C32 Marine Engines (RND) - Maintenance Intervals

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C32 MARINE ENGINE(RND)

Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7782-01-01)

®© 2007 CaterpillarAll Rights Reserved

®

SEBU7782-01 75Maintenance Section

Maintenance Interval Schedule

i02860509

Maintenance Interval ScheduleSMCS Code: 1000; 7500

Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. Forinformation on service hours and fuel consumption,see this Operation and Maintenance Manual,“Maintenance Recommendations” topic (GeneralMaintenance Information ).

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When RequiredAftercooler Core - Clean/Test ............................... 77Battery - Replace .................................................. 78Battery or Battery Cable - Disconnect .................. 79Engine - Clean ...................................................... 91Engine Oil Level Gauge - Calibrate ...................... 95Engine Storage Procedure - Check .................... 100Fuel System - Prime ........................................... 101Heat Exchanger - Inspect .................................... 110Sea Water Strainer - Clean/Inspect ..................... 117Zinc Rods - Inspect/Replace ............................... 120

DailyCooling System Coolant Level - Check ................ 87Engine Air Cleaner Service Indicator - Inspect ..... 93Engine Oil Level - Check ...................................... 95Fuel System Primary Filter/Water Separator -Drain ................................................................. 103Marine Transmission Oil Level - Check ............... 112Walk-Around Inspection ....................................... 119

Initial 10 Service HoursBelts - Inspect/Adjust ............................................ 80

Every 50 Service Hours or WeeklyAftercooler Condensate Drain Valve -Inspect/Clean ...................................................... 77

Every 250 Service Hours or 1 YearBattery Electrolyte Level - Check .......................... 79Belts - Inspect/Adjust/Replace .............................. 80Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 87Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 89Engine Oil Sample - Obtain .................................. 96Fuel Tank Water and Sediment - Drain ............... 109Hoses and Clamps - Inspect/Replace ................. 111

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 88Engine Valve Lash - Inspect/Adjust .................... 100

Every 500 Service Hours (Deep Sump)Engine Air Cleaner Element - Clean/Replace ....... 92Engine Crankcase Breather - Clean ..................... 94Engine Oil and Filter - Change ............................. 97Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 102Fuel System Secondary Filter - Replace ............ 103

Every 1000 Service HoursAftercooler Core - Clean/Test ............................... 77Closed Crankcase Ventilation (CCV) Fumes DisposalFilter - Replace .................................................... 81Turbocharger - Inspect ......................................... 118

Every YearCooling System Coolant Sample (Level 2) -Obtain ................................................................. 88

Every 3000 Service HoursAuxiliary Water Pump (Bronze Impeller) -Inspect ................................................................ 78Cooling System Coolant (DEAC) - Change .......... 82Cooling System Coolant Extender (ELC) - Add .... 86Cooling System Water Temperature Regulator -Replace ............................................................... 90Crankshaft Vibration Damper - Inspect ................. 91Engine Mounts - Inspect ....................................... 95Engine Speed/Timing Sensors - Check/Clean/Calibrate .............................................................. 99Engine Valve Lash - Inspect/Adjust .................... 100Engine Valve Rotators - Inspect ......................... 101Heat Exchanger - Inspect .................................... 110Starting Motor - Inspect ....................................... 117

76 SEBU7782-01Maintenance SectionMaintenance Interval Schedule

Every 5000 Service HoursAlternator - Inspect ............................................... 78Cooling System Coolant (ELC) - Change ............. 84Cylinder Head Grounding Stud - Inspect/Clean/Tighten ................................................................ 91Water Pump - Inspect ......................................... 120

OverhaulOverhaul (Top End) .............................................. 112Overhaul Considerations ..................................... 113


Aftercooler Condensate Drain Valve - Inspect/Clean

i02098179

Aftercooler Condensate DrainValve - Inspect/CleanSMCS Code: 1063-042-DN, VL

g01069660Illustration 31(1) Adapter(2) Valve(3) Plunger(4) Valve seat

The engine boost pressure forces the plunger tomove down to the valve seat. The plunger mustclose against the seat at a pressure of 27.5 kPa(4 psi). When the engine is stopped, the absenceof boost pressure allows the plunger to rise to theopen position, which allows condensation from theaftercooler to drain out.

The plunger must be able to move freely in order toclose the system when the engine is running. Theplunger must be able to move freely in order to allowcondensation to drain from the aftercooler whenthe engine is stopped. Residue from normal engineoperation could cause the plunger to stick.

1. Remove the valve from the adapter. Check thevalve in order to determine if the plunger movesfreely. If the plunger does not move easily, cleanthe valve with solvent.

2. Reassemble the aftercooler condensate drainvalve. Refer to the Operation and MaintenanceManual for more information on the propertorques.

i02864432

Aftercooler Core - Clean/Test(Engines that are Sea WaterAftercooled and Equippedwith Crankcase FumesRecirculation System)SMCS Code: 1064-070; 1064-081

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

2. Turn the aftercooler core upside-down in order toremove debris.

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

3. Back flush the core with cleaner.

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

Table 25

Hydrosolv Liquid Cleaners(1)

Description Container

1U-5490 Hydrosolv 4165 19 L (5 US gal)

174-6854 Hydrosolv 100 19 L (5 US gal)(1) Use a two to five percent concentration of the cleanerat temperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

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

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

78 SEBU7782-01Maintenance SectionAlternator - 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 lessthan 205 kPa (30 psi) for cleaning purposes.

