Manual de Servicio Generador Engine 3456

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7829-03March 2006

Operation andMaintenanceManual3456 Generator SetsC1G1-Up (Generator Set)C3G1-Up (Generator Set)C4G1-Up (Generator Set)C2T1-Up (Generator Set)

112 SEBU7829-03Maintenance SectionMaintenance Interval Schedule

i02516954

Maintenance Interval Schedule(Prime Power Generator Sets)SMCS Code: 1000; 7500

Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICHEVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When Required

Battery - Replace ................................................. 118Battery or Battery Cable - Disconnect ................ 120Engine - Clean .................................................... 128Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................. 128Ether Starting Aid Cylinder - Replace ................. 136Fuel System - Prime ........................................... 137Generator - Dry ................................................... 141Generator Set - Test ........................................... 144Rotating Rectifier - Test ...................................... 153Severe Service Application - Check ................... 154

Daily

Annunciator Panel - Inspect ................................. 116Cooling System Coolant Level - Check .............. 124Engine Air Cleaner Service Indicator - Inspect ... 131Engine Oil Level - Check .................................... 132Fuel System Primary Filter/Water Separator -Drain ................................................................. 138Generator Load - Check ..................................... 143Power Factor - Check ......................................... 152Walk-Around Inspection ...................................... 157

Every Week

Bearing Temperature - Measure/Record ............ 120Electrical Connections - Check ........................... 127Generator - Inspect ............................................. 142Generator Lead - Check ..................................... 143

Instrument Panel - Inspect .................................. 146

Every 2000 Service Hours or 6 Months

Generator Set Vibration - Inspect ....................... 144Insulation - Test ................................................... 146

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

Engine Valve Lash - Inspect/Adjust .................... 135

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

Aftercooler Core - Clean/Test .............................. 115Alternator and Fan Belts - Inspect/Adjust/Replace .............................................................. 115Battery Electrolyte Level - Check ......................... 119Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 125Cylinder Head Grounding Stud - Inspect/Clean/Tighten .............................................................. 127Engine Crankcase Breather - Clean ................... 131Engine Oil Sample - Obtain ................................ 132Engine Oil and Filter - Change ........................... 133Engine Protective Devices - Check .................... 135Fan Drive Bearing - Lubricate ............................. 137Fuel System Secondary Filter - Replace ............ 139Fuel Tank Water and Sediment - Drain ............... 140Hoses and Clamps - Inspect/Replace ................ 145Magnetic Pickups - Clean/Inspect ...................... 149Radiator - Clean .................................................. 152Rotating Rectifier - Check ................................... 153

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

Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 138

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

Alternator - Inspect .............................................. 115Crankshaft Vibration Damper - Inspect ............... 126

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

Alternator - Inspect .............................................. 115Cooling System Coolant (DEAC) - Change ........ 120Cooling System Coolant Extender (ELC) - Add .. 123Cooling System Water Temperature Regulator -Replace ............................................................. 126Engine Mounts - Inspect ..................................... 132Engine Speed/Timing Sensors - Check/Clean/Calibrate ............................................................ 135Engine Valve Lash - Inspect/Adjust .................... 135Engine Valve Rotators - Inspect ......................... 136Starting Motor - Inspect ...................................... 156Turbocharger - Inspect ........................................ 156

SEBU7829-03 113Maintenance Section

Maintenance Interval Schedule

Water Pump - Inspect ......................................... 158

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

Cooling System Coolant (ELC) - Change ........... 122

Overhaul

Overhaul Considerations .................................... 149

114 SEBU7829-03Maintenance SectionMaintenance Interval Schedule

i02516958

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

Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICHEVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When Required

Battery or Battery Cable - Disconnect ................ 120Ether Starting Aid Cylinder - Replace ................. 136Fuel System - Prime ........................................... 137Fuel System Primary Filter/Water Separator -Drain ................................................................. 138Generator Load - Check ..................................... 143Generator Set - Test ........................................... 144Rotating Rectifier - Test ...................................... 153

Every Week

Automatic Start/Stop - Inspect ............................. 117Battery Charger - Check ...................................... 118Battery Electrolyte Level - Check ......................... 119Bearing Temperature - Measure/Record ............ 120Cooling System Coolant Level - Check .............. 124Electrical Connections - Check ........................... 127Engine Air Cleaner Service Indicator - Inspect ... 131Engine Oil Level - Check .................................... 132Fuel Tank Water and Sediment - Drain ............... 140Generator - Inspect ............................................. 142Generator Lead - Check ..................................... 143Jacket Water Heater - Check .............................. 149Power Factor - Check ......................................... 152Standby Generator Set MaintenanceRecommendations ............................................ 155

Every Year

Alternator - Inspect .............................................. 115

Alternator and Fan Belts - Inspect/Adjust/Replace .............................................................. 115Cooling System Supplemental Coolant Additive(SCA) - Test/Add ............................................... 125Crankshaft Vibration Damper - Inspect ............... 126Engine - Clean .................................................... 128Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................. 128Engine Crankcase Breather - Clean ................... 131Engine Mounts - Inspect ..................................... 132Engine Oil Sample - Obtain ................................ 132Engine Oil and Filter - Change ........................... 133Engine Performance - Test ................................. 134Engine Protective Devices - Check .................... 135Engine Valve Lash - Inspect/Adjust .................... 135Engine Valve Rotators - Inspect ......................... 136Fan Drive Bearing - Lubricate ............................. 137Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 138Fuel System Secondary Filter - Replace ............ 139Generator - Dry ................................................... 141Generator Set Vibration - Inspect ....................... 144Hoses and Clamps - Inspect/Replace ................ 145Insulation - Test ................................................... 146Radiator - Clean .................................................. 152Starting Motor - Inspect ...................................... 156Water Pump - Inspect ......................................... 158

Every 3 Years

Cooling System Coolant (DEAC) - Change ........ 120Cooling System Coolant Extender (ELC) - Add .. 123Cooling System Water Temperature Regulator -Replace ............................................................. 126Cylinder Head Grounding Stud - Inspect/Clean/Tighten .............................................................. 127Engine Speed/Timing Sensors - Check/Clean/Calibrate ............................................................ 135Hoses and Clamps - Replace ............................. 146Rotating Rectifier - Check ................................... 153Turbocharger - Inspect ........................................ 156

Every 6 Years

Cooling System Coolant (ELC) - Change ........... 122


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 orderto remove 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 15 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 15

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 cleaner attemperatures 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.

i00072207

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. Refer to the Service Manual.

