C18 GENERATOR SET - pgsitecld.persiangig.com/dl/sTAlx/GSc3HpPIcm/C18_Generator_Set... · 2014. 5. 2. · SEBU7898-12 111 Maintenance Section Aftercooler Core - Clean/Test i01546702

SAFETY.CAT.COM™

C18 GENERATOR SETMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7898-12)

®© 2009 CaterpillarAll Rights Reserved

®

108 SEBU7898-12Maintenance SectionMaintenance Interval Schedule

i03671315

Maintenance Interval Schedule(Prime Product)SMCS Code: 1000; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible forthe performance of maintenance, including alladjustments, the use of proper lubricants, fluids,filters, and the installation of new componentsdue to normal wear and aging. The performanceof this product may be diminished if propermaintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Replace ................................................. 114Battery or Battery Cable - Disconnect ................. 115Engine - Clean .................................................... 125Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................. 125Ether Starting Aid Cylinder - Replace ................. 133Fuel System - Prime ........................................... 134Generator - Dry ................................................... 138Generator Bearing - Lubricate ............................ 140Generator Set - Test ........................................... 144Generator Set Alignment - Check ....................... 145Rotating Rectifier - Test ...................................... 159Severe Service Application - Check ................... 160

Daily

Annunciator Panel - Inspect ................................. 111Cooling System Coolant Level - Check .............. 120Engine Air Cleaner Service Indicator - Inspect ... 128Engine Oil Level - Check .................................... 129Fuel System Primary Filter/Water Separator -Drain ................................................................. 136Generator Bearing Temperature - Test/Record ... 143Generator Load - Check ..................................... 144Power Factor - Check ......................................... 158Walk-Around Inspection ...................................... 163

Every Week

Automatic Start/Stop - Inspect ............................. 113Electrical Connections - Check ........................... 125Generator - Inspect ............................................. 139Generator Lead - Check ..................................... 144Instrument Panel - Inspect .................................. 147Jacket Water Heater - Check .............................. 151Space Heater - Check ........................................ 161Standby Generator Set MaintenanceRecommendations ............................................ 161

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 121

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 121

Every 2000 Service Hours or 6 Months

Generator Set Vibration - Inspect ....................... 145Generator Set Vibration - Test/Record ................ 145Insulation - Test ................................................... 147

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 121Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 122

First 9500 L (2500 US gal) of Fuel or 250Service Hours

Engine Valve Lash - Inspect/Adjust .................... 132

Every 9500 L (2500 US gal) of Fuel or 250Service Hours or Yearly

Aftercooler Core - Clean/Test .............................. 111Battery Electrolyte Level - Check ......................... 115Belts - Inspect/Adjust/Replace ............................. 116Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 122Cylinder Head Grounding Stud - Inspect/Clean/Tighten .............................................................. 124Engine Oil Sample - Obtain ................................ 130Engine Oil and Filter - Change ........................... 130Engine Protective Devices - Check .................... 132Fan Drive Bearing - Lubricate ............................. 134Fuel System Secondary Filter - Replace ............ 136Fuel Tank Water and Sediment - Drain ............... 137Hoses and Clamps - Inspect/Replace ................ 146Magnetic Pickups - Clean/Inspect ...................... 151Radiator - Clean .................................................. 158Rotating Rectifier - Check ................................... 159

SEBU7898-12 109Maintenance Section

Maintenance Interval Schedule

Every 19 000 L (5000 US gal) of Fuel or 250Service Hours

Engine Crankcase Breather - Clean ................... 129

Every 19 000 L (5000 US gal) of Fuel or 500Service Hours

Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 134

Every 114 000 L (30 000 US gal) of Fuel or3000 Service Hours or 2 Years

Crankshaft Vibration Damper - Inspect ............... 124

Every 114 000 L (30 000 US gal) of Fuel or3000 Service Hours or 3 Years

Alternator - Inspect .............................................. 111Cooling System Coolant (DEAC) - Change ......... 116Cooling System Coolant Extender (ELC) - Add ... 119Cooling System Water Temperature Regulator -Replace ............................................................. 123Crankshaft Vibration Damper - Inspect ............... 124Engine Mounts - Inspect ..................................... 129Engine Speed/Timing Sensors - Check/Clean/Calibrate ............................................................ 132Engine Valve Lash - Inspect/Adjust .................... 132Engine Valve Rotators - Inspect ......................... 133Starting Motor - Inspect ...................................... 162Turbocharger - Inspect ........................................ 162Water Pump - Inspect ......................................... 164

