C-12 and C12 MARINE ENGINES - Oxford Yacht Agencyoya.com/service/mechanical/C_12_Maintenance.pdf · C-12 and C12 MARINE ENGINES ... Guide, NEHS0526 or consult your Caterpillar dealer

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C-12 and C12MARINE ENGINESMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7599-07)

®© 2009 CaterpillarAll Rights Reserved

®

SEBU7599-07 65Maintenance Section

Maintenance Interval Schedule

i03634261

Maintenance Interval ScheduleSMCS Code: 1000; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible forthe performance of maintenance, including alladjustments, the use of proper lubricants, fluids,filters, and the installation of new componentsdue to normal wear and aging. The performanceof this product may be diminished if propermaintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Replace .................................................. 69Battery or Battery Cable - Disconnect .................. 70Engine - Clean ...................................................... 83Engine Oil Level Gauge - Calibrate ...................... 86Engine Storage Procedure - Check ...................... 91Fuel System - Prime ............................................. 92Heat Exchanger - Inspect/Clean ........................... 96Maintenance Recommendations .......................... 99Sea Water Strainer - Clean/Inspect .................... 103Zinc Rods - Inspect/Replace ............................... 107

Daily

Closed Crankcase Ventilation (CCV) Filter ServiceIndicator - Inspect ............................................... 71Cooling System Coolant Level - Check ................ 79Engine Air Cleaner Service Indicator - Inspect ..... 84Engine Oil Level - Check ...................................... 86Fuel System Primary Filter/Water Separator -Drain ................................................................... 94Walk-Around Inspection ...................................... 106

Initial 20 to 40 Service Hours

Belts - Inspect/Adjust/Replace .............................. 70

Every 50 Service Hours or Weekly

Aftercooler Condensate Drain Valve -Inspect/Clean ...................................................... 67

Sea Water Strainer - Clean/Inspect .................... 103Zinc Rods - Inspect/Replace ............................... 107

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 79

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)


Every Year


Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 78

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 75

First 12 750 L (3375 US gal) of Fuel or 250Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 91Engine Valve Rotators - Inspect ........................... 91Fuel Injector - Inspect/Adjust ................................ 92

Every 12 750 L (3375 US gal) of Fuel or 250Service Hours or Yearly

Auxiliary Water Pump (Rubber Impeller) -Inspect/Replace .................................................. 69Battery Electrolyte Level - Check .......................... 70Belts - Inspect/Adjust/Replace .............................. 70Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 81Engine - Clean ...................................................... 83Engine Air Cleaner Element - Clean/Replace ....... 83Engine Crankcase Breather - Clean ..................... 85Engine Oil Sample - Obtain .................................. 88Engine Oil and Filter - Change ............................. 89Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 93Fuel System Secondary Filter - Replace .............. 94Fuel Tank Water and Sediment - Drain ................. 95Hoses and Clamps - Inspect/Replace .................. 98Marine Transmission Oil Cooler - Clean/Inspect .. 101

Every 36 900 L (9750 US gal) of Fuel or 750Service Hours

Closed Crankcase Ventilation (CCV) Fumes DisposalFilter - Replace .................................................... 72

66 SEBU7599-07Maintenance SectionMaintenance Interval Schedule

Every 49 210 L (13 000 US gal) of Fuel or1000 Service Hours or 2 Years

Aftercooler Core - Clean/Test ............................... 67Engine Valve Lash - Inspect/Adjust ...................... 91Engine Valve Rotators - Inspect ........................... 91Fuel Injector - Inspect/Adjust ................................ 92Heat Exchanger - Inspect/Clean ........................... 96Turbocharger - Inspect/Clean ............................. 104


Auxiliary Water Pump (Bronze Impeller) -Inspect/Replace .................................................. 68Cooling System Coolant (DEAC) - Change .......... 73Cooling System Water Temperature Regulator -Replace ............................................................... 81Crankshaft Vibration Damper - Inspect ................. 82Engine Mounts - Inspect ....................................... 86Engine Speed/Timing Sensor - Clean/Inspect ...... 90


Alternator - Inspect ............................................... 68Starting Motor - Inspect ...................................... 103Water Pump - Inspect ......................................... 107

Every 378 540 L (100 000 US gal) of Fuel or8500 Service Hours

Maintenance Recommendations .......................... 99Overhaul (Major) ................................................. 101


Aftercooler Condensate Drain Valve - Inspect/Clean

i02456287

Aftercooler Condensate DrainValve - Inspect/CleanSMCS Code: 1063-042-DN, VL

g00103601Illustration 31

(1) Drain lines. (2) Adapter. (3) Valve. (4) Plunger. (5) Valve seat.

The turbocharger boost pressure forces plunger (4)to move down to valve seat (5). The plunger mustclose against the seat at a pressure of 27.5 kPa(4 psi). When the engine is stopped, the absenceof boost pressure allows the plunger to rise to theopen position, which allows condensation from theaftercooler to drain out.

The plunger must be able to move freely in order toclose the system when the engine is running. Theplunger must be able to move freely in order to allowcondensation to drain from the aftercooler whenthe engine is stopped. Residue from normal engineoperation could cause the plunger to stick.

1. Remove valve (3) from adapter (2). Check thevalve in order to determine if plunger (4) movesfreely. If the plunger does not move easily, cleanthe valve with solvent.

2. Remove drain lines (1). Check the lines forplugging. Clean the lines, if necessary. Pressureair or a flexible rod with a small diameter can beused to clean the lines.

3. Reassemble the aftercooler condensate drainvalve. Refer to the Specifications, SENR3130,“Torque Specifications” for the correct torquevalues .

i03635591

Aftercooler Core - Clean/TestSMCS Code: 1064-070; 1064-081

Note: An aftercooler that circulates fresh wateror treated water may require cleaning less oftenthan an aftercooler which circulates salt water.The maintenance interval for an aftercooler whichcirculates fresh water or treated water should beevaluated when the aftercooler is cleaned and testedafter the first 1000 hours of engine operation. Theinterval will vary depending on operating conditions.

Clean the Aftercooler CoreRemove the core. Refer to the Disassembly andAssembly Manual, “Aftercooler - Remove” for theprocedure.

1. Turn the aftercooler core on one side in orderto remove debris. Remove the debris that isaccessible.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

2. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 11 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 11

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Hydrosolv 100 19 L (5 US gallon)(1) Use a two to five percent concentration of the cleanerat temperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

3. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris from the insideand from the outside of the core.

Note: Do not use high pressure when the fins arecleaned. High pressure can damage the fins.

4. Wash the core with hot, soapy water.

68 SEBU7599-07Maintenance SectionAlternator - Inspect

5. Flush the core thoroughly in order to removeresidue and remaining debris. Flush the core withclean, fresh water until the water that is exiting thecore is clear and free of debris.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

6. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

Test the Aftercooler Core1. Inspect the core for trapped debris andcleanliness. If necessary, remove the debris andrepeat the cleaning procedure.

2. Inspect the core for damage and perform apressure test in order to detect leaks. Many shopsthat service radiators are equipped to performpressure tests.

3. Plug both ends of the aftercooler core andpressurize the core to 205 kPa (30 psi). Submergethe core in water. Look for bubbles which arebeing emitted from the core. The bubbles areevidence of leaks.

4. If any leaks are found, do not attempt to repair thecore.

Install a core that is clean and a core that passes thepressure test in step 3. Refer to the Disassemblyand Assembly Manual, “Aftercooler - Install” for theprocedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

i02676048

Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspect theammeter (if equipped) during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system. Makerepairs, as required.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i03091745

Auxiliary Water Pump (BronzeImpeller) - Inspect/ReplaceSMCS Code: 1371-510

Impellers and seals require periodic inspection.Impellers have a service life that is limited. Theservice life depends on the engine operatingconditions.

Inspect the components more frequently when thepump is exposed to debris, sand, or other abrasivematerials. Inspect the components if the pump isoperating at a differential pressure of more than103 kPa (15 psi).

Refer to Disassembly and Assembly, “Auxiliary WaterPump - Remove” in order to remove the auxiliarywater pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Disassemble” in order todisassemble the auxiliary water pump.

Inspect the following components for wear ordamage:

• Bearings

• Impeller

• Seals

• Wear plate


Auxiliary Water Pump (Rubber Impeller) - Inspect/Replace

If wear or damage is found, replace the componentswhich are worn or damaged. Use the proper repairkit for the pump.

Refer to Disassembly and Assembly, “Auxiliary WaterPump - Assemble” in order to assemble the auxiliarywater pump. Refer to Disassembly and Assembly ,“Auxiliary Water Pump - Install” in order to install theauxiliary water pump.

i03091750

Auxiliary Water Pump (RubberImpeller) - Inspect/ReplaceSMCS Code: 1371-510

Impellers and seals require periodic inspection.Impellers have a service life that is limited. Theservice life depends on the engine operatingconditions.

