0309613 JOHNSON WASHER,Water tube

Under severe or dusty conditions, or where average operating speeds are less than 40 km/h (25 mph), such as inner city garbage compactors, delivery trucks or drill rigs, the maintenance interval should be reduced to 2000 Service Hours or 40 000 km (24,000 Miles), whichever occurs first.
Perform all previous maintenance as outlined in the Maintenance Intervals along with the maintenance requirements of this interval.Valve Lash and Injector Fuel Timing
Check - Adjust
Initial valve lash and Injector Fuel Timing check and/or adjustment on new or rebuilt engines is recommended at the first scheduled oil change interval or 250 Service Hours, whichever occurs first, due to initial wear and seating of valve train components. All subsequent checks and adjustments are to be made at PM Level 2. Be sure to have a qualified mechanic check and/or adjust Injector Fuel Timing. Special tools and training are required.Refer to the Diesel Engine Repair Manual for the complete procedure to perform this maintenance. The correct Fuel Timing specification is given on the Engine Information Plate. Fuel Timing specifications may be different for different engine applications and/or power ratings.Engine Mounts
Inspect - Check
Caterpillar recommends checking the engine mounts for deterioration and proper bolt torque. This will prevent excessive engine vibration caused from improper mounting. Refer to the chart Torque For Metric Fasteners in the Torque Specifications section of this publication for recommended torque values.Refer to GMC TopKick/Chevrolet Kodiak Service Manual for necessary repair or replacement procedures for engine mounts.Visconic Dampers
Inspect - Check
Inspect the dampers for evidence of dents, cracks or leaks of the fluid. Damage to or failure of the dampers will increase torsional vibrations and result in damage to the crankshaft and other engine components. A failing vibration damper will cause more gear train noise at variable points in the speed range.Refer to the Diesel Engine Repair Manual for the necessary replacement procedure.Turbocharger
Inspect - Check
1. Remove the exhaust outlet piping and inlet piping from the turbocharger.2. Turn the turbine and compressor wheel by hand.3. The assembly should turn freely.4. Inspect the turbine wheel and compressor wheel for contact with the turbocharger housing.5. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing.6. Visually check for oil leaks. If service is required, refer to PM Level 3 in the Maintenance Section of this publication for turbocharger service options.Cooling System
Clean and Flush
Do not change the coolant until you read and understand the material in the "Cooling System Specifications" section of this publication. This procedure is to be used for normal maintenance of cooling system surfaces to return to "like new" condition.For heavy build-up of scale and deposits, a severe acid type commercial cleaner or mechanical cleaning will be required.
Our recommended intervals for performing maintenance on the cooling system are based on experience and gathered data relative to the performance characteristics of this engine and its components. Performing maintenance on the cooling system is important because the cooling system has a direct effect on the operation and service life of the engine.Improper maintenance can result in a variety of problems that could shorten the engine's service life or result in poor engine performance.When you drain, clean, flush and replace the coolant, small particles, undesirable chemicals, scale and other deposit formations are removed. These deposits reduce the necessary heat transfer characteristics of the cooling system.Failure to clean and change the coolant as recommended will reduce the efficiency of the cooling system and, in some cases, result in an increase in fuel consumption.Total disregard for performing maintenance on the cooling system can eventually cause engine overheating problems that could result in severe damage to the engine and its components.By performing maintenance on the cooling system, spending money on repairs that could have been prevented may be avoided.1. Remove the radiator filler cap slowly and cooling system drain plug to relieve pressure.2. Remove the cooling system drain plugs or open the drain valve and allow the coolant to drain.3. Install the drain plugs or close the drain valve. Fill the system with clean water and a 6 to 10% concentration of cooling system cleaner.
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for the Cat 3116 engine.
A 33-47 L (9-12 gal) cooling system capacity requires 3.8 L (1 gal) of Caterpillar Cooling System Cleaner to accommodate the 6-10 percent concentration. Caterpillar Cooling System Cleaner is available through your GMC TopKick/Chevrolet Kodiak dealer, who is an authorized Cat 3116 engine dealer.4. Start and run the engine for 90 minutes. Stop the engine and drain the cleaning solution.5. Flush the system with water, with the engine stopped, until the draining water is clear.6. Close the drain valve.7. Add the coolant solution. See "Cooling System Specifications" and "Lubricant Viscosities and Refill Capacities." Do not add supplemental coolant additive or change element at this time, unless you are not using Caterpillar Antifreeze which contains additive.8. Start the engine and operate it with the radiator cap off, until the thermostat opens and the level stabilizes.9. Maintain the coolant level to within 1 cm (1/2 in) of the bottom of the fill pipe.10. Install the cap.11. Stop the engine.Thermostat
Replace Thermostat
Replacing your thermostat prior to failure is a good preventive maintenance practice because it reduces your chances for unscheduled downtime. Failure to replace your thermostat on a regularly scheduled basis could cause severe engine damage and cost you money.Since Caterpillar engines incorporate a shunt design cooling system, it is mandatory to always operate the engine with a thermostat.If your thermostat fails in the closed position, it will cause excessive overheating. Excessive overheating could result in cylinder head cracking or piston seizure problems.If your 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 accelerating ring and cylinder wear.Depending on load, a