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

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

8. Install the core. Refer to the Service Manual forthe procedure.

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

i02676048

Alternator - InspectSMCS Code: 1405-040

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

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

i01042055

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

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

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

Check the following components for wear or damage:

• Bearings

• Impeller

• Seals

• Wear plate

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

i02153996

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.


Battery Electrolyte Level - Check

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

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

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe cable from the NEGATIVE “-” battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE“+” battery terminal to the starting motor.Disconnect the cable from the POSITIVE “+”battery terminal.

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

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

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

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

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535

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

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

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

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

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

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

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

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

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

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

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

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

80 SEBU7782-01Maintenance SectionBelts - Inspect/Adjust

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

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

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

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

i02856845

Belts - Inspect/AdjustSMCS Code: 1357-025; 1357-040

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

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

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

• Belts

• Pulleys

• Bearings

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

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

Alternator Belt Adjustment

g00960176Illustration 32(1) Adjusting nuts(2) Mounting bolt(3) Mounting bolt(4) Mounting bolt

1. Remove the drive belt guard.

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

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

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

5. Reinstall the drive belt guard.

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

i02856850

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

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

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


Closed Crankcase Ventilation (CCV) Fumes Disposal Filter - Replace

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

• Belts

• Pulleys

• Bearings

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

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

Alternator Belt Adjustment

g00960176Illustration 33(1) Adjusting nuts(2) Mounting bolt(3) Mounting bolt(4) Mounting bolt

1. Remove the drive belt guard.

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

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

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

5. Reinstall the drive belt guard.

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

i01735844

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

g00889933Illustration 34(1) Air cleaner element(2) Fumes disposal filter

The Closed Crankcase Ventilation system (CCV)requires the replacement of the fumes disposal filter.The service interval of the CCV will be affected bythe following items:

• Engine load

• Soot concentration

• Condition of the engine

Use the following steps in order to ensure the properreplacement of the fumes disposal filter.

1. Remove air cleaner element (1).

2. Remove fumes disposal filter (2).

3. Install a new fumes disposal filter (2).

82 SEBU7782-01Maintenance SectionCooling System Coolant (DEAC) - Change

4. Install air cleaner element (1).

i02070334

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

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

• The engine overheats frequently.

• Foaming of the coolant

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

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

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

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

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

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

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

Allow the coolant to drain.

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

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

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

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

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

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add .5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

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

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

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


Cooling System Coolant (DEAC) - Change

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

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

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



3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add .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 the engine and run the engine at low idle for aminimum of 90 minutes. The coolant temperatureshould be at least 82 °C (180 °F).

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

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


FillRefer to the Operation and Maintenance Manual,“Refill Capacities and Recommendations” topic forthe capacity of the engine’s system and for coolantrecommendations.

Engines that are Equipped with a CoolantRecovery Tank


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and Maintenance Manual,“Refill Capacities and Recommendations” topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

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

3. Add coolant to the cooling system until the coolingsystem is full.

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

84 SEBU7782-01Maintenance SectionCooling System Coolant (ELC) - Change

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

6. Pour coolant into the coolant recovery tank untilthe coolant reaches the “COLD FULL” mark.DO NOT fill the coolant recovery tank above the“COLD FULL” mark.

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

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

Engines that are Not Equipped with aCoolant Recovery Tank


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and Maintenance Manual,“Refill Capacities and Recommendations” topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

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

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (.5 inch) to the proper level on the sightglass (if equipped).

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


i02070355

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

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

• The engine overheats frequently.

• Foaming of the coolant

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

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

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

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

Drain


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

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

Allow the coolant to drain.

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


Cooling System Coolant (ELC) - Change

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

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

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



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

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


Fill

Engines that are Equipped with a CoolantRecovery Tank


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

2. Start the engine and operate the engine at lowidle. Increase the engine rpm to high idle. Operatethe engine at high idle for one minute in order topurge air from the cavities of the engine block.Stop the engine.

3. Pour more ELC into the cooling system until thecooling system is full.

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

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

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

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


Engines that are NOT Equipped with aCoolant Recovery Tank


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

86 SEBU7782-01Maintenance SectionCooling System Coolant Extender (ELC) - Add

2. Start the engine and operate the engine at lowidle. Increase the engine rpm to high idle. Operatethe engine at high idle for one minute in order topurge air from the cavities of the engine block.Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (.5 inch) to the proper level on the sightglass (if equipped).

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


i02482066

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

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

NOTICEUse only Cat Extended Life Coolant (ELC) Extenderwith Cat ELC.

Do NOT use conventional supplemental coolant addi-tive (SCA) with Cat ELC. Mixing Cat ELC with conven-tional coolants and/or conventional SCA reduces theCat ELC service life.

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

Personal injury can result from hot coolant, steamand alkali.

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

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

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

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

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

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

Dispose of all fluids according to local regulations andmandates.

