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3116 and 3126 Marine Engines - Maintenance - Safety

1. 69 Heat Exchanger Inspect iesene 74 Every 91 000 L 24 000 US gal of Fuel or 3000 Service Hours or 2 Years Coolant Temperature Regulator Replace 59 Overhaul Overhaul Considerations sssuusse 77 52 Maintenance Section Aftercooler Core Clean Test SEBU6164 08 101089688 Aftercooler Core Clean Test SMCS Code 1064 070 1064 081 1 Remove the core Refer to the Service Manual for the procedure 2 Turn the aftercooler core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of hot Hydrosolv 100 liquid cleaner at a concentration of 30 and at a temperature of 66 to 82 C 150 to 180 F Table 11 lists the recommended Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 11 Hydrosolv Liquid Cleaners Container 4 L 1 US gal Description 1U 8804 Hydrosolv 100 1U 5492 Hydrosolv 100 19 L 5 US gal 8T 7571 Hydrosolv 100 208 L 55 US gal 1 Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of th
2. 2 Remove breather assembly 2 and seal 3 3 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 4 Install a breather element that is clean and dry Install seal 3 and breather assembly 2 5 Install the hose Install hose clamp 1 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torque 102456872 Engine Mounts Inspect SMCS Code 1152 040 1152 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to Special Publication SENR3130 Torque Specifications for the recommended torques Refer to the OEM recommendations for more information 101007363 Engine Oil Level Check SMCS Code 1348 535 FLV Check the oil level after the engine has stopped This maintenance procedure must be performed on a level surface rom RR C ADD FULL 5 900110310 Illustration 31 Y ADD mark X FULL mark 1 Maintain the oil level between the ADD mark Y and the FULL mark X on the oil level gauge Do not fill the crankcase above FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause y
3. Inspect Replace SMCS Code 7554 040 7554 510 Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death Leaks that are the size of a pin hole are included Refer to Operation and Maintenance Manual General Hazard Information for more information Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions Replace any hose which exhibits any of the following conditions Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation e Hoses which are cracked e Hoses which are soft e Outer covering that is chafed or cut SEBU6164 08 75 Maintenance Section Hoses and Clamps Inspect Replace e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering e Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps Inspect all clamps for the following conditions Replace any clamp which exhibits signs of any of the following conditions e Cracking e Loo
4. 2 Inspect the zinc rod Ensure that the zinc rod will remain effective until the next scheduled inspection a If the zinc rod has deteriorated excessively install a new zinc rod Illustration 40 g00481100 b Tap the zinc rod lightly with a hammer If the zinc rod flakes install a new zinc rod 3 If the zinc rod will be reused scrape the layer of oxidation from the zinc rod before installation The layer of oxidation reduces the effectiveness of the zinc rod Replace the Zinc Rods 1 Unscrew the old zinc rod from the plug If not enough material remains or the zinc rod has broken off drill the old zinc rod from the plug 2 Clean the plug g00480345 Illustration 41 1 Shoulder of the zinc rod 2 Threads of the zinc rod 3 External threads of the plug Note DO NOT apply adhesive or sealant to threads 2 of the zinc rod 3 Apply 98 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
5. 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 Operation and Maintenance Manual Engine Oil Level Check in order to ensure that the lubrication system is filled with the proper amount of engine oil 7 Start the engine Inspect the lubrication system for leaks Air System 1 Remove the hose clamps 2 Disconnect the old hose 3 Replace the old hose with a new hose 4 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 Note The bellows and the V clamps that are used on the bellows should never be reused 5 Start the engine Inspect the air lines for leaks 101081132 Overhaul Considerations SMCS Code 7595 043 The following items can increase the engine service life before an overhaul is required e Use only lubricants that are recommended by Caterpillar e Follow the recommended guidelines for maintenance e Use an S O S Oil Analysis to determine the maximum interval for changing the oil filter and the oil e Follow the rating definitions that are recommended for the engine Repair of Piston Ring And Bore As An Indicator Investigate the piston the ring and the
6. Specifications for more information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 5 Fill the cooling system with a mixture of clean water and Cat Fast Acting Cooling System Cleaner 6 Choose 1 of the following options e Add 0 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity e For cooling systems with heavy deposits or plugging add 0 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity 7 Install the cooling system filler cap 8 Start and run the engine at low idle for a minimum of 30 minutes For cooling systems with heavy deposits or plugging run the engine for 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 9 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water If equipped be sure to flush t
7. 1 Year Auxiliary Water Pump Rubber Impeller Inspect aai aeter etti sce ee ad dade ated 52 Battery Electrolyte Level Check 53 Belts Inspect Adjust Replace 53 Coolant Sample Level 1 Obtain 58 Cooling System Supplemental Coolant Additive SCA Test Add sssssssssssssss 60 Engine Crankcase Breather Clean 64 Engine Oil Sample Obtain ssssse 66 Engine Oil and Filter Change 67 Fuel System Primary Filter Water Separator Element Replace sss 71 Fuel System Secondary Filter Replace 72 Fuel Tank Water and Sediment Drain 73 Hoses and Clamps Inspect Replace 74 Sea Water Strainer Clean Inspect 80 Water Pump Inspect sessssssessesss 81 Every 30 000 L 8000 US gal of Fuel or 1000 Service Hours or 2 Years Aftercooler Core Clean Test ssssss 52 Engine Protective Devices Check 68 Engine Speed Timing Sensor Clean Inspect 69 Turbocharger Inspect ssseeeess 80 Every 60 000 L 16 000 US gal of Fuel or 2000 Service Hours Engine Mounts Inspect n 64 Engine Valve Lash Check sssssss 69 Fuel Injection Timing Check