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.

i00841051

Alternator and Fan Belts -Inspect/Adjust/ReplaceSMCS Code: 1357-039

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).

116 SEBU7829-03Maintenance SectionAnnunciator Panel - Inspect

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.

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

• 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 16 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 16

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.

118 SEBU7829-03Maintenance 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 17 describes the effects of overcharging ondifferent types of batteries.

Table 17

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.

i02340858

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. If batteriesare properly charged, ammeter reading should bevery near zero, when the engine is in operation.

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.

120 SEBU7829-03Maintenance SectionBattery or Battery Cable - Disconnect

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.

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.

i01952106

Bearing Temperature -Measure/RecordSMCS Code: 4471-082-TA

Bearing temperature detectors are optional ongenerators. Bearing temperature detectors areused with equipment that has been provided bythe customer in order to measure the bearingtemperature. Bearing temperature detectors mayhelp to prevent premature bearing failure.

A bearing temperature that is 50 °C (122 °F) abovethe ambient temperature may require a change inoperation. The unit should be shut down in order toprevent damage if the bearing temperature is 50 °C(122 °F) above the ambient temperature.

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 to theSpecifications 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 (ifequipped) 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 to theSpecifications 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.

122 SEBU7829-03Maintenance 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 (ifequipped) 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.

i02173402

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 (ifequipped) 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. For the proper torque, refer to theSpecifications Manual, SENR3130, “TorqueSpecifications”.

Fill


1. Fill the cooling system with Extended Life Coolant(ELC). See Special Publication, SEBU6385,“Caterpillar On-highway Diesel Truck EngineFluids Recommendations” 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.

124 SEBU7829-03Maintenance 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 79Cooling 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 80

Typical filler cap gaskets


Cooling System Supplemental Coolant Additive (SCA) - Test/Add

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.

i02456600

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 the eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an S·O·S Coolant Analysis.

Test for SCA Concentration

Coolant and SCA

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

Use the 8T-5296 Coolant Conditioner Test Kitor use the 4C-9301 Coolant Conditioner Test Kitin order to check the concentration of the SCA.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” for moreinformation.

Water and SCA

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

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the SpecialPublication, SEBU6251, “Caterpillar CommercialDiesel Engine Fluids Recommendations” for moreinformation.

S·O·S Coolant AnalysisS·O·S coolant samples can be analyzed at yourCaterpillar dealer. S·O·S Coolant Analysis is aprogram that is based on periodic samples.

Level 1

Level 1 is a basic analysis of the coolant. Thefollowing items are tested:

• Glycol Concentration

• Concentration of SCA

• pH

• Conductivity

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an S·O·S CoolantAnalysis.

Level 2

This level coolant analysis is recommended when theengine is overhauled. Refer to this Operations andMaintenance Manual, “Overhaul Considerations” forfurther information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engine’s heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.

126 SEBU7829-03Maintenance SectionCooling System Water Temperature Regulator - Replace


1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Referto the Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” for more information on SCArequirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

i00912898

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.

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 the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

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.


Cylinder Head Grounding Stud - Inspect/Clean/Tighten

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.

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

128 SEBU7829-03Maintenance SectionEngine - Clean

• 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.

• 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.


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

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.


(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.

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

130 SEBU7829-03Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

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.



Engine 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.


Typical 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).

i01564253

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.

132 SEBU7829-03Maintenance SectionEngine Mounts - Inspect

g00812591Illustration 87Typical example(1) Hose clamp(2) Cover clamp(3) Crankcase breather cover

1. Loosen hose clamp (1) and remove the hose fromcrankcase breather (2).

2. Remove the crankcase breather (2).

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 crankcase breather (2). Refer to theOperation and Maintenance Manual for the propertorque.

5. Install the hose. Install hose clamp (1). Refer tothe Operation and Maintenance Manual for theproper 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.


(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.

i01935337

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.


Engine Oil and Filter - Change

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.

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.

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, PEHP6001,“How To Take A Good Oil Sample”. Consult yourCaterpillar 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.

• 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.

134 SEBU7829-03Maintenance SectionEngine Performance - Test

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 89Typical 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.

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.


Engine Protective Devices - Check

• 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


Left 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.

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

136 SEBU7829-03Maintenance SectionEngine Valve Rotators - Inspect

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.The valve rotators should turn slightly when thevalves close.

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.


Fan Drive Bearing - Lubricate

i02239650

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 92Typical 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 Bearing Lubricant or the equivalent.

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 Service Manual for 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 container tocatch 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.

138 SEBU7829-03Maintenance SectionFuel System Primary Filter/Water Separator - Drain

i01254694

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543


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

Bowl (1) should be monitored daily for signs of water.If water is present, drain the water from the bowl.

1. Open drain (3). The drain is a self-ventilated drain.Catch the draining water in a suitable container.Dispose of the water properly.

2. Close drain (3).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

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.

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


g00668636Illustration 94(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.


Fuel System Secondary Filter - Replace

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 thefilters as a guide for proper tightening. Tighten thefilter for an additional 3/4 turn by hand. Do notovertighten the filter.

