C9 - Marine Engine - Manual de Mantencion y Operacion

SEBU7719-12
July 2009
Operation and
Maintenance
Manual
C9 Marine Engine
C9B1-Up (Engine)
CSN1-Up (Engine)
X9X1-Up (Engine)
Z9X1-Up (Engine)
X9Y1-Up (Engine)
SAFETY.CAT.COM
SEBU7719-12 65
Maintenance Section
Maintenance Interval Schedule
i03634265 Every 50 Service Hours or Weekly

Maintenance Interval Schedule Aftercooler Condensate Drain Valve -
Inspect/Clean ...................................................... 67
SMCS Code: 1000; 7500 Sea Water Strainer - Clean/Inspect .................... 108
Zinc Rods - Inspect/Replace ................................ 111
Ensure that all safety information, warnings,
and instructions are read and understood before Initial 250 Service Hours (or at first oil
any operation or any maintenance procedures change)
are performed. The user is responsible for
the performance of maintenance, including all Engine Valve Lash - Inspect/Adjust ...................... 96
adjustments, the use of proper lubricants, fluids, Injector Bolt Torque - Check ............................... 101
filters, and the installation of new components
due to normal wear and aging. The performance Every 250 Service Hours
of this product may be diminished if proper
maintenance intervals and procedures are not Drive Shaft Slip Joint - Lubricate .......................... 82
followed. Components may experience accelerated Drive Shaft Universal Joints - Lubricate ................ 83
wear if proper maintenance intervals and procedures
are not followed. Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)
Note: Use whichever of the following that occurs
first in order to determine the maintenance intervals: Cooling System Coolant Sample (Level 2) -
fuel consumption, service hours, and calendar time Obtain ................................................................. 80
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be Every 2250 Service Hours
performed.
Drive Shaft Universal Joints - Replace ................. 84
Products that operate in severe operating conditions
may require more frequent maintenance. Every Year
Cooling System Coolant Sample (Level 2) -
When Required Obtain ................................................................. 80
Battery - Replace .................................................. 69
Battery or Battery Cable - Disconnect .................. 70
Every 3000 Service Hours or 3 Years
Drive Shaft Universal Joints - Lubricate ................ 83 Cooling System Coolant (DEAC) - Change .......... 72
Engine - Clean ...................................................... 88
Engine Oil Level Gauge - Calibrate ...................... 91 Every 6000 Service Hours or 3 Years
Engine Storage Procedure - Check ...................... 95
Fuel System - Prime ............................................. 96 Cooling System Coolant Extender (ELC) - Add .... 77
Heat Exchanger - Inspect ................................... 100
Maintenance Recommendations ........................ 103 Every 12 000 Service Hours or 6 Years
Sea Water Strainer - Clean/Inspect .................... 108
Zinc Rods - Inspect/Replace ................................ 111 Cooling System Coolant (ELC) - Change ............. 75
Daily Every 7100 L (1875 US gal) of Fuel or 250

Service Hours or 1 Year
Closed Crankcase Ventilation (CCV) Filter Service
Indicator - Inspect ............................................... 71 Auxiliary Water Pump (Rubber Impeller) -
Cooling System Coolant Level - Check ................ 78 Inspect ................................................................ 68
Engine Air Cleaner Service Indicator - Inspect ..... 90 Battery Electrolyte Level - Check .......................... 69
Engine Oil Level - Check ...................................... 91 Belts - Inspect/Adjust/Replace .............................. 70
Fuel System Primary Filter/Water Separator - Cooling System Supplemental Coolant Additive
Drain ................................................................... 97 (SCA) - Test/Add ................................................. 80
Walk-Around Inspection ....................................... 110 Engine Oil Sample - Obtain .................................. 92
Engine Oil and Filter - Change ............................. 93
Initial 20 to 40 Service Hours Fuel Tank Water and Sediment - Drain ................. 99
Hoses and Clamps - Inspect/Replace ................ 100
Belts - Inspect/Adjust/Replace .............................. 70
66 SEBU7719-12
Maintenance Section
Maintenance Interval Schedule
Every 14 200 L (3750 US gal) of Fuel or 500

Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 79
Engine Air Cleaner Element - Clean/Replace ....... 88
Engine Valve Lash - Inspect/Adjust ...................... 96
Fuel System Primary Filter (Water Separator)
Element - Replace .............................................. 97
Fuel System Secondary Filter - Replace .............. 98

Service Hours or 1 Year
Closed Crankcase Ventilation (CCV) Fumes Disposal
Filter - Replace .................................................... 71

Service Hours or 2 Years
Aftercooler Core - Clean/Test ............................... 67
Engine Crankcase Breather - Clean ..................... 90
Engine Mounts - Check ........................................ 91
Heat Exchanger - Inspect ................................... 100
Injector Bolt Torque - Check ............................... 101
Turbocharger - Inspect ........................................ 109
Every 56 800 L (15 000 US gal) of Fuel or

2000 Service Hours
Alternator - Inspect ............................................... 68
Cooling System Water Temperature Regulator -
Replace ............................................................... 81
Crankshaft Vibration Damper - Inspect ................. 81
Engine Speed/Timing Sensor - Clean/Inspect ...... 95
Starting Motor - Inspect ...................................... 109
Water Pump - Inspect .......................................... 110

3000 Service Hours
Maintenance Recommendations ........................ 103
Overhaul (Top End) ............................................. 108

5000 Service Hours
Maintenance Recommendations ........................ 103
Overhaul (Major) ................................................. 105
SEBU7719-12 67
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean
i02279433 i03635591
Aftercooler Condensate Drain Aftercooler Core - Clean/Test

Valve - Inspect/Clean SMCS Code: 1064-070; 1064-081
SMCS Code: 1063-042-DN, VL
Note: An aftercooler that circulates fresh water
or treated water may require cleaning less often
than an aftercooler which circulates salt water.
The maintenance interval for an aftercooler which
circulates fresh water or treated water should be
evaluated when the aftercooler is cleaned and tested
after the first 1000 hours of engine operation. The
interval will vary depending on operating conditions.
Clean the Aftercooler Core

Remove the core. Refer to the Disassembly and
Assembly Manual, “Aftercooler - Remove” for the
procedure.
g00908758
Illustration 33 1. Turn the aftercooler core on one side in order
(1) Drain lines. (2) Adapter. (3) Valve. (4) Plunger. (5) Valve seat. to remove debris. Remove the debris that is
accessible.
The engine boost pressure forces plunger (4) to
move down to valve seat (5). The plunger must NOTICE
close against the seat at a pressure of 27.5 kPa Do not use a high concentration of caustic cleaner to
(4 psi). When the engine is stopped, the absence clean the core. A high concentration of caustic cleaner
of boost pressure allows the plunger to rise to the can attack the internal metals of the core and cause
open position, which allows condensation from the leakage. Only use the recommended concentration of
aftercooler to drain out. cleaner.
The plunger must be able to move freely in order to

2. Back flush the core with cleaner.
close the system when the engine is running. The
plunger must be able to move freely in order to allow
Caterpillar recommends the use of Hydrosolv
condensation to drain from the aftercooler when
liquid cleaner. Table 9 lists Hydrosolv liquid
the engine is stopped. Residue from normal engine
cleaners that are available from your Caterpillar
operation could cause the plunger to stick.
dealer.
1. Remove valve (3) from adapter (2). Check the Table 9
valve in order to determine if plunger (4) moves
freely. If the plunger does not move easily, clean Hydrosolv Liquid Cleaners(1)
the valve with solvent. Part
Description Size
Number
2. Remove drain lines (1). Check the lines for
plugging. Clean the lines, if necessary. Pressure 1U-5490 Hydrosolv 4165 19 L (5 US gallon)
air or a flexible rod with a small diameter can be 174-6854 Hydrosolv 100 19 L (5 US gallon)
used to clean the lines. (1) Use a two to five percent concentration of the cleaner
at temperatures up to 93°C (200°F). Refer to Application
3. Reassemble the aftercooler condensate drain Guide, NEHS0526 or consult your Caterpillar dealer for more
valve. For the proper torque, refer to the information.
Specifications Manual, SENR3130, “Torque
Specifications”. 3. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside
and from the outside of the core.
Note: Do not use high pressure when the fins are

cleaned. High pressure can damage the fins.
4. Wash the core with hot, soapy water.

68 SEBU7719-12
Maintenance Section
Alternator - Inspect
5. Flush the core thoroughly in order to remove i02676048

residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the Alternator - Inspect
core is clear and free of debris.
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection

of the alternator. Inspect the alternator for loose
Personal injury can result from air pressure. connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
Personal injury can result without following prop- order to ensure proper battery performance and/or
er procedure. When using pressure air, wear a pro- proper performance of the electrical system. Make
tective face shield and protective clothing. repairs, as required.
The maximum air pressure for cleaning purposes Check the alternator and the battery charger for
must be reduced to 205 kPa (30 psi) when the air proper operation. If the batteries are properly
nozzle is deadheaded. charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
6. Dry the core with compressed air. Direct the air in batteries should be kept warm because temperature
the reverse direction of the normal flow. 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.
Test the Aftercooler Core When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
1. Inspect the core for trapped debris and may not fully charge. A battery with a low charge will
cleanliness. If necessary, remove the debris and freeze more easily than a battery with a full charge.
repeat the cleaning procedure.
2. Inspect the core for damage and perform a i01041983

pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform Auxiliary Water Pump (Rubber
pressure tests. Impeller) - Inspect
3. Plug both ends of the aftercooler core and SMCS Code: 1371-040
pressurize the core to 205 kPa (30 psi). Submerge
the core in water. Look for bubbles which are Impellers and seals require periodic inspection.
being emitted from the core. The bubbles are Impellers have a service life that is limited. The
evidence of leaks. service life depends on the engine operating
conditions.
4. If any leaks are found, do not attempt to repair the
core. Inspect the components more frequently when the
pump is exposed to debris, sand, or other abrasive
Install a core that is clean and a core that passes the materials. Inspect the components if the pump is
pressure test in step 3. Refer to the Disassembly operating at a differential pressure of more than
and Assembly Manual, “Aftercooler - Install” for the 103 kPa (15 psi).
procedure.
Check the following components for wear or damage:
For more information on cleaning the core, consult
your Caterpillar dealer. • Bearings
• 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.
SEBU7719-12 69
Maintenance Section
Battery - Replace
i02153996 8. Connect the cable from the ground plane to the

NEGATIVE “-” battery terminal.
Battery - Replace
SMCS Code: 1401-510 i02601752
Battery Electrolyte Level -

