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3208 MARINE ENGINE

1. g00462947 Illustration 37 1 Hose clamp 2 Clip 3 Housing 1 Loosen hose clamp 1 Remove the hose 2 Unfasten clips 2 Remove the cover and the seal from housing 3 3 5 E RK Illustration 38 g00462957 3 Housing 4 Nut 5 Filter element 3 Remove nuts 4 Remove filter elements 5 from housing 3 Discard the used elements 4 Clean the inside of the filter housing with a clean cloth 5 Install new elements 5 and tighten nuts 4 6 Clean the cover and the seal with a clean cloth Inspect the condition of the seal Replace the seal if necessary 7 Install the seal and the cover Fasten clips 2 96 Maintenance Section Overhaul Considerations 8 Install the hose Tighten hose clamp 1 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques i00896306 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand A decreased average power demand should increase both the engine service life and the overhaul interval The need for an overhaul is generally indicated by increased fuel consumption and by reduced power The following factors are important when a decision is being made on the proper time for an engine overhaul e Need for preventive maintena
2. mre SEES a ne ae D Illustration 31 g00467033 1 Vent valve Base Can Element 5 Drain plug XIS 2 3 4 5 1 Close the main fuel supply valve 2 Remove drain plug 5 Depress vent valve 1 in order to start the flow of fuel Allow the fuel to drain into a suitable container Dispose of the fuel properly 3 Install the drain plug 89 Maintenance Section Fuel System Secondary Filter Replace 4 Remove can 3 from base 2 5 Remove element 4 from the can Dispose of the used element 6 Remove the gasket Clean the following components e Can e Gasket e Base Inspect the gasket for damage and for deterioration Replace the gasket if necessary 7 Install the gasket Lubricate the gasket with clean diesel fuel 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 8 Install a new element in the can The can may be filled with fuel at this time 9 Install the can on the base Tighten the can by hand Do not use tools in order to tighten the can NOTICE The water separator is under suction during normal engine operation Ensure that the vent plug is tight ened securely
3. Illustration 41 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 42 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 9S 3263 Thread Lock Compound to shoulder 1 of a new zinc rod Apply the compound ONLY to the shoulder of the zinc rod Install the zinc rod onto the plug 105 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
4. po 2ra oar fail cet lt P a eae Typical location of aftercooler drain Illustration 15 g00466348 Inspect the plug for the aftercooler drain if equipped Ensure that the plug is one of the following plugs e 101 3713 Tethered Plug e 9x 8406 Plug stainless steel NOTICE A failed aftercooler drain plug can cause the engine compartment to fill with sea water Any plugs used in the aftercooler drain port other than those recom mended above may corrode Use only those recom mended plugs 100744980 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 Hydrosolv liquid cleaner Table 23 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 23 Hydrosolv Liquid Cleaners Description Container 1U 8812 Hydrosolv 4165
5. NOTICE Never wire brush or scrape a fuel injection nozzle Wire brushing or scraping a fuel injection nozzle will damage the finely machine orifice Proper tools for cleaning and testing the fuel injection nozzles can be obtained from Caterpillar dealers The following items are symptoms of a malfunction of the fuel injection nozzle e Abnormal engine operation e Smoke emission e Engine knock Each fuel injection nozzle must be isolated one at a time in order to determine the malfunctioning fuel injection nozzle 1 Start the engine 2 Loosen each fuel line nut one at a time at the fuel injection pump A cloth or similar material must be used in order to prevent fuel from spraying on the hot exhaust components Tighten each nut before loosening the next nut 3 A defective fuel injection nozzle may be identified when a fuel line nut is loosened and the following conditions are present e The exhaust smoke is partially eliminated or the exhaust smoke is completely eliminated e Engine performance is not affected A fuel injection nozzle that is suspected of being defective should be removed A new fuel injection nozzle should be installed in the cylinder in order to determine if the removed fuel injection nozzle is defective Removal and Installation of the Fuel Injection Nozzles For the removal and the installation of fuel injection nozzles special tooling is required Refer to the Service Manual for more
6. 2 Install the sea water strainer Fill the sea water strainer and the suction line for the auxiliary water pump with water 101 Maintenance Section Starting Motor Inspect 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 100912946 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities
7. 743 mm 29 2 inch 11 degrees 725 mm 28 5 inch 741 mm 29 2 inch 10 degrees 723 mm 28 4 inch 739 mm 29 1 inch 10 degrees 721 mm 28 4 inch 737 mm 29 0 inch 9 degrees 719 mm 28 3 inch 735 mm 29 0 inch 9 degrees 717 mm 28 2 inch 749 mm 28 8 inch 8 degrees 715 mm 28 2 inch 732 mm 28 8 inch 8 degrees 714 mm 28 1 inch 730 mm 28 7 inch 7 degrees 713 mm 28 1 inch 728 mm 28 7 inch 7 degrees 711 mm 28 0 inch 726 mm 28 6 inch 6 degrees 707 mm 27 8 inch 723 mm 28 5 inch 6 degrees 706 mm 27 8 inch 722 mm 28 4 inch 5 degrees 703 mm 27 6 inch 719 mm 28 3 inch 5 degrees 701 mm 27 6 inch 718 mm 28 3 inch 4 degrees 697 mm 27 5 inch 715 mm 28 1 inch 4 degrees 697 mm 27 4 inch 714 mm 28 1 inch 3 degrees 694 mm 27 3 inch 711 mm 28 0 inch 3 degrees 693 mm 27 3 inch 710 mm 28 0 inch 2 degrees 690 mm 27 2 inch 707 mm 27 8 inch 2 degrees 689 mm 27 1 inch 706 mm 27 8 inch 1 degree 684 mm 26 9 inch 702 mm 27 6 inch 1 degree 684 mm 26 9 inch 702 mm 27 6 inch O degrees 679 mm 26 7 inch 698 mm 27 5 inch O degrees 679 mm 26 7 inch 697 mm 27 4 inch 1 degree 673 mm 26 5 inch 693 mm 27 3 inch 1 degree 673 mm 26 5 inch 692 mm 27 3 inch 2 degrees 667 mm 26 3 inch 689 mm 27 1 inch 2 degrees 668 mm 26 3 inch 689 mm 27 1 inch 3 degrees 660 mm 25 7 inch 683 mm 26 9 inch 3 deg
8. e Outer covering that is ballooning locally e Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect th
9. 2 at the cylinder head 6 Unlock and operate the priming pump plunger until the flow of fuel from the fuel injection lines is continuous and free of air bubbles 7 Lock the priming pump plunger 8 Tighten the fuel injection line nuts 2 Refer to Specifications for more information on the proper torques Ensure that any spilled fuel is cleaned up 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 9 Start the engine 100914347 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1260 1263 510 1263 Water in the fuel can cause the engine to run rough Water in the fuel may cause fuel system components 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 The primary filter water separator should be changed when the vacuum gauge if equipped registers 50 to 70 kPa 15 to 20 In 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
10. 4 L 1 US gal 1U 5490 Hydrosolv 4165 19 L 5 US gal 8T 7570 Hydrosolv 4165 208 L 55 US gal 1U 8804 Hydrosolv 100 4 L 1 US gal 1U 5492 Hydrosolv 100 19 L 5 US gal 81 7571 Hydrosolv 100 208 L 55 US gal 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water 58 Maintenance Section Alternator Inspect 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 C
