CATERPILLAR 3208 GUIDE FOR INDUSTRIAL AND GENERATOR SET ENGINES, Study Guides, Projects, Research of Mechanics

Download CATERPILLAR 3208 GUIDE FOR INDUSTRIAL AND GENERATOR SET ENGINES and more Study Guides, Projects, Research Mechanics in PDF only on Docsity! CATERPILLAR PvB LCATIONS Deer, Cahy Operation IMaAIntenance 3208 Industrial and Generator Set Engines 29A225-UP 30A210-UP Ele be Ky 4) Table of Contents General Information 0.0.0... cece cece tices 9 Seria! Number and Information Plate LOCALION oo. ec cetetesestesesee tees tssesceetsccseseeesteenes 9 Operation Section GAUGES oestrone 40 Automatic Start-Stop oo... 12 Before Starting the EnQine oo... cee 13 Starting the ENgINe wo eee 14 After Starting the Engine . 16 Operating the ENGIN€ wees 7 Stopping the Engine 0... cesses 17 After Stopping the Engine ......0.. ee 18 Lifting the Engine 0.0... 18 Engine Storage oo... scenes 19 Maintenance Section Maintenance Recommendations ..... Coolant, Fuel and Lubricant Specifications oc cece 25 Engine Specifications oor 27 Recommended Lubricant Viscosities ............ 28 Refill Capacitios oo. cciccsceeseseseeeeeeenes 29 Oil and Filter Change Interval Chart (Service Hours of Engine Operation) .. . 2 Lubrication and Preventive Maintenance SCHEMUIC oo... estes eeeesseree eee eseneeeeeeennteneennens 30 DIY oe eee ceteteseeeeccecaeteatetetetetsecenseenenenes 31 First Oi! Change interval Only - New, Rebuilt or Remanufactured ENQiN@S oo. eceeceeceececescestee tees teseetenesteeseneeseareenes 35 Every 100 Service Hours or Two Weeks, Whichever Occurs First Oil and Filter Change Interval - Every _______ Service Hours or Three Months, Whichever Occurs First Every 1200 Service Hours or One Year, Whichever Occurs First Every 24C0 Service Hours or Two Years, Whichever Occurs First .......0ccecce eens 52 Every 4000 Service HOUrs oo... eee 59 When Required oo... cect neeessieeeee 60 Preventive Maintenance Recommendations for Standby Generator Sets 0.00.0... 62 Troubleshooting 2... cece nesses 66 Safety Diesel fuel and ail lubricants are flammable, Do not weld on pipes or tubes that contain oil. Clean them thoroughly with nonflammable solvent before welding. Boe not smoke while refueling. Loose or damaged lines, or tubes that allow oii, fuel or coolant to leak can cause overheating and/or fire. Do not bend or strike high pressure lines. Do not install bent or damaged lines and tubes. Do not replace steel tubes with copper tubes. Do not allow debris, dirt and foreign material to accumulate around or on the engine. Overheating or fire could result. Wiring must be kept in good condition, properly routed and firmly attached. Routinely inspect wiring for wear or deterioration. Loose, unattached, or unnecessary wiring must be eliminated. All wires and cables must be of the recommended gauge and fused if necessary. Do not use smaller gauge wire or bypass fuses. Tight connections, recommended wiring and cables properly cared for will help prevent arcing or sparking which could cause a fire. Batteries must be kept clean, covers on all cells, recommended cables and connections used and battery box covers in place when operating. Do not smoke when observing battery electrolyte level. Batteries give off flammable fumes. Never disconnect any charging unit circuit or battery circuit cable from the battery when charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode. When starting from an external power source attach the ground cable last, and remove it first, to prevent sparks from occurring near the battery. Attach the ground cable from the booster source to the starter ground terminal. Always have a fire extinguisher on hand and know how to use it. Inspect and have it serviced as recommended on its instruction plate or decal. Burn Prevention To prevent personal injury, do not step up on engine to remove the radiator filler cap. Use an adequate ladder. Always inspect the cooling system with the engine stopped and cool. Extreme caution should be used whenever draining a lubricant. The lubricant may be hot and could cause personal injury. Relieve all pressure in air, oil, fuel or water systems before any lines, fittings or related items are disconnected or removed. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to prevent being burned by hot oil sprayed by the valves, Do not touch any part of an operating engine. Allow the engine to cool before any repairs are performed on the engine. Use caution when removing cover plates. Gradually loosen (do not remove) the last two bolts or nuts located at opposite ends of the cover or device. Pry cover loose to relieve any spring or other pressure, before removing the jast bolts or nuts. Use caution when removing radiator filler cap, grease fittings, pressure taps, breathers or drain plugs. Hoid a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure, Stop any fuel or oil leak as soon as it is discovered. Cooling system conditioner contains alkali; do not drink, or let conditioner contact skin or get in eyes. Battery electrolyte contains acid. Avoid contact with skin or eyes. Preparing to Start Be sure all protective guards and covers are installed if an engine must be started to make adjustments or checks. To help prevent an accident caused by parts in rotation, work carefully around them. Never start an engine with the governor linkage disconnected. Make provisions for shutting off air supply to stop the engine if there is an overspeed on start-up after servicing the engine. Inspect engine for potential hazards. See the “Maintenance Section’’ of this guide for adjustment, or the Service Manual for repairs. Starting Do not start the engine or move any of the controls if there is a warning tag attached to the controls. Make sure no one is working on, or close to the engine or engine driven components before starting it. Start and operate engine in well ventilated area. If it is necessary to operate in a closed area, vent exhaust to the outside. Model Views 3208 NATURALLY ASPIRATED ENGINE oll CRANKCASE GAUGE FUEL SHUT-OFF FILLER PLUG SOLENOID POSITIVE CRANKCASE VENTILATION VALVE (PCV) THERMOSTAT HOUSING WATER PUMP TIMING POINTER General Information The Caterpillar 3208 Engine is a 10.4 liters (636 cu. in.) displacement, 114 mm (4.5 in.) bore, 127 mm (5.0 in.) stroke, four stroke cycle, 8 cylinder 90° Vee design engine. The firing order is 1-2-7-3-4-5-6-8 and the direction of rotation is counterclockwise, as viewed from the flywheel. The engine can be either naturally aspirated or turbocharged, with direct fuel injection. A mechanical governor controls the fuel injection pump output to maintain the engine rpm selected by the operator. individual injection pumps, one for each cylinder, meter and pump fuel under high pressure to an injection valve for each cylinder. Automatic timing advance provides the best fuel injection timing over the full range of engine speed The cooling system consists of a belt driven centrifugal pump, with two thermostats which regulate engine coolant temperature, an oil cooler and a radiator incorporating a shunt system. The engine fubricating oil, which is both cooled and filtered, is supplied by a gear- type pump. Bypass vaives provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high, or if either the oil cooler or the oil filter elements should become clogged Efficient engine performance depends on adherence to proper operation and maintenance recommendations, and use of recommended fuels and lubrication oils Follow the recommended maintenance schedule. Serial Number and Information Plate Location Serial Number Plate (Earlier Engines) Located on the right rear side of the cylinder block. Serial Number Plate (Later Engines) Located on the left front side of the cylinder block. Information Plate CATERPILLARS 9L6531 10 ser. vo, I vena 10 ER ruc OEM PART NO, eng HIGH IDLE RPA STATIC Runt Serr one | Atrirupe SPECIFICATION| Located on the ieft valve cover. Gauges Your engine may not have the same or all of the gauges as shown in the itustrations. The illustrations shown are of typical gauges. Gauges provide a ‘‘look” inside the engine. Be sure they are in good working order. You can determine what is “normal” operating range by observing the gauges over a period of time. The cause of any sudden or significant change in the readings should be determined and corrected. Water Temperature — Indicates engine coolant temperature. it should normally indicate between 71°C (160°F) and 93°C (200°F). Somewhat higher temperatures may occur under certain conditions, Maximum allowable temperature is 99°C (210°F) with the cooling system pressurized PRESSURE Oil Pressure — Indicates engine oil pressure. The oii pressure should be between 240 and 480 kPa (35 and 70 psi) when the AMPERES engine is running at rated engine speed, with SAE 10W30 oil, at operating temperature. A lower pressure is normal at low idling speed. If no pressure is Ammeter — Indicates the indicated, stop the engine. amount of charge or discharge in the battery charging circuit. Normai operation of the indicator shouid be slightly to the positive (right) side of "0" (zero). With the engine running, during normal operation, if the indicator is constantly to the negative (left) side of “0” (zero) or shows excessive charge, have the charging system checked for malfunction. 