0395419 JOHNSON SOLENOID ASSY.

Replacement of Components
Replace the following components during the major overhaul.
Aftertreatment Diesel Oxidation Catalyst (DOC)
Camshaft bearings
Connecting rod bearings
Crankshaft seals
Crankshaft thrust washer (plate)
Crankshaft vibration damper
Electronic fuel injectors
Engine control module
Engine mounts
Engine sensors (temperature, level, pressure, speed)
Engine wire harness
Exhaust bellows, gaskets, and hardware
Fuel pressure regulating valve
Fuel priming pump
Gear train bushings and bearings
Jacket water heater element
Main bearings
NOx Reduction System (NRS) coolers, bellows, and clamps
Nonmetallic fuel lines (if equipped)
Piston rings
Seals, gaskets, O-rings, and bellows
Software updateInspection, 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 Caterpillar dealer can provide these services and components.
Camshaft followers
Connecting rods
Cylinder head assembly
Cylinder liners
Coolant pumps - jacket water and SCAC
Exhaust bellows
Fuel transfer pump
NRS valve
Oil cooler
Oil pump
Pistons
Piston pins
Prelube pump
Spacer plate
Spacer plate (head)
TurbochargersInspection 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
Coolant tubes (brackets, clips, housings, elbows)
Crankshaft
Cylinder block
Driven equipment (alignment)
Flywheel
Front gear train
Heat shields
NRS venturi
Oil suction screen
Rear gear train
Rocker arms
Rocker arm shaftInspect the camshaft for damage to the journals and the lobes. Inspect the following components for signs of wear and/or for signs of fatigue:
camshaft followersInspect the crankshaft for any of the following conditions:
deflection
damage to the journals
bearing material that has seized to the journalsNote: 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 cooler core and the aftercooler core. Then, pressure test both of these cores. For instructions on cleaning the cores, see this Operation and Maintenance Manual, "Aftercooler Core - Clean/Test" topic.Clean the oil suction screen. Also, remove side covers 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 I). 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 probably contained minerals which were deposited on the engine over time.A coolant analysis can be conducted 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:
Caterpillar dealer
Local water utility company
Agricultural agent
Independent laboratoryCaterpillar recommends an S O S coolant analysis (Level II). This 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 I 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 engines' 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 Caterpillar dealer.