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3116 and 3126 Marine Engines: Maintenance Intervals
3116 and 3126 Marine Engines: Maintenance Intervals
COM
2007 Caterpillar
All Rights Reserved
61
Maintenance Section
Maintenance Interval Schedule
i01059376
NOTICE
Do not use a high concentration of caustic cleaner to Auxiliary Water Pump - Inspect
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause SMCS Code: 1371-040
leakage. Only use the recommended concentration of
cleaner. Impellers require periodic inspection and seals
require periodic inspection. Impellers have a service
3. Back flush the core with cleaner. life that is limited. The service life depends on the
engine operating conditions.
Caterpillar recommends the use of hot Hydrosolv
100 liquid cleaner at a concentration of 30% and Inspect the components of the pump more
at a temperature of 66 to 82C (150 to 180F). frequently when the pump is exposed to debris,
Table 35 lists the recommended Hydrosolv liquid sand, or other abrasive materials. Inspect the
cleaners that are available from your Caterpillar components if the pump is operating at a differential
dealer. pressure of more than 103 kPa (15 psi).
i00037658
Battery - Recycle
Personal injury can result from air pressure.
SMCS Code: 1401-561
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro- 1. Always recycle a battery. Never discard a battery.
tective face shield and protective clothing.
2. Always return used batteries to one of the
Maximum air pressure at the nozzle must be less following locations.
than 205 kPa (30 psi) for cleaning purposes.
A battery supplier
6. Dry the core with compressed air. Direct the air
in the reverse direction of the normal flow. An authorized battery collection facility
63
Maintenance Section
Battery Electrolyte Level - Check
Clean the battery case with one of the following To maximize the engine performance, inspect the
cleaning solutions: belts for wear and for cracking. Replace belts that
are worn or damaged.
A mixture of 0.1 L (.12 qt) of baking soda and
1 L (1 qt) of clean water For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only
A mixture of 0.1 L (.12 qt) of ammonia and 1 L one belt of a matched set will cause the new belt to
(1 qt) of clean water carry more load because the older belt is stretched.
The additional load on the new belt could cause the
Thoroughly rinse the battery case with clean new belt to break.
water.
If the belts are too loose, vibration causes
Use a fine grade of sandpaper to clean the unnecessary wear on the belts and pulleys. Loose
terminals and the cable clamps. Clean the items belts may slip enough to cause overheating.
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal If the belts are too tight, unnecessary stresses are
of material can cause the clamps to not fit placed on the pulley bearings and on the belts. This
properly. Coat the clamps and the terminals with may shorten the service life of the components.
5N-5561 Lubrication Compound, petroleum jelly
or MPGM grease. Remove the belt guard. Inspect the condition and
adjustment of the alternator belts and accessory
drive belts (if equipped).
64
Maintenance Section
Cooling System Coolant (DEAC) - Change
To check the belt tension, apply 110 N (25 lb ft) Water Pump Belt
of force midway between the pulleys. A correctly
adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
(0.59 inch).
1. Slightly loosen mounting bolts (2) and adjusting Cooling System Coolant
bolt (1). (DEAC) - Change
2. Move the pulley in order to adjust the belt SMCS Code: 1350-070; 1395-044
tension.
Clean the cooling system and flush the cooling
3. Tighten adjusting bolt (1) and mounting bolts (2). system before the recommended maintenance
Refer to the Operation and Maintenance Manual, interval if the following conditions exist:
Torque Specifications topic (Maintenance
Section).
The engine overheats frequently.
4. Install the belt guard.
Foaming of the coolant
If new belts are installed, check the belt tension
again after 30 minutes of engine operation at the
The oil has entered the cooling system and the
coolant is contaminated.
rated rpm.
The fuel has entered the cooling system and the
coolant is contaminated.
65
Maintenance Section
Cooling System Coolant (DEAC) - Change
2. Close the drain valve (if equipped). Clean the Engines that are Equipped with a Coolant
drain plugs. Install the drain plugs. Refer to Recovery Tank
the Specifications Manual for your particular
engine for more specific information on the
proper torques. Refer to the Specifications, NOTICE
SENR3130, Torque Specifications for more Fill the cooling system no faster than 19 L (5 US gal)
general information on the proper torques. per minute to avoid air locks.