10  ®) Tachometer — indicates engine rpm (speed). \\ \ Fuel Level — Indicates fuel level in the fuel tank. Electrically operated, it registers oniy when the switch is ON. an Fuel Pressure — Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range. When the filter element becomes clogged the indicator will move to the OUT position or if equipped with a numerical indicator and it registers below 140 kPa (20 psi), wash the primary fuel filter and replace the secondary filter element. Service Hour Meter — Indicates the total number of hours the engine has operated. Starting the Engine NOTICE Do not engage starter when flywheel is turning. Do not start engine under load. Above — 12°C (10°F) ‘1. Place transmission in NEUTRAL. Open the main electrical circuit breaker on generator sets. NOTE: For air start systems, before starting the engine, check the air supply. There must be 690 kPa (100 psi) air pressure available. 2. Turn start switch to START position or push the air start button in. Release the switch or button as soon as the engine starts. 3. Allow the engine to idle for three to five minutes, or until the water temperature gauge has begun to rise. 4. Do hot apply load to the engine or increase engine speed until the oil pressure gauge indicates normal. NOTICE If oil pressure does not raise within 15 sec- onds after the engine starts, stop the engine and make necessary corrections. 5. Operate the engine at low load and rpm until the coolant temperature is 66°C (150°F) or higher. Check all gauges during the warmup period. 14 Below — 12°C (10°F) PPh Ether is poisonous and flammable. Breathing ether vapors or repeated con- tact of ether with skin can cause personal injury. Use ether only in weil ventilated areas. Use ether with care to avoid fires. Do not cylinders. smoke while changing ether Do not store ether cylinders in the opera- tor’s compartment or living areas. Do not store ether cylinders in direct sun- light or at temperatures above 49°C (102°F). - Discard ether cylinders properly. Do not puncture or burn ether cylinders. Keep ether cylinders out of the reach of unauthorized personnel. 1. Depress ether switch, if equipped, and hold for 3 seconds, then release. NOTE: For air start system, before starting the engine, check the air supply. There must be 690 kPa (100 psi) air pressure available. 2. Turn the start switch to START position or push the air start button in. 3. Begin cranking engine and depress ether switch and hold for 3 seconds then release. Additional injections of ether may be required to start and/or achieve low idle speed. NOTICE Do not use excessive starting fluid during starting or after the engine is running. After every 30 seconds of engine cranking, allow 2 minutes for the starter motor to cool. if oil pressure does not rise within 15 sec- onds after the engine starts, stop the engine and make necessary corrections. 4. As soon as the engine starts, release the starter switch and reduce rpm to low idle. 5. Do not apply load to the engine or increase engine rem until the oil pressure gauge indicates normal. 6. Operate the engine at tow load and rpm until the coolant temperature is 66°C (150°F)} or higher. Check ail gauges during the warmup period. For starting below —18°C (0°F), use of optional cold weather starting aids are recommended. A coolant heater or extra battery capacity may be required. Temperatures below —23°C (— 10°F) consult your Caterpillar dealer, or refer to the Cold Weather Operation Guide, Form SEBU5338, available from your Caterpillar dealer. 15 Starting From External Electrical Source Always wear protective glasses when working with batteries. Prevent sparks near the batteries. They could cause vapors to explode. Do not al- low cable ends to contact each other or the engine. Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause per- sonal injury if it contacts skin or eyes. Do not allow the free end of booster cables to make contact with each other or touch the engine. This will help avoid sparks. NOTICE Be sure the main power switch is in the OFF position before attaching the booster cables to the engine being started. When using booster cables, be sure to con- nect in parallel: POSITIVE (+) to POSITIVE (+) and NEGATIVE (—) to NEGATIVE (—). Use only equa! voltage for boost starting. The use of a welder or higher voltage will damage the electrical system. Starting the Engine Engines without engine-to-frame ground straps can be damaged by electrical discharge. To prevent electrical discharge damage, check to make sure the system has an engine-to-frame ground strap. For engines which have the alternator connected to an engine component, the ground strap must connect that component to the frame. Some engines have starter-to-frame ground straps. But, many of these starters are not electrically grounded to the engine. They have electrical insulation systems. For this reason, the starter-to- frame ground strap may not be an acceptable ground. Connect one end of cable to the POSITIVE {-+) (ungrounded) terminal of the battery on the engine being started. Connect the other end to the POSITIVE (+) terminal of the power source. Connect one end of the second cable to the NEGATIVE (—) terminal of the power source. Connect the other end to the frame of the engine to be started. Turn the start switch on. Start the engine. Disconnect the cable from the engine frame first. Disconnect the other end from the NEGATIVE (—) terminal of the power source. Disconnect the cable from the POSITIVE (++) terminal of the battery. Disconnect the other end from the POSITIVE {+) terminal of the power source. 16 After Starting the Engine NOTICE If oif pressure does not rise within 15 sec- onds after the engine starts, stop the engine and make necessary corrections. 1. Do not apply a load to the engine, or increase the speed, until oil pressure gauge indicates normal 2. Operate the engine at low load until all systems reach operating temperatures. Check all gauges during the warmup period. Engine Storage Generali Information These instructions give procedures and recommendations that will keep the possibility of damage at a minimum when engines are in storage for one year or less. After one year, the complete protection procedure must be followed again if the engine is kept in storage. The best protection for outside parts of the engine is by thorough use of paint. Paint is a good protection for storage of a period up to 2 years. Thoroughly clean the engine and repaint areas with paint damage with good quality paint if an engine is not used, oil can run off the cylinder walls, piston rings, main bearings, connecting rod bearings, crankshaft, gears and other parts that normally get lubrication. This lack of lubricant lets corrosion start on the metal, especially in areas of high humidity (water content of the air). When the engine is started again, before these surfaces get oil, the metal-to-metal contact will cause wear. To keep this wear at a minimum, use the starter to turn the engine with the throttle in fuel OFF position until oil pressure is shown on the pressure gauge. Use an air compressor with a sprayer attachment to spray external engine parts with a mixture of 50% VCI oil and 50% engine oil for preparation of the engine for storage. It should be possible to change the nozzle adjustment to give either spray or fog. The fog adjustment is better if access to components is difficult. The spray is better for parts on the outside. 19 Volatile Corrosion Inhibitor (VCI) (NOX- RUST VCI #10 oil or equivalent) oil gives both liquid and vapor protection of ferrous metal surfaces against corrosion caused by moisture. In a closed compartment, protection is either by direct contact with VCI oil or by contact with the VCl vapors. See your local supplier for a similar type oil. Additional information as to ordering and use of NOX-RUST VCI #10 and NOX-RUST 1031B rust preventive and a list of suppliers outside the U.S.A. are available from: Daubert Chemical Co, 1200 Jorie Blvd. Oakbrook, IL 60521 Telephone: (312) 582-1000 NOTE: Attach a “DO NOT OPERATE” tag on the start switch, start button or air start knob, before servicing the engine. These tags, Form SEHS7332, are available from your Caterpillar dealer. Storage Procedure 1. Clean the outside of the engine and repaint areas with paint damage with good quality paint. 2. Remove the batteries and use them in some other place or put them in storage where they can be checked and electrically charged again when needed. If the batteries are not removed, wash the tops. Put an electrical charge to the battery to a specific gravity of 1.275. Disconnect the battery terminals. Put a plastic cover over the battery. 