3054 Operator Manual

SAFETY.CAT.
COM
3054, 3054B and 3056

MARINE ENGINES
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU7423-02-01)
© 2007 Caterpillar
All Rights Reserved
75
Maintenance Section
Maintenance Interval Schedule
i01579850 Engine Mounts - Inspect ....................................... 99

Engine Oil Sample - Obtain ................................ 100
Maintenance Interval Schedule Fuel System Secondary Filter - Replace ............ 105
(3054B Marine Naturally Fuel Tank Water and Sediment - Drain ............... 106
Fuel Transfer Pump Strainer - Clean .................. 107
Aspirated) Heat Exchanger - Inspect ................................... 107
Hoses and Clamps - Inspect/Replace ................ 108
SMCS Code: 1000; 7500
S/N: CSH1-Up
Every 7500 L (2000 US gal) of Fuel or 1000
Service Hours
Note: Before performing any operation or Engine Valve Lash - Inspect/Adjust .................... 102
maintenance procedures, ensure that the Safety Marine Transmission Oil Cooler - Clean/Inspect .. 109
Information, warnings, and instructions are read
and understood.
Every 15 000 L (4000 US gal) of Fuel or 2000
To determine the maintenance intervals, use fuel Service Hours or 2 Years
consumption, service hours, or calendar time, Alternator - Inspect ............................................... 79
whichever occurs first. Experience has shown Cooling System Coolant (DEAC) - Change .......... 82
that maintenance intervals are most accurately Cooling System Water Temperature Regulator -
scheduled on the basis of fuel consumption. Replace ............................................................... 93
Fuel Injection Nozzles - Test/Exchange .............. 103
Before each consecutive interval is performed, all Starting Motor - Inspect ...................................... 114
of the maintenance items from the previous interval Water Pump - Inspect ......................................... 116
must also be performed.
When Required Service Hours
Battery - Replace .................................................. 81 Cooling System Coolant Extender (ELC) - Add .... 90
Battery or Battery Cable - Disconnect .................. 82
Fuel Control Linkage - Check/Lubricate ............. 102
Every 45 600 L (12 000 US gal) of Fuel or
Fuel System - Prime ........................................... 103
6000 Service Hours
Daily Cooling System Coolant (ELC) - Change ............. 87
Cooling System Coolant Level - Check ................ 91
Engine Oil Level - Check ...................................... 99
Marine Transmission Oil Level - Check ............... 109 9000 Service Hours
Walk-Around Inspection ...................................... 116 Overhaul Considerations .................................... 109
First 270 L (70 US gal) of Fuel or First 25 to
50 Service Hours
Alternator Belt - Inspect/Adjust/Replace ............... 80
Engine Valve Lash - Inspect/Adjust .................... 102

Service Hours or 1 Year
Engine Oil and Filter - Change ........................... 100

Auxiliary Water Pump (Rubber Impeller) -
Inspect ................................................................ 80
Battery Electrolyte Level - Check .......................... 81
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 91
Crankshaft Vibration Damper - Inspect ................. 93
Engine Air Cleaner Element - Clean/Replace ....... 94
Engine Crankcase Breather - Clean/Replace ....... 96
76
Maintenance Section
i01547565 Engine Oil Sample - Obtain ................................ 100

Fuel System Secondary Filter - Replace ............ 105
Maintenance Interval Schedule Fuel Tank Water and Sediment - Drain ............... 106
(3054 Marine Turbocharged) Fuel Transfer Pump Strainer - Clean ..................
Heat Exchanger - Inspect ...................................
107
107
SMCS Code: 1000; 7500 Hoses and Clamps - Inspect/Replace ................ 108
S/N: CYK1-Up Every 9400 L (2500 US gal) of Fuel or 1000

Service Hours
Note: Before performing any operation or
maintenance procedures, ensure that the Safety Engine Valve Lash - Inspect/Adjust .................... 102
Information, warnings, and instructions are read Marine Transmission Oil Cooler - Clean/Inspect .. 109
and understood.
To determine the maintenance intervals, use fuel Service Hours or 2 Years
consumption, service hours, or calendar time,
whichever occurs first. Experience has shown Alternator - Inspect ............................................... 79
that maintenance intervals are most accurately Cooling System Coolant (DEAC) - Change .......... 82
scheduled on the basis of fuel consumption. Cooling System Water Temperature Regulator -
Replace ............................................................... 93
Before each consecutive interval is performed, all Fuel Injection Nozzles - Test/Exchange .............. 103
of the maintenance items from the previous interval Starting Motor - Inspect ...................................... 114
must also be performed. Turbocharger - Inspect ........................................ 115
Water Pump - Inspect ......................................... 116
When Required
Battery - Replace .................................................. 81 Service Hours
Battery or Battery Cable - Disconnect .................. 82
Fuel Control Linkage - Check/Lubricate ............. 102 Cooling System Coolant Extender (ELC) - Add .... 90
Daily 6000 Service Hours
Cooling System Coolant Level - Check ................ 91 Cooling System Coolant (ELC) - Change ............. 87
Marine Transmission Oil Level - Check ............... 109 Every 84 000 L (22 000 US gal) of Fuel or
Walk-Around Inspection ...................................... 116 9000 Service Hours
First 270 L (70 US gal) of Fuel or First 25 to Overhaul Considerations .................................... 109
50 Service Hours


Inspect ................................................................ 80
(SCA) - Test/Add ................................................. 91
Engine Mounts - Inspect ....................................... 99
77
Maintenance Section
i01547566 Heat Exchanger - Inspect ................................... 107

Hoses and Clamps - Inspect/Replace ................ 108
Maintenance Interval Schedule Sea Water Strainer - Clean/Inspect .................... 112
(3056 Marine Turbocharged
Aftercooled) Service Hours
SMCS Code: 1000; 7500 Aftercooler Core - Clean/Test ............................... 79
S/N: CKS1-Up
Note: Before performing any operation or
maintenance procedures, ensure that the Safety
Service Hours
Information, warnings, and instructions are read Marine Transmission Oil Cooler - Clean/Inspect .. 109
and understood.
To determine the maintenance intervals, use fuel
whichever occurs first. Experience has shown Alternator - Inspect ............................................... 79
that maintenance intervals are most accurately Starting Motor - Inspect ...................................... 114
scheduled on the basis of fuel consumption. Turbocharger - Inspect ........................................ 115
Before each consecutive interval is performed, all Every 28 500 L (7500 US gal) of Fuel or 2000
of the maintenance items from the previous interval Service Hours or 2 Years
must also be performed.
Cooling System Coolant (DEAC) - Change .......... 82
When Required Cooling System Water Temperature Regulator -
Replace ............................................................... 93
Battery - Replace .................................................. 81 Engine Valve Lash - Inspect/Adjust .................... 102
Battery or Battery Cable - Disconnect .................. 82 Fuel Injection Nozzles - Test/Exchange .............. 103
Fuel Control Linkage - Check/Lubricate ............. 102 Water Pump - Inspect ......................................... 116
Daily 3000 Service Hours or 2 Years
Cooling System Coolant Level - Check ................ 91 Cooling System Coolant Extender (ELC) - Add .... 90
Marine Transmission Oil Level - Check ............... 109 Every 87 000 L (23 000 US gal) of Fuel or
Walk-Around Inspection ...................................... 116
6000 Service Hours
First 700 L (185 US gal) of Fuel or First 25 to Cooling System Coolant (ELC) - Change ............. 87
50 Service Hours Overhaul Considerations .................................... 109

Inspect ................................................................ 80
(SCA) - Test/Add ................................................. 91
Fuel Tank Water and Sediment - Drain ............... 106
Fuel Transfer Pump Strainer - Clean .................. 107
78
Maintenance Section
i01547567 Engine Oil and Filter - Change ........................... 100

Maintenance Interval Schedule Fuel Tank Water and Sediment - Drain ............... 106
(3056 Marine Naturally Fuel Transfer Pump Strainer - Clean ..................
Heat Exchanger - Inspect ...................................
107
107
Aspirated) Hoses and Clamps - Inspect/Replace ................ 108
Sea Water Strainer - Clean/Inspect .................... 112
SMCS Code: 1000; 7500
S/N: CKS1-Up
Service Hours
Note: Before performing any operation or Engine Crankcase Breather - Clean/Replace ....... 96
maintenance procedures, ensure that the Safety
Information, warnings, and instructions are read
and understood.
Service Hours
To determine the maintenance intervals, use fuel Marine Transmission Oil Cooler - Clean/Inspect .. 109
whichever occurs first. Experience has shown Every 22 800 L (6000 US gal) of Fuel or 2000
that maintenance intervals are most accurately
scheduled on the basis of fuel consumption.
Alternator - Inspect ............................................... 79
Before each consecutive interval is performed, all Starting Motor - Inspect ...................................... 114
of the maintenance items from the previous interval
must also be performed. Every 22 800 L (6000 US gal) of Fuel or 2000
Service Hours or 2 Years
When Required
Cooling System Coolant (DEAC) - Change .......... 82
Battery - Replace .................................................. 81 Cooling System Water Temperature Regulator -
Battery or Battery Cable - Disconnect .................. 82 Replace ............................................................... 93
Fuel Control Linkage - Check/Lubricate ............. 102 Engine Valve Lash - Inspect/Adjust .................... 102
Fuel System - Prime ........................................... 103 Fuel Injection Nozzles - Test/Exchange .............. 103
Water Pump - Inspect ......................................... 116
Daily
Cooling System Coolant Level - Check ................ 91 Every 34 000 L (9000 US gal) of Fuel or 3000
Engine Oil Level - Check ...................................... 99 Service Hours or 2 Years
Marine Transmission Oil Level - Check ............... 109 Cooling System Coolant Extender (ELC) - Add .... 90
Walk-Around Inspection ...................................... 116
First 470 L (125 US gal) of Fuel or First 25 to 6000 Service Hours or 4 Years
50 Service Hours
Cooling System Coolant (ELC) - Change ............. 87
9000 Service Hours
Service Hours or 1 Year Overhaul Considerations .................................... 109

Inspect ................................................................ 80
(SCA) - Test/Add ................................................. 91
Engine Mounts - Inspect ....................................... 99
79
Maintenance Section
Aftercooler Core - Clean/Test
i01546702 7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
Aftercooler Core - Clean/Test radiators are equipped to perform pressure tests.
If necessary, repair the core.
SMCS Code: 1064-070; 1064-081
8. Install the core. Refer to the Service Manual for
S/N: CKS1-Up
the procedure.
1. Remove the core. Refer to the Service Manual
For more information on cleaning the core, consult
for the procedure.
your Caterpillar dealer.
2. Turn the aftercooler core upside-down in order
to remove debris. i00072207
NOTICE Alternator - Inspect

Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner SMCS Code: 1405-040
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of Caterpillar recommends a scheduled inspection
cleaner. of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect
the ammeter (if equipped) during engine operation
3. Back flush the core with cleaner. in order to ensure proper battery performance
and/or proper performance of the electrical system.
Caterpillar recommends the use of Hydrosolv Make repairs, as required. Refer to the Service
liquid cleaner. Table 38 lists Hydrosolv liquid Manual.
cleaners that are available from your Caterpillar
dealer. Check the alternator and the battery charger for
proper operation. If the batteries are properly
Table 38
charged, the ammeter reading should be very near
Hydrosolv Liquid Cleaners(1) zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
Part
Number
Description Size affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
1U-5490 Hydrosolv 4165 19 L (5 US gallon) not crank the engine, even if the engine is warm.
174-6854 Hydrosolv 100 19 L (5 US gallon)
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
(1) Use a two to five percent concentration of the cleaner may not fully charge. A battery with a low charge will
at temperatures up to 93 C (200 F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
freeze more easily than a battery with a full charge.
information.
4. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the

core thoroughly with clean water.
Personal injury can result from air pressure.
Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be 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.
80
Maintenance Section
Alternator Belt - Inspect/Adjust/Replace
i01431888 If new belts are installed, check the belt adjustment

again after 30 minutes of engine operation at the
Alternator Belt - rated rpm.
Inspect/Adjust/Replace
Replacement of Multiple Drive Belts
SMCS Code: 1357-036; 1357-510
For applications that require multiple drive belts,
Inspection replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt
to carry more load because the older belts are
stretched. The additional load on the new belt could
cause the new belt to break.
i01041983
Auxiliary Water Pump (Rubber

Impeller) - Inspect
SMCS Code: 1371-040
Impellers and seals require periodic inspection.

Impellers have a service life that is limited. The
service life depends on the engine operating
conditions.
Inspect the components more frequently when the

pump is exposed to debris, sand, or other abrasive
materials. Inspect the components if the pump is
operating at a differential pressure of more than
g00750216
Illustration 35 103 kPa (15 psi).
The belt guard must be removed for inspection, adjustment and
replacement. Check the following components for wear or
(1) Mounting bolts damage:
(2) Adjustment bolt
(3) Typical belt tension gauge • Bearings
To maximize the engine performance, inspect the • Impeller
belt for wear and for cracking. Check the belt
tension. Adjust the belt tension in order to minimize • Seals
belt slippage. Belt slippage will decrease the life
of the belt. • Wear plate
For the correct tension on the belt, refer to If wear or damage is found, replace the components
Specifications, “Belt Tension Chart”. which are worn or damaged. Use the proper repair
kit for the pump. Refer to the Disassembly and
Adjustment Assembly for more information on servicing the
auxiliary water pump.
1. Remove the belt guard.
2. Loosen mounting bolts (1) and adjusting bolt (2).
3. Slide the alternator in the direction that will give

the correct tension.
4. Tighten adjusting bolt (2). Tighten mounting bolts

(1). Refer to the Operation and Maintenance
Manual, “Torque Specifications” for the proper
torques.
5. Reinstall the belt guard.

81
Maintenance Section
Battery - Replace
i01505178 8. Connect the cable from the NEGATIVE “- VE”

terminal on the starter motor to the NEGATIVE
Battery - Replace “-” battery terminal.
SMCS Code: 1401-510
i01206348
Battery Electrolyte Level -

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

The battery cables or the batteries should not be can burn the skin and clothing. Always wear a face
removed with the battery cover in place. The bat- shield and protective clothing when working on or
tery cover should be removed before any servic- near batteries.
ing is attempted.
Removing the battery cables or the batteries with 1. Remove the filler caps. Maintain the electrolyte
the cover in place may cause a battery explosion level to the “FULL” mark on the battery.
resulting in personal injury.
If the addition of water is necessary, use distilled
water. If distilled water is not available use
1. Turn the key start switch to the OFF position. clean water that is low in minerals. Do not use
Remove the key and all electrical loads. artificially softened water.
2. Turn OFF the battery charger. Disconnect the 2. Check the condition of the electrolyte with the
charger. 1U-7298 Coolant/Battery Tester ( C) or the
1U-7297 Coolant/Battery Tester ( F).
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “- VE” 3. Keep the batteries clean.
terminal on the starter motor. Disconnect the
cable from the NEGATIVE “-” battery terminal. Clean the battery case with one of the following
cleaning solutions:
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
on the starting motor. Disconnect the cable from
• A mixture of 0.1 L (0.11 qt) of baking soda and
1 L (1 qt) of clean water
the POSITIVE “+” battery terminal.
Note: Always recycle a battery. Never discard a

• A mixture of 0.1 L (0.11 qt) of ammonia and
1 L (1 qt) of clean water
battery. Return used batteries to an appropriate
recycling facility. Thoroughly rinse the battery case with clean
water.
5. Remove the used battery.
Use a fine grade of sandpaper to clean the
6. Install the new battery. terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
Note: Before the cables are connected, ensure that remove material excessively. Excessive removal
the key start switch is OFF. of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with
7. Connect the cable from the starting motor to the 5N-5561 Silicone Lubricant, petroleum jelly or
POSITIVE “+” battery terminal. MPGM grease.
82
Maintenance Section
Battery or Battery Cable - Disconnect
i01492654
NOTICE
Battery or Battery Cable - Use of commercially available cooling system clean-
Disconnect ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
SMCS Code: 1402-029 proved for Caterpillar engines.
Note: Inspect the water pump and the water

temperature regulator after the cooling system has
The battery cables or the batteries should not be been drained. This is a good opportunity to replace
removed with the battery cover in place. The bat- the water pump, the water temperature regulator
tery cover should be removed before any servic- and the hoses, if necessary.
ing is attempted.
Drain
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
Pressurized System: Hot coolant can cause seri-
1. Turn the start switch to the OFF position. Turn the ous burns. To open the cooling system filler cap,
ignition switch (if equipped) to the OFF position stop the engine and wait until the cooling system
and remove the key and all electrical loads. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
2. Disconnect the negative battery terminal at the sure.
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.
i01550274
Cooling System Coolant

(DEAC) - Change Illustration 36
g00740037
SMCS Code: 1350-070; 1395-044 Typical example

(1) Expansion tank
(2) Cooling system filler cap
3054 and 3054B Marine Engines
1. Stop the engine and allow the engine to cool.
Clean the cooling system and flush the cooling Loosen the cooling system filler cap slowly
system before the recommended maintenance in order to relieve any pressure. Remove the
interval if the following conditions exist: cooling system filler cap.
• 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

83
Maintenance Section
Cooling System Coolant (DEAC) - Change
For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-8665

Inside Illinois: 1-800-541-8665
Canada: 1-800-523-8665
Flush
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the drain valve (if equipped). Clean the

drain plugs. Install the drain plugs. Refer to the
Operation and Maintenance Manual for more
information on the proper torques.
NOTICE
g00782650 Fill the cooling system no faster than 19 L (5 US gal)
Illustration 37
per minute to avoid air locks.
(3) Drain plug on the cylinder block
(4) Fuel transfer pump
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start and run the engine at low idle for a minimum

of 30 minutes with a coolant temperature of at
least 82 C (180 F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
g00782614
Illustration 38
To avoid damage to the cooling system, make sure
(5) Drain plug on the pipe for the jacket water pump to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
2. Open the cooling system drain valve (if cleaning agent are gone.
equipped). If the cooling system is not equipped
with a drain valve, remove the cooling system
drain plugs. 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
Remove the drain plug from the cylinder block in order to relieve any pressure. Remove the
(3). The drain plug for the cylinder block is cooling system filler cap. Open the drain valve
located near the fuel transfer pump (4). Remove (if equipped) or remove the cooling system
the drain plug from the pipe (5) for the jacket drain plugs. Allow the water to drain. Flush the
water pump. Allow the coolant to drain. cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
NOTICE the drain plugs. Refer to the Operation and
Maintenance Manual for more information on the
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used proper torques.
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
84
Maintenance Section
Cooling Systems with Heavy Deposits or 1. Fill the system to the top with the mixture of
Plugging coolant/antifreeze that is recommended. Refer to
the Operation and Maintenance Manual for more
Note: For the following procedure to be effective, information on cooling system specifications. Do
there must be some active flow through the cooling not install the cooling system filler cap.
system components.
2. Start and run the engine at low idle. Increase the
1. Flush the cooling system with clean water in engine rpm to 1500 rpm. Run the engine at 1500
order to remove any debris. rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
drain plugs. Install the drain plugs. Refer to the 3. Add coolant/antifreeze into the cooling system
Operation and Maintenance Manual for more until the cooling system is full to the top.
4. Clean the cooling system filler cap. Inspect
the gasket for the cooling system filler cap. If
NOTICE the gasket for the cooling system filler cap is
Fill the cooling system no faster than 19 L (5 US gal) damaged, discard the old cooling system filler
per minute to avoid air locks. cap and install a new cooling system filler cap. If
the gasket for the cooling system filler cap is not
3. Fill the cooling system with a mixture of clean damaged, use a 9S-8140 Pressurizing Pump in
water and Caterpillar Fast Acting Cooling System order to pressure test the cooling system filler
Cleaner. Add 0.5 L (1 pint) of cleaner per cap. The correct pressure for the cooling system
3.8 to 7.6 L (1 to 2 US gal) of the cooling system filler cap is stamped on the face of the cooling
capacity. Install the cooling system filler cap. system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a
4. Start and run the engine at low idle for a new cooling system filler cap.
minimum of 90 minutes. The coolant temperature
should be at least 82 C (180 F). 5. Pour coolant/antifreeze into the recovery tank
until the coolant reaches “COLD FULL” mark. Do
not fill the recovery tank above “COLD FULL”
NOTICE mark.
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com- 6. Clean the filler cap for the expansion tank. Install
ponents. the filler cap for the expansion tank. Start the
engine. Inspect the cooling system for leaks and
To avoid damage to the cooling system, make sure for proper operating temperature.
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone. 3056 Marine Engine
Clean the cooling system and flush the cooling
5. Stop the engine and allow the engine to cool. system before the recommended maintenance
Loosen the cooling system filler cap slowly interval if the following conditions exist:
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve • The engine overheats frequently.
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the • Foaming is observed.
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install • The oil has entered the cooling system and the
the drain plugs. Refer to the Operation and coolant is contaminated.
proper torques. • The fuel has entered the cooling system and the
Fill
NOTICE
NOTICE Use of commercially available cooling system clean-
Fill the cooling system no faster than 19 L (5 US gal) ers may cause damage to cooling system compo-
per minute to avoid air locks. nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
85
Maintenance Section

been drained. This is a good opportunity to replace
the water pump, the water temperature regulator
and the hoses, if necessary.
Drain

