3412 Cat Engine

(1)

®

MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

(2)

December 2005

Operation and

Maintenance

Manual

3408C, 3412, 3412C and 3412D High

Performance Marine Engines

REA1-Up (Engine) 8RG1-Up (Engine) 3JK1-Up (Engine) 7BL1-Up (Engine)

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Maintenance Interval Schedule

i02469150

Maintenance Interval Schedule

SMCS Code: 1000; 7500 S/N: 8RG1-Up

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance.

Note: Before each consecutive interval is performed,

all maintenance from the previous interval must be performed.

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

The operating conditions may cause the following maintenance items to be performed at a ““When Required”” maintenance interval: “Aftercooler Core - Clean/Test”, “Heat Exchanger - Inspect”, “Seawater Strainer - Clean/Inspect”, and “Zinc Rods Inspect/Replace” . Refer to these sections in this Operation and Maintenance Manual in order to determine if these maintenance items need to be performed at the service hour interval listed in the Maintenance Interval Schedule or at the “When Required” interval.

When Required

Aftercooler Core - Clean/Test ... 79

Battery - Recycle ... 80

Battery or Battery Cable - Disconnect ... 81

Fuel System - Prime ... 100

Heat Exchanger - Inspect ... 103

Sea Water Strainer - Clean/Inspect ... 110

Zinc Rods - Inspect/Replace ... 113

Daily

Cooling System Coolant Level - Check ... 86

Engine Air Cleaner Service Indicator - Inspect ... 94

Engine Oil Level - Check ... 96

Marine Transmission Oil Level - Check ... 107

Walk-Around Inspection ... 111

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ... 87

Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)

Every Year

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 86

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ... 84

Every 3800 L (1000 US gal) of Fuel or 50

Service Hours

First 12 750 L (3375 US gal) of Fuel or 250

Service Hours

Engine Valve Lash - Inspect/Adjust ... 98

Every 12 750 L (3375 US gal) of Fuel or 250

Service Hours or Yearly

Alternator Belt - Inspect/Adjust/Replace ... 79

Battery Electrolyte Level - Check ... 81

Cooling System Supplemental Coolant Additive (SCA) - Test/Add ... 88

Engine Air Cleaner Element - Clean/Replace ... 90

Engine Crankcase Breather - Clean ... 95

Engine Oil Sample - Obtain ... 96

Engine Oil and Filter - Change ... 97

Fuel System Primary Filter - Clean/Replace ... 101

Fuel System Secondary Filter - Replace ... 102

Fuel Tank Water and Sediment - Drain ... 103

Hoses and Clamps - Inspect/Replace ... 106

Every 76 000 L (20 000 US gal) of Fuel or

1000 Service Hours

(4)

Every 76 500 L (20 250 US gal) of Fuel or

1500 Service Hours

Engine Speed/Timing Sensors - Check/Clean/ Calibrate ... 98

Engine Valve Rotators - Inspect ... 99

Every 153 500 L (40 500 US gal) of Fuel or

3000 Service Hours

Alternator - Inspect ... 79

Auxiliary Water Pump - Inspect ... 80

Cooling System Coolant (DEAC) - Change ... 81

Cooling System Water Temperature Regulator -Replace ... 90

Crankshaft Vibration Damper - Inspect ... 90

Engine Mounts - Inspect ... 95

Fuel Injection Nozzles - Test/Exchange ... 99

Starting Motor - Inspect ... 110

Turbocharger - Inspect ... 110

Water Pump - Inspect ... 112

Every 570 000 L (150 000 US gal) of Fuel or

10 000 Service Hours

Overhaul Considerations ... 107

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i02469128

Maintenance Interval Schedule

SMCS Code: 1000; 7500 S/N: REA1-Up

S/N: 3JK1-Up S/N: 7BL1-Up

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance.

Note: Before each consecutive interval is performed,

all maintenance from the previous interval must be performed.

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

The operating conditions may cause the following maintenance items to be performed at a ““When Required”” maintenance interval: “Aftercooler Core - Clean/Test”, “Heat Exchanger - Inspect”, “Seawater Strainer - Clean/Inspect”, and “Zinc Rods Inspect/Replace” . Refer to these sections in this Operation and Maintenance Manual in order to determine if these maintenance items need to be performed at the service hour interval listed in the Maintenance Interval Schedule or at the “When Required” interval.

