Caterpillar C18 Marine Engine-Maintenance Intervals - Power And

SAFETY.CAT.COM™

C18 MARINE ENGINEMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7689-10)

®© 2009 CaterpillarAll Rights Reserved

®

SEBU7689-10 81Maintenance Section

Maintenance Interval Schedule

i03542891

Maintenance Interval ScheduleSMCS Code: 1000; 7500

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

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

Use distance, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

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

Some maintenance intervals will depend on theoperating environment of the vessel and on theoperating time. Operating in water that contains silt,sediment, the algae and salt will adversely affect themaintenance intervals for some items. In addition,intermittent use of the vessel will adversely affect themaintenance intervals for some items.

When Required

Battery - Recycle .................................................. 85Battery - Replace .................................................. 85Battery or Battery Cable - Disconnect .................. 86Engine - Clean .................................................... 100Engine Oil Level Gauge - Calibrate .................... 104Engine Storage Procedure - Check ..................... 110Fuel System - Prime ............................................ 112Heat Exchanger - Inspect ................................... 121Maintenance Recommendations ........................ 123Sea Water Strainer - Clean/Inspect .................... 129Zinc Rods - Inspect/Replace ............................... 132

Daily

Closed Crankcase Ventilation (CCV) Filter ServiceIndicator - Inspect ............................................... 87Cooling System Coolant Level - Check ................ 95Engine Air Cleaner Service Indicator - Inspect ... 102Engine Oil Level - Check .................................... 103Fuel System Primary Filter/Water Separator -Drain .................................................................. 114Walk-Around Inspection ...................................... 131

Initial 20 to 40 Service Hours

Belts - Inspect/Adjust/Replace .............................. 86

Every 50 Service Hours or Weekly

Aftercooler Condensate Drain Valve -Inspect/Clean ...................................................... 83Sea Water Strainer - Clean/Inspect .................... 129Zinc Rods - Inspect/Replace ............................... 132

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 98

Every 500 Service Hours


Every Year


Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 95

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 92

First 14 400 L (3750 US gal) of Fuel or 250Service Hours

Engine Valve Lash - Inspect/Adjust ..................... 110Fuel Injector - Inspect/Adjust ............................... 111

Every 14 400 L (3750 US gal) of Fuel or 250Service Hours or 1 Year

Auxiliary Water Pump (Rubber Impeller) -Inspect ................................................................ 85Battery Electrolyte Level - Check .......................... 86Belts - Inspect/Adjust/Replace .............................. 86Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 98Engine - Clean .................................................... 100Engine Air Cleaner Element - Clean/Replace ..... 100Engine Crankcase Breather - Clean ................... 102Engine Oil Sample - Obtain ................................ 105Engine Oil and Filter - Change ........................... 105Fuel System Primary Filter (Water Separator)Element - Replace ............................................. 113Fuel System Secondary Filter - Replace ............. 115Fuel Tank Water and Sediment - Drain ............... 120Hoses and Clamps - Inspect/Replace ................ 122

82 SEBU7689-10Maintenance SectionMaintenance Interval Schedule

Every 28 500 L (7500 US gal) of Fuel or 500Service Hours or 1 Year (Deep Sump)

Engine Oil and Filter - Change ........................... 105

Every 57 000 L (15 000 US gal) of Fuel or1000 Service Hours

Aftercooler Core - Clean/Test ............................... 83Closed Crankcase Ventilation (CCV) Fumes DisposalFilter - Replace .................................................... 87Heat Exchanger - Inspect ................................... 121Turbocharger - Inspect ........................................ 130


Auxiliary Water Pump (Bronze Impeller) -Inspect ................................................................ 84Cooling System Coolant (DEAC) - Change .......... 89Cooling System Water Temperature Regulator -Replace ............................................................... 99Crankshaft Vibration Damper - Inspect ................. 99Engine Mounts - Inspect ..................................... 103Engine Speed/Timing Sensor - Clean/Inspect .... 109Engine Valve Lash - Inspect/Adjust ..................... 110Engine Valve Rotators - Inspect .......................... 111Fuel Injector - Inspect/Adjust ............................... 111Starting Motor - Inspect ...................................... 129


Alternator - Inspect ............................................... 84Maintenance Recommendations ........................ 123Oil Cooler Core - Check/Clean/Test .................... 125Overhaul (Top End) ............................................. 128Water Pump - Inspect ......................................... 132

Every 570 000 L (150 000 US gal) of Fuel or10 000 Service Hours

Maintenance Recommendations ........................ 123Overhaul (Major) ................................................. 126


Aftercooler Condensate Drain Valve - Inspect/Clean

i03626622

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

NOTICEFailure to keep the condensate drain valve functionalcan cause severe damage to the engine.

g01638393Illustration 37Typical

g01348104Illustration 38

(1) Valve(2) Plunger(3) Valve seat

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

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

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

2. Reassemble the aftercooler condensate drainvalve. See Specifications Manual, SENR3130,“Torque Specifications” for more information onthe proper torques.

i03635591

Aftercooler Core - Clean/TestSMCS Code: 1064-070; 1064-081

Note: An aftercooler that circulates fresh wateror treated water may require cleaning less oftenthan an aftercooler which circulates salt water.The maintenance interval for an aftercooler whichcirculates fresh water or treated water should beevaluated when the aftercooler is cleaned and testedafter the first 1000 hours of engine operation. Theinterval will vary depending on operating conditions.

Clean the Aftercooler CoreRemove the core. Refer to the Disassembly andAssembly Manual, “Aftercooler - Remove” for theprocedure.

1. Turn the aftercooler core on one side in orderto remove debris. Remove the debris that isaccessible.

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

2. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 13 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 13

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

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

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

84 SEBU7689-10Maintenance SectionAlternator - Inspect

3. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris from the insideand from the outside of the core.

Note: Do not use high pressure when the fins arecleaned. High pressure can damage the fins.

4. Wash the core with hot, soapy water.

5. Flush the core thoroughly in order to removeresidue and remaining debris. Flush the core withclean, fresh water until the water that is exiting thecore is clear and free of debris.

Personal injury can result from air pressure.

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

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

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

Test the Aftercooler Core1. Inspect the core for trapped debris andcleanliness. If necessary, remove the debris andrepeat the cleaning procedure.

2. Inspect the core for damage and perform apressure test in order to detect leaks. Many shopsthat service radiators are equipped to performpressure tests.

3. Plug both ends of the aftercooler core andpressurize the core to 205 kPa (30 psi). Submergethe core in water. Look for bubbles which arebeing emitted from the core. The bubbles areevidence of leaks.

4. If any leaks are found, do not attempt to repair thecore.

Install a core that is clean and a core that passes thepressure test in step 3. Refer to the Disassemblyand Assembly Manual, “Aftercooler - Install” for theprocedure.

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

i02676048

Alternator - InspectSMCS Code: 1405-040

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

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

i01042055

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

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

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

Check the following components for wear or damage:

• Bearings

• Impeller

• Seals

• Wear plate

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


Auxiliary Water Pump (Rubber Impeller) - Inspect

i01041983

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

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

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

Check the following components for wear or damage:

• Bearings

• Impeller

• Seals

• Wear plate

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

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• Recycling facility

i02153996

Battery - ReplaceSMCS Code: 1401-510

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

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

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

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

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

2. Turn OFF the battery charger. Disconnect thecharger.

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

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

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

5. Remove the used battery.

6. Install the new battery.

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

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

86 SEBU7689-10Maintenance SectionBattery Electrolyte Level - Check

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

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535

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

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

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

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

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

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

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

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

Thoroughly rinse the battery case with clean water.

