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Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine. 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. This includes leaks that are the size of a pin hole. Refer to Operation and Maintenance Manual, "General Hazard Information" for more information.

Inspect the Hoses and the Clamps

Inspect all hoses for leaks that are caused by the following conditions. Replace any hose which exhibits any of the following conditions. Failure to replace a 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

• 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. This 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

Cooling System

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 in order 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 filler cap for the cooling system. Inspect the gaskets on the filler cap. 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

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 in order to allow 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.

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

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" in order 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.

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