Inspect the components more frequently when thepump is exposed to debris, sand, or other abrasivematerials. Inspect the components if the pump isoperating at a differential pressure of more than103 kPa (15 psi).

Refer to Disassembly and Assembly, “Auxiliary WaterPump - Remove” in order to remove the auxiliarywater pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Disassemble” in order todisassemble the auxiliary water pump.

Inspect the following components for wear ordamage:

• Bearings

• Impeller

• Seals

• Wear plate

If wear or damage is found, replace the componentswhich are worn or damaged. Use the proper repairkit for the pump.

Refer to Disassembly and Assembly, “Auxiliary WaterPump - Assemble” in order to assemble the auxiliarywater pump. Refer to Disassembly and Assembly ,“Auxiliary Water Pump - Install” in order to install theauxiliary water pump.

i02153996

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved 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 withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe cable from the NEGATIVE “-” battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE“+” battery terminal to the starting motor.Disconnect the cable from the POSITIVE “+”battery terminal.

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

70 SEBU7599-07Maintenance SectionBattery Electrolyte Level - Check

8. Connect the cable from the ground plane to theNEGATIVE “-” battery terminal.

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

The battery cables or the batteries should not beremoved 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 withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i02856850

Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

InspectionInspect the alternator belt and any accessory beltsfor wear and for cracking. Replace the belts if thebelts are not in good condition.

To check the belt tension, apply 110 N (25 lb) of forcemidway between the pulleys. A correctly adjustedbelt will deflect 13 to 19 mm (0.50 to 0.75 inch).

Slippage of loose belts can reduce the efficiencyof the driven components. Vibration of loose beltscan cause unnecessary wear on the followingcomponents:

• Belts

• Pulleys


Closed Crankcase Ventilation (CCV) Filter Service Indicator - Inspect

• Bearings

If the belts are too tight, unnecessary stress is placedon the components. This reduces the service life ofthe components.

ReplacementFor applications that require multiple drive belts,replace the drive belts in matched sets. Replacingone drive belt of a matched set will cause the newdrive belt to carry more load because the older drivebelts are stretched. The additional load on the newdrive belt could cause the new drive belt to fail.

Alternator Belt Adjustment

g00960176Illustration 32(1) Adjusting nuts(2) Mounting bolt(3) Mounting bolt(4) Mounting bolt

1. Remove the drive belt guard.

2. Loosen mounting bolts (2), (3), and (4). Loosenadjusting nuts (1).

3. Turn adjusting nuts (1) in order to increase ordecrease the drive belt tension.

4. Tighten adjusting nuts (1). Tighten mounting bolts(2), (3), and (4).

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belttension again after 30 minutes of engine operation atthe rated rpm.

i01852860

Closed Crankcase Ventilation(CCV) Filter Service Indicator- InspectSMCS Code: 1317-040-FI


(1) Plastic cover(2) Service indicator

The Closed Crankcase Ventilation system (CCV)is equipped with a service indicator. If the fumesdisposal filter becomes plugged prior to the normalservice interval, increased restriction of the filter willcause the crankcase pressure to become positive.When the pressure continues to rise, the serviceindicator will show through the plastic cover. Theservice indicator indicates the need for the fumesdisposal filter to be changed. Refer to the Operationand Maintenance Manual, “Closed CrankcaseVentilation (CCV) Fumes Disposal Filter - Replace”topic for more information.

Note: Check the service indicator when the engine isrunning at low idle.

72 SEBU7599-07Maintenance SectionClosed Crankcase Ventilation (CCV) Fumes Disposal Filter - Replace

i01105975

Closed Crankcase Ventilation(CCV) Fumes Disposal Filter -ReplaceSMCS Code: 1317-510-FI

g00585620Illustration 34Typical example of the Closed Crankcase Ventilation system(CCV)(1) Crankcase breather(2) Fumes disposal filter base and fumes disposal filter(3) Air cleaner

The Closed Crankcase Ventilation system (CCV)requires the replacement of the fumes disposal filter.The service interval of the CCV will be affected bythe following items:

• Engine load

• Soot concentration

• Condition of the engine

The CCV is equipped with a service indicator. If thefumes disposal filter becomes plugged prior to thenormal service interval, increased restriction of thefilter will cause the vacuum to become positive. Whenthe pressure continues to rise, the service indicatorwill show through the cap. The service indicatorindicates the need for the fumes disposal filter to bechanged. Reset the service indicator by using thefollowing procedure:

Resetting the Service Indicator


1. Remove the plastic cover (4).

2. Push down on the service indicator (5).

3. Replace the cover (4).

4. Replace the fumes disposal filter by using thefollowing procedure:

Replacing the Fumes DisposalFilter

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Note:When possible, perform the maintenance whilethe engine is off.


1. Release the latches (7) that hold the canister tothe filter base assembly (6).


Cooling System Coolant (DEAC) - Change

Note: The canister (8) may be difficult to removewhile the engine is operating. The canister hasnegative air pressure while the engine is operating.This creates a vacuum.

2. Lower the canister (8) in order to expose theelement. There may be oil in the bottom of thecanister. 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 capof the used element.

5. Replace the O-ring seal on the bottom of the filterbase assembly.

6. Install the new O-ring on the top end cap of theelement. Install the element into the correct place.

7. Replace the canister (8) and align the canisterwith the boss on the filter base assembly (6).

8. Clamp the latches (7) in the closed position.

i02456328

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

g00104910Illustration 37Cooling System Filler Cap

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

g00104911Illustration 38(1) Aftercooler drain plug. (2) Oil cooler drain plug. (3) Drain Plugfor the water temperature regulator.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove the cooling system drain plugs.

Remove the drain plug from the bottom of thewater cooled exhaust manifold. Remove the drainplug for the water temperature regulator (3),aftercooler drain plug (1) and oil cooler drain plug(2). Allow the coolant to drain.

74 SEBU7599-07Maintenance SectionCooling System Coolant (DEAC) - Change

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-8665Inside Illinois: 1-800-541-8665Canada: 1-800-523-8665

Flush1. Flush the cooling system with clean water in orderto remove any debris.

2. Close the drain valve (if equipped). Cleanthe drain plugs. Install the drain plugs. Referto the Specifications, SENR3130, “TorqueSpecifications” for more information on the propertorques.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add .5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 30 minutes with a coolant temperature of atleast 82°C (180°F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve(if equipped). Clean the drain plugs. Install thedrain plugs. Refer to Specifications, SENR3130,“Torque Specifications” for more information onthe proper torques.

Cooling Systems with HeavyDeposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water in orderto remove any debris.

2. Close the drain valve (if equipped). Cleanthe drain plugs. Install the drain plugs.Refer to Specifications, SENR3130, “TorqueSpecifications” for more information on the propertorques.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L(1 to 2 US gal) of the cooling system capacity.Install the cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 90 minutes. The coolant temperature should beat least 82°C (180°F).


Fill

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

Engines That Are Equipped with aCoolant Recovery Tank

1. Fill the system to the top with the mixture of coolantthat is recommended. Refer to this Operationand Maintenance Manual, “Refill Capacities andRecommendations” for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at 1500rpm for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.


Cooling System Coolant (ELC) - Change

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap.If the gasket for the cooling system filler cap isdamaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket for the cooling system filler cap is notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system filler cap.The correct pressure for the cooling system fillercap is stamped on the face of the cooling systemfiller cap. If the cooling system filler cap does notretain the correct pressure, install a new coolingsystem filler cap.

g00103638Illustration 39(1)Filler cap for the recovery tank. (2) “COLD FULL” mark. (3)“LOW ADD” mark.

5. Pour coolant into the recovery tank until thecoolant reaches “COLD FULL” mark (2). Do not fillthe recovery tank above “COLD FULL” mark (2).

6. Clean the filler cap for the recovery tank. Installthe filler cap for the recovery tank. Start theengine. Inspect the cooling system for leaks andfor proper operating temperature.

Engines That Are Not Equipped with aCoolant Recovery Tank

1. Fill the cooling system with coolant. Refer tothis Operation and Maintenance Manual, “RefillCapacities and Recommendations” for moreinformation on cooling system specifications. Donot install the cooling system filler cap.


3. Check the coolant level. Maintain the coolant levelwithin 13 mm (.5 inch) below the bottom of thepipe for filling. Maintain the coolant level at theproper level on the sight glass (if equipped).

4. Clean the cooling system filler cap. Inspectthe gasket for the cooling system filler cap. Ifthe gasket for the cooling system filler cap isdamaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket for the cooling system filler cap is notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system filler cap.The correct pressure for the cooling system fillercap is stamped on the face of the cooling systemfiller cap. If the cooling system filler cap does notretain the correct pressure, install a new coolingsystem filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i02456377

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-070; 1395-044

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

76 SEBU7599-07Maintenance SectionCooling System Coolant (ELC) - Change

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

Use only clean water to flush the cooling systemwhen Extended Life Coolant (ELC) is drained andreplaced.

