CATERPILLAR” ss ‘September 1988 = Operation & Maintenances. : So 3408 and 3412 nee ee and EPG Diesel Engines 81Z1-UPQ\ IMPORTANT SAFETY NOTICE Most accidents involving engine opers jatety rules of precautions. An accident can ing potentially hazardous situations: Improper operation is dangerous and could result in injury or death. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE OPERATING THIS ENGINE. @ outlined in the “Safety” Section of jon of operations where hazards exist. Warning decals have also been put on the engine to provide instructions and to identity specific hazards which, it ot heeded, could cause bodily injury or death to you or other persons. These warnings in the Guide and on the engine ns that may result only in engine damage are identified by CAUTION decals on the engine and in the Guide. pillar cannot anticipate every possible circumstance that ht involve a potential hazard. The warnings in this Guide and fon the engine are therefore not all inclusive. if an operation is not performed as specitically recommended by Caterpillar, you must satisty yourselt that it is safe for you and others. You ‘should also ensure that the engine will not be damaged or made tunsate by the method of operation you choose. ‘The proper and safe lubrication and maintenance procedures for this engine, recommended by Caterpillar, are outlined in the "Lubrication & Maintenance” Section of this Guide. Improper performance of lubrication ot maintenance procedures is dar erous and could result in injury or death. Read and understand the “Lubrication & Maintenance” Section before performing any lubrication (oF maintenance.FOREWORD ‘This guide contains operation insttuctons and bce tion and maintenance information, ‘The operation sectonis a reterence for the new oper: stor and a retrosher for the experienced one. Read — ‘Staty — and Keep It handy. lustrations guide the operator through correct proce ‘ures of checking, staring, operating ané stopping the engine ‘The maintenance sections a guide to equipment care ‘Te tustrated, step-by-step natructions are grouped by servicing intervals. ems inthe Lubiction and Manto nance Chart” are raferanced to the detased instructions that folow Use the service meter to determine servicing ite: vals, Calendar inervais shown may be used stead of Service meter intervals f they provide mare convenient Servicing schedules and approximate the indicated ser- vce meter reading. Recommended service should al ways be performed at the terval thal occurs f Under extremely severe, dusty of wet operating com tions, mere requent ication than spectied inthe ‘Laincation and Maintenance Chart” may be neces Perform service on items at mutes of the original ‘equrement. For example, at Every 500 Service Meter Unis, alza service those items bsted under Every 250 Service Moter Uns, Every 80 Service Moter Units and Every 10 Service Meter Unis ‘Some photographs in this publication show details or attachmants that may Be diferent fam your engine ‘Also, guards and covers may have boon removod for Iustrative purposes. Cominuing improvement and advancement of product design may have caused changes fo you engine which fire not Included nthe pubieaton Each publication I reviewed and revised, as euied to update and include these changes in lator edions Whenever a question arises regarding your engine or this pubteation. please consult your Caterpilar dealer for the latest avaiable information, Engine Identification Caterpilar engines are dentiied with SERIAL NUM. BERS and ARRANGEMENT NUMBERS. in some cases MODIFICATION NUMBERS are also used. These nur bors are shown on the serial number plate mounted on the engine CCaterpilar dealers needa these numbers to deter rine wich componente ware included on te engine when ft wag assembled at the factory. Ths permits ‘accurate Identification of replacement part numbers Ordering Parts Qualty Caterpiar replacement parts are avaiable from Caterpilar dealers throughout the worl. Thee parts stocks are upto date and clude al pars normally Fequirod 0 protect your vvestment In Caterpilar er fines. When ordering parts, your order should specity the quant, part number part name and sal nomber frrangement number and modiication number of the fengne for which te parts are needed Fin doubt about {he part azmber, please provi your dealer wth com plete description ofthe nooded item,TABLE OF CONTENTS Mooel. VIEWS SAFETY PRECAUTIONS OPERATING INSTRUCTIONS PRE-START INSPECTION AND PROCEDURES STARTING THE ENGINE AIR STARTING STARTING AIDS GENERATOR AFTER ENGINE STARTS. [STARTING THE LOAD ENGINE OPERATION ALTITUDE OPERATION STOPPING AFTER STOPPING CHECKS AND PROCEDURES [ATTACHMENTS AUTOMATIC START-STOP WOODWARD GOVERNORS EMERGENCY SHUTOFF DEVICES. "AND ALARWS. EMERGENCY STOPPING MAINTENANCE RECOMMENDATIONS SPECIFICATIONS. LUBRICATION FUEL (COOLANT LUBRICATION AND MAINTENANCE INSTAUCTIONS LUBRICATION AND MAINTENANCE ‘CHART LUBRICATION INSTRUCTIONS ‘COOLING SYSTEM FusL SYSTEM AIRINDUCTION AND EXHAUST ‘SYSTEMS, ELECTRICAL SYSTEM POWER COUPLINGS ENGINE STORAGE GENERATOR STORAGE PREVENTIVE MAINTENANCE RECOMMEND: IRVONS FON STANDBY GENERATOR SETS (GENERATOR MAINTENANCE ‘TROUBLESHOOTING MAINTENANCE RECORD Ey ea 32 99 «a 58 56 580 560 ss 87 63408 GENERATOR SET ENGINE GAUGE PANEL COOLANT FILL CAP GeneRaron | expansion ranx FUEL. PRIMING. ; at FAN DRIVE, see FUEL, FILTER on COOLER + CRANKCASE DRAIN lL FILTER‘TEMPERATURE REGULATOR Goo “-/ water PUMP % y one on cOoLeR” 3408 INDUSTRIAL ENGINE GOVERNOR AFTERCOOLER aim cLeANER — I oneurers CRANKCASE ORAINTEMPERATURE REGULATORS . a ’ GovenNgn AFTERGOOLER OIL FILL CaP 3412 INDUSTRIAL ENGINE CONTROL PANEL, AIR CLEANER OW FILTERS ™/™ celenron —--PUELFILTERSSAFETY PRECAUTIONS Safety is everyone's business ands basicaly th use of good common sense. A general quide of ‘Safety precautions ara given below. but each instal- iatonfas tgown peculiarities which cannot always be predicted and covered by established ules. Past Sxpenience and common sense are neoded for the ecessary safety measures. Attention to safety will Relp avotd senius accidents. Be alert, Watch for haraids, Use preventive measures. Correct de fieieneies immediately ‘The fallowing safety precautions are # general ‘guide to sate operation “To prevent personal injury, install guards over all exposed rotating parts. 2.To prevent hearing damage, woar ear protec- tive devices vf working Insida an enclosed en bine room with engine running 3. To prevent head injury, wear safety hat when lnorking in the area of overhead equipment. 4. Wear safety glasses and shoes as requited. Do not wear loose clothing whenever working around engines er machinery. Wipe up spilled ol, fuel or coolant. Keep batteries in a well ventilated area. Do not Smoke aroundatierles. Hydrogen gas, whichis, present nthe area of the batteries, is highly explosive. Provide adequate and sate waste oll disposal ‘store oily rags in fireproof containers, Don't leave rags on engine. A WARNING When using pressure air, woar safety and provective clothi Surer used for cleaning 2ikgiem®, 10. Remove all tools, Toase items fram the engine before starting, 11, Disconnect and tape the battery ground lead Detore working on an engine topreventacciden: {al starting. Be sure an automatic startstop sys tem cannot operate and start tho engine while working on 6 12, Do not attempt repairs you do not understand. Follow instructions. 13, Stop engine before adjusting or repairing en gine or driven equipment. 14. Remove radiator cap slowly. Cooling systems Ean be pressurized and hot fluid wil flash to Stoam as pressure is removed 46: Never start an engine with the governor linkage disconnected 16. Replace or repair broken or damaged equip ment. Use proper tools 47. Do not smoke while retueling. Observe NO SMOKING sighs. 18, Never store flammable liquids near the engine 19. All electrical equipment must be grounded ac- cording to local Building codes, 20. Check all connections periodically for tightness ‘and insulation 21. Insulate all connections and disconnected 22. Do not use carbon tetrachloride tire extin uishers, Fumes are toxic and the liquid has @ Seteriorating effect on Insulation. £28, Do not touch the heat sink on the generator Fegulstor when the generater Is running. Its tlectrically "nat 24. Do not work on electrically “hot” equipment 25. Always disconnect the engine starter circuit when working on the goneratcr. 26. Hot engine oil can cause burns when drained. ‘Allow the ol to €00! below I40"F or provide pro- fection whon draining the hot oi 27. Never remove a plug to chock pressure withthe gine running, Shut down the engine and as Sure there is ne pressure before removing plug 28. Whon starting an engine after repair, make pro Vistons for shutting of aie supply in case theres fan overepeed on start up. 29. Never look into an open cylinder port and turn over the engine. Oil or water in the cylinder wil be ejected violently.OPERATION INSTRUCTIONS PRE-START INSPECTION AND PROCEDURES 1. Make a "walk-arouna'” ingpection ofthe engine and components for the all, water oF fuel leaks and general appearance. Correct minor adjust iments betore they develop nto major repair jobs. 2. Check the erankease oil love). Maintain the oil level Between the ADD and FULL marks on the lipstick. See OIL SPECIFICATIONS for typo of wannine hac oe cana ee anh tn pind roy eutwara unr igh pressure ond euuse eaeecne 4. Check the engine jacket coolant level. Slowly turn the pressure cap unt the cap is removed Maintaincoolantloveltothe base at the ilipipe. 5. Chock the fuel supply. Keep fuel tanks full, as partially tiles tanks will collect moisture. See {he FUEL SPECIFICATIONS for type of Tue! KEEP THE FUEL SUPPLY CLEAN 6. Open the raw water valve on the engine jacket heat exchanger system (i so equipped). Prime the raw water pump the raw water system has boen draine 7. Reset shutolt devices. See the topic, AT. TACHMENTS, Emorgency Shutolf Devices and Raarms OVERSPEED RESETtthe engine is equipped with an ar saety shutoff antral. ang nas inpped to the shutot! position Foset the latch fo the run position Oe AIR SHUTOFF RESET £8, Open theusl supply valve. the engine has not fun for some time it may be necessary to arime the system. See the topic, PRIMING THE FUEL System 9. Disconnect any battery charger which is not protected against starting motor drain, 10. Disengage the clutoh, or open the circuit breaker on a generator sat. STARTING THE ENGINE CAUTION Do not engage the starter when the flywheel Is moving. Electric Starting 1. Move the govarnor control lever to approximate half engine speed position 2. Use starting aids if required. See the topic, STARTING AIDS. 43, Push the START button: or turn the HEAT- START switch fo the START position. depend- ‘ngupon the control he engine has. Release the ‘control's soon a8 the angine starts. For generator sole, place the AUTO-MAN switch Inthe MAN position tocrank the engine. As soon as the engine starts, and the engine spoed reac! {600 rpm and oil prossure ts approximately 22 psi (1 Skovem), the starter motor will disconnect from the elreut. (The STOP position is used f0 stop the iesel engine.) Ifthe engine fails to startin 10 seconds, move the ‘governor control lever to the fuel off position, then ontinue to crank for 10 seconds. This wll clear the ylinders of unburned Tush. It the engine falls to start after 80 seconds of cranking, allow the engine to cool for 2 minutes botore repeating the starting procedure, CAUTION Prolonged cranking at low oil pressure can actl- wate the mechanical safety shut-off. If the reset ever isin the shut-off position, reset the mechanical shut-off controlcaution NEVER use starting aids when the engine is ‘warm and running. It the engine is equipped with a Woodward PSG Governor. see the topie, WOODWARD GOVER- NORS Yor the governor operation instructions. Air Starting 1, Open and close the blood valve onthe bottom of the alr tank to drain condensation and ail car ryover 2. Check the air supply pressure. The air start ‘must have 100 PSI (7 xg/em) to operate prop erly. 8. Keep ol level, in the oiler jar. at least halt fll ‘Add’ necessary. See the LUBRICATION AND MAINTENANCE PROCEDURES, Filing Motor Oiler 4. Push the ar valve controlin to crank the engine. ‘As soon as ho angine starts, release the valve. Starting Aids Many variables can affect cold weather starting Use the chart as a guide, but actual experience wil determine when aids are necessary and how they ‘Should be used. Your engine may have one or more fof the following starting aids: Glow Plugs (Precombustion Chamber Engines Only) 1. Push in an turn the HEAT-START switch tothe HEAT position and nold for the approximate heating time shawn in the STARTING AID CHART Orr o starr e SX 2. Turn the HEAT-STAAT switch to the START position HEATA, oF o HEAT A ASTART £ 3. I necessary, when the engine starts turn the HEAT-START switch tothe HEAT position. Hold the switen in this position until the engine is Funning smoothly 4, Release the switch s weata: Xa start s CAUTION NEVER use glow plugs when the engine is warm ‘and running,‘STARTING AID CHART ‘STARTING TEMPERATURE ‘STARTING AID HEATING TIME Above 60 (15°C) None None aor 030 : Teal Gscwoo Giow Pug i apr oor, ae ec eemel Glow Pgs 2 Minute Below OF (-2007 Gow Plugs antes Heating of jacket water/and or crankcase ol; and/or use of extra battery capacity may be required Starting Fluid A warninc tions on the container. CAUTION Spray starting fluid only while cranking the gine. 1. Heatthe glow plugs (If equipped) forthe approx imate neating me shown inthe STARTING AID CHART. OFF HEATA_— ASTART Tuen the HEAT-STAAT switch to START posi CAUTION Wait at least 2 seconds before spraying starting fuld again. 3. If necessary, repeat the procedure. 4. Alter the engine starts, it may be necessary to feturn the HEAT-STAAT switch to the HEAT position until the engine runs smoothly Jacket Water Heater (attachment) Invery low temperatures, the lubricating oll must be marmad to allow starting. A jacket water heater an maintain the water temperature. at approx mately 90°F (32°C). The warm water willkeep the ol inthe upper partol the engine block warm enough to tow wnen starting, Dipstick Oil Heater CAUTION Contact your Caterpillar dealer before installing 4 dipstick crankcase ol heater tion While cranking, spray starting uid into the Siriniet or sircleaner for approximately 1 9ec na 10 GENERATOR Starting Single Unit Operation iminary engine starting checks. Be sure the main or line circuit broaker is open. Start the engine and allow it to warm up. Close the main circuit breaker Apply the load. Donat try to apply full/oadin one. ‘move, rather apply the load in increments to ‘maintain system frequency ata constant level Make all pe 1 2 3 4 5.‘Standby Generator Sets Most standby units are automatic. They start pickup the load, run and stop without an operatorin dance. Standby units ean not change the gov mor control selting automatically. The throtile ‘must be preset forthe proper operation ofthat unit Whenever the set's exorcised oF operated manu ally. bo sure the throttle setting is correct for au- omatie operation. Check all switches to seo thoy 2a properly set: Start Selector Switch in AUTOMA- ‘Tie'postion ane any Emergency Stop Switches in RUN position Paralteling Units may be paralleleg at no load or paralleled with units undertoad. To parallel two or more units the folowing conditions must be met 1. Same phase rotation 2. Same voltage level 3, Same voltage droop. 4. Same frequency 5. Voltagos must be in phaso. The fist condition is established by “phased wiring connections of initial Installation The second and third conditions are usually es- tablished by semi-permanent adjustments to tho generator contrels ‘The fourth and fifth conditions ate under contro! of the operation in manual paralleling systems (or Under automatic contrl in automatic parallling systems). To Parallel 1, Start the unit to be paralleled 2. Turn the synchronizer lights on 3. Alter the engine has tun long enough to warm up, bring Itup to synchronous speed (the same frequency as the unit on the line). The sy hronizinglignts wil Bogin to link 4, Using the governor contol, adjust the speed Until the lights Bink very slowly, ‘5 The lights are off when the voltages of the two units are in phase. At this point, very quickly Close the breaker while the lights are out Ths trguaney of eineomign Load Division ‘Once two units have been paralleled, their share of the load is determines by the governor control setting. If two units of the same capacity and the ‘Same governor characteristics have the same gov: ‘ernor control setting they wil share the load equal Wy ‘To add load ta one engine, slowly increase the governor control setting of that engine, oF slowly Socrease the governor contra setting of the engine ‘iving up load. Load Transfer [At this point open the circuit breaker to remove ‘any remaining ioag on tho outgoing generator sot 1. Increase the governor speed contro! ofthe unit 1 the high idle position to assume the load. 2. Reduce the governor speed control of the out {going unit until the generator amperage Is at a minimum. (The amperage may never be zero due ocireulaling currents) Atthis point transter the load Stopping ‘Toremove a generator Irom the line do the follow: ing: 1. Check the load. it must be loss than the rated Capacity of ramaining units 2. Be sure the NEUTRAL of one of the remaining units 18 grounded, 3, Remove the load from the outgoing unit as de Seribed in Load Division and Load Transter 4 Open the eireult breaker 5 lun the engine for § minutes without a load, to low it to e001 Stop the engine After Engine Starts A, warning 3 oF adjustments, ‘work on machinery wl 1, Observe the oil pressure gauge immediately alter starting CAUTION Pressure is not indicated within seconds, ‘stop the engine and have necessary repairs made. u2. Move the governor control to low idle allow the {gine foreach normal operating range (usvally Soveral minutes). Make another "walk-around Inspection for leaks, etc STARTING THE LOAD Driven Equipment without Load To engage the stiven equipment before applying toad 1. Move the governor control half engine speed, 2. Engage the driven equipment without load on the equipment 3, Make sure the engine and equipment gauges register In the operating range. 4, Move the governor contralto high ile ulload) position. 5. Apply the load to the driven equipment. Driven Equipment With Load 1, Move the governor control to half engine speed. Make sure the engine gauges register in the normal operating range: 2, Move the governor control to high idle (ull load) position. 