Manual Mantenimiento Motor Cat

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7656-02December 2005

Operation andMaintenanceManualC1.5 and C2.2 Marine Generator SetsTAF1-Up (Generator)TAG1-Up (Generator Set)JAW1-Up (Generator Set)

52 SEBU7656-02Maintenance SectionMaintenance Interval Schedule

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Maintenance Interval ScheduleSMCS Code: 1000; 7500

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

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

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

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

When Required

Battery - Replace .................................................. 55Battery or Battery Cable - Disconnect .................. 56Engine - Clean ...................................................... 61Engine Air Cleaner Element (Single Element) -Replace ............................................................... 62Fuel System - Prime ............................................. 69Generator Set - Test ............................................. 75Rotating Rectifier - Test ........................................ 81

Daily

Cooling System Coolant Level - Check ................ 59Electrical Connections - Check ............................. 61Engine Air Cleaner Service Indicator - Inspect ..... 63Engine Oil Level - Check ...................................... 65Generator Load - Check ....................................... 75Walk-Around Inspection ........................................ 83

Every Week

Generator - Inspect ............................................... 73

Every 100 Service Hours or 3 Months

Insulation - Test ..................................................... 77

Every 500 Service Hours or 1 Year

Alternator Belt - Inspect/Adjust/Replace ............... 53Auxiliary Water Pump (Rubber Impeller) -Inspect ................................................................ 54Battery Electrolyte Level - Check .......................... 55

Engine Oil and Filter - Change ............................. 66Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 70Fuel System Secondary Filter - Replace .............. 71Fuel Tank Water and Sediment - Drain ................. 73Glow Plugs - Inspect ............................................. 76Sea Water Strainer - Clean/Inspect ...................... 82

Every 1000 Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 68Hoses and Clamps - Inspect/Replace .................. 76

Every 1000 Service Hours or 1 Year

Rotating Rectifier - Check ..................................... 81


Engine Crankcase Breather - Clean/Replace ....... 64


Alternator - Inspect ............................................... 53Engine Mounts - Inspect ....................................... 65Fuel Injection Nozzles - Test/Exchange ................ 68Starting Motor - Inspect ........................................ 82Water Pump - Inspect ........................................... 83

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -Replace ............................................................... 60

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 59

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 56

Initial Oil Change

Engine Valve Lash - Inspect/Adjust ...................... 68

Overhaul

Overhaul Considerations ...................................... 80

SEBU7656-02 53Maintenance SectionAlternator - Inspect

i00072207

Alternator - InspectSMCS Code: 1405-040

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

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

i01857509

Alternator Belt -Inspect/Adjust/ReplaceSMCS Code: 1357-036; 1357-510

Inspection

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

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

g00946887Illustration 57The belt cover must be removed for inspection, adjustment andreplacement on open generator sets.(1) Mounting bolts(2) Adjustment bolt

To maximize the engine performance, inspect thebelt for wear and for cracking. Check the belt tension.Adjust the belt tension in order to minimize beltslippage. Belt slippage will decrease the life of thebelt.

For the correct tension on the belt, refer toSpecifications, “Belt Tension Chart”.

Adjustment1. Remove the belt cover, if equipped.

2. Loosen mounting bolts (1) and adjusting bolt (2).

3. Slide the alternator in the direction that will givethe correct tension.

4. Tighten adjusting bolt (2). Tighten mounting bolts(1).

5. Reinstall the belt cover, if equipped.

If new belts are installed, check the belt adjustmentagain after 30 minutes of engine operation at therated rpm.

54 SEBU7656-02Maintenance SectionAuxiliary Water Pump (Rubber Impeller) - Inspect

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Auxiliary Water Pump (RubberImpeller) - InspectSMCS Code: 1371-040



Impellers and seals require periodic inspection.Impellers have a service life that is limited. Theservice life depends on the engine operatingconditions.

Inspect the components more frequently when thepump is exposed to debris, sand, or other abrasivematerials.