When Required

Battery - Recycle ... 80

Battery or Battery Cable - Disconnect ... 81

Fuel System - Prime ... 100

Daily

Cooling System Coolant Level - Check ... 86

Engine Air Cleaner Service Indicator - Inspect ... 94

Engine Oil Level - Check ... 96

Marine Transmission Oil Level - Check ... 107

Walk-Around Inspection ... 111

Every 250 Service Hours

Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)

Every Year

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 86

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ... 84

Every 3800 L (1000 US gal) of Fuel or 50

Service Hours

Every 12 750 L (3375 US gal) of Fuel or 250

Service Hours or Yearly

First 19 000 L (5000 US gal) of Fuel or 250

Service Hours

Every 19 000 L (5000 US gal) of Fuel or 250

Service Hours or Yearly

Alternator Belt - Inspect/Adjust/Replace ... 79

Cooling System Supplemental Coolant Additive (SCA) - Test/Add ... 88

Engine Air Cleaner Element - Clean/Replace ... 90

Engine Crankcase Breather - Clean ... 95

Engine Oil Sample - Obtain ... 96

Engine Oil and Filter - Change ... 97

Fuel System Primary Filter - Clean/Replace ... 101

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Fuel Tank Water and Sediment - Drain ... 103

Hoses and Clamps - Inspect/Replace ... 106

Every 76 000 L (20 000 US gal) of Fuel or

1000 Service Hours

Every 114 000 L (30 000 US gal) of Fuel or

1500 Service Hours

Engine Speed/Timing Sensors - Check/Clean/ Calibrate ... 98

Engine Valve Rotators - Inspect ... 99

Every 228 000 L (60 000 US gal) of Fuel or

3000 Service Hours

Alternator - Inspect ... 79

Auxiliary Water Pump - Inspect ... 80

Cooling System Coolant (DEAC) - Change ... 81

Cooling System Water Temperature Regulator -Replace ... 90

Crankshaft Vibration Damper - Inspect ... 90

Engine Mounts - Inspect ... 95

Fuel Injection Nozzles - Test/Exchange ... 99

Starting Motor - Inspect ... 110

Turbocharger - Inspect ... 110

Water Pump - Inspect ... 112

Every 760 000 L (200 000 US gal) of Fuel or

10 000 Service Hours

Overhaul Considerations ... 107

(7)

Aftercooler Core - Clean/Test

i02475204

Aftercooler Core - Clean/Test

SMCS Code: 1064-070; 1064-081

1. Remove the core. Refer to the Service Manual

for the procedure.

2. Turn the aftercooler core upside-down in order

to remove debris.

NOTICE

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

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 32 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer.

Table 32

Hydrosolv Liquid Cleaners(1)

Description Container

1U-5490 Hydrosolv 4165 19 L (5 US gal) 174-6854 Hydrosolv 100 19 L (5 US gal)

(1) _{Use a two to five percent concentration of the cleaner at}

temperatures up to 93°C (200°F). Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer for more 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 propro-tective 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.

7. Inspect the core in order to ensure cleanliness.

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

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

the procedure.

For more information on cleaning the core, consult your Caterpillar dealer.

i00072207

Alternator - Inspect

SMCS Code: 1405-040

Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required. Refer to the Service Manual. Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge.

i00664822

Alternator Belt

-Inspect/Adjust/Replace

SMCS Code: 1357-036; 1357-510

Inspection

To maximize the engine performance, inspect the belt for wear and for cracking. Check the belt tension. Adjust the belt tension in order to minimize belt slippage. Belt slippage will decrease the life of the belt.

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

(8)

Auxiliary Water Pump - Inspect

Adjustment

g00122875

Illustration 28

(1) Typical Adjusting Nuts. (2) Mounting Bolt.

1. Remove the belt guard.

2. Loosen mounting bolt (2) and adjusting nuts (1). 3. Turn adjusting nuts (1) in order to increase or

decrease the belt tension.

4. Tighten adjusting nuts (1). Tighten mounting bolt

(2). Refer to the Operation and Maintenance Manual for the proper torques.

5. Reinstall the belt guard.

If new alternator belts are installed, check the belt adjustment again after 30 minutes of engine operation at the rated rpm.

Replacement

For applications that require multiple drive belts, replace these belts in matched sets. Replacing only one alternator 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 alternator belt could cause the new belt to break. Refer to the Service Manual for more information on the procedures for the following topics:

•

Removal of an alternator belt

•

Installation of an alternator belt

i01059376

Auxiliary Water Pump - Inspect

SMCS Code: 1371-040

Impellers require periodic inspection and seals require periodic inspection. Impellers have a service life that is limited. The service life depends on the engine operating conditions.

Inspect the components of the pump 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 103 kPa (15 psi).

Check the following components for wear and check the following components for damage:

•

Cam

•

Impeller

•

Seals

•

Wear plate

If wear is found or if damage is found, replace the components which are worn or replace the components which are damaged. Use the proper repair kit for the pump. Refer to the Disassembly and Assembly for more information on servicing the auxiliary water pump.

i00993589

Battery - Recycle

SMCS Code: 1401-561

Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:

•

A battery supplier

•

An authorized battery collection facility

•

Recycling facility

(9)

Battery Electrolyte Level - Check

i02340858

Battery Electrolyte Level

-Check

SMCS Code: 1401-535

When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are properly charged, ammeter reading should be very near zero, when the engine is in operation.