2. Engage the load ENGINE OPERATION After the engine starts, and at frequent intervals, while the engine is operating, the gauges should be Observed. Determine the normal reading for each {auge. Investigate the cause whenever there is @ Signficant change inthe reading, Gauges ‘Tachometer “Ihe tachometer indicates engine RPM. The high lle RPM and the (ull load APM are stamped on the tengine’s information plate. The engine can be op- erated between these two speed limits for long periods of fme without shortening engine lite, Pro: fonged operation at high ide with lite or no load can cause adverse engine operation Engine Oll Pressure It the gauge reading fluctuates after the load is stable: 1, Remove the load 2. Reduce engine speed to low idle 3, Observe the oil eval. Maintain the oll evel b ween the ADD and FULL mark onthe dipstick It the reading continues to fluctuate when the olf levels correct stop engine and call your Cate pillar dealer. Engine Jacket Water Temperature The engine should operate within the NORMAL (green) range. I the engine is operating inthe (red) ange and steam becomes apparent4, Reduce the load and engine RPM. 2, Inspect for coolant leaks, 3, Determine if the engine must be shut down im- ‘mediately: orif the engine can be safely cooled By reducing the loa See COOLING SYSTEM MAINTENANCE IN- STRUCTIONS, CAUTION Do not add cold water to ahot engine: Cracking af engine components may secur. Aliow the en- Sine fo.cool, then add cool Iv the temperature gauge reading registers in or rear the cold range {white) while operating under Toad 1. Check the water temperature gauge for accu ray. 2. Check the temperature regulators for proper temperature range. Replace regulators. If necessary See COOLING SYSTEM MAINTENANCE for DETAUS. Fuel pressure If the fue iter gauge registers in the OUT range, clean the primary fue! filer, so equipped. install few secondary or final us! fiter elements H gauge Siill registers OUT. See the FUEL MAINTENANCE INSTRUCTIONS ang FUEL SPECIFICATIONS. Amme The ammeter reading is normal when the ingi- ceatoris at or on the (2) side of 2er0, when the fengine is running at rated speed. It indicator isto the lolt(-) sido of zero, investigate and correct Air Cleaner Service Indicator ‘When the gauge Indicator locks inthe red range, service the air cleaner. With the engine stopped: See AIR INDUCTION AND EXHAUST SYSTEM MAINTENANCE INSTRUCTIONS Calibrated Gauges Calibrated gauges are used on some engines to ‘monitor tho engine systoms. Ifan abnormal engine Condition develops, determine ane analyze and Correct the cause before a failure and downtime The operating limits gon in the “OPERATING. RANGES FOR ENGINES" chart are based on the tengine running at continuous rated speed and load, afer warm-up, using SAE 30, oll. It any of the gauges rogister st oF outside the operating limits, Investigate and correct any malfunction, See TROUBLESHOOTING GUIDE tor guidance. WaRNING ‘Shut the engine down if work on or around the ‘engine ie requir DO_NOT OPERATE THE ENGINE WITH THE GAUGES REGISTERING AT OR OUTSIDE THE tinarrs B(a eee I ‘Tachometer. ‘Left Inlet manifold temperature Right inlet manifold temperature. {Left and right exhaust manifold temepratures. 5. Engine oll temperature 6. Engine jacket water lemperature. 7. Engine oll pressure. 8. Fuel pressure. OPERATING RANGES FOR ENGINES WITH CALIBRATED GAUGES (Engine running at continuous rating and load.) (OPERATING RANGE GAUGE iu MAXIMUM Teckel Walr Temperature (Ould Wer (70) 2IOF (OO) Inet Mario Ar Temperature Mercooled (0) 00°F (149°0) Newateroooed (OD 200°F (149°0) Bihaust Temperature ‘Atocooled Po) eo 4270) Non-atteroookd (OD BO0F 4270), Oi Temperature ‘atoreooles (eo) 200 (N00) Non-atiercaled (OD W2F (770), BOF (100) Tene 20 PSI(ia8 KPa) | 62 PSI(A27 KPa) i (15 halen?) (¢kgfom?) Fuel Pressure 17 PSI(117 KPa) | 90PSI(207 Pa) inigion’) fryerAltitude Operation ‘The fuel system settings and altitude limits aro stamped on the engine information plate. When an fengine 's moved to a higher altitude, these settings must be changes by your Caterpillar dealer in order te provent damaging tho turbocharger, and to pro Vide maximum engine efficiency a It the engine is moves to lower alttuce than that which is stampad on the angine information plate, the engine can be operated safely; however, tl oliver less than rated horsepower, ang the fol Setungs should be changed by your Calerpliar ealer to obtain rated horsepower Stopping 1. Flywheel clutch operation: Quickly pull the Clutch ever tothe released position. For electic Set operation, sec the GENERATOR SET OP- ERATION instructions. For Woodward Gover for operation, see the topic, WOODWARD GOVERNORS: Stopping the Engine 2. Reduce engine speed to hall speed. Aun for 5 minutes to e201 engine 3. Reduce engine speed to low isle 4. Observe the crankcase oll level while the on: {gine is ing, Maintain the oll evel between the ADD and FULL marks on the side of the cipstick Stamped, CHECK WITH ENGINE RUNNING, See the LUBRICATION AND MAINTENANCE SECTION, 5. Stop the engine. After Stopping Checks ‘And Procedures 1. Fill the fual tank, See the LUBRICATION AND MAINTENANCE SECTION: Fuel Tank Maint Drain the raw water system it below freezing mperatures aro expected: see: Draining Raw ater System 1 below freezing temperatures are expected, allow the engine jacket water expansion tank 0 foe; then check the coolant for proper anti: ze protection. Add pormanent-type anti reeze, i roquired 4 Repair any leaks, make major adjustments, tignten loose bolts, ete 5. Odserve the Service Meter reading. Pertorm the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART SERVICE METERATTACHMENTS, Automatic Start-Stop {An automatic start-stop system is used when an ‘ongine must star! when a specific condition occurs with no one invattendance. The engine will start Increase speed, pick-up te load, operate the load Unt a second gondition occurs, remove the load, feoel and stop. The folowing conditions must exist for the engine to start unattended: Either the ambient (engine room) temperature must be al least 70°F (20°C): oF, the engine jacket Water temperature must be at least 80°F (92°C) ‘Gne or two 3 kw jacket water heaters can maintain this temperature. Protection Devices The Caterpillar generator mounted control pane! {is equipped with protection devices to protect the fongine wile cranking. Batteries. Lights or buttons may indicate itafaulthas occur red inthe battery charging system causing the bat tery to be elther undercharges or overcharged Overcranking ‘Atimer allows the engine to crank either once for 0seconds, orto crank inrough ston second erank- ing eyeles (depending upon the device used) while Unattended. ittne engine doos not start before the time elapsed, the fuel system will be shutot! and a light will naicate a starting failure Engine Operation Prealarm systems provide an audible and/or a visual indication for fow cil pressure, high water temperature, low tue! supply or low jacket water temperature before the condition becomes ertical hose alarms are self resetting when the condition is corrected, ‘The engine may also be equipped with shutdown, devices. low oll pressure, high jacket water temp- feralure of an engine overspeed condition occurs, the engine wil be shutdown and a corresponding button or light wil indicate the cause of the shut Gown, These devices must Oe reset alter repairs have been made ang betore starting. See the topic, EMERGENCY SHUTOFF DEVICES AND ALARMS. Generator set control panels should be equipped with-an ammeter. a lrequeney moter and a voltme- Ter" Depending upon the type of operation, the panel may alse be oquipped with other meters ang fights. Know these instruments and their normal readings. They will indicate how the generator setis performing Shutting Down timer allows tho transter switch to transter the fad to another source and to cantinue engine run- ring for up to 2 minutes for cooling purposes before stopping, Engine Exerciser At preset times, the exerciser will start run and stop the engine in atder to ensure both proper lub tation of all engine paris and proper equipment ‘operation if and when the standby unit is needed Become familiar with all instructions included withthe equipmentWoodward Governors Woodward Governors are usually electrically op erated trom a contro! panel Generator Set Control Panel ‘The generator set control panel is located on top of the generator andis equipped withthe following Controls and gauges Panel lights (1) are controlled by an ON/OFF switen (7)-An ammeter (2) requency meter (3) anc a voltmeter (8) show the output of the generator. ‘Two gauges (5 and) show engine oll pressure and water tomporature respectively. Tho am’ Selector switch (12) gives the operator a choice of whieh phase (71. T2.6r T3) of the generator output the ammeter (2) wil show. Voltage level rheostat {@) takes the place of the voltage level rheostat in the generator regulator assembly Tho engine control switch (8) has four positions MANUAL. AUTOMATIC, STOP and OFF Placing the control in the MANUAL position will start the tengine and allow the operator io manually connect the ganerator to the load. the unit Is used for standby application with a remate transfer switch the AUTOMATIC position 1 Used. In this position the engine will automatically start and take up the load when commercial power has stopped. Placing the control inthe STOP or OFF position will stop the engine. Whenin the AUTOMATIC or MANUAL posi- tian, the engine will automatically stop if the com- mercial power nas started or the engne has afault ‘The PSG governor control switch allows the ‘operator to contra the engine rpm trom the panel. the engine 's equipped with glow plugs. they are Controliad by an ON/OFF heat switch (15). Ifthe engine has a fault, engine talurelight/roset sswiteh (11) wilh operate. ‘The lgat/switen (11) wil activate a shutdown relay to stop the engine. A Shutdown indicator (14) will also operate to show the cause ofthe fault. The shutdown indicators (14) {ive an indication that the fault was either oll pres Sure, water temperature or overspeed. A four shutdown indicator will show an overerank cond. tion. AD.C. ammeter and a governor contrel switch Will take the place of buttons (10 and 13) respec. tively itordered. The shutdown indicators have four ‘auxiliary contacts: one for each time ts shutown indicator operates. The contacts are connected toa emote annunciator panel orderea ‘The shutdown indicator lights can be checked for malfunction by depressing he shutdown indicators Replace burned ut bulbs immediately CONTROL PANEL 4. Panel lights. 2. Alternating current ammeter. 3. Frequency meter. 4. Alternating current voltme: ter. 5. Oil pressure gauge. 6. Water temperature ‘gauge. 7. ON/OFF toggle switch for panel lights. 8. Engine control switch. 9 Voltage level rheostat. 10. Button (direct current ammeter # ordered). 11. Ene ‘ine failure light/reset switch, 12. Ammeter selector Switch. 13.Button (governor control switch fengine is equipped with a PSG governor). 14. Shutdown indicator (oll pressure, wator temperature, ov speed and overcrank). 15. Button; heat switch (iso ‘equipped). 16. Panel; prealarm module (i 0 equip. ped).Starting The Engine 1 Perform all prestart checks outlined previously. 2, Place the CONTROL switch in the MANUAL. position to crank the engine. ‘3, When the engine staris and engine rpm reaches {600 rpm and the ol pressure registers 22 pst (1.5 kg/m) the Starting motor will automati- cally disconect from the start circuit 4. Stat the load. Regulate the engine speed with the RAISE- LOWER ewiteh tothe requited instrument pane! gauge readings. ‘Stopping The Engine 1 Remove the load. See GENERATOR SET OP. ERATION inetructions ifequipped with an elec inie set generator. 2, Reduce engine speed to low idle: Push down and hold the RAISE-LOWER switch until the en- {ine low idle speed Is reached 43. While the engine is idling, check the engine oi level Oi level must be maintained between the ‘ADO and FULL marks on the side of tha dipstick marked "CHECK WITH ENGINE RUNNING 4. Stop the engine. Solenoid Shutoft ‘a. Move the control switch to the STOP or OFF positions. (Do not confuse this with the PRAISE-LOWER™ switch) ON-OFF-STOP SWITCH is PSG Governor: . Move the shutotf lover forward, oF hold the lever up. depending upon Installation. Hold the lever in this position until the engine stops, 5. Fill the fuel tank. See the LUBRICATION AND MAINTENANCE section. 6. Drain the raw water system if below freezing temperatures are expecte 7. Observe the Service Meter reading. Perform the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART. Emergency Shutoff Devices And Alarms Pails the shulelf devices, the conditions which cause ‘each control to function, and the resetting proce- ‘ure required to start your engine. CAUTION Always determine the cause of the shutdown, fand have the necessary repairs made before Starting the engine. See TROUBLESHOOTING GUIDE: Do not use an emergency shutoff device for @ normal stopping procedure, The operation of all electric shutoff controls is, similar: A critical operating condition actuates Switch which closes the citeult to the shutoff sol ‘enotd, whion stops the engine. The shutoff control may require resetting betore the engine can start High Water Temperature Shutoff “The shutott switch is located in the water temper- ature regulator housing, Excessive water tempera- ture closes the switch. No resetting procedure is required: As the coolant cools, the switch opens, CAUTION ‘The sensing element must be submerged in the ‘Coolant to operate. Coolant level must be main- tained in order for the shutoff to operate. Low Oil Pressure Shutoff Switch ‘CAUTION Does not protect system from rapid oll loss, such as line breakage.‘This device is usually mounted on the side ofthe ‘engine, and oil lines ave connected to the switch {Low ail pressure closes the switch Manually operated systems require resetting of this switch before starting. Automatic. starl-stop Systems vse a pressure switch which resets sel! To reset the switch. push the button until it latches. Alter the engine starts and develops oll pressure. the bution wil move tothe extended run hing posivon CAUTION ‘The button must be in the RUN position to pro- tect the engine, It the button remains in the reset position, the engine oll pump may not be developing normal ollipressure and checks shoul Overspeed Shutoff Switch (Electronic) ‘This switen senses engine speod. The contro! box is mounted on the engine block. Excessive on ine speed closes a circu! broaker. To reset tho Switch, push the reset button, CAUTION To provide overspeed protection there must be Fuel/Oil Pressure Switch ‘This switch is mounted in the tual manifold bet ‘naen the outlet side of the fuel Miter and the fuel injection pump. Low fuel pressure opens the switch and the electrical cireuit to either the shutoff so fold or the cirult between the alternator and the faternator regulator While the engine Is stopped ‘pen these circuits to prevent the battery trom De- ‘coming discharged, This switch can also be used with an electric gov ‘ernor, In this application, 01 pressure closes the ‘Switch o allow the electric governor fo control en- sine speed, ‘This switch does not require resetting Air Safety Shutoff Control The air shutotf control is an attachment to the safety shutolt devices, When an emergency condi tions occurs, the solenoid pushes the rack into the shutoff posiiion and a solenoid trips a butterfly Yalve, located in the inlet manifolg, o the closed position. The alr safoty shutot" contral mustboreset Before starting, ‘Alarm Switches: Alarm switches are set a a lass critical tempera ture, pressure, or level limit than the comparable shutoff eantrol. The purpose of the alarm switch is to warn the operator'an unsafe operating condition is starting to oceur, and that corrective measures Should be taken (o avoid possible damage to the tengine and/or a possible Shutdown of me engine caution Even though it could be hazardous to have the ‘engine stop unexpectantly, t the engine over- Speeds, it should be stopped Immediately 19When the preset temperature, prossure or fluid level occurs, eltheralightor an audible alarm willbe ‘energized. The light of alarm will continue to oper- fate unt the condition is corrected. When the condi- tion is corrected tne alarm will automatically rest fand tho ight will ture of. ‘CAUTION ‘The cause of the shutdown must be investigated and corrected before starling and operating the engine, Testing Indicator Lights Most control panels are equipped with a test switen. By turning the switch ON. al ofthe Indicator lights can be checked for proper operation. Test tho Indicator lights periogically, replace burned out light bults immediatly ‘Alarm Shutoff Switch {A switch may be installed in the alarm circuit for silencing the alarm while the engine is stopped for fepairs. Be sure the switch Is moved to the closed (Gn) position and the warning lights are lit before starting CAUTION Place switch in the closed (ON) position when the engine Is started, so the engine will be pro- tected Output Shaft Governor Operation When the load can overspeed the torque convor- tor output shatt, an output shaft governar should be installed. The output shalt govornor sa speediimit- Ing device which automatically adjusts engine gov- ‘omor setting according to toad requirement. Determining Cause Of ‘Shutdown CAUTION HW the engine has been shutdown by a safety device, da not start the engine and place it into Service without having the cause of the shut- down investigated and corrected. Low Oil Pressure Checks Ifthe iow oil pressure shutotf controlhas stopped the engine, make the following checks: 1. Check the water temperature gauge. Determine iftme engine was overneated. Check forexternal water leaks 20 A warninc jing water. Do not the hi cap 2. Check the oil level, Oil level must be between the ADD and FULL marks on the side of the Uipstick stamped CHECK WITH ENGINE STOPPED. 2.11 the oil level is below the AOD mark, check for oil spray and/or oll accumulations. it any fare found, have the necessary repairs made. Betore starting, add oll to the FULL mark 4, Reset the shutotl contro 5, Remove the load and start the engine at its slowest spec. Be prepared to shut the en fine down manually. 