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MAINTENANCE INTERVALS - Safety

1. EC 1 Coolants 1 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified Note Check the SCA Supplemental Coolant Additive of the conventional coolant at every oil change or at every 250 hours Perform this check at the interval that occurs first S O S Services Coolant Analysis Level 1 A coolant analysis Level 1 is a test of the properties of the coolant The following properties of the coolant are tested Glycol concentration for freeze protection and boil protection Ability to protect from erosion and corrosion e pH Conductivity Visual analysis Odor analysis The results are reported and appropriate recommendations are made S O S Services Coolant Analysis Level 2 A coolant analysis Level 2 is a comprehensive chemical evaluation of the coolant This analysis is also a check of the overall condition of the cooling system The S O S coolant analysis Level 2 has the following features Full coolant analysis Level 1 Identification of metal corrosion and of contaminants Identification of buildup of the impurities that cause corrosion Identification of buildup of the impurities that cause scaling Determination of the possibility of electrolysis within the cooling system of the engine The results are reported and appropriate recommendations are made For more information on S O S coolant analysis consult your Cat dealer
2. Illustration 100 g01197946 4 Install cover 2 Fasten latches 1 Engine Air Cleaner Service Indicator Inspect If Equipped SMCS Code 7452 040 Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner housing or in a remote location Illustration 101 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximat
3. 7 The engine is now ready to start Operate the engine at low idle for a minimum of 5 minutes immediately after air has been removed from the fuel system Note Running the engine for this period will help ensure that the pump is completely free of air SEBU7919 04 147 Maintenance Section Fuel System Primary Filter Water Separator Element Replace Priming the Fuel System with a Protection and Paralleling Unit PPU Use the following procedure in order to remove air from the fuel system Illustration 112 1 Hold the toggle switch 1 in the ON position for 3 minutes to prime the system Note Damage to the following components may occur if the starting motor is used excessively to purge the air from the fuel system fuel injection pump the battery and the starting motor NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 2 The engine is now ready to start g01231641 102214246 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ 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 when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean
4. Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Note Failure to properly close the drain can allow air into the system which could have detrimental results to performance 150 Maintenance Section Generator Dry SEBU7919 04 Check the fuel daily Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled Allow five to ten minutes before performing this procedure Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The
5. Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Note If replacing only the water temperature regulator only drain the coolant to a level that is below the water temperature regulator housing Refer to two articles in the Disassembly and Assembly Manual Water Temperature Regulator Remove and Water Temperature Regulator Install for the replacement procedure or consult your Cat dealer 101595880 Electrical Connections Check SMCS Code 4459 535 Check all exposed electrical connections for tightness Check the following devices for loose mounting or for physical damage e transformers e fuses e capacitors e lightning arrestors Check all lead wires and electrical connections for proper clearance 102659941 Enclosure Inspect SMCS Code 7263 040 7274 040 NOTICE Do not spray or splash water into the generator air inlet or exhaust openings Ensure that the openings are covered in order to prevent water from entering the electrical windings and bearings The interior of the enclosure package and the exterior of the enclosure package should be kept clean Wash the interior of the enclosure package and the exterior of the enclosure pack
6. 0 5 inch below the neck of the filler tube Install the cooling system filler cap 4 Start and run the engine until the temperature 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 slowly in order to relieve any pressure Remove the cooling system filler cap Remove the drain plugs 3 4 and 5 Allow the water to drain Flush the cooling system with clean water Clean the drain plugs Install the drain plugs For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Make sure that all the plugs that were removed in the previous steps have been installed Remove plug 6 Remove filler cap and begin filling the system with the proper mixture of ELC and water Refer to this Operation and Maintenance Manual Fluid 9sRecommendations for proper coolant Install plug 6 as the coolant begins to run out of the hole for plug 6 For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications After the plugs are installed continue filling the system until the coolant level is approximately 12 mm 0 5 inch below the neck of the filler tube Install the cooling system filler cap 2 Start and run the engine until the engine reaches normal operating temperature Stop the eng
7. 116 Maintenance Section Refill Capacities SEBU7919 04 Greases If it is necessary to choose a single grease always choose a grease that meets or exceeds the requirements of the most demanding application Remember that the products which barely meet the minimum performance requirements can be expected to barely produce the minimum lives of your parts False economy is being used if a grease is purchased with the lowest cost as the only consideration Instead use the grease that yields the lowest total operating cost The cost should be based on an analysis that includes the costs of parts labor downtime and the cost of the amount of grease that is required For more information refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations SEBU7919 04 117 Maintenance Section Maintenance Recommendations Maintenance Recommendations i01179728 General Maintenance Information SMCS Code 4450 7000 Note Read the warnings and read the instructions that are contained in the Safety Section of this manual These warnings and instructions must be understood before you perform any operation or any maintenance procedures Rotating electric machines are complex structures that are exposed to the following forms of stress e mechanical e electrical e thermal e environmental These stresses may be of varying magnitudes The electrical insulation systems are very susce
8. Cover 2 Remove screws 2 and cover 3 142 Maintenance Section Engine Crankcase Breather Replace SEBU7919 04 Illustration 105 g01158042 4 diaphragm 5 Spring 3 Remove diaphragm 4 and spring 5 Replace these parts with a new diaphragm and a new spring 4 Installation is the reverse of removal Turbocharged Engines Replace the Housing of the Crankcase Ventilator Filter and the Crankcase Ventilator Filter O Illustration 106 g01158045 1 Disconnect the hoses from the housing 1 for the crankcase ventilator filter Remove the housing 1 g01158053 Illustration 107 2 Lid 3 O ring 4 Crankcase ventilator filter 5 O ring 6 Housing for the crankcase ventilator filter 2 Turn lid 2 in a counterclockwise direction for approximately 15 degrees Remove the Lid 3 Remove O ring 3 4 Remove crankcase ventilator filter 4 5 Remove O ring 5 6 Install a new O ring 5 7 Install a new crankcase ventilator filter 4 8 Install a new O ring 3 9 Install lid 2 SEBU7919 04 143 Maintenance Section Engine Mounts Inspect 102456872 Engine Mounts Inspect SMCS Code 1152 040 1152 Inspect the engine mounts for deterioration and for proper bolt torque Engine vibration can be caused by the following conditions e Improper mounting of the engine e Deterioration of the en
9. SEBU6251 Biodiesel A blend of greater than 20 percent biodiesel may be acceptable in some cases See your Cat dealer for more information Note A complete Cat S O S Services oil analysis program is recommended strongly when using biodiesel blends above 5 percent Table 16 Biodiesel Blends for Cat Commercial Diesel Engines eT Distillate diesel Biodiesel blend Final blend fuel used for stock blend Caterpillar il Caterpillar biodiesel B20 ASTM distillate diesel dee oui D7467 and Tai specification API oravit fuel specification ASTM D6751 Soe y ASTM D975 or or EN14214 EN590 Fuel Additives Cat Diesel Fuel Conditioner Refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations for further information Cat Diesel Fuel System Cleaner Refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations for further information Aftermarket Fuel Additives There are many different types of fuel additives that are available to use Caterpillar does not generally recommend the use of fuel additives Note For best results your fuel supplier should treat the fuel when additives are needed Refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations for further information Cooling System Note Refer to Special Publication SEBU6251 Cat Commercial Die
10. for the Electronic Control Module ECM C 20 Amp Circuit Breaker This circuit breaker is for the control panel 104232973 Control Panel Inspect Test SMCS Code 4490 040 4490 081 7451 040 7451 081 Inspect the instrument panel for good condition Perform the self test All of the warning lamps should illuminate If a warning lamp does not illuminate replace the bulb immediately If the alarm does not sound investigate the problem and correct the problem Check the condition of all of the gauges If a gauge is broken repair the gauge or replace the gauge immediately Frequently monitor the gauges during normal operation Record the data in a log Compare the new data to the data that was previously recorded Comparing the new data to the recorded data will help to establish the trends of engine performance A gauge reading that is abnormal may indicate a problem with operation or a problem with the gauge 104862569 Coolant Change SMCS Code 1350 044 1352 1395 044 1395 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Note Inspect the water pump and the water temperature regulator after the cooling system has been drained If necessary replace the water pump the water temperature regulator and the hoses Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine
11. Cleaner Elements 3 Cover the turbocharger air inlet with tape in order to keep out dirt 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the turbocharger air inlet Install the secondary air cleaner element Install a primary 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 Cleaner Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Cat dealers The Cat clean ing process uses proven procedures to assure consis tent quality and sufficient filter life Observe the following guidelines if you attempt to clean 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 remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tea
12. Engine equipped with air to air aftercooling ATAAC requires a minimum of 30 percent glycol to help prevent water pump cavitation NOTICE Do not use a commercial coolant antifreeze that only meets the ASTM D3306 specification This type of coolant antifreeze is made for light duty automotive applications Use only the coolant antifreeze that is recommended Note A mixture of SCA and water is not recommended for use in the cooling system of the C4 4 marine auxiliary generator The use of SCA and water in the cooling system could result in damage to the aluminum components Table 17 Coolant Recommendations for use in Cat Diesel Engines Service Required Recommendations Product Hoursn2e Maintenanc Add Cat ELC Cat ELC Cat Extended Life Coolant 12000 hours or 6 years Extender at 6000 service hours or one half of service life Preferred Cat ELI Cat Extended Life Inhibitor 12000 hours Add Cat ELC Extender at 6000 service hours maximum of 275 ppm ore years or one half of service life Cat EC 1 specification and ASTM D6210 and Organic Additive Technology OAT based on a combination of a monocarboxylic acid and a dicarboxylic acid 6000 hours Paa E Min requirements Phosphate borate and silicate free ore Veas or one half of Tolyltriazole minimum typical concnetration of 900 ppm y service life Nitrite minimum typical concentration of 500 ppm in new coolan
13. Reduced engine efficiency and increased fuel consumption translates into higher operating costs Therefore Caterpillar recommends repairing out of spec parts or replacing out of spec parts Inspection and or Replacement Crankshaft Bearings Crankshaft Seals Thrust Bearings Main Bearings and Rod Bearings The following components may not last until the second overhaul e Thrust bearings e Main bearings e Rod bearings e Crankshaft seals Caterpillar recommends the installation of new parts at each overhaul period Inspect these parts while the engine is disassembled for an overhaul Inspect the crankshaft for any of the following conditions e Deflection e Damage to the journals e Bearing material that has seized to the journals Check the journal taper and the profile of the crankshaft journals Check these components by interpreting the wear patterns on the following components e Rod bearing e Main bearings Note If the crankshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the crankshaft Inspect the camshaft for damage to the journals and to the lobes Note If the camshaft is removed for any reason use the magnetic particle inspection process to check for cracks in the camshaft Inspect the following components for signs of wear or for signs of scuffing e Camshaft bearings e Camshaft followers Caterpillar recommends replacing the crankshaft
14. Tighten or replace hose clamps which are loose Replace the Hoses and the Clamps NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Cooling System Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved 1 Stop the engine 2 Allow the engine to cool 3 Before servicing a coolant hose slowly loosen the filler cap for the cooling system in order to relieve any pressure 4 Remove the filler cap for the cooling system 5 Drain the cool