All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water.

2. Check the condition of the electrolyte with the

245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the following cleaning solutions:

•

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

•

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

Thoroughly rinse the battery case with clean water. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit properly. Coat the clamps and the terminals with5N-5561 Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable

-Disconnect

SMCS Code: 1402-029

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

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

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

ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.

2. Disconnect the negative battery terminal at the

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

3. Tape the leads in order to help prevent accidental

starting.

4. Proceed with necessary system repairs. Reverse

the steps in order to reconnect all of the cables.

i00640375

Cooling System Coolant

(DEAC) - Change

SMCS Code: 1350-070; 1395-044

Flush the cooling system and clean the cooling system before the recommended maintenance interval if the following conditions exist:

•

Coolant is dirty.

•

Coolant is heavily contaminated by oil.

•

Coolant is heavily contaminated by fuel.

•

The engine overheats frequently.

•

Foaming is observed.

(10)

Cooling System Coolant (DEAC) - Change

NOTICE

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

Note: Inspect the water pump and the water

temperature regulator after the cooling system has been drained. This is a good opportunity to replace any of the following items, if a replacement is needed: the water pump, the water temperature regulator, and the hoses.

Drain

1. Stop the engine and allow the engine to cool. 2. Take extreme care to loosen the cooling system

filler cap slowly so you can relieve any pressure. Carefully remove the cooling system filler cap.

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

If the cooling system is not equipped with a drain valve, remove the following cooling system drain plugs:

•

Drain plug for water temperature regulator

•

Drain plug for oil cooler

4. Allow the coolant to drain.

NOTICE

Dispose of used engine coolant properly or recycle. 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 Caterpillar to reclaim the used coolant.

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-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain valve (if equipped). If the cooling

system is not equipped with a drain valve, clean the drain plugs and the drain plug fittings. Reinstall these drain plugs:

•

drain plug for water temperature regulator

•

drain plug for oil cooler

Note: Refer to the Operation and Maintenance

Manual, “Torque Specifications” for more information on the proper torques.

NOTICE

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

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Reinstall cooling system filler cap (3).

4. Now, run the engine at low idle for a minimum

of 30 minutes. Make sure that the coolant temperature remains at a minimum temperature of 82°C (180°F).

5. Stop the engine and allow the engine to cool. 6. Loosen the cooling system filler cap slowly.

This relieves the pressure from the system. Remove cooling system filler cap.

7. Open the drain valve (if equipped), or remove the

following cooling system drain plugs:

•

8. Allow the mixture of both the water and the cleaner

to drain.

9. Flush the cooling system with clean water until the

draining water is clean.

•

(11)

Cooling System Coolant (DEAC) - Change

Cooling Systems with Heavy

Deposits or Plugging

Note: For the following procedure to be effective,

there must be some active flow through the cooling system components.

•

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Reinstall cooling system filler cap.

4. Now, run the engine at low idle for a minimum of 90

minutes. Make sure that the coolant temperature remains at a temperature of at least 82°C (180°F).

5. Stop the engine and allow the engine to cool. 6. Loosen cooling system filler cap slowly in order

to relieve any pressure. Remove cooling system filler cap .

7. Open the drain valve (if equipped). If the cooling

system is not equipped with a drain valve, remove the following cooling system drain plugs:

•

8. Allow the mixture of both the water and the cleaner

to drain. Flush the cooling system with clean water until the draining water is transparent.

system is not equipped with a drain valve, clean the cooling system drain plugs and the drain plug fittings.

Reinstall these drain plugs:

•

• Engines That Are Equipped with a

Coolant Recovery Tank

Manual (Maintenance Section) for more information on cooling system specifications.

1. Fill the system with the mixture of

coolant/antifreeze that is recommended.

2. Reinstall recovery tank’s filler cap.

3. Place the marine transmission into the NEUTRAL

position.

4. Now, run the engine at low idle. Increase the

engine rpm to 1500 rpm. Run the engine at this rate for one minute in order to purge the air from the cavities of the engine block. Stop the engine.

5. Remove recovery tank’s filler cap.

6. Pour coolant/antifreeze into the tank until the

coolant reaches the “COLD FULL” mark. Do not fill the tank above the “COLD FULL” mark.

7. Clean the recovery tank’s filler cap, and then

reinstall this filler cap.

8. Start the engine. Inspect the cooling system for

leaks and for proper operating temperature.

Engines That Are Not Equipped with a

Coolant Recovery Tank

1. Fill the system with coolant/antifreeze. Do not

install the cooling system filler cap.

position.

3. Run the engine at low idle. Increase the engine

rpm to 1500 rpm. Run the engine at this rate for one minute in order to purge the air from the cavities of the engine block. Stop the engine.

4. Check the coolant level. Maintain the coolant level

within 13 mm (.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within 13 mm (.5 inch) to the proper level on the sight glass (if equipped).

