SAFETY.CAT.

COM™

3406E and C15

MARINE ENGINES
Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7005-08)

® ®
© 2009 Caterpillar
All Rights Reserved

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 SEBU7005-08 83
Maintenance Section
Engine Oil Level - Check

i01406091 i02358169

Engine Oil Level - Check Engine Oil Level Gauge -

SMCS Code: 1348-535-FLV Calibrate
SMCS Code: 1326-524
Check the oil level after the engine has stopped.
The engine is shipped with an engine oil level gauge
that is not marked. The engine oil level gauge is
not marked because the following features can be
different for each engine:

• Angle of the installation

• Side for service
The same two features will affect “ADD” mark (Y)
and “FULL” mark (X) that is engraved on the engine
oil level gauge.

The engine oil level gauge must be calibrated after

Illustration 56
g00107788 the engine is installed in the vessel.
(1) Oil level gauge
(2) Oil filler cap

g00110310
Illustration 58
Oil Level Gauge “ADD” mark (Y) and “FULL” mark (X)
g00110310
Illustration 57
Oil level gauge NOTICE
(Y) “ADD” mark Refer to the Operation and Maintenance Manual for
(X) “FULL” mark more information on lubricant specifications.

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

“FULL” mark (X) on oil level gauge (1). Do not fill 1. Operate the engine until normal operating
the crankcase above “FULL” mark (X). temperature is achieved. Stop the engine.
Remove one of the drain plugs for the engine
crankcase. Allow the engine oil to drain until the
NOTICE oil pan is completely drained.
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into 2. Remove the used engine oil filter. Install the new
the oil. The air bubbles created from the crankshaft engine oil filter. Install the drain plug for the engine
dipping into the oil reduces the oil's lubricating char- crankcase. Tighten the drain plug for the engine
acteristics and could result in the loss of power. crankcase to 70 ± 14 N·m (50 ± 10 lb ft).

2. Remove oil filler cap (2) and add oil, if necessary. Note: The engine may be equipped with auxiliary
Clean the oil filler cap. Reinstall the oil filler cap. engine oil filters. The extra filters require more engine
oil than the standard amounts. Refer to the OEM
specifications.

3. Add the recommended oil grade and weight of

engine oil to the crankcase:

Standard Sump ............................... 45.4 L (48 qt)

Deep Sump ........................................ 64 L (68 qt)

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 84 SEBU7005-08
Maintenance Section
Engine Oil Sample - Obtain

4. Start the engine. Ensure that the lubrication To ensure that the sample is representative of the
system and the new engine oil filter is filled. oil in the crankcase, obtain a warm, well mixed oil
Inspect the lubrication system for leaks. sample.

5. Stop the engine and allow the engine oil to drain To avoid contamination of the oil samples, the tools
into the engine crankcase for approximately five and the supplies that are used for obtaining oil
minutes. samples must be clean.

6. Check the engine oil level. Use a marking pen in Caterpillar recommends using the sampling valve
order to engrave “ADD” mark (Y). in order to obtain oil samples. The quality and the
consistency of the samples are better when the
7. Add 3.8 liter (4 qt) of the recommended oil grade sampling valve is used. The location of the sampling
and weight of engine oil to the crankcase. Full valve allows oil that is flowing under pressure to be
volume will now be 49.2 L (52 qt) for the standard obtained during normal engine operation.
sump, or 68.1 L (72 qt) for the deep sump. Allow
the engine oil to drain into the engine crankcase The 169-8373 Fluid Sampling Bottle is
for approximately five minutes. recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
8. Check the engine oil level. Use a marking pen in needed for obtaining oil samples. Instructions are
order to engrave “FULL” mark (X). also provided.

i03542996 NOTICE
Always use a designated pump for oil sampling, and
Engine Oil Sample - Obtain use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
SMCS Code: 1000-008; 1348-554-SM; contaminate the samples that are being drawn. This
7542-554-OC, SM contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
In addition to a good preventive maintenance dealers and customers.
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order If the engine is not equipped with a sampling valve,
to monitor the condition of the engine and the use the 1U-5718 Vacuum Pump. The pump is
maintenance requirements of the engine. S·O·S oil
designed to accept sampling bottles. Disposable
analysis provides infrared analysis, which is required tubing must be attached to the pump for insertion
for determining nitration and oxidation levels. into the sump.

Obtain the Sample and the Analysis For instructions, see Special Publication, PEgj0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin. i01536470

Engine Oil and Filter - Change

Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order SMCS Code: 1318-510; 1348-044
to help obtain the most accurate analysis, provide
the following information:

• Engine model
Hot oil and hot components can cause personal
• Service hours on the engine injury. Do not allow hot oil or hot components to
contact the skin.
• 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

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 SEBU7005-08 85
Maintenance Section
Engine Oil and Filter - Change

Do not drain the oil when the engine is cold. As the oil Nonferrous metals may indicate wear on the
cools, suspended waste particles settle on the bottom aluminum parts, brass parts or bronze parts of
of the oil pan. The waste particles are not removed the engine. Parts that may be affected include
with the draining cold oil. Drain the crankcase with the following items: main bearings, rod bearings,
the engine stopped. Drain the crankcase with the turbocharger bearings, and cylinder heads.
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained Due to normal wear and friction, it is not
properly. uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
Failure to follow this recommended procedure will to arrange for a further analysis if an excessive
cause the waste particles to be recirculated through amount of debris is found in the oil filter.
the engine lubrication system with the new oil.