15. an acceptable value the winding should be reconditioned Note For additional information refer to Special Instruction SEHS9124 Drying Methods The following methods can be used for drying a generator e Self circulating air method e Oven method NOTICE Do not allow the winding temperature to exceed 85 C 185 0 F Temperatures that are greater than 85 C 185 0 F will damage the winding insulation Self Circulating Air Method Note Disable the excitation before using this method Run the engine and disconnect the generator load This will help circulate air Operate the generator space heaters Oven Method Place the entire generator inside a forced air drying oven for four hours at 65 C 149 F NOTICE Use a forced air type oven rather than a radiant type oven Radiant type ovens can cause localized overheating 102283395 Generator Inspect SMCS Code 4450 040 Personal injury or death can result from improper troubleshooting and repair procedures The following troubleshooting and repair proce dures should only be performed by qualified per sonnel familiar with this equipment SEBU7919 04 151 Maintenance Section Generator Inspect The high voltage that is produced by an operating generator 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 po
16. and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 130 SEBU7919 04 Maintenance Section Coolant Change Illustration 87 g01157267 Typical example 1 Header tank 2 Cooling system filler cap 1 Stop the engine and allow the engine to cool Loosen cooling system filler cap 2 slowly in order to relieve any pressure Remove cooling system filler cap 2 Illustration 89 g01156305 l ee Illustration 90 g01341440 Illustration 88 g01156304 2 Remove the drain plug 4 from the cylinder block Remove the drain plug 3 from the water cooled exhaust manifold Remove drain plug 5 from the heat exchange Remove drain plug 6 from the radiator if equi
17. charge will freeze more easily than a battery with a full charge 101942284 Automatic Start Stop Inspect SMCS Code 4462 The generator set must be ready to operate under a load at any time After performing maintenance on the generator set inspect the position of the control switches Ensure the following conditions e The starting system is enabled e The control switches are in the correct position for automatic starting e The switchgear and the automatic transfer switches that are associated with the generator are enabled 101041983 Auxiliary Water Pump Rubber Impeller Inspect SMCS Code 1371 040 Impellers and seals require periodic inspection Impellers have a service life that is limited The service life depends on the engine operating conditions Inspect the components more frequently when the pump is exposed to debris sand or other abrasive materials Inspect the components if the pump is operating at a differential pressure of more than 103 kPa 15 psi Check the following components for wear or damage e Bearings e Impeller e Seals e Wear plate If wear or damage is found replace the components which are worn or damaged Use the proper repair kit for the pump Refer to the Disassembly and Assembly for more information on servicing the auxiliary water pump 102039199 Battery Recycle SMCS Code 1401 005 1401 510 1401 535 1401 561 1401 Always recycle a battery Never discar
18. dealer for assistance in determining the typical oil consumption rate for your engine When an engine s oil consumption has risen to three times the original oil consumption rate due to normal wear an engine overhaul should be scheduled There may be a corresponding increase in blowby and a slight increase in fuel consumption Overhaul Options Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons Costly unplanned downtime can be avoided Many original parts can be reused according to the standards for reusable parts The engine s service life can be extended without the risk of a major catastrophe due to engine failure The best cost value relationship per hour of extended life can be attained After Failure Overhaul If a major engine failure occurs and the engine must be removed from the hull many options are available An overhaul should be performed if the engine block or the crankshaft needs to be repaired If the engine block is repairable and or the crankshaft is repairable the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core This lower cost can be attributed to three aspects e Specially designed Caterpillar engine features e Caterpillar dealer exchange components e Caterpillar remanufactured exchange components Overhaul Recommendation To minimize downtime Caterpillar recommends a sche
19. disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Illustration 85 g01157422 The belt cover must be removed for inspection adjustment and replacement 1 Mounting bolt 2 Adjustment bolt 3 Adjustment bolt To maximize the engine performance inspect the belt for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the life of the belt For the correct tension on the belt refer to Specifications Belt Tension Chart Adjustment 1 Remove the belt cover 2 Loosen mounting bolts 1 and adjusting bolts 2 and 3 3 Slide the alternator in the direction that will give the correct tension 4 Tighten adjusting bolts 2 and 3 Tighten mounting bolt 1 SEBU7919 04 129 Maintenance Section Circuit Breakers Reset 5 Reinstall the belt cover if equipped If new belts are installed check the belt adjustment again after 30 minutes of engine operation at the rated rom 102456186 Circuit Breakers Reset SMCS Code 1417 529 1420 529 B C 60 20 g01225779 Illustration 86 Push in on the circuit breaker in order to reset the circuit breaker A 60 Amp Circuit Breaker This circuit breaker is for the battery charger and the circuit for the alternator B 15 Amp Circuit Breaker This circuit breaker is
20. factor is used to mean the portion of current that is supplied to a system that is doing useful work The portion of the current that is not doing useful work is absorbed in maintaining the magnetic field in motors This current reactive load can be maintained without engine power 101593517 Generator Set Test SMCS 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 high voltage and current are present Improper test equipment can fail and present a high voltage shock hazard to its user Make sure the testing equipment is designed for and 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 disconnected from utility and or other generators power service and either locked out or tagged DO NOT OPERATE Make sure the generator engine is stopped Make sure all batteries are disconnected Make sure all capacitors are discharged SEBU7919 04 153 Maintenance Section Generator Set Vibration Test Record Table 23 Tools Needed Part Number Part Quantity Digital 6V 7070 Multimeter 1 12 VDC battery 1 Potential 1 Transformer The generator set functional test is a simplified test that can be performed in order to determine if the generator
21. following conditions Failure to replace a hose which exhibits any of the following conditions may result in a hazardous situation Hoses which are cracked Hoses which are soft 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 Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps Inspect all clamps for the following conditions Replace any clamp which exhibits signs of any of the following conditions e Cracking e Looseness SEBU7919 04 157 Maintenance Section Hoses and Clamps Inspect Replace e Damage Inspect all couplings for leaks Replace any coupling which exhibits signs of leaks Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen which can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Replace hoses that are cracked or soft Replace hoses that show signs of leakage Replace hoses that show signs of damage Replace hose clamps that are cracked or damaged
22. fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Turn the fuel supply valve to the OFF position before performing this maintenance Place a tray under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel immediately SEBU7919 04 149 Maintenance Section Fuel Tank Water and Sediment Drain Illustration 114 g00802952 1 Cap 2 Fuel filter base 3 Quick release collar 4 Fuel filter 5 Drain valve for fuel filter 1 Close the fuel supply valve 2 Clean the outside of the fuel filter assembly Open drain valve 5 and drain the fuel and water from fuel filter 4 into a suitable container Note If the fuel filter element is not equipped with a drain remove cap 1 Remove the nylon insert in order to reduce the level of fuel in the fuel filter element A reduction in the level of fuel in the fuel filter element will help prevent fuel from being spilled when the element is removed NOTICE Do not use a tool in order to remove the fuel filter Attempting to remove the fuel filter with a filter wrench or a filter strap could damage the locking ring 3 Hold fuel filter 4 and rotate quick release collar 3 counterclockwise Remove quick release collar 3 The used element should be removed and discarded Note If the element is equipped with a sediment bowl remove the sediment bowl from the eleme
23. generator 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 disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Illustration 115 g00992269 1 Positive DC terminal or Negative DC terminal 2 AC terminal 3 AC terminal 4 AC terminal The following procedure tests all three diodes within a block Check the positive rectifier block and the negative rectifier block If any meter reading does not fall within the given ranges replace the rectifier block 1 Set the digital multimeter on the diode range Remove all leads from the rectifier block 2 To test the negative rectifier block follow these steps a Place the red test lead on the negative terminal 1 Place the black test lead on the following rectifier terminals AC terminal 2 AC terminal 3 and AC terminal 4 All readings on the meter should be between 0 4 and 1 0 b Place the black test lead on the negative terminal 1 Place the red test lead on the following rectifier terminals AC terminal 2 AC terminal 3 and AC terminal 4 In all cases the meter should read OL overload 3 To test the positive rectifier block follow t
24. information on drying methods refer to Special Instructions SEHS9124 Cleaning and Drying of Electric Set Generators 101878834 Generator Load Check SMCS Code 4450 535 LA 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 high voltage and current are present Improper test equipment can fail and present a high voltage shock hazard to its user Make sure the testing equipment is designed for and correctly operated for high voltage and cur rent tests being made During normal operation monitor the power factor and monitor generator loading When a three phase generator is installed or when a three phase generator is reconnected ensure that the total current in any one phase does not exceed the nameplate rating Each phase should carry the same load This allows the three phase generator to work at the rated capacity If one phase current exceeds the nameplate amperage an electrical imbalance will occur An electrical imbalance can result in an electrical overload and an electrical imbalance can result in overheating on three phase generators This is not applicable to single phase generators The power factor can be referred to as the efficiency of the load This can be expressed as the ratio of kVA to actual kW The power factor can be calculated by dividing kW by kVA Power factor is expressed as a decimal Power
25. inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel may result in damage to the pistons the valves and the cylinder head Disconnect batteries before performance of any service work Hot engine components can cause injury from burns Before performing maintenance on the engine allow the engine and the components to cool Personal injury can result from rotating and mov ing parts Stay clear of all rotating and moving parts Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified The machine must be parked on a level surface and the engine stopped NOTICE Turbocharger 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 engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied
26. insulation test should be performed more frequently in the following cases e The generator set is operating in a humid environment e The generator set is not protected from the elements in an enclosed area e The generator set has not been run under load for 3 months Note The use of space heaters may be needed around the generator set in the following cases e The generator set has not been run under load for 3 months e The generator set is exposed to a sea water environment e The humidity is above 75 percent e A test result was below 3 megohms Recondition or replace the winding in the following cases e The measured insulation resistance falls below the specified amount The cleanup procedure does not correct the discrepancy e The measured insulation resistance falls below the specified amount The drying procedure does not correct the discrepancy The specified insulation resistance is an approximate value The generator may be operated with less than the specified value However a generator that has a low winding insulation resistance will be more likely to have a failure SEBU7919 04 155 Maintenance Section Heat Exchanger Inspect Personal injury or death can result from improper troubleshooting and repair procedures The following troubleshooting and repair proce dures should only be performed by qualified per sonnel familiar with this equipment The insulation test gives accurate r
27. is functional The generator set functional test should be performed on a generator set that is under load The generator set functional test determines if the following statements happen e A phase voltage is being generated e The phase voltages are balanced e The phase voltages change relative to engine speed The generator set functional test consists of the following steps 1 Stop the generator Connect the potential transformer s high voltage winding to the generator terminals T1 and T2 Connect the voltmeter to the low voltage winding If two transformers are available connect the high voltage winding of the second transformer to the generator terminals T1 and T3 Connect the secondary terminals that correspond to generator terminal T2 of both transformers together 2 Disconnect wires E and E from the voltage regulator 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 voltage terminals of the transformer that correspond to the following generator terminals T1 and T2 T2 and T3 and T3 and T1 Record the voltages 104497390 Generator Set Vibration Test Record SMCS Code 4450 081 VI Excessive vibration will indicate a problem with the generator set The vibration may be caused by the following Misalignment of the coupling between the engine
