SAFETY.CAT.

COM

3176C and 3196

MARINE ENGINES
Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7040-04-01)

© 2007 Caterpillar
All Rights Reserved
60 SEBU7040-04
Maintenance Section
Maintenance Interval Schedule

i02507419 PM Level 1 - Every 9500 L (2500 US gal) of

Fuel or 250 Service Hours or 1 Year
Maintenance Interval Schedule
Aftercooler Condensate Drain Valve -
SMCS Code: 1000; 7500 Inspect/Clean ...................................................... 62
Alternator - Inspect ............................................... 63
Ensure that all safety information, warnings, and Alternator Belt - Inspect/Adjust/Replace ............... 63
instructions are read and understood before any Auxiliary Water Pump - Inspect ............................. 63
operation or any maintenance procedures are Battery Electrolyte Level - Check .......................... 64
performed. Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 74
The user is responsible for the performance of Engine Air Cleaner Element - Clean/Replace ....... 76
maintenance, including all adjustments, the use of Engine Crankcase Breather - Clean ..................... 78
proper lubricants, fluids, filters, and the replacement Engine Oil Sample - Obtain .................................. 81
of components due to normal wear and aging. Failure Engine Oil and Filter - Change ............................. 82
to adhere to proper maintenance intervals and Fuel System Primary Filter (Water Separator)
procedures may result in diminished performance of Element - Replace .............................................. 86
the product and/or accelerated wear of components. Fuel System Secondary Filter - Replace .............. 87
Fuel Tank Water and Sediment - Drain ................. 88
Use mileage, fuel consumption, service hours, or Hoses and Clamps - Inspect/Replace .................. 89
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals. Every 28 500 L (7500 US gal) of Fuel or 750
Products that operate in severe operating conditions Service Hours or 1 Year
may require more frequent maintenance.
Closed Crankcase Ventilation (CCV) Fumes Disposal
Note: Before each consecutive interval is performed, Filter - Replace .................................................... 66
all maintenance from the previous interval must be
performed. Every 38 000 L (10 000 US gal) of Fuel or
1000 Service Hours
When Required
Aftercooler Core - Clean/Test ............................... 62
Battery - Replace .................................................. 64 Heat Exchanger - Inspect ..................................... 88
Battery or Battery Cable - Disconnect .................. 65 Turbocharger - Inspect .......................................... 93
Engine Oil Level Gauge - Calibrate ...................... 79
Engine Storage Procedure - Check ...................... 83 PM Level 2 - Every 114 000 L (30 000 US gal)
Fuel System - Prime ............................................. 84 of Fuel or 3000 Service Hours or 2 Years
Daily Cooling System Coolant (DEAC) - Change .......... 67
Cooling System Coolant Extender (ELC) - Add .... 72
Closed Crankcase Ventilation (CCV) Filter Service Cooling System Water Temperature Regulator -
Indicator - Inspect ............................................... 65 Replace ............................................................... 75
Cooling System Coolant Level - Check ................ 73 Crankshaft Vibration Damper - Inspect ................. 75
Engine Air Cleaner Service Indicator - Inspect ..... 77 Engine Mounts - Inspect ....................................... 79
Engine Oil Level - Check ...................................... 79 Engine Speed/Timing Sensors - Check/Clean/
Fuel System Primary Filter/Water Separator - Calibrate .............................................................. 83
Drain ................................................................... 85 Engine Valve Lash - Inspect/Adjust ...................... 84
Marine Transmission Oil Level - Check ................ 90 Engine Valve Rotators - Inspect ........................... 84
Walk-Around Inspection ........................................ 94
Every 190 000 L (50 000 US gal) of Fuel or
Between 250 Service Hours and 1000 Service 5000 Service Hours
Hours (or between first and fourth oil change)
Starting Motor - Inspect ........................................ 93
Engine Valve Lash - Inspect/Adjust ...................... 84 Water Pump - Inspect ........................................... 95
Engine Valve Rotators - Inspect ........................... 84
Every 228 000 L (60 000 US gal) of Fuel or
Every 1900 L (500 US gal) of Fuel or 50 6000 Service Hours or 4 Years
Service Hours
Cooling System Coolant (ELC) - Change ............. 69
Zinc Rods - Inspect/Replace ................................. 95
SEBU7040-04 61
Maintenance Section
Maintenance Interval Schedule

Every 380 000 L (100 000 US gal) of Fuel or

10 000 Service Hours
Cylinder Head Grounding Stud - Inspect/Clean/
Tighten ................................................................ 76
Overhaul Considerations ...................................... 90
62 SEBU7040-04
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean

i02456287 i01546702

Aftercooler Condensate Drain Aftercooler Core - Clean/Test

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

2. Turn the aftercooler core upside-down in order

to remove debris.

NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.

3. Back flush the core with cleaner.

g00103601
Illustration 20 Caterpillar recommends the use of Hydrosolv
(1) Drain lines. (2) Adapter. (3) Valve. (4) Plunger. (5) Valve seat. liquid cleaner. Table 17 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
The turbocharger boost pressure forces plunger (4) dealer.
to move down to valve seat (5). The plunger must
close against the seat at a pressure of 27.5 kPa Table 17
(4 psi). When the engine is stopped, the absence Hydrosolv Liquid Cleaners(1)
of boost pressure allows the plunger to rise to the
open position, which allows condensation from the Part
Description Size
aftercooler to drain out. Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
The plunger must be able to move freely in order to
close the system when the engine is running. The 174-6854 Hydrosolv 100 19 L (5 US gallon)
plunger must be able to move freely in order to allow (1) Use a two to five percent concentration of the cleaner at
condensation to drain from the aftercooler when temperatures up to 93°C (200°F). Refer to Application
the engine is stopped. Residue from normal engine Guide, NEHS0526 or consult your Caterpillar dealer for more
information.
operation could cause the plunger to stick.

1. Remove valve (3) from adapter (2). Check the 4. Steam clean the core in order to remove any
valve in order to determine if plunger (4) moves residue. Flush the fins of the aftercooler core.
freely. If the plunger does not move easily, clean Remove any other trapped debris.
the valve with solvent.
5. Wash the core with hot, soapy water. Rinse the
2. Remove drain lines (1). Check the lines for core thoroughly with clean water.
plugging. Clean the lines, if necessary. Pressure
air or a flexible rod with a small diameter can be
used to clean the lines.
Personal injury can result from air pressure.
3. Reassemble the aftercooler condensate drain
valve. Refer to the Specifications, SENR3130, Personal injury can result without following prop-
“Torque Specifications” for the correct torque er procedure. When using pressure air, wear a pro-
values . tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

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

the reverse direction of the normal flow.
SEBU7040-04 63
Maintenance Section
Alternator - Inspect

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

Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.

8. Install the core. Refer to the Service Manual for

the procedure.

For more information on cleaning the core, consult

your Caterpillar dealer.

i00072207

Alternator - Inspect
SMCS Code: 1405-040 g00122875
Illustration 21
Caterpillar recommends a scheduled inspection (1) Adjusting nuts
(2) Mounting bolt
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in 1. Remove the belt guard.
order to ensure proper battery performance and/or
proper performance of the electrical system. Make 2. Loosen mounting bolt (2) and adjusting nuts (1).
repairs, as required. Refer to the Service Manual.
3. Turn adjusting nuts (1) in order to increase or
Check the alternator and the battery charger for decrease the belt tension.
proper operation. If the batteries are properly
charged, the ammeter reading should be very near 4. Tighten adjusting nuts (1). Tighten mounting
zero. All batteries should be kept charged. The bolt (2). Refer to the Specifications, SENR3130,
batteries should be kept warm because temperature “Torque Specifications” for the proper torques.
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will 5. Reinstall the belt guard.
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time If new belts are installed, check the belt adjustment
or if the engine is run for short periods, the batteries again after 30 minutes of engine operation at the
may not fully charge. A battery with a low charge will rated rpm.
freeze more easily than a battery with a full charge.
Replacement
i02456322
For applications that require multiple drive belts,
Alternator Belt - replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry
Inspect/Adjust/Replace more load because the older belts are stretched. The
additional load on the new belt could cause the new
SMCS Code: 1357-036; 1357-510 belt to break.

Inspection Refer to the Service Manual for more information on

the procedures for the following topics: belt removal
To maximize the engine performance, inspect the and installation of the belt.
belt for wear and for cracking. Check the belt tension.
Adjust the belt tension in order to minimize belt i01059376
slippage. Belt slippage will decrease the life of the
belt. Auxiliary Water Pump - Inspect
To check the belt tension, apply 110 N (25 lb) of force SMCS Code: 1371-040
midway between the pulleys. A correctly adjusted
belt will deflect 13 to 19 mm (0.50 to 0.75 inch). Impellers require periodic inspection and seals
require periodic inspection. Impellers have a service
life that is limited. The service life depends on the
engine operating conditions.
64 SEBU7040-04
Maintenance Section
Battery - Replace

Inspect the components of the pump more frequently 3. The NEGATIVE “-” cable connects the NEGATIVE
when the pump is exposed to debris, sand, or other “-” battery terminal to the ground plane. Disconnect
abrasive materials. Inspect the components if the the cable from the NEGATIVE “-” battery terminal.
pump is operating at a differential pressure of more
than 103 kPa (15 psi). 4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
Check the following components for wear and check Disconnect the cable from the POSITIVE “+”
the following components for damage: battery terminal.

• Cam Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate
• Impeller recycling facility.

• Seals 5. Remove the used battery.

• Wear plate 6. Install the new battery.