Drain the Engine Oil

After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:

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

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

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

remove the oil drain plug in order to allow the oil Illustration 59
g00103713
to drain. If the engine is equipped with a shallow
Typical filter mounting base and filter gasket
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
After the oil has drained, the oil drain plugs should be
removed.
cleaned and installed. Tighten the oil drain plugs to
70 ± 14 N·m (50 ± 10 lb ft).
4. Apply clean engine oil to the new oil filter gasket.

Replace the Oil Filter NOTICE

Do not fill the oil filters with oil before installing them.
NOTICE This oil would not be filtered and could be contaminat-
Caterpillar oil filters are built to Caterpillar speci- ed. Contaminated oil can cause accelerated wear to
fications. Use of an oil filter not recommended by engine components.
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering 5. Install the oil filter. Tighten the oil filter until the
the engine lubricating system. Only use oil filters oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
recommended by Caterpillar.
shown on the oil filter. Do not overtighten the oil
filter.
1. Remove the oil filter with a 1U-8760 Chain
Wrench. Fill the Engine Crankcase
2. Cut the oil filter open with a 175-7546 Oil Filter 1. Remove the oil filler cap. Refer to the Operation
Cutter. Break apart the pleats and inspect the and Maintenance Manual for more information on
oil filter for metal debris. An excessive amount lubricant specifications. Fill the crankcase with the
of metal debris in the oil filter may indicate early proper amount of oil. Refer to the Operation and
wear or a pending failure. Maintenance Manual for more information on refill
capacities.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.

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 86 SEBU7005-08
Maintenance Section
Engine Speed/Timing Sensors - Check/Clean/Calibrate

Camshaft Speed/Timing Sensor

NOTICE
If equipped with an auxiliary oil filter or system, extra
oil must be added when filling the crankcase. Follow
the OEM or filter manufacturer's recommendations. If
the extra oil is not added, the engine may starve for
oil.

NOTICE
To help prevent crankshaft or bearing damage, crank
engine to fill all filters before starting. Do not crank
engine for more than 30 seconds.

2. Start the engine and run the engine at “LOW

IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.

3. Stop the engine and allow the oil to drain back to

the sump for a minimum of ten minutes.
g01171816
Illustration 60
4. Remove the oil level gauge in order to check the (1) Harness assembly
oil level. Maintain the oil level between the “ADD” (2) Sensor
and “FULL” marks on the oil level gauge. (3) Bolt

i03569636
Removal Procedure
Engine Speed/Timing Sensors 1. Disconnect the harness assembly.
- Check/Clean/Calibrate 2. Remove the bolt and the sensor.
SMCS Code: 1912-040; 1912-070; 1912-524 3. Remove the O-ring seal from the sensor.

NOTICE Procedure for Cleaning, Inspecting, and

Keep all parts clean from contaminants.
Calibration
Contaminants may cause rapid wear and shortened
Check the condition of the plastic end of the sensor
component life.
for wear and for contaminants. Clean the metal
shavings and other debris from the face of the sensor.
NOTICE Use the procedure in the Troubleshooting Guide in
Care must be taken to ensure that fluids are contained order to calibrate the sensor.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to Installation Procedure
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 1. Install a new O-ring seal on the sensor. Lubricate
nent containing fluids. the O-ring seal with clean engine oil.

Refer to Special Publication, NENG2500, “Caterpillar 2. Position the sensor in the housing and install the
Dealer Service Tool Catalog” or refer to Special Pub- bolt.
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col- 3. Connect the harness assembly.
lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

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 SEBU7005-08 87
Maintenance Section
Engine Storage Procedure - Check

Crankshaft Speed/Timing Sensor i02703023

Engine Storage Procedure -

Check
SMCS Code: 1000-535

Caterpillar recommends storage procedures and

start-up procedures for all engines that are stored
for more than 1 month. These procedures provide
maximum protection to internal engine components.
Refer to Special Instruction, SEHS9031, “Storage
Procedure For Caterpillar Products” for information
on these procedures.

g01894553
An extension of the oil change interval to 12 months
Illustration 61 is permitted if you follow the required procedures for
(4) Sensor storage and start-up. This extension is permitted if the
(5) Harness assembly following intervals in the Operation and Maintenance
(6) O-ring
Manual, “Maintenance Interval Schedule” have not
been reached:
Removal Procedure
• Operating hours
1. Disconnect the harness assembly.
• Fuel consumption
2. Remove the bolt and the sensor.

3. Remove the O-ring seal from the sensor. i00869413

Engine Valve Lash -

Procedure for Cleaning, Inspecting, and
Calibration Inspect/Adjust
SMCS Code: 1102-025
Check the condition of the plastic end of the sensor
for wear and for contaminants. Clean the metal
The initial valve lash adjustment on new engines,
shavings and other debris from the face of the sensor.
rebuilt engines, or remanufactured engines is
Use the procedure in the Troubleshooting Guide in
recommended at the first scheduled oil change. The
order to calibrate the sensor.
initial adjustment is necessary due to initial wear of
the valve train components and seating of the valve
Installation Procedure train components.
1. Install a new O-ring seal on the sensor. Lubricate This maintenance is recommended by Caterpillar
the O-ring seal with clean engine oil. as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
2. Install the position sensor in the front housing and life.
install the bolt.

3. Connect the harness assembly. Adjustment of the Electronic Unit

Injector
Adjust the electronic unit injector (preload) at the
same interval as the valve lash adjustment. The
operation of Caterpillar engines with improper valve
adjustments and with improper adjustments of the
electronic unit injector can reduce engine efficiency.
This reduced efficiency could result in excessive fuel
usage and/or shortened engine component life.