8. 6 14 inch 137 mm 5 39 inch 14 degrees 151 mm 5 95 inch 133 mm 5 24 inch 13 degrees 148 mm 5 83 inch 129 mm 5 08 inch 12 degrees 144 mm 5 67 inch 125 mm 4 92 inch 11 degrees 139 mm 5 47 inch 119 mm 4 69 inch 10 degrees 136 mm 5 35 inch 115 mm 4 53 inch 9 degrees 130 mm 5 12 inch 114 mm 4 49 inch 8 degrees 128 mm 5 04 inch 113 mm 4 45 inch 7 degrees 121 mm 4 76 inch 114 mm 4 49 inch 6 degrees 117 mm 4 61 inch 107 mm 4 21 inch 5 degrees 113 mm 4 45 inch 100 mm 3 94 inch 4degrees 112 mm 4 41 inch 93 mm 3 66 inch 3 degrees 111 mm 4 37 inch 88 mm 3 47 inch 2degrees 109 mm 4 29 inch 81 mm 3 19 inch 1 degree 102 mm 4 02 inch 76 mm 2 99 inch 0 degrees 96 mm 3 78 inch 70 mm 2 76 inch 1 The angle indicates the number of degrees that the front of the engine is raised 66 Maintenance Section Engine Oil Sample Obtain SEBU6164 08 Table 14 Engine Oil Level Gauge 4KG05783 UP 1SK01725 UP 8NM01466 UP 6SR1 UP 1ZJ1 UP 6MK1 UP Angle FULL Mark X ADD Mark Y 10 degrees 125 mm 4 92 inch 114 mm 4 49 inch 9 degrees 124 mm 4 89 inch 106 mm 4 17 inch 8 degrees 122 mm 4 80 inch 102 mm 4 02 inch 7 degrees 120 mm 4 72 inch 96 mm 3 78 inch 6degrees 115 mm 4 53 inch 89 mm 3 50 inch 5 degrees 110 mm 4 33 inch
9. 81 mm 3 19 inch 4degrees 101 mm 3 98 inch 71 mm 2 80 inch 3 degrees 94 mm 3 70 inch 66 mm 2 60 inch 2 degrees 90 mm 3 54 inch 59 mm 2 32 inch 1 degree 82 mm 3 23 inch 52 mm 2 05 inch 0 degrees 76 mm 2 99 inch 46 mm 1 81 inch 1 degree 65 mm 2 56 inch 39 mm 1 54 inch 2degrees 59 mm 2 32 inch 33 mm 1 30 inch 3 degrees 53 mm 2 09 inch 26 mm 1 02 inch 4 degrees 46 mm 1 81 inch 20 mm 0 79 inch 5 degrees 39 mm 1 54 inch 12 mm 0 47 inch 1 The angle indicates the number of degrees that the front of the engine is raised A negative angle indicates the number of degrees that the front of the engine is lowered Verifying the Calibration of the Oil Level Gauge Caterpillar recommends verifying the calibration of the oil level gauge at the first oil change Use the following procedure to verify the FULL mark on the oil level gauge Note The vessel must be level in order to perform this procedure 1 Operate the engine until normal operating temperature is achieved Stop the engine Remove one of the drain plugs for the engine crankcase Allow the engine oil to drain 2 Remove the used engine oil filter Install the new engine oil filter Install the crankcase drain plug and tighten the crankcase drain plug 3 Add 25 L 26 5 qt of the recommended oil grade and weight of engine oil to the crankcase Note The engine may be equipped with auxili
10. Close the main fuel supply valve OO Illustration 38 g01453091 1 Element 2 Bowl 3 Drain 2 Remove element 1 from the element mounting base while bowl 2 is attached 3 Dispose of the contents of the filter Remove bowl 2 from element 1 The bowl is reusable Do not discard the bowl Dispose of the used element 4 Remove the O ring from the gland of the bowl Clean the following components e Bowl e O ring e Mounting base Inspect the O ring for damage and for deterioration Replace the O ring if necessary 5 Lubricate the O ring with clean diesel fuel 6 Install bowl 2 on a new element Tighten the bowl by hand Do not use tools in order to tighten the bowl NOTICE The primary filter water separator may be prefilled with fuel to avoid rough running stalling of the engine due to air Do not fill the secondary filter with fuel before installation The fuel would not be filtered and could be contaminated Contaminated fuel will cause accel erated wear to fuel system parts 72 Maintenance Section Fuel System Secondary Filter Replace SEBU6164 08 7 Lubricate the top seal of element 1 with clean diesel fuel The element may be filled with fuel at this time Install the new element on the mounting base Tighten the element by hand NOTICE The water separator is under suction during normal engine operation Ensure that the vent plug is tight ened securely t
11. If replacing only the water temperature regulator only drain the coolant to a level that is below the water temperature regulator housing Refer to two articles in the Disassembly and Assembly Manual Water Temperature Regulator Remove and Water Temperature Regulator Install for the replacement procedure or consult your Cat dealer 102456600 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Note Test the concentration of the Supplemental Coolant Additive SCA or test the SCA concentration as part of an S O S Coolant Analysis Test for SCA Concentration Coolant and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Use the 8T 5296 Coolant Conditioner Test Kit or use the 4C 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for more information Water and SCA NOTICE Do not exceed the recommended eight percent sup plemental coolant additive concentration Test the concentration of the SCA with the 8T 5296 Coolant Conditioner Test Kit Refer to the Special Publication SEBU6251 Caterpillar Commercial Diesel Engine
12. bore or repair the piston the ring and the bore if one of the following conditions occurs e Oil consumption is in excess of 1 quart of oil per 60 gallons of fuel that is consumed The oil consumption must not be caused by leakage e Crankcase blowby is in excess of 2 cubic feet per hour per horsepower Measure the crankcase blowby with an 8T 2700 Blowby Indicator e Fuel consumption has increased Loss of power has occurred The cylinder head must be removed in order to repair the piston the ring and the bore After removing the cylinder head inspect the valves and the valve seats Repair the valve and the valve seats if necessary Determine if any other components of the engine should be inspected Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons Avoid costly unplanned downtime Reuse many original parts according to the standards for reusable parts Extend the engine s service life without the risk of a major catastrophe due to engine failure Attain the best cost value relationship per hour of extended life After Failure Overhaul If a major engine failure occurs and the engine must be removed from the hull many options are available An overhaul should be performed if the engine block or the crankshaft needs to be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be be
13. cooler e Marine gear oil cooler e Aftercooler Heat exchanger Refer to the Operation and Maintenance Manual Aftercooler Core Clean Test topic Maintenance Section for the cleaning procedure Obtain Coolant Analysis The concentration of supplemental coolant additive SCA should be checked regularly with test kits or with S O S Coolant Analysis Level 1 Further coolant analysis is recommended when the engine is overhauled For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals that were deposited on the engine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis can be obtained by consulting your local water utility company or an agricultural agent Private laboratories are also available for water analysis Caterpillar Inc recommends an S O S Coolant Analysis Level 2 S O S Coolant Analysis Level 2 An S O S Coolant Analysis Level 2 is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level 2 provides the following information e Complete S O S Coolant Analysis Level 1 e Visual inspection of properties e Identification of metal corrosion e dentific
14. engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 64 Maintenance Section Engine Crankcase Breather Clean SEBU6164 08 101007514 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE Perform this maintenance with the engine stopped If the crankcase breather is not maintained on a regular basis the crankcase breather will become plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage e le 00516808 Illustration 30 1 Hose clamp 2 Breather assembly 3 Seal 1 Loosen hose clamp 1 and remove the hose from breather assembly 2
15. in order to close the drain valve If the engine is not equipped with a drain valve remove the oil drain plug in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Gp Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine 68 Maintenance Section Engine Protective Devices Check SEBU6164 08 Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items
16. main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 33 900103713 Typical filter mounting base and filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations for more information NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with
17. perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately SEBU6164 08 69 Maintenance Section Engine Speed Timing Sensor Clean Inspect Engine Speed Timing Sensor Clean Inspect Magnetic Pick ups SMCS Code 1905 040 1905 070 1907 040 1907 070 Illustration 34 900293335 Typical example 1 Magnetic pickup 2 Flywheel housing 4 8 e EL as M o g00293337 Illustration 35 Typical magnetic pickup 1 Remove magnetic pickup from flywheel housing Check the condition of the end of the magnetic pickup Check for signs of wear and contaminants 2 Clean the metal shavings and other debris from the face of the magnet 3 Install the magnetic pickup and adjust the magnetic pickup Contact your Cat dealer for further information 104242309 Engine Valve Lash Check SMCS Code 1105 535 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train componen
18. procedure 74 Maintenance Section Heat Exchanger Inspect SEBU6164 08 Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 101057362 Heat Exchanger Inspect SMCS Code 1379 040 The interval for the maintenance of the tube and fin heat exchanger depends on th
19. remove any debris 2 Close the drain valve 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 NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve 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 Maintenance Section Coolant Change SEBU6164 08 Systems Filled with Cat DEAC Conventional Coolant which does not Meet the Cat EC 1 Requirements or Supplemental Coolant Additive SCA and Water 3 Flush the cooling system with clean water in order to remove any debris 4 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Specifications Manual SENR3130 Torque
20. 2633320 Typical air cleaner element 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 Replacing the Air Cleaner Element Note Replace an old air cleaner element with a new air cleaner element after the old element has been cleaned six times 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 Illustration 28 902633322 Do not use paint a waterproof cover or plastic as a protective covering for storage An air flow restriction may result To protect against dirt and damage wrap the air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the air cleaner element into a box for storage For identification mark the o
21. Fluids Recommendations for more information S O S Coolant Analysis S O S coolant samples can be analyzed at your Caterpillar dealer S O S Coolant Analysis is a program that is based on periodic samples Level 1 Level 1 is a basic analysis of the coolant The following items are tested SEBU6164 08 61 Maintenance Section Engine Air Cleaner Element Single Element Inspect Clean Replace Glycol Concentration e Concentration of SCA e pH e Conductivity The results are reported and recommendations are made according to the results Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S O S Coolant Analysis Level 2 This level coolant analysis is recommended when the engine is overhauled Refer to this Operations and Maintenance Manual Overhaul Considerations for further information Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both
22. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR s LL 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 104871889 Maintenance Interval Schedule SMCS Code 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous inte
23. SEBU6164 08 73 Maintenance Section Fuel Tank Water and Sediment Drain Illustration 39 g01076474 1 Drain 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 Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Open drain 1 Catch the draining water in a suitable container Dispose of the water properly NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system 2 Close drain 1 104363480 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp 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
24. ace the components which are worn or damaged Use the proper repair kit for the pump Refer to the Disassembly and Assembly Manual for more information on servicing the auxiliary water pump 100993589 Battery Recycle SMCS Code 1401 005 1401 510 1401 535 1401 561 1401 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier SEBU6164 08 53 Maintenance Section Battery Electrolyte Level Check e An authorized battery collection facility e Recycling facility 102601752 Battery Electrolyte Level Check SMCS Code 1401 535 FLV When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery cas
25. al that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the rod bearings and main bearings SEBU6164 08 79 Maintenance Section Overhaul Considerations Note If the crankshaft or the camshaft are removed for any reason use the magnetic particle inspection process to check for cracks Replace the crankshaft vibration damper if any of the following conditions are found e Engine failure due to a broken crankshaft e Excessive wear of the front main bearing Excessive wear of the gear train that is not caused by a lack of lubrication Visconic damper that is dented cracked or leaking Visconic damper that is discolored from heat e Rubber damper that is deteriorated and cracked e Rubber damper with slippage of the outer ring Inspect the gear train for the following conditions e Worn gear teeth e Unusual fit e Unusual wear Testing Test the following components during the overhaul e Fuel injection nozzles e Fuel injection pump e Governor Testing the fuel system during the overhaul will ensure that your engine operates at peak efficiency Your Caterpillar dealer can provide these services and components in order to ensure that your fuel system is operating within the appropriate specifications Cleaning The following components should be cleaned and pressure tested during the overhaul Engine oil