Every 228 000 L (60 000 US gal) of Fuel or 12000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............ 118

Every 600 000 L (158 500 US gal) of Fuel

Overhaul (Top End) ............................................. 154Overhaul Considerations .................................... 155

Every 1 200 000 L (317 000 US gal) of Fuel

Overhaul (Major) ................................................. 151Overhaul Considerations .................................... 155

Overhaul

Generator Bearing - Inspect/Replace ................. 140

110 SEBU7898-12Maintenance SectionMaintenance Interval Schedule

i03671310

Maintenance Interval Schedule(Standby)SMCS Code: 1000; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible forthe performance of maintenance, including alladjustments, the use of proper lubricants, fluids,filters, and the installation of new componentsdue to normal wear and aging. The performanceof this product may be diminished if propermaintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Replace ................................................. 114Battery or Battery Cable - Disconnect ................. 115Ether Starting Aid Cylinder - Replace ................. 133Fuel System - Prime ........................................... 134Fuel System Primary Filter/Water Separator -Drain ................................................................. 136Generator Bearing - Lubricate ............................ 140Generator Load - Check ..................................... 144Generator Set - Test ........................................... 144Rotating Rectifier - Test ...................................... 159

Every Week

Automatic Start/Stop - Inspect ............................. 113Battery Charger - Check ...................................... 114Battery Electrolyte Level - Check ......................... 115Cooling System Coolant Level - Check .............. 120Electrical Connections - Check ........................... 125Engine Air Cleaner Service Indicator - Inspect ... 128Engine Oil Level - Check .................................... 129Fuel Tank Water and Sediment - Drain ............... 137Generator - Inspect ............................................. 139Generator Bearing Temperature - Test/Record ... 143Generator Lead - Check ..................................... 144Instrument Panel - Inspect .................................. 147Jacket Water Heater - Check .............................. 151Power Factor - Check ......................................... 158Space Heater - Check ........................................ 161

Standby Generator Set MaintenanceRecommendations ............................................ 161

Every Year

Alternator - Inspect .............................................. 111Belts - Inspect/Adjust/Replace ............................. 116Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 121Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 122Crankshaft Vibration Damper - Inspect ............... 124Engine - Clean .................................................... 125Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................. 125Engine Mounts - Inspect ..................................... 129Engine Oil Sample - Obtain ................................ 130Engine Oil and Filter - Change ........................... 130Engine Performance - Test ................................. 132Engine Protective Devices - Check .................... 132Engine Valve Lash - Inspect/Adjust .................... 132Engine Valve Rotators - Inspect ......................... 133Fan Drive Bearing - Lubricate ............................. 134Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 134Fuel System Secondary Filter - Replace ............ 136Generator - Dry ................................................... 138Generator Set Vibration - Inspect ....................... 145Generator Set Vibration - Test/Record ................ 145Hoses and Clamps - Inspect/Replace ................ 146Insulation - Test ................................................... 147Radiator - Clean .................................................. 158Starting Motor - Inspect ...................................... 162Water Pump - Inspect ......................................... 164

Every 3 Years

Cooling System Coolant (DEAC) - Change ......... 116Cooling System Coolant Extender (ELC) - Add ... 119Cooling System Water Temperature Regulator -Replace ............................................................. 123Cylinder Head Grounding Stud - Inspect/Clean/Tighten .............................................................. 124Engine Speed/Timing Sensors - Check/Clean/Calibrate ............................................................ 132Rotating Rectifier - Check ................................... 159Turbocharger - Inspect ........................................ 162

Every 6 Years

Cooling System Coolant (ELC) - Change ............ 118

Commissioning

Generator Set Alignment - Check ....................... 145


Aftercooler Core - Clean/Test

i01546702

Aftercooler Core - Clean/TestSMCS Code: 1064-070; 1064-081

1. Remove the core. Refer to the Service Manualfor the procedure.

2. Turn the aftercooler core upside-down in order toremove debris.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 18 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 18

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Hydrosolv 100 19 L (5 US gallon)(1) Use a two to five percent concentration of the cleanerat temperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

4. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

7. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

8. Install the core. Refer to the Service Manual forthe procedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

i02676048

Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspect theammeter (if equipped) during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system. Makerepairs, as required.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i01148030

Annunciator Panel - InspectSMCS Code: 4490-040

Inspect the annunciator panel for good condition.Perform a lamp test. All of the warning lamps shouldilluminate. If a warning lamp does not illuminate,replace the bulb immediately. If the alarm doesnot sound, investigate the problem and correct theproblem.

