- Marine Engine:
- C8.7 (S/N: CS71-UP)
Introduction
Before you attempt the procedures documented in this Special Instruction, make sure that you have read and understand the information in this document.
Safety Section
Before performing any of the following procedure, ensure that the machine has been properly locked out/ tagged out.
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Removal Procedure
- Set the engine to Top Dead Center (TDC) for number 1 piston. Refer to Testing and Adjusting, UENR4352, "Finding Top Center Position for No. 1 Piston".
- Loosen hose clamp (1) from hose (2).
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| Illustration 1 | g03842779 |
(1) 438-5193 Hose Clamp (2) 452-1783 Hose (3) 451-9183 Air Filter Gp (4) 439-7464 Bolts (5) 439-7202 Bolts (6) 439-5566 Tube As (7) 463-7537 Heat Shield As (8) 439-5569 Tube As (9) 442-9570 Water Lines Gp | |
- Disconnect the sensors for air filter group (3) .
- Loosen the clamp for air filter group (3). Remove the air filter group along with hose (2) .
- Loosen water lines group (9) from the top of the turbocharger and move out of the way.
- Remove bolts (4) from tube assembly (8) and move the tube assembly out of the way.
- Remove bolts (5) from tube assembly (6) and move the tube assembly out of the way.
- Remove heat shield (7) from the exhaust side of the turbocharger.
- Remove band clamps (10) and (11) from the turbocharger.
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| Illustration 2 | g03843002 |
(10) 449-0833 Band Clamp (11) 439-0502 Band Clamp | |
- Remove four nuts (14) to remove turbocharger group (13) 15 kg (33 lb).
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| Illustration 3 | g03843042 |
(13) 439-0447 Turbocharger Gp (14) 439-1039 Nuts | |
- Remove fuel lines group (15) .
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| Illustration 4 | g03843065 |
(15) 438-6107 Fuel Lines Gp (16) 438-6053 Bolts (17) 438-6036 Fuel Filter Gp (18) 451-8589 Engine Oil Filter Gp (19) 439-7195 Bolts (33) 438-5186 Bolts | |
- Remove engine oil filter group (18) by removing four bolts (19) and bolts (33) attached to the side of the base.
- Remove fuel filter group (17) by removing four bolts (16) .
- Remove hose clamp (23) and then move hose (22) out of the way.
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| Illustration 5 | g03843293 |
(20) 434-7530 Bolts (21) 438-7229 Flywheel Housing Cover Assembly (22) 438-5207 Hose (23) 438-5192 Hose Clamp | |
- Remove bolts (20) in order to remove flywheel housing cover assembly (21) .
- Remove bolts (24) in order to remove valve cover (25) .
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| Illustration 6 | g03843360 |
(24) 450-0589 Bolts (25) 431-5073 Valve Cover | |
- Loosen nuts (26) and then loosen bolts (27) to allow for removal of the camshaft. Make sure that the camshaft will be able to clear the rollers located on the back of the rocker arm mechanisms.
Note: Make sure that the camshaft will be able to clear the rollers located on the back of the rocker arm mechanisms.
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| Illustration 7 | g03843381 |
(26) 433-7050 Nuts (27) 433-7049 Bolts | |
- Mark the camshaft gear, fuel pump gear, and idler gear for alignment before removal in the locations shown above. Remove four bolts (28) and then remove camshaft gear (29) .
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| Illustration 8 | g03843392 |
(28) 438-0903 Bolts (29) 431-4120 Camshaft Gear | |
- Remove five bolts (30) and then remove sealing plate (31) .
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| Illustration 9 | g03843435 |
(30) 438-0901 Bolts (31) 431-4124 Sealing Plate | |
- Remove camshaft (32) 13 kg (29 lb) from the engine. Make sure to keep the camshaft balanced during removal to ensure that the journals do not hit the bearings.
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| Illustration 10 | g03843450 |
(32) 431-4118 Camshaft | |
Installation Procedure
- Install camshaft (32) 13 kg (29 lb) from the engine. Make sure to keep the camshaft balanced during installation to ensure that the journals do not hit the bearings.
Note: Make sure to keep the camshaft balanced during removal to ensure that the journals do not hit the bearings.