3. Loosen all fan, alternator belts, etc. Attach a tag to indicate what work has been done. Engine Storage 4, Put a waterproof cover over engines with enclosures stored outdoors. Make the cover tight, but loose enough to allow air to circulate around the engine to prevent damage to exposed metal parts from condensation. NOTE: Remove the waterproof cover every two or three months and check the engine for corrosion. If the engine has signs of corrosion at the check period, follow the protection procedure again. To operate the engine, it is not necessary to temove the preservative oil mixture. If a compartment under protection of VCl vapors is opened, put more VCl mixture in to make up for the vapor loss. NOTE: Install all covers and/or put tape over all openings, air intake, exhaust openings, flywheel housing, crankcase breathers, dipstick tubes, etc. Make sure all covers are air tight and weatherproof. Use a waterproof, weather resistant, tape. 5. Put lubricant on all points given in the Lubrication and Maintenance Chart. 6. Put a heavy amount of multipurpose grease on all outside parts that move: rod threads, ball joints, linkage, etc. 7. Oil and oil filter elements used less than 50 hours in the engine do not need to be changed. (Otherwise, change the oil, filing the engine to the ‘‘add oil” mark on the dipstick.) Add 3% to 4% of VCI oil per engine volume. If the engine is drained, install a mixture of 50% VCI oil and 50% engine oil in the crankcase and in all lubricating oil compartments at the rate of one part VCI oil mixture per fifteen parts of compartment capacity at full level. If possible, operate the engine three to five minutes. Put tape over all openings to seal VCI vapors in the engine. 20 NOTE: If necessary, drain some lubricant to add the mixture. 8. Remove any dirt from the air cleaner. Check all seals and gaskets. 9. Remove the air filter elements. Turn the engine at cranking speed with throttle control in fuel OFF position, remove pressure plug for boost pressure and use a sprayer to add a mixture of 50% VCI oil and 50% engine oil. Minimum application rate is 5.5 mililiters per liter (3 oz. per 1000 cubic inches) of engine displacement. 10. Fil the oil reservoir for the air starter with a mixture of 50% VCI oil and 50% engine oil. 11. Use a sprayer to put a mixture of 50% VCI oil and 50% engine oil into the exhaust openings. Minimum application rate is 5.5 milliliters per liter (3 oz. per 1000 cubic inches) of engine displacement. 12, Also, use a sprayer to apply a mixture of 50% VCI oil and 50% engine oil on the flywheel, ring gear teeth and starter pinion. Install the covers to keep the vapors in. 13. Remove the fuel nozzles and install 30 milltiters (1 0z) of 50% VCI oil and 50% engine oil in each cylinder. Test (using calibrating oil) then install fuel nozzles and tighten all fittings to the correct torque. Use an engine turning tool to turn the engine over slowly two complete revolutions in the direction of normal rotation, to put oil on the cylinder walls. 14. Remove the fuel from the secondary fuel filter housing or change the spin-on fuel filter element to get out any dirt and water. Clean the primary fuel filter, fill with calibration of and operate the priming pump. This will get clean oil to the secondary fuel filter and engine, and help to prevent ‘‘sticky”’ fuel pump nozzles during extended storage. Calibrating oil is available from your Caterpillar dealer in two sizes, 208 liters (55 gallons} or 19 liters (5 gallons). Open the fuel tank drain vaive and remove any water or dirt from the inside of the fuel tank. The fuel must be treated with a Biocide, which prevents bacteria and fungi from contaminating diese! fuel that contains some water. Microbial contamination can cause severe fuel system blockage, filter plugging, fuel pump sticking and corrosion. Additional information as to ordering and use of diesel fuel Biocide and a list of suppliers outside the U.S.A. are available from: Amalgamated Coat & Petroleum Specialists, Inc. C.P.S. Associates 9214 Ernst Road Fort Wayne, Indiana 46809 Telephone (219) 747-7080 Methyl Cellosolve will help assimilate water in the fuel and prevent freezing problems. Fill the fuel tank with the treated fuel, Seal all openings to the tank to prevent evaporation of the fuel. 15. Withdraw a sampie of coolant and check it for clarity (rust) and freezing point. If it contains suspended particles or does not provide freeze protection to at least — 23°C (— 10°F), the coolant should be replaced. Completely drain the cooling system, if needed. The cooling system must be thoroughly flushed and chemically cleaned. 