Check
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas- SMCS Code: 1401-535
es to ignite. This can result in severe personal in-
jury or death. When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
Ensure proper ventilation for batteries that are in may not fully recharge. Ensure a full charge in order
an enclosure. Follow the proper procedures in or- to help prevent the battery from freezing.
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
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.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic- 1. Remove the filler caps. Maintain the electrolyte
ing is attempted. level to the “FULL” mark on the battery.
Removing the battery cables or the batteries with If the addition of water is necessary, use distilled
the cover in place may cause a battery explosion water. If distilled water is not available use clean
resulting in personal injury. water that is low in minerals. Do not use artificially
softened water.
1. Turn the key start switch to the OFF position. 2. Check the condition of the electrolyte with the
Remove the key and all electrical loads. 245-5829 Coolant Battery Tester Refractometer.
2. Turn OFF the battery charger. Disconnect the 3. Keep the batteries clean.
charger.
Clean the battery case with one of the following
3. The NEGATIVE “-” cable connects the NEGATIVE cleaning solutions:
“-” battery terminal to the ground plane. Disconnect
the cable from the NEGATIVE “-” battery terminal.
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
battery terminal.
Thoroughly rinse the battery case with clean water.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate Use a fine grade of sandpaper to clean the
recycling facility. terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
5. Remove the used battery. remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
6. Install the new battery. Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
Note: Before the cables are connected, ensure that
the key start switch is OFF.
7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.
70 SEBU7719-12
Maintenance Section
Battery or Battery Cable - Disconnect
i01492654 Inspect the belt for wear and for cracking. Replace a
belt that is worn or damaged.
Battery or Battery Cable -
Disconnect
SMCS Code: 1402-029
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.
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 Illustration 35

g01745233
battery that goes to the start switch. Ensure that Belt tensioner
the cable cannot contact the terminal. When four
(A) Minimum travel
12 volt batteries are involved, the negative side of (3) Spring
two batteries must be disconnected.
Belt tension should be visually checked between the
3. Tape the leads in order to help prevent accidental initial 20 to 40 hours of engine operation.
starting.
Inspect the belt tensioner for the following conditions:
4. Proceed with necessary system repairs. Reverse unusual noise, excessive looseness, and shaking of
the steps in order to reconnect all of the cables. the bearings. The minimum travel is 71 degrees. The
torque for the spring at 25 degrees from the free arm
i03378020 position should be 15.3 ± 2.3 N·m (11 ± 2 lb ft).
Belts - Inspect/Adjust/Replace If a new belt is installed, check the belt tension again
after 30 minutes of engine operation at the rated rpm.
SMCS Code: 1357-025; 1357-040; 1357-510
Install the belt guard.
Remove the belt guard.
g01745153
Illustration 34
Alternator and serpentine belt
(1) Belt tensioner
(2) Serpentine belt
SEBU7719-12 71
Maintenance Section
Closed Crankcase Ventilation (CCV) Filter Service Indicator - Inspect
i01852860 i01797874
Closed Crankcase Ventilation Closed Crankcase Ventilation

(CCV) Filter Service Indicator (CCV) Fumes Disposal Filter -
- Inspect Replace
SMCS Code: 1317-040-FI SMCS Code: 1317-510-FI
g00744250 g00920660
Illustration 36 Illustration 37
(1) Plastic cover (1) Crankcase breather
(2) Service indicator (2) Filter base and filter for fumes disposal
(3) Air cleaner
The Closed Crankcase Ventilation system (CCV)
is equipped with a service indicator. If the fumes The Closed Crankcase Ventilation system (CCV)
disposal filter becomes plugged prior to the normal requires the replacement of the fumes disposal filter.
service interval, increased restriction of the filter will The service interval of the CCV will be affected by
cause the crankcase pressure to become positive. the following items:
When the pressure continues to rise, the service
indicator will show through the plastic cover. The • Engine load
service indicator indicates the need for the fumes
disposal filter to be changed. Refer to the Operation • Soot concentration
and Maintenance Manual, “Closed Crankcase
Ventilation (CCV) Fumes Disposal Filter - Replace” • Condition of the engine
topic for more information.
The CCV is equipped with a service indicator. If the
Note: Check the service indicator when the engine is fumes disposal filter becomes plugged prior to the
running at low idle. normal service interval, increased restriction of the
filter will cause the vacuum to become positive. When
the pressure continues to rise, the service indicator
will show through the cap. The service indicator
indicates the need for the fumes disposal filter to be
changed. Reset the service indicator.
72 SEBU7719-12
Maintenance Section
Cooling System Coolant (DEAC) - Change
Resetting the Service Indicator 1. Release the latches (7) that hold the canister to
the filter base assembly (6).
Note: Removal of the canister (8) may be difficult

while the engine is operating. The canister has
negative air pressure while the engine is operating.
This creates a vacuum.
2. Lower the canister (8) in order to expose the

element. There may be oil in the bottom of the
canister. Avoid spilling the oil.
3. Remove the filter element by pulling down.

Dispose of the used element properly.
4. Remove the O-ring assembly on the top end cap

g00585674
Illustration 38 of the used element.
(4) Plastic cover
(5) Service indicator 5. Replace the O-ring seal on the bottom of the filter
base assembly.
1. Remove the plastic cover (4).
6. Install the new O-ring on the top end cap of the
2. Push down on the service indicator (5). element. Install the element into the correct place.
3. Replace the cover (4). 7. Replace the canister (8) and align the canister
with the boss on the filter base assembly (6).
4. Replace the fumes disposal filter.
8. Clamp the latches (7) in the closed position.
Replacing the Fumes Disposal
Filter i02223747
Cooling System Coolant

(DEAC) - Change
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to SMCS Code: 1350-070; 1395-044
contact the skin.
Clean the cooling system and flush the cooling
system before the recommended maintenance
Note: When possible, perform the maintenance while interval if the following conditions exist:
the engine is off.
• The engine overheats frequently.
• Foaming of the coolant
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the

NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
g00585616 proved for Caterpillar engines.
Illustration 39
(6) Filter base assembly
(7) Latches
(8) Canister
SEBU7719-12 73
Maintenance Section
Note: Inspect the water pump and the water Outside Illinois: 1-800-542-TOOL
temperature regulator after the cooling system has Inside Illinois: 1-800-541-TOOL
been drained. This is a good opportunity to replace Canada: 1-800-523-TOOL
the water pump, the water temperature regulator and
the hoses, if necessary.
Flush
Drain 1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the

Pressurized System: Hot coolant can cause seri- drain plugs. Install the drain plugs. Refer to the
ous burns. To open the cooling system filler cap, Specifications Manual for your particular engine for
stop the engine and wait until the cooling system more specific information on the proper torques.
components are cool. Loosen the cooling system Refer to the Specifications, SENR3130, “Torque
pressure cap slowly in order to relieve the pres- Specifications” for more general information on
sure. the proper torques.
NOTICE
1. Stop the engine and allow the engine to cool. Fill the cooling system no faster than 19 L (5 US gal)
Loosen the cooling system filler cap slowly in per minute to avoid air locks.
order to relieve any pressure. Remove the cooling
system filler cap.
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 the engine 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 com-
ponents.
g00944223
Illustration 40
To avoid damage to the cooling system, make sure
Locations of the cooling system drain plugs to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
2. Open the cooling system drain valve (if equipped). cleaning agent are gone.
If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
5. Stop the engine and allow the engine to cool.
Allow the coolant to drain. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
NOTICE cooling system filler cap. Open the drain valve
Dispose of used engine coolant properly or recycle. (if equipped) or remove the cooling system drain
Various methods have been proposed to reclaim used plugs. Allow the water to drain. Flush the cooling
coolant for reuse in engine cooling systems. The full system with clean water. Close the drain valve (if
distillation procedure is the only method acceptable by equipped). Clean the drain plugs. Install the drain
Caterpillar to reclaim the used coolant. plugs. Refer to the Specifications Manual for your
particular engine for more specific information on
the proper torques. Refer to the Specifications,
For information regarding the disposal and the SENR3130, “Torque Specifications” for more
recycling of used coolant, consult your Caterpillar general information on the proper torques.
dealer or consult Caterpillar Dealer Service Tools
Group:
74 SEBU7719-12
Maintenance Section
Cooling Systems with Heavy Fill

Deposits or Plugging Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
Note: For the following procedure to be effective,
for information regarding acceptable water,
there must be some active flow through the cooling
coolant/antifreeze, and supplemental coolant
system components.
additive requirements. Refer to the Operation
and Maintenance Manual, “Refill Capacities and
1. Flush the cooling system with clean water in order
Recommendations” topic for the capacity of the
to remove any debris.
engine's system.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the Engines that are Equipped with a Coolant
Specifications Manual for your particular engine for Recovery Tank
more specific information on the proper torques.
Refer to the Specifications, SENR3130, “Torque
NOTICE
Specifications” for more general information on
Fill the cooling system no faster than 19 L (5 US gal)
the proper torques.
per minute to avoid air locks.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) 1. Fill the cooling system with coolant/antifreeze.
per minute to avoid air locks. Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
(Maintenance Section) for more information on
3. Fill the cooling system with a mixture of clean cooling system specifications. Do not install the
water and Caterpillar Fast Acting Cooling System cooling system filler cap.
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. 2. Start the engine and run the engine at low idle.
Install the cooling system filler cap. Increase the engine rpm to 1500 rpm. Run the
engine at high idle for one minute in order to purge
4. Start the engine and run the engine at low idle for a the air from the cavities of the engine block. Stop
minimum of 90 minutes. The coolant temperature the engine.
should be at least 82 °C (180 °F).
3. Add coolant to the cooling system until the cooling
NOTICE system is full.
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com- 4. Clean the cooling system filler cap. Inspect the
ponents. gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
To avoid damage to the cooling system, make sure is damaged, discard the old cooling system filler
to completely flush the cooling system with clear wa- cap and install a new cooling system filler cap.
ter. Continue to flush the system until all signs of the If the gasket that is on the cooling system filler
cleaning agent are gone. 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
5. Stop the engine and allow the engine to cool. cooling system filler cap is stamped on the face of
Loosen the cooling system filler cap slowly the cooling system filler cap. If the cooling system
in order to relieve any pressure. Remove the filler cap does not retain the correct pressure,
cooling system filler cap. Open the drain valve install a new cooling system filler cap.
(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 Specifications Manual for your
particular engine for more specific information on
the proper torques. Refer to the Specifications,
SENR3130, “Torque Specifications” for more
general information on the proper torques.
SEBU7719-12 75
Maintenance Section
Cooling System Coolant (ELC) - Change
4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If
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.
g00103638
5. Start the engine. Inspect the cooling system for
Illustration 41 leaks and for proper operating temperature.
(1) Recovery tank filler cap
(2) “COLD FULL” mark
(3) “LOW ADD” mark i02223774
5. Loosen the cap for the coolant recovery tank Cooling System Coolant (ELC)
slowly in order to relieve any pressure. Remove
the cap for the coolant recovery tank.
- Change
SMCS Code: 1350-070; 1395-044
6. Pour coolant into the coolant recovery tank until
the coolant reaches the “COLD FULL” mark. Clean the cooling system and flush the cooling
DO NOT fill the coolant recovery tank above the system before the recommended maintenance
“COLD FULL” mark. interval if the following conditions exist:
7. Clean the cap for the coolant recovery tank. Install
• The engine overheats frequently.
8. Start the engine. Inspect the cooling system for

• Foaming of the coolant
leaks and for proper operating temperature.
• The oil has entered the cooling system and the
Engines that are Not Equipped with a
Coolant Recovery Tank • The fuel has entered the cooling system and the
NOTICE Note: When the cooling system is cleaned, only
Fill the cooling system no faster than 19 L (5 US gal) clean water is needed when the ELC is drained and
per minute to avoid air locks. replaced.
1. Fill the cooling system with coolant/antifreeze. Note: Inspect the water pump and the water
Refer to the Operation and Maintenance Manual, temperature regulator after the cooling system has
“Refill Capacities and Recommendations” topic been drained. This is a good opportunity to replace
(Maintenance Section) for more information on the water pump, the water temperature regulator and
cooling system specifications. Do not install the the hoses, if necessary.
cooling system filler cap.
Drain
2. Start the engine 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. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
3. Check the coolant level. Maintain the coolant level stop the engine and wait until the cooling system
within 13 mm (.5 inch) below the bottom of the components are cool. Loosen the cooling system
pipe for filling. Maintain the coolant level within pressure cap slowly in order to relieve the pres-
13 mm (.5 inch) to the proper level on the sight sure.
glass (if equipped).
76 SEBU7719-12
Maintenance Section
Cooling System Coolant (ELC) - Change

Loosen the cooling system filler cap slowly in NOTICE
order to relieve any pressure. Remove the cooling Fill the cooling system no faster than 19 L (5 US gal)
system filler cap. per minute to avoid air locks.
3. Fill the cooling system with clean water. Install the

4. Start the engine and run the engine at low

idle until the temperature reaches 49 to 66 °C
(120 to 150 °F).