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

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

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

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

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

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

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

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

i02856850

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

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

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

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

• Belts

• Pulleys


Closed Crankcase Ventilation (CCV) Filter Service Indicator - Inspect

• Bearings

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

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

Alternator Belt Adjustment

g00960176Illustration 39(1) Adjusting nuts(2) Mounting bolt(3) Mounting bolt(4) Mounting bolt

1. Remove the drive belt guard.

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

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

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

5. Reinstall the drive belt guard.

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

i01852860

Closed Crankcase Ventilation(CCV) Filter Service Indicator- InspectSMCS Code: 1317-040-FI


(1) Plastic cover(2) Service indicator

The Closed Crankcase Ventilation system (CCV)is equipped with a service indicator. If the fumesdisposal filter becomes plugged prior to the normalservice interval, increased restriction of the filter willcause the crankcase pressure to become positive.When the pressure continues to rise, the serviceindicator will show through the plastic cover. Theservice indicator indicates the need for the fumesdisposal filter to be changed. Refer to the Operationand Maintenance Manual, “Closed CrankcaseVentilation (CCV) Fumes Disposal Filter - Replace”topic for more information.

Note: Check the service indicator when the engine isrunning at low idle.

i03615046

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

The engine may look like one of the engines whichare pictured below.

88 SEBU7689-10Maintenance SectionClosed Crankcase Ventilation (CCV) Fumes Disposal Filter - Replace


g01637466Illustration 42(1) Crankcase breather(2) Filter base and filter for fumes disposal(3) Air cleaner

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

• Engine load

• Soot concentration

• Condition of the engine

The CCV is equipped with a service indicator. If thefumes disposal filter becomes plugged prior to thenormal service interval, increased restriction of thefilter will cause the vacuum to become positive. Whenthe pressure continues to rise, the service indicatorwill show through the cap. The service indicatorindicates the need for the fumes disposal filter to bechanged. Reset the service indicator by using thefollowing procedure:

Resetting the Service Indicator


(4) Plastic cover(5) Service indicator

1. Remove the plastic cover.

2. Push down on the service indicator.

3. Replace the cover.

Replacing the Fumes DisposalFilter

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

Note:When possible, perform the maintenance whilethe engine is off.


Cooling System Coolant (DEAC) - Change

g01938796Illustration 44(6) Filter base assembly(7) Latches(8) Canister

1. Release the latches that hold the canister to thefilter base assembly .

Note: Removal of the canister may be difficult whilethe engine is operating. The canister has negative airpressure while the engine is operating. This createsa vacuum.

2. Lower the canister in order to expose the element.There may be oil in the bottom of the canister.Avoid spilling the oil.

3. Remove the filter element by pulling down.Dispose of the used element properly.

4. Remove the O-ring assembly on the top end capof the used element.

5. Replace the O-ring seal on the bottom of the filterbase assembly.

6. Install the new O-ring on the top end cap of theelement. Install the element into the correct place.

7. Replace the canister and align the canister withthe boss on the filter base assembly.

8. Clamp the latches in the closed position.

i03211768

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

Personal injury can result from hot coolant, steamand alkali.

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

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

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

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

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

Dispose of all fluids according to local regulations andmandates.

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

• The engine overheats frequently.

• Foaming of the coolant

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

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

90 SEBU7689-10Maintenance SectionCooling System Coolant (DEAC) - Change

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

Drain


1. Stop the engine and allow the engine to cool.Loosen expansion tank filler cap (1) slowly in orderto relieve any pressure. Remove the expansiontank filler cap.

2. Open the cooling system drain valve (if equipped).

3. In order to fully drain the coolant, remove thefollowing plugs:

a. Remove plug (2) in order to vent the water nearthe water temperature regulator.

g01355995Illustration 46Commercial application

g01637916Illustration 47Pleasure craft

b. Remove drain plug (3) from the bottom heatexchanger.


c. Remove drain plug (4) from the bottom of thewater cooled exhaust manifold.

d. Remove drain plugs (5) from the bottom of thejacket water pump inlet.

e. Remove drain plug (6) from the bottom of theoil cooler.

4. Allow coolant to drain.


Cooling System Coolant (DEAC) - Change

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

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

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

Flush

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

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

2. Close the drain valve (if equipped). Clean thedrain plugs. Reinstall the drain plugs. Refer tothe Operation and Maintenance Manual for moreinformation on the proper torques.

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

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe expansion tank filler cap.

4. Start the engine and run the engine for a minimumof 30 minutes with a coolant temperature of atleast 82°C (180°F).

5. Stop the engine and allow the engine to cool.Loosen the expansion tank filler cap slowlyin order to relieve any pressure. Remove theexpansion tank filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve (ifequipped). Clean the drain plugs. Reinstall thedrain plugs. Refer to the Specifications Manual formore information on the proper torques.

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

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


3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the expansion tank filler cap.

4. Start and run the engine at low idle for a minimumof 90 minutes. The coolant temperature should beat least 82°C (180°F).

5. Stop the engine and allow the engine to cool.Loosen the expansion tank filler cap slowly in orderto relieve any pressure. Remove the expansiontank filler cap. Open the drain valve (if equipped)or remove the cooling system drain plugs. Allowthe water to drain. Flush the cooling system withclean water. Close the drain valve (if equipped).Clean the drain plugs. Reinstall the drain plugs.Refer to the Operation and Maintenance Manualfor more information on the proper torques.

Fill


Engines That Are Equipped with aCoolant Recovery Tank

1. Fill the system to the top with the mixture ofcoolant/antifreeze that is recommended. Refer tothe Operation and Maintenance Manual for moreinformation on cooling system specifications.

2. Reinstall the filler cap on the coolant recoverytank.

3. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at 1500rpm for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

4. Remove filler cap from the coolant recovery tank.

92 SEBU7689-10Maintenance SectionCooling System Coolant (ELC) - Change

5. Pour the coolant/antifreeze into the tank until thecoolant reaches the “COLD FULL” mark. Do notfill the tank above the “COLD FULL” mark.

6. Clean the filler cap. Install the filler cap ontothe recovery tank. Start the engine. Inspect thecooling system for leaks and for proper operatingtemperature.

Engines That Are Not Equipped with aCoolant Recovery Tank

1. Fill the expansion tank with the coolant/antifreeze.Do not install the expansion tank filler cap.


3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the expansion tank filler cap. Inspect thegasket on the filler cap for the expansion tank.If the gasket for the filler cap for the expansiontank is damaged, discard the old filler cap andinstall a new filler cap for the expansion tank. Ifthe gasket for the filler cap for the expansion tankis not damaged, use a 9S-8140 PressurizedPump Group in order to pressure test the filler capfor the expansion tank. The correct pressure forthe filler cap of the expansion tank is stamped onthe face of the filler cap for the expansion tank. Ifthe expansion tank filler cap does not retain thecorrect pressure, install a new expansion tankfiller cap.

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

i03211792

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








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

• The engine overheats frequently.

• Foaming of the coolant

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

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

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


Cooling System Coolant (ELC) - Change

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

Drain


1. Stop the engine and allow the engine to cool.Loosen expansion tank filler cap (1) slowly in orderto relieve any pressure. Remove the expansiontank filler cap.