6. Be alert for unusual sounds or noises. If the fengine knocks, stop the engine immediately ‘and call your Caterpilar deaier 7.1f the engine blows excessive black exhaust for has excessive crankcase blow-by, the en- fine may need recanaiioning. Stop the en- ine and call your Caterpillar dealer 8.1f the engine runs satistactorily, observe the ‘oll pressure gauge. if satisfactory pressure is hot indicated, shut the engine down: call your Caterpillar dealer 9.1 proper oil pressure Is registered, check to see if the reset knob has moved to the un position. If the knob does not move, stop the Engine. Check the shutoff control, the ol line ‘nd ihe oll pressure gauge. Have necessary Fopairs mado. 10.1f the oll pressure gauge registers normal oll pressure, it the knob on the shutot! control moves t0 the run position, and if the engine operation is otherwise satisfactory, determine ifthe high water temperatura shutott may have shut down the engine High Water Temperature Checks—Engine Running +, Detormine if the load was too great for the engine! Reduce the load ang allow the engine to coo! while running 2.1 pressure steam or water leaks are visible, temove the load and stop the engine. Have ‘necessary repairs made. 3. Check for collapsing or deteriorated water hoses, Have repairs mado,4. Check for noisy water pump operation. Have nocessary repairs made 5. Refill the cooling system with a solution of water and permanent-lype antifreeze if below freezing temperatures are expected: or with a solution of approved water and Caterpillar Corrosion Inhibitor or equivalent, Foliow the Instructions on the container A wanninc High Water Temperature ‘Checks—Engine Stopped and Cold 1. Check coolant level. Determine if the cootant has proper anifreeze protection. A $0-50 solu- tion 6 permanent-type antireeze and approved ‘water willgive protection below 20°F (29°C) 2. Check tobe sure the raw water valve has been ‘opened. 3. Check engine room vents and/or louvers. Be sure the angina is receiving sulficient air 4. Be sure temperature regulators are operating at proper temperature range. 5. Inspect all water noses caretully for collapsing, external andinternal failures. Replace hoses as required, 6. Have the cooling system cleaned CAUTION If severe or prolonged 0 red, contact your fengine checked for po: ible damage. Emergency Stopping To stop in an emergency: Mechanical Governor Control Pll upward on the hand grip, and move the con: trol to the shutott position Woodward PSG Governor Move the lever forward against the stop; hold the lover unt the engine is stopped. Electric Shutoff Solenoid Push and hold the ON-OFF-STOP switch in the ‘STOP position unt the engine stops Air Controls Push and hold the ON:OFF-STOP switch in the ‘STOP position untirthe engine stops.MAINTENANCE RECOMMENDATIONS Cooling CAUTION Never add coolant to an overheated engine; allow the engine fo coal Hest. Check specie gravity of antifreeze solution tre- {quently in cold weather fo assure adequate protec- tion Coolant should be drained and replaced “Every 2000 Service Meter Units.” With additions of Caterpillar Cooling System inhibitor or the use of Coolant Conc- tioner Elemente a8 recommended, the drain period ‘canbe extended o""Every 4000 Service Meter Units.” All water is corrosive at engine operating tempers = The cooling system should be protected with Inhibitor at ll mes regardless of concentration of ‘nlilreeze. This can be done by maintaining 2 3% Concentration of guid Caterpilar Cooling System Inmbitor or by using Coolant Conaltioner Element Never use both the liquid cooling system inhib land coolant elements at the same time. Do not use Caterpillar Cooling System Inhibitor or Coolant Concitioner Elements with Dowtherm 208 Full-Fill Coolant Whenever ctaning and rafiing cooling system, a ways recheck the coolant level when he engine reaches ‘Normal operating tempersture Filing at over U.S. gallos (19 Mors) per minute can cause ar pockets inthe cooing system Premix antifreeze solution to provide protection to the lowest expected ambient temperature, Pure unciutes fnttroeze wil freeze a1 10"F (28°C). Operate with a thermostat in the cooing system all year-round. Cooing System problems can arise without 2 ihermastat. Electrical caurion When using jumper cables to start the engine, b Sure to connect in parallel POSITIVE (-) to POS! ive (/) and NEGATIVE (~) to NEGATIVE (~ ) ‘Scheduled Oil Sampling Use Scheduled Ol Sampling to monitor the engine's condition and maintenance requrements. Each of sample should be taken when the ois hot and well mived, to insure @ sample whichis representa tive ofthe ol nthe compartment CConsutt your Caterpilar dealer for complete informa: tion endassistance mestablehing a Scheudied Ol Sav ping program for your equipment Fuel CAUTION Fil tue! tank atthe end of each day of oper Grive out moisture laden air and to prevent conden- Sation: Do not fil the tank tothe brim. The fuel @x- ands when it gets warm and may overflow: ‘Water and sediment shoud be drained from the fue tank atthe start of]each shit or after the ful tank has been tiled and alowed to stand for 5 to 10 minutes Drain ful tank of moisture and sediment as required by prevaling conditions ‘ter changing fue titers, always bleas tel system to remove air bsobes fom system. Air intake Service air cleaners when RED band in indicator locks in vise positonSPECIFICATIONS LUBRICATION SPECIFICATIONS Crankcase Lubricating Oils Use ols which meet Engine Service Classification CD (MIL-L-2104) oF CD/TO-2. Tose are agdiive-ype ols that have been approved for use in Caterpllar Dose Engines. Consut the "EMA Lubreating Oils Data Book,” Form 'SEBUS939, for listing of CD ol brand. ‘The proper SAE grade of oo seletis determined by the ambien! temperature at which the engine is started and the maximum ambient temperature in which the engine wil be operating, See chert for recommended viscosity and temperature range To determine i the olin the crankeaso wil tow in cold weather. remove tol dipstick before staring! the ol ‘wil Tow aff the is fhid enough to eeulate propery Lubricating Grease Uso Multipurpose- ps 1¢ Grease (MPGM) which Contains 3-88 molybdenum disulfide contorming to MIL:M-7866, and a suitable corrosion inhibitor NLGINo. 2 Gradels eutable formost temperatures Use NUGI No. 0 of No. 1 Grade for extremely low temperature Recommended Lubricant Viscosities "Wer spetng tion SP [277 er oe Cal Wey Reason Gian avd Maviaranos Gace, Fors SED, Air Starting Motor Oiler: Use SAE 10W in all temperatures. Flywheel Clutch Bearing Reservoir: Use SAE 30 ‘nal temperatures, REFILL CAPACITIES WODEL | US.GAL | LITRE | IMP. GAL. 3406 72 | 455. 10 ae 6 305. 13FUEL SPECIFICATIONS. No, 2 tue! oil and No. 20 diesel fuel are recom: mended tor use In Caterpilar Diesel Engines, In Extreme caid tomporatures use No.1 fuel cil or No, 1D iasel fuel In selecting a fuel, note that distilate fuels are especially desirable because the {uel is heated toa Vaporous stale and condensed, thus eliminating all Sediment and residue, “There is considerable variation in the composi- tion of fuels aistabuted under the No.2 grade clas- Sieations, For desirable engine service its most important to give special attention to cetane no. later and sediment pour point. cloud point and Sulphur content USE THE LOWEST PRICE OIS- TIWUATE FUEL WHICH MEETS THE FOLLOWING REQUIREMENTS. Water ang Sediment 0.1% sogimont Cotane No. (PC Enaine) ‘35 minimum {Orengine) 40 minimum Pour Point {G'F (6°0) below ‘ambient temperature Cloud Point ‘No higher tran ‘biient temper ‘Adjust oll change period Gravity 33:40 AP. at 60'F (15.6°C) *See the topic SULPHUR CONTENT. Catane No: This s an indication of a fuet's igni- tion quality and should notbe loss than 35 or the PC tengine and 40 for the DI engine, For high altitude operation or cold weather starting, anigher cotano number fs required Water and Sediment: A good clean fue! will con: tain no more than 0 1% sediment and water. Dirty {els lead to early filter plugging and in aoaition can {esultin the formation of gums and resins reducing fter and engine ite Sulphur Content” Pour Point: The pour point of the fuel has no effect on engine performance, as tong as the fuel is fiuid enough to flow from the fuel tank the engine, ‘The pour point of the fuel should be al loast 10°F (G:C) Below tno lowest almospherle temperature at finich the engine must start and operate. Ine tremely cold temperatures it may be necessary to Use No. t fuel gilor No. 1D diesel fuel Cloud Point: Cloud point is the temperature at which wax crystals become visible and is general ‘above the pour point of the fuel. The cloud por Should be ho higher than the Towest atmospheric {emporatore at which the engine must start 1o keep the fuel iter elements from plugging with wax crys tals Sulfur Content: The percentage of sur inthe tut ‘wifatect he engine of recommendations. H the fel has ‘ver 0.5 sulfur content, he CD engine oil must have a “TBN of 20 mes the percentage of fuel sultur TEN as, Tneasuted by the ASTAID 2856 method). Your o supp shoul be able to furnish te corect ol Gravity: Gravity isthe measurement of heat units inacortainamount of fuel The heavier the fuel (the lower the number) the morefeat units per volume. fa fuel with ahigher A P.. gravity is used the power, roduced will be lower. Select fucis with the lower Keil gravity reacing ‘Some fuel specifications that meet the above re urements are ASTM—D396--No. 1 & No. 2fusle (burner fuels) ASTM 0975 -No. 1D &No.20 diese! vel ails BS2a69—Class At to Class A2 engine fuels Bs2869—Ciass C & Class D burner fuels DINS1601—Diesel fuel DINS1603—EL heating oil Authorizes dealers are familiar with fuels that have given good results in Caterpillar Diesel En- {ines and should be consulted regarding fuel use ‘then abnormal conditions occur COOLANT SPECIFICATIONS Water used in the jacket water cooling system should be clean, ang as free as possible trom scale {forming minerals or earrasive chemicals. Artificially Softened water should not be used. Treating the water with Caterpillar Coolant Inhibitor. or equiva- Tent will help prevent the formation of rust and pit- ting. It will also retard, and in some cases com- pletely siminate, mineral depasits in the engine. ‘The mast efficient and satislactory corrosion pro toction for the cooling systam is to maintain proper level of coolant innibter and antilteeze solution {ine use of auxiliary water filters Is rot recom mended. During freezing weather use the proper perma: rent type antireeze and water solution to prevent freezing Before placing the engine in operation, make sure a 3% concentration of Caterpillar Corrosion Inhibitor or equivalent hae been added to the coo! Ing system. This 3% concentration must be main: tained in cooling systems which ae filled with water land systems protected with etfiiene glycol anti feeze mixture, regardless of anlireeze concentra- ton WARNING ‘void contact withLUBRICATION AND MAINTENANCE INSTRUCTIONS Regular service intervals, along with close daily visual inspection and the adherence tothe instruc- tions and schedules, will assure many hours of trouble-tree service. if correction steps are taken immediately on discovery of any abnormal cond tion, fewer forced stops and more economical oper ‘tion wil reeute. The Lubrication and Maintenance Chart is in- tonded as a quide and adjustments in the schedule ‘may be necessary. depending on conditions under ‘ane the engine fe operating” A thorough analysis ‘should be made before adjusting the maintenance Schedule ‘Some items to consider in establishing @ new schedule are: Severe dust or dirty condiions, fuel Eonsumption a good measurement to establish In- tervals ae ft ingicates the amount of work por- formed). As a guideline, the 3408 Engine with a 12 {gal (45 itr) (10 imp. gal.) capacity erankease will Use approximately 4000 gal. (15.000 tlre) (3332 imp. gal.) between oil changes." The 3412 Engine with @-18 gal. (60.5 lire) (13 Imp. gal.) capacity Grankcase willuse approximately 5100 gal(19,200 litre) (4288 imp. gal) between oll changes.” Rleducing or extending the maintenance intervals should be done only after complete study and ‘enough time to gain adequate experience to meet Sspeciic operations “with 0.5% oles ful sulphur content Caterpiliar scheduled ol sampling: Scheduled ol ‘sampling is a program which analyzes oll samples {akon trom an engine at regular intarvals (usually at ‘ll change periods). This all analysis does not int ate tho condition of the oll, but rather, itis a Scheduled procedure tadetermine engine condition at regular intervals By analyzing luoncating oll for foreign and wear particies, The scheduled oil sampling will give the following benefit: assures the owner that maintenance has been performed It will show the first signs of excessive wear meaning a possible upcoming failure, allowing time for a scheduled repair Iwill warn maintenance personnel of improper ot lack of maintenance and presence of fuel dilution or antitesze in ol is particularly helplul in preventing wear due to dir entry trom air cleaner oF ilet piping, Feegular sampling is especially advantageous for new enginos to establish wear trends trom the be: ‘inning. The results of the oll analysis are inter broted by experienced, highly trained personnel Contact your Caterpillar dealertor datailed informa:LUBRICATION AND MAINTENANCE CHART ‘The LUBRICATION AND MAINTENANCE CHART ists The mainten time intervals ae expressed in Service Motor Units. The Service Meter on the e ai serviceable items commonly dered on this engine na shows the taal unnber of unis the engine has fun. Use the Service Meter readings for determinmng your maintenance ee dies Borforn tne maintenance at mufiplintervals ofthe units shown Fox exarnble, when the Service Met "EVERY 10 SERVICE METERUNTS: shouldbe serviced now forthe ‘SERVICE METER UNITS: should be serviced fr ne second time. ‘Shows 1007 on the da, al tems isted under tenth time, are a iloms under “EVERY 50 Diesel fuels, lubricants and coolant make-up water 10 | Fie | senvice rem (lusmearon [ Late Fron Cer Eresare Calor | MeStoter| ee | apes ter Oa Eaao0 [S@Sregs, ut Pe [oa euene mer oo [Tiree Cnc Goriral Lover Shaft aonenoe ana [Bee orrom enna sea Eanes | 26 [a a ase [| sn [8 | se are explained in the ‘Spectteatons _BERWICE METER WATS T isence em Lt Geese Pere Toe Te | ql ‘Stroe alte Fel Tara Ar Scppng [39> sess “Replace Final Fuel Filter 40 | now 8 | 1 rere a ia aaa fecal | 1 ea eee - 4 Tree ata Ta NOTE A: NOTE B NOTE C: NOTE D: NOTE E: NoTES ‘The percentage of sulturin the fuel wil affect the engine ol recommendations i the fuel has ‘ver 0.5% sulfur content, the CD engine ol must have @ TBN of 20 times the percentage of fuel Sulfur (TEN as measured by the ASTM D-2896 method). Ifthe sulfur contents greater than 415% by weight. use an ol with a TBN of 30 and reduce the ol change interval By one Mal Consult your Caterpilar dealer for correct engine ol recommendations. ‘Check fuel pressure gauge dally. Replace when FUEL PRESSURE gauge registers OUT or 20 PSI(128 kPa) ‘The element can be cleaned approximately 3 times. Caretuly inspect the element after each leaning. It engine isnot equipped with air cleaner service indicator, check element every 250, Service Meter Units, or more often under dusty conditions. after servicing the ar cleaner, the exhaust smoke andjor loss of power continues, install anew element, Authorized Caterpilar dealers are equipped with the necessary tools, personnel and procedures to perform these services. Initial valve lash adjustment on new. rebut or remanufactured enginesis recommended atthe fist Seheduled oi change interval, due to intial wear and seating of valve train components. ‘Subsequent adjustments should be made at every 2000 Service Meter Units or One year. Whichever Occurs First orLUBRICATION INSTRUCTIONS Crankcase Lubrication Oil The Lubrication and Maintenance Charts lis the ‘normal oll change periods as dotermined by fuel Sulphur content. (Make an initial oil-and filter ‘change after th fst 10 service meter units of oper faton for reconditioned engines) See the OIL SPECIFICATIONS to aid in the proper oll SAE viscosity selection. The proper SAE Miscosity of oi to select is determined by the am bient temperature at which he engine is started and operated: Checking Oil Level The dipstick is stamped on both sides of the blade, One side is marked and to be read when checking the oll level with the ENGINE STOPPED. The ather side is marked and to be road with the ENGINE IOLING-HOT OIL. Each side Is stamped tovemind you not to OVERFILL the crankcase with CAUTION Be sure to read the correct side of the dipstick. ‘The ADD and FULL levels are notthe same when checking the oll while stopped or while idling Checking Oil Pressure Immediately after starting, and frequently during ‘operation, observe the ol pressure gauge reading ‘The indieator should registerin the NORMAL range ¥ See It the indicator fluctuates or registers below NORMAL range: 1, Move the governor contro to low idle position 2, Check the oitlavel. Be sure to read the ENGINE IDLING sige of the dipstick 28. Ad oll uni the ol levels at the FULL mark on the ENGINE IDLING side of the dipstick: Do not overt 4, Cheek for oil leaks, 5. necessary, stop the engine and have repairs made. Draining Engine Oil With engine slopped and oll warm: 1. Remove the crankcase oil crain plug. 2. Allow the oil to drain 3. Clean and install the drain plug (OR, if a sump pump is used: 1, Connect a suitable drain line and container to the pump outet 2. With engine stopped and oil warm, open the sump pump valve Io the engine crankcase orain Tino: the two marks on the valve must be turned 50 that ona mars points to the pump, and the Second mark points ta the engine drain line 8. Operate the sump pump handle unt the crank: cave is empty 4. Close the valve to the engine crankcase drain Tine Cleaning the Breather 4, Release the hose clamp and disconnect the fumes disposal tube 2. Remove the breather assembly.8 Wash the breather in solvent 4. Apply athin coat of clean oil tothe gasket ofthe new titer Allow to drain dry and then wipe. 5. Inspect the gasket. Install a new gasket if nocossary, 6. Install the breather 7, Connect the tumes disposal ube Pd . 5. Install the new titer: Hand tighten the iter ea turn after th urn afer the titor gasket contacts the base - 3" Bseoacar Use rotation index numbers. which are painted 7 ‘onthe liter can, ae aguige forproper lightening, Changing Oil Filter 1- Unscrew and remove the Filter Filling the Crankcase 1. Fll he crankcase to the sate starting range on the ENGINE STOPPED side of ho aipstick: See the Lubrication Specifications for refill capacity sa pret a ico tached inside the titer base: Leaking will occur wa A a SSS Between the new titer gasket and ths Old gas ps Mesonkag 2. Be sure ne or gas i nt oman a Bas =A ELE RE 2, Stat the engine and check for oil leaks. 