CAT + Caterpillar 3406E Marine Engine Operation & Maintenance Manual by Heavy Equipment Manual

Product:MARINEENGINE

Model:3406EMARINEENGINE9WR

Configuration:3406EMarineEngine9WR00001-UP

OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015 s00037353

Foreword

SMCS-1000

LiteratureInformation

Thismanualcontainssafety,operationinstructions,lubricationandmaintenanceinformation.This manualshouldbestoredinorneartheengineareainaliteratureholderorliteraturestoragearea. Read,studyandkeepitwiththeliteratureandengineinformation.

EnglishistheprimarylanguageforallCatpublications.TheEnglishusedfacilitatestranslationand consistencyinelectronicmediadelivery.

Somephotographsorillustrationsinthismanualshowdetailsorattachmentsthatmaybedifferent fromyourengine.Guardsandcoversmayhavebeenremovedforillustrativepurposes.Continuing improvementandadvancementofproductdesignmayhavecausedchangestoyourenginewhichare notincludedinthismanual.Wheneveraquestionarisesregardingyourengine,orthismanual,please consultwithyourCatdealerforthelatestavailableinformation.

Safety

Thissafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifieshazardous, warningsituations.Readandunderstandthebasicprecautionslistedinthesafetysectionbefore operatingorperforminglubrication,maintenanceandrepaironthisproduct.

Operation

Operatingtechniquesoutlinedinthismanualarebasic.Theyassistwithdevelopingtheskillsand techniquesrequiredtooperatetheenginemoreefficientlyandeconomically.Skillandtechniques developastheoperatorgainsknowledgeoftheengineanditscapabilities.

Theoperationsectionisareferenceforoperators.Photographsandillustrationsguidetheoperator throughproceduresofinspecting,starting,operatingandstoppingtheengine.Thissectionalso includesadiscussionofelectronicdiagnosticinformation.

Maintenance

Themaintenancesectionisaguidetoenginecare.Theillustrated,step-by-stepinstructionsare groupedbyfuelconsumption,servicehoursand/orcalendartimemaintenanceintervals.Itemsinthe maintenanceschedulearereferencedtodetailedinstructionsthatfollow.

Usefuelconsumptionorservicehourstodetermineintervals.Calendarintervalsshown(daily, annually,etc.)maybeusedinsteadofservicemeterintervalsiftheyprovidemoreconvenient schedulesandapproximatetheindicatedservicemeterreading.

Recommendedserviceshouldbeperformedattheappropriateintervalsasindicatedinthe MaintenanceIntervalSchedule.Theactualoperatingenvironmentoftheenginealsogovernsthe MaintenanceIntervalSchedule.Therefore,underextremelysevere,dusty,wetorfreezingcold operatingconditions,morefrequentlubricationandmaintenancethanisspecifiedintheMaintenance IntervalSchedulemaybenecessary.

Themaintenancescheduleitemsareorganizedforapreventivemaintenancemanagementprogram.If thepreventivemaintenanceprogramisfollowed,aperiodictune-upisnotrequired.The implementationofapreventivemaintenancemanagementprogramshouldminimizeoperatingcosts throughcostavoidancesresultingfromreductionsinunscheduleddowntimeandfailures.

MaintenanceIntervals

Performmaintenanceonitemsatmultiplesoftheoriginalrequirement.Eachleveland/orindividual itemsineachlevelshouldbeshiftedaheadorbackdependinguponyourspecificmaintenance practices,operationandapplication.Werecommendthatthemaintenanceschedulesbereproduced anddisplayedneartheengineasaconvenientreminder.Wealsorecommendthatamaintenance recordbemaintainedaspartoftheengine'spermanentrecord.

SeethesectionintheOperationandMaintenanceManual,"MaintenanceRecords"forinformation regardingdocumentsthataregenerallyacceptedasproofofmaintenanceorrepair.Yourauthorized Catdealercanassistyouinadjustingyourmaintenancescheduletomeettheneedsofyouroperating environment.