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 88 SEBU7005-08
Maintenance Section
Engine Valve Rotators - Inspect

NOTICE NOTICE
Only qualified service personnel should perform this A valve rotator which does not operate properly will
maintenance. Refer to the Service Manual or your accelerate valve face wear and valve seat wear and
Caterpillar dealer for the complete valve lash adjust- shorten valve life. If a damaged rotator is not replaced,
ment procedure. valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
Operation of Caterpillar engines with improper valve and cylinder head damage.
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. If a valve fails to rotate, consult your Caterpillar
dealer.

i03120546

Ensure that the engine can not be started while Fuel Injector - Inspect/Adjust
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor SMCS Code: 1290-025
to turn the flywheel.

Hot engine components can cause burns. Allow

Inspect
additional time for the engine to cool before mea- Inspect the injector mechanism for signs of wear.
suring/adjusting valve lash clearance.

Adjust
i01597115
Table 10
Engine Valve Rotators - Inspect Required Tools

SMCS Code: 1109-040 Part

Part Name Quantity
Number
9U-7227 Injector Height Gauge 1

When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.

Engine valve rotators rotate the valves when the

engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.

Perform the following steps after the engine valve

lash is set, but before the valve covers are installed:

1. Start the engine according to Operation and

Maintenance Manual, “Engine Starting” (Operation Illustration 62
g01385601
Section) for the procedure.
Injector Mechanism

2. Operate the engine at low idle. (1) Rocker arm

(2) Adjustment screw
(3) Locknut
3. Observe the top surface of each valve rotator. The (4) 9U-7227 Injector Height Gauge
valve rotators should turn slightly when the valves
close. To make an adjustment to the unit injectors on
cylinders 4, 5, 6, 9, 11, and 12 use the following
procedure:

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 SEBU7005-08 89
Maintenance Section
Fuel System - Prime

1. Put the No. 1 piston at the top center position

on the compression stroke. Refer to Testing and
Adjusting, “Finding Top Center Position for No. 1
Piston”.

2. Injector height gauge (4) is used in order to obtain

a dimension of 78.0 ± 0.2 mm (3.07 ± 0.01 inch).
The dimension is measured from the top of the
unit injector to the machined ledge of the fuel
injector body.

3. Turn unit injector adjustment screw (2) clockwise

until the correct height is obtained.

4. Hold the adjustment screw in this position and g00107947

tighten locknut (3) to a torque of 100 ± 10 N·m Illustration 63
(75 ± 7 lb ft). (1) Fuel priming pump
(2) Fuel filter plug
(3) Connector cap
5. To make an adjustment to the unit injectors on (4) Fuel outlet line on the ECM
cylinders 1, 2, 3, 7, 8, and 10 remove the timing (5) Fuel filter
bolt. Turn the flywheel by 360 degrees in the
direction of engine rotation. The direction of
engine rotation is counterclockwise, as the engine
is viewed from the flywheel end. This will put the
number 11 piston at the top center position on the
compression stroke.

6. Repeat Steps 3 through 4.

7. Remove the timing bolt from the flywheel after all

the unit injector adjustments have been made.
Reinstall the valve mechanism covers.

i01406690

Fuel System - Prime Illustration 64

g00110065

(6) Air purge plug for the fuel system

SMCS Code: 1258-548 (7) Fuel return
(8) Fuel inlet

Priming the fuel system fills the dry fuel filters.

Priming the fuel system also removes air from the
Fuel leaked or spilled onto hot surfaces or elec- fuel system. This procedure is used primarily when
trical components can cause a fire. To help pre- the engine runs out of fuel. This procedure can
vent possible injury, turn the start switch off when also be used when a unit injector is replaced or the
changing fuel filters or water separator elements. Electronic Control Module (ECM) is replaced.
Clean up fuel spills immediately.
Note: During any periodic service of the fuel filter, DO
NOT remove fuel filter plug (2) in the fuel filter base
in order to release air from the fuel system. Periodic
removal of this fuel filter plug (2) will result in the
increased wear on the threads in the fuel filter base.
This can lead to fuel leakage. However, the fuel filter
plug (2) in the fuel filter base can be used to purge air
from the fuel system if the engine runs out of fuel.

1. Loosen connector cap (3).

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

priming pump until fuel appears at connector cap
(3). Tighten connector cap (3).

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 90 SEBU7005-08
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

3. Loosen fuel return (7) for two full turns. Operate Replace the Element
fuel priming pump (1) until fuel appears at fuel
return (7). Tighten the fuel return (7).

4. Continue to operate fuel priming pump (1) until a

strong pressure is felt on the fuel priming pump Fuel leaked or spilled onto hot surfaces or elec-
and until the check valve clicks. This procedure trical components can cause a fire. To help pre-
may require considerable priming. Lock fuel vent possible injury, turn the start switch off when
priming pump (1). changing fuel filters or water separator elements.
Clean up fuel spills immediately.
5. Crank the engine after pressurizing the fuel
system.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

6. If the engine does not start, open fuel priming

pump (1) and repeat Steps 1 through 5 in order
to start the engine.

