer before the engine fails. This will provide you
per 60 gallons of fuel that is consumed. The oil with the best cost/value relationship.
consumption must not be caused by leakage.
78 SEBU6164-08
Maintenance Section
Overhaul Considerations

Note: Overhaul programs vary according to the Reduced engine efficiency and increased fuel
engine application and according to the dealer that consumption translates into higher operating costs.
performs the overhaul. Consult your Caterpillar Therefore, Caterpillar Inc. recommends repairing
dealer for specific information about the available out-of-spec parts or replacing out-of-spec parts.
overhaul programs and about overhaul services for
extending the engine life. Component Replacement
If an overhaul is performed without overhaul service Replace the following components during the
from your Caterpillar dealer, be aware of the following overhaul:
maintenance recommendations.
• Piston Rings
Rebuild or Exchange
• Thrust bearings
Inspect the following components according to the
instructions that are found in various Caterpillar • Main bearings
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are • Connecting rod bearings
needed for inspecting the engine parts.
• Gaskets and seals
• Cylinder head assembly
• Engine mounts
• Connecting rods
• Hoses
• Pistons
Inspection
• Turbocharger
Inspect the following components according to
• Oil pump the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
• Fuel ratio control Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
• Cam followers Parts”.

• Fuel Transfer pump • Camshaft

• Timing advance • Camshaft bearings
If the parts comply with the established inspection • Crankshaft
specifications that are expressed in the reusable
parts guideline, the parts should be reused. • Crankshaft vibration damper
Parts that are not within the established inspection • Gear train
specifications should be salvaged, repaired, or
replaced. Inspect the camshaft for damage to the journals and
the lobes. Inspect the camshaft bearings for signs of
Using out-of-spec parts can result in the following wear and/or for signs of fatigue.
problems:
Inspect the crankshaft for any of the following
• Unscheduled downtime conditions:

• Costly repairs • Deflection

• Damage to other engine parts • Damage to the journals
• Reduced engine efficiency • Bearing material that has seized to the journals
• Increased fuel consumption Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the rod bearings
and main bearings.
SEBU6164-08 79
Maintenance Section
Overhaul Considerations

Note: If the crankshaft or the camshaft are removed Refer to the Operation and Maintenance Manual,
for any reason, use the magnetic particle inspection “Aftercooler Core - Clean/Test” topic (Maintenance
process to check for cracks. Section) for the cleaning procedure.

Replace the crankshaft vibration damper if any of the Obtain Coolant Analysis
following conditions are found:
The concentration of supplemental coolant additive
• Engine failure due to a broken crankshaft (SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further
• Excessive wear of the front main bearing coolant analysis is recommended when the engine
is overhauled.
• Excessive wear of the gear train that is not caused
by a lack of lubrication For example, considerable deposits are found in the
water jacket areas on the external cooling system, but
• Visconic damper that is dented, cracked, or leaking the concentrations of coolant additives were carefully
maintained. The coolant water probably contained
• Visconic damper that is discolored from heat minerals that were deposited on the engine over time.

• Rubber damper that is deteriorated and cracked A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
• Rubber damper with slippage of the outer ring cooling system. A full water analysis can be obtained
by consulting your local water utility company or
Inspect the gear train for the following conditions: an agricultural agent. Private laboratories are also
available for water analysis.
• Worn gear teeth
Caterpillar Inc. recommends an S·O·S Coolant
• Unusual fit Analysis (Level 2).

• Unusual wear S·O·S Coolant Analysis (Level 2)

Testing An S·O·S Coolant Analysis (Level 2) is a

comprehensive coolant analysis which completely
Test the following components during the overhaul: analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2) provides
• Fuel injection nozzles the following information:

• Fuel injection pump • Complete S·O·S Coolant Analysis (Level 1)

• Governor • Visual inspection of properties
Testing the fuel system during the overhaul will • Identification of metal corrosion
ensure that your engine operates at peak efficiency.
Your Caterpillar dealer can provide these services • Identification of contaminants
and components in order to ensure that your
fuel system is operating within the appropriate • Identification of built up impurities (corrosion and
specifications. scale)

Cleaning S·O·S Coolant Analysis (Level 2) provides a report of

the results of both the analysis and the maintenance
The following components should be cleaned and recommendations that are based on the analysis.
pressure tested during the overhaul:
For more information about coolant analysis, consult
• Engine oil cooler your Caterpillar dealer.

