Operation and Maintenance Manual Excerpt...Starting Motor - Inspect ..... 94 Turbocharger - Inspect ..... 94 Every 13 600 L (3600 US gal) of Fuel or 2000 ... Caterpillar recommends

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7533June 2001

Operation andMaintenanceManual3034 Marine EngineCPP1-Up (Engine)

67Maintenance Section

Maintenance Interval Schedule

i01523760

Maintenance Interval Schedule(Turbocharged 3034 MarineEngine)SMCS Code: 1000; 7500

Note: Before performing any operation ormaintenance procedures, ensure that the SafetyInformation, warnings, and instructions are readand understood.

To determine the maintenance intervals, use fuelconsumption, service hours, or calendar time,whichever occurs first . Experience has shownthat maintenance intervals are most accuratelyscheduled on the basis of fuel consumption.

Before each consecutive interval is performed, allof the maintenance items from the previous intervalmust also be performed.

When Required

Battery - Replace .................................................. 70Battery or Battery Cable - Disconnect .................. 71Engine Storage Procedure - Check ...................... 84Fuel Control Linkage - Check/Lubricate ............... 85Fuel System - Prime ............................................. 86

Daily

Cooling System Coolant Level - Check ................ 77Engine Oil Level - Check ...................................... 82Marine Transmission Oil Level - Check ................. 90Walk-Around Inspection ........................................ 95

First 340 L (90 US gal) of Fuel or First 25 to50 Service Hours

Alternator Belt - Inspect/Adjust/Replace ............... 69Engine Valve Lash - Inspect/Adjust ...................... 85

Every 3400 L (900 US gal) of Fuel or 500Service Hours or 1 Year

Alternator Belt - Inspect/Adjust/Replace ............... 69Auxiliary Water Pump (Rubber Impeller) -Inspect ................................................................ 70

Battery Electrolyte Level - Check .......................... 70Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 77

Engine Air Cleaner Element - Clean/Replace ....... 79Engine Mounts - Inspect ....................................... 81Engine Oil Sample - Obtain .................................. 82Engine Oil and Filter - Change ............................. 83Fuel System Secondary Filter - Replace .............. 87Hoses and Clamps - Inspect/Replace .................. 89Sea Water Strainer - Clean/Inspect ...................... 93

Every 6800 L (1800 US gal) of Fuel or 1000Service Hours

Alternator - Inspect ............................................... 69Engine Valve Lash - Inspect/Adjust ...................... 85Fuel Tank Water and Sediment - Drain ................. 89Marine Transmission Oil Cooler - Clean/Inspect ... 90Starting Motor - Inspect ........................................ 94Turbocharger - Inspect .......................................... 94

Every 13 600 L (3600 US gal) of Fuel or 2000Service Hours

Cooling System Coolant (DEAC) - Change .......... 71Cooling System Water Temperature Regulator -Replace ............................................................... 78

Water Pump - Inspect ........................................... 96


Cooling System Coolant Extender (ELC) - Add .... 76Engine Crankcase Breather - Clean/Replace ....... 80Fuel Injection Nozzles - Test/Exchange ................ 85

Every 40 800 L (10 800 US gal) of Fuel or6000 Service Hours

Cooling System Coolant (ELC) - Change ............. 74Overhaul Considerations ...................................... 91

68Maintenance SectionMaintenance Interval Schedule

i01523739

Maintenance Interval Schedule(Naturally Aspirated 3034Marine Engine)SMCS Code: 1000; 7500

Note: Before performing any operation ormaintenance procedures, ensure that the SafetyInformation, warnings, and instructions are readand understood.

To determine the maintenance intervals, use fuelconsumption, service hours, or calendar time,whichever occurs first . Experience has shownthat maintenance intervals are most accuratelyscheduled on the basis of fuel consumption.

Before each consecutive interval is performed, allof the maintenance items from the previous intervalmust also be performed.

When Required

Battery - Replace .................................................. 70Battery or Battery Cable - Disconnect .................. 71Engine Storage Procedure - Check ...................... 84Fuel Control Linkage - Check/Lubricate ............... 85Fuel System - Prime ............................................. 86

Daily

Cooling System Coolant Level - Check ................ 77Engine Oil Level - Check ...................................... 82Marine Transmission Oil Level - Check ................. 90Walk-Around Inspection ........................................ 95

First 270 L (70 US gal) of Fuel or First 25 to50 Service Hours

Alternator Belt - Inspect/Adjust/Replace ............... 69Engine Valve Lash - Inspect/Adjust ...................... 85

Every 2700 L (700 US gal) of Fuel or 500Service Hours or 1 Year

Alternator Belt - Inspect/Adjust/Replace ............... 69Auxiliary Water Pump (Rubber Impeller) -Inspect ................................................................ 70

Battery Electrolyte Level - Check .......................... 70Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 77