Overhaul

MajorengineoverhauldetailsarenotcoveredintheOperationandMaintenanceManualexceptfor theintervalandthemaintenanceitemsinthatinterval.Majorrepairsarebestlefttotrainedpersonnel oranauthorizedCatdealer.YourCatdealeroffersavarietyofoptionsregardingoverhaulprograms. Ifyouexperienceamajorenginefailure,therearealsonumerousafterfailureoverhauloptions availablefromyourCatdealer.Consultwithyourdealerforinformationregardingtheseoptions.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.

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Product:MARINEENGINE

Model:3406EMARINEENGINE9WR

Configuration:3406EMarineEngine9WR00001-UP

OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015

AftercoolerCondensateDrainValve-Inspect/Clean

SMCS-1063-042-DN

Illustration1g00107725

(1)Drainlines

(2)Adapter

(3)Valve

(4)Plunger

(5)Valveseat

i01406045

Theengineboostpressureforcesplunger(4)tomovedowntovalveseat(5).Theplungermustclose againsttheseatatapressureof27.5kPa(4psi).Whentheengineisstopped,theabsenceofboost pressureallowstheplungertorisetotheopenposition,whichallowscondensationfromthe aftercoolertodrainout.

Theplungermustbeabletomovefreelyinordertoclosethesystemwhentheengineisrunning.The plungermustbeabletomovefreelyinordertoallowcondensationtodrainfromtheaftercoolerwhen theengineisstopped.Residuefromnormalengineoperationcouldcausetheplungertostick.

1.Removevalve(3)fromadapter(2).Checkthevalveinordertodetermineifplunger(4)moves freely.Iftheplungerdoesnotmoveeasily,cleanthevalvewithsolvent.

2.Removedrainlines(1).Checkthelinesforplugging.Cleanthelines,ifnecessary.Pressureair oraflexiblerodwithasmalldiametercanbeusedtocleanthelines.

3.Reassembletheaftercoolercondensatedrainvalve.RefertotheOperationandMaintenance Manualformoreinformationonthepropertorques.

SunJun2020:37:44UTC+05302021

This is the sample of the manual if you need complete manual Click Here to download

Product:MARINEENGINE

Model:3406EMARINEENGINE9WR

Configuration:3406EMarineEngine9WR00001-UP

OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015 i04363377

AftercoolerCore-Clean/Test

SMCS-1064-070;1064-081

Note:Anaftercoolerthatcirculatesfreshwaterortreatedwatermayrequirecleaninglessoftenthan anaftercoolerwhichcirculatessaltwater.Themaintenanceintervalforanaftercoolerwhich circulatesfreshwaterortreatedwatershouldbeevaluatedwhentheaftercooleriscleanedandtested afterthefirst1000hoursofengineoperation.Theintervalwillvarydependingonoperating conditions.

CleantheAftercoolerCore

Removethecore.RefertotheDisassemblyandAssemblyManual,"Aftercooler-Remove"forthe procedure.

1.Turntheaftercoolercoreononesideinordertoremovedebris.Removethedebristhatis accessible.

NOTICE

Donotuseahighconcentrationofcausticcleanertocleanthecore.A highconcentrationofcausticcleanercanattacktheinternalmetalsof thecoreandcauseleakage.Onlyusetherecommendedconcentration ofcleaner.

2.Backflushthecorewithcleaner.

CaterpillarrecommendstheuseofHydrosolvliquidcleaner.Table1listsHydrosolvliquid cleanersthatareavailablefromyourCatdealer.

PartNumberDescriptionSize

1U-5490Hydrosolv416519L(5USgallon)

174-6854Hydrosolv10019L(5USgallon)

(1)Useatwotofivepercentconcentrationofthecleanerattemperaturesupto93°C(200°F).ConsultyourCat dealerformoreinformation.

3.Steamcleanthecoreinordertoremoveanyresidue.Flushthefinsoftheaftercoolercore. Removeanyothertrappeddebrisfromtheinsideandfromtheoutsideofthecore.

Note:Donotusehighpressurewhenthefinsarecleaned.Highpressurecandamagethefins.