28. or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Note High pressure fuel lines may be installed between the high pressure fuel pump and the fuel injectors High pressure fuel lines are constantly charged with high pressure Do not check the high pressure fuel lines with the engine or the starting motor in operation Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure fuel lines Waiting for 10 minutes will to allow the pressure to be purged 1 Drain the fuel from the fuel system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 6 Carefully inspect the engine for any spilled fuel Make sure that no fuel remains on or close to the engine Note Fuel must be added to the fuel system ahead of the fuel filter 7 Refill the f
29. ring 2 counterclockwise Remove locking ring 2 The used element should be removed and discarded Note If the element is equipped with a sediment bowl remove the sediment bowl from the element Thoroughly clean the sediment bowl Inspect the O ring seals for wear or damage Install new O ring seals if necessary Install the sediment bowl onto the new element Hand tighten the sediment bowl Hand tightening is the only method that should be used NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts 4 Ensure that the filter head is clean Push a new element fully into the filter head 5 Hold the element in place Fit locking ring 2 into position Rotate the locking ring clockwise in order to fasten the element to the filter head Note If the nylon insert was removed install the nylon insert and install cap 1 6 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information 101713207 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE 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 when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a
30. starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance 103230840 Stator Lead Check SMCS Code 4459 535 Ensure that the stator output leads are routed out of the generator in a manner that prevents the leads from rubbing against metal objects Visually inspect the following areas for cracking and physical damage e stator output leads e protective sleeving e insulation SEBU7919 04 165 Maintenance Section Stator Winding Temperature Test 103725200 Stator Winding Temperature Test SMCS Code 4453 081 TA Some generators are provided with optional 100 Ohm Resistance Temperature Detectors RTD When the temperature of the stator winding is suspected to be high measure the temperature If the generator is furnished with Resistance Temperature Detectors the detectors are installed in the slots of the main armature stator The detectors are used with equipment that is available from the factory This equipment is used in order to measure the main armature s winding temperature 104871070 Turbocharger Inspect SMCS Code 1052 040 Periodic inspection and cleaning are recommended for the turbocharger compressor housing
31. tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank during the following conditions e Weekly e Oil change e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank A four micron c absolute filter for the breather vent on the fuel tank is also recommended If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used 103642821 Generator Dry SMCS Code 4450 569 NOTICE Do not operate the generator if the windings are wet If the generator is operated when the windings are wet damage can occur due to insulation breakdown When moisture is present or when moisture is suspected in a generator the generator must be dried before being energized If the drying procedure does not restore the insulation resistance to
32. the aftercooler removal procedure 3 Turn the aftercooler core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 4 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 21 lists Hydrosolv liquid cleaners that are available from your Cat dealer Table 21 Hydrosolv Liquid Cleaners Part Pa Number Description Size 1U 5490 Hydrosolv 4165 174 6854 Hydrosolv 100 19 L 5 US gallon 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Cat dealer for more information 5 Steam clean the core in order to remove any residue Flush the tubes of the heat exchanger core Remove any other trapped debris 6 Wash the core with hot soapy water Rinse the core 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 less than 205 kPa 30 psi for cleaning purposes 7 Dry the core with compressed air Direct
33. the air in the reverse direction of the normal flow 8 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 9 Install the aftercooler Refer to the Disassembly and Assembly Manual Aftercooler Remove and Install article for the installation procedure For more information on cleaning the core consult your Cat dealer 126 Maintenance Section Alternator Inspect SEBU7919 04 102676048 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low
34. the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 148 Maintenance Section Fuel System Secondary Filter Replace SEBU7919 04 Turn the fuel supply valve to the OFF position before performing this maintenance Place a tray under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel immediately Illustration 113 g00741109 1 Cap 2 Locking ring 3 Element 4 Water separator bowl 5 Drain 1 Close the fuel supply valve 2 Clean the outside of the fuel filter assembly Drain the fuel into a suitable container by using the fuel drain on the bottom of element 3 Drain the water from water separator 4 into a suitable container Not all engines are equipped with a water separator Note The fuel level in element 3 should be reduced before removal of the element Remove cap 1 if the element is not equipped with a drain on the bottom Remove the nylon insert in order to reduce the level of fuel in the element A reduction in the level of fuel in the element will help prevent fuel from being spilled when the element is removed NOTICE Do not use a tool in order to remove the fuel filter Attempting to remove the fuel filter with a filter wrench or a filter strap could damage the locking ring 3 Hold element 3 and rotate locking
35. this Operation and Maintenance Manual Coolant Change for additional information in filling the cooling system Refer to the Operation and Maintenance Manual Fluid Recommendations for information on the correct mixture and type of coolant Refer to the Operation and Maintenance Manual Refill Capacities for the cooling system capacity 3 Clean filler cap and the receptacle Reinstall the filler cap and inspect the cooling system for leaks Note The coolant will expand as the coolant heats up during normal engine operation The additional volume will be forced into the coolant tank during engine operation When the engine is stopped and cool the coolant will return to the engine 104333559 Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and corrosion The analysis also tests the ability of the coolant to protect the engine from boiling and freezing S O S Systems Coolant Analysis can be done at your Cat dealer Cat S O S coolant analysis is the best way to monitor the condition of your coolant and your cooling system S O S coolant analysis is a program that is based on periodic samples Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with one of the following coolants Cat ELC Extended Life Coolant Cat ELI Extended Life Inhibit
36. 0 Nea Cat DEO ngine Vl SAE 10W 30 Note Cat DEO ULS and Cat DEO multigrade oils are the preferred oils for use in this Cat Diesel Engine Commercial Oil Note Non Cat commercial oils are second choice oils for your engine NOTICE Caterpillar does not warrant the quality or perfor mance of non Cat fluids The three current Caterpillar ECF specifications are Cat ECF 1 a Cat ECF 2 and Cat ECF 3 Each higher Cat ECF specification provides increased performance over lower Cat ECF specifications A commercial oil must meet the following standards to be considered an equivalent of a Cat Diesel Engine Oil SEBU7919 04 109 Maintenance Section Refill Capacities Table 12 Cat Engine Crankcase Fluids ECF Definitions Cat Performance Requirement Cat ECF Specifications Requirements API CJ 4 Oil Category performance Cat ECF 3 A requirements API CI 4 Cl 4 PLUS Oil Category performance requirements Passing standard Cat C13 engine Cat ECF 2 test per API requirements Oils of sulfated ash gt 1 50 percent are not allowed API CH 4 Oil Category performance requirements For oils that are between 1 30 percent and 1 50 percent sulfated ash passing one additional Cat 1P SCOTE test ASTM D6681 is required Cat ECF 1 a Oils of sulfated ash gt 1 50 percent are not allowed In selecting oil for any engine application both of the fol
37. 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 4 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Note If electrical electronic components are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow from the welder could severely damage the component 5 Protect the wiring harness from welding debris and spatter 6 Use standard welding practices to weld the materials 120 SEBU7919 04 Maintenance Section Maintenance Recommendations 103643560 Generator Start up Checklist SMCS Code 4450 Table 19 GENERATOR START UP CHECKLIST RATING INFORMATION Engine Serial Number Arrangement Number Generator Serial Number Arrangement Number GENERATOR NAME PLATE INFORMATION Voltage Package prime continuous standby Amperage Kilowatts Storage Location Generator Alignment Main Stator Megohmmeter Reading Before Storage After Storage Generator dried for 24 hours prior to start up Y N Drying method SPACE HEATERS Yes No Co
38. C Cat SCA Conventional Heavy Duty Coolants Cat ELC Cat ELI Commercial EC 1 Coolants 1 The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified Every 250 hours Yearly Optional Yearly Note Check the SCA Supplemental Coolant Additive of the conventional coolant at every oil change or at every 250 hours Perform this check at the interval that occurs first Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Cat dealer NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Submit the sample for Level 1 analysis Note Level 1 results may indicate a need for Level 2 Analysis 104638756 Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 An S 0 S Coolant Analysis Level 2 is a comprehensive chemical evaluation of the coolant This
39. D381 ISO Resins mL maximum 6246 1 Alternatively to ensure a minimum cetane number of 35 PC engines and 40 DI engines distillate diesel fuel should have a minimum cetane index of 37 5 PC engines and 44 2 DI engines when the ASTM D4737 96a test method is used A fuel with a higher cetane number may be required for operation at a higher altitude or in cold weather 2 Via standards tables the equivalent kg m kilograms per cubic meter using the ASTM D287 test method temperature of 15 56 C 60 F for the minimum API gravity of 30 is 875 7 kg m and for the maximum API gravity of 45 is 801 3 kg m 3 Certain Cat fuel systems and engine components can operate on fuel with a maximum sulfur content of 3 Contact your Cat dealer for guidance about appropriate maintenance intervals and fluids for engines operating on fuel with sulfur levels between 0 1 and 3 4 An engine which operates on fuel with 0 1 1000 ppm of sulfur or more is operating in a severe service application Refer to this Operation and Maintenance Manual Severe Service Application for information about operating an engine in a severe service application 5 Follow the test conditions and procedures for gasoline motor Biodiesel A biodiesel blend of up to 20 percent may be used in the engine when the fuel blend meets the recommendations in table 16 and meets the recommendations in Special Publication
40. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR eon 2012 Operation and Maintenance Manual C4 4 Marine Generator Set MMC1 Up Generator Set 108 Maintenance Section Refill Capacities SEBU7919 04 Maintenance Section Refill Capacities 104856732 Refill Capacities SMCS Code 1000 1348 1395 7560 Lubrication Capacities The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters Auxiliary oil filter systems will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter Table 9 C4 4 Marine Generator Set Engine Approximate Refill Capacity of the Lubrication System Compartment or System Liters Quarts Standard Sump 8 0 8 5 1 These values are the approximate capacities for the crankcase oil sump which include the standard factory installed oil filters Engines with auxiliary oil filters will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter Coolant Capacities To maintain the cooling system the total cooling system capacity must be known The approximate capacity for the engine cooling system is listed External system capacities will vary among applications Refer to the OEM specifications for the external system capacity
41. NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Perform the Operation and Maintenance Manual Engine Air Cleaner Service Indicator Inspect procedure before performing the following procedure NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Note This type of air cleaner is only available on open generator sets N ae Illustration 98 g01197946 1 Unfasten latches 1 Remove cover 2 y ty ANN TSUSRCERE MARREN S34 ot an Illustration 99 g01197952 2 Remove air cleaner element 3 3 Inspect the replacement element for the following items damage dirt and debris Install a clean undamaged air filter element 3 Make sure that the element is properly seated in the air cleaner housing 140 Maintenance Section Engine Air Cleaner Service Indicator Inspect SEBU7919 04 N