Drain


Filler Cap for the Cooling System

1. Stop the engine and allow the engine to cool.Loosen the filler cap for the cooling system slowlyin order to relieve any pressure. Remove the fillercap for the cooling system.

g00105135Illustration 41(1) Aftercooler drain plug. (2) Oil cooler drain plug. (3) Drain plugfor the water temperature regulator.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove the cooling system drain plugs.

Remove the drain plug from the bottom of thewater cooled exhaust manifold. Remove the drainplug for the water temperature regulator (3),aftercooler drain plug (1) and oil cooler drain plug(2). Allow the coolant to drain.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside U.S.A.: (309) 675-6277Inside U.S.A.: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOLCSTG COSA Geneva, Switzerland:41-22-849 40 56

Clean the Cooling System1. Flush the cooling system with clean water in orderto remove any debris.

2. Close the drain valve (if equipped). Cleanthe drain plugs. Install the drain plugs.Refer toSpecifications, SENR3130, “TorqueSpecifications” for more information on the propertorques.


3. Fill the cooling system with clean water. Install thecooling system filler cap. Operate the engine untilthe temperature reaches 49 °C (120 °F) to 66 °C(150 °F).


Cooling System Coolant (ELC) - Change

4. Start and run the engine at low idle until thetemperature reaches 49 to 66°C (120 to 150°F).


Fill the Cooling System



1. Fill the cooling system to the top with Cat ELC.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” formore information on coolant specifications. Do notinstall the filler cap for the recovery tank.


3. Check the coolant level. Maintain the coolant tothe proper level on the sight gauge (if equipped).If a sight gauge is not equipped, maintain thecoolant within 13 mm (.5 inch) below the bottom ofthe filler pipe.

4. Clean the cooling system filler cap. Inspectthe filler cap gasket. If the filler cap gasket isdamaged, discard the old cooling system filler capand install a new cooling system filler cap. If thefiller cap gasket is not damaged, use a 9S-8140Pressurizing Pump in order to pressure test thecooling system filler cap. The correct pressure forthe cooling system filler cap is stamped on theface of the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.

g00103638Illustration 42(1) Filler cap for the recovery tank. (2) “COLD FULL” mark. (3)“LOW ADD” mark.

5. Pour Cat ELC into the recovery tank until thecoolant reaches “COLD FULL” mark (2). Do not fillthe tank above “COLD FULL” mark (2).

6. Clean the filler cap. Install the filler cap. Start theengine. Inspect the cooling system for leaks andfor proper operating temperature.

Engines That Are Not Equipped with aCoolant Recovery Tank


1. Fill the cooling system to the top with Cat ELC.Refer to this Operation and Maintenance Manual,“Refill Capacitties and Recommendations” formore information on cooling system specifications.Do not install the cooling system filler cap.


3. Check the coolant level. Maintain the coolant levelwithin 13 mm (.5 inch) below the bottom of thepipe for filling. Maintain the coolant level at theproper level on the sight glass (if equipped).

78 SEBU7599-07Maintenance SectionCooling System Coolant Extender (ELC) - Add

4. Clean the filler cap. Inspect the gasket for thefiller cap for the cooling system. If the gasket isdamaged, discard the old filler cap for the coolingsystem and install a new filler cap. If the gasketfor the cooling system filler cap is not damaged,use a 9S-8140 Pressurizing Pump in order topressure test the cooling system filler cap. Thecorrect pressure for the cooling system filler capis stamped on the face of the cooling system fillercap. If the cooling system filler cap does not retainthe correct pressure, install a new cooling systemfiller cap.

5. Start the engine. Inspect the cooling systemfor leaks. Inspect the cooling system for properoperating temperature.

i02482066

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-045; 1395-081

Cat ELC (Extended Life Coolant) does not requirethe frequent additions of any supplemental coolingadditives which are associated with the presentconventional coolants. The Cat ELC Extender onlyneeds to be added once.

NOTICEUse only Cat Extended Life Coolant (ELC) Extenderwith Cat ELC.

Do NOT use conventional supplemental coolant addi-tive (SCA) with Cat ELC. Mixing Cat ELC with conven-tional coolants and/or conventional SCA reduces theCat ELC service life.

Check the cooling system only when the engine isstopped and cool.


At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.




1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolant fromthe cooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to therequirements for your engine's cooling systemcapacity. Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”article for more information.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.


Cooling System Coolant Level - Check

i02456586

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.


g00103638Illustration 43(1) Filler cap(2) “COLD FULL” mark(3) “LOW ADD” mark

1. Observe the coolant level in the coolant recoverytank. Maintain the coolant level to “COLD FULL”mark (2) on the coolant recovery tank.

2. Loosen filler cap (1) slowly in order to relieve anypressure. Remove the filler cap.

3. Pour the proper coolant mixture into the tank.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” forinformation about coolants. Do not fill the coolantrecovery tank above “COLD FULL” mark (2).

4. Clean filler cap (1) and the receptacle. Reinstallthe filler cap and inspect the cooling system forleaks.

Note: The coolant will expand as the coolant heatsup during normal engine operation. The additionalvolume will be forced into the coolant recovery tankduring engine operation. When the engine is stoppedand cool, the coolant will return to the engine.

Engines That Are Not Equippedwith a Coolant Recovery Tank


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.


Typical filler cap gaskets

3. Clean the cooling system filler cap and inspectthe condition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i02837191

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems thatare filled with Cat ELC should have a Coolant Sample(Level 2) that is obtained at the recommended intervalthat is stated in the Maintenance Interval Schedule.

80 SEBU7599-07Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants:

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 12

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC Every 250Hours(1) Yearly(1)(2)

Cat ELC Optional(2) Yearly(2)

(1) This is the recommended interval for coolant samples for allconventional heavy-duty coolant/antifreeze. This is also therecommended interval for coolant samples of commercialcoolants that meet the Cat EC-1 specification for enginecoolant.

(2) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis,see this Operation and Maintenance Manual, “RefillCapacities and Recommendations” or consult yourCaterpillar dealer.

i01987714

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542


Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

For additional information about coolantanalysis, see Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” or consult your Caterpillar dealer.


Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i03509177

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Note: This maintenance is NOT required forcooling systems that are filled with Extended LifeCoolant.

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

NOTICEExcessive supplemental coolant additive concentra-tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine'sheat transfer characteristics. Reduced heat transfercould cause cracking of the cylinder head and otherhigh temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the waterpump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” and to Special Publica-tion, GECJ0003, “Cat Shop Supplies and Tools” fortools and supplies suitable to collect and contain flu-ids on Caterpillar products.

Dispose of all fluids according to applicable regula-tions and mandates.

Note: Caterpillar recommends an S·O·S coolantanalysis (Level 1).

Cooling Systems that UseConventional Coolant

Test the Concentration of the SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Test the concentration of the SCA with the 4C-9301Coolant Conditioner Test Kit.

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

3. Add the proper amount of SCA. For theproper amount of SCA, refer to this Operationand Maintenance Manual, “Refill Capacitiesand Recommendations” topic. The properconcentration of SCA depends on the type ofcoolant that is used. For the proper concentrationof SCA, refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations”.

4. Clean the cooling system filler cap. Install thecooling system filler cap.

i03645060

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime. Refer to thisOperation and Maintenance Manual, “MaintenanceInterval Schedule” for the proper maintenanceinterval.

82 SEBU7599-07Maintenance SectionCrankshaft Vibration Damper - Inspect

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in the closedposition can cause excessive overheating. Excessiveoverheating could result in cracking of the cylinderhead or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup inside thecylinders. This excessive carbon buildup could resultin an accelerated wear of the piston rings and wearof the cylinder liner.

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the enginemay overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to two articles in the Disassembly andAssembly Manual, “Water Temperature Regulators- Remove and Water Temperature Regulators -Install” for the replacement procedure of the watertemperature regulator, or consult your Caterpillardealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling system toa level that is below the water temperature regulatorhousing.

i03175962

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the crankshaft vibration damper or failureof the crankshaft vibration damper can increasetorsional vibrations. This can result in damage tothe crankshaft and to other engine components. Adeteriorating damper can cause excessive gear trainnoise at variable points in the speed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

g01134779Illustration 45Viscous vibration damper

Typical example(1) Crankshaft pulley(2) Weight(3) Case

InspectionInspect the damper for the following conditions:

• The damper is dented, cracked, or fluid is leakingfrom the damper.

• The paint on the damper is discolored fromexcessive heat.

• The damper is bent.

• The bolt holes are worn or there is a loose fit forthe bolts.


Engine - Clean

• The engine has had a crankshaft failure due totorsional forces.