4.Washthecorewithhot,soapywater.

5.Flushthecorethoroughlyinordertoremoveresidueandremainingdebris.Flushthecorewith clean,freshwateruntilthewaterthatisexitingthecoreisclearandfreeofdebris.

Personalinjurycanresultfromairpressure.

Personalinjurycanresultwithoutfollowingproperprocedure.When usingpressureair,wearaprotectivefaceshieldandprotectiveclothing.

Themaximumairpressureforcleaningpurposesmustbereducedto 205kPa(30psi)whentheairnozzleisdeadheaded.

6.Drythecorewithcompressedair.Directtheairinthereversedirectionofthenormalflow.

TesttheAftercoolerCore

1.Inspectthecorefortrappeddebrisandcleanliness.Ifnecessary,removethedebrisandrepeat thecleaningprocedure.

2.Inspectthecorefordamageandperformapressuretestinordertodetectleaks.Manyshops thatserviceradiatorsareequippedtoperformpressuretests.

3.Plugbothendsoftheaftercoolercoreandpressurizethecoreto205kPa(30psi).Submergethe coreinwater.Lookforbubbleswhicharebeingemittedfromthecore.Thebubblesare evidenceofleaks.

4.Ifanyleaksarefound,donotattempttorepairthecore.

Installacorethatiscleanandacorethatpassesthepressuretestinstep3.RefertotheDisassembly andAssemblyManual,"Aftercooler-Install"fortheprocedure.

Formoreinformationoncleaningthecore,consultyourCatdealer.

AllRightsReserved.

PrivateNetworkForSISLicensees.

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Product:MARINEENGINE

Model:3406EMARINEENGINE9WR

Configuration:3406EMarineEngine9WR00001-UP

OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015 i05592931

AftercoolerCore-Replace-AftercoolerCore-Replace

SMCS-1064-510

Anaftercoolerthatcirculatessaltwatermustbereplacedmoreoftenthananaftercoolerthatcirculates freshwaterortreatedwater.RefertoDisassemblyandAssembly,"Aftercooler-Remove"andreferto DisassemblyandAssembly,"Aftercooler-Install"fortheprocedures.

Note:

•Replacingtheaftercoolercoreatacalendarintervalisonlyrequiredforaftercoolercoreswhich circulatesaltwater.

•Topendoverhaulandmajoroverhaulalsoincludereplacinganaftercoolercorethatcirculates saltwater.Considerationshouldbegiventothecalendarandoverhaulintervalstoavoid unnecessaryreplacement.

•Actualcorelifeismostlydependentonengineloadfactors,watercleanliness,galvanic corrosion,andlevelsofelectrolysis.

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OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015 i04360176

EngineAirCleanerElement(SingleElement)Inspect/Clean/Replace

SMCS-1051;1054-040;1054-070;1054-510

NOTICE

Neverruntheenginewithoutanaircleanerelementinstalled.Never runtheenginewithadamagedaircleanerelement.Donotuseair cleanerelementswithdamagedpleats,gasketsorseals.Dirtentering theenginecausesprematurewearanddamagetoenginecomponents. Aircleanerelementshelptopreventairbornedebrisfromenteringthe airinlet.

NOTICE

Neverservicetheaircleanerelementwiththeenginerunningsincethis willallowdirttoentertheengine.

(1)Aircleanerelement

(2)Vacuumlimiterelement

ServicingtheAirCleanerElement

Iftheaircleanerelementbecomesplugged,theaircansplitthematerialoftheaircleanerelement. Unfilteredairwilldrasticallyaccelerateinternalenginewear.YourCatdealerhastheproperair cleanerelementsforyourapplication.ConsultyourCatdealerforthecorrectaircleanerelement.

•Checktheprecleaner(ifequipped)dailyforaccumulationofdirtanddebris.Removeanydirt anddebris,asneeded.

•Operatingconditions(dust,dirtanddebris)mayrequiremorefrequentserviceoftheaircleaner element.

•Theaircleanerelementmaybecleaneduptosixtimesiftheelementisproperlycleanedand inspected.