42. Sea Water Cooling System for the procedure Illustration 116 g00751785 Typical example of a sea water pump 2 Disconnect both hoses 2 from the sea water pump 1 Illustration 117 g00751786 3 Remove the drain plug 3 from the front cover of the heat exchanger 4 Ensure that the drain hole is not plugged 4 Use the turning tool on the front of the crankshaft in order to rotate the engine This will ensure that all of the water has drained from the sea water pump Illustration 118 g00752040 2 Remove the hose clamp 2 for the sea water strainer Remove the sea water strainer 1 and clean the screen Use clean water to clean the screen Remove any dirt and debris 3 Install the sea water strainer 1 Install the hose and the hose clamp 2 Fill the sea water strainer and the suction line for the auxiliary water pump with water Filling the Sea Water Cooling System Turbocharged Engines Illustration 119 g00751785 164 Maintenance Section Space Heater Test SEBU7919 04 1 Connect the hoses 2 at the sea water pump 1 3 4 Illustration 120 g00751786 2 Install the drain plug 3 in the front cover of the heat exchanger 4 3 Open the valve for the sea water 104865112 Space Heater Test SMCS Code 4450 081 HTR A Caterpillar generator can operate in high humidity conditions without probl
43. This capacity information will be needed in order to determine the amount of coolant antifreeze that is required for the total cooling system Table 10 C4 4 Marine Generator Set Engine Approximate Refill Capacity of the Cooling System Compartment or System Liters Quarts Engine only 13 13 7 External system 18 19 Total cooling system 1 The external system includes an expansion tank with the following components heat exchanger aftercooler piping and keel cooling system 2 Add the capacity for the engine only to the capacity for the external system Enter the total in this row 104862012 Fluid Recommendations SMCS Code 1280 1348 1395 7560 Diesel Engine Oil Cat Diesel Engine Oil Cat DEO Cat oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Cat engines Cat oils are currently used to fill Cat Diesel Engines at the factory These oils are offered by Cat dealers for continued use when the engine oil is changed Consult your Cat dealer for more information on these oils Due to significant variations in the quality and in the performance of commercially available oils Caterpillar makes the following recommendations Table 11 Cat Lubricants Viscosity Grade SAE 15W 40 Diesel Cat DEO ULS Engine SAE 10W 30 Oil Ultra Low Sulf Cat Cold Weather i ulur DEO ULS SAE OW 40 SAE 15W 4
44. ack to the sump for a minimum of ten minutes 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the oil level gauge 146 Maintenance Section Engine Valve Lash Check SEBU7919 04 104242309 Engine Valve Lash Check SMCS Code 1105 535 The initial valve lash adjustment on new engines rebuilt engines or remanufactured engines is recommended at the first scheduled oil change The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components The maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule to help provide maximum engine life Note Only qualified service personnel should perform this maintenance For procedures on adjusting the valve lash and adjusting the valve bridge see System Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust Consult your Cat dealer for assistance Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance 104521055 Fuel System Prime SMCS Code 1250 548 1258 548 If air enters the fuel system the air must be p
45. age with soap and water Ensure that the air discharge for the exhaust duct is clear Clean debris twigs and leaves away from the enclosure package as needed Lubricate the hinges on the door as needed Use Caterpillar Multipurpose Lithium Complex Grease MPGL If Caterpillar Multipurpose Lithium Complex Grease MPGL is not available use a similar multipurpose grease 136 Maintenance Section Engine Clean SEBU7919 04 Note Only chrome hinges require lubrication Powder black door hinges do not require lubrication i02668687 Engine Clean SMCS 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 from utility and or other generators locked out and tagged Do Not Operate NOTICE Water or condensation can cause damage to gen erator components Protect all electrical components from exposure to water NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine Note Do not steam clean the generator Water may damage the generator A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance 104322011 Engine Air Cleaner Element Dual Element Inspect Clean Rep
46. an oil analysis program to determine oil drain intervals is required if fuel sulfur is above 0 5 5000 ppm 4 For fuels of sulfur levels that exceed 1 0 percent 10 000 ppm refer to TBN and engine oil guidelines given in Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations Engine Oil 5 Cat DEO ULS may be used if an oil analysis program is followed High fuel sulfur levels may reduce the oil drain intervals S O S Services Oil Analysis Caterpillar has developed a maintenance tool that evaluates oil degradation the maintenance management also detects the early signs of wear on internal components The Caterpillar tool for oil analysis is called S O S oil analysis and the tool is part of the S O S Services program S O S oil analysis divides oil analysis into four categories e Component wear rate e Oil condition e Oil contamination e Identification of oil These four types of analysis are used to monitor the condition of your equipment The four types of analysis will also help you identify potential problems A properly administered S O S oil analysis program will reduce repair costs and the program will lessen the impact of downtime The S O S Oil Analysis program uses a wide range of tests to determine the condition of the oil and the crankcase Guidelines that are based on experience and a correlation to failures have been established for these tests Exceeding one or more of
47. analysis is also a check of the overall condition of the cooling system The S O S Coolant Analysis Level 2 has the following features Full coolant analysis Level 1 Identification of metal corrosion and contaminants Identification of buildup of the impurities that cause corrosion and scaling Determination of the possibility of electrolysis within the cooling system of the engine The results are reported and appropriate recommendations are made Obtaining the Sample Refer to Operation and Maintenance Manual Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For further information refer to this Operation and Maintenance Manual Fluid Recommendations 104751906 Coolant Temperature Regulator Replace SMCS Code 1355 510 Illustration 93 g00944247 Top view of the expansion tank SEBU7919 04 135 Maintenance Section Electrical Connections Check Replace the water temperature regulator before the water temperature regulator fails Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fa
48. and the generator Faulty mounting or play in the coupling Incorrect balancing of the generator shaft or engine crankshaft A three phase generator has too much load on a single phase There is a short circuit in the stator Check for vibration damage Vibration may cause the following problems e loose fittings e loose bolts e excessive noise e cracked insulation The following areas are susceptible to vibration damage stator output leads protective sleeving insulation exposed electrical connections transformers fuses capacitors Check the vibration level of the generator set by using a broad spectrum analyzer Record the results 154 Maintenance Section Generator Winding Insulation Test SEBU7919 04 104863034 Generator Winding Insulation Test SMCS Code 4453 081 4454 081 4457 081 4470 081 The high voltage that is produced by an operating generator 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 disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Table 24 TOOLS NEEDED Part Number Tool Quantity 142 5055 Insulation Tester 1 Megohmmeter Personal injury
49. ant from the cooling system to a level that is below the hose that is being replaced Drain the coolant into a suitable clean container The coolant can be reused 6 Remove the hose clamps 7 Disconnect the old hose 8 Replace the old hose with a new hose 9 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 10 Refill the cooling system 11 Clean the filler cap for the cooling system Inspect the gaskets on the filler cap Replace the filler cap if the gaskets are damaged Install the filler cap 12 Start the engine Inspect the cooling system for leaks Fuel System Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved 158 Maintenance Section Hoses and Clamps Inspect Replace SEBU7919 04 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose
50. at has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements Ifa primary air cleaner element that passes inspection will not be used the primary air cleaner element can be stored for future use Illustration 97 g00281694 SEBU7919 04 139 Maintenance Section Engine Air Cleaner Element Single Element Inspect Replace Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air cleaner elements in Volatile Corrosion Inhibited VCI paper Place the primary air cleaner element into a box for storage For identification mark the outside of the box and mark the primary air cleaner element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 104871243 Engine Air Cleaner Element Single Element Inspect Replace SMCS Code 1051 1054 040 1054 510 The high voltage that is produced by an operating generator 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
51. ation thoroughly check the air cleaner elements for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes SEBU7919 04 137 Maintenance Section Engine Air Cleaner Element Dual Element Inspect Clean Replace Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 94 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Turbocharger air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air
52. atteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with the 245 5829 Coolant Battery Tester Refractometer 3 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e A mixture of 0 1 kg 0 2 Ib of baking soda and 1 L 1 qt of clean water e 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 the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit properly Coat the clamps and the terminals with 5N 5561 Silicone Lubricant petroleum jelly or MPGM 128 Maintenance Section Belts Inspect Adjust Replace SEBU7919 04 104521280 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Fan Drive Belt Inspection To maximize the engine performance inspect the belts for wear and for cracking Check the b
53. aximum pressure of 207 kPa 30 psi Illustration 95 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside To help prevent damage to the paper pleats aim the hose so that the air flows inside the element along the length of the filter Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements Inspecting the Primary Air Cleaner Elements Illustration 96 g00281693 Inspect the clean dry primary air cleaner element Use a 60W blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If necessary compare the primary air cleaner element to a new primary air cleaner element th
54. by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require precision clearances The turbocharger cartridge must be balanced due to high rpm Severe Service Applications can accelerate component wear Severe Service Applications require more frequent inspections of the cartridge 166 Maintenance Section Varistor Check SEBU7919 04 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Removal and Installation R
55. curs when the engine has not been operated recently allowing the oil to become more viscous due to cooler ambient temperatures Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature Supplemental heat may be necessary for cold soaked starts that are above the minimum temperature depending on factors such as parasitic load Total Base Number TBN and Fuel Sulfur Levels The use of Cat S O S Services oil analysis is recommended strongly for determining oil life The minimum required Total Base Number TBN for oil depends on the fuel sulfur level The TBN for new oil is typically determined by the ASTM D2896 procedure For direct injection engines that use distillate fuel the following guidelines apply 110 Maintenance Section Refill Capacities SEBU7919 04 Table 14 TBN recommendations for applications in Cat Engines TBN of pec a Cat Engine Oils Commercial P PP Engine Oils 0 05 percent Cat DEO ULS Min 7 500ppm Cat DEO gt 0 05 0 2 percent gt 500 ear Min 10 2000 ppm 2 Above 0 2 percent above Cat DEO Min 10 2000ppm 94 1 Cat DEO ULS applies to Cat DEO ULS SAE 15W 40 SAE10W 30 and Cat DEO Cold Weather SAE OW 40 Cat DEO applies to Cat DEO SAE 15W 40 and SAE 10W 30 2 Use of an oil analysis program to determine oil drain intervals is strongly recommended if fuel sulfur is between 0 05 500 ppm and 0 5 5000 ppm 3 Use of
56. d a battery Return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e A recycling facility 101878164 Battery Replace SMCS Code 1401 510 Batteries give off combustible gases which can explode 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 in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced SEBU7919 04 127 Maintenance Section Battery Charger Check The battery cables or the batteries should not be removed 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 with the cover in place may cause a battery explosion resulting in personal injury 1 Switch the engine to the OFF position Remove all electrical loads 2 Turn off any battery chargers Disconnect any battery chargers 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starter motor Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the POSITIVE terminal on the starting motor Disconnect the cable
57. der to the com ponent that will be welded Place the clamp as close as possible to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 1 Stop the engine Turn the switched power to the OFF position 2 Disconnect the negative battery cable from the battery If a battery disconnect switch is provided open the switch 3 Disconnect the J1 P1 and J2 P2 connectors from the ECM Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins SEBU7919 04 119 Maintenance Section Maintenance Recommendations Illustration 84 g01075639 Use the example above The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components 1 Engine 2 Welding electrode 3 Keyswitch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electrical Electronic component 8 Minimum distance between the component that is being welded and any electrical electronic component
