3126B Marine Engines: Maintenance Intervals

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COM
3126B
MARINE ENGINES
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU7242-05-01)
2007 Caterpillar
All Rights Reserved
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SEBU7242-05 57
Maintenance Section
Maintenance Interval Schedule
i02507477 First 5700 L (1500 US gal) of Fuel or 200

Service Hours
(High Performance) Engine Valve Lash - Inspect/Adjust ...................... 80
SMCS Code: 1000; 7500 PM Level 1 - Every 5700 L (1500 US gal) of

Fuel or 200 Service Hours or 1 Year
Ensure that all safety information, warnings, and
Aftercooler Condensate Drain Valve -
instructions are read and understood before any
Inspect/Clean ...................................................... 61
operation or any maintenance procedures are Alternator Belt - Inspect/Adjust/Replace ............... 62
performed.
Auxiliary Water Pump - Inspect ............................. 63
Battery Electrolyte Level - Check .......................... 63
The user is responsible for the performance of Cooling System Supplemental Coolant Additive
maintenance, including all adjustments, the use of
(SCA) - Test/Add ................................................. 72
proper lubricants, fluids, filters, and the replacement
Engine Air Cleaner Element - Clean/Replace ....... 74
of components due to normal wear and aging. Failure Engine Crankcase Breather - Clean ..................... 76
to adhere to proper maintenance intervals and
Engine Oil Sample - Obtain .................................. 78
procedures may result in diminished performance of
Engine Oil and Filter - Change ............................. 78
the product and/or accelerated wear of components. Fuel System Primary Filter (Water Separator)
Element - Replace .............................................. 82
Use mileage, fuel consumption, service hours, or
Fuel System Secondary Filter - Replace .............. 83
calendar time, WHICH EVER OCCURS FIRST, Fuel Tank Water and Sediment - Drain ................. 84
in order to determine the maintenance intervals.
Hoses and Clamps - Inspect/Replace .................. 85
Products that operate in severe operating conditions
may require more frequent maintenance.
Every 17 000 L (4500 US gal) of Fuel or 600
Note: Before each consecutive interval is performed, Service Hours
all maintenance from the previous interval must be Closed Crankcase Ventilation (CCV) Fumes Disposal
performed. Filter - Replace .................................................... 65
Turbocharger - Inspect/Clean ............................... 90
When Required
Battery - Replace .................................................. 63 PM Level 2 - Every 28 400 L (7500 US gal) of
Battery or Battery Cable - Disconnect .................. 64 Fuel or 1000 Service Hours or 2 Years
Engine Oil Level Gauge - Calibrate ...................... 77
Aftercooler Core - Clean/Test ............................... 61
Engine Storage Procedure - Check ...................... 80
Heat Exchanger - Inspect ..................................... 85
Fuel System - Prime ............................................. 80
Every 85 200 L (22 500 US gal) of Fuel or
Daily
3000 Service Hours or 3 Years
Closed Crankcase Ventilation (CCV) Filter Service
Cooling System Coolant (DEAC) - Change .......... 66
Indicator - Inspect ............................................... 64
Cooling System Coolant Level - Check ................ 71 Cooling System Coolant Extender (ELC) - Add .... 70
Engine Air Cleaner Service Indicator - Inspect ..... 75
Engine Oil Level - Check ...................................... 76 PM Level 3 - Every 56 800 L (15 000 US gal)
Fuel System Primary Filter/Water Separator - of Fuel or 2000 Service Hours
Drain ................................................................... 82
Alternator - Inspect ............................................... 62
Fuel System Water Separator - Drain ................... 83 Cooling System Water Temperature Regulator -
Marine Transmission Oil Level - Check ................ 86
Replace ............................................................... 73
Walk-Around Inspection ........................................ 91
Crankshaft Vibration Damper - Inspect ................. 74
Engine Mounts - Inspect ....................................... 76
Every 1400 L (375 US gal) of Fuel or 50 Engine Valve Lash - Inspect/Adjust ...................... 80
Service Hours Starting Motor - Inspect ........................................ 89
Water Pump - Inspect ........................................... 91
Zinc Rods - Inspect/Replace ................................. 92
Every 5700 L (1500 US gal) of Fuel or 150 Every 170 400 L (45 000 US gal) of Fuel or
Service Hours for Engines Used in Severe 6000 Service Hours or 6 Years
Applications Cooling System Coolant (ELC) - Change ............. 68
Engine Oil and Filter - Change ............................. 78

58 SEBU7242-05
Maintenance Section
Overhaul
Overhaul Considerations ...................................... 86

SEBU7242-05 59
Maintenance Section
i02507545 PM Level 1 - Every 5700 L (1500 US gal) of

Fuel or 200 Service Hours or 1 Year
(Commercial Ratings) Aftercooler Condensate Drain Valve -
Inspect/Clean ...................................................... 61
Alternator Belt - Inspect/Adjust/Replace ............... 62
SMCS Code: 1000; 7500
Auxiliary Water Pump - Inspect ............................. 63
Ensure that all safety information, warnings, and Battery Electrolyte Level - Check .......................... 63
Cooling System Supplemental Coolant Additive
instructions are read and understood before any
(SCA) - Test/Add ................................................. 72
operation or any maintenance procedures are
performed. Fuel Tank Water and Sediment - Drain ................. 84
Hoses and Clamps - Inspect/Replace .................. 85
The user is responsible for the performance of
maintenance, including all adjustments, the use of Every 17 000 L (4500 US gal) of Fuel or 500
proper lubricants, fluids, filters, and the replacement Service Hours
of components due to normal wear and aging. Failure Engine Air Cleaner Element - Clean/Replace ....... 74
to adhere to proper maintenance intervals and
Engine Crankcase Breather - Clean ..................... 76
procedures may result in diminished performance of
Engine Oil Sample - Obtain .................................. 78
the product and/or accelerated wear of components. Engine Oil and Filter - Change ............................. 78
Fuel System Primary Filter (Water Separator)
Use mileage, fuel consumption, service hours, or
Element - Replace .............................................. 82
calendar time, WHICH EVER OCCURS FIRST, Fuel System Secondary Filter - Replace .............. 83
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Every 17 000 L (4500 US gal) of Fuel or 600
Service Hours
Note: Before each consecutive interval is performed, Closed Crankcase Ventilation (CCV) Fumes Disposal
all maintenance from the previous interval must be Filter - Replace .................................................... 65
performed. Turbocharger - Inspect/Clean ............................... 90
When Required PM Level 2 - Every 28 400 L (7500 US gal) of
Battery - Replace .................................................. 63 Fuel or 1000 Service Hours or 2 Years
Battery or Battery Cable - Disconnect .................. 64
Aftercooler Core - Clean/Test ............................... 61
Engine Oil Level Gauge - Calibrate ...................... 77
Heat Exchanger - Inspect ..................................... 85
Engine Storage Procedure - Check ...................... 80
Fuel System - Prime ............................................. 80
Daily 3000 Service Hours or 3 Years
Cooling System Coolant (DEAC) - Change .......... 66
Closed Crankcase Ventilation (CCV) Filter Service
Cooling System Coolant Extender (ELC) - Add .... 70
Indicator - Inspect ............................................... 64
Cooling System Coolant Level - Check ................ 71
Engine Air Cleaner Service Indicator - Inspect ..... 75 PM Level 3 - Every 56 800 L (15 000 US gal)
Engine Oil Level - Check ...................................... 76 of Fuel or 2000 Service Hours
Fuel System Primary Filter/Water Separator -
Alternator - Inspect ............................................... 62
Drain ................................................................... 82
Cooling System Water Temperature Regulator -
Fuel System Water Separator - Drain ................... 83 Replace ............................................................... 73
Marine Transmission Oil Level - Check ................ 86
Crankshaft Vibration Damper - Inspect ................. 74
Walk-Around Inspection ........................................ 91
Engine Mounts - Inspect ....................................... 76
Engine Valve Lash - Inspect/Adjust ...................... 80
Every 1400 L (375 US gal) of Fuel or 50 Starting Motor - Inspect ........................................ 89
Service Hours Water Pump - Inspect ........................................... 91
Zinc Rods - Inspect/Replace ................................. 92
First 5700 L (1500 US gal) of Fuel or 200 6000 Service Hours or 6 Years
Service Hours Cooling System Coolant (ELC) - Change ............. 68
Engine Valve Lash - Inspect/Adjust ...................... 80

60 SEBU7242-05
Maintenance Section
Overhaul
Overhaul Considerations ...................................... 86

SEBU7242-05 61
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean
i02053386 i01546702
Aftercooler Condensate Drain Aftercooler Core - Clean/Test

Valve - Inspect/Clean SMCS Code: 1064-070; 1064-081
SMCS Code: 1063-042-DN, VL
1. Remove the core. Refer to the Service Manual
for the procedure.
2. Turn the aftercooler core upside-down in order

to remove debris.
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.
3. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv

liquid cleaner. Table 12 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.
Table 12
g00701341 Hydrosolv Liquid Cleaners(1)
Illustration 17
(1) Valve Part
(2) Plunger Description Size
Number
(3) Valve seat
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
The boost pressure forces plunger (2) to move down
174-6854 Hydrosolv 100 19 L (5 US gallon)
on valve seat (3). The plunger must close against
the seat at a pressure of 27.5 kPa (4 psi). When the (1) Use a two to five percent concentration of the cleaner at
engine is stopped, the absence of boost pressure temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
allows the plunger to rise to the open position. This information.
allows the condensation from the aftercooler to drain
out. 4. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
The plunger must be able to move freely in order to Remove any other trapped debris.
close the system when the engine is running. The
plunger must be able to move freely in order to allow 5. Wash the core with hot, soapy water. Rinse the
condensation to drain from the aftercooler when core thoroughly with clean water.
the engine is stopped. Residue from normal engine
operation could cause the plunger to stick.
1. Remove valve (1) from the housing. Check the

valve in order to determine if plunger (2) moves Personal injury can result from air pressure.
freely. If the plunger does not move easily, clean
the valve with solvent. Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
2. Reassemble the aftercooler condensate drain tective face shield and protective clothing.
valve. Refer to the Specifications, SENR3130,
Torque Specifications. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
6. Dry the core with compressed air. Direct the air in

the reverse direction of the normal flow.

