42089A 2 Mercury COVER ASSEMBLY

Walk-Around Inspection
Inspect Engine for Leaks and Loose Connections
A walk-around inspection should only take a few minutes of your time. By taking the time to make these checks, costly repairs and accidents can be avoided and your equipment will be ready to run should the need arise.For maximum engine service life, make a thorough inspection before starting the engine. Look for items such as oil or coolant leaks, loose bolts, worn fan belts, loose connections and trash build up. Remove trash build up and have repairs made as needed.* All guards must be in place. Repair or replace missing or damaged guards.* Wipe all fittings, caps and plugs before servicing to reduce the chance of system contamination.
For any type of leak (coolant, lubricant, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.
* Make sure cooling lines are properly clamped and tight. Check for loose fittings or leaks. Check the condition of all pipes and fittings.* Inspect the water pump for coolant leaks at the weep hole. The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract.Excessive coolant leakage may indicate the need to replace the water pump seal. For removal and installation of water pumps and/or seals, see the Service Manual for this engine or consult your Caterpillar dealer.* Inspect the lubrication system for leaks at the front and rear crankshaft seals, oil pan, oil filters and valve covers.
Fuel line clamps should not be overtightened. Over-tightening causes the clamps to butterfly, which results in low clamping force, fuel line vibration and eventual failure. Refer to the Torque Specifications in this manual.
* Inspect the fuel system for leaks, loose fuel line clamps and fittings and loose or worn hoses.* Inspect the air inlet system piping and elbows for cracks and loose clamps.* Inspect the radiator core for leaks and trash build up. Clean the front of the radiator with a stainless steel brush and soapy water.* Inspect the radiator and cooling system hoses and elbows for cracks and loose clamps. Depending on your findings and operating environment, the maintenance interval for cleaning the radiator can be extended from a Daily to an as needed basis.* Inspect the fan and accessory drive belts for cracks, breaks or other damage.Belts for multiple groove pulleys must be replaced as matched sets. If only one belt of a two or three belt set is replaced, it will carry more of a load than the belts not replaced since the older belts are stretched. The additional load on the new belt could cause it to break.* Drain water and sediment from fuel storage and day tanks on a daily basis to ensure only clean fuel enters the fuel system.* Inspect the wiring and wiring harnesses for loose connections and worn or frayed wires.* Disconnect any battery chargers that are not protected against the starting motor current drain. Check the condition and the electrolyte level of batteries, unless equipped with a maintenance free battery.* Inspect the engine-to-frame ground strap for good connection and condition.* Inspect the control panel. Perform a control panel lamp test to ensure that the fault indicators operate properly.* Check the condition of all of the gauges. Replace any gauges which are cracked or cannot be calibrated.Engine Crankcase
Check Oil Level
The preferred time to check the oil level is when the engine is stopped. This maintenance should be performed on as level a surface as possible.
Oil level gauge (dipstick) (1) and oil filler cap (2). 1. Maintain the oil level between the ADD and FULL marks on the ENGINE STOPPED side of the dipstick. Do not fill the crankcase above the FULL mark.
Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduce the oil's lubricating characteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil if necessary. Clean the oil filler cap. Clean the oil filler cap receptacle. Install the oil filler cap.Cooling System
Check Coolant Level
Check the coolant level with the engine stopped and cool.
Radiator filler cap.1. Remove the radiator filler cap slowly to relieve any pressure.2. Maintain the coolant level within 13 mm (1/2 inch) below the bottom of the fill pipe.
Typical filler cap gaskets.3. Clean the radiator filler cap. Inspect the radiator filler cap gaskets. Replace the radiator filler cap if the gaskets are damaged. Clean the radiator filler cap receptacle. Install the radiator filler cap.4. Inspect for coolant leaks.air Cleaner
Check Service Indicator
Typical service indicator, mounted on the air cleaner housing.A service indicator is mounted on the air cleaner housing. A colored piston showing in the window indicates the need for servicing the air cleaner.
Typical service indicator.Observe the service indicator. Clean or replace the air cleaner element when the yellow diaphragm enters the red zone or the red piston locks in the visible position. If the service indicator shows red at any time, clean the air cleaner element or install a new element.Inspect the service indicator daily for cracks, holes, or loose fittings. If any of these conditions are present, repair or replace the service indicator.Test Service Indicator
Service indicators are inexpensive but important instruments.* Check for ease of resetting. The service indicator should reset in less than three pushes.* Check the movement of the yellow core when the engine is accelerated to rated speed. The yellow core should latch approximately at the greatest vacuum that is attained.If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indicator will not reset, the service