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
g00740078
pressure cap slowly in order to relieve the pres- Illustration 41
sure. (4) Heat exchanger
(5) Drain plug for the heat exchanger
g00740037
Illustration 39 g00740080
Illustration 42
The 3056 Marine engine is shown.
(6) Drain plug on the water cooled exhaust manifold
(1) Expansion tank
2. Open the cooling system drain valve (if
1. Stop the engine and allow the engine to cool. equipped). If the cooling system is not equipped
Loosen the cooling system filler cap slowly with a drain valve, remove the cooling system
in order to relieve any pressure. Remove the drain plugs.
cooling system filler cap.
Remove the drain plug from the cylinder block(3).
The drain plug is located above the starter
motor. Remove the drain plug (5) for the heat
exchanger (4). Remove the drain plug from the
bottom of the water cooled exhaust manifold (6).
Allow the coolant to drain.
NOTICE
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
g00740076 For information regarding the disposal and the

Illustration 40
(3) Drain plug on the cylinder block dealer or consult Caterpillar Service Technology
Group:
86
Maintenance Section
Outside Illinois: 1-800-542-8665 2. Close the drain valve (if equipped). Clean the
Inside Illinois: 1-800-541-8665 drain plugs. Install the drain plugs. Refer to the
Canada: 1-800-523-8665 Operation and Maintenance Manual for more
Flush
NOTICE
1. Flush the cooling system with clean water in Fill the cooling system no faster than 19 L (5 US gal)
order to remove any debris. per minute to avoid air locks.

drain plugs. Install the drain plugs. Refer to the 3. Fill the cooling system with a mixture of clean
Operation and Maintenance Manual for more water and Caterpillar Fast Acting Cooling System
information on the proper torques. Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) 4. Start and run the engine at low idle for a
per minute to avoid air locks. minimum of 90 minutes. The coolant temperature
should be at least 82 C (180 F).
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System NOTICE
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L Improper or incomplete rinsing of the cooling system
(4 US gal) of the cooling system capacity. Install can result in damage to copper and other metal com-
the cooling system filler cap. ponents.
4. Start and run the engine at low idle for a minimum To avoid damage to the cooling system, make sure
of 30 minutes with a coolant temperature of at to completely flush the cooling system with clear wa-
least 82 C (180 F). ter. Continue to flush the system until all signs of the
cleaning agent are gone.
NOTICE
Improper or incomplete rinsing of the cooling system 5. Stop the engine and allow the engine to cool.
can result in damage to copper and other metal com- Loosen the cooling system filler cap slowly
ponents. in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
To avoid damage to the cooling system, make sure (if equipped) or remove the cooling system
to completely flush the cooling system with clear wa- drain plugs. Allow the water to drain. Flush the
ter. Continue to flush the system until all signs of the cooling system with clean water. Close the drain
cleaning agent are gone. valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and
5. Stop the engine and allow the engine to cool. Maintenance Manual for more information on the
Loosen the cooling system filler cap slowly proper torques.
cooling system filler cap. Open the drain valve Fill
drain plugs. Allow the water to drain. Flush the NOTICE
cooling system with clean water. Close the drain Fill the cooling system no faster than 19 L (5 US gal)
valve (if equipped). Clean the drain plugs. Install per minute to avoid air locks.
the drain plugs. Refer to the Operation and
proper torques. 1. Fill the system to the top with the mixture of
coolant/antifreeze that is recommended. Refer to
the Operation and Maintenance Manual for more
Cooling Systems with Heavy Deposits or
information on cooling system specifications. Do
Plugging not install the cooling system filler cap.
Note: For the following procedure to be effective, 2. Start and run the engine at low idle. Increase the
there must be some active flow through the cooling engine rpm to 1500 rpm. Run the engine at 1500
system components. rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
1. Flush the cooling system with clean water in
order to remove any debris.
87
Maintenance Section
Cooling System Coolant (ELC) - Change
3. Add coolant/antifreeze into the cooling system

until the cooling system is full to the top.
4. Clean the cooling system filler cap. Inspect

the gasket for the cooling system filler cap. If
the gasket for the cooling system filler cap is
damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket for the cooling system filler cap is not
damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
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 g00740037
new cooling system filler cap. Illustration 43
Typical example
5. Pour coolant/antifreeze into the recovery tank (1) Expansion tank
until the coolant reaches “COLD FULL” mark. Do (2) Cooling system filler cap
not fill the recovery tank above “COLD FULL”
mark. 1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap (2) slowly
6. Clean the filler cap for the expansion tank. Install in order to relieve any pressure. Remove the
the filler cap for the expansion tank. Start the cooling system filler cap (2).
engine. Inspect the cooling system for leaks and
for proper operating temperature.
i01550285
Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-070; 1395-044
3054 and 3054B Marine Engines

When the cooling system is cleaned, only clean
water is needed when the ELC is drained and
replaced.

g00782650
and the hoses, if necessary. Illustration 44
Drain (4) Fuel transfer pump

sure.
88
Maintenance Section
3. Fill the cooling system with clean water. Install

the cooling system filler cap.
4. Start and run the engine at low idle until the

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

Loosen the cooling system filler cap slowly
cooling system filler cap. Open the drain valve
drain plugs. Allow the water to drain. Flush the
valve (if equipped). Clean the drain plugs. Install
g00782614 the drain plugs. Refer to the Operation and
Illustration 45 Maintenance Manual for more information on the
(5) Drain plug on the pipe for the jacket water pump proper torques.
2. Open the cooling system drain valve (if Fill

drain plugs. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Remove the drain plug from the cylinder block per minute to avoid air locks.
(3). The drain plug for the cylinder block is
located near the fuel transfer pump (4). Remove 1. Fill the cooling system to the top with the
the drain plug from the pipe for the jacket water ELC. Refer to the Operation and Maintenance
pump (5). Allow the coolant to drain. Manual for more information on cooling system
specifications. Do not install the cooling system
NOTICE filler cap.
Various methods have been proposed to reclaim used 2. Start and run the engine at low idle. Increase the
coolant for reuse in engine cooling systems. The full engine rpm to 1500 rpm. Run the engine at 1500
distillation procedure is the only method acceptable by rpm for one minute in order to purge the air from
Caterpillar to reclaim the used coolant. the cavities of the engine block. Stop the engine.
3. Add the ELC into the cooling system until the

For information regarding the disposal and the cooling system is full to the top.
dealer or consult Caterpillar Service Technology 4. Clean the cooling system filler cap. Inspect
Group: the gasket for the cooling system filler cap. If
Outside Illinois: 1-800-542-8665 damaged, discard the old cooling system filler
Inside Illinois: 1-800-541-8665 cap and install a new cooling system filler cap. If
Canada: 1-800-523-8665 the gasket for the cooling system filler cap is not
damaged, use a 9S-8140 Pressurizing Pump in
Flush order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
1. Flush the cooling system with clean water in filler cap is stamped on the face of the cooling
order to remove any debris. system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a
2. Close the drain valve (if equipped). Clean the new cooling system filler cap.
drain plugs. Install the drain plugs. Refer to the
Operation and Maintenance Manual for more 5. Pour the ELC into the recovery tank until the
information on the proper torques. coolant reaches the “COLD FULL” mark. Do not
fill the tank above “COLD FULL” mark.
NOTICE
6. Clean the cooling system filler cap. Install the
Fill the cooling system no faster than 19 L (5 US gal)
cooling system filler cap. Start the engine.
per minute to avoid air locks.
Inspect the cooling system for leaks and for
proper operating temperature.
89
Maintenance Section
3056 Marine Engine

When the cooling system is cleaned, only clean
water is needed when the ELC is drained and
replaced.

and the hoses, if necessary.
Drain
g00740076
Illustration 47
sure.
g00740078
Illustration 48
(4) Heat exchanger
(5) Drain plug for the heat exchanger
g00740037
Illustration 46
The 3056 Marine engine is shown.
(1) Expansion tank

Loosen the cooling system filler cap (2) slowly
cooling system filler cap (2).
g00740080
Illustration 49
(6) Drain plug on the water cooled exhaust manifold
2. Open the cooling system drain valve (if

drain plugs.
90
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Remove the drain plug from the cylinder block Fill

(3). The drain plug is located above the starter
motor. Remove the drain plug (5) for the heat NOTICE
exchanger (4). Remove the drain plug from the Fill the cooling system no faster than 19 L (5 US gal)
bottom of the water cooled exhaust manifold (6). per minute to avoid air locks.
Allow the coolant to drain.
NOTICE 1. Fill the cooling system to the top with the

Dispose of used engine coolant properly or recycle. ELC. Refer to the Operation and Maintenance
Various methods have been proposed to reclaim used Manual for more information on cooling system
coolant for reuse in engine cooling systems. The full specifications. Do not install the cooling system
distillation procedure is the only method acceptable by filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at 1500
For information regarding the disposal and the rpm for one minute in order to purge the air from
recycling of used coolant, consult your Caterpillar the cavities of the engine block. Stop the engine.
dealer or consult Caterpillar Service Technology
Group: 3. Add the ELC into the cooling system until the
cooling system is full to the top.
Outside Illinois: 1-800-542-8665
Inside Illinois: 1-800-541-8665 4. Clean the cooling system filler cap. Inspect
Canada: 1-800-523-8665 the gasket for the cooling system filler cap. If
Flush damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
1. Flush the cooling system with clean water in the gasket for the cooling system filler cap is not
order to remove any debris. damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler
2. Close the drain valve (if equipped). Clean the cap. The correct pressure for the cooling system
drain plugs. Install the drain plugs. Refer to the filler cap is stamped on the face of the cooling
Operation and Maintenance Manual for more system filler cap. If the cooling system filler cap
information on the proper torques. does not retain the correct pressure, install a
new cooling system filler cap.
NOTICE 5. Pour the ELC into the recovery tank until the
Fill the cooling system no faster than 19 L (5 US gal) coolant reaches the “COLD FULL” mark. Do not
per minute to avoid air locks. fill the tank above “COLD FULL” mark.
3. Fill the cooling system with clean water. Install 6. Clean the cooling system filler cap. Install the
the cooling system filler cap. cooling system filler cap. Start the engine.
Inspect the cooling system for leaks and for
4. Start and run the engine at low idle until the proper operating temperature.
temperature reaches 49 to 66 C (120 to 150 F).
i00259474
Loosen the cooling system filler cap slowly Cooling System Coolant
cooling system filler cap. Open the drain valve Extender (ELC) - Add
drain plugs. Allow the water to drain. Flush the SMCS Code: 1352-045; 1395-081
valve (if equipped). Clean the drain plugs. Install Caterpillar Extended Life Coolant (ELC) does not
the drain plugs. Refer to the Operation and require the frequent Supplemental Coolant Additive
Maintenance Manual for more information on the (SCA) additions associated with the present
proper torques. conventional coolants. The Extender only needs to
be added once.
Check the cooling system only when the engine is

stopped and cool.
91
Maintenance Section
Cooling System Coolant Level - Check
1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant

from the cooling system in order to add the
Extender.
3. Add Extender according to the requirements for

your engine’s cooling system capacity. Refer to
the Operation and Maintenance Manual, “Refill
Capacities” in the Maintenance Section for the
capacity of the cooling system for your engine.
Refer to the Operation and Maintenance Manual,
“Cooling System Specifications” information for g00103639
the Caterpillar ELC Extender additions. Illustration 50
4. Clean the cooling system filler cap. Inspect the 4. Clean filler cap and the receptacle. Reinstall the
cooling system filler cap gaskets. Replace the filler cap and inspect the cooling system for
cooling system filler cap if the cooling system leaks.
filler cap gaskets are damaged. Install the
cooling system filler cap. Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery
i01406468 tank during engine operation. When the engine is
stopped and cool, the coolant will return to the
Cooling System Coolant Level engine.
- Check
i01463635
SMCS Code: 1395-082
Cooling System Supplemental
Check the coolant level when the engine is stopped
and cool. Coolant Additive (SCA) -
Test/Add
1. Observe the coolant level in the coolant recovery
tank. Maintain the coolant level to “COLD FULL” SMCS Code: 1352-045; 1395-081
mark on the coolant recovery tank.
Cooling system coolant additive contains alkali.