Fill
Refer to the Operation and Maintenance Manual,
Coolant Specifications topic for information g00103638
regarding acceptable water, coolant/antifreeze, and Illustration 18
supplemental coolant additive requirements. Refer (1) Recovery tank filler cap
to the Operation and Maintenance Manual, Refill (2) COLD FULL mark
(3) LOW ADD mark
Capacities topic for the capacity of the engines
system.
5. Loosen the cap for the coolant recovery tank
slowly in order to relieve any pressure. Remove
the cap for the coolant recovery tank.
67
Maintenance Section
Cooling System Coolant (ELC) - Change
Engines that are Not Equipped with a The engine overheats frequently.
Coolant Recovery Tank
Foaming of the coolant
NOTICE The oil has entered the cooling system and the
Fill the cooling system no faster than 19 L (5 US gal) coolant is contaminated.
per minute to avoid air locks.
The fuel has entered the cooling system and the
1. Fill the cooling system with coolant/antifreeze. coolant is contaminated.
Refer to the Operation and Maintenance
Manual, Cooling System Specifications topic Note: When the cooling system is cleaned, only
(Maintenance Section) for more information on clean water is needed when the ELC is drained
cooling system specifications. Do not install the and replaced.
cooling system filler cap.
Note: Inspect the water pump and the water
2. Start the engine and run the engine at low idle. temperature regulator after the cooling system has
Increase the engine rpm to 1500 rpm. Run the been drained. This is a good opportunity to replace
engine at high idle for one minute in order to the water pump, the water temperature regulator
purge the air from the cavities of the engine and the hoses, if necessary.
block. Stop the engine.
Drain
3. Check the coolant level. Maintain the coolant
level within 13 mm (.5 inch) below the bottom
of the pipe for filling. Maintain the coolant level
within 13 mm (.5 inch) to the proper level on the
Pressurized System: Hot coolant can cause seri-
sight glass (if equipped).
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
4. Clean the cooling system filler cap. Inspect the
components are cool. Loosen the cooling system
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap pressure cap slowly in order to relieve the pres-
sure.
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler 1. Stop the engine and allow the engine to cool.
cap is not damaged, perform a pressure test. A Loosen the cooling system filler cap slowly
9S-8140 Pressurizing Pump is used to perform in order to relieve any pressure. Remove the
the pressure test. The correct pressure for the cooling system filler cap.
cooling system filler cap is stamped on the face
of the cooling system filler cap. If the cooling 2. Open the cooling system drain valve (if
system filler cap does not retain the correct equipped). If the cooling system is not equipped
pressure, install a new cooling system filler cap. with a drain valve, remove the cooling system
drain plugs.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature. Allow the coolant to drain.
68
Maintenance Section
Cooling System Coolant (ELC) - Change
Fill
NOTICE
Dispose of used engine coolant properly or recycle. Engines that are Equipped with a Coolant
Various methods have been proposed to reclaim used Recovery Tank
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology 1. Fill the cooling system with Extended Life Coolant
Group: (ELC). Refer to the Operation and Maintenance
Manual, Cooling System Specifications topic
Outside Illinois: 1-800-542-TOOL (Maintenance Section) for more information on
Inside Illinois: 1-800-541-TOOL cooling system specifications. Do not install the
Canada: 1-800-523-TOOL cooling system filler cap.
Engines That Are Equipped with a 2. Maintain the coolant level within 13 mm (.5 inch)
of the bottom of the filler pipe. If the engine is
Coolant Recovery Tank equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
g00103638
Illustration 20
(1) Filler cap. (2) COLD FULL mark. (3) LOW ADD mark. g00103639
Illustration 21
Typical filler cap gaskets
1. Observe the coolant level in the coolant recovery
tank. Maintain the coolant level to COLD FULL
3. Clean the cooling system filler cap and inspect
mark (2) on the coolant recovery tank.
the condition of the filler cap gaskets. Replace
the cooling system filler cap if the filler cap
2. Loosen filler cap (1) slowly in order to relieve any
gaskets are damaged. Reinstall the cooling
pressure. Remove the filler cap.
system filler cap.