Replace the damper if any of these conditions exist.

Removal and InstallationRefer to this Operation and Maintenance Manual,“Belts - Inspect/Adjust/Replace” for informationon removing and on installing the belt. Refer tothe Disassembly and Assembly Manual, “VibrationDamper and Pulley - Remove and Install” forinformation on removing and installing the damper.

i01646701

Engine - CleanSMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when you clean the engine. Avoidelectrical components such as the alternator, thestarter, and the ECM.

i01708992

Engine Air Cleaner Element -Clean/ReplaceSMCS Code: 1054-070; 1054-510


(1) Vacuum regulator filter element(2) Air cleaner element

Note: The air cleaner element should be replacedafter three cleanings.

Note: Use the 102-9720 Cleaning Kit. This productcontains the detergent and oil that is made specificallyfor the maintenance of the air cleaner elements.

1. Remove the vacuum regulator filter element (1)and the air cleaner element (2).

Note: The same procedure is used for cleaning boththe air filter element and the vacuum regulator filterelement.

2. Tap the element in order to dislodge dirt particles.Gently brush the element with a soft bristle brush.

Note: The element may be oiled and the elementmay be reinstalled , if complete cleaning is notpractical at this time. Refer to step 6.

NOTICEDo not use gasoline, steam, caustic or unapproveddetergents, or parts cleaning solvents. Do not use highpressure water or air to clean the air cleaner element.Any of those liquids or methods can cause air cleanerelement damage.

3. Spray the element with the cleaning solution.Allow the element to stand for 10 minutes.

84 SEBU7599-07Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

4. Rinse the element with low water pressure. Themaximum water pressure for this procedure is275 kPa (40 psi). Tap water is acceptable. Startto rinse the element from the clean side (inside).Next, clean the dirty side (outside) in order toflush out dirt. Inspect the element for tears and/orholes after the element is cleaned. Do not reusedamaged elements.

NOTICEDo not use compressed air, open flame, or hot air todry the air cleaner element. Excess heat shrinks cot-ton fiber, and compressed air may blow holes in thematerial. Allow the air cleaner element to air dry.

5. Shake excess water off the element and allow theelement to air dry. Drying the element in the sunspeeds the process.

NOTICEDo not use transmission fluid, engine oil, diesel fuel,or other lubricant to oil the air cleaner element. Theair cleaner element can not function correctly if im-proper oil is used. Never operate an engine with adry air cleaner element. The air cleaner element cannot function correctly without oil. Always saturate theclean air cleaner element with the recommended oil.

6. The dry element should be oiled before installation.Apply small amounts of oil across the top of eachpleat. Allow the oil to wick into the element for 20minutes. Oil any remaining “white” spots.

7. Inspect the housing and the clamp for air cleanerelement (2). Replace the housing and the clamp,if necessary. Install the clean, oiled air cleanerelement. Refer to the Torque Specifications,SENR3130 for more information on the propertorques.

8. Install the vacuum regulator filter element (1) onthe vacuum regulator filter.

i02456843

Engine Air Cleaner ServiceIndicator - InspectSMCS Code: 7452-040

g01045984Illustration 47Typical example(1) Service indicator

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differentialgauge for inlet air pressure. The gauge indicatesthe pressure differential between the inlet side ofthe air cleaner element and the outlet side of the aircleaner element. As the air cleaner element becomesdirty, the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the recommendations for the vessel or followthe recommendations in the air cleaner OEM in orderto service the air cleaner element.

A service indicator may be mounted on the aircleaner element or in a remote location.


Typical Service Indicator


Engine Crankcase Breather - Clean

Observe the service indicator. The air cleanerelement should be cleaned or replaced when theyellow diaphragm enters the red zone or the redpiston locks in the visible position. If the serviceindicator appears red at any time, clean the aircleaner element or install a new air cleaner element.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated rpm.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty.Replace the service indicator annually regardlessof the operating conditions. Replace the serviceindicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

Service the Air Cleaner Element

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

If the air cleaner element becomes plugged, theair can split the filter material. Unfiltered air willdrastically accelerate internal engine wear. YourCaterpillar dealer has air filter elements in order toservice this unit. Consult your Caterpillar dealer forthe correct air cleaner element.

If the service indicator appears red at any time, cleanthe air cleaner element or install a new air cleanerelement. Clean the air cleaner element or replace theair cleaner element at 250 hour intervals.

i02027506

Engine Crankcase Breather -CleanSMCS Code: 1317-070

g01046003Illustration 49Typical example(1) Crankcase breather

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.

1. Loosen the hose clamp and remove the hose fromthe breather cover.

2. Loosen the four bolts for the breather cover andremove the breather cover.

3. Remove the breather element and wash thebreather element in solvent that is clean andnonflammable. Allow the breather element to dry.

4. Install a breather element that is clean and dry.Install the breather cover and install the bolts.Refer to the Specifications, SENR3130, “TorqueSpecifications Module” for the proper torques.

86 SEBU7599-07Maintenance SectionEngine Mounts - Inspect

5. Install the hose. Install hose clamp. Refer to theSpecifications, SENR3130, “Torque SpecificationsModule” for the proper torques.

i02456872

Engine Mounts - InspectSMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration should bereplaced. Refer to Special Publication, SENR3130,“Torque Specifications” for the recommendedtorques. Refer to the OEM recommendations formore information.

i00573217

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Check the oil level after the engine has stopped.

g00105043Illustration 50(1) Oil level gauge. (2) Oil filler cap.

g00110310Illustration 51(Y) “ADD” mark. (X) “FULL” mark.

1. Maintain the oil level between “ADD” mark (Y) and“FULL” mark (X) on oil level gauge (1). Do not fillthe crankcase above “FULL” mark (X).

NOTICEOperating your engine when the oil level is above the“FULL” mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil's lubricating char-acteristics and could result in the loss of power.

2. Remove oil filler cap (2) and add oil, if necessary.Clean the oil filler cap. Reinstall the oil filler cap.

i03163760

Engine Oil Level Gauge -CalibrateSMCS Code: 1326-524

g00882677Illustration 52(Y) “ADD” mark. (X) “FULL” mark. (Z) “Effective Length”.

(Z-LH Service Engines) 642 mm (25.3 inch)(Z-RH Service Engines) 479 mm (18.9 inch)

The engine is shipped with an engine oil level gaugethat is not marked. The engine oil level gauge is notmarked because the angle of the installation andthe side for servicing the engine oil can be differentfor each engine. The angle of the installation andthe side for servicing the engine oil will affect “ADD”mark (Y) and “FULL” mark (X) that is engraved onthe engine oil level gauge.

The engine oil level gauge should be calibrated afterthe engine is installed in the vessel. Use the followingprocedure in order to verify that “ADD” mark (Y)is correct. Use the following procedure in order toestablish actual “FULL” mark (X) on the engine oillevel gauge. Refer to table 13 and table 14 in orderto determine the location for the “ADD” and “FULL”marks for a particular installation.

1. Operate the engine until normal operatingtemperature is achieved. Stop the engine.Remove one of the drain plugs for the enginecrankcase. Allow the engine oil to drain.


Engine Oil Level Gauge - Calibrate

2. Remove the used engine oil filter. Install the newengine oil filter. Install the drain plug for the enginecrankcase. See this Operation and MaintenanceManual, “Engine Oil and Filter - Change” for theprocedure for replacing the filter. Tighten the drainplug for the engine crankcase to 70 ± 14 N·m(50 ± 10 lb ft).

Note: The engine may be equipped with auxiliaryengine oil filters. Volumes that are different from thestandard amounts may be required. Refer to theOEM specifications.

3. Pour 24.6 L (26 qt) of engine oil into the enginecrankcase. Allow enough time for the engine oil todrain into the engine crankcase. Approximately 20minutes should be allowed. Check the engine oillevel. Wait for a few minutes. Check the engineoil level again. Proceed after the engine oil levelstops changing.

4. Mark the engine oil level on the engine oil levelgauge. Use a marking pen in order to engrave“ADD” mark (Y).

5. Pour 3.8 L (4 qt) of engine oil into the enginecrankcase. Allow enough time for the engine oil todrain into the engine crankcase.

6. Mark the engine oil level on the engine oil levelgauge. Use a marking pen in order to engrave“FULL” mark (X).

7. Start the engine. Ensure that the lubricationsystem is filled. Inspect the lubrication system forleaks.

8. Stop the engine and allow enough time for theengine oil to drain into the engine crankcase.

9. Check the engine oil level on the engine oil levelgauge. If the engine oil level is not at calibrated“FULL” mark (X), fill the sump to the calibrated“FULL” mark. Record the amount of oil that isadded. Add both the 28.4 L (30 qt) of oil that wasadded to the engine before Step 9 and the amountof oil that was added in Step 9. Record this totalamount of oil for future changes of the engine oil.