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

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

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

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


Cooling System Coolant Level - Check

i02456586

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

Engines That Are Equipped with aCoolant Recovery Tank

g00103638Illustration 35(1) Filler cap(2) “COLD FULL” mark(3) “LOW ADD” mark

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

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

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

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

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

Engines That Are Not Equippedwith a Coolant Recovery Tank


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

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

g00103639Illustration 36Typical filler cap gaskets

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

4. Inspect the cooling system for leaks.

i02837191

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

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

88 SEBU7782-01Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

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

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

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 26

Recommended Interval

Type of Coolant Level 1 Level 2

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

Cat ELC Optional(2) Yearly(2)

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

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

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

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

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

Use the following guidelines for proper sampling ofthe coolant:

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

• Keep the unused sampling bottles stored in plasticbags.

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

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

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

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis,see this Operation and Maintenance Manual, “RefillCapacities and Recommendations” or consult yourCaterpillar dealer.

i01987714

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


Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

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


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

i02839449

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

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

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

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

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


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

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

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

Cooling Systems that UseConventional CoolantThis maintenance procedure is required forconventional coolants such as DEAC.Thismaintenance is NOT required for cooling systemsthat are filled with Extended Life Coolant.

Test the Concentration of the SCA

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

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit.

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

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

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

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

90 SEBU7782-01Maintenance SectionCooling System Water Temperature Regulator - Replace

Cooling Systems that Use Waterand SCA

Test the Concentration of the SCA

Test the concentration of the SCA with a 298-5311Coolant Nitrite Test Kit for SCA or perform an S·O·SCoolant Analysis. The test kit includes the followingitems: a tool for the testing, 30 ampoules for testingnitrite, instructions, and a case. 294-7420 TestKit contains the refill ampoules for the 298-5311Coolant Nitrite Test Kit. Use the instructions that areincluded with the test kit in order to properly conductthe testing.

Refer to this Operation and Maintenance Manual,“Maintenance Interval Schedule” for the times atwhich the procedures should be conducted. Test theconcentration of the SCA more frequently if morefrequent testing is indicated by the results of theS·O·S Coolant Analysis.

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

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

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

3. Add the proper amount of SCA. For the properamount of SCA, refer to this Operation andMaintenance Manual, “Refill Capacities andRecommendations” topic. For the properconcentration of SCA, refer to Special Publication,SEBU6251, “Caterpillar Commercial DieselEngine Fluids Recommendations”.

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

i02623972

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

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

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

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

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

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

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

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

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


Crankshaft Vibration Damper - Inspect

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

i02784484

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

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

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

Removal and InstallationRefer to the Disassembly and Assembly Manual forthe damper removal procedure and for the damperinstallation procedure.

Visconic DamperThe visconic damper has a weight that is locatedinside a fluid filled case. The weight moves in thecase in order to limit torsional vibration. Inspect thedamper for evidence of dents, cracks or leaks of thefluid.

Replace the damper if the damper is dented, crackedor leaking. Refer to the Service Manual or consultyour Caterpillar dealer for damper replacement.

i02863392

Cylinder Head Grounding Stud- Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079

Inspect the harness for good connections. Inspectthe condition of the harness.

The cylinder head grounding stud must have a wireground to the battery. Tighten the cylinder headgrounding stud at every oil change. Ground wiresand straps should be combined at engine grounds.All grounds should be tight and free of corrosion.

• Clean the cylinder head grounding stud and theterminals for the cylinder head ground strap witha clean cloth.

• If the connections are corroded, clean theconnections with a solution of baking soda andwater.

• Keep the cylinder head grounding stud and thestrap clean and coated with MPGM grease orpetroleum jelly.

i01646701

Engine - CleanSMCS Code: 1000-070

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

Moisture can create paths of electrical conductiv-ity.

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

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

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

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

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

92 SEBU7782-01Maintenance SectionEngine Air Cleaner Element - Clean/Replace

i01727320

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

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

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

g00887344Illustration 37

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

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

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

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

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

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

4. Shake excess water off the air cleaner element ,and allow the air cleaner element to air dry. Dryingthe air cleaner element in the sun speeds theprocess.

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

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

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


Engine Air Cleaner Service Indicator - Inspect

Type 2


1. Disconnect latches (1).

2. Remove cover (2).


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

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

5. Install the air cleaner element (3).

g00888209Illustration 39Sequence for latches

6. Install cover (2). Fasten cover (2) with latches(1)in the sequence that is shown in Illustration 39.

Type 3


1. Disconnect latches (1).

2. Remove cover (2).


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

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

5. Install the air cleaner element (3).

6. Install cover (2).

7. Fasten cover (2) with latches (1).

i01900118

Engine Air Cleaner ServiceIndicator - Inspect(If Equipped)SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

94 SEBU7782-01Maintenance SectionEngine Crankcase Breather - Clean

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

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

g00103777Illustration 41Typical service indicator

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

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

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

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

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

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

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

i02263740

Engine Crankcase Breather -CleanSMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

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

g01136454Illustration 42Typical example(1) Hose clamp(2) Breather assembly(3) Retaining clamp(4) Seal

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

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

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


Engine Mounts - Inspect

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

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

i02456872

Engine Mounts - InspectSMCS Code: 1152-040

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

• Improper mounting of the engine

• Deterioration of the engine mounts

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

i02703852

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

g01356472Illustration 43Right hand service shown

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

g00110310Illustration 44Oil level gauge(Y) “ADD” mark(X) “FULL” mark

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

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

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

i02817772

Engine Oil Level Gauge -CalibrateSMCS Code: 1326-524

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

• Angle of the installation

• Side for service

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

Note: The engine may be equipped with auxiliaryengine oil filters. The extra filters require moreengine oil than the standard amounts. Refer to thespecifications of the original equipment manufacturer(OEM).