3. Pour the proper coolant mixture into the tank.
4. Inspect the cooling system for leaks.
Refer to the coolant specifications in the
maintenance information for your product. Do
not fill the coolant recovery tank above COLD i00992487
FULL mark (2).
Cooling System Supplemental
4. Clean filler cap (1) and the receptacle. Reinstall
the filler cap and inspect the cooling system for
Coolant Additive (SCA) -
leaks. Test/Add
Note: The coolant will expand as the coolant heats SMCS Code: 1352-045; 1395-081
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
Cooling system coolant additive contains alkali.
engine.
To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
Engines That Are Not Equipped coolant additive.
with a Coolant Recovery Tank
Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration
as part of an SOS Coolant Analysis.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Test for SCA Concentration
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Coolant/Antifreeze and SCA
pressure cap slowly in order to relieve the pres-
sure. NOTICE
Do not exceed the recommended six percent supple-
1. Remove the cooling system filler cap slowly in mental coolant additive concentration.
order to relieve pressure.
71
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Use the 8T-5296 Coolant Conditioner Test Kit Add the SCA, If Necessary
or use the 4C-9301 Coolant Conditioner Test Kit
in order to check the concentration of the SCA.
NOTICE
Refer to the Operation and Maintenance Manual for
Do not exceed the recommended amount of sup-
more information on conventional coolant/antifreeze
plemental coolant additive concentration. Excessive
cooling system maintenance.
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
Water and SCA cooling system, reducing the engines heat transfer
characteristics. Reduced heat transfer could cause
NOTICE cracking of the cylinder head and other high temper-
Do not exceed the recommended eight percent sup- ature components. Excessive supplemental coolant
plemental coolant additive concentration. additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
Test the concentration of the SCA with the 8T-5296 coolant additive and the spin-on element (if equipped)
Coolant Conditioner Test Kit. Refer to the Operation at the same time. The use of those additives together
and Maintenance Manual, Water/Supplemental could result in supplemental coolant additive concen-
Coolant Additive (SCA) topic (Maintenance tration exceeding the recommended maximum.
Section). Refer to the Operation and Maintenance
Manual, Conventional Coolant/Antifreeze Cooling
System Maintenance topic (Maintenance Section).
SOS Coolant Analysis Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
SOS coolant samples can be analyzed at your stop the engine and wait until the cooling system
Caterpillar dealer. SOS Coolant Analysis is a components are cool. Loosen the cooling system
program that is based on periodic samples. pressure cap slowly in order to relieve the pres-
sure.
Level 1
1. Slowly loosen the cooling system filler cap in
Level 1 is a basic analysis of the coolant. The order to relieve the pressure. Remove the cooling
following items are tested: system filler cap.
i00912898 i01008141
Refer to the Service Manual for the replacement Note: Use the 102-9720 Cleaning Kit. This
procedure of the water temperature regulator, or product contains the detergent and oil that is made
consult your Caterpillar dealer. specifically for the maintenance of the AIRSEP
elements.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system 1. Remove the vacuum limiter element and the
to a level that is below the water temperature AIRSEP element.
regulator housing.
73
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
2. Cover the air inlet opening with a clean cloth, or 9. Remove the seal from the air inlet opening.
seal with tape in order to prevent dirt and debris Install the clean, oiled element. Refer to the
from entering the engine. Operation and Maintenance Manual, Torque
Specifications topic (Maintenance Section).
3. Tap the element in order to dislodge dirt
particles. Gently brush the element with a soft Single Element Air Cleaner
bristle brush.
NOTICE
Do not use gasoline, steam, caustic or unapproved
detergents, or parts cleaning solvents. Do not use high
pressure water or air to clean the air cleaner element.
Any of those liquids or methods can cause air cleaner
element damage.