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| Illustration 11 | g03843450 |
(32) 431-4118 Camshaft | |
- Clean rear sealing groove (A) of sealing plate (31). Apply Loctite 5970, 5900, or equivalent to the rear groove of the sealing plate as shown in Illustration 12. Install the sealing plate using five bolts (30) .
Note: Ensure that the Loctite does not enter the lower two holes of the sealing plate. These holes are for oil return for the cylinder head.
- Tighten the bolts to 20 ± 2 N·m (177 ± 17.7 lb in) in this sequence first (1, 2, 3, 4, 5) .
- Tighten the bolts again to 20 ± 2 N·m (177 ± 17.7 lb in) using this sequence (1, 3, 5, 2, 4).
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| Illustration 12 | g03843575 |
(A) Rear sealing groove (30) 438-0901 Bolts (31) 431-4124 Sealing Plate | |
- Ensure that the marks made previously are aligned during installation. Install camshaft gear (29) and four bolts (28) .
- Tighten the bolts to 25 ± 1.25 N·m (221.3 ± 11 lb in).
- Turn the bolts an additional 45° ± 5 °.
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| Illustration 13 | g03843392 |
(28) 438-0903 Bolts (29) 431-4120 Camshaft Gear | |
- Tighten bolts (26) to 105 ± 11 N·m (77 ± 8 lb ft) using the sequence shown above.
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| Illustration 14 | g03843605 |
(26) 433-7050 Nuts (27) 433-7049 Bolts | |
- Check the camshaft gear backlash. Refer to Testing and Adjusting, UENR4352, "Rear Gear Group - Time" for the proper procedure.
- Set valve lash and tighten nuts (26) using the reference below.
ReferenceTesting and Adjusting, UENR4352, "Engine Valve Lash - Inspect/Adjust"
- Install valve cover (25) with bolts (24). Tighten to 9 ± 1 N·m (80 ± 9 lb in) using the sequence shown above.
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| Illustration 15 | g03843617 |
(24) 450-0589 Bolts (25) 431-5073 Valve Cover | |
- Install flywheel housing cover assembly (21) using bolts (20) .
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| Illustration 16 | g03843293 |
(20) 434-7530 Bolts (21) 438-7229 Flywheel Housing Cover Assembly (22) 438-5207 Hose (23) 438-5192 Hose Clamp | |
- Install hose (22) and secure using hose clamp (23) .
- Install fuel filter group (17) using four bolts (16) .
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| Illustration 17 | g03843065 |
(15) 438-6107 Fuel Lines Gp (16) 438-6053 Bolts (17) 438-6036 Fuel Filter Gp (18) 451-8589 Engine Oil Filter Gp (19) 439-7195 Bolts (33) 438-5186 Bolts | |
- Install engine oil filter group (18) using four bolts (19) and bolts (33) attached to the side of the base.
- Install fuel lines group (15) .
- Install turbocharger group (13) using four nuts (14). Tighten to 61 ± 6 N·m (45 ± 4 lb ft) using a crosswise order.
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| Illustration 18 | g03843042 |
(13) 439-0447 Turbocharger Gp (14) 439-1039 Nuts | |
- Install band clamps (10) and (11) on the turbocharger.
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| Illustration 19 | g03843002 |
(10) 449-0833 Band Clamp (11) 439-0502 Band Clamp | |
- Install heat shield (7) on the exhaust side of the turbocharger.
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| Illustration 20 | g03842779 |
(1) 438-5193 Hose Clamp (2) 452-1783 Hose (3) 451-9183 Air Filter Gp (4) 439-7464 Bolts (5) 439-7202 Bolts (6) 439-5566 Tube As (7) 463-7537 Heat Shield As (8) 439-5569 Tube As (9) 442-9570 Water Lines Gp | |
- Install tube assembly (6) using bolts (5) .
- Install tube assembly (8) using bolts (4) .
- Install water lines group (9) on the top of the turbocharger.
- Install air filter group (3) along with hose (2). Tighten the clamp for air filter group.
- Connect the sensors for air filter group, fuel filter base, and oil filter base.
- Install hose (2) and tighten hose clamp (1) .