78403A 2 Mercruiser ALTERNATOR ASSEMBLY

Replacement of Components
Replace the following worn components with new components during the in-frame overhaul.
Aftercooler core
Aftertreatment catalysts
Aftertreatment sensors (Temperature, Level, Pressure)
Connecting rod bearings
Crankshaft seals
Crankshaft thrust washer
Crankshaft vibration damper bolts
Exhaust manifold bellows, clamps, bolts
Exhaust manifold seals
Common rail fuel injectors
Flex pipe bellows and clamps
Flex pipe bellows heat shields
Flywheel bolts
Fuel injectors
Fuel transfer pump
High-pressure fuel pump
Hydraulic Lash Adjusters(HLA) pushrods
Inlet manifold gaskets and seals
Main bearings
Piston rings
TurbochargerInspection, Reconditioning, 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.
Camshaft followers
Coolant temperature regulator (Jacket Water)
Crankshaft vibration damper
Cylinder head assembly
Fuel pressure regulating valve
Jacket water pump
Oil cooler bypass valve
Oil cooler core
Oil pressure regulating valve
Pre-lube pump
Rocker shaft
Rocker arms
Starting motors
SCAC water pumpInspection 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 air regulator
Aftertreatment air stainer
Aftertreatment DEF nozzle
Aftertreatment DEF strainer
Aftertreatment solenoid valve
Camshaft
Camshaft bearings
Crankshaft
Driven equipment (alignment)
Engine control module
Engine heat shielding
Engine wiring harness
Exhaust bellows shields
Exhaust manifold
Turbine outlet elbows
Flywheel
Flywheel ring gear
Flexible heat shielding
Front gear train
Gear train bushings and bearings
Gear train front
Gear train rear
High-pressure fuel lines
Inlet manifold
Oil pump
SoftwareInspect 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 bearings
Camshaft followersInspect 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 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 a conventional heavy-duty antifreeze/coolant solution, 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 water in 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:
Cat dealer
Local water utility company
Agricultural agent
Independent laboratoryCat 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 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.