5008340 EVINRUDE Service Manual Set - English

Water Pumps and Fuel Transfer Pump
Inspect/Replace Seals
Jacket Water Pump
Separate Circuit Aftercooler Water Pump
Fuel Transfer PumpVisually inspect the water pumps and fuel transfer pump for leaks. If leaking is observed, replace all seals. Refer to the Service Manual for the procedure to replace the seals.Inspect the component for wear, cracks, pin holes and proper operation. If repairs or replacement is needed, see the Service Manual or contact your Caterpillar dealer.Maintenance Options
Rebuild with New Parts - Genuine Caterpillar parts are constantly tested and modified to incorporate the latest design advancements. Your Caterpillar dealer can rebuild or provide the parts needed for overhauling the components. Your benefit; long lasting replacement parts at competitive prices. New Components - Replace worn or failing components with new components. Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts and instructions to repair the components, in either the owner's maintenance shop or at a Caterpillar servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts cost. Exchange - This cost-cutting service permits you to exchange worn engine components for quality Caterpillar Remanufactured or Caterpillar dealer rebuilt components on an over-the-counter basis. When you need them, these parts are ready for a substantial savings in both time and money. Caterpillar Factory Remanufactured Components - The latest remanufacturing techniques and procedures are used to restore components to like-new performance capability and to Caterpillar's original functional specifications. Usually Caterpillar Remanufactured Components have a warranty identical to that of a new part. Remanufactured parts may not be available in your area. Contact your Caterpillar dealer for information.Before deciding which method is best, make sure all of the options and costs associated with repair have been considered. Some considerations are:* The costs associated with using separate parts from inventory versus the cost of a repair kit.* Downtime costs while the product is being rebuilt or repaired.* Total parts and labor costs for repairs versus the actual Remanufactured cost.* Remanufactured components from Caterpillar (if available) are covered by a standard, factory warranty.Caterpillar Recommendation
To minimize downtime, Caterpillar recommends that the use of Remanufactured components (subject to availability) is the most cost effective option.If there is a component you need, contact your Caterpillar dealer to see if it is offered under his Dealer Exchange Component Program.Removal and Installation
Refer to the established procedure in the Service Manual for this engine to remove and install these components or contact your Caterpillar dealer for assistance.Woodward Governor/Actuator
Replace Oil
Drain
1. Install a 1/8 NPT nipple into the petcock and attach a drain tube to it. Place the other end of the drain tube in a suitable container to catch the oil. 2. Remove the plug from the top of the actuator or sight gauge, open the petcock, and drain the oil into a container.3. After the oil is drained, close the petcock, remove the tube and nipple and dispose of the oil.Fill
4. Fill the Governor/Actuator with oil as recommended in the Lubricant Specifications and Refill Capacities topics in this publication. 5. Add oil to the proper level on the sight gauge. The oil level must be checked again immediately after the engine is started and the oil level adjusted to the mid point (black line) of the sight gauge. To adjust the oil level to this point, add or remove oil.Check for Proper Operation
The engine can overspeed due to improper reassembly or adjustment, which could result in personal injury or death.Be prepared to STOP the engine by activating the emergency air shutoff or by manually closing the air inlets.
After filling the Governor/Actuator with engine oil as recommended, check for proper operation.Refer to the Engine Controls section of this manual for additional information or contact your Caterpillar dealer.Electronic Governor Rack Sensor (If Equipped)
Calibrate
Refer to the Service Manual for the correct procedure to calibrate the rack sensor.Magnetic Pickup(s)
This maintenance procedure was to be performed at the initial 3 Month or 72 500 km (45,000 mile) interval under the topic Engine Protection Devices. Refer to the maintenance intervals in the Maintenance Schedule.Check/Clean
1. Remove magnetic pickup(s) one at a time from the sensor block and check condition of the magnet(s).2. Clean metal shavings and other debris from the face of the magnet(s).3. Install magnetic pickup(s) into sensor block by turning pickup threads (CW) until magnet comes in contact with the flywheel ring gear tooth.4. Back out the pickup thread (CCW) 1.2 0.1 turns (430 30°) to maintain a clearance between the magnetic pickup and the flywheel ring gear tooth to 1.69 0.14 mm (.066 .006 in.). Tighten locknut 47 7 N m (35 5 lb ft).For additional information on the magnetic pickup(s) for your engine, refer to the Service Manual.Oil Suction Screen
Clean Element
Remove the element from crankcase (oil pan). 1. Loosen bolts from cover. Remove cover and gasket and slide suction screen from tube and remove suction screen.2. Wash element in clean nonflammable solvent. Allow the element to dry before installation.3. Put clean engine oil on part to make installation easier. Install elements and new gasket seal.4. Install cover and bolts. Tighten bolts to proper torque. Refer to the Torque Specifications section of this manual for information.Turbocharger
Inspect for Proper Operation
Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage.Minor leakage of a turbocharger housing under extended low idle operation will not cause problems as long as no turbocharger bearing failure occurred.When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine speed up at no load), DO NOT continue engine operation until the turbocharger is repaired or replaced.