If wear is found or if damage is found, replace Note: Before the cables are connected, ensure that
the components which are worn or replace the the key start switch is OFF.
components which are damaged. Use the proper
repair kit for the pump. Refer to the Disassembly 7. Connect the cable from the starting motor to the
and Assembly for more information on servicing the POSITIVE “+” battery terminal.
auxiliary water pump.
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
i02153996

Battery - Replace i02340858

SMCS Code: 1401-510 Battery Electrolyte Level -

Check
SMCS Code: 1401-535
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas- When the engine is not run for long periods of time or
es to ignite. This can result in severe personal in- when the engine is run for short periods, the batteries
jury or death. may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
Ensure proper ventilation for batteries that are in are properly charged, ammeter reading should be
an enclosure. Follow the proper procedures in or- very near zero, when the engine is in operation.
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
The battery cables or the batteries should not be near batteries.
removed with the battery cover in place. The bat-
tery cover should be removed before any servic- 1. Remove the filler caps. Maintain the electrolyte
ing is attempted. level to the “FULL” mark on the battery.
Removing the battery cables or the batteries with If the addition of water is necessary, use distilled
the cover in place may cause a battery explosion water. If distilled water is not available use clean
resulting in personal injury. water that is low in minerals. Do not use artificially
softened water.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads. 2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
2. Turn OFF the battery charger. Disconnect the
charger. 3. Keep the batteries clean.
SEBU7040-04 65
Maintenance Section
Battery or Battery Cable - Disconnect

Clean the battery case with one of the following i01852860

cleaning solutions:
Closed Crankcase Ventilation
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
(CCV) Filter Service Indicator
- Inspect
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water SMCS Code: 1317-040-FI

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -

Disconnect
g00744250
Illustration 22
(1) Plastic cover
(2) Service indicator
SMCS Code: 1402-029
The Closed Crankcase Ventilation system (CCV)
is equipped with a service indicator. If the fumes
disposal filter becomes plugged prior to the normal
The battery cables or the batteries should not be service interval, increased restriction of the filter will
removed with the battery cover in place. The bat- cause the crankcase pressure to become positive.
tery cover should be removed before any servic- When the pressure continues to rise, the service
ing is attempted. indicator will show through the plastic cover. The
service indicator indicates the need for the fumes
Removing the battery cables or the batteries with disposal filter to be changed. Refer to the Operation
the cover in place may cause a battery explosion and Maintenance Manual, “Closed Crankcase
resulting in personal injury. Ventilation (CCV) Fumes Disposal Filter - Replace”
topic for more information.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position Note: Check the service indicator when the engine is
and remove the key and all electrical loads. running at low idle.

2. Disconnect the negative battery terminal at the

battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.

3. Tape the leads in order to help prevent accidental

starting.

4. Proceed with necessary system repairs. Reverse

the steps in order to reconnect all of the cables.
66 SEBU7040-04
Maintenance Section
Closed Crankcase Ventilation (CCV) Fumes Disposal Filter - Replace

i01105975 Resetting the Service Indicator

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

g00585674
Illustration 24

1. Remove the plastic cover (4).

2. Push down on the service indicator (5).

3. Replace the cover (4).

4. Replace the fumes disposal filter by using the

following procedure:

Replacing the Fumes Disposal

Illustration 23
g00585620 Filter
Typical example of the Closed Crankcase Ventilation system
(CCV)
(1) Crankcase breather
(2) Fumes disposal filter base and fumes disposal filter Hot oil and hot components can cause personal
(3) Air cleaner
injury. Do not allow hot oil or hot components to
contact the skin.
The Closed Crankcase Ventilation system (CCV)
requires the replacement of the fumes disposal filter.
The service interval of the CCV will be affected by Note: When possible, perform the maintenance while
the following items: the engine is off.

• Engine load
• Soot concentration
• Condition of the engine
The CCV is equipped with a service indicator. If the
fumes disposal filter becomes plugged prior to the
normal service interval, increased restriction of the
filter will cause the vacuum to become positive. When
the pressure continues to rise, the service indicator
will show through the cap. The service indicator
indicates the need for the fumes disposal filter to be
changed. Reset the service indicator by using the
g00585616
following procedure: Illustration 25

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

the filter base assembly (6).
SEBU7040-04 67
Maintenance Section
Cooling System Coolant (DEAC) - Change

Note: The canister (8) may be difficult to remove Drain

while the engine is operating. The canister has
negative air pressure while the engine is operating.
This creates a vacuum.
Pressurized System: Hot coolant can cause seri-
2. Lower the canister (8) in order to expose the ous burns. To open the cooling system filler cap,
element. There may be oil in the bottom of the stop the engine and wait until the cooling system
canister. Avoid spilling the oil. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
3. Remove the filter element by pulling down. sure.
Dispose of the used element properly.

4. Remove the O-ring assembly on the top end cap

of the used element.

5. Replace the O-ring seal on the bottom of the filter

base assembly.

6. Install the new O-ring on the top end cap of the

element. Install the element into the correct place.

7. Replace the canister (8) and align the canister

with the boss on the filter base assembly (6).

8. Clamp the latches (7) in the closed position.

g00104910
Illustration 26
i02456328 Cooling System Filler Cap

Cooling System Coolant 1. Stop the engine and allow the engine to cool.
(DEAC) - Change Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
SMCS Code: 1350-070; 1395-044 system filler cap.

Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated.
g00104911
NOTICE Illustration 27
Use of commercially available cooling system clean- (1) Aftercooler drain plug. (2) Oil cooler drain plug. (3) Drain Plug
ers may cause damage to cooling system compo- for the water temperature regulator.
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines. 2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has Remove the drain plug from the bottom of the
been drained. This is a good opportunity to replace water cooled exhaust manifold. Remove the drain
the water pump, the water temperature regulator and plug for the water temperature regulator (3),
the hoses, if necessary. aftercooler drain plug (1) and oil cooler drain plug
(2). Allow the coolant to drain.
68 SEBU7040-04
Maintenance Section
Cooling System Coolant (DEAC) - Change

Cooling Systems with Heavy

NOTICE Deposits or Plugging
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used Note: For the following procedure to be effective,
coolant for reuse in engine cooling systems. The full there must be some active flow through the cooling
distillation procedure is the only method acceptable by system components.
Caterpillar to reclaim the used coolant.
1. Flush the cooling system with clean water in order
For information regarding the disposal and the to remove any debris.
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology 2. Close the drain valve (if equipped). Clean
Group: the drain plugs. Install the drain plugs.
Refer to Specifications, SENR3130, “Torque
Outside Illinois: 1-800-542-8665 Specifications” for more information on the proper
Inside Illinois: 1-800-541-8665 torques.
Canada: 1-800-523-8665
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Flush Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
1. Flush the cooling system with clean water in order Install the cooling system filler cap.
to remove any debris.
4. Start and run the engine at low idle for a minimum
2. Close the drain valve (if equipped). Clean of 90 minutes. The coolant temperature should be
the drain plugs. Install the drain plugs. Refer at least 82°C (180°F).
to the Specifications, SENR3130, “Torque
Specifications” for more information on the proper 5. Stop the engine and allow the engine to cool.
torques. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
3. Fill the cooling system with a mixture of clean cooling system filler cap. Open the drain valve (if
water and Caterpillar Fast Acting Cooling System equipped) or remove the cooling system drain
Cleaner. Add .5 L (1 pint) of cleaner per 15 L plugs. Allow the water to drain. Flush the cooling
(4 US gal) of the cooling system capacity. Install system with clean water. Close the drain valve
the cooling system filler cap. (if equipped). Clean the drain plugs. Install the
drain plugs. Refer to Specifications, SENR3130,
4. Start and run the engine at low idle for a minimum “Torque Specifications” for more information on
of 30 minutes with a coolant temperature of at the proper torques.
least 82°C (180°F).
Fill
NOTICE
Improper or incomplete rinsing of the cooling system
NOTICE
can result in damage to copper and other metal com-
Fill the cooling system no faster than 19 L (5 US gal)
ponents.
per minute to avoid air locks.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa- Engines That Are Equipped with a
ter. Continue to flush the system until all signs of the
cleaning agent are gone. Coolant Recovery Tank
1. Fill the system to the top with the mixture of
5. Stop the engine and allow the engine to cool. coolant that is recommended. Refer to this
Loosen the cooling system filler cap slowly Operation and Maintenance Manual, “Refill
in order to relieve any pressure. Remove the Capacities and Recommendations” for more
cooling system filler cap. Open the drain valve (if information on cooling system specifications. Do
equipped) or remove the cooling system drain not install the cooling system filler cap.
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve 2. Start and run the engine at low idle. Increase the
(if equipped). Clean the drain plugs. Install the engine rpm to 1500 rpm. Run the engine at 1500
drain plugs. Refer to Specifications, SENR3130, rpm for one minute in order to purge the air from
“Torque Specifications” for more information on the cavities of the engine block. Stop the engine.
the proper torques.
SEBU7040-04 69
Maintenance Section
Cooling System Coolant (ELC) - Change

3. Check the coolant level. Maintain the coolant level 3. Check the coolant level. Maintain the coolant level
within 13 mm (.5 inch) below the bottom of the within 13 mm (.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within pipe for filling. Maintain the coolant level at the
13 mm (.5 inch) to the proper level on the sight proper level on the sight glass (if equipped).
glass (if equipped).
4. Clean the cooling system filler cap. Inspect
4. Clean the cooling system filler cap. Inspect the the gasket for the cooling system filler cap. If
gasket that is on the cooling system filler cap. the gasket for the cooling system filler cap is
If the gasket for the cooling system filler cap is damaged, discard the old cooling system filler
damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If
cap and install a new cooling system filler cap. If the gasket for the cooling system filler cap is not
the gasket for the cooling system filler cap is not damaged, use a 9S-8140 Pressurizing Pump in
damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system filler cap.
order to pressure test the cooling system filler cap. The correct pressure for the cooling system filler
The correct pressure for the cooling system filler cap is stamped on the face of the cooling system
cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not
filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling
retain the correct pressure, install a new cooling system filler cap.
system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.

i02456377

Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-070; 1395-044

Personal injury can result from hot coolant, steam

g00103638 and alkali.
Illustration 28
(1)Filler cap for the recovery tank. (2) “COLD FULL” mark. (3)
At operating temperature, engine coolant is hot
“LOW ADD” mark.
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
5. Pour coolant into the recovery tank until the
steam. Any contact can cause severe burns.
coolant reaches “COLD FULL” mark (2). Do not fill
the recovery tank above “COLD FULL” mark (2).
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
6. Clean the filler cap for the recovery tank. Install
cooling system pressure cap is cool enough to
the filler cap for the recovery tank. Start the
touch with your bare hand.
engine. Inspect the cooling system for leaks and
for proper operating temperature.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
Engines That Are Not Equipped with a burns.
Coolant Recovery Tank
Cooling System Coolant Additive contains alkali.
1. Fill the cooling system with coolant. Refer to Avoid contact with skin and eyes.
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” for more
information on cooling system specifications. Do
not install the cooling system filler cap.