58. duled engine overhaul by your Caterpillar dealer before the engine fails This will provide you with the best cost value relationship Note Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life If an overhaul is performed without overhaul service from your Caterpillar dealer be aware of the following maintenance recommendations Rebuild or Exchange Cylinder Head Assembly Oil Pump and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications The Special Publication SEBF8029 lists the reusability publications that are needed for inspecting the engine parts 160 Maintenance Section Overhaul Considerations SEBU7919 04 If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline the parts should be reused Parts that are not within the established inspection specifications should be dealt with in one of the following manners e Salvaging e Repairing e Replacing Using out of spec parts can result in the following problems e Unscheduled downtime e Costly repairs e Damage to other engine parts e Reduced engine efficiency e Increased fuel consumption
59. e on the shaft If the measured end play is greater than the Service Manual specifications the turbocharger should be repaired or replaced An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications 5 Inspect the bore of the turbine housing for corrosion 6 Clean the turbocharger housing and clean the backing plate of the cartridge with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 103291822 Varistor Check SMCS Code 4466 535 The varistor must be checked at regular intervals Refer to Systems Operation Testing and Adjusting KENR5284 Varistor Test for instructions 103291802 Varistor Inspect SMCS Code 4466 040 The varistor must be visually inspected at regular intervals For generator sets with 1400 or with 1600 frames discoloration of the varistor indicates that replacement of the varistor is necessary For generator sets with 1800 frames physical signs of failure indicate that replacement of the varistor is necessary 101491868 Voltage and Frequency Check SMCS Code 4450 535 EL Check for the proper voltage setting and check for the proper frequency setting Check for stabilit
60. e oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual Refill Capacitites and Recommendations for more information on the proper type of oil Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual Refill Capacitites and Recommendations for the proper amount of oil NOTICE If 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 overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain b
61. e pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers If the engine is not equipped with a sampling valve use the 1U 5718 Vacuum Pump The pump is designed to accept sampling bottles Disposable tubing must be attached to the pump for insertion into the sump For instructions see Special Publication PEGJ0047 How To Take A Good S 0 S Oil Sample Consult your Cat dealer for complete information and assistance in establishing an S O S program for your engine 102307330 Engine Oil and Filter Change SMCS Code 1318 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil NOTICE Care must be taken to ensure that fluids are contained during pe
62. e readings at full load AO BO Co Air gap on main stator Top Bottom Air gap on exciter stator Top Bottom Air gap of PMG Top Bottom Ambient air to generator at full load Temperature Supplier air opening to generator Size of Opening SWITCH GEAR PARALLEL OPERATION Manufacturer Setting 1 Setting 2 Setting 3 Comments Circuit breaker type Overload setting Reverse power relay VAR PF Controller Load share INSTALLATION amp LOAD INFORMATION Neutral grounding system UPS Enclosure type Size Motor Other loads Total SKVA Lighting Total HP Computers Welding Non linear Other FULL LOAD DATA Voltage Amps kW KVARS P F SEBU7919 04 123 Maintenance Section Maintenance Interval Schedule 104863170 Maintenance Interval Schedule SMCS Code 1000 4450 7500 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of all maintenance including the following procedures all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Note Use whichever of the follow
63. eeeneees 143 Generator Load Check 0 eeecceeeeeeeeeeteeeeeeeaes 152 Walk Around Inspection cceeeeeeeeeeeereeeees 166 Every Week Automatic Start Stop Inspect eee 126 Space Heater Test ceeeeeeeeeeeeteceeeeeeeeeees 164 Stator Winding Temperature Test 0 165 Voltage and Frequency Check n se 166 Every 250 Service Hours Coolant Sample Level 1 Obtain ee 133 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Coolant Sample Level 2 Obtain 0 134 Every 500 Service Hours or 1 Year Engine Air Cleaner Element Single Element Inspect Replace cceccecceeceeeeeeeeteeteenneeaeees 139 Every 2000 Service Hours or 6 Months Stator Lead Check 00 ccceeeeeeeeeeeeceecaeeeeeeeeees 164 Every Year Coolant Sample Level 2 Obtain 134 Varistor ChecK 2 ccecceeceeeeeeeeeeeteeesenteeaeees 166 Varistor Inspect ic tatiecsetledotectediastenestedadeteetiens 166 Every 14 200 L 3750 US gal of Fuel or 500 Service Hours Battery Charger Check c ccccceeeseeeeeeeneeeees 127 Every 6900 L 1820 US gal of Fuel or 500 Service Hours or 1 Year Auxiliary Water Pump Rubber Impeller INSPEC et a teat a cn iatee tat ete 126 Battery Electrolyte Level Check n 127 Engine Air Cleaner Element Dual Element Inspect Clean Replace 136 Engine Crankcase Breather Rep
64. efer to Disassembly and Assembly Turbocharger Remove for the removal procedure Refer to Disassembly and Assembly Turbocharger Install for the installation procedure Consult with your Caterpillar dealer for further information Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor 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 dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters This restriction causes the turbocharger to slobber 4 Use a dial indicator to check the end clearanc
65. elt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the life of the belts Adjustment If the belts are too loose the belts will vibrate This vibration is enough to cause unnecessary wear on the belts and on the pulleys If the belts are too tight unnecessary stresses are placed upon the pulley bearings and upon the belts These stresses will shorten the life of the belts and of the pulley bearings If new belts are installed check the tension again after 30 minutes of engine operation at the rated rpm For the correct tension on the belt refer to Specifications Belt Tension Chart Replacement For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break Refer to the Service Manual for more information on the procedures for the following topics belt removal and belt installation procedure Alternator Belt Inspection The high voltage that is produced by an operating generator 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
66. ely at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in SEBU7919 04 141 Maintenance Section Engine Crankcase Breather Replace 102312484 Engine Crankcase Breather Replace SMCS Code 1317 510 Turbocharged Engines and Naturally Aspirated Engines Note The housing for the crankcase ventilator filter must also be replaced on engines that are turbocharged Refer to Replace the Housing of the Crankcase Ventilator Filter and the Crankcase Ventilator Filter Replace the Breather on the Valve Cover Illustration 103 g01158031 1 Dust cover 1 Remove dust cover 1 g01158025 Illustration 102 The crankcase breather is located on the valve cover Illustration 104 g01158039 2 Screws 3
67. ems However problems can occur when the generator is idle and the surrounding air is warmer than the generator Moisture can form on the windings that will result in poor performance from the windings Moisture can also result in damage to the windings Whenever the generator is not active ensure that the space heaters are in operation Table 27 Tools Needed Part Number Part Quantity Digital 237 5130 Multimeter 1 1 Stop the generator set 2 Remove the panels in order to allow access to the regulator and control terminal strips Locate terminal strip TS1 3 For 240 V systems use the multimeter to measure the voltage between terminal H1 and terminal H4 If voltage is not present disconnect the power source to terminal H1 and terminal H4 and check for 3 to 12 ohms resistance If there is no resistance check the generator service manual for further information For 120 V systems use the multimeter to measure the voltage between terminal H1 and terminal H2 If voltage is not present disconnect the power source to terminal H1 terminal H2 terminal H3 and terminal H4 Check for 3 to 12 ohms resistance If there is no resistance check the generator service manual for further information 100651416 Starting Motor Inspect SMCS Code 1451 040 1453 040 Caterpillar Inc recommends a scheduled inspection of the starting motor If the
68. ent P97 3016 temperature ISO D5453 20846 Sulfur O0 or or D2622 ISO 20884 1 4 cSt minimum and 20 0 cSt maximum as delivered to the fuel injection Kinematic pumps i i Viscosity 1 4 cSt minimum and 4 5 cSt maximum as delivered to the rotary fuel injection pumps Water and 0 05 PATSA MSO Sediment maximum D2709 3734 No 0 Water 0 05 D6304 equivalent maximum test 0 05 ISo Sediment maximum D473 3735 weight Specifications Requirements ASTM ISO Test Test Aromatics 35 maximum D1319 oes 3837 0 01 7 Ash maximum D482 ISO 6245 weight Carbon 0 35 ISO Residue on maximum D524 4262 10 Bottoms weight 40 minimum i 7 Cetane DI engines pee ISO Number 1 35 minimum D6890 5165 PC engines The cloud point must not exceed So Cloud Point the lowest D2500 3015 expected ambient temperature Copper Strip No 3 D130 ISO Corrosion maximum 2160 10 at 282 C 540 F maximum Distillation D86 a 90 at 360 C 680 F maximum wae a ISO Flash Point legal limit D93 2719 continued continued 112 Maintenance Section Refill Capacities SEBU7919 04 Table 15 contd Caterpillar Specification for Distillate Fuel for Nonroad Diesel Engines Specifications Requirements ASTM ISO Test Test Gums and 10 mg per 100
69. esults only when the generator windings are free of moisture and the generator windings are at room temperature Each winding must have a minimum insulation resistance of 1 megohm Main Armature Stator L4 1 Remove the load from the generator by either of the following e Open the line circuit breaker e Open the following load connections T1 T2 T3 and TO Prevent these wires from coming into contact with each other and prevent these wires from contacting ground 2 Isolate the main armature L4 from the voltage regulator by disconnecting the wires for voltage sensing If generator lead TO is connected to the generator frame or ground open the connection 3 Connect one test lead of the insulation tester megohmmeter to the generator enclosure ground 4 Connect the other test lead of the insulation tester megohmmeter to generator lead TO 5 The insulation resistance must be 1 megohm or more Exciter Field Stator L1 1 Isolate exciter field L1 from the voltage regulator by disconnecting wires 5 and 6 Prevent these wires from coming into contact with each other and prevent these wires from contacting ground 2 Connect one test lead of the insulation tester megohmmeter to the generator enclosure ground 3 Connect one test lead of the insulation tester megohmmeter to exciter field lead 5 or 6 4 Measure the resistance of the exciter field winding insulation to ground The insu
70. ever be reused 5 Start the engine Inspect the air lines for leaks SEBU7919 04 159 Maintenance Section Overhaul Considerations 101585907 Overhaul Considerations SMCS Code 7595 043 Reduced hours of operation at full load will result in a lower average power demand A decreased average power demand should increase both the engine service life and the overhaul interval The need for an overhaul is generally indicated by increased fuel consumption and by reduced power The following factors are important when a decision is being made on the proper time for an engine overhaul e The need for preventive maintenance e The quality of the fuel that is being used e The operating conditions e The results of the S O S analysis Oil Consumption as an Overhaul Indicator Oil consumption fuel consumption and maintenance information can be used to estimate the total operating cost for your Caterpillar engine Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals Oil consumption is in proportion to the percentage of the rated engine load As the percentage of the engine load is increased the amount of oil that is consumed per hour also increases The oil consumption rate brake specific oil consumption is measured in grams per kW h lb per bhp The brake specific oil consumption BSOC depends on the engine load Consult your Caterpillar
71. f oil Air pressure should be a maximum of 210 kPa 30 psi in order to prevent mechanical damage to the insulation If the above cleaning procedures are not effective consult a Caterpillar dealer Cleaning Disassembled Generators NOTICE Do not use water to clean the generator NOTICE Do not use trichloroethane perchlorethylene trichloroethane or any alkaline products to clean the generator 152 Maintenance Section Generator Load Check SEBU7919 04 An initial insulation resistance check should be made on the generator in order to confirm electrical integrity A minimum reading of one megohm would be expected with severely contaminated generators A zero megohm reading may indicate an insulation breakdown An insulation breakdown requires more than cleaning An insulation breakdown requires repair Use the following for cleaning the stator the rotor the exciter and the diode bridge e Unleaded Gasoline e Toluene e Benzene e Ciclohexare Avoid permitting the solvent to run into the slots Apply the solvent with a brush Use a sponge on the windings frequently in order to remove the debris Dry the winding with a dry cloth Allow the solvent to evaporate before reassembling the generator Allow the generator to dry at room temperature Check the insulation resistance The insulation resistance should now be normal If the insulation resistance is not normal repeat the procedure Note For more