(12)

Cooling System Coolant (ELC) - Change

5. Clean cooling system’s filler cap . Also clean the

receptacle for this filler cap, and inspect the filler cap gasket.

•

If the filler cap gasket is damaged, discard the old cooling system filler cap and install a new cooling system filler cap.

•

If the filler cap gasket is not damaged, use a 9S-8140 Pressurized Pump Group to pressure test the cooling system filler cap.

•

If the cooling system filler cap does not maintain the correct pressure, install a new cooling system filler cap.

Note: The correct pressure for the cooling system

filler cap is stamped on the filler cap’s face .

6. Reinstall filler cap.

7. Start the engine. Inspect the cooling system for

leaks and for proper operating temperature.

i00670148

Cooling System Coolant (ELC)

- Change

SMCS Code: 1350-070; 1395-044

Flush the cooling system and clean the cooling system before the recommended maintenance interval under the following conditions:

•

The coolant is dirty.

•

The coolant is heavily contaminated by oil.

•

The coolant is heavily contaminated by fuel.

•

The engine overheats frequently.

•

Foaming is observed.

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

NOTICE

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

Note: Inspect the water pump and the water

temperature regulator after the cooling system has been drained. This is a good opportunity to replace any of the following items, if a replacement is needed: the water pump, the water temperature regulator, and the hoses.

Drain

1. Stop the engine and allow the engine to cool. 2. Take extreme care to slowly loosen the coolant

system’s filler cap. This relieves the pressure

from the cooling system. Remove this filler cap.

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

If the cooling system is not equipped with a drain valve, remove the cooling system drain plugs:

•

Drain plug from the bottom of the water cooled

exhaust manifold

•

Drain plug for the water temperature regulator

•

Drain plug for the aftercooler

•

Drain plug for the oil cooler

4. Allow the coolant to drain.

NOTICE

Dispose of used engine coolant properly or recycle. 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 Caterpillar to reclaim the used coolant.

For information regarding both the disposal of used coolant and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Service Technology Group:

Outside of Illinois: 1-800-542-TOOL Inside of Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL

Flush

system is not equipped with a drain valve, clean the drain plugs:

•

drain plug for oil cooler

(13)

Cooling System Coolant (ELC) - Change

Manual (Maintenance Section), “Torque

Specifications” for more information on the proper torques.

Reinstall both drain plugs.

3. Fill the cooling system with clean water, and

reinstall the coolant filler cap.

4. Operate the engine until the temperature reaches

49 to 66°C (120 to 150°F).

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

Open the drain valve (if equipped), or remove the cooling system drain plugs:

•

Drain plug on the bottom of the water cooled exhaust manifold

•

Drain plug for the water temperature regulator

•

Drain plug for the aftercooler

•

Drain plug for the oil cooler

6. Allow the water to drain.

7. Take extra care to loosen the coolant filler cap slowly. This helps to relieve the cooling system’s

pressure. Remove the coolant filler cap.

8. Flush the cooling system with clean water. 9. Repeat step 2 through step 5.

Fill

Engines That Are Equipped with a

Coolant Recovery Tank

1. Fill the expansion tank with ELC. Fill the expansion

tank to the top . Refer to the Operation and Maintenance Manual (Maintenance Section), “Cooling System Specifications” for more information on cooling system specifications.

2. Reinstall the filler cap for the recovery tank. 3. Place the marine transmission into the NEUTRAL

position. Run the engine at low idle.

4. Increase the engine rpm to 1500 rpm. Run the

engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Then, stop the engine.

5. Slowly loosen the filler cap for the recovery tank

in order to relieve any pressure. Remove the filler cap for the recovery tank.

6. Pour ELC into the tank until the coolant reaches

the “COLD FULL” mark. DO NOT fill the tank above the “COLD FULL” mark.

7. Clean the filler cap for the recovery tank. Then,

reinstall this filler cap.

8. Start the engine. Inspect the coolant recovery

tank for both coolant leaks and proper operating temperature.

Engines That Are Not Equipped with a

Coolant Recovery Tank

1. Fill the expansion tank with ELC. Do not reinstall

the cooling system filler cap.

position. Run the engine at low idle.

3. Increase the engine rpm to 1500 rpm. Run the

engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Then, stop the engine.

4. Check the coolant level. Maintain the coolant level

within 13 mm (.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within 13 mm (.5 inch) to the proper level on the sight glass (if equipped).

5. Clean the coolant filler cap, and check the

expansion tank’s filler cap gasket:

•

If the gasket is damaged, discard the old coolant filler cap and install a new cooling system filler cap.

•

If the gasket is not damaged, use a9S-8140 Pressurized Pump Group to pressure test the cooling system filler cap. The correct filler cap pressure for the expansion tank is stamped on the face of the coolant filler cap.

•

If the coolant filler cap does not retain the correct pressure, install a new filler cap.