NOTICE
Engine Air Cleaner Service
Do not use transmission fluid, engine oil, diesel fuel, Indicator - Inspect
or other lubricant to oil the air cleaner element. The
air cleaner element can not function correctly if im- SMCS Code: 7452-040
proper oil is used. Never operate an engine with a
dry air cleaner element. The air cleaner element can Some engines may be equipped with a different
not function correctly without oil. Always saturate the service indicator.
clean air cleaner element with the recommended oil.
Some engines are equipped with a differential
gauge for inlet air pressure. The differential gauge
7. The dry element should be oiled before for inlet air pressure displays the difference in the
installation. Apply small amounts of oil across pressure that is measured before the air cleaner
the top of each pleat. Allow the oil to soak into element and the pressure that is measured after
the element for 20 minutes. Oil any remaining the air cleaner element. As the air cleaner element
white spots. becomes dirty, the pressure differential rises. If your
engine is equipped with a different type of service
8. Inspect the housing and the clamp for the indicator, follow the OEM recommendations in order
element. Replace the housing and the clamp, to service the air cleaner element.
if necessary.
A service indicator may be mounted on the air
cleaner element or in a remote location.
74
Maintenance Section
Engine Crankcase Breather - Clean
i01007514
NOTICE
Perform this maintenance with the engine stopped.
Improper mounting of the engine The engine oil level gauge must be calibrated after
the engine is installed in the vessel. Table 36 and
Deterioration of the engine mounts Table 37 list the corresponding ADD mark, FULL
mark and the angle of installation. Use a marking
Any engine mount that shows deterioration should pen in order to engrave ADD mark (Y) and FULL
be replaced. Refer to the Service Manual for mark (X) on the engine oil level gauge according to
the recommended torques. Refer to the OEM the information in Table 36 or Table 37.
recommendations for more information.
i01007363
(1) The angle indicates the number of degrees that the front of
the engine is raised. A negative angle indicates the number of
Engine Oil Sample - Obtain
degrees that the front of the engine is lowered.
SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
Verifying the Calibration of the Oil
Level Gauge In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
Caterpillar recommends verifying the calibration of analysis at regularly scheduled intervals in order
the oil level gauge at the first oil change. Use the to monitor the condition of the engine and the
following procedure to verify the FULL mark on maintenance requirements of the engine.
the oil level gauge:
Obtain the Sample and the Analysis
Note: The vessel must be level in order to perform
this procedure.
2. Remove the used engine oil filter. Install the new Before you take the oil sample, complete the Label,
engine oil filter. Install the crankcase drain plug PEEP5031 for identification of the sample. In order
and tighten the crankcase drain plug. to help obtain the most accurate analysis, provide
the following information:
3. Add 25 L (26.5 qt) of the recommended oil grade
and weight of engine oil to the crankcase. Engine model
77
Maintenance Section
Engine Oil and Filter - Change
The number of hours that have accumulated Engine Oil and Filter - Change
since the last oil change
SMCS Code: 1318-510; 1348-044
The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the Hot oil and hot components can cause personal
oil in the crankcase, obtain a warm, well mixed oil injury. Do not allow hot oil or hot components to
sample. contact the skin.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil Do not drain the oil when the engine is cold. As
samples must be clean. the oil cools, suspended waste particles settle
on the bottom of the oil pan. The waste particles
Caterpillar recommends using the sampling valve are not removed with the draining cold oil. Drain
in order to obtain oil samples. The quality and the the crankcase with the engine stopped. Drain the
consistency of the samples are better when the crankcase with the oil warm. This draining method
sampling valve is used. The location of the sampling allows the waste particles that are suspended in the
valve allows oil that is flowing under pressure to be oil to be drained properly.
obtained during normal engine operation.
Failure to follow this recommended procedure will
The 8T-9190 Fluid Sampling Bottle Group is cause the waste particles to be recirculated through
recommended for use with the sampling valve. The the engine lubrication system with the new oil.
bottle group includes the parts that are needed
for obtaining oil samples. Instructions are also Drain the Engine Oil
provided.