•Theaircleanerelementshouldbereplacedatleastonetimeperyear.Thisreplacementshould beperformedregardlessofthenumberofcleanings.

Replacethedirtypaperaircleanerelementswithcleanaircleanerelements.Beforeinstallation,the aircleanerelementsshouldbethoroughlycheckedfortearsand/orholesinthefiltermaterial.Inspect thegasketorthesealoftheaircleanerelementfordamage.Maintainasupplyofsuitableaircleaner elementsforreplacementpurposes.

Note:Usethe102-9720CleaningKitinordertocleantheaircleanerelement.Theseproductscontain thedetergentandoilthatismadespecificallyforthemaintenanceoftheaircleanerelements.

1.Removetheaircleanerelement.Taptheaircleanerelementinordertodislodgedirtparticles. Gentlybrushtheaircleanerelementwithasoftbristlebrush.

NOTICE

Donotusegasoline,steam,causticorunapproveddetergents,orparts cleaningsolvents.Donotusehighpressurewaterorairtocleantheair cleanerelement.Anyofthoseliquidsormethodscancauseaircleaner elementdamage.

2.Spraytheaircleanerelementwiththecleaningsolution.Allowtheaircleanerelementtostand for20minutes.

3.Rinsetheaircleanerelementwithlowwaterpressure.Themaximumwaterpressureforthis procedureis275kPa(40psi).Tapwaterisacceptable.Starttorinsetheaircleanerelement fromthecleanside(inside).Next,cleanthedirtyside(outside)inordertoflushoutdirt.Inspect theaircleanerelementfortearsand/orholesaftertheaircleanerelementiscleaned.Donot reuseadamagedaircleanerelements.

NOTICE

Donotusecompressedair,openflame,orhotairtodrytheaircleaner element.Excessheatshrinkscottonfiber,andcompressedairmay blowholesinthematerial.Allowtheaircleanerelementtoairdry.

4.Shakeexcesswaterofftheaircleanerelementandallowtheaircleanerelementtoairdry. Dryingtheaircleanerelementinthesunspeedstheprocess.

NOTICE

Donotusetransmissionfluid,engineoil,dieselfuel,orotherlubricant tooiltheaircleanerelement.Theaircleanerelementcannotfunction correctlyifimproperoilisused.Neveroperateanenginewithadryair cleanerelement.Theaircleanerelementcannotfunctioncorrectly withoutoil.Alwayssaturatethecleanaircleanerelementwiththe recommendedoil.

5.Thedryaircleanerelementshouldbeoiledbeforeinstallation.Applysmallamountsofoil acrossthetopofeachpleat.Allowtheoilwickintotheaircleanerelementfor20minutes.Oil anyremaining"white"spots.

6.Inspectthehousingandtheclampforaircleanerelement.Replacethehousingandtheclamp,if necessary.Installtheclean,oiledaircleanerelement.RefertoSpecifications,SENR3130, "TorqueSpecifications"formoreinformationonthepropertorques.

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Product:MARINEENGINE

Model:3406EMARINEENGINE9WR

Configuration:3406EMarineEngine9WR00001-UP

OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015

Alternator-Inspect

SMCS-1405-040

i02676048

Caterpillarrecommendsascheduledinspectionofthealternator.Inspectthealternatorforloose connectionsandproperbatterycharging.Inspecttheammeter(ifequipped)duringengineoperationin ordertoensureproperbatteryperformanceand/orproperperformanceoftheelectricalsystem.Make repairs,asrequired.

Checkthealternatorandthebatterychargerforproperoperation.Ifthebatteriesareproperlycharged, theammeterreadingshouldbeverynearzero.Allbatteriesshouldbekeptcharged.Thebatteries shouldbekeptwarmbecausetemperatureaffectsthecrankingpower.Ifthebatteryistoocold,the batterywillnotcranktheengine.Thebatterywillnotcranktheengine,eveniftheengineiswarm. Whentheengineisnotrunforlongperiodsoftimeoriftheengineisrunforshortperiods,the batteriesmaynotfullycharge.Abatterywithalowchargewillfreezemoreeasilythanabatterywith afullcharge.