6. Start the engine. Inspect the expansion tank

for both coolant leaks and proper operating temperature.

(14)

Cooling System Coolant Extender (ELC) - Add

i00670616

Cooling System Coolant

Extender (ELC) - Add

SMCS Code: 1352-045; 1395-081

Caterpillar Extended Life Coolant (ELC) does not require frequent additions of Supplemental Coolant Additive (SCA). Only add any SCA after an addition is determined from the results with an SCA test kit. Check the cooling system after the engine is stopped and after the engine is cool.

1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling system filler cap.

2. Drain enough coolant from the cooling system in

order to allow enough room for the addition of this Extender.

3. Add Extender according to the requirements for

your engine’s cooling system capacity.

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 the Caterpillar ELC Extender additions.

4. Clean the cooling system filler cap, and inspect

the cooling system filler cap’s gaskets. Replace the cooling system filler cap if these gaskets are damaged.

5. Reinstall the cooling system filler cap.

Replace the SCA Element (If

Equipped)

g00292998

Illustration 29

(1) Inlet valve. (2) Outlet valve. (3) SCA element.

1. Close inlet valve (1) for the SCA maintenance

element, and close the outlet valve (2) as well.

2. Remove the SCA element (3). Remember to

properly discard the SCA element.

3. Clean the SCA element’s mounting base, and

make sure that the old gasket is removed.

4. Coat the gasket for the new SCA element (3) with

coolant.

Note: Refer to Operation and Maintenance, “Cooling

System Specifications” for the proper SCA element for your system.

5. Place the element into position. Tighten the SCA

element until the seal contacts the base. Tighten the SCA element (3) by another three quarters of a turn by hand. Do not overtighten the SCA element.

6. Open inlet valve (1) and open outlet valve (2). 7. Remove the cooling system filler cap, and start

the engine in order to check for leaks. Allow the coolant level to stabilize.

8. Add the necessary amount of coolant/water

mixture in order to increase the coolant level to the proper level. The proper level for the coolant/water mixture is an amount that is at 13 mm (0.5 inch) below the bottom of the pipe. If equipped, use a sight glass to make sure that an appropriate amount of coolant/water mixture is added.

9. Clean the cooling system filler cap, and inspect

the filler cap’s gaskets. Replace any damaged gasket. Also, clean the receptacle for the cooling system filler cap. Finally, install the cooling system filler cap.

i02456586

Cooling System Coolant Level

- Check

SMCS Code: 1395-082

Check the coolant level when the engine is stopped and cool.

(15)

Cooling System Coolant Sample (Level 1) - Obtain

Engines That Are Equipped with a

Coolant Recovery Tank

g00103638

Illustration 30 (1) Filler cap

(2) “COLD FULL” mark (3) “LOW ADD” mark

1. Observe the coolant level in the coolant recovery

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

2. Loosen filler cap (1) slowly in order to relieve any

pressure. Remove the filler cap.

3. Pour the proper coolant mixture into the tank.

Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” for information about coolants. Do not fill the coolant recovery tank above “COLD FULL” mark (2).

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

the filler cap and inspect the cooling system for leaks.

Note: The coolant will expand as the coolant heats

up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool, the coolant will return to the engine.

Engines That Are Not Equipped

with a Coolant Recovery Tank

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

1. Remove the cooling system filler cap slowly in

order to relieve pressure.

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

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

g00103639

Illustration 31

Typical filler cap gaskets

3. Clean the cooling system filler cap and inspect

the condition of the filler cap gaskets. Replace the cooling system filler cap if the filler cap gaskets are damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i02326688

Cooling System Coolant

Sample (Level 1) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling system is filled with Cat ELC (Extended Life Coolant). Cooling systems that

are filled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant instead of Cat ELC. This includes the following

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Cooling System Coolant Sample (Level 2) - Obtain

Table 33

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC Every 250_Hours₍₁₎ Yearly(1)(2)

Cat ELC Optional(2) _Yearly(2) (1) _{This is the recommended interval for coolant samples for all}

conventional heavy-duty coolant/antifreeze. This is also the recommended interval for coolant samples of commercial coolants that meet the Cat EC-1 specification for engine coolant.

(2) _{The Level 2 Coolant Analysis should be performed sooner if a}

problem is suspected or identified.

•

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

•

Cat DEAC (Diesel Engine Antifreeze/Coolant)

•

Commercial heavy-duty coolant/antifreeze

NOTICE

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

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

Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer.

Use the following guidelines for proper sampling of the coolant:

•

Complete the information on the label for the sampling bottle before you begin to take the samples.

•

Keep the unused sampling bottles stored in plastic bags.

•

Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.

•

Keep the lids on empty sampling bottles until you are ready to collect the sample.

•

Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.

•

Never collect samples from expansion bottles.

•

Never collect samples from the drain for a system. Submit the sample for Level 1 analysis.