2. Start and run the engine at low idle. Increase the

engine rpm to 1500 rpm. Run the engine at 1500
rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
70 SEBU7040-04
Maintenance Section
Cooling System Coolant (ELC) - Change

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

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and g00105135

Illustration 30
mandates.
(1) Aftercooler drain plug. (2) Oil cooler drain plug. (3) Drain plug
for the water temperature regulator.
Use only clean water to flush the cooling system
when Extended Life Coolant (ELC) is drained and 2. Open the cooling system drain valve (if equipped).
replaced. If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs.
Drain Remove the drain plug from the bottom of the
water cooled exhaust manifold. Remove the drain
plug for the water temperature regulator (3),
aftercooler drain plug (1) and oil cooler drain plug
(2). Allow the coolant to drain.

For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
Group:

Outside U.S.A.: (309) 675-6277

Inside U.S.A.: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Illustration 29
g00105134 CSTG COSA Geneva, Switzerland:
Filler Cap for the Cooling System 41-22-849 40 56

1. Stop the engine and allow the engine to cool. Clean the Cooling System
Loosen the filler cap for the cooling system slowly
in order to relieve any pressure. Remove the filler 1. Flush the cooling system with clean water in order
cap for the cooling system. to remove any debris.

2. Close the drain valve (if equipped). Clean

the drain plugs. Install the drain plugs.
Refer toSpecifications, SENR3130, “Torque
Specifications” for more information on the proper
torques.

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

3. Fill the cooling system with clean water. Install the

cooling system filler cap. Operate the engine until
the temperature reaches 49 °C (120 °F) to 66 °C
(150 °F).
SEBU7040-04 71
Maintenance Section
Cooling System Coolant (ELC) - Change

4. Start and run the engine at low idle until the

temperature reaches 49 to 66°C (120 to 150°F).

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

Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve
(if equipped). Clean the drain plugs. Install the
drain plugs. Refer to Specifications, SENR3130,
“Torque Specifications” for more information on
the proper torques.
g00103638
Illustration 31
Fill the Cooling System (1) Filler cap for the recovery tank. (2) “COLD FULL” mark. (3)
“LOW ADD” mark.
Engines That Are Equipped with a
Coolant Recovery Tank 5. Pour Cat ELC into the recovery tank until the
coolant reaches “COLD FULL” mark (2). Do not fill
the tank above “COLD FULL” mark (2).
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) 6. Clean the filler cap. Install the filler cap. Start the
per minute to avoid air locks. engine. Inspect the cooling system for leaks and
for proper operating temperature.
1. Fill the cooling system to the top with Cat ELC.
Refer to this Operation and Maintenance Manual, Engines That Are Not Equipped with a
“Refill Capacities and Recommendations” for Coolant Recovery Tank
more information on coolant specifications. Do not
install the filler cap for the recovery tank.
NOTICE
2. Start and run the engine at low idle. Increase the Fill the cooling system no faster than 19 L (5 US gal)
engine rpm to 1500 rpm. Run the engine at 1500 per minute to avoid air locks.
rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine. 1. Fill the cooling system to the top with Cat ELC.
Refer to this Operation and Maintenance Manual,
3. Check the coolant level. Maintain the coolant to “Refill Capacitties and Recommendations” for
the proper level on the sight gauge (if equipped). more information on cooling system specifications.
If a sight gauge is not equipped, maintain the Do not install the cooling system filler cap.
coolant within 13 mm (.5 inch) below the bottom of
the filler pipe. 2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at 1500
4. Clean the cooling system filler cap. Inspect rpm for one minute in order to purge the air from
the filler cap gasket. If the filler cap gasket is the cavities of the engine block. Stop the engine.
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the 3. Check the coolant level. Maintain the coolant level
filler cap gasket is not damaged, use a 9S-8140 within 13 mm (.5 inch) below the bottom of the
Pressurizing Pump in order to pressure test the pipe for filling. Maintain the coolant level at the
cooling system filler cap. The correct pressure for proper level on the sight glass (if equipped).
the cooling system filler cap is stamped on the
face of the cooling system filler cap. If the cooling
system filler cap does not retain the correct
pressure, install a new cooling system filler cap.
72 SEBU7040-04
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

4. Clean the filler cap. Inspect the gasket for the

filler cap for the cooling system. If the gasket is
damaged, discard the old filler cap for the cooling
Personal injury can result from hot coolant, steam
system and install a new filler cap. If the gasket
and alkali.
for the cooling system filler cap is not damaged,
use a 9S-8140 Pressurizing Pump in order to
At operating temperature, engine coolant is hot
pressure test the cooling system filler cap. The
and under pressure. The radiator and all lines
correct pressure for the cooling system filler cap
to heaters or the engine contain hot coolant or
is stamped on the face of the cooling system filler
steam. Any contact can cause severe burns.
cap. If the cooling system filler cap does not retain
the correct pressure, install a new cooling system
Remove cooling system pressure cap slowly to
filler cap.
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
5. Start the engine. Inspect the cooling system
touch with your bare hand.
for leaks. Inspect the cooling system for proper
operating temperature.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
i02482066 burns.

Cooling System Coolant Cooling System Coolant Additive contains alkali.

Extender (ELC) - Add Avoid contact with skin and eyes.

SMCS Code: 1352-045; 1395-081 NOTICE

Care must be taken to ensure that fluids are contained
Cat ELC (Extended Life Coolant) does not require during performance of inspection, maintenance, test-
the frequent additions of any supplemental cooling ing, adjusting and repair of the product. Be prepared to
additives which are associated with the present collect the fluid with suitable containers before open-
conventional coolants. The Cat ELC Extender only ing any compartment or disassembling any compo-
needs to be added once. nent containing fluids.

NOTICE Refer to Special Publication, NENG2500, “Caterpillar

Use only Cat Extended Life Coolant (ELC) Extender Dealer Service Tool Catalog” for tools and supplies
with Cat ELC. suitable to collect and contain fluids on Caterpillar
products.
Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven- Dispose of all fluids according to local regulations and
tional coolants and/or conventional SCA reduces the mandates.
Cat ELC service life.
1. Loosen the cooling system filler cap slowly in
Check the cooling system only when the engine is order to relieve pressure. Remove the cooling
stopped and cool. system filler cap.

2. It may be necessary to drain enough coolant from

the cooling system in order to add the Cat ELC
Extender.

3. Add Cat ELC Extender according to the

requirements for your engine’s cooling system
capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
article for more information.

4. Clean the cooling system filler cap. Inspect the

gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
SEBU7040-04 73
Maintenance Section
Cooling System Coolant Level - Check

i02456586 Engines That Are Not Equipped

Cooling System Coolant Level with a Coolant Recovery Tank
- Check
SMCS Code: 1395-082
Pressurized System: Hot coolant can cause seri-
Check the coolant level when the engine is stopped ous burns. To open the cooling system filler cap,
and cool. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
Engines That Are Equipped with a sure.
Coolant Recovery Tank
1. Remove the cooling system filler cap slowly in
order to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)

of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.

g00103638
Illustration 32
(1) Filler cap
(2) “COLD FULL” mark
(3) “LOW ADD” mark

1. Observe the coolant level in the coolant recovery

tank. Maintain the coolant level to “COLD FULL”
mark (2) on the coolant recovery tank. g00103639
Illustration 33
2. Loosen filler cap (1) slowly in order to relieve any Typical filler cap gaskets
pressure. Remove the filler cap.
3. Clean the cooling system filler cap and inspect
3. Pour the proper coolant mixture into the tank. the condition of the filler cap gaskets. Replace the
Refer to this Operation and Maintenance Manual, cooling system filler cap if the filler cap gaskets are
“Refill Capacities and Recommendations” for damaged. Reinstall the cooling system filler cap.
information about coolants. Do not fill the coolant
recovery tank above “COLD FULL” mark (2). 4. Inspect the cooling system for leaks.

4. Clean filler cap (1) and the receptacle. Reinstall

the filler cap and inspect the cooling system for
leaks.

Note: The coolant will expand as the coolant heats

up during normal engine operation. The additional
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
and cool, the coolant will return to the engine.
74 SEBU7040-04
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i02456600 • Glycol Concentration

Cooling System Supplemental • Concentration of SCA
Coolant Additive (SCA) -
• pH
Test/Add
• Conductivity
SMCS Code: 1352-045; 1395-081
The results are reported, and recommendations
are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
Cooling system coolant additive contains alkali. managing your equipment with an S·O·S Coolant
To help prevent personal injury, avoid contact with Analysis.
the skin and the eyes. Do not drink cooling system
coolant additive. Level 2
This level coolant analysis is recommended when the
Note: Test the concentration of the Supplemental engine is overhauled. Refer to this Operations and
Coolant Additive (SCA) or test the SCA concentration Maintenance Manual, “Overhaul Considerations” for
as part of an S·O·S Coolant Analysis. further information.

Test for SCA Concentration Add the SCA, If Necessary

Coolant and SCA
NOTICE
Do not exceed the recommended amount of sup-
NOTICE plemental coolant additive concentration. Excessive
Do not exceed the recommended six percent supple- supplemental coolant additive concentration can form
mental coolant additive concentration. deposits on the higher temperature surfaces of the
cooling system, reducing the engine’s heat transfer
Use the 8T-5296 Coolant Conditioner Test Kit characteristics. Reduced heat transfer could cause
or use the 4C-9301 Coolant Conditioner Test Kit cracking of the cylinder head and other high temper-
in order to check the concentration of the SCA. ature components. Excessive supplemental coolant
Refer to this Operation and Maintenance Manual, additive concentration could also result in radiator
“Refill Capacities and Recommendations” for more tube blockage, overheating, and/or accelerated water
information. pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped)
Water and SCA at the same time. The use of those additives together
could result in supplemental coolant additive concen-
tration exceeding the recommended maximum.
NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296 Pressurized System: Hot coolant can cause seri-
Coolant Conditioner Test Kit. Refer to the Special ous burns. To open the cooling system filler cap,
Publication, SEBU6251, “Caterpillar Commercial stop the engine and wait until the cooling system
Diesel Engine Fluids Recommendations” for more components are cool. Loosen the cooling system
information. pressure cap slowly in order to relieve the pres-
sure.
S·O·S Coolant Analysis
1. Slowly loosen the cooling system filler cap in
S·O·S coolant samples can be analyzed at your order to relieve the pressure. Remove the cooling
Caterpillar dealer. S·O·S Coolant Analysis is a system filler cap.
program that is based on periodic samples.
Note: Always discard drained fluids according to
Level 1 local regulations.