Use the following procedure in order to disassemblethe auxiliary water pump.

g00953966Illustration 58

1. Remove screws (1) and plate (2).

2. Remove O-ring (3) and rubber cap (4).

3. Remove impeller (5).

4. Check the following components for wear ordamage: the impeller, the O-ring seal, and the endplate. Replace any worn components.

Use the following procedure in order to assemble theauxiliary water pump.

1. Clean the contact surfaces of the pump body andthe end plate.


2. Apply liquid soap to the blades of impeller (5) uponinstallation. The blades of the impeller shouldbe bent in a counterclockwise position. Refer toIllustration 59. Install the impeller.


3. Install the rubber end cap (4).

4. Install O-ring seal (3) and plate (2). Fasten theplate with bolts (1).

Refer to the Disassembly and Assembly for moreinformation on servicing the auxiliary water pump.

SEBU7656-02 55Maintenance Section

Battery - Replace

i01878164

Battery - ReplaceSMCS Code: 1401-510

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

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

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

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

1. Switch the engine to the OFF position. Removeall electrical loads.

2. Turn off any battery chargers. Disconnect anybattery chargers.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the NEGATIVE “-” terminalon the starter motor. Disconnect the cable fromthe NEGATIVE “-” battery terminal.

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

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

5. Remove the used battery.

6. Install the new battery.

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

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

8. Connect the cable from the NEGATIVE “-” terminalon the starter motor to the NEGATIVE “-” batteryterminal.

i02340858

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing. If batteriesare properly charged, ammeter reading should bevery near zero, when the engine is in operation.

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

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

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

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

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

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

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

Thoroughly rinse the battery case with clean water.

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

56 SEBU7656-02Maintenance SectionBattery or Battery Cable - Disconnect

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Battery or Battery Cable -DisconnectSMCS Code: 1402-029

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

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

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

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal.

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

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

i02013208

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

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

• The engine overheats frequently.

• Foaming is observed.

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

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

When the cooling system is cleaned, only clean wateris needed when the ELC is drained and replaced.

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



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

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

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

DrainNote: Stop the engine and allow the engine to coolbefore draining the coolant. Begin with step 3 foropen generator sets.


Cooling System Coolant (ELC) - Change

g00954159Illustration 61C2.2 is shown.

1. Turn fasteners (1) on the inside of the enclosurein a counterclockwise direction in order to loosenthe fasteners.

Note: The top panel on the enclosure for the C1.5has four fasteners.


2. Remove the top panel (2) that is toward the frontof the generator in order to access the coolingsystem filler cap. Tilt the front of the panel upward.Pull the panel toward the front of the unit. Thiswill disengage the pins (3) from the frame of theenclosure.


3. Loosen the cooling system filler cap (4) slowly inorder to relieve any pressure. Remove the coolingsystem filler cap (4).

g00946927Illustration 64Typical example

(5) Drain plug for the cylinder block


Typical example(6A) Drain plug for the heat exchanger on the C2.2 genset(6B) Drain plug for the heat exchanger on the C1.5 genset

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

58 SEBU7656-02Maintenance SectionCooling System Coolant (ELC) - Change

The drain plug for the cylinder block is located onthe right side of the engine. Remove the drain plug(5) from the cylinder block . The heat exchangeris located on the left side of the engine. Removethe drain plug for the heat exchanger (6). Allowthe coolant to drain.

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

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

Outside Illinois: 1-800-542-8665Inside Illinois: 1-800-541-8665Canada: 1-800-523-8665

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

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual for moreinformation on the proper torques.

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

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

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve (ifequipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve (ifequipped). Clean the drain plugs. Install the drainplugs. Refer to the Operation and MaintenanceManual for more information on the propertorques.

Fill1. Fill the cooling system to the top with thecoolant. Refer to the Operation and MaintenanceManual for more information on cooling systemspecifications. Do not install the cooling systemfiller cap.

2. Start and run the engine for one minute in orderto purge the air from the cavities of the engineblock. Stop the engine.

