Caterpillar 3208 Marine Engine Maintenance Intervals

56 Maintenance Section Maintenance Interval Schedule i00917973 Maintenance Interval Schedule SMCS Code: 1000; 7500 Note: Ensure that the Safety Information, warnings, and instructions are read and understood before operation or maintenance procedures are performed. Before each consecutive interval is performed, all of the maintenance requirements from the previous interval must also be performed. Note: For engines that are equipped with AIRSEP® engine air cleaners, the turbocharger should be inspected every 1000 service hours. When Required Belt - Inspect/Adjust/Replace ................................ 59 Battery - Recycle .................................................. 61 Battery or Battery Cable - Disconnect .................. 62 Engine Oil Level Gauge - Calibrate ...................... 78 Fuel System - Prime ............................................. 87 Daily Cooling System Coolant Level - Check ................ 66 Engine Air Cleaner Service Indicator - Inspect ..... 75 Engine Oil Level - Check ...................................... 77 Fuel System Water Separator - Drain ................... 90 Marine Transmission Oil Level - Check ................ 95 Walk-Around Inspection ...................................... 102 Every 1900 L (500 US gal) of Fuel or 50 Service Hours Aftercooler Drain Plug - Inspect ............................ 57 Engine Air Cleaner Element (Foam) - Clean/Replace .................................................... 71 Zinc Rods - Inspect/Replace ............................... 104 Initial 9000 L (2400 US gal) of Fuel or 250 Service Hours or 1 Year Engine Valve Lash - Inspect/Adjust ...................... 84 Every 9000 L (2400 US gal) of Fuel or 250 Service Hours or Yearly Auxiliary Water Pump - Inspect ............................. 59 Belt - Inspect/Adjust/Replace ................................ 59 Battery Electrolyte Level - Check .......................... 61 Cooling System Supplemental Coolant Additive (SCA) - Test/Add ................................................. 67 Engine Air Cleaner Element - Clean/Replace ....... 72 Engine Crankcase Breather - Clean ..................... 76 Engine Oil Sample - Obtain .................................. 81 Engine Oil and Filter - Change ............................. 82 Engine Protective Devices - Check ...................... 83 Exhaust Restrictor - Inspect/Adjust ....................... 84 Fuel System Primary Filter/Water Separator Element - Replace ............................................................. 88 Fuel System Secondary Filter - Replace .............. 89 Fuel Tank Water and Sediment - Drain ................. 91 Hoses and Clamps - Inspect/Replace .................. 93 Magnetic Pickups - Clean/Inspect ........................ 94 Oil Fumes Filter - Replace .................................... 95 Sea Water Strainer - Clean/Inspect .................... 100 Every 36 000 L (9000 US gal) of Fuel or 1000 Service Hours or 2 Years Aftercooler Core - Clean/Test ............................... 57 Cooling System Coolant (DEAC) - Change .......... 62 Cooling System Water Temperature Regulator - Replace ............................................................... 69 Engine - Clean ...................................................... 71 Governor Housing - Drain ..................................... 92 Marine Transmission Oil Cooler - Clean/Inspect .. 94 PCV Valve - Inspect .............................................. 99 Every 72 000 L (19 000 US gal) of Fuel or 2000 Service Hours Alternator - Inspect ............................................... 58 Crankshaft Vibration Damper - Inspect ................. 70 Engine Mounts - Inspect ....................................... 77 Engine Valve Lash - Inspect/Adjust ...................... 84 Fuel Injection Nozzles - Test/Exchange ................ 86 Fuel Ratio Control - Inspect/Adjust ....................... 87 Heat Exchanger - Inspect ..................................... 92 Starting Motor - Inspect ...................................... 101 Turbocharger - Inspect ........................................ 101 Every 108 000 L (28 500 US gal) of Fuel or 3000 Service Hours or 2 Years Cooling System Coolant Extender (ELC) - Add .... 66 Water Pump - Inspect ......................................... 103 Every 114 000 L (30 000 US gal) of Fuel Overhaul Considerations ...................................... 96 Every 216 000 L (57 000 US gal) of Fuel or 6000 Service Hours or 4 Years Cooling System Coolant (ELC) - Change ............. 64

