CAT + Caterpillar 3516C Generator Set Operation & Maintenance Manual by Heavy Equipment Manual

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets

MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016 s00037353

Foreword

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.

MonSep413:41:55UTC+05302023

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

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016 i02624677

AirShutoff-Test-EnginesThatAreEquippedwithADEM IIorADEMIIIEngineControlModules(Ifequipped)

SMCS-1078-081

Illustration1g01285348

Typicalairshutoffsona3500Bengine (1)Airshutoffs

Illustration2g01285609 LefthandsideairshutoffintheOPENposition

Illustration3g01285610 RighthandsideairshutoffintheOPENposition

RefertotheTroubleshootingGuide,"AirShutoffSystem"informationinyourServiceManualfor furtherinformationabouttheelectricalsystemfortheairshutoffsystem.

EnginesThatAreEquippedwithADEMIIEngineControl Modules

Note:Donotstarttheengine.Ensurethattheenginecontrolisinthe"OFF"position.

1.EnsurethatbothairshutoffgatesarelatchedintheOPENpositionandensurethatbothair shutoffswitchesareconnected.Turnonthepowertotheenginecontrolpanel.Bothair shutoffgatesshouldremainopen.Ifbothairshutoffgatesdonotremainopen,checkthe wiringfortheairshutoffswitches.

2.WiththepowerfortheenginecontrolpanelintheONposition,activatethe "EMERGENCYSTOP"switch.Bothoftheairshutoffgatesshouldclose.Ifbothair shutoffgatesclose,proceedtostep3.Ifbothairshutoffgatesdonotclose,checkthewiring fortheairshutoffswitchesandcheckthewiringforthesolenoids.Activatethe "EMERGENCYSTOP"switchagain.Whenbothairshutoffgatesclose,proceedtostep3.

3.TurnthepowertotheenginecontrolpaneltotheOFFposition.Ensurethatthe "EMERGENCYSTOP"switchisintheRUNposition.Latchonlytherightsideairshutoff gatetotheOPENposition.TurnthepowerfortheenginecontrolpaneltotheONposition. Therightsideairshutoffgateshouldclose.Iftherightsideairshutoffcloses,proceedto step4.Iftherightsideairshutoffgatedoesnotclose,checktheairshutoffswitchforthe rightsideairshutoffandcheckthewiringfortherightsideairshutoff.Whentherightside airshutoffcloses,proceedtostep4.

4.TurnthepowerfortheenginecontrolpaneltotheOFFposition.Latchonlytheleftsideair shutoffgatetotheOPENposition.TurnthepowerfortheenginecontrolpaneltotheON position.Theleftsideairshutoffgateshouldclose.Iftheleftsideairshutoffgateclosesthe testiscomplete.Iftheleftsideairshutoffgatedoesnotclose,checktheswitchandthe wiringfortheleftsideairshutoff.

Note:Testingisonlycompletewhentheenginesuccessfullypassesstep1throughstep4.

5.Operatetheenginenormally.Ensurethattheairshutoffgatescontinuetobelatched.

EnginesThatAreEquippedwithADEMIIIEngineControl Modules

Note:Donotstarttheengine.Ensurethattheenginecontrolisinthe"OFF"position.

1.EnsurethatbothairshutoffgatesarelatchedintheOPENposition.Ensurethatbothair shutoffswitchesareconnected.TurnthepowerfortheenginecontrolpaneltotheON position.TheairshutoffgatesshouldremainintheOPENpositions.Iftheairshutoffgates donotremainintheOPENpositions,checkthewiringfortheairshutoffs.Whenstep1has beensuccessfullycompleted,proceedtostep2.

2.WhilethepowerfortheenginecontrolpanelisintheONposition,activatethe "EMERGENCYSTOP"switch.Bothairshutoffgatesshouldclose.Iftheairshutoffgates donotclose,checkthewiringfortheairshutoffsandthewiringforthesolenoids.Bothair shutoffgatesmustclosebeforeproceedingtostep3.