3. Add the ELC into the cooling system until thecooling system is full to the top.

4. Clean the cooling system filler cap. Inspectthe gasket for the cooling system filler cap. Ifthe gasket for the cooling system filler cap isdamaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket for the cooling system filler cap is notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system filler cap.The correct pressure for the cooling system fillercap is stamped on the face of the cooling systemfiller cap. If the cooling system filler cap does notretain the correct pressure, install a new coolingsystem filler cap.


5. Fill expansion tank (1) to the proper level, ifequipped.

6. Install the cooling system filler cap. Start theengine. Inspect the cooling system for leaks andfor proper operating temperature. Maintain thecoolant level in the expansion tank at the properlevel, if equipped.


Cooling System Coolant Extender (ELC) - Add

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









Caterpillar Extended Life Coolant (ELC) does notrequire the frequent Supplemental Coolant Additive(SCA) additions that are associated with conventionalcoolants. The Extender only needs to be added once.

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

1. Loosen the cooling system filler cap on the heatexchanger slowly in order to relieve pressure.Remove the cooling system filler cap.

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

Note: Do not add the Extender to the coolantrecovery tank, if equipped. Add the Extender directlyto the heat exchanger.

3. Add Extender according to the requirements foryour engine’s cooling system capacity. Refer tothe Operation and Maintenance Manual, “RefillCapacities” in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to the Operation and Maintenance Manual,“Cooling System Specifications” information forthe Caterpillar ELC Extender additions.

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

i01877220

Cooling System Coolant Level- CheckSMCS Code: 1395-082




60 SEBU7656-02Maintenance SectionCooling System Water Temperature Regulator - Replace






Generator Sets with CoolantRecovery TanksNote: The coolant will expand as the coolant heatsup during normal engine operation. The additionalvolume will be forced into the coolant recovery tankduring engine operation. When the engine is stoppedand cool, the coolant will return to the engine.

1. Check the coolant level when the engine isstopped and cool.

2. Observe the coolant level in the coolant recoverytank. Maintain the coolant level at the “COLD”mark.

3. Pour the proper coolant mixture into thecoolant recovery tank. Refer to the Operationand Maintenance Manual, “Cooling SystemSpecifications” for information on the correctmixture and type of coolant. Refer to the Operationand Maintenance Manual, “Refill Capacities” forthe cooling system capacity. Do not fill the coolantrecovery tank above “COLD FULL” mark.

Generator Sets without CoolantRecovery TanksNote: The coolant will expand as the coolant heatsup during normal engine operation. The additionalvolume will be forced out of the heat exchangerduring engine operation.

1. Check the coolant level when the engine isstopped and cool.

2. Loosen filler cap on the heat exchanger slowly inorder to relieve any pressure. Remove the fillercap.

3. Maintain the coolant level within 13 mm (0.5 inch)of the top of the heat exchanger.

4. Pour the proper coolant mixture into the heatexchanger, if necessary. Refer to the Operationand Maintenance Manual, “Cooling SystemSpecifications” for information on the correctmixture and type of coolant. Refer to the Operationand Maintenance Manual, “Refill Capacities” forthe cooling system capacity.

5. Clean filler cap and the filler neck. Reinstall thefiller cap.

i00912898

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

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

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

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


Electrical Connections - Check

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

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

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

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

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

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

i01595880

Electrical Connections - CheckSMCS Code: 4459-535

Check all exposed electrical connections fortightness.

Check the following devices for loose mounting orfor physical damage:

• transformers

• fuses

• capacitors

• lightning arrestors

Check all lead wires and electrical connections forproper clearance.

i01866598

Engine - CleanSMCS Code: 1000-070

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

Moisture could create paths of electrical conduc-tivity.

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

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

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

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

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

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

62 SEBU7656-02Maintenance SectionEngine Air Cleaner Element (Single Element) - Replace

i02013257

Engine Air Cleaner Element(Single Element) - ReplaceSMCS Code: 1051; 1054-510



Open Generator SetsPerform the Operation and Maintenance Manual,“Engine Air Cleaner Service Indicator-Inspect”procedure before performing the following procedure.