7. When the ECM is replaced, loosen the fuel outlet

line on the ECM (4) in order to purge the air from
g00668636
the fuel system. Operate fuel priming pump (1) Illustration 65
until fuel appears at the fuel outlet line on the (1) Bowl
ECM (4). Tighten the fuel outlet line on the ECM. (2) Element
Perform Steps 3 through 5. (3) Drain

8. When a unit injector is replaced, perform Steps 3 1. Stop the engine.

through 5.
2. Turn the start switch to the “OFF” position.

i02049797 3. Shut off the fuel tank supply valve to the engine.
Fuel System Primary Filter 4. If the primary fuel filter is equipped with a drain
(Water Separator) Element - valve (3), open the drain valve in order to drain any
fuel from the filter case. Close the drain valve (3).
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ NOTICE
Use a suitable container to catch any fuel that might
Water in the fuel can cause the engine to run rough. spill. Clean up any spilled fuel immediately.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water, 5. Remove the fuel filter bowl (1) and wash the fuel
the element should be changed before the regularly filter bowl with clean diesel fuel.
scheduled interval.
6. Remove the fuel filter (2).
The primary filter/water separator also provides
filtration in order to help extend the life of the 7. Clean the gasket sealing surface of the fuel filter
secondary fuel filter. The element should be changed base. Ensure that all of the old gasket is removed.
regularly. Install a vacuum gauge. Change the
element for the primary filter/water separator if the 8. Apply clean diesel fuel to the new fuel filter gasket.
pressure is at 50 to 70 kPa (15 to 20 inches Hg).

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 SEBU7005-08 91
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i01463757
NOTICE
In order to maximize fuel system life and prevent pre-
Fuel System Primary
mature wear out from abrasive particles in the fuel, Filter/Water Separator - Drain
use Caterpillar fuel filters.
SMCS Code: 1260-543; 1263-543
Consult your Caterpillar dealer for proper part num-
bers.

9. Install the new fuel filter (2). Spin the fuel filter
onto the fuel filter base until the gasket contacts
the base. Use the rotation index marks on the
filters as a guide for proper tightening. Tighten the
filter for an additional 3/4 turn by hand. Do not
overtighten the filter.

NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contami-
nated. Contaminated fuel will cause accelerated wear
to fuel system parts. Illustration 66
g00668636

(1) Bowl
(2) Element
10. Install the clean fuel filter bowl (1) on the new fuel (3) Drain
filter.
Bowl (1) should be monitored daily for signs of water.
NOTICE If water is present, drain the water from the bowl.
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight- 1. Open drain (3). The drain is a self-ventilated drain.
ened securely to help prevent air from entering the fu- Catch the draining water in a suitable container.
el system. Dispose of the water properly.

2. Close drain (3).

11. Open the fuel tank supply valve.

12. Start the engine and check for leaks. Run the NOTICE
engine for one minute. Stop the engine and check The water separator is under suction during normal
the engine for leaks again. engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
Detection of leaks is very difficult especially if system.
the engine is running. The primary filter/water
separator is under suction. A leak will allow air to
enter the fuel. The air in the fuel can cause low i01007602
power due to aeration of the fuel. If air enters the
fuel, check the components for overtightening or Fuel System Secondary Filter -
undertightening. Replace
SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

1. Stop the engine.

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 92 SEBU7005-08
Maintenance Section
Fuel Tank Water and Sediment - Drain

2. Turn off the start switch, or disconnect the battery i03645042

(starting motor) when maintenance is performed
on fuel filters. Fuel Tank Water and Sediment
3. Shut off the fuel tank supply valve to the engine.
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Use a suitable container to catch any fuel that might NOTICE
spill. Clean up any spilled fuel immediately. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
4. Unlock the fuel priming pump (if equipped). This
collect the fluid with suitable containers before open-
relieves any residual pressure in the fuel system.
ing any compartment or disassembling any compo-
nent containing fluids.
5. Remove the used fuel filter. Use a cloth, or use a
container to catch excess fuel.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
6. Clean the gasket sealing surface of the fuel filter
lication, PECJ0003, “Caterpillar Shop Supplies and
base. Ensure that all of the old gasket is removed.
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
7. Apply clean diesel fuel to the new fuel filter gasket.
Dispose of all fluids according to local regulations and
NOTICE mandates.
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler- Fuel Tank
ated wear to fuel system parts.
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
8. Install a new fuel filter, and tighten the fuel filter excessive wear to the fuel system. Condensation
until the gasket contacts the base. occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
9. Tighten the fuel filter by hand according to the fuel system and the fuel returns to the fuel tank. This
instructions that are shown on the fuel filter. causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
Do not overtighten the fuel filter. sources can help to eliminate water in the fuel.
10. Lock the fuel priming pump (if equipped). Open
the fuel tank supply valve. Drain the Water and the Sediment
11. If the engine stalls, refer to the Operation and Fuel tanks should contain some provision for draining
Maintenance Manual, “Fuel System - Prime” topic water and draining sediment from the bottom of the
(Maintenance Section) for more information. fuel tanks.

Open the drain valve on the bottom of the fuel tank

in order to drain the water and the sediment. Close
the drain valve.

Note: Failure to properly close the drain can allow air

into the system, which could have detrimental results
to performance.

Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.

