0326230 JOHNSON WASHER, Plug

Table 1
Overhaul Schedule
First Occurrence Following Intermediate Overhaul
Fuel Consumption 4542492 L (1200000 US gal) 4542492 L (1200000 US gal) 4542492 L (1200000 US gal) 4542492 L (1200000 US gal)
Load Factor < 25 Per Cent 25 - 30 Per Cent 30 - 50 Per Cent > 40 Per Cent
Service Hours 24000 21000 18500 16000
Load Cycles(1)(2) 192000 192000 192000 192000
(1) A load cycle has been defined as an increase of at least an 80 per cent rated power followed by a decrease of at least 80 per cent rated power. Load cycles of less than 80 per cent rated power may also impact the engine overhaul interval. This impact requires your specific operating profile to determine your appropriate interval.
(2) Determining the appropriate overhaul interval will require understanding of the locomotive operating profile. The profile includes total operating hours, amount of fuel burned, load factor, load cycles, and total number of engine starts. Caterpillar requires the use of data recorders to help determine the operating profile and to set appropriate intervals for a fleet on a given route. Changes in operating profiles (a different deployment or change in the operating profile for the existing route) may require adjustment of overhaul intervals to ensure reliable performance. Failure to follow the overhaul intervals may result in unplanned repairs. For assistance with calculating load cycles, installing data recording equipment and/or confirming overhaul intervals, contact your Cat dealer.Inspection of Components
Inspect the following components according to the instructions that are in Cat reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".
Aftertreatment dosing cabinet
Aftertreatment CEM
Camshaft
Crankshaft
Driven equipment (Alignment)
Engine cylinder block
Flywheel
High-pressure fuel lines
Gear train (front and rear gears)
Oil suction screenReconditioning or Exchanging of Components
Inspect the following components according to the instructions that are in Cat 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.
Aftertreatment DEF injector
Aftertreatment DEF pump
Camshaft followers
Connecting rods
Cooling system including, tubes, brackets, clips, housings, and elbows
Crankshaft vibration damper
Cylinder head assembly
Cylinder liners
Engine mounts
Exhaust manifolds
Fuel pressure regulating valve
Fuel transfer pump
Jacket water pump
Oil cooler bypass valve
Oil cooler core
Oil lubrication system including tubes, brackets, clips, housings, and elbows
Oil pressure regulating valve
Oil Prelube pump
Oil pump
Rocker arms
SCAC water pump
Software update
Starter motorReplacement of Components
Replace the following components during the major overhaul:
Aftercooler core
Aftercooler gaskets and air inlet bolts
Aftertreatment air regulator
Aftertreatment air strainer
Aftertreatment catalysts
Aftertreatment CEM sensors and harnesses
Aftertreatment DEF strainer
Aftertreatment dosing cabinet sensors, harnesses, and solenoid valves
Aftertreatment sensors including temperature, DEF level, and pressure
Air inlet compression bellows
Air inlet manifold gaskets and seals
Camshaft bearings
Camshaft thrust washers
Connecting rod bearings
Coolant (SCA) temperature regulator (ESTAT)
Crankshaft seals
Crankshaft thrust washers
Engine control module
Engine sensors - level, pressure, speed, and temperature
Engine wiring harness
Exhaust bellow shields
Exhaust manifold bellows, clamps, and bolts
Exhaust manifold (Turbine inlet) supports and hardware
Exhaust manifold seals
Flexible pipe bellow, turbine outlet elbows, and clamps
Flexible pipe heat shielding
Flywheel ring gear
Gear train (spring type gears)
Fuel accumulator
Fuel boost pump
Fuel priming solenoid
Gear train bushings and bearings
Main bearings
Pistons
Piston pins
Piston rings
Torsional coupling
TurbochargersCleaning 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 - Inspect/Clean" 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 antifreeze/coolant, 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 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 inside 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