Markings on the Engine Oil Level Gauge for theC-12 Marine Engine

Note: Use the following tables if these conditionsexist:

• The engine is installed with an angle in the tables. .

• No auxiliary engine oil filters are used on theengine.

Table 13

C-12 Marine EngineMarkings for the Engine Oil Level Gauge (mm)

LH Service (1)

Tilt Angle(2)LH Service“ADD” Mark

Y

LH Service“FULL” Mark

X

-15° 120 mm (4.7 inch) 133 mm (5.2 inch)

-13° 113 mm (4.4 inch) 125 mm (4.9 inch)

-11° 110 mm (4.3 inch) 124 mm (4.9 inch)

-9° 106 mm (4.2 inch) 118 mm (4.6 inch)

-7° 100 mm (3.9 inch) 110 mm (4.3 inch)

-5° 93 mm (3.7 inch) 106 mm (4.2 inch)

-3° 87 mm (3.4 inch) 99 mm (3.9 inch)

-1° 82 mm (3.2 inch) 93 mm (3.7 inch)

0° 79 mm (3.1 inch) 89 mm (3.5 inch)

1° 73 mm (2.9 inch) 85 mm (3.3 inch)

3° 68 mm (2.7 inch) 81 mm (3.2 inch)

5° 63 mm (2.5 inch) 74 mm (2.9 inch)

7° 54 mm (2.1 inch) 67 mm (2.6 inch)

9° 47 mm (1.9 inch) 61 mm (2.4 inch)

11° 38 mm (1.5 inch) 52 mm (2.0 inch)

13° 30 mm (1.2 inch) 43 mm (1.7 inch)

15° 19 mm (0.7 inch) 36 mm (1.4 inch)(1) (Z-LH Service Engines) 642 mm (25.3 inch).(2) The tilt angles in this chart are the engine installation anglesfor the vessel. A positive angle indicates that the front of theengine is raised.

88 SEBU7599-07Maintenance SectionEngine Oil Sample - Obtain

Table 14

C-12 Marine EngineMarkings for the Engine Oil Level Gauge (mm)

RH Service (1)

Tilt Angle(2)RH Service“ADD” Mark

Y

RH Service“FULL” Mark

X

-15° 25 mm (1.0 inch) 44 mm (1.7 inch)

-13° 37 mm (1.5 inch) 55 mm (2.2 inch)

-11° 48 mm (1.9 inch) 65 mm (2.6 inch)

-9° 57 mm (2.2 inch) 73 mm (2.9 inch)

-7° 65 mm (2.6 inch) 81 mm (3.2 inch)

-5° 72 mm (2.8 inch) 88 mm (3.5 inch)

-3° 79 mm (3.1 inch) 96 mm (3.8 inch)

-1° 86 mm (3.4 inch) 102 mm (4.0 inch)

0° 89 mm (3.5 inch) 106 mm (4.2 inch)

1° 94 mm (3.7 inch) 110 mm (4.3 inch)

3° 101 mm (4.0 inch) 116 mm (4.6 inch)

5° 107 mm (4.2 inch) 122 mm (4.8 inch)

7° 115 mm (4.5 inch) 125 mm (4.9 inch)

9° 121 mm (4.8 inch) 136 mm (5.4 inch)

11° 127 mm (5.0 inch) 140 mm (5.5 inch)

13° 134 mm (5.3 inch) 145 mm (5.7 inch)

15° 135 mm (5.3 inch) 150 mm (5.9 inch)(1) (Z-RH Service Engines) 479 mm (18.9 inch).(2) The tilt angles in this chart are the engine installation anglesfor the vessel. A positive angle indicates that the front of theengine is raised.

NOTICERefer to Special Publication, SEBU6251, “Caterpil-lar Commercial Diesel Engines Fluids Recommenda-tions”.

i03542996

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis


Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.


Engine Oil and Filter - Change

For instructions, see Special Publication, PEgj0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Caterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02456905

Engine Oil and Filter - ChangeSMCS Code: 1318-510; 1348-044





Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles settle on the bottomof the oil pan. The waste particles are not removedwith the draining cold oil. Drain the crankcase withthe engine stopped. Drain the crankcase with theoil warm. This draining method allows the wasteparticles that are suspended in the oil to be drainedproperly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Use one of thefollowing methods to drain the engine crankcase oil:

• If the engine is equipped with a manual sumppump, turn the drain valve knob counterclockwisein order to pump the oil out of the oil pan. After theoil has drained, turn the drain valve knob clockwisein order to close the drain valve.

• If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oilto drain. If the engine is equipped with a shallowsump, remove the bottom oil drain plugs from bothends of the oil pan.

After the oil has drained, the oil drain plugs should becleaned and installed. Tighten the oil drain plugs to70 ± 14 N·m (50 ± 10 lb ft).

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter. Break apart the pleats and inspect theoil filter for metal debris. An excessive amountof metal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.

90 SEBU7599-07Maintenance SectionEngine Speed/Timing Sensor - Clean/Inspect

g00103713Illustration 53Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasket isremoved.

4. Apply clean engine oil to the new oil filter gasket.

NOTICEDo 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 toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that areshown on the oil filter. Do not overtighten the oilfilter.

Fill the Engine Crankcase1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual, “Refill Capacities andRecommendations” for more information onlubricant specifications. Fill the crankcase with theproper amount of oil.

NOTICEIf equipped with an auxiliary oil filter or system, extraoil must be added when filling the crankcase. Followthe OEM or filter manufacturer's recommendations. Ifthe extra oil is not added, the engine may starve foroil.

NOTICETo help prevent crankshaft or bearing damage, crankengine to fill all filters before starting. Do not crankengine for more than 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the oil level gauge.

i03535100

Engine Speed/Timing Sensor -Clean/InspectSMCS Code: 1905-040; 1905-070; 1907-040;1907-070

g01863196Illustration 54View of the front of a typical C12 Marine Engine(1) Speed/timing sensor (camshaft)(2) Speed/timing sensor (crankshaft)

1. Remove the speed/timing sensors.

2. Inspect the condition of the plastic end ofthe speed/timing sensors for wear and/orcontaminants.

3. Clean the metal shavings and other debris fromthe face of the speed/timing sensors.

4. Install the speed/timing sensors. Ensure that thesensor is seated before the bolt is tightened.Tighten each bolt to a torque of 28 ± 7 N·m(21 ± 5 lb ft).


Engine Storage Procedure - Check

i02703023

Engine Storage Procedure -CheckSMCS Code: 1000-535

Caterpillar recommends storage procedures andstart-up procedures for all engines that are storedfor more than 1 month. These procedures providemaximum protection to internal engine components.Refer to Special Instruction, SEHS9031, “StorageProcedure For Caterpillar Products” for informationon these procedures.

An extension of the oil change interval to 12 monthsis permitted if you follow the required procedures forstorage and start-up. This extension is permitted if thefollowing intervals in the Operation and MaintenanceManual, “Maintenance Interval Schedule” have notbeen reached:

• Operating hours

• Fuel consumption

i03539022

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Note: Only qualified service personnel shouldperform this maintenance.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. Thisreduced efficiency could result in excessive fuelusage and/or shortened engine component life.

Refer to Testing and Adjusting, “Engine Valve Lash -Inspect/Adjust” for the inspection and the adjustmentprocedures.

i01597115

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to help prevent being burned byhot oil or spray.

Engine valve rotators rotate the valves when theengine runs. This helps to prevent deposits frombuilding up on the valves and the valve seats.

Perform the following steps after the engine valvelash is set, but before the valve covers are installed:

1. Start the engine according to Operation andMaintenance Manual, “Engine Starting” (OperationSection) for the procedure.

2. Operate the engine at low idle.

3. Observe the top surface of each valve rotator. Thevalve rotators should turn slightly when the valvesclose.

NOTICEA valve rotator which does not operate properly willaccelerate valve face wear and valve seat wear andshorten valve life. If a damaged rotator is not replaced,valve face guttering could result and cause pieces ofthe valve to fall into the cylinder. This can cause pistonand cylinder head damage.

If a valve fails to rotate, consult your Caterpillardealer.

92 SEBU7599-07Maintenance SectionFuel Injector - Inspect/Adjust

i03534881

Fuel Injector - Inspect/AdjustSMCS Code: 1290-025

Be sure the engine cannot be started while thismaintenance is being performed. To prevent pos-sible injury, do not use the starting motor to turnthe flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting the unit injectors.

The electronic unit injectors use high voltage. Dis-connect the unit injector enable circuit connectorin order to prevent personal injury. Do not comein contact with the injector terminals while the en-gine is running.

The operation of Caterpillar engines with improperadjustments of the electronic unit injector can reduceengine efficiency. This reduced efficiency could resultin excessive fuel usage and/or shortened enginecomponent life.

