0398090 OWNERS MANUAL, Jo. 3RC Models JOHNSON
J3RCUA, J4RCUD
OWNERS
Price: query
Rating:
Number on catalog scheme: 14
BRP JOHNSON entire parts catalog list:
Information:
Recommended Interval for Major Overhaul
A major overhaul is recommended at the following intervals:
Table 1
Recommended Intervals for Major Overhaul (1)
C8.7 Engines Every
148000 L (39102 US gal) of fuel or 4000 service hours
( 1 ) Use the interval that occurs first.Replacement of Components
Replace the following components during the major overhaul:
Camshaft bearings
Connecting rod bearings
Crankshaft seals
Crankshaft thrust bearings
Electronic common rail injectors
Engine mounts
Fuel rail
Gear train bushings
Gear train bearings
High-pressure fuel pump
High-pressure fuel relief valve
Inlet air heater
Insulation
Main bearings
Piston rings
Water pumpInspection, Reconditioning, or Exchanging of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".Recondition the worn components or exchange the components, if necessary. Your Cat dealer can provide these services and components.
Camshaft followers
Compressor
Compressor clutch
Connecting rods
Crankshaft vibration damper
Cylinder head assembly
Cylinder liners
Exhaust manifold and piping
Exhaust manifold seals and gaskets
Fuel priming pump
Inlet manifold gaskets
Inlet manifold seals
Oil cooler core
Oil pump
Pistons
Piston pins
Rocker arms
Sea water pump
Software update
Spacer plate
TurbochargerInspection of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".
Camshaft
Crankshaft
Driven equipment (alignment)
Engine cylinder block
Engine control module
Engine electrical connectors and sensors
Engine wiring harness
Flywheel
Oil suction screen
Rear gear train
Rocker arm shaftInspect the camshaft for damage to the journals and the lobes.Inspect the crankshaft for any of the following conditions:
Deflection
Damage to the journals
Bearing material that has seized to the journalsCheck the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:
rod bearing
main bearingsNote: If the crankshaft or the camshaft are removed for any reason, use the magnetic particle inspection process to check for cracks.Replace the crankshaft vibration damper if any of the following conditions occur:
Engine failure due to a broken crankshaft
Excessive wear of the front bearing for the crankshaft
Excessive wear of the gear train that is not caused by a lack of lubricationInspect the gears of the gear train and inspect the gear train bushings for the following conditions:
Worn gear teeth
Unusual fit
Unusual wearIn addition to the inspection of components, inspect the alignment of the driven equipment. See the Application and Installation Guide for the engine or see the literature that is provided by the OEM of the driven equipment.Cleaning of Components
Clean the oil suction screen. Also, remove side covers in order to clean the oil sump. For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module.Obtain a Coolant Analysis
For conventional heavy-duty coolant or antifreeze, check the concentration of supplemental coolant additive (SCA) regularly. The concentration of SCA can be checked with an S O S coolant analysis (Level 1). A more detailed coolant analysis is recommended periodically.For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals which were deposited on the engine over time.A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis may be obtained from the following sources:
Cat dealer
Local water utility company
Agricultural agent
Independent laboratoryCaterpillar recommends an S O S coolant analysis (Level II) which is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system. The following services are provided:
Full Level 1 analysis
Identification of the source of metal corrosion and of contaminants
Identification of buildup of the impurities that cause corrosion
Identification of buildup of the impurities that cause scaling
Determination of possible electrolysis within the engine cooling systemA report of the results of the analysis is provided. Maintenance recommendations are based on the results.For more information about S O S coolant analysis, consult your Cat dealer.
A major overhaul is recommended at the following intervals:
Table 1
Recommended Intervals for Major Overhaul (1)
C8.7 Engines Every
148000 L (39102 US gal) of fuel or 4000 service hours
( 1 ) Use the interval that occurs first.Replacement of Components
Replace the following components during the major overhaul:
Camshaft bearings
Connecting rod bearings
Crankshaft seals
Crankshaft thrust bearings
Electronic common rail injectors
Engine mounts
Fuel rail
Gear train bushings
Gear train bearings
High-pressure fuel pump
High-pressure fuel relief valve
Inlet air heater
Insulation
Main bearings
Piston rings
Water pumpInspection, Reconditioning, or Exchanging of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".Recondition the worn components or exchange the components, if necessary. Your Cat dealer can provide these services and components.
Camshaft followers
Compressor
Compressor clutch
Connecting rods
Crankshaft vibration damper
Cylinder head assembly
Cylinder liners
Exhaust manifold and piping
Exhaust manifold seals and gaskets
Fuel priming pump
Inlet manifold gaskets
Inlet manifold seals
Oil cooler core
Oil pump
Pistons
Piston pins
Rocker arms
Sea water pump
Software update
Spacer plate
TurbochargerInspection of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".
Camshaft
Crankshaft
Driven equipment (alignment)
Engine cylinder block
Engine control module
Engine electrical connectors and sensors
Engine wiring harness
Flywheel
Oil suction screen
Rear gear train
Rocker arm shaftInspect the camshaft for damage to the journals and the lobes.Inspect the crankshaft for any of the following conditions:
Deflection
Damage to the journals
Bearing material that has seized to the journalsCheck the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:
rod bearing
main bearingsNote: If the crankshaft or the camshaft are removed for any reason, use the magnetic particle inspection process to check for cracks.Replace the crankshaft vibration damper if any of the following conditions occur:
Engine failure due to a broken crankshaft
Excessive wear of the front bearing for the crankshaft
Excessive wear of the gear train that is not caused by a lack of lubricationInspect the gears of the gear train and inspect the gear train bushings for the following conditions:
Worn gear teeth
Unusual fit
Unusual wearIn addition to the inspection of components, inspect the alignment of the driven equipment. See the Application and Installation Guide for the engine or see the literature that is provided by the OEM of the driven equipment.Cleaning of Components
Clean the oil suction screen. Also, remove side covers in order to clean the oil sump. For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module.Obtain a Coolant Analysis
For conventional heavy-duty coolant or antifreeze, check the concentration of supplemental coolant additive (SCA) regularly. The concentration of SCA can be checked with an S O S coolant analysis (Level 1). A more detailed coolant analysis is recommended periodically.For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals which were deposited on the engine over time.A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis may be obtained from the following sources:
Cat dealer
Local water utility company
Agricultural agent
Independent laboratoryCaterpillar recommends an S O S coolant analysis (Level II) which is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system. The following services are provided:
Full Level 1 analysis
Identification of the source of metal corrosion and of contaminants
Identification of buildup of the impurities that cause corrosion
Identification of buildup of the impurities that cause scaling
Determination of possible electrolysis within the engine cooling systemA report of the results of the analysis is provided. Maintenance recommendations are based on the results.For more information about S O S coolant analysis, consult your Cat dealer.
Parts owners JOHNSON:
0210829
0210828
0398089