57 Maintenance Section Aftercooler Drain Plug - Inspect i00913406 Aftercooler Drain Plug - Inspect SMCS Code: 1063-040 g00466348 Illustration 15 Typical location of aftercooler drain Inspect the plug for the aftercooler drain (if equipped). Ensure that the plug is one of the following plugs: • 101-3713 Tethered Plug • 9x-8406 Plug (stainless steel) NOTICE A failed aftercooler drain plug can cause the engine compartment to fill with sea water. Any plugs used in the aftercooler drain port, other than those recommended above, may corrode. Use only those recommended plugs. i00744980 Aftercooler Core - Clean/Test SMCS Code: 1064-070; 1064-081 1. Remove the core. Refer to the Service Manual for the procedure. 2. Turn the aftercooler core upside-down in order to remove debris. NOTICE Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner. 3. Back flush the core with cleaner. Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 23 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer. Table 23 Hydrosolv Liquid Cleaners (1) Description Container 1U-8812 Hydrosolv 4165 4 L (1 US gal) 1U-5490 Hydrosolv 4165 19 L (5 US gal) 8T-7570 Hydrosolv 4165 208 L (55 US gal) 1U-8804 Hydrosolv 100 4 L (1 US gal) 1U-5492 Hydrosolv 100 19 L (5 US gal) 8T-7571 Hydrosolv 100 208 L (55 US gal) (1) Use a two to five percent concentration of the cleaner at temperatures up to 93°C (200°F). Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer for more information. 4. Steam clean the core in order to remove any residue. Flush the fins of the aftercooler core. Remove any other trapped debris. 5. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

58 Maintenance Section Alternator - Inspect Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. 6. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow. 7. Inspect the core in order to ensure cleanliness. Pressure test the core. Many shops that service radiators are equipped to perform pressure tests. If necessary, repair the core. 8. Install the core. Refer to the Service Manual for the procedure. For more information on cleaning the core, consult your Caterpillar dealer. i00997205 Alternator - Inspect SMCS Code: 1405-040 Note: This engine is equipped with an alternator circuit breaker. Note the location of the alternator circuit breaker for your particular application. If the alternator circuit breaker trips, you will need to reset the breaker in order for the charging system to operate. Refer to the information that is provided by the OEM for more information. Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required. Refer to the Service Manual. Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge.

59 Maintenance Section Auxiliary Water Pump - Inspect i00911249 Auxiliary Water Pump - Inspect SMCS Code: 1371-040 Impellers and seals require periodic inspection. Impellers have a service life that is limited. The service life depends on the engine operating conditions. Inspect the components more frequently when the pump is exposed to debris, sand, or other abrasive materials. Inspect the components if the pump is operating at a differential pressure of more than 103 kPa (15 psi). Check the following components for wear or damage: • Bearings • Cam • Impeller • Seals • Wear plate If wear or damage is found, replace the components which are worn or damaged. Use the proper repair kit for the pump. Refer to the Disassembly and Assembly for more information on servicing the auxiliary water pump. i00912007 Belt - Inspect/Adjust/Replace SMCS Code: 1357-039 Inspection Belt tension should be checked initially between the first 20 to 40 hours of engine operation. After the initial check, the belt tension should be checked at Every 250 Service Hours or Three Months. To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged. For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break. If the belts are too loose, vibration causes unnecessary wear on the belts and pulleys. Loose belts may slip enough to cause overheating. If the belts are too tight, unnecessary stresses are placed on the pulley bearings and on the belts. This may shorten the service life of the components. Remove the belt guard. Inspect the condition and adjustment of the alternator belts and accessory drive belts (if equipped). If the belts do not require replacement or adjustment, install the belt guard. If the belts require adjustment or replacement, perform the following procedure to adjust the belt tension.

60 Maintenance Section Belt - Inspect/Adjust/Replace Adjustment Alternator Belt g00465617 Illustration 16 Typical illustration (1) Mounting bolt (2) Adjustment bolt (3) Bracket bolts 1. Slightly loosen mounting bolt (1) and adjusting bolt (2). 2. Move the alternator in order to adjust the belt tension. If the alternator will not adjust, it may be necessary to slightly loosen bracket bolts (3). Refer to the Specifications, “Belt Tension Chart” topic. 3. Tighten adjusting bolt (2) and mounting bolt (1). Tighten bracket bolts (3) if the bracket bolts were loosened. Refer to the Operation and Maintenance Manual, “Torque Specifications” topic (Maintenance Section). 4. Install the belt guard. If new belts are installed, check the belt tension again after 30 minutes of engine operation at the rated rpm. Auxiliary Water Pump Belt g00465541 Illustration 17 Typical illustration (1) Mounting bolts (2) Slotted hole 1. Slightly loosen mounting bolts (1). 2. Adjust the belt tension with a pry bar in slotted hole (2). Refer to the Specifications, “Belt Tension Chart” topic. 3. Tighten mounting bolts (2). Refer to the Operation and Maintenance Manual, “Torque Specifications” topic (Maintenance Section). 4. Install the belt guard. If new belts are installed, check the belt tension again after 30 minutes of engine operation at the rated rpm.