NOTICEDo not fill the fuel filters with fuel before installing them.The fuel would not be filtered and could be contami-nated. Contaminated fuel will cause accelerated wearto fuel system parts.

10. Install the clean fuel filter bowl (1) on the new fuelfilter.

NOTICEThe water separator is under suction during normalengine operation. Ensure that the vent plug is tight-ened securely to help prevent air from entering the fu-el system.

11.Open the fuel tank supply valve.

12.Start the engine and check for leaks. Run theengine for one minute. Stop the engine and checkthe engine for leaks again.

Detection of leaks is very difficult especially ifthe engine is running. The primary filter/waterseparator is under suction. A leak will allow air toenter the fuel. The air in the fuel can cause lowpower due to aeration of the fuel. If air enters thefuel, check the components for overtightening orundertightening.

i01250684

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE



(1) Fuel priming pump(2) Fuel filter(3) Fuel block(4) Fuel filter air purge plug

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.

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

1. It may be necessary to relieve residual fuelpressure from the fuel system before removingthe fuel filter.

Loosen the fuel filter air purge plug (4) in order topurge any residual pressure.

NOTICEDo not loosen fuel lines or fittings at the fuel manifoldor ECM. The engine components may be damaged.

2. Remove the used fuel filter.

140 SEBU7829-03Maintenance SectionFuel Tank Water and Sediment - Drain

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

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

NOTICEIn order to maximize fuel system life and preventpremature wear out from abrasive particles in thefuel, a two micron absolute high efficiency fuel filteris required for all Caterpillar Electronic Unit Injectors.Caterpillar High Efficiency Fuel Filters meet theserequirements. Consult your Caterpillar dealer for theproper part numbers.

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

5. Install the new fuel filter. Spin the fuel filter ontothe fuel filter base until the gasket contacts thebase. Use the rotation index marks on the filtersas a guide for proper tightening. Tighten thefilter for an additional 3/4 turn by hand. Do notovertighten the filter.

6. Open the fuel tank supply valve and prime the fuelsystem.

i02436696

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S

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.

Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A 2 micron filter for the breather vent on thefuel tank is also recommended. Refer to SpecialPublication, SENR9620, “Improving Fuel SystemDurablity”.


Generator - Dry

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i01936148

Generator - DrySMCS Code: 4450-569

Personal injury or death can result from impropertroubleshooting and repair procedures.

The following troubleshooting and repair proce-dures should only be performed by qualified per-sonnel familiar with this equipment.

Note: The use of space heaters and occasionalcranking of the engine will help to avoid dryingthe generator. Space heaters should be usedcontinuously while the machine is stopped in orderfor the space heaters to be effective.

Refer to Safety Section, “Generator Isolating forMaintenance” for information regarding the procedureto safely isolate the generator.

If the insulation resistance values are less than 1megohm for the stator or the insulation resistancevalues are less than 100,000 ohms for the otherwindings, one of the following drying proceduresmust be selected. This decision should be based onthe following factors:

• the size of the unit

• the location of the unit

• the equipment that is available

• the experience of personnel

Measure insulation resistance at one hour intervals.Typically, the insulation resistance will slowly dropwhile the temperature is rising. The insulationresistance will then start to increase at a slow rateuntil the insulation resistance reaches a constantlevel.

The following methods can be used for drying agenerator:

• Self-circulating air method

• Oven method

• Controlled current method

Self-Circulating Air MethodBlow hot air into the air intake for the generator.Disconnect the exciter field and run the engine. Thiswill help circulate air. Operate the generator spaceheaters.

Oven MethodDisconnect the AVR. Place the entire generatorinside a forced air drying oven for 24 hours at 110 °C(230 °F).

NOTICEUse a forced air type oven rather than a radiant typeoven.

Radiant type ovens can cause localized overheating.

Controlled Current MethodTable 18

Tools Needed

PartNumber

Description Qty

8T-0900 Clamp on ammeter (0 -1200 amperes)

1

External 24 Volt DC PowerSource

1

Rheostat 1

Heat can be used in order to dry the generatorwindings. This heat can be created by allowing acontrolled current to flow through the generator. Nohigh voltages are generated during the followingprocedure. Therefore, insulation breakdown will notoccur.

1. Disconnect the AVR.

2. Short circuit the three output power terminals withconnectors that are capable of supporting therated current. Try not to exceed 6 Amp per squaremillimeter.

3. Use a clamp-on ammeter in order to monitor thecurrent through the short circuit connections.

4. Connect a 24 volt DC power source in series witha rheostat of 100 ohms or 50 Watts to the fieldterminals of the exciter. Make the connectionswith the correct polarity.

142 SEBU7829-03Maintenance SectionGenerator - Inspect

5. Open all the openings on the generator in order toallow air flow.

6. Operate the generator at the rated speed. Adjustthe current in the exciter field with the rheostat.Obtain the rated output current in the short circuitconnections.

i01461264

Generator - InspectSMCS Code: 4450-040

Personal injury or death can result from impropertroubleshooting and repair procedures.

The following troubleshooting and repair proce-dures should only be performed by qualified per-sonnel familiar with this equipment.

Refer to Safety Section, “Generator Isolating forMaintenance” for information regarding the procedureto safely isolate the generator.

Proper maintenance of electrical equipment requiresperiodic visual examination of the generator andperiodic visual examination of the windings. Propermaintenance of electrical equipment also requiresappropriate electrical checks and appropriate thermalchecks. Insulation material should be examined forcracks. The insulation material should be examinedfor accumulations of dirt and dust. If there is aninsulation resistance value that is below normal, aconductive path may be present. This conductivepath may be made of one of the following materials:

• Carbon

• Salt

• Metal dust

• Dirt that is saturated with moisture

These contaminants will develop a conductive pathwhich may produce shorts. Cleaning is advisable ifheavy accumulations of dirt can be seen or if heavyaccumulations of dust can be seen. If excess dirt isthe cause of a restriction in the ventilation, cleaningis also advisable. Restricted ventilation will causeexcessive heating.