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

96 SEBU7782-01Maintenance SectionEngine Oil Sample - Obtain

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

Note: If the engine has oil in the crankcase, skip Step2 and proceed to Step 3.

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

• Deep Oil Sump: Fill the crankcase with 109.9 L(116 qt) of the recommended oil if the oil filtersare full.

Note: If the oil filters are dry, add an additional 2 L(2.1 qt) for each oil filter on the engine.

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

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

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

4. If needed, replace the engine oil filter by usingthe procedure in this Operation and MaintenanceManual, “Engine Oil and Filter - Change ”.

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

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

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

• Deep Oil Sump: Fill the crankcase with 109.9 L(116 qt) of the recommended oil if the oil filtersare full.

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

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

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

11.Add 28.3 L (30 qt) of the recommended oil gradeand weight of engine oil to the crankcase with adeep sump. Allow the oil to drain into the sump forapproximately 20 minutes.

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

g00110310Illustration 45Oil Level Gauge “ADD” mark (Y) and “FULL” mark (X)

i01935337

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

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

Obtain the Sample and the Analysis

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

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

• Engine model

• Service hours on the engine


Engine Oil and Filter - Change

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

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

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

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

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

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


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

For instructions, see Special Publication, PEHP6001,“How To Take A Good Oil Sample”. Consult yourCaterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02863572

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

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

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

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

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

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

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

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

Replace the Oil Filter With theEngine Stopped (Standard OilFilters)

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

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

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

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

98 SEBU7782-01Maintenance SectionEngine Oil and Filter - Change

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

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

g00103713Illustration 46Typical filter mounting base and filter gasket

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

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

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

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

Replacing the Engine Oil FiltersDuring Engine Operation (DuplexOil Filters)

This filter contains hot, pressurized oil that cancause burns and fire hazards, which may resultin bodily injury or death. Follow the instructionsgiven in this Operation and Maintenance Manualand stop the engine if rapid air movement existsto blow the oil.


If the engine is equipped with duplex oil filters, theengine oil filter elements can be changed while theengine is in operation. This is useful if the oil filterelements require more frequent replacement thanthe engine oil.



Engine Speed/Timing Sensors - Check/Clean/Calibrate

1. Open the “FILL” valve for a minimum of fiveminutes in order to fill the oil filter elements thatwill not be serviced. The oil filters that will not beserviced must be full of engine oil. Close the FILLvalve.

2. Move the control valve to the “AUX RUN” positionin order to change the main oil filter elements.Move the selector valve to the “MAIN RUN”position in order to change the auxiliary oil filterelements.

3. Allow the oil pressure gauge for the oil filter thatis being changed to reach a “ZERO” pressurereading.

4. Perform Step 1 through Step 5 of “Replace the OilFilter with the Engine Stopped”.

5. Open the “FILL” valve for a minimum of fiveminutes in order to fill the new oil filter elements.

6. Close the “FILL” valve. Rotate the control valveto the “RUN” position for the oil filter that wasserviced.

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

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

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

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

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

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

i02267169

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

g01137086Illustration 49Front view(1) Secondary speed/timing sensor(2) Primary speed/timing sensor

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

2. Clean the metal shavings and other debris fromthe face of the speed/timing sensors. Use theprocedure in the Service Manual in order tocalibrate the speed/timing sensors.

Refer to the Service Manual for more information onthe speed/timing sensors.

100 SEBU7782-01Maintenance SectionEngine Storage Procedure - Check

i01458399

Engine Storage Procedure -CheckSMCS Code: 1000-535

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

• Mileage

• Operating hours

• Fuel consumption

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

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

i01849001

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

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

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

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

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

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

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

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

The following components should be inspected andadjusted when the valves are inspected and adjusted.

• Valve actuators

• Injectors

• Compression brakes

Refer to the Service Manual for more information.


Engine Valve Rotators - Inspect

i01597115

Engine Valve Rotators - InspectSMCS Code: 1109-040

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

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

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

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

2. Operate the engine at low idle.

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

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

If a valve fails to rotate, consult your Caterpillardealer.

i02728734

Fuel System - PrimeSMCS Code: 1258-548

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

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

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

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


102 SEBU7782-01Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace

g01368408Illustration 51(1) Fuel priming pump(2) Fuel filter base(3) Secondary fuel filter

Follow the procedure below in order to prime theengine with fuel.

1. Turn the priming pump plunger (4)counterclockwise in order to unlock theplunger. Manually pump the plunger in order to fillthe fuel lines and the fuel filters with fuel.

2. As the air is purged from the fuel system, fuelpressure will increase. This will create resistancein the plunger. Continue to pump the plunger untila strong resistance is felt. The number of strokeswill vary with the amount of air in the fuel lines.

3. After resistance is felt in the plunger, push in theplunger. Lock the plunger by turning the plungerclockwise.

4. Start the engine at low idle.

5. If the engine runs rough, continue to run theengine at low idle until the engine runs smoothly.

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

i02053433

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.Water in the fuel may cause a electronic unit injectorto fail. If the fuel has been contaminated with water,the element should be changed before the regularlyscheduled interval.