11. Cleaner Elements 74 Maintenance Section Engine Air Cleaner Element Clean Replace Washing the Paper Air Cleaner Elements with Nonsudsing Detergent Do not wash air cleaner elements in any flammable solution such as diesel fuel or gaso line Doing so can cause fire or an engine runaway and can result in personal injury Washing with nonsudsing detergent is effective for cleaning elements that have deposits of carbon or oil Use a cleaning agent that is specifically manufactured for cleaning paper air cleaner elements Cleaning with pressurized water pressurized air or vacuum cleaning is recommended prior to washing with nonsudsing detergent 1 Place the element into a wash tank so that the gasket is up The wash tank should be equipped with a rack so that the element does not sit on the bottom of the wash tank Note Caterpillar does not recommend a process for washing the element which includes vigorously shaking By vigorously shaking the element carbon particles may be distributed 2 Fill the wash tank with the cleaning agent and warm water to a maximum temperature of 60 C 140 F Follow the manufacturers recommendations for the cleaning agent Allow the element to soak for six hours 3 Drain the wash tank Do not use the cleaning agent more than one time Remove the element from the wash tank Rinse the element by performing the method for cleaning with pressurized water Note Refer to Drying t
12. Level Il 99 Maintenance Section PCV Valve Inspect S O S Coolant Analysis Level II An S O S Coolant Analysis Level Il is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level Il provides the following information e Complete S O S Coolant Analysis Level 1 Visual inspection of properties Identification of metal corrosion Identification of contaminants Identification of built up impurities corrosion and scale S 0 S Coolant Analysis Level Il 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 i00915290 PCV Valve Inspect SMCS Code 1074 040 I T SANI AA FES Me SE E g00467453 Illustration 39 Typical PCV valve location 1 Clean the outside of the PCV valve and clean the area around the PCV valve 2 Inspect the condition of the PCV hose Replace the PCV hose if necessary Illustration 40 g00467461 1 Cover 2 Inner sleeve 3 Gasket 4 Housing 5 Piston 6 6 Diaphragm 3 Remove the screws and washers that hold cover 1 in place 4 Remove cover 1 and the spring 5 Remove the diaphragm assembly inner sleeve 2 and gasket 3 f
13. 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 Refer to the Service Manual for the replacement procedure of the water temperature regulator or consult your Caterpillar dealer Note If only the water temperature regulators are replaced drain the coolant from the cooling system to a level that is below the water temperature regulator housing 70 Maintenance Section Crankshaft Vibration Damper Inspect 100894991 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Rubber Damper Your engine may be equipped with a rubber damper The rubber damper uses a ring which is mounted in rubber in order to reduce vibrations in the crankshaft Insp
14. 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 65 Maintenance Section Cooling System Coolant ELC Change For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section 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 cle
15. 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 e 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 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 92 Maintenance Section Governor Housing Drain i00908299 Governor Housing Drain SMCS Code 1287 543 Illustration 34 g00463489 1 Governor housing 2 Bolt 3 Plug The governor housing 1 is mounted on the rear of the fuel injection pump Condensation can collect over time in the governor housing There are two drains w
16. four 12 volt batteries are involved the negative side of two batteries must be disconnected 3 Tape the leads in order to help prevent accidental starting 4 Proceed with necessary system repairs Reverse the steps in order to reconnect all of the cables Cooling System Coolant DEAC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated The fuel has entered the cooling system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in
17. 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 90 Maintenance Section Fuel System Water Separator Drain 6 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Use the rotation index marks on the filters as a guide for proper tightening Tighten the filter for an additional 3 4 turn by hand Do not overtighten the filter 100909035 Fuel System Water Separator Drain SMCS Code 1263 543 Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire ree SRE SS a Ss Zn Re ae D Illustration 33 g00467033 1 Vent valve Base Can Element 5 Drain plug XIS 2 3 4 5 Water in the fuel can cause fuel system components to fail Drain the water separator daily Drain the water separator more frequently when a large concentration of water is present in the fuel system 1 Close the fuel supply valve NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 2 Remove drain plug 5 Depress vent valve 1 in order to start the flow Allow the water to drain into a suitable container Allow the water to flow until fuel flows from the drain 3 Inst
18. into the High Idle position Slight spring tension should be felt when the governor lever goes over center 4 Use the circlip from the pin assembly in order to attach cable end 4 to the pin on lever 2 5 Use one 4B 4276 Washer and one 7H 9737 Cotter Pin in order to connect cable end 1 to the right side of lever assembly 3 as shown g00467629 5 7E 8661 Cable Adjust Throttle Cable Adjust the throttle cable so that there is a slight compressive force in the Low Idle position 86 Maintenance Section Fuel Injection Nozzles Test Exchange 100626014 Fuel Injection Nozzles Test Exchange SMCS Code 1254 013 1254 081 Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire 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 Fuel injection nozzles are subject to tip wear Tip wear is a result of fuel contamination Tip wear can cause the following problems e Increased fuel consumption e Black smoke e Misfire e Rough running Fuel Injection nozzles should be cleaned inspected tested and replaced if necessary Refer to Special Instruction SEHS7292 for using the 8S 2245 Injection Cleaning Tool Group Consult your Caterpillar dealer about cleaning the fuel injection nozzle and testing the fuel injection nozzle
19. large amount of gear train wear that is not caused by a lack of oil Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement 71 Maintenance Section Engine Clean 100737417 Engine Clean SMCS Code 1000 070 NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance 100911444 Engine Air Cleaner Element Foam Clean Replace SMCS Code 1054 070 1054 510 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine 1 Remove the air cleaner cover and the element 2 Cover the air inlet opening with a clean cloth or seal with tape in order to prevent dirt and debris from entering the engine 3 Clean th
20. 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 e Engine oil cooler e Marine gear oil cooler e Aftercooler e Heat exchanger Refer to the Operation and Maintenance Manual Aftercooler Core Inpect Clean 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 I 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
21. the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information 100915472 Exhaust Restrictor Inspect Adjust SMCS Code 1061 025 1061 040 Your engine may be equipped with an exhaust restrictor in order to reduce white smoke during engine warm up Inspect Exhaust Back Pressure NOTICE If the exhaust restrictor opens too slow the result is power loss and increased black smoke If the exhaust restrictor opens too fast cold starting will produce more white smoke Avoid these problems by keeping the exhaust restrictor properly adjusted Before adjusting the linkage perform the following steps 1 Start the engine Run the engine at low idle rpm 2 Ensure that the restrictor is in the CLOSED position Adjust th