After the engine has been run at the normal
NOTICE operating temperature, stop the engine. Use one of
Do not use the same vacuum sampling pump for ex- the following methods to drain the engine crankcase
tracting oil samples that is used for extracting coolant oil:
samples.
If the engine is equipped with a drain valve, turn
A small residue of either type sample may remain in the drain valve knob counterclockwise in order to
the pump and may cause a false positive analysis for drain the oil. After the oil has drained, turn the
the sample being taken. drain valve knob clockwise in order to close the
drain valve.
Always use a designated pump for oil sampling and a
designated pump for coolant sampling. If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
Failure to do so may cause a false analysis which to drain. If the engine is equipped with a shallow
could lead to customer and dealer concerns. sump, remove the bottom oil drain plugs from
both ends of the oil pan.
If the engine is not equipped with a sampling valve, After the oil has drained, the oil drain plugs should
use the 1U-5718 Vacuum Pump. The pump is be cleaned and installed.
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump. Replace the Oil Filter
For instructions, see Special Publication, PEHP6001, NOTICE
How To Take A Good Oil Sample. Consult your Caterpillar oil filters are built to Caterpillar speci-
Caterpillar dealer for complete information and fications. Use of an oil filter not recommended by
assistance in establishing an SOS program for Caterpillar could result in severe engine damage to
your engine. the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
78
Maintenance Section
Engine Protective Devices - Check
1. Remove the oil filter with a 1U-8760 Chain Fill the Engine Crankcase
Wrench.
1. Remove the oil filler cap. Refer to the Operation
2. Cut the oil filter open with a 4C-5084 Oil Filter and Maintenance Manual for more information on
Cutter. Break apart the pleats and inspect the oil lubricant specifications. Fill the crankcase with
filter for metal debris. An excessive amount of the proper amount of oil. Refer to the Operation
metal debris in the oil filter may indicate early and Maintenance Manual for more information
wear or a pending failure. on refill capacities.
i00626013
3. Clean the sealing surface of the filter mounting Alarms and shutoffs must function properly. Alarms
base. Ensure that all of the old oil filter gasket provide timely warning to the operator. Shutoffs help
is removed. to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
4. Apply clean engine oil to the new oil filter gasket. in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
NOTICE
Do not fill the oil filters with oil before installing them. A calibration check of the engine protective devices
This oil would not be filtered and could be contaminat- will ensure that the alarms and shutoffs activate
ed. Contaminated oil can cause accelerated wear to at the setpoints. Ensure that the engine protective
engine components. devices are functioning properly.
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.
79
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
During testing, abnormal operating conditions must be Ensure that the engine can not be started while
simulated. this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
The tests must be performed correctly in order to pre- to turn the flywheel.
vent possible damage to the engine.
Hot engine components can cause burns. Allow
To prevent damage to the engine, only authorized additional time for the engine to cool before mea-
service personnel or your Caterpillar dealer should suring/adjusting valve lash clearance.
perform the tests.
Ensure that the engine is stopped before measuring
Visual Inspection the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance
Visually check the condition of all gauges, sensors is performed.
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring Refer to the Service Manual for more information.
or components should be repaired or replaced
immediately. i00850658
i00869628
Fuel Injection Timing - Check
Engine Valve Lash - SMCS Code: 1251-036-TM; 1290-036-TM
Inspect/Adjust Note: The correct fuel timing specification is
found on the Engine Information Plate. Fuel
SMCS Code: 1102-025 timing specifications may vary for different engine
applications and/or for different power ratings.
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is A qualified mechanic should adjust the fuel injector
recommended at the first scheduled oil change. timing because special tools and training are
The adjustment is necessary due to the initial wear required.
of the valve train components and to the seating of
the valve train components. Refer to your Caterpillar dealer for the complete
adjustment procedure for the fuel injector timing.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine i01015310
life.
Fuel Inlet Screen - Clean
NOTICE SMCS Code: 1256-070
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Fuel leaked or spilled onto hot surfaces or electri-
Operation of Caterpillar engines with improper valve cal components can cause a fire.