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
Illustration 42
g00944223 system with clean water. Close the drain valve (if
Locations of the cooling system drain plugs equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your
2. Open the cooling system drain valve (if equipped). particular engine for more specific information on
If the cooling system is not equipped with a drain the proper torques. Refer to the Specifications,
valve, remove the cooling system drain plugs. SENR3130, “Torque Specifications” for more
general information on the proper torques.
Allow the coolant to drain.
Fill
NOTICE
Dispose of used engine coolant properly or recycle. Engines that are Equipped with a Coolant
Various methods have been proposed to reclaim used Recovery Tank
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant. NOTICE
per minute to avoid air locks.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools 1. Fill the cooling system with Extended Life Coolant
Group: (ELC). Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
Outside Illinois: 1-800-542-TOOL topic (Maintenance Section) for more information
Inside Illinois: 1-800-541-TOOL on cooling system specifications. Do not install the
Canada: 1-800-523-TOOL cooling system filler cap.
2. Start the engine and operate the engine at

Flush low idle. Increase the engine rpm to 1500 rpm.
Operate the engine at 1500 rpm for one minute in
1. Flush the cooling system with clean water in order order to purge air from the cavities of the engine
to remove any debris. block. Stop the engine.
2. Close the drain valve (if equipped). Clean the 3. Pour more ELC into the cooling system until the
drain plugs. Install the drain plugs. Refer to the cooling system is full.
Specifications Manual for your particular engine for
more specific information on the proper torques.
Refer to the Specifications, SENR3130, “Torque
Specifications” for more general information on
the proper torques.
SEBU7719-12 77
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
4. Clean the cooling system filler cap. Inspect the 1. Fill the cooling system with Extended Life Coolant
gasket that is on the cooling system filler cap. If (ELC). Refer to the Operation and Maintenance
the gasket that is on the cooling system filler cap Manual, “Refill Capacities and Recommendations”
is damaged, discard the old cooling system filler topic (Maintenance Section) for more information
cap and install a new cooling system filler cap. If on cooling system specifications. Do not install the
the gasket that is on the cooling system filler cap is cooling system filler cap.
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler 2. Start the engine and operate the engine at
cap. The correct pressure for the cooling system low idle. Increase the engine rpm to 1500 rpm.
filler cap is stamped on the face of the cooling Operate the engine at 1500 rpm for one minute in
system filler cap. If the cooling system filler cap order to purge air from the cavities of the engine
does not retain the correct pressure, install a new 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
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, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
g00103638
Illustration 43 filler cap is stamped on the face of the cooling
(1) Recovery tank filler cap system filler cap. If the cooling system filler cap
(2) “COLD FULL” mark does not retain the correct pressure, install a new
(3) “LOW ADD” mark cooling system filler cap.
5. Loosen the cap for the coolant recovery tank 5. Start the engine. Inspect the cooling system for
slowly in order to relieve any pressure. Remove leaks and for proper operating temperature.
6. Pour Extended Life Coolant (ELC) into the coolant i02482066

recovery tank until the coolant reaches the “COLD
FULL” mark. DO NOT fill the coolant recovery tank Cooling System Coolant
above the “COLD FULL” mark. Extender (ELC) - Add
7. Clean the cap for the coolant recovery tank. Install SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require
8. Start the engine. Inspect the cooling system for the frequent additions of any supplemental cooling
leaks and for proper operating temperature. additives which are associated with the present
conventional coolants. The Cat ELC Extender only
Engines that are NOT Equipped with a needs to be added once.
Coolant Recovery Tank
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
NOTICE with Cat ELC.
per minute to avoid air locks. Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
tional coolants and/or conventional SCA reduces the
Cat ELC service life.
Check the cooling system only when the engine is

stopped and cool.
78 SEBU7719-12
Maintenance Section
Cooling System Coolant Level - Check
i02456586
Cooling System Coolant Level

Personal injury can result from hot coolant, steam
and alkali. - Check
At operating temperature, engine coolant is hot SMCS Code: 1395-082
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or Check the coolant level when the engine is stopped
steam. Any contact can cause severe burns. and cool.
Remove cooling system pressure cap slowly to Engines That Are Equipped with a
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to Coolant Recovery Tank
touch with your bare hand.
Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
g00103638
ing any compartment or disassembling any compo- Illustration 44
nent containing fluids. (1) Filler cap
(2) “COLD FULL” mark
Refer to Special Publication, NENG2500, “Caterpillar (3) “LOW ADD” mark
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 1. Observe the coolant level in the coolant recovery
products. tank. Maintain the coolant level to “COLD FULL”
mark (2) on the coolant recovery tank.
Dispose of all fluids according to local regulations and
mandates. 2. Loosen filler cap (1) slowly in order to relieve any
pressure. Remove the filler cap.
1. Loosen the cooling system filler cap slowly in 3. Pour the proper coolant mixture into the tank.
order to relieve pressure. Remove the cooling Refer to this Operation and Maintenance Manual,
system filler cap. “Refill Capacities and Recommendations” for
information about coolants. Do not fill the coolant
2. It may be necessary to drain enough coolant from recovery tank above “COLD FULL” mark (2).
the cooling system in order to add the Cat ELC
Extender. 4. Clean filler cap (1) and the receptacle. Reinstall
the filler cap and inspect the cooling system for
3. Add Cat ELC Extender according to the leaks.
requirements for your engine's cooling system
capacity. Refer to the Operation and Maintenance Note: The coolant will expand as the coolant heats
Manual, “Refill Capacities and Recommendations” up during normal engine operation. The additional
article for more information. volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
4. Clean the cooling system filler cap. Inspect the and cool, the coolant will return to the engine.
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
SEBU7719-12 79
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Engines That Are Not Equipped i01980429
with a Coolant Recovery Tank Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
NOTICE
stop the engine and wait until the cooling system
Always use a designated pump for oil sampling, and
components are cool. Loosen the cooling system
use a separate designated pump for coolant sampling.
pressure cap slowly in order to relieve the pres-
Using the same pump for both types of samples may
sure.
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
1. Remove the cooling system filler cap slowly in rect interpretation that could lead to concerns by both
order to relieve pressure. dealers and customers.
2. Maintain the coolant level within 13 mm (0.5 inch) For conventional heavy-duty coolant/antifreeze,
of the bottom of the filler pipe. If the engine is check the concentration of supplemental coolant
equipped with a sight glass, maintain the coolant additive (SCA) regularly. The concentration of SCA
level to the proper level in the sight glass. can be checked with an S·O·S coolant analysis
(Level 1).
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of

the coolant:
Illustration 45
g00103639 • Never collect samples from expansion bottles.
Typical filler cap gaskets
• Never collect samples from the drain for a system.
3. Clean the cooling system filler cap and inspect • Keep the unused sampling bottles stored in plastic
the condition of the filler cap gaskets. Replace the bags.
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap. • Keep the lids on empty sampling bottles until you
are ready to collect the sample.
4. Inspect the cooling system for leaks.
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
from any other location.
• In order to avoid contamination, immediately place

the sample in the tube that is provided for mailing.
Refer to Special Publication, SEBU6251, “Caterpillar

Commercial Engine Fluids Recommendations”.
Submit the sample for Level 1 analysis.

80 SEBU7719-12
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Note: Level 1 results may indicate a need for

Level 2 Analysis.
Cooling system coolant additive contains alkali.
For additional information about coolant analysis,
To help prevent personal injury, avoid contact with
see this Operation and Maintenance Manual, “S·O·S
the skin and eyes. Do not drink cooling system
Coolant Analysis” or consult your Caterpillar dealer.
coolant additive.
i01980525
NOTICE
Cooling System Coolant Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
Sample (Level 2) - Obtain faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 could cause cracking of the cylinder head and other
high temperature components.
NOTICE
Always use a designated pump for oil sampling, and Excessive supplemental coolant additive concentra-
use a separate designated pump for coolant sampling. tion could also result in blockage of the heat exchang-
Using the same pump for both types of samples may er, overheating, and/or accelerated wear of the water
contaminate the samples that are being drawn. This pump seal.
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both Do not exceed the recommended amount of supple-
dealers and customers. mental coolant additive concentration.
Obtain the sample of the coolant as close as possible NOTICE

to the recommended sampling interval. Supplies Care must be taken to ensure that fluids are contained
for collecting samples can be obtained from your during performance of inspection, maintenance, test-
Caterpillar dealer. ing, adjusting and repair of the product. Be prepared to
Refer to Operation and Maintenance Manual, ing any compartment or disassembling any compo-
“Cooling System Coolant Sample (Level 1) - nent containing fluids.
Obtain” for the guidelines for proper sampling
of the coolant. Also refer to Special Publication, Refer to Special Publication, NENG2500, “Caterpillar
SEBU6251, “Caterpillar Commercial Engine Fluids Dealer Service Tool Catalog” and to Special Publica-
Recommendations”. tion, GECJ0003, “Cat Shop Supplies and Tools” for
tools and supplies suitable to collect and contain flu-
Submit the sample for Level 2 analysis. ids on Caterpillar products.
For additional information about coolant analysis, Dispose of all fluids according to applicable regula-
see this Operation and Maintenance Manual, “S·O·S tions and mandates.
Coolant Analysis” or consult your Caterpillar dealer.
Note: Caterpillar recommends an S·O·S coolant
i03509177 analysis (Level 1).
Cooling System Supplemental Cooling Systems that Use
Coolant Additive (SCA) - Conventional Coolant
Test/Add
Test the Concentration of the SCA
SMCS Code: 1352-045; 1395-081
Note: This maintenance is NOT required for NOTICE

cooling systems that are filled with Extended Life Do not exceed the recommended six percent supple-
Coolant. mental coolant additive concentration.
Test the concentration of the SCA with the 4C-9301

Coolant Conditioner Test Kit.
SEBU7719-12 81
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Add the SCA, If Necessary A water temperature regulator that fails in a

partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed

Pressurized System: Hot coolant can cause seri- position can cause excessive overheating. Excessive
ous burns. To open the cooling system filler cap, overheating could result in cracking of the cylinder
stop the engine and wait until the cooling system head or piston seizure problems.
pressure cap slowly in order to relieve the pres- A water temperature regulator that fails in the open
sure. position will cause the engine operating temperature
to be too low during partial load operation. Low
1. Remove the cooling system filler cap slowly. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
2. If necessary, drain some coolant in order to allow cylinders. This excessive carbon buildup could result
space for the addition of the SCA. in an accelerated wear of the piston rings and wear
of the cylinder liner.
3. Add the proper amount of SCA. For the
proper amount of SCA, refer to this Operation NOTICE
and Maintenance Manual, “Refill Capacities Failure to replace your water temperature regulator
and Recommendations” topic. The proper on a regularly scheduled basis could cause severe
concentration of SCA depends on the type of engine damage.
coolant that is used. For the proper concentration
of SCA, refer to Special Publication, SEBU6251, Caterpillar engines incorporate a shunt design cooling
“Caterpillar Commercial Diesel Engine Fluids system and require operating the engine with a water
Recommendations”. temperature regulator installed.
4. Clean the cooling system filler cap. Install the If the water temperature regulator is installed incor-
cooling system filler cap. rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
i01852885
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Cooling System Water
Do not use liquid gasket material on the gasket or
Temperature Regulator - cylinder head surface.
Replace
Refer to the Service Manual for the replacement
SMCS Code: 1355-510 procedure of the water temperature regulator, or
consult your Caterpillar dealer.
Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i03175962
Crankshaft Vibration Damper