Engine Air Cleaner Element - Clean/Replace ....... 79Engine Mounts - Inspect ....................................... 81Engine Oil Sample - Obtain .................................. 82Engine Oil and Filter - Change ............................. 83Fuel System Secondary Filter - Replace .............. 87Hoses and Clamps - Inspect/Replace .................. 89Sea Water Strainer - Clean/Inspect ...................... 93

Every 5400 L (1400 US gal) of Fuel or 1000Service Hours

Alternator - Inspect ............................................... 69Engine Valve Lash - Inspect/Adjust ...................... 85Fuel Tank Water and Sediment - Drain ................. 89Marine Transmission Oil Cooler - Clean/Inspect ... 90Starting Motor - Inspect ........................................ 94


Cooling System Coolant (DEAC) - Change .......... 71Cooling System Water Temperature Regulator -Replace ............................................................... 78

Engine Crankcase Breather - Clean/Replace ....... 80Water Pump - Inspect ........................................... 96


Cooling System Coolant Extender (ELC) - Add .... 76Fuel Injection Nozzles - Test/Exchange ................ 85


Cooling System Coolant (ELC) - Change ............. 74Overhaul Considerations ...................................... 91


Alternator - Inspect

i00072207

Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspectthe ammeter (if equipped) during engine operationin order to ensure proper battery performanceand/or proper performance of the electrical system.Make repairs, as required. Refer to the ServiceManual.

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

i01526416

Alternator Belt -Inspect/Adjust/ReplaceSMCS Code: 1357-036; 1357-510

Inspection

To maximize the engine performance, inspect thebelt for wear and for cracking. Check the belttension. Adjust the belt tension in order to minimizebelt slippage. Belt slippage will decrease the lifeof the belt.

For the correct tension on the belt, refer toSpecifications, “Belt Tension Chart”.

Adjustment

Note: Do not remove bolt (1) or loosen bolt (1)that holds the bracket for the alternator to thethermostat housing. The seal for the thermostat maybe damaged. This could result in a coolant leak.

g00792918Illustration 26

1. Remove the belt guard, if equipped.

2. Loosen mounting bolt (3) and adjusting bolt (2).

3. Slide the alternator in the direction that will givethe correct tension.

4. Tighten adjusting bolt (2). Tighten mounting bolt(3). Refer to the Operation and MaintenanceManual, “Torque Specifications” for the propertorques.

5. Reinstall the belt guard, if equipped.

If new belts are installed, check the belt adjustmentagain after 30 minutes of engine operation at therated rpm.

Replacement of Multiple Drive Belts

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new beltto carry more load because the older belts arestretched. The additional load on the new belt couldcause the new belt to break.

70Maintenance SectionAuxiliary Water Pump (Rubber Impeller) - Inspect

i01041983

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

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

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

Check the following components for wear ordamage:

• Bearings

• Impeller

• Seals

• Wear plate

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

i01505178

Battery - ReplaceSMCS Code: 1401-510

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

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

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

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

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

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the NEGATIVE “- VE”terminal on the starter motor. Disconnect thecable from the NEGATIVE “-” battery terminal.

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

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

5. Remove the used battery.

6. Install the new battery.

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

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

8. Connect the cable from the NEGATIVE “- VE”terminal on the starter motor to the NEGATIVE“-” battery terminal.

i01206348

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods oftime or when the engine is run for short periods,the batteries may not fully recharge. Ensure a fullcharge in order to help prevent the battery fromfreezing. If batteries are properly charged, ammeterreading should be very near zero.


Battery or Battery Cable - Disconnect

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

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

If the addition of water is necessary, use distilledwater. If distilled water is not available useclean water that is low in minerals. Do not useartificially softened water.

2. Check the condition of the electrolyte with the1U-7298 Coolant/Battery Tester (�C) or the1U-7297 Coolant/Battery Tester (�F).

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 L (0.11 qt) of baking soda and1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and1 L (1 qt) of clean water

Thoroughly rinse the battery case with cleanwater.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitproperly. Coat the clamps and the terminals with5N-5561 Silicone Lubricant, petroleum jelly orMPGM grease.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

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

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

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

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

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

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

i01528086

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

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

• The engine overheats frequently.

• Foaming is observed.

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

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

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

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

72Maintenance SectionCooling System Coolant (DEAC) - Change

Drain

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

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.


Drain for the cylinder block for the naturally aspirated 3034 Marineengine

(1) Drain for the cylinder block(2) Fuel filter


Drain for the cylinder block for the turbocharged 3034 Marineengine

(3) Drain for the cylinder block(4) Closed crankcase breather


(5) Drain plug for the heat exchanger(6) Heat exchanger

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equippedwith a drain valve, remove the cooling systemdrain plugs.


Cooling System Coolant (DEAC) - Change

On naturally aspirated engines, remove the drainplug from the cylinder block (1). The drain plug islocated near the fuel filter (2). On turbochargedengines, remove the drain plug from the cylinderblock (3). The drain plug is located near theclosed crankcase breather (4). Remove the drainplug (5) for the heat exchanger (6). Allow thecoolant to drain.