2. Open the cooling system drain valve (if equipped).

3. In order to fully drain the coolant, remove thefollowing plugs:

a. Remove plug (2) in order to vent the water nearthe water temperature regulator.

g01355995Illustration 50Commercial application

g01637916Illustration 51Pleasure craft

b. Remove drain plug (3) from the bottom heatexchanger.


c. Remove drain plug (4) from the bottom of thewater cooled exhaust manifold.

d. Remove drain plugs (5) from the bottom of thejacket water pump inlet.

e. Remove drain plug (6) from the bottom of theoil cooler.

4. Allow coolant to drain.

94 SEBU7689-10Maintenance SectionCooling System Coolant (ELC) - Change

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

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

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

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


3. Fill the cooling system with clean water. Reinstallthe expansion tank filler cap. Operate theengine until the temperature reaches 49 to 66°C(120 to 150°F).

4. Stop the engine and allow the engine to cool.Loosen the expansion tank filler cap slowlyin order to relieve any pressure. Remove theexpansion tank filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water.

5. If necessary, repeat step 2 through step 4.

Fill



1. Fill the expansion tank to the top with theELC. Refer to the Operation and MaintenanceManual for more information on cooling systemspecifications.

2. Reinstall the filler cap for the recovery tank.


4. Loosen the filler cap of the recovery tank slowly inorder to relieve any pressure. Remove the fillercap from the recovery tank.

5. Pour the ELC into the tank until the coolantreaches the “COLD FULL” mark. Do not fill thetank above the “COLD FULL” mark.

6. Clean the filler cap of the recovery tank. Reinstallthe filler cap onto the recovery tank. Startthe engine. Inspect the coolant recovery tankfor coolant leaks and for proper operatingtemperature.

Engines That Are Not Equipped with aCoolant Recovery Tank

1. Fill the expansion tank with the ELC. Do notreinstall the expansion tank filler cap.


3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the expansion tank filler cap. Inspect thegasket of the filler cap for the expansion tank. Ifthe gasket is damaged, discard the old expansiontank filler cap and install a new expansion tankfiller cap. If the gasket is not damaged, use a9S-8140 Pressurized Pump Group in order topressure test the expansion tank filler cap. Thecorrect pressure for the filler cap of the expansiontank is stamped on the face of the filler cap forthe expansion tank. If the expansion tank filler capdoes not retain the correct pressure, install a newexpansion tank filler cap.

5. Start the engine. Inspect the engine for coolantleaks and for proper operating temperature.


Cooling System Coolant Extender (ELC) - Add

i02482066

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

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

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

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

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


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

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

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

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




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

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

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

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

i02456586

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

96 SEBU7689-10Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain


g00103638Illustration 53(1) Filler cap(2) “COLD FULL” mark(3) “LOW ADD” mark

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

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

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

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

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

Engines That Are Not Equippedwith a Coolant Recovery Tank

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

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

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

g00103639Illustration 54Typical filler cap gaskets

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

4. Inspect the cooling system for leaks.

i03619060

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

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

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

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

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze


Cooling System Coolant Sample (Level 1) - Obtain

Table 14

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC Every 500Hours(1)

Initial 500 Hoursand Yearly(1)(2)

Cat ELC Optional(2) Initial 500 Hoursand Yearly(2)

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

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

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

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


Coolant sampling valve on bottom of the inlet bonnet for the oilcooler

The coolant sampling valve for the engine coolant islocated on the right side of the engine on the inletbonnet for the oil cooler.


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.


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

Use the following guidelines for proper sampling ofthe coolant:

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

• Keep the unused sampling bottles stored in plasticbags.

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

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

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

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

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

98 SEBU7689-10Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

i01987714

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


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

Submit the sample for Level 2 analysis.

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

i03509177

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

Note: This maintenance is NOT required forcooling systems that are filled with Extended LifeCoolant.

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

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

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

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


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

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

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

Cooling Systems that UseConventional Coolant

Test the Concentration of the SCA

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

Test the concentration of the SCA with the 4C-9301Coolant Conditioner Test Kit.


Cooling System Water Temperature Regulator - Replace

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

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

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

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

i03645060

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime. Refer to thisOperation and Maintenance Manual, “MaintenanceInterval Schedule” for the proper maintenanceinterval.

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

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

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

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

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

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

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

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

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

i03175962

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

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

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

100 SEBU7689-10Maintenance SectionEngine - Clean

g01134779Illustration 56Viscous vibration damper

Typical example(1) Crankshaft pulley(2) Weight(3) Case

InspectionInspect the damper for the following conditions:

• The damper is dented, cracked, or fluid is leakingfrom the damper.

• The paint on the damper is discolored fromexcessive heat.

• The damper is bent.

• The bolt holes are worn or there is a loose fit forthe bolts.

• The engine has had a crankshaft failure due totorsional forces.

Replace the damper if any of these conditions exist.

Removal and InstallationRefer to this Operation and Maintenance Manual,“Belts - Inspect/Adjust/Replace” for informationon removing and on installing the belt. Refer tothe Disassembly and Assembly Manual, “VibrationDamper and Pulley - Remove and Install” forinformation on removing and installing the damper.

i01646701

Engine - CleanSMCS Code: 1000-070

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

Moisture can create paths of electrical conductiv-ity.

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

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

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

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

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

i01756656

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

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


Engine Air Cleaner Element - Clean/Replace

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

g00898593Illustration 57(1) Air cleaner element

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

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

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

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

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

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

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

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

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

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

Type 2


1. Disconnect latches (1).

2. Remove cover (2).

3. Remove the air cleaner element.

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

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

5. Install the air cleaner element.

102 SEBU7689-10Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

6. Install cover (2).

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

i03612108

Engine Air Cleaner ServiceIndicator - InspectSMCS Code: 7452-040

A service indicator may be mounted on the aircleaner element or in a remote location.

g01640336Illustration 59Typical air cleaner service indicator

Some engines may be equipped with a differentservice indicator.

Observe the service indicator. Clean the air cleanerelement or replace the air cleaner element when thefollowing conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

• The air restriction reaches 6 kPa (25 inches of H2O).

Test the Service IndicatorService indicators are important instruments.

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

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

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

g00351792Illustration 60Porous filter

A porous filter is part of a fitting that is used formounting of the service indicator. Inspect the filterfor cleanliness. Clean the filter, if necessary. Usecompressed air or a clean, nonflammable solvent.

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

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

i02751871

Engine Crankcase Breather -CleanSMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

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


Engine Mounts - Inspect


1. Loosen hose clamp (1) and remove breather hose(2) from valve cover (3).

2. Remove valve cover (3). Refer to the Disassemblyand Assembly Manual.


3. Wash breather (4) in solvent that is clean andnonflammable. Allow the breather to dry beforeinstallation.

4. Install the valve cover. Refer to the Disassemblyand Assembly Manual.

5. Install the breather hose on the valve cover. Installthe hose clamp.

i02456872

Engine Mounts - InspectSMCS Code: 1152-040

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

• Improper mounting of the engine

• Deterioration of the engine mounts

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

i02703852

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

g01356472Illustration 63Right hand service shown

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


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

104 SEBU7689-10Maintenance SectionEngine Oil Level Gauge - Calibrate

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

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

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

i02703804

Engine Oil Level Gauge -CalibrateSMCS Code: 1326-524

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

• Angle of the installation

• Side for service

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

Note: The engine may be equipped with auxiliaryengine oil filters. The extra filters require more engineoil than the standard amounts. Refer to the OEMspecifications.

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

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

Note: If the engine has oil in the crankcase, skip step2 and proceed to step 3.

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

• Standard Oil Sump: Fill the crankcase with45.4 L (48 qt) of the recommended oil.