• Marine gear oil cooler

• Aftercooler
• Heat exchanger
80 SEBU6164-08
Maintenance Section
Sea Water Strainer - Clean/Inspect

i00905687 i01057899

Sea Water Strainer - Turbocharger - Inspect

Clean/Inspect SMCS Code: 1052-040
SMCS Code: 1371-040; 1371-070
Periodic cleaning is recommended for the
turbocharger compressor (inlet side). The following
The sea water strainer must be clean in order to
items collect in the turbocharger compressor housing
allow proper engine cooling. Check the sea water
since the fumes from the crankcase travel through
strainer for plugging. Inspect the sea water strainer the inlet air: oil, by-products from oil, and by-products
more frequently if the vessel is being operated
from combustion. The buildup reduces boost and air
in water which is shallow or dirty. Refer to the
flow. The buildup also contributes to loss of engine
OEM recommendations for more information about power, increased black smoke, and overall loss of
inspecting and cleaning the sea water strainer.
engine efficiency.
Ensure that the auxiliary water pump is primed and
that the suction line is open. Cleaning and Inspecting
1. Remove the sea water strainer and clean the 1. Remove the air inlet piping from the turbocharger
screen. Remove any dirt and debris. and remove the compressor housing from the
turbocharger.
2. Install the sea water strainer. Fill the sea water
strainer and the suction line for the auxiliary water 2. Clean the turbocharger compressor housing with
pump with water. Hydrosolv Liquid Cleaners and a hard bristle
brush.
i04237689 3. Clean the turbocharger compressor wheel and
clean the backplate assembly with 4C-4079
Transmission Oil Level - Check Brake and Electric Cleaner.
SMCS Code: 3030-535-FLV
i00893389
Check the marine transmission oil level according to
the instructions that are provided by the OEM of the Walk-Around Inspection
transmission or the OEM of the vessel.
SMCS Code: 1000-040
For the lubrication requirements of the transmission,
refer to the recommendations on the nameplate or Inspect the Engine for Leaks and
the service information for the transmission.
for Loose Connections
Marine Transmission Operation, A walk-around inspection should only take a few
Maintenance, Warranty, and Parts minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
Support
For maximum engine service life, make a thorough
For information on maintenance and operation of the inspection of the engine compartment before starting
marine transmission, consult your Cat dealer and/or the engine. Look for items such as oil leaks or coolant
the OEM dealer of the transmission.
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
All support for the warranty of the transmission will be
the responsibility of the OEM. All parts support for the
transmission will be the responsibility of the OEM. • The guards must be in the proper place. Repair
damaged guards or replace missing guards.
This parts support includes both the installation of
parts and the resolution of any service problems.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
SEBU6164-08 81
Maintenance Section
Water Pump - Inspect

• Inspect the wiring and the wiring harnesses for

NOTICE loose connections and for worn wires or frayed
For any type of leak (coolant, lube, or fuel) clean up the wires.
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels • Inspect the ground strap for a good connection and
more often than recommended until the leak is found for good condition.
or fixed, or until the suspicion of a leak is proved to be
unwarranted. • Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte level
NOTICE of the batteries, unless the engine is equipped with
Accumulated grease and/or oil on an engine or deck is a maintenance free battery.
a fire hazard. Remove this debris with steam cleaning
or high pressure water. • Check the condition of the gauges. Replace any
gauges which are cracked or any gauges that can
not be calibrated.
• Ensure that cooling lines are properly clamped and
that cooling lines are tight. Check for leaks. Check
the condition of all pipes. i03543200