For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” or consult your Caterpillar dealer.

i01987714

Cooling System Coolant

Sample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

NOTICE

Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis.

For additional information about coolant analysis, see Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids Recommendations” or consult your Caterpillar dealer.

i02456600

Cooling System Supplemental

Coolant Additive (SCA)

-Test/Add

SMCS Code: 1352-045; 1395-081

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

(17)

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Note: Test the concentration of the Supplemental

Coolant Additive (SCA) or test the SCA concentration as part of an S·O·S Coolant Analysis.

Test for SCA Concentration

Coolant and SCA

NOTICE

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

Use the8T-5296 Coolant Conditioner Test Kit or use the4C-9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA. Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” for more information.

Water and SCA

NOTICE

Do not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the8T-5296 Coolant Conditioner Test Kit. Refer to the Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for more information.

S·O·S Coolant Analysis

S·O·S coolant samples can be analyzed at your Caterpillar dealer. S·O·S Coolant Analysis is a program that is based on periodic samples.

Level 1

Level 1 is a basic analysis of the coolant. The following items are tested:

•

Glycol Concentration

•

Concentration of SCA

•

pH

•

Conductivity

The results are reported, and recommendations are made according to the results. Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S·O·S Coolant Analysis.

Level 2

This level coolant analysis is recommended when the engine is overhauled. Refer to this Operations and Maintenance Manual, “Overhaul Considerations” for further information.

Add the SCA, If Necessary

NOTICE

Do not exceed the recommended amount of sup-plemental coolant additive concentration. Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine’s heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temper-ature components. Excessive supplemental coolant additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal wear. Never use both liquid supplemental coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could result in supplemental coolant additive concen-tration exceeding the recommended maximum.

Pressurized System: Hot coolant can cause seri-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 pressure cap slowly in order to relieve the pres-sure.

1. Slowly loosen the cooling system filler cap in

order to relieve the pressure. Remove the cooling system filler cap.

Note: Always discard drained fluids according to

local regulations.

2. If necessary, drain some coolant from the cooling

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

3. Add the proper amount of SCA. Refer

to the Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids Recommendations” for more information on SCA requirements.

4. Clean the cooling system filler cap. Inspect the

gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling system filler cap with a new cooling system filler cap. Install the cooling system filler cap.

(18)

Cooling System Water Temperature Regulator - Replace

i00912898

Cooling System Water

Temperature Regulator

-Replace

SMCS Code: 1355-510

Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice. Replacing the water temperature regulator reduces the chances for unscheduled downtime.

A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine.

A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in cracking of the cylinder head or piston seizure problems.

A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner.

NOTICE

Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage.

Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed.

If the water temperature regulator is installed incor-rectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure that the water temperature regulator vent hole is open. Do not use liquid gasket material on the gasket or cylinder head surface.

Refer to the Service Manual for the replacement procedure of the water temperature regulator, or consult your Caterpillar dealer.

Note: If only the water temperature regulators are

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

i00072369

Crankshaft Vibration Damper

- Inspect

SMCS Code: 1205-040

Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. This can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range.

The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine.

Removal and Installation

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

Visconic Damper

The visconic damper has a weight that is located inside a fluid filled case. The weight moves in the case in order to limit torsional vibration. Inspect the damper for evidence of dents, cracks or leaks of the fluid.

Replace the damper if the damper is dented, cracked or leaking. Refer to the Service Manual or consult your Caterpillar dealer for damper replacement.

i01083053

Engine Air Cleaner Element

-Clean/Replace

SMCS Code: 1054-070; 1054-510

AIRSEP®

NOTICE

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

NOTICE

Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

(19)

Engine Air Cleaner Element - Clean/Replace

Note: Use the102-9720 Cleaning Kit. This product contains the detergent and oil that is made specifically for the maintenance of the AIRSEP® elements.

1. Remove the vacuum limiter element and the

AIRSEP® element.

2. Cover the air inlet opening with a clean cloth, or

seal with tape in order to prevent dirt and debris from entering the engine.

3. Tap the element in order to dislodge dirt particles.

Gently brush the element with a soft bristle brush. NOTICE

Do not use gasoline, steam, caustic or unapproved detergents, or parts cleaning solvents. Do not use high pressure water or air to clean the air cleaner element. Any of those liquids or methods can cause air cleaner element damage.

4. Spray the element with the cleaning solution.

Allow the element to stand for 20 minutes.

5. Rinse the 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 element from the clean side (inside). Next, clean the dirty side (outside) in order to flush out dirt. Inspect the element for tears and/or holes after the element is cleaned. Do not reuse damaged elements.

NOTICE

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

6. Shake excess water off the element, and allow

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

NOTICE

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

7. The dry element should be oiled before installation.

Apply small amounts of oil across the top of each pleat. Allow the oil to soak into the element for 20 minutes. Oil any remaining “white” spots.

8. Inspect the housing and the clamp for the element.

Replace the housing and the clamp, if necessary.

