9442487 Volvo.Penta Cable terminal

Repair of Piston, Ring, And Bore As An Indicator
Investigate the piston, the ring, and the bore or repair the piston, the ring, and the bore if one of the following conditions occurs:
Oil consumption is in excess of 1 quart of oil per 60 gallons of fuel that is consumed. The oil consumption must not be caused by leakage.
Crankcase blowby is in excess of 2 cubic feet per hour per horsepower. Measure the crankcase blowby with an 8T-2700 Blowby Indicator .
Fuel consumption has increased.
Loss of power has occurred.The cylinder head must be removed in order to repair the piston, the ring, and the bore. After removing the cylinder head, inspect the valves and the valve seats. Repair the valve and the valve seats, if necessary. Determine if any other components of the engine should be inspected.Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best value for the following reasons:
Avoid costly unplanned downtime.
Reuse many original parts according to the standards for reusable parts.
Extend the engine's service life without the risk of a major catastrophe due to engine failure.
Attain the best cost/value relationship per hour of extended life.After Failure Overhaul
If a major engine failure occurs and the engine must be removed from the hull, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired.If the engine block is repairable and/or the crankshaft is repairable, the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core.This lower cost can be attributed to three aspects:
Specially designed Caterpillar engine features
Caterpillar dealer exchange components
Caterpillar Inc. remanufactured exchange componentsOverhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. This will provide you with the best cost/value relationship.Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life.If an overhaul is performed without overhaul service from your Caterpillar dealer, be aware of the following maintenance recommendations.Rebuild or Exchange
Inspect the following components according to the instructions that are found in various Caterpillar reusability publications. The Special Publication, SEBF8029 lists the reusability publications that are needed for inspecting the engine parts.
Cylinder head assembly
Connecting rods
Pistons
Turbocharger
Oil pump
Fuel ratio control
Cam followers
Fuel Transfer pump
Timing advanceIf the parts comply with the established inspection specifications that are expressed in the reusable parts guideline, the parts should be reused.Parts that are not within the established inspection specifications should be salvaged, repaired, or replaced.Using out-of-spec parts can result in the following problems:
Unscheduled downtime
Costly repairs
Damage to other engine parts
Reduced engine efficiency
Increased fuel consumptionReduced engine efficiency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.Component Replacement
Replace the following components during the overhaul:
Piston Rings
Thrust bearings
Main bearings
Connecting rod bearings
Gaskets and seals
Engine mounts
HosesInspection
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
Camshaft bearings
Crankshaft
Crankshaft vibration damper
Gear trainInspect the camshaft for damage to the journals and the lobes. Inspect the camshaft bearings for signs of wear and/or for signs of fatigue.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 rod bearings and main bearings.Note: 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 are found:
Engine failure due to a broken crankshaft
Excessive wear of the front main bearing
Excessive wear of the gear train that is not caused by a lack of lubrication
Visconic damper that is dented, cracked, or leaking
Visconic damper that is discolored from heat
Rubber damper that is deteriorated and cracked
Rubber damper with slippage of the outer ringInspect the gear train for the following conditions:
Worn gear teeth
Unusual fit
Unusual wearTesting
Test the following components during the overhaul:
Fuel injection nozzles
Fuel injection pump
GovernorTesting the fuel system during the overhaul will ensure that your engine operates at peak efficiency. Your Caterpillar dealer can provide these services and components in order to ensure that your fuel system is operating within the appropriate specifications.Cleaning
The following components should be cleaned and pressure tested during the overhaul:
Engine oil cooler
Marine gear oil cooler
Aftercooler
Heat exchangerRefer to the Operation and Maintenance Manual, "Aftercooler Core - Clean/Test" topic (Maintenance Section) for the cleaning procedure.Obtain Coolant Analysis
The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits or with S O S Coolant Analysis (Level 1). Further coolant analysis is recommended when the engine is overhauled.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 that were deposited on the engine over time.A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis.Caterpillar Inc. recommends an S O S Coolant Analysis (Level 2).S O S Coolant Analysis (Level 2)
An S O S Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. An S O S Coolant Analysis (Level 2) provides the following information:
Complete S O S Coolant Analysis (Level 1)
Visual inspection of properties
Identification of metal corrosion
Identification of contaminants
Identification of built up impurities (corrosion and scale)S O S Coolant Analysis (Level 2) provides a report of the results of both the analysis and the maintenance recommendations that are based on the analysis.For more information about coolant