26. 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 filtration in order to help extend the life of the secondary fuel filter The element should be changed regularly If a vacuum gauge is installed the primary filter water separator should be changed at 50 to 70 kPa 15 to 20 inches Hg Replace the Element Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 1
27. ant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling System filler cap 2 If necessary drain enough coolant from the cooling system in order to add the Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for the cooling system capacity Refer to this Operation and Maintenance Manual Refill Capacities for the coolant capacity 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap For further information refer to this Operation and Maintenance Manual Fluid Recommendations 104550124 Coolant Level Check SMCS Code 1395 082 Check the coolant lev
28. ary engine oil filters which require additional oil Refer to the OEM specifications NOTICE To help prevent crankshaft or bearing damage crank engine to fill all filters before starting Do not crank engine for more than 30 seconds NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again Turbocharger if equipped damage can result if the engine rpm is not kept low until the engine oil light gauge verifies the oil pressure is sufficient 4 Start the engine Ensure that the lubrication system and the new engine oil filter is filled Inspect the lubrication system for leaks 5 Stop the engine and allow the engine oil to drain into the engine crankcase for approximately ten minutes 6 Check the engine oil level If necessary use a marking pen in order to correct the FULL mark X 104237495 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In
29. ation of contaminants e Identification of built up impurities corrosion and scale S O S Coolant Analysis Level 2 provides a report of the results of both the analysis and the maintenance recommendations that are based on the analysis For more information about coolant analysis consult your Caterpillar dealer 80 Maintenance Section Sea Water Strainer Clean Inspect SEBU6164 08 100905687 Sea Water Strainer Clean Inspect SMCS Code 1371 040 1371 070 The sea water strainer must be clean in order to allow proper engine cooling Check the sea water strainer for plugging Inspect the sea water strainer more frequently if the vessel is being operated in water which is shallow or dirty Refer to the OEM recommendations for more information about inspecting and cleaning the sea water strainer Ensure that the auxiliary water pump is primed and that the suction line is open 1 Remove the sea water strainer and clean the Screen Remove any dirt and debris 2 Install the sea water strainer Fill the sea water strainer and the suction line for the auxiliary water pump with water 104237689 Transmission Oil Level Check SMCS Code 3030 535 FLV Check the marine transmission oil level according to the instructions that are provided by the OEM of the transmission or the OEM of the vessel For the lubrication requirements of the transmission refer to the recommendations on the nameplate or the service infor
30. cap Replace the filler cap if the gaskets are damaged Install the filler cap 12 Start the engine Inspect the cooling system for leaks Fuel System Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Note High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors High pressure fuel lines are constantly charged with high pressure Do not check the high pressure fuel lines with the engine or the starting motor in operation Wait for 10 minutes after th
31. com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve 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
32. cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration 25 900103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and inspect the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 Inspect the cooling system for leaks 104333559 Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and corrosion The analysis also tests the ability of the coolant to protect the engine from boiling and freezing S O S Systems Coolant Analysis can be done at your Cat dealer Cat S O S coolant analysis is the best way to monitor the condition of your coolant and your cooling system S O S coolant analysis is a program that is based on periodic samples Note Obtaining a Coolant Sample Level 1 is 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 Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any of the fol
33. e engine stops before you perform any service or repair on high pressure fuel lines Waiting for 10 minutes will to allow the pressure to be purged 1 Drain the fuel from the fuel system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 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 6 Carefully inspect the engine for any spilled fuel Make sure that no fuel remains on or close to the engine Note Fuel must be added to the fuel system ahead of the fuel filter 7 Refill the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime for information about priming the engine with fuel 8 Start the engine Inspect the fuel system for leaks Lubrication System Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 1 Drain the oil from the lubrication system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications
34. e aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the core Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer 104601721 Auxiliary Water Pump Rubber Impeller Inspect SMCS Code 1371 040 Impellers and seals require periodic inspection Impellers have a service life that is limited The service life depends on the engine operating conditions Inspect the components more frequently when the pump is exposed to debris sand or other abrasive materials Inspect the components if the pump is operating at a differential pressure of more than 103 kPa 15 psi Check the following components for wear or damage e Bearings e Impeller e Seals e Wear plate e Key If wear or damage is found repl