21 16. Refill the cooling system with a coolant solution that is 50% water and 50% ethylene glycol. Install a new precharge coolant conditioner element (if equipped with coolant conditioner elements). A 3% to 6% concentration of coolant conditioner does not have to be added, if the cooling system is filled with coolant solution to the top of the filler neck. Attach a tag indicating what has been done. NOTE: Do not use coolant conditioner elements or liquid coolant conditioner with Dowtherm 209 Full-Fill coolant. Procedure for Operation After Storage 1. Remove all outside protective covers, and any tape or grease which were used for protection. 2. Drain the VCI oil and engine oil mixture from the engine, if the oi! has been in the engine for more than one year, or if the engine was left drained before adding the VCi mixture. If storage was short term, the engine can be operated with a 3% to 4% VCl mixture in the engine. 3. Tighten the fan and alternator beits, connect the batteries and check the oil and coolant level. 4, Use an engine turning tool to turn the engine two complete revolutions in the direction of normal rotation, to make sure there are not hydraulic locks or resistance. 5. Before starting the engine, remove the valve cover or covers and put a large amount of engine oil on the valve mechanism to prevent damage to the valves. Maintenance Recommendations Coolant Conditioner Elements For engines equipped with coolant conditioner elements, install a new maintenance element at every oil change interval. Use a precharge element only when filing the system on new, rebuilt or remanufactured engines, or changing coolant. Your Caterpillar dealer can provide you with the correct coolani conditioner element. General Coolant should be drained and replaced every 2400 service hours or 2 years, when Caterpillar cooling system conditioner, or equivaient, is added, as recommended. Premix antifreeze solution to provide protection to the lowest expected outside temperature. Pure undiluted antifreeze will freeze at —23°C (— 10°F). A mixture of 50% ethylene glycol and 50% water will protect the coolant from freezing down to a temperature of —37°C (34°F). Use clean water that is low in scale forming mineral. Do not use softened water. Filling at over 20 titers (5 U.S. gallons) per minute can cause air pockets in the cooling system. After draining and refilling the cooling system, start and operate the engine with the fill cap off until the coolant level stabilizes. Add 3% to 6% liquid coolant conditioner or instail a precharge ccotant conditioner element. Operate with a thermostat in the cooling system year-round. Overheating will occur without a thermostat. 24 Fuel System NOTICE Fill the fuel tank at the end of each day of operation to drive out moist air and to pre- vent condensation. Do not fill the tank to the top. Fuel expands as it gets warm and may overflow. Do not fill the fuel filters with fuel before in- stalling them. Contaminated fuel will cause accelerated wear to the fuel system parts. After changing the fuel filters, bleed the fuel system to remove air bubbles from the system. Drain water and sediment from the water separator daily and the fuel storage tank weekly, and before the tank is refilled. This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. Use only fuel as recommended in the “Coolant, Fuel and Lubricant Specifications” section of this guide. Air Intake System An air cleaner service indicator may be mounted on the air cleaner. A colored piston showing in the window indicates the need for servicing the air cleaner. Replace the filter element at least once a year. Inspect the air intake system hoses, elbows and gaskets for cracks or damage, replace as needed. Check for loose clamps, tighten as needed. Scheduled Oil Sampling (S-O-S) Use Scheduled Oi! Sampling (S-O-S) to monitor the condition and maintenance requirements of your engine. Each oil sample should be taken when the oil is hot and well mixed, to ensure that the sample is representative of the oil in the compartment. Coolant, Fuel and Lubricant Specifications Cooiant Specifications S-O+S Interval Chart Compartment interval Engine Oil At Oil Change(1) (See page 29. Consult your Caterpillar dealer for complete information and assistance