62 SEBU7242-05
Maintenance Section
Alternator - Inspect
7. Inspect the core in order to ensure cleanliness. i01323511

Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests. Alternator Belt -
If necessary, repair the core. Inspect/Adjust/Replace
8. Install the core. Refer to the Service Manual for SMCS Code: 1357-036; 1357-510
the procedure.
For more information on cleaning the core, consult Inspection

your Caterpillar dealer.
i00072207
Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection

of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required. Refer to the Service Manual.
Check the alternator and the battery charger for

proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
g00700096
affects the cranking power. If the battery is too cold, Illustration 18
the battery will not crank the engine. The battery will (1) Belt tensioner
not crank the engine, even if the engine is warm. (2) Serpentine belt
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries Remove the belt guard.
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge. Belt tension should be visually checked between
the first 20 to 40 hours of engine operation.
After the initial check, the belt tension should be

checked at Every 200 Service Hours or 1 Year.
To maximize the engine performance, inspect the

belts for wear and for cracking. Replace belts that are
worn or damaged.
If new belts are installed, check the belt tension again

after 30 minutes of engine operation at the rated rpm.
Inspect the belt tensioner for unusual noise,

excessive looseness and/or shaking of the bearings.
Install the belt guard.

SEBU7242-05 63
Maintenance Section
Auxiliary Water Pump - Inspect
i01059376
Auxiliary Water Pump - Inspect

The battery cables or the batteries should not be
SMCS Code: 1371-040 removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
Impellers require periodic inspection and seals ing is attempted.
require periodic inspection. Impellers have a service
life that is limited. The service life depends on the Removing the battery cables or the batteries with
engine operating conditions. the cover in place may cause a battery explosion
resulting in personal injury.
Inspect the components of the pump more frequently
when the pump is exposed to debris, sand, or other 1. Turn the key start switch to the OFF position.
abrasive materials. Inspect the components if the Remove the key and all electrical loads.
pump is operating at a differential pressure of more
than 103 kPa (15 psi). 2. Turn OFF the battery charger. Disconnect the
charger.
Check the following components for wear and check
the following components for damage: 3. The NEGATIVE - cable connects the NEGATIVE
- battery terminal to the ground plane. Disconnect
Cam the cable from the NEGATIVE - battery terminal.
Impeller 4. The POSITIVE + cable connects the POSITIVE
+ battery terminal to the starting motor.
Seals Disconnect the cable from the POSITIVE +
battery terminal.
Wear plate
Note: Always recycle a battery. Never discard a
If wear is found or if damage is found, replace battery. Return used batteries to an appropriate
the components which are worn or replace the recycling facility.
components which are damaged. Use the proper
repair kit for the pump. Refer to the Disassembly 5. Remove the used battery.
and Assembly for more information on servicing the
auxiliary water pump. 6. Install the new battery.
i02153996
Note: Before the cables are connected, ensure that
the key start switch is OFF.
Battery - Replace
7. Connect the cable from the starting motor to the
SMCS Code: 1401-510 POSITIVE + battery terminal.
8. Connect the cable from the ground plane to the

NEGATIVE - battery terminal.
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas- i02340858
es to ignite. This can result in severe personal in-
jury or death. Battery Electrolyte Level -
Ensure proper ventilation for batteries that are in
Check
an enclosure. Follow the proper procedures in or- SMCS Code: 1401-535
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are When the engine is not run for long periods of time or
serviced. when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero, when the engine is in operation.

64 SEBU7242-05
Maintenance Section
Battery or Battery Cable - Disconnect
1. Turn the start switch to the OFF position. Turn the

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

i01852860
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.

Closed Crankcase Ventilation
(CCV) Filter Service Indicator
Clean the battery case with one of the following
cleaning solutions:
- Inspect
SMCS Code: 1317-040-FI
A mixture of 0.1 kg (0.2 lb) of baking soda and
1 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 the

terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
g00744250
Illustration 19
i01492654
(1) Plastic cover
(2) Service indicator
Battery or Battery Cable -
The Closed Crankcase Ventilation system (CCV)
Disconnect is equipped with a service indicator. If the fumes
disposal filter becomes plugged prior to the normal
SMCS Code: 1402-029 service interval, increased restriction of the filter will
cause the crankcase pressure to become positive.
When the pressure continues to rise, the service
indicator will show through the plastic cover. The
The battery cables or the batteries should not be service indicator indicates the need for the fumes
removed with the battery cover in place. The bat- disposal filter to be changed. Refer to the Operation
tery cover should be removed before any servic- and Maintenance Manual, Closed Crankcase
ing is attempted. Ventilation (CCV) Fumes Disposal Filter - Replace
topic for more information.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion Note: Check the service indicator when the engine is
resulting in personal injury. running at low idle.

SEBU7242-05 65
Maintenance Section
Closed Crankcase Ventilation (CCV) Fumes Disposal Filter - Replace
i01413013 Resetting the Service Indicator

Closed Crankcase Ventilation
(CCV) Fumes Disposal Filter -
Replace
SMCS Code: 1317-510-FI
g00585674
Illustration 21
1. Remove plastic cover (4).
2. Push down on service indicator (5).
3. Replace cover (4).
4. Replace the fumes disposal filter by using the

following procedure:
Replacing the Fumes Disposal

Illustration 20
g00744007 Filter
(1) Air cleaner
(2) Crankcase breather
(3) Fumes disposal filter
Hot oil and hot components can cause personal
The Closed Crankcase Ventilation system (CCV) injury. Do not allow hot oil or hot components to
requires the replacement of the fumes disposal contact the skin.
filter. The service interval of the Closed Crankcase
Ventilation system (CCV) will be affected by the
following items: Note: When possible, perform the maintenance while
the engine is off.
Engine load
Soot concentration
Condition of the engine
The Closed Crankcase Ventilation system (CCV)
is equipped with a service indicator. If the fumes
disposal filter becomes plugged prior to the normal
service interval, increased restriction of the filter will
cause the vacuum to become positive. When the
pressure continues to rise, the service indicator will
show through the cap. The service indicator indicates
the need for the fumes disposal filter to be changed.
Reset the service indicator by using the following
g00585616
procedure: Illustration 22
1. Release latches (7) that hold the canister to filter

base assembly (6).

66 SEBU7242-05
Maintenance Section
Cooling System Coolant (DEAC) - Change
Note: Removal of canister (8) may be difficult while Drain

the engine is operating. The canister has negative air
pressure while the engine is operating. This creates
a vacuum.
Pressurized System: Hot coolant can cause seri-
2. Lower canister (8) in order to expose the element. ous burns. To open the cooling system filler cap,
There may be oil in the bottom of the canister. stop the engine and wait until the cooling system
Avoid spilling the oil. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
3. Remove the filter element by pulling down. sure.
4. Ensure that the O-ring is installed on the top of
the new element. Place the new element in the 1. Stop the engine and allow the engine to cool.
correct position on filter base assembly (6). Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
5. Ensure that the O-ring is installed on the lip which system filler cap.
is located at the top of canister (8). Install canister
(8) and align the canister with the boss on filter 2. Open the cooling system drain valve (if equipped).
base assembly (6). If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
6. Clamp latches (7) in the closed position.
Allow the coolant to drain.
7. Dispose of the used element properly.
NOTICE
i01081100
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
Cooling System Coolant coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
(DEAC) - Change Caterpillar to reclaim the used coolant.
SMCS Code: 1350-070; 1395-044
For information regarding the disposal and the
Clean the cooling system and flush the cooling recycling of used coolant, consult your Caterpillar
system before the recommended maintenance dealer or consult Caterpillar Service Technology
interval if the following conditions exist: Group:
The engine overheats frequently. Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Foaming of the coolant Canada: 1-800-523-TOOL
The oil has entered the cooling system and the Flush
coolant is contaminated.
1. Flush the cooling system with clean water in order
The fuel has entered the cooling system and the to remove any debris.
coolant is contaminated.
2. Close the drain valve (if equipped). Clean the
NOTICE drain plugs. Install the drain plugs. Refer to the
Use of commercially available cooling system clean- Specifications Manual for your particular engine for
ers may cause damage to cooling system compo- more specific information on the proper torques.
nents. Use only cooling system cleaners that are ap- Refer to the Specifications, SENR3130, Torque
proved for Caterpillar engines. Specifications for more general information on
the proper torques.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has NOTICE
been drained. This is a good opportunity to replace Fill the cooling system no faster than 19 L (5 US gal)
the water pump, the water temperature regulator and per minute to avoid air locks.
the hoses, if necessary.