- Inspect
SMCS Code: 1205-040
g00944247
Illustration 46
Damage to the crankshaft vibration damper or failure
Top view of the expansion tank
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to
Replace the water temperature regulator before the crankshaft and to other engine components. A
the water temperature regulator fails. This is a deteriorating damper can cause excessive gear train
recommended preventive maintenance practice. noise at variable points in the speed range.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime.
82 SEBU7719-12
Maintenance Section
Drive Shaft Slip Joint - Lubricate
The damper is mounted to the crankshaft which is i03595100

located behind the belt guard on the front of the
engine. Drive Shaft Slip Joint -
Lubricate
(If Equipped with a Pod Drive
Unit)
SMCS Code: 3253-086-JT
S/N: X9Y1-Up
This maintenance procedure must be performed

with the engine stopped. Attach a “Do Not Operate”
warning tag or a similar warning tag to the start
switch or to the controls. These warning tags (Special
Instruction, SEHS7332) are available from your
Caterpillar dealer. Attach the warning tags to the
engine and to each operator control station.
g01134779
Illustration 47
Viscous vibration damper
Typical example
(1) Crankshaft pulley
(2) Weight
(3) Case
Inspection
g00104545
Inspect the damper for the following conditions: Illustration 48
• The damper is dented, cracked, or fluid is leaking Do not allow unauthorized personnel on the engine or
from the damper. around the engine while this maintenance procedure
is being performed.
• The paint on the damper is discolored from
excessive heat.
• The damper is bent. The drive shaft rotates between the engine and the
transmission when the engine is running. Contact
• The bolt holes are worn or there is a loose fit for with the rotating shaft may result in personal in-
the bolts.
jury or death.
• The engine has had a crankshaft failure due to Do not allow personnel near the drive shaft when
torsional forces.
the engine is running.
Replace the damper if any of these conditions exist.
Removal and Installation

Refer to this Operation and Maintenance Manual,
“Belts - Inspect/Adjust/Replace” for information
on removing and on installing the belt. Refer to
the Disassembly and Assembly Manual, “Vibration
Damper and Pulley - Remove and Install” for
information on removing and installing the damper.
SEBU7719-12 83
Maintenance Section
Drive Shaft Universal Joints - Lubricate
Removal of the Drive Shaft Guard Installation of the Drive Shaft Guard
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened

component life.
g01733575
Illustration 49
1. Remove bolts (1) and spacers (2).
2. Remove bolts (4) in order to separate guard

assemblies (3). Remove guard assemblies (3).
g01733575
Illustration 51
Lubrication of the Slip Joint
1. Place guard assemblies (3) in position. Install
bolts (4) in order to connect guard assemblies (3).
2. Install spacers (2) and bolts (1).
i03598802
Drive Shaft Universal Joints -

Lubricate
(If Equipped with a Pod Drive
Unit which has Replacement
Universal Joints)
SMCS Code: 3251-086; 3253
S/N: X9Y1-Up
Note: The universal joints which are shipped with

the engine are greased for the life of the universal
g01921893
Illustration 50 joints. The universal joints which may be used
Left side view of a C9 Marine Engine with a Pod Drive Unit to replace the original universal joints must be
(5) Partial view of the left side of the engine lubricated upon installation to the drive shaft and
(6) Drive shaft at every 250 service hours.
(7) Partial view of the Pod drive unit
(8) Grease fitting for the slip joint
As needed, lubricate the slip joint with Cat

Multipurpose Grease.
84 SEBU7719-12
Maintenance Section
Drive Shaft Universal Joints - Replace
This maintenance procedure must be performed

warning tag or a similar warning tag to the start
switch or to the controls. These warning tags (Special
g01926037
Illustration 53
Replacement universal joint with grease fitting
Lubricate the replacement universal joints with Cat

Multipurpose Grease.
g00104545 i03598805
Illustration 52
Do not allow unauthorized personnel on the engine or

Drive Shaft Universal Joints -
around the engine while this maintenance procedure Replace
is being performed. (If Equipped with a Pod Drive
Unit)
SMCS Code: 3251-510; 3253
The drive shaft rotates between the engine and the
transmission when the engine is running. Contact S/N: X9Y1-Up
with the rotating shaft may result in personal in-
jury or death. This maintenance procedure must be performed
Do not allow personnel near the drive shaft when warning tag or a similar warning tag to the start
the engine is running. switch or to the controls. These warning tags (Special
Before lubricating the universal joints, inspect the
rubber seals. Seals which are worn or damaged
may cause failure of the universal joints. Replace
any universal joint which has a seal which is worn
or damaged.
Before lubricating the universal joints, inspect the

amount of play in the universal joints. Excessive
play in the universal joint indicates that the universal
joint may fail. Replace any universal joint which has
excessive play.
g00104545
Illustration 54
Do not allow unauthorized personnel on the engine or

around the engine while this maintenance procedure
is being performed.
SEBU7719-12 85
Maintenance Section
The drive shaft rotates between the engine and the

transmission when the engine is running. Contact
with the rotating shaft may result in personal in-
jury or death.
Do not allow personnel near the drive shaft when

the engine is running.
Removal Procedure
NOTICE
Contaminants may cause rapid wear and shortened

component life.
Removal of the Coupling Guard g01733193

Illustration 56
2. Remove bolts (5) and plate assembly (4).
Removal of the Drive Shaft Guard
g01732736
Illustration 55
1. Remove bolts (1), bolts (3), and coupling guard

assembly (2).
g01924256
Illustration 57
1. Remove bolts (6) and spacers (7).
2. Remove bolts (9) in order to separate guard

assemblies (8). Remove guard assemblies (8).
86 SEBU7719-12
Maintenance Section
Removal of the Drive Shaft and the

Universal Joints
g01924620
Illustration 60
3. Remove retaining rings (13) and universal joints

(12) from both ends of the drive shaft (11).
Installation Procedure
Installation of the Universal Joints and
g01924273
Illustration 58 the Drive Shaft
1. Support the end of drive shaft (11). The weight
of drive shaft (11) is approximately 27 kg (60 lb).
Remove bolts (10) and disconnect drive shaft (11).
g01924620
Illustration 61
1. Inspect retaining rings (13) for wear and damage.

Replace any retaining rings (13) which are worn
or damaged. Install new universal joints (12) and
undamaged retaining rings (13) onto drive shaft
(11).
g01924275
Illustration 59
2. Support the end of drive shaft (11). The weight

of drive shaft (11) is approximately 27 kg (60 lb).
Remove bolts (12) and the nuts. Remove drive
shaft (11).
SEBU7719-12 87
Maintenance Section
Installation of the Drive Shaft Guard
g01924275
Illustration 62
g01924256
Illustration 64
2. Place drive shaft (11) in position. Support the end
of drive shaft (11). The weight of drive shaft (11) 1. Place guard assemblies (8) in position. Install
is approximately 27 kg (60 lb). Install the nuts and bolts (9) in order to connect guard assemblies (8).
bolts (12).
2. Install spacers (7) and bolts (6).
Installation of the Coupling Guard
g01924273
Illustration 63
3. Place drive shaft (11) in position. Support the end

of drive shaft (11). The weight of drive shaft (11) is Illustration 65
g01733193
approximately 27 kg (60 lb). Install bolts (10).
1. Install plate assembly (4) and bolts (5).
88 SEBU7719-12
Maintenance Section
Engine - Clean
• Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
i03465400
Engine Air Cleaner Element -

Clean/Replace
SMCS Code: 1054-070; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
g01732736
Illustration 66 engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
2. Install coupling guard assembly (2), bolts (3), and borne debris from entering the air inlet.
bolts (1).
NOTICE
i01646701 Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Engine - Clean
SMCS Code: 1000-070
Servicing the Air Cleaner Elements
Note: The air filter system may not have been
provided by Caterpillar. The procedure that follows is
Personal injury or death can result from high volt- for a Caterpillar air filter. Refer to the OEM information
age. for the correct procedure for the cleaning of an air
cleaner which is produced by an OEM.
Moisture can create paths of electrical conductiv-
ity. If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Make sure that the electrical system is OFF. Lock Unfiltered air will drastically accelerate internal
out the starting controls and tag the controls “DO engine wear.
NOT OPERATE”.
• Check the precleaner (if equipped) and the dust
bowl daily for accumulation of dirt and debris.
NOTICE Remove any dirt and debris, as needed.
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid • Operating in dirty conditions may require more
spills whenever a significant quantity accumulates on frequent service of the air cleaner element.
the engine.
• A Caterpillar air cleaner element may be used up
Periodic cleaning of the engine is recommended. to six times if the element is correctly cleaned and
Steam cleaning the engine will remove accumulated correctly inspected. If the air filter is produced by
oil and grease. A clean engine provides the following an OEM, contact the OEM in order to determine
benefits: the number of cleanings that are allowed.
• Easy detection of fluid leaks • When the engine is operating in environments that
are dusty or dirty, the air cleaner element may
• Maximum heat transfer characteristics require more frequent replacement.
SEBU7719-12 89
Maintenance Section
Engine Air Cleaner Element - Clean/Replace
• The air cleaner element should be replaced at least 4. When the air cleaner elements are cleaned,
one time per year. This replacement should be always begin with the clean side (inside) in order to
performed regardless of the number of cleanings. force dirt particles toward the dirty side (outside).
Aim the air hose so that air flows along the length
of the filter. Follow the direction of the paper pleats
Cleaning the Air Cleaner Element in order to prevent damage to the pleats. Do not
Cleaning the air filter element will not extend the life aim the air directly at the face of the paper pleats.
of the air filter element.
5. Inspect the air cleaner element for damage. Refer
Visually inspect the air cleaner element before to “Inspecting the Air Cleaner Element” for the
inspection procedure.
cleaning. Inspect the air cleaner element for damage.
Refer to “Inspecting the Air Cleaner Element” for the
inspection procedure. 6. Remove the tape from the air inlet. Install an air
cleaner element that is new or cleaned.
7. Install the air cleaner cover.
Personal injury can result from air pressure. 8. Reset the air cleaner service indicator.
Personal injury can result without following prop- Inspecting the Air Cleaner Element
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Pressurized air can be used to clean an air cleaner

element that has not been cleaned more than six
times. Use filtered, dry air with a maximum pressure
of 205 kPa (30 psi). Pressurized air will not remove
deposits of carbon and oil.
Note: Do not tap or strike the air cleaner element.