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OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015

AuxiliaryWaterPump(BronzeImpeller)-Inspect

SMCS-1371-040

i06638150

Impellersandsealsrequireperiodicinspection.Impellershaveaservicelifethatislimited.The servicelifedependsontheengineoperatingconditions.

Inspectthecomponentsmorefrequentlywhenthepumpisexposedtodebris,sand,orotherabrasive materials.Inspectthecomponentsifthepumpisoperatingatadifferentialpressurelessthan103kPa (15psi).

Checkthefollowingcomponentsforwearordamage:

•Bearings

•Impeller

•Seals

•Wearplate

Ifwearordamageisfound,replacethecomponentswhicharewornordamaged.Usetheproper repairkitforthepump.RefertotheDisassemblyandAssemblyformoreinformationonservicingthe auxiliarywaterpump.

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Product:MARINEENGINE

Model:3406EMARINEENGINE9WR

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OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015

AuxiliaryWaterPump(RubberImpeller)-Inspect

SMCS-1371-040

i06638162

Impellersandsealsrequireperiodicinspection.Impellershaveaservicelifethatislimited.The servicelifedependsontheengineoperatingconditions.

Inspectthecomponentsmorefrequentlywhenthepumpisexposedtodebris,sand,orotherabrasive materials.Inspectthecomponentsifthepumpisoperatingatadifferentialpressurelessthan103kPa (15psi).

Checkthefollowingcomponentsforwearordamage:

•Bearings

•Impeller

•Seals

•Wearplate

Ifwearordamageisfound,replacethecomponentswhicharewornordamaged.Usetheproper repairkitforthepump.RefertotheDisassemblyandAssemblyformoreinformationonservicingthe auxiliarywaterpump.

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OperationandMaintenanceManual

3406EandC15MarineEngines

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Battery-Replace

SMCS-1401-510

Batteriesgiveoffcombustiblegaseswhichcanexplode.Asparkcan causethecombustiblegasestoignite.Thiscanresultinseverepersonal injuryordeath.

Ensureproperventilationforbatteriesthatareinanenclosure.Follow theproperproceduresinordertohelppreventelectricalarcsand/or sparksnearbatteries.Donotsmokewhenbatteriesareserviced.

Thebatterycablesorthebatteriesshouldnotberemovedwiththe batterycoverinplace.Thebatterycovershouldberemovedbeforeany servicingisattempted.

Removingthebatterycablesorthebatterieswiththecoverinplacemay causeabatteryexplosionresultinginpersonalinjury.

Note:Alwaysrecycleabattery.Neverdiscardabattery.Returnusedbatteriestoanappropriate recyclingfacility.

1.TurnthekeystartswitchtotheOFFposition.Removethekeyandallelectricalloads.

2.TurnOFFthebatterycharger.Disconnectthecharger.

3.TurnbatteryisolatorswitchtoOFFposition.

4.TheNEGATIVE"-"cableconnectstheNEGATIVE"-"batteryterminaltothegroundplane. DisconnectthecablefromtheNEGATIVE"-"batteryterminal.

5.ThePOSITIVE"+"cableconnectsthePOSITIVE"+"batteryterminaltothestartingmotor. DisconnectthecablefromthePOSITIVE"+"batteryterminal.

Note:Alwaysrecycleabattery.Neverdiscardabattery.Returnusedbatteriestoanappropriate recyclingfacility.

6.Removetheusedbattery.

7.Installthenewbattery.

Note:Beforethecablesareconnected,ensurethatthekeystartswitchisOFF.

8.ConnectthecablefromthestartingmotortothePOSITIVE"+"batteryterminal.

9.ConnectthecablefromthegroundplanetotheNEGATIVE"-"batteryterminal.

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OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015

BatteryElectrolyteLevel-Check

SMCS-1401-535-FLV

i07185134

Whentheenginehasnotrunforlongorshortperiodsoftime,thebatteriesmaynotfullyrecharge. Ensureafullchargetohelppreventthebatteryfromfreezing.