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 SEBU7005-08 93
Maintenance Section
Heat Exchanger - Inspect

Fill the fuel tank after operating the engine in Operating the engine in water that contains
order to drive out moist air. This will help prevent silt, sediment, salt, algae, or other significant
condensation. Do not fill the tank to the top. The contaminants will have an adverse effect on the heat
fuel expands as the fuel gets warm. The tank may exchanger system. In addition, intermittent use of
overflow. the vessel will adversely affect the heat exchanger
system.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel The following items indicate that the heat exchanger
supply pipe. Some fuel tanks use supply lines that may require cleaning:
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular • Increased coolant temperature
maintenance of the fuel system filter is important.
• Engine overheating
Fuel Storage Tanks
• Excessive pressure drop between the water inlet
Drain the water and the sediment from the fuel and the water outlet
storage tank during the following conditions:
An operator that is familiar with the normal operating
temperature of the coolant can determine when
• Weekly the coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger is
• Oil change required if the engine is overheating.
• Refill of the tank For information on maintenance of the heat
This will help prevent water or sediment from being exchanger and cleaning of the heat exchanger, refer
to Disassembly and Assembly, “Heat Exchanger -
pumped from the storage tank into the engine fuel
Disassemble”.
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended. Refer
Your Caterpillar dealer has the equipment and the
to Special Publication, SENR9620, “Improving Fuel
personnel in order to measure the pressure drop
System Durablity”.
across the heat exchanger.
If a bulk storage tank has been refilled or moved
Consult your Caterpillar dealer or refer to the
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal Service Manual for service information for the heat
exchanger.
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel. i02121526
When possible, water separators should be used.
Hoses and Clamps -
i01065537 Inspect/Replace
Heat Exchanger - Inspect SMCS Code: 7554-040; 7554-510

SMCS Code: 1379-040 Inspect all hoses for leaks that are caused by the
following conditions:
The interval for the maintenance of the plate type heat
exchanger depends on the operating environment of • Cracking
the vessel and on the operating time. The raw/sea
water that is circulated through the heat exchanger • Softness
and the amount of operating time of the vessel affects
the following items: • Loose clamps
• Cleanliness of the heat exchanger plates Replace hoses that are cracked or soft. Tighten any
loose clamps.
• Effectiveness of the heat exchanger system

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 94 SEBU7005-08
Maintenance Section
Maintenance Recommendations

2. Loosen the cooling system filler cap slowly in

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

• End fittings that are damaged or leaking 5. Disconnect the old hose.

• Outer covering that is chafed or cut 6. Replace the old hose with a new hose.

• Exposed wire that is used for reinforcement 7. Install the hose clamps with a torque wrench.

• Outer covering that is ballooning locally Note: Refer to the Specifications, SENR3130,
“Torque Specifications” in order to locate the proper
• Flexible part of the hose that is kinked or crushed torques.

• Armoring that is embedded in the outer covering 8. Refill the cooling system.
A constant torque hose clamp can be used in place 9. Clean the cooling system filler cap. Inspect the
of any standard hose clamp. Ensure that the constant cooling system filler cap's gaskets. Replace
torque hose clamp is the same size as the standard the cooling system filler cap if the gaskets are
clamp. damaged. Install the cooling system filler cap.
Due to extreme temperature changes, the hose will 10. Start the engine. Inspect the cooling system for
heat set. Heat setting causes hose clamps to loosen. leaks.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
i03646846
Each installation application can be different. The
differences depend on the following factors: Maintenance
Recommendations
• Type of hose
SMCS Code: 1000
• Type of fitting material
• Anticipated expansion and contraction of the hose Maintenance Information
The operating conditions of an engine affect the
• Anticipated expansion and contraction of the maintenance intervals and the time between
fittings
overhauls for the engine. The following conditions
affect the maintenance intervals and the expected
Replace the Hoses and the Clamps overhaul interval for the engine.

Severe Operation

Pressurized System: Hot coolant can cause seri- Severe operation is the use of an engine that
ous burns. To open the cooling system filler cap, exceeds current published standards for the engine.
stop the engine and wait until the cooling system Caterpillar maintains standards for the following
components are cool. Loosen the cooling system engine parameters:
pressure cap slowly in order to relieve the pres-
sure. • Horsepower
• Range of rpm
1. Stop the engine. Allow the engine to cool.
• Fuel consumption

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 SEBU7005-08 95
Maintenance Section
Maintenance Recommendations

• Fuel quality Cleanliness

• Altitude Unless the equipment is cleaned regularly, extended

operation in a dirty environment and in a dusty
• Maintenance intervals environment can damage components. Built up mud,
dirt, and dust can encase components. This can
• Selection of oil make maintenance difficult. The buildup can contain
corrosive chemicals. Corrosive chemicals and salt
• Selection of coolant can damage some components.

• Environmental qualities Improper Operating Procedures

• Installation • Extended operation at low idle
Refer to the standards for your engine or consult your • Minimum cool down periods after high load factor
Caterpillar dealer in order to determine if your engine operation
is operating within the defined parameters.
• Operating the engine beyond the guidelines for the
Severe operation can accelerate component wear. engine rating
Engines that are operating under severe conditions
may need more frequent maintenance intervals for • Operating the engine at loads that are greater than
the following reasons: the rated load

• Maximum reliability • Operating the engine at speeds that are greater

than the rated speed
• Retention of full service life
• Use of the engine for an application that is not
Because of individual applications, it is not possible approved
to identify all of the factors which can contribute to
severe operation. Consult your Caterpillar dealer
about the maintenance that is needed for your
Improper Maintenance Practices
specific engine.
• Extension of maintenance intervals
The following factors can contribute to severe
operation: environment, improper operating • Not using recommended fuel, lubricants, and
antifreeze/coolant solutions
procedures, and improper maintenance practices.