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

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

Note: This type of air cleaner is only available onopen generator sets.


1. Unfasten latches (1).


2. Remove cover (2).


3. Remove air cleaner element (3).

4. Inspect the replacement element for the followingitems:damage, dirt, and debris.


5. Install a clean, undamaged air filter element (3).Make sure that the element is properly seated inthe air cleaner housing.


Engine Air Cleaner Service Indicator - Inspect


6. Install cover (2). Fasten latches (1).

Enclosed Generator SetsThe air cleaner is located at the rear of the unit ontop of the generator.


Note: This type of air cleaner is only available onenclosed generator sets.

1. Remove bolts (1) and cover (2).


2. Clean screen (3) with pressurized air orpressurized water.

3. Install cover (2) and secure the cover with bolts(1).

i01900118

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

Some engines may be equipped with a differentservice indicator.

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

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

64 SEBU7656-02Maintenance SectionEngine Crankcase Breather - Clean/Replace

g00103777Illustration 74Typical service indicator

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

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

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

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

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

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

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

i01866338

Engine Crankcase Breather -Clean/ReplaceSMCS Code: 1317-070; 1317-510









Engine Mounts - Inspect

g00955947Illustration 75Typical example(1) Breather cover(2) Bolts for breather cover(3) Vent hole in breather cover(4) Spring(5) Diaphragm and plate(6) Cavity(7) Vent hole

1. Loosen bolts (2) and remove breather cover (1)from the valve mechanism cover. Clean vent hole(3) in breather cover (1).

2. Remove spring (4). Remove the diaphragm andplate (5).

3. Clean vent hole (7). Clean cavity (6) for thebreather assembly in the valve mechanism cover.

NOTICEMake sure that the components of the breather as-sembly are installed correctly. Engine damage mayoccur if the breather assembly is not working properly.

4. Install a new diaphragm and plate (4) for thebreather assembly. Install a new spring (3). Installbreather assembly into cavity (5) of the valvemechanism cover.

5. Install breather cover (1) and four bolts (2).Tighten the bolts.

i02456872

Engine Mounts - InspectSMCS Code: 1152-040

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

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration should bereplaced. Refer to Special Publication, SENR3130,“Torque Specifications” for the recommendedtorques. Refer to the OEM recommendations formore information.

i00623423

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

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

g00110310Illustration 76(Y) “ADD” mark. (X) “FULL” mark.

NOTICEPerform this maintenance with the engine stopped.

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

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

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

66 SEBU7656-02Maintenance SectionEngine Oil and Filter - Change

i01855644

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



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






Note: Shorten the oil change interval to 250service hours or 6 months if the generator setis operating at a load factor that is greater than40 percent.

• A generator set that operates at 1500 rpmor 50 Hz will use 2.53 Liters per hour(0.67 US gallons per hour) of fuel with a loadfactor of 40%.

• A generator set that operates at 1800 rpmor 60 Hz will use 3.04 Liters per hour(0.80 US gallons per hour) of fuel with a loadfactor of 40%.

Note: If you are using a fuel with a sulfur contentthat is greater than 0.5% you must shorten theengine oil change interval, unless you use anengine oil that is highly alkaline. Refer to Table 18.

Table 18

Fuel Sulfur Content Oil Change Interval

Less than 0.5% 500 service hours or12 months

0.5% to 1.0% 375 service hours or8 months

Greater than 1.0% 250 service hours or6 months

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

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

Drain the Engine Oil


1. Disconnect fitting (1) from bracket (2).

2. Connect fitting (1) to a sump drain pump andpump the oil out of the engine.

3. Fasten fitting (1) to bracket (2) after the oil hasbeen pumped out of the engine.


Engine Oil and Filter - Change

Replace the Oil Filter

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


1. Remove the oil filter (3).


Typical mounting base for the oil filter and oil filter gasket

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

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

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

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

Fill the Engine Crankcase

g00946327Illustration 80(4) Engine oil filler cap

1. Remove the oil filler cap (4). Refer to theOperation and Maintenance Manual, “LubricantSpecifications” for more information on theproper type of oil. Fill the crankcase with theproper amount of oil. Refer to the Operation andMaintenance Manual, “Refill Capacities” for theproper amount of oil. Install engine oil filler cap(4). Allow time for the oil to drain into the oil panand check the oil level.