Inwarmerclimates,checktheelectrolytelevelmorefrequently.

Ensurethattheelectrolytelevelis13mm(0.5inch)abovethetopoftheseparators.

Alllead-acidbatteriescontainsulfuricacidwhichcanburntheskinand clothing.Alwayswearafaceshieldandprotectiveclothingwhen workingonornearbatteries.

1.Removethefillercaps.Maintaintheelectrolyteleveltothe"FULL"markonthebattery.

Iftheadditionofwaterisnecessary,usedistilledwater.Ifdistilledwaterisnotavailable,use cleanwaterthatislowinminerals.Donotuseartificiallysoftenedwater.

2.Checktheconditionoftheelectrolytewiththe245-5829CoolantBatteryTesterRefractometer.

3.Keepthebatteriesclean.

Cleanthebatterycasewithoneofthefollowingcleaningsolutions:

Amixtureof0.1kg(0.2lb)ofbakingsodaand1L(1qt)ofcleanwater

Amixtureof0.1L(0.11qt)ofammoniaand1L(1qt)ofcleanwater

Thoroughlyrinsethebatterycasewithcleanwater.

Usethe1U-9921BatteryServiceTooltocleanthebatteryterminals.Useawirebrushtoclean thecableclamps.Cleantheitemsuntilthesurfacesarebrightorshiny.DONOTremove materialexcessively.Excessiveremovalofmaterialcancausetheclampstofitimproperly. Coattheclampsandtheterminalswith5N-5561SiliconeLubricant,petroleumjellyorMPGM.

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OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015

BatteryorBatteryCable-Disconnect

SMCS-1401;1402-029

Thebatterycablesorthebatteriesshouldnotberemovedwiththe batterycoverinplace.Thebatterycovershouldberemovedbeforeany servicingisattempted.

Removingthebatterycablesorthebatterieswiththecoverinplacemay causeabatteryexplosionresultinginpersonalinjury.

i06738663

1.TurnthestartswitchtotheOFFposition.Turntheignitionswitch(ifequipped)totheOFF positionandremovethekeyandallelectricalloads.

2.Disconnectthenegativebatteryterminalatthebatterythatgoestothestartswitch.Ensurethat thecablecannotcontacttheterminal.Whenfour12voltbatteriesareinvolved,thenegative sideoftwobatteriesmustbedisconnected.

3.Tapetheleadsinordertohelppreventaccidentalstarting.

Product:MARINEENGINE

Model:3406EMARINEENGINE9WR

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OperationandMaintenanceManual

3406EandC15MarineEngines

MediaNumber-SEBU7005-12PublicationDate-01/05/2015DateUpdated-04/05/2015 i02229322

Belts-Inspect/Adjust/Replace

SMCS-1357-025;1357-040;1357-510

Inspection

Inspectthealternatorbeltandanyaccessorybeltsforwearandforcracking.Replacethebeltsifthe beltsarenotingoodcondition.

CheckthebelttensionaccordingtotheinformationintheServiceManual,"Specifications".

Slippageofloosebeltscanreducetheefficiencyofthedrivencomponents.Vibrationofloosebelts cancauseunnecessarywearonthefollowingcomponents:

•Belts

•Pulleys

•Bearings

Ifthebeltsaretootight,unnecessarystressisplacedonthecomponents.Thisreducestheservicelife ofthecomponents.

Replacement

Forapplicationsthatrequiremultipledrivebelts,replacethedrivebeltsinmatchedsets.Replacing onedrivebeltofamatchedsetwillcausethenewdrivebelttocarrymoreloadbecausetheolder drivebeltsarestretched.Theadditionalloadonthenewdrivebeltcouldcausethenewdrivebeltto fail.

AlternatorBeltAdjustment

Illustration1g00960176

(1)Adjustingnuts (2)Mountingbolt (3)Mountingbolt (4)Mountingbolt

1.Removethedrivebeltguard.

2.Loosenmountingbolts(2),(3),and(4).Loosenadjustingnuts(1).

3.Turnadjustingnuts(1)inordertoincreaseordecreasethedrivebelttension.