Check the condition of all of the gauges. If a gaugeis broken, repair the gauge or replace the gaugeimmediately.

Frequently monitor the following parameters duringnormal engine operation:

• Engine Oil Pressure

• Engine Coolant Temperature

112 SEBU7898-12Maintenance SectionAnnunciator Panel - Inspect

• Inlet Air Restriction

• Exhaust Temperature

Record the data in a log. Compare the new data tothe data that was previously recorded. Comparingthe new data to the recorded data will establish thenormal gauge readings for the engine. A gaugereading that is abnormal may indicate a problem withengine operation. Abnormal gauge readings mayalso indicate a possible problem with the gauge.

Record the Performance of theEngineTable 19 is offered as an example for use as a dailyengine log. Record the engine performance regularly.Retain the recorded information for reference.Compare the recorded data in order to provide anindication of engine condition.

Records of engine performance are an importantelement of a maintenance program. Recordinformation about the engine operation on a dailybasis. This will help to reveal the trends of the engineperformance. Records of engine performance willalso provide a baseline for evaluating the mechanicalcondition of the engine.

The data on engine performance can help to predictproblems with operation. This data can provideyour Caterpillar dealer with information that isuseful for recommending maintenance managementinformation. A maintenance program that is properlymanaged will provide your engine with an optimumservice life.


Automatic Start/Stop - Inspect

Table 19

Daily Engine Log

Date

Authorization

Engine Serial Number

Engine Hours

Engine Speed

Percent Load

Ambient Temperature

Inlet Air Restriction

Engine Coolant Temperature

Engine Oil Temperature

Engine Oil Pressure

System Battery Voltage

Exhaust Manifold Temperature

Generator Voltage

Generator Amperage

Comments

i01942284

Automatic Start/Stop - InspectSMCS Code: 4462

The generator set must be ready to operate under aload at any time. After performing maintenance onthe generator set, inspect the position of the controlswitches. Ensure the following conditions:

• The starting system is enabled.

• The control switches are in the correct position forautomatic starting.

• The switchgear and the automatic transfer switchesthat are associated with the generator are enabled.

114 SEBU7898-12Maintenance SectionBattery - Replace

i02153996

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe cable from the NEGATIVE “-” battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE“+” battery terminal to the starting motor.Disconnect the cable from the POSITIVE “+”battery terminal.

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE “-” battery terminal.

i01917570

Battery Charger - CheckSMCS Code: 1401-535

Checking Before Start-UpCheck the battery charger for proper operation. Ifthe batteries are properly charged, the needle of theammeter will register near “0” (zero).

The battery charger must not produce excessivecurrent during start-up. Alternatively, the chargermust be automatically disconnected for start-up.If the engine has an alternator, the charger mustbe automatically disconnected during start-up andduring engine operation.

Charging the Battery

Never disconnect any charging unit circuit or bat-tery circuit cable from the battery when the charg-ing unit is operated. A spark can cause an explo-sion from the flammable vapor mixture of hydro-gen and oxygen that is released from the elec-trolyte through the battery outlets. Injury to per-sonnel can be the result.

Perform the following procedure to charge thebattery:

1. Ensure that the charger is turned OFF.

2. Adjust the voltage of the charger in order to matchthe voltage of the battery.

3. Connect the POSITIVE “+” lead of the chargerto the POSITIVE “+” battery terminal. Connectthe NEGATIVE “-” lead of the charger to theNEGATIVE “-” battery terminal.

4. Turn ON the battery charger.

Overcharging of Batteries

Overcharging reduces the service life of batteries.Use a battery charger that will not overcharge thebattery. DO NOT charge the battery if the meter ofthe battery charger is in the RED zone.

Overcharging is indicated by the following symptoms:

• The battery is very warm to the touch.


Battery Electrolyte Level - Check

• A strong odor of acid is present.

• The battery emits smoke or a dense vapor (gas).

Perform one of the following procedures if the batteryshows symptoms of overcharging:

• Reduce the rate of charging by a significantamount. Complete the charging at the reducedrate.

• Turn OFF the charger.

Table 20 describes the effects of overcharging ondifferent types of batteries.

Table 20

Effects of Overcharging Batteries

Type of Battery Effect

All of the battery cells havea low level of electrolyte.

When the plates of thebattery are inspectedthrough the filler holes, theplates may appear to bewarped. This is caused byan excessive temperature.