Only qualified service personnel should performthis maintenance. Refer to the Systems Operation,Testing and Adjusting, “Electronic Unit Injector -Test” for the test procedure, and Systems Operation,Testing and Adjusting, “Electronic Unit Injector -Adjust” for the adjustment procedure for the injectors.

i01645814

Fuel System - PrimeSMCS Code: 1258-548

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 whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.


Priming the fuel system fills the fuel filters. Primingthe fuel system also removes air from the fuelsystem. This procedure is used primarily when theengine runs out of fuel.

Note: DO NOT remove plug (1) in the fuel filter basein order to release air from the fuel system duringperiodic service of the fuel filter. Periodic removal ofthe plug will result in increased wear of the threadsin the fuel filter base. This can lead to fuel leakage.However, the plug in the fuel filter base can be usedto bleed air from the fuel system if the engine runsout of fuel.

1. Open fuel priming pump (2) and operate the fuelpriming pump until a strong pressure is felt onthe fuel priming pump and until the check valve“clicks”. This procedure will require considerablestrokes. Lock the fuel priming pump.

2. Crank the engine after pressurizing the system.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

3. If the engine does not start, open fuel primingpump (2) and repeat Steps 1 and 2 in order tostart the engine.


Fuel System Primary Filter (Water Separator) Element - Replace

i02927282

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.Water in the fuel may cause an electronic unit injectorto fail. If the fuel has been contaminated with water,the element should be changed before the regularlyscheduled interval.

The primary filter/water separator also providesfiltration in order to help extend the life of thesecondary fuel filter. The element should be changedregularly. If a vacuum gauge is installed, theprimary filter/water separator should be changed at50 to 70 kPa (15 to 20 inches Hg).

Replace the Element





NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

1. Close the main fuel supply valve.

g01453091Illustration 56(1) Element(2) Bowl(3) Drain

2. Remove element (1) from the element mountingbase while bowl (2) is attached.

3. Dispose of the contents of the filter. Remove bowl(2) from element (1). The bowl is reusable. Do notdiscard the bowl. Dispose of the used element.

4. Remove the O-ring from the gland of the bowl.Clean the following components:

• Bowl

• O-ring

• Mounting base

Inspect the O-ring for damage and fordeterioration. Replace the O-ring, if necessary.

5. Lubricate the O-ring with clean diesel fuel.

6. Install bowl (2) on a new element. Tighten thebowl by hand. Do not use tools in order to tightenthe bowl.

NOTICEThe primary filter/water separatormay be prefilled withfuel to avoid rough running/stalling of the engine dueto air. Do not fill the secondary filter with fuel beforeinstallation. The fuel would not be filtered and couldbe contaminated. Contaminated fuel will cause accel-erated wear to fuel system parts.

7. Lubricate the top seal of element (1) with cleandiesel fuel. The element may be filled with fuel atthis time. Install the new element on the mountingbase. Tighten the element by hand.

94 SEBU7599-07Maintenance SectionFuel System Primary Filter/Water Separator - Drain

NOTICEThe water separator is under suction during normalengine operation. Ensure that the vent plug is tight-ened securely to help prevent air from entering the fu-el system.

8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run theengine for one minute. Stop the engine and checkfor leaks again.

Detecting leaks is difficult while the engine isrunning. The primary filter/water separator isunder suction. A leak will allow air to enter the fuel.The air in the fuel can cause low power due toaeration of the fuel. If air enters the fuel, check thecomponents for overtightening or undertightening.

i02927285

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543





NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

g01453091Illustration 57(1) Element(2) Bowl(3) Drain

Bowl (2) should be monitored daily for signs of water.If water is present, drain the water from the bowl.

1. Open drain (3). The drain is a self-ventilated drain.Catch the draining water in a suitable container.Dispose of the water properly.

2. Close drain (3).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i03539225

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE


1. Stop the engine.

2. Turn off the start switch or disconnect the battery(starting motor) when maintenance is performedon fuel filters.

3. Shut off the fuel tank supply valve to the engine.


Fuel Tank Water and Sediment - Drain

4. Unlock the fuel priming pump in order to relieveresidual pressure in the fuel system.


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.


5. Remove the used fuel filter.

6. Clean the gasket sealing surface of the fuel filterbase. Ensure that all of the old gasket is removed.

NOTICEIn order to meet expected fuel system component life,4 micron(c) absolute or less secondary fuel filtrationis required for all Caterpillar diesel engines that areequipped with common-rail fuel systems, and for allCaterpillar diesel engines that are equipped with unitinjected fuel systems. For all other Caterpillar dieselengines (mostly older engines with pump, line andnozzle type fuel systems), the use of 4 micron(c) ab-solute or less secondary fuel filtration is strongly rec-ommended. Note that all current Caterpillar diesel en-gines are factory equipped with Caterpillar AdvancedEfficiency 4 micron(c) absolute fuel filters.

7. Apply clean diesel fuel to the new fuel filter gasket.

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

8. Install a new fuel filter. Tighten the fuel filter untilthe gasket contacts the base. Tighten the fuelfilter by hand according to the instructions that areshown on the fuel filter. Do not overtighten the fuelfilter.

Note: Do not remove the plug in the fuel filter basein order to release air from the fuel system duringperiodic service of the fuel filter. Periodic removal ofthe plug will result in increased wear of the threads inthe fuel filter base.

9. Operate the fuel priming pump until a strongpressure is felt on the fuel priming pump anduntil the check valve “clicks”. This procedure willrequire considerable strokes. Lock the fuel primingpump.

10.Open the fuel tank supply valve. If necessary,reconnect the battery to the starting motor.

11.Start the engine according to the normal operatingprocedures. Immediately increase the engine rpmbetween 1000 to 1200 rpm with no load. Theengine will begin to misfire briefly until air fromthe fuel filter is purged. No damage to the enginewill occur.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

12. If the engine stalls during the purging of the air,refer to the Operation and Maintenance Manual,“Fuel System - Prime” for more information.

i03645042

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S




96 SEBU7599-07Maintenance SectionHeat Exchanger - Inspect/Clean

Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Note: Failure to properly close the drain can allow airinto the system, which could have detrimental resultsto performance.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A four micron(c) absolute filter for the breathervent on the fuel tank is also recommended. Referto Special Publication, SENR9620, “Improving FuelSystem Durablity”.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i03538175

Heat Exchanger - Inspect/CleanSMCS Code: 1379-040; 1379-070


At operating temperature, engine coolant is hotand under pressure. The heat exchanger and alllines to heaters or the engine contain hot coolantor steam. Any contact can cause severe burns.

Remove the filler cap slowly to relieve pressureonly when the engine is stopped and the filler capfor the heat exchanger is cool enough to touchwith your bare hand.

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.


Heat Exchanger - Inspect/Clean




The interval for the maintenance of the heatexchanger depends on the operating environment ofthe vessel and on the operating time. The sea waterthat is circulated through the heat exchanger and theamount of operating time of the vessel affects thefollowing items:

• Cleanliness of the tubes for the heat exchanger

• Effectiveness of the heat exchanger system

Operating in water that contains the following willadversely affect the heat exchanger system: silt,sediment, salt, and algae. In addition, intermittent useof the vessel will adversely affect the heat exchangersystem.

InspectThe following items indicate that the heat exchangermay require cleaning:

• Increased coolant temperature

• Engine overheating

• Excessive pressure drop between the water inletand the water outlet

An operator that is familiar with the normal operatingtemperature of the coolant can determine whenthe coolant temperature is out of the normal range.Inspection and maintenance of the heat exchangerare required if the engine is overheating.

CleanRemove the heat exchanger. Refer to theDisassembly and Assembly Manual, “HeatExchanger - Remove” for the procedure.

1. Drain the heat exchanger.

2. Remove the heat exchanger.

3. Turn the heat exchanger core upside-down inorder to remove debris.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

4. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 15 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 15

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Hydrosolv 100 19 L (5 US gallon)(1) Use a two to five percent concentration of the cleanerat temperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

5. Steam clean the core in order to remove anyresidue. Flush the tubes of the heat exchangercore. Remove any other trapped debris.

6. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

7. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

8. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

98 SEBU7599-07Maintenance SectionHoses and Clamps - Inspect/Replace

9. Install the heat exchanger. Refer to Disassemblyand Assembly, “Heat Exchanger - Install” for theprocedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

i02121526

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardclamp.

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

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

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.

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 propertorques.

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap's gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10.Start the engine. Inspect the cooling system forleaks.


Maintenance Recommendations

i03646846

MaintenanceRecommendationsSMCS Code: 1000

Maintenance InformationThe operating conditions of an engine affect themaintenance intervals and the time betweenoverhauls for the engine. The following conditionsaffect the maintenance intervals and the expectedoverhaul interval for the engine.