Environmental Factors Overhaul Information

Extreme Ambient Temperatures Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
Extended operation in environments that are power demand should increase both the engine
extremely cold or hot can damage components. Valve service life and the overhaul interval.
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very The need for an overhaul is generally indicated by
cold temperatures. Extremely hot inlet air reduces increased fuel consumption and by reduced power.
the performance capabilities of the engine.
The following factors are important when a decision
Note: See this Operation and Maintenance Manual, is being made on the proper time for an engine
“Cold Weather Operation” topic (Operation Section), overhaul:
or see Supplement, SEBU5898, “Cold Weather
Recommendations”. • 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

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 96 SEBU7005-08
Maintenance Section
Overhaul (Major)

Note: Refer to this Operation and Maintenance • The best cost/value relationship per hour of
Manual, “Overhaul (Major)” for further information extended life can be attained.
about the major overhaul.
After Failure Overhaul
Oil Consumption as an Overhaul If a major engine failure occurs and the engine must
Indicator be removed from the hull, many options are available.
An overhaul should be performed if the engine block
Oil consumption, fuel consumption, and maintenance or the crankshaft needs to be repaired.
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil If the engine block is repairable and/or the crankshaft
consumption can also be used to estimate the is repairable, the overhaul cost should be between 40
required capacity of a makeup oil tank that is suitable percent and 50 percent of the cost of a new engine
for the maintenance intervals. with a similar exchange core.

Oil consumption is in proportion to the percentage This lower cost can be attributed to three aspects:
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is • Specially designed Caterpillar engine features
consumed per hour also increases.
• Caterpillar dealer exchange components
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per • Caterpillar Inc. remanufactured exchange
bhp). The brake specific oil consumption (BSOC) components
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine. i03398635

When an engine's oil consumption has risen to three

Overhaul (Major)
times the original oil consumption rate due to normal
SMCS Code: 7595-020-MJ
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
The need for a major overhaul is determined by
and a slight increase in fuel consumption.
several factors.

Overhaul Options • An increase of oil consumption

Before Failure Overhaul • An increase of crankcase blowby
To minimize downtime, Caterpillar Inc. recommends • The total amount of fuel consumption
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you • The service hours of the engine
with the best cost/value relationship.
• The wear metal analysis of the lube oil
Note: Overhaul programs vary according to the
engine application and according to the dealer that • An increase in the levels of noise and vibration
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available An increase of wear metals in the lube oil indicates
overhaul programs and about overhaul services for that the bearings and the surfaces that wear may
extending the engine life. need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
A planned overhaul before failure may be the best require service.
value for the following reasons:
Note: It is possible for oil analysis to indicate a
• Costly unplanned downtime can be avoided. decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
• Many original parts can be reused according to the occurs. Also, the increased use of lube oil will dilute
standards for reusable parts. the wear metals.

• The engine's service life can be extended without Monitor the engine as the engine accumulates
the risk of a major catastrophe due to engine service hours. Consult your Caterpillar dealer about
failure. scheduling a major overhaul.

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 SEBU7005-08 97
Maintenance Section
Overhaul (Major)

Note: The driven equipment may also require service Inspection, Reconditioning or
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Exchanging of Components
Inspect the following components according to
For the major overhaul, all of the bearings,
the instructions that are in Caterpillar reusability
seals, gaskets, and components that wear are
publications. Refer to Guidelines for Reusable
disassembled. The parts are cleaned and inspected.
Parts and Salvage Operations, SEBF8029, “Index
If necessary, the parts are replaced. The crankshaft
of Publications on Reusability or Salvage of Used
is measured for wear. The crankshaft may require
Parts”.
regrinding. Alternatively, the crankshaft may be
replaced with a Caterpillar replacement part.
Recondition the worn components or exchange the
components, if necessary. Your Caterpillar dealer can
Your Caterpillar dealer can provide these services
provide these services and components.
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications. • Camshaft followers
• Camshaft thrust washers
Replacement of Components
• Connecting rods
Replace the following components during the major
overhaul: • Crankshaft vibration damper
• Camshaft bearings • Cylinder head assembly
• Connecting rod bearings • Cylinder liners
• Crankshaft seals • Engine mounts
• Crankshaft thrust washers • Scavenge oil pump
• Electronic unit injectors • Engine wiring harness
• Gear train bushings • Exhaust manifold seals
• Gear train bearings • Exhaust manifold bellows
• Main bearings • Fuel pressure regulating valve
• Piston rings • Fuel priming pump
• Aftercooler core • Fuel transfer pump
International Convention for Safety of • Inlet manifold gaskets
Life at Sea (SOLAS)
• Inlet manifold seals
Caterpillar recommends replacing the following:
• Oil cooler core
• All shields that have been installed to cover up fuel • Oil pump
and oil line connections per (SOLAS) regulations

• All marine certification society approved tapes are • Pistons

installed in order to cover up fuel line connections
and oil line connections according to the SOLAS • Piston pins
regulations.
• Prelube pump
• Pushrods
• Rocker arms
• Spacer plate

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 98 SEBU7005-08
Maintenance Section
Overhaul (Major)

• Software update • Excessive wear of the front bearing for the

crankshaft
• Turbocharger
• Excessive wear of the gear train that is not caused
by a lack of lubrication
Inspection of Components
Inspect the following components according to Inspect the gears of the gear train and inspect the
gear train bushings for the following conditions:
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index • Worn gear teeth
of Publications on Reusability or Salvage of Used
Parts”. • Unusual fit

• Camshaft • Unusual wear

In addition to the inspection of components, inspect
• Crankshaft the alignment of the driven equipment. See the
Application and Installation Guide for the engine or
• Driven equipment (alignment) see the literature that is provided by the OEM of the
driven equipment.
• Engine cylinder block
• Engine control module Cleaning of Components
• Flywheel Clean the oil suction screen. Also, remove side
covers in order to clean the oil sump. For instructions
• Front gear train (gears) on removal and installation of components, see
the Service Manual, “Disassembly and Assembly”
• Oil suction screen module.