Caterpillar General ServiceBatteriesCaterpillar Premium HighOutput Batteries

The battery may not passa load test.

The battery may not accepta charging current.

Caterpillar MaintenanceFree Batteries

The battery may not passa load test.

Checking After StoppingEnsure that the battery charger is connectedproperly. Observe the meter of the charger. Recordthe amperage.

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

116 SEBU7898-12Maintenance SectionBelts - Inspect/Adjust/Replace

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i02673191

Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

InspectionTo maximize the engine performance, inspect thebelts for wear and for cracking. Check the belttension. Adjust the belt tension in order to minimizebelt slippage. Belt slippage will decrease the life ofthe belts.

To check the belt tension, apply 110 N (25 lb) of forcemidway between the pulleys. A correctly adjustedbelt will deflect 13 to 19 mm (0.50 to 0.75 inch).

AdjustmentIf the belts are too loose, the belts will vibrate. Thisvibration is enough to cause unnecessary wear onthe belts and on the pulleys.

If the belts are too tight, unnecessary stresses areplaced upon the pulley bearings and upon the belts.These stresses will shorten the life of the belts and ofthe pulley bearings.

If new belts are installed, check the tension againafter 30 minutes of engine operation at the rated rpm.

ReplacementFor applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

Refer to the Service Manual for more information onthe procedures for the following topics: belt removaland belt installation procedure.

i02139869

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove one of the drain plugs.

Note: If equipped, be sure to drain the heater andany related supply and return lines.

Allow the coolant to drain.


Cooling System Coolant (DEAC) - Change

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Dealer Service ToolGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer tothe Specifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 30 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. If equipped, be sure toflush the heater and any related supply and returnlines. Close the drain valve (if equipped). Cleanthe drain plugs. Install the drain plugs. Refer tothe Specifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.

Cooling Systems with HeavyDeposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water in orderto remove any debris.

Note: If equipped, be sure to flush the heater andany related supply and return lines.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer tothe Specifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.


3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 90 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

118 SEBU7898-12Maintenance SectionCooling System Coolant (ELC) - Change

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve(if equipped). Clean the drain plugs. Install thedrain plugs. Refer to the Specifications Manual,SENR3130, “Torque Specifications” for moreinformation on the proper torques.

Fill


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and Maintenance Manual,“Refill Capacitites and Recommendations” topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system fillercap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the face ofthe cooling system filler cap. If the cooling systemfiller cap does not retain the correct pressure,install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i02694670

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drained andreplaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove the cooling system drain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.


Cooling System Coolant Extender (ELC) - Add

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Dealer Service ToolGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.

Note: If equipped, be sure to flush the heater andany related supply and return lines.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. For theproper torque, refer to the Specifications Manual,SENR3130, “Torque Specifications”.


3. Fill the cooling system with clean water. Install thecooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush thecooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. For the proper torque, refer tothe Specifications Manual, SENR3130, “TorqueSpecifications”.

Fill


1. Fill the cooling system with Extended Life Coolant(ELC). See Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations” for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler cap isnot damaged, use a 9S-8140 Pressurizing Pumpin order to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i02482066

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-045; 1395-081

Cat ELC (Extended Life Coolant) does not requirethe frequent additions of any supplemental coolingadditives which are associated with the presentconventional coolants. The Cat ELC Extender onlyneeds to be added once.

NOTICEUse only Cat Extended Life Coolant (ELC) Extenderwith Cat ELC.

Do NOT use conventional supplemental coolant addi-tive (SCA) with Cat ELC. Mixing Cat ELC with conven-tional coolants and/or conventional SCA reduces theCat ELC service life.

Check the cooling system only when the engine isstopped and cool.

120 SEBU7898-12Maintenance SectionCooling System Coolant Level - Check

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolant fromthe cooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to therequirements for your engine's cooling systemcapacity. Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”article for more information.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

i01197583

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

g00285520Illustration 64Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.

g00103639Illustration 65

Typical filler cap gaskets


Cooling System Coolant Sample (Level 1) - Obtain

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i02837191

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems thatare filled with Cat ELC should have a Coolant Sample(Level 2) that is obtained at the recommended intervalthat is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants:

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 21

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC Every 250Hours(1) Yearly(1)(2)

Cat ELC Optional(2) Yearly(2)

(1) This is the recommended interval for coolant samples for allconventional heavy-duty coolant/antifreeze. This is also therecommended interval for coolant samples of commercialcoolants that meet the Cat EC-1 specification for enginecoolant.