SEBU7242-05 67
Maintenance Section
Cooling System Coolant (DEAC) - Change
3. Fill the cooling system with a mixture of clean 3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(4 US gal) of the cooling system capacity. Install (1 to 2 US gal) of the cooling system capacity.
the cooling system filler cap. Install the cooling system filler cap.
4. Start the engine and run the engine at low idle for a 4. Start the engine and run the engine at low idle for a
minimum of 30 minutes. The coolant temperature minimum of 90 minutes. The coolant temperature
should be at least 82 C (180 F). should be at least 82 C (180 F).
NOTICE NOTICE
Improper or incomplete rinsing of the cooling system Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com- can result in damage to copper and other metal com-
ponents. ponents.
To avoid damage to the cooling system, make sure To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa- to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the ter. Continue to flush the system until all signs of the
cleaning agent are gone. cleaning agent are gone.
5. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your plugs. Refer to the Specifications Manual for your
particular engine for more specific information on particular engine for more specific information on
the proper torques. Refer to the Specifications, the proper torques. Refer to the Specifications,
SENR3130, Torque Specifications for more SENR3130, Torque Specifications for more
general information on the proper torques. general information on the proper torques.
Cooling Systems with Heavy Fill

Deposits or Plugging Refer to the Operation and Maintenance Manual,
Coolant Specifications topic for information
Note: For the following procedure to be effective,
regarding acceptable water, coolant/antifreeze, and
there must be some active flow through the cooling
system components. supplemental coolant additive requirements. Refer
to the Operation and Maintenance Manual, Refill
Capacities topic for the capacity of the engines
1. Flush the cooling system with clean water in order
to remove any debris. system.
2. Close the drain valve (if equipped). Clean the Engines that are Equipped with a Coolant
drain plugs. Install the drain plugs. Refer to the Recovery Tank
Specifications Manual for your particular engine for
more specific information on the proper torques.
Refer to the Specifications, SENR3130, Torque NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Specifications for more general information on
per minute to avoid air locks.
the proper torques.
NOTICE 1. Fill the cooling system with coolant/antifreeze.

Fill the cooling system no faster than 19 L (5 US gal) Refer to the Operation and Maintenance
per minute to avoid air locks. Manual, Cooling System Specifications topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.

68 SEBU7242-05
Maintenance Section
Cooling System Coolant (ELC) - Change
2. Start the engine and run the engine at low idle. Engines that are Not Equipped with a
Increase the engine rpm to 1500 rpm. Run the Coolant Recovery Tank
engine at high idle for one minute in order to purge
the air from the cavities of the engine block. Stop
the engine. NOTICE
3. Add coolant to the cooling system until the cooling per minute to avoid air locks.
system is full.
1. Fill the cooling system with coolant/antifreeze.
4. Clean the cooling system filler cap. Inspect the Refer to the Operation and Maintenance
gasket that is on the cooling system filler cap. If Manual, Cooling System Specifications topic
the gasket that is on the cooling system filler cap (Maintenance Section) for more information on
is damaged, discard the old cooling system filler cooling system specifications. Do not install the
cap and install a new cooling system filler cap. cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A 2. Start the engine and run the engine at low idle.
9S-8140 Pressurizing Pump is used to perform Increase the engine rpm to 1500 rpm. Run the
the pressure test. The correct pressure for the engine at high idle for one minute in order to purge
cooling system filler cap is stamped on the face of the air from the cavities of the engine block. Stop
the cooling system filler cap. If the cooling system the engine.
filler cap does not retain the correct pressure,
install a new cooling system filler cap. 3. Check the coolant level. Maintain the coolant level
within 13 mm (.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (.5 inch) to the proper level on the sight
glass (if equipped).
4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A
9S-8140 Pressurizing Pump is used to perform
the pressure test. The correct pressure for the
g00103638 cooling system filler cap is stamped on the face of
Illustration 23
the cooling system filler cap. If the cooling system
(1) Recovery tank filler cap filler cap does not retain the correct pressure,
(2) COLD FULL mark
(3) LOW ADD mark
install a new cooling system filler cap.
5. Loosen the cap for the coolant recovery tank 5. Start the engine. Inspect the cooling system for
slowly in order to relieve any pressure. Remove leaks and for proper operating temperature.
the cap for the coolant recovery tank.
i01083041
6. Pour coolant into the coolant recovery tank until
the coolant reaches the COLD FULL mark. Cooling System Coolant (ELC)
DO NOT fill the coolant recovery tank above the
COLD FULL mark.
- Change
SMCS Code: 1350-070; 1395-044
7. Clean the cap for the coolant recovery tank. Install
Clean the cooling system and flush the cooling
system before the recommended maintenance
8. Start the engine. Inspect the cooling system for
interval if the following conditions exist:
leaks and for proper operating temperature.
The engine overheats frequently.
Foaming of the coolant

SEBU7242-05 69
Maintenance Section
Cooling System Coolant (ELC) - Change
The oil has entered the cooling system and the 2. Close the drain valve (if equipped). Clean the
coolant is contaminated. drain plugs. Install the drain plugs. Refer to the
Specifications Manual for your particular engine for
The fuel has entered the cooling system and the more specific information on the proper torques.
coolant is contaminated. Refer to the Specifications, SENR3130, Torque
Specifications for more general information on
Note: When the cooling system is cleaned, only the proper torques.
clean water is needed when the ELC is drained and
replaced. NOTICE
Note: Inspect the water pump and the water per minute to avoid air locks.
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and 3. Fill the cooling system with clean water. Install the
the hoses, if necessary. cooling system filler cap.
4. Start the engine and run the engine at low

Drain idle until the temperature reaches 49 to 66 C
(120 to 150 F).
5. Stop the engine and allow the engine to cool.

Pressurized System: Hot coolant can cause seri- Loosen the cooling system filler cap slowly
ous burns. To open the cooling system filler cap, in order to relieve any pressure. Remove the
stop the engine and wait until the cooling system cooling system filler cap. Open the drain valve (if
components are cool. Loosen the cooling system equipped) or remove the cooling system drain
pressure cap slowly in order to relieve the pres- plugs. Allow the water to drain. Flush the cooling
sure. system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
1. Stop the engine and allow the engine to cool. plugs. Refer to the Specifications Manual for your
Loosen the cooling system filler cap slowly in particular engine for more specific information on
order to relieve any pressure. Remove the cooling the proper torques. Refer to the Specifications,
system filler cap. SENR3130, Torque Specifications for more
general information on the proper torques.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain Fill
valve, remove the cooling system drain plugs.
Engines that are Equipped with a Coolant
Allow the coolant to drain.
Recovery Tank
NOTICE
Dispose of used engine coolant properly or recycle. NOTICE
Various methods have been proposed to reclaim used Fill the cooling system no faster than 19 L (5 US gal)
coolant for reuse in engine cooling systems. The full per minute to avoid air locks.
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant. 1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
For information regarding the disposal and the Manual, Cooling System Specifications topic
recycling of used coolant, consult your Caterpillar (Maintenance Section) for more information on
dealer or consult Caterpillar Service Technology cooling system specifications. Do not install the
Group: cooling system filler cap.
Outside Illinois: 1-800-542-TOOL 2. Place the transmission in neutral. Start the engine
Inside Illinois: 1-800-541-TOOL and operate the engine at low idle. Increase the
Canada: 1-800-523-TOOL engine rpm to 1500 rpm. Operate the engine at
1500 rpm for one minute in order to purge air from
the cavities of the engine block. Stop the engine.
Flush
3. Pour more ELC into the cooling system until the
1. Flush the cooling system with clean water in order cooling system is full.
to remove any debris.

70 SEBU7242-05
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
4. Clean the cooling system filler cap. Inspect the 1. Fill the cooling system with Extended Life Coolant
gasket that is on the cooling system filler cap. If (ELC). Refer to the Operation and Maintenance
the gasket that is on the cooling system filler cap Manual, Cooling System Specifications topic
is damaged, discard the old cooling system filler (Maintenance Section) for more information on
cap and install a new cooling system filler cap. If cooling system specifications. Do not install the
the gasket that is on the cooling system filler cap is cooling system filler cap.
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler 2. Place the transmission in neutral. Start the engine
cap. The correct pressure for the cooling system and operate the engine at low idle. Increase the
filler cap is stamped on the face of the cooling engine rpm to 1500 rpm. Operate the engine at
system filler cap. If the cooling system filler cap 1500 rpm for one minute in order to purge air from
does not retain the correct pressure, install a new the cavities of the engine block. Stop the engine.
cooling system filler cap.
3. Check the coolant level. Maintain the coolant level
within 13 mm (.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (.5 inch) to the proper level on the sight
glass (if equipped).
4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap is
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
g00103638
Illustration 24 filler cap is stamped on the face of the cooling
(1) Recovery tank filler cap system filler cap. If the cooling system filler cap
(2) COLD FULL mark does not retain the correct pressure, install a new
(3) LOW ADD mark cooling system filler cap.
5. Loosen the cap for the coolant recovery tank 5. Start the engine. Inspect the cooling system for
slowly in order to relieve any pressure. Remove leaks and for proper operating temperature.
6. Pour Extended Life Coolant (ELC) into the coolant i02482066

recovery tank until the coolant reaches the COLD
FULL mark. DO NOT fill the coolant recovery Cooling System Coolant
tank above the COLD FULL mark. Extender (ELC) - Add
7. Clean the cap for the coolant recovery tank. Install SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require
8. Start the engine. Inspect the cooling system for the frequent additions of any supplemental cooling
leaks and for proper operating temperature. additives which are associated with the present
conventional coolants. The Cat ELC Extender only
Engines that are NOT Equipped with a needs to be added once.
Coolant Recovery Tank
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
NOTICE with Cat ELC.
per minute to avoid air locks. Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
tional coolants and/or conventional SCA reduces the
Cat ELC service life.
Check the cooling system only when the engine is

stopped and cool.

