3208 Marine Engine Hoses and Clamps - Inspect/Replace Caterpillar


Hoses and Clamps - Inspect/Replace
`
1.1. Inspect Tubes, Hoses, Bellows, and Clamps
2.1. Replace the Hoses and the Clamps
3.2. Cooling System
4.2. Fuel System
5.2. Lubrication System
6.2. Air System

Hoses and clamps must be inspected periodically and replaced at the recommended interval to ensure safe and continuous operation of the engine. Failure to replace a fuel hose at the recommended change interval may result in a hazardous situation. Take proper safety precautions before inspecting or replacing hoses and clamps.

Note: Always use a board or cardboard when the engine components are checked for leaks. Leaking fluid that is under pressure can cause serious injury or possible death. Leaks that are the size of a pin hole are included. Refer to Operation and Maintenance Manual, "General Hazard Information" for more information.

Note: Ensure that the hose is compatible with the application.

Inspect Tubes, Hoses, Bellows, and Clamps

Inspect all tubes and hoses for leaks that are caused by the following conditions. Replace any tube or hose which exhibits any of the following conditions. Failure to replace a tube or hose which exhibits any of the following conditions may result in a hazardous situation.

  • Hoses which are cracked

  • Hoses which are soft

  • Outer covering that is chafed or cut

  • Exposed wire that is used for reinforcement

  • Outer covering that is ballooning locally

  • Flexible part of the hose that is kinked or crushed

  • Armoring that is embedded in the outer covering

  • Exhaust bellows for leaks or damage

  • Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps

Inspect all clamps for the following conditions. Replace any clamp which exhibits signs of any of the following conditions.

  • Cracking

  • Looseness

  • Damage

Inspect all couplings for leaks. Replace any coupling which exhibits signs of leaks.

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

  • Type of hose

  • Type of fitting material

  • Anticipated expansion and contraction of the hose

  • Anticipated expansion and contraction of the fittings

Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen which can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.

Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace hose clamps which are loose.

Replace the Hoses and the Clamps


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.


Cooling System

------ WARNING! ------

Pressurized System: Hot coolant can cause serious 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.


------ WARNING! ------

Personal injury can result from removing hoses or fittings in a pressure system.

Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.


  1. Stop the engine.

  2. Allow the engine to cool.

  3. Before servicing a coolant hose, slowly loosen the filler cap for the cooling system to relieve any pressure.

  4. Remove the filler cap for the cooling system.

  5. Drain the coolant from the cooling system to a level that is below the hose that is being replaced. Drain the coolant into a suitable clean container. The coolant can be reused.

  6. Remove the hose clamps.

  7. Disconnect the old hose.

  8. Replace the old hose with a new hose.

  9. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.

  10. Refill the cooling system.

  11. Clean the coolant filler cap. Inspect the gaskets on the filler cap. Inspect the gasket seat. Inspect the vacuum valve and seat for debris or damage. Replace the filler cap if the gaskets are damaged. Install the filler cap.

  12. Start the engine. Inspect the cooling system for leaks.

Fuel System

------ WARNING! ------

Personal injury can result from removing hoses or fittings in a pressure system.

Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.


------ WARNING! ------

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.



NOTICE

Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.



NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components.


    Note: High-pressure fuel lines may be installed between the high-pressure fuel pump and the fuel injectors. High-pressure fuel lines are constantly charged with high pressure. Do not check the high-pressure fuel lines with the engine or the starting motor in operation. Wait for 10 minutes after the engine stops before you perform any service or repair on high-pressure fuel lines. Waiting for 10 minutes will allow the pressure to be purged.

  1. Drain the fuel from the fuel system to a level that is below the hose that is being replaced.

  2. Remove the hose clamps.

  3. Disconnect the old hose.

    Note: When servicing fuel system, use cap/s or cover/s as required to protect the system and maintain fuel system cleanliness.

  4. Replace the old hose with a new hose.

  5. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.

  6. Carefully inspect the engine for any spilled fuel. Make sure that no fuel remains on or close to the engine.

    Note: Fuel must be added to the fuel system ahead of the fuel filter.

  7. Refill the fuel system. Refer to this Operation and Maintenance Manual, "Fuel System - Prime" for information about priming the engine with fuel.

  8. Start the engine. Inspect the fuel system for leaks.

Lubrication System

------ WARNING! ------

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.


  1. Drain the oil from the lubrication system to a level that is below the hose that is being replaced.

  2. Remove the hose clamps.

  3. Disconnect the old hose.

  4. Replace the old hose with a new hose.

  5. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.

  6. Refill the lubrication system. Refer to this Operation and Maintenance Manual, "Engine Oil Level - Check" to ensure that the lubrication system is filled with the proper amount of engine oil.

  7. Start the engine. Inspect the lubrication system for leaks.

Air System

  1. Remove the hose clamps.

  2. Disconnect the old hose.

  3. Replace the old hose with a new hose.

  4. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.

    Note: The bellows and the V-clamps that are used on the exhaust bellows should never be reused.

  5. Start the engine. Inspect the air lines for leaks.