• Deep Oil Sump: Fill the crankcase with 64.3 L(68 qt) of the recommended oil.

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

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

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

4. Replace the engine oil filter by using the procedurein this Operation and Maintenance Manual,“Engine Oil and Filter - Change ”.

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

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

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

• Standard Oil Sump: Fill the crankcase with45.4 L (48 qt) of the recommended oil.

• Deep Oil Sump: Fill the crankcase with 64.3 L(68 qt) of the recommended oil.

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

9. Stop the engine and allow the engine oil to draininto the engine crankcase for approximately tenminutes.

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

11.Add 3.8 L (4 qt) of the recommended oil gradeand weight of engine oil to the crankcase. Add thisamount for both standard sumps and deep sumps.

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


Engine Oil Sample - Obtain


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

i03542996

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

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

Obtain the Sample and the Analysis

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

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

• Engine model

• Service hours on the engine

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

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

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

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

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

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


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

For instructions, see Special Publication, PEgj0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Caterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02683617

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

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.

If the engine is equipped with duplex oil filters, theengine oil filter elements can be changed while theengine is in operation. This is useful if the oil filterelements require more frequent replacement than theengine oil. Refer to “Replacing the Engine Oil FiltersDuring Engine Operation”.

The oil change interval can be affected by severalfactors:

• Air/fuel ratio

106 SEBU7689-10Maintenance SectionEngine Oil and Filter - Change

• Ambient air conditions

• Engine application

• Fuel type

• Oil type

• Size of the oil sump

The S·O·S oil analysis program analyzes used oil inorder to determine if the oil change interval is suitablefor your specific engine.

Drain the OilDo not drain the oil when the engine is cold. As theoil cools, waste particles settle on the bottom of theoil pan. The waste particles are not removed whenthe cold oil is drained. Drain the crankcase when theoil is warm. This method allows proper draining of thewaste particles that are suspended in the oil.

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

1. After the engine has been operated at normaloperating temperature, STOP the engine.

2. Drain the oil according to the equipment on theengine.

Note: Drain the oil into a suitable container. DO NOTdrain the oil into the bilge sump. Dispose of the oilaccording to local regulations.

g01348195Illustration 66Oil drain plug

Note: If a suction device is used in order to removethe oil from the oil pan, ensure that the suction deviceis clean. This will prevent dirt from entering into theoil pan. Be careful not to strike the engine oil suctiontubes or the piston cooling jets.

a. If the engine does not have a drain valve or apump, remove an oil drain plug. Allow the oil todrain. After the oil has drained, clean the drainplug and clean the fitting for the drain plug.Install the drain plug. Tighten the drain plug to70 ± 15 N·m (52 ± 11 lb ft).

b. If the engine has an oil drain valve, open thevalve. After the oil has drained, close the valve.

c. If the engine has a pump for removing dirty oil,connect a hose to the outlet of the pump. Placethe hose in a suitable container. Open the valvefor the drain line. The two marks on the valvemust be turned so that one mark points to thepump and the second mark points to the drainline. Operate the pump until the crankcaseis empty. Close the valve to the drain line.Disconnect the hose.

d. If the oil drain valve has a “quick connect”coupling, attach the coupling. Open the drainvalve in order to drain the crankcase. Afterthe oil has drained, close the drain valve.Disconnect the coupling.

3. Replace the engine oil filter elements before fillingthe crankcase with new oil.

Replace the Oil Filter ElementsReplace the engine oil filters when any of thefollowing conditions occur:

• Every oil change

• The engine oil filter differential pressure reaches103 kPa (15 psi).

• The oil filter elements have been used for 1000service hours.

Note: Do not attempt to clean the used oil filters.Used oil filters will retain waste particles. The used oilfilters would not filter the oil properly.

Service tools are available to aid in the service of oilfilters. Consult your Caterpillar dealer for the partnames and the part numbers. Follow the instructionsthat are supplied with the service tools. If the servicetools are not used, perform the following appropriateprocedure.


Engine Oil and Filter - Change

Replacing the Engine Oil Filters With theEngine Stopped (Standard Oil Filters)


Standard Oil Filters

Right hand service

Perform the following procedure after the oil hasbeen drained.

1. Remove used oil filters and properly discard theused oil filters.

g00103713Illustration 68Typical filter mounting base and filter gasket

2. Clean the sealing surface of the filter mountingbase. Make sure that the former oil filter gasketsare removed.

3. Apply a thin film of clean engine oil to the seal ofeach new filter gasket.

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

4. Install the filters by hand. Tighten each filter untilthe sealing surface contacts the base. Note theposition of the index marks on each filter in relationto a fixed point on the filter base.

Note: Caterpillar filters have rotation index marksthat are spaced 90° or 1/4 of a turn away from eachother. When you tighten the filters, use the rotationindex marks as a guide.

5. Tighten each filter according to the instructionsthat are printed on the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filters to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filters. Do not overtighten the oil filter.

Replacing the Engine Oil Filters DuringEngine Operation (Duplex Oil FilterSystem Only)

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

g01356340Illustration 69Duplex Oil Filter System

Left hand service

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

108 SEBU7689-10Maintenance SectionEngine Oil and Filter - Change


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

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

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

4. Perform Step 1 through Step 5 of “Replacing theEngine Oil Filters With the Engine Stopped”.

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

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

7. Inspect the oil filters for oil leaks. If any leaks exist,stop the engine and make any necessary repairs.

8. If the engine oil filters were replaced withoutchanging the crankcase oil, maintain the oil levelbetween the “FULL” mark and the “ADD” mark onthe oil level gauge. If necessary, add oil.

Fill the Crankcase

NOTICEOnly use oils that are recommended by Caterpillar.For the proper oil to use, refer to this Operation andMaintenanceManual, “Engine Oil” topic (MaintenanceSection).

NOTICEIf the engine is equipped with an auxiliary oil filtersystem, extra oil must be added when filling thecrankcase. If equipped with an auxiliary oil filtersystem that is not supplied by Caterpillar, follow therecommendations of the OEM.

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can cause the crankshaft to dipinto the oil. This will reduce the power that is devel-oped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil's ability to lubricate, reduction of oilpressure, inadequate cooling, oil blowing out of thecrankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, drain some of the oil immediately.

1. Remove the oil filler cap. Fill the crankcasethrough the oil filler tube only. For the amountof oil and type of oil to use, refer to Operationand Maintenance Manual, “Refill Capacities andRecommendations” (Maintenance Section). Cleanthe oil filler cap. Install the oil filler cap.

NOTICETo prevent crankshaft or bearing damage, crank en-gine with fuel off to fill all filters before starting.

Do Not crank engine for more than 30 seconds.

2. Close the fuel supply line and crank the engineuntil the oil pressure gauge indicates 70 kPa(10 psi). Open the fuel supply line. Allow thestarting motor to cool for two minutes beforecranking again.


Engine Speed/Timing Sensor - Clean/Inspect

3. Ensure that the oil level is to the “FULL” mark onthe oil level gauge. Start the engine and operatethe engine at low idle for two minutes. This willensure that the lubrication system has oil and thatthe oil filters are filled with oil. Inspect the engineand the oil filters for oil leaks. If any leaks exist,stop the engine and make any necessary repairs.

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

5. Remove the oil level gauge and check the oillevel. Maintain the oil level between the “FULL”mark and the “ADD” mark on the oil level gauge. Ifnecessary, add oil.