5. Alter the engine is warm, check the ci evel with the engine iling 4. Add oll necessaty to maintain the oil level at the FULL mark on the ENGINE IDLING side of the dipstickFan Drive Bearings Lubricate the fan drive bearings with lubricating ‘grease through one iting, oF 2 strokes. sssss0 PRESSURE \= Firing ND 29867 FITTING A001 It the grease fiting i not readiy accessible, t may be recassary 0 1. Remove the 454550 Fitng (tle from the fanmount- ingbashet seb antl te 200857 Figs place 2 Install the 484550 Fitting (retin place ofthe 204867 Frit Woodward PSG Governor Synchronizing Motor Fil the oll cup on the synchronizing motor with clean engine oll with same viscosity as used inthe engine. Air Starting Motor “The motor oiler lubricates the vanes ofthe start: Ing motor witha fine oll mist as the motor I operat ing ‘When the oll jar becomes hall empty, remove the oilfiler plug and fille jar with clean engine oi with the same viscosity as used in the engine. 30 CAUTION Never allow the jar to Become empty. The start- Ing motor will be damaged by lack of proper lubrication. Adjusting Oiler Feed It necessary, adjust the oiler to release approxi mately four drops of oll per minute info the stating motor air stream 1, The engine must be operated iong enough to have the oil warm, Then stop the engine. 2. Move the governor control lever to the SHUT: (OFF position 3. Push in on the ai start control and crank the engine 4. Count the drops of ol released por minute into the alr stream 22 Tum the needle valve (the uppermost knob on the ler) counterclockwise to Increase the hhumber of drops. b. Tum the needle valve clockwise to decrease the numberof 6rops. Emptying Oil Collector Jar Empty the oil collector jar whenever tho jar be: ‘comes hall ful, The callector ar collects both the ol fatter thas lubricated the starting motor vanes, ang the moisture condensation from the compressed fir, Do not fil the oiler jar with this used cilPower Coupling Attachment Heavy Duty Clutch Main Shaft Bearings. ‘The heavy duty flywheel clutch main shaft Bear Ing is oil lubricated. The remaining bearings are lubricated with grease Chock the main shaft bearing oil reservoir level with engine stopped. Maintain the oil level at the FULL mark on the oll level gauge. Add oll through the filer tube on top of the bearing cage housing Use the same type of oll as used in the engine crankcase. See the OIL SPECIFICATIONS. ~% To drain the reservoir: Remove the drain plug located on the lower left side of the shaft bearing reservorr. Drain and install the drain plug. Filio the FULL mark onthe ol fevel gauge. Install th filer cap. CF Enclosed Clutch Shaft Bearings (Grease Lubricated) Lubricate the shaft bearings through 1 fiting Front/Rear Clutch Engaging Collar Lubricate through 1 fiting—2 strokes. Control Lever Shaft Bearings Lubricate through 2 fitings—2 s one Clutch Pilot Bearing Lubricate sparingly through 1 fitting on end of shat Ilfiting snot accessible, remove the plugon the circumference ofthe shaft rear the housing and stall a grease iting. Relnstal plug after luovieat- ing. a ‘@COOLING SYSTEM Coolant Conditioner Element WARNING [At Operating Temperature, engine coolant is hot and under pressure. ‘Check coolant level ONLY, when engine is stopped Sand radiatar cap is cool enough to touch with Your Romove filer cap slowly to Cooling System Inhibitor contains alkali. Avaid co face urchin ana eyes to preven personal inry.1-Cose int valve and out wave a element base caution All water is corrasive at engine operating tempera- ture Use eth F Cooling System Inhibitor liquid, or the coolant conditioner element 10 teither plain water of ethylene glycol solution 1o not add both the fand the coolant conditioner element at the same time, cAUTION When changing antireeze solu maintenance fiter element with the correct pre- Charge element CAUTION ‘The normal coolant conditioner element must not be Used with Dowtherm 209 coolant. 2. Remove the coolant conditioner element, Discard ‘element cAuTION Excessive coolant conditioner (greater than the rec- ‘ommended 6% inital) together with concentrations ‘ofantifreeze greater than 65% cause deposits to form Sha" may result in radiator tube Blockage and ‘Overheating \Wnen trash engine coolant consisting of eter pan 3- Clean clement mounting base. Make certain af oft water or water and antifreeze is stale. precharge Seen" gasket material = removed biement shoul be instal for use unl the frst normal slement change period 928. Start engine and check for leaks.COOLING SYSTEM Coolant Level Chock the engine coolant daily with the engine stopped and cool. 1. Slowly turn the filler cap to the frst stop to re- lease pressure, Awarning Be careful: If the engine is warm-steam may spray outward under high pressure, 2. Push the cap down and turn until the cap Is releases, 4. Maintain coolant ieveltothe base of hefillpipe. 4. Make-up coolant should be with water free as possible from scale forming minerals (not So {ened water) and a permanent type antifreeze Containing rust inhiitor of @ solution of ws fand Caterpiliar Corrosion Inhibitor. Fallow fecommendations given on the container. Maintain a9% concent sion Inhibitor 7 of Caterpillar Corto: CAUTION Do not use with Dowtherm 208. 34 Make-up water added without he proper propor- tions of coolant corrosion inhibitor can cause excessive lime dapasits and corrosion. CAUTION ‘Add coolant slowly to a hot engine to prevent possible cracking or distorting the cylinder ead. ltatossof coolant is noticeable, check tor leaks in the system. After filing the system, start the engine land recheck the coolant level after narmal operat ing temperature is reaches. Running the engine at ‘operating temperature wil permit the temperature Feguiator to open and allow the coolant to circulate through the entira system and purge air from the engine {Wa permanent antitro0ze solution is used in the cooling system, either renew therustinibitar every three months by adding Caterpillar Corrosion Ir hibitor or crain the entire cooling system annually ‘and relill with rosh coolant solution Drai jing The Cooling System To clean the cooling eysiom or replace the coat solution, itis necessary to completely drain the Cooling system: 1. Stop the engine 2. Slowly turn the pressure cap until the cap is removed. A warning Be careful. if the engine 1s warm-steam may Spray outward under high pressure ahaa 3 ne the radiator drain valve4. Remove biock an oil cooler drain plugs. y Draining Heat Exchanger Cooling System 1. Stop the engine 2 Siomly turn the heat exchanger pressure cap to ‘he tet sop and release me pressure, AX waRNING careful. If the engine is warm-steam may 1y outward under high pressure. 3. Push the eap down and tuin until the cap is released 4, Remove the drain plage te oi black and lines Iv the ambient tomperature is expected to go below freozing, raintneraw water ire between the heat exchanger and the raw water pump. in tank, pump, RAW WATER PUMP DRAIN Cleaning The Radiator (External): Every 250 hours clean dirt and trash trom bet- woon the tubes of the radiator which may cause excessively high operating temperature, Wash, brush orbiow the dirt out wth whichever method Is available and most affective Cleaning The Cooling System (Internal): Clean the cooling system periodically, Mineral deposits can cause serious engine damage by 7 tarding ine anster of heat tothe coolant. A deposit of lime 1/32 inch thick insulates the same amount 852 Inches of steel, reducing the heat transfer sub- Stantlally. Loose scale and sediment deposited in the cooling system will reduce circulation, resulting impossible engine damage To clean, stop the engine when it Is at normal ‘operating temperature and drain 22 quickly as pos sible Flush thoroughly, then fill with a salution of one: pound of Oxalie Acid or Sodium Busullate per live ‘allons of water. Fun the engine at operating temp: Brature onechalf to one hour, then drain ane flush Until water is clear Fill wth a solution of one-hall ound of Sal Soda per ten galons of water and run the engine ten minutes. Drain, flush ad fil with water, adding coolant conditioner and the desired amount of anitreezs, Cooling System Pressure ‘pressure relief cap on the radiator or expansion tank controls the pressure of the cooling system ‘and provents the loss of coolant through the Fadiator overtiow tube. Pressurizing the cooling system serves two pur poses. Fist, it permits sale operation at coolant Temperatures higher han the normal boiling poi, providing a margin of cooling for Intermittent peak Toads. Secondly it prevents cavitation in tho water pump, and reduces the possibility of air or steam pockets forming in the coolant passages. Proper DSperation of the pressure ralet cap assembly 1S essential. A pressure relief cap allows pressure {and some water, ifthe cooling system is to0 full) 10 Bseape when the pressure in Ihe cooling system exceeds the capacity of the pressure cap. Loss af pressure will cause steam 10 form when coolant Femperature Is abave the normal boiling point The cooling system is designed to work under a pressure of 4.7 PSI (7 PSI ws recommended) 10 Sllow a high heat transter tor sizeof radiator and an Combination. In a pressurized sysiom, a leaking fadiator cap allows loss of presoure and coolant Fora simple check of eocling system pressure. in ‘stall a prossure gauge Inthe radiator top tank and prossurize the system. Do his by ether vaingan ait 38valve and external air supply, hand pump, or by ‘operating the machine until the coolant reaches feperating temperature. System pressure should ‘ise to approxmately 7 PSI, and any additional pressure should force air past the roliot valve Through the overtiow opening. Do not allow pres- Sure fo exceed 10 PSI, The system should hold minimum pressure of approximately 7 PSI, and a PRESSURIZING THE SYSTEM pressure must remain constant withthe alt supply Shut of ore engine running ata constant temper ature. It the pressure isn’t maintained, overtiow oss can ‘occur as cooling system temperature rises. Do nat remove the cap while the system is at operating temperature, Check coolant level only when cole It the system does not hold pressure, find the leak Carefully inspect the radiator cap, seals. sealing surfaces and the top tank Tiler neck sutface for damage RADIATOR CAP Testing The Temperature Gauge Remember that boiling point temperature and pressure go hand-in-hand and neither one can be fested logiealy withaut considering the other. For examplo, the effect of pressurization and allitude fn the boiling point of water 1s shown inthe chart. ance CcoouNG SYSTEM PRESSURE 0000 | i a fine ravnenve’ 10180210 mada isis et OWING POINT OF WATER 36overheating and loss of coolants a problem, a prossureioss nthe system could be the cause. an Sverneating condition is indicated on the tempera- {ure gauge and loss of coolant isnot evident, check the accuracy of the temperature gauge. Make this heck By installing a thermometer with a sutable bushing into the cylinder head Start the engine. Partially cover the radiator to reduce air flow and cooling. The teading on the Instrument panel gauge should agres with the reac Ing.on the thermometer A warning Use CAUTION when working around moving pares with the engine running CHECKING COOLANT TEMPERATURE WITH THERMOMETER Temperature Regulators There (9 temperature regulator located at the frontof each cylinder head Tho opening temperature ofthe regulator (Bench test inantmogphericpreseure) should be 180 = 2°F (62 °C) Tne regulator shouldbe uly open at approximate ly or"F (32°C) +, Remove the regulator from the housing 2. Suomerge the regulator and a thermomotorina pan of water as shown 3, Apply heat to the pan an stir the water to main: fain uniformity 4. Observe the opening temperature of the reg ulator Ifthe regulator does not operate correctly, install => -REGULATOR Cooling System Hoses Inspect all coolant hoses annually and replace it they show signs of cracking or leaking, Periodically Feplace all hoses, as ls many timos dificult to {stermine the condition of a mater hose by visual Inspection and feel, Coolant hoses are expendable ‘tems and periodic replacements considered good maintenance practice. Air, Gases And Steam In The System Incomplete or improper filing is 2 major cause of airin the cooling system. Also, \eaks In various Componente such as the alfercooler, ana hoses fallow air to enter tho cooling system, especially on the inlet side of the water pump Alrin the system produces foaming or aeration and affects water purmp performance. The air bub: bes insulate various parts of the engine from the Coolant, and hot spots form. As the air bubbles cir 37‘ulate or break up, coolant contacts the hot sut= faces. creating steam. The steam pockets have basically the same effect as at bubbles, accelerat ing the formation of more steam. Consequently, ‘coolant ciecharges tivough the overflow. Exhaust gas leakage intothe system causes simi larconditions, Exhaust gas can enter through inter- al cracks or defective cylinder head gaskets, ‘Most of he causes can be checked by a visual Inspection, while others require disassembly ora simple tes Airinthe cooling systemis one cause of overheat- ing which ean be focated by a simple test known as the "boitle test". The equipment required to per- form such a test consists of@ 1 pint bottle, a bucket of water. and alength of hose with an inside diame- ter large enough 10 ft over the end of the cadiator overtiow pipe. To Test Fille cooling system to proper level. Wire open. te rellel valve in the ragiator cap. Install the Fasiator cap and tighten. Assemble the rubber hose fver the ond ot the overlow pipe Start the engine and operate it at high idle speed for atleast five minutes after the engine reaches ‘operating temperature. Block off part of the ar flow through the radiator to maintain operating tempera: ture, Alter the temperature has stabilized and all ‘expansion airhas vented out, place the loose end of the hoseinihe water filled bottle whichis invertedin the Bucket of water! takes lege than a minuto to displace the waterin the pintbottla, leakage intothe Cooling system ie excessive, Loose precombustion chambers, faulty precom- buation chamber seals, aloose cylinder head, or & Samaged head gasket are possible causes of arin the cooling system. In any case, tho cause should ‘be corrected immadiately, 38 Water Pump ‘The water pump circulates the coolant through the altercooler and oll cooler, the cylinder block, fylinder head, and fadiator Poor coolant circula tion causes overheating. A badly corroded or worn water pump Impeller, ot van a logse impeller, re- ‘duces circulation and efficiency Every 2000 hours inspect the water pump and rebuild as necessary, oF install a rebuilt pump to feduce downtime to a minimum. Your authorized ‘dealer Is familiar wth warn replacement limits and with disassembly and assembly procedures. Raw Water Zinc Rods (Salt Water Only) Salt water has a highly covrosive reaction with metal by a chemical action called "electrolysis". To Prevent this chemical action taking place, with parts Usedin the raw water system, zine plugs are laced Inthe raw water piping. Zinc's relatively soft metal Which reacts quite readily with the salt water. Thus, by the deterioration of the Zino, the raw mater sys tem paris are protected trom corresion ‘The zinc rods must be inspectod regularly and be replaced as they become deteriorated. The zinc rod plugs are painted rea for easy identification, Fan Belts Examine the drive belts annually for wear and replace if they show signs of wear. Loose or worn pulley grooves cause belt slippage and low fan Speed. It fan bells are too loose, they vibrate ‘enough tocause unnecessary woar on the bells and pulleys and possibly sip enough to cause overheat ‘ng fone batt ina set requires replacement. always. installa new matched sat ol bels-nover replace just the worn belt if only the worn belt's replaced, the ‘how belt wil carry all the foad-ae st wil not be Stretched as much as the alder belts-and all the belts wil fail in rapid succession. BELT TENSION‘Adjustment: Check new belts for adjustment after the first 10 hours and every 250 hours thereafter. To check bolts-apply 25 ibs. (11-5 kg) force midway botweon pulleys. Correctly adjusted belts will dtlect "inch {12.8 mm) to % inch (18 mm) for the frst check. Maintain later aglustments at 7/8 inch (23 mm). To Adjust: Loosen the lockbolts on the fan pulley adjusting bracket and adjust fan pulley with he adjusting bolt Aor belt tension is corcect, tighten lockbolts. Readjust alternator belt tension and tighten ad justing nuts Wit) i ll Aftercooler ‘Some engines may be equipped with an after: cooler, The allercooler isa simple device resembl- ing a email radiator core. Water from the engine asses trough the core tubes. Engine infet ai Wwarmedby the turbocharger compressors directed through the core ang around the tubes. Since the temperature of the waters lower than the air, the ait Is cooled as it leaves the aftercooler and becomes ‘more dense ae t enters the intake manifols. This freans more ait (oxygen) is available for combus- tion, resulting in more fuel being Burned and more power produced. ‘One degree increase in inlet alr temperature in- creases exhaust temperature approximately three degrees, Restrictions to either coolant or ai flow Feduce aitercooler efficiency and severly affect tho fengine and cooling system When engine is being rebuilt, remove the atte cooler and clean core, water and air passages FUEL SYSTEM Care Of The Fuel Supply Too much amphasis cannot be placed on the im: portance of using only clean diesel fue. It's impor- {anttobuy clean fueland keep itclean. The besttvel can be rendered unsatisfactory by inadequate sior- {9¢ facitioe or careless Nancling Effort should be constantly expended to prevent contamination of the fuel. An important step is 10 educe the number of times the fuel must be hand. Ted. When the fuel can be delivered by the dis. ‘mibutor to storage tanks and then pumped from the Storage tank tothe diosel fuel tank, the handling Is, Feduced to a minimum, Care Of The Diesel Fue! Tank Fillthe fuel tank at the end ofthe day, because the incoming fuel mil drive aut the movsture laden air land prevent condensation. The strainer in the fuel tank filer opening should be removed and cleaned regularly Draining Fuel Tank Sediment Accumulation Openthe drain cock and drain any sediment or water hich may accumulate in the fuel tank betore Starting the engine. In tomperatures below freez- ing. drain shortly aitor the engine has stopped to prevent water freezing in the bottom of the tank and ther fow points in the system Fuel Filtering System ‘As either the primary {uel fiter element or the final fuel titer element gradually become clogged with foreign material, lack of horsepower willbe noticed ‘and the position ofthe fuel gauge inieator will work back trom the anginal position in the NORMAL (a. teen of approximately’ 30 Psi) range ta the OUT (red or approximately 20 PSI) range. Every 250 hours or nen the indicator shows nthe OUT (re) range, the metalic primary fusl titer element (it equipped) snould be removed and washed. W the Indicator stil shows inthe OUT (red) range, the final Iilter element should be replaced with a Caterpillar fiter element. Other make fuel titers may not mest tering or capacity requirements. See the topics, PRIMARY FUELFILTER and FINAL FUEL FILTER 39Primary Fuel Filter (Optional) ‘To remove the fiter element, stop the engine and shutoff the diesel fuel tank valve. Loosen the nut on the titer cover angiowar thofiter case. Remove the Element and wash in clean solvent or diesel fuel Reinstall the element ELEMENT CASE Final Fuel Filter ‘The fiter elament collects and holds contamin. ants and cannol be washed or atherwise restored To remove the used filler, proceed as follows: 1. Stop the engine and close the diesel fue! line valve (it equipped) 4 2, Unscrew and remove titer. 