SEBU7242-05 71
Maintenance Section
Cooling System Coolant Level - Check
i02456586
Cooling System Coolant Level

Personal injury can result from hot coolant, steam
and alkali. - Check
At operating temperature, engine coolant is hot SMCS Code: 1395-082
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or Check the coolant level when the engine is stopped
steam. Any contact can cause severe burns. and cool.
Remove cooling system pressure cap slowly to Engines That Are Equipped with a
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to Coolant Recovery Tank
touch with your bare hand.
Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
g00103638
ing any compartment or disassembling any compo- Illustration 25
nent containing fluids. (1) Filler cap
(2) COLD FULL mark
Refer to Special Publication, NENG2500, Caterpillar (3) LOW ADD mark
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar 1. Observe the coolant level in the coolant recovery
products. tank. Maintain the coolant level to COLD FULL
mark (2) on the coolant recovery tank.
Dispose of all fluids according to local regulations and
mandates. 2. Loosen filler cap (1) slowly in order to relieve any
pressure. Remove the filler cap.
1. Loosen the cooling system filler cap slowly in 3. Pour the proper coolant mixture into the tank.
order to relieve pressure. Remove the cooling Refer to this Operation and Maintenance Manual,
system filler cap. Refill Capacities and Recommendations for
information about coolants. Do not fill the coolant
2. It may be necessary to drain enough coolant from recovery tank above COLD FULL mark (2).
the cooling system in order to add the Cat ELC
Extender. 4. Clean filler cap (1) and the receptacle. Reinstall
the filler cap and inspect the cooling system for
3. Add Cat ELC Extender according to the leaks.
requirements for your engines cooling system
capacity. Refer to the Operation and Maintenance Note: The coolant will expand as the coolant heats
Manual, Refill Capacities and Recommendations up during normal engine operation. The additional
article for more information. volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
4. Clean the cooling system filler cap. Inspect the and cool, the coolant will return to the engine.
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.

72 SEBU7242-05
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Engines That Are Not Equipped i02456600
with a Coolant Recovery Tank Cooling System Supplemental

Coolant Additive (SCA) -
Test/Add
ous burns. To open the cooling system filler cap, SMCS Code: 1352-045; 1395-081
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
sure. Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
1. Remove the cooling system filler cap slowly in the skin and the eyes. Do not drink cooling system
order to relieve pressure. coolant additive.
2. Maintain the coolant level within 13 mm (0.5 inch) Note: Test the concentration of the Supplemental
of the bottom of the filler pipe. If the engine is Coolant Additive (SCA) or test the SCA concentration
equipped with a sight glass, maintain the coolant as part of an SOS Coolant Analysis.
level to the proper level in the sight glass.
Test for SCA Concentration
Coolant and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Use the 8T-5296 Coolant Conditioner Test Kit

or use the 4C-9301 Coolant Conditioner Test Kit
in order to check the concentration of the SCA.
Refer to this Operation and Maintenance Manual,
Refill Capacities and Recommendations for more
Illustration 26
g00103639 information.
Typical filler cap gaskets
Water and SCA
3. Clean the cooling system filler cap and inspect
the condition of the filler cap gaskets. Replace the NOTICE
cooling system filler cap if the filler cap gaskets are Do not exceed the recommended eight percent sup-
damaged. Reinstall the cooling system filler cap. plemental coolant additive concentration.
4. Inspect the cooling system for leaks.

Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Refer to the Special
Publication, SEBU6251, Caterpillar Commercial
Diesel Engine Fluids Recommendations for more
information.
SOS Coolant Analysis

SOS coolant samples can be analyzed at your
Caterpillar dealer. SOS Coolant Analysis is a
program that is based on periodic samples.
Level 1
Level 1 is a basic analysis of the coolant. The
following items are tested:

SEBU7242-05 73
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Glycol Concentration 3. Add the proper amount of SCA. Refer

to the Special Publication, SEBU6251,
Concentration of SCA Caterpillar Commercial Diesel Engines Fluids
Recommendations for more information on SCA
pH requirements.
Conductivity 4. Clean the cooling system filler cap. Inspect the

gaskets of the cooling system filler cap. If the
The results are reported, and recommendations gaskets are damaged, replace the old cooling
are made according to the results. Consult your system filler cap with a new cooling system filler
Caterpillar dealer for information on the benefits of cap. Install the cooling system filler cap.
managing your equipment with an SOS Coolant
Analysis.
i00912898
Level 2 Cooling System Water

This level coolant analysis is recommended when the Temperature Regulator -
engine is overhauled. Refer to this Operations and Replace
Maintenance Manual, Overhaul Considerations for
further information. SMCS Code: 1355-510
Add the SCA, If Necessary Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
NOTICE Replacing the water temperature regulator reduces
Do not exceed the recommended amount of sup- the chances for unscheduled downtime.
plemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form A water temperature regulator that fails in a
deposits on the higher temperature surfaces of the partially opened position can cause overheating or
cooling system, reducing the engines heat transfer overcooling of the engine.
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temper- A water temperature regulator that fails in the closed
ature components. Excessive supplemental coolant position can cause excessive overheating. Excessive
additive concentration could also result in radiator overheating could result in cracking of the cylinder
tube blockage, overheating, and/or accelerated water head or piston seizure problems.
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped) A water temperature regulator that fails in the open
at the same time. The use of those additives together position will cause the engine operating temperature
could result in supplemental coolant additive concen- to be too low during partial load operation. Low
tration exceeding the recommended maximum. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
sure.
1. Slowly loosen the cooling system filler cap in

order to relieve the pressure. Remove the cooling
system filler cap.
Note: Always discard drained fluids according to

local regulations.
2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow
space for the extra SCA.

74 SEBU7242-05
Maintenance Section
Crankshaft Vibration Damper - Inspect
Replace the damper if the damper is dented, cracked

NOTICE or leaking. Refer to the Service Manual or consult
Failure to replace your water temperature regulator your Caterpillar dealer for damper replacement.
on a regularly scheduled basis could cause severe
engine damage.
i02053406
Caterpillar engines incorporate a shunt design cooling Engine Air Cleaner Element -
system and require operating the engine with a water
temperature regulator installed. Clean/Replace
If the water temperature regulator is installed incor- SMCS Code: 1054-070; 1054-510
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or

cylinder head surface.
Refer to the Service Manual for the replacement

procedure of the water temperature regulator, or
consult your Caterpillar dealer.
Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i00072369
Crankshaft Vibration Damper

- Inspect Illustration 27
g00743906
(1) Air cleaner element

SMCS Code: 1205-040
Note: Use the 102-9720 Cleaning Kit in order
Damage to the crankshaft vibration damper or failure to clean the air cleaner element. These products
of the crankshaft vibration damper can increase contain the detergent and oil that is made specifically
torsional vibrations. This can result in damage to for the maintenance of the air cleaner elements.
the crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train 1. Remove air cleaner element (1). Tap the air
noise at variable points in the speed range. cleaner element in order to dislodge dirt particles.
Gently brush the air cleaner element with a soft
The damper is mounted to the crankshaft which is bristle brush.
located behind the belt guard on the front of the
engine. NOTICE
Do not use gasoline, steam, caustic or unapproved
Removal and Installation detergents, or parts cleaning solvents. Do not use high
pressure water or air to clean the air cleaner element.
Refer to the Service Manual for the damper removal Any of those liquids or methods can cause air cleaner
procedure and for the damper installation procedure. element damage.
Visconic Damper 2. Spray air cleaner element (1) with the cleaning
solution. Allow the air cleaner element to stand
The visconic damper has a weight that is located for 20 minutes.
inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration. Inspect the
damper for evidence of dents, cracks or leaks of the
fluid.

SEBU7242-05 75
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
3. Rinse air cleaner element (1) with low water Some engines are equipped with a differential gauge
pressure. The maximum water pressure for this for inlet air pressure. The differential gauge for inlet
procedure is 275 kPa (40 psi). Tap water is air pressure displays the difference in the pressure
acceptable. Start to rinse the air cleaner element that is measured before the air cleaner element and
from the clean side (inside). Next, clean the dirty the pressure that is measured after the air cleaner
side (outside) in order to flush out dirt. Inspect the element. As the air cleaner element becomes dirty,
air cleaner element for tears and/or holes after the pressure differential rises. If your engine is
the air cleaner element is cleaned. Do not reuse equipped with a different type of service indicator,
damaged air cleaner elements. follow the OEM recommendations in order to service
the air cleaner service indicator.
NOTICE
Do not use compressed air, open flame, or hot air to The service indicator may be mounted on the air
dry the air cleaner element. Excess heat shrinks cot- cleaner housing or in a remote location.
ton fiber, and compressed air may blow holes in the
material. Allow the air cleaner element to air dry.
4. Shake excess water off air cleaner element (1),

and allow the air cleaner element to air dry. Drying
the air cleaner element in the sun speeds the
process.
NOTICE
Do not use transmission fluid, engine oil, diesel fuel,
or other lubricant to oil the air cleaner element. The
air cleaner element can not function correctly if im-
proper oil is used. Never operate an engine with a
dry air cleaner element. The air cleaner element can g00103777
Illustration 28
not function correctly without oil. Always saturate the
clean air cleaner element with the recommended oil. Typical service indicator
Observe the service indicator. The air cleaner

5. The dry air cleaner element should be oiled before element should be cleaned or the air cleaner element
installation. Apply small amounts of oil across the should be replaced when one of the following
top of each pleat. Allow the oil wick into the air conditions occur:
cleaner element for 20 minutes. Oil any remaining
white spots. The yellow diaphragm enters the red zone.
6. Inspect the housing and the clamp for air cleaner The red piston locks in the visible position.
element (1). Replace the housing and the clamp,
if necessary. Install the clean, oiled air cleaner
element. Refer to Specifications, SENR3130, Test the Service Indicator
Torque Specifications for more information on
the proper torques. Service indicators are important instruments.
Check for ease of resetting. The service indicator

i01900118 should reset in less than three pushes.
Engine Air Cleaner Service Check the movement of the yellow core when the
Indicator - Inspect engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
(If Equipped) greatest vacuum that is attained.
SMCS Code: 7452-040 If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
Some engines may be equipped with a different the service indicator should be replaced. If the new
service indicator. service indicator will not reset, the hole for the service
indicator may be plugged.