Inspect the Used Oil Filter ElementsCut the oil filter open with a 175-7546 Oil FilterCutter Gp. Break apart the pleats and inspect the oilfilter for metal debris. An excessive amount of metaldebris in the oil filter may indicate early wear or apending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are foundin the element. Ferrous metals may indicate wearon the steel and the cast iron parts of the engine.Nonferrous metals may indicate wear on thealuminum parts, the brass parts, or the bronze partsof the engine. Parts that may be affected include thefollowing components: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Aluminum debris may indicate problems with thebearings of the front gears. If you find aluminumdebris, inspect the crankshaft vibration damper andthe idler gear bearings.

Due to normal wear and friction, it is not uncommonto find small amounts of debris in the oil filter element.If an excessive amount of debris is found in the oilfilter element, consult your Caterpillar dealer in orderto arrange for further oil analysis.

i03572058

Engine Speed/Timing Sensor -Clean/InspectSMCS Code: 1905-040; 1905-070; 1907-040;1907-070

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.




Camshaft Speed/Timing Sensor

g01368433Illustration 71(1) Bolt(2) Sensor(3) Harness assembly

Removal Procedure

1. Disconnect the harness assembly.

2. Remove the bolt and the sensor.

3. Remove the O-ring seal from the sensor.

Procedure for Cleaning and Inspecting

Check the condition of the plastic end of the sensorfor wear and for contaminants. Clean the metalshavings and other debris from the face of the sensor.

Installation Procedure

1. Install a new O-ring seal on the sensor. Lubricatethe O-ring seal with clean engine oil.

2. Position the sensor in the housing and install thebolt.

110 SEBU7689-10Maintenance SectionEngine Storage Procedure - Check

3. Connect the harness assembly.

Crankshaft Speed/Timing Sensor

g01900805Illustration 72(4) Bolt(5) Sensor(6) Harness

Removal Procedure

1. Disconnect the harness assembly.

2. Remove the bolt and the sensor.

3. Remove the O-ring seal from the sensor.

Procedure for Cleaning and Inspecting

Check the condition of the plastic end of the sensorfor wear and for contaminants. Clean the metalshavings and other debris from the face of the sensor.

Installation Procedure

1. Install a new O-ring seal on the sensor. Lubricatethe O-ring seal with clean engine oil.

2. Install the position sensor in the front housing andinstall the bolt.

3. Connect the harness assembly.

i02703023

Engine Storage Procedure -CheckSMCS Code: 1000-535

Caterpillar recommends storage procedures andstart-up procedures for all engines that are storedfor more than 1 month. These procedures providemaximum protection to internal engine components.Refer to Special Instruction, SEHS9031, “StorageProcedure For Caterpillar Products” for informationon these procedures.

An extension of the oil change interval to 12 monthsis permitted if you follow the required procedures forstorage and start-up. This extension is permitted if thefollowing intervals in the Operation and MaintenanceManual, “Maintenance Interval Schedule” have notbeen reached:

• Operating hours

• Fuel consumption

i00869413

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

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

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

Adjustment of the Electronic UnitInjectorAdjust the electronic unit injector (preload) at thesame interval as the valve lash adjustment. Theoperation of Caterpillar engines with improper valveadjustments and with improper adjustments of theelectronic unit injector can reduce engine efficiency.This reduced efficiency could result in excessive fuelusage and/or shortened engine component life.


Engine Valve Rotators - Inspect

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

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

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

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

i01597115

Engine Valve Rotators - InspectSMCS Code: 1109-040

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

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

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

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

2. Operate the engine at low idle.

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

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

If a valve fails to rotate, consult your Caterpillardealer.

i03534881

Fuel Injector - Inspect/AdjustSMCS Code: 1290-025

Be sure the engine cannot be started while thismaintenance is being performed. To prevent pos-sible injury, do not use the starting motor to turnthe flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting the unit injectors.

The electronic unit injectors use high voltage. Dis-connect the unit injector enable circuit connectorin order to prevent personal injury. Do not comein contact with the injector terminals while the en-gine is running.

The operation of Caterpillar engines with improperadjustments of the electronic unit injector can reduceengine efficiency. This reduced efficiency could resultin excessive fuel usage and/or shortened enginecomponent life.

Only qualified service personnel should performthis maintenance. Refer to the Systems Operation,Testing and Adjusting, “Electronic Unit Injector -Test” for the test procedure, and Systems Operation,Testing and Adjusting, “Electronic Unit Injector -Adjust” for the adjustment procedure for the injectors.

112 SEBU7689-10Maintenance SectionFuel System - Prime

i03570039

Fuel System - PrimeSMCS Code: 1258-548

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




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

Note: Refer to this Operation and MaintenanceManual, “Fuel System Secondary Filter - Replace” forinformation on replacing the filter.


Hand priming pump(1) Air purge screw(2) Fuel pressure regulating valve

The Secondary Fuel Filter HasBeen Replaced1. Turn the ignition switch to the “OFF” position.

2. Open the air purge screw for the fuel filter by threefull turns. Do not remove the air purge screw.

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

3. Start the engine. The engine should start and theengine should run smoothly. If the engine doesnot start after 30 seconds, allow the starting motorto cool for two minutes before attempting to startthe engine again.

Note: You may use the hand priming pump for thefuel filter (if equipped) instead of starting the engineand running the engine.

4. While the engine is running, observe the air purgescrew. When a small drop of fuel appears at thethreads of the air purge screw, close and tightenair purge screw.

Note: There may be a noticeable change in thesound of the running engine when the air purgescrew is tightened. The change in the sound of theengine is normal.

Note: Failure to tighten all fittings could result inserious fuel leaks.

5. Clean any residual fuel from the enginecomponents.

The Engine Has Been Run Out ofFuel1. Turn the ignition switch to the “OFF” position.

2. Fill the fuel tank(s) with clean diesel fuel.

3. Open the fuel pressure regulating valve by twoand one half turns. The regulating valve is locatedin the integral fuel filter base.

Note: Do not remove the regulating valve completely.Open the valve enough to allow the air that is trappedin the cylinder head to be purged from the fuelsystem.


Fuel System Primary Filter (Water Separator) Element - Replace


4. Crank the engine for 30 seconds. Use a suitablecontainer to catch the fuel while you crank theengine. Allow the starting motor to cool for twominutes.

Note: You may use the hand priming pump for thefuel filter (if equipped) instead of cranking the engine.

5. Crank the engine for 30 seconds. Allow thestarting motor to cool for two minutes.

6. Close and tighten the fuel pressure regulatingvalve.


8. Repeat Step 7 until the engine starts and theengine runs.


9. Clean any residual fuel from the enginecomponents.

The Engine Has Been Rebuilt1. Turn the ignition switch to the “OFF” position.

2. Fill the fuel tank (s) with clean diesel fuel.

3. Open the the air purge screw for the fuel filter bythree full turns. Do not remove the air purge screw.

4. Open the fuel pressure regulating valve by twoand one half turns. The regulating valve is locatedin the integral fuel filter base.

Note: Do not remove the regulating valve completely.Open the valve enough to allow the air that is trappedin the cylinder head to be purged from the fuelsystem.


5. Crank the engine for 30 seconds. Use a suitablecontainer to catch the fuel while you crank theengine. Allow the starting motor to cool for twominutes.

Note: You may use the hand priming pump for thefuel filter (if equipped) instead of cranking the engine.


7. Close and tighten the air purge screw.


9. Close and tighten the fuel pressure regulatingvalve.


10.Crank the engine for 30 seconds. Allow thestarting motor to cool for two minutes.

11.Repeat Step 10 until the engine starts and runs.