Level 1 is a basic analysis of the coolant. The 2. If necessary, drain some coolant from the cooling
following items are tested: system into a suitable container in order to allow
space for the extra SCA.
SEBU7040-04 75
Maintenance Section
Cooling System Water Temperature Regulator - Replace

3. Add the proper amount of SCA. Refer

to the Special Publication, SEBU6251, NOTICE
“Caterpillar Commercial Diesel Engines Fluids Failure to replace your water temperature regulator
Recommendations” for more information on SCA on a regularly scheduled basis could cause severe
requirements. engine damage.

4. Clean the cooling system filler cap. Inspect the Caterpillar engines incorporate a shunt design cooling
gaskets of the cooling system filler cap. If the system and require operating the engine with a water
gaskets are damaged, replace the old cooling temperature regulator installed.
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap. If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
i00912898
ulator is installed in the original position. Ensure that
Cooling System Water the water temperature regulator vent hole is open.
Temperature Regulator - Do not use liquid gasket material on the gasket or
Replace cylinder head surface.

SMCS Code: 1355-510 Refer to the Service Manual for the replacement
procedure of the water temperature regulator, or
Replace the water temperature regulator before consult your Caterpillar dealer.
the water temperature regulator fails. This is a
recommended preventive maintenance practice. Note: If only the water temperature regulators are
Replacing the water temperature regulator reduces replaced, drain the coolant from the cooling system to
the chances for unscheduled downtime. a level that is below the water temperature regulator
housing.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine. i00072369

A water temperature regulator that fails in the closed Crankshaft Vibration Damper
position can cause excessive overheating. Excessive - Inspect
overheating could result in cracking of the cylinder
head or piston seizure problems. SMCS Code: 1205-040
A water temperature regulator that fails in the open Damage to the crankshaft vibration damper or failure
position will cause the engine operating temperature of the crankshaft vibration damper can increase
to be too low during partial load operation. Low torsional vibrations. This can result in damage to
engine operating temperatures during partial loads the crankshaft and to other engine components. A
could cause an excessive carbon buildup inside the deteriorating damper can cause excessive gear train
cylinders. This excessive carbon buildup could result noise at variable points in the speed range.
in an accelerated wear of the piston rings and wear
of the cylinder liner. The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.

Removal and Installation

Refer to the Service Manual for the damper removal
procedure and for the damper installation procedure.

Visconic Damper
The visconic damper has a weight that is located
inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration. Inspect the
damper for evidence of dents, cracks or leaks of the
fluid.
76 SEBU7040-04
Maintenance Section
Cylinder Head Grounding Stud - Inspect/Clean/Tighten

Replace the damper if the damper is dented, cracked i01708992

or leaking. Refer to the Service Manual or consult
your Caterpillar dealer for damper replacement. Engine Air Cleaner Element -
Clean/Replace
i01684727
SMCS Code: 1054-070; 1054-510
Cylinder Head Grounding Stud
- Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079

g00105025
Illustration 35
(1) Vacuum regulator filter element
(2) Air cleaner element

g00738038 Note: The air cleaner element should be replaced

Illustration 34 after three cleanings.
Typical example for location of cylinder head grounding stud
(1) Cylinder head grounding stud Note: Use the 102-9720 Cleaning Kit. This product
contains the detergent and oil that is made specifically
Inspect the wiring harness for good connections. for the maintenance of the air cleaner elements.

The cylinder head grounding stud must have a wire 1. Remove the vacuum regulator filter element (1)
ground to the battery. Tighten the cylinder head and the air cleaner element (2).
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds. Note: The same procedure is used for cleaning both
All grounds should be tight and free of corrosion. the air filter element and the vacuum regulator filter
element.
• Clean the cylinder head grounding stud and the
terminals with a clean cloth. 2. Tap the element in order to dislodge dirt particles.
Gently brush the element with a soft bristle brush.
• If the connections are corroded, clean the
connections with a solution of baking soda and Note: The element may be oiled and the element
water. may be reinstalled , if complete cleaning is not
practical at this time. Refer to step 6.
• Keep the cylinder head grounding stud and the
strap clean and coated with MPGM grease or NOTICE
petroleum jelly. Do not use gasoline, steam, caustic or unapproved
detergents, or parts cleaning solvents. Do not use high
pressure water or air to clean the air cleaner element.
Any of those liquids or methods can cause air cleaner
element damage.

3. Spray the element with the cleaning solution.

Allow the element to stand for 10 minutes.
SEBU7040-04 77
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

4. Rinse the element with low water pressure. The i00072989

maximum water pressure for this procedure is
275 kPa (40 psi). Tap water is acceptable. Start Engine Air Cleaner Service
to rinse the element from the clean side (inside).
Next, clean the dirty side (outside) in order to
Indicator - Inspect
flush out dirt. Inspect the element for tears and/or SMCS Code: 7452-040
holes after the element is cleaned. Do not reuse
damaged elements.

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

5. Shake excess water off the element and allow the

element to air dry. Drying the element in the sun
speeds the process.

NOTICE g00105037
Illustration 36
Do not use transmission fluid, engine oil, diesel fuel,
or other lubricant to oil the air cleaner element. The Service Indicator
air cleaner element can not function correctly if im-
proper oil is used. Never operate an engine with a Some engines may be equipped with a different
dry air cleaner element. The air cleaner element can service indicator.
not function correctly without oil. Always saturate the
clean air cleaner element with the recommended oil. Some engines are equipped with a differential
gauge for inlet air pressure. The gauge reads the
difference between inlet air pressure before the air
6. The dry element should be oiled before installation. cleaner element and after the air cleaner element.
Apply small amounts of oil across the top of each As the air cleaner element becomes dirty, the
pleat. Allow the oil to wick into the element for 20 pressure differential rises. If your engine is equipped
minutes. Oil any remaining “white” spots. with a different type of service indicator, follow
the recommendations for the vessel or follow the
7. Inspect the housing and the clamp for air cleaner recommendations in the air cleaner OEM in order to
element (2). Replace the housing and the clamp, service the air cleaner element.
if necessary. Install the clean, oiled air cleaner
element. Refer to the Torque Specifications, A service indicator may be mounted on the air
SENR3130 for more information on the proper cleaner element or in a remote location.
torques.

8. Install the vacuum regulator filter element (1) on

the vacuum regulator filter.

g00103777
Illustration 37
Typical Service Indicator
78 SEBU7040-04
Maintenance Section
Engine Crankcase Breather - Clean

Observe the service indicator. The air cleaner If the service indicator appears red at any time, clean
element should be cleaned or replaced when the the air cleaner element or install a new air cleaner
yellow diaphragm enters the red zone or the red element. Clean the air cleaner element or replace the
piston locks in the visible position. If the service air cleaner element at 250 hour intervals.
indicator appears red at any time, clean the air
cleaner element or install a new air cleaner element. Refer to the Operation and Maintenance Manual for
more information on servicing the air cleaner element.
Test the Service Indicator
i01102895
Service indicators are important instruments.
Engine Crankcase Breather -
• Check for ease of resetting. The service indicator Clean
should reset in less than three pushes.
SMCS Code: 1317-070
• Check the movement of the yellow core when the
engine is accelerated to the engine rated rpm.
The yellow core should latch approximately at the
greatest vacuum that is attained.

If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.

The service indicator may need to be replaced

frequently in environments that are severely dusty (if
applicable). Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and Illustration 38
g00580871
whenever major engine components are replaced. Typical example
(1) Hose clamp
Note: When a new service indicator is installed, (2) Four bolts
excessive force may crack the top of the service (3) Breather cover
indicator. Tighten the service indicator to a torque
of 2 N·m (18 lb in).
NOTICE
Perform this maintenance with the engine stopped.
Service the Air Cleaner Element
If the crankcase breather is not maintained on a
NOTICE
regular basis, the crankcase breather will become
Never run the engine without an air cleaner element
plugged. A plugged crankcase breather will cause
installed. Never run the engine with a damaged air
excessive crankcase pressure that may cause
cleaner element. Do not use air cleaner elements with
crankshaft seal leakage.
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
1. Loosen hose clamp (1) and remove the hose from
components. Air cleaner elements help to prevent air-
breather cover (3).
borne debris from entering the air inlet.
2. Loosen four bolts (2) for the breather cover and
NOTICE remove breather cover (3).
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine. 3. Remove the breather element and wash the
breather element in solvent that is clean and
nonflammable. Allow the breather element to dry.
If the air cleaner element becomes plugged, the
air can split the filter material. Unfiltered air will 4. Install a breather element that is clean and dry.
drastically accelerate internal engine wear. Your Install breather cover (3) and install bolts (2).
Caterpillar dealer has air filter elements in order to Refer to the Operation and Maintenance Manual
service this unit. Consult your Caterpillar dealer for for the proper torques.
the correct air cleaner element.
SEBU7040-04 79
Maintenance Section
Engine Mounts - Inspect

5. Install the hose. Install hose clamp (1). Refer to 1. Maintain the oil level between “ADD” mark (Y) and
the Operation and Maintenance Manual for the “FULL” mark (X) on oil level gauge (1). Do not fill
proper torques. the crankcase above “FULL” mark (X).

i02456872 NOTICE
Operating your engine when the oil level is above the
Engine Mounts - Inspect “FULL” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
SMCS Code: 1152-040 dipping into the oil reduces the oil’s lubricating char-
acteristics and could result in the loss of power.
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions: 2. Remove oil filler cap (2) and add oil, if necessary.
Clean the oil filler cap. Reinstall the oil filler cap.
• Improper mounting of the engine
i01708884
• Deterioration of the engine mounts
Engine Oil Level Gauge -
Any engine mount that shows deterioration should be
replaced. Refer to Special Publication, SENR3130, Calibrate
“Torque Specifications” for the recommended
torques. Refer to the OEM recommendations for SMCS Code: 1326-524
more information.

i00573217

Engine Oil Level - Check

SMCS Code: 1348-535-FLV
g00882677
Illustration 41
Check the oil level after the engine has stopped.
(Y) “ADD” mark. (X) “FULL” mark. (Z) “Effective Length”.
(Z-LH Service Engines) 642 mm (25.3 inch)
(Z-RH Service Engines) 479 mm (18.9 inch)

The engine is shipped with an engine oil level gauge

that is not marked. The engine oil level gauge is not
marked because the angle of the installation and
the side for servicing the engine oil can be different
for each engine. The angle of the installation and
the side for servicing the engine oil will affect “ADD”
mark (Y) and “FULL” mark (X) that is engraved on
the engine oil level gauge.

