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Removing The Cutter Engine (Engine A)
THE ROTATING CUTTER WILL CAUSE SERIOUS INJURIES. DISENGAGE THE CUTTER CLUTCH, SHUT ENGINE A (CATERPILLAR 3412) DOWN AND TAG THE ENGINE CONTROL BEFORE WORKING ON OR NEAR THE CUTTER.
1. Remove the cutter assembly from the machine (see Cutter 1.0-3).2. Remove the power take-off (see page 4.0-1). 3. Close the fuel shutoff valves under the fuel tank. 4. Remove the plug from the lower radiator line and drain the coolant from the radiator.5. Remove the radiator brace rod and the lines from between the engine and radiator. Cover all openings.
ER-1000B DECKING6. Attach a lifting device to the exhaust duct, unbolt the duct from the engine, then lift the exhaust duct away.7. Remove the decking and the decking support from the front of the engine frame (left side of machine). 8. Remove the throttle cable bracket, cable guide and cable from the engine and lay them aside. 9. Disconnect at the engine the supply and return hoses from the fuel manifold and from the final fuel filter. Cap or plug all openings immediately. 10. Disconnect the tachometer cable. 11. Disconnect the battery cable from the left starter solenoid and the thermocouple cable from the thermocouple.12. Disconnect the following front engine harness wires: #16 black and #16 white wires from the starter and glow plug relays.#16 red wire from the right starter solenoid.#16 orange wire from the water temperature sender.#16 blue wire from the oil pressure sender.#16 yellow wire from the rack terminal.13. Disconnect any remaining hoses or wires as necessary to allow removal of the engine.14. Attach a lifting beam and device to the engine lifting lugs. The engine weighs approximately 4100 pounds.15. Remove the engine mounting bolts and lift the engine up and away.Building The Engine Up
The simplest way to build up a new engine is to position the new engine beside the old one and properly support both so they can safely be worked on. Then remove one component at a time from the old engine and install it on the new engine until all required components have been transferred to the new engine. Components that may have to be transferred include: 1. Engine power wiring harness.2. Starter and glow plug relays. 3. Thermocouple.4. Water temperature sender.5. Oil pressure sender6. Tachometer drive elbow. 7. Radiator brace bracket.8. Grab rail.Installing The Cutter Engine (Engine A)
1. Check that the mounting area on the machine is clear of all hoses, wires, control cables, etc.2. Set the main battery disconnect switch at "Off".3. Attach a lifting device to the engine lifting lugs and move the engine into position. The engine weighs approximately 4100 pounds. 4. Install the front engine mounting bolts. Tighten the rear support bolts to support the engine. 5. Install the decking and decking support on the front of the engine frame (left side of machine). 6. Connect the wiring harness wires to the various engine components. 7. Connect the tachometer cable. 8. Slide the throttle cable guide over the cable, then install the throttle cable, bracket and guide. 9. Connect to the engine the supply and return hoses from the fuel manifold and from the final fuel filter. 10. Install the radiator brace. 11. Install the exhaust duct and the lines between the engine and radiator.12. Install the power take-off (see page 4.0-12).13. Fill the engine radiator with a 50/50 mixture of water and ethylene glycol type permanent antifreeze. 14. Open the fuel shutoff valves under the fuel tank.15. Check the engine oil level. Add oil as necessary.16. Unlock the fuel priming pump.17. Operate the priming pump until increased resistance is felt, then lock the fuel priming pump.
ALWAYS START ENGINE B (CATERPILLAR 3208) BEFORE STARTING ENGINE A (CATERPILLAR 3412) AND ALWAYS CHECK THAT THE AIR BOX COVER IS CLOSED BEFORE STARTING ENGINE B. COOLING AIR WILL NOT FLOW THROUGH THE RADIATORS UNLESS ENGINE B IS RUNNING AND THE AIR BOX COVER IS CLOSED. THE HYDRAULIC MACHINE CONTROLS WILL NOT OPERATE UNLESS ENGINE B IS RUNNING.
18. BE SURE THE CUTTER CLUTCH IS DISENGAGED, set the main battery disconnect switch at "On", then start the cutter engine and run it at the lowest RPM possible. Check the engine oil pressure gauge for an immediate indication. If no engine oil pressure is indicated within 5 seconds, SHUT THE ENGINE DOWN and correct the problem.If the engine misfires or smokes, loosen a fuel injection line nut; allow the fuel to flow until free of air bubbles. Tighten the line nut, open the next line nut and continue priming each successive line.19. Run the engine 30 minutes or until smooth operation, normal noise level and stable temperature of the engine are ensured.20. Shut down the engine, set the main battery disconnect switch at "Off", then install the cutter assembly (see Cutter 1.0-5).