12.Clean any residual fuel from the enginecomponents.

i02049797

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

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

The primary filter/water separator also providesfiltration in order to help extend the life of thesecondary fuel filter. The element should be changedregularly. Install a vacuum gauge. Change theelement for the primary filter/water separator if thepressure is at 50 to 70 kPa (15 to 20 inches Hg).

Replace the Element


114 SEBU7689-10Maintenance SectionFuel System Primary Filter/Water Separator - Drain

g00668636Illustration 74(1) Bowl(2) Element(3) Drain

1. Stop the engine.

2. Turn the start switch to the “OFF” position.

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

4. If the primary fuel filter is equipped with a drainvalve (3), open the drain valve in order to drain anyfuel from the filter case. Close the drain valve (3).

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

5. Remove the fuel filter bowl (1) and wash the fuelfilter bowl with clean diesel fuel.

6. Remove the fuel filter (2).

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

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

NOTICEIn order to maximize fuel system life and prevent pre-mature wear out from abrasive particles in the fuel,use Caterpillar fuel filters.

Consult your Caterpillar dealer for proper part num-bers.

9. Install the new fuel filter (2). Spin the fuel filteronto the fuel filter base until the gasket contactsthe base. Use the rotation index marks on thefilters as a guide for proper tightening. Tighten thefilter for an additional 3/4 turn by hand. Do notovertighten the filter.

NOTICEDo not fill the fuel filters with fuel before installing them.The fuel would not be filtered and could be contami-nated. Contaminated fuel will cause accelerated wearto fuel system parts.

10. Install the clean fuel filter bowl (1) on the new fuelfilter.

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

11.Open the fuel tank supply valve.

12.Start the engine and check for leaks. Run theengine for one minute. Stop the engine and checkthe engine for leaks again.

Detection of leaks is very difficult especially ifthe engine is running. The primary filter/waterseparator is under suction. A leak will allow air toenter the fuel. The air in the fuel can cause lowpower due to aeration of the fuel. If air enters thefuel, check the components for overtightening orundertightening.

i02927285

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



Fuel System Secondary Filter - Replace






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

Bowl (2) should be monitored daily for signs of water.If water is present, drain the water from the bowl.

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

2. Close drain (3).

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

i03572801

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

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






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

Replacing the Fuel Filter Elementswith the Engine Stopped


116 SEBU7689-10Maintenance SectionFuel System Secondary Filter - Replace

g01902879Illustration 76Right hand service(1) Fuel priming pump(2) Fuel filter

1. Stop the engine.

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

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


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

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

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

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

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

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

Note: DO NOT remove the plug in the fuel filter basein order to release the air from the fuel system duringperiodic service of the fuel filter. Periodic removal ofthe plug will result in increased wear of the threads inthe fuel filter base.

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

10.Open the fuel tank supply valve.

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


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

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

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



Replacing the Main Fuel Filter

g01902892Illustration 77Duplex fuel filtersEngines are shipped from the factory with the control valve in theMAIN RUN position.

(3) Fuel pressure gauge for the main fuel filter(4) Plate that shows the position of the valve(5) Fuel pressure gauge for the auxiliary fuel filter(6) Control valve(7) Auxiliary fuel filter(8) Main fuel filter

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


1. Move the control valve to the LH FLOW - RH FILLposition as marked on plate. The fuel pressuregauge for the main fuel filter should indicatefull pressure. The fuel pressure gauge for theauxiliary fuel filter should indicate slight pressure.Five minutes may be required in order to fill theauxiliary fuel filter. The auxiliary fuel filter mustbecome full of fuel.


2. Move the control valve to the AUX RUN position.The fuel pressure gauge for the auxiliary fuel filtershould indicate full pressure. The fuel pressuregauge for the main fuel filter should indicate nopressure.



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

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

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

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

118 SEBU7689-10Maintenance SectionFuel System Secondary Filter - Replace


7. Move the control valve to the RH FLOW - LHFILL position. The fuel pressure gauge for theauxiliary fuel filter should indicate full pressure.The fuel pressure gauge for the main fuel filtershould indicate slight pressure. Five minutes maybe required in order to fill the main fuel filter. Themain filter must become full of fuel.


8. Move the control valve to the MAIN RUN position.The fuel pressure gauge for the main fuel filtershould indicate full pressure. The fuel pressuregauge for the auxiliary fuel filter should indicateno pressure.

replacing the Auxiliary Fuel Filter

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

g01902892Illustration 82Duplex fuel filters

The engine is operating with the control valve in the AUX RUNposition.(3) Fuel pressure gauge for the main fuel filter(4) Plate that shows the position of the valve(5) Fuel pressure gauge for the auxiliary fuel filter(6) Control valve(7) Auxiliary fuel filter(8) Main fuel filter

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


1. Move the control valve to the RH FLOW - LH FILLposition. The fuel pressure gauge for the auxiliaryfuel filter should indicate full pressure. The fuelgauge for the main fuel filter should indicateslight pressure. Five minutes may be required forfilling the main fuel filter. The main fuel filter mustbecome full of fuel.




2. Move the control valve to the MAIN RUN position.The fuel pressure gauge for the main fuel filtershould indicate full pressure. The fuel pressuregauge for the auxiliary fuel filter should indicateno pressure.



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

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

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

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


7. Move the control valve to the LH FLOW - RH FILLposition. The fuel pressure gauge for the mainfuel filter should indicate full pressure. The fuelpressure gauge for the auxiliary fuel filter shouldindicate slight pressure. Allow five minutes inorder to fill the auxiliary fuel filter. The auxiliaryfuel filter must become full of fuel.


8. Move the control valve to the AUX RUN position.The fuel pressure gauge for the auxiliary fuel filtershould indicate full pressure. The fuel pressuregauge for the main fuel filter should indicate nopressure.

Move the control valve to the FLOW BOTH positionafter both fuel filters are replaced.

120 SEBU7689-10Maintenance SectionFuel Tank Water and Sediment - Drain

i03645042

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




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

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

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

Note: Failure to properly close the drain can allow airinto the system, which could have detrimental resultsto performance.

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

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

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

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

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A four micron(c) absolute filter for the breathervent on the fuel tank is also recommended. Referto Special Publication, SENR9620, “Improving FuelSystem Durablity”.

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


Heat Exchanger - Inspect

i02683693

Heat Exchanger - InspectSMCS Code: 1379-040










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

• Cleanliness of the heat exchanger plates

• Effectiveness of the heat exchanger system

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

The following items indicate that the heat exchangermay require cleaning:

• Increased coolant temperature

• Engine overheating

• Excessive pressure drop between the water inletand the water outlet

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

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

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

Cleaning the Plate Type Heat Exchanger

Refer to the Disassembly and Assembly Manualfor the engine. The heat exchanger must bedisassembled in order to be cleaned. TheDisassembly and Assembly Manual will containinstructions for cleaning the heat exchanger prior toreassembly. The following general guidelines are forcleaning a plate type heat exchanger. Refer to Table15 for types of cleaners.

122 SEBU7689-10Maintenance SectionHoses and Clamps - Inspect/Replace

NOTICEDo not use hydrochloric acid to clean stainless steelplates.

Do not use hydrofluoric acid to clean titanium plates.

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

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

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

Do not use Halogenated hydrocarbons such asChlorothene and Carbon Tetrachloride

Do not use Aromatics such as Benzene and Toluene.

