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Engine Protective Devices
Inspect/Check
The alarm and shutoff controls should be checked for proper operation in order to ensure engine protection. The manual shutoff devices should be tested for proper operation.All checks and tests should be made by Caterpillar authorized service personnel or other qualified mechanics. Consult with your Caterpillar dealer for assistance.Visual Inspection
Visually check the condition of all sensors and wiring. Look for loose, broken, or damaged wiring and components. Repair or replace any damaged wiring or components immediately.Engine Mounts
Inspect
Crankshaft vibration damper (1) and engine mounts (2).Inspect the engine mounts for deterioration and proper bolt torque. Engine vibration may be caused by improper engine mounting and/or engine mount deterioration. Any engine mount showing deterioration should be replaced. Refer to the Torque Specifications section of this publication for recommended bolt torque values. See the Marine Engine Application and Installation Guide for more information.Crankshaft Vibration Damper
Inspect
Damage to, or failure of, the crankshaft vibration damper will increase torsional vibrations and result in damage to the crankshaft and other engine components. A deteriorating damper will cause excessive gear train noise at variable points in the speed range.The damper is mounted to the crankshaft, located behind the belt guard on the front of the engine.Removal and Installation
Refer to the Service Manual for the damper removal procedure and for the damper installation procedure.Rubber Damper
If your engine is equipped with a rubber damper, inspect the damper for:* rubber deterioration, cracking* movement of the rubber from the original locationThe rubber damper should be replaced if any of these conditions are found.Visconic Damper
The visconic damper has a weight, located inside a fluid filled case. The weight moves in the case to limit torsional vibration. Inspect the damper for evidence of dents, cracks or leaks of the fluid.Replace the visconic damper if the damper is dented, cracked, or leaking. Refer to the Service Manual or contact your Caterpillar dealer for damper replacement.Turbocharger
Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet side) and the aftercooler core. Since the crankcase fumes are ingested through the inlet air system, oil and combustion by-products may collect in these two areas.This buildup, over time, can contribute to loss of engine power, increased black smoke, and overall loss of engine efficiency. This buildup is only a possible contributor to these conditions.Operating the engine until the turbocharger fails can severely damage the turbocharger's compressor wheel and/or the engine. Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter the engine cylinder, causing additional damage to the piston, valve, and cylinder head.
Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage.Minor leakage of a turbocharger housing under extended low idle operation will not cause problems as long as a turbocharger bearing failure has NOT occurred.When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine speed up at no load), DO NOT continue engine operation until the turbocharger is repaired or replaced.
An inspection/check of your turbocharger will minimize unscheduled downtime and reduce the chance for potential damage to other engine parts. Turbocharger components require precision clearances and balancing due to operation at high rotational (torsional) speeds. Severe Service Applications can accelerate component wear and may suggest the need to Inspect/Repair/Replace the cartridge at reduced intervals to ensure maximum reliability and retention of the full core.Removal and InstallationFor removal and installation, or repair/replacement options of turbochargers, see your Caterpillar dealer. Refer to the Service Manual for this engine or consult your Caterpillar dealer for the procedure and specifications.Clean/Inspect/Check
1. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. Visually check for oil leaks.2. Turn the compressor wheel and turbine wheel by hand. The assembly should turn freely. Inspect the compressor wheel and turbine wheel for contact with the turbocharger housing. There should NOT be any visible signs of contact between the turbine or compressor wheel and the turbocharger housing. If there is any indication of contact between the rotating wheel(s) and the housing, the turbocharger should be reconditioned or replaced.3. Check the compressor wheel for cleanliness. If only the blade side of the wheel is dirty, dirt and/or moisture is passing through the air filtering system. If oil is found only on the back side of the wheel, it indicates a possible turbocharger oil seal leak.The leak may be the result of extended engine operation at low idle or an intake air line restriction (plugged air filters), which causes the turbocharger to "slobber".4. Use a dial indicator to check end clearance on the shaft. Attach the dial indicator point on the end of turbocharger shaft. Push and pull the other end of the shaft. Note the total dial indicator reading. If the measured end play is greater than the Service Manual specifications, repair or replace the turbocharger. Measured end play less than the minimum Service Manual specifications could indicate carbon build up on the turbine wheel. The turbocharger should be disassembled for cleaning and inspection if the measured end play is less than the minimum Service Manual specifications.5. Inspect the turbine housing bore for corrosion.6. Clean the turbocharger housing with standard shop solvents and a soft bristle brush.7. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.Water Separator
Replace Element
The water separator functions as the primary fuel filter. A large amount of water in the fuel can cause the engine to misfire or run rough and may cause a fuel injector to fail. If the fuel has been contaminated with a large amount of water, the element should be replaced before the 1200 hour interval.Replace the element any time the water separator becomes so contaminated that the water level can not be seen through the transparent cover.
Turn the disconnect switch OFF or disconnect the battery when changing fuel filters or water separator elements. Drain the fuel from the water separator into a container before removing the water separator retaining