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Page 1

®© 2010 Caterpillar
All Rights Reserved

®

MAINTENANCE INTERVALS
Operation and Maintenance
Manual Excerpt

Page 2

SEBU6497-07
December 2005

Operation and
Maintenance
Manual
3408C, 3412, 3412C and 3412D High
Performance Marine Engines
REA1-Up (Engine)
8RG1-Up (Engine)
3JK1-Up (Engine)
7BL1-Up (Engine)

Page 20

92 SEBU6497-07
Maintenance Section
Engine Air Cleaner Element - Clean/Replace

Visually inspect the element before cleaning. Inspect
the element for damage to the seal, the gaskets, and
the outer cover. Discard any damaged elements.

There are four common methods that are used to
clean elements:

• Pressurized water

• Pressurized air

• Vacuum cleaning

• Washing with nonsudsing detergent

Pressurized Water

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

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

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

Note: Refer to “Drying the Paper Air Cleaner
Elements”. Refer to “Inspecting the Paper Air Cleaner
Elements”.

Pressurized Air

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

g00281692Illustration 32

Note: When the paper air cleaner elements are
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).

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

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

Vacuum Cleaning

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

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

Washing the Paper Air Cleaner Elements with
Nonsudsing Detergent

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

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

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

Note: Caterpillar does not recommend a process
for washing the element which includes vigorously
shaking. By vigorously shaking the element, carbon
particles may be distributed.

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

Page 21

SEBU6497-07 93
Maintenance Section

Engine Air Cleaner Element - Clean/Replace

3. Drain the wash tank. Do not use the cleaning agent
more than one time. Remove the element from
the wash tank. Rinse the element by performing
the method for cleaning with pressurized water.

Note: Refer to “Drying the Paper Air Cleaner
Elements”. Refer to “Inspecting the Paper Air Cleaner
Elements”.

Drying the Paper Air Cleaner Elements

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

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

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

Inspecting the Paper Air Cleaner
Elements

g00281693Illustration 33

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

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

Storing Paper Air Cleaner Elements

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

g00281694Illustration 34

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

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

• Date of the cleaning

• Number of cleanings

Store the box in a dry location.

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

Page 40

112 SEBU6497-07
Maintenance Section
Water Pump - Inspect

For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:

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

• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.

NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.

NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.

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

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

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.

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

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

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

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

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

Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.

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

• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.

• Inspect the ground strap for a good connection and
for good condition.

• Inspect the ECM to the cylinder head ground strap
for a good connection and for good condition.

• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.

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

i01057943

Water Pump - Inspect
SMCS Code: 1361-040; 1361

A failed water pump might cause severe engine
overheating problems that could result in the following
conditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Visually inspect the water pump for leaks. If any
leaking is observed, replace the water pump seal
or the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure.

Note: Refer to the Service Manual or consult your
Caterpillar dealer if any repair is needed or any
replacement is needed.

Page 41

SEBU6497-07 113
Maintenance Section

Zinc Rods - Inspect/Replace

i01421084

Zinc Rods - Inspect/Replace
SMCS Code: 1388-040; 1388-510

Corrosion in sea water circuits can result in premature
deterioration of system components, leaks, and
possible cooling system contamination.

Zinc rods are inserted in the sea water cooling
system of the engine in order to help prevent the
corrosive action of salt water. The reaction of the zinc
to the sea water causes the zinc rods to deteriorate.
The zinc rods deteriorate instead of engine parts
for the cooling system that are more critical. Rapid
deterioration of zinc rods may indicate the presence
of uncontrolled electrical currents from improperly
installed electrical attachments or improperly
grounded electrical attachments.

The zinc rods must be inspected at the proper
intervals. The zinc rods must be replaced when
deterioration occurs.

Inspect the Zinc Rods
The zinc rods are red for easy identification. Table
37 shows the locations of the zinc rods and the
quantities of the zinc rod:

Table 37

Locations of the Zinc Rods

Location Quantity

Inlet Adapter of the Heat Exchanger 1

Outlet Elbow of the Heat Exchanger 1

Outlet Elbow of the Auxiliary Water Pump 1

1. Remove the zinc rod.

g00104048Illustration 43

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

g00104049Illustration 44

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

2. Apply 9S-3263 Compound to the shoulder of a
new zinc rod. Apply the compound only to the
shoulder of the zinc rod. Install the zinc rod into
the plug.

3. Coat the external threads of the plug with
5P-3413 Pipe Sealant. Install the zinc rod. Refer
to Operation and Maintenance Manual for more
information on torque specifications.

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