Pressurized System: Hot coolant can cause seri- To help prevent personal injury, avoid contact with
ous burns. To open the cooling system filler cap, the skin and the eyes. Do not drink cooling system
stop the engine and wait until the cooling system coolant additive.
sure. Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration
as part of an S·O·S Coolant Analysis.
2. Loosen filler cap slowly in order to relieve any
pressure. Remove the filler cap.
Test for SCA Concentration
3. Pour the proper coolant mixture into the tank.
Refer to the Operation and Maintenance Manual, Coolant/Antifreeze and SCA
“Cooling System Specifications” for information
on the correct mixture and type of coolant. Refer NOTICE
to the Operation and Maintenance Manual, “Refill Do not exceed the recommended six percent supple-
Capacities” for the cooling system capacity. Do mental coolant additive concentration.
not fill the coolant recovery tank above “COLD
FULL” mark.
92
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Use the 8T-5296 Coolant Conditioner Test Kit or Add the SCA, If Necessary
use the 4C-9301 Coolant Conditioner Test Kit in
order to check the concentration of the SCA. Refer
NOTICE
to the Operation and Maintenance Manual for more
Do not exceed the recommended amount of sup-
information.
plemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
Water and SCA deposits on the higher temperature surfaces of the
cooling system, reducing the engine’s heat transfer
NOTICE characteristics. Reduced heat transfer could cause
Do not exceed the recommended eight percent sup- cracking of the cylinder head and other high temper-
plemental coolant additive concentration. ature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
Test the concentration of the SCA with the 8T-5296 pump seal wear. Never use both liquid supplemental
Coolant Conditioner Test Kit. Refer to the Operation coolant additive and the spin-on element (if equipped)
and Maintenance Manual, “Water/Supplemental at the same time. The use of those additives together
Coolant Additive (SCA)” topic (Maintenance could result in supplemental coolant additive concen-
Section). Refer to the Operation and Maintenance tration exceeding the recommended maximum.
Manual, “Conventional Coolant/Antifreeze Cooling
System Maintenance” topic (Maintenance Section).
S·O·S Coolant Analysis

S·O·S coolant samples can be analyzed at your ous burns. To open the cooling system filler cap,
Caterpillar dealer. S·O·S Coolant Analysis is a stop the engine and wait until the cooling system
program that is based on periodic samples. components are cool. Loosen the cooling system
Level 1 sure.
Level 1 is a basic analysis of the coolant. The 1. Slowly loosen the cooling system filler cap in
following items are tested: order to relieve the pressure. Remove the cooling
system filler cap.
• Glycol Concentration
Note: Always discard drained fluids according to
• Concentration of SCA local regulations.
• pH 2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow
• Conductivity space for the extra SCA.
The results are reported, and recommendations 3. Add the proper amount of SCA. Refer to the
are made according to the results. Consult your Operation and Maintenance Manual for more
Caterpillar dealer for information on the benefits of information on SCA requirements.
managing your equipment with an S·O·S Coolant
Analysis. 4. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
Level 2 gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
This level coolant analysis is recommended cap. Install the cooling system filler cap.
when the engine is overhauled. Refer to the
Operations and Maintenance Manual, “Overhaul
Considerations” for further information.
93
Maintenance Section
Cooling System Water Temperature Regulator - Replace
i00912898 i00934535
Cooling System Water Crankshaft Vibration Damper

Temperature Regulator - - Inspect
Replace SMCS Code: 1205-040
SMCS Code: 1355-510
Damage to the crankshaft vibration damper or
failure of the crankshaft vibration damper can
Replace the water temperature regulator before
increase torsional vibrations. This can result in
the water temperature regulator fails. This is a
damage to the crankshaft and to other engine
recommended preventive maintenance practice.
components. A damper that is damaged can cause
Replacing the water temperature regulator reduces
excessive gear train noise at variable points in the
the chances for unscheduled downtime.
speed range.
A water temperature regulator that fails in a
The damper is mounted to the crankshaft which is
partially opened position can cause overheating or located behind the belt guard on the front of the
overcooling of the engine.
engine.
A water temperature regulator that fails in the
closed position can cause excessive overheating. Visconic Damper
Excessive overheating could result in cracking of
the cylinder head or piston seizure problems. The visconic damper has a weight that is located
inside a fluid filled case. The weight moves in the
A water temperature regulator that fails in the open case in order to limit torsional vibration.
position will cause the engine operating temperature
to be too low during partial load operation. Low Inspect the damper for evidence of fluid leaks. If
engine operating temperatures during partial loads a fluid leak is found, determine the type of fluid.
could cause an excessive carbon buildup inside The fluid in the damper is silicone. Silicone has
the cylinders. This excessive carbon buildup could the following characteristics: transparent, viscous,
result in an accelerated wear of the piston rings and smooth, and difficult to remove from surfaces.
wear of the cylinder liner.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
NOTICE
seals.
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
Inspect the damper and repair or replace the
engine damage.
damper for any of the following reasons:
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water • The damper is dented, cracked, or leaking.
temperature regulator installed.
• The paint on the damper is discolored from heat.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head • The engine has had a failure because of a broken
crankshaft.
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open. • Analysis of the oil has revealed that the front main
bearing is badly worn.
Do not use liquid gasket material on the gasket or
cylinder head surface. • There is a large amount of gear train wear that is
not caused by a lack of oil.
Refer to the Service Manual for the replacement Refer to the Service Manual or consult your
procedure of the water temperature regulator, or Caterpillar dealer for information about damper
consult your Caterpillar dealer. replacement.
Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system
to a level that is below the water temperature
regulator housing.
94
Maintenance Section
Engine Air Cleaner Element - Clean/Replace
i01508037
Engine Air Cleaner Element -

Clean/Replace
SMCS Code: 1054-070; 1054-510
Turbocharged Engines
g00782913
Illustration 51
Air cleaner that is disassembled
(1) Adapter (3) Support screen (5) Air cleaner housing
(2) Support shaft (4) Air cleaner element (6) Pin that holds the support shaft in place
95
Maintenance Section
Engine Air Cleaner Element - Clean/Replace
5. Place the cleaned element (4) or a new element

in the housing of the air cleaner (5). Insert the
support screen (3) into the housing. Ensure that
the end of the support screen (3) is engaged in
the recess in the filter body. Insert the support
shaft(2) into the housing.
6. Install the adapter (1) onto the air cleaner

housing and install the hose clamp. Install the
adapter (1) onto the turbocharger. Install the
bracket onto the air cleaner housing. Refer to
the Operation and Maintenance Manual, “Torque
Specifications” for more information on the
proper torques.
g00782915
Illustration 52
Assembled air cleaner
Naturally Aspirated Engines
(1) Adapter
(2) Support shaft
(3) Support screen
(4) Air cleaner element
(5) Air cleaner housing
(6) Pin that holds the support shaft in place
1. Remove the hose clamp from the adapter (1)

that is attached to the turbocharger. Remove the
bracket from the air cleaner housing. Remove
the air cleaner housing (5). Remove the hose
clamp from the adapter (1). Remove the rubber
hose from the air cleaner housing.
2. Remove the support shaft (2) from the air cleaner

housing (5). Remove the support screen (3)
from the air cleaner housing (5). Remove the air
cleaner element (4).
3. Clean the inside of the air cleaner housing with

a clean, damp cloth. Wipe the inside of the air
cleaner housing dry.
g00782998
Illustration 53
NOTICE 3054 Marine engine

Do not use gasoline, steam, caustic or unapproved (1) Inlet manifold
detergents, or parts cleaning solvents. Do not use high (2) Air cleaner element
pressure water or air to clean the air cleaner element.
Any of those liquids or methods can cause air cleaner
element damage.
4. Wash the air cleaner element in a solution of

soap and water. Rinse the air cleaner element
with low water pressure. The maximum water
pressure for this procedure is 275 kPa (40 psi).
Tap water is acceptable. Start to rinse the air
cleaner element from the clean side (inside).
Next, clean the dirty side (outside) in order to
flush out dirt. Inspect the air cleaner element for
tears and/or holes after the air cleaner element
is cleaned. Do not reuse damaged air cleaner
g00749515
elements. Allow the element to air dry. Drying the Illustration 54
element in the sun speeds the process. 3056 Marine engine
(1) Inlet manifold
(2) Air cleaner element
96
Maintenance Section
Engine Crankcase Breather - Clean/Replace
Note: The air cleaner element is in the air inlet i01576128

manifold on naturally aspirated engines. There is no
air cleaner assembly on naturally aspirated engines. Engine Crankcase Breather -
1. Remove the air cleaner element (2) from the air
Clean/Replace
inlet manifold (1). SMCS Code: 1317-070; 1317-510
2. Clean the inside of the housing of the air inlet
manifold with a clean, damp cloth. Wipe the 3054 and 3054B Marine Engines
inside of the air inlet manifold dry.
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.
3. Wash the air cleaner element in a solution of

soap and water. Rinse the air cleaner element
with low water pressure. The maximum water
pressure for this procedure is 275 kPa (40 psi).
Tap water is acceptable. Start to rinse the air
cleaner element from the clean side (inside).
Next, clean the dirty side (outside) in order to
flush out dirt. Inspect the air cleaner element for
tears and/or holes after the air cleaner element
is cleaned. Do not reuse damaged air cleaner
elements. Allow the element to air dry. Drying the
element in the sun speeds the process. Illustration 55 g00783070
(1) Vent hole