35. e operating environment of the vessel and on the operating time The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items e Cleanliness of the tubes of the heat exchanger e Effectiveness of the heat exchanger system Operating in water that contains silt sediment salt algae etc will adversely affect the heat exchanger system In addition intermittent use of the vessel will adversely affect the heat exchanger system The following items indicate that the heat exchanger may require cleaning Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range Inspection and maintenance of the heat exchanger are required if the engine is overheating Your Caterpillar dealer has the equipment and the trained personnel that are needed in order to measure the pressure drop across the heat exchanger The procedure for cleaning the heat exchanger is similar to the procedure that is used for cleaning the aftercooler core Refer to the Operation and Maintenance Manual Aftercooler Core Clean Test topic Maintenance Section For more information on servicing the heat exchanger consult your Caterpillar dealer 104301694 Hoses and Clamps
36. e with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 101492654 Battery or Battery Cable Disconnect SMCS Code 1401 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal at the battery that goes to the start switch Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system r
37. ear of the cylinder liner A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface 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 Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Note
38. efore cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Inspect the filter material for rips and for tears Discard any damaged air cleaner elements There are two common methods that are used to clean air cleaner elements Pressurized air e 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 The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded Illustration 26 902633318 Typical air cleaner element Note When the air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose towards the inside of the element along the length of the filter to help prevent damage to the paper pleats Do not aim the stream of air directly at the air cleaner element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is a good method for cleaning air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Inspecting the Air Cleaner Element Illustration 27 90
39. el when the engine is stopped and cool Engines That Are Equipped with a Coolant Recovery Tank To oj olo To oT uem Illustration 24 900103638 1 Filler cap 2 COLD FULL mark 3 LOW ADD mark 1 Observe the coolant level in the coolant recovery tank Maintain the coolant level to COLD FULL mark 2 on the coolant recovery tank 2 Loosen filler cap 1 slowly in order to relieve any pressure Remove the filler cap 58 Maintenance Section Coolant Sample Level 1 Obtain SEBU6164 08 3 Pour the proper coolant mixture into the tank Refer to this Operation and Maintenance Manual Refill Capacities for information about coolants Do not fill the coolant recovery tank above COLD FULL mark 2 4 Clean filler cap 1 and the receptacle Reinstall the filler cap and inspect the cooling system for leaks Note The coolant will expand as the coolant heats up during normal engine operation The additional volume will be forced into the coolant recovery tank during engine operation When the engine is stopped and cool the coolant will return to the engine Engines That Are Not Equipped with a Coolant Recovery Tank Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the
40. epairs Reverse the steps in order to reconnect all of the cables 104745128 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspection Belt tension should be checked initially between the first 20 to 40 hours of engine operation Check the belt tension Refer to the Operation and Maintenance Manual Maintenance Interval Schedule topic Maintenance Section for the proper intervals To check the belt tension apply 110 N 25 Ib ft of force midway between the pulleys A correctly adjusted belt will deflect 9 mm 0 35 inch to 15 mm 0 59 inch To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged 54 Maintenance Section Coolant Change SEBU6164 08 For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating If the belts are too tight unnecessary stresses are placed on the pulley bearings and on the belts 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 d
41. er to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Stop the engine and allow the engine to cool Ensure that the engine will not start when the cooling system is drained 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 3 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Note If equipped be sure to drain the heater and any related supply and return lines Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Cat dealer or consult Cat Dealer Service Tool Group Inside USA 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL International 1 309 578 7372 Flush Systems Filled with Cat ELC Cat ELI ora Conventional Coolant that Meets the Cat EC 1 Requirements and the Standards of ASTM D6210 1 Flush the cooling system with clean water in order to
42. fications 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 104538352 Coolant Change SMCS Code 1350 044 1352 1395 044 1395 Refer to this Operation and Maintenance Manual Fluid Recommendations for the correct intervals for changing the coolant Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently SEBU6164 08 55 Maintenance Section Coolant Change e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Drain the Cooling System Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 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 Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or ref
43. formed sooner if a problem is suspected or identified Every 250 hours Yearly Optional Yearly Note Check the SCA Supplemental Coolant Additive of the conventional coolant at every oil change or at every 250 hours Perform this check at the interval that occurs first Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Cat dealer NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Submit the sample for Level 1 analysis Note Level 1 results may indicate a need for Level 2 Analysis 104638756 Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 An S O S Coolant Analysis Level 2 is a comprehensive chemical evaluation of the coolant This analysis is also a check of the overall condition of the cooling system The S O S Coolant Analysis Level 2 has the following features Full c
44. h a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Cat dealer has the proper air cleaner elements for your application Consult your Cat dealer for the correct air cleaner element Check the precleaner if equipped daily for 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 element The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Cleaning the Air Cleaner Element Use a clean air cleaner element while dirty elements are being cleaned 62 Maintenance Section SEBU6164 08 Engine Air Cleaner Element Single Element Inspect Clean Replace NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the air cleaner elements b