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

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

Outside Illinois: 1-800-542-8665Inside Illinois: 1-800-541-8665Canada: 1-800-523-8665

Flush

1. Flush the cooling system with clean water inorder to remove any debris.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual for moreinformation on the proper torques.

NOTICEDo not fill the cooling system faster than 5 L(1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

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

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

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush thecooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. Refer to the Operation andMaintenance Manual for more information on theproper torques.

Cooling Systems with HeavyDeposits or Plugging

Note: For the following procedure to be effective,there must be some active flow through the coolingsystem components.





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

4. Start and run the engine at low idle for aminimum of 90 minutes. The coolant temperatureshould be at least 82�C (180�F).

74Maintenance SectionCooling System Coolant (ELC) - Change

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.


Fill



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

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

3. Add coolant/antifreeze into the cooling systemuntil the cooling system is full to the top.

4. Clean the cooling system filler cap. Inspectthe gasket for the cooling system filler cap. Ifthe gasket for the cooling system filler cap isdamaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket for the cooling system filler cap is notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install anew cooling system filler cap.

5. Pour coolant/antifreeze into the recovery tankuntil the coolant reaches “COLD FULL” mark. Donot fill the recovery tank above “COLD FULL”mark.

6. Clean the filler cap for the expansion tank. Installthe filler cap for the expansion tank. Start theengine. Inspect the cooling system for leaks andfor proper operating temperature.

i01528733

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

When the cooling system is cleaned, only cleanwater is needed when the ELC is drained andreplaced.

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

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.


Cooling System Coolant (ELC) - Change


Drain for the cylinder block for the naturally aspirated 3034 Marineengine

(1) Drain for the cylinder block(2) Fuel filter


Drain for the cylinder block for the turbocharged 3034 Marineengine

(3) Drain for the cylinder block(4) Closed crankcase breather


(5) Drain for the heat exchanger(6) Heat exchanger

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equippedwith a drain valve, remove the cooling systemdrain plugs.

Remove the drain plug for the cylinder block (1)for naturally aspirated engines. The drain plug islocated near the fuel filter (2). Remove the drainplug for the cylinder block (3) for turbochargedengines. The drain plug is located near theclosed crankcase breather (4). Remove the drainplug (5) from the heat exchanger (6). Allow thecoolant to drain.

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

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

Outside Illinois: 1-800-542-8665Inside Illinois: 1-800-541-8665Canada: 1-800-523-8665

Flush


76Maintenance SectionCooling System Coolant Extender (ELC) - Add




3. Fill the cooling system with clean water. Installthe cooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66�C (120 to 150�F).


Fill



1. Fill the cooling system to the top with theELC. Refer to the Operation and MaintenanceManual for more information on cooling systemspecifications. Do not install the cooling systemfiller cap.

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

3. Add the ELC into the cooling system until thecooling system is full to the top.

4. Clean the cooling system filler cap. Inspectthe gasket for the cooling system filler cap. Ifthe gasket for the cooling system filler cap isdamaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket for the cooling system filler cap is notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install anew cooling system filler cap.

5. Pour the ELC into the recovery tank until thecoolant reaches the “COLD FULL” mark. Do notfill the tank above “COLD FULL” mark.

6. Clean the cooling system filler cap. Install thecooling system filler cap. Start the engine.Inspect the cooling system for leaks and forproper operating temperature.

i00259474

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

Caterpillar Extended Life Coolant (ELC) does notrequire the frequent Supplemental Coolant Additive(SCA) additions associated with the presentconventional coolants. The Extender only needs tobe added once.

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

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

2. It may be necessary to drain enough coolantfrom the cooling system in order to add theExtender.

3. Add Extender according to the requirements foryour engine’s cooling system capacity. Refer tothe Operation and Maintenance Manual, “RefillCapacities” in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to the Operation and Maintenance Manual,“Cooling System Specifications” information forthe Caterpillar ELC Extender additions.

4. Clean the cooling system filler cap. Inspect thecooling system filler cap gaskets. Replace thecooling system filler cap if the cooling systemfiller cap gaskets are damaged. Install thecooling system filler cap.


Cooling System Coolant Level - Check

i01406468

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

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


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

3. Pour the proper coolant mixture into the tank.Refer to the Operation and Maintenance Manual,“Cooling System Specifications” for informationon the correct mixture and type of coolant. Referto the Operation and Maintenance Manual, “RefillCapacities” for the cooling system capacity. Donot fill the coolant recovery tank above “COLDFULL” mark.


4. Clean filler cap and the receptacle. Reinstall thefiller cap and inspect the cooling system forleaks.

Note: The coolant will expand as the coolant heatsup during normal engine operation. The additionalvolume will be forced into the coolant recoverytank during engine operation. When the engine isstopped and cool, the coolant will return to theengine.

i01463635

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

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

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an S·O·S Coolant Analysis.

Test for SCA Concentration

Coolant/Antifreeze and SCA

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

Use the 8T-5296 Coolant Conditioner Test Kit oruse the 4C-9301 Coolant Conditioner Test Kit inorder to check the concentration of the SCA. Referto the Operation and Maintenance Manual for moreinformation.

