0305216 JOHNSON GEAR, Reverse

Walk-Around Inspection
Inspect Engine for Leaks and Loose Connections
A walk-around inspection is recommended to ensure the installation is clean and leaks are kept to a minimum. This should only take a few minutes and by taking the time to make these checks, costly repairs and accidents can be avoided and the equipment will be ready to run should the need arise.For maximum service life of your engine(s), make a thorough inspection before starting the engine. Look for such items as oil or coolant leaks, loose bolts, worn belts, loose connections and trash build-up. Remove trash build-up and have repairs made as needed.
Accumulated grease and oil on an engine or deck is a fire hazard. Remove this debris with steam cleaning or high pressure water, Every 3 Month interval or 72 500 km (45,000 miles), or each time any significant quantity of fluid is spilled on an engine or deck.
Check the fluid levels more frequently than the recommended maintenance intervals and continue to monitor fluid levels until any leak is found and fixed. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more frequently than the recommended intervals.* Wipe all fittings, caps and plugs before performing maintenance to reduce the chance of system contamination. Inspect:* Cooling system lines and air intake system hoses, piping and elbows for cracks and loose clamps. Check the condition of all pipes and fittings.* Water pumps for coolant leaks. The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract. If leaks are found, check the coolant level frequently and continue to monitor the level until the water pump is repaired. Excessive coolant leakage may indicate the need to replace the water pump seal.For removal and installation of water pumps and/or seals, see the Service Manual for this engine or consult your Caterpillar dealer. Inspect: * Lube system for oil leaks, such as front and rear crankshaft seals, oil pan, oil filters and valve covers.* Fuel system for leaks, loose fuel line clamps and fittings, and loose or worn hoses. Inspect:* Wiring and wiring harnesses for loose connections and worn or frayed wires.Check condition of gauges. Replace if cracked or cannot be calibrated.While operating, frequently observe the engine oil pressure, oil filter differential, fuel pressure, fuel filter differential, water temperature and the air cleaner differential gauges.All guards must be in place. Repair or replace missing or damaged guards.Check condition of batteries and the level of electrolyte, unless equipped with a maintenance free battery.Refer to OEM or locomotive manufacturers' recommendations for battery maintenance.* Check the air system pressure. Adjust if necessary. Fill all air system lubricators.Refer to OEM or locomotive manufacturer's recommendations.Check Fluid Levels
Air Starting Motor and Air Prelube Pump Lubricators (If Equipped)
Never allow the air lubricator jar to become empty. The starting and prelube pump motors will be damaged by lack of proper lubrication.
The vanes of the starting and air prelube pump motors are lubricated with a fine mist from the motor oiler while the motor is operating. When the oiler bowl becomes half empty, shut off the air supply to the starting motor control valve, remove the filler plug and fill the bowl with lubricant (10 weight non-detergent engine oil or diesel fuel).Drain and Clean Bowl, Adjust Oiler Feed
When the fluid is contaminated, the oiler bowl may need cleaning. Use the following procedure to clean bowl and adjust oiler feed.1. Shut off the air supply to the starting motor control valve; remove the filler plug.2. Open the drain valve at the bottom of the bowl. This valve releases pressure from the bowl and allows the lubricant to drain.3. Remove and clean the bowl, using warm water only.4. Dry the bowl. Inspect for cracks. Replace if necessary.5. Fill bowl with lubricant. (Refer to Lubricant Specs in this manual.)6. Install bowl and close the drain valve.7. Turn on the air supply to the starting motor control valve.If necessary, adjust the oiler feed to release approximately four drops of lubricant per minute into the starting motor air stream and prelube pump.8. Be sure the fuel supply to the engine is turned off.9. Pull up on the air start control lever and crank the engine.10. Count the drops of lubricant released per minute into the air stream.* Turn the valve needle (the uppermost knob on the oiler) counterclockwise to increase the number of drops per minute.* Turn the valve needle clockwise to decrease the number of drops per minute. Drip rates should only be made under an average steady flow condition. Once established, the lubricator will automatically adjust the drip rate proportionally to variations in air flow.Clean Air Starter Screen (If Equipped)
1. Remove the pipe plug.2. Carefully remove the screen and clean it with a nonflammable solvent. Allow to dry.3. Install the screen and pipe plug.4. Tighten the pipe plug securely.Engine Crankcase
Make sure you read and understand the information in the Safety and Lubricant Specifications sections of this manual before you proceed with maintenance of this system.
Check Oil Level
Check the engine crankcase lube oil on a daily basis. Remove the oil fill cap to relieve the crankcase pressure. Failure to relieve the crankcase pressure will result in an inaccurate oil level reading.Oil level gage assembly (dipstick) guide tube length and gage markings may produce erratic oil level readings. This is because the guide tube is shorter than the length of the dipstick and may cause engine oil to splash up inside the dipstick guide tube.When this happens, the oil covers a greater length of the dipstick. To solve this situation, refer to your Caterpillar dealer for pre-marked dipsticks and additional information. * If checking the oil level with the engine STOPPED, maintain the oil level to the FULL mark on the ENGINE STOPPED WITH OIL COLD side of the dipstick.* If the engine will not be shut down for maintenance, check the crankcase oil level while the engine