0307754 JOHNSON GEAR,Reversing

Alternator, Air Starting Motor and Water Pump
Inspect/Rebuild or Exchange
Air Starting MotorOne unscheduled failure caused by any of these components will cost more in downtime than maintaining them before failure. The cost incurred to maintain these components before failure as recommended, could be significantly less than if the component fails.It is less costly to maintain components before failure than it is to operate the engine until the component fails.By maintaining these components before failure, unscheduled downtime will be minimized and the chances for potential damage to other engine parts reduced. The prevention of unscheduled downtime saves money and lowers operating costs.If the engine is operated until the component(s) fails, it could cause additional damage to the engine. For example: A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head, a piston seizure or other potential damage to the engine. Damage to the turbocharger compressor wheel could cause parts from the compressor wheel to enter the engine cylinder and cause additional damage to the piston, valve and cylinder head.If the engine is operated until the water pump fails, the repair costs could be as much as twenty-five times or more the repair before failure cost. This excessive cost is due to the additional engine damage that could have been prevented.Our recommended intervals for performing preventive maintenance on these components are based on experience and gathered data relative to the expectant life of the engine and its components. These maintenance intervals were developed as a service for the owner's use to minimize unexpected and costly repairs as well as to serve as an aid to lowering operating costs.Failure to follow the recommendations could result in unexpected, costly repairs and unscheduled downtime.Caterpillar recommends that the most cost effective method of operation for these components is to inspect the unit before it fails.Maintenance Options
New Parts - Genuine Caterpillar parts are constantly tested and modified to incorporate the latest design advances. Your Caterpillar dealer can provide the parts needed for rebuilding the components. Your benefit: Long-lasting replacement parts at competitive prices. 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. Remanufactured - This process uses manufacturing techniques and procedures to restore the components to like-new performance capability. This process always involves an end product which conforms to the manufacturer's "original" functional specifications. Remanufactured parts may not be available in your area. Contact your Caterpillar dealer for information. New Components - Replace worn or failing components with new components.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.Thermostats
Replace Thermostats, Gaskets and Seals
Replacing your thermostats prior to failure is a good preventive maintenance practice because it reduces your chances for unscheduled downtime. Failure to replace your thermostats on a regularly scheduled basis could cause severe engine damage and cost you money.For Caterpillar engines, it is mandatory to always operate with thermostats.If a thermostat fails in the closed position, it will cause excessive overheating. Excessive overheating could result in cylinder head cracking or piston seizure problems.If a thermostat fails in the open position, it will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon build-up inside the cylinder. This excessive carbon build-up could result in accelerated ring and liner wear.Depending on load, a thermostat that fails in a partially opened position can cause either an overheating or an overcooling condition.Caterpillar recommends the replacement of the thermostats on a regularly scheduled basis to be the most cost effective way to operate your engine.Remove Thermostats
1. Loosen the filler cap slowly to relieve any pressure and remove the cap.2. Drain the coolant from the cooling system to a level below the thermostat housing.
If the thermostat is installed wrong, it will cause the engine to overheat.
3. Refer to the "Service Manual".4. Add coolant to the cooling system to bring it to the proper level by mixing a solution of acceptable water and Caterpillar antifreeze. Add liquid cooling system conditioner only if the concentration is not within 3% to 6% or if any other ethylene glycol antifreeze is used. See the "Cooling System - Clean and Change" section of this Manual or contact your Caterpillar dealer for assistance.5. Start the engine and inspect for leaks and proper operating temperature.