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

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

2. Start the engine and run the engine for fifteenminutes. Perform this procedure in order to ensurethat the lubrication system has oil and that the oilfilters are filled. Inspect the oil filter for oil leaks.

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

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

68 SEBU7656-02Maintenance SectionEngine Valve Lash - Inspect/Adjust

i00869628

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

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

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

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

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

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

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

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenance isperformed.

Refer to the Service Manual for more information.

i00626014

Fuel Injection Nozzles -Test/ExchangeSMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

Fuel injection nozzles are subject to tip wear. Tipwear is a result of fuel contamination. Tip wear cancause the following problems:

• Increased fuel consumption

• Black smoke

• Misfire

• Rough running

Fuel Injection nozzles should be cleaned, inspected,tested, and replaced, if necessary. Refer to SpecialInstruction, SEHS7292 for using the 8S-2245Injection Cleaning Tool Group. Consult yourCaterpillar dealer about cleaning the fuel injectionnozzle and testing the fuel injection nozzle.

NOTICENever wire brush or scrape a fuel injection nozzle.Wire brushing or scraping a fuel injection nozzle willdamage the finely machine orifice. Proper tools forcleaning and testing the fuel injection nozzles can beobtained from Caterpillar dealers.

The following items are symptoms of a malfunction ofthe fuel injection nozzle:

• Abnormal engine operation

• Smoke emission

• Engine knock

Each fuel injection nozzle must be isolated one ata time in order to determine the malfunctioning fuelinjection nozzle.

1. Start the engine.

SEBU7656-02 69Maintenance SectionFuel System - Prime

2. Loosen each fuel line nut one at a time at the fuelinjection pump. A cloth or similar material must beused in order to prevent fuel from spraying on thehot exhaust components. Tighten each nut beforeloosening the next nut.

3. A defective fuel injection nozzle may be identifiedwhen a fuel line nut is loosened and the followingconditions are present:

• The exhaust smoke is partially eliminated or theexhaust smoke is completely eliminated.

• Engine performance is not affected.

A fuel injection nozzle that is suspected of beingdefective should be removed. A new fuel injectionnozzle should be installed in the cylinder in orderto determine if the removed fuel injection nozzle isdefective.

Removal and Installation of theFuel Injection NozzlesFor the removal and the installation of fuel injectionnozzles, special tooling is required. Refer to theService Manual for more information. Consult yourCaterpillar dealer for assistance.

i02013262

Fuel System - PrimeSMCS Code: 1258-548



Priming the fuel system fills the fuel filter. Primingthe fuel system removes air bubbles from the fuelsystem. Prime the fuel system under the followingconditions:

• Fuel system that is run dry

• Storage

• Fuel filter maintenance

• Disconnecting fuel lines and installing fuel lines

• Repair of leaks in the fuel lines

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

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


1. Loosen the vent screw (1) on the fuel filter.

Note: The priming lever of the fuel transfer pumpcannot be operated if the cam is at the maximum liftposition. If this occurs, the crankshaft must be rotatedone revolution.

2. Operate the priming lever (2) for the fuel transferpump until the flow of fuel from vent (1) iscontinuous and free of air bubbles.

3. Tighten vent (1).

70 SEBU7656-02Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace

g00946416Illustration 82Typical example

4. Loosen vent (3) on the fuel injection pump.


Note: The priming lever of the fuel transfer pumpcannot be operated if the cam is at the maximum liftposition. If this occurs, the crankshaft must be rotatedone revolution.

5. Operate the priming lever (2) for the fuel transferpump until the flow of fuel from vent (3) iscontinuous and free of air bubbles.

6. Tighten vent (3).

NOTICEIf the engine fails to start within 15 seconds, releasethe starter switch or button and wait 30 seconds toallow the starting motor to cool before attempting tostart the engine again.