3.TurnthepowerfortheenginecontrolpaneltotheOFFposition.Resetthe"EMERGENCY STOP"switchtotheRUNposition.ResettherightsideairshutofftotheOPENposition. TurnthepowerfortheenginecontrolpaneltotheONposition.Select"Run/Start"onthe enginecontrolpanel.Theengineshouldfailtostart.Iftheenginedoesnotstart,proceed to4.Iftheenginestarts,turnofftheengine.Checktherightsideairshutoff.Checkthe wiringfortherightsideairshutoff.Retesttheairshutoff.Whentheprocedurein3is followedandtheenginefailstostart,proceedto4.

4.Resetthe"EMERGENCYSTOP"switchtotheRUNposition.Setthepowerfortheengine controlpaneltotheONposition.Activatethe"EMERGENCYSTOP"switch.Bothair shutoffgatesshouldclose.SetpowerfortheenginecontrolpaneltotheOFFposition.Reset the"EMERGENCYSTOP"switchtotheRUNposition.Resettheleftsideairshutofftothe OPENposition.TurnthepowerfortheenginecontrolpaneltotheONposition.Select "START/RUN"ontheenginecontrolpanel.Theengineshouldfailtostart.Iftheengine doesnotstart,proceedto5.Iftheenginestarts,turnofftheengine.Checktheleftsideair shutoff.Checkthewiringfortheleftsideairshutoff.Retesttheleftsideairshutoff.When theprocedureinstep4isfollowedandtheenginefailstostart,proceedto5.

5.TurnthepowerfortheenginecontrolpaneltotheONposition.Resetbothairshutoffs.Start theengine.Disconnectonlytherightsideairshutoff.Bothairshutoffgatesshouldclose. Theengineshouldshutdown.Iftheenginedoesnotshutdown,usethe"EMERGENCY STOP"switchtostoptheengine.Checkthewiringforbothairshutoffs.Usetheabove procedureinordertoretesttherightsideairshutoff.Whentheprocedureinstep5is followedandresultsofthetestaresuccessful,reconnecttherightsideairshutoff.Reset bothairshutoffs.

6.TurnthepowerfortheenginecontrolpaneltotheONposition.Resetbothairshutoffs.Start theengine.Disconnectonlytheleftsideairshutoff.Bothairshutoffgatesshouldclose.The engineshouldshutdown.Iftheenginedoesnotshutdown,usethe"EMERGENCYSTOP" switchtostoptheengine.Checkthewiringforbothairshutoffs.Usetheaboveprocedurein ordertoretesttheleftsideairshutoff.Whentheprocedurein6isfollowedandtheresults ofthetestaresuccessful,reconnecttherightsideairshutoff.Resetbothairshutoffs.

7.Testingiscompleteonlywhentheenginesuccessfullypassessteps1through6.

8.Resetbothairshutoffs.Ensurethatthe"EMERGENCYSTOP"switchhasbeenreset. Operatetheenginenormally.

MonSep413:45:18UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016 i02622938

AirShutoffDamper-Remove/Check-ifequipped

SMCS-1078-011;1078-535

Illustration1g01286554

Typicalairshutoff(backview) (1)Airshutoffgate (2)Damperassembly

Thevibrationdamperontheairshutoffminimizesthevibrationoftheairshutoffgatewhenthe engineisoperatingandtheairshutoffgateisinthelatchedposition.Thecomponentsofthe damperassemblymustberemovedinordertoensurecorrectperformanceofthedamper.

Illustration2g01286567

Damperassembly (3)Plug (4)Sealring (5)Housing (6)Spring (7)Plunger

1.Thebodyofthedampershouldnotbeloosenedorremovedfromtheairshutoffwhenthe plungerisremoved.Inordertoremovetheplungerwithoutlooseningorremovingthe damper,unscrewtheplugwiththefollowingtools:a6.35mm(0.25inch)Allenwrenchand anopenendwrench.

2.Checkthesealringfordamageorwear.Ifnecessary,replacethesealring.

3.Inspecttheinternalpartsofthevibrationdamperforwearordamage.Cleanthecomponents with138-8440componentcleaner.