(2) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis,see this Operation and Maintenance Manual, “RefillCapacities and Recommendations” or consult yourCaterpillar dealer.

i01987714

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542


Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

122 SEBU7898-12Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

Submit the sample for Level 2 analysis.

For additional information about coolantanalysis, see Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” or consult your Caterpillar dealer.

i02839449

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

NOTICEExcessive supplemental coolant additive concentra-tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine'sheat transfer characteristics. Reduced heat transfercould cause cracking of the cylinder head and otherhigh temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the waterpump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” and to Special Publica-tion, GECJ0003, “Cat Shop Supplies and Tools” fortools and supplies suitable to collect and contain flu-ids on Caterpillar products.

Dispose of all fluids according to applicable regula-tions and mandates.

Note: Caterpillar recommends an S·O·S coolantanalysis (Level 1).

Cooling Systems that UseConventional CoolantThis maintenance procedure is required forconventional coolants such as DEAC.Thismaintenance is NOT required for cooling systemsthat are filled with Extended Life Coolant.

Test the Concentration of the SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit.

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

3. Add the proper amount of SCA. For theproper amount of SCA, refer to this Operationand Maintenance Manual, “Refill Capacitiesand Recommendations” topic. The properconcentration of SCA depends on the type ofcoolant that is used. For the proper concentrationof SCA, refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations”.

4. Clean the cooling system filler cap. Install thecooling system filler cap.


Cooling System Water Temperature Regulator - Replace

Cooling Systems that Use Waterand SCA

Test the Concentration of the SCA

Test the concentration of the SCA with a 298-5311Coolant Nitrite Test Kit for SCA or perform an S·O·SCoolant Analysis. The test kit includes the followingitems: a tool for the testing, 30 ampoules for testingnitrite, instructions, and a case. 294-7420 TestKit contains the refill ampoules for the 298-5311Coolant Nitrite Test Kit. Use the instructions that areincluded with the test kit in order to properly conductthe testing.

Refer to this Operation and Maintenance Manual,“Maintenance Interval Schedule” for the times atwhich the procedures should be conducted. Test theconcentration of the SCA more frequently if morefrequent testing is indicated by the results of theS·O·S Coolant Analysis.

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

3. Add the proper amount of SCA. For the properamount of SCA, refer to this Operation andMaintenance Manual, “Refill Capacities andRecommendations” topic. For the properconcentration of SCA, refer to Special Publication,SEBU6251, “Caterpillar Commercial DieselEngine Fluids Recommendations”.

4. Clean the cooling system filler cap. Install thecooling system filler cap.

i03645060

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime. Refer to thisOperation and Maintenance Manual, “MaintenanceInterval Schedule” for the proper maintenanceinterval.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in the closedposition can cause excessive overheating. Excessiveoverheating could result in cracking of the cylinderhead or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup inside thecylinders. This excessive carbon buildup could resultin an accelerated wear of the piston rings and wearof the cylinder liner.

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the enginemay overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to two articles in the Disassembly andAssembly Manual, “Water Temperature Regulators- Remove and Water Temperature Regulators -Install” for the replacement procedure of the watertemperature regulator, or consult your Caterpillardealer.

124 SEBU7898-12Maintenance SectionCrankshaft Vibration Damper - Inspect

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling system toa level that is below the water temperature regulatorhousing.

i00894991

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the crankshaft vibration damper or failureof the crankshaft vibration damper can increasetorsional vibrations. This can result in damage tothe crankshaft and to other engine components. Adeteriorating damper can cause excessive gear trainnoise at variable points in the speed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

Rubber DamperYour engine may be equipped with a rubber damper.The rubber damper uses a ring which is mounted inrubber in order to reduce vibrations in the crankshaft.

Inspect the damper and repair or replace the damperfor any of the following reasons:

• There is deterioration and cracking of the rubber.

• There is slippage of the outer ring from the originalposition.

• The engine has had a failure because of a brokencrankshaft.

• Analysis of the oil has revealed that the front mainbearing is badly worn.

• There is a large amount of gear train wear that isnot caused by lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

Visconic DamperYour engine may be equipped with a visconicdamper. The visconic damper has a weight that islocated inside a fluid filled case. The weight moves inthe case in order to limit torsional vibration.

Inspect the damper for evidence of fluid leaks. Ifa fluid leak is found, determine the type of fluid.The fluid in the damper is silicone. Silicone hasthe following characteristics: transparent, viscous,smooth, and difficult to remove from surfaces.