The engine oil level gauge should be calibrated after

the engine is installed in the vessel. Use the following
Illustration 39
g00105043 procedure in order to verify that “ADD” mark (Y)
is correct. Use the following procedure in order to
(1) Oil level gauge. (2) Oil filler cap.
establish actual “FULL” mark (X) on the engine oil
level gauge. Refer to table 18 and table 19 in order
to determine the location for the “ADD” and “FULL”
marks for a particular installation.

NOTICE
Refer to the Operation and Maintenance Manual for
more information on lubricant specifications.
g00110310
Illustration 40
(Y) “ADD” mark. (X) “FULL” mark.
80 SEBU7040-04
Maintenance Section
Engine Oil Level Gauge - Calibrate

1. Operate the engine until normal operating • No auxiliary engine oil filters are used on the
temperature is achieved. Stop the engine. engine.
Remove one of the drain plugs for the engine
crankcase. Allow the engine oil to drain. Table 18
3176C and 3196 Marine Engine
2. Remove the used engine oil filter. Install the new Oil Gauge Markings (mm)
engine oil filter. Install the drain plug for the engine LH Service (1)
crankcase. Tighten the drain plug for the engine
LH Service LH Service
crankcase to 70 ± 14 N·m (50 ± 10 lb ft).
Tilt Angle(2) “ADD” Mark “FULL” Mark
Y X
Note: The engine may be equipped with auxiliary
engine oil filters. Volumes that are different from the -15° 120 mm (4.7 inch) 133 mm (5.2 inch)
standard amounts may be required. Refer to the -13° 113 mm (4.4 inch) 125 mm (4.9 inch)
OEM specifications.
-11° 110 mm (4.3 inch) 124 mm (4.9 inch)
3. Pour 20.8 L (22 qt) of engine oil into the engine -9° 106 mm (4.2 inch) 118 mm (4.6 inch)
crankcase. Allow enough time for the engine oil to
drain into the engine crankcase. Approximately 20 -7° 100 mm (3.9 inch) 110 mm (4.3 inch)
minutes should be allowed. Check the engine oil
-5° 93 mm (3.7 inch) 106 mm (4.2 inch)
level. Wait for a few minutes. Check the engine
oil level again. Proceed after the engine oil level -3° 87 mm (3.4 inch) 99 mm (3.9 inch)
stops changing.
-1° 82 mm (3.2 inch) 93 mm (3.7 inch)
4. Mark the engine oil level on the engine oil level 0° 79 mm (3.1 inch) 89 mm (3.5 inch)
gauge. Use a marking pen in order to engrave
1° 73 mm (2.9 inch) 85 mm (3.3 inch)
“ADD” mark (Y).
3° 68 mm (2.7 inch) 81 mm (3.2 inch)
5. Pour 3.8 L (4 qt) of engine oil into the engine
5° 63 mm (2.5 inch) 74 mm (2.9 inch)
crankcase. Allow enough time for the engine oil to
drain into the engine crankcase. 7° 54 mm (2.1 inch) 67 mm (2.6 inch)

6. Mark the engine oil level on the engine oil level 9° 47 mm (1.9 inch) 61 mm (2.4 inch)
gauge. Use a marking pen in order to engrave
“FULL” mark (X). 11° 38 mm (1.5 inch) 52 mm (2.0 inch)

7. Start the engine. Ensure that the lubrication

system is filled. Inspect the lubrication system for 13° 30 mm (1.2 inch) 43 mm (1.7 inch)
leaks. 15° 19 mm (0.7 inch) 36 mm (1.4 inch)
(1) (Z-LH Service Engines) 642 mm (25.3 inch).
8. Stop the engine and allow enough time for the (2) The tilt angles in this chart are the engine installation angles
engine oil to drain into the engine crankcase. for the vessel. A positive angle indicates that the front of the
engine is raised.
9. Check the engine oil level on the engine oil level
gauge. If the engine oil level is not at calibrated
“FULL” mark (X), fill the sump to the calibrated
“FULL” mark. Record the amount of oil that is
added. This additional engine oil is the system
capacity plus the engine oil in the sump. This
additional engine oil is the amount of engine oil
that is required when the engine oil is changed.
Record the engine oil capacity for the system for
future changes of the engine oil.

3176C and 3196 Marine Engine Dipstick Markings

Note: Use the following tables if these conditions

exist:

• The engine is installed with a 0 degree slant angle.

SEBU7040-04 81
Maintenance Section
Engine Oil Sample - Obtain

Table 19 Obtain the Sample and the Analysis

3176C and 3196 Marine Engine
Oil Gauge Markings (mm)
RH Service (1)
RH Service RH Service Hot oil and hot components can cause personal
Tilt Angle(2) “ADD” Mark “FULL” Mark injury. Do not allow hot oil or hot components to
Y X contact the skin.
-15° 25 mm (1.0 inch) 44 mm (1.7 inch)
-13° 37 mm (1.5 inch) 55 mm (2.2 inch) Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
-11° 48 mm (1.9 inch) 65 mm (2.6 inch) to help obtain the most accurate analysis, provide
-9° 57 mm (2.2 inch) 73 mm (2.9 inch) the following information:

-7° 65 mm (2.6 inch) 81 mm (3.2 inch) • Engine model

-5° 72 mm (2.8 inch) 88 mm (3.5 inch)
• Service hours on the engine
-3° 79 mm (3.1 inch) 96 mm (3.8 inch)
-1° 86 mm (3.4 inch) 102 mm (4.0 inch) • The number of hours that have accumulated since
the last oil change
0° 89 mm (3.5 inch) 106 mm (4.2 inch)
1° 94 mm (3.7 inch) 110 mm (4.3 inch) • The amount of oil that has been added since the
last oil change
3° 101 mm (4.0 inch) 116 mm (4.6 inch)
To ensure that the sample is representative of the
5° 107 mm (4.2 inch) 122 mm (4.8 inch)
oil in the crankcase, obtain a warm, well mixed oil
7° 115 mm (4.5 inch) 125 mm (4.9 inch) sample.
9° 121 mm (4.8 inch) 136 mm (5.4 inch)
To avoid contamination of the oil samples, the tools
11° 127 mm (5.0 inch) 140 mm (5.5 inch) and the supplies that are used for obtaining oil
samples must be clean.
13° 134 mm (5.3 inch) 145 mm (5.7 inch)
15° 135 mm (5.3 inch) 150 mm (5.9 inch) Caterpillar recommends using the sampling valve
(1)
in order to obtain oil samples. The quality and the
(Z-RH Service Engines) 479 mm (18.9 inch).
(2) The tilt angles in this chart are the engine installation angles
consistency of the samples are better when the
for the vessel. A positive angle indicates that the front of the sampling valve is used. The location of the sampling
engine is raised. valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
i01935337
The 169-8373 Fluid Sampling Bottle is
Engine Oil Sample - Obtain recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
SMCS Code: 1000-008; 1348-554-SM; needed for obtaining oil samples. Instructions are
7542-554-OC, SM also provided.

In addition to a good preventive maintenance NOTICE

program, Caterpillar recommends using S·O·S oil Always use a designated pump for oil sampling, and
analysis at regularly scheduled intervals in order use a separate designated pump for coolant sampling.
to monitor the condition of the engine and the Using the same pump for both types of samples may
maintenance requirements of the engine. S·O·S oil contaminate the samples that are being drawn. This
analysis provides infrared analysis, which is required contaminate may cause a false analysis and an incor-
for determining nitration and oxidation levels. rect interpretation that could lead to concerns by both
dealers and customers.

If the engine is not equipped with a sampling valve,

use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
82 SEBU7040-04
Maintenance Section
Engine Oil and Filter - Change

For instructions, see Special Publication, PEHP6001, Replace the Oil Filter
“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and
NOTICE
assistance in establishing an S·O·S program for your
Caterpillar oil filters are built to Caterpillar speci-
engine.
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
i01536470 the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
Engine Oil and Filter - Change the engine lubricating system. Only use oil filters
recommended by Caterpillar.
SMCS Code: 1318-510; 1348-044
1. Remove the oil filter with a 1U-8760 Chain
Wrench.

Hot oil and hot components can cause personal 2. Cut the oil filter open with a 175-7546 Oil Filter
injury. Do not allow hot oil or hot components to Cutter. Break apart the pleats and inspect the oil
contact the skin. filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear
Do not drain the oil when the engine is cold. As the oil or a pending failure.
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed Use a magnet to differentiate between the ferrous
with the draining cold oil. Drain the crankcase with metals and the nonferrous metals that are found in
the engine stopped. Drain the crankcase with the the oil filter element. Ferrous metals may indicate
oil warm. This draining method allows the waste wear on the steel and cast iron parts of the engine.
particles that are suspended in the oil to be drained
properly. Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
Failure to follow this recommended procedure will the engine. Parts that may be affected include
cause the waste particles to be recirculated through the following items: main bearings, rod bearings,
the engine lubrication system with the new oil. turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is not

Drain the Engine Oil uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
After the engine has been run at the normal operating to arrange for a further analysis if an excessive
temperature, stop the engine. Use one of the amount of debris is found in the oil filter.
following methods to drain the engine crankcase oil:

• If the engine is equipped with a drain valve, turn the

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.