7. Crank the engine. Start the engine. The enginemay run rough. Run the engine at low load untilthe engine runs smoothly. If the engine will notstart, further priming may be necessary. If theengine starts and if the engine continues to misfireor smoke, one or more of the following conditionsmay be present:

• The fuel system requires more priming.

• There may be an air leak in the fuel system.

i02462826

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





Turn the fuel supply valve to the OFF position beforeperforming this maintenance. Place a tray under thefuel filter in order to catch any fuel that might spill.Clean up any spilled fuel immediately.


Fuel System Secondary Filter - Replace

g00741109Illustration 84(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. Drainthe fuel into a suitable container by using the fueldrain on the bottom of the element (3). Drain thewater from the water separator (4) into a suitablecontainer. Not all engines are equipped with awater separator.

Note: The fuel level in the element (3) should bereduced before removal of the element. Remove cap(1) if the element is not equipped with a drain on thebottom. Remove the nylon insert in order to reducethe level of fuel in the element. A reduction in thelevel of fuel in the element will help prevent fuel frombeing spilled when the element is removed.

NOTICEDo not use a tool in order to remove the fuel filter.Attempting to remove the fuel filter with a filter wrenchor a filter strap could damage the locking ring.

3. Hold element (3) and rotate locking ring (2)counterclockwise. Remove locking ring (2). Theused element should be removed and discarded.

Note: If the element is equipped with a sedimentbowl, remove the sediment bowl from the element.Thoroughly clean the sediment bowl. Inspect theO-ring seals for wear or damage. Install new O-ringseals, if necessary. Install the sediment bowl onto thenew element. Hand tighten the sediment bowl. Handtightening is the only method that should be used.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

4. Ensure that the filter head is clean. Push a newelement fully into the filter head.

5. Hold the element in place. Fit locking ring (2) intoposition. Rotate the locking ring clockwise in orderto fasten the element to the filter head.

Note: If the nylon insert was removed, install thenylon insert and install cap (1).

6. Prime the fuel system. Refer to the Operation andMaintenance Manual, “Fuel System - Prime” formore information.

i01878422

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





72 SEBU7656-02Maintenance SectionFuel System Secondary Filter - Replace




1. Close the fuel supply valve.


2. Clean the outside of the fuel filter assembly (1).

3. Loosen bolt (2).

4. Remove fuel filter element assembly (3).


5. Assemble the following items: seals (8), seal (7),element (9), and base (10). Place washer (5) andseal (6) on bolt (4).

6. Fasten the assembly to the fuel filter base withbolt (4).

The fuel system will need to be primed after thenew filter is installed. Refer to the Operation andMaintenance Manual, “Fuel System - Prime”.


Fuel Tank Water and Sediment - Drain

i02436696

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


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


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

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

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

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

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

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

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

• Weekly

• Oil change

• Refill of the tank

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

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

i01880220

Generator - InspectSMCS Code: 4450-040

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

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

74 SEBU7656-02Maintenance SectionGenerator - Inspect



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

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

• Carbon

• Salt

• Metal dust

• Dirt that is saturated with moisture

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

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

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

• The extent of the cleaning procedure that is beingattempted

• The type of enclosure of the generator

• The voltage rating of the generator

• The type of dirt that is being removed

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

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

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

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

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

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


Generator Load - Check

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

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

i01878834

Generator Load - CheckSMCS Code: 4450-535-LA


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

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

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

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

When a three-phase generator is installed or whena three-phase generator is reconnected, ensure thatthe total current in any one phase does not exceedthe nameplate rating. Each phase should carry thesame load. This allows the three-phase generatorto work at the rated capacity. If one phase currentexceeds the nameplate amperage, an electricalimbalance will occur. An electrical imbalance canresult in an electrical overload and an electricalimbalance can result in overheating on three-phasegenerators. This is not applicable to single-phasegenerators.