22. the new oil Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil e Ifthe engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve knob clockwise in order to close the drain valve e If the engine is not equipped with a drain valve remove the oil drain plug in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed Replace the Oil Filter NOTICE 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 4C 5084 Oil Filter Cutter 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 nonf
23. to help prevent air from entering the fu el system 10 Open the main fuel supply valve 11 Start the engine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Leaks are difficult to detect 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 ensure that all components are properly tightened i00908585 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 g00463611 Illustration 32 NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components 1 Stop the engine 2 Shut off the fuel tank supply valve NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately 3 Remove fuel filter 2 4 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is removed 5 Apply clean diesel fuel to the new fuel filter
24. 3208 MARINE ENGINE Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU6090 03 01 2007 Caterpillar CATERPILLAR All Rights Reserved 56 Maintenance Section Maintenance Interval Schedule 100917973 Maintenance Interval Schedule SMCS Code 1000 7500 Note Ensure that the Safety Information warnings and instructions are read and understood before operation or maintenance procedures are performed Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed Note For engines that are equipped with AIRSEP engine air cleaners the turbocharger should be inspected every 1000 service hours When Required Belt Inspect Adjust Replace cceeceeeee 59 Battery Recycle ooo eeeceeeeeeeeneeeeeeeeeneeeeeteennaeees 61 Battery or Battery Cable Disconnect 62 Engine Oil Level Gauge Calibrate oe 78 Fuel System Prime cc ccceceeeeeeeeeeeeeeeeeeeeeneeees 87 Daily Cooling System Coolant Level Check 0 66 Engine Air Cleaner Service Indicator Inspect 75 Engine Oil Level Check ee eeeceeeeeeteeeeeeenneeees 77 Fuel System Water Separator Drain 008 90 Marine Transmission Oil Level Check 95 Walk Around Inspection ccceeeseeeeeeeeeeeeees 102 Every 1900 L 500 US gal of Fuel or 50 Service Hours Af
25. 5 degrees 677 mm 26 7 inch 702 mm 27 6 inch 6 degrees 673 mm 26 5 inch 700 mm 27 6 inch 7 degrees 670 mm 26 4 inch 698 mm 27 5 inch 8 degrees 670 mm 26 4 inch 696 mm 27 4 inch 9 degrees 663 mm 26 1 inch 694 mm 27 3 inch 10 degrees 662 mm 26 1 inch 693 mm 27 3 inch 1 A positive 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 80 Maintenance Section Engine Oil Level Gauge Calibrate Table 26 Table 27 3208 Marine Engines 01Z1 Up 3208 Marine Engines 012Z21 Up Oil Level Gauge Calibration Oil Level Gauge Calibration Left Hand Service Right Hand Service Angle X FULL Mark Y ADD Mark Angle X FULL Mark Y ADD Mark 15 degrees 743 mm 29 3 inch 759 mm 29 9 inch 15 degrees 743 mm 29 3 inch 757 mm 29 8 inch 14 degrees 738 mm 29 1 inch 755 mm 29 7 inch 14 degrees 739 mm 29 1 inch 754 mm 29 7 inch 13 degrees 734 mm 28 9 inch 752 mm 29 6 inch 13 degrees 734 mm 28 9 inch 748 mm 29 4 inch 12 degrees 733 mm 28 8 inch 748 mm 29 4 inch 12 degrees 730 mm 28 8 inch 745 mm 29 3 inch 11 degrees 737 mm 28 6 inch
26. 911249 Auxiliary Water Pump 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 Cam e Impeller e Seals e Wear plate If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump Refer to the Disassembly and Assembly for more information on servicing the auxiliary water pump 100912007 Belt Inspect Adjust Replace SMCS Code 1357 039 Inspection Belt tension should be checked initially between the first 20 to 40 hours of engine operation After the initial check the belt tension should be checked at Every 250 Service Hours or Three Months To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged 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 bel
27. Auxiliary Water Pump Belt Illustration 17 g00465541 Typical illustration 1 Mounting bolts 2 Slotted hole 1 Slightly loosen mounting bolts 1 2 Adjust the belt tension with a pry bar in slotted hole 2 Refer to the Specifications Belt Tension Chart topic 3 Tighten mounting bolts 2 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section 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 61 Maintenance Section Battery Recycle 100037658 Battery Recycle SMCS Code 1401 561 1 Always recycle a battery Never discard a battery 2 Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 100914454 Battery Electrolyte Level Check SMCS Code 1401 081 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 If batteries are properly charged ammeter reading should be very near zero 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 Maintai
28. Cleaning Paper Air Cleaner Elements 5 Remove the seal from the air inlet opening Install an element that is new or cleaned Cleaning Paper Air Cleaner Elements The element can be used up to six times if the element is properly cleaned and inspected When the element is cleaned check for rips or tears in the filter material The element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean elements while dirty elements are being cleaned 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 element before cleaning Inspect the element for damage to the seal the gaskets and the outer cover Discard any damaged elements There are four common methods that are used to clean elements e Pressurized water e Pressurized air e Vacuum cleaning e Washing with nonsudsing detergent Pressurized Water Pressurized water will clean the element unless carbon and oil have accumulated on the surface of the element The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Do not use a spray nozzle Note When the element is cleaned always begin with the clean side inside in order to force dirt particles toward the dirt
29. al for more information on lubricant specifications Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual for more information on refill capacities NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 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 o
30. all the drain plug Dispose of the liquid properly 4 Open the fuel supply valve 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 91 Maintenance Section Fuel Tank Water and Sediment Drain 100073301 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive fuel system wear 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 Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the
31. an water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications 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 one 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 13 mm 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump in order to pressure test the cooling system fille