45. hat are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked or any gauges that can not be calibrated 103543200 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed 82 Maintenance Section Zinc Rods Ins
46. he heater and any related supply and return lines Close the drain valve 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 Fill the Cooling System NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system Refer to this Operation and Maintenance Manual Fluid Recommendations for more information on cooling system specifications Refer to this Operation and Maintenance Manual Refill Capacities for information about the capacity of the cooling system Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for 1 minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 18 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap Only install the used filler cap if the gasket is not damaged Use a 98 8140 Pressurizing Pump to pressure test a reinstalled cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of
47. ipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEGJ0047 How To Take A Good S O S Oil Sample Consult your Cat dealer for complete information and assistance in establishing an S O S program for your engine 102107152 Engine Oil and Filter Change SMCS Code 1318 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil If the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve knob clockwise
48. l system component that will be disconnected Fit a suitable cover over any dis connected fuel system components If the engine is not equipped with a fuel priming pump it may be necessary to fill the fuel filter with clean fuel The following procedure will only allow filtered fuel to enter the fuel system ve Wi IET pate o d 900516900 llustration 37 1 Plug 2 Fuel filter 1 Remove plug 1 in order to fill fuel filter 2 Ensure that air is able to vent from the fitting of the plug while the fuel filter is being filled Clean up any spilled fuel immediately Clean plug 1 Install plug 1 NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 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 3 Maintain the engine rpm until the engine operates smoothly 4 Reduce the engine rpm to low idle 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
49. liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recommended maximum Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to the Special Publication SEBUG251 Caterpillar Commercial Diesel Engines Fluids Recommendations for more information on SCA requirements 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling system filler cap with a new cooling system filler cap Install the cooling system filler cap 104441631 Engine Air Cleaner Element Single Element Inspect Clean Replace SMCS Code 1051 1054 040 1054 070 1054 510 NOTICE Never run the engine without an air cleaner element installed Never run the engine wit
50. lowing coolants Cat DEAC Cat SCA and Conventional Heavy Duty Coolants For additional information about coolant analysis and about other coolants see this Operation and Maintenance Manual Fluid Recommendations or consult your Cat dealer Sampling Conditions 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 Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample SEBU6164 08 59 Maintenance Section Coolant Sample Level 2 Obtain e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination e Never collect samples from expansion bottles e Never collect samples from the drain for a system Timing of the Sampling Table 12 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC Cat SCA Conventional Heavy Duty Coolants Cat ELC Cat ELI Commercial EC 1 Coolants 1 The Level 2 Coolant Analysis should be per
51. mation for the transmission Marine Transmission Operation Maintenance Warranty and Parts Support For information on maintenance and operation of the marine transmission consult your Cat dealer and or the OEM dealer of the transmission All support for the warranty of the transmission will be the responsibility of the OEM All parts support for the transmission will be the responsibility of the OEM This parts support includes both the installation of parts and the resolution of any service problems 101057899 Turbocharger Inspect SMCS Code 1052 040 Periodic cleaning is recommended for the turbocharger compressor inlet side The following items collect in the turbocharger compressor housing since the fumes from the crankcase travel through the inlet air oil by products from oil and by products from combustion The buildup reduces boost and air flow The buildup also contributes to loss of engine power increased black smoke and overall loss of engine efficiency Cleaning and Inspecting 1 Remove the air inlet piping from the turbocharger and remove the compressor housing from the turbocharger 2 Clean the turbocharger compressor housing with Hydrosolv Liquid Cleaners and a hard bristle brush 3 Clean the turbocharger compressor wheel and clean the backplate assembly with 4C 4079 Brake and Electric Cleaner 100893389 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Lo
52. mps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover Inspect the fuel system for leaks Look for loose fuel line clamps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system e Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Disconnect any battery chargers t
53. n diesel fuel to the new fuel filter gasket NOTICE Do not fill the secondary fuel filter with fuel before in stalling The fuel would not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 8 Install a new fuel filter and tighten the fuel filter until the gasket contacts the base 9 Tighten the fuel filter by hand according to the instructions that are shown on the fuel filter Do not overtighten the fuel filter 10 Lock the fuel priming pump if equipped Open the fuel tank supply valve 11 If the engine stalls refer to the Operation and Maintenance Manual Fuel System Prime topic Maintenance Section for more information 104170131 Fuel System Water Separator 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 changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE The water separator is not a filter It separates water from the fuel The engine should never be allowed to run with the water level in the separator more than 1 2 full or en gine damage may result A water separator is recommended The water separator should be installed between the fuel tank and the engine fuel inlet Drain the water and sediment from the water separator on a daily basis