• If the engine is not equipped with a drain valve,

remove the oil drain plug in order to allow the oil
to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
ends of the oil pan.

After the oil has drained, the oil drain plugs should be
cleaned and installed. Tighten the oil drain plugs to
g00103713
70 ± 14 N·m (50 ± 10 lb ft). Illustration 42
Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mounting

base. Ensure that all of the old oil filter gasket is
removed.

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

SEBU7040-04 83
Maintenance Section
Engine Speed/Timing Sensors - Check/Clean/Calibrate

i00096280
NOTICE
Do not fill the oil filters with oil before installing them.
Engine Speed/Timing Sensors
This oil would not be filtered and could be contaminat- - Check/Clean/Calibrate
ed. Contaminated oil can cause accelerated wear to
engine components. SMCS Code: 1912-040; 1912-070; 1912-524

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

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual for more information on
lubricant specifications. Fill the crankcase with the
proper amount of oil. Refer to the Operation and
Maintenance Manual for more information on refill
g00105127
capacities. Illustration 43
Primary Speed/Timing Sensor (1) and Backup Speed/Timing
Sensor (2)
NOTICE
If equipped with an auxiliary oil filter or system, extra
1. Remove the speed/timing sensors from the front
oil must be added when filling the crankcase. Follow
housing. Check the condition of the plastic end
the OEM or filter manufacturer’s recommendations. If
of the speed/timing sensors for wear and/or
the extra oil is not added, the engine may starve for
contaminants.
oil.
2. Clean the metal shavings and other debris from
NOTICE the face of the speed/timing sensors. Use the
To help prevent crankshaft or bearing damage, crank procedure in the Service Manual in order to
engine to fill all filters before starting. Do not crank calibrate the speed/timing sensors.
engine for more than 30 seconds.
Refer to the Service Manual for more information on
the speed/timing sensors.
2. Start the engine and run the engine at “LOW
IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has i01430860
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks. Engine Storage Procedure -
Check
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes. SMCS Code: 1000-535

4. Remove the oil level gauge in order to check the Caterpillar requires all engines that are stored for
oil level. Maintain the oil level between the “ADD” more than 3 months to follow storage procedures
and “FULL” marks on the oil level gauge. and start-up procedures. These procedures provide
maximum protection to internal engine components.
Refer to Special Instruction, SEHS9031, “Storage
Procedure For Caterpillar Products” for information
on these procedures.

An extension of the oil change interval to 12 months

is permitted if you follow the required procedures for
storage and start-up. This extension is permitted if the
following intervals in the Operation and Maintenance
Manual, “Maintenance Interval Schedule” have not
been reached:
84 SEBU7040-04
Maintenance Section
Engine Valve Lash - Inspect/Adjust

• Operating hours i01597115

• Fuel consumption Engine Valve Rotators - Inspect

SMCS Code: 1109-040
i00869413

Engine Valve Lash -

Inspect/Adjust When inspecting the valve rotators, protective
glasses or face shield and protective clothing
SMCS Code: 1102-025 must be worn, to help prevent being burned by
hot oil or spray.
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The Engine valve rotators rotate the valves when the
initial adjustment is necessary due to initial wear of engine runs. This helps to prevent deposits from
the valve train components and seating of the valve building up on the valves and the valve seats.
train components.
Perform the following steps after the engine valve
This maintenance is recommended by Caterpillar lash is set, but before the valve covers are installed:
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine 1. Start the engine according to Operation and
life. Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
Adjustment of the Electronic Unit 2. Operate the engine at low idle.
Injector
3. Observe the top surface of each valve rotator.
Adjust the electronic unit injector (preload) at the The valve rotators should turn slightly when the
same interval as the valve lash adjustment. The valves close.
operation of Caterpillar engines with improper valve
adjustments and with improper adjustments of the NOTICE
electronic unit injector can reduce engine efficiency. A valve rotator which does not operate properly will
This reduced efficiency could result in excessive fuel accelerate valve face wear and valve seat wear and
usage and/or shortened engine component life. shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
NOTICE the valve to fall into the cylinder. This can cause piston
Only qualified service personnel should perform this and cylinder head damage.
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust- If a valve fails to rotate, consult your Caterpillar
ment procedure. dealer.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re- i00103413
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. Fuel System - Prime
SMCS Code: 1258-548

Ensure that the engine can not be started while

this maintenance is being performed. To help pre- Fuel leaked or spilled onto hot surfaces or elec-
vent possible injury, do not use the starting motor trical components can cause a fire. To help pre-
to turn the flywheel. vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Hot engine components can cause burns. Allow Clean up fuel spills immediately.
additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
SEBU7040-04 85
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i01341997

Fuel System Primary

Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
g00105140
Illustration 44
Plug (1), Fuel Priming Pump (2), and Fuel Filter (3)
NOTICE
Priming the fuel system fills the fuel filters. Priming Use a suitable container to catch any fuel that might
the fuel system also removes air from the fuel spill. Clean up any spilled fuel immediately.
system. This procedure is used primarily when the
engine runs out of fuel.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
Note: DO NOT remove plug (1) in the fuel filter base
clean the area around a fuel system component that
in order to release air from the fuel system during
will be disconnected. Fit a suitable cover over discon-
periodic service of the fuel filter. Periodic removal of
nected fuel system component.
the plug will result in increased wear of the threads
in the fuel filter base. This can lead to fuel leakage.
However, the plug in the fuel filter base can be used
to bleed air from the fuel system if the engine runs
out of fuel.

1. Open fuel priming pump (2) and operate the fuel

priming pump until a strong pressure is felt on
the fuel priming pump and until the check valve
“clicks”. This procedure will require considerable
strokes. Lock the fuel priming pump.

2. Crank the engine after pressurizing the system.

NOTICE
Do not crank the engine continuously for more than g00709596
Illustration 45
30 seconds. Allow the starting motor to cool for two
(1) Element
minutes before cranking the engine again.
(2) Bowl
(3) Drain
3. If the engine does not start, open fuel priming
pump (2) and repeat Steps 1 and 2 in order to Bowl (2) should be monitored daily for signs of water.
start the engine. 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).

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.
86 SEBU7040-04
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

i02053433 • O-ring
Fuel System Primary Filter • Mounting base
(Water Separator) Element - Inspect the O-ring for damage and for
Replace deterioration. Replace the O-ring, if necessary.

SMCS Code: 1260-510-FQ; 1263-510-FQ 5. Lubricate the O-ring with clean diesel fuel.

Water in the fuel can cause the engine to run rough. 6. Install bowl (2) on a new element. Tighten the
Water in the fuel may cause a electronic unit injector bowl by hand. Do not use tools in order to tighten
to fail. If the fuel has been contaminated with water, the bowl.
the element should be changed before the regularly
scheduled interval. NOTICE
The primary filter/water separator may be prefilled with
The primary filter/water separator also provides fuel to avoid rough running/stalling of the engine due
filtration in order to help extend the life of the to air. Do not fill the secondary filter with fuel before
secondary fuel filter. The element should be changed installation. The fuel would not be filtered and could
regularly. If a vacuum gauge is installed, the be contaminated. Contaminated fuel will cause accel-
primary filter/water separator should be changed at erated wear to fuel system parts.
50 to 70 kPa (15 to 20 inches Hg).

Replace the Element 7. Lubricate the top seal of element (1) with clean
diesel fuel. The element may be filled with fuel at
this time. Install the new element on the mounting
base. Tighten the element by hand.

Fuel leaked or spilled onto hot surfaces or electri- NOTICE

cal components can cause a fire. The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
1. Close the main fuel supply valve. ened securely to help prevent air from entering the fu-
el system.

8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run the

engine for one minute. Stop the engine and check
for leaks again.

Detecting leaks is difficult while the engine is

running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel.
The air in the fuel can cause low power due to
aeration of the fuel. If air enters the fuel, check the
components for overtightening or undertightening.
g00104012
Illustration 46
Element (1), Bowl (2), and Drain (3)

2. Remove element (1) from the element mounting

base while bowl (2) is attached.

3. Dispose of the contents of the filter. Remove bowl

(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.

4. Remove the O-ring from the gland of the bowl.

Clean the following components:

• Bowl
SEBU7040-04 87
Maintenance Section
Fuel System Secondary Filter - Replace

i00581566
NOTICE
Fuel System Secondary Filter - Do not fill the secondary fuel filter with fuel before in-
Replace stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
SMCS Code: 1261-510-SE ated wear to fuel system parts.

8. Install new fuel filter (3). Tighten the fuel filter until
the gasket contacts the base. Tighten the fuel
Fuel leaked or spilled onto hot surfaces or elec- filter by hand according to the instructions that are
trical components can cause a fire. To help pre- shown on the fuel filter. Do not overtighten the fuel
vent possible injury, turn the start switch off when filter.
changing fuel filters or water separator elements.
Clean up fuel spills immediately. Note: DO NOT remove plug (1) in the fuel filter base
in order to release air from the fuel system during
periodic service of the fuel filter. Periodic removal of
the plug will result in increased wear of the threads in
the fuel filter base.

9. Operate fuel priming pump (2) until a strong

pressure is felt on the fuel priming pump and
until the check valve “clicks”. This procedure
will require considerable strokes. Lock the fuel
priming pump.

10. Open the fuel tank supply valve.

11. Start the engine according to the normal operating

procedures. Immediately increase the engine rpm
Illustration 47
g00103835 between 1000 to 1200 rpm with no load. The
(1) Plug. (2) Fuel priming pump. (3) Fuel Filter.
engine will begin to misfire briefly until air from
the fuel filter is purged. No damage to the engine
1. Stop the engine. will occur.

2. Turn off the start switch or disconnect the battery NOTICE

(starting motor) when maintenance is performed Do not crank the engine continuously for more than
on fuel filters. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
3. Shut off the fuel tank supply valve to the engine.
12. If the engine stalls during the purging of the air,
NOTICE refer to the Operation and Maintenance Manual,
Use a suitable container to catch any fuel that might “Fuel System - Prime” in the Maintenance Section
spill. Clean up any spilled fuel immediately. for more information.