61 Maintenance Section Battery - Recycle i00037658 Battery - Recycle SMCS Code: 1401-561 1. Always recycle a battery. Never discard a battery. 2. Always return used batteries to one of the following locations. • A battery supplier • An authorized battery collection facility • Recycling facility i00914454 Battery Electrolyte Level - Check SMCS Code: 1401-081 When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are properly charged, ammeter reading should be very near zero. All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries. 1. Remove the filler caps. Maintain the electrolyte level to the “FULL” mark on the battery. If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water. 2. Check the condition of the electrolyte with the 1U-7298 Coolant/Battery Tester (°C) or the 1U-7297 Coolant/Battery Tester (°F). 3. Keep the batteries clean. Clean the battery case with one of the following cleaning solutions: • A mixture of 0.1 L (.12 qt) of baking soda and 1 L (1 qt) of clean water • A mixture of 0.1 L (.12 qt) of ammonia and 1 L (1 qt) of clean water Thoroughly rinse the battery case with clean water. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit properly. Coat the clamps and the terminals with 5N-5561 Lubrication Compound, petroleum jelly or MPGM grease.

62 Maintenance Section Battery or Battery Cable - Disconnect i00095575 Battery or Battery Cable - Disconnect SMCS Code: 1402-029 1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads. 2. Disconnect the negative battery terminal at the battery that goes to the start switch. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, the negative side of two batteries must be disconnected. 3. Tape the leads in order to help prevent accidental starting. 4. Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the cables. i00906400 Cooling System Coolant (DEAC) - Change SMCS Code: 1350-070; 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. • Foaming is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. NOTICE Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are ap- proved for Caterpillar engines. Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary. 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 system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. 2. Open the cooling system drain valve (if equipped). If the cooling system is not equipped with a drain valve, remove one of the drain plugs. Allow the coolant to drain.

63 Maintenance Section Cooling System Coolant (DEAC) - Change NOTICE Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Service Technology Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL Flush 1. Flush the cooling system with clean water in order to remove any debris. 2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Operation and Maintenance Manual, “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Install the cooling system filler cap. 4. Start and run the engine at low idle for a minimum of 30 minutes. The coolant temperature should be at least 82 °C (180 °F). NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone. 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain valve (if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Operation and Maintenance Manual, “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. Cooling Systems with Heavy Deposits or Plugging Note: For the following procedure to be effective, there must be some active flow through the cooling system components. 1. Flush the cooling system with clean water in order to remove any debris. 2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Operation and Maintenance Manual, “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the cooling system filler cap. 4. Start and run the engine at low idle for a minimum of 90 minutes. The coolant temperature should be at least 82 °C (180 °F). NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

64 Maintenance Section Cooling System Coolant (ELC) - Change 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain valve (if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Operation and Maintenance Manual, “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. Fill NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 1. Fill the cooling system with coolant/antifreeze. Refer to the Operation and Maintenance Manual, “Cooling System Specifications” topic (Maintenance Section) for more information on cooling system specifications. Do not install the cooling system filler cap. 2. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Stop the engine. 3. Check the coolant level. Maintain the coolant level within 13 mm (.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within 13 mm (.5 inch) to the proper level on the sight glass (if equipped). 4. Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket that is on the cooling system filler cap is not damaged, perform a pressure test. A 9S-8140 Pressurizing Pump is used to perform the pressure test. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap. 5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature. i00906586 Cooling System Coolant (ELC) - Change SMCS Code: 1350-070; 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. • Foaming is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced. Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary. 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 system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. 2. Open the cooling system drain valve (if equipped). If the cooling system is not equipped with a drain valve, remove the cooling system drain plugs. Allow the coolant to drain. NOTICE Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant.

Caterpillar 3208 Marine Engine Maintenance Intervals

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