LAMP GP-FLOOD 2196482 - Caterpillar

The maintenance intervals that are listed in this Operation and Maintenance Manual, "Maintenance Interval Schedule" are expressed in service hours. A more accurate figure to use is fuel consumption. Fuel consumption corresponds more accurately to the engine load.Refer to this Operation and Maintenance Manual, "Maintenance Recommendations" to determine the maintenance interval for a Major Overhaul.During a Major Overhaul, some components are replaced for wear.Your Cat dealer can provide these services and components. Your Cat dealer can ensure that the components are operating within the appropriate specifications.If you elect to perform a Major Overhaul overhaul without the services of a Cat dealer, be aware of the following recommendations.For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module.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
Crankshaft
Driven equipment (alignment)
Engine control module
Engine cylinder block
Exhaust bellows shields
Flywheel
Front gear train (gears)
High-pressure fuel lines
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.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 temperature regulator (ESTAT)
Crankshaft vibration damper
Crankshaft vibration damper bolts
Cylinder head assembly
Cylinder liners
Engine mounts
Exhaust manifolds
Fuel pressure regulating valve
Fuel priming pump
Fuel transfer pump
Jacket water pump
Oil cooler bypass valve
Oil cooler core
Oil pressure regulating valve
Oil pump
Pistons
Piston pins
Prelube pump
Pushrods
Rocker arms
SCAC water pump
Software update
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
Camshaft bearings
Camshaft thrust washers
Connecting rod bearings
Crankshaft seals
Crankshaft thrust washers
Electronic unit injectors
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
Flywheel bolts
High-pressure fuel pump
Gear train bearings
Gear train bushings
Inlet manifold gaskets
Inlet manifold seals
Main bearings
Piston rings
Turbocharger cartridgesCleaning of Components
Clean the oil cooler core and