• Check the marine transmission oil level. Refer to Water Pump - Inspect
the OEM specification for the marine transmission
or refer to the OEM specification for the vessel. SMCS Code: 1361-040

• Inspect the water pumps for coolant leaks. A failed water pump might cause severe engine
overheating problems that could result in the following
Note: The water pump seal is lubricated by coolant conditions:
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and • Cracks in the cylinder head
the parts contract.
• A piston seizure
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of • Other potential damage to the engine
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the A failed water pump might cause severe engine
engine or consult your Caterpillar dealer. overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
• Inspect the lubrication system for leaks at the front damage to the engine.
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover. Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
• Inspect the fuel system for leaks. Look for loose the water pump seals. Refer to two articles in the
fuel line clamps. Disassembly and Assembly Manual, “Water Pump
- Disassemble and Water Pump - Assemble” for
• Inspect the piping for the air inlet system and the the disassembly and assembly procedure. If it is
elbows for cracks and for loose clamps. necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
• Inspect the alternator belt and the accessory drive “Water Pump - Remove and Water Pump - Install”.
belts for cracks, breaks or other damage.
Inspect the water pump for wear, cracks, pin holes
Belts for multiple groove pulleys must be replaced as and proper operation. Refer to the Parts Manual
matched sets. If only one belt is replaced, the belt will for the correct part numbers for your engine or
carry more load than the belts that are not replaced. consult your Caterpillar dealer if repair is needed or
The older belts are stretched. The additional load on replacement is needed.
the new belt could cause the belt to break.

• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
82 SEBU6164-08
Maintenance Section
Zinc Rods - Inspect/Replace

i01007424

Zinc Rods - Inspect/Replace

SMCS Code: 1388-040; 1388-510

Corrosion in sea water circuits can result in premature

deterioration of cooling system components, leaks,
and possible cooling system contamination. The
corrosion may be caused by the lack of zinc rods in
the sea water system.

Zinc rods are inserted in the sea water cooling system

of the engine in order to help prevent the corrosive
oxidation that is caused by sea water. The reaction
g00481100
of the zinc to the sea water causes the zinc rods to Illustration 40
oxidize rather than the cooling system components.
Rapid deterioration of zinc rods may indicate b. Tap the zinc rod lightly with a hammer. If the
the presence of uncontrolled electrical currents zinc rod flakes, install a new zinc rod.
from improperly installed electrical attachments or
improperly grounded electrical attachments. 3. If the zinc rod will be reused, scrape the layer of
oxidation from the zinc rod before installation. The
The zinc rods must be inspected at the proper layer of oxidation reduces the effectiveness of the
intervals. The zinc rods must be replaced when zinc rod.
deterioration occurs.
Replace the Zinc Rods
Inspect the Zinc Rods
1. Unscrew the old zinc rod from the plug.
The zinc rods are red for easy identification. Table
15 shows the locations of the zinc rods and the If not enough material remains or the zinc rod has
quantities of the zinc rod: broken off, drill the old zinc rod from the plug.

Table 15 2. Clean the plug.

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. Illustration 41

g00480345

(1) Shoulder of the zinc rod

2. Inspect the zinc rod. (2) Threads of the zinc rod
(3) External threads of the plug
Ensure that the zinc rod will remain effective until
the next scheduled inspection. Note: DO NOT apply adhesive or sealant to threads
(2) of the zinc rod.
a. If the zinc rod has deteriorated excessively,
install a new zinc rod. 3. Apply 9S-3263 Thread Lock Compound to
shoulder (1) of a new zinc rod. Apply the
compound ONLY to the shoulder of the zinc rod.
Install the zinc rod onto the plug.
SEBU6164-08 83
Maintenance Section
Zinc Rods - Inspect/Replace

4. Coat external threads (3) of the plug with 5P-3413

Pipe Sealant. Install the zinc rod. Refer to the
Operation and Maintenance Manual, “Torque
Specifications” topic (Maintenance Section).