32. ars Aftercooler Core Clean Test seeeeeeeees 57 Cooling System Coolant DEAC Change 62 Cooling System Water Temperature Regulator Replace nina ne ee ees 69 Engine Clean erias rT a N 71 Governor Housing Drain a a 92 Marine Transmission Oil Cooler Clean Inspect 94 PCV Valve Inspect ee eeeeeeeeeeeeeeceeeeeeeeeeeeeeteees 99 Every 72 000 L 19 000 US gal of Fuel or 2000 Service Hours Alternator Inspect ccccccceseeseeeseeeeeeeeeeeeeeeeeess 58 Crankshaft Vibration Damper Inspect 70 Engine Mounts Inspect eeen 77 Engine Valve Lash Inspect Adjust eee 84 Fuel Injection Nozzles Test Exchange 86 Fuel Ratio Control Inspect Adjust 0 0 87 Heat Exchanger Inspect iseeneses 92 Starting Motor Inspect oe 101 Turbocharger Inspect eeeeeeeeeeeeetteeeeeeeaes 101 Every 108 000 L 28 500 US gal of Fuel or 3000 Service Hours or 2 Years Cooling System Coolant Extender ELC Add 66 Water Pump Inspect cccceceeeeeeeeeeeeesenereeeees 103 Every 114 000 L 30 000 US gal of Fuel Overhaul Considerations 96 Every 216 000 L 57 000 US gal of Fuel or 6000 Service Hours or 4 Years Cooling System Coolant ELC Change 64 57 Maintenance Section Aftercooler Drain Plug Inspect 100913406 Aftercooler Drain Plug Inspect SMCS Code 1063 040 R u
33. aterpillar dealer 100997205 Alternator Inspect SMCS Code 1405 040 Note This engine is equipped with an alternator circuit breaker Note the location of the alternator circuit breaker for your particular application If the alternator circuit breaker trips you will need to reset the breaker in order for the charging system to operate Refer to the information that is provided by the OEM for more information Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge 59 Maintenance Section Auxiliary Water Pump Inspect 100
34. ch 1 A positive 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 Table 25 3208 Marine Engine 75V1 Up Oil Level Gauge Calibration Right Hand Service Angle X FULL Mark Y ADD Mark 15 degrees 756 mm 29 8 inch 771 mm 30 4 inch 14 degrees 752 mm 29 6 inch 768 mm 30 2 inch 13 degrees 749 mm 29 5 inch 763 mm 30 0 inch 12 degrees 745 mm 29 3 inch 760 mm 29 9 inch 11 degrees 741 mm 29 2 inch 757 mm 29 8 inch 10 degrees 737 mm 29 0 inch 752 mm 29 6 inch 9 degrees 733 mm 28 9 inch 749 mm 29 5 inch 8 degrees 730 mm 28 7 inch 746 mm 29 4 inch 7 degrees 726 mm 28 6 inch 742 mm 29 2 inch 6 degrees 722 mm 28 4 inch 738 mm 29 1 inch 5 degrees 718 mm 28 3 inch 735 mm 28 9 inch 4 degrees 714 mm 28 1 inch 730 mm 28 7 inch 3 degrees 710 mm 28 0 inch 726 mm 28 6 inch 2 degrees 706 mm 27 8 inch 723 mm 28 5 inch 1 degree 702 mm 27 6 inch 719 mm 28 3 inch O degrees 697 mm 27 4 inch 715 mm 28 1 inch 1 degree 692 mm 27 2 inch 712 mm 28 0 inch 2 degrees 689 mm 27 1 inch 710 mm 28 0 inch 3 degrees 685 mm 27 0 inch 707 mm 27 8 inch 4 degrees 680 mm 26 8 inch 704 mm 27 7 inch
35. charger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 100893389 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose 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 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 condi
36. e inside of the air cleaner cover and the body with a clean dry cloth 4 Wash the element in warm water and mild nonsudsing household detergent Rinse the element after washing 5 Inspect the element for deterioration Replace the element if the element is deteriorated or torn 6 Remove the seal from the air inlet opening Install the element and the air cleaner cover 72 Maintenance Section Engine Air Cleaner Element Clean Replace 100912642 Engine Air Cleaner Element Clean Replace SMCS Code 1054 070 1054 510 AIRSEP NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Note Use the 102 9720 Cleaning Kit This product contains the detergent and oil that is made specifically for the maintenance of the AIRSEP elements 1 Remove the vacuum limiter element and the AIRSEP element 2 Cover the air inlet opening with a clean cloth or seal with tape in order to prevent dirt and debris from entering the engine 3 Tap the element in order to dislodge dirt particles Gen
37. e low idle screw in order to obtain 650 rpm 3 Measure the exhaust back pressure before the restrictor No adjustment is needed if the exhaust back pressure is at least 34 kPa 5 psi Perform the adjustment procedure if the exhaust back pressure is too low Note Set the low idle operating rpm to the desired rpm after adjusting the linkage Linkage Adjustment 85 Maintenance Section Exhaust Restrictor Inspect Adjust Illustration 29 1 7E 8660 Cable End 3 Lever assembly 2 Lever 4 7E 8660 Cable End 1 Install the 7E 8671 Terminal Eye Pin Assembly in lever 2 Install four 4B 4276 Washers over the threaded end of the pin Install the threaded end of the pin through the lever Install the star washer and the nut Tighten the nut 2 Install two 7E 8660 Cable Ends 1 and 4 on the 7E 8661 Cable 5 Put a 1 mm 0 04 inch shim between the governor lever and the low idle stop bolt Place the restrictor in the CLOSED position Adjust the cable ends Connect the cable ends to the levers Remove the shim Note Do not force lever 2 to override the spring during the adjustment of the cable ends 1 and 4 3 Ensure that the throttle will go into the Low Idle position The governor lever should be against the low idle stop bolt Ensure that the throttle will go
38. e old hose 6 Replace the old hose with a new hose Note For torques on hose clamps see this Operation and Maintenance Manual Torque Specifications Maintenance Section 7 Install the hose clamps with a torque wrench Note For the proper coolant to use see this Operation and Maintenance Manual Coolant Recommendations Maintenance Section 8 Refill the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 94 Maintenance Section Magnetic Pickups Clean Inspect Magnetic Pickups Clean Inspect SMCS Code 7400 040 7400 070 Illustration 35 g00293335 Typical example 1 Magnetic pickup 2 Flywheel housing zE TAS A EL os S e o g00293337 Illustration 36 Typical magnetic pickup 1 Remove magnetic pickup 1 from flywheel housing 2 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 Refer to the Service Manual fo
39. e pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEHP6001 How To Take A Good Oil Sample Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine 82 Maintenance Section Engine Oil and Filter Change 100652130 Engine Oil and Filter Change SMCS Code 1318 510 1348 044 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
40. ears red at any time clean the air cleaner element or install a new air cleaner element Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated rpm The yellow core should latch approximately at the greatest vacuum that is attained 76 Maintenance Section Engine Crankcase Breather Clean 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 i00906289 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 beco
41. ect the damper and repair or replace the damper for any of the following reasons e There is deterioration and cracking of the rubber There is slippage of the outer ring from the original position e The engine has had a failure because of a broken crankshaft Analysis of the oil has revealed that the front main bearing is badly worn e There is a large amount of gear train wear that is not caused by lack of oil Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement Visconic Damper Your engine may be equipped with a visconic damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibration Inspect the damper for evidence of fluid leaks If a fluid leak is found determine the type of fluid The fluid in the damper is silicone Silicone has the following characteristics transparent viscous smooth and difficult to remove from surfaces If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper and repair or replace the damper for any of the following reasons The damper is dented cracked or leaking The paint on the damper is discolored from heat The engine has had a failure because of a broken crankshaft Analysis of the oil has revealed that the front main bearing is badly worn There is a