4.Tightenadjustingnuts(1).Tightenmountingbolts(2),(3),and(4).

5.Reinstallthedrivebeltguard.

Ifnewdrivebeltsareinstalled,checkthedrivebelttensionagainafter30minutesofengineoperation attheratedrpm.

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OperationandMaintenanceManual

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Coolant-Change

SMCS-1350-044;1352;1395-044

RefertothisOperationandMaintenanceManual,"FluidRecommendations"forthecorrectintervals forchangingthecoolant.

Cleanthecoolingsystemandflushthecoolingsystembeforetherecommendedmaintenanceinterval ifthefollowingconditionsexist:

•Theengineoverheatsfrequently.

•Foamingisobserved.

•Theoilhasenteredthecoolingsystemandthecoolantiscontaminated.

•Thefuelhasenteredthecoolingsystemandthecoolantiscontaminated.

DraintheCoolingSystem

PressurizedSystem:Hotcoolantcancauseseriousburns.Toopenthe coolingsystemfillercap,stoptheengineandwaituntilthecooling systemcomponentsarecool.Loosenthecoolingsystempressurecap slowlyinordertorelievethepressure.

NOTICE

Caremustbetakentoensurethatfluidsarecontainedduring performanceofinspection,maintenance,testing,adjusting,andrepair oftheproduct.Bepreparedtocollectthefluidwithsuitablecontainers beforeopeninganycompartmentordisassemblinganycomponent containingfluids.

RefertoSpecialPublication,NENG2500,"CatDealerServiceTool Catalog"orrefertoSpecialPublication,PECJ0003,"CatShop SuppliesandToolsCatalog"fortoolsandsuppliessuitabletocollect andcontainfluidsonCatproducts.

Disposeofallfluidsaccordingtolocalregulationsandmandates.

1.Stoptheengineandallowtheenginetocool.Ensurethattheenginewillnotstartwhenthe coolingsystemisdrained.

2.Loosenthecoolingsystemfillercapslowlyinordertorelieveanypressure.Removethe coolingsystemfillercap.

3.Openthecoolingsystemdrainvalve(ifequipped).Ifthecoolingsystemisnotequippedwitha drainvalve,removeoneofthedrainplugs.

Note:Ifequipped,besuretodraintheheaterandanyrelatedsupplyandreturnlines.

Allowthecoolanttodrain.

NOTICE

Disposeofusedenginecoolantproperlyorrecycle.Variousmethods havebeenproposedtoreclaimusedcoolantforreuseinenginecooling systems.Thefulldistillationprocedureistheonlymethodacceptable byCaterpillartoreclaimtheusedcoolant.

Forinformationregardingthedisposalandtherecyclingofusedcoolant,consultyourCatdealeror consultCatDealerServiceToolGroup:

InsideUSA1-800-542-TOOL

InsideIllinois1-800-541-TOOL

Canada1-800-523-TOOL

International1-309-578-7372 Flush

SystemsFilledwithCatELC,CatELI,oraConventionalCoolantthatMeetsthe CatEC-1RequirementsandtheStandardsofASTMD6210

1.Flushthecoolingsystemwithcleanwaterinordertoremoveanydebris.

2.Closethedrainvalve(ifequipped).Cleanthedrainplugs.Installthedrainplugs.Refertothe SpecificationsManual,SENR3130,"TorqueSpecifications"formoreinformationontheproper torques.

NOTICE

Fillthecoolingsystemnofasterthan19L(5USgal)perminuteto avoidairlocks.

3.Fillthecoolingsystemwithcleanwater.Installthecoolingsystemfillercap.

4.Startandruntheengineatlowidleuntilthetemperaturereaches49to66°C(120to150°F).

5.Stoptheengineandallowtheenginetocool.Loosenthecoolingsystemfillercapslowlyin ordertorelieveanypressure.Removethecoolingsystemfillercap.Openthedrainvalve(if equipped)orremovethecoolingsystemdrainplugs.Allowthewatertodrain.Flushthe coolingsystemwithcleanwater.Closethedrainvalve(ifequipped).Cleanthedrainplugs. Installthedrainplugs.RefertotheSpecificationsManual,SENR3130,"TorqueSpecifications" formoreinformationonthepropertorques.