4. Unlock fuel priming pump (2) in order to relieve

residual pressure in the fuel system.

5. Remove used fuel filter (3). Use a cloth or use a

container in order to catch excess fuel.

6. Clean the gasket sealing surface of the fuel filter

base. Ensure that all of the old gasket is removed.

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

88 SEBU7040-04
Maintenance Section
Fuel Tank Water and Sediment - Drain

i02436696 Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that
- Drain take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
SMCS Code: 1273-543-M&S maintenance of the fuel system filter is important.

NOTICE Fuel Storage Tanks

Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Drain the water and the sediment from the fuel
ing, adjusting and repair of the product. Be prepared to storage tank during the following conditions:
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- • Weekly
nent containing fluids.
• Oil change
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies • Refill of the tank
suitable to collect and contain fluids on Caterpillar
products. This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
Dispose of all fluids according to local regulations and tank. A 2 micron filter for the breather vent on the
mandates. fuel tank is also recommended. Refer to Special
Publication, SENR9620, “Improving Fuel System
Durablity”.
Fuel Tank
If a bulk storage tank has been refilled or moved
Fuel quality is critical to the performance and to the recently, allow adequate time for the sediment to
service life of the engine. Water in the fuel can cause settle before filling the engine fuel tank. Internal
excessive wear to the fuel system. Condensation baffles in the bulk storage tank will also help trap
occurs during the heating and cooling of fuel. The sediment. Filtering fuel that is pumped from the
condensation occurs as the fuel passes through the storage tank helps to ensure the quality of the fuel.
fuel system and the fuel returns to the fuel tank. This When possible, water separators should be used.
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. i01065537

Heat Exchanger - Inspect

Drain the Water and the Sediment
SMCS Code: 1379-040
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the The interval for the maintenance of the plate type heat
fuel tanks. exchanger depends on the operating environment of
the vessel and on the operating time. The raw/sea
Open the drain valve on the bottom of the fuel tank water that is circulated through the heat exchanger
in order to drain the water and the sediment. Close and the amount of operating time of the vessel affects
the drain valve. the following items:

Check the fuel daily. Drain the water and sediment • Cleanliness of the heat exchanger plates
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the • Effectiveness of the heat exchanger system
fuel tank has been filled. Allow five to ten minutes
before performing this procedure. Operating the engine in water that contains
silt, sediment, salt, algae, or other significant
Fill the fuel tank after operating the engine in contaminants will have an adverse effect on the heat
order to drive out moist air. This will help prevent exchanger system. In addition, intermittent use of
condensation. Do not fill the tank to the top. The the vessel will adversely affect the heat exchanger
fuel expands as the fuel gets warm. The tank may system.
overflow.
The following items indicate that the heat exchanger
may require cleaning:

• Increased coolant temperature

SEBU7040-04 89
Maintenance Section
Hoses and Clamps - Inspect/Replace

• Engine overheating • Flexible part of the hose that is kinked or crushed

• Excessive pressure drop between the water inlet • Armoring that is embedded in the outer covering
and the water outlet
A constant torque hose clamp can be used in place
An operator that is familiar with the normal operating of any standard hose clamp. Ensure that the constant
temperature of the coolant can determine when torque hose clamp is the same size as the standard
the coolant temperature is out of the normal range. clamp.
Inspection and maintenance of the heat exchanger is
required if the engine is overheating. Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
For information on maintenance of the heat This can result in leaks. A constant torque hose
exchanger and cleaning of the heat exchanger, refer clamp will help to prevent loose hose clamps.
to Disassembly and Assembly, “Heat Exchanger -
Disassemble”. Each installation application can be different. The
differences depend on the following factors:
Your Caterpillar dealer has the equipment and the
personnel in order to measure the pressure drop • Type of hose
across the heat exchanger.
• Type of fitting material
Consult your Caterpillar dealer or refer to the
Service Manual for service information for the heat • Anticipated expansion and contraction of the hose
exchanger.
• Anticipated expansion and contraction of the
fittings
i02121526

Hoses and Clamps - Replace the Hoses and the Clamps

Inspect/Replace
SMCS Code: 7554-040; 7554-510
Pressurized System: Hot coolant can cause seri-
Inspect all hoses for leaks that are caused by the ous burns. To open the cooling system filler cap,
following conditions: stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Cracking pressure cap slowly in order to relieve the pres-
sure.
• Softness
• Loose clamps 1. Stop the engine. Allow the engine to cool.

Replace hoses that are cracked or soft. Tighten any 2. Loosen the cooling system filler cap slowly in
loose clamps. order to relieve any pressure. Remove the cooling
system filler cap.
NOTICE Note: Drain the coolant into a suitable, clean
Do not bend or strike high pressure lines. Do not in- container. The coolant can be reused.
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and 3. Drain the coolant from the cooling system to a
hoses. Leaks can cause fires. Inspect all lines, tubes level that is below the hose that is being replaced.
and hoses carefully. Tighten all connections to the rec-
ommended torque. 4. Remove the hose clamps.

Check for the following conditions: 5. Disconnect the old hose.

• End fittings that are damaged or leaking 6. Replace the old hose with a new hose.

• Outer covering that is chafed or cut 7. Install the hose clamps with a torque wrench.

• Exposed wire that is used for reinforcement Note: Refer to the Specifications, SENR3130,
“Torque Specifications” in order to locate the proper
• Outer covering that is ballooning locally torques.
90 SEBU7040-04
Maintenance Section
Marine Transmission Oil Level - Check

8. Refill the cooling system. • The quality of the fuel that is being used
9. Clean the cooling system filler cap. Inspect the • The operating conditions
cooling system filler cap’s gaskets. Replace
the cooling system filler cap if the gaskets are • The results of the S·O·S analysis
damaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system for

Oil Consumption as an Overhaul
leaks. Indicator
Oil consumption, fuel consumption, and maintenance
i01089872 information can be used to estimate the total
Marine Transmission Oil Level operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
- Check required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
SMCS Code: 3081-535
Oil consumption is in proportion to the percentage
Check the marine transmission oil level according to of the rated engine load. As the percentage of the
the instructions that are provided by the OEM of the engine load is increased, the amount of oil that is
transmission or the OEM of the vessel. consumed per hour also increases.

For the lubrication requirements of the transmission, The oil consumption rate (brake specific oil
refer to the recommendations on the nameplate or consumption) is measured in grams per kW/h (lb per
the “Owner’s Manual” for the transmission. bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
Marine Transmission Operation, dealer for assistance in determining the typical oil
consumption rate for your engine.
Maintenance, Warranty, and Parts
Support When an engine’s oil consumption has risen to three
times the original oil consumption rate due to normal
For information on maintenance and operation of the wear, an engine overhaul should be scheduled.
marine transmission, consult your Caterpillar dealer There may be a corresponding increase in blowby
and/or the OEM dealer of the transmission. and a slight increase in fuel consumption.

All support for the warranty of the transmission will be Overhaul Options
the responsibility of the OEM. All parts support for the
transmission will be the responsibility of the OEM. Before Failure Overhaul
This parts support includes both the installation of
parts and the resolution of any service problems. A planned overhaul before failure may be the best
value for the following reasons:
i02378613
• Costly unplanned downtime can be avoided.
Overhaul Considerations • Many original parts can be reused according to the
standards for reusable parts.
SMCS Code: 7595-043

Reduced hours of operation at full load will result in a • The engine’s service life can be extended without
the risk of a major catastrophe due to engine
lower average power demand. A decreased average
failure.
power demand should increase both the engine
service life and the overhaul interval.
• The best cost/value relationship per hour of
extended life can be attained.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
After Failure Overhaul
The following factors are important when a decision
If a major engine failure occurs and the engine must
is being made on the proper time for an engine
be removed from the hull, many options are available.
overhaul:
An overhaul should be performed if the engine block
or the crankshaft needs to be repaired.
• The need for preventive maintenance
SEBU7040-04 91
Maintenance Section
Overhaul Considerations

If the engine block is repairable and/or the crankshaft • Costly repairs

is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine • Damage to other engine parts
with a similar exchange core.
• Reduced engine efficiency
This lower cost can be attributed to three aspects:
• Increased fuel consumption
• Specially designed Caterpillar engine features
Reduced engine efficiency and increased fuel
• Caterpillar dealer exchange components consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
• Caterpillar Inc. remanufactured exchange out-of-spec parts or replacing out-of-spec parts.
components
Inspection and/or Replacement
Overhaul Recommendation
Crankshaft Bearings, Valve Rotators, and
To minimize downtime, Caterpillar Inc. recommends Crankshaft Seals
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you The following components may not last until the
with the best cost/value relationship. second overhaul.