42. ements in Volalite Corrosion Inhibited VCI paper 75 Maintenance Section Engine Air Cleaner Service Indicator Inspect Place the element into a box for storage For identification mark the outside of the box and mark the element Include the following information e Date of the cleaning e Number of cleanings Store the box in a dry location For more detailed information on cleaning the paper air cleaner element refer to Special Publication SEBF8062 Procedure to Inspect and Clean Air Filters 100619874 Engine Air Cleaner Service Indicator Inspect 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 gauge reads the difference between inlet air pressure before the air cleaner element and 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 element A service indicator may be mounted on the air cleaner element or in a remote location Illustration 23 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or replaced when the yellow diaphragm enters the red zone or the red piston locks in the visible position If the service indicator app
43. errous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 28 g00103713 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 83 Maintenance Section Engine Protective Devices Check Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manu
44. 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 69 Maintenance Section Cooling System Water Temperature Regulator Replace 100912898 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system
45. g 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 e Oil pump Fuel ratio control e Cam followers e Fuel Transfer pump e Timing advance If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be 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 98 Maintenance Section Overhaul Considerations Inspection Inspect the following components according to the instructions that are in Caterpillar reusability publications Refer to Guidelines for Reusable Parts a
46. gine 75V1 Up Oil Level Gauge Calibration Left Hand Service Angle X FULL Mark Y ADD Mark 15 degrees 759 mm 29 9 inch 773 mm 30 4 inch 14 degrees 755 mm 29 7 inch 769 mm 30 3 inch 13 degrees 751 mm 29 6 inch 766 mm 30 2 inch 12 degrees 748 mm 29 4 inch 762 mm 30 0 inch 11 degrees 743 mm 29 6 inch 758 mm 29 8 inch 10 degrees 739 mm 29 1 inch 755 mm 29 7 inch 9 degrees 735 mm 28 9 inch 752 mm 29 6 inch 8 degrees 732 mm 28 8 inch 748 mm 29 4 inch 7 degrees 728 mm 28 7 inch 748 mm 29 4 inch 6 degrees 723 mm 28 5 inch 740 mm 29 1 inch 5 degrees 719 mm 28 3 inch 736 mm 29 0 inch 4 degrees 714 mm 28 1 inch 732 mm 28 8 inch 3 degrees 711 mm 28 0 inch 728 mm 28 7 inch 2 degrees 707 mm 27 8 inch 725 mm 28 5 inch 1 degree 702 mm 27 6 inch 720 mm 28 3 inch O degrees 698 mm 27 5 inch 716 mm 28 2 inch 1 degree 693 mm 27 3 inch 713 mm 28 1 inch 2 degrees 689 mm 27 1 inch 710 mm 28 0 inch 3 degrees 683 mm 26 9 inch 707 mm 27 8 inch 4 degrees 679 mm 26 7 inch 704 mm 27 7 inch 5 degrees 676 mm 26 6 inch 702 mm 27 6 inch 6 degrees 671 mm 26 4 inch 700 mm 27 6 inch 7 degrees 669 mm 26 3 inch 698 mm 27 5 inch 8 degrees 665 mm 26 2 inch 695 mm 27 4 inch 9 degrees 661 mm 26 0 inch 693 mm 27 3 inch 10 degrees 659 mm 25 9 inch 692 mm 27 3 in
47. guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 2 Remove oil filler cap 2 and add oil if necessary Clean the oil filler cap Reinstall the oil filler cap 100917087 Engine Oil Level Gauge Calibrate SMCS Code 1326 524 The engine is shipped with an engine oil level gauge that is not marked The engine oil level gauge is not marked because the angle of the installation and the location of the engine oil level gauge can be different for each engine The angle of the installation and the location of the engine oil level gauge will affect ADD mark Y and FULL mark X These marks are engraved on the engine oil level gauge The engine oil level gauge must be calibrated after the engine is installed in the vessel Tables 24 through 27 list the installation angles front to rear and the corresponding oil level marks Use a marking pen in order to engrave ADD mark Y and FULL mark X on the engine oil level gauge according to the information in Tables 24 through 27 Illustration 27 g00468470 Oil level gauge X FULL mark Y ADD mark 79 Maintenance Section Engine Oil Level Gauge Calibrate Table 24 3208 Marine En
48. he Paper Air Cleaner Elements Refer to Inspecting the Paper Air Cleaner Elements Drying the Paper Air Cleaner Elements The oven method may be used in order to dry the elements If an oven is used do not expose the elements to temperatures that exceed 82 C 160 F Note Do not use compressed air in order to dry the elements The elements may be allowed to air dry Allow two days for the elements to air dry before the elements are inspected and installed Inspecting the Paper Air Cleaner Elements Illustration 21 g00281693 Inspect the clean dry element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the element Rotate the element Inspect the element for tears and or holes Inspect the element for light that may show through the filter material If it is necessary in order to confirm the result compare the element to a new element that has the same part number Do not use an element that has any tears and or holes in the filter material Do not use an element with damaged pleats gaskets or seals Discard damaged elements Storing Paper Air Cleaner Elements If an element that passes inspection will not be used the element can be stored for future use Illustration 22 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage Restricted air flow may result To protect against dirt and damage wrap the el
49. hich are located at the rear bottom of the governor housing Perform the following procedure in order to drain the water from the governor housing 1 Remove bolt 2 and plug 3 2 Allow the water and sediment to drain 3 Install bolt 2 and plug 3 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torques 4 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime topic Maintenance Section for more information on priming the fuel system i00916040 Heat Exchanger Inspect SMCS Code 1379 040 The interval for the maintenance of the plate type heat exchanger depends on the operating environment of the vessel and on the operating time The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items e Cleanliness of the heat exchanger plates e Effectiveness of the heat exchanger system Operating 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 e Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal opera
50. il Level Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin oi a ae PE Illustration 25 g00463731 Typical example 1 Oil level gauge 2 Oil filler cap e lt ADD FULL 5 g00110310 Illustration 26 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped 1 Maintain the oil level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X 78 Maintenance Section Engine Oil Level Gauge Calibrate NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can enable the crankshaft to dip into the oil This will reduce the power that is de veloped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling of the pistons oil blow ing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will enable deposits to form on the pistons and in the combustion chamber De posits in the combustion chamber lead to the following problems