Take extreme care in order to avoid damage to the g00281693
Illustration 68
air cleaner elements.
1. Remove the cover of the canister for the air filter. Inspect the clean, dry air cleaner element. Use a 60
Remove the air cleaner element. watt blue light in a dark room or in a similar facility.
Place the blue light in the air cleaner element. Rotate
2. Cover the air inlet with tape in order to keep dirt the air cleaner element. Inspect the air cleaner
out. element for tears and/or holes. Inspect the air cleaner
element for light that may show through the filter
3. Clean the inside of the air cleaner cover and body material. If it is necessary in order to confirm the
with a clean, dry cloth. result, compare the air cleaner element to a new air
cleaner element that has the same part number.
Do not use an air cleaner element that has any tears

and/or holes in the filter material. Do not use an air
cleaner element with damaged pleats, gaskets or
seals. Discard damaged air cleaner elements.
g00281692
Illustration 67
90 SEBU7719-12
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
i01900118 • Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
Engine Air Cleaner Service The yellow core should latch approximately at the
Indicator - Inspect greatest vacuum that is attained.
(If Equipped) If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
SMCS Code: 7452-040 the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Some engines may be equipped with a different indicator may be plugged.
service indicator.
The service indicator may need to be replaced
Some engines are equipped with a differential gauge frequently in environments that are severely dusty, if
for inlet air pressure. The differential gauge for inlet necessary. Replace the service indicator annually
air pressure displays the difference in the pressure regardless of the operating conditions. Replace the
that is measured before the air cleaner element and service indicator when the engine is overhauled, and
the pressure that is measured after the air cleaner whenever major engine components are replaced.
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is Note: When a new service indicator is installed,
equipped with a different type of service indicator, excessive force may crack the top of the service
follow the OEM recommendations in order to service indicator. Tighten the service indicator to a torque
the air cleaner service indicator. of 2 N·m (18 lb in).
The service indicator may be mounted on the air

cleaner housing or in a remote location. i02675394
Engine Crankcase Breather -

Clean
SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
NOTICE
If the crankcase breather is not maintained on a regu-
lar basis, it can become plugged. A plugged breather
will cause excessive crankcase pressure that may
g00103777
cause crankshaft seal leakage.
Illustration 69
Typical service indicator
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
• Check for ease of resetting. The service indicator

should reset in less than three pushes.
SEBU7719-12 91
Maintenance Section
Engine Mounts - Check
i01007363
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Check the oil level after the engine has stopped.

This maintenance procedure must be performed on
a level surface.
g00110310
Illustration 71
(Y) “ADD” mark
(X) “FULL” mark
Illustration 70
g01344110 1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the oil level gauge.
(1) Breather assembly
(2) Bolt
Do not fill the crankcase above “FULL” mark (X).
1. Remove bolt (2) and the washer. Remove the NOTICE

breather assembly (1) and the seal. Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into
2. Wash the breather element in solvent that is clean the oil. The air bubbles created from the crankshaft
and nonflammable. Allow the breather element to dipping into the oil reduces the oil's lubricating char-
dry before installation. acteristics and could result in the loss of power.
3. Install a breather element that is clean and dry.

Install breather assembly (1) and the seal. 2. Remove oil filler cap and add oil, if necessary.
Clean the oil filler cap. Reinstall the oil filler cap.
4. Install bolt (2) and the washer. Refer
to Specifications, SENR3130, “Torque i02753824
Specifications” for the correct torque.
Engine Oil Level Gauge -
i02783454 Calibrate
Engine Mounts - Check SMCS Code: 1326-524
SMCS Code: 1152-535 The angle of installation will affect the “ADD” mark
(Y) and the “FULL” mark (X) that is engraved on the
Inspect the engine mounts for deterioration and for engine oil level gauge.
proper bolt torque. Engine vibration can be caused
by the following conditions: The engine oil level gauge must be calibrated after
the engine is installed in the vessel. Use a marking
• Improper mounting of the engine pen in order to engrave “ADD” mark (Y) and “FULL”
mark (X) on the engine oil level gauge.
• Deterioration of the engine mounts
Any engine mount that shows deterioration should be
replaced. Refer to Special Publication, SENR3130,
“Torque Specifications” for the recommended
torques. Refer to the OEM recommendations for
more information.
92 SEBU7719-12
Maintenance Section
Engine Oil Sample - Obtain
8. Stop the engine. Allow the engine oil to drain

into the engine crankcase for approximately five
minutes.
9. Check the engine oil level. Use a marking pen in

order to engrave “ADD” mark (Y).
10. Add 3.8 L (4 qt) of the recommended oil grade

Illustration 72
g00110310 and weight of engine oil to the crankcase. Full
Oil Level Gauge volume will now be 27.5 L (29.0 qt). Allow the
engine oil drain into the engine crankcase for
(Y) “ADD” mark
(X) “FULL” mark approximately five minutes.
11. Check the engine oil level. Use a marking pen in

Drain and Fill Method order to engrave “FULL” mark (X).
NOTICE
i01852939
Refer to the Operation and Maintenance Manual for
more information on lubricant specifications. Engine Oil Sample - Obtain
Note: Check the oil. Many engines are shipped SMCS Code: 1000-008; 1348-554-SM;
without oil. 7542-554-OC, SM
1. Operate the engine until normal operating In addition to a good preventive maintenance
temperature is achieved. Stop the engine. program, Caterpillar recommends using S·O·S oil
Remove one of the drain plugs for the engine analysis at regularly scheduled intervals in order
crankcase. Allow the engine oil to drain. to monitor the condition of the engine and the
maintenance requirements of the engine.
2. Remove the used engine oil filter. Install the drain
plug for the engine crankcase. Tighten the drain Obtain the Sample and the Analysis
plug for the engine crankcase to 70 ± 14 N·m
(50 ± 10 lb ft).
Note: The engine may be equipped with auxiliary

engine oil filters. The extra filters require more engine Hot oil and hot components can cause personal
oil than the standard amounts. Refer to the OEM injury. Do not allow hot oil or hot components to
specifications. contact the skin.
3. Clean the sealing surface of the filter mounting

Before you take the oil sample, complete the Label,
base. Ensure that all of the old oil filter gasket is
PEEP5031 for identification of the sample. In order
removed.
to help obtain the most accurate analysis, provide
the following information:
4. Apply clean engine oil to the new oil filter gasket.
5. Install the oil filter. Tighten the oil filter until the • Engine model
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are • Service hours on the engine
shown on the oil filter. Do not overtighten the oil
filter. • The number of hours that have accumulated since
the last oil change
6. Add the recommended oil grade and weight of
engine oil to the crankcase: • The amount of oil that has been added since the
last oil change
Standard Sump ............................ 23.7 L (25.0 qt)
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
7. Start the engine. Ensure that the lubrication
sample.
system and the new engine oil filter is filled.
Inspect the lubrication system for leaks.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
SEBU7719-12 93
Maintenance Section
Engine Oil and Filter - Change
i03401064

SMCS Code: 1318-510; 1348-044
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
g00944301
Illustration 73 of the oil pan. The waste particles are not removed
Oil Sampling Valve with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
Caterpillar recommends using the sampling valve oil warm. This draining method allows the waste
in order to obtain oil samples. The quality and the particles that are suspended in the oil to be drained
consistency of the samples are better when the properly.
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be Failure to follow this recommended procedure will
obtained during normal engine operation. cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The Drain the Engine Oil
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are After the engine has been run at the normal operating
also provided. temperature, stop the engine. Attach a “DO NOT
OPERATE” or a similar warning tag to the ignition
NOTICE keyswitch before the engine is serviced.
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant NOTICE
samples. Care must be taken to ensure that fluids are contained
A small residue of either type sample may remain in ing, adjusting and repair of the product. Be prepared to
the pump and may cause a false positive analysis for collect the fluid with suitable containers before open-
the sample being taken. ing any compartment or disassembling any compo-
nent containing fluids.
Always use a designated pump for oil sampling and a
designated pump for coolant sampling. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
Failure to do so may cause a false analysis which lication, PECJ0003, “Caterpillar Shop Supplies and
could lead to customer and dealer concerns. Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is Dispose of all fluids according to local regulations and
designed to accept sampling bottles. Disposable mandates.
tubing must be attached to the pump for insertion
into the sump. 1. Remove the oil drain plug in order to allow the oil
to drain.
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your 2. After the oil has drained, the oil drain plug should
Caterpillar dealer for complete information and be cleaned and installed.
assistance in establishing an S·O·S program for your
engine.
94 SEBU7719-12
Maintenance Section
Replace the Oil Filter

NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
1. Remove the oil filter with a 185-3630 Strap

Wrench.
g00103713
Illustration 75
Typical filter mounting base and filter gasket
3. Clean the sealing surface of the filter mounting

base. Ensure that all of the old oil filter gasket is
removed.
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
g00588944 engine components.
Illustration 74
Element with debris
5. Install the oil filter. Tighten the oil filter until the
2. Cut the oil filter open with a 175-7546 Oil Filter oil filter gasket contacts the base. Tighten the oil
Cutter . Break apart the pleats and inspect the filter by hand according to the instructions that are
oil filter for metal debris. An excessive amount shown on the oil filter. Do not overtighten the oil
of metal debris in the oil filter may indicate early filter.
wear or a pending failure.
Fill the Engine Crankcase
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in 1. Remove the oil filler cap. Fill the crankcase with
the oil filter element. Ferrous metals may indicate the proper amount of oil. Refer to the Operation
wear on the steel and cast iron parts of the engine. and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section)
Nonferrous metals may indicate wear on the for more information.
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings, NOTICE
turbocharger bearings, and cylinder heads. If equipped with an auxiliary oil filter or system, extra
oil must be added when filling the crankcase. Follow
Due to normal wear and friction, it is not the OEM or filter manufacturer's recommendations. If
uncommon to find small amounts of debris in the the extra oil is not added, the engine may starve for
oil filter. Consult your Caterpillar dealer in order oil.
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter. NOTICE
To help prevent crankshaft or bearing damage, crank
engine to fill all filters before starting. Do not crank
engine for more than 30 seconds.
SEBU7719-12 95
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect
2. Start the engine and run the engine at “LOW Procedure for Cleaning and
IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
Inspecting
oil and that the oil filters are filled. Inspect the oil
Check the condition of the plastic end of the
filter for oil leaks.
speed/timing sensors for wear and/or contaminants.
Clean the metal shavings and other debris from the
3. Stop the engine and allow the oil to drain back to
face of the speed/timing sensors.
the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the Installation Procedure
oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the “ENGINE STOPPED” 1. Install the O-ring seal on speed/timing sensor (2).
side of the oil level gauge. Install the O-ring seal on speed/timing sensor (5).
2. Lubricate the bores for the speed/timing sensors

i03397361 with clean engine oil.
Engine Speed/Timing Sensor - 3. Position speed/timing sensor (2) and speed/timing
Clean/Inspect sensor (5) on the front housing. Install bracket (4)
and bolt (1).
SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070 4. Connect harness assembly (3) to speed/timing
sensor (2). Connect harness assembly (6) to
NOTICE speed/timing sensor (5).
5. If necessary, calibrate the speed/timing sensors.
Contaminants may cause rapid wear and shortened Refer to Troubleshooting, “Engine Speed/Timing
component life. Sensor - Calibrate ” for the calibration procedure.
i02703023
Engine Storage Procedure -

Check
SMCS Code: 1000-535
Caterpillar recommends storage procedures and

start-up procedures for all engines that are stored
for more than 1 month. These procedures provide
maximum protection to internal engine components.
Refer to Special Instruction, SEHS9031, “Storage
Procedure For Caterpillar Products” for information
g01146856 on these procedures.
Illustration 76
Left side of a typical C9 Marine Engine An extension of the oil change interval to 12 months
is permitted if you follow the required procedures for
Removal Procedure storage and start-up. This extension is permitted if the
following intervals in the Operation and Maintenance
1. Disconnect harness assembly (3) from Manual, “Maintenance Interval Schedule” have not
speed/timing sensor (2). Disconnect harness been reached:
assembly (6) from speed/timing sensor (5).
• Operating hours
2. Remove bolt (1) and bracket (4).
• Fuel consumption
3. Remove speed/timing sensor (2) from the front
housing. Remove the O-ring seal from the
speed/timing sensor. Remove speed/timing
sensor (5) from the front housing. Remove the
O-ring seal from the speed/timing sensor.
96 SEBU7719-12
Maintenance Section
Engine Valve Lash - Inspect/Adjust
i02744961 i01853016
Engine Valve Lash - Fuel System - Prime

