39601-93902 Suzuki Receptacle Assembly, Lighting

Table 1
Overhaul Schedule
Fuel Consumption 4542492 L (1200126 US gal) 4542492 L (1200126 US gal) 4542492 L (1200126 US gal) 4542492 L (1200126 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) To illustrate engine capability, 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, requiring your specific operating profile to determine your appropriate interval.
(2) Determining the appropriate overhaul interval will require understanding of the locomotive operating profile including 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".
Camshaft
Coolant - hoses, tube, bracket, clips, housings, elbows
Crankshaft
Driven equipment (alignment)
Engine cylinder block
Flywheel
Gear train - front and rear gear
High-pressure fuel lines
Oil suction screen
Oil system - hoses, tubes, bracket, clips, housings, elbowsInspect the camshaft for damage to the journals and the lobes.Inspect 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.Inspect 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.Rebuilding or Exchanging of Components
Rebuild or exchange 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
Connecting rods
Coolant Pump - Jacket water & SCAC
Crankshaft vibration damper
Cylinder head assembly
Cylinder liners
Engine mounts
Exhaust manifolds
Exhaust bellows shields
Fuel pressure regulating valve
Fuel priming pump
Fuel transfer pump
Oil cooler bypass valve
Oil cooler core
Oil prelube pump
Oil pressure regulating valve
Oil pump
Pistons
Piston pins
Prelube pump
Pushrods
Rocker arms
Software update
Starter Motor
TurbochargersReplace 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 lubricationReplacement of Components
Replace the following worn components with new components.
Aftercooler core
Aftercooler gaskets & air inlet bolts
Air inlet compressor bellows
Air inlet manifold gaskets and seals
Camshaft bearings
Camshaft thrust washers
Connecting rod bearings
Crankshaft seals
Crankshaft thrust washers
Engine control module
Engine heat shielding
Engine sensors (temperature, fluid levels, speed, pressures)
Engine wiring harness
Exhaust manifold bellows, clamps, and bolts
Exhaust manifold seals
Flywheel ring gear
Fuel boost pump
Fuel priming solenoid
Gear train - spring type gears
Gear train bushing and bearings
Hoses - Lube, Fuel, Coolant
Main bearings
Piston rings
Torsional Coupling
Turbocharger cartridges
Water temperature regulator (estat)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 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 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