76 SEBU7242-05
Maintenance Section
Engine Crankcase Breather - Clean
The service indicator may need to be replaced 5. Install the hose. Install the hose clamp.
frequently in environments that are severely dusty, if Refer to Specifications, SENR3130, Torque
necessary. Replace the service indicator annually Specifications for the proper torques.
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
i02456872
whenever major engine components are replaced.
Note: When a new service indicator is installed,

Engine Mounts - Inspect
excessive force may crack the top of the service SMCS Code: 1152-040
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in). Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
i02053400 by the following conditions:
Engine Crankcase Breather - Improper mounting of the engine

Clean Deterioration of the engine mounts
SMCS Code: 1317-070 Any engine mount that shows deterioration should be
replaced. Refer to Special Publication, SENR3130,
NOTICE Torque Specifications for the recommended
Perform this maintenance with the engine stopped. torques. Refer to the OEM recommendations for
more information.
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become i01007363
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause Engine Oil Level - Check
crankshaft seal leakage.
SMCS Code: 1348-535-FLV
Check the oil level after the engine has stopped.

This maintenance procedure must be performed on
a level surface.
g00110310
Illustration 30
g00638236 (Y) ADD mark
Illustration 29 (X) FULL mark
(1) Bolt
(2) Breather assembly 1. Maintain the oil level between the ADD mark (Y)
and the FULL mark (X) on the oil level gauge.
1. Loosen the hose clamp and remove the hose from Do not fill the crankcase above FULL mark (X).
breather assembly (2).
2. Loosen bolt (1). Remove breather assembly (2) NOTICE

and the seal. Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
3. Wash the breather element in solvent that is clean the oil. The air bubbles created from the crankshaft
and nonflammable. Allow the breather element to dipping into the oil reduces the oils lubricating char-
dry before installation. acteristics and could result in the loss of power.
4. Install a breather element that is clean and dry. 2. Remove oil filler cap and add oil, if necessary.
Install breather assembly (2) and the seal. Tighten Clean the oil filler cap. Reinstall the oil filler cap.
bolt (1).

SEBU7242-05 77
Maintenance Section
Engine Oil Level Gauge - Calibrate
i01094856 Calibration of Oil Level Gauge

Engine Oil Level Gauge - Table 13
Calibrate Engine Oil Level Gauge

Angle(1) FULL Mark (X) ADD Mark (Y)
SMCS Code: 1326-524
10 degrees 125 mm (4.92 inch) 114 mm (4.49 inch)
The engine is shipped with an engine oil level gauge
that is not marked. The engine oil level gauge is
not marked because the angle of installation can be 8 degrees 122 mm (4.80 inch) 102 mm (4.02 inch)
different for each engine. The angle of installation will
affect the ADD mark (Y) and the FULL mark (X)
that is engraved on the engine oil level gauge. 6 degrees 115 mm (4.53 inch) 89 mm (3.50 inch)
The engine oil level gauge must be calibrated after
the engine is installed in the vessel. Table 13 lists 4 degrees 101 mm (3.98 inch) 71 mm (2.80 inch)
the corresponding ADD mark, FULL mark and the
angle of installation. Use a marking pen in order to 3 degrees 94 mm (3.70 inch) 66 mm (2.60 inch)
engrave ADD mark (Y) and FULL mark (X) on the 2 degrees 90 mm (3.54 inch) 59 mm (2.32 inch)
engine oil level gauge according to the information
in Table 13. 1 degree 82 mm (3.23 inch) 52 mm (2.05 inch)
-1 degree 65 mm (2.56 inch) 39 mm (1.54 inch)
-2 degrees 59 mm (2.32 inch) 33 mm (1.30 inch)
g00110310 -5 degrees 39 mm (1.54 inch) 12 mm (0.47 inch)
Illustration 31
(1) The angle indicates the number of degrees that the front of
Oil Level Gauge
the engine is raised. A negative angle indicates the number of
(Y) ADD mark degrees that the front of the engine is lowered.
(X) FULL mark
Verifying the Calibration of the Oil

Level Gauge
Caterpillar recommends verifying the calibration of
the oil level gauge at the first oil change. Use the
following procedure to verify the FULL mark on the
oil level gauge:
Note: The vessel must be level in order to perform

this procedure.
1. Operate the engine until normal operating

temperature is achieved. Stop the engine.
Remove one of the drain plugs for the engine
crankcase. Allow the engine oil to drain.
2. Remove the used engine oil filter. Install the new

engine oil filter. Install the crankcase drain plug
and tighten the crankcase drain plug.
3. Add 25 L (26.5 qt) of the recommended oil grade

and weight of engine oil to the crankcase.
Note: The engine may be equipped with auxiliary

engine oil filters which require additional oil. Refer to
the OEM specifications.

78 SEBU7242-05
Maintenance Section
Engine Oil Sample - Obtain
The number of hours that have accumulated since

NOTICE the last oil change
To help prevent crankshaft or bearing damage, crank
engine to fill all filters before starting. Do not crank The amount of oil that has been added since the
engine for more than 30 seconds. last oil change
To ensure that the sample is representative of the

NOTICE oil in the crankcase, obtain a warm, well mixed oil
Do not crank the engine for more than 30 seconds. sample.
Allow the starting motor to cool for two minutes before
cranking again. To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
Turbocharger (if equipped) damage can result, if the samples must be clean.
engine rpm is not kept low until the engine oil light/
gauge verifies the oil pressure is sufficient. Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
4. Start the engine. Ensure that the lubrication sampling valve is used. The location of the sampling
system and the new engine oil filter is filled. valve allows oil that is flowing under pressure to be
Inspect the lubrication system for leaks. obtained during normal engine operation.
5. Stop the engine and allow the engine oil to drain The 169-8373 Fluid Sampling Bottle is
into the engine crankcase for approximately ten recommended for use with the sampling valve. The
minutes. fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
6. Check the engine oil level. If necessary, use a also provided.
marking pen in order to correct the FULL mark
(X).
NOTICE
Always use a designated pump for oil sampling, and
i01935337 use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
Engine Oil Sample - Obtain contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
SMCS Code: 1000-008; 1348-554-SM; rect interpretation that could lead to concerns by both
7542-554-OC, SM dealers and customers.
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil If the engine is not equipped with a sampling valve,
analysis at regularly scheduled intervals in order use the 1U-5718 Vacuum Pump. The pump is
to monitor the condition of the engine and the designed to accept sampling bottles. Disposable
maintenance requirements of the engine. SOS oil tubing must be attached to the pump for insertion
analysis provides infrared analysis, which is required into the sump.
for determining nitration and oxidation levels.
For instructions, see Special Publication, PEHP6001,
How To Take A Good Oil Sample. Consult your
Obtain the Sample and the Analysis Caterpillar dealer for complete information and
assistance in establishing an SOS program for your
engine.
Hot oil and hot components can cause personal i02107152

injury. Do not allow hot oil or hot components to
contact the skin. Engine Oil and Filter - Change
SMCS Code: 1318-510; 1348-044
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Hot oil and hot components can cause personal
Engine model injury. Do not allow hot oil or hot components to
contact the skin.
Service hours on the engine

SEBU7242-05 79
Maintenance Section
Engine Oil and Filter - Change
Do not drain the oil when the engine is cold. As the oil Nonferrous metals may indicate wear on the
cools, suspended waste particles settle on the bottom aluminum parts, brass parts or bronze parts of
of the oil pan. The waste particles are not removed the engine. Parts that may be affected include
with the draining cold oil. Drain the crankcase with the following items: main bearings, rod bearings,
the engine stopped. Drain the crankcase with the turbocharger bearings, and cylinder heads.
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained Due to normal wear and friction, it is not
properly. uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
Failure to follow this recommended procedure will to arrange for a further analysis if an excessive
cause the waste particles to be recirculated through amount of debris is found in the oil filter.
the engine lubrication system with the new oil.
Drain the Engine Oil

After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
If the engine is equipped with a drain valve, turn the

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
If the engine is not equipped with a drain valve,

remove the oil drain plug in order to allow the oil Illustration 32
g00103713
to drain. If the engine is equipped with a shallow
Typical filter mounting base and filter gasket
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
After the oil has drained, the oil drain plugs should
removed.
be cleaned and installed.
4. Apply clean engine oil to the new oil filter gasket.
Replace the Oil Filter
NOTICE
NOTICE Do not fill the oil filters with oil before installing them.
Caterpillar oil filters are built to Caterpillar speci- This oil would not be filtered and could be contaminat-
fications. Use of an oil filter not recommended by ed. Contaminated oil can cause accelerated wear to
Caterpillar could result in severe engine damage to engine components.
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters 5. Install the oil filter. Tighten the oil filter until the
recommended by Caterpillar. oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
1. Remove the oil filter with a 1U-8760 Chain filter.
Wrench.
2. Cut the oil filter open with a 175-7546 Oil Filter

Fill the Engine Crankcase
Cutter Gp. Break apart the pleats and inspect the 1. Remove the oil filler cap. Refer to the Operation
oil filter for metal debris. An excessive amount and Maintenance Manual, Refill Capacities and
of metal debris in the oil filter may indicate early Recommendations for more information.
wear or a pending failure.
Use a magnet to differentiate between the ferrous NOTICE

metals and the nonferrous metals that are found in If equipped with an auxiliary oil filter system or a re-
the oil filter element. Ferrous metals may indicate mote oil filter system, follow the OEM or filter manu-
wear on the steel and cast iron parts of the engine. facturers recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.