Inspect/Adjust SMCS Code: 1258-548
SMCS Code: 1102-025
The initial valve lash adjustment on new engines,

rebuilt engines, or remanufactured engines is Fuel leaked or spilled onto hot surfaces or elec-
recommended at the first scheduled oil change. The trical components can cause a fire. To help pre-
adjustment is necessary due to the initial wear of vent possible injury, turn the start switch off when
the valve train components and to the seating of the changing fuel filters or water separator elements.
valve train components. Clean up fuel spills immediately.
This maintenance is recommended by Caterpillar

as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, “Valve Lash and Valve Bridge
Adjustment” article or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
g00944345
duced efficiency could result in excessive fuel usage Illustration 77
and/or shortened engine component life.
Priming the fuel system fills the fuel filters. Priming
the fuel system also removes air from the fuel
system. This procedure is used primarily when the
engine runs out of fuel.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre- 1. Unlock the fuel priming pump by turning the
vent possible injury, do not use the starting motor handle counterclockwise. Move the plunger for
to turn the flywheel. the fuel priming pump in and out until a strong
pressure is felt on the fuel priming pump and until
Hot engine components can cause burns. Allow the check valve clicks. This procedure will require
additional time for the engine to cool before mea- considerable strokes. Lock the fuel priming pump.
suring/adjusting valve lash clearance.
2. Crank the engine after the system is pressurized.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement, NOTICE
allow the valves to cool before this maintenance is Do not crank the engine continuously for more than
performed. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Refer to the Engine Specifications in this Operation
and Maintenance Manual, “Engine Description” 3. If the engine does not start, repeat Steps 1 and 2
section for more information. in order to start the engine.
SEBU7719-12 97
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i02067545 • Gasket
Fuel System Primary Filter • Base
(Water Separator) Element - Inspect the gasket for damage and for
Replace deterioration. Replace the gasket, if necessary.
SMCS Code: 1260-510-FQ; 1263-510-FQ 7. Install the gasket. Lubricate the gasket with clean
diesel fuel.
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause fuel system components NOTICE
to fail. If the fuel has been contaminated with water, The primary filter/water separator may be prefilled with
the element should be changed before the regularly fuel to avoid rough running/stalling of the engine due
scheduled interval. to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts.
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when 8. Install a new element in the case. The case may
changing fuel filters or water separator elements. be filled with fuel at this time.
Clean up fuel spills immediately.
9. Install the case on the base. Tighten the case by
hand. Do not use tools in order to tighten the case.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.
10. Open the main fuel supply valve.
11. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and check
for leaks again.
g00907911
Illustration 78
(1) Vent plug i02675481
(2) Base
(3) Case Fuel System Primary
(4)
(5)
Element
Drain plug Filter/Water Separator - Drain
1. Close the main fuel supply valve. SMCS Code: 1260-543; 1263-543
2. Remove drain plug (5). Depress vent plug (1) in

order to start the flow of fuel. Allow the fuel to
drain into a suitable container. Dispose of the fuel Fuel leaked or spilled onto hot surfaces or elec-
properly. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
3. Install the drain plug. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
4. Remove case (3) from base (2).
5. Remove element (4) from the case. Dispose of NOTICE

the used element. Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
6. Remove the gasket. Clean the following
components:
• Case
98 SEBU7719-12
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE NOTICE
Do not allow dirt to enter the fuel system. Thoroughly Care must be taken to ensure that fluids are contained
clean the area around a fuel system component that during performance of inspection, maintenance, test-
will be disconnected. Fit a suitable cover over discon- ing, adjusting and repair of the product. Be prepared to
nected fuel system component. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-

mandates.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
g01344138
clean the area around a fuel system component that
Illustration 79 will be disconnected. Fit a suitable cover over any dis-
(1) Vent plug connected fuel system components.
(2) Case
(3) Element
(4) Drain 1. Stop the engine.
1. Open drain (4). Open vent plug (1). Catch the 2. Turn off the start switch, or disconnect the battery
draining water in a suitable container. Dispose of (starting motor) when maintenance is performed
the water properly. on fuel filters.
2. Close drain (4) and vent plug (1). 3. Shut off the fuel tank supply valve to the engine.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.
i03403800
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE
g00944360
Illustration 80
(1) Fuel Priming Pump
(2) Fuel Filter
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre- 4. Unlock fuel priming pump (1) (if equipped). This
vent possible injury, turn the start switch off when relieves any residual pressure in the fuel system.
changing fuel filters or water separator elements.
Clean up fuel spills immediately. 5. Remove fuel filter (2). Use a cloth, or use a
container to catch excess fuel.
6. Clean the gasket sealing surface of the fuel filter

base. Ensure that all of the old gasket is removed.
7. Apply clean diesel fuel to the new fuel filter gasket.

SEBU7719-12 99
Maintenance Section
Fuel Tank Water and Sediment - Drain
Fuel Tank
NOTICE
Do not fill the secondary fuel filter with fuel before in- Fuel quality is critical to the performance and to the
stalling. The fuel would not be filtered and could be service life of the engine. Water in the fuel can cause
contaminated. Contaminated fuel will cause acceler- excessive wear to the fuel system. Condensation
ated wear to fuel system parts. occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
NOTICE causes water to accumulate in fuel tanks. Draining
In order to meet expected fuel system component the fuel tank regularly and obtaining fuel from reliable
life, 4 micron(c) absolute or less secondary fuel fil- sources can help to eliminate water in the fuel.
tration is required for all Caterpillar Diesel Engines
that are equipped with unit injected fuel systems. Note
that all current Caterpillar Diesel Engines are factory
Drain the Water and the Sediment
equipped with Caterpillar Advanced Efficiency 4 mi- Fuel tanks should contain some provision for draining
cron(c) absolute fuel filters.
water and draining sediment from the bottom of the
fuel tanks.
Caterpillar does not warrant the quality or perfor-
mance of non-Caterpillar fluids and filters.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
8. Install a new fuel filter, and tighten the fuel filter the drain valve.
until the gasket contacts the base.
Note: Failure to properly close the drain can allow air
9. Tighten the fuel filter by hand according to the into the system, which could have detrimental results
instructions that are shown on the fuel filter. to performance.
Do not overtighten the fuel filter. Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
10. Lock fuel priming pump (1) (if equipped). Open the water and sediment from the fuel tank after the
the fuel tank supply valve. fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
11. If the engine stalls, refer to the Operation and
Maintenance Manual, “Fuel System - Prime” topic Fill the fuel tank after operating the engine in
(Maintenance Section) for more information. order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
i03645042 overflow.
Fuel Tank Water and Sediment Some fuel tanks use supply pipes that allow water
- Drain and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
SMCS Code: 1273-543-M&S take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
NOTICE maintenance of the fuel system filter is important.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Fuel Storage Tanks
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Drain the water and the sediment from the fuel
ing any compartment or disassembling any compo- storage tank during the following conditions:
• Weekly
Dealer Service Tool Catalog” or refer to Special Pub- • Oil change
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col- • Refill of the tank

mandates.
100 SEBU7719-12
Maintenance Section
Heat Exchanger - Inspect
This will help prevent water or sediment from being • Excessive pressure drop between the water inlet
pumped from the storage tank into the engine fuel and the water outlet
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended. Refer An operator that is familiar with the normal operating
to Special Publication, SENR9620, “Improving Fuel temperature of the coolant can determine when
System Durablity”. the coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger
If a bulk storage tank has been refilled or moved are required if the engine is overheating.
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal Your Caterpillar dealer has the equipment and the
baffles in the bulk storage tank will also help trap trained personnel that are needed in order to measure
sediment. Filtering fuel that is pumped from the the pressure drop across the heat exchanger.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. The procedure for cleaning the heat exchanger is
similar to the procedure that is used for cleaning
the aftercooler core. Refer to the Operation and
i01853051
Maintenance Manual, “Aftercooler Core - Clean/Test”
Heat Exchanger - Inspect topic (Maintenance Section). For more information on
servicing the heat exchanger, consult your Caterpillar
SMCS Code: 1379-040 dealer.
i02121526
Hoses and Clamps -

Inspect/Replace
SMCS Code: 7554-040; 7554-510
Inspect all hoses for leaks that are caused by the

following conditions:
• Cracking
• Softness
g00944384
Illustration 81
Heat Exchanger • Loose clamps
The interval for the maintenance of the tube and Replace hoses that are cracked or soft. Tighten any
fin heat exchanger depends on the operating loose clamps.
environment of the vessel and on the operating time.
The sea water that is circulated through the heat NOTICE
exchanger and the amount of operating time of the Do not bend or strike high pressure lines. Do not in-
vessel affects the following items: stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
• Cleanliness of the tubes of the heat exchanger hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
• Effectiveness of the heat exchanger system ommended torque.
Operating in water that contains impurities will

adversely affect the heat exchanger system. In Check for the following conditions:
addition, intermittent use of the vessel will adversely
affect the heat exchanger system. • End fittings that are damaged or leaking
The following items indicate that the heat exchanger • Outer covering that is chafed or cut
may require cleaning:
• Exposed wire that is used for reinforcement
• Increased coolant temperature
• Outer covering that is ballooning locally
• Engine overheating
• Flexible part of the hose that is kinked or crushed
SEBU7719-12 101
Maintenance Section
Injector Bolt Torque - Check
• Armoring that is embedded in the outer covering 9. Clean the cooling system filler cap. Inspect the
cooling system filler cap's gaskets. Replace
A constant torque hose clamp can be used in place the cooling system filler cap if the gaskets are
of any standard hose clamp. Ensure that the constant damaged. Install the cooling system filler cap.
torque hose clamp is the same size as the standard
clamp. 10. Start the engine. Inspect the cooling system for
leaks.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
i01923113
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. Injector Bolt Torque - Check
Each installation application can be different. The SMCS Code: 1290-535-MT
differences depend on the following factors:
Table 10
• Type of hose Required Parts
• Type of fitting material Part Number Description
• Anticipated expansion and contraction of the hose 4C-9612 Silicone Sealant
• Anticipated expansion and contraction of the
fittings Use the following procedure in order to check the
torque of the bolts that fasten the injector to the
Replace the Hoses and the Clamps cylinder head.
NOTICE
Pressurized System: Hot coolant can cause seri- Contaminants may cause rapid wear and shortened
ous burns. To open the cooling system filler cap, component life.
stop the engine and wait until the cooling system
pressure cap slowly in order to relieve the pres- NOTICE
sure. Care must be taken to ensure that fluids are contained
1. Stop the engine. Allow the engine to cool. ing, adjusting and repair of the product. Be prepared to
2. Loosen the cooling system filler cap slowly in ing any compartment or disassembling any compo-
order to relieve any pressure. Remove the cooling nent containing fluids.
system filler cap.
Note: Drain the coolant into a suitable, clean Tools and Shop Products Guide” for tools and supplies
container. The coolant can be reused. suitable to collect and contain fluids on Caterpillar
products.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced. Dispose of all fluids according to local regulations and
mandates.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.
Note: Refer to the Specifications, SENR3130,

“Torque Specifications” in order to locate the proper
torques.
8. Refill the cooling system.

102 SEBU7719-12
Maintenance Section
Injector Bolt Torque - Check
g00952713
Illustration 82
1. Remove bolts (2) and the washers from valve

mechanism cover (1).
2. Remove valve mechanism cover (1) and the seal

from valve cover base (3).
g01000836
Illustration 83
SEBU7719-12 103
Maintenance Section
Maintenance Recommendations
5. Check the condition of the valve cover seal.