Water and SCA

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

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the Operationand Maintenance Manual, “Water/SupplementalCoolant Additive (SCA)” topic (MaintenanceSection). Refer to the Operation and MaintenanceManual, “Conventional Coolant/Antifreeze CoolingSystem Maintenance” topic (Maintenance Section).

78Maintenance SectionCooling System Water Temperature Regulator - Replace

S·O·S Coolant Analysis

S·O·S coolant samples can be analyzed at yourCaterpillar dealer. S·O·S Coolant Analysis is aprogram that is based on periodic samples.

Level 1

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

• Glycol Concentration

• Concentration of SCA

• pH

• Conductivity

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an S·O·S CoolantAnalysis.

Level 2

This level coolant analysis is recommendedwhen the engine is overhauled. Refer to theOperations and Maintenance Manual, “OverhaulConsiderations” for further information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engine’s heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.


1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Refer to theOperation and Maintenance Manual for moreinformation on SCA requirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

i00912898

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

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

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


Engine Air Cleaner Element - Clean/Replace

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup insidethe cylinders. This excessive carbon buildup couldresult in an accelerated wear of the piston rings andwear of the cylinder liner.

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

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

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

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

Refer to the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling systemto a level that is below the water temperatureregulator housing.

i01531406

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

Naturally Aspirated Engines


(1) Air cleaner housing(2) Hose clamp


(1) Air cleaner housing(3) Element

1. Loosen the hose clamp (2) that holds the aircleaner housing (1). Remove the air cleanerhousing (1).

80Maintenance SectionEngine Crankcase Breather - Clean/Replace

2. Remove the element (3) from the air cleanerhousing (1).

3. Clean the inside of the air cleaner housing (1)with a clean, damp cloth. Wipe the inside of theair cleaner housing dry.

4. Insert a new element (3) into the air cleanerhousing (1).

5. Install the air cleaner housing (1) onto the inletmanifold. Install the hose clamp and tightenthe hose clamp (2). Refer to Operation andMaintenance Manual, “Torque Specifications” forthe proper torque.

Turbocharged Engines


(1) Hose clamp(2) Element

1. Remove the hose clamp (1) from the adapterthat is attached to the turbocharger. Remove theelement (2).

2. Clean the inside of the adapter with a clean,damp cloth. Wipe the inside of the adapter dry.

3. Install a new element (2) onto the adapter. Installthe hose clamp and tighten the hose clamp (1).Refer to Operation and Maintenance Manual,“Torque Specifications” for the proper torque.

i01532312

Engine Crankcase Breather -Clean/ReplaceSMCS Code: 1317-070; 1317-510



(1) Breather hose(2) Set screws(3) Breather cover(4) Vent hole(5) Diaphragm(6) Spring(7) Breather port

Note: Keep the area around vent hole (4) clean. Donot restrict the vent hole.

1. Remove four set screws (2). Remove breathercover (3).

2. Remove diaphragm (5) and spring (6).

3. Clean breather port (7), breather hose (1), andvent hole (4).

4. Install spring (6) and diaphragm (5) in breatherport (7). If necessary, install a new spring (6) anda new diaphragm (5).

5. Install breather cover (3) and four set screws (2).


Engine Mounts - Inspect



(1) Hose clamp(2) Valve assembly(3) Vent hole(4) Housing(5) Hose clamp

NOTICEEnsure that the components of the breather assemblyare installed in the correct positions. If not installedcorrectly, engine damage can result.

Note: Keep the area around vent hole (3) clean. Donot restrict the vent hole.

1. Loosen hose clamps (1) and (5). Remove thehoses from the breather assembly.

2. Pull the valve assembly (2) out of the housing(4). Discard the valve assembly (2).

3. Remove the hoses and the housing (4).Thoroughly clean the hoses and the housing.Ensure that the hoses and the housing are dry.

4. Install the hoses and the housing (4). Install anew valve assembly (2) into the housing (4).

5. Connect the hose to the valve assembly (2).Tighten hose clamps (1) and (5). Refer to theOperation and Maintenance Manual, “TorqueSpecifications”.

Breather Deflector


(6) Hose adapter(7) Breather deflector(8) Square face of the breather deflector(9) O-ring

The breather deflector (7) is installed onturbocharged 3034 engines. The breather deflector(7) should be cleaned on alternate service intervalsfor the engine crankcase breather.

1. Remove the breather deflector. Refer to theDisassembly and Assembly Manual, “BreatherDeflector - Remove and Install”.

2. Clean the breather deflector (7) and the hoseadapter (6) with soap and water. Ensure that thecomponents are dry before reassembly.

3. Install a new O-ring (9) on the hose adapter (6).

4. Install the breather deflector (7). Refer to theDisassembly and Assembly Manual, “BreatherDeflector - Remove and Install”.

i00259257

Engine Mounts - InspectSMCS Code: 1152-040

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

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the Service Manual forthe recommended torques. Refer to the OEMrecommendations for more information.