NOTICETo avoid the possibility of deterioration to the genera-tor windings, do not clean the generator unless thereis visual, electrical, or thermal evidence that dirt ispresent.

If harmful dirt accumulations are present, a varietyof cleaning techniques are available. The cleaningprocedure that is used may be determined by one ofthe items on the following list:

• The extent of the cleaning procedure that is beingattempted

• The type of enclosure of the generator

• The voltage rating of the generator

• The type of dirt that is being removed

Cleaning (Assembled Generators)Cleaning may be required at the point of installation.At this point, complete disassembly of the generatormay not be necessary or feasible. In this case,a vacuum cleaner should be used to pick up thefollowing items: dry dirt, dust, and carbon. This willprevent the spreading of these contaminants.

A small nonconductive tube may need to beconnected to the vacuum cleaner. This will allow thevacuum cleaner to clean the surfaces that are notexposed. After most of the dust has been removed,a small brush may be attached to the vacuum hosein order to loosen dirt that is more firmly attached tothe surface.

After the initial cleaning with a vacuum, compressedair may be used to remove the remaining dust anddirt. Compressed air that is used for cleaning shouldbe free of moisture and free of oil. Air pressureshould be a maximum of 210 kPa (30 psi) in order toprevent mechanical damage to the insulation. If theabove cleaning procedures are not effective, consulta Caterpillar dealer.

Cleaning (DisassembledGenerators)An initial insulation resistance check should bemade on the generator in order to confirm electricalintegrity. A minimum reading of one megohm wouldbe expected with severely contaminated generators.A zero megohm reading may indicate an insulationbreakdown. An insulation breakdown requires morethan cleaning. An insulation breakdown requiresrepair.


Generator Lead - Check

A high pressure wash is normally an effective wayto clean windings. This includes windings that havebeen exposed to flooding or windings that have beencontaminated by salt. A solution of hot water anddetergent is used for this method of cleaning.

A high pressure wash sprays a high velocity fluidstream of this solution over the generator that isbeing cleaned. This detergent washing is followed bymultiple sprays of clean water. The clean water isused in order to remove the detergent or the cleanwater is used in order to dilute the detergent.

Allow the generator to dry at room temperature.Check the insulation resistance. The insulationresistance should now be normal. If the insulationresistance is not normal, repeat the procedure. Itmay be necessary to use solvents if the generatoris contaminated with oil or if the generator iscontaminated with grease.

Note: For more information on drying methods, referto Special Instructions, SEHS9124, “Cleaning andDrying of Electric Set Generators”.

i02517207

Generator Lead - CheckSMCS Code: 4450-535

The generator set may have braided cables betweenthe generator and the breaker instead of wire cables.Check for signs of wear along the braided cables.Pay particular attention to the cables at the housingfor the breaker and the generator terminal box.

If the rubber mats or the insulation on the braidedcables show signs of wear at points of contactwith other surfaces, replace the mats or the cableimmediately. If your generator set does not haverubber mats in place, contact your Caterpillar dealer.

i01228480

Generator Load - CheckSMCS Code: 4450-535-LA

During normal operation, monitor the power factorand monitor generator loading.

When a generator is installed or when a generatoris reconnected, ensure that the total current in anyone phase does not exceed the nameplate rating.Each phase should carry the same load. This allowsthe generator to work at the rated capacity. If onephase current exceeds the nameplate amperage,an electrical imbalance will occur. An electricalimbalance can result in an electrical overload and anelectrical imbalance can result in overheating .

The power factor can be referred to as the efficiencyof the load. This can be expressed as the ratio of kVAto actual kW. The power factor can be calculated bydividing kW by kVA. Power factor is expressed as adecimal. Power factor is used to mean the portionof current that is supplied to a system that is doinguseful work. The portion of the current that is notdoing useful work is absorbed in maintaining themagnetic field in motors. This current (reactive load)can be maintained without engine power.

Electric sets normally have a low idle setting thatis higher than industrial engines. Low idle will beapproximately 66% of the full speed that is achievedby 60 Hz units. This would be equal to 80% of the fullspeed that is achieved by 50 Hz units.

Some electric sets are equipped with Woodwardgovernors and some electric sets are equippedwith Caterpillar electronic governors. These electricsets have no low idle stop. On electric sets withmechanical governors and natural gas electric sets,the low idle is set at the factory. Adjustment of thelow idle on these machines should only be done bya Caterpillar dealer.

Note: Operating the electric set at low idle speed foran extended time will cause some voltage regulatorsto shut off. The electric set must be completely shutdown and the electric set must be restarted. Thiswill allow the voltage regulator to again produce anoutput.

144 SEBU7829-03Maintenance SectionGenerator Set - Test

i01593517

Generator Set - TestSMCS Code: 4450-081

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

When power generation equipment must be in op-eration to make tests and/or adjustments, highvoltage and current are present.

Improper test equipment can fail and present ahigh voltage shock hazard to its user.

Make sure the testing equipment is designed forand correctly operated for high voltage and cur-rent tests being made.

When servicing or repairing electric power gener-ation equipment:

• Make sure the unit is off-line (disconnectedfrom utility and/or other generators powerservice), and either locked out or tagged DONOT OPERATE.

• Make sure the generator engine is stopped.

• Make sure all batteries are disconnected.

• Make sure all capacitors are discharged.

Table 19

Tools Needed

Part Number Part Quantity

6V-7070 DigitalMultimeter 1

12 VDC battery 1

PotentialTransformer 1

The generator set functional test is a simplified testthat can be performed in order to determine if thegenerator is functional. The generator set functionaltest should be performed on a generator set that isunder load.