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
80
Maintenance Section
Fuel System - Prime
g00521058
Illustration 29
Location of fuel inlet screen
g00516899
Illustration 30
1. Disconnect the fuel supply line.
(1) Select knob
(2) Plunger
2. Remove the fuel inlet screen.
3. Clean the fuel inlet screen with a nonflammable 1. Turn select knob (1) counterclockwise until the
solvent. indicator is in line with the body of the priming
pump.
4. Install the fuel inlet screen.
2. Unlock the plunger and operate the plunger until
5. Connect the fuel supply line. a resistance is felt. A considerable number of
pump strokes may be required.
Prime the fuel system in order to fill the fuel filter. Note: If the engine will not start, further priming may
Prime the fuel system in order to purge trapped be necessary. If the engine continues to misfire
air. The fuel system should be primed under the or smoke after starting, further priming may be
following conditions: necessary.
If the engine is not equipped with a fuel priming The primary filter/water separator also provides
pump, it may be necessary to fill the fuel filter with filtration in order to help extend the life of the
clean fuel. The following procedure will only allow secondary fuel filter. The element should be
filtered fuel to enter the fuel system. changed regularly. The primary filter/water separator
should be changed when the vacuum gauge (if
equipped) registers 50 to 70 kPa (15 to 20 In Hg).
g00516900
Illustration 31
(1) Plug
(2) Fuel filter
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. g00467033
Illustration 32
(1) Vent valve
(2) Base
2. Start the engine and immediately increase the (3) Can
engine rpm to one half of the rated rpm. (4) Element
(5) Drain plug
3. Maintain the engine rpm until the engine operates
smoothly. 1. Close the main fuel supply valve.
4. Reduce the engine rpm to low idle. 2. Remove drain plug (5). Depress vent valve (1)
in order to start the flow of fuel. Allow the fuel to
drain into a suitable container. Dispose of the
i00914347 fuel properly.
Fuel System Primary 3. Install the drain plug.
Filter/Water Separator Element
4. Remove can (3) from base (2).
- Replace
5. Remove element (4) from the can. Dispose of
SMCS Code: 1260-510-FQ; 1263-510-FQ
the used element.
Water in the fuel can cause the engine to run rough.
6. Remove the gasket. Clean the following
Water in the fuel may cause fuel system components
components:
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval. Can
Gasket
Base
82
Maintenance Section
Fuel System Secondary Filter - Replace
Inspect the gasket for damage and for 2. Turn off the start switch, or disconnect the battery
deterioration. Replace the gasket, if necessary. (starting motor) when maintenance is performed
on fuel filters.
7. Install the gasket. Lubricate the gasket with
clean diesel fuel. 3. Shut off the fuel tank supply valve to the engine.
NOTICE NOTICE
The primary filter/water separator may be prefilled with Use a suitable container to catch any fuel that might
fuel to avoid rough running/stalling of the engine due spill. Clean up any spilled fuel immediately.
to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel- 4. Unlock the fuel priming pump (if equipped). This
erated wear to fuel system parts. relieves any residual pressure in the fuel system.
i00073301
Fuel Tank
Fuel quality is critical to the performance and to
the service life of the engine. Water in the fuel can
cause excessive fuel system wear. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through
g00467033
Illustration 33 the fuel system and the fuel returns to the fuel tank.
(1) Vent valve This causes water to accumulate in fuel tanks.
(2) Base Draining the fuel tank regularly and obtaining fuel
(3) Can from reliable sources can help to eliminate water
(4) Element
(5) Drain plug
in the fuel.
Water in the fuel can cause fuel system components Drain the Water and the Sediment
to fail. Drain the water separator daily. Drain the
water separator more frequently when a large Fuel tanks should contain some provision for
concentration of water is present in the fuel system. draining water and draining sediment from the
bottom of the fuel tanks.