82Maintenance SectionEngine Oil Level - Check

i00623423

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

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


(Y) “ADD” mark. (X) “FULL” mark.

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between “ADD” mark (Y)and “FULL” mark (X) on oil level gauge (1). Donot fill the crankcase above “FULL” mark (X).

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

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

i01534451

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

7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

Obtain the Sample and the Analysis


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

• Engine model

• Service hours on the engine

• The number of hours that have accumulatedsince the last oil change

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

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

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

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

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

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.


Engine Oil and Filter - Change

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

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

i01558369

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


Do not drain the oil when the engine is cold. Asthe oil cools, suspended waste particles settleon the bottom of the oil pan. The waste particlesare not removed with the draining cold oil. Drainthe crankcase with the engine stopped. Drain thecrankcase with the oil warm. This draining methodallows the waste particles that are suspended in theoil to be drained properly.

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

Drain the Engine Oil


Manual sump pump for the engine oil

1. Connect a suitable hose to the outlet of themanual sump pump for the engine oil. Placethe opposite end of the hose into a suitablecontainer. The container should hold at least18 L (19 qt) of oil.

2. Pump the handle of the manual sump pump untilthe oil has been removed from the engine intothe suitable container. Dispose of the used oil inaccordance with local regulations.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter. Break apart the pleats and inspect the oilfilter for metal debris. An excessive amount ofmetal debris in the oil filter may indicate earlywear or a pending failure.

84Maintenance SectionEngine Storage Procedure - Check

Use a magnet to differentiate between theferrous metals and the nonferrous metals thatare found in the oil filter element. Ferrous metalsmay indicate wear on the steel and cast ironparts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.


Typical mounting base for the oil filter and oil filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasketis removed.

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

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

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

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to theOperation and Maintenance Manual, “LubricantSpecifications” for more information on theproper type of oil. Fill the crankcase with theproper amount of oil. Refer to the Operation andMaintenance Manual, “Refill Capacities” for theproper amount of oil.

NOTICEIf 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 overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain backto the sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the oil level gauge.

i01430860

Engine Storage Procedure -CheckSMCS Code: 1000-535

Caterpillar requires all engines that are stored formore than 3 months to follow storage proceduresand start-up procedures. These procedures providemaximum protection to internal engine components.Refer to Special Instruction, SEHS9031, “StorageProcedure For Caterpillar Products” for informationon these procedures.

An extension of the oil change interval to 12months is permitted if you follow the requiredprocedures for storage and start-up. This extensionis permitted if the following intervals in the Operationand Maintenance Manual, “Maintenance IntervalSchedule” have not been reached:

• Operating hours


Engine Valve Lash - Inspect/Adjust

• Fuel consumption

i00869628

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

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

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

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

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

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

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

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenanceis performed.

Refer to the Service Manual for more information.

i01432350

Fuel Control Linkage -Check/LubricateSMCS Code: 1257-086; 1257-535

Check the fuel control linkage for proper operation.If necessary, adjust the fuel control linkage. Avariety of linkages can be used. The type of linkagedepends on the type of installation. Therefore, referto the OEM of the vessel for the specific type offuel control linkage.

Some fuel control linkages require lubrication.Lubricate the grease fittings with 1P-0808Multipurpose Grease or the equivalent.

i00626014

Fuel Injection Nozzles -Test/ExchangeSMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

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

Fuel injection nozzles are subject to tip wear. Tipwear is a result of fuel contamination. Tip wear cancause the following problems:

• Increased fuel consumption

• Black smoke

• Misfire

• Rough running

Fuel Injection nozzles should be cleaned, inspected,tested, and replaced, if necessary. Refer to SpecialInstruction, SEHS7292 for using the 8S-2245Injection Cleaning Tool Group. Consult yourCaterpillar dealer about cleaning the fuel injectionnozzle and testing the fuel injection nozzle.

86Maintenance SectionFuel System - Prime

NOTICENever wire brush or scrape a fuel injection nozzle.Wire brushing or scraping a fuel injection nozzle willdamage the finely machine orifice. Proper tools forcleaning and testing the fuel injection nozzles can beobtained from Caterpillar dealers.

The following items are symptoms of a malfunctionof the fuel injection nozzle:

• Abnormal engine operation

• Smoke emission

• Engine knock

Each fuel injection nozzle must be isolated one at atime in order to determine the malfunctioning fuelinjection nozzle.

1. Start the engine.

2. Loosen each fuel line nut one at a time at the fuelinjection pump. A cloth or similar material mustbe used in order to prevent fuel from spraying onthe hot exhaust components. Tighten each nutbefore loosening the next nut.

3. A defective fuel injection nozzle may be identifiedwhen a fuel line nut is loosened and the followingconditions are present:

• The exhaust smoke is partially eliminated orthe exhaust smoke is completely eliminated.

• Engine performance is not affected.