80 SEBU7242-05
Maintenance Section
Engine Storage Procedure - Check
This maintenance is recommended by Caterpillar

NOTICE as part of a lubrication and preventive maintenance
To prevent crankshaft bearing damage, crank the en- schedule in order to help provide maximum engine
gine with the fuel OFF. This will fill the oil filters before life.
starting the engine. Do not crank the engine for more
than 30 seconds. NOTICE
Only qualified service personnel should perform this
2. Start the engine and run the engine at LOW maintenance. Refer to the Service Manual or your
IDLE for two minutes. Perform this procedure in Caterpillar dealer for the complete valve lash adjust-
order to ensure that the lubrication system has ment procedure.
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks. Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
3. Stop the engine and allow the oil to drain back to duced efficiency could result in excessive fuel usage
the sump for a minimum of ten minutes. and/or shortened engine component life.
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the ADD
and FULL marks on the oil level gauge.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
i01430860 vent possible injury, do not use the starting motor
to turn the flywheel.
Engine Storage Procedure -
Check Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
SMCS Code: 1000-535 suring/adjusting valve lash clearance.
Caterpillar requires all engines that are stored for Ensure that the engine is stopped before measuring
more than 3 months to follow storage procedures the valve lash. To obtain an accurate measurement,
and start-up procedures. These procedures provide allow the valves to cool before this maintenance is
maximum protection to internal engine components. performed.
Refer to Special Instruction, SEHS9031, Storage
Procedure For Caterpillar Products for information Refer to the Service Manual for more information.
on these procedures.
An extension of the oil change interval to 12 months i02113137

is permitted if you follow the required procedures for
storage and start-up. This extension is permitted if the Fuel System - Prime
following intervals in the Operation and Maintenance
Manual, Maintenance Interval Schedule have not SMCS Code: 1258-548
been reached:
Operating hours
Fuel leaked or spilled onto hot surfaces or elec-
Fuel consumption trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
i00869628
Clean up fuel spills immediately.
Engine Valve Lash -
Inspect/Adjust NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
SMCS Code: 1102-025 clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
The initial valve lash adjustment on new engines, connected fuel system components.
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
Prime the fuel system in order to fill the fuel filter.
adjustment is necessary due to the initial wear of
Prime the fuel system in order to purge trapped air.
the valve train components and to the seating of the
The fuel system should be primed under the following
valve train components.
conditions:

SEBU7242-05 81
Maintenance Section
Fuel System - Prime
Running out of fuel

Storage
Replacement of the fuel filter
Engines that are Equipped with a

Fuel Priming Pump
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
fittings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.
g01076450
Illustration 33
1. Open the fuel priming pump and operate the fuel (1) Plug
priming pump until a strong pressure is felt. This (2) Fuel filter
procedure will require considerable strokes. Lock
the fuel priming pump. 1. Remove plug (1) in order to fill fuel filter (2).
Ensure that air is able to vent from the fitting of
the plug while the fuel filter is being filled. Clean
NOTICE up any spilled fuel immediately. Clean plug (1).
Do not crank the engine continuously for more than Install plug (1).
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
NOTICE
Do not crank the engine continuously for more than
2. Promptly start the engine. If the engine runs 30 seconds. Allow the starting motor to cool for two
rough, continue to operate the engine at low idle. minutes before cranking the engine again.
Do not raise the engine rpm above an idle, until
the engine operates smoothly.
2. Start the engine and operate the engine at low
3. If the engine does not start, open the fuel priming idle. Do not raise the engine speed above an idle,
pump and repeat Steps 1 and 2 in order to start until the engine operates smoothly.
the engine.
Fuel Filter Bases that are Not Equipped
Engines that are Not Equipped with with a Plug
a Fuel Priming Pump
NOTICE
If the engine is not equipped with a fuel priming Do not crank the engine continuously for more than
pump, you can use the following procedures to prime 30 seconds. Allow the starting motor to cool for two
the fuel system. These procedures will allow only minutes before cranking the engine again.
filtered fuel to enter the fuel system.
1. Operate the starting motor. This will fill the fuel
Fuel Filter Bases that are Equipped with filter and the fuel lines with fuel.
a Plug
2. Once the engine starts, operate the engine at low
idle. Do not raise the engine speed above an idle,
NOTICE until the engine operates smoothly.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.

82 SEBU7242-05
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
i01463757 The primary filter/water separator also provides

filtration in order to help extend the life of the
Fuel System Primary secondary fuel filter. The element should be changed
Filter/Water Separator - Drain regularly. If a vacuum gauge is installed, the
primary filter/water separator should be changed at
SMCS Code: 1260-543; 1263-543 50 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.
g00668636
Illustration 34
(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. g00104012
Illustration 35
2. Close drain (3). Element (1), Bowl (2), and Drain (3)
2. Remove element (1) from the element mounting

NOTICE base while bowl (2) is attached.
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight- 3. Dispose of the contents of the filter. Remove bowl
ened securely to help prevent air from entering the fuel (2) from element (1). The bowl is reusable. Do not
system. discard the bowl. Dispose of the used element.
4. Remove the O-ring from the gland of the bowl.

i02053433 Clean the following components:
Fuel System Primary Filter Bowl
(Water Separator) Element -
O-ring
Replace
Mounting base
SMCS Code: 1260-510-FQ; 1263-510-FQ
Inspect the O-ring for damage and for
Water in the fuel can cause the engine to run rough. deterioration. Replace the O-ring, if necessary.
Water in the fuel may cause a electronic unit injector
to fail. If the fuel has been contaminated with water, 5. Lubricate the O-ring with clean diesel fuel.
the element should be changed before the regularly
scheduled interval. 6. Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools in order to tighten
the bowl.

SEBU7242-05 83
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE NOTICE
The primary filter/water separator may be prefilled with Use a suitable container to catch any fuel that might
fuel to avoid rough running/stalling of the engine due spill. Clean up any spilled fuel immediately.
to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel- 4. Unlock the fuel priming pump (if equipped). This
erated wear to fuel system parts. relieves any residual pressure in the fuel system.
5. Remove the used fuel filter. Use a cloth, or use a

7. Lubricate the top seal of element (1) with clean container to catch excess fuel.
diesel fuel. The element may be filled with fuel at
this time. Install the new element on the mounting 6. Clean the gasket sealing surface of the fuel filter
base. Tighten the element by hand. base. Ensure that all of the old gasket is removed.
NOTICE 7. Apply clean diesel fuel to the new fuel filter gasket.
engine operation. Ensure that the vent plug is tight- NOTICE
ened securely to help prevent air from entering the fu- Do not fill the secondary fuel filter with fuel before in-
el system. stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
8. Open the main fuel supply valve.
9. Start the engine and check for leaks. Run the 8. Install a new fuel filter, and tighten the fuel filter
engine for one minute. Stop the engine and check until the gasket contacts the base.
for leaks again.
9. Tighten the fuel filter by hand according to the
Detecting leaks is difficult while the engine is instructions that are shown on the fuel filter.
running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel. Do not overtighten the fuel filter.
The air in the fuel can cause low power due to
aeration of the fuel. If air enters the fuel, check the 10. Lock the fuel priming pump (if equipped). Open
components for overtightening or undertightening. the fuel tank supply valve.
11. If the engine stalls, refer to the Operation and

i01007602
Maintenance Manual, Fuel System - Prime topic
Fuel System Secondary Filter - (Maintenance Section) for more information.
Replace
i02112513
SMCS Code: 1261-510-SE

Fuel System Water Separator
- Drain
Fuel leaked or spilled onto hot surfaces or elec- SMCS Code: 1263-543
trical components can cause a fire. To help pre-
Clean up fuel spills immediately. Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
1. Stop the engine.
Clean up fuel spills immediately.
2. Turn off the start switch, or disconnect the battery
(starting motor) when maintenance is performed
on fuel filters.
3. Shut off the fuel tank supply valve to the engine.

84 SEBU7242-05
Maintenance Section
Fuel Tank Water and Sediment - Drain
i02436696
NOTICE
The water separator is not a filter. It separates water
Fuel Tank Water and Sediment
from the fuel. - Drain
The engine should never be allowed to run with the SMCS Code: 1273-543-M&S
water level in the separator more than 1/2 full or en-
gine damage may result. NOTICE
Care must be taken to ensure that fluids are contained
A water separator is recommended. The water during performance of inspection, maintenance, test-
separator should be installed between the fuel ing, adjusting and repair of the product. Be prepared to
tank and the engine fuel inlet. Drain the water and collect the fluid with suitable containers before open-
sediment from the water separator on a daily basis. ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar

Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and

mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
Illustration 36
g01076474 excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
(1) Drain
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
1. Open drain (1). Catch the draining water in a
causes water to accumulate in fuel tanks. Draining
suitable container. Dispose of the water properly.
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
NOTICE
engine operation. Ensure that the drain valve is tight-
Drain the Water and the Sediment
ened securely to help prevent air from entering the fuel
Fuel tanks should contain some provision for draining
system.
water and draining sediment from the bottom of the
fuel tanks.
2. Close drain (1).
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank after operating the engine in

order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.

SEBU7242-05 85
Maintenance Section
Heat Exchanger - Inspect
Some fuel tanks use supply pipes that allow water Excessive pressure drop between the water inlet
and sediment to settle below the end of the fuel and the water outlet
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If An operator that is familiar with the normal operating
the engine is equipped with this system, regular temperature of the coolant can determine when
maintenance of the fuel system filter is important. the coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger
are required if the engine is overheating.
Fuel Storage Tanks
Drain the water and the sediment from the fuel Your Caterpillar dealer has the equipment and the
trained personnel that are needed in order to measure
storage tank during the following conditions:
the pressure drop across the heat exchanger.
Weekly The procedure for cleaning the heat exchanger is
similar to the procedure that is used for cleaning
Oil change the aftercooler core. Refer to the Operation and
Maintenance Manual, Aftercooler Core - Clean/Test
Refill of the tank topic (Maintenance Section). For more information on
This will help prevent water or sediment from being servicing the heat exchanger, consult your Caterpillar
dealer.
pumped from the storage tank into the engine fuel
tank. A 2 micron filter for the breather vent on the
fuel tank is also recommended. Refer to Special i02121526
Publication, SENR9620, Improving Fuel System
Durablity. Hoses and Clamps -
If a bulk storage tank has been refilled or moved
Inspect/Replace
recently, allow adequate time for the sediment to SMCS Code: 7554-040; 7554-510
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
Inspect all hoses for leaks that are caused by the
sediment. Filtering fuel that is pumped from the following conditions:
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
Cracking
i01057362 Softness
Heat Exchanger - Inspect Loose clamps
SMCS Code: 1379-040 Replace hoses that are cracked or soft. Tighten any
loose clamps.
The interval for the maintenance of the tube and
fin heat exchanger depends on the operating
NOTICE
environment of the vessel and on the operating time.
Do not bend or strike high pressure lines. Do not in-
The sea water that is circulated through the heat
stall bent or damaged lines, tubes or hoses. Repair
exchanger and the amount of operating time of the
any loose or damaged fuel and oil lines, tubes and
vessel affects the following items:
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
Cleanliness of the tubes of the heat exchanger ommended torque.
Effectiveness of the heat exchanger system
Check for the following conditions:
Operating in water that contains silt, sediment, salt,
algae, etc will adversely affect the heat exchanger End fittings that are damaged or leaking
system. In addition, intermittent use of the vessel will
adversely affect the heat exchanger system. Outer covering that is chafed or cut
The following items indicate that the heat exchanger Exposed wire that is used for reinforcement
may require cleaning:
Outer covering that is ballooning locally
Increased coolant temperature
Flexible part of the hose that is kinked or crushed
Engine overheating