40 3. Clean the gasket sealing surfaces on the fer bases. 4. Lubricate the new fiter gasket with clean diese! ‘CAUTION Do not pour fuel into the new titer fore installing. Prime the system as In the topic, PRIMING THE FUEL SYS) ment be- structed eM. 5. Tighten the Titer by hand until tne gasket con: tacts the base, then lighten Ys 10% turn more. 6. Start the engine and run at 1000 rpm for several minutes and check or leaks. the engine fails10 Start, prime the fuel system. See the topic TO PRIME THE SYSTEM peKeep New Fuel Filters On Hand Extra filters should be kept on hand for replace: ment. Always keep titers wrapped in their original Earton to ingure against dust and dit accumulation tihich wil shorten the life al the iters may cause amage to the fuel injaction equipment, To Prime The System It ir is trapped in the fuel system, the diesel engine will eter not start or wil! mistife Thon itis ecessary fo prime the system. The tuolpriming pump is mauntedon the fuel iter base. Ifthe uel iter is changed or ithe engine has ‘un out of fuel, prime the fuel system as follows: XS 3 apni no sno nt sexed rete ees LOOSENING FUEL INJECTION LINE TO BLEED SYSTEM wer” 4 Fuel Injection Equipment When improper uel injection is atfecting engine operation, a systematic chack should be made to Setermine the cause. The most likely cause si or Water in the fuel Drain the sediment from the fel tank. Check the ive! pressure gauge as mentioned In tho topic, FUEL FILTERING SYSTEM. Replace the fiters necessary. Then prime the fuel system Until clean fuel reaches the fuel Injection pumps. I the ue system Is air bound, priming the system will ‘overcome the diticuty Ifthe engine is running irregularly, smoking, oF knocking, a fuel injection valve may not be spraying the fuel properly Direct Injection System ‘The fuel system of direct injection engines is es sentially the same as precombustion chamber en- fines. The absence of the precombustion chamber Fequlros a afferent fuel nozzle and adapter. Exter- pally the erect injection tue! nozzle resembles the recombustion chamber aozzle except itis longer Intength. Nozzle testing and replacement proce: dure is the same as illustrated for tho precombus- tion chamber engines, except that an extracting tool Is used fo remove the fuel nozzle and adapter. The seal on the adapter should be Inspected and re placed if damaged Precombustion Chamber Injection System ‘Testing Fuel Injection Valves Whenever an engine performs in such a manner thal a Tue! injection valve is suspecteg of causing trouble, test all tual injection valves. To tost ihe Injection valves: Loosen the fuel injection ine nut at the fuel injection pumps, one at atime, while the fengine is running. When a nut 's loosened and the ‘exhaust emoking is. completely or partly lim fated and the irregulanty in running sot affected, LOOSENING FUEL INJECTION LINE NUT TO TEST VALVE athis identities the probable location of a detective Valve and anew one should be installed in that Sylindar to defintely determine'l the valve removed was detective, Never wite brush or scrape a fuel injection nozzie assomely as this wil damage the finely machined orice. Your authorized dealer has the proper tools for eleaning and testing fue injec: Before removing your fuel injection nozzle assembly, Caterpillar recommends that you contact your Caterpillar desir for more detailed information. Remove Fuel Injection Valve Clean dirt trom around the valve cover and re- move Betore removing an injection valve, cleanthe Gin from around the valve and line connections. Bisconnect the lead wire from the glow plugs (130 equipped) Loosen the fuel injection line atthe valve housing andaisconnectitiram the valve. Immediately install plugs to prevent aint fram entering the fuel injection ling. Remove the vaive retainer nut and it out the {el injection nozzle assembly and Vody as unt. the fuel injection valve mill oot be immediately in Stalled, caps should be put on tho valve body to Prevent dit entering he valve assembly a Installing Fuel Injection Valves. NOTE: The compression seal washer and thecarbondam (sea) shouts be replaced each time the rozzle is tested Betore installation of @ fue! injection vaive, be sure the wrench ig clean, Install the fuel injection Valve in the folowing manner 1. Screw the valve body into the fuel injection valve nozzle assembly only finger tight 2. Insert tne nozzle assembly and valve body a5 2 Unit into the precompustion chamber opening ‘Turning the body ina clockwise direction and at the same time pressing down will assure align ment of the serrations. 5. Install the retainer nut and tighten toa torque ot 55 lost. (7.6 meg) (9 prevent leaks Deiween the nozzle assembly and the nozzle assembly Seats INSTALLING RETAINER NUT CAUTION Do not overtighten. Use torque wrench 4.Connect the fuel injection line and tighten theFuel Injection Pumps To check or replace fuel injection pumps, t0 c’eeek fuel injection ting, injection pump iter set- fing, fuel rack setting and governor adjustments, is tecommended they be performed by an au: thorized dealer Governor (Chock the engine high and low idle RPM at the first oll change pariog and every 1,250 service hours thereatter’ To check, remove tachometer Grivecable (or cap) trom the tachometer crive hous- Ing infront ofthe fuel pump housing. See th infor. mation plate on the engine for engine RPM. Its Focommended this adjustment be made by an au- thorized deater Air-Fuel Ratio Control ‘The air-fuel ratio control is a dovice to contro the smoke emission of an engine during its operation ‘when low inlet manifold pressure exists Low inlet manifold pressure occurs during opera- tion a low torque output. During this type of opera: tion the ar-uet ratio control regulates the maximum {ol injected into each cylinder. It the controling Giaphragm within the air-fuel ratio control should fupture, the fuel aystom willbe restricted the same fit would be with fow inlet manifold pressure, Slow engine response and low power may indicate a heed for adjustment or repair Authorized dealers fare equipped with the necessary tools, personnel {and procadures to perform these service. AIR FUEL AIO CONTROL | AIR INDUCTION AND EXHAUST SYSTEMS Air Cleaners (Caterpillar Dry-type Air Cleaners Only) Regular service intervals, along with close visual inspection of the air cleaner, are nocossary for proper claaning of the engine iniet ai. The service Interval wil vary wth the woather and working con- ions. Where dust conditions are severe, it willbe necessary lo service the air cleaner frequent. In amp weather and other conditions of litle or no dust, the service interval can be extended, To extend the service life of the element, the exhaust and air cleaner inlet pipes should be ar- fanged so that exhaust and/or oll fumes do not fentar tho engine air cleaner. Visual inspection of the gaskets and seals is im- portant in Keeping dust from bypassing the alr Eleaner. Any dittallowed to enter, accelerates wear throughout the engine. Ifthe condition at any of ho replaceable seals and gaskets s questionable, re place them. ifthe sealing enas ofthe Titer oloment Srthe element pleats are damaged, replace the element Extra filter elements should be kept on hand for teplacement or for use in the alr cleaner while te ‘element that was removed is being cleaned ‘The air service cleaner indicator is connected to the air inlet pipe between the air cleaner and the turbocharger. It contains a red marked piston which gradually rises with restriction tothe ar flaw When the entire piston is visibie it wil lock in this position. This indicates a need for air cleaner ser ice. the piston wil remain inthis position whether br not the engine is running. After servicing the air Cleaner. reset he piston by depressing he plunger Inthe bottom of ne Indicator AIR CLEANER SERVICE INDICATOR 43Excessive engine exhaust smoke and/or loss of power may indicate the need for servicing the air leaner. Never service the aircleaner while the on fino is running Single Stage Air Cleaner ‘Changing Fliter Element CAUTION Service the ar cleaner with the engine stopped. 1. Remove the air cleaner cover and element, 2. Cover the air inlet opening to prevent foreign objects from entering the engine. Clean the inside of he air cleaner cover and the air cleaner body 4. Inspect the replacement element for damage ‘and cleantiness wile reseing he tity hme. wi save yu down 44 65, Remove the covering rom the airinlet opening 6, Insta the element caution Install the air cleaner element as shown in the Mlustration: Note the arrows indicating alt low ‘on the side of the element, and the position of the gasket & 7. Install he air cleaner cover {8 Reset the service indicator button by pushing 9. Clean the used aie cleaner element. See the insttuctions for clearing Cleaning Filter Elements Cleaning Elements With Air 4. Use clean, dry air—30 PSI (2 kg/em) maximum Hold the nozzie atleast one inch tram the element and at a sight angle A wanninc When using pressure alr, woar safety land protective clothing. Use no mare than 30 PEI (2 kglem pressure2, Direct the airstream along the complete length 21 gach poston the CLEANEST side ! te 0 ‘ment. (This wil loosen the ait irom the disor side.) 3. Blow the loosened ait from the DIATY side. 4, Direct the air from the CLEAN side through to the DIRTY side to remove att blown ints the pleating Cleaning Elements With Water 1 Use clean water at no more than 40 psi (9 kg/ com). Do not use a nozzle, 2 Direct the water along the complete length of ‘each pleat on the CLEAN side of the element 43. Direct water along the complete length of each pleat on the DIRTY side of the element 4. Rinse the CLEAN side of the element. 5, Allow the cleaned element to dry thoroughly Cleaning Elements With Detergent 1. Wash both sides ofthe element in a solution of warm water and non-sudsing detergent 2. Rinse the CLEANEST side of the element with Glean water 40 psi (3 kg/em!) maximum along with the complete lengtn of each pleat 3. Rinse the opposite side ofthe element along the ‘complete length of each pleat 4. Rinse the frst side again toremove all loosened ict 5. Allow the cleaned element to dry thoroughly Inspecting Cleaned Elements Place a lignted electric bulb Behind the cleaned, tied fiter element. Carefully check each pleat fot holes or tears. if just one small hole or tears foun, ‘iscard that element ang install anew element Storing Cleaned Elements 4. Wrap usable elements in heavy paper 2. Store the wrapped elementina dry, clean place Dust Collector Cap Servicing Dust Collector Cap 1 Remove the cap trom the air cleaner inlet 2, Clean the bottom grill using pressu maximum 90 psi— 2.0 kg/em), or low sudsing ‘etergent and water Install the cap. WARNING. Protective eye glasses must be worn when using pressure air. Soot Filters Soo! filers are used to remove soot and other large aroorne particles trom the a intake system. The panel type Soot fiers made of a bonded fiber, structvally supported with son reting. Soo titers are recommended for use in any ‘pplication where there isa possibly fr exhaust air to be induced into the engine ar ntake system The 00 ters should not be cleaned. Replace the fiter wenever the ai cleaner elements are serviced. Valve Adjustments ‘There are two rocker arms per cylinder, one rocker arm for the two oxhaust valves and one focker arm for the two inlet valves. Each pair of valvesis connected by a bridge which s actuated by tho rocker arm. The valvesin each pair are asjusteg simultaneously by the agjusting screw in tho fockor Chock the bridge and valve adjustment with the engine stopped. ADJUSTING SCREW Rocker EXHAUST VALVE utr: BRIDGE empae ve _/ BRIOGE 45Clean no at om te ase ofthe wales covers VALVE LOCATION andiinen remove covers. Remave the piug rom the EXHAUST timing hole. ming bolt ang access cover. Rotate e a the fywheei inthe diection of engine rotation until 8 (0-7er) the timing bolt can be instalieg in the fiywheel and the No. "piston is on compression stroke, ° INTAKE 015" (0.380) ane 408 ipppes 7 wre 6 ie Bridge Adjustment Check the bridge agjustment screw and loeknut fortightness. tne adjusting serew and locknut are tights proceed! withthe valve lash adjustment. the bitage adjusting seraw canbe turned with a screws: fiver without nalding the locknut. the bridge re- ‘quires adjustment. The bridge adjustment must be fhade before the valve lash is cnocked for proper Clearance, Make bridge adjustment as follows: 1. Back off adjusting screw several turns (coun forclockwise) making sure i is not In contact ‘withthe valve stem 2. Finmly press straight down on the rocker arm above point of contact with bridge INSTALLING ENGINE TURNING TOOL ADJUSTING BRIDGE Both the inlet and exhaust valves wil be closeg _%: Tumthe adjusting screw clockwise unilcontact ‘on compression stroke. First check the bridge ad- ismade with the valve stem, then tum the adjust pace cee enteevaie ue eine ing screm an adotvonal 90: or 1/12 wn (ithe ‘Sidancebetweenthe wo poinsonihe locket. 484. Hold the agjusting screw in this position and Nighten the locknut 10 20 1b. (27-2 Nm). TIGHTENING ADJUSTING ‘SCREW LOCKNUT Valve Lash Adjustment To prevent possible injury, do not use the starter motor to turn the flywheel, Hot engine components can cause burs. Al- low additional time for the engine to cool before measuring valve clearance, ‘CAUTION Measure the valve lash withthe engine stopped. To obtain an accurate measurement, alow at least 20 minutes for the valves to cooltocylinder head and block temperature. aranceis within £0.08 mm (003 sminal clearance gWven, acumen is Tribe valve in) of the Alter checking the bridge adjustment, make the valve lash adjustment With No.1 piston at TOC on compression, chock valve lash betwoen tho broge and rocker aim See chart for cylinder and vaive acjusiing soee To adjust, loosen valve adjusting oeknut and turn adjusting screw to allow Tesier gauge ass Betwoon top of wriage ante valve key frm: Sethe niet val lash at_015-(0 30 re) and exhaust valve lash at 080" (0.75 many wf fey 3. After proper adjustment, tighten the adjusting ‘row locknut to 22 Ib. (29.9 Nim) and re check lash clearance “74. Turn flywheel 360° in direction of engine rota lion. Align fiywheel timing bolt with the timing hole in the flywheel 3408—No, 6 Cylinder will be at TDG on com: pression stroke (al valves closed) 3412—-No. 11 Cylinder will be at TOC on com rossion stk (all valves closed}. 5. Check lash and adjust as necessary on all maining valves, see valve adjusting sequence chart Tighten locknut and recheck lash clearance. 7. Remove engine turning too! and install timing access cover, timing bell ane plug, Chock Valve Rotation: Alter checking valve lash and betore the valve covers areinstalled, check the Yalves for rotation 1 Mark a line on each valve retainer 2. Stat the engine and run at low id. 3. Watch the line mark on each valve retainer Each valve tolainer shouls turn slightly each time thevalve closes. It they do not turn, contact your Caterpillar dealer. 4, Stop tho engine 5. Inspect tho valve cover gasket and install anew cone as necessary. Install he valve cover, Restriction Of Air Inlet And Exhaust Wan air iniot restriction is euspected inthe piping or air filer element, check with a differential Sure gauge or manometer. Remove the at cleaner service indicator and connect alferential pressure Gauge of manometer in the service indicator con ection. Theairiniet piping or air cleaner should not Fesirict airflow more than 20 inches (762 mm) of ‘water diference in pressure 48 CHECKING AIR INLET FOR RESTRICTION Restriction of the exhaust system (back pres: sure) Ie measured witha differential pressure ‘gauge or manometer” This pressure aiference is Measured between the turbocharger outlet and fambient aie and should be ne more than 20 inches (G45 mm) of water, An exhaust pressure tap te pro: Vided in the turbocharger outlet elbow This check Should be performed with the engine at operating temperature and developing ful rated power CHECKING EXHAUST SYSTEM BACK PRESSURE, Crankease Pressure Excessive crankcase pressure can be a result of combustion gas leaking past broken or damages Pistons, worn cylinder liner wails. and/or piston Fings. This condition wil usually be accompanied By Irregular engine operation and excess fumes trom crankcase Breather opening. This prossure can Cause the breather slement to become restricted in fan unusually short time. In adation, 1 can cause fngine olltoleak past gaskets and seals that woule function properly under normal conditionsTurbocharger Every 4000 hours or it any unusual sound or vib ration inthe turbocharger Is noticed, a quick check bf beering condition can be made without dieas: Sembiing the turbocharge. This ean be done by re moving the piping trom the turbocharger and in. Specting the compressor impeller, turbine whee! ‘and compressor caver. Rotate the compressor and turbine wheet assembly by hand and observe by fooling oxcoss end play and radial clearance. The rotating assembly should rotate realy with no 1Ub. bing o* binging. I there is. any indication of the impeller rubbing the compressor cover or the tut bine wheel rubbing the turbine housing, recondition the turbocharger er replace with a new or rebuilt End clearance is best checked with a dial int calor, Attach a dial ingieator mith the indicator point fon the.end ofthe snatt, Mave the shat irom one ong to end making note of the total indicator reading, Eng play should be between .003 in. (0.076 mm) and 008 n.