A fuel injection nozzle that is suspected ofbeing defective should be removed. A newfuel injection nozzle should be installed in thecylinder in order to determine if the removed fuelinjection nozzle is defective.

Removal and Installation of theFuel Injection Nozzles

For the removal and the installation of fuel injectionnozzles, special tooling is required. Refer to theService Manual for more information. Consult yourCaterpillar dealer for assistance.

i01533023

Fuel System - PrimeSMCS Code: 1258-548

Priming the fuel system fills the fuel filter. Primingthe fuel system removes air bubbles from the fuelsystem. Prime the fuel system under the followingconditions:

• Fuel system that is run dry

• Storage

• Fuel filter maintenance

• Disconnecting fuel lines and installing fuel lines

• Repair of leaks in the fuel lines

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

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



Fuel System Secondary Filter - Replace


1. Loosen the vent plug (1) on the fuel injectionpump.

Note: The priming lever of the fuel transfer pumpcannot be operated if the cam is at the maximumlift position. If this occurs, the crankshaft must berotated one revolution.

2. Operate the priming lever for the fuel transferpump (2) until the flow of fuel from the vent plug(1) is continuous and free of air bubbles. Tightenvent plug (1).

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

3. Ensure that the manual stop control (if equipped)is in the RUN position. Start the engine. Theengine may run rough. Run the engine at lowidle until the engine runs smoothly. If the enginewill not start, further priming may be necessary.If the engine starts and if the engine continuesto misfire or smoke, then the fuel system mayrequire more priming. Check for any leaks in thefuel system.

4. Ensure that all fuel connections are secure andtightened to the proper torque. Ensure that anyspilled fuel is cleaned up.

i01539757

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




Turn the fuel supply valve to the OFF position beforeperforming this maintenance. Place a tray under thefuel filter in order to catch any fuel that might spill.Clean up any spilled fuel immediately.

1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly.


(1) Bolt(2) Seal(3) O-ring(4) Fuel filter element(5) Seal(6) Bottom cover

88Maintenance SectionFuel System Secondary Filter - Replace

3. Hold the bottom cover (6) of the filter assembly.Remove bolt (1) from the center of the element.

4. Lower the bottom cover (6).

5. Remove the fuel filter element (4) and disposeof the element properly.

6. Clean the inside surfaces of the fuel filter base.Clean the bottom cover (6).

7. Install new seals (2) and (5). Install new O-ring(3). Lubricate the seals and the O-ring with cleandiesel fuel.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

8. Insert bottom cover (6) onto new element (4).Ensure that the element is installed properly tothe bottom cover (6). Place the element (4) to thefuel filter base. Install the bolt (1).

9. Prime the fuel system. Refer to the Operationand Maintenance Manual, “Fuel System-Prime”for more information.




Turn the fuel supply valve to the OFF position beforeperforming this maintenance. Place a tray under thefuel filter in order to catch any fuel that might spill.Clean up any spilled fuel immediately.

1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly.


(1) Fuel filter base(2) Quick release collar(3) Fuel filter element(4) Drain

3. Loosen drain (4) and drain the fuel into a suitablecontainer.

4. Hold fuel filter element (3). At the same time,rotate the quick release collar (2) to the left.

5. Pull the fuel filter element (3) straight down inorder to remove the element. Dispose of theelement properly.

6. Clean the inside surfaces of the fuel filter base.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

7. Push the new fuel filter element (3) into the fuelfilter base (1). Rotate the quick release collar (2)to the right in order to fasten the element to thefuel filter base (1). Ensure that drain (4) is closed.

8. Prime the fuel system. Refer to the Operationand Maintenance Manual, “Fuel System-Prime”for more information.


Fuel Tank Water and Sediment - Drain

i00073301

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

Fuel Tank

Fuel quality is critical to the performance and tothe service life of the engine. Water in the fuel cancause excessive fuel system wear. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes throughthe fuel system and the fuel returns to the fuel tank.This causes water to accumulate in fuel tanks.Draining the fuel tank regularly and obtaining fuelfrom reliable sources can help to eliminate waterin the fuel.

Drain the Water and the Sediment

Fuel tanks should contain some provision fordraining water and draining sediment from thebottom of the fuel tanks.

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

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

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

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

Fuel Storage Tanks

Drain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank.

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

i00907072

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

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

• Cracking

• Softness

• Loose clamps

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

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

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used inplace of any standard hose clamp. Ensure that theconstant torque hose clamp is the same size asthe standard clamp.

90Maintenance SectionMarine Transmission Oil Cooler - Clean/Inspect

Due to extreme temperature changes, the hosewill heat set. Heat setting causes hose clamps toloosen. This can result in leaks. A constant torquehose clamp will help to prevent loose hose clamps.

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

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of thehose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


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

2. Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

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

3. Drain the coolant from the cooling system toa level that is below the hose that is beingreplaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

Note: For torques on hose clamps, see thisOperation and Maintenance Manual, “TorqueSpecifications” (Maintenance Section).

