0385413 JOHNSON GEARCASE ASSY., Complete

Introduction
Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.Commissioning Procedure for the Cooling System
During the commissioning procedure of Keel coolers, the entire system must be properly flushed with fresh clean water that is not recirculated, before the system is connected to the engine.Flushing the Cooling System
During the flushing procedure, the water pressure within the system should not exceed 172 kPa (25 psi) or maximum pressure rating of ship board cooler and plumbing system.
Adequate pressure is required to ensure adequate flowrates. Use component data for the JW or Aux pump curves to determine minimum flow rate required for your particular engine and cooling circuit. For example, a T2 C32 rated at 2100 keel system must have flowrates between 135 G/min and 165 G/min for the aux circuit.
The system must be flushed in both directions for a minimum of 10 minutes in each direction to completely clear all debris from the system.After the system is flushed, the system must be filled and the system must be maintained with the proper chemical requirements. The quality of the water must also be maintained. Refer to Operation and Maintenance Manual, SEBU6251, "Caterpillar Commercial Diesel Engine Fluids Recommendations".Perform this process for each circuit.Coolant Analysis
Obtaining a Representative Coolant Sample
Illustration 1 g02137675
Top view of the engine
(1) Location of the coolant sample port of the auxiliary circuit
Illustration 2 g02137678
Right side view of engine
(2) Location of the coolant sample port for the jacket water
A sampling valve must be in a full flow circuit for the jacket water and the auxiliary cooling system. These valves will allow an accurate, representative coolant sample. Refer to Illustration 1 and Illustration 2 for locations for proper sampling.
The following parts are required to install a sampling port for the auxiliary circuit (1). The sampling port of the auxiliary circuit is not installed at the factory.
154-9023 Valve
3J-7354 O-Ring Seal
5P-9617 Adapter
3J-1907 O-Ring Seal
157-0670 Dust Cap
The engine must run for a minimum of one hour. The engine must be at the normal operating temperature before the coolant sample is obtained.
While the engine is running, use 169-8373 Fluid Sampling Bottle and 162-8873 Holder. Connect the holder to the sampling valve to obtain a fluid sample. Use a clean kit for each sample.
Illustration 3 g02137769
(A) Clean fluid sample
(B) Contaminated fluid sample
The coolant must meet Caterpillar standards for cleanliness, quality of water, and corrosion protection as determined by a Level 2 S O S analysis. The fluid sample must be free and clear of settled solids when the sample is viewed by the naked eye. Also, the fluid sample must be free and clear of suspended solids when the sample is viewed by the naked eye. Refer to Illustration 3 for examples of fluid samples.
If the fluid sample contains solids or the sample fails the Level 2 S O S analysis, then the steps that are outlined below must be taken to restore the coolant to the correct chemistry and criteria of cleanliness.Remedial Steps
Flush the system to remove any debris from the system. See "Flushing the Cooling System" above.
Add a supplemental coolant additive or a glycol base coolant to restore the chemical requirement. Refer to Operation and Maintenance Manual, SEBU6251, "Caterpillar Commercial Diesel Engine Fluids Recommendations".
The coolant must be sampled at 250-hour intervals. The coolant sample must meet the standards of a Level 2 S O S analysis until the proper chemistry is maintained. Maintain an ongoing program to sample the coolant at a Level 1 S O S analysis and a Level 2 S O S analysis that is outlined in the maintenance interval schedule.