9. Remove the seal from the air inlet opening.

Install the clean, oiled element. Refer to the Specifications Manual for your particular engine for more specific information on the proper torques. Refer to the Specifications, SENR3130, “Torque Specifications” for more general information on the proper torques.

Paper Air Cleaner Element

NOTICE

Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

1. Remove the cover. Remove the element. 2. Cover the air inlet opening with a clean cloth, or

seal with tape in order to prevent dirt from entering the engine.

3. Clean the inside of the air cleaner cover and body

with a clean, dry cloth.

4. Clean the element and inspect the element.

Replace the element, if necessary. Refer to “Cleaning Paper Air Cleaner Elements”.

5. Remove the seal from the air inlet opening. Install

an element that is new or cleaned.

Cleaning Paper Air Cleaner Elements

The element can be used up to six times if the element is properly cleaned and inspected. When the element is cleaned, check for rips or tears in the filter material. The element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. Use clean elements while dirty elements are being cleaned.

NOTICE

Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Engine damage could result.

(20)

Visually inspect the element before cleaning. Inspect the element for damage to the seal, the gaskets, and the outer cover. Discard any damaged elements. There are four common methods that are used to clean elements:

•

Pressurized water

•

Pressurized air

•

Vacuum cleaning

•

Washing with nonsudsing detergent

Pressurized Water

Pressurized water will clean the element unless carbon and oil have accumulated on the surface of the element. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Do not use a spray nozzle.

Note: When the element is cleaned, always begin

with the clean side (inside) in order to force dirt particles toward the dirty side (outside).

Aim the hose so that the water flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Do not aim the stream of water directly at the element. Dirt could be forced further into the pleats.

Note: Refer to “Drying the Paper Air Cleaner

Elements”. Refer to “Inspecting the Paper Air Cleaner Elements”.

Pressurized Air

Pressurized air can be used to clean elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi).

g00281692

Illustration 32

Note: When the paper air cleaner elements are

cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside).

Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the element. Dirt could be forced further into the pleats.

Note: Refer to “Inspecting the Paper Air Cleaner

Elements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaning paper air cleaner elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.

Note: Refer to “Inspecting the Paper Air Cleaner

Elements”.

Washing the Paper Air Cleaner Elements with Nonsudsing Detergent

Do not wash air cleaner elements in any flammable solution such as diesel fuel or gaso-line. Doing so can cause fire or an engine runaway and can result in personal injury.

Washing with nonsudsing detergent is effective for cleaning elements that have deposits of carbon or oil. Use a cleaning agent that is specifically manufactured for cleaning paper air cleaner elements. Cleaning with pressurized water, pressurized air, or vacuum cleaning is recommended prior to washing with nonsudsing detergent.

1. Place the element into a wash tank so that the

gasket is up. The wash tank should be equipped with a rack so that the element does not sit on the bottom of the wash tank.

Note: Caterpillar does not recommend a process

for washing the element which includes vigorously shaking. By vigorously shaking the element, carbon particles may be distributed.

2. Fill the wash tank with the cleaning agent

and warm water to a maximum temperature of 60 °C (140 °F). Follow the manufacturers recommendations for the cleaning agent. Allow the element to soak for six hours.

(21)

3. Drain the wash tank. Do not use the cleaning agent

more than one time. Remove the element from the wash tank. Rinse the element by performing the method for cleaning with pressurized water.

Note: Refer to “Drying the Paper Air Cleaner

Elements”. Refer to “Inspecting the Paper Air Cleaner Elements”.

Drying the Paper Air Cleaner Elements

The oven method may be used in order to dry the elements. If an oven is used, do not expose the elements to temperatures that exceed 82 °C (160 °F).

Note: Do not use compressed air in order to dry the

elements.

The elements may be allowed to air dry. Allow two days for the elements to air dry before the elements are inspected and installed.

Inspecting the Paper Air Cleaner

Elements

g00281693

Illustration 33

Inspect the clean, dry element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the element. Rotate the element. Inspect the element for tears and/or holes. Inspect the element for light that may show through the filter material. If it is necessary in order to confirm the result, compare the element to a new element that has the same part number.

Do not use an element that has any tears and/or holes in the filter material. Do not use an element with damaged pleats, gaskets or seals. Discard damaged elements.

Storing Paper Air Cleaner Elements

If an element that passes inspection will not be used, the element can be stored for future use.

g00281694

Illustration 34

Do not use paint, a waterproof cover, or plastic as a protective covering for storage. Restricted air flow may result. To protect against dirt and damage, wrap the elements in Volalite Corrosion Inhibited (VCI) paper.

Place the element into a box for storage. For identification, mark the outside of the box and mark the element. Include the following information:

•

Date of the cleaning

•

Number of cleanings

Store the box in a dry location.

For more detailed information on cleaning the paper air cleaner element, refer to Special Publication, SEBF8062, “Procedure to Inspect and Clean Air Filters”.