51. information Consult your Caterpillar dealer for assistance 87 Maintenance Section Fuel Ratio Control Inspect Adjust 100908934 Fuel Ratio Control Inspect Adjust SMCS Code 1278 025 1278 040 Slow engine response and low power may indicate a need for adjustment or repair of the fuel ratio control Refer to the Service Manual or your Caterpillar dealer for the complete adjustment procedure on the fuel ratio control i00909629 Fuel System Prime SMCS Code 1258 1280 045 Priming the fuel system fills the fuel filter Priming the fuel system removes air bubbles from the fuel system Prime the fuel system under the following conditions e Fuel system that is run dry e Storage Fuel filter maintenance e Disconnecting fuel lines and installing fuel lines e Repair of leaks in the fuel lines 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 Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately T i z p e272 l Z i a a 1 H o 2 ES O 10 F p 8 es g00464247 Illustration 30 Top view 1 Vent valve 2 Fuel injection line nuts NOTICE Do not allow dirt to enter the fue
52. information on the proper torques NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 3 Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 3 8 to 7 6 L 1 to 2 US gal of the cooling system capacity Install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 90 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 64 Maintenance Section Cooling System Coolant ELC Change 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Fill NOTICE Fill
53. l system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 88 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 1 Open vent valve 1 on the fuel injection pump and turn on the fuel tank supply valve 2 Unlock and operate the priming pump plunger until the flow of fuel from the vent valve is continuous and free of air bubbles 3 Close vent valve 1 and lock the priming pump plunger Ensure that any spilled fuel is cleaned up NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 4 Start the engine The engine may run rough Run the engine at low idle until the engine runs smoothly If the engine will not start further priming may be necessary If the engine starts and the engine continues to misfire or smoke further priming may be necessary If further priming is necessary perform Steps 5 through 9 NOTICE Do not let the tops of fuel nozzles turn when the fuel line nuts are loosened or tightened The nozzles will be damaged if the top of the nozzle turns in the body The engine will be damaged if a defective fuel injec tion nozzle is used because the shape of fuel spray pattern that comes out of the nozzles will not be cor rect 5 Loosen fuel injection line nuts
54. m 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 28 shows the locations of the zinc rods and the quantities of the zinc rod Table 28 Locations of the Zinc Rods Location Quantity Right Heat Exchanger Bonnet 2 Left Heat Exchanger Bonnet 1 Transmission Oil Cooler 2 Exhaust Elbow 2 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 1 Remove the zinc rod 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
55. me plugged A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage Illustration 24 g00463048 Typical example 1 Hose clamp 2 Breather assembly 3 Retaining clamp 1 Loosen hose clamp 1 and remove the hose from breather assembly 2 2 Loosen the retaining clamp 3 Remove breather assembly 2 and the seal 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 breather assembly and seal 2 and install clamp 3 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torques 5 Install the hose Install hose clamp 1 Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for the proper torques 77 Maintenance Section Engine Mounts Inspect 100259257 Engine Mounts Inspect SMCS Code 1152 040 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine e Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced Refer to the Service Manual for the recommended torques Refer to the OEM recommendations for more information i00908787 Engine O
56. n 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 1U 7298 Coolant Battery Tester C or the 1U 7297 Coolant Battery Tester F 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 L 12 qt of baking soda and 1L 1 qt of clean water e A mixture of 0 1 L 12 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 Lubrication Compound petroleum jelly or MPGM grease 62 Maintenance Section Battery or Battery Cable Disconnect i00095575 Battery or Battery Cable Disconnect SMCS Code 1402 029 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
57. nce e Quality of the fuel that is being used e Operating conditions e Results of the S O S analysis Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h b per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons 97 Maintenance Section Overhaul Considerations Avoid costly unplanned downtime e Reuse many original parts according to the standards for reusable parts e Extend the engine
58. nd 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 material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the rod bearings and main bearings 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 e 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
59. of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rom Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge Removal and Installation For options regarding the removal installation repair and replacement consult your Caterpillar dealer Refer to the Service Manual for this engine for the procedure and specifications 102 Maintenance Section Walk Around Inspection Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should t
60. order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plugs Allow the coolant to drain 63 Maintenance Section Cooling System Coolant DEAC Change NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Service Technology Group Outside Illinois 1 800 542 TOOL Inside Illinois 1 800 541 TOOL Canada 1 800 523 TOOL Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section 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 a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner Add 5 L 1 pint of cleaner per 15 L 4 US gal of the cooling system capacity Install the cooling
61. r cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 66 Maintenance Section Cooling System Coolant Extender ELC Add 100259474 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 Caterpillar Extended Life Coolant ELC does not require the frequent Supplemental Coolant Additive SCA additions associated with the present conventional coolants The Extender only needs to be added once Check the cooling system only when the engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to the Operation and Maintenance Manual Refill Capacities in the Maintenance Section for the capacity of the cooling system for your engine Refer to the Operation and Maintenance Manual Cooling System Specifications information for the Caterpillar ELC Extender additions 4 Clean the cooling system filler cap Inspect the cooling system filler cap gasket
62. r the installation procedure i00916467 Marine Transmission Oil Cooler Clean Inspect SMCS Code 3320 040 3320 070 The procedure for cleaning the marine transmission oil cooler is the same 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 marine transmission oil cooler refer to the OEM recommendations or consult your Caterpillar dealer 95 Maintenance Section Marine Transmission Oil Level Check i00649765 Marine Transmission Oil Level Check SMCS Code 3081 535 Marine Transmission Operation Maintenance Warranty and Parts Support Caterpillar Inc encourages customers to refer to a Caterpillar dealer and or to the OEM dealer for information on the following items e Marine transmission operation e Maintenance of the marine transmission All support for the warranty will be the responsibility of the OEM All parts support for the marine transmission will be the responsibility of the OEM This parts support includes both the installation of parts and the resolution of any service problems Refer to the OEM recommendations on the nameplate for the following information about the model of the marine transmission e Lubrication specifications e Requirements for maintenance 100907230 Oil Fumes Filter Replace SMCS Code 1317 510