Replace the seal if cuts, cracking or other
deterioration is present. Position the seal in the
valve mechanism cover. Apply 4C-9612 Silicone
Sealant on both sides of the seal joint. Position
valve mechanism cover (1) and the seal on valve
cover base (3).
g01000838
Illustration 84 g00746188
Illustration 86
View A-A
Bolt tightening sequence for the valve mechanism cover
(4) Bolt
(5) Bolt
(6) Exhaust side of cylinder head 6. Install bolts (2) and the washers. Tighten the bolts
(7) Inlet side of cylinder head in a numerical sequence to a torque of 28 ± 7 N·m
(21 ± 5 lb ft). Refer to Illustration 86.
3. Tighten the bolt for the injector (4) that is closest
to the exhaust side (6) of the cylinder head to a
i03635511
torque of 12 ± 1 N·m (9 ± 1 lb ft).
4. Tighten the bolt for the injector (5) that is closest

Maintenance
to the inlet side (7) of the cylinder head to a torque Recommendations
of 12 ± 1 N·m (9 ± 1 lb ft).
SMCS Code: 1000
Maintenance Information
The operating conditions of an engine affect the
maintenance intervals and the time between
overhauls for the engine. The following conditions
affect the maintenance intervals and the expected
overhaul interval for the engine.
Severe Operation
Severe operation is the use of an engine that
exceeds current published standards for the engine.
Caterpillar maintains standards for the following
engine parameters:
• Horsepower
• Range of rpm
g00952713
Illustration 85 • Fuel consumption
• Fuel quality
• Altitude
104 SEBU7719-12
Maintenance Section
Maintenance Recommendations
• Maintenance intervals Improper Operating Procedures

• Selection of oil • Extended operation at low idle
• Selection of coolant • Minimum cool down periods after high load factor
operation
• Environmental qualities
• Operating the engine beyond the guidelines for the
• Installation engine rating
Refer to the standards for your engine or consult your • Operating the engine at loads that are greater than
Caterpillar dealer in order to determine if your engine the rated load
is operating within the defined parameters.
• Operating the engine at speeds that are greater
Severe operation can accelerate component wear. than the rated speed
Engines that are operating under severe conditions
may need more frequent maintenance intervals for • Use of the engine for an application that is not
the following reasons: approved
• Maximum reliability Improper Maintenance Practices

• Retention of full service life • Extension of maintenance intervals
Because of individual applications, it is not possible • Not using recommended fuel, lubricants, and
to identify all of the factors which can contribute to antifreeze/coolant solutions
severe operation. Consult your Caterpillar dealer
about the maintenance that is needed for your
specific engine. Overhaul Information
The following factors can contribute to severe Reduced hours of operation at full load will result in a
operation: environment, improper operating lower average power demand. A decreased average
procedures, and improper maintenance practices. power demand should increase both the engine
service life and the overhaul interval.
Environmental Factors The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
Extreme Ambient Temperatures
The following factors are important when a decision
Extended operation in environments that are
is being made on the proper time for an engine
extremely cold or hot can damage components. Valve
overhaul:
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot inlet air reduces • The need for preventive maintenance
the performance capabilities of the engine.
• The quality of the fuel that is being used
Note: See this Operation and Maintenance Manual,
“Cold Weather Operation” topic (Operation Section), • The operating conditions
or see Supplement, SEBU5898, “Cold Weather
Recommendations”. • The results of the S·O·S analysis
Note: Refer to this Operation and Maintenance
Cleanliness
Manual, “Overhaul (Top)” for further information
about the top overhaul.
Unless the equipment is cleaned regularly, extended
operation in a dirty environment and in a dusty
Note: Refer to this Operation and Maintenance
environment can damage components. Built up mud,
Manual, “Overhaul (Major)” for further information
dirt, and dust can encase components. This can about the major overhaul.
make maintenance difficult. The buildup can contain
corrosive chemicals. Corrosive chemicals and salt
can damage some components.
SEBU7719-12 105
Maintenance Section
Overhaul (Major)
Oil Consumption as an Overhaul After Failure Overhaul

Indicator If a major engine failure occurs and the engine must
be removed from the hull, many options are available.
Oil consumption, fuel consumption, and maintenance
An overhaul should be performed if the engine block
information can be used to estimate the total
or the crankshaft needs to be repaired.
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
If the engine block is repairable and/or the crankshaft
required capacity of a makeup oil tank that is suitable
is repairable, the overhaul cost should be between 40
for the maintenance intervals.
percent and 50 percent of the cost of a new engine
with a similar exchange core.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
This lower cost can be attributed to three aspects:
engine load is increased, the amount of oil that is
consumed per hour also increases.
• Specially designed Caterpillar engine features
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per • Caterpillar dealer exchange components
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar • Caterpillar Inc. remanufactured exchange
components
dealer for assistance in determining the typical oil
consumption rate for your engine.
i03398635
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal Overhaul (Major)
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby SMCS Code: 7595-020-MJ
and a slight increase in fuel consumption.
The need for a major overhaul is determined by
Overhaul Options several factors.
Before Failure Overhaul • An increase of oil consumption
To minimize downtime, Caterpillar Inc. recommends • An increase of crankcase blowby

a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you • The total amount of fuel consumption
with the best cost/value relationship.
• The service hours of the engine
Note: Overhaul programs vary according to the
engine application and according to the dealer that • The wear metal analysis of the lube oil
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available • An increase in the levels of noise and vibration
overhaul programs and about overhaul services for
extending the engine life. An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
A planned overhaul before failure may be the best need to be serviced. An increase in the levels of
value for the following reasons: noise and vibration indicates that rotating parts
require service.
• Costly unplanned downtime can be avoided. Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
• Many original parts can be reused according to the liners may be worn so that polishing of the bore
standards for reusable parts.
occurs. Also, the increased use of lube oil will dilute
the wear metals.
• The engine's service life can be extended without
the risk of a major catastrophe due to engine
failure. Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
• The best cost/value relationship per hour of
extended life can be attained.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
106 SEBU7719-12
Maintenance Section
Overhaul (Major)
For the major overhaul, all of the bearings, Recondition the worn components or exchange the
seals, gaskets, and components that wear are components, if necessary. Your Caterpillar dealer can
disassembled. The parts are cleaned and inspected. provide these services and components.
If necessary, the parts are replaced. The crankshaft
is measured for wear. The crankshaft may require • Camshaft followers
regrinding. Alternatively, the crankshaft may be
replaced with a Caterpillar replacement part. • Camshaft thrust washers
Your Caterpillar dealer can provide these services • Connecting rods
and components. Your Caterpillar dealer can ensure
that the components are operating within the • Crankshaft vibration damper
appropriate specifications.
• Cylinder head assembly
Replacement of Components
• Cylinder liners
Replace the following components during the major
overhaul: • Engine mounts
• Camshaft bearings • Scavenge oil pump
• Connecting rod bearings • Engine wiring harness
• Crankshaft seals • Exhaust manifold seals
• Crankshaft thrust washers • Exhaust manifold bellows
• Electronic unit injectors • Fuel pressure regulating valve
• Gear train bushings • Fuel priming pump
• Gear train bearings • Fuel transfer pump
• Main bearings • Inlet manifold gaskets
• Piston rings • Inlet manifold seals
• Aftercooler core • Oil cooler core

• Oil pump
International Convention for Safety of
Life at Sea (SOLAS) • Pistons
Caterpillar recommends replacing the following: • Piston pins
• All shields that have been installed to cover up fuel • Prelube pump
and oil line connections per (SOLAS) regulations
• Pushrods
• All marine certification society approved tapes are
installed in order to cover up fuel line connections • Rocker arms
and oil line connections according to the SOLAS
regulations. • Spacer plate
Inspection, Reconditioning or • Software update

Exchanging of Components • Turbocharger
Inspect the following components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
Parts”.
SEBU7719-12 107
Maintenance Section
Overhaul (Major)
Inspection of Components • Excessive wear of the gear train that is not caused
by a lack of lubrication
Inspect the following components according to
the instructions that are in Caterpillar reusability Inspect the gears of the gear train and inspect the
publications. Refer to Guidelines for Reusable gear train bushings for the following conditions:
of Publications on Reusability or Salvage of Used • Worn gear teeth
Parts”.
• Unusual fit
• Camshaft
• Unusual wear
• Crankshaft
In addition to the inspection of components, inspect
• Driven equipment (alignment) the alignment of the driven equipment. See the
Application and Installation Guide for the engine or
• Engine cylinder block see the literature that is provided by the OEM of the
driven equipment.
• Engine control module
Cleaning of Components
• Flywheel
Clean the oil suction screen. Also, remove side
• Front gear train (gears) covers in order to clean the oil sump. For instructions
on removal and installation of components, see
• Oil suction screen the Service Manual, “Disassembly and Assembly”
module.
• Rear gear train
Inspect the camshaft for damage to the journals and Obtain a Coolant Analysis
the lobes.
For conventional heavy-duty coolant or antifreeze,
Inspect the crankshaft for any of the following check the concentration of supplemental coolant
conditions: additive (SCA) regularly. The concentration of SCA
can be checked with an S·O·S coolant analysis (Level
• Deflection I). A more detailed coolant analysis is recommended
periodically.
• Damage to the journals
For example, considerable deposits are found in the
• Bearing material that has seized to the journals water jacket areas on the external cooling system,
but the concentrations of coolant additives were
Check the journal taper and the profile of the carefully maintained. The coolant water probably
crankshaft journals. Check these components by contained minerals which were deposited on the
interpreting the wear patterns on the following engine over time.
components:
A coolant analysis can be conducted in order to verify
• rod bearing the condition of the water that is being used in the
cooling system. A full water analysis may be obtained
• main bearings from the following sources:
Note: If the crankshaft or the camshaft are removed • Caterpillar dealer

for any reason, use the magnetic particle inspection
process to check for cracks. • Local water utility company
Replace the crankshaft vibration damper if any of the • Agricultural agent
following conditions occur:
• Independent laboratory
• Engine failure due to a broken crankshaft
Caterpillar recommends an S·O·S coolant analysis
• Excessive wear of the front bearing for the (Level II). This is a comprehensive chemical
crankshaft evaluation of the coolant. This analysis is also a
check of the overall condition of the inside of the
cooling system. The following services are provided:
108 SEBU7719-12
Maintenance Section
Overhaul (Top End)
• Full Level I analysis Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
• Identification of the source of metal corrosion and interval. The part must be replaced with a part that
of contaminants meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
• Identification of buildup of the impurities that cause a rebuilt part, or a used part. Some worn components
corrosion may be exchanged with your Caterpillar dealer for a
credit on replacement parts. Consult your Caterpillar
• Identification of buildup of the impurities that cause dealer about repair options for your engine.
scaling
If you elect to perform an overhaul without the
• Determination of possible electrolysis within the services of a Caterpillar dealer, be aware of the
engines' cooling system recommendations in Table 11.
A report of the results of the analysis is provided. Table 11

Maintenance recommendations are based on the Recommendations for Top End Overhauls (1)
results.
Service Top End Overhaul
For more information about S·O·S coolant analysis, Inspect Cylinder head assemblies
consult your Caterpillar dealer. Rebuild
Replace Valves
i03638175 Rocker arms