Table 15

Problem Source Cleaners(1)

Scaling

Calciumcarbonate

Calcium sulfateSilicates

Sediment(2)

Corrosionproducts

Metal oxidesSilt

Diatomicorganisms

Gross fouling

SeaweedChips of woodand fibersMusselsBarnacles

Biological growthBacteriaNematodesProtozoa

Nitric acidSulfamic acidCitric acid

Phosphoric acidComplexingagentsSodium

polyphosphates

ResidueOily filmsAsphaltFats

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

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

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

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

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

1. Drain the heat exchanger.

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

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

4. Assemble the heat exchanger.

i02121526

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

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

• Cracking

• Softness

• Loose clamps

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

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

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

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

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


Maintenance Recommendations

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

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


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

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

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

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

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

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

8. Refill the cooling system.

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

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

i03635511

MaintenanceRecommendationsSMCS Code: 1000

Maintenance InformationThe operating conditions of an engine affect themaintenance intervals and the time betweenoverhauls for the engine. The following conditionsaffect the maintenance intervals and the expectedoverhaul interval for the engine.

Severe Operation

Severe operation is the use of an engine thatexceeds current published standards for the engine.Caterpillar maintains standards for the followingengine parameters:

• Horsepower

• Range of rpm

• Fuel consumption

• Fuel quality

• Altitude

• Maintenance intervals

• Selection of oil

• Selection of coolant

• Environmental qualities

• Installation

Refer to the standards for your engine or consult yourCaterpillar dealer in order to determine if your engineis operating within the defined parameters.

Severe operation can accelerate component wear.Engines that are operating under severe conditionsmay need more frequent maintenance intervals forthe following reasons:

• Maximum reliability

• Retention of full service life

Because of individual applications, it is not possibleto identify all of the factors which can contribute tosevere operation. Consult your Caterpillar dealerabout the maintenance that is needed for yourspecific engine.

124 SEBU7689-10Maintenance SectionMaintenance Recommendations

The following factors can contribute to severeoperation: environment, improper operatingprocedures, and improper maintenance practices.

Environmental Factors

Extreme Ambient Temperatures

Extended operation in environments that areextremely cold or hot can damage components. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesthe performance capabilities of the engine.

Note: See this Operation and Maintenance Manual,“Cold Weather Operation” topic (Operation Section),or see Supplement, SEBU5898, “Cold WeatherRecommendations”.

Cleanliness

Unless the equipment is cleaned regularly, extendedoperation in a dirty environment and in a dustyenvironment can damage components. Built up mud,dirt, and dust can encase components. This canmake maintenance difficult. The buildup can containcorrosive chemicals. Corrosive chemicals and saltcan damage some components.

Improper Operating Procedures

• Extended operation at low idle

• Minimum cool down periods after high load factoroperation

• Operating the engine beyond the guidelines for theengine rating

• Operating the engine at loads that are greater thanthe rated load

• Operating the engine at speeds that are greaterthan the rated speed

• Use of the engine for an application that is notapproved

Improper Maintenance Practices

• Extension of maintenance intervals

• Not using recommended fuel, lubricants, andantifreeze/coolant solutions

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

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

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

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Note: Refer to this Operation and MaintenanceManual, “Overhaul (Top)” for further informationabout the top overhaul.

Note: Refer to this Operation and MaintenanceManual, “Overhaul (Major)” for further informationabout the major overhaul.

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

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

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

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


Oil Cooler Core - Check/Clean/Test

Overhaul Options

Before Failure Overhaul

To minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.

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

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

• Costly unplanned downtime can be avoided.

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

• The engine's service life can be extended withoutthe risk of a major catastrophe due to enginefailure.

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

After Failure Overhaul

If a major engine failure occurs and the engine mustbe removed from the hull, many options are available.An overhaul should be performed if the engine blockor the crankshaft needs to be repaired.

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

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

i03634803

Oil Cooler Core -Check/Clean/Test(If Equipped)SMCS Code: 1378-070; 1378-081; 1378-535

Clean the Oil Cooler CoreRemove the core. Refer to the Disassembly andAssembly Manual, “Oil Cooler - Remove” for theprocedure.

1. Turn the oil cooler core on one side in orderto remove debris. Remove the debris that isaccessible.

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

2. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 16 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 16

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

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

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

3. Steam clean the core in order to remove anyresidue. Flush the fins of the oil cooler core.Remove any other trapped debris from the insideand from the outside of the core.

4. Wash the core with hot, soapy water.

5. Flush the core thoroughly in order to removeresidue and remaining debris. Flush the core withclean, fresh water until the water that is exiting thecore is clear and free of debris.

126 SEBU7689-10Maintenance SectionOverhaul (Major)

Personal injury can result from air pressure.

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

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

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

Test the Oil Cooler Core1. Inspect the core for trapped debris andcleanliness. If necessary, remove the debris andrepeat the cleaning procedure.

2. Inspect the core for damage and perform apressure test in order to detect leaks. Many shopsthat service radiators are equipped to performpressure tests.

3. Plug both ends of the oil cooler core andpressurize the core to 205 kPa (30 psi). Submergethe core in water. Look for bubbles which arebeing emitted from the core. The bubbles areevidence of leaks.

4. If any leaks are found, do not attempt to repair thecore.

Install a core that is clean and a core that passes thepressure test in step 3. Refer to the Disassemblyand Assembly Manual, “Oil Cooler - Install” for theprocedure.

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

i03398635

Overhaul (Major)SMCS Code: 7595-020-MJ

The need for a major overhaul is determined byseveral factors.

• An increase of oil consumption

• An increase of crankcase blowby

• The total amount of fuel consumption

• The service hours of the engine

• The wear metal analysis of the lube oil

• An increase in the levels of noise and vibration

An increase of wear metals in the lube oil indicatesthat the bearings and the surfaces that wear mayneed to be serviced. An increase in the levels ofnoise and vibration indicates that rotating partsrequire service.

Note: It is possible for oil analysis to indicate adecrease of wear metals in the lube oil. The cylinderliners may be worn so that polishing of the boreoccurs. Also, the increased use of lube oil will dilutethe wear metals.

Monitor the engine as the engine accumulatesservice hours. Consult your Caterpillar dealer aboutscheduling a major overhaul.

Note: The driven equipment may also require servicewhen the engine is overhauled. Refer to the literaturethat is provided by the OEM of the driven equipment.

For the major overhaul, all of the bearings,seals, gaskets, and components that wear aredisassembled. The parts are cleaned and inspected.If necessary, the parts are replaced. The crankshaftis measured for wear. The crankshaft may requireregrinding. Alternatively, the crankshaft may bereplaced with a Caterpillar replacement part.

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

Replacement of ComponentsReplace the following components during the majoroverhaul:

• Camshaft bearings

• Connecting rod bearings

• Crankshaft seals

• Crankshaft thrust washers

• Electronic unit injectors

• Gear train bushings

• Gear train bearings

• Main bearings

• Piston rings

• Aftercooler core


Overhaul (Major)

International Convention for Safety ofLife at Sea (SOLAS)

Caterpillar recommends replacing the following:

• All shields that have been installed to cover up fueland oil line connections per (SOLAS) regulations

• All marine certification society approved tapes areinstalled in order to cover up fuel line connectionsand oil line connections according to the SOLASregulations.

Inspection, Reconditioning orExchanging of ComponentsInspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

Recondition the worn components or exchange thecomponents, if necessary. Your Caterpillar dealer canprovide these services and components.