(0.203 mm). end play exceeds 008m (0.203 mm) rebuild or replace the turbocharger. End clearance less than 003 in. (0.076 mm) could Indicate build-up on the turbine wheel and should be disassembled for cleaning and inspection, CHECKING TURBOCHARGER ROTATING ‘ASSEMBLY END PLAY Amore ralable check of bearing condition canbe made only when the turbocharger ie disassembled land the bearings, shalt journal and housing bore Glamaters can aclually be measured. This services availabie from an authorized dealer Radial clearance can also be checked with a dial Indicator. Remove the oll return line Irom the (ur ocharger Attach adialinsicator with an extension Indicator point long enough to contact tho. shaft through tho ail roturn Mole. Maxo sure the contact polntts centered on the shaft (highest indieator Feading) ‘Raise both ends of the shaft all the way then push down in the opposite. direction. Total movement of the indicator should be between 005 In (0.13 mm) and 008 In. (0.28 mm). Itvacialciear ‘ance exceeds 009 In. (0.23 rm) or minimum clear ‘nce Is under 009 in. (0.13 mm) the turbocharger ‘should be disassembled ang inebearings checked CHECKING THE TURBOCHARGER RADIAL CLEARANCE It a turbocharger fails, try to determine cause of failure and eliminate betore installing a rebuilt oF ‘ew turbocharger. When installing a new or rebull Turbocharger always perform the folowing stops: {A Inspect the air induction and exhaust system for tho presence of foreign particles which could sultin repeat failure. BB, Change the air cleaner element ©. Ghange the oil filters. 1D Drain and refill te engine crankcase. E_ Pre-lubricate the replacement turbocharger by filing the center housing with ol 49ELECTRICAL SYSTEM ‘The following topics describe care and mainte hance of the sleciical system components. These Components functioning together produce the Sneroy needed for operating the electrical equip- mont on tne engine and each is dependent upon the thers for satstactory eperation. In tho event of failure or improper operation, tis essential to check the entire electrical system as a defect in one com ponent can cause damage to another. Many electrical system problems canbe traced to loose or corroded connections. Keep connections tight and make sure the wiring insulation is in satis factory condition, Most ol the electrical system test ing ean be partormea while the components are on the engine. It should be romombered, i a malfunc- tion is found on test. the component must be re ‘moved for further esting. fepair oF replacement. femtonea oy Battery Every 250 hours check the electrolyte level of ‘each cell and the general condition of the battery Maintain the electrolyte level to the base of each Vent well. The make-up water must be one of the Faitowing (in order of preference) 4, Distilled water 2 Ocorless, tasteless drinking water 8. Iron tree water A wanninc Never add acid or electrolyte. Cleaning Battery Mix @ weak solution of baking soda and water. Apply ne solution with a sol oristle brush. Be care fullnot to get cleaning solution into the battery CLEANING BATTERY TERMINALS 50 ‘Thoroughly rinse the battery and battery tray with clean water, Apply grease te the battery cable Elamps and terminals and to all threads, Testing The Electrolyte Solution “The general condition of a battery can be deter mined by measuring the specific gravity of the elec- Trolyte solution and adjusting the reading to 80°F (27°C), tthe electrayte level js too low to allow {aking a hydrometer reading. add make-up water to the correct level and then charge the battery 2to4 hours before faking a reading 4. Insert the hydrometer into a cell. Fill the hiya. fometer barrel while halding it vertically. The float must nat rag on the wall of the barrel 2, Read the hydrometer 11265 100% charged 4.225 - 75% charged 45190 50% charges 41185 25% chargeo 41120: Dischargeo 1.000 - Water 4, Test each cell in the same manner, 4.1K thore ig mare than .050 (50 gravity points) Variation betwoen the highest and lowest read Ing. he battery should be replaced 5, Adjust the readings to 80°F (27°C). a.For every 10°F (5,5°) the electrolyte temper- ‘ture s above 80°F (27°C), add 004 (4 gravity points) to he specilic gravity readings b. For every 10°F (5.5°C) the electrolyte temp. ‘ature below 80°F (27°C), subtract 004 (4 gravity points) trom tno specilic gravity read: fh The corrected reading is of most importance dur Ing cold weather when the hyorometer reading 1s llways corrected toa lower specific gravity reading low roading signifies the battery has less availa ble power to erank the engine ana that booster Dat tories may be required Cae. ‘TESTING ELECTROLYTE SOLUTIONInstalling Battery 1. Be sure the battery tray is clean and free of foreign objects 2.Be sure terminal posts and cable clamps are 3. Place the battery in the tay. Tighten the hold down clamps evenly untilthe battery is snug, Do ‘ot overtighten. Connect the “hot” terminal first. Be sure the top of the cable terminal is pushed down even with the top of the terminal post. Tighten the clamp fimly WARNING Always connect the “hot” terminal first to ‘minimize arcing. Otherwise injury or damage ould result. 5. Connect the “grounded' terminal last Be sure the top of the: cable terminal fs pushed down feven withthe top of the forminal post. Tighten the clamp firmly ©. Apply a thin coating of grease over the cable Clamps. terminals and hold down fasteners. Checking Charge Rate 1 Alter starting the engine, the ammeter indicator should rogisior to the right of zero, but should never be "pegged 2. Alter the engine has been running, the indicator ‘should be [ust to the right of Zero {the indicator remains taro the right of zero, or remains to the lett of 2070 with an increase of tengine speod, have the electrical charging sys tom checked Charging the Battery Mover make nce the une where btteres 1, Connect positive charger clamp to positive bat tery terminal 2. Connect negative charger clamp to negative battery terminal 3. Connect charger power cord to proper outlet. 4, Allow battery to charge slowly. CAUTION battery Is charged too rapidly, the battery will be damaged. 5. Aftr tho battery is charged, disconnect charger ower cord trom outlet. remove charger clamp icom negative battery terminal. remove charger clamp from positive battery terminal Connecting Booster Batteries CAUTION Keep rod and black terminals from touching each other. a 7 - 24 VOLT STARTING USING 12 VOLT BATTERIES Ae Tr 24 VOLT STARTING USING 6 VOLT BATTERIES 5130 VOLT STARTING USING 6 VOLT BATTERIES 41. Remove al filer caps trom all batteries before Connecting jumper cables 2. Connect red jumper cable to “hot” terminal of ‘booster battery 3, Connect black cable to "ground Dooster battery 4. Connect other end a red cable to “hot "terminal of engine battery, 5. Connect other end of black cable tothe starter ‘ground terminal, # equipped with a starter 0 Ground cable Ifthe starteris not grounded with acable, attach the Black cable terminal ta good ground on tengine of engine frame, at & point away trom, fand below the battery. Start the engine using starting aids as in- structed in the Operation Instructions. terminal of Disconnecting Booster Batteries [As soon as engine starts: Disconnect black jumper cable from engine Disconnect red jumper cable from engine. Disconnect black cable from booster battery Disconnect red cable from booster battery Charge booster batteries to full capacity with a battery charger Cold Weather Battery Maintenance General Maintenance 1. tr aging make-up water, charge the batten ‘The added water could dite the lective enough without eharging to oauge treezing ane permanent damage to the battery. ef 2. Keep the batteries fully charged either by operating the charging system orby using aba tery charger 82 23. Keep the battery warm when not in use. In an Unneated area, the heat from alighted electric Bulb is usually sutficient CAUTION Use only a shop cord with a heavy wire guard ‘around the light bulb Do not tay a lighted bulb divectly on a battery ‘case: the heat at point of contact could malt the battery case. Dornotlay cioth or flammable material in contact with alighted Bulb; charsing and/or fire could result 4, Use starting aids as instructed for starting the engine 5. Use booster batteries as required, Connect the bateres as instructed below. 6. abatteryignot going tobe usedtfor aperiog of time, be sure the battery is fully charged while ‘rad. Use battery hydrometer to check the Specie gravity of each cll, and use a battery charger to Keep the battery charged, See the Instructions below. Voltage Test (After Load) ‘A load test should be made on a battery that ais charges very rapidly when inuse. To do this apply 2 Fesistance of three times the ampere/hour rating of the battery across the battery main terminals. Allow the resistance to discharge the the battery for 15 ‘Seconds and immediately test ne batlery voltage, A B volt battery in good condition will est 45 vols: a 12 voltbattery in good condition willtest 8 volts and 224 volt battory will fost 18 vols. Starter No periodic service is indicated for the electric starter brushes between general reconcitioning periods. The brushes should only be inspected aftor Famovai o the starter from the engine and removal of me commutator end beating Irae. The electric Starter commutator end and drive end bearings are quipped with wicks for lubrication purposes. The Wwieke should be saturated with oll whenever the electric starter Is removed or disassembled. Wis suggested that cleaning and reconditioning be entrusted to your authorized a Pinion Clearance Adjustment Whenever the solenoid is installed. the pinion laarance should be adjusted. The adjusiment Should be mage with the starting motor removed Bench test and adjust the pinion clearance at Installation of solenoid as follows:SW TERMINAL — CIRCUIT FOR CHECKING AND ADJUSTING PINION CLEARANCE 1 Install the solenoié without connector trom the MOTOR terminal on solenoid fo tha motor 2. Connect a battory. of the same voltage as the solenoid, to the terminal marked SW. 3. Connect the other side of battery to ground te. ‘minal or to solenoid frame. pene ar {rs al | i Hime \\in Pmow oO oO | Nai h\ ADJUSTING PINION CLEARANCE. 4. MOMENTARILY flash a jumper wire trom the solenoid terminal marked MOTOR to the frame ‘oF ground terminal ‘The pinion wil shift imo {ranking position ane will fama there until the battery is disconnected 5. Push pinion towards commutator end to elim hate tfee movement. 6. Pinion clearance should be .36 In. (9.14 mm) 7. Adjust clearance by removing plug and tuening shaft nut ‘ADJUSTING PINION CLEARANCE Charging System Alternator Regulator The alternator regulator is adjusted at the factor for average aparating conaiione ane may req readjustment to provide the proper chargingrat for the particular oporating conditions. The condition and state of charge ofthe battery at sch regular inspection willingieate fhe alternator isoperating efficiently” An adjustment is necessary when the battry is always in alow state of charge or lan excessive amount of water must be added ta he battory (more than one ounce of water per cel per week br per every 50 service hours), ‘When the alternators ether charging the battery too much or not enough, an adjustment can 00 ‘mado tothe alternator charging rate Alternator Regulator (Delco-Remy) To make an adjustment to the voltage output, remove the voltage adjustment cap (1) from the alternator. turn the cap 90°, and install again into {he alternator. The voltage adjustment cap has four Positions: HI. LO, and two positions between the high and the low getting Ne ae Alternator Regulator (Motorola) To make an adjustment to the voltage output, ‘emove the cap (1) rom the alternator regulator and change the regulator adjustment with a scrowd: To increase the voltage turn the adjustment screw clockwise. The adjustment scrow under the ap (1) has five positions (number tis the last post- tion clockwise) 63‘djsiment | : Position Srila Regulator | 2025 | 206 | 280 [274 | 268 Votage |= 95 {= 3|=3|=3|=3 Never operate the charging alternator with an open circu between It and battery. CAUTION Do not attempt to polarize the alternator. it an ‘accidental connection is made between the "+" terminal theal the transistors in the regulator will be damaged. Alternator Belts Every 250 hours examine the drive belts for wear and replace if they show signs of wear the worn bal Rew belt will be cartying all! the loadsasit wl not bo stretched as much as the older belis-and allot the Betts wil fain rapid succession, TTonly the worn belt's replaced, the Adjustment Check the new belts after the frst 10 hours and ‘every 250 houre thereatter for adjustment. To check bolts-apply 25 lbs (11.5) force midway betw BELT TENSION Lt \ 54 the pulleys. Correctly adjusted belts will detect» tn. (12.5 mm) to % in. (19 mm) for the first check. Maintain lator agjustments at 7/8 In. (28 mm) To adjust, loosen mounting bolts and locknut on adjusting bat, Turn adjusting nus to inerease oF Sebteaoe alternator bet tension. Tighten locknut And mounting balls itbeits are operated too loose they wil stapcaus. ing unnecessary wear tthe bes and pulleys Belt tipping may eause tho altemator to operate at a Below normal rato and possible failure ofthe elec: Ica! systom I the belts are too tight, unnecessary stresses aroplaced upon the pulleybearings and bets which imight shorten tho ite of bath ALTERNATOR BELT ADJUSTMENT Glow Plugs Testing Glow Plugs Glow plugs can be checked with an ammeter Disconnect the wite fead from the glow plug term! nalon the HEAT-START switch Insallan ammeter, Inseries, between the disconnected lead and the terminal an the switch. Ooservs the ammeter with IheHEAT-START suiten turned to the HEAT posi lign. Each 12 volt glow plug draws approximately 12:5 amperes, The ampere draw of one glow plug ied by the number of engine cylinders wil be the total ampere draw of the glow plugs in tha en gine. A low reading isn indleation of one or more detective glow plugs. Disconnect one glow plug lead at a time and observe the ammeter with the ‘Switch turned to HEAT The disconnected glow plug that does not change the ammeter reading is the dotectve glow plug. Replacing Glow Plugs To remove a detective glow plug disconnect the lead from the glow plug and unscrew the glow plug ‘rom the precombustion chamber. Apply antise Zure compound tothe thread ot anew glow plug and install the glow plug into the precembustion chamber. Tighten It 0.8 torque of 10 to 72 pounds feetPOWER COUPLING SYSTEM Flywheel And/Or Front Power Take-Off Clutches Checking Clutch Adjustment While engaging the clutch to pick up the load, ‘check the ciuten acjustment. The clutch should en: ‘gage witha hard push ang distinc snap, itengage- ‘ment is "soft", adjust the clutch Adjusting Clutch Engagement 1 Stop the engine an remove the cluteh inspec: tion cover, 2. Turn the cluteh uni the ock pin, engaged inthe locking'ring, 1s visible, 3. Pul the lock pin out and rotate the locking ring clockwise unl the lack pin pops info the next = 4. Test the clutch adjustment If stil 00 “sot rotate the ring to the noxt nateh. Ifthe adjust. ‘ments 100 tight-turn tne ring back one Noten, 5. Install the cover Generator Set Your electric set engine may be equipped with a Caterpillar SR& Generator The SRa Ganerstoris.a brushless design, and therefore requires no Periodic maintenance ather than lubrication of the Fear bearing. See Lubrication Instructions, “The generator serial number is stamped on the gonerator housing. The fst group of numbers, Feaing from tha lett, indicates the frame size. Fol Towing this number are the letters BS. BH or 8 The latte B indicates the generator is of the SRE design. The loter 5, H or G indicates tne voltage Fating of the generator. The following numerical Sits are tho serial number of the generator in that articular rame size and voltage rating. Acomplete Explanation of the numbers and letters in the serial umber are found In tho GENERATOR SET SYS TEMS OPERATION SECTION, Always use the complete serial number in your communications with your Gaterpiliar dealer It you have a generator af other than Caterpillar design, seo the Manufacturers Instasctions. GENERATOR SERIAL NUMBER LOCATION 86Engine Storage General Information ‘These instructions give procedures and recommendations that will Keep the possibilty of damage at a minimum when engines are in Storage for one year or less After one year, he complete protection procedure must be followed again i the engine is keptin storage “The best protection for outside parts ofthe engine is by thorough use of paint Paints a {good protection for a period storage of upto two years. Theroughly clean the engine and repaint areas hat have pant damage witha good quality pair. If an engine is not used, ol can runoff the Cylinder walls, piston rings, main bearings, ‘connecting rod bearings, crankshall, oars and ‘other parts that normally get lubtcaton. This lack ff lubneant les corrasion start an the meta! ‘especialy in areas of high humiity (water ‘content ofthe a). \Whan the engine is started again, before these surfaces get i, the metal-metal contact wil Cause wear. To keep ths wear al a minimum, Uso tho starter to tun the engine with the thettle In fue! OFF postion unt ol prassuto is shown on the pressure gauge. Use an air compressor witha sprayer attachment to spray external engine pars with a mixture of 50% VC oll and £0% engine ol to prepare the fengine for storage. should be possible 10 Change the nozzle adjustment to give either spray oF fog, The fog adjustment fs beer ‘access to components is dificult. The spray is batter for parts on the outside ‘Yolalile Conosion inhibitor (VC) (NOX RUST VL 410 olor equivalent) ol gives both quid ard vapor protection of ferrous metal suraces, against corosion caused by moisture. a Closed compartment protection is either by tect contact with VOI lor by contact with the \VCi vapors. See your lacal supp for ‘simian type ol. Adational information as to ordering and use of NOXRUST VCi #10 and NOXRUST 10318 rust preventive and a Iist of suppliers utsice the US.A. are avalae trom Daubert Chemical Co, 1200 vorie Bla Cakyook. HL 60521 Toloptione: (312) 582-1000 NOTE: Attach a ‘DO NOT OPERATE" tag on the art switch, start button or ar start knob, before serviong the engjne, These fags, Form SEHS7S32, are avalabe from your Caterpiar ale. Storage Procedure 1, Clean tne outsice of the engine and repaint areas that have paint damage wr @ goed quality paint 22. Remove the batteries and use them in some ‘other place or put them in storage where they can be checked and eectrially charges agan when needed. It he batteries are rot removed, ‘wash the tops, Pu an electrical charge tothe battery toa spectic gravity of 1275. Disconnect the battery terminals. Pt aplastic cover over the battery 8. Loosen al fan aiternator belts. ete. Attach a {ag to indicate what work nas been dove. 4, Pura waterproo! cover over engines with enclosures stored ouldoots. Make Ihe cover Ugh, ut loose enough to alow ato crcusate ‘around the engine to prevent damage to ‘exposed metal parts trom condensation NOTE: Remove the waterproot cover every two three months and check the engine for Corrosion. I the engine has Sgns of corasion at the check pariad, follow the protection procedure again. To operate tho engine, it's not necessary to temove the preservative o! mixture. Ha compartment under protection of VCl vapors is ‘opened, pul more VO mixture in 19 make up for the vapor loss, NOTE: Install all covers andjor put tape over ll ‘openings, a intake, exhaust openings. ywnes! housing, crankcase breathers. dipstick tubes, etc. Make sure all covers ate ar tight and \weathererool, Use a wateroroot, weather resistant tape 56'5. Put lubricant on all points given in the: Lubrication and Martanance Chart 6. Put a heavy amount of mutiourpose grease ‘onal ouside parts thal move; rod thveads, ball ‘pts linkage, ele 7. 