Inspect
Overhaul (Top End) Replace
Valve bridges
Fuel Injectors
SMCS Code: 7595-020-TE (1) For instructions on removal and installation of components,
see the Service Manual, “Disassembly and Assembly” module.
A top end overhaul involves the removal, the
inspection, and the rework of the cylinder head
components. A few additional components are i00905687
replaced and serviced.
Sea Water Strainer -
Your Caterpillar dealer can provide these services Clean/Inspect
and components. Your Caterpillar dealer can ensure
that the components are operating within the SMCS Code: 1371-040; 1371-070
appropriate specifications.
The sea water strainer must be clean in order to
The following definitions explain the terminology for allow proper engine cooling. Check the sea water
the services that are performed during an overhaul: strainer for plugging. Inspect the sea water strainer
more frequently if the vessel is being operated
Inspect – Inspect the components according to in water which is shallow or dirty. Refer to the
the instructions that are in Caterpillar reusability OEM recommendations for more information about
publications. Refer to Guidelines for Reusable inspecting and cleaning the sea water strainer.
of Publications on Reusability or Salvage of Used Ensure that the auxiliary water pump is primed and
Parts”. The guidelines were developed in order to that the suction line is open.
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not 1. Remove the sea water strainer and clean the
required if the existing parts can still be used, screen. Remove any dirt and debris.
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service 2. Install the sea water strainer. Fill the sea water
Manual, “Specifications” module. strainer and the suction line for the auxiliary water
pump with water.
Rebuild – The component is reconditioned in order
to comply with reusability guidelines.
SEBU7719-12 109
Maintenance Section
Starting Motor - Inspect
i00651416 Note: Turbocharger components require precision

clearances. The turbocharger cartridge must
Starting Motor - Inspect be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
SMCS Code: 1451-040; 1453-040 Severe Service Applications require more frequent
inspections of the cartridge.
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation. Removal and Installation
Check the starting motor for proper operation. Check For options regarding the removal, installation, repair
the electrical connections and clean the electrical and replacement, consult your Caterpillar dealer.
connections. Refer to the Service Manual for more Refer to the Service Manual for this engine for the
information on the checking procedure and for procedure and specifications.
specifications or consult your Caterpillar dealer for
assistance. Cleaning and Inspecting
i02877697
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
Turbocharger - Inspect inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
SMCS Code: 1052-040; 1052 from entering during reassembly.
Periodic inspection and cleaning is recommended 2. Turn the compressor wheel and the turbine wheel
for the turbocharger compressor housing (inlet side). by hand. The assembly should turn freely. Inspect
Any fumes from the crankcase are filtered through the compressor wheel and the turbine wheel for
the air inlet system. Therefore, by-products from oil contact with the turbocharger housing. There
and from combustion can collect in the turbocharger should not be any visible signs of contact between
compressor housing. Over time, this buildup can the turbine wheel or compressor wheel and the
contribute to loss of engine power, increased black turbocharger housing. If there is any indication of
smoke and overall loss of engine efficiency. contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
If the turbocharger fails during engine operation, the turbocharger must be reconditioned.
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the 3. Check the compressor wheel for cleanliness.
turbocharger compressor wheel can cause additional If only the blade side of the wheel is dirty, dirt
damage to the pistons, the valves, and the cylinder and/or moisture is passing through the air filtering
head. system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
NOTICE oil seal.
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems. The presence of oil may be the result of extended
Loss of engine lubricant can result in serious engine engine operation at low idle. The presence of oil
damage. may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
Minor leakage of a turbocharger housing under ex- turbocharger to slobber.
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc- 4. Inspect the bore of the turbine housing for
curred. corrosion.
When a turbocharger bearing failure is accompanied 5. Clean the turbocharger housing with standard
by a significant engine performance loss (exhaust shop solvents and a soft bristle brush.
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or 6. Fasten the air inlet piping and the exhaust outlet
replaced. piping to the turbocharger housing.
An inspection of the turbocharger can minimize

unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
110 SEBU7719-12
Maintenance Section
Walk-Around Inspection
i03607157 • Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Walk-Around Inspection
• Inspect the piping for the air inlet system and the
SMCS Code: 1000-040 elbows for cracks and for loose clamps.
A walk-around inspection should only require a few • Inspect the alternator belt and the accessory drive
minutes. When the time is taken to perform these belts for cracks, breaks or other damage.
checks, costly repairs and accidents can be avoided.
Belts for multiple groove pulleys must be replaced as
Inspect the Engine for Leaks and matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
for Loose Connections The older belts are stretched. The additional load on
the new belt could cause the belt to break.
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
• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
leaks, loose bolts, worn belts, loose connections and fuel enters the fuel system.
trash buildup. Make repairs, as needed:
• Inspect the wiring and the wiring harnesses for
• The guards must be in the proper place. Repair loose connections and for worn wires or frayed
damaged guards or replace missing guards. wires.
• Wipe all caps and plugs before the engine is • Inspect the ground strap for a good connection and
serviced in order to reduce the chance of system for good condition.
contamination.
• Inspect the ECM to the cylinder head ground strap
NOTICE for a good connection and for good condition.
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct • Disconnect any battery chargers that are not
the leak. If leaking is suspected, check the fluid levels protected against the current drain of the starting
more often than recommended until the leak is found motor. Check the condition and the electrolyte level
or fixed, or until the suspicion of a leak is proved to be of the batteries, unless the engine is equipped with
unwarranted. a maintenance free battery.
NOTICE • Check the condition of the gauges. Replace any

gauges which are cracked and replace any gauges
Accumulated grease and/or oil on an engine or deck is
that can not be calibrated.
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
Inspect the Area Around the Drive
• Ensure that the cooling lines are tight and ensure Shaft (Engines which are Equipped
that the cooling lines are properly clamped. Check with Pod Drive Units)
for leaks. Check the condition of all pipes.
Inspect the area around the drive shaft in order to
• Inspect the water pumps for coolant leaks. ensure that no wires may come into contact with the
drive shaft. Remove any material which may come
Note: The water pump seal is lubricated by coolant into contact with the drive shaft.
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract. i03543200
Excessive coolant leakage may indicate the need Water Pump - Inspect
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps SMCS Code: 1361-040; 1361
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer. A failed water pump might cause severe engine
overheating problems that could result in the following
conditions:
• 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. • Cracks in the cylinder head
SEBU7719-12 111
Maintenance Section
Zinc Rods - Inspect/Replace
• A piston seizure Inspect the Zinc Rods

• Other potential damage to the engine The zinc rods are red for easy identification. Table
12 shows the locations of the zinc rods and the
A failed water pump might cause severe engine quantities of the zinc rod:
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential Table 12
damage to the engine. Locations of the Zinc Rods
Visually inspect the water pump for leaks. If leaking Location Quantity
of the water pump seals is observed, replace all of Heat Exchanger 1
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump Transmission Oil Cooler(1) 2
- Disassemble and Water Pump - Assemble” for Located in front of the aftercooler 1
the disassembly and assembly procedure. If it is (1) Zinc rods will only be located in marine transmission oil coolers
necessary to remove the water pump, refer to two that are cooled with sea water.
articles in the Disassembly and Assembly Manual,
“Water Pump - Remove and Water Pump - Install”. 1. Remove the zinc rod.
Inspect the water pump for wear, cracks, pin holes 2. Inspect the zinc rod.
and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or Ensure that the zinc rod will remain effective until
consult your Caterpillar dealer if repair is needed or the next scheduled inspection.
replacement is needed.
a. If the zinc rod has deteriorated excessively,
i02077120 install a new zinc rod.

SMCS Code: 1388-040; 1388-510
Inspect the zinc rods within 24 hours of initially

filling the plumbing with sea water. If no significant
corrosion is noted, inspect the zinc rods again after
seven days or 50 hours of engine operation and after
having been immersed in sea water. If no significant
deterioration is noted, continue inspections after
every 50 hours of engine operation.
Corrosion in sea water circuits can result in premature

deterioration of cooling system components, leaks, g00481100
and possible cooling system contamination. The Illustration 87
corrosion may be caused by the lack of zinc rods in
the sea water system. b. Tap the zinc rod lightly with a hammer. If the
zinc rod flakes, install a new zinc rod.
Zinc rods are inserted in the sea water cooling system
of the engine in order to help prevent the corrosive 3. If the zinc rod will be reused, scrape the layer of
oxidation that is caused by sea water. The reaction oxidation from the zinc rod before installation. The
of the zinc to the sea water causes the zinc rods to layer of oxidation reduces the effectiveness of the
oxidize rather than the cooling system components. zinc rod.
Rapid deterioration of zinc rods may indicate
the presence of uncontrolled electrical currents Replace the Zinc Rods
from improperly installed electrical attachments or
improperly grounded electrical attachments. 1. Unscrew the old zinc rod from the plug.
The zinc rods must be inspected at the proper If not enough material remains or the zinc rod has
intervals. The zinc rods must be replaced when broken off, drill the old zinc rod from the plug.
deterioration occurs.
2. Clean the plug.
112 SEBU7719-12
Maintenance Section
g00480345
Illustration 88
(1) Shoulder of the zinc rod
(2) Threads of the zinc rod
(3) External threads of the plug
Note: DO NOT apply adhesive or sealant to threads

(2) of the zinc rod.
3. Apply 9S-3263 Thread Lock Compound to

shoulder (1) of a new zinc rod. Apply the
compound ONLY to the shoulder of the zinc rod.
Install the zinc rod onto the plug.
4. Coat external threads (3) of the plug with 5P-3413

Pipe Sealant. Install the zinc rod.

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SEBU7719-12

i03634265 Every 50 Service Hours or Weekly

Daily Every 7100 L (1875 US gal) of Fuel or 250

Every 14 200 L (3750 US gal) of Fuel or 500

Every 21 300 L (5625 US gal) of Fuel or 750

Every 28 400 L (7500 US gal) of Fuel or 1000

Every 56 800 L (15 000 US gal) of Fuel or

Every 91 000 L (24 000 US gal) of Fuel or

Every 170 400 L (45 000 US gal) of Fuel or

Aftercooler Condensate Drain Aftercooler Core - Clean/Test

Clean the Aftercooler Core

The plunger must be able to move freely in order to

Note: Do not use high pressure when the fins are

4. Wash the core with hot, soapy water.

5. Flush the core thoroughly in order to remove i02676048

Caterpillar recommends a scheduled inspection

2. Inspect the core for damage and perform a i01041983

i02153996 8. Connect the cable from the ground plane to the

Battery Electrolyte Level -

7. Connect the cable from the starting motor to the

The battery cables or the batteries should not be

Removing the battery cables or the batteries with

1. Turn the start switch to the OFF position. Turn the

2. Disconnect the negative battery terminal at the Illustration 35

Closed Crankcase Ventilation Closed Crankcase Ventilation

Note: Removal of the canister (8) may be difficult

2. Lower the canister (8) in order to expose the

3. Remove the filter element by pulling down.

4. Remove the O-ring assembly on the top end cap

Cooling System Coolant

• The fuel has entered the cooling system and the

2. Close the drain valve (if equipped). Clean the

Cooling Systems with Heavy Fill

4. Clean the cooling system filler cap. Inspect the

8. Start the engine. Inspect the cooling system for

1. Stop the engine and allow the engine to cool.

3. Fill the cooling system with clean water. Install the

4. Start the engine and run the engine at low

5. Stop the engine and allow the engine to cool.

2. Start the engine and operate the engine at

4. Clean the cooling system filler cap. Inspect the

6. Pour Extended Life Coolant (ELC) into the coolant i02482066

Check the cooling system only when the engine is

Cooling System Coolant Level

Do not attempt to tighten hose connections when

Cooling System Coolant Additive contains alkali.

Engines That Are Not Equipped i01980429

with a Coolant Recovery Tank Cooling System Coolant

Obtain the sample of the coolant as close as possible

Use the following guidelines for proper sampling of

• Obtain coolant samples directly from the coolant

• In order to avoid contamination, immediately place

Refer to Special Publication, SEBU6251, “Caterpillar

Submit the sample for Level 1 analysis.

Note: Level 1 results may indicate a need for

Obtain the sample of the coolant as close as possible NOTICE

Note: This maintenance is NOT required for NOTICE

Test the concentration of the SCA with the 4C-9301

Add the SCA, If Necessary A water temperature regulator that fails in a

A water temperature regulator that fails in the closed

Note: If only the water temperature regulators are

Crankshaft Vibration Damper

The damper is mounted to the crankshaft which is i03595100