4. Insert the cleaned element (2) or a new element (2) Hose clamp
into the air inlet manifold. (3) Bolts that hold the breather assembly
(4) Hose clamp
(5) Breather assembly
(6) Hose clamp
NOTICE
Ensure that the components of the breather assembly
are installed in the correct positions. If not installed
correctly, engine damage can result.
Note: Keep the area around vent hole (1) clean. Do

not restrict the vent hole.
1. Loosen hose clamps (2), (4), and (6). Remove

the hoses from the breather assembly (5).
2. Remove two bolts (3) that hold the breather

assembly (5) to the cylinder block. Remove the
breather assembly (5) from the engine.
3. Discard the breather assembly (5). Install a new

breather assembly by using the two bolts (3).
“Torque Specifications” for the correct torques.
97
Maintenance Section
4. Install the hoses and tighten the hose clamps An internal port in the rocker cover allows the gases
(2), (4), and (6). Refer to the Operation and in the crankcase to pass into the breather body
Maintenance Manual, “Standard Torque for through an element (3). The gases flow through a
Constant Torque Hose Clamps” for the correct series of baffles (5) and into the valve cover through
torques. holes at the bottom of the chamber for the baffles.
Valve (1) controls the flow of gases which pass from
the breather through the plastic outlet elbow (7) to
3056 Marine Engine the intake manifold.
Turbocharged Engines The valve cover and the breather assembly are
made of a composite material. The valve cover and
the breather assembly should be removed and
installed with care.
Disassembly
NOTICE
Do not use excessive force to remove the hose from
the breather outlet elbow. If the breather outlet elbow
breaks away from the breather body, see the proce-
dure to repair the connection for the breather outlet
elbow.
1. Release the hose clamp and carefully remove

the hose from elbow (7).
2. Remove the valve cover. Refer to the Service

Manual for more information.
NOTICE
Use care not to damage the breather cover or the
breather body with a pry bar.
3. Remove the bolts and carefully remove the

breather cover from the breather body. It may
be necessary to use a suitable pry bar in order
to remove the breather cover from the breather
body. Ensure that the pry bar does not damage
the breather cover or the breather body. Gasket
(6) should be removed and discarded.
4. Release clip retainers (2) on valve (1). Push

g00749578
valve (1) out of the breather cover.
Illustration 56
(1) Valve 5. Element (3) should be removed and discarded.
(2) Clips
(3) Element
(4) Clip retainers NOTICE
(5) Baffles To prevent damage to the breather valve, remove the
(6) Gasket
(7) Elbow
breather valve before the cover is washed.
The crankcase breather removes the combustion NOTICE

gases from the engine crankcase. The crankcase Ensure that all the cleaning fluid is removed before the
breather directs the gases to the induction system. breather is assembled.
6. Use a clean nonflammable solvent to wash the

body of the breather, the cover, baffle (5), and
elbow (7). Thoroughly dry the components after
cleaning the components.
98
Maintenance Section
7. Ensure that the holes in the bottom of the Naturally Aspirated Engines
chamber for baffles (5 ) are not restricted. If
necessary, clean the holes. Disassembly
Assembly
1. Install baffles (5) into the grooves in the breather

body.
2. Install a new element (3) into the breather body.
3. Install a new valve (1) into the breather cover.

Ensure that clip retainers (2) are engaged
correctly.
4. Install a new gasket (6). The gasket is installed

dry. Put the cover and valve assembly into
position on the breather body. Loosely install the
g00749571
bolts. Tighten the bolts gradually and tighten the Illustration 57
bolts evenly to a torque of 3 N·m (27 lb in). (1) Crankcase breather cover
(2) Element
(3) Hose clamp
NOTICE (4) O-ring seal
Do not use excessive force to fit the hose to the
breather outlet elbow. 1. Loosen the hose clamp (3) from the crankcase
breather cover (1). Remove the hose from the
5. Ensure that there is no restriction in elbow (7) or crankcase breather cover.
in the breather hose. Carefully install the breather
hose on elbow (7). Tighten the hose clamps that 2. Remove the crankcase breather cover (1).
fasten the hose to the elbow. Remove the element (2) from the housing.
Procedure to Repair the Connection for the Outlet 3. Use a clean nonflammable solvent to wash the
Elbow of the Breather element.
If the outlet elbow for the crankcase breather NOTICE

breaks, then use the following procedure in order Ensure that all the cleaning fluid is removed before the
to repair the elbow. breather is assembled.
NOTICE 4. Use a clean nonflammable solvent to wash the

Thoroughly clean the inside of the breather body after crankcase breather cover (1). Thoroughly dry the
it has been drilled. components after cleaning the components.
Assembly
1. Ensure that the breather body is secure. Use a
22.5 mm (0.89 inch) drill in order to drill to a
depth of 10.0 mm (0.39 inch). Drill the depth in 1. Inspect the O-ring seal (4). If the O-ring seal is
damaged, then replace the O-ring seal.
order to remove the broken connection of the
outlet elbow. Thoroughly clean the inside of the
breather body. 2. Install the cleaned element or install a new
element.
2. Thoroughly clean the contact faces of the elbow
(7) and the breather cover. 3. Press the crankcase breather cover (1) onto the
base.
3. Install elbow (7). Ensure that the contact surface
of the connection for the elbow has a rough 4. Ensure that the hose that connects to the
crankcase breather is cleaned. Use a clean
finish. Put the elbow into position on the breather
nonflammable solvent to wash the hose.
body.
5. Install the hose and tighten the hose clamp (3).
4. Apply Permabond® E3524 adhesive. Refer to the
instructions on the adhesive. The adhesive will
secure the elbow to the breather body.
99
Maintenance Section
Engine Mounts - Inspect
i00259257
Engine Mounts - Inspect

SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for

proper bolt torque. Engine vibration can be caused
by the following conditions:
• Improper mounting of the engine

• Deterioration of the engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the Service Manual for
the recommended torques. Refer to the OEM
recommendations for more information.
i01515143
Engine Oil Level - Check Illustration 59

g00740949
Location of the engine oil level gauge on the 3056 Marine engine
SMCS Code: 1348-535-FLV
(1) Oil filler cap
(2) Oil level gauge (dipstick)
Check the engine oil level after the engine has
stopped.
g00110310
Illustration 60
(Y) “ADD” mark. (X) “FULL” mark.
1. Maintain the oil level between “ADD” mark (Y)

and “FULL” mark (X) on oil level gauge (2). Do
not fill the crankcase above “FULL” mark (X).
g00786237 NOTICE
Illustration 58 Operating your engine when the oil level is above the
Location of the engine oil level gauge on the 3054 Marine engine “FULL” mark could cause your crankshaft to dip into
(1) Oil filler cap the oil. The air bubbles created from the crankshaft
(2) Oil level gauge (dipstick) dipping into the oil reduces the oil’s lubricating char-
acteristics and could result in the loss of power.
2. Remove oil filler cap (1) and add oil, if necessary.

Clean the oil filler cap. Reinstall the oil filler cap.
“Refill Capacities” for the engine oil capacity.
100
Maintenance Section
Engine Oil Sample - Obtain
i01534451
NOTICE
Engine Oil Sample - Obtain Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
SMCS Code: 1000-008; 1348-554-SM; samples.
7542-554-OC, SM
A small residue of either type sample may remain in
In addition to a good preventive maintenance the pump and may cause a false positive analysis for
program, Caterpillar recommends using S·O·S oil
the sample being taken.
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the Always use a designated pump for oil sampling and a
maintenance requirements of the engine.
designated pump for coolant sampling.
Obtain the Sample and the Analysis Failure to do so may cause a false analysis which
could lead to customer and dealer concerns.
If the engine is not equipped with a sampling valve,

Hot oil and hot components can cause personal use the 1U-5718 Vacuum Pump. The pump is
injury. Do not allow hot oil or hot components to designed to accept sampling bottles. Disposable
contact the skin. tubing must be attached to the pump for insertion
into the sump.
Before you take the oil sample, complete the Label, For instructions, see Special Publication, PEHP6001,
PEEP5031 for identification of the sample. In order “How To Take A Good Oil Sample”. Consult your
to help obtain the most accurate analysis, provide Caterpillar dealer for complete information and
the following information: assistance in establishing an S·O·S program for
your engine.
• Engine model
• Service hours on the engine i01558369
• 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 169-8373 Fluid Sampling Bottle 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.
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
101
Maintenance Section
Engine Oil and Filter - Change
Drain the Engine Oil Use a magnet to differentiate between the

ferrous metals and the nonferrous metals that
are found in the oil filter element. Ferrous metals
may indicate wear on the steel and cast iron
parts of the engine.
Nonferrous metals may indicate wear on the

aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not

uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
g00749474
Illustration 61
Manual sump pump for the engine oil
1. Connect a suitable hose to the outlet of the

manual sump pump for the engine oil. Place
the opposite end of the hose into a suitable
container. The container should hold at least
18 L (19 qt) of oil.
g00741009
2. Pump the handle of the manual sump pump until Illustration 62
the oil has been removed from the engine into Typical mounting base for the oil filter and oil filter gasket
the suitable container. Dispose of the used oil in
accordance with local regulations. 3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket
Replace the Oil Filter is removed.
4. Apply clean engine oil to the new oil filter gasket.

NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by NOTICE
Caterpillar could result in severe engine damage to Do not fill the oil filters with oil before installing them.
the engine bearings, crankshaft, etc., as a result of This oil would not be filtered and could be contaminat-
the larger waste particles from unfiltered oil entering ed. Contaminated oil can cause accelerated wear to
the engine lubricating system. Only use oil filters engine components.
recommended by Caterpillar.
5. Install the oil filter. Tighten the oil filter until the
1. Remove the oil filter with a 1U-8760 Chain oil filter gasket contacts the base. Tighten the oil
Wrench. filter by hand according to the instructions that
are shown on the oil filter. Do not overtighten the
2. Cut the oil filter open with a 175-7546 Oil Filter oil filter.
Cutter. Break apart the pleats and inspect the oil
filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early
wear or a pending failure.
102
Maintenance Section
Engine Valve Lash - Inspect/Adjust
Fill the Engine Crankcase