in establishing a Scheduled Oil Sampling program for your engine. Electrical System Engines installed without an engine-to-frame ground strap can be damaged by electrical discharge. To prevent electrical discharge damage, check to make sure the engine's electrical system has an engine-to-frame ground strap. For engines which have the alternator connected to an engine component, the ground strap must connect that component to the frame. NOTICE Some engines have starter-to-frame ground straps. But, many of these starters are not elec- trically grounded to the engine. They have electrical insulation systems. For this reason, the starter-to-frame ground strap may not be an acceptable ground. Use a separate engine-to- frame ground strap. When boost starting the engine, follow the in- structions in the “Starting From An External Source” in the “Starting the Engine” section to properly start the engine. Your engine may have a 12 or 24 Volt starting system. Use only the same voltage for boost starting. The use of a higher voltage or a welder will damage the electrical system. 25 NOTICE Use a mixture of water, antifreeze and cooling system conditioner. Pure, undiluted antifreeze will freeze at -23°C (-10°F). Always add cooling system conditioner to water, or install a coolant conditioner element (if equipped). Never use water only. To prevent overinhibiting the cooling system, never use both liquid cooling system conditioner and a coolant conditioner element (if equipped) at the same time. Do not use Caterpillar cooling system condition- er or coolant conditioner elements with Dowtherm 209 Full-Fill coolant. Follow the in- ‘structions provided with the Dowtherm 209 Full- Fill coolant. Refer to “Know Your Cooling System,” Form SEBD0518, for more detailed specifications and instructions on water and cooling system conditioner sampling and testing Water Acceptable water for use in the ethylene glycol- type antifreeze and water mixture is shown in the chart below: Acceptable Water 50% Antifreeze Without Water Content 50% Water Antifreeze . 100 ppm 50 ppm Chlorides or less or jess 100 ppm 50 ppm Sulfates or less or less Hardness as 200 ppm 100 ppm CaCO; or less or less. : q 500 ppm 250 ppm Dissolved Solids or less or less pH 6.5 or higher | 6.5 or higher ppm = parts per million Coolant, Fuel and Lubricant Specifications Antitreeze Use ethylene glycol-type antifreeze. Use the correct amount, mixed with water, to provide freeze protection to the lowest expected outside temperature. Cooling System Conditioner (Liquid) Use Caterpillar cooling system conditioner or equivalent. Add the correct amount of cooling system conditioner at every oil change interval to maintain a 3% to 6% concentration. Conditioner can be purchased from your Caterpillar dealer. Coolant Conditioner Eiements (If Equipped) Coolant conditioner elements should be used to maintain a 3% to 6% concentration of conditioner. Install! a new maintenance element at every oil change interval. Use a precharge element when filling the complete system or changing coolant. Your Caterpillar dealer can provide you with the correct coolant conditioner element. * Fuel Specifications and Information Types of Fuel Caterpillar engines have the ability to burn a wide variety of fuels. These fuels are divided into two general groups, preferred and permissible. The preferred fuels provide maximum engine service life and performance, They are distillate fuels. They are commonly called diese! fuel, furnace oil, gas oil or kerosene. The permissible fuels are crude oils or biended fuels. Use of these fuels can result in higher maintenance costs and reduced engine service life. Refer to ‘Fuels for Caterpillar Diesel Engines,’’ Form SEHS7067, for a detailed summary of preferred and permissible fuels and their specifications. 26 Refer to S.A.E. J313 Diesel Fuels for information about better quality fuels, such as ignition quality, gravity/density, viscosity, cloud point, sulfur content, etc. Fuet Sulfur Content The percentage of sulfur in the fuel will affect the engine oi! recommendations. If the fuel has over 0.5% sulfur content, the CD/SE or CD/SF engine oil must have a TBN of 20 times the percentage of fuel sulfur (TBN as measured by the ASTM D- 2896 method). Fuel sulfur is chemically changed during combustion to form sulfuric acid. The acid chemically attacks metal surfaces and causes corrosive wear. Higher engine oil TBN values are essential to minimize corrosive wear. Periodicaily request