(22)

Engine Air Cleaner Service Indicator - Inspect

i00641711

Engine Air Cleaner Service

Indicator - Inspect

SMCS Code: 7452-040

g00291942

Illustration 35

Typical air cleaner service indicator that is mounted on the air cleaner housing

An air cleaner service indicator may be mounted on the air cleaner element or in a remote location. Some vessels are equipped with a low air pressure indicator that monitors the inlet air pressure. This indicator measures air pressure before the air is drawn through the air cleaner element. Then, the indicator monitors the pressure level after the air has passed through the air cleaner element. As the air cleaner element becomes dirty, this air cleaner pressure differential rises.

Some vessels may be equipped with a different air cleaner indicator.

If your vessel is equipped with a different type of air cleaner indicator, follow the recommendations for the vessel. You can also follow the recommendations in the air cleaner OEM in order to service the air cleaner element.

g00103777

Illustration 36

Typical Air Cleaner Service Indicator

Observe the air cleaner service indicator. You should clean the air cleaner element, or you should replace the air cleaner element under two conditions:

•

The yellow diaphragm enters the red zone.

•

The service indicator displays the red color at any

time.

•

The red piston locks in the visible position.

Test the Air Cleaner Service

Indicator

Air cleaner service indicators are important, inexpensive instruments. Two methods can be used to test the service indicator.

•

Check for ease of resetting. The service indicator should reset in less than three pushes.

•

Check the movement of the yellow core when the engine is accelerated to the engine rated rpm. The yellow core should latch at the approximate greatest vacuum that is attained.

The air cleaner service indicator should be replaced under certain conditions and at certain times:

•

The service indicator does not reset easily.

•

The yellow core does not latch at the greatest

vacuum.

•

The engine is used for a year.

•

The engine is overhauled.

•

Major engine components are replaced.

Note: Replace the air cleaner service indicator

often whenever you operate in a severely dusty environment.

If the new service indicator will not reset, the hole for the service indicator may be plugged.

Note: When a new service indicator is installed,

excessive force may crack the top of the service indicator. Tighten the service indicator to a torque of 2 N·m (18 lb in).

(23)

Engine Crankcase Breather - Clean

Service the Air Cleaner Service

Indicator

NOTICE

Never service the air cleaner element with the engine running since this will allow dirt to enter the engine. If the air cleaner element becomes plugged, the air can split the filter material. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has air filter elements for this unit. Consult your Caterpillar dealer for the correct air cleaner element.

If the air cleaner service indicator appears red at any time, clean the air cleaner element or install a new air cleaner element. At 250 hour intervals, clean the air cleaner element or replace the air cleaner element . Refer to the Operation and Maintenance Manual (Maintenance Section) for more information on servicing the air cleaner element.

i02263740

Engine Crankcase Breather

-Clean

SMCS Code: 1317-070

NOTICE

Perform this maintenance with the engine stopped. If the crankcase breather is not maintained on a regular basis, the crankcase breather will become plugged. A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage.

g01136454 Illustration 37 Typical example (1) Hose clamp (2) Breather assembly (3) Retaining clamp (4) Seal

1. Loosen hose clamp (1) and remove the hose from

breather assembly (2).

2. Loosen retaining clamp (3). Remove the breather

assembly and seal (4).

3. Wash the breather element in solvent that is clean

and nonflammable. Allow the breather element to dry before installation.

4. Install a breather element that is clean and dry.

Install the seal, the breather assembly, and the clamp. Refer to the Specifications, SENR3130 in order to locate the proper torques.

5. Install the hose. Install the hose clamp. Refer to

the Specifications, SENR3130 in order to locate the proper torques.

i02456872

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 Special Publication, SENR3130, “Torque Specifications” for the recommended torques. Refer to the OEM recommendations for more information.

(24)

Engine Oil Level - Check

i01007363

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Check the oil level after the engine has stopped. This maintenance procedure must be performed on a level surface.

g00110310

Illustration 38 (Y) “ADD” mark (X) “FULL” mark

1. Maintain the oil level between the “ADD” mark (Y)

and the “FULL” mark (X) on the oil level gauge. Do not fill the crankcase above “FULL” mark (X).

NOTICE

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

2. Remove oil filler cap and add oil, if necessary.

Clean the oil filler cap. Reinstall the oil filler cap.

i01935337

Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM;

7542-554-OC, SM

In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. S·O·S oil analysis provides infrared analysis, which is required for determining nitration and oxidation levels.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

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

•

Engine model

•

Service hours on the engine

•

The number of hours that have accumulated since the last oil change

•

The amount of oil that has been added since the last oil change

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

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

Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle is

recommended for use with the sampling valve. The fluid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided.

NOTICE

If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump.

For instructions, see Special Publication, PEHP6001, “How To Take A Good Oil Sample”. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your engine.