7. Install the hose clamps with a torque wrench.

Note: For the proper coolant to use, see thisOperation and Maintenance Manual, “CoolantRecommendations” (Maintenance Section).

8. Refill the cooling system.

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

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

i01534361

Marine Transmission OilCooler - Clean/InspectSMCS Code: 3320-040; 3320-070

Refer to the Operation and Maintenance Manual,“Overhaul Considerations” for the completeprocedure on cleaning the marine transmission oilcooler. For more information on servicing the marinetransmission oil cooler, consult your Caterpillardealer.

i01089872

Marine Transmission Oil Level- CheckSMCS Code: 3081-535

Check the marine transmission oil level accordingto the instructions that are provided by the OEM ofthe transmission or the OEM of the vessel.

For the lubrication requirements of the transmission,refer to the recommendations on the nameplate orthe “Owner’s Manual” for the transmission.

Marine Transmission Operation,Maintenance, Warranty, and PartsSupport

For information on maintenance and operation ofthe marine transmission, consult your Caterpillardealer and/or the OEM dealer of the transmission.

All support for the warranty of the transmission willbe the responsibility of the OEM. All parts supportfor the transmission will be the responsibility ofthe OEM. This parts support includes both theinstallation of parts and the resolution of any serviceproblems.


Overhaul Considerations

i01535071

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will resultin a lower average power demand. A decreasedaverage power demand should increase both theengine service life and the overhaul interval.

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

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

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Oil Consumption as an OverhaulIndicator

Oil consumption, fuel consumption, andmaintenance information can be used to estimatethe total operating cost for your Caterpillar engine.Oil consumption can also be used to estimatethe required capacity of a makeup oil tank that issuitable for the maintenance intervals.

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

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

When an engine’s oil consumption has risen tothree times the original oil consumption rate dueto normal wear, an engine overhaul should bescheduled. There may be a corresponding increasein blowby and a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

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

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according tothe standards for reusable parts.

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

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

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed from the hull, many options areavailable. An overhaul should be performed if theengine block or the crankshaft needs to be repaired.

If the engine block is repairable and/or thecrankshaft is repairable, the overhaul cost shouldbe between 40 percent and 50 percent of the costof a new engine with a similar exchange core.

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar remanufactured exchange components

Overhaul Recommendation

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

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

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of thefollowing maintenance recommendations.

Rebuild or Exchange

Cylinder Head Assembly, Oil Pump, and FuelTransfer Pump

These components should be inspected accordingto the instructions that are found in variousCaterpillar reusability publications. The SpecialPublication, SEBF8029 lists the reusabilitypublications that are needed for inspecting theengine parts.

92Maintenance SectionOverhaul Considerations

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

Using out-of-spec parts can result in the followingproblems:

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine efficiency

• Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operatingcosts. Therefore, Caterpillar recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Crankshaft Bearings and Crankshaft Seals

The following components may not last until thesecond overhaul.

• Thrust bearings

• Main bearings

• Rod bearings

• Crankshaft seals

Caterpillar recommends the installation of new partsat each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

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

• Rod bearing

• Main bearings

Note: If the crankshaft is removed for any reason,use the magnetic particle inspection process tocheck for cracks in the crankshaft.

Inspect the camshaft for damage to the journalsand to the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to checkfor cracks in the camshaft.

Inspect the following components for signs of wearor for signs of scuffing:

• Camshaft bearings

• Camshaft followers

Caterpillar recommends replacing the crankshaftvibration damper.

Oil Cooler Core and Marine Transmission OilCooler

During an overhaul, Caterpillar recommends theremoval of the oil cooler core and the marinetransmission oil cooler core. Clean the cores. Then,pressure test the cores.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core and the marine transmission oil coolercore.

1. Remove the oil cooler core and the marinetransmission oil cooler core. Refer to the ServiceManual for information on removal of the cores.

2. Remove any debris from the cores. To removedebris from the cores, turn the cores onto oneend.

3. Flush the cores internally with cleaner in order toloosen foreign substances. This will also helpto remove oil from the oil cooler core and themarine transmission oil cooler core.


Sea Water Strainer - Clean/Inspect

Note: Caterpillar recommends the use of HydrosolvLiquid Cleaners. Table 36 lists the Hydrosolv LiquidCleaners that are available from your Caterpillardealer.

Table 36

Hydrosolv Liquid Cleaners

PartNumber Description Size

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

174-6854 Hydrosolv 100 19 L (5 US gallon)

4. Use steam to clean the cores. This removes anyremaining residue from the cleaner. Flush the finsof each of the cores. Remove any other trappeddebris.

5. Wash the cores with hot, soapy water. Rinse thecores 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 lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the cores with compressed air. Direct the airin the reverse direction of the normal flow.

7. Inspect the components in order to ensurecleanliness. The cores should be pressuretested. Repair cores, if necessary. Install theoil cooler core and the marine transmission oilcooler core. Refer to the Service Manual forinformation on installation of the cores.