01 and oil fiter ements used less than 50 hours in the engine do nat need ta be changed. (Otherarsa, change tne oi, fing the engine to the “ada oi’ mark on the dipstick) Add 3% to 4% of VC il por engine volume, If the engine is rained, installa mixture of 50% VCI ol and 50% engine olin the crankcase and inal kercating © compartments al the rate of ana part VC! ot "mixture ar flleen parts of compartment capacity at fll level. possible, operate the engine three lo fe minutes, Put tape overall openings to seal YVCl vapors in the engine. NOTE: i necessary, drain some lubricant o ado tothe mature . Remove any dit om the cleaner. Check al'seals ana gaskets 9. Remove the ac fiter elements. Turn the engine a cranking speed with theatle conta! in ‘uot OFF postion, remove pressure pug for boost pressure and use a Sorayer to ac a metute of §0% VOI oi and 50% engine ol ‘Minmum appication rate is 5.5 mliters per iter (@.oz. per 1000 cubic inches) of engine displacement, 10. Fi tho oi reservoi forthe air starter with @ rete of 50% VOI i and 50% engine al 11. Use 2 sprayer to put a mixture of 50% ver oil and 50% engne ol into the exraust openings. Moimum apgiication rato is 5.5 milters par Her (02. per 1000 cubic inches) of engine elsplacement 12. Aso, use a sorayer to apply a mixture of {50% VC ol and 50% engine oon the yee ting gear teeth and starter peion, Install the covers to keep the vapors in 13, Remove the fuel nozzles and instal 30 mites (102) of 50% VCi 0: and 5D% engine dilin each cylinder. Test (using carating a) then install fuel nozzles and tighten al fitings to the correct torque. Use an engine tuning tol to turn the engine over slowly two complete revolubons in the arecton of normal rotation, to pt ol on the cyinder wale, 14, Remove the tue! trom the secondary fue! fiter using or change the spinon fuel ter clement to get out any dirt and water. Clean the primary fuel iter, with calration oven ‘operate the priming pum, This wil gat clean of to the secondary fuel titer ang engine, and help to prevent sticky" fue! pump nozzles during extended storage, CCalbrationoilis avaiaie rom your Caterpillar dealer in two sizes, 208 iters (85 gallons) or 19 ers (6 galons). Open the fue tank drain valve land remave any watar or drt from the inside of the fuel tan, The fuel must be treated with @ Biocide, which prevents bacteria and fungi tem contaminating tesa fuel that contans some water. Micradla cconlarination can cause severe fue system blockage iter plugging, fue! pump sticking and Additional information as 1 ordering and use of (diesel ual Blocide and a ist of suppliers outside the USA. are avaiable fom ‘Amalgamated Coal & Petroleum Specials, nc CPS. Associates 9214 Emst Roa Fort Wayne, Indana 46809 Telephone (219) 747-7080 Math! Cellosave will hep assimilate water inthe fal and prevont freezing proolams, Fil the fuel {tank with the treatogfuol Seal al openings tothe tank to prevent evaporation ofthe ‘slEngine Storage 15. witncraw a sample of coolant and check it for cary (rst) and freezing pont. It contains suspended parties or does not provide 0026 protection 1 a least ~29°C (— 10°F), the coolant ‘Should be drained. Completely akan the cooing system, if needed. The cooing system must be ‘thoroughy fushed and chemcaly cleaned, 1G. etn tne cooing system witha coolant solution thats 60% water and 60% etnyone ‘lol. Install anew precharge coolant Canctioner etment (equipped vith cootant Conditioner ements) A 3% to 6% ‘concentration of coslant conditioner does not have to be added, if the cooling system fled ‘ith cootant soktion tothe Tap of te filer neck, Attach tag indicating what has been done. NOTE! Do not use coolant conditioner elements lof iguct coolant cond toner with Dowherm 208 FutFil coolant Procedure for Operation After Storage 1. Remove ail outside protective covers, and any tape or grease used for protection 2. orain the VOI oll and engine oil mixture trom {he engine the oll has been inthe engine for ‘mote tran one year, or the engine was ett ‘rained before adding the VOI motu. It storage ‘as sho term, the engine can be operated with 2.3% 04% VOI mxture inthe engine 3. Tighten the fan and alternator belts. Connect the baltores, check the ol and the coolant level 4. Use an erg rig tal tun te engine ‘No cones evens ite rertonof wena eat tose sue hers te Ml Prorl oek entance, 5. Botare starting the engine, remove the valve ‘over oF covers anc put a large amount of engine ol on the valve mechanism fo prevent ‘damage tothe valves, 6. To get immediate lubrication and prevent damage tothe engne in the hist seconds alter Starting, iis necessary o pressure hbricate the engine (Soe Procedure fot Pressure Lubrication “anh flows) Pime the engine wth clean dese! tual before stating 7. Crank engine with fue! off until oil pressure is observed. 8. On the frst day of operation, check the complete engine several imes for leaks and Correct operation. Q. See Foxn SEBU5898, Colt Weathor (Operation Gude, if the engine is removed from slorage in temperatures iss than 23°C (10°F). 10. after startup, add coating system ‘conditioner as needed. Pressure Lubrication Introduction Ibis very important for an engine to have adequate (needed) Mrcaton during the fst Seconds of operation. A dry start (without needed! lubrication) of an engine can cause bearing damage. An engine generally has enough ol onthe parts for lubrication during engine startup However, this lubrication may nat be enough or ‘may be ost the engine has been in storage for Any length of ime. To prevent the possblty of a dy start and bearing damage during the frst seconds of operation, pressure lubrication of the engine ss necessary (tithe main oi passages with oll under pressure} ‘An optional prelube pump or manual sump pump fare avaiable on some engines. When the purnp is installed, the crankcase can be filed with the Ccortect quantity of al. Then the elude pumo will send oll 0 all pats of the engine so i wil nave ‘enough lubrication before starting Procedure for Pressure Lubrication 1. connect the oi supply to the main oi passage ofthe engne 2. i the crankcase with the correct amount of Oi, The amount of ol usad in the pressure lubrication procedure must be subtracted from the Refll Capacty Chart gwen in the Operation land Maintenance Gude NOTE: Use a minimum of 30% of the engine of Capacity itmay be nacassary to fil the tank several tenes. 568Initial Operation After Engine Storage 1. Fatiowing engine storage, only an operational check atthe fst statis nocessary belore opection 2. The purpose of tis fst operational check is lobe sure thatthe pressures and temperatures in the cooling, fuel and Lubrication systems are correct, and any laaks are corrected B. Tobe sure ota sale, uniform chock at fest ‘operation. use he following procedure: 4. Tum the engine at cranking speed vith the trot in ue! OFF postion nti ol pressure is present, Operate the engine or 5 minutes at low ide speed unti the coctant temperature 1s 88°C (150°F) or higher Generator Storage Storage Procedure \When @ generators in storage for any length of time, mosture condenses in the windings. Minimize the condensation by uso ofa cry storage space and space heaters, Refer 10 stop 2 below Ha brushype generator (SACRA) isto be in storage for a year of more, ift ne brushes off the Sip ning 1 prevert damage to the slp ang by chemical action Alter Storage NOTE: Tost the main stator windings with a megohmmeter inthe folowing stuations 1. Before intial startup of generator st. 2. Every 3 months" if generator is operating in fa humic envranment 3. generator has not been run under lad for 3 monte" or more. “This a guideline only. t may be necessary to megger more request if envronment i extremely humid, sally orf the last megger test 1was cose to 1 megorm, The megohmmelr testis daseribed in Service ‘Manuals SEN2180 or SENA7968.& reading of 11 meghom or less indicates thatthe winding has absorbed too much moisture, To Remove Moisture To remove moisture caused by hgh hums, use one ofthe folowing methads t0 make the ‘generator dry 1. Energize space heaters in generator it so equioped. 2. Putte generator in an oven at a temperature Of nat moee than 85°C (185°F) forfour ours CAUTION lWanovenis used for drying, use a forced aetype rather than a radiant type. Radiant ovens can ‘cause localized overheating 3. space heaters ofthe same type used in ‘marine applications, can be insted on (ganaralors (See the Parts Book | These heaters heat the windings to remove moisture and should ‘be connected al all imes in high humic ‘conditions whenever the generator s not running 4, Use canvas enclosure around the ‘generator and heating lamps to merease the Temperature. Make an opening in tha top for release of moisture. 5. Send a iow votage current trough the ‘windings fo inrease the temperature of the ‘windings. Do not exceed 85°C (185°F), Ihe megohmmeter test reads under 1 megohm after the drying iit goes below t megotn ‘Shorly alter dying, contact your Caterpils dealer. Tha insulation has deteriorated and ‘Should Ba conditionedPreventive Maintenance Recommendations for Standby Generator Sets Information relating to maintenance procedures is included in hs engine guide. Further information is avaiable inthe Servce Manual, or consul your Caterpilar dealer Standby Generators. ‘Standby generat sets may not be needed very often, Bu when they ae, is usualy under ‘emergency canations, Maintenance of these Standby units s very imporlant They must ‘always be in excelent operating carson, ready to work under ioag at ary time Its ‘ecommended that tne folowing Preventive Maintenance Program be establishes ‘The stop-manual-automatic switch on the cranking panel must be set at “stop” position ‘when performing maintenance or repair work ‘on a standby generator set. This prevents the Unit from starting if a power failure or voltage ‘drop should occur while working on the unit. Failure to comply could resultin personal inju- ry or death, Make any necessary repairs withthe engine stopped and the slaving system disabled Maintain a log oa record keeping systern to ‘document al gauge reacings, problems, repairs ‘and martenanee performed on the ecxipment ‘Space Heaters Moisture is a natura enemy of ganerators and al lecttical equipment. Every effort must be made to keop the generator as dry as possible. Space healers should Be operated inside the generator when itis notin use to maintain the integrity of the generator windings. 56DPreventive Maintenance for Standby Generator Set Engines To Be Performed By An Authorized Operator Item Service Weekly: Before Starting the Engine Walctroundnepecten ‘Chock th engine, raat and generator for debi, orig cect, _ Toone or broken tings, guts and conponens epi a crasay Bais [Inspect tor ween, broken or GOS Bes lena, fn, vs, et) ‘Cecing System Maran propor coolant ev ‘Check proper operation, Maan 32°C (SF coolant onporatre "hr Cina indeator ‘Check he nestor Changstne a Seana sles hen handeatr Sinorrage temas ockod gine Grankeass ‘Cheek hole Mantantllavel between he aaa amar | onthe engine stoned sd o he aastek i Goverer (Check and main the ol vel it equre) Foe System ‘Check freaks nd ran water separator (equipped Keap lian ee fat Choc ue er nator easeped ([ReSrsten it Eases Drain condensate; check a prev Toran ecient nec, TOOT Te ti conson ota aes Rena or sace anon oom | Sate Cher ‘heck for proper operation. Dscannect cage blr stating fe ge tana apa tana mareg eae Weekly: With Engine Running es arte Engr Tae egbe apcataie We mindos vila poomg rae hocks I equred ho engine may be opeted Taras tan as 30 ‘nates. Thain must betondosl aporodiong: than S0mnutes ‘Oi Pressure a “Check for proper operating oll pressure, Refer to the Operation section fins que lor the cone! pressure veaaing | Fo ress ‘Check for proper operating fuel pressure. Ar to thw Opraon ea pai terri ge orto crac prossre rain Engin Ganicass ‘Check he oevel Manta theolleveibatweenmeaddaraulmanks _ nthe engine running side of he Stk Frequaney (pn ad Genaaied Watage ‘Ghackanrecord readings. NOTE. Te operang voage ol acai ut ‘Streo genet yl 0 sigh grr mene operating vorsoe 3 ahaa nono agan warm Tefuoe vata ir Generator wi decree a antrum ov when tis generar | stabiizes at 100°C (212°F), Most of the voltage docease occurs in | ‘bout SO mnuts, General. terpetueso goreratrs stab ze with (datr toners — Che or prop Sertan abe To open ane cose Fee) Leaks and Notes heck or leaks ad unveval noes. NOTE. Engine mt sapped = belre mang nacessary epars. Weekly: After Stopping the Engine fi ‘Automatic Switches tf Equipped} ‘Check that all switches are in prope’ position for automatic start. Foal evel ‘Chek heft eve rll wen blow tee-ourths fa [ame crag ————SSSSSSSC«*d ame care avon ascrrecies RecrS eG | 56,Preventive Maintenance For Standby Generator Set Engines To Be Performed By An Authorized Mechanic Item Yearly: Before Starting the E1 Waist nepecton obec SSoseer baton tings, gundsancomponss Rapa ewe Check or aks. Aad cont corestene (if raured Cran water an seamen om tank, Change tu ie [spect clean or elas “Check and misin oi evel eared Engine Cranage ‘Check olive Mactan ol level bet ween he ai aa marks on ngine stopped seo the dpsten Engin Crakcase Breather ‘ciean, “} ‘ave Lash ‘Cneck, cot essary. Ree to the engre Servee Wanval for rope proceoue are setnge | Tnnaoes (Chaka inkages. cessary Lubricate al neage iti ‘Alarms afd ShuldOwn Devens | Cheek test for opr operation. [ cheek eects evk, clean terials and connections, We down. dean as needed peter _| esneeded ‘Genersior NOTE Refer to the generator Serves | Luticte bearing vacuum clean and check wing ot te uso. Manual fr inforvation rating fo use of the me-| exater and itor Oreck enero nage win magotnete and _sohmetr and ow reestanc readngs ‘Check opera of space hee Yearly: With Engine Running ‘Sarthe Engine ‘heck al gauges ol reeure oe prestore rom (reaver generat | elope Terorati foreoret aaa | Engine Grankeass (Check te olavel. Manan the olvelbetween he a4 eu marke (Rodater towers ‘Cheek or proper operation (ab oops and ose res Leaks and Noes (Chk or aks and unweus owes. NOTE. Eng Before making necessary repairs, engine miami ot 30% ated [ioemnmarto two hours Gauge Pessina ‘ler approximately one nou eco he recigs Of alo ie Sisal petrol ev gm ogee eres age | Scrcometereogne|acet wate temperate cohscsienpersue tt le ‘Saupped nd rant vaca eaueed) | Yearly: After Stopping the Engine [eee or Ast Vole 0 pars aguas oe OTe OREN | Engine Crankcase ‘Change ol take sample for analysis. Change filters, oA old fiter open Sno spec fo foregn rat foetae ere tar eve FS tree our ater Cre ecrt cer amge readng A Check a a siches ain opr poston er avons sat—| 50FPreventive Maintenance For Standby Generator Set Engines To Be Performed By An Authorized Mechanic | tem Every Three Years: Before Starting the Engine | Betoe Staring | service Pro al Yeary Boer Starting th Engine Pravaniive Mawienance procedures Coaing System ber Hoses and Bas (Bates is recomend that al hoses ena pal Be _| Extra tee heme ae cen ad ah cooling ate esas ona) Pee minmze dwnme and addtions repair cos oF component feures Replace at bateres at the ioral Turbocnager Tespet par orreploefnacessary a minoaeadaora assooated ponent ares Enaine Peer a complete angie sdalnent and tne up [Every Three Years: With Engine Running Engine Aung | | Exnaust Sysor “Every Three Years: After Stopping the Engine ‘ter S109 | T chock freaks. Rapa a elace dlecive components wih eng | | Ste sal Yary Wi Engrs Runang revenive Martone proc | Stppes | Sure as al Yary Altar Stopping tha Ege Proven Maintenance | | pocedies 566Gonerator Maintenance ~ When Required Voltage Regulator and Generator Clean and Inspect Before working inside the generator, make sure that the starter motor can not be activat- fed by any automatic or manual signal. ‘When the engine-generatoris operating, volt- ‘ages up to 600V are present in these areas, near of on the regulator: 1. The regulator terminal strip 2. The excitation transformer terminal strip (self-excited generator only) Do not short these terminals to ground with any partof the bady or any conductive materi- al, Loss of lite of injury could result trom electrical shock or injury from molten metal. {An electrical shock can be received from the Fegulator capacitor (C1) when the engine- generator is not in operation. To avoid Possible injury, discharge the stored charge using an 100 ohm resistor across C1 terminals, CAUTION Electronic components in the regulator can be ‘damaged during generator operation if contact, Is made between the part and ground. 