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

Replace the Element

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

1. Close the main fuel supply valve.

g00104012Illustration 52Element (1), Bowl (2), and Drain (3)

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

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

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

• Bowl


Fuel System Primary Filter/Water Separator - Drain

• O-ring

• Mounting base

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

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

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

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

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

NOTICEThe water separator is under suction during normalengine operation. Ensure that the vent plug is tight-ened securely to help prevent air from entering the fu-el system.

8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run theengine for one minute. Stop the engine and checkfor leaks again.

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

i01463757

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

g00668636Illustration 53(1) Bowl(2) Element(3) Drain

Bowl (1) should be monitored daily for signs of water.If water is present, drain the water from the bowl.

1. Open drain (3). The drain is a self-ventilated drain.Catch the draining water in a suitable container.Dispose of the water properly.

2. Close drain (3).

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

i02863788

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

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. Clean up fuelspills immediately.

104 SEBU7782-01Maintenance SectionFuel System Secondary Filter - Replace




NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: If the engine is equipped with duplex fuelfilters, the fuel filter elements can be changed whilethe engine is in operation. Refer to “Replacing theFuel Filter Elements During Engine Operation ForEngines That Are Equipped With Duplex Fuel Filters”.

Replacing the Fuel Filter Elementswith the Engine Stopped

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

g01369362Illustration 54Right hand service(1) Fuel priming pump(2) Fuel filter

1. Stop the engine.

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

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

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

4. Unlock fuel priming pump (1) in order to relieveresidual pressure in the fuel system.

5. Remove used fuel filter (2). Use a cloth or use acontainer in order to catch excess fuel.

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

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

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


Fuel System Secondary Filter - Replace

8. Install the new fuel filter. Tighten the fuel filter untilthe gasket contacts the base. Tighten the fuelfilter by hand according to the instructions that areshown on the fuel filter. Do not overtighten the fuelfilter.

Note: Do not remove the plug in the fuel filter base inorder to release the air from the fuel system duringperiodic service of the fuel filter. Periodic removal ofthe plug will result in increased wear of the threads inthe fuel filter base.

9. Operate the fuel priming pump plunger until astrong resistance is felt and until the check valveclicks. This procedure will require considerablestrokes. Lock the fuel priming pump.

10.Open the fuel tank supply valve.

11.Start the engine according to the normal operatingprocedures. Immediately increase the engine rpmbetween 1000 to 1200 rpm with no load. Theengine will begin to misfire briefly until air fromthe fuel filter is purged. No damage to the enginewill occur.

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

12. If the engine stalls during the purging of the air,refer to the Operation and Maintenance Manual,“Fuel System - Prime” in the Maintenance Sectionfor more information.

Replacing the Fuel Filter ElementsDuring Engine Operation ForEngines That Are Equipped WithDuplex Fuel FiltersIf the engine is equipped with duplex fuel filters, thefuel filters can be changed while the engine is inoperation.

This filter contains pressurized fuel that can causea fire hazard, which may result in bodily injury ordeath. Follow the instructions given in this Opera-tion and Maintenance Manual and stop the engineif rapid air movement exists to blow the fuel.

Changing the Main Fuel Filter

g01369366Illustration 55Duplex fuel filtersEngines are shipped from the factory with the control valve (6) inthe MAIN RUN position.(3) Fuel pressure gauge for the main fuel filter(4) Plate that shows the position of the valve(5) Fuel pressure gauge for the auxiliary fuel filter(6) Control valve(7) Auxiliary fuel filter(8) Main fuel filter

Use the following procedure in order to change themain fuel filter while the engine is in operation.



1. Move control valve (6) to the RH FLOW andLH FILL position as marked on plate (4). Fuelpressure gauge (3) for the main fuel filter shouldindicate full pressure. Fuel pressure gauge (5)for the auxiliary fuel filter should indicate slightpressure. Allow the auxiliary fuel filter (7) to fill forfive minutes. The auxiliary fuel filter must becomefull of fuel.


2. Move control valve (6) to the “AUX RUN” position.Fuel pressure gauge (5) for the auxiliary fuelfilter should indicate full pressure. Fuel pressuregauge (3) for the main fuel filter should indicateno pressure.



3. Remove used main fuel filter (8). Use a cloth oruse a container in order to catch excess fuel.

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

5. Apply clean diesel fuel to the new main fuel filtergasket.

6. Install new main fuel filter (8). Tighten the fuel filteruntil the gasket contacts the base. Tighten the fuelfilter by hand according to the instructions that areshown on the fuel filter. Do not overtighten the fuelfilter.


7. Move control valve (6) to the “LH FLOW and RHFILL” position. Fuel pressure gauge (5) for theauxiliary fuel filter should indicate full pressure.Fuel pressure gauge (3) for the main fuel filtershould indicate slight pressure. Allow the mainfuel filter (8) to fill for five minutes. The main filtermust become full of fuel.


Fuel System Secondary Filter - Replace


8. Move control valve (6) to the “MAIN RUN” position.The fuel pressure gauge (3) for the main fuel filtershould indicate full pressure. The fuel pressuregauge (5) for the auxiliary fuel filter should indicateno pressure.