• Camshaft followers

• Camshaft thrust washers

• Connecting rods

• Crankshaft vibration damper

• Cylinder head assembly

• Cylinder liners

• Engine mounts

• Scavenge oil pump

• Engine wiring harness

• Exhaust manifold seals

• Exhaust manifold bellows

• Fuel pressure regulating valve

• Fuel priming pump

• Fuel transfer pump

• Inlet manifold gaskets

• Inlet manifold seals

• Oil cooler core

• Oil pump

• Pistons

• Piston pins

• Prelube pump

• Pushrods

• Rocker arms

• Spacer plate

• Software update

• Turbocharger

Inspection of ComponentsInspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

• Camshaft

• Crankshaft

• Driven equipment (alignment)

• Engine cylinder block

• Engine control module

• Flywheel

• Front gear train (gears)

• Oil suction screen

• Rear gear train

Inspect the camshaft for damage to the journals andthe lobes.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

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

128 SEBU7689-10Maintenance SectionOverhaul (Top End)

• rod bearing

• main bearings

Note: If the crankshaft or the camshaft are removedfor any reason, use the magnetic particle inspectionprocess to check for cracks.

Replace the crankshaft vibration damper if any of thefollowing conditions occur:

• Engine failure due to a broken crankshaft

• Excessive wear of the front bearing for thecrankshaft

• Excessive wear of the gear train that is not causedby a lack of lubrication

Inspect the gears of the gear train and inspect thegear train bushings for the following conditions:

• Worn gear teeth

• Unusual fit

• Unusual wear

In addition to the inspection of components, inspectthe alignment of the driven equipment. See theApplication and Installation Guide for the engine orsee the literature that is provided by the OEM of thedriven equipment.

Cleaning of ComponentsClean the oil suction screen. Also, remove sidecovers in order to clean the oil sump. For instructionson removal and installation of components, seethe Service Manual, “Disassembly and Assembly”module.

Obtain a Coolant AnalysisFor conventional heavy-duty coolant or antifreeze,check the concentration of supplemental coolantadditive (SCA) regularly. The concentration of SCAcan be checked with an S·O·S coolant analysis (LevelI). A more detailed coolant analysis is recommendedperiodically.

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant water probablycontained minerals which were deposited on theengine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis may be obtainedfrom the following sources:

• Caterpillar dealer

• Local water utility company

• Agricultural agent

• Independent laboratory

Caterpillar recommends an S·O·S coolant analysis(Level II). This is a comprehensive chemicalevaluation of the coolant. This analysis is also acheck of the overall condition of the inside of thecooling system. The following services are provided:

• Full Level I analysis

• Identification of the source of metal corrosion andof contaminants

• Identification of buildup of the impurities that causecorrosion

• Identification of buildup of the impurities that causescaling

• Determination of possible electrolysis within theengines' cooling system

A report of the results of the analysis is provided.Maintenance recommendations are based on theresults.

For more information about S·O·S coolant analysis,consult your Caterpillar dealer.

i03648042

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

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

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

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


Sea Water Strainer - Clean/Inspect

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

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

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

If you elect to perform an overhaul without theservices of a Caterpillar dealer, be aware of therecommendations in Table 17.

Table 17

Recommendations for Top End Overhauls (1)

Service Top End Overhaul

Cylinder head assembliesInspectRebuildReplace Valves

Rocker arms

Valve bridgesInspectReplace

Fuel Injectors

Clean/Test Oil cooler core(2)Aftercooler core (Fresh water or

treated water system)(3)

Replace Cylinder head gasketsAftercooler core (salt water system)

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

(2) Refer to this Operation and Maintenance Manual, “Oil CoolerCore - Check/Clean/Test” for the procedure.

(3) Refer to this Operation and Maintenance Manual, “AftercoolerCore - Clean/Test” for the procedure.

i00905687

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

The sea water strainer must be clean in order toallow proper engine cooling. Check the sea waterstrainer for plugging. Inspect the sea water strainermore frequently if the vessel is being operatedin water which is shallow or dirty. Refer to theOEM recommendations for more information aboutinspecting and cleaning the sea water strainer.

Ensure that the auxiliary water pump is primed andthat the suction line is open.

1. Remove the sea water strainer and clean thescreen. Remove any dirt and debris.

2. Install the sea water strainer. Fill the sea waterstrainer and the suction line for the auxiliary waterpump with water.

i01113939

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

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

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

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

Electric Starting MotorNote: Problems with the electric starting motor canbe caused by the following conditions: malfunction ofthe solenoid and malfunction of the electric startingsystem.

Inspect the electrical system for the followingconditions:

130 SEBU7689-10Maintenance SectionTurbocharger - Inspect

• Loose connections

• Corrosion

• Wires that are worn or frayed

• Cleanliness

Make repairs, if necessary.

Air Starting Motor

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

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

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

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

If the teeth of the starting motor pinion and/or theflywheel ring gear are damaged, the air circuit forthe starting motor must be examined in order todetermine the cause of the problem.

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

Consult your Caterpillar dealer for assistance.

i01539769

Turbocharger - InspectSMCS Code: 1052-040; 1052

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

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

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

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

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

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

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

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

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


Walk-Around Inspection

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

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

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

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

5. Inspect the bore of the turbine housing forcorrosion.

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

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

i02706582

Walk-Around InspectionSMCS Code: 1000-040

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

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

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

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

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

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

• Ensure that the cooling lines are tight and ensurethat the cooling lines are properly clamped. Checkfor leaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

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

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

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

• Inspect the fuel system for leaks. Look for loosefuel line clamps.

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

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

132 SEBU7689-10Maintenance SectionWater Pump - Inspect

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

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

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

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

• Inspect the ECM to the cylinder head ground strapfor a good connection and for good condition.

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

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

i03543200

Water Pump - InspectSMCS Code: 1361-040; 1361

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

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

A failed water pump might cause severe engineoverheating problems that could result in cracks inthe cylinder head, a piston seizure or other potentialdamage to the engine.

Visually inspect the water pump for leaks. If leakingof the water pump seals is observed, replace all ofthe water pump seals. Refer to two articles in theDisassembly and Assembly Manual, “Water Pump- Disassemble and Water Pump - Assemble” forthe disassembly and assembly procedure. If it isnecessary to remove the water pump, refer to twoarticles in the Disassembly and Assembly Manual,“Water Pump - Remove and Water Pump - Install”.

Inspect the water pump for wear, cracks, pin holesand proper operation. Refer to the Parts Manualfor the correct part numbers for your engine orconsult your Caterpillar dealer if repair is needed orreplacement is needed.

i03612482

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

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

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

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

Inspect the zinc rods within 24 hours of initiallyfilling the plumbing with sea water. If no significantcorrosion is noted, inspect the zinc rods weekly orinspect the zinc rods after each 50 hours of engineoperation. If no significant deterioration is noted,inspect the zinc rods weekly or inspect the zinc rodsafter each 50 hours of engine operation.

Locations of the Zinc Rods

g01937139Illustration 87One or two zinc rods may be located in the oil cooler.


Zinc Rods - Inspect/Replace

g01937142Illustration 88One zinc rod is located on top of the auxiliary water pump.

g01937141Illustration 89One zinc rod is located in the intake for the heat exchanger. One zinc rod is located in the outlet for the heat exchanger.

Inspect the Zinc Rods1. Remove the zinc rod.


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

Replace the Zinc Rods


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

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

134 SEBU7689-10Maintenance SectionZinc Rods - Inspect/Replace

3. Coat the external threads of the plug with5P-3413 Pipe Sealant. Install the zinc rod. Referto the Specifications Manual for more informationon torque specifications.

Caterpillar C18 Marine Engine-Maintenance Intervals - Power And

Documents

Transcript of Caterpillar C18 Marine Engine-Maintenance Intervals - Power And