Severe Operation

Severe operation is the use of an engine thatexceeds current published standards for the engine.Caterpillar maintains standards for the followingengine parameters:

• Horsepower

• Range of rpm

• Fuel consumption

• Fuel quality

• Altitude

• Maintenance intervals

• Selection of oil

• Selection of coolant

• Environmental qualities

• Installation

Refer to the standards for your engine or consult yourCaterpillar dealer in order to determine if your engineis operating within the defined parameters.

Severe operation can accelerate component wear.Engines that are operating under severe conditionsmay need more frequent maintenance intervals forthe following reasons:

• Maximum reliability

• Retention of full service life

Because of individual applications, it is not possibleto identify all of the factors which can contribute tosevere operation. Consult your Caterpillar dealerabout the maintenance that is needed for yourspecific engine.

The following factors can contribute to severeoperation: environment, improper operatingprocedures, and improper maintenance practices.

Environmental Factors

Extreme Ambient Temperatures

Extended operation in environments that areextremely cold or hot can damage components. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesthe performance capabilities of the engine.

Note: See this Operation and Maintenance Manual,“Cold Weather Operation” topic (Operation Section),or see Supplement, SEBU5898, “Cold WeatherRecommendations”.

Cleanliness

Unless the equipment is cleaned regularly, extendedoperation in a dirty environment and in a dustyenvironment can damage components. Built up mud,dirt, and dust can encase components. This canmake maintenance difficult. The buildup can containcorrosive chemicals. Corrosive chemicals and saltcan damage some components.

Improper Operating Procedures

• Extended operation at low idle

• Minimum cool down periods after high load factoroperation

• Operating the engine beyond the guidelines for theengine rating

• Operating the engine at loads that are greater thanthe rated load

• Operating the engine at speeds that are greaterthan the rated speed

• Use of the engine for an application that is notapproved

Improper Maintenance Practices

• Extension of maintenance intervals

• Not using recommended fuel, lubricants, andantifreeze/coolant solutions

100 SEBU7599-07Maintenance SectionMaintenance Recommendations

Overhaul InformationReduced hours of operation at full load will result in alower average power demand. A decreased averagepower demand should increase both the engineservice life and the overhaul interval.

The need for an overhaul is generally indicated byincreased fuel consumption and by reduced power.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Note: Refer to this Operation and MaintenanceManual, “Overhaul (Major)” for further informationabout the major overhaul.

Oil Consumption as an OverhaulIndicatorOil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h (lb perbhp). The brake specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillardealer for assistance in determining the typical oilconsumption rate for your engine.

When an engine's oil consumption has risen to threetimes the original oil consumption rate due to normalwear, an engine overhaul should be scheduled.There may be a corresponding increase in blowbyand a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

To minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealer thatperforms the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The engine's service life can be extended withoutthe risk of a major catastrophe due to enginefailure.

• The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the engine mustbe removed from the hull, many options are available.An overhaul should be performed if the engine blockor the crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost should be between 40percent and 50 percent of the cost of a new enginewith a similar exchange core.

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents


Marine Transmission Oil Cooler - Clean/Inspect

i00916467

Marine Transmission OilCooler - Clean/InspectSMCS Code: 3320-040; 3320-070

The procedure for cleaning the marine transmissionoil cooler is the same procedure that is used forcleaning the aftercooler core. Refer to the Operationand Maintenance Manual, “Aftercooler Core -Clean/Test” topic (Maintenance Section). For moreinformation on servicing the marine transmission oilcooler, refer to the OEM recommendations or consultyour Caterpillar dealer.

i03398635

Overhaul (Major)SMCS Code: 7595-020-MJ

The need for a major overhaul is determined byseveral factors.

• An increase of oil consumption

• An increase of crankcase blowby

• The total amount of fuel consumption

• The service hours of the engine

• The wear metal analysis of the lube oil

• An increase in the levels of noise and vibration

An increase of wear metals in the lube oil indicatesthat the bearings and the surfaces that wear mayneed to be serviced. An increase in the levels ofnoise and vibration indicates that rotating partsrequire service.

Note: It is possible for oil analysis to indicate adecrease of wear metals in the lube oil. The cylinderliners may be worn so that polishing of the boreoccurs. Also, the increased use of lube oil will dilutethe wear metals.

Monitor the engine as the engine accumulatesservice hours. Consult your Caterpillar dealer aboutscheduling a major overhaul.

Note: The driven equipment may also require servicewhen the engine is overhauled. Refer to the literaturethat is provided by the OEM of the driven equipment.

For the major overhaul, all of the bearings,seals, gaskets, and components that wear aredisassembled. The parts are cleaned and inspected.If necessary, the parts are replaced. The crankshaftis measured for wear. The crankshaft may requireregrinding. Alternatively, the crankshaft may bereplaced with a Caterpillar replacement part.

Your Caterpillar dealer can provide these servicesand components. Your Caterpillar dealer can ensurethat the components are operating within theappropriate specifications.

Replacement of ComponentsReplace the following components during the majoroverhaul:

• Camshaft bearings

• Connecting rod bearings

• Crankshaft seals

• Crankshaft thrust washers

• Electronic unit injectors

• Gear train bushings

• Gear train bearings

• Main bearings

• Piston rings

• Aftercooler core

International Convention for Safety ofLife at Sea (SOLAS)

Caterpillar recommends replacing the following:

• All shields that have been installed to cover up fueland oil line connections per (SOLAS) regulations

• All marine certification society approved tapes areinstalled in order to cover up fuel line connectionsand oil line connections according to the SOLASregulations.

Inspection, Reconditioning orExchanging of ComponentsInspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

102 SEBU7599-07Maintenance SectionOverhaul (Major)

Recondition the worn components or exchange thecomponents, if necessary. Your Caterpillar dealer canprovide these services and components.

• Camshaft followers

• Camshaft thrust washers

• Connecting rods

• Crankshaft vibration damper

• Cylinder head assembly

• Cylinder liners

• Engine mounts

• Scavenge oil pump

• Engine wiring harness

• Exhaust manifold seals

• Exhaust manifold bellows

• Fuel pressure regulating valve

• Fuel priming pump

• Fuel transfer pump

• Inlet manifold gaskets

• Inlet manifold seals

• Oil cooler core

• Oil pump

• Pistons

• Piston pins

• Prelube pump

• Pushrods

• Rocker arms

• Spacer plate

• Software update

• Turbocharger

Inspection of ComponentsInspect the following components according tothe instructions that are in Caterpillar reusabilitypublications. Refer to Guidelines for ReusableParts and Salvage Operations, SEBF8029, “Indexof Publications on Reusability or Salvage of UsedParts”.

• Camshaft

• Crankshaft

• Driven equipment (alignment)

• Engine cylinder block

• Engine control module

• Flywheel

• Front gear train (gears)

• Oil suction screen

• Rear gear train

Inspect the camshaft for damage to the journals andthe lobes.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

• rod bearing

• main bearings

Note: If the crankshaft or the camshaft are removedfor any reason, use the magnetic particle inspectionprocess to check for cracks.

Replace the crankshaft vibration damper if any of thefollowing conditions occur:

• Engine failure due to a broken crankshaft

• Excessive wear of the front bearing for thecrankshaft


Sea Water Strainer - Clean/Inspect

• Excessive wear of the gear train that is not causedby a lack of lubrication

Inspect the gears of the gear train and inspect thegear train bushings for the following conditions:

• Worn gear teeth

• Unusual fit

• Unusual wear

In addition to the inspection of components, inspectthe alignment of the driven equipment. See theApplication and Installation Guide for the engine orsee the literature that is provided by the OEM of thedriven equipment.

Cleaning of ComponentsClean the oil suction screen. Also, remove sidecovers in order to clean the oil sump. For instructionson removal and installation of components, seethe Service Manual, “Disassembly and Assembly”module.

Obtain a Coolant AnalysisFor conventional heavy-duty coolant or antifreeze,check the concentration of supplemental coolantadditive (SCA) regularly. The concentration of SCAcan be checked with an S·O·S coolant analysis (LevelI). A more detailed coolant analysis is recommendedperiodically.

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant water probablycontained minerals which were deposited on theengine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis may be obtainedfrom the following sources:

• Caterpillar dealer

• Local water utility company

• Agricultural agent

• Independent laboratory

Caterpillar recommends an S·O·S coolant analysis(Level II). This is a comprehensive chemicalevaluation of the coolant. This analysis is also acheck of the overall condition of the inside of thecooling system. The following services are provided:

• Full Level I analysis

• Identification of the source of metal corrosion andof contaminants

• Identification of buildup of the impurities that causecorrosion

• Identification of buildup of the impurities that causescaling

• Determination of possible electrolysis within theengines' cooling system

A report of the results of the analysis is provided.Maintenance recommendations are based on theresults.