Illustration3g01286606

Damperplunger

4.Removetheplungerfromthespring.Visuallyinspecttheexposedendoftheplungerfor dirt,fouling,damage,andwear.Ifdistance"A"islessthan18.3mm(0.72inch)orifa visualinspectionrevealsdirt,fouling,damage,orwearontheactiveendoftheplunger,

replacetheplunger.Insertthetaperedendofaclean,undamagedplungerintothespring. Installtheopenendofthespringintotheplug.Apply9S-3263threadlockorapply9S-4030 threadlockontothethreadsoftheplug.Screwtheassemblyintothedamperbody.The threadlockshouldcureforaminimumof1hourbeforetheairshutoffisused.

MonSep413:45:44UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016 i04342909

Alternator-Inspect

SMCS-1405-040

Inspectthealternatorforthefollowingconditions:

•Properconnections

•Cleanportsforcoolingairflow

•Properchargingofthebattery

Observetheammeterduringengineoperationinordertoensureproperbatteryperformance and/orproperperformanceoftheelectricalsystem.

Makerepairs,ifnecessary.SeetheServiceManualforserviceprocedures.ConsultyourCat dealerforassistance.

MonSep413:46:04UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016 i01041029

Batteries-Replace

SMCS-1401-510

Batteriesgiveoffcombustiblegaseswhichcanexplode.Asparkcan causethecombustiblegasestoignite.Thiscanresultinseverepersonal injuryordeath.

Ensureproperventilationforbatteriesthatareinanenclosure.Follow theproperproceduresinordertohelppreventelectricalarcsand/or sparksnearbatteries.Donotsmokewhenbatteriesareserviced.

1.TurnthekeystartswitchtotheOFFposition.Removethekeyandallelectricalloads.

2.TurnOFFthebatterycharger.Disconnectthecharger.

3.TheNEGATIVE"-"cableconnectstheNEGATIVE"-"batteryterminaltotheground plane.DisconnectthecablefromtheNEGATIVE"-"batteryterminal.

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

Note:Alwaysrecycleabattery.Neverdiscardabattery.Returnusedbatteriestoan appropriaterecyclingfacility.

5.Removetheusedbattery.

6.Installthenewbattery.

Note:Beforeconnectingthecables,ensurethatthekeystartswitchisOFF.

7.ConnectthecablefromthestartingmotortothePOSITIVE"+"batteryterminal.

8.ConnectthecablefromthegroundplanetotheNEGATIVE"-"batteryterminal.

MonSep413:46:20UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016

BatteryElectrolyteLevel-Check

SMCS-1401-535-FLV

Whentheenginehasnotrunforlongorshortperiodsoftime,thebatteriesmaynotfullyrecharge. Ensureafullchargetohelppreventthebatteryfromfreezing.

Inwarmerclimates,checktheelectrolytelevelmorefrequently.

Ensurethattheelectrolytelevelis13mm(0.5inch)abovethetopoftheseparators.

Alllead-acidbatteriescontainsulfuricacidwhichcanburntheskinand clothing.Alwayswearafaceshieldandprotectiveclothingwhen workingonornearbatteries.

1.Removethefillercaps.Maintaintheelectrolyteleveltothe"FULL"markonthebattery.

Iftheadditionofwaterisnecessary,usedistilledwater.Ifdistilledwaterisnotavailable, usecleanwaterthatislowinminerals.Donotuseartificiallysoftenedwater.

2.Checktheconditionoftheelectrolytewiththe245-5829CoolantBatteryTester Refractometer.

3.Keepthebatteriesclean.

Cleanthebatterycasewithoneofthefollowingcleaningsolutions:

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

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

Thoroughlyrinsethebatterycasewithcleanwater.

i07185134

Usethe1U-9921BatteryServiceTooltocleanthebatteryterminals.Useawirebrushto cleanthecableclamps.Cleantheitemsuntilthesurfacesarebrightorshiny.DONOT removematerialexcessively.Excessiveremovalofmaterialcancausetheclampstofit improperly.Coattheclampsandtheterminalswith5N-5561SiliconeLubricant,petroleum jellyorMPGM.