Changing the Auxiliary Fuel Filter

The procedure for changing the auxiliary fuel filter issimilar to the procedure for changing the main fuelfilter.

g01369374Illustration 60Duplex fuel filtersThe engine is operating with the control valve (6) in the “AUXRUN” position.(3) Fuel pressure gauge for the main fuel filter(4) Plate that shows the position of the valve(5) Fuel pressure gauge for the auxiliary fuel filter(6) Control valve(7) Auxiliary fuel filter(8) Main fuel filter

Use the following procedure in order to change theauxiliary fuel filter while the engine is in operation.



1. Move control valve (6) to the “LH FLOW and RHFILL” position. Fuel pressure gauge (5) for theauxiliary fuel filter should indicate full pressure.Fuel gauge (3) for the main fuel filter shouldindicate slight pressure. Allow the main fuel filter(8) to fill for five minutes. The main fuel filter mustbecome full of fuel.


2. Move control valve (6) to the “MAIN RUN” position.Fuel pressure gauge (3) for the main fuel filtershould indicate full pressure. Fuel pressure gauge(5) for the auxiliary fuel filter should indicate nopressure.



3. Remove used auxiliary fuel filter (7). Use a clothor use a container in order to catch excess fuel.

4. Clean the gasket sealing surface of the auxiliaryfuel filter base. Ensure that all of the old gasketis removed.

5. Apply clean diesel fuel to the new auxiliary fuelfilter gasket.

6. Install new auxiliary fuel filter (7). Tighten the fuelfilter until the gasket contacts the base. Tightenthe fuel filter by hand according to the instructionsthat are shown on the fuel filter. Do not overtightenthe fuel filter.


7. Move control valve (6) to the “RH FLOW andLH FILL” position. Fuel pressure gauge (3) forthe main fuel filter should indicate full pressure.Fuel pressure gauge (5) for the auxiliary fuel filtershould indicate slight pressure. Allow the auxiliaryfuel filter (7) to fill for five minutes. The auxiliaryfuel filter must become full of fuel.


Fuel Tank Water and Sediment - Drain


8. Move control valve (6) to the “AUX RUN” position.Fuel pressure gauge (5) for the auxiliary fuelfilter should indicate full pressure. Fuel pressuregauge (3) for the main fuel filter should indicateno pressure.

i02571779

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




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

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

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

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

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

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

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

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A 4 micron [c] filter for the breather vent onthe fuel tank is also recommended. Refer to SpecialPublication, SENR9620, “Improving Fuel SystemDurablity”.

110 SEBU7782-01Maintenance SectionHeat Exchanger - Inspect

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

i02683693

Heat Exchanger - InspectSMCS Code: 1379-040

Personal injury can result from hot coolant, steamand alkali.

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

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

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.




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

• Cleanliness of the heat exchanger plates

• Effectiveness of the heat exchanger system

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

The following items indicate that the heat exchangermay require cleaning:

• Increased coolant temperature

• Engine overheating

• Excessive pressure drop between the water inletand the water outlet

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

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

Consult your Caterpillar dealer or refer to theService Manual for service information for the heatexchanger.

Cleaning the Plate Type Heat Exchanger

Refer to the Disassembly and Assembly Manualfor the engine. The heat exchanger must bedisassembled in order to be cleaned. TheDisassembly and Assembly Manual will containinstructions for cleaning the heat exchanger prior toreassembly. The following general guidelines are forcleaning a plate type heat exchanger. Refer to Table27 for types of cleaners.


Hoses and Clamps - Inspect/Replace

NOTICEDo not use hydrochloric acid to clean stainless steelplates.

Do not use hydrofluoric acid to clean titanium plates.

Water that contains more than 300 ppm of chlorineshould not be used to prepare cleaning solutions.

Do not use Ketones such as Acetone and Methyle-tyketone.

Do not use esters such as Ethylacetate and Butylac-etate.

Do not use Halogenated hydrocarbons such asChlorothene and Carbon Tetrachloride

Do not use Aromatics such as Benzene and Toluene.

Table 27

Problem Source Cleaners(1)

Scaling

Calciumcarbonate

Calcium sulfateSilicates

Sediment(2)

Corrosionproducts

Metal oxidesSilt

Diatomicorganisms

Gross fouling

SeaweedChips of woodand fibersMusselsBarnacles

Biological growthBacteriaNematodesProtozoa

Nitric acidSulfamic acidCitric acid

Phosphoric acidComplexingagentsSodium

polyphosphates

ResidueOily filmsAsphaltFats

Paraffinic orNaphtha basedsolvent such asKerosene.(3)(4)

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

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

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

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

1. Drain the heat exchanger.

2. Disassemble the heat exchanger and remove theplates. Keep the plates in order.

3. Clean the plates with a cleaning solution and asoft brush. Pressurized water may also be used.Do not use steel wool or a wire brush, which mayscratch the plate. Any iron scratches on the platescan lead to corrosion of the plates. Rinse theplates with water.

4. Assemble the heat exchanger.

i02121526

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

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

• Cracking

• Softness

• Loose clamps

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

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

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

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

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

112 SEBU7782-01Maintenance SectionMarine Transmission Oil Level - Check

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

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


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

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

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

3. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: Refer to the Specifications, SENR3130,“Torque Specifications” in order to locate the propertorques.

8. Refill the cooling system.

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

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

i01089872

Marine Transmission Oil Level- CheckSMCS Code: 3081-535

Check the marine transmission oil level according tothe instructions that are provided by the OEM of thetransmission or the OEM of the vessel.