86 SEBU7242-05
Maintenance Section
Marine Transmission Oil Level - Check
Armoring that is embedded in the outer covering 9. Clean the cooling system filler cap. Inspect the
cooling system filler caps gaskets. Replace
A constant torque hose clamp can be used in place the cooling system filler cap if the gaskets are
of any standard hose clamp. Ensure that the constant damaged. Install the cooling system filler cap.
torque hose clamp is the same size as the standard
clamp. 10. Start the engine. Inspect the cooling system for
leaks.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
i01089872
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. Marine Transmission Oil Level
Each installation application can be different. The - Check
differences depend on the following factors:
SMCS Code: 3081-535
Type of hose
Check the marine transmission oil level according to
Type of fitting material the instructions that are provided by the OEM of the
transmission or the OEM of the vessel.
Anticipated expansion and contraction of the hose
For the lubrication requirements of the transmission,
Anticipated expansion and contraction of the refer to the recommendations on the nameplate or
fittings the Owners Manual for the transmission.
Replace the Hoses and the Clamps Marine Transmission Operation,

Maintenance, Warranty, and Parts
Support
Pressurized System: Hot coolant can cause seri- For information on maintenance and operation of the
ous burns. To open the cooling system filler cap, marine transmission, consult your Caterpillar dealer
stop the engine and wait until the cooling system and/or the OEM dealer of the transmission.
pressure cap slowly in order to relieve the pres- All support for the warranty of the transmission will be
sure. the responsibility of the OEM. All parts support for the
transmission will be the responsibility of the OEM.
1. Stop the engine. Allow the engine to cool. This parts support includes both the installation of
parts and the resolution of any service problems.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling i02378613
system filler cap.
Overhaul Considerations
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused. SMCS Code: 7595-043
3. Drain the coolant from the cooling system to a Reduced hours of operation at full load will result in a
level that is below the hose that is being replaced. lower average power demand. A decreased average
power demand should increase both the engine
4. Remove the hose clamps. service life and the overhaul interval.
5. Disconnect the old hose. The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
6. Replace the old hose with a new hose.
The following factors are important when a decision
7. Install the hose clamps with a torque wrench. is being made on the proper time for an engine
overhaul:
Note: Refer to the Specifications, SENR3130,
Torque Specifications in order to locate the proper The need for preventive maintenance
torques.
The quality of the fuel that is being used
8. Refill the cooling system.

SEBU7242-05 87
Maintenance Section
The operating conditions If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
The results of the SOS analysis percent and 50 percent of the cost of a new engine
with a similar exchange core.
Oil Consumption as an Overhaul This lower cost can be attributed to three aspects:
Indicator
Specially designed Caterpillar engine features
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total Caterpillar dealer exchange components
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the Caterpillar Inc. remanufactured exchange
required capacity of a makeup oil tank that is suitable components
for the maintenance intervals.
Oil consumption is in proportion to the percentage Overhaul Recommendation

of the rated engine load. As the percentage of the
To minimize downtime, Caterpillar Inc. recommends
engine load is increased, the amount of oil that is
consumed per hour also increases. a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you
with the best cost/value relationship.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
Note: Overhaul programs vary according to the
bhp). The brake specific oil consumption (BSOC)
engine application and according to the dealer that
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
consumption rate for your engine.
overhaul programs and about overhaul services for
When an engines oil consumption has risen to three extending the engine life.
times the original oil consumption rate due to normal
If an overhaul is performed without overhaul service
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby from your Caterpillar dealer, be aware of the following
maintenance recommendations.
and a slight increase in fuel consumption.
Overhaul Options Rebuild or Exchange

Cylinder Head Assembly, Cylinder Packs, Oil
Before Failure Overhaul
Pump, and Fuel Transfer Pump
A planned overhaul before failure may be the best
These components should be inspected according to
value for the following reasons:
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
Costly unplanned downtime can be avoided. SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
Many original parts can be reused according to the
standards for reusable parts.
If the parts comply with the established inspection
specifications that are expressed in the reusable
The engines service life can be extended without parts guideline, the parts should be reused.
the risk of a major catastrophe due to engine
failure.
Parts that are not within the established inspection
specifications should be dealt with in one of the
The best cost/value relationship per hour of following manners:
extended life can be attained.
After Failure Overhaul Salvaging
If a major engine failure occurs and the engine must Repairing

be removed from the hull, many options are available.
An overhaul should be performed if the engine block Replacing
or the crankshaft needs to be repaired.
Using out-of-spec parts can result in the following
problems:
Unscheduled downtime

88 SEBU7242-05
Maintenance Section
Costly repairs Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for
Damage to other engine parts cracks in the camshaft.
Reduced engine efficiency Inspect the following components for signs of wear or
for signs of scuffing:
Increased fuel consumption
Camshaft bearings
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs. Camshaft followers
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts. Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Inspection and/or Replacement
Oil Cooler Core and Aftercooler Core
Crankshaft Bearings, Valve Rotators, and
Crankshaft Seals During an overhaul, Caterpillar Inc. recommends the
removal of both the oil cooler core and the aftercooler
The following components may not last until the core. Clean the oil cooler core and the aftercooler
second overhaul. core. Then, pressure test both of these cores.
Thrust bearings NOTICE

Do not use caustic cleaners to clean the core.
Main bearings
Caustic cleaners can attack the internal metals of the
Rod bearings core and cause leakage.
Valve rotators
Note: Use this cleaning procedure to clean the oil
Crankshaft seals cooler core and the aftercooler core.
Caterpillar Inc. recommends the installation of new 1. Remove the oil cooler core and the aftercooler
parts at each overhaul period. core.
Inspect these parts while the engine is disassembled 2. Remove any debris from the oil cooler core and
for an overhaul. the aftercooler core. To remove debris from the oil
cooler core, turn the oil cooler core onto one end.
Inspect the crankshaft for any of the following To remove debris from the aftercooler core, turn
conditions: the aftercooler core upside-down.
Deflection 3. Flush the oil cooler core and the aftercooler core
internally with cleaner in order to loosen foreign
Damage to the journals substances. This will also help to remove oil from
the oil cooler core and the aftercooler core.
Bearing material that has seized to the journals
Note: Caterpillar Inc. recommends the use of
Check the journal taper and the profile of the Hydrosolv Liquid Cleaners. Table 14 lists the
crankshaft journals. Check these components by Hydrosolv Liquid Cleaners that are available from
interpreting the wear patterns on the following your Caterpillar dealer.
components:
Rod bearing
Main bearings
Note: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check
for cracks in the crankshaft.
Inspect the camshaft for damage to the journals and

to the lobes.

SEBU7242-05 89
Maintenance Section
Starting Motor - Inspect
Table 14 A coolant analysis can be conducted in order to verify

Hydrosolv Liquid Cleaners(1)
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
Part
Description Size by consulting your local water utility company or
Number an agricultural agent. Private laboratories are also
1U-5490 Hydrosolv 4165 19 L (5 US gallon) available for water analysis.
174-6854 Hydrosolv 100 19 L (5 US gallon) Caterpillar Inc. recommends an SOS Coolant

(1) Use a two to five percent concentration of the cleaner at Analysis (Level 2).
temperatures up to 93C (200F).
SOS Coolant Analysis (Level 2)
4. Use steam to clean the oil cooler core and the
aftercooler core. This removes any remaining An SOS Coolant Analysis (Level 2) is a
residue from the cleaner. Flush the fins of the oil comprehensive coolant analysis which completely
cooler core and the aftercooler core. Remove any analyzes the coolant and the effects on the cooling
other trapped debris. system. An SOS Coolant Analysis (Level 2) provides
the following information:
5. Wash the oil cooler core and the aftercooler core
with hot, soapy water. Rinse the oil cooler core and Complete SOS Coolant Analysis (Level 1)
the aftercooler core thoroughly with clean water.
Visual inspection of properties
Identification of metal corrosion
Personal injury can result from air pressure. Identification of contaminants
Personal injury can result without following prop-
Identification of built up impurities (corrosion and
er procedure. When using pressure air, wear a pro- scale)
tective face shield and protective clothing.
SOS Coolant Analysis (Level II) provides a report of
Maximum air pressure at the nozzle must be less the results of both the analysis and the maintenance
than 205 kPa (30 psi) for cleaning purposes. recommendations.
6. Dry the oil cooler core and the aftercooler core For more information about coolant analysis, see
with compressed air. Direct the air in the reverse your Caterpillar dealer.
direction of the normal flow.
i00651416
7. Inspect the components in order to ensure
cleanliness. The oil cooler core and the aftercooler Starting Motor - Inspect
core should be pressure tested. Repair the oil
cooler core and the aftercooler core, if necessary. SMCS Code: 1451-040; 1453-040
Install the oil cooler core and the aftercooler core.
Caterpillar Inc. recommends a scheduled inspection
For more information about cleaning the cores, of the starting motor. If the starting motor fails, the
consult your Caterpillar dealer. engine may not start in an emergency situation.
Obtain Coolant Analysis Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
The concentration of supplemental coolant additive connections. Refer to the Service Manual for more
(SCA) should be checked regularly with test kits information on the checking procedure and for
or with SOS Coolant Analysis (Level 1). Further specifications or consult your Caterpillar dealer for
coolant analysis is recommended when the engine assistance.
is overhauled.
For example, considerable deposits are found in the

water jacket areas on the external cooling system, but
the concentrations of coolant additives were carefully
maintained. The coolant water probably contained
minerals that were deposited on the engine over time.