Note: Overhaul programs vary according to the • Thrust bearings

engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar • Main bearings
dealer for specific information about the available
overhaul programs and about overhaul services for • Rod bearings
extending the engine life.
• Valve rotators
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following • Crankshaft seals
maintenance recommendations.
Caterpillar Inc. recommends the installation of new
parts at each overhaul period.
Rebuild or Exchange
Inspect these parts while the engine is disassembled
Cylinder Head Assembly, Cylinder Packs, Oil
for an overhaul.
Pump, and Fuel Transfer Pump
Inspect the crankshaft for any of the following
These components should be inspected according to
conditions:
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are • Deflection
needed for inspecting the engine parts.
• Damage to the journals
If the parts comply with the established inspection
specifications that are expressed in the reusable • Bearing material that has seized to the journals
parts guideline, the parts should be reused.
Check the journal taper and the profile of the
crankshaft journals. Check these components by
Parts that are not within the established inspection
specifications should be dealt with in one of the interpreting the wear patterns on the following
components:
following manners:

• Salvaging • Rod bearing

• Repairing • Main bearings

Note: If the crankshaft is removed for any reason,
• Replacing use the magnetic particle inspection process to check
Using out-of-spec parts can result in the following for cracks in the crankshaft.
problems:
Inspect the camshaft for damage to the journals and
to the lobes.
• Unscheduled downtime
92 SEBU7040-04
Maintenance Section
Overhaul Considerations

Note: If the camshaft is removed for any reason, use 4. Use steam to clean the oil cooler core and the
the magnetic particle inspection process to check for aftercooler core. This removes any remaining
cracks in the camshaft. residue from the cleaner. Flush the fins of the oil
cooler core and the aftercooler core. Remove any
Inspect the following components for signs of wear or other trapped debris.
for signs of scuffing:
5. Wash the oil cooler core and the aftercooler core
• Camshaft bearings with hot, soapy water. Rinse the oil cooler core and
the aftercooler core thoroughly with clean water.
• Camshaft followers
Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Personal injury can result from air pressure.
Oil Cooler Core and Aftercooler Core
Personal injury can result without following prop-
During an overhaul, Caterpillar Inc. recommends the er procedure. When using pressure air, wear a pro-
removal of both the oil cooler core and the aftercooler tective face shield and protective clothing.
core. Clean the oil cooler core and the aftercooler
core. Then, pressure test both of these cores. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
NOTICE
Do not use caustic cleaners to clean the core. 6. Dry the oil cooler core and the aftercooler core
with compressed air. Direct the air in the reverse
Caustic cleaners can attack the internal metals of the direction of the normal flow.
core and cause leakage.
7. Inspect the components in order to ensure
cleanliness. The oil cooler core and the aftercooler
Note: Use this cleaning procedure to clean the oil core should be pressure tested. Repair the oil
cooler core and the aftercooler core. cooler core and the aftercooler core, if necessary.
Install the oil cooler core and the aftercooler core.
1. Remove the oil cooler core and the aftercooler
core. For more information about cleaning the cores,
consult your Caterpillar dealer.
2. Remove any debris from the oil cooler core and
the aftercooler core. To remove debris from the oil Obtain Coolant Analysis
cooler core, turn the oil cooler core onto one end.
To remove debris from the aftercooler core, turn The concentration of supplemental coolant additive
the aftercooler core upside-down. (SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further
3. Flush the oil cooler core and the aftercooler core coolant analysis is recommended when the engine
internally with cleaner in order to loosen foreign is overhauled.
substances. This will also help to remove oil from
the oil cooler core and the aftercooler core. For example, considerable deposits are found in the
water jacket areas on the external cooling system, but
Note: Caterpillar Inc. recommends the use of the concentrations of coolant additives were carefully
Hydrosolv Liquid Cleaners. Table 20 lists the maintained. The coolant water probably contained
Hydrosolv Liquid Cleaners that are available from minerals that were deposited on the engine over time.
your Caterpillar dealer.

Table 20
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
Hydrosolv Liquid Cleaners(1) cooling system. A full water analysis can be obtained
Part by consulting your local water utility company or
Description Size an agricultural agent. Private laboratories are also
Number
available for water analysis.
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon) Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
(1) Use a two to five percent concentration of the cleaner at
temperatures up to 93°C (200°F).
SEBU7040-04 93
Maintenance Section
Starting Motor - Inspect

S·O·S Coolant Analysis (Level 2) If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
An S·O·S Coolant Analysis (Level 2) is a and/or to the engine may occur. Damage to the
comprehensive coolant analysis which completely turbocharger compressor wheel can cause additional
analyzes the coolant and the effects on the cooling damage to the pistons, the valves, and the cylinder
system. An S·O·S Coolant Analysis (Level 2) provides head.
the following information:
NOTICE
• Complete S·O·S Coolant Analysis (Level 1) Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
• Visual inspection of properties Loss of engine lubricant can result in serious engine
damage.
• Identification of metal corrosion
Minor leakage of a turbocharger housing under ex-
• Identification of contaminants tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
• Identification of built up impurities (corrosion and curred.
scale)
When a turbocharger bearing failure is accompanied
S·O·S Coolant Analysis (Level II) provides a report of by a significant engine performance loss (exhaust
the results of both the analysis and the maintenance smoke or engine rpm up at no load), do not continue
recommendations. engine operation until the turbocharger is repaired or
replaced.
For more information about coolant analysis, see
your Caterpillar dealer.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
i00651416 turbocharger can also reduce the chance for potential
damage to other engine parts.
Starting Motor - Inspect
Note: Turbocharger components require precision
SMCS Code: 1451-040; 1453-040 clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Caterpillar Inc. recommends a scheduled inspection
Applications can accelerate component wear.
of the starting motor. If the starting motor fails, the Severe Service Applications require more frequent
engine may not start in an emergency situation. inspections of the cartridge.
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical Removal and Installation
connections. Refer to the Service Manual for more
information on the checking procedure and for For options regarding the removal, installation, repair
specifications or consult your Caterpillar dealer for and replacement, consult your Caterpillar dealer.
assistance. Refer to the Service Manual for this engine for the
procedure and specifications.
i01539769
Cleaning and Inspecting
Turbocharger - Inspect
1. Remove the exhaust outlet piping and remove
SMCS Code: 1052-040; 1052 the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean
Periodic inspection and cleaning is recommended the interior of the pipes in order to prevent dirt
for the turbocharger compressor housing (inlet side). from entering during reassembly.
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
94 SEBU7040-04
Maintenance Section
Walk-Around Inspection

2. Turn the compressor wheel and the turbine wheel For maximum engine service life, make a thorough
by hand. The assembly should turn freely. Inspect inspection of the engine compartment before starting
the compressor wheel and the turbine wheel for the engine. Look for items such as oil leaks or coolant
contact with the turbocharger housing. There leaks, loose bolts, worn belts, loose connections and
should not be any visible signs of contact between trash buildup. Make repairs, as needed:
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of • The guards must be in the proper place. Repair
contact between the rotating turbine wheel or the damaged guards or replace missing guards.
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned. • Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
3. Check the compressor wheel for cleanliness. contamination.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering NOTICE
system. If oil is found only on the back side of the For any type of leak (coolant, lube, or fuel) clean up the
wheel, there is a possibility of a failed turbocharger fluid. If leaking is observed, find the source and correct
oil seal. the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
The presence of oil may be the result of extended or fixed, or until the suspicion of a leak is proved to be
engine operation at low idle. The presence of oil unwarranted.
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber. NOTICE
Accumulated grease and/or oil on an engine or deck is
4. Use a dial indicator to check the end clearance a fire hazard. Remove this debris with steam cleaning
on the shaft. If the measured end play is greater or high pressure water.
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the • Ensure that cooling lines are properly clamped
and tight. Check for leaks. Check the condition of
minimum Service Manual specifications could
all pipes.
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less • Check the marine transmission oil level. Refer to
the OEM specification for the marine transmission
than the minimum Service Manual specifications.
or refer to the OEM specification for the vessel.
5. Inspect the bore of the turbine housing for
corrosion. • Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant
6. Clean the turbocharger housing with standard
in the cooling system. It is normal for a small amount
shop solvents and a soft bristle brush.
of leakage to occur as the engine cools down and
the parts contract.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
i00073831 water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
Walk-Around Inspection engine or consult your Caterpillar dealer.

SMCS Code: 1000-040 • Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
Inspect the Engine for Leaks and pan, the oil filters and the valve cover.
for Loose Connections • Inspect the fuel system for leaks. Look for loose
fuel line clamps.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these • Inspect the piping for the air inlet system and the
checks, costly repairs and accidents can be avoided. elbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drive

belts for cracks, breaks or other damage.
SEBU7040-04 95
Maintenance Section
Water Pump - Inspect

Belts for multiple groove pulleys must be replaced as i02456923

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced. Zinc Rods - Inspect/Replace
The older belts are stretched. The additional load on
the new belt could cause the belt to break. SMCS Code: 1388-040; 1388-510

• Drain the water and the sediment from fuel tanks Corrosion in sea water circuits can result in premature
on a daily basis in order to ensure that only clean deterioration of system components, leaks, and
fuel enters the fuel system. possible cooling system contamination. The cause
for the premature corrosion may be the lack of zinc
• Inspect the wiring and the wiring harnesses for rods in the sea water system.
loose connections and for worn wires or frayed
wires. Zinc rods are inserted in the sea water cooling
system of the engine in order to help prevent the
• Inspect the ground strap for a good connection and corrosive action of salt water. The reaction of the zinc
for good condition. to the sea water causes the zinc rods to deteriorate.
The zinc rods deteriorate instead of engine parts
• Inspect the ECM to the cylinder head ground strap for the cooling system that are more critical. Rapid
for a good connection and for good condition. deterioration of zinc rods may indicate the presence
of uncontrolled electrical currents from improperly
• Disconnect any battery chargers that are not installed electrical attachments or improperly
protected against the current drain of the starting grounded electrical attachments.
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with The zinc rods must be inspected at the proper
a maintenance free battery. intervals. The zinc rods must be replaced when
deterioration occurs.
• Check the condition of the gauges. Replace any
gauges which are cracked or can not be calibrated. Inspect the Zinc Rods
The zinc rods are red for easy identification. Table
i01057943
21 shows the locations of the zinc rods and the
Water Pump - Inspect quantities of the zinc rod:

Table 21
SMCS Code: 1361-040; 1361
Locations of the Zinc Rods
A failed water pump might cause severe engine
Location Quantity
overheating problems that could result in the following
conditions: Right Heat Exchanger Bonnet 2
Left Heat Exchanger Bonnet 1
• Cracks in the cylinder head
Transmission Oil Cooler 2
• A piston seizure Fuel Cooler 2
• Other potential damage to the engine
1. Remove the zinc rod.
Visually inspect the water pump for leaks. If any
leaking is observed, replace the water pump seal
or the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure.

Note: Refer to the Service Manual or consult your

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

g00104048
Illustration 48
96 SEBU7040-04
Maintenance Section
Zinc Rods - Inspect/Replace

2. Tap the zinc rod lightly with a hammer. If the zinc

rod has deteriorated, or if the zinc rod flakes,
install a new zinc rod.

Replace the Zinc Rods

g00104049
Illustration 49

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

2. Apply 9S-3263 Compound to the shoulder of a

new zinc rod. Apply the compound only to the
shoulder of the zinc rod. Install the zinc rod into
the plug.

3. Coat the external threads of the plug with

5P-3413 Pipe Sealant. Install the zinc rod.
Refer to Special Publication, SENR3130, “Torque
Specifications” for more information on torque
specifications.