The generator set functional test determines if thefollowing statements happen:

• A phase voltage is being generated.

• The phase voltages are balanced.

• The phase voltages change relative to enginespeed.

The generator set functional test consists of thefollowing steps:

1. Stop the generator. Connect the potentialtransformer’s high voltage winding to thegenerator terminals (T1) and (T2). Connectthe voltmeter to the low voltage winding. If twotransformers are available, connect the highvoltage winding of the second transformer to thegenerator terminals (T1) and (T3). Connect thesecondary terminals that correspond to generatorterminal (T2) of both transformers together.

2. Disconnect wires “E+” and “E-” from the voltageregulator. Disconnect the generator from the load.

3. Connect a 12 VDC automotive battery to wires“E+” and “E-”.

4. Measure the AC voltage across the low voltageterminals of the transformer that correspond to thefollowing generator terminals: “T1” and “T2”, “T2”and “T3”, and “T3” and “T1”. Record the voltages.

i01228545

Generator Set Vibration -InspectSMCS Code: 4450-040-VI

Check for vibration damage. Vibration may cause thefollowing problems:

• loose fittings

• loose bolts

• excessive noise

• cracked insulation

The following areas are susceptible to vibrationdamage:

• stator output leads

• protective sleeving

• insulation

• exposed electrical connections

• transformers

• fuses

• capacitors


Hoses and Clamps - Inspect/Replace

• lightning arrestors

Check the generator set’s vibration level by using abroad spectrum analyzer.

i02121526

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardclamp.

Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosen.This can result in leaks. A constant torque hoseclamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


1. Stop the engine. Allow the engine to cool.

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

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: Refer to the Specifications, SENR3130,“Torque Specifications” in order to locate the propertorques.

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap’s gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10.Start the engine. Inspect the cooling system forleaks.

146 SEBU7829-03Maintenance SectionHoses and Clamps - Replace

i02164888

Hoses and Clamps - ReplaceSMCS Code: 1380-510

Note: For instructions on draining the cooling systemand filling the cooling system, see this Operationand Maintenance Manual, “Cooling System Coolant(DEAC) - Change” topic or see the Operation andMaintenance Manual, “Cooling System Coolant(ELC) - Change” topic (Maintenance Section).

1. Drain the cooling system.

2. Remove the used hoses and clamps. Discard theitems.

3. Install new hoses and clamps. For thecorrect torque to use on the hose clamps,see the Specifications, SENR3130, “TorqueSpecifications”, “Hose Clamps” topic.

4. Fill the cooling system.

5. Start the engine. Inspect the hose connectionsfor leaks.

i01917577

Instrument Panel - InspectSMCS Code: 7451-040

Inspect the instrument panel for good condition.Perform the self 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 gauges during normaloperation.

Record the data in a log. Compare the new data tothe data that was previously recorded. Comparingthe new data to the recorded data will help toestablish the trends of engine performance. A gaugereading that is abnormal may indicate a problem withoperation or a problem with the gauge.

i01951994

Insulation - TestSMCS Code: 4453-081; 4454-081; 4457-081;4470-081

Recommended Periodic InsulationTests

The high voltage that is produced by an operatinggenerator set can cause severe injury or death.Before performing any maintenance or repairs,ensure that the generator will not start.

Place the engine control switch in the “OFF” posi-tion. Attach “DO NOT OPERATE” tags to all start-ing controls. Disconnect the batteries or disablethe starting system. Lock out all switchgear andautomatic transfer switches that are associatedwith the generator.

Table 20

Tools Needed

142-5055 Insulation Testing Gp

9U-6003 Insulation Testing Gp

Periodically, use an insulation tester to check theinsulation resistance of the generator’s main statorwinding. The frequency of this test is determined bythe generator’s environment. Previous insulationtester readings will also determine the frequency ofthis test.

Test the main stator windings with an insulation testerin the following situations:

• The generator set is started for the first time.

• The generator set is removed from storage.

• The generator set is operating in a humidenvironment. Test every three months.

• The generator set is not protected from theelements in an enclosed area. Test every threemonths.

• The generator set is installed in an enclosed area.This area needs to be low in humidity and this areaneeds to have steady temperatures. Test everytwelve months (minimum).


Insulation - Test

• The generator set has not been run under loadfor three months. Test the generator set weekly.Use space heaters around the generator set if thegenerator is exposed to a sea water environment orif the humidity is above 75 percent. Also use spaceheaters if a test result was below 3 megohms.

Space heaters must be used whenever the generatorset is not under load. Space heaters must also beused whenever salt is present or whenever highhumidity is present. Using a space heater in thisfashion is the only way to maintain insulation testerreadings above one megohm. Use space heatersonly when the generator is not running.

For additional information, refer to Special Instruction,SEHS9124, “Cleaning and Drying of Electric SetGenerators”.

Recommended Procedure for APeriodic Insulation Test

Personal injury or death can result from electro-cution.

The megohmmeter is applying a high voltage tothe circuit.

To avoid electrocution, do not touch the instru-ment leads without first discharging them. Whenfinished testing also discharge the generatorwindings.

1. Take the generator out of service.

2. Visually inspect the generator for moisture. Ifmoisture exists, do not perform this insulationtest. Dry the unit first. Refer to Special Instruction,SEHS9124, “Cleaning and Drying of Electric SetGenerators”.

3. Inspect the installation. Determine the equipmentthat will be tested by the insulation tester.

4. Discharge the capacitance of the windings.

5. Isolate the stator windings of the generator bydisconnecting all other leads and cables from thegenerator terminals. This includes connectionsto the voltage regulator, the control panel, theswitchgear or other devices.