SystemsFilledwithCatDEAC,ConventionalCoolantwhichdoesnotMeetthe CatEC-1Requirements,orSupplementalCoolantAdditive(SCA)andWater

3.Flushthecoolingsystemwithcleanwaterinordertoremoveanydebris.

4.Closethedrainvalve(ifequipped).Cleanthedrainplugs.Installthedrainplugs.Refertothe SpecificationsManual,SENR3130,"TorqueSpecifications"formoreinformationontheproper torques.

NOTICE

Fillthecoolingsystemnofasterthan19L(5USgal)perminuteto avoidairlocks.

5.FillthecoolingsystemwithamixtureofcleanwaterandCatFastActingCoolingSystem Cleaner.

6.Choose1ofthefollowingoptions.

Add0.5L(1pint)ofcleanerper15L(4USgal)ofthecoolingsystemcapacity.

Forcoolingsystemswithheavydepositsorplugging,add0.5L(1pint)ofcleanerper 3.8to7.6L(1to2USgal)ofthecoolingsystemcapacity.

7.Installthecoolingsystemfillercap.

8.Startandruntheengineatlowidleforaminimumof30minutes.Forcoolingsystemswith heavydepositsorplugging,runtheenginefor90minutes.Thecoolanttemperatureshouldbeat least82°C(180°F).

NOTICE

Improperorincompleterinsingofthecoolingsystemcanresultin damagetocopperandothermetalcomponents.

Toavoiddamagetothecoolingsystem,makesuretocompletelyflush thecoolingsystemwithclearwater.Continuetoflushthesystemuntil allsignsofthecleaningagentaregone.

9.Stoptheengineandallowtheenginetocool.Loosenthecoolingsystemfillercapslowlyin ordertorelieveanypressure.Removethecoolingsystemfillercap.Openthedrainvalve(if equipped)orremovethecoolingsystemdrainplugs.Allowthewatertodrain.Flushthe coolingsystemwithcleanwater.Ifequipped,besuretoflushtheheaterandanyrelatedsupply andreturnlines.Closethedrainvalve(ifequipped).Cleanthedrainplugs.Installthedrain plugs.RefertotheSpecificationsManual,SENR3130,"TorqueSpecifications"formore informationonthepropertorques.

FilltheCoolingSystem

NOTICE

Fillthecoolingsystemnofasterthan19L(5USgal)perminuteto avoidairlocks.

1.Fillthecoolingsystem.RefertothisOperationandMaintenanceManual,"Fluid Recommendations"formoreinformationoncoolingsystemspecificationsRefertothis OperationandMaintenanceManual,"RefillCapacities"forinformationaboutthecapacityof thecoolingsystem.Donotinstallthecoolingsystemfillercap.

2.Startandruntheengineatlowidle.Increasetheenginerpmtohighidle.Runtheengineathigh idlefor1minuteinordertopurgetheairfromthecavitiesoftheengineblock.Stoptheengine.

3.Checkthecoolantlevel.Maintainthecoolantlevelwithin13mm(0.5inch)belowthebottom ofthepipeforfilling.Maintainthecoolantlevelwithin13mm(0.5inch)totheproperlevelon thesightglass(ifequipped).

4.Cleanthecoolingsystemfillercap.Inspectthegasketthatisonthecoolingsystemfillercap. Onlyinstalltheusedfillercapifthegasketisnotdamaged.Usea9S-8140PressurizingPump topressuretestareinstalledcoolingsystemfillercap.Thecorrectpressureforthecooling systemfillercapisstampedonthefaceofthecoolingsystemfillercap.Ifthecoolingsystem fillercapdoesnotretainthecorrectpressure,installanewcoolingsystemfillercap.

5.Starttheengine.Inspectthecoolingsystemforleaksandforproperoperatingtemperature.

SunJun2020:39:59UTC+05302021

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