If the fluid leak is oil, inspect the crankshaft seals forleaks. If a leak is observed, replace the crankshaftseals.

Inspect the damper and repair or replace the damperfor any of the following reasons:

• The damper is dented, cracked, or leaking.

• The paint on the damper is discolored from heat.

• The engine has had a failure because of a brokencrankshaft.

• Analysis of the oil has revealed that the front mainbearing is badly worn.

• There is a large amount of gear train wear that isnot caused by a lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

i01259098

Cylinder Head Grounding Stud- Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079


Cylinder head grounding stud (side view)

Inspect the harness for good connections. Inspectthe condition of the harness.


Electrical Connections - Check

The cylinder head grounding stud must have a wireground to the battery. Tighten the cylinder headgrounding stud at every oil change. Ground wiresand straps should be combined at engine grounds.All grounds should be tight and free of corrosion.

• Clean the cylinder head grounding stud and theterminals for the cylinder head ground strap witha clean cloth.

• If the connections are corroded, clean theconnections with a solution of baking soda andwater.

• Keep the cylinder head grounding stud and thestrap clean and coated with MPGM grease orpetroleum jelly.

i01228274

Electrical Connections - CheckSMCS Code: 4459-535

Check all exposed electrical connections fortightness.

Check the following devices for loose mounting orfor physical damage:

• transformers

• fuses

• capacitors

• lightning arrestors

Check all lead wires and electrical connections forproper clearance.

i01866598

Engine - CleanSMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture could create paths of electrical conduc-tivity.

Make sure the unit is off line (disconnected fromutility and/or other generators), locked out andtagged "Do Not Operate".

NOTICEWater or condensation can cause damage to gen-erator components. Protect all electrical componentsfrom exposure to water.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Do not steam clean the generator. Water maydamage the generator.

Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

i01553486

Engine Air Cleaner Element(Dual Element) - Clean/ReplaceSMCS Code: 1054-037; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner ElementsIf the air cleaner element becomes plugged, the aircan split the material of the air cleaner element.Unfiltered air will drastically accelerate internal enginewear. Your Caterpillar dealer has the proper aircleaner elements for your application. Consult yourCaterpillar dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

126 SEBU7898-12Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element fordamage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primaryair cleaner element and a secondary air cleanerelement. The primary air cleaner element can beused up to six times if the element is properly cleanedand inspected. The primary air cleaner elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require morefrequent replacement.

g00736431Illustration 67(1) Cover(2) Primary air cleaner element(3) Secondary air cleaner element(4) Turbocharger air inlet

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air CleanerElements”.

3. Cover the turbocharger air inlet with tape in orderto keep dirt out.

4. Clean the inside of the air cleaner cover and bodywith a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Install aprimary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

Cleaning the Primary Air CleanerElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices that are available at Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacement shouldbe performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.


Engine Air Cleaner Element (Dual Element) - Clean/Replace

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elements fordamage to the seal, the gaskets, and the outer cover.Discard any damaged air cleaner elements.

There are two common methods that are used toclean primary air cleaner elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air with amaximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended priorto vacuum cleaning. Vacuum cleaning will not removedeposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.Use a 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air cleanerelement. Rotate the primary air cleaner element.Inspect the primary air cleaner element for tearsand/or holes. Inspect the primary air cleaner elementfor light that may show through the filter material. If itis necessary in order to confirm the result, comparethe primary air cleaner element to a new primary aircleaner element that has the same part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse a primary air cleaner element with damagedpleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspectionwill not be used, the primary air cleaner element canbe stored for future use.

128 SEBU7898-12Maintenance SectionEngine Air Cleaner Service Indicator - Inspect


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage, wrapthe primary air cleaner elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe box and mark the primary air cleaner element.Include the following information:

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i01900118

Engine Air Cleaner ServiceIndicator - Inspect(If Equipped)SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the aircleaner housing or in a remote location.

g00103777Illustration 71Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).


Engine Crankcase Breather - Clean

i02263740

Engine Crankcase Breather -CleanSMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.

g01136454Illustration 72Typical example

(1) Hose clamp(2) Breather assembly(3) Retaining clamp(4) Seal

1. Loosen hose clamp (1) and remove the hose frombreather assembly (2).

2. Loosen retaining clamp (3). Remove the breatherassembly and seal (4).

3. Wash the breather element in solvent that is cleanand nonflammable. Allow the breather element todry before installation.

4. Install a breather element that is clean and dry.Install the seal, the breather assembly, and theclamp. Refer to the Specifications, SENR3130 inorder to locate the proper torques.