For the lubrication requirements of the transmission,refer to the recommendations on the nameplate orthe “Owner’s Manual” for the transmission.

Marine Transmission Operation,Maintenance, Warranty, and PartsSupportFor information on maintenance and operation of themarine transmission, consult your Caterpillar dealerand/or the OEM dealer of the transmission.

All support for the warranty of the transmission will bethe responsibility of the OEM. All parts support for thetransmission will be the responsibility of the OEM.This parts support includes both the installation ofparts and the resolution of any service problems.

i02863869

Overhaul (Top End)SMCS Code: 7595-020-TE

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

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

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


Overhaul Considerations

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

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

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

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of therecommendations in Table 28.

Table 28

Recommendations for Top End Overhauls (1)

Service Top End Overhaul

Cylinder head assembliesInspectRebuildReplace Valves

Rocker armsInspectReplace

Valve bridges

Cylinder head gasketsReplace

Aftercooler core(2)

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

(2) Sea water aftercooled systems only

i02863871

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will result in alower average power demand. A decreased averagepower demand should increase both the engineservice life and the overhaul interval.

The need for an overhaul is generally indicated byincreased fuel consumption and by reduced power.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Using Fuel Consumption ForCalculating the Overhaul IntervalsExperience has shown that the interval foran overhaul is most accurately based on fuelconsumption. Fuel consumption corresponds moreaccurately to the engine load.

114 SEBU7782-01Maintenance SectionOverhaul Considerations

Table 29

Schedule for Overhaul IntervalsFuel Consumption for C32 ACERT Commercial Diesel Engines

Rating

IntervalA B C D

Top End Overhaul 1,000,000 L (264,000 US gal)

Major Overhaul 2,000,000 L (528,000 US gal)

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

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

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

When an engine’s oil consumption has risen to threetimes the original oil consumption rate due to normalwear, an engine overhaul should be scheduled.There may be a corresponding increase in blowbyand a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

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

• Costly unplanned downtime can be avoided.

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

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

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

After Failure Overhaul

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

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

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

Overhaul RecommendationTo minimize downtime, a scheduled engine overhaulby your Caterpillar dealer is recommended. This willprovide you with the best cost/value relationship.

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

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


Overhaul Considerations

Unit Fuel Injector

Clean the fuel injector body and replace the O-rings.Replace the O-rings and the gasket on the injectorsleeve. Clean the area around the injector seatingin the injector sleeve. Refer to the Service Manualfor the complete procedure, or consult with yourCaterpillar dealer for assistance.

Rebuild or Exchange

Cylinder Head Assembly, Connecting Rods,Pistons, Cylinder Liners, Turbocharger, CylinderPacks, Oil Pump, and Fuel Transfer Pump

These components should be inspected according tothe instructions that are found in various Caterpillarreusability publications. The Special Publication,SEBF8029 lists the reusability publications that areneeded for inspecting the engine parts.

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

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

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

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine efficiency

• Increased fuel consumption

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

Inspection and/or Replacement

Piston Rings, Crankshaft Bearings, ValveRotators, and Crankshaft Seals

The following components may not last until thesecond overhaul.

• Thrust bearings

• Main bearings

• Rod bearings

• Valve rotators

• Crankshaft seals

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

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

• Rod bearing

• Main bearings

Note: If the crankshaft is removed for any reason,use the magnetic particle inspection process to checkfor cracks in the crankshaft.

Inspect the camshaft for damage to the journals andto the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to check forcracks in the camshaft.

Inspect the following components for signs of wear orfor signs of scuffing:

• Camshaft bearings

• Camshaft followers

Caterpillar Inc. recommends replacing the crankshaftvibration damper.

Oil Cooler Core and Aftercooler Core

During an overhaul, the removal of the oil coolercore and the aftercooler core is recommended. Theoil cooler core and the aftercooler core should becleaned and pressure tested.

116 SEBU7782-01Maintenance SectionOverhaul Considerations

Note: For sea water aftercooled systems, replacethe aftercooler core at the first top end overhaul, thesecond top end overhaul, and the major overhaul.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core and the aftercooler core.

1. Remove the oil cooler core and the aftercoolercore.

2. Remove any debris from the oil cooler core andthe aftercooler core. To remove debris from the oilcooler core, turn the oil cooler core onto one end.To remove debris from the aftercooler core, turnthe aftercooler core upside-down.

3. Flush the oil cooler core and the aftercooler coreinternally with cleaner in order to loosen foreignsubstances. This will also help to remove oil fromthe oil cooler core and the aftercooler core.

Note: The use of Hydrosolv Liquid Cleaners isrecommended. Table 30 lists the Hydrosolv LiquidCleaners that are available from your Caterpillardealer.

Table 30

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Hydrosolv 100 19 L (5 US gallon)(1) Use a two to five percent concentration of the cleanerat temperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

4. Use steam to clean the oil cooler core and theaftercooler core. This removes any remainingresidue from the cleaner. Flush the fins of the oilcooler core and the aftercooler core. Remove anyother trapped debris.

5. Wash the oil cooler core and the aftercooler corewith hot, soapy water. Rinse the oil cooler core andthe aftercooler core thoroughly with clean water.

Personal injury can result from air pressure.