63. r the condition of the engine and the maintenance requirements of the engine 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 taking the sample complete the Label PEEP5031 for identification of the sample To help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The oils hours of use e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil 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 8T 9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve The bottle group includes the parts that are needed for obtaining oil samples Instructions are also provided NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in th
64. rder 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 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 84 Maintenance Section Engine Valve Lash Inspect Adjust 100869628 Engine Valve Lash Inspect Adjust SMCS Code 1102 025 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for
65. rees 664 mm 26 1 inch 685 mm 27 0 inch 4 degrees 655 mm 25 8 inch 679 mm 26 7 inch 4 degrees 657 mm 25 8 inch 680 mm 26 8 inch 5 degrees 650 mm 25 6 inch 676 mm 26 6 inch 5 degrees 652 mm 25 7 inch 677 mm 26 6 inch 6 degrees 643 mm 25 3 inch 671 mm 26 4 inch 6 degrees 646 mm 25 4 inch 673 mm 26 5 inch 7 degrees 640 mm 25 2 inch 669 mm 26 3 inch 7 degrees 643 mm 25 3 inch 670 mm 26 4 inch 8 degrees 635 mm 25 0 inch 665 mm 26 2 inch 8 degrees 638 mm 25 1 inch 666 mm 26 2 inch 9 degrees 629 mm 24 8 inch 661 mm 26 0 inch 9 degrees 633 mm 24 9 inch 663 mm 26 1 inch 10 degrees 627 mm 24 7 inch 659 mm 26 0 inch 10 degrees 631 mm 24 9 inch 662 mm 26 1 inch 1 A positive 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 1 A positive 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 81 Maintenance Section Engine Oil Sample Obtain Engine Oil Sample Obtain SMCS Code 1000 008 1348 554 SM 7542 554 OC SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals in order to monito
66. rom housing 4 6 Disassemble the diaphragm assembly 100 Maintenance Section Sea Water Strainer Clean Inspect 7 Clean all of the parts Inspect all of the parts Replace any part that is worn or damaged Always install a new gasket and a new diaphragm when the PCV valve is being serviced 8 Assemble the diaphragm assembly Use a new diaphragm 6 9 Coat both flange sides of the diaphragm with gasket cement in order to prevent diaphragm 6 from distorting and cracking Install the diaphragm so that the face of the diaphragm that is marked piston face faces piston 5 10 Coat the new gasket 3 with gasket cement Install the gasket against the rear face of inner sleeve 2 11 Install the diaphragm assembly in housing 4 12 Install the spring and cover 1 Install the screws and washers that hold the cover in place i00905687 Sea Water Strainer Clean Inspect SMCS Code 1371 040 1371 070 The sea water strainer must be clean in order to allow proper engine cooling Check the sea water strainer for plugging Inspect the sea water strainer more frequently if the vessel is being operated in water which is shallow or dirty Refer to the OEM recommendations for more information about inspecting and cleaning the sea water strainer Ensure that the auxiliary water pump is primed and that the suction line is open 1 Remove the sea water strainer and clean the screen Remove any dirt and debris
67. s Replace the cooling system filler cap if the cooling system filler cap gaskets are damaged Install the cooling system filler cap i00893001 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool Engines That Are Equipped with a Coolant Recovery Tank To oj oTo To oT Illustration 18 g00103638 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 3 Pour the proper coolant mixture into the tank Refer to the coolant specifications in the maintenance information for your product 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 67 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add Engines That Are Not Equipped with a Coolant Recovery Tank Pressurized System Ho
68. 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 between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features e Caterpillar dealer exchange components e Caterpillar Inc remanufactured exchange components Overhaul Recommendation To minimize downtime 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 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 accordin
69. ssive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recommended maximum Pressurized System Hot coolant can cause seri ous burns To open the cooling system 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 Operation and Maintenance Manual for more information on SCA requirements 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system
70. stem for leaks and for proper operating temperature i00906586 Cooling System Coolant ELC Change SMCS Code 1350 070 1395 044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove the cooling system drain plugs Allow the coolant to drain NOTICE Dispose of used engine
71. system filler cap 4 Start and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C 180 F NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear wa ter Continue to flush the system until all signs of the cleaning agent are gone 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more information on the proper torques Cooling Systems with Heavy Deposits or Plugging Note For the following procedure to be effective there must be some active flow through the cooling system components 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain valve if equipped Clean the drain plugs Install the drain plugs Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section for more
72. t Kit or use the 40 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to the Operation and Maintenance Manual for more information on conventional coolant antifreeze cooling system maintenance 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 Operation and Maintenance Manual Water Supplemental Coolant Additive SCA topic Maintenance Section Refer to the Operation and Maintenance Manual Conventional Coolant Antifreeze Cooling System Maintenance topic Maintenance Section 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 68 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add Level 1 Level 1 is a basic analysis of the coolant The following items are tested e Glycol Concentration e Concentration of SCA e pH e Conductivity The results are reported and recommendations are made according to the results Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S O S Coolant Analysis Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Exce
73. t coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 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 19 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and inspect the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 Inspect the cooling system for leaks 100992487 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 Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Use the 8T 5296 Coolant Conditioner Tes