90 SEBU7242-05
Maintenance Section
Turbocharger - Inspect/Clean
i01411756 Cleaning and Inspecting

Turbocharger - Inspect/Clean 1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
SMCS Code: 1052-571 inspect the piping for the presence of oil.
Periodic inspection and cleaning is recommended 2. Turn the compressor wheel and the turbine wheel
for the turbocharger compressor housing (inlet side). by hand. The assembly should turn freely. Inspect
Any fumes from the crankcase are filtered through the compressor wheel and the turbine wheel for
the air inlet system. Therefore, by-products from oil contact with the turbocharger housing. There
and from combustion can collect in the turbocharger should not be any visible signs of contact between
compressor housing. Over time, this buildup can the turbine wheel or compressor wheel and the
contribute to loss of engine power, increased black turbocharger housing. If there is any indication of
smoke and overall loss of engine efficiency. contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
If the turbocharger fails during engine operation, the turbocharger must be reconditioned.
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the 3. Check the compressor wheel for cleanliness.
turbocharger compressor wheel can cause additional If only the blade side of the wheel is dirty, dirt
damage to the pistons, the valves, and the cylinder and/or moisture is passing through the air filtering
head. system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
NOTICE oil seal.
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems. The presence of oil may be the result of extended
Loss of engine lubricant can result in serious engine engine operation at low idle. The presence of oil
damage. may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
Minor leakage of a turbocharger housing under ex- the turbocharger to slobber.
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc- 4. Use a dial indicator to check the end clearance
curred. on the shaft. If the measured end play is greater
than the Service Manual specifications, the
When a turbocharger bearing failure is accompanied turbocharger should be repaired or replaced.
by a significant engine performance loss (exhaust An end play measurement that is less than the
smoke or engine rpm up at no load), do not continue minimum Service Manual specifications could
engine operation until the turbocharger is repaired or indicate carbon buildup on the turbine wheel. The
replaced. turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
5. Inspect the bore of the turbine housing for
turbocharger can also reduce the chance for potential
corrosion.
damage to other engine parts.
6. Clean the turbocharger housing and clean the
Note: Turbocharger components require precision
backing plate of the cartridge with standard shop
clearances. The turbocharger cartridge must
solvents and a soft bristle brush.
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
7. Fasten the air inlet piping and the exhaust outlet
Severe Service Applications require more frequent
piping to the turbocharger housing.
inspections of the cartridge.
Removal and Installation

For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the
procedure and specifications.

SEBU7242-05 91
Maintenance Section
Walk-Around Inspection
i00073831 Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil
Walk-Around Inspection pan, the oil filters and the valve cover.
SMCS Code: 1000-040 Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Inspect the Engine for Leaks and
for Loose Connections Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
checks, costly repairs and accidents can be avoided.
Belts for multiple groove pulleys must be replaced as
For maximum engine service life, make a thorough matched sets. If only one belt is replaced, the belt will
inspection of the engine compartment before starting carry more load than the belts that are not replaced.
the engine. Look for items such as oil leaks or coolant The older belts are stretched. The additional load on
leaks, loose bolts, worn belts, loose connections and the new belt could cause the belt to break.
trash buildup. Make repairs, as needed:
Drain the water and the sediment from fuel tanks
The guards must be in the proper place. Repair on a daily basis in order to ensure that only clean
damaged guards or replace missing guards. fuel enters the fuel system.
Wipe all caps and plugs before the engine is Inspect the wiring and the wiring harnesses for
serviced in order to reduce the chance of system loose connections and for worn wires or frayed
contamination. wires.
NOTICE Inspect the ground strap for a good connection and

For any type of leak (coolant, lube, or fuel) clean up the for good condition.
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels Inspect the ECM to the cylinder head ground strap
more often than recommended until the leak is found for a good connection and for good condition.
or fixed, or until the suspicion of a leak is proved to be
unwarranted. Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte level
NOTICE
of the batteries, unless the engine is equipped with
Accumulated grease and/or oil on an engine or deck is
a maintenance free battery.
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
Check the condition of the gauges. Replace any
gauges which are cracked or can not be calibrated.
Ensure that cooling lines are properly clamped
and tight. Check for leaks. Check the condition of
i01057943
all pipes.
Water Pump - Inspect
Check the marine transmission oil level. Refer to
the OEM specification for the marine transmission SMCS Code: 1361-040; 1361
or refer to the OEM specification for the vessel.
A failed water pump might cause severe engine
Inspect the water pumps for coolant leaks. overheating problems that could result in the following
conditions:
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount Cracks in the cylinder head
of leakage to occur as the engine cools down and
the parts contract. A piston seizure
Excessive coolant leakage may indicate the need Other potential damage to the engine
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.

92 SEBU7242-05
Maintenance Section
Zinc Rods - Inspect/Replace
Visually inspect the water pump for leaks. If any a. If the zinc rod has deteriorated excessively,
leaking is observed, replace the water pump seal install a new zinc rod.
or the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure.
Note: Refer to the Service Manual or consult your

Caterpillar dealer if any repair is needed or any
replacement is needed.
i02053417

SMCS Code: 1388-040; 1388-510
Corrosion in sea water circuits can result in premature

deterioration of cooling system components, leaks, Illustration 37
g00481100
and possible cooling system contamination. The
corrosion may be caused by the lack of zinc rods in b. Tap the zinc rod lightly with a hammer. If the
the sea water system. zinc rod flakes, install a new zinc rod.
Zinc rods are inserted in the sea water cooling system 3. If the zinc rod will be reused, scrape the layer of
of the engine in order to help prevent the corrosive oxidation from the zinc rod before installation. The
oxidation that is caused by sea water. The reaction layer of oxidation reduces the effectiveness of the
of the zinc to the sea water causes the zinc rods to zinc rod.
oxidize rather than the cooling system components.
Rapid deterioration of zinc rods may indicate
the presence of uncontrolled electrical currents Replace the Zinc Rods
from improperly installed electrical attachments or
improperly grounded electrical attachments. 1. Unscrew the old zinc rod from the plug.
The zinc rods must be inspected at the proper If not enough material remains or the zinc rod has
intervals. The zinc rods must be replaced when broken off, drill the old zinc rod from the plug.
deterioration occurs.
2. Clean the plug.
Inspect the Zinc Rods
The zinc rods are red for easy identification. Table
15 shows the locations of the zinc rods and the
quantities of the zinc rod:
Table 15
Locations of the Zinc Rods
Location Quantity
Heat Exchanger 3
Transmission Oil Cooler(1) 2
Aftercooler 2
g00480345
(1) Illustration 38
Zinc rods will only be located in marine transmission oil coolers
that are cooled with sea water. (1) Shoulder of the zinc rod
(2) Threads of the zinc rod
(3) External threads of the plug
1. Remove the zinc rod.
2. Inspect the zinc rod. Note: DO NOT apply adhesive or sealant to threads
(2) of the zinc rod.
Ensure that the zinc rod will remain effective until
the next scheduled inspection. 3. Apply 9S-3263 Thread Lock Compound to
shoulder (1) of a new zinc rod. Apply the
compound ONLY to the shoulder of the zinc rod.
Install the zinc rod onto the plug.

SEBU7242-05 93
Maintenance Section
4. Coat external threads (3) of the plug with

5P-3413 Pipe Sealant. Install the zinc rod.
Refer to Specifications, SENR3130, Torque
Specifications.

3126B Marine Engines: Maintenance Intervals

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What maintenance is required for engines used in severe applications?

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What is the purpose of zinc rods in marine engine cooling systems?

SAFETY.CAT.

Excerpted from Operation & Maintenance Manual (SEBU7242-05-01)

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i02507477 First 5700 L (1500 US gal) of Fuel or 200

SMCS Code: 1000; 7500 PM Level 1 - Every 5700 L (1500 US gal) of

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i02507545 PM Level 1 - Every 5700 L (1500 US gal) of

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Aftercooler Condensate Drain Aftercooler Core - Clean/Test

2. Turn the aftercooler core upside-down in order

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv

1. Remove valve (1) from the housing. Check the

6. Dry the core with compressed air. Direct the air in

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7. Inspect the core in order to ensure cleanliness. i01323511

For more information on cleaning the core, consult Inspection

Caterpillar recommends a scheduled inspection

Check the alternator and the battery charger for

After the initial check, the belt tension should be

To maximize the engine performance, inspect the

If new belts are installed, check the belt tension again

Inspect the belt tensioner for unusual noise,

Install the belt guard.

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Auxiliary Water Pump - Inspect

8. Connect the cable from the ground plane to the

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1. Turn the start switch to the OFF position. Turn the

2. Check the condition of the electrolyte with the

3. Keep the batteries clean.

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

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the

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i01413013 Resetting the Service Indicator

1. Remove plastic cover (4).

2. Push down on service indicator (5).

3. Replace cover (4).

4. Replace the fumes disposal filter by using the

Replacing the Fumes Disposal

1. Release latches (7) that hold the canister to filter

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Note: Removal of canister (8) may be difficult while Drain

The engine overheats frequently. Outside Illinois: 1-800-542-TOOL

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Cooling Systems with Heavy Fill

NOTICE 1. Fill the cooling system with coolant/antifreeze.

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4. Clean the cooling system filler cap. Inspect the

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4. Start the engine and run the engine at low

5. Stop the engine and allow the engine to cool.