MonSep413:46:35UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets

MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016

Belts-Inspect/Adjust/Replace

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

Inspection

i06581592

Inspectthealternatorbeltandthefandrivebeltsforwearandforcracking.Replacethebeltsifthe beltsarenotingoodcondition.

CheckthebelttensionaccordingtotheinformationintheServiceManual,"Specifications".

Slippageofloosebeltscanreducetheefficiencyofthedrivencomponents.Vibrationofloose beltscancauseunnecessarywearonthefollowingcomponents:

•Belts

•Pulleys

•Bearings

Ifthebeltsaretootight,unnecessarystressisplacedonthecomponents.Beltsthataretootight reducestheservicelifeofthecomponents.

AdjustingtheAlternatorBelt

Illustration1g01092641

Typicalalternator (1)Mountingbolt (2)Adjustingnuts (3)Mountingbolt

1.Loosenmountingbolt(1),adjustingnuts(2)andmountingbolt(3).

2.Turnadjustingnuts(2)toincreaseordecreasethedrivebelttension.

3.Tightenadjustingnuts(2).Tightenmountingbolt(3).Tightenmountingbolt(1).Forthe propertorque,seetheServiceManual,"Specifications"module.

Note:Ifnewdrivebeltsareinstalled,checkthedrivebelttensionagainafter30minutesof engineoperationattheratedrpm.

4.Stoptheengine.

5.Usethe491-2178Belttensionmetertooltocheckthetensionwiththealternatorguard installed.

Note:Thecurrentguarddesignallowsforinspectionofthebelttensionwithoutremovalof theguard.

AdjustingtheFanDriveBelt

1.Loosenthemountingboltforthepulley.

2.Loosentheadjustingnutforthepulley.

3.Movethepulleytoadjustthebelttension.

4.Tightentheadjustingnuttothepropertorque.

5.Tightenthemountingbolttothepropertorque.

Forthepropertorquespecifications,refertotheServiceManual,"Specifications"module.

Replacement

Forapplicationsthatrequiremultipledrivebelts,replacethedrivebeltsinmatchedsets. Replacingonedrivebeltofamatchedsetwillcausethenewdrivebelttocarrymoreloadbecause theolderdrivebeltsarestretched.Theadditionalloadonthenewdrivebeltcouldcausethenew drivebelttofail.

MonSep413:46:56UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016 i06585652

Catalyst(DOC)-Inspect-DynamicGasBlending(DGB) EquippedEnginesonly

SMCS-1091-040

CatalystHousingInspect

TheDieselOxidationcatalyst(DOC)mustbeinspectedperiodicallytoensuresafeand continuousoperationoftheengine.Failuretoidentifyhousingcracksandloosebricksmayresult inshortenedlifeoftheDOC.TakepropersafetyprecautionsbeforeinspectingorrepairingDOCs.

Note:FailuretorepairaDOCmayresultinshortenedlifeoftheDOC.

1.RemovetheDOCinsulatedcoverandinspectforthefollowingconditions:

Externalhousingseamcrackingorseparation

Inletflangecrackingorseparation

Exhaustbellowsdamage

Mountingfeetcrackingordamage

CatalystBrickInspect

Note:FailuretoreplaceadamagedDOCmayresultinnon-compliancewithemissions regulations.

1.Lifttheraincapandinspectforthefollowingconditions:

Catalystbrickcrackingordamage

Loosecatalystbricks

Note:Catalystbricksmaybecomelooseafterlonghoursofoperationorthemounting structurebecomescompromised.

Eachinstallationapplicationisdifferent.Thedifferencesdependonthefollowingfactors:

Geometryofsupportingstructure

DOCmountingfeetisolators

MonSep413:47:18UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets

MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016 i06580270

CatalystModule-Check-DieselOxidationCatalyst

Mounting-DynamicGasBlending(DGB)EquippedEngines only

SMCS-1091-535

Checkthemountingofthedieseloxidationcatalystmoduletoensureproperoperation.