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

i02377583

Generator Set - TestSMCS Code: 4450-081

DANGER: Shock/Electrocution Hazard-Do not op-erate this equipment or work on this equipmentunless you have read and understand the instruc-tions and warnings in the Operation and Mainte-nance Manual. Failure to follow the instructions orheed the warnings will result in serious injury ordeath.


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

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

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

When servicing or repairing electric power gener-ation equipment:

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

• Make sure the generator engine is stopped.

• Make sure all batteries are disconnected.

• Make sure all capacitors are discharged.

Table 19

Tools Needed

Part Number Part Quantity

237-5130 DigitalMultimeter 1

12 VDC battery 1

PotentialTransformer 1

76 SEBU7656-02Maintenance SectionGlow Plugs - Inspect

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

The generator set functional test determines if thefollowing statements happen:

• A phase voltage is being generated.

• The phase voltages are balanced.

• The phase voltages change relative to enginespeed.

The generator set functional test consists of thefollowing steps:

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

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

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

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

i01160284

Glow Plugs - InspectSMCS Code: 1412-040

The glow plugs in the engine are sometimesnecessary for cold weather starting. The engine maynot start if the glow plugs are not operating correctly.The engine may also run rough in cold weather untilthe engine is warm.

When the glow plugs are inspected look for thefollowing conditions:

• Loose wire connections or frayed wires

• Blisters on the tip of the glow plug

• Cracks or missing pieces on the tip of the glow plug

The heating element of the glow plug may alsobe burned out. This is not physically visible. Anohmmeter may be used to test the continuity of theglow plug.

Replace the glow plug, if necessary.

i01880226

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



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

• Cracking

• Softness

• Loose clamps

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

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

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally


Insulation - Test

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

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

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

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

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


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

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

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

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

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

Note: Refer to the Specifications, SENR3130 inorder to locate the proper torques.

7. Install the hose clamps with a torque wrench.

Note: For the proper coolant to use, see thisOperation and Maintenance Manual, “CoolantRecommendations” (Maintenance Section).

8. Refill the cooling system.

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

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

i01593535

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

Recommended Periodic InsulationTests



Table 20

Tools Needed

142-5055 Insulation Testing Gp

9U-6003 Insulation Testing Gp

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

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

• The generator set is started for the first time.

• The generator set is removed from storage.

78 SEBU7656-02Maintenance SectionInsulation - Test

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

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

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

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

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

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

Recommended Procedure for APeriodic Insulation Test

Personal injury or death can result from electro-cution.

The megohmmeter is applying a high voltage tothe circuit.

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

1. Take the generator out of service.

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

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

4. Discharge the capacitance of the windings.

5. Disconnect “101” from ground.

6. Disconnect the regulator sensing lead wires: “0”,“110”, “220”, and 380.

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

8. Connect the insulation tester’s BLACK lead to“101”.

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

10.Use the 30/60 Time Resistance Method:

a. Apply voltage.

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

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

d. Record temperature.

e. Record humidity.

f. Remove voltage.

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

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

Note: The results from the insulation resistancechecks indicate when cleaning and/or repairing isbecoming critical. Generally, insulation resistancewill vary greatly with temperature. Therefore, alwaystest at the same temperature and humidity. Refer toIllustration 87.

Serial Number (Engine)___________________________________

Serial Number (Generator)_______________________________


Insulation - Test


80 SEBU7656-02Maintenance SectionOverhaul Considerations

i01878912

Overhaul ConsiderationsSMCS Code: 7595-043

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

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

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

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

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

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

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

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

Overhaul RecommendationTo minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.

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

Testing

Test the following components during the overhaul.

• Fuel injection nozzles

• Fuel injection pump

Testing the fuel system during the overhaul willensure that your engine operates at peak efficiency.Your Caterpillar dealer can provide these servicesand components in order to ensure that yourfuel system is operating within the appropriatespecifications.

Obtain Coolant Analysis

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

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

S·O·S Coolant Analysis (Level II)

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

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

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

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

For more information about coolant analysis, seeyour Caterpillar dealer.


