09440-35004 Suzuki Spring

Recommended Interval for Major Overhaul
A major overhaul is recommended at the following intervals:
Table 1
Recommended Intervals for Major Overhaul(1)
Engines with "Commercial" ratings Every 200627 L (53000 US gal) of fuel or 5000 service hours
Engines with "High Performance" ratings Every 140060 L (37000 US gal) of fuel or 5000 service hours
(1) Use the interval that occurs first.Replacement of Components
Replace the following components during the major overhaul:
Camshaft bearings
Connecting rod bearings
Crankshaft seals
Crankshaft thrust washers
Electronic unit injectors
Gear train bushings
Gear train bearings
Main bearings
Piston rings
Aftercooler core
HEUI pumpInternational Convention for Safety of Life at Sea (SOLAS)
Caterpillar recommends replacing the following:
All shields that have been installed to cover up fuel and oil line connections per (SOLAS) regulations
All marine certification society approved tapes are installed to cover up fuel line connections and oil line connections according to the SOLAS regulations.Inspection, Reconditioning, or Exchanging of Components
Inspect the following components according to the instructions that are in Caterpillar 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 Caterpillar dealer can provide these services and components.
Camshaft followers
Camshaft thrust washers
Connecting rods
Crankshaft vibration damper
Cylinder head assembly
Cylinder liners
Engine mounts
Scavenge oil pump
Engine wiring harness
Exhaust manifold seals
Exhaust manifold bellows
Fuel pressure regulating valve
Fuel priming pump
Fuel transfer pump
Inlet manifold gaskets
Inlet manifold seals
Oil cooler core
Oil pump
Pistons
Piston pins
Prelube pump
Pushrods
Rocker arms
Spacer plate
Software update
TurbochargerInspection of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".
Camshaft
Crankshaft
Driven equipment (alignment)
Engine cylinder block
Engine control module
Flywheel
Front gear train (gears)
Oil suction screen
Rear gear trainInspect 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.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 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 coolant or antifreeze, check the concentration of supplemental coolant additive (SCA) regularly. The concentration of SCA can be checked with an S O S coolant analysis (Level I). 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:
Caterpillar dealer
Local water utility company
Agricultural agent
Independent laboratoryCaterpillar recommends an S O S coolant analysis (Level II). An S O S coolant analysis (Level II) 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 I 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 engines 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 Caterpillar dealer.