1. Close the fuel supply valve.
Open the drain valve on the bottom of the fuel tank
NOTICE in order to drain the water and the sediment. Close
Use a suitable container to catch any fuel that might the drain valve.
spill. Clean up any spilled fuel immediately.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
2. Remove drain plug (5). Depress vent valve (1) in the water and sediment from the fuel tank after the
order to start the flow. Allow the water to drain fuel tank has been filled. Allow five to ten minutes
into a suitable container. Allow the water to flow before performing this procedure.
until fuel flows from the drain.
Fill the fuel tank after operating the engine in
3. Install the drain plug. Dispose of the liquid order to drive out moist air. This will help prevent
properly. condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
4. Open the fuel supply valve. overflow.
NOTICE Some fuel tanks use supply pipes that allow water
The water separator is under suction during normal and sediment to settle below the end of the fuel
engine operation. Ensure that the drain valve is tight- supply pipe. Some fuel tanks use supply lines that
ened securely to help prevent air from entering the fuel take fuel directly from the bottom of the tank. If
system. the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Weekly
Oil change
Refill of the tank
84
Maintenance Section
Governor Oil Supply Screen - Clean/Replace
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Overhaul Considerations
SMCS Code: 7595-043
3. Install the magnetic pickup and adjust the Follow the rating definitions that are recommended
magnetic pickup. Refer to the Service Manual for for the engine.
the installation procedure.
Repair of Piston, Ring, And Bore
As An Indicator
Investigate the piston, the ring, and the bore or
repair the piston, the ring, and the bore if one of the
following conditions occurs:
87
Maintenance Section
Overhaul Considerations
Increased fuel consumption Check the journal taper and the profile of the
crankshaft journals. Check these components by
Reduced engine efficiency and increased fuel interpreting the wear patterns on the rod bearings
consumption translates into higher operating costs. and main bearings.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts. Note: If the crankshaft or the camshaft are removed
for any reason, use the magnetic particle inspection
Component Replacement process to check for cracks.
Replace the following components during the Replace the crankshaft vibration damper if any of
overhaul: the following conditions are found:
Aftercooler i00905687
SOS Coolant Analysis (Level 2) provides a report of 3. Clean the turbocharger compressor wheel and
the results of both the analysis and the maintenance clean the backplate assembly with 4C-4079
recommendations that are based on the analysis. Brake and Electric Cleaner.
Inspect the Engine for Leaks and Inspect the lubrication system for leaks at the
front crankshaft seal, the rear crankshaft seal, the
for Loose Connections oil pan, the oil filters and the valve cover.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
Inspect the fuel system for leaks. Look for loose
fuel line clamps.
checks, costly repairs and accidents can be
avoided.
Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
For maximum engine service life, make a thorough
inspection of the engine compartment before
starting the engine. Look for items such as oil leaks
Inspect the alternator belt and the accessory
drive belts for cracks, breaks or other damage.
or coolant leaks, loose bolts, worn belts, loose
connections and trash buildup. Make repairs, as Belts for multiple groove pulleys must be replaced
needed: as matched sets. If only one belt is replaced, the
belt will carry more load than the belts that are
The guards must be in the proper place. Repair not replaced. The older belts are stretched. The
damaged guards or replace missing guards. additional load on the new belt could cause the
belt to break.
Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the Inspect the wiring and the wiring harnesses for
fluid. If leaking is observed, find the source and correct loose connections and for worn wires or frayed
the leak. If leaking is suspected, check the fluid levels wires.
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be Inspect the ground strap for a good connection
unwarranted. and for good condition.
Ensure that cooling lines are properly clamped Check the condition of the gauges. Replace any
and that cooling lines are tight. Check for leaks. gauges which are cracked or any gauges that
Check the condition of all pipes. can not be calibrated.
Visually inspect the water pump for leaks. If any 2. Inspect the zinc rod.
leaking is observed, replace the water pump
seal or the water pump assembly. Refer to the Ensure that the zinc rod will remain effective until
Service Manual for the disassembly and assembly the next scheduled inspection.
procedure.
a. If the zinc rod has deteriorated excessively,
Note: Refer to the Service Manual or consult your install a new zinc rod.
Caterpillar dealer if any repair is needed or any
replacement is needed.
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