6. Connect the insulation tester’s RED lead toground.

7. Connect the insulation tester’s BLACK lead to thewye point or star point of the generator’s windings.

8. For units that are 600 volts or less, set the voltageto 500 Volts. For units that are more than 600volts, set the voltage to 1000 Volts.

9. Use the 30/60 Time Resistance Method:

a. Apply voltage.

b. Observe the readings at 30 seconds. Observethe readings at 60 seconds.

c. Record the 60 second reading. This readingmust be corrected for temperature.

d. Record temperature.

e. Record humidity.

f. Remove voltage.

10.Evaluate the readings. The actual value of theresistance may vary greatly between generators.For this reason, the insulation’s condition must beevaluated. Base this evaluation on the comparisonbetween the 60 second resistance readings andthe readings that were taken on previous dates.These two readings must be taken under similarconditions. If a 60 second resistance readinghas a 50 percent reduction from the previousreading, the insulation may have absorbed toomuch moisture.

Switch the insulation tester to the “OFF” position.This will discharge the insulation tester’s leads.Disconnect the insulation tester’s leads.

Note: The results from the insulation resistancechecks indicate when cleaning and/or repairing isbecoming critical. Generally, insulation resistancewill vary greatly with temperature. Therefore, alwaystest at the same temperature and humidity. Refer toIllustration 96.

Serial Number (Engine)___________________________________

Serial Number (Generator)_______________________________

148 SEBU7829-03Maintenance SectionInsulation - Test



Jacket Water Heater - Check

i01917546

Jacket Water Heater - Check(Standby Generator Sets (IfEquipped))SMCS Code: 1383-535

Jacket water heaters help to improve startability inambient temperatures that are below 21 °C (70 °F).All installations that require automatic starting shouldhave jacket water heaters.

Check the operation of the jacket water heater. Foran ambient temperature of 0 °C (32 °F), the heatershould maintain the jacket water coolant temperatureat approximately 32 °C (90 °F).

i00906366

Magnetic Pickups -Clean/InspectSMCS Code: 1907-040; 7400-040; 7400-070

g00293335Illustration 97Typical example

(1) Magnetic pickup(2) Flywheel housing

g00293337Illustration 98Typical magnetic pickup

1. Remove magnetic pickup (1) from flywheelhousing (2). Check the condition of the end of themagnetic pickup. Check for signs of wear andcontaminants.

2. Clean the metal shavings and other debris fromthe face of the magnet.

3. Install the magnetic pickup and adjust themagnetic pickup. Refer to the Service Manual forthe installation procedure.

i02018788

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will result in alower average power demand. A decreased averagepower demand should increase both the engineservice life and the overhaul interval.

The need for an overhaul is generally indicated byincreased fuel consumption and by reduced power.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Oil Consumption as an OverhaulIndicatorOil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h (lb perbhp). The brake specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillardealer for assistance in determining the typical oilconsumption rate for your engine.

150 SEBU7829-03Maintenance SectionOverhaul Considerations

When an engine’s oil consumption has risen to threetimes the original oil consumption rate due to normalwear, an engine overhaul should be scheduled.There may be a corresponding increase in blowbyand a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The engine service life can be extended without therisk of a major catastrophe due to engine failure.

• The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine block orthe crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost should be between 40percent and 50 percent of the cost of a new enginewith a similar exchange core.

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

Overhaul RecommendationTo minimize downtime, a scheduled engine overhaulby your Caterpillar dealer is recommended. This willprovide you with the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealer thatperforms the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of the followingmaintenance recommendations.

Unit Fuel Injector

Clean the fuel injector body and replace the O-rings.Replace the O-rings and the gasket on the injectorsleeve. Clean the area around the injector seatingin the injector sleeve. Refer to the Service Manualfor the complete procedure, or consult with yourCaterpillar dealer for assistance.

Rebuild or Exchange

Cylinder Head Assembly, Connecting Rods,Pistons, Cylinder Liners, Turbocharger, CylinderPacks, Oil Pump, and Fuel Transfer Pump

These components should be inspected according tothe instructions that are found in various Caterpillarreusability publications. The Special Publication,SEBF8029 lists the reusability publications that areneeded for inspecting the engine parts.

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

Using out-of-spec parts can result in the followingproblems:

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine efficiency

• Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Piston Rings, Crankshaft Bearings, ValveRotators, and Crankshaft Seals

The following components may not last until thesecond overhaul.


Overhaul Considerations

• Thrust bearings

• Main bearings

• Rod bearings

• Valve rotators

• Crankshaft seals

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

• Rod bearing

• Main bearings

Note: If the crankshaft is removed for any reason,use the magnetic particle inspection process to checkfor cracks in the crankshaft.

Inspect the camshaft for damage to the journals andto the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to check forcracks in the camshaft.

Inspect the following components for signs of wear orfor signs of scuffing:

• Camshaft bearings

• Camshaft followers

Caterpillar Inc. recommends replacing the crankshaftvibration damper.

Oil Cooler Core and Aftercooler Core

During an overhaul, the removal of the oil coolercore and the aftercooler core is recommended. Theoil cooler core and the aftercooler core should becleaned and pressure tested.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core and the aftercooler core.

1. Remove the oil cooler core and the aftercoolercore.

2. Remove any debris from the oil cooler core andthe aftercooler core. To remove debris from the oilcooler core, turn the oil cooler core onto one end.To remove debris from the aftercooler core, turnthe aftercooler core upside-down.

3. Flush the oil cooler core and the aftercooler coreinternally with cleaner in order to loosen foreignsubstances. This will also help to remove oil fromthe oil cooler core and the aftercooler core.

Note: The use of Hydrosolv Liquid Cleaners isrecommended. Table 21 lists the Hydrosolv LiquidCleaners that are available from your Caterpillardealer.