NOTICE
1. Remove the oil filler cap. Refer to the Only qualified service personnel should perform this
Operation and Maintenance Manual, “Lubricant maintenance. Refer to the Service Manual or your
Specifications” for more information on the Caterpillar dealer for the complete valve lash adjust-
proper type of oil. Fill the crankcase with the ment procedure.
proper amount of oil. Refer to the Operation and
Maintenance Manual, “Refill Capacities” for the Operation of Caterpillar engines with improper valve
proper amount of oil. adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
NOTICE and/or shortened engine component life.
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer’s recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
NOTICE vent possible injury, do not use the starting motor
To prevent crankshaft bearing damage, crank the en- to turn the flywheel.
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more Hot engine components can cause burns. Allow
than 30 seconds. additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
2. Start the engine and run the engine at “LOW
IDLE” for two minutes. Perform this procedure in Ensure that the engine is stopped before measuring
order to ensure that the lubrication system has the valve lash. To obtain an accurate measurement,
oil and that the oil filters are filled. Inspect the oil allow the valves to cool before this maintenance
filter for oil leaks. is performed.
3. Stop the engine and allow the oil to drain back Refer to the Service Manual for more information.
to the sump for a minimum of ten minutes.
i01432350
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the “ADD” Fuel Control Linkage -
and “FULL” marks on the oil level gauge.
Check/Lubricate
i00869628 SMCS Code: 1257-086; 1257-535
Engine Valve Lash - Check the fuel control linkage for proper operation.
Inspect/Adjust If necessary, adjust the fuel control linkage. A
variety of linkages can be used. The type of linkage
SMCS Code: 1102-025 depends on the type of installation. Therefore, refer
to the OEM of the vessel for the specific type of
The initial valve lash adjustment on new engines, fuel control linkage.
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. Some fuel control linkages require lubrication.
The adjustment is necessary due to the initial wear Lubricate the grease fittings with 1P-0808
of the valve train components and to the seating of Multipurpose Grease or the equivalent.
the valve train components.
This maintenance is recommended by Caterpillar

as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
103
Maintenance Section
Fuel Injection Nozzles - Test/Exchange
i00626014 2. Loosen each fuel line nut one at a time at the fuel
injection pump. A cloth or similar material must
Fuel Injection Nozzles - be used in order to prevent fuel from spraying on
Test/Exchange the hot exhaust components. Tighten each nut
before loosening the next nut.
SMCS Code: 1254-013; 1254-081
3. A defective fuel injection nozzle may be identified
when a fuel line nut is loosened and the following
conditions are present:
Fuel leaked or spilled onto hot surfaces or electri- • The exhaust smoke is partially eliminated or
cal components can cause a fire. the exhaust smoke is completely eliminated.
NOTICE
• Engine performance is not affected.
Do not allow dirt to enter the fuel system. Thoroughly A fuel injection nozzle that is suspected of
clean the area around a fuel system component that being defective should be removed. A new
will be disconnected. Fit a suitable cover over discon- fuel injection nozzle should be installed in the
nected fuel system component. cylinder in order to determine if the removed fuel
injection nozzle is defective.
Fuel injection nozzles are subject to tip wear. Tip
wear is a result of fuel contamination. Tip wear can Removal and Installation of the
cause the following problems:
Fuel Injection Nozzles
• Increased fuel consumption
For the removal and the installation of fuel injection
• Black smoke nozzles, special tooling is required. Refer to the
Service Manual for more information. Consult your
• Misfire Caterpillar dealer for assistance.
• Rough running i01508873
Fuel Injection nozzles should be cleaned, inspected, Fuel System - Prime

tested, and replaced, if necessary. Refer to Special
Instruction, SEHS7292 for using the 8S-2245 SMCS Code: 1258-548
Injection Cleaning Tool Group. Consult your
Caterpillar dealer about cleaning the fuel injection Priming the fuel system fills the fuel filter. Priming
nozzle and testing the fuel injection nozzle. the fuel system removes air bubbles from the fuel
system. Prime the fuel system under the following
NOTICE conditions:
Never wire brush or scrape a fuel injection nozzle.
Wire brushing or scraping a fuel injection nozzle will • Fuel system that is run dry
damage the finely machine orifice. Proper tools for
cleaning and testing the fuel injection nozzles can be • Storage
obtained from Caterpillar dealers.
• Fuel filter maintenance
The following items are symptoms of a malfunction • Disconnecting fuel lines and installing fuel lines
of the fuel injection nozzle:
• Repair of leaks in the fuel lines
• Abnormal engine operation
• Smoke emission
• Engine knock Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
Each fuel injection nozzle must be isolated one at a vent possible injury, turn the start switch off when
time in order to determine the malfunctioning fuel changing fuel filters or water separator elements.
injection nozzle. Clean up fuel spills immediately.
1. Start the engine.

104
Maintenance Section
Fuel System - Prime
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
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.
g00749721
Illustration 65
Fuel line for the air inlet heater for the 3056 Marine engine is shown
3. The engine may be equipped with an air inlet

heater. Loosen the nut for the air inlet heater.
Operate the priming lever for the fuel transfer
pump until the flow of fuel from the fuel line is
continuous and free of air bubbles. Tighten the
union nut for the air inlet heater.
g00749720
Illustration 63
Typical location of vent on top of the fuel filters
Dual fuel filters shown
1. Loosen the bolt at the top of the fuel filter in

order to open a vent.
g00286062
Illustration 66
Fuel lines for two of the fuel injectors
4. Loosen two of the fuel line nuts at two of the fuel

injection nozzles in order to open two vents.
NOTICE
Do not crank the engine continuously for more than
Illustration 64
g00286060 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Priming lever for the fuel transfer pump
Note: The priming lever of the fuel transfer pump 5. Ensure that the manual stop control (if equipped)
cannot be operated if the cam is at the maximum is in the RUN position. Crank the starting motor
lift position. If this occurs, the crankshaft must be until the flow of fuel from the vents is continuous
rotated one revolution. and free of air bubbles. Tighten the fuel line nuts
to 22 N·m (16 lb ft).
2. Operate the priming lever for the fuel transfer
pump until the flow of fuel from the vent is 6. Ensure that all fuel line connections are secure
continuous and free of air bubbles. Tighten the and tightened to the proper torque. Ensure that
bolt at the top of the fuel filter. any spilled fuel is cleaned up.
105
Maintenance Section
Fuel System Secondary Filter - Replace
7. Start the engine. The engine may run rough. 3. Loosen the drain valve (3) at the bottom of
Run the engine at low idle until the engine runs the fuel filter (2). Drain the fuel into a suitable
smoothly. If the engine will not start, further container.
priming may be necessary. If the engine starts
and if the engine continues to misfire or smoke, 4. Loosen and remove the old fuel filter (2) from
then the fuel system may require more priming. the fuel filter base (1). Dispose of the element
Check for any leaks in the fuel system. properly.
Note: Replacement fuel filters have an inner seal

i01550569
assembly. The seal is held into position by a plastic
Fuel System Secondary Filter - clip. Damage to the fuel injection pump may occur
if the seals are not installed correctly.
Replace
5. Lightly lubricate the two O-ring seals of the new
SMCS Code: 1261-510-SE fuel filter assembly (2) with clean diesel fuel.
3054 and 3054B Marine Engine 6. Install the new fuel filter assembly (2) to the fuel
filter base (1). Tighten 1/2 of a turn to 3/4 of a
turn past hand tightening.
7. Prime the fuel system. Refer to the Operation

Fuel leaked or spilled onto hot surfaces or elec- and Maintenance Manual, “Fuel System-Prime”
trical components can cause a fire. To help pre- for more information.
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. 3056 Marine Engine
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly Fuel leaked or spilled onto hot surfaces or elec-
clean the area around a fuel system component that trical components can cause a fire. To help pre-
will be disconnected. Fit a suitable cover over discon- vent possible injury, turn the start switch off when
nected fuel system component. changing fuel filters or water separator elements.
Turn the fuel supply valve to the OFF position before
performing this maintenance. Place a tray under the
NOTICE
fuel filter in order to catch any fuel that might spill.
Do not allow dirt to enter the fuel system. Thoroughly
Clean up any spilled fuel immediately.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
1. Turn the fuel supply valve to the OFF position.
Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled
fuel immediately. 1. Turn the fuel supply valve to the OFF position.
Place a tray under the fuel filter in order to catch
2. Clean the outside of the fuel filter assembly. any fuel that might spill. Clean up any spilled
fuel immediately.
2. Clean the outside of the fuel filter assembly.
Note: Both of the fuel filter elements need to be

replaced at the same time if the engine is equipped
with two fuel filter elements.
g00803020
Illustration 67
106
Maintenance Section
Fuel Tank Water and Sediment - Drain
i00073301
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
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
g00749869
Illustration 68 the fuel system and the fuel returns to the fuel tank.
This causes water to accumulate in fuel tanks.
3. Hold the bottom cover (4) of the filter assembly. Draining the fuel tank regularly and obtaining fuel
Remove the bolt (1) from the center of the from reliable sources can help to eliminate water
element. in the fuel.
4. Lower the bottom cover (4).

Drain the Water and the Sediment
5. Remove the fuel filter element (3) and dispose of
Fuel tanks should contain some provision for
the elements properly.
draining water and draining sediment from the
bottom of the fuel tanks.
6. Clean the inside surfaces of the fuel filter base
(2). Clean the bottom cover (4).
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
7. Replace the O-ring on the fuel filter base (2).
the drain valve.
Replace the O-ring on the bottom cover (4).
Check the fuel daily. Drain the water and sediment
NOTICE from the fuel tank after operating the engine or drain
Do not fill fuel filters with fuel before installing them. the water and sediment from the fuel tank after the
Contaminated fuel will cause accelerated wear to fuel fuel tank has been filled. Allow five to ten minutes
system parts. before performing this procedure.
Fill the fuel tank after operating the engine in

8. Insert bottom cover (4) onto new element (3).
order to drive out moist air. This will help prevent
Ensure that the element is installed properly to
condensation. Do not fill the tank to the top. The
the bottom cover (4). Place the element (3) to the
fuel expands as the fuel gets warm. The tank may
fuel filter base (2). Install the bolt (1).
overflow.
Some fuel tanks use supply pipes that allow water
and Maintenance Manual, “Fuel System-Prime”
and sediment to settle below the end of the fuel
for more information.
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks

Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Oil change
• Refill of the tank
107
Maintenance Section
Fuel Transfer Pump Strainer - Clean
This will help prevent water or sediment from being 1. Remove the cover and seal (2) from the top of
pumped from the storage tank into the engine fuel fuel transfer pump (1). Remove strainer (3).
tank.
2. Use nonflammable solvent in order to clean
If a bulk storage tank has been refilled or moved the strainer, the cover, and the seal. Carefully
recently, allow adequate time for the sediment to wash any sediment from the chamber of the fuel
settle before filling the engine fuel tank. Internal transfer pump.
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the 3. Assemble the clean, dry fuel transfer pump.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. NOTICE
Ensure that the lift pump cover is secure so that air
i01190897 does not enter the fuel system.
Fuel Transfer Pump Strainer - 4. Turn the fuel supply to the ON position.
Clean
SMCS Code: 1256-070-STR and Maintenance Manual for more information on
priming the fuel system.
i01505499
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre- Heat Exchanger - Inspect
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. SMCS Code: 1379-040
The interval for the maintenance of the tube
type heat exchanger depends on the operating
NOTICE environment of the vessel and on the operating
Do not allow dirt to enter the fuel system. Thoroughly time. The sea water that is circulated through the
clean the area around a fuel system component that heat exchanger and the amount of operating time
will be disconnected. Fit a suitable cover over discon- of the vessel affects the following items:
• Cleanliness of the tubes for the heat exchanger
Cleaning the Strainer and the • Effectiveness of the heat exchanger system
Sediment Chamber for the Fuel
Operating in water that contains silt, sediment, salt,
Transfer Pump algae, etc will adversely affect the heat exchanger
system. In addition, intermittent use of the vessel
Turn the fuel supply valve to the OFF position before will adversely affect the heat exchanger system.
the maintenance is performed.
The following items indicate that the heat exchanger
may require cleaning:
• Increased coolant temperature