• Rear gear train Obtain a Coolant Analysis

Inspect the camshaft for damage to the journals and
For conventional heavy-duty coolant or antifreeze,
the lobes. check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA
Inspect the crankshaft for any of the following
can be checked with an S·O·S coolant analysis (Level
conditions: I). A more detailed coolant analysis is recommended
periodically.
• Deflection
For example, considerable deposits are found in the
• Damage to the journals water jacket areas on the external cooling system,
but the concentrations of coolant additives were
• Bearing material that has seized to the journals carefully maintained. The coolant water probably
contained minerals which were deposited on the
Check the journal taper and the profile of the
engine over time.
crankshaft journals. Check these components by
interpreting the wear patterns on the following
A coolant analysis can be conducted in order to verify
components:
the condition of the water that is being used in the
cooling system. A full water analysis may be obtained
• rod bearing from the following sources:
• main bearings • Caterpillar dealer
Note: If the crankshaft or the camshaft are removed
for any reason, use the magnetic particle inspection • Local water utility company
process to check for cracks.
• Agricultural agent
Replace the crankshaft vibration damper if any of the
following conditions occur: • Independent laboratory

• Engine failure due to a broken crankshaft

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 SEBU7005-08 99
Maintenance Section
Sea Water Strainer - Clean/Inspect

Caterpillar recommends an S·O·S coolant analysis i00651416

(Level II). This is a comprehensive chemical
evaluation of the coolant. This analysis is also a Starting Motor - Inspect
check of the overall condition of the inside of the
cooling system. The following services are provided: SMCS Code: 1451-040; 1453-040

• Full Level I analysis Caterpillar Inc. recommends a scheduled inspection

of the starting motor. If the starting motor fails, the
• Identification of the source of metal corrosion and engine may not start in an emergency situation.
of contaminants
Check the starting motor for proper operation. Check
• Identification of buildup of the impurities that cause the electrical connections and clean the electrical
corrosion connections. Refer to the Service Manual for more
information on the checking procedure and for
• Identification of buildup of the impurities that cause specifications or consult your Caterpillar dealer for
scaling assistance.

• Determination of possible electrolysis within the i01539769

engines' cooling system
Turbocharger - Inspect
A report of the results of the analysis is provided.
Maintenance recommendations are based on the SMCS Code: 1052-040; 1052
results.
Periodic inspection and cleaning is recommended
For more information about S·O·S coolant analysis, for the turbocharger compressor housing (inlet side).
consult your Caterpillar dealer. Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
i00905687
compressor housing. Over time, this buildup can
Sea Water Strainer - contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
Clean/Inspect
If the turbocharger fails during engine operation,
SMCS Code: 1371-040; 1371-070 damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
The sea water strainer must be clean in order to turbocharger compressor wheel can cause additional
allow proper engine cooling. Check the sea water damage to the pistons, the valves, and the cylinder
strainer for plugging. Inspect the sea water strainer head.
more frequently if the vessel is being operated
in water which is shallow or dirty. Refer to the NOTICE
OEM recommendations for more information about Turbocharger bearing failures can cause large quan-
inspecting and cleaning the sea water strainer. tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
Ensure that the auxiliary water pump is primed and damage.
that the suction line is open.
Minor leakage of a turbocharger housing under ex-
1. Remove the sea water strainer and clean the tended low idle operation should not cause problems
screen. Remove any dirt and debris. as long as a turbocharger bearing failure has not oc-
curred.
2. Install the sea water strainer. Fill the sea water
strainer and the suction line for the auxiliary water When a turbocharger bearing failure is accompanied
pump with water. by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.

An inspection of the turbocharger can minimize

unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.

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 100 SEBU7005-08
Maintenance Section
Walk-Around Inspection

Note: Turbocharger components require precision 6. Clean the turbocharger housing with standard
clearances. The turbocharger cartridge must shop solvents and a soft bristle brush.
be balanced due to high rpm. Severe Service
Applications can accelerate component wear. 7. Fasten the air inlet piping and the exhaust outlet
Severe Service Applications require more frequent piping to the turbocharger housing.
inspections of the cartridge.
i02706582
Removal and Installation
Walk-Around Inspection
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer. SMCS Code: 1000-040
Refer to the Service Manual for this engine for the
procedure and specifications. Inspect the Engine for Leaks and
Cleaning and Inspecting for Loose Connections
A walk-around inspection should only require a few
1. Remove the exhaust outlet piping and remove minutes. When the time is taken to perform these
the air inlet piping from the turbocharger. Visually checks, costly repairs and accidents can be avoided.
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt For maximum engine service life, make a thorough
from entering during reassembly. inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
2. Turn the compressor wheel and the turbine wheel leaks, loose bolts, worn belts, loose connections and
by hand. The assembly should turn freely. Inspect trash buildup. Make repairs, as needed:
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
compressor wheel and the turbocharger housing, contamination.
the turbocharger must be reconditioned.