72. from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the cable from the NEGATIVE terminal on the starter motor to the NEGATIVE battery terminal 101942625 Battery Charger Check SMCS Code 1401 535 Check the battery charger for proper operation If the batteries are properly charged the needle of the ammeter will register near 0 zero The batteries should be kept warm when possible The temperature of the battery will affect cranking power A battery that is too cold will not crank the engine even if the engine is warm The batteries may not fully recharge when the engine is not run for long periods of time The batteries may not fully recharge if the engine only runs for short periods Ensure a full charge in order to help prevent the battery from freezing 102601752 Battery Electrolyte Level Check SMCS Code 1401 535 FLV When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing All lead acid b
73. gine mounts Any engine mount that shows deterioration should be replaced Refer to Special Publication SENR3130 Torque Specifications for the recommended torques Refer to the OEM recommendations for more information 100623423 Engine Oil Level Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin e lt ADD FULL 5 g00110310 Illustration 108 Y ADD mark X FULL mark NOTICE Perform 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 fill the crankcase above FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping 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 104237495 Engine Oil Sample Obtain SMCS Code 1348 554 SM In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regularly scheduled intervals S O S oil analysis provides infrared analysis which is required for determining nitration and oxidation levels Obta
74. hese steps a Place the red test lead on the positive rectifier terminal 1 Place the black test lead on the following rectifier terminals AC terminal 2 AC terminal 3 and AC terminal 4 In all cases the meter should read OL overload b Place the black test lead on the positive rectifier terminal 1 Place the red test lead on the following rectifier terminals AC terminal 2 AC terminal 3 and AC terminal 4 All readings on the meter should be between 0 4 and 1 0 Note For further information contact your Cat dealer 102312204 Sea Water Strainer Clean Inspect SMCS Code 1371 040 1371 070 The sea water strainer must be clean in order to allow proper engine cooling Check the sea water strainer for plugging Inspect the sea water strainer more frequently if the vessel is being operated in water which is shallow or dirty The sea water strainer protects the aftercooler from debris The sea water strainer will catch pieces of the rubber impeller from the raw water pump due to a failure from debris The sea water strainer is installed on turbocharged engines only Drain the Sea Water Cooling System Turbocharged Engines 1 Close the valve for the sea water SEBU7919 04 163 Maintenance Section Sea Water Strainer Clean Inspect Clean the Sea Water Strainer Turbocharged Engines 1 Ensure that the sea water cooling system is drained Refer to Drain the
75. high pressure fuel lines in order to remove air pressure from the fuel system Engine Oil To relieve pressure from the lubricating system turn off the engine 103642798 Welding on Engines with Electronic Controls SMCS Code 1000 NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult the OEM of the equip ment or your Caterpillar dealer regarding welding on a chassis frame or rail Proper welding procedures are necessary in order to avoid damage to the engine s ECM sensors and associated components When possible remove the component from the unit and then weld the component If removal of the component is not possible the following procedure must be followed when you weld on a unit that is equipped with a Caterpillar Electronic Engine The following procedure is considered to be the safest procedure to weld on a component This procedure should provide a minimum risk of damage to electronic components NOTICE Do not ground the welder to electrical components such as the ECM or sensors Improper grounding can cause damage to the drive train the bearings hy draulic components electrical components and other components Do not ground the welder across the centerline of the package Improper grounding could cause damage to the bearings the crankshaft the rotor shaft and other components Clamp the ground cable from the wel
76. ically by the coolant supplier The coolant manufacturer is responsible for ensuring compatibility and acceptable performance To help ensure expected performance EC 1 coolants require the one time maintenance addition of an ex tender at coolant service mid life Do not use an ex tender with a coolant unless the extender has been approved specifically for use by the coolant manufac turer The coolant manufacturer is responsible for en suring compatibility and acceptable performance Failure to follow these recommendations can result in shortened cooling system component life Cat ELC can be recycled into conventional coolants For more information refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations S O S Services Coolant Analysis Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and corrosion The analysis also tests the ability of the coolant to protect the engine from boiling and freezing S O S coolant analysis can be done at your Cat dealer Cat S O S coolant analysis is the best way to monitor the condition of your coolant and your cooling system S O S coolant analysis is a program that is based on periodic samples Table 18 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEAC Conventional Heavy Duty Coolants Every 250 hours Yearly Cat ELC Cat ELI i 1 Commercial Optional Yearly
77. ils in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed If the water temperature regulator is installed incor rectly the engine may overheat causing cylinder head damage Ensure that the new water temperature reg ulator is installed in the original position Ensure that the water temperature regulator vent hole is open Do not use liquid gasket material on the gasket or cylinder head surface NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids
78. in the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Before you take the oil sample complete the Label PEEP5031 for identification of the sample In order to help obtain the most accurate analysis provide the following information e Engine model e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change To ensure that the sample is representative of the oil in the crankcase obtain a warm mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Caterpillar recommends using the sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when the sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation The 169 8373 Fluid Sampling Bottle is recommended for use with the sampling valve The fluid sampling bottle includes the parts that are needed for obtaining oil samples Instructions are also provided 144 Maintenance Section Engine Oil and Filter Change SEBU7919 04 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the sam
79. ine and allow the engine to cool 3 Remove the filler cap Maintain the coolant level 12 mm 0 5 inch below the neck of the filler tube 4 Clean the cooling system filler cap Inspect the gasket for the cooling system filler cap If the gasket for the cooling system filler cap is damaged discard the cap and install a new cooling system filler cap If the gasket for the cooling system filler cap is not damaged use a 9S 8140 Pressurizing Pump to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 5 Pour the ELC into the recovery tank until the coolant reaches the COLD FULL mark if equipped Do not fill the tank above the COLD FULL mark 6 Clean the cooling system filler cap Install the cooling system filler cap Start the engine Inspect the cooling system for leaks and for proper operating temperature 132 Maintenance Section Coolant Extender ELC Add SEBU7919 04 104862631 Coolant Extender ELC Add SMCS Code 1352 544 NL Note Refer to this Operation and Maintenance Manual Fluid Recommendations Cooling System for the maintenance interval for the addition of the coolant extender Cat ELC Extended Life Coolant and Cat ELI Extended Life Inhibitor do not require
80. ine over time A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system A full water analysis can be obtained by consulting your local water utility company or an agricultural agent Private laboratories are also available for water analysis Caterpillar recommends an S O S Coolant Analysis Level Il S O S Coolant Analysis Level Il An S 0 S Coolant Analysis Level Il is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system An S O S Coolant Analysis Level Il provides the following information e Complete S O S Coolant Analysis Level I e Visual inspection of properties e Identification of metal corrosion e Identification of contaminants e Identification of built up impurities corrosion and scale S 0 S Coolant Analysis Level Il provides a report of the results of both the analysis and the maintenance recommendations For more information about coolant analysis see your Caterpillar dealer 104864876 Rotating Rectifier Inspect Test SMCS Code 4465 040 4465 081 Inspect Check the exciter armature Ensure that the rotating rectifier is tight If a failure of a rectifier is suspected refer to the Rotating Rectifier Test section below 162 Maintenance Section Sea Water Strainer Clean Inspect SEBU7919 04 Test The high voltage that is produced by an operating
81. ing that occurs first in order to determine the maintenance intervals fuel consumption service hours and calendar time Before each consecutive interval is performed all maintenance from the previous intervals must be performed Products that operate in severe operating conditions may require more frequent maintenance When Required Battery Recycle ooo ccceeeeeneeneeeeeeenteeeeeeenaaes 126 Battery Replace ooo eeeeeeeeeteeeeeeesteeeeeeeaaes 126 Circuit Breakers Reset l enn 129 Coolant Change nassos rediad 129 Coolant Extender ELC Add s es 132 Enclosure Inspect 2 cceceeeeeeeeeeecceeceeeeeeeeees 135 Engine Clean ccccceceseeceeeeeseeceeeeeeeeeceeeeeneenees 136 Engine Air Cleaner Element Dual Element Inspect Clean Replace n 136 Engine Air Cleaner Element Single Element Inspect Replace ceeecccececeeeeeeeeeteeteteteeeeees 139 Fuel System Prime cccceeeceeeeeeeeeeeeteeeeeeenaaes 146 Generator Dry ccceeeeeecteeeeeeeeecteeeeeeeneeeeeeenaaes 150 Generator Set Test aaaeei 152 Generator Winding Insulation Test 0 0 0 154 Daily Belts Inspect Adjust Replace ccee 128 Control Panel Inspect Test 0eseeeeeees 129 Coolant Level Check eecceeeeeeeeneeeeeenaes 132 Electrical Connections Check eese 135 Engine Air Cleaner Service Indicator Inspect 140 Engine Oil Level Check ecceeeeeteee
82. ings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Caterpillar 1 Remove the oil filter with a 1U 8760 Chain Wrench 2 Cut the oil filter open with a 175 7546 Oil Filter Cutter Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter DT tse Illustration 110 g00741009 Typical mounting base for the oil filter and oil filter gasket 3 Clean the sealing surface of the filter mounting base Ensure that all of the old oil filter gasket is removed 4 Apply clean engine oil to the new oil filter gasket NOTICE Do not fill th
83. is visual electrical or thermal evidence that dirt is present If harmful dirt accumulations are present a variety of cleaning techniques are available The cleaning procedure that is used may be determined by one of the items on the following list e The extent of the cleaning procedure that is being attempted e The type of enclosure of the generator e The voltage rating of the generator e The type of dirt that is being removed Cleaning Assembled Generators NOTICE Do not use water to clean the generator NOTICE Do not use trichloroethane perchlorethylene trichloroethane or any alkaline products to clean the generator Cleaning may be required at the point of installation At this point complete disassembly of the generator may not be necessary or feasible In this case a vacuum cleaner should be used to pick up the following items dry dirt dust and carbon This will prevent the spreading of these contaminants A small nonconductive tube may need to be connected to the vacuum cleaner This will allow the vacuum cleaner to clean the surfaces that are not exposed After most of the dust has been removed a small brush may be attached to the vacuum hose in order to loosen dirt that is more firmly attached to the surface After the initial cleaning with a vacuum compressed air may be used to remove the remaining dust and dirt Compressed air that is used for cleaning should be free of moisture and free o
84. lace 141 Engine Mounts Inspect ieee 143 Engine Oil Sample Obtain a a 143 Engine Oil and Filter Change s e 144 Fuel System Primary Filter Water Separator Element Replace ccecceceeeeeeeeeeeeeeees 147 Fuel System Secondary Filter Replace 148 Fuel Tank Water and Sediment Drain 149 Heat Exchanger Inspect iseenesesse 155 Hoses and Clamps Inspect Replace 156 Sea Water Strainer Clean Inspect 2 162 Every 13 800 L 3650 US gal of Fuel or 1000 Service Hours or 1 Year Engine Valve Lash Check seisseen 146 Every 27 600 L 7290 US gal of Fuel or 2000 Service Hours or 2 Years Aftercooler Core Inspect Clean Test 125 Alternator Inspect c cceeeeceeeeeeeeeeeeeseeeaeees 126 124 Maintenance Section Maintenance Interval Schedule SEBU7919 04 Coolant Temperature Regulator Replace 134 Generator Inspect cccceceeeeeeseeeeeeeenteeeeees 150 Generator Set Vibration Test Record 153 Rotating Rectifier Inspect Test ee 161 Starting Motor Inspect seeen 164 Turbocharger Inspect n se 165 Water Pump Inspect c cecceeeeeeeeeeeeetreeees 167 Every 165 600 L 43 750 US gal of Fuel or 12 000 Service Hours Overhaul Considerations ccccccccceeeeeeeeeeeeeeees 159 SEBU7919 04 125 Maintenance Section Aftercooler C
85. lace SMCS Code 1051 1054 040 1054 070 1054 510 NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Your Cat dealer has the proper air cleaner elements for your application Consult your Cat dealer for the correct air cleaner element Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before install