54. o help prevent air from entering the fu el system 8 Open the main fuel supply valve 9 Start the engine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Detecting leaks is difficult while the engine is running The primary filter water separator is under suction A leak will allow air to enter the fuel The air in the fuel can cause low power due to aeration of the fuel If air enters the fuel check the components for overtightening or undertightening 101007602 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 1 Stop the engine 2 Turn off the start switch or disconnect the battery starting motor when maintenance is performed on fuel filters 3 Shut off the fuel tank supply valve to the engine NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 4 Unlock the fuel priming pump if equipped This relieves any residual pressure in the fuel system 5 Remove the used fuel filter Use a cloth or use a container to catch excess fuel 6 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 7 Apply clea
55. oolant analysis Level 1 Identification of metal corrosion and contaminants Identification of buildup of the impurities that cause corrosion and scaling Determination of the possibility of electrolysis within the cooling system of the engine The results are reported and appropriate recommendations are made Obtaining the Sample Refer to Operation and Maintenance Manual Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For further information refer to this Operation and Maintenance Manual Fluid Recommendations 104240223 Coolant Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine 60 Maintenance Section SEBU6164 08 Cooling System Supplemental Coolant Additive SCA Test Add A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and w
56. order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine SEBU6164 08 67 Maintenance Section Engine Oil and Filter Change e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equ
57. ose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination SEBU6164 08 81 Maintenance Section Water Pump Inspect NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water Ensure that cooling lines are properly clamped and that cooling lines are tight Check for leaks Check the condition of all pipes e Check the marine transmission oil level Refer to the OEM specification for the marine transmission or refer to the OEM specification for the vessel e Inspect the water pu
58. ot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved Stop the engine N Allow the engine to cool Before servicing a coolant hose slowly loosen the filler cap for the cooling system in order to relieve any pressure AR Remove the filler cap for the cooling system a 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 o Remove the hose clamps 76 Maintenance Section Hoses and Clamps Inspect Replace SEBU6164 08 N Disconnect the old hose co Replace the old hose with a new hose 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 10 Refill the cooling system 11 Clean the filler cap for the cooling system Inspect the gaskets on the filler
59. our crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 Remove oil filler cap and add oil if necessary Clean the oil filler cap Reinstall the oil filler cap SEBU6164 08 65 Maintenance Section Engine Oil Level Gauge Calibrate 101139872 Engine Oil Level Gauge Calibrate SMCS Code 1326 524 1326 The engine is shipped with an engine oil level gauge that is not marked The engine oil level gauge is not marked because the angle of installation can be different for each engine The angle of installation will affect the ADD mark Y and the FULL mark X that is engraved on the engine oil level gauge The engine oil level gauge must be calibrated after the engine is installed in the vessel Table 13 and Table 14 list the corresponding ADD mark FULL mark and the angle of installation Use a marking pen in order to engrave ADD mark Y and FULL mark X on the engine oil level gauge according to the information in Table 13 or Table 14 ER FULL Illustration 32 900110310 Oil Level Gauge Y ADD mark X FULL mark Calibration of Oil Level Gauge Table 13 Engine Oil Level Gauge 4KG1 05782 1SK1 01724 8NM1 01465 Angle FULL Mark X ADD Mark Y 15 degrees 156 mm
60. pect Replace SEBU6164 08 101007424 Zinc Rods Inspect Replace SMCS Code 1388 040 1388 510 Corrosion in sea water circuits can result in premature deterioration of cooling system components leaks and possible cooling system contamination The corrosion may be caused by the lack of zinc rods in the sea water system Zinc rods are inserted in the sea water cooling system of the engine in order to help prevent the corrosive oxidation that is caused by sea water The reaction of the zinc to the sea water causes the zinc rods to oxidize rather than the cooling system components Rapid deterioration of zinc rods may indicate the presence of uncontrolled electrical currents from improperly installed electrical attachments or improperly grounded electrical attachments The zinc rods must be inspected at the proper intervals The zinc rods must be replaced when deterioration occurs Inspect the Zinc Rods The zinc rods are red for easy identification Table 15 shows the locations of the zinc rods and the quantities of the zinc rod Table 15 Locations of the Zinc Rods Location Quantity Heat Exchanger 3 Transmission Oil Cooler 2 Exhaust Elbow 1 Aftercooler 5 1 Zinc rods will only be located in marine transmission oil coolers that are cooled with sea water 2 Exhaust elbows that are aftermarket may or may not be equipped with zinc rods 3 3126 Engine Only 1 Remove the zinc rod
61. possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately Prime the fuel system in order to fill the fuel filter Prime the fuel system in order to purge trapped air The fuel system should be primed under the following conditions e Running out of fuel e Storage e Replacement of the fuel filter Engines that are Equipped with a Fuel Priming Pump Illustration 36 900516899 1 Select knob 2 Plunger 1 Turn select knob 1 counterclockwise until the indicator is in line with the body of the priming pump 2 Unlock the plunger and operate the plunger until a resistance is felt A considerable number of pump strokes may be required 3 Push in plunger 2 and tighten by hand 4 Turn select knob 1 clockwise until the indicator is in line with the fuel outlet NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 5 Promptly start the engine If the engine runs rough increase the engine rpm to one half of the rated rpm Note If the engine will not start further priming may be necessary If the engine continues to misfire or smoke after starting further priming may be necessary Engines that are Not Equipped with a Fuel Priming Pump NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fue