5. Install the hose. Install the hose clamp. Refer tothe Specifications, SENR3130 in order to locatethe proper torques.

i02139969

Engine Mounts - InspectSMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the Specifications Manual,SENR3130, “Torque Specifications”. Refer to yourCaterpillar dealer for more information.

i00623423

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g00110310Illustration 73(Y) “ADD” mark. (X) “FULL” mark.

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between “ADD” mark (Y) and“FULL” mark (X) on oil level gauge (1). Do not fillthe crankcase above “FULL” mark (X).

NOTICEOperating your engine when the oil level is above the“FULL” mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil's lubricating char-acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

130 SEBU7898-12Maintenance SectionEngine Oil Sample - Obtain

i03542996

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis


Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEgj0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Caterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02107152

Engine Oil and Filter - ChangeSMCS Code: 1318-510; 1348-044


Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles settle on the bottomof the oil pan. The waste particles are not removedwith the draining cold oil. Drain the crankcase withthe engine stopped. Drain the crankcase with theoil warm. This draining method allows the wasteparticles that are suspended in the oil to be drainedproperly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Use one of thefollowing methods to drain the engine crankcase oil:

• If the engine is equipped with a drain valve, turn thedrain valve knob counterclockwise in order to drainthe oil. After the oil has drained, turn the drain valveknob clockwise in order to close the drain valve.


Engine Oil and Filter - Change

• If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oilto drain. If the engine is equipped with a shallowsump, remove the bottom oil drain plugs from bothends of the oil pan.

After the oil has drained, the oil drain plugs shouldbe cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter Gp. Break apart the pleats and inspect theoil filter for metal debris. An excessive amountof metal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.

g00103713Illustration 74Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasket isremoved.

4. Apply clean engine oil to the new oil filter gasket.

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that areshown on the oil filter. Do not overtighten the oilfilter.

Fill the Engine Crankcase1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual, “Refill Capacities andRecommendations” for more information.

NOTICEIf equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturer's recommendations. Under filling or overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

132 SEBU7898-12Maintenance SectionEngine Performance - Test

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the oil level gauge.

i01042067

Engine Performance - TestSMCS Code: 1000-081

Operate the engine for a minimum of two hours at aminimum load of 60 percent.

• Monitor the operation of the generator set.

• Observe the gauges. Ensure that the gauges arein the normal ranges.

• Record the data. Maintain a record of the data forthe engine performance.

i00626013

Engine Protective Devices -CheckSMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual InspectionVisually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

i01161856

Engine Speed/Timing Sensors- Check/Clean/CalibrateSMCS Code: 1912-040; 1912-070; 1912-524

g00618934Illustration 75Left side view

(1) Primary speed/timing sensor(2) Secondary speed/timing sensor

1. Remove the speed/timing sensors from the fronthousing. Check the condition of the plastic endof the speed/timing sensors for wear and/orcontaminants.

2. Clean the metal shavings and other debris fromthe face of the speed/timing sensors. Use theprocedure in the Service Manual in order tocalibrate the speed/timing sensors.

Refer to the Service Manual for more information onthe speed/timing sensors.

i00869413

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change. Theinitial adjustment is necessary due to initial wear ofthe valve train components and seating of the valvetrain components.


Engine Valve Rotators - Inspect

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

Adjustment of the Electronic UnitInjectorAdjust the electronic unit injector (preload) at thesame interval as the valve lash adjustment. Theoperation of Caterpillar engines with improper valveadjustments and with improper adjustments of theelectronic unit injector can reduce engine efficiency.This reduced efficiency could result in excessive fuelusage and/or shortened engine component life.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

i01597115

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to help prevent being burned byhot oil or spray.

Engine valve rotators rotate the valves when theengine runs. This helps to prevent deposits frombuilding up on the valves and the valve seats.

Perform the following steps after the engine valvelash is set, but before the valve covers are installed:

1. Start the engine according to Operation andMaintenance Manual, “Engine Starting” (OperationSection) for the procedure.

2. Operate the engine at low idle.

3. Observe the top surface of each valve rotator. Thevalve rotators should turn slightly when the valvesclose.

NOTICEA valve rotator which does not operate properly willaccelerate valve face wear and valve seat wear andshorten valve life. If a damaged rotator is not replaced,valve face guttering could result and cause pieces ofthe valve to fall into the cylinder. This can cause pistonand cylinder head damage.