Rotating Rectifier - Check

i01880286

Rotating Rectifier - CheckSMCS Code: 4465-535



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

i01880296

Rotating Rectifier - TestSMCS Code: 4465-081



Testing A Brushless ExciterRotating Rectifier With AnOhmmeterTable 21

Tools Needed

Part Number Part Name Quantity

6V-7070 DigitalMultimeter

1

9U-7330 Multimeter 1

146-4080 DigitalMultimeter(RS-232)

1

7X-1710 Multimeter ProbeGroup

1


If the failure of a rectifier is suspected, use thefollowing procedure.

1. Remove the cover from the exciter.

2. Remove the nut that secures the rectifier to theheat sink.

3. Remove the diode lead.

4. Lift the rectifier from the heat sink.

5. Refer to Illustration 88. Connect the ohmmeter’sleads across the rectifier. Note the meter reading.

6. Reverse the ohmmeter leads. Note the meterreading.

The ohmmeter should indicate a low resistancewhen the ohmmeter leads are across the rectifier inone direction. The ohmmeter should indicate a highresistance when the leads are reversed.

If the ohmmeter indicates a low resistance in bothdirections, the rectifier is shorted. A high resistancein both directions indicates an open rectifier.

82 SEBU7656-02Maintenance SectionSea Water Strainer - Clean/Inspect

Replace any faulty rectifiers with rectifiers that havecomparable operating characteristics. Include thefollowing information when a rectifier is being orderedfor replacement:

• Part Number of the rectifier

• Model number of the exciter

• Type of the exciter

• Serial number of the generator

Testing a Brushless ExciterRotating Rectifier With A Test Light

g00555113Illustration 89Test Light

If an ohmmeter is not available, a rectifier can betested by using a test light. A test light consists oftwo standard flashlight batteries and a flashlight bulb.Refer to Illustration 89.

If the failure of a rectifier is suspected, use thefollowing procedure.

1. Remove the cover from the exciter.

2. Remove the nut that secures the rectifier to theheat sink.

3. Remove the diode lead.

4. Lift the rectifier from the heat sink.

5. Connect the leads of the test light across therectifier. Notice if the bulb is illuminated.

6. Reverse the leads of the test light across therectifier. Notice if the bulb is illuminated.

The bulb should be illuminated when the leads of thetest light are across the rectifier in one direction. Thebulb should not be illuminated when the leads arereversed.

If the bulb is illuminated in both directions, the rectifieris shorted. If the bulb is not illuminated in eitherdirection, the rectifier is open.

Replace any faulty rectifiers with rectifiers that havecomparable operating characteristics. Include thefollowing information when a rectifier is being orderedfor replacement:

• Part Number of the rectifier

• Model number of the exciter

• Type of the exciter

• Serial number of the generator

i00905687

Sea Water Strainer -Clean/InspectSMCS Code: 1371-040; 1371-070

The sea water strainer must be clean in order toallow proper engine cooling. Check the sea waterstrainer for plugging. Inspect the sea water strainermore frequently if the vessel is being operatedin water which is shallow or dirty. Refer to theOEM recommendations for more information aboutinspecting and cleaning the sea water strainer.

Ensure that the auxiliary water pump is primed andthat the suction line is open.

1. Remove the sea water strainer and clean thescreen. Remove any dirt and debris.

2. Install the sea water strainer. Fill the sea waterstrainer and the suction line for the auxiliary waterpump with water.

i00651416

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

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

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


Walk-Around Inspection

i01585919

Walk-Around InspectionSMCS Code: 1000-040

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

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

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

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

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

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

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

• Inspect the water pumps for coolant leaks.

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

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pumps and the installation of water pumpsand/or seals, refer to the Service Manual for theengine or consult your Caterpillar dealer.

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

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

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

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

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

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

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

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

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

• Check the condition of the gauges. Replace anygauges which are cracked or any gauges that cannot be calibrated.

i01057943

Water Pump - InspectSMCS Code: 1361-040; 1361

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

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

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

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

Documents

Manual Mantenimiento Motor Cat