For more information about cleaning the cores,consult your Caterpillar dealer.

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level I). Furthercoolant analysis is recommended when the engineis overhauled.

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

A coolant analysis can be conducted in orderto verify the condition of the water that is beingused in the cooling system. A full water analysiscan be obtained by consulting your local waterutility company or an agricultural agent. Privatelaboratories are also available for water analysis.

Caterpillar recommends an S·O·S Coolant Analysis(Level II).

S·O·S Coolant Analysis (Level II)

An S·O·S Coolant Analysis (Level II) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. 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 andscale)

S·O·S Coolant Analysis (Level II) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, seeyour Caterpillar dealer.

i01556871

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

The sea water strainer must be clean in order toallow proper engine cooling. Check the sea waterstrainer for plugging. Inspect the sea water strainermore frequently if the vessel is being operatedin water which is shallow or dirty. The sea waterstrainer protects the aftercooler from debris. Thesea water strainer will catch pieces of the rubberimpeller from the raw water pump due to a failurefrom debris.

1. Close the valve for the sea water. The locationof the valve and the type of the valve may varywith each vessel.

94Maintenance SectionStarting Motor - Inspect


2. Remove the hose clamp (2) on each side ofthe sea water strainer. Remove the sea waterstrainer (1).

3. Use clean water to clean the sea water strainer(1). Remove any dirt and debris. If there is debrisfrom the impeller, the impeller may need to bereplaced. Refer to Operation and MaintenanceManual, “Auxiliary Water Pump (Rubber Impeller)- Inspect” for replacement information.

4. Install the sea water strainer (1). Install the hoseand each hose clamp (2).

5. Open the valve for the sea water.

i00651416

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

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation.Check the electrical connections and clean theelectrical connections. Refer to the Service Manualfor more information on the checking procedure andfor specifications or consult your Caterpillar dealerfor assistance.

i01539769

Turbocharger - InspectSMCS Code: 1052-040

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inletside). Any fumes from the crankcase are filteredthrough the air inlet system. Therefore, by-productsfrom oil and from combustion can collect in theturbocharger compressor housing. Over time, thisbuildup can contribute to loss of engine power,increased black smoke and overall loss of engineefficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage tothe turbocharger compressor wheel can causeadditional damage to the pistons, the valves, andthe cylinder head.

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

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

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

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

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

Removal and Installation

For options regarding the removal, installation,repair and replacement, consult your Caterpillardealer. Refer to the Service Manual for this enginefor the procedure and specifications.


Walk-Around Inspection

Cleaning and Inspecting

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

2. Turn the compressor wheel and the turbinewheel by hand. The assembly should turn freely.Inspect the compressor wheel and the turbinewheel for contact with the turbocharger housing.There should not be any visible signs of contactbetween the turbine wheel or compressorwheel and the turbocharger housing. If there isany indication of contact between the rotatingturbine wheel or the compressor wheel and theturbocharger housing, the turbocharger must bereconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty,dirt and/or moisture is passing through the airfiltering system. If oil is found only on the backside of the wheel, there is a possibility of a failedturbocharger oil seal.

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

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

5. Inspect the bore of the turbine housing forcorrosion.

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

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

i00893389

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose Connections

A walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can beavoided.

For maximum engine service life, make a thoroughinspection of the engine compartment beforestarting the engine. Look for items such as oil leaksor coolant leaks, loose bolts, worn belts, looseconnections and trash buildup. Make repairs, asneeded:

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

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

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

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

• Ensure that cooling lines are properly clampedand that cooling lines are tight. Check for leaks.Check the condition of all pipes.

• Check the marine transmission oil level. Refer tothe OEM specification for the marine transmissionor refer to the OEM specification for the vessel.

• Inspect the water pumps for coolant leaks.

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

96Maintenance SectionWater Pump - Inspect

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

• Inspect the lubrication system for leaks at thefront crankshaft seal, the rear crankshaft seal, theoil pan, the oil filters and the valve cover.

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

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

• Inspect the alternator belt and the accessorydrive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replacedas matched sets. If only one belt is replaced, thebelt will carry more load than the belts that arenot replaced. The older belts are stretched. Theadditional load on the new belt could cause thebelt to break.

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

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

• Inspect the ground strap for a good connectionand for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolytelevel of the batteries, unless the engine isequipped with a maintenance free battery.

• Check the condition of the gauges. Replace anygauges which are cracked or any gauges thatcan not be calibrated.

i01057943

Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in thefollowing conditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Visually inspect the water pump for leaks. If anyleaking is observed, replace the water pumpseal or the water pump assembly. Refer to theService Manual for the disassembly and assemblyprocedure.

Note: Refer to the Service Manual or consult yourCaterpillar dealer if any repair is needed or anyreplacement is needed.

Documents

Operation and Maintenance Manual Excerpt...Starting Motor - Inspect ..... 94 Turbocharger - Inspect ..... 94 Every 13 600 L (3600 US gal) of Fuel or 2000 ... Caterpillar recommends