If a valve fails to rotate, consult your Caterpillardealer.

i00805059

Ether Starting Aid Cylinder -Replace(If Equipped)SMCS Code: 1456-510-CD


Typical example

1. Loosen the ether cylinder clamp. Unscrew andremove the empty ether cylinder.

2. Remove the used gasket. Install the new gasketthat is provided with each new ether cylinder.

3. Install the new ether cylinder. Hand tighten theether cylinder. Tighten the ether cylinder clampsecurely.

134 SEBU7898-12Maintenance SectionFan Drive Bearing - Lubricate

i02784507

Fan Drive Bearing - LubricateSMCS Code: 1359-086-BD

Some of the fan drives have grease fittings and someof the fan drives do not have grease fittings. If there isno grease fitting, periodic lubrication is not required.The fan drive requires grease only if the fan driveis equipped with a zerk.

g00746166Illustration 77Typical location of the grease fitting (if equipped) that is for the fandrive bearing

The pulley is shown with the belt guards that have been removed.

Lubricate the grease fitting that is on the fan drivebearing with High Speed Ball Bearing Grease or theequivalent.

Inspect the fan drive pulley assembly for wear or fordamage. If the shaft is loose, an inspection of theinternal components should be performed. Refer tothe Systems Operation Testing and Adjusting Manualfor additional information.

i00838960

Fuel System - PrimeSMCS Code: 1258-548

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

Priming the fuel system fills the fuel filters. Primingthe fuel system also removes air from the fuelsystem. This procedure is used primarily when theengine runs out of fuel.

Note: DO NOT remove the fitting in the fuel filterbase in order to release air from the fuel systemduring periodic service of the fuel filter. Periodicremoval of the fitting will result in increased wear ofthe threads in the fuel filter base. This can lead to fuelleakage. However, the fitting in the fuel filter basecan be used to purge air from the fuel system if theengine runs out of fuel.

1. Loosen the fuel filter air purge plug two full turns.Unlock and operate the priming pump until fuelappears at the fitting. This procedure will requireconsiderable strokes. Use a cloth or a containerto catch the excess fuel.

2. Tighten the fuel filter air purge plug. Open fuelpriming pump and operate the fuel priming pumpuntil a strong pressure is felt on the fuel primingpump. Push the priming pump plunger inward.Tighten the plunger by hand, and promptlycontinue with the next step.

3. Crank the engine after pressurizing the system.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

4. If the engine will not start, allow the starting motorto cool for 2 minutes. Repeat Steps 2 and 3 inorder to start the engine. Further priming may benecessary to help purge the fuel lines of air, if:

• The engine starts, but runs rough.

• The engine started, but continues to misfire orsmoke.

5. Run the engine at low idle until the engine runssmoothly.

i02049797

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.Water in the fuel may cause an electronic unit injectorto fail. If the fuel has been contaminated with water,the element should be changed before the regularlyscheduled interval.


Fuel System Primary Filter (Water Separator) Element - Replace

The primary filter/water separator also providesfiltration in order to help extend the life of thesecondary fuel filter. The element should be changedregularly. Install a vacuum gauge. Change theelement for the primary filter/water separator if thepressure is at 50 to 70 kPa (15 to 20 inches Hg).

Replace the Element

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

g00668636Illustration 78(1) Bowl(2) Element(3) Drain

1. Stop the engine.

2. Turn the start switch to the “OFF” position.

3. Shut off the fuel tank supply valve to the engine.

4. If the primary fuel filter is equipped with a drainvalve (3), open the drain valve in order to drain anyfuel from the filter case. Close the drain valve (3).

NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

5. Remove the fuel filter bowl (1) and wash the fuelfilter bowl with clean diesel fuel.

6. Remove the fuel filter (2).

7. Clean the gasket sealing surface of the fuel filterbase. Ensure that all of the old gasket is removed.

8. Apply clean diesel fuel to the new fuel filter gasket.

NOTICEIn order to maximize fuel system life and prevent pre-mature wear out from abrasive particles in the fuel,use Caterpillar fuel filters.

Consult your Caterpillar dealer for proper part num-bers.

9. Install the new fuel filter (2). Spin the fuel filteronto the fuel filter base until the gasket contactsthe base. Use the rotation index marks on t

C18 GENERATOR SET - pgsitecld.persiangig.com/dl/sTAlx/GSc3HpPIcm/C18_Generator_Set... · 2014. 5. 2. · SEBU7898-12 111 Maintenance Section Aftercooler Core - Clean/Test i01546702

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