74. t with the recommended oil 7 The dry element should be oiled before installation Apply small amounts of oil across the top of each pleat Allow the oil to soak into the element for 20 minutes Oil any remaining white spots 8 Inspect the housing and the clamp for the element Replace the housing and the clamp if necessary 9 Remove the seal from the air inlet opening Install the clean oiled element Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section Paper Air Cleaner Element NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine 1 Remove the cover Remove the element 2 Cover the air inlet opening with a clean cloth or seal with tape in order to prevent dirt from entering the engine 3 Clean the inside of the air cleaner cover and body with a clean dry cloth 73 Maintenance Section Engine Air Cleaner Element Clean Replace 4 Clean the element and inspect the element Replace the element if necessary Refer to
75. tercooler Drain Plug Inspect s 57 Engine Air Cleaner Element Foam Clean Replace 20 cccceeceeeeeeeeeeeceeeeeeeteeeeeeeeees 71 Zinc Rods Inspect Replace 2 0seeee 104 Initial 9000 L 2400 US gal of Fuel or 250 Service Hours or 1 Year Engine Valve Lash Inspect Adjust eee 84 Every 9000 L 2400 US gal of Fuel or 250 Service Hours or Yearly Auxiliary Water Pump Inspect seeee 59 Belt Inspect Adjust Replace ceeeeeee 59 Battery Electrolyte Level Check n se 61 Cooling System Supplemental Coolant Additive SCA Test Add ccs catetieetee dine cetacean 67 Engine Air Cleaner Element Clean Replace 72 Engine Crankcase Breather Clean n 76 Engine Oil Sample Obtain 0 eeeeeeeeeeeeeees 81 Engine Oil and Filter Change 0 ee 82 Engine Protective Devices Check 83 Exhaust Restrictor Inspect Adjust eeee 84 Fuel System Primary Filter Water Separator Element Replace E tees oa ab ay cedars 88 Fuel System Secondary Filter Replace 89 Fuel Tank Water and Sediment Drain 91 Hoses and Clamps Inspect Replace 93 Magnetic Pickups Clean Inspect 05 94 Oil Fumes Filter Replace ccceeeeeeeeteees 95 Sea Water Strainer Clean Inspect 100 Every 36 000 L 9000 US gal of Fuel or 1000 Service Hours or 2 Ye
76. the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to the Operation and Maintenance Manual Cooling System Specifications topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to 1500 rpm Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 3 Check the coolant level Maintain the coolant level within 13 mm 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 5 inch to the proper level on the sight glass if equipped 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a pressure test A 9S 8140 Pressurizing Pump is used to perform the pressure test The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling sy
77. ting 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 the same 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 93 Maintenance Section Hoses and Clamps Inspect Replace i00907072 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps 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 Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement
78. tion of all pipes Check the marine transmission oil level Refer to the OEM specification for the marine transmission or refer to the OEM specification for the vessel Inspect the water pumps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down 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 103 Maintenance Section Water Pump Inspect 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 e Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean f
79. tly brush the element with a soft bristle brush NOTICE Do not use gasoline steam caustic or unapproved detergents or parts cleaning solvents Do not use high pressure water or air to clean the air cleaner element Any of those liquids or methods can cause air cleaner element damage 4 Spray the element with the cleaning solution Allow the element to stand for 20 minutes 5 Rinse the element with low water pressure The maximum water pressure for this procedure is 275 kPa 40 psi Tap water is acceptable Start to rinse the element from the clean side inside Next clean the dirty side outside in order to flush out dirt Inspect the element for tears and or holes after the element is cleaned Do not reuse damaged elements NOTICE Do not use compressed air open flame or hot air to dry the air cleaner element Excess heat shrinks cot ton fiber and compressed air may blow holes in the material Allow the air cleaner element to air dry 6 Shake excess water off the element and allow the element to air dry Drying the element in the sun speeds the process NOTICE Do not use transmission fluid engine oil diesel fuel or other lubricant to oil the air cleaner element The air cleaner element can not function correctly if im proper oil is used Never operate an engine with a dry air cleaner element The air cleaner element can not function correctly without oil Always saturate the clean air cleaner elemen
80. ts 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 This may shorten the service life of the components Remove the belt guard Inspect the condition and adjustment of the alternator belts and accessory drive belts if equipped If the belts do not require replacement or adjustment install the belt guard If the belts require adjustment or replacement perform the following procedure to adjust the belt tension 60 Maintenance Section Belt Inspect Adjust Replace Adjustment Alternator Belt Illustration 16 g00465617 Typical illustration 1 Mounting bolt 2 Adjustment bolt 3 Bracket bolts 1 Slightly loosen mounting bolt 1 and adjusting bolt 2 2 Move the alternator in order to adjust the belt tension If the alternator will not adjust it may be necessary to slightly loosen bracket bolts 3 Refer to the Specifications Belt Tension Chart topic 3 Tighten adjusting bolt 2 and mounting bolt 1 Tighten bracket bolts 3 if the bracket bolts were loosened Refer to the Operation and Maintenance Manual Torque Specifications topic Maintenance Section 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
81. uel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery e Check the condition of the gauges Replace any gauges which are cracked or any gauges that can not be calibrated i00869632 Water Pump Inspect SMCS Code 1361 040 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine Visually inspect the water pump for leaks If any leaking is observed replace each water pump seal Refer to the Service Manual for the disassembly and assembly procedure Inspect the water pump for any of the following conditions e Wear e Cracks e Pin holes e Proper operation Note Refer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed 104 Maintenance Section Zinc Rods Inspect Replace 100917820 Zinc Rods Inspect Replace SMCS Code 1388 040 1388 510 Corrosion in sea water circuits can result in premature deterioration of cooling syste
82. urn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Use a dial indicator to check the end clearance on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbo
83. y side outside Aim the hose so that the water flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of water directly at the element Dirt could be forced further into the pleats Note Refer to Drying the Paper Air Cleaner Elements Refer to Inspecting the Paper Air Cleaner Elements Pressurized Air Pressurized air can be used to clean elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 20 g00281692 Note When the paper 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 so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the element Dirt could be forced further into the pleats Note Refer to Inspecting the Paper Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning paper 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 Note Refer to Inspecting the Paper Air

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