0309582 JOHNSON SHIFT ROD, Lower

Additional Heavy Fuel Requirements
Fuel Tests
1. Test and analyze bunkered fuel on a regular basis to track contaminant levels.2. Before bunkering fuel, test compatibility of bunkered fuel with fuel being purchased. Use separate tanks if possible for bunker fuels.3. Analyze lube oil (using Scheduled Oil Sampling or an alternate laboratory) on a regular basis for wear metals, differential infrared analysis, kinematic viscosity (ASTM D664) and TBN level (ASTM D2896).Engine Operation
Excessive operation at low engine load can be detrimental to engine component life. Refer to the chart below for the approximate time at low load while utilizing heavy fuels. If operation at low load is expected beyond these times, the engine should be operated utilizing No. 2 or marine diesel fuel. Switch over must be accomplished so unit injectors are not starved of fuel. It is preferable to change fuels via a mixing tank, so cold No. 2 fuel is not put into a hot system, causing gaseous mixture in fuel line. The mixing tank should be capable of supplying 15 minutes of fuel to the engine.Maintenance
These maintenance items will be required in addition to the maintenance found in the Maintenance Schedule.1. Maintain and monitor fuel treatment equipment on a Daily basis.2. Record engine temperatures to assure adequate jacket water temperature, aftercooler temperature, and air intake temperature on a Daily basis.3. Wash the turbocharger exhaust turbine at least Every Week (according to Maintenance Schedule).4. Check and record exhaust temperature Daily.5. Monitor fuel and oil filter differential pressures on a shift basis, checking for plugging.6. Every 3 Months of operation, check one cylinder head for exhaust valve seating and carbon build-up. Check for adequate operation of the valve rotor and check the fuel injector for an adequate nozzle spray pattern. Contact your Caterpillar dealer or Caterpillar factory contact for additional information and assistance.Engine Jacket Water Preheating
Before starting an engine that is burning heavy fuel, the jacket water should be heated. This reduces the viscosity of the fuel to the unit injector and improves starting. The jacket water preheater should be turned OFF after the engine has started and while the engine is running. Fuel Filter Preheating
Extreme care and caution should be taken. DO NOT overheat fuel or fuel filter element. Engine damage and personal injury could result.
When operating on heavy fuel with a viscosity greater than 40 cST @ 50°C (122°F), the final fuel filter should be steam jacketed and remote (off engine) mounted.The viscosity of the fuel in the filter housings must be reduced to 1000 cSt or less before the fuel conditioning system can be operated. This allows the fuel to be pumped through the filter without collapsing the fuel filter elements. Required fuel temperature and preheat time vary with fuel type and installation.Fuel Filter Maintenance
For maintenance procedure of fuel filters that are engine mounted; maintenance is the same for engines burning distillate fuel, or heavy fuel with a viscosity of 40 cSt @ 50°C (122°F) or less. The procedure can be found in the Every 3 Month maintenance interval.For maintenance procedure of remote fuel filters when used with fuels that have a viscosity above 40 cSt @ 50°C (122°F), refer to the Every 3 Month maintenance interval.Unit Injector Tip Cooling
During operation of engine using heavy fuel, the injector tip must be furnished with a supply of coolant to control wear and maintain proper temperature control. When operating on fuels up to 40 cSt @ 50°C (122°F), the injector tip cooling is provided by routing combustion fuel through the tip.The engine is equipped with the required piping and additional external plumbing is not necessary.When heavy fuels above 40 cSt @ 50°C (122°F) are burned, an external injector tip cooling module is required. The coolant should be SAE 30 or SAE 40 weight engine oil, and maintained at 60 to 65°C (140 to 149°F) to the engine. Coolant level, temperature and pressure should be checked Daily.The module should be operated any time the engine is running, regardless of the type fuel being burned. This prevents high temperature degradation of the coolant by continually supplying fresh coolant to the injector tips. The module does not have to be operated before starting the engine.Engine Oil Centrifuging
During operation on heavy fuel, a higher level of combustion products is introduced into the crankcase when compared to operation on distillate fuel. To extend engine oil life, it is recommended that a remote mounted centrifugal separator be used to clean the engine crankcase oil.The flow rate is determined by engine power output. The engine oil should be processed at a flow of at least 0.13 L/BkW-hr for arrangements with lube oil feed ON during sediment discharge. For arrangements with the lube oil feed OFF during sediment discharge, a flow of 0.14 L/BkW-hr should be used. A solid bowl separator should not be used due to the frequent cleaning required.