Table 21

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 cleaner attemperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

4. Use steam to clean the oil cooler core and theaftercooler core. This removes any remainingresidue from the cleaner. Flush the fins of the oilcooler core and the aftercooler core. Remove anyother trapped debris.

5. Wash the oil cooler core and the aftercooler corewith hot, soapy water. Rinse the oil cooler core andthe aftercooler core thoroughly with clean water.

152 SEBU7829-03Maintenance SectionPower Factor - Check




6. Dry the oil cooler core and the aftercooler corewith compressed air. Direct the air in the reversedirection of the normal flow.

7. Inspect the components in order to ensurecleanliness. The oil cooler core and the aftercoolercore should be pressure tested. Repair the oilcooler core and the aftercooler core, if necessary.Install the oil cooler core and the aftercooler core.

For more information about cleaning the cores,consult your Caterpillar dealer.

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level 1). Furthercoolant analysis is recommended when the engineis overhauled.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company oran agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar Inc. recommends an S·O·S CoolantAnalysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level 2) providesthe following information:

• Complete S·O·S Coolant Analysis (Level 2)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level 2) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, consultyour Caterpillar dealer.

i01191656

Power Factor - CheckSMCS Code: 4450-535-PWR

The power factor of a system can be determined bya power factor meter or by calculations. The powerfactor can be calculated by dividing kW by kVA.Power factor is expressed as a decimal.

i01604510

Radiator - CleanSMCS Code: 1353-070

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the radiator for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. Clean the radiator, if necessary.




Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fan’s air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the fins. Slowly move theair nozzle in a direction that is parallel with the tubes.This will remove debris that is between the tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.


Rotating Rectifier - Check

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may be openedwith a “comb”. Inspect these items for good condition:welds, mounting brackets, air lines, connections,clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning andinspection, refer to Special Publication, SEBD0518,“Know Your Cooling System”.

i01880286

Rotating Rectifier - CheckSMCS Code: 4465-535



Check the exciter armature. Ensure that the rotatingrectifier is tight. If a failure of a rectifier is suspected,refer to Maintenance Procedure, “Rotating Rectifier -Test”.

i01936391

Rotating Rectifier - TestSMCS Code: 4465-081



Use the following procedure in order to test therotating rectifier.

1. Stop the generator set. Disconnect the wires forthe AVR and isolate the wires for the AVR.

2. Make an assembly for separate excitation. Theassembly can use a 12 volt battery or a variableDC power supply as a power source. Refer toStep 3 for an assembly that uses a 12 Volt battery.Refer to Step 4 for an assembly that uses avariable DC power supply.

g01015807Illustration 99(A) Exciter Field(B) Diode (1 Amp)(C) Rheostat (50 Ohms 300 Watts)

3. Connect a 12 volt battery in series with a rheostat(C) of “50 Ohms 300 Watts” and a diode (B) onboth wires for the exciter field (5+ and 6-). Go tostep 5.

154 SEBU7829-03Maintenance SectionSevere Service Application - Check

g01015808Illustration 100(D) AC supply(E) Variable power supply(F) Exciter field(G) Diode bridge

4. Connect a variable power supply and a diodebridge to both of the wires for the exciter field (5+)and (6-).

5. The assembly should have characteristics that arecompatible with the power for the field excitationof the generator.

6. Operate the generator set at rated speed.

7. Gradually increase the current of the exciter fieldby adjusting the rheostat or the variable powersupply. Measure the output voltage and thecurrent at no load. Measure the output voltageand measure the current at no load.

8. The generator is operating properly when theoutput voltage is at the rated value and the outputvoltage is balanced within one percent for therated level of excitation.

i00151038

Severe Service Application -CheckSMCS Code: 1000-535

Severe service is an application of an engine thatexceeds current published standards for that engine.Caterpillar maintains standards for the followingengine parameters:

• Performance (power range, speed range, and fuelconsumption)

• Fuel quality

• Altitude range

• Maintenance intervals

• Oil selection and maintenance

• Coolant selection and maintenance

• Environmental qualities

• Installation

Refer to the standards for the engine or consult withyour Caterpillar dealer in order to determine if theengine is operating within the defined parameters.

Severe service operation can accelerate componentwear. Engines that operate under severe conditionsmay need more frequent maintenance intervals inorder to ensure maximum reliability and retention offull service life.

Due to individual applications, it is not possible toidentify all of the factors which can contribute tosevere service operation. Consult your Caterpillardealer for the unique maintenance that is necessaryfor the engine.

The operating environment, improper operatingprocedures and improper maintenance procedurescan be factors which contribute to severe serviceconditions.

Environmental FactorsAmbient temperatures – The engine may beexposed to extended operation in extremelycold environments or hot environments. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesengine performance.

Air Quality – The engine may be exposed toextended operation in an environment that is dirtyor dusty, unless the equipment is cleaned regularly.Mud, dirt and dust can encase components.Maintenance can be very difficult. The buildup cancontain corrosive chemicals.

Buildup – Compounds, elements, corrosivechemicals and salt can damage some components.

Altitude – Problems can arise when the engine isoperated at altitudes that are higher than the intendedsettings for that application. Necessary adjustmentsshould be made.

Improper Operating Procedures• Extended operation at low idle

• Frequent hot shutdowns


Standby Generator Set Maintenance Recommendations

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Improper Maintenance Procedures• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants andcoolant/antifreeze

i01943204

Standby GeneratorSet MaintenanceRecommendationsSMCS Code: 4450-041

A standby generator set may not need to be usedvery often. However, the generator set is usuallyneeded for operation in an emergency situation.Maintenance of the standby generator set is veryimportant for the following reasons:

• The generator set must always be in excellentoperating condition.

• The generator set must be ready to work underload at any time.