3. Check the compressor wheel for cleanliness. NOTICE

If only the blade side of the wheel is dirty, dirt For any type of leak (coolant, lube, or fuel) clean up the
and/or moisture is passing through the air filtering fluid. If leaking is observed, find the source and correct
system. If oil is found only on the back side of the the leak. If leaking is suspected, check the fluid levels
wheel, there is a possibility of a failed turbocharger more often than recommended until the leak is found
oil seal. or fixed, or until the suspicion of a leak is proved to be
unwarranted.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil NOTICE
may also be the result of a restriction of the line for Accumulated grease and/or oil on an engine or deck is
the inlet air (plugged air filters), which causes the a fire hazard. Remove this debris with steam cleaning
turbocharger to slobber. or high pressure water.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater • Ensure that the cooling lines are tight and ensure
than the Service Manual specifications, the that the cooling lines are properly clamped. Check
turbocharger should be repaired or replaced. for leaks. Check the condition of all pipes.
An end play measurement that is less than the
minimum Service Manual specifications could • Inspect the water pumps for coolant leaks.
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning Note: The water pump seal is lubricated by coolant
and for inspection if the measured end play is less in the cooling system. It is normal for a small amount
than the minimum Service Manual specifications. of leakage to occur as the engine cools down and
the parts contract.
5. Inspect the bore of the turbine housing for
corrosion.

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 SEBU7005-08 101
Maintenance Section
Water Pump - Inspect

Excessive coolant leakage may indicate the need • A piston seizure

to replace the water pump seal. For the removal of
water pumps and the installation of water pumps • Other potential damage to the engine
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer. A failed water pump might cause severe engine
overheating problems that could result in cracks in
• Inspect the lubrication system for leaks at the front the cylinder head, a piston seizure or other potential
crankshaft seal, the rear crankshaft seal, the oil damage to the engine.
pan, the oil filters and the valve cover.
Visually inspect the water pump for leaks. If leaking
• Inspect the fuel system for leaks. Look for loose of the water pump seals is observed, replace all of
fuel line clamps. the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump
• Inspect the piping for the air inlet system and the - Disassemble and Water Pump - Assemble” for
elbows for cracks and for loose clamps. the disassembly and assembly procedure. If it is
necessary to remove the water pump, refer to two
• Inspect the alternator belt and the accessory drive articles in the Disassembly and Assembly Manual,
belts for cracks, breaks or other damage. “Water Pump - Remove and Water Pump - Install”.

Belts for multiple groove pulleys must be replaced as Inspect the water pump for wear, cracks, pin holes
matched sets. If only one belt is replaced, the belt will and proper operation. Refer to the Parts Manual
carry more load than the belts that are not replaced. for the correct part numbers for your engine or
The older belts are stretched. The additional load on consult your Caterpillar dealer if repair is needed or
the new belt could cause the belt to break. replacement is needed.

• Drain the water and the sediment from fuel tanks i01851812
on a daily basis in order to ensure that only clean
fuel enters the fuel system. Zinc Rods - Inspect/Replace
• Inspect the wiring and the wiring harnesses for SMCS Code: 1388-040; 1388-510
loose connections and for worn wires or frayed
wires. Corrosion in sea water circuits can result in premature
deterioration of system components, leaks, and
• Inspect the ground strap for a good connection and possible cooling system contamination.
for good condition.
Zinc rods are inserted in the sea water cooling
• Inspect the ECM to the cylinder head ground strap system of the engine in order to help prevent the
for a good connection and for good condition. corrosive action of salt water. The reaction of the zinc
to the sea water causes the zinc rods to deteriorate.
• Disconnect any battery chargers that are not The zinc rods deteriorate instead of engine parts
protected against the current drain of the starting for the cooling system that are more critical. Rapid
motor. Check the condition and the electrolyte level deterioration of zinc rods may indicate the presence
of the batteries, unless the engine is equipped with of uncontrolled electrical currents from improperly
a maintenance free battery. installed electrical attachments or improperly
grounded electrical attachments.
• Check the condition of the gauges. Replace any
gauges which are cracked and replace any gauges The zinc rods must be inspected at the proper
that can not be calibrated. intervals. The zinc rods must be replaced when
deterioration occurs.
i03543200
Inspect the zinc rods within 24 hours of initially
Water Pump - Inspect filling the plumbing with sea water. If no significant
corrosion is noted, inspect the zinc rods again after
SMCS Code: 1361-040; 1361 seven days or 50 hours of engine operation after
having been immersed in sea water. If no significant
A failed water pump might cause severe engine deterioration is noted, continue inspections after
overheating problems that could result in the following every 50 hours of engine operation.
conditions:

• Cracks in the cylinder head

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 102 SEBU7005-08
Maintenance Section
Zinc Rods - Inspect/Replace

Inspect the Zinc Rods 2. Apply 9S-3263 Compound to the shoulder of

a new zinc rod. Apply the compound only to the
The zinc rods are red for easy identification. Table shoulder of the zinc rod. Install the zinc rod into
11 shows the locations of the zinc rods and the the plug.
quantities of the zinc rod:
3. Coat the external threads of the plug with
Table 11 5P-3413 Pipe Sealant. Install the zinc rod. Refer
Locations of the Zinc Rods to Operation and Maintenance Manual for more
information on torque specifications.
Location Quantity
Inlet Adapter of the Heat Exchanger 1
Outlet Elbow of the Heat Exchanger 1
Outlet Elbow of the Auxiliary Water Pump 1
Outlet Adapter for the Aftercooler 1

1. Remove the zinc rod.

g00104048
Illustration 67

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

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

Replace the Zinc Rods

g00104049
Illustration 68

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

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