0384139 JOHNSON PROP., 13-3/8 x 17 - SST

Introduction
The replacement engine is a Tier I level 3406C mechanical jacket water aftercooler (JWAC) engine. Refer to Table 1 for the engine arrangement numbers. The original machines were equipped with a 3406 mechanical engine without a JWAC. The original 3406 engine is not regulated for emissions. This Special Instruction provides the information needed to install the Tier 1 level replacement engine.
Table 1
Engine Arrangements
Original Engine Replacement Engine
6N-2585 213-3610(1)
1W-1428
100-5082(2)
(1) New Repower Engine
(2) Current Tier 1 JWAC EngineThis Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.Note: This special instruction is for documentation only. This instruction contains some procedures that are based on customer feedback. Additional parts and labor hours may be needed to complete this engine replacement. Variations in machine serial number breaks or options could cause a discrepancy in the modifications, parts needed, and labor hours to complete this repower. This documentation is to assist Cat dealer personnel and is a guideline to follow in completing the repower. If errors are identified, contact Emissions Repower Solutions or the dealer Technical Communicator for assistance. The following information is required when contacting Emissions Repower Solutions:
Machine serial number
Original engine arrangement
Original engine serial number
Emissions engine arrangement number
Details of the error
Photos before and after the solution was appliedRegister the Retrofit
Reference: Special Instruction, REHS5097, "Instructions to Register the Retrofit"Documenting changes to a machine configuration is an advantage to Caterpillar and the dealer technicians that are sent to repair a machine. By identifying that the machine has been reconfigured, the technician will have a better opportunity to have the correct parts, tooling, and service information. Identifying that the machine has been reconfigured will also allow Caterpillar to include the retrofitted serial numbers in applicable Service Letters.Safety
Personal injury or death can result from sudden machine movement.Sudden movement of the machine can cause injury to persons on or near the machine.To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.
Do not attempt to assemble this machine until you read and you understand the assembly instructions.Improper assembly procedures could result in injury or death.
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Welding on Electronically Controlled Engines
Proper welding procedures are necessary to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
Disconnect the electronic components of the engine from the wiring harnesses: ECM, throttle actuator, actuator of the compressor for the turbocharger bypass, fuel metering valve, and sensors.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Connect the ground cable of the welder directly to the engine component that will be welded. Place the clamp as close as possible to the weld to reduce the possibility of welding current damage to the engine bearings to the electrical components and to other engine components.
Use standard welding procedures to weld the materials together.Required Parts
Refer to Parts Manual, SEBP1637.Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.Note: If you are required to fabricate a part, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.Note: A breakdown of the kit provides a parts list for the repower. The kit part number is not serviceable. Order the engine arrangement plus the list of parts provided in the kit.
Table 2
Repower Parts
221-0157 Engine Conversion Ar
Qty Part Number Part Name Description
1 213-3610 Engine Ar New repower engine
1 460-4795 Kit-Conversion (Repower) This kit is non-serviceable and provides a breakdown of the serviceable parts required for the repower, excluding the engine and optional groups. For line d