Establishing a Preventive Maintenance Program willprovide these benefits:

• Maximum availability of the standby generator set

• Longer service life for the generator set

• Minimum of expensive repairs

Your Caterpillar dealer can help you to establish aneffective Preventive Maintenance Program for yourgenerator set. Consult your Caterpillar dealer fordetails.

Maintenance and OperationProcedures



The recommended maintenance for the generator setis listed in this Operation and Maintenance Manual,“Maintenance Interval Schedule (Standby GeneratorSets)” (Maintenance Section).

Maintenance and Repair

The maintenance that is recommended for EveryWeek can be performed by an authorized operator.The maintenance that is recommended for thesubsequent maintenance intervals must beperformed by an authorized service technician or byyour Caterpillar dealer.

Unless other instructions are provided, performmaintenance and repairs under the followingconditions:

• The engine is stopped.

• The starting system is disabled.

• The generator does not pose an electrical shockhazard.

Operation

To ensure proper operation, the generator set must beexercised regularly. For instructions on operating thegenerator set, see the Operation and MaintenanceManual for the generator set control panel.

For these operation procedures, follow theinstructions that are provided in this Operation andMaintenance Manual, “Operation Section”: startingthe engine, engine operation, and stopping theengine.

156 SEBU7829-03Maintenance SectionStarting Motor - Inspect

Record Keeping

Maintain a record in order to document these items:gauge readings, maintenance that is performed,problems, and repairs.

Space Heaters

Moisture causes damage to generators and otherelectrical equipment. Make every effort to keep thegenerator set as dry as possible.

Generators can operate without problems in humidenvironments. However, problems can occur whenthe generator is inactive. Moisture can condense onthe windings. This can result in poor performance.Also, damage to the windings can occur.

Use space heaters in order to help keep the windingsdry. When the generator is not active, ensure that thespace heaters are operating. When the generator isoperating, turn OFF the space heaters.

i00651416

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation. Checkthe electrical connections and clean the electricalconnections. Refer to the Service Manual for moreinformation on the checking procedure and forspecifications or consult your Caterpillar dealer forassistance.

i01539769

Turbocharger - InspectSMCS Code: 1052-040; 1052

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inlet side).Any fumes from the crankcase are filtered throughthe air inlet system. Therefore, by-products from oiland from combustion can collect in the turbochargercompressor housing. Over time, this buildup cancontribute to loss of engine power, increased blacksmoke and overall loss of engine efficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinderhead.

NOTICETurbocharger bearing failures can cause large quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.

An inspection of the turbocharger can minimizeunscheduled downtime. An inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts.

Note: Turbocharger components require precisionclearances. The turbocharger cartridge mustbe balanced due to high rpm. Severe ServiceApplications can accelerate component wear.Severe Service Applications require more frequentinspections of the cartridge.

Removal and InstallationFor options regarding the removal, installation, repairand replacement, consult your Caterpillar dealer.Refer to the Service Manual for this engine for theprocedure and specifications.

Cleaning and Inspecting1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil. Cleanthe interior of the pipes in order to prevent dirtfrom entering during reassembly.


Walk-Around Inspection

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel forcontact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and theturbocharger housing. If there is any indication ofcontact between the rotating turbine wheel or thecompressor wheel and the turbocharger housing,the turbocharger must be reconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbochargeroil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the linefor the inlet air (plugged air filters), which causesthe turbocharger to slobber.

4. Use a dial indicator to check the end clearanceon the shaft. If the measured end play is greaterthan the Service Manual specifications, theturbocharger should be repaired or replaced.An end play measurement that is less than theminimum Service Manual specifications couldindicate carbon buildup on the turbine wheel. Theturbocharger should be disassembled for cleaningand for inspection if the measured end play is lessthan the minimum Service Manual specifications.

5. Inspect the bore of the turbine housing forcorrosion.

6. Clean the turbocharger housing with standardshop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.

i01908686

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that cooling lines are properly clamped.Check for leaks. Check the condition of all pipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pump and the installation of water pump and/orseals, refer to the Service Manual for the engine orconsult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

158 SEBU7829-03Maintenance SectionWater Pump - Inspect

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the engine-to-frame ground strap for agood connection and for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges which are cracked or replace any gaugesthat can not be calibrated.

Inspect the InsulationA visual inspection should be initially directed atthe areas that are most prone to damage anddeterioration. The most prone areas to damage anddeterioration are listed below:

• Ground Insulation. Ground insulation is insulationthat is intended to isolate components that arecarrying current from components that are notcarrying current.

• Support Insulation. Support insulation isusually made from one of the following items:a compressed lamination of fibrous materials,polyester, or felt pads that have been impregnatedwith various types of bonding agents.

There are many different types of damage that canoccur in these areas. Several of the different types ofdamage are listed below:

Thermal Aging – Thermal aging can cause thedegradation of insulation or the deterioration ofinsulation. An examination of the coils may revealthat the insulation has expanded into the ventilationducts. This is the result of a loss of bond whichwill cause the insulation material to separate. Theinsulation material could also separate from theconductors on the windings.

Abrasion – The surfaces of coils and the surfacesof connectors may be damaged by abrasion. Thesesurfaces may also be damaged by contaminationfrom other sources. An example of these sourceswould be chemicals or abrasive substances.

Cracking – Cracking of insulation may result frommechanical stress. The structure that is used to bracethe stator winding will become loose if the problemis not corrected. Further mechanical damage orelectrical damage may also result.

Erosion – Erosion can be caused when foreignsubstances rub against the surfaces of the insulation.

i01057943

Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in the followingconditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Visually inspect the water pump for leaks. If anyleaking is observed, replace the water pump sealor the water pump assembly. Refer to the ServiceManual for the disassembly and assembly procedure.

Note: Refer to the Service Manual or consult yourCaterpillar dealer if any repair is needed or anyreplacement is needed.

Manual de Servicio Generador Engine 3456

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