56H If Moisture is allowed to remain in contact with an ‘octal winding, somo of the moisture vl teventually be absorbed. Tres wit lower the resistance ofthe minding msultion, The insulation used on the windings af Caterpiar (enerators is mostue restart, but constan aualy lower the Dit can make the problem worse because it can hald the moisture in contact wih the insulation Salt (om sea ai) can also make the prcbier much worse. This is because salt tends to Absorb massure from the air When the salt and maisture combine, ey make a good electtcal ‘conducter. (Clean tho voltage regulator ana generat ‘and debris. Use @ brush fa loosen accu of dit and a vacuum system for ‘Compressed air not recommended, because of ‘moisture present in the form of condensate Carbon tracking on insulators can be caused by ‘det or loose connections. These carbon pathe ‘must be cleaned oF the insulators replaces Failure fo correct a carton tracking probiem vl ‘eventually suit in a short in the eecrcal or \isualy check for loose or broken wires and ‘connections. Check the wires and connections ‘on the reguator assembly. Check that al cult boards are (uly plugged in ther sockets, Check all wires and connections inthe generat. Make lany necessary ropa tothe wring as requires Rotor tothe ‘Eloctric Set Generator Service Manual for testing and adjusting or disassembly and assembly procedures,‘Space Heaters The SR generator can operate in high hurichty Cconattions without problems. However, problems ‘can occur whan the generator ide and the Surrounding iris warmer than the generator. Moisture can fom on the windings and result in poor performance and even result in damage 10 the wingings. Whenever the generator i notin use, insure tha! the space heaters are in operation. {in external source of either 115 of 290 (200 v at 50 2) volts AC. required to operate the space heaters. ‘Space Heater Connection to External Source: Hi, H2, H3, Ha Terminal Strip Terminals Ee {1118 VAC source is available, connect both heaters in parallel across the source (L112), 230 VAC source is available, connect Both heaters in series across the Sours (L1-L2}, 561 Recommended Periodic Insulation Resistance Checks Use a megohmmeter to check geneeator winding insulation resistance periodicaly. The frequency ofthe megohmmeter testis determined by the {generators envionment and by prevous ‘megohmmeter test inicatons. ‘Megohmmeter test every 6 months ithe {enerator is installed in an enclosed area with Felatiely low humdty and mineral temperature variations, Megohmmeter test every 3 maths if the {generators not protected from the elements by an enclosed area, Megohinmeter test every week and use space heaters if the gonerator expose to a sea \waler enusonment or 1 tha surounding ‘conditions are very rumis ative humty ‘above 75%) or ita recent megohmmeter last reading was less than 3 megan In applications where sat and high humicity are present, space heaters must be operated ‘whenever tne generator not operating under toad, Ths s the only way to maintain megohmmeter test readings above 1 megoten Reler to the Testing and Adjusting section of the Electric Sel Generator Seq Mara forthe. proper procedure to lest the windings.Generator Maintenance - Every 4000 Service Hours Generator Bearing Lubricate 1. Remove the cow cover from the rear of the 5. install the lower plug. Wipe ait excess: gereralor housing, grease, 22. Remove the right side and lower grease pipe 6. Remove the fitting from tne right side grease peg pe 3. saa rease fitting in the right sie 7. Start the engjne and allow the grease to Teaded grease pine expand 4, Lubricate at smal frame generators with a 8. stop te engne. install the plug in the aight grease gun using two (2) pumps of grease. Fo side grease ppe and wipe olf excess grease 680 and ger Yam Pumps of grease © ators, three (3) . instal the cow cover Use Multipurpose type Grease (MPG). NLGI No, 2 Grade s suitable Tor mast temperatures, Use NLGINo. 1 0° O Grade for extremely ow temperatures. 56troubleshooting INDEX Tem PROBLEM 1. Engine Fails to Start 2 Misting 3. Stalls at Low Speed 4. Erratic Engine Speed 5. Low Power 8. Excessive Vibration 7. Heavy Combustion Knock 8 Valve Train Clicking Knock 5. Olin Coolant 10. Mechanical Knock M1. Excessive Fuel Consumption 12. Lous Valve Train Noise 18. Excessive Valve Lash 14. Valve Spring Retainer Free 15. Slobber 1. ENGINE FAILS TO START Possible Causes No Fue! to Engine Shutoff Solenois Sticking” Fuel Transfer Pump Engine Improperly Timed Glow Plug Failure Automatic and Safety Shutott Controls ‘Optenal Equipment ITEM PROBLEM 15, Valve Lash Close-up 17. Promalure Engine Wear 18. Coolant in Engine Lubricating Oil 18. Excessive Black or Grey Smoke 20. Excessive White or Blue Smoke 21. Low Engine Oil Pressure 22. High Lubricating Oi! Consumption 23. Abnormal Engine Coolant Temperature 24. Starting Motor Fails to Crank 25. Alternator Fails to Charge 26. Alternator Charging Rate Low or Unsteady 27. Alternator Charging Rate High 28. Alternator Noisy Remedy ‘Check for empty tue! tank, plugged fuel tank connections, obstructed or kinked fuel suction lines, uel transter pump fallure, or plugged Tue! titers, Solenoid must be energized to shul off engine. Actua the controlthat operates ihe shutot! solenoid and listen for {clicking sound I elieking sound ie not evident and en- {gine will not stat, remove the solenoid. Agaln try to start tho engine. the engine starts, the soieneid le Bad. Re Place the solencia At cranking speed, the fuel ranster pump should supply fuel othe engine at 3 PSI (20 kPa). I! {uel pressure is ess than 3 PSI (20 kPa), replace the vel ler. Cheek for airin fuel system, sticking. binding oF detective tual bypass valve. If préssure 1s still low, roplace the fuel transfer pump See your authorized dealer ‘Check glow plugs. Check shutoff controls to ensure they are set properly. See Starting Procedures. 872. MISFIRING. Possible Causes Defective Fue! Injection Nozzle or Fuel Pump Improper Valve Lash Incorrect Fuel Injection Timing Low Fuel Supply Pressure Broken or Leaking High Pressure Fuel Line Air in Fuel System Bent oF Broken Push Rod 3. STALLS AT LOW SPEED lale Speed Too Low Low Fuel Supply Pressure Detective Fuel Nozzle Detective or Damaged Fue! Injection Pumps: High Parasitic Loads 4. ERRATIC ENGINE SPEED Governor Control Linkage Governor Failure Remedy Fun the engine at the speed where the dofect is most, pronounced. Momentarily loosen the fuel line nut on the Injection pump to "cut out” that cylinder. Check each cy linder in thie manner. Ione is founa where loosening ‘makes no diference in irregular operation, the pump and ‘nozzle for only that cylinder need be treated Set to specified clearance. See your authorized dealer Check fuel supply line for leaks orkinks, arin uel system, Sticking, binding” or defective fuel bypass valve. Replace {uettiter. Check Tuel pressure. Fuel ranster pump should Supply fuel at 20 to 30PSI(1 402.1 Kg/om*) oineengine ‘ahen the engine is Tully loaded Replace the line Find source of air entry and correct. Bleed system Replace push rod. ‘See your authorized dealer. CCheck fuel supply line for leaks or kinks, arin fuel system, sticking, binding. or defective fuel bypass valve. Replace fuel ter. Check fuel pressure, Fuel transfer pump shall Supply fuel 9201030 PSI(1-4 92.1 kg/em*) one engine wien the engine is fully loaded. Foplace nozzle. Replace damaged or detective parts." Check for excessive loading due 10 auxiliary attache- ments Adjust external linkage fo obtain sulficient travel. Replace itdamages, bent, of linkage Is 100 short Look for damaged or broken springs. linkage, or other Components. Determine ifthe rack can be moved manu- Sally Ihany cistrose ie noted in any of these components, so as necessary." 585. LOW POWER, Possible Causes Fuel Nozzle Failure Poor Quality Fue! Turbocharger Carbones or Otherwise Dragging Leaks in Air Induction System Incorrect Fuel Injection Timing Excossive Valve Lash Low Fuel Supply Pressure 6. EXCESSIVE VIBRATION Remedy Run the engine at the speed where the defect is most ‘pronounced. Momentary loosen the fuelling nut on the lection pump to "cut out” that cylinder. Check each cy- linder in this manner. If one Is found where loosening ‘makes no difference in irregular operation the pump and ‘nozzle for only that cylinder need be tested Drain, clean and bleed tuel system. Replace vel iter. Fil fuel tank with proper grade of fuel Inspect and repair orreplace turbocharger as necessary.” Chock inlet manifold pressure. Check air cleaner for re striction. See your authorized dealer Set to specified clearance, Check tue! supply tne or leaks or kinks, arin uel system, sticking, binding or detective fuel bypass valve, Replace fuel ites. Check uel pressure. Fuel ranster pump should supply fuel to2ato SOPSi(1 i021 Kg/em"}otheengine whi the engine is fully loaded Loose, Worn or Detective Engine MountsTighten all mounting bolts securely. Replace components Loose Pulley and Damper Loose or Worn Coupling on Driven Equipment Defective Damper or Pulley Mistring Unbalanced Fan Blade ‘as necessary, Retighten Inspect, align and tighten coupling to driven equipment, Replace damper or pulley. ‘See ITEM 2. ‘Chock by loosening or removing fan belts. ane operating fengine for “short duration” at affected speed range to see it vibration is still present. If not, replace fan assembly, 597. HEAVY COMBUSTION KNOCK Possible Causes Air in Fuel System Defective Fuel Injection Pump Plunger ‘and Barrel Assembly Detective Fuel Injection Nozzle Incorrect Fuel Injection Timing Remedy Bleed air from system. Replace” Replace See your authorized dealer.” 8. VALVE TRAIN CLICKING NOISE Excessive Valve Lash Broken Valve Spring(s) Ingutficient Lubrication 8. OIL IN COOLANT Failed Oi Cooler Core Faliog Head or Spacer Plate Gaskets Cracked or Detective Cylinder Block Cracked of Detective Head 10. MECHANICAL KNOCK Engine Connecting Rod Bearing Failure Main Bearing Failure Damaged Timing Gear Train Broken Crankshatt Fue! Dilution of Crankcase Oi! 60 ‘Set to speoitied clearance, Replace valve spring(s) and all ether damaged compo- nents" Check lubrication n valve compartment. Should be very wet at all speeds Oil passages should be cleaned, espe Cally those leading to the cylinder head Replace oll cooler core. Replace head and spac: plate gaskets, Foplace cylinder block. Replace cylinder head. Replace the b the connecting rod and crankshaft: Replace necessary” Replace bearings.~ Replace components as necessary." oplace crankshaft." Correct fue! leakage into crankcase oll11. EXCESSIVE FUEL CONSUMPTION Possible Causes Fuel System Leaks Fue! and Combustion Knock Incorrect Fuel Injection Timing 12. LOUD VALVE TRAIN NOISE Bont or Broken Valves Broken Camshatt Broken or Severely Worn Valve Lifters 13. EXCESSIVE VALVE LASH Severely Worn Cam Lobes Broken or Severely Worn Valve Lifters Valve Tip Wear Moderate Valve Litter Face Wear Push Rod Wear Rocker Arm Anvil Wear Insutticlont Lubrication Remedy Large changes in fuel consumption may result. Internal leaks wi probably be accomaanied by low engine ‘oll pressure and increased oll level in the engine oi sump. Repiace leaking components. ‘Small But measurable increases in tuel consumption may. betthe result of detective fuel nozzles, misiing ot factors Contributing to loss of power. See ITEM 2 and ITEM 5. ‘See your authori 1d dealer Replace damaged parts." Replace all damaged parts. Clean engine thoroughly Replace camshatt and valve lifters. Check for sticking valves and bent valve stems, Clean engine thoroughly, Set valve lash to speciied clearance. ‘Check valve lash. Replace camshalt and followers. Clean ‘engine thoroughly, Setvaivelasn to speciied clearance. Replace valve lifters. Check camshatt for wear. Check for sticking valves and bent valve stems. Clean engine thoroughly. Set valve lash 10 speciliod clearance, ‘Sotvaive lash to specitied clearance. itwoar is excessive, replace valve. Setvalve lash to spocitied clearance. itwearis excessive, roplace valve iter Set valvelash to spectied clearance. Itwearis excessive, replace push rod Setvalve ash to specitied clearance. Ifwearis excessive, replace rocker arm Check lubrication in valve should be very wet at high idle spoeds, butonly damp atow ilo. Oil passages should be leaned, especially those leading to the cylinder head. 614. VALVE SPRING RETAINER FREE Pot ble Causes Broken Keopers Broken Valve Spring Broken Valve 15. SLOBBER Excessive Valve Guide Wear Excessive Lubricating Olin Valve Compariment Worn Piston Rings and/or Liners 16. VALVE LASH CLOSE-UP Valve Face and/or Seat Wear 17. PREMATURE ENGINE WEAR Intake Piping Failure (Air Cleaner) Excessive Fuel Dilution of Lubricating 01 Dirt in Lubricating Out Remedy Extensive engine damage may result from dropped valve, Replace all damagod par Roplace valve spring.” Foplace valve and any other damaged pars.” Recondition cylinder head assembly." Check rocker arm shaft and plugs to assure that they are In place. Inspect and replace components as necessary.” Adjust valves to specified clearance. Recondition cylinder head. Inspect all gaskets and piping for leaks. Repal al leaks, Foplace leaking components. This will probably be ac. Companies by high fuel consumption and low engine oi pressure. Tighten fuel injection line fittings under valve cover Locate and correct source of ditt entry. Change lubricat- ng of. Change ai titer. 18. COOLANT IN ENGINE LUBRICATING OIL, (O11 Cooler Faiture Cylinder Head Gasket Failure Cracked or Detective Cylinder Head Cracked or Detective Cylinder Block ‘ure to portorm mete senna 62 Replace oll cooler core, Replace gasket. Maintain proper torque on cylinder head bolts oplace cylinder head." Roplace cylinder block.”18. COOLANT IN ENGINE LUBRICATING OIL (Cont'd) Possible Causes Remedy Cylinder Liner Seal Leaking Replace seals." Cracked or Detective Cylinder Liners Replace cylinder liners." 19. EXCESSIVE BLACK OR GRAY SMOKE Insufficient Combustion Air Check air cleaner for restriction. Check inlet mariolé pressure. Inspect turbocharger for proper operation. Fuel Nozzle Plugged or Leaking Feplace nozzle. Incorrect Fuel injection Timing ‘See your authorized doaior. uct Ratio Contro! Improperly Adjusted Adjust fuel ratio control.” 20. EXCESSIVE WHITE OR BLUE SMOKE Valve Guides Worn Recondition cylinder head assembly.” Piston Fings Worn, Stuck or Broken Replace." High Crankcase Oil Level ‘Avoid ovetiling, Determine cause and drain excess oll Misting See ITEM 2 Fuel injection Pump Timing Wrong See your authorized dealer. ‘icin Fuel System Bloed fuel system. 21. LOW ENGINE OIL PRESSURE Engine Oil Diluted with Fuel Oi! ‘Cheek li-type seal on fuel transter pump drive shalt. Drain crankcase and refill with clean lubricant Excessive Crankshaft Bearing Replace bearings and/or crankshaft.” Check ol fiter op- Clearance eration Excessive Timing Gear Bearing Ingpect bearings and replace components as necessary. Clearances Excessive Rocker Arm Bore of CCheck lubrication, Replace components 2s necessary. locker Atm Shalt Wear Defective Oi! Pump Repair or replace. Detective Suction Bell Replace. 6321. LOW ENGINE OIL PRESSURE (Cont'd) Possible Causes Remedy Clogged Oi Filter or Cooler Repair or replace as necessary. Coil Pump Reliot Valve Stuck Clean valve and housing. Replace if necessary 22. HIGH LUBRICATING OIL CONSUMPTION Olt Leaks Replace gaskets or seals and tighten all connections. Excessive Oil to Intake See ITEM 15, Valve Guides. Excessive Valve Guide Wear See ITEM 15. Ccrankoase Oi! Level Too High ‘Avoid ovetiling. Determine cause and drain excess ol High Oil Temperature ‘Check ell cooler bypass valve. Replaceii detective. Clean oil cooler core. Worn Piston Rings and/or Liner Replace components as necessary.” 23, ABNORMAL ENGINE COOLANT TEMPERATURE ‘Combustion Gases in Coolant Determine point at which gases enter the system. Repair fr replace components as nocessary Defective Water Temperature Regulator Check temperature regulator for proper opening tempera~ or Temperature Gauge ture and correct instalation. Check temperature gauge. Replace if necessary Coolant Level Low Determine cause—teplace leaking gaskots and hoses, Tighten connections, Add coolant. [Air Flow Through Radiator Restricted Remove all debris from outer surtace of radiator Detective Water Pump ‘Check water pump impeller Repair water pump as neces- say. II correct size radi Radiator Smal for Engine Application Ins Fan Improperly Positioned in Shroud Position fan correctly." of Not Shrouded os23. ABNORMAL ENGINE COOLANT TEMPERATURE Possible Causes Remedy Incorrect Fuel Injoction Timing See your authorized dealer Incortect Water Piping Connections Check shunt line (it equipped) and vent line for correct ‘rom Engine to Radiator installation 24, STARTING MOTOR FAILS TO CRANK Low Output from Battery Check battery and charge or replace. Detective Wiking oF Switch Repair or replace, Detective Solenois Replace Detective Starting Motor Repair 25. ALTERNATOR FAILS TO CHARGE Drive Belt Loose ‘Adjust bet. Open or High Resistance in Charging Inspect all cables and connectors. Clean. rolighten or er Ground Return Circuits"? roplace detective parts. or Battery Connections Excossively Worn, Open or Replace brush assembly. Defective Brushes ‘Open Rotor Field Coit Replace rotor assembly.” 26. ALTERNATOR CHARGING RATE LOW OR UNSTEADY Drive Belt Loose Adjust bot lotermittent or High Resistance in inspect all cables and connectors. Clean, retighten or Charging or Ground Return Circuits replace detective parts. or Battory Connections Excessively Worn, Sticky, of Replace brush assembly." Detective Brushes Faulty Regulator Replace regulator." Shorted or Open Rectilier Diodes _—_—Replace detective rectilier diode assembly in alternator Grounded or Shorted Rotor Replace rotor assembly." 6027. ALTERNATOR CHARGING RATE HIGH Possible Causes Fomedy Loose Connections Tighten connections to alternator and regulator Detective Regulator Foplace regulator. 28. ALTERNATOR NOISY Detective Drive Beit Replace bolt Misaligned Beit or Pulley ‘ign drive pulley, alternator pulley and belt. Loose Pulley Tighten pulley nut, Hkeyway is worn, installa new pulley, Worn Bearings Replace bearings, Shorted Rectitiors in Alternator Feplace diode assembly.” ‘Armature of Rotor Shaft Bent Replace component. “Auinnze dealers ava aquppea win he necessary tls en personne! ani wih dsassomaly ana assembiy proce 66MODEL SERIAL NO. pate | Hours [Our FUEL MAINTENANCE RECORD uae [~basrs LABOR ow [PART Down TIME SERVIGE PERFORMED erseswodsey a ‘lanaoud nouvuana9 wamod 9119373 ONY ‘SNOISSIWSNYUL SN ONY S3NION3 INTUWN "TWUNLINOROY "WALSAONT AQueuepM seyidiayeD" © Caterpiiar- is % 3 Al Rights Reserved Printed in U.S.A.