Misalignmentoftheengineandthedieseloxidationcatalystmodulemaydamagetheexhaust bellows.Misalignmentcanbecausedbythefollowingconditions:

•Impropermounting

•Loosebolts

•Deteriorationoftheisolators

Ensurethatthemountingboltsaretightenedtothepropertorque.Forstandardtorques,referto Specifications,SENR3130,TorqueSpecifications.

Ensurethattheisolatorsarefreeofoilandcontamination.Inspecttheisolatorsfordeterioration. Ensurethattheboltsfortheisolatorsaretightenedtothepropertorque.

Replaceanyisolatorthatshowsdeterioration.Formoreinformation,seetheliteraturethatis providedbytheOEMoftheisolators.AlsoseetheApplicationandInstallationGuideforthe DOC.ConsultyourCatdealerforassistance.

MonSep413:47:39UTC+05302023

Product:GENERATORSET

Model:3516CGENERATORSETGS2

Configuration:3516CGeneratorSetGS200001-UP

OperationandMaintenanceManual

3500PetroleumEnginesandPetroleumGeneratorSets MediaNumber-SEBU8101-19PublicationDate-01/07/2015DateUpdated-08/03/2016

CoolingSystemCoolant(DEAC)-Change

SMCS-1350-044

Cleanthecoolingsystembeforetherecommendedmaintenanceintervalifthefollowing conditionsexist:

•Theengineoverheatsfrequently.

•Foamingisobserved.

•Oilhasenteredthecoolingsystemandthecoolantiscontaminated.

•Fuelhasenteredthecoolingsystemandthecoolantiscontaminated.

DraintheCoolingSystem

1.Stoptheengineandallowtheenginetocool.Ensurethattheenginewillnotstartwhenthe coolingsystemisdrained.

2.Loosenthecoolingsystemfillercapslowlyinordertorelieveanypressure.Removethe coolingsystemfillercap.

i04035990

Illustration1g02232739

Locationsofthedrainplugs

(1)Oilcooler

(2)Jacketwaterdrain

(3)SCACwaterdrain

3.Openthecoolingsystemdrainvalves(ifequipped).Ifthecoolingsystemisnotequipped withdrainvalves,removedrainplugs(1),(2),(3).Allowthecoolanttodrain.

Disposeofusedenginecoolantproperlyorrecycle.Variousmethods havebeenproposedtoreclaimusedcoolantforreuseinenginecooling systems.Thefulldistillationprocedureistheonlymethodacceptable byCaterpillartoreclaimtheusedcoolant.

Forinformationregardingthedisposalandtherecyclingofusedcoolant,consultyourCaterpillar dealerorconsultDealerServiceToolsGroup:

OutsideIllinois:1-800-542-TOOLInsideIllinois:1-800-541-TOOLCanada:1-800-523-TOOL

CleantheCoolingSystem

1.Afterthecoolingsystemhasbeendrained,flushthecoolingsystemwithcleanwaterin ordertoremoveanydebris.

2.Closethecoolingsystemdrainvalves(ifequipped).Cleanthedrainplugsandinstallthe drainplugs.

NOTICE

Useofcommerciallyavailablecoolingsystemcleanersmaycause damagetocoolingsystemcomponents.Useonlycoolingsystem cleanersthatareapprovedforCaterpillarengines.

3.FillthecoolingsystemwithamixtureofcleanwaterandCaterpillarFastActingCooling SystemCleaner.Add.5L(1pt)ofcleanerper15L(4USgal)ofthecoolingsystem capacity.Installthecoolingsystemfillercap.

4.Starttheengine.Operatetheengineforaminimumof30minuteswithacoolant temperatureofatleast82°C(180°F).

5.Stoptheengineandallowtheenginetocool.Loosenthecoolingsystemfillercapslowlyin ordertorelieveanypressure.Removethecoolingsystemfillercap.Openthecooling systemdrainvalves(ifequipped)orremovethedrainplugs.

NOTICE

Improperorincompleterinsingofthecoolingsystemcanresultin damagetocopperandothermetalcomponents.

Toavoiddamagetothecoolingsystem,makesuretocompletelyflush thecoolingsystemwithclearwater.Continuetoflushthesystemuntil allsignsofthecleaningagentaregone.

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