• Engine overheating
• Excessive pressure drop between the water inlet
and the water outlet
An operator that is familiar with the normal operating

temperature of the coolant can determine when
the coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger
g00286056 are required if the engine is overheating.
Illustration 69
(1) Fuel transfer pump
(2) Cover and seal
(3) Strainer
108
Maintenance Section
Hoses and Clamps - Inspect/Replace
The procedure for cleaning the heat exchanger Each installation application can be different. The
is the same procedure that is used for cleaning differences depend on the following factors:
the aftercooler core. Refer to the Operation and
Maintenance Manual, “Aftercooler Core - Clean/Test” • Type of hose
topic (Maintenance Section). For more information
on servicing the heat exchanger, consult your • Type of fitting material
Caterpillar dealer.
• Anticipated expansion and contraction of the
hose
i00907072
Hoses and Clamps - • Anticipated expansion and contraction of the

fittings
Inspect/Replace
SMCS Code: 7554-040; 7554-510
Replace the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the
following conditions:
• Cracking ous burns. To open the cooling system filler cap,
• Softness components are cool. Loosen the cooling system
• Loose clamps sure.
Replace hoses that are cracked or soft. Tighten any
loose clamps. 1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly

NOTICE in order to relieve any pressure. Remove the
Do not bend or strike high pressure lines. Do not in- cooling system filler cap.
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and Note: Drain the coolant into a suitable, clean
hoses. Leaks can cause fires. Inspect all lines, tubes container. The coolant can be reused.
and hoses carefully. Tighten all connections to the rec-
ommended torque. 3. Drain the coolant from the cooling system to
a level that is below the hose that is being
Check for the following conditions: replaced.
• End fittings that are damaged or leaking 4. Remove the hose clamps.
• Outer covering that is chafed or cut 5. Disconnect the old hose.
• Exposed wire that is used for reinforcement 6. Replace the old hose with a new hose.
• Outer covering that is ballooning locally Note: For torques on hose clamps, see this
Operation and Maintenance Manual, “Torque
• Flexible part of the hose that is kinked or crushed Specifications” (Maintenance Section).
• Armoring that is embedded in the outer covering 7. Install the hose clamps with a torque wrench.
A constant torque hose clamp can be used in Note: For the proper coolant to use, see this
place of any standard hose clamp. Ensure that the Operation and Maintenance Manual, “Coolant
constant torque hose clamp is the same size as Recommendations” (Maintenance Section).
the standard clamp.
8. Refill the cooling system.
Due to extreme temperature changes, the hose
will heat set. Heat setting causes hose clamps to 9. Clean the cooling system filler cap. Inspect the
loosen. This can result in leaks. A constant torque cooling system filler cap’s gaskets. Replace
hose clamp will help to prevent loose hose clamps. the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
109
Maintenance Section
Marine Transmission Oil Cooler - Clean/Inspect
10. Start the engine. Inspect the cooling system for i01546654
leaks.
Overhaul Considerations
i00916467 SMCS Code: 7595-043
Marine Transmission Oil Reduced hours of operation at full load will result
Cooler - Clean/Inspect in a lower average power demand. A decreased
average power demand should increase both the
SMCS Code: 3320-040; 3320-070 engine service life and the overhaul interval.
The procedure for cleaning the marine transmission The need for an overhaul is generally indicated by
oil cooler is the same procedure that is used for increased fuel consumption and by reduced power.
cleaning the aftercooler core. Refer to the Operation
and Maintenance Manual, “Aftercooler Core - The following factors are important when a decision
Clean/Test” topic (Maintenance Section). For more is being made on the proper time for an engine
information on servicing the marine transmission overhaul:
oil cooler, refer to the OEM recommendations or
consult your Caterpillar dealer. • The need for preventive maintenance
• The quality of the fuel that is being used
i01089872
Marine Transmission Oil Level • The operating conditions

- Check • The results of the S·O·S analysis
SMCS Code: 3081-535 Oil Consumption as an Overhaul
Check the marine transmission oil level according Indicator
to the instructions that are provided by the OEM of
the transmission or the OEM of the vessel. Oil consumption, fuel consumption, and
maintenance information can be used to estimate
For the lubrication requirements of the transmission, the total operating cost for your Caterpillar engine.
refer to the recommendations on the nameplate or Oil consumption can also be used to estimate
the “Owner’s Manual” for the transmission. the required capacity of a makeup oil tank that is
suitable for the maintenance intervals.
Marine Transmission Operation, Oil consumption is in proportion to the percentage
Maintenance, Warranty, and Parts of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
Support consumed per hour also increases.
For information on maintenance and operation of
The oil consumption rate (brake specific oil
the marine transmission, consult your Caterpillar consumption) is measured in grams per kW/h
dealer and/or the OEM dealer of the transmission.
(lb per bhp). The brake specific oil consumption
(BSOC) depends on the engine load. Consult your
All support for the warranty of the transmission will Caterpillar dealer for assistance in determining the
be the responsibility of the OEM. All parts support
typical oil consumption rate for your engine.
for the transmission will be the responsibility of
the OEM. This parts support includes both the When an engine’s oil consumption has risen to
installation of parts and the resolution of any service
three times the original oil consumption rate due
problems.
to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best

value for the following reasons:
110
Maintenance Section
• Costly unplanned downtime can be avoided. If the parts comply with the established inspection
specifications that are expressed in the reusable
• Many original parts can be reused according to parts guideline, the parts should be reused.
the standards for reusable parts.
Parts that are not within the established inspection
• The engine’s service life can be extended without specifications should be dealt with in one of the
the risk of a major catastrophe due to engine following manners:
failure.
• Salvaging
• The best cost/value relationship per hour of
extended life can be attained. • Repairing
After Failure Overhaul • Replacing
If a major engine failure occurs and the engine Using out-of-spec parts can result in the following
must be removed from the hull, many options are problems:
available. An overhaul should be performed if the
engine block or the crankshaft needs to be repaired. • Unscheduled downtime
If the engine block is repairable and/or the • Costly repairs
crankshaft is repairable, the overhaul cost should
be between 40 percent and 50 percent of the cost • Damage to other engine parts
of a new engine 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 recommends repairing
• Caterpillar remanufactured exchange components out-of-spec parts or replacing out-of-spec parts.
Overhaul Recommendation Inspection and/or Replacement
To minimize downtime, Caterpillar recommends Crankshaft Bearings, Crankshaft Seals, Thrust

a scheduled engine overhaul by your Caterpillar Bearings, Main Bearings, and Rod Bearings
dealer before the engine fails. This will provide you
with the best cost/value relationship. The following components may not last until the
second overhaul.
Note: Overhaul programs vary according to the
engine application and according to the dealer • Thrust bearings
that performs the overhaul. Consult your Caterpillar
dealer for specific information about the available • Main bearings
overhaul programs and about overhaul services for
extending the engine life. • Rod bearings
If an overhaul is performed without overhaul service • Crankshaft seals
from your Caterpillar dealer, be aware of the
following maintenance recommendations. Caterpillar recommends the installation of new parts
at each overhaul period.
Rebuild or Exchange
Inspect these parts while the engine is disassembled
for an overhaul.
Cylinder Head Assembly, Oil Pump, and Fuel
Transfer Pump
Inspect the crankshaft for any of the following
conditions:
These components should be inspected according
to the instructions that are found in various
Caterpillar reusability publications. The Special • Deflection
Publication, SEBF8029 lists the reusability
publications that are needed for inspecting the • Damage to the journals
engine parts.
111
Maintenance Section
• Bearing material that has seized to the journals 3. Flush the cores internally with cleaner in order to
loosen foreign substances. This will also help
Check the journal taper and the profile of the to remove oil from the oil cooler core and the
crankshaft journals. Check these components by aftercooler core.
interpreting the wear patterns on the following
components: Note: Caterpillar recommends the use of Hydrosolv
Liquid Cleaners. Table 39 lists the Hydrosolv Liquid
• Rod bearing Cleaners that are available from your Caterpillar
dealer.
• Main bearings
Table 39
Note: If the crankshaft is removed for any reason, Hydrosolv Liquid Cleaners(1)
use the magnetic particle inspection process to
check for cracks in the crankshaft. Part
Description Size
Number
Inspect the camshaft for damage to the journals 1U-5490 Hydrosolv 4165 19 L (5 US gallon)
and to the lobes.
174-6854 Hydrosolv 100 19 L (5 US gallon)
Note: If the camshaft is removed for any reason, use (1) Use a two to five percent concentration of the cleaner
the magnetic particle inspection process to check at temperatures up to 93 C (200 F). Refer to Application
for cracks in the camshaft. Guide, NEHS0526 or consult your Caterpillar dealer for more
information.
Inspect the following components for signs of wear

4. Use steam to clean the cores. This removes any
or for signs of scuffing:
remaining residue from the cleaner. Flush the fins
of each of the cores. Remove any other trapped
• Camshaft bearings debris.
• Camshaft followers 5. Wash the cores with hot, soapy water. Rinse the
cores thoroughly with clean water.
Caterpillar recommends replacing the crankshaft
vibration damper.
Oil Cooler Core, Aftercooler Core, and Heat

Exchanger Core Personal injury can result from air pressure.
During an overhaul, Caterpillar recommends the Personal injury can result without following prop-
removal of the oil cooler core, the aftercooler core, er procedure. When using pressure air, wear a pro-
and the heat exchanger. Clean the cores. Then, tective face shield and protective clothing.
pressure test the cores.
Maximum air pressure at the nozzle must be less
NOTICE than 205 kPa (30 psi) for cleaning purposes.
Do not use caustic cleaners to clean the core.
6. Dry the cores with compressed air. Direct the air
Caustic cleaners can attack the internal metals of the in the reverse direction of the normal flow.
core and cause leakage.
7. Inspect the components in order to ensure
Note: Use this cleaning procedure to clean the cleanliness. The oil cooler core, the aftercooler
oil cooler core, the aftercooler core, and the heat core, and the heat exchanger core should be
exchanger core. pressure tested. Repair cores, if necessary.
Install the oil cooler core, the aftercooler core,
1. Remove the oil cooler core, the aftercooler core, and the heat exchanger core.
and the heat exchanger core.
For more information about cleaning the cores,
2. Remove any debris from the cores. To remove consult your Caterpillar dealer.
debris from the oil cooler core, turn the oil cooler
core onto one end. To remove debris from
the aftercooler core, turn the aftercooler core
upside-down. To remove debris from the heat
exchanger core, turn the heat exchanger core
onto one end.
112
Maintenance Section
Sea Water Strainer - Clean/Inspect
Obtain Coolant Analysis i01509547
The concentration of supplemental coolant additive Sea Water Strainer -

(SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level I). Further
Clean/Inspect
coolant analysis is recommended when the engine SMCS Code: 1371-040; 1371-070
is overhauled.
S/N: CKS1-Up
For example, considerable deposits are found in the
water jacket areas on the external cooling system, The sea water strainer must be clean in order to
but the concentrations of coolant additives were allow proper engine cooling. Check the sea water
carefully maintained. The coolant water probably strainer for plugging. Inspect the sea water strainer
contained minerals that were deposited on the more frequently if the vessel is being operated
engine over time. in water which is shallow or dirty. The sea water
strainer protects the aftercooler from debris. The
A coolant analysis can be conducted in order sea water strainer will catch pieces of the rubber
to verify the condition of the water that is being impeller from the raw water pump due to a failure
used in the cooling system. A full water analysis from debris. The sea water strainer is installed on
can be obtained by consulting your local water turbocharged engines only.
utility company or an agricultural agent. Private
laboratories are also available for water analysis. Drain the Sea Water Cooling
Caterpillar recommends an S·O·S Coolant Analysis System
(Level II).
S·O·S Coolant Analysis (Level II)
1. Close the valve for the sea water.
An S·O·S Coolant Analysis (Level II) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level II)
provides the following information:
• Complete S·O·S Coolant Analysis (Level I)

• Visual inspection of properties
• Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
S·O·S Coolant Analysis (Level II) provides a report of

the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see g00751785

Illustration 70
your Caterpillar dealer.
2. Disconnect both hoses (2) from the sea water
pump (1).
113
Maintenance Section
Sea Water Strainer - Clean/Inspect
3. Install the sea water strainer (1). Install the hose

and the hose clamp (2). Fill the sea water strainer
and the suction line for the auxiliary water pump
with water.
Filling the Sea Water Cooling

System
g00751786
Illustration 71
3. Remove the drain plug (3) from the front cover

of the heat exchanger (4). Ensure that the drain
hole is not plugged.
4. Use the turning tool on the front of the crankshaft

in order to rotate the engine. This will ensure
that all of the water has drained from the sea
water pump.
g00751785
Illustration 73
Clean the Sea Water Strainer
1. Connect the hoses (2) at the sea water pump (1).
1. Ensure that the sea water cooling system is
drained. Refer to “Drain the Sea Water Cooling
System” for the procedure.
g00752040
Illustration 72
g00751786
Illustration 74
2. Remove the hose clamp (2) for the sea water
strainer. Remove the sea water strainer (1) and 2. Install the drain plug (3) in the front cover of the
clean the screen. Use clean water to clean the heat exchanger (4).
screen. Remove any dirt and debris.
114
Maintenance Section
Starting Motor - Inspect
3. Open the valve for the sea water. 4. Use the turning tool on the front of the crankshaft
to rotate the engine. This will ensure that all of
the water has drained from the sea water pump.
Sea Water Cooling System for
Naturally Aspirated Engines Fill
Naturally aspirated engines do not have a sea
water strainer. However, if the sea water cooling
system needs to be drained, then use the following
procedure:
Drain
1. Close the valve for the sea water.
g00751785
Illustration 77
1. Connect the hoses (2) at the sea water pump (1).
g00751785
Illustration 75
2. Disconnect both hoses (2) from the sea water

pump (1).
g00751788
Illustration 78
2. Install hose (4) for the marine gear oil cooler and
hose clamp (3).
3. Open the valve for the sea water.
i00651416
Illustration 76
g00751788 Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
3. Remove hose clamp (3) and hose (4) for the
marine gear oil cooler. Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
115
Maintenance Section
Turbocharger - Inspect
Check the starting motor for proper operation. Removal and Installation
Check the electrical connections and clean the
electrical connections. Refer to the Service Manual For options regarding the removal, installation,
for more information on the checking procedure and repair and replacement, consult your Caterpillar
for specifications or consult your Caterpillar dealer dealer. Refer to the Service Manual for this engine
for assistance. for the procedure and specifications.
i01539769 Cleaning and Inspecting

Turbocharger - Inspect 1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
SMCS Code: 1052-040 inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
Periodic inspection and cleaning is recommended from entering during reassembly.
for the turbocharger compressor housing (inlet
side). Any fumes from the crankcase are filtered 2. Turn the compressor wheel and the turbine
through the air inlet system. Therefore, by-products wheel by hand. The assembly should turn freely.
from oil and from combustion can collect in the Inspect the compressor wheel and the turbine
turbocharger compressor housing. Over time, this wheel for contact with the turbocharger housing.
buildup can contribute to loss of engine power, There should not be any visible signs of contact
increased black smoke and overall loss of engine between the turbine wheel or compressor
efficiency. wheel and the turbocharger housing. If there is
any indication of contact between the rotating
If the turbocharger fails during engine operation, turbine wheel or the compressor wheel and the
damage to the turbocharger compressor wheel turbocharger housing, the turbocharger must be
and/or to the engine may occur. Damage to reconditioned.
the turbocharger compressor wheel can cause
additional damage to the pistons, the valves, and 3. Check the compressor wheel for cleanliness.
the cylinder head. If only the blade side of the wheel is dirty,
dirt and/or moisture is passing through the air
NOTICE filtering system. If oil is found only on the back
Turbocharger bearing failures can cause large quan- side of the wheel, there is a possibility of a failed
tities of oil to enter the air inlet and exhaust systems. turbocharger oil seal.
Loss of engine lubricant can result in serious engine
damage. The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
Minor leakage of a turbocharger housing under ex- may also be the result of a restriction of the line
tended low idle operation should not cause problems for the inlet air (plugged air filters), which causes
as long as a turbocharger bearing failure has not oc- the turbocharger to slobber.
curred.
4. Use a dial indicator to check the end clearance
When a turbocharger bearing failure is accompanied on the shaft. If the measured end play is greater
by a significant engine performance loss (exhaust than the Service Manual specifications, the
smoke or engine rpm up at no load), do not continue turbocharger should be repaired or replaced.
engine operation until the turbocharger is repaired or An end play measurement that is less than the
replaced. minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel.
The turbocharger should be disassembled for
An inspection of the turbocharger can minimize cleaning and for inspection if the measured end
unscheduled downtime. An inspection of the play is less than the minimum Service Manual
turbocharger can also reduce the chance for specifications.
potential damage to other engine parts.
5. Inspect the bore of the turbine housing for
Note: Turbocharger components require precision corrosion.
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service 6. Clean the turbocharger housing with standard
Applications can accelerate component wear. shop solvents and a soft bristle brush.
Severe Service Applications require more frequent
inspections of the cartridge. 7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
116
Maintenance Section
Walk-Around Inspection
i00893389 Excessive coolant leakage may indicate the need

to replace the water pump seal. For the removal of
Walk-Around Inspection water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
SMCS Code: 1000-040 engine or consult your Caterpillar dealer.
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.
NOTICE • Disconnect any battery chargers that are not

protected against the current drain of the starting
Accumulated grease and/or oil on an engine or deck is
motor. Check the condition and the electrolyte
a fire hazard. Remove this debris with steam cleaning
level of the batteries, unless the engine is
or high pressure water.
equipped with a maintenance free battery.
• 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.
• Check the marine transmission oil level. Refer to i01057943

the OEM specification for the marine transmission
or refer to the OEM specification for the vessel. Water Pump - Inspect
• Inspect the water pumps for coolant leaks. SMCS Code: 1361-040; 1361
Note: The water pump seal is lubricated by coolant A failed water pump might cause severe engine
in the cooling system. It is normal for a small amount overheating problems that could result in the
of leakage to occur as the engine cools down and following conditions:
the parts contract.
• Cracks in the cylinder head
• A piston seizure
117
Maintenance Section
Water Pump - Inspect
• Other potential damage to the engine

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.

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SAFETY.CAT.

3054, 3054B and 3056

Excerpted from Operation & Maintenance Manual (SEBU7423-02-01)

i01579850 Engine Mounts - Inspect ....................................... 99

Every 1875 L (500 US gal) of Fuel or 250

Every 3750 L (1000 US gal) of Fuel or 500

i01547565 Engine Oil Sample - Obtain ................................ 100

S/N: CYK1-Up Every 9400 L (2500 US gal) of Fuel or 1000

Every 2350 L (625 US gal) of Fuel or 250

Every 4700 L (1250 US gal) of Fuel or 500

i01547566 Heat Exchanger - Inspect ................................... 107

Every 5700 L (1500 US gal) of Fuel or 400

i01547567 Engine Oil and Filter - Change ........................... 100

Every 4700 L (1250 US gal) of Fuel or 400

i01546702 7. Inspect the core in order to ensure cleanliness.

NOTICE Alternator - Inspect

4. Steam clean the core in order to remove any

5. Wash the core with hot, soapy water. Rinse the

Personal injury can result from air pressure.

Personal injury can result without following prop-

Maximum air pressure at the nozzle must be less

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

i01431888 If new belts are installed, check the belt adjustment

Auxiliary Water Pump (Rubber

Impellers and seals require periodic inspection.

Inspect the components more frequently when the

2. Loosen mounting bolts (1) and adjusting bolt (2).

3. Slide the alternator in the direction that will give

4. Tighten adjusting bolt (2). Tighten mounting bolts

5. Reinstall the belt guard.

i01505178 8. Connect the cable from the NEGATIVE “- VE”

Battery Electrolyte Level -

All lead-acid batteries contain sulfuric acid which

Note: Always recycle a battery. Never discard a

Note: Inspect the water pump and the water

3. Tape the leads in order to help prevent accidental

4. Proceed with necessary system repairs. Reverse

Cooling System Coolant

SMCS Code: 1350-070; 1395-044 Typical example

• The fuel has entered the cooling system and the

For information regarding the disposal and the

Outside Illinois: 1-800-542-8665

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

4. Start and run the engine at low idle for a minimum

Note: Inspect the water pump and the water

Pressurized System: Hot coolant can cause seri-

g00740076 For information regarding the disposal and the

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

3. Add coolant/antifreeze into the cooling system

4. Clean the cooling system filler cap. Inspect

Cooling System Coolant (ELC)

3054 and 3054B Marine Engines

Note: Inspect the water pump and the water

Pressurized System: Hot coolant can cause seri-

3. Fill the cooling system with clean water. Install

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

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

2. Open the cooling system drain valve (if Fill

3. Add the ELC into the cooling system until the

3056 Marine Engine

Note: Inspect the water pump and the water

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