86. lation resistance must be a minimum of 0 25 megohm 250000 ohms Exciter Armature Rotor L2 1 Isolate exciter armature L2 from the rectifier circuit Disconnect the three wires of the exciter armature from the rectifier blocks 2 Connect one test lead of the insulation tester megohmmeter to the rotor shaft 3 Connect one test lead of the insulation tester megohmmeter to any one exciter field lead 4 The insulation resistance must be a minimum of 0 25 megohm 250000 ohms 101592749 Heat Exchanger Inspect SMCS Code 1379 040 The interval for the maintenance of the tube type heat exchanger depends on the operating environment of the vessel and on the operating time The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items e Cleanliness of the tubes for the heat exchanger e Effectiveness of the heat exchanger system Operating in water that contains silt sediment salt algae etc will adversely affect the heat exchanger system In addition intermittent use of the vessel will adversely affect the heat exchanger system The following items indicate that the heat exchanger may require cleaning e Increased coolant temperature e Engine overheating e Excessive pressure drop between the water inlet and the water outlet An operator that is familiar with the normal operating temperature of the coolant can determine when the coola
87. lowing must be satisfied the oil viscosity and the category of oil performance or the specification for oil performance Using only one of these parameters will not sufficiently define oil for an engine application The proper SAE viscosity grade of oil is determined by the following temperatures minimum ambient temperature during cold engine start up and maximum ambient temperature during engine operation Refer to Table 13 minimum temperature in order to determine the required oil viscosity for starting a cold engine Refer to Table 13 maximum temperature in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated Note Generally use the highest oil viscosity that is available to meet the requirement for the temperature at start up Table 13 Lubricant Viscosities for Ambient Temperatures Oil Type and A C F Oil Performance Vi iti Requirements Iscosities Min Max Min Max Cat DEO ULS E E Cold Weather SAE OW 40 40 40 40 104 A e eaa karaoa Cat DEO ULS 3 Cat DEO Pea 10 50 14 122 SAE OW 40 40 40 40 104 SAE 5W 30 30 30 22 86 SAE OW 30 40 30 40 86 z SAE 5W 40 30 50 22 122 Commercial Oils ECF 1a ECF 2 SAE 10W ECF 3 30 18 40 O 104 SAE 10W _ A 18 50 0 122 sos ha 9 5 50 15 122 Note A cold soaked start oc
88. mments Space heaters operating properly Space heater operated 48 hrs before start up MEGOHMMETER TEST SEHS9124 30 sec 60 sec 30 sec 60 sec Ambient Comments reading reading corrected corrected temp Beginning of Main Stator mite Main Rotor Exciter Stator Exciter Rotor PMG Stator Start up Main Stator Main Rotor Exciter Stator Exciter Rotor PMG Stator Regulator Voltage Amps Comments No Load F1 to F2 DC 20 to 22 AC 20 to 24 AC 22 to 24 AC 26 to 28 AC 26 to 30 AC 28 to 30 AC continued SEBU7919 04 121 Maintenance Section Maintenance Recommendations Table 19 contd GENERATOR START UP CHECKLIST Full Load Generator Excitation Name DC Compare with F1 to F2 Plate Information F1 to F2 DC 20 to 22 AC 20 to 24 AC 22 to 24 AC 26 to 28 AC 26 to 30 AC 28 to 30 AC 122 SEBU7919 04 Maintenance Section Maintenance Recommendations Table 20 GENERATOR START UP CHECKLIST CONT ELECTRICAL Yes No Comments Unit properly grounded Check diodes Over current protection Over voltage protection Check for loose wiring Adjust voltage Adjust frequency Verify kilowatt transducer if applicable MECHANICAL Data Comments Bearing temperature readings at full load Front Rear Stator temperatur
89. nt Thoroughly clean the sediment bowl Inspect the O ring seals Install new O ring seals if necessary Install the sediment bowl to the new element Hand tighten the sediment bowl Hand tightening is the only method that should be used NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts 4 Ensure that the fuel filter base is clean Push a new fuel filter fully into the fuel filter base 5 Hold the fuel filter in place Fit locking ring 3 into position Rotate the locking ring clockwise in order to fasten the fuel filter to the fuel filter base Note If the nylon insert was removed install the nylon insert and install cap 1 6 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime 104363480 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products
90. nt temperature is out of the normal range Inspection and maintenance of the heat exchanger are required if the engine is overheating 156 Maintenance Section Hoses and Clamps Inspect Replace SEBU7919 04 Cleaning the Heat Exchanger 1 Remove the heat exchanger Refer to the Service Manual for the procedure 2 Turn the heat exchanger core upside down in order to remove debris NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 3 Back flush the core with cleaner Caterpillar recommends the use of Hydrosolv liquid cleaner Table 25 lists Hydrosolv liquid cleaners that are available from your Caterpillar dealer Table 25 Hydrosolv Liquid Cleaners Part agi Number Description Size 1U 5490 Hydrosolv 4165 174 6854 Hydrosolv 100 19 L 5 US gallon 19 L 5 US gallon 1 Use a two to five percent concentration of the cleaner at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpillar dealer for more information 4 Steam clean the core in order to remove any residue Flush the tubes of the heat exchanger core Remove any other trapped debris 5 Wash the core with hot soapy water Rinse the core thoroughly with clean water Personal injury can resul
91. or and Conventional Heavy Duty Coolant Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any of the following coolants Cat DEAC Cat SCA and Conventional Heavy Duty Coolants For additional information about coolant analysis and about other coolants see this Operation and Maintenance Manual Fluid Recommendations or consult your Cat dealer Sampling Conditions If the engine is equipped with a sampling port the engine should be running at operating temperature when the sample is obtained If the engine is not equipped with a sampling port the coolant should be warm Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample 134 Maintenance Section Coolant Sample Level 2 Obtain SEBU7919 04 e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination e Never collect samples from expansion bottles e Never collect samples from the drain for a system Timing of the Sampling Table 22 Recommended Interval Type of Coolant Level 1 Level 2 Cat DEA
92. or death can result from electro cution The megohmmeter is applying a high voltage to the circuit To avoid electrocution do not touch the instru ment leads without first discharging them When finished testing also discharge the generator windings The following materials will cause the winding insulation to deteriorate moisture dust grease and other foreign matter within the generator This deterioration reduces the resistance of the insulation This test will measure the resistance of the winding insulation The insulation tester megohmmeter produces a high potential voltage between the test leads During the test a small amount of current flows The tester converts this current to a resistance reading The insulation test is performed as part of periodic maintenance in order to detect the deterioration of the winding insulation When there is a rapid decrease in the insulation resistance in a short amount of time the generator needs to be cleaned Note For information on generator cleaning refer to Special Instruction SEHS9124 When generators have not been used recently moisture can accumulate Therefore the insulation test should be performed on generators that have been idle If moisture is known to exist the windings must be dried prior to testing Refer to Testing and Adjusting Generator Dry The insulation test should be performed on generators that are being used for the first time The
93. ore Inspect Clean Test 104862171 Aftercooler Core Inspect Clean Test SMCS Code 1064 040 1064 070 1064 081 The interval for the cleaning of the aftercooler core depends on the operating environment of the vessel and on the operating time The sea water that is circulated through the aftercooler and the amount of operating time of the vessel affects the following items e Cleanliness of the tubes for the aftercooler e Effectiveness of the aftercooler Operating in water that contains the following will adversely affect the aftercooler silt sediment salt and algae Note Adjust the frequency of cleaning according to the effects of the operating environment NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Drain the aftercooler 2 Remove the aftercooler Refer to the Disassembly and Assembly Manual Aftercooler Remove and Install article for
94. pped Allow the coolant to drain NOTICE Dispose of used engine coolant properly or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant SEBU7919 04 131 Maintenance Section Coolant Change For information regarding the disposal and the recycling of used coolant consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool Group Inside USA 1 800 542 TOOL Inside Illinois 1 800 541 8 TOOL Canada 1 800 523 TOOL International 1 309 578 7372 Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Clean the drain plugs Install the drain plugs For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks Illustration 91 g01157269 3 Make sure that all the plugs that were removed in the previous steps have been installed Remove plug 6 Remove filler cap and begin filling the system with clean water Install plug 6 as the water begins to run out of the hole for plug 6 For the proper torque refer to the Specifications Manual SENR3130 Torque Specifications After the plugs are installed continue filling the system until the water level is approximately 12 mm
95. ptible to damage that is caused by the stresses that are listed above Exposure to these stresses may shorten the effective life of the electrical insulation system Therefore the service life of an electric machine will largely depend on the serviceability of the electrical insulation systems An inspection program and a testing procedure are recommended An inspection program and a testing procedure will ensure that the equipment is maintained in satisfactory condition This will increase field reliability A regular maintenance and inspection program can provide an evaluation of the present condition of the equipment A regular maintenance program and a regular inspection program can also reveal future problems The frequency of this maintenance program will depend on the following factors e application e environmental conditions e operator s experience e operator s philosophy A regular maintenance program is strongly recommended This program would involve the following steps e periodic disassembly e knowledgeable visual examination of the equipment e the application of electrical tests Never perform a test over the rated potential These tests can damage insulation that is contaminated or insulation that is in marginal condition For more information refer to I E E E Standard 432 1992 or consult a Caterpillar dealer 102909163 System Pressure Release SMCS Code 1250 1300 1350 5050 Coolant System P
96. r a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauges Replace any gauges which are cracked or any gauges that can not be calibrated 103543200 Water Pump Inspect SMCS Code 1361 040 A failed water pump might cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head a piston seizure or other potential damage to the engine Visually inspect the water pump for leaks If leaking of the water pump seals is observed replace all of the water pump seals Refer to two articles in the Disassembly and Assembly Manual Water Pump Disassemble and Water Pump Assemble for the disassembly and assembly procedure If it is necessary to remove the water pump refer to two articles in the Disassembly and Assembly Manual Water Pump Remove and Water Pump Install 168 Maintenance Section Water Pump Inspect SEBU7919 04 Inspect the water pump for wear cracks pin holes and proper operation Refer to the Parts Manual for the correc
97. r dealer for more information 4 Use steam to clean the cores This removes any remaining residue from the cleaner Flush the fins of each of the cores Remove any other trapped debris 5 Wash the cores with hot soapy water Rinse the cores 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 less than 205 kPa 30 psi for cleaning purposes 6 Dry the cores with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the components in order to ensure cleanliness The oil cooler core and the heat exchanger core should be pressure tested Repair cores if necessary Install the oil cooler core and the heat exchanger 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 kits or with S O S Coolant Analysis Level I Further coolant analysis is recommended when the engine is overhauled For example considerable deposits are found in the water jacket areas on the external cooling system but the concentrations of coolant additives were carefully maintained The coolant water probably contained minerals that were deposited on the eng
98. rant the quality or perfor mance of non Cat fluids and filters For more information refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations or consult your Cat dealer for further information SEBU7919 04 111 Maintenance Section Refill Capacities Specifications for Distillate Diesel Fuel Note Diesel fuel used to operate a Cat Marine Diesel Engine which is certified to US EPA Tier 3 Standards must also meet the Cat Specification for Distillate Diesel Fuel for Off Highway Diesel Engines The acceptability of these fuels for use is determined on a case by case basis A complete fuel analysis is required Consult your Cat dealer for further information NOTICE The footnotes are a key part of the Caterpillar Specifi cation for Distillate Diesel Fuel for Off Highway Diesel Engines Table Read ALL of the footnotes Table 15 Table 15 contd Caterpillar Specification for Distillate Fuel for Nonroad Diesel Engines Caterpillar Specification for Distillate Fuel for Nonroad Diesel Engines Specifications Requirements ASTM ISO Test Test Minimum of 80 reflectance No ee after aging for D6468 equivalent y 180 minutes test at 150 C 302 F 30 minimum No API Gravity D287 equivalent 45 maximum test 6 C 10 F minimum M ISO Pour Point below ambi
99. ressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure To relieve the pressure from the coolant system turn off the engine Allow the cooling system pressure cap to cool Remove the cooling system pressure cap slowly in order to relieve pressure Fuel System To relieve the pressure from the fuel system turn off the engine High Pressure Fuel Lines If Equipped Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head These fuel lines are different from fuel lines on other fuel systems This is because of the following differences e The high pressure fuel lines are constantly charged with high pressure 118 Maintenance Section Maintenance Recommendations SEBU7919 04 e The internal pressures of the high pressure fuel lines are higher than other types of fuel system Before any service or repair is performed on the engine fuel lines perform the following tasks 1 Stop the engine 2 Wait for ten minutes Do not loosen the
100. rformance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Remove the oil drain plug from the oil pan or use one of the following methods in order to drain the engine oil into a suitable container Dispose of the used oil in accordance with local regulations Drain Valve If Equipped Illustration 109 g01155733 Drain valve for the engine oil 1 The oil drain valve may be connected to the used oil tank for the vessel The drain valve may have a plug that is threaded into the end of the valve or the fittings on the valve If there is a plug remove the plug 2 Open the drain valve and allow the oil to drain into a suitable container or the piping for used oil on the vessel Dispose of the used oil in accordance with local regulations SEBU7919 04 145 Maintenance Section Engine Oil and Filter Change Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci fications Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bear
101. rs in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air cleaner elements while dirty elements are being cleaned NOTICE Do not clean the air cleaner elements by bumping or tapping 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 Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements e Pressurized air e Vacuum cleaning 138 Maintenance Section SEBU7919 04 Engine Air Cleaner Element Dual Element Inspect Clean Replace Pressurized Air 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 less than 205 kPa 30 psi for cleaning purposes Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a m
102. s according to local regulations and mandates 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 If necessary drain enough coolant from the cooling system in order to add the Cat ELC Extender 3 Add Cat ELC Extender according to the requirements for the cooling system capacity Refer to this Operation and Maintenance Manual Refill Capacities for the coolant capacity 4 Clean the cooling system filler cap Inspect the gaskets on the cooling system filler cap Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap For further information refer to this Operation and Maintenance Manual Fluid Recommendations 104862649 Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and cool Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure SEBU7919 04 133 Maintenance Section Coolant Sample Level 1 Obtain Illustration 92 g01342207 Typical header tank 1 Loosen filler cap slowly in order to relieve any pressure Remove the filler cap 2 Pour the proper coolant mixture into the tank until the coolant reaches the baffle 1 Refer to
103. sel Engine Fluids Recommendations for complete information about the proper fluids for use in the cooling system The cooling system operates under pressure which is controlled by the radiator pressure cap Removing the cap while the system is hot may al low the escape of hot coolant and steam causing serious burns Before you remove the radiator cap allow the sys tem to cool Use a thick cloth and turn the radiator cap slowly to the first stop to allow pressure to es cape before fully removing the cap Avoid contact with coolant NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to cool first NOTICE If the engine is to be stored in or shipped to an area with below freezing temperatures the cooling system must be either protected to the lowest outside temper ature or drained completely in order to prevent dam age caused by freezing coolant SEBU7919 04 113 Maintenance Section Refill Capacities Never operate an engine without water temperature regulators in the cooling system Water temperature regulators help to maintain the engine coolant at the proper operating temperature Cooling system problems can develop without water temperature regulators Removing the regulators allows some coolant to bypass the radiator potentially causing overheating 114 Maintenance Section Refill Capacities SEBU7919 04 Coolant Recommendations Note A Cat Diesel
104. si tion Attach DO NOT OPERATE tags to all start ing controls Disconnect the batteries or disable the starting system Lock out all switchgear and automatic transfer switches that are associated with the generator Refer to Safety Section Generator Isolating for Maintenance for information regarding the procedure to safely isolate the generator Proper maintenance of electrical equipment requires periodic visual examination of the generator and periodic visual examination of the windings Proper maintenance of electrical equipment also requires appropriate electrical checks and appropriate thermal checks Insulation material should be examined for cracks The insulation material should be examined for accumulations of dirt and dust If there is an insulation resistance value that is below normal a conductive path may be present This conductive path may be made of one of the following materials e Carbon e Salt e Metal dust e Dirt that is saturated with moisture These contaminants will develop a conductive path which may produce shorts Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen If excess dirt is the cause of a restriction in the ventilation cleaning is also advisable Restricted ventilation will cause excessive heating NOTICE To avoid the possibility of deterioration to the genera tor windings do not clean the generator unless there
105. t 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 less than 205 kPa 30 psi for cleaning purposes 6 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 7 Inspect the core in order to ensure cleanliness Pressure test the core Many shops that service radiators are equipped to perform pressure tests If necessary repair the core 8 Install the heat exchanger Refer to the Service Manual for the procedure For more information on cleaning the core consult your Caterpillar dealer 104301694 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Hoses and clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death Leaks that are the size of a pin hole are included Refer to Operation and Maintenance Manual General Hazard Information for more information Inspect the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions Replace any hose which exhibits any of the
106. t part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed
107. the frequent additions of any supplemental cooling additives The Cat ELC Extender will only be added one time Note Do not use conventional supplemental coolant additive SCA with Cat ELC or with Cat ELI Check the cooling system only when the engine is stopped and cool Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Cat Dealer Service Tool Catalog or refer to Special Publication PECJ0003 Cat Shop Supplies and Tools Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluid
108. these guidelines could indicate serious fluid degradation or a pending component failure A trained person at your Cat dealership should make the final analysis NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Refer to Special Publication SEBU6251 Cat Commercial Diesel Engine Fluids Recommendations in order to obtain additional information about S O S Services oil analysis You can also contact your local Cat dealer Fuel Note Caterpillar strongly recommends the filtration of fuel through a fuel filter with a rating of four microns c absolute or less This filtration should be located on the device that dispenses the fuel to the fuel tank for the engine This filtration should also be located on the device that dispenses fuel from the bulk storage tank Series filtration is recommended NOTICE In order to meet expected fuel system component life 4 micron c absolute or less secondary fuel filtration is required for all Cat Diesel Engines that are equipped with unit injected fuel systems All current Cat Diesel Engines are factory equipped with Cat Advanced Effi ciency 4 micron c absolute fuel filters Caterpillar does not war
109. tight Check for leaks Check the condition of all pipes e Inspect the water pumps for coolant leaks Note The water pump seal is lubricated by coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of water pumps and the installation of water pumps and or seals refer to the Service Manual for the engine or consult your Caterpillar dealer e Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the valve cover Inspect the fuel system for leaks Look for loose fuel line clamps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap fo
110. ts SCA Supplemental Acceptable Cat DEAC Cat Diesel Engine Antifreeze Coolant sl ee PAE intervals ASTM D6210 and Min requirements for fully Nitrite as NO2 concentration Minimum of 1200 ppm 70 3000 hours SCA at formulated Heavy Duty grains US gal and maximum of 2400 ppm 140 grains US gal or Dears maintenance Commercial coolants Silicon concentration minimum of 100 ppm and y intervals maximum of 275 ppm ASTM D4985 and 1 SCA at initial Min requirements for Nitrite as NO2 concentration Minimum of 1200 ppm 70 3000 hours fill and SCA at Commercial coolants grains US gal and maximum of 2400 ppm 140 grains US gal ord vear Maintenance requiring SCA precharge Silicon concentration minimum of 100 ppm and y intervals 1 New Coolants at 50 volume percent diluted Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets Reagent 4 ASTM D1193 requirements 2 Maintain the in service coolant at the given limits 3 When referring to the service hours use the interval that occurs first These coolant change intervals are only achievable with annual S O S Services Level 2 coolant sampling analysis SEBU7919 04 115 Maintenance Section Refill Capacities NOTICE Use Only Approved SCAs and Extenders Conventional coolants require the maintenance ad dition of SCA throughout the expected life of the coolants Do NOT use an SCA with a coolant unless approved specif
111. uel system Refer to this Operation and Maintenance Manual Fuel System Prime for information about priming the engine with fuel 8 Start the engine Inspect the fuel system for leaks Lubrication System Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 1 Drain the oil from the lubrication system to a level that is below the hose that is being replaced 2 Remove the hose clamps 3 Disconnect the old hose 4 Replace the old hose with a new hose 5 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps 6 Refill the lubrication system Refer to this Operation and Maintenance Manual Engine Oil Level Check in order to ensure that the lubrication system is filled with the proper amount of engine oil 7 Start the engine Inspect the lubrication system for leaks Air System 1 Remove the hose clamps 2 Disconnect the old hose 3 Replace the old hose with a new hose 4 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for information about selecting and installing the proper hose clamps Note The bellows and the V clamps that are used on the bellows should n
112. urged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur e The fuel tank is empty or the fuel tank has been partially drained e The low pressure fuel lines are disconnected e A leak exists in the low pressure fuel system e The fuel filter is replaced e A new injection pump is installed Use the following procedure in order to remove air from the fuel system Priming the Fuel System with the START Switch 1 Remove the cover for the fuel injectors Refer to the Disassembly and Assembly Manual 2 Turn the key switch to the RUN position Leave the key switch in the RUN position for 3 minutes 3 Turn the key switch to the OFF position g01003929 Illustration 111 Injector nuts Note Damage to the following components may occur if the starting motor is used excessively to purge the air from the fuel system fuel injection pump the battery and the starting motor 4 Loosen the flare nuts 1 for the high pressure fuel lines on all of the fuel injectors NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 5 Observe the connection at the flare nut Operate the starting motor and crank the engine until the fuel is free of air 6 Tighten the flare nuts 1 to a torque of 30 N m 22 Ib ft
113. vibration damper Oil Cooler Core and Heat Exchanger Core During an overhaul Caterpillar recommends the removal of the oil cooler core and the heat exchanger Clean the cores Then pressure test the cores NOTICE Do not use caustic cleaners to clean the core Caustic cleaners can attack the internal metals of the core and cause leakage Note Use this cleaning procedure to clean the oil cooler core and the heat exchanger core 1 Remove the oil cooler core and the heat exchanger core 2 Remove any debris from the cores To remove debris from the oil cooler core turn the oil cooler core onto one end To remove debris from the heat exchanger core turn the heat exchanger core onto one end 3 Flush the cores internally with cleaner in order to loosen foreign substances This will also help to remove oil from the oil cooler core SEBU7919 04 161 Maintenance Section Rotating Rectifier Inspect Test Note Caterpillar recommends the use of Hydrosolv Liquid Cleaners Table 26 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer Table 26 Hydrosolv Liquid Cleaners Part Par Number 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 at temperatures up to 93 C 200 F Refer to Application Guide NEHS0526 or consult your Caterpilla
114. y For the correct voltage and frequency refer to the generator set s Serial Plate 102489875 Walk Around Inspection SMCS Code 1000 040 Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided SEBU7919 04 167 Maintenance Section Water Pump Inspect For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed e The guards must be in the proper place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an engine or deck is a fire hazard Remove this debris with steam cleaning or high pressure water e Inspect the radiator cores for cleanliness e Ensure that cooling lines are properly clamped and that cooling lines are

MAINTENANCE INTERVALS - Safety

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