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

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

6. Dry the oil cooler core and the aftercooler corewith compressed air. Direct the air in the reversedirection of the normal flow.

7. Inspect the components in order to ensurecleanliness. The oil cooler core and the aftercoolercore should be pressure tested. Repair the oilcooler core and the aftercooler core, if necessary.Install the oil cooler core and the aftercooler core.

For more information about cleaning the cores,consult your Caterpillar dealer.

Obtain Coolant Analysis

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

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

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

S·O·S Coolant Analysis (Level 2)

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

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

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)


Sea Water Strainer - Clean/Inspect

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

For more information about coolant analysis, consultyour Caterpillar dealer.

i01556871

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

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

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


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

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

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

5. Open the valve for the sea water.

i02618737

Starting Motor - Inspect(If equipped)SMCS Code: 1451-040; 1453-040

Air Starting MotorIf the starting motor fails, the engine may not start inan emergency situation. A scheduled inspection ofthe starting motor is recommended.

The starting motor pinion and the flywheel ring gearmust be in good condition in order for the engineto start properly. The engine will not start if thestarting motor pinion does not engage the flywheelring gear. The teeth of the starting motor pinion andthe flywheel ring gear can be damaged because ofirregular engagement.

Inspect the starting motor for proper operation. Listenfor grinding when the engine is started. Inspect theteeth of the starting motor pinion and the flywheelring gear. Look for patterns of wear on the teeth. Lookfor teeth that are broken or chipped. If damaged teethare found, the starting motor pinion and the flywheelring gear must be replaced.

Personal injury or death can result from improp-erly checking for a leak.

Always use a board or cardboard when checkingfor a leak. Escaping air or fluid under pressure,even a pin-hole size leak, can penetrate body tis-sue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treatedimmediately by a doctor familiar with this type ofinjury.

Inspect all of the components in the air circuit forthe starting motor. Inspect all of the air lines andconnections for leaks.

If damaged teeth are found, the air circuit forthe starting motor must be examined in order todetermine the cause of the problem.

Electric Starting MotorIf the starting motor fails, the engine may not start inan emergency situation. A scheduled inspection ofthe starting motor is recommended.

118 SEBU7782-01Maintenance SectionTurbocharger - Inspect

The starting motor pinion and the flywheel ring gearmust be in good condition in order for the engineto start properly. The engine will not start if thestarting motor pinion does not engage the flywheelring gear. The teeth of the starting motor pinion andthe flywheel ring gear can be damaged because ofirregular engagement.

Inspect the starting motor for proper operation. Listenfor grinding when the engine is started. Inspect theteeth of the starting motor pinion and the flywheelring gear. Look for patterns of wear on the teeth. Lookfor teeth that are broken or chipped. If damaged teethare found, the starting motor pinion and the flywheelring gear must be replaced.

Problems with the electric starting motor can becaused by the following conditions: malfunction ofthe solenoid and malfunction of the electric startingsystem.

Inspect the electrical system for the followingconditions:

• Loose connections

• Corrosion

• Wires that are worn or frayed

• Cleanliness

Removal and Installation of theStarting MotorRefer to the Service Manual, “Disassembly andAssembly” module for information on removing thestarting motor and installing the starting motor.

Consult your Caterpillar dealer for assistance and/orfor options on replacement of the starting motor.

i01539769

Turbocharger - InspectSMCS Code: 1052-040; 1052

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

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

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

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

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

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

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

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

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


Walk-Around Inspection

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel forcontact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and theturbocharger housing. If there is any indication ofcontact between the rotating turbine wheel or thecompressor wheel and the turbocharger housing,the turbocharger must be reconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbochargeroil seal.

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

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

5. Inspect the bore of the turbine housing forcorrosion.

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

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

i01063972

Walk-Around InspectionSMCS Code: 1000-040

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

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

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

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

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

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

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

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

• Inspect the water pumps for coolant leaks.

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

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

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

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

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

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

120 SEBU7782-01Maintenance SectionWater Pump - Inspect

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

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

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

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

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

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

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

i01057943

Water Pump - InspectSMCS Code: 1361-040; 1361

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

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Visually inspect the water pump for leaks. If anyleaking is observed, replace the water pump sealor the water pump assembly. Refer to the ServiceManual for the disassembly and assembly procedure.

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

i01851812

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

Corrosion in sea water circuits can result in prematuredeterioration of system components, leaks, andpossible cooling system contamination.

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

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

Inspect the zinc rods within 24 hours of initiallyfilling the plumbing with sea water. If no significantcorrosion is noted, inspect the zinc rods again afterseven days or 50 hours of engine operation afterhaving been immersed in sea water. If no significantdeterioration is noted, continue inspections afterevery 50 hours of engine operation.

Inspect the Zinc RodsThe zinc rods are red for easy identification. Table31 shows the locations of the zinc rods and thequantities of the zinc rod:

Table 31

Locations of the Zinc Rods

Location Quantity

Inlet Adapter of the Heat Exchanger 1

Outlet Elbow of the Heat Exchanger 1

Outlet Elbow of the Auxiliary Water Pump 1

Outlet Adapter for the Aftercooler 1

1. Remove the zinc rod.


Zinc Rods - Inspect/Replace


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

Replace the Zinc Rods


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

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

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

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C32 Marine Engines (RND) - Maintenance Intervals

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