62. rive 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 e If the engine is equipped with a refrigerant compressor air conditioner the belts for the following components will have automatic belt tensioners the alternator the fan drive and the accessories e If the engine is not equipped with a refrigerant compressor the alternator is used to adjust the belt tension Adjustment Alternator Belt Illustration 22 901075759 1 Adjusting bolt 2 Mounting bolts 1 Slightly loosen mounting bolts 2 and adjusting bolt 1 2 Move the pulley in order to adjust the belt tension 3 Tighten adjusting bolt 1 and mounting bolts 2 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 again after 30 minutes of engine operation at the rated rpm Water Pump Belt Illustration 23 g01075753 Exploded view of the drive assembly for a water pump belt 1 Mounting bolt 2 Square hole 3 Adjusting bolt 1 Slightly loosen mounting bolts 1 and adjusting bolt 3 2 Adjust the belt tension with a square drive in square hole 2 3 Tighten adjusting bolt 3 and mounting bolt 1 For the proper torque refer to the Speci
63. rvals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Battery Recycle sess 52 Battery or Battery Cable Disconnect 53 Coolant Change ssseeee 54 Coolant Extender ELC Add 57 Engine Air Cleaner Element Single Element Inspect Clean Replace sssssessss 61 Engine Oil Level Gauge Calibrate 65 Fuel System Prime esseee 70 Daily Coolant Level Check sese 57 Engine Air Cleaner Service Indicator Inspect 63 Engine Oil Level Check ssssssss 64 Fuel System Water Separator Check Drain 72 Transmission Oil Level Check 80 Walk Around Inspection sesesssssss 80 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Coolant Sample Level 2 Obtain 59 Every Year Coolant Sample Level 2 Obtain 59 Every 1500 L 400 US gal of Fuel or 50 Service Hours Zinc Rods Inspect Replace 82 First 7500 L 2000 US gal of Fuel or 250 Service Hours Engine Valve Lash Check seese 69 Fuel Injection Timing Check 69 Every 7500 L 2000 US gal of Fuel or 250 Service Hours or
64. seness e Damage 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 e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen which can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Replace hoses that are cracked or soft Replace hoses that show signs of leakage Replace hoses that show signs of damage Replace hose clamps that are cracked or damaged Tighten or replace hose clamps which are loose Replace the Hoses and the Clamps 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 Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Cooling System Pressurized System H
65. tablished inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be salvaged repaired or replaced Using out of spec parts can result in the following problems e Unscheduled downtime e Costly repairs e Damage to other engine parts e Reduced engine efficiency e Increased fuel consumption Reduced engine efficiency and increased fuel consumption translates into higher operating costs Therefore Caterpillar Inc recommends repairing out of spec parts or replacing out of spec parts Component Replacement Replace the following components during the overhaul e Piston Rings e Thrust bearings e Main bearings e Connecting rod bearings e Gaskets and seals e Engine mounts e Hoses Inspection Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts and Salvage Operations SEBF8029 Index of Publications on Reusability or Salvage of Used Parts e Camshaft e Camshaft bearings e Crankshaft e Crankshaft vibration damper e Gear train Inspect the camshaft for damage to the journals and the lobes Inspect the camshaft bearings for signs of wear and or for signs of fatigue Inspect the crankshaft for any of the following conditions e Deflection e Damage to the journals e Bearing materi
66. the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature SEBU6164 08 57 Maintenance Section Coolant Extender ELC Add 104862631 Coolant Extender ELC Add SMCS Code 1352 544 NL Note Refer to this Operation and Maintenance Manual Fluid Recommendations Cooling System for the maintenance interval for the addition of the coolant extender Cat ELC Extended Life Coolant and Cat ELI Extended Life Inhibitor do not require the frequent additions of any supplemental cooling additives The Cat ELC Extender will only be added one time Note Do not use conventional supplemental coolant additive SCA with Cat ELC or with Cat ELI Check the cooling system only when the engine is stopped and cool Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Cool
67. the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 100626013 Engine Protective Devices Check SMCS Code 7400 535 Alarms and shutoffs must function properly Alarms provide timely warning to the operator Shutoffs help to prevent damage to the engine It is impossible to determine if the engine protective devices are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints Ensure that the engine protective devices are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damage to the engine only authorized service personnel or your Caterpillar dealer should
68. ts 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 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 Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injector timing because special tools and training are required Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injector timing 70 Maintenance Section Fuel System Prime SEBU6164 08 i01007661 Fuel System Prime SMCS Code 1250 548 1258 548 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent
69. tween 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features e Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchange components Overhaul Recommendation To minimize downtime Caterpillar Inc recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails This will provide you with the best cost value relationship 78 Maintenance Section Overhaul Considerations SEBU6164 08 Note Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life If an overhaul is performed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations Rebuild or Exchange Inspect the following components according to the instructions that are found in various Caterpillar reusability publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts e Cylinder head assembly e Connecting rods e Pistons Turbocharger Oil pump Fuel ratio control e Cam followers e Fuel Transfer pump e Timing advance If the parts comply with the es
70. utside of the box and mark the air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 7452 040 Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location Illustration 29 900103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the

3116 and 3126 Marine Engines - Maintenance - Safety

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