For more information about S·O·S coolant analysis,consult your Caterpillar dealer.

i00905687

Sea Water Strainer -Clean/InspectSMCS Code: 1371-040; 1371-070

The sea water strainer must be clean in order toallow proper engine cooling. Check the sea waterstrainer for plugging. Inspect the sea water strainermore frequently if the vessel is being operatedin water which is shallow or dirty. Refer to theOEM recommendations for more information aboutinspecting and cleaning the sea water strainer.

Ensure that the auxiliary water pump is primed andthat the suction line is open.

1. Remove the sea water strainer and clean thescreen. Remove any dirt and debris.

2. Install the sea water strainer. Fill the sea waterstrainer and the suction line for the auxiliary waterpump with water.

i02618737

Starting Motor - Inspect(If equipped)SMCS Code: 1451-040; 1453-040

Air Starting MotorIf the starting motor fails, the engine may not start inan emergency situation. A scheduled inspection ofthe starting motor is recommended.

104 SEBU7599-07Maintenance SectionTurbocharger - Inspect/Clean

The starting motor pinion and the flywheel ring gearmust be in good condition in order for the engineto start properly. The engine will not start if thestarting motor pinion does not engage the flywheelring gear. The teeth of the starting motor pinion andthe flywheel ring gear can be damaged because ofirregular engagement.

Inspect the starting motor for proper operation. Listenfor grinding when the engine is started. Inspect theteeth of the starting motor pinion and the flywheelring gear. Look for patterns of wear on the teeth. Lookfor teeth that are broken or chipped. If damaged teethare found, the starting motor pinion and the flywheelring gear must be replaced.

Personal injury or death can result from improp-erly checking for a leak.

Always use a board or cardboard when checkingfor a leak. Escaping air or fluid under pressure,even a pin-hole size leak, can penetrate body tis-sue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treatedimmediately by a doctor familiar with this type ofinjury.

Inspect all of the components in the air circuit forthe starting motor. Inspect all of the air lines andconnections for leaks.

If damaged teeth are found, the air circuit forthe starting motor must be examined in order todetermine the cause of the problem.

Electric Starting MotorIf the starting motor fails, the engine may not start inan emergency situation. A scheduled inspection ofthe starting motor is recommended.

The starting motor pinion and the flywheel ring gearmust be in good condition in order for the engineto start properly. The engine will not start if thestarting motor pinion does not engage the flywheelring gear. The teeth of the starting motor pinion andthe flywheel ring gear can be damaged because ofirregular engagement.

Inspect the starting motor for proper operation. Listenfor grinding when the engine is started. Inspect theteeth of the starting motor pinion and the flywheelring gear. Look for patterns of wear on the teeth. Lookfor teeth that are broken or chipped. If damaged teethare found, the starting motor pinion and the flywheelring gear must be replaced.

Problems with the electric starting motor can becaused by the following conditions: malfunction ofthe solenoid and malfunction of the electric startingsystem.

Inspect the electrical system for the followingconditions:

• Loose connections

• Corrosion

• Wires that are worn or frayed

• Cleanliness

Removal and Installation of theStarting MotorRefer to the Service Manual, “Disassembly andAssembly” module for information on removing thestarting motor and installing the starting motor.

Consult your Caterpillar dealer for assistance and/orfor options on replacement of the starting motor.

i03543183

Turbocharger - Inspect/CleanSMCS Code: 1052-571

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inlet side).Any fumes from the crankcase are filtered throughthe air inlet system. Therefore, by-products from oiland from combustion can collect in the turbochargercompressor housing. Over time, this buildup cancontribute to loss of engine power, increased blacksmoke and overall loss of engine efficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinderhead.

Disconnect batteries before performance of anyservice work.


Turbocharger - Inspect/Clean

Hot engine components can cause injury fromburns. Before performing maintenance on theengine, allow the engine and the components tocool.

Personal injury can result from rotating and mov-ing parts.

Stay clear of all rotating and moving parts.

Never attempt adjustments while the machine ismoving or the engine is running unless otherwisespecified.

The machine must be parked on a level surfaceand the engine stopped.

NOTICETurbocharger bearing failures can cause large quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.




An inspection of the turbocharger can minimizeunscheduled downtime. An inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts.

Note: Turbocharger components require precisionclearances. The turbocharger cartridge mustbe balanced due to high rpm. Severe ServiceApplications can accelerate component wear.Severe Service Applications require more frequentinspections of the cartridge.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Removal and InstallationRefer to Disassembly and Assembly, “Turbocharger- Remove” for the removal procedure. Refer toDisassembly and Assembly, “Turbocharger - Install”for the installation procedure. Consult with yourCaterpillar dealer for further information.

Cleaning and Inspecting1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil.

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel forcontact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and theturbocharger housing. If there is any indication ofcontact between the rotating turbine wheel or thecompressor wheel and the turbocharger housing,the turbocharger must be reconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbochargeroil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the line forthe inlet air (plugged air filters), which causes theturbocharger to slobber.

106 SEBU7599-07Maintenance SectionWalk-Around Inspection

4. Use a dial indicator to check the end clearanceon the shaft. If the measured end play is greaterthan the Service Manual specifications, theturbocharger should be repaired or replaced.An end play measurement that is less than theminimum Service Manual specifications couldindicate carbon buildup on the turbine wheel. Theturbocharger should be disassembled for cleaningand for inspection if the measured end play is lessthan the minimum Service Manual specifications.

5. Inspect the bore of the turbine housing forcorrosion.

6. Clean the turbocharger housing and clean thebacking plate of the cartridge with standard shopsolvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.

i02706582

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only require a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that the cooling lines are tight and ensurethat the cooling lines are properly clamped. Checkfor leaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pumps and the installation of water pumpsand/or seals, refer to the Service Manual for theengine or consult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the ECM to the cylinder head ground strapfor a good connection and for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges which are cracked and replace any gaugesthat can not be calibrated.

SEBU7599-07 107Maintenance SectionWater Pump - Inspect

i03543200

Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in the followingconditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

A failed water pump might cause severe engineoverheating problems that could result in cracks inthe cylinder head, a piston seizure or other potentialdamage to the engine.

Visually inspect the water pump for leaks. If leakingof the water pump seals is observed, replace all ofthe water pump seals. Refer to two articles in theDisassembly and Assembly Manual, “Water Pump- Disassemble and Water Pump - Assemble” forthe disassembly and assembly procedure. If it isnecessary to remove the water pump, refer to twoarticles in the Disassembly and Assembly Manual,“Water Pump - Remove and Water Pump - Install”.

Inspect the water pump for wear, cracks, pin holesand proper operation. Refer to the Parts Manualfor the correct part numbers for your engine orconsult your Caterpillar dealer if repair is needed orreplacement is needed.

i02456923

Zinc Rods - Inspect/ReplaceSMCS Code: 1388-040; 1388-510

Corrosion in sea water circuits can result in prematuredeterioration of system components, leaks, andpossible cooling system contamination. The causefor the premature corrosion may be the lack of zincrods in the sea water system.

Zinc rods are inserted in the sea water coolingsystem of the engine in order to help prevent thecorrosive action of salt water. The reaction of the zincto the sea water causes the zinc rods to deteriorate.The zinc rods deteriorate instead of engine partsfor the cooling system that are more critical. Rapiddeterioration of zinc rods may indicate the presenceof uncontrolled electrical currents from improperlyinstalled electrical attachments or improperlygrounded electrical attachments.

The zinc rods must be inspected at the properintervals. The zinc rods must be replaced whendeterioration occurs.

Inspect the Zinc RodsThe zinc rods are red for easy identification. Table16 shows the locations of the zinc rods and thequantities of the zinc rod:

Table 16

Locations of the Zinc Rods

Location Quantity

Right Heat Exchanger Bonnet 2

Left Heat Exchanger Bonnet 1

Transmission Oil Cooler 2

Fuel Cooler 2

1. Remove the zinc rod.


2. Tap the zinc rod lightly with a hammer. If the zincrod has deteriorated, or if the zinc rod flakes,install a new zinc rod.

Replace the Zinc Rods


108 SEBU7599-07Maintenance SectionZinc Rods - Inspect/Replace

1. Unscrew the old zinc rod or drill the old zinc rodfrom the plug. Clean the plug.

2. Apply 9S-3263 Compound to the shoulder ofa new zinc rod. Apply the compound only to theshoulder of the zinc rod. Install the zinc rod intothe plug.

3. Coat the external threads of the plug with5P-3413 Pipe Sealant. Install the zinc rod.Refer to Special Publication, SENR3130, “TorqueSpecifications” for more information on torquespecifications.

Documents

C-12 and C12 MARINE ENGINES - Oxford Yacht Agencyoya.com/service/mechanical/C_12_Maintenance.pdf · C-12 and C12 MARINE ENGINES ... Guide, NEHS0526 or consult your Caterpillar dealer