fuel sulfur content information from your fuel supplier. Fuel sulfur content can change with each bulk delivery. Fuel Cetane Requirement The minimum fuel cetane number recommended for the direct injection engine is 40. Fuel Cloud Point Fuel waxing can plug the fuel filters in cold weather. The fuel cloud point must be below the temperature of the surrounding air to prevent filter waxing and power loss. Fuel heating attachments are available from your Caterpillar dealer to minimize fuel filter waxing. Refill Capacities — (Approximate) Compartment U.S. Imperial or System Quarts | Liters | Quarts ENGINE CRANKCASE including FILTERS( Serial No. 42 | 11.62) | 100) 90N1-44127 2) or 14 | or 13 (or11.5 Serial No. 90N44128-Up 14 13 11.5 Serial No. 3Z1-Up 20 19 16.5 Serial No. 29A225-Up 18 17 15 Serial No. 30A210-Up 3) 18(3) 178) 15(3} Serial No. 30A210-Up (4) 2014) 194) | 16.54 Clutch Rear Bearing 1 EJ 8 COOLING SYSTEM Engine Only 26 24.5 21.5 Standard Radiator 38.8 37.5 32.5 High Capacity Radiator 40 38 33.5 {additional oil is required with the use of auxiliary filters. Make sure to add enough oil to fill the auxiliary oil circuit. {2)These engines originally had an 11.5 liters (+2 U.S. quarts) capacity. The dipsticks on these engines should be re-marked for 13 liters (14 U.S. quarts) capacity. Consult your Caterpillar engine dealer for procedure. (}Turbocharged engines WITHOUT piston cooling jets should use these refill capacities. These engines will have an engine oil cooler that is approximately 254 mm (10" long). {4)Turbocharged engines WITH piston cooling jets should use these refill capacities. These engines will have an engine oil cooler that is approximately 356 mm (14" long). NOTE: For remanufactured engines, use the Reference Serial No (Ref. Ser. No.) to determine the crankcase refill capacity. Remanu- factured engines with Ref. Ser. No. 90N1-44 127, have the correct dipstick markings for 13 jiters (14 U.S. quarts) capacity. 29 Oil and Filter Change Interval (Service Hours of Engine Operation) Minimum API Oil Classification When Crankcase Refill Diesel Fuel Capacity Including | Sulfur Content is 0.5% Filters (U.S. Quarts) or Less CD/SE or CD/SFO 300 Service Hours 18 and 20 quarts (Turbocharged Engines) 18 quarts 300 Service (Non-Turbocharged Engines) Hours 14 quarts 200 Service {Non-Turbocharged Hours Engines) (if fuel contains more than 0.5% sulfur use only Cd/SE or CDYSF oil with a TBN of 20 times the percentage of fuel sulfur. Coolant Conditioner Cooling system coolant conditioner is necessary to prevent cylinder wall pitting. Most antifreeze solutions DO NOT contain sufficient coolant conditioners. See topics “Cooling System,” “Coolant, Fue! and Lubricant Specifications” and “Maintenance Recommendations” for precharge and maintenance recommendations and procedures.  Lubrication and Preventive Maintenance Schedule NOTE: Performance of this Lubrication and Maintenance schedule is the owner's responsibility. item | Service | Lube. |Page| Daily Walk-Around Inspection inspect engine. 3 Engine Crankcase Measure oil level. CD/SE, | 31 (Engine Stopped) CD/SF, Cooling System Check cooiant level - inspect. 32 Fuel Tank Drain water and sediment. 32 Air Cleaner Check air cleaner indicator. 32 Clutch Adjustment Check adjustment 33 Water Separator Drain water and sediment - inspect. Lt 33 First Oit Change Interval Only — New, Rebuilt or Remanufactured Engines Engine Valve Lash Check and adjust valve lash at the first 35 NOTE: Check and adjust at first oil change intervai, | scheduled oil change interval, due to ini- then every 1200 service hours or one year. tial wear and seating of valve train com- ponents. Every 100 Service Hours or Two Weeks, Whichever Occurs First Clutch Control Lever [ Lubricate 2 fittings. MPG | 36 Pilot Bearing (Standard and Heavy Duty) | Lubricate 7 fitting MPG | 36 Flywheel Clutch (Standard) Lubricate 7 fitting. mPa | 37 (Heavy Duty) Maintain oil at proper level. cp Oil and Fitter Change Interval Every _______ Service Hours or Three Months Whichever Occurs First NOTE: Make sure to fill in the number of service hours in the blank space above for the oil and filter change interval. This interval in service hours is determined by the crankcase capacity and the API classification of oil used. Refer to the two charts on preceding page. PM1 Engine Crankcase Change oil and filters. CD/SE, | 38 CO/SF, Cooling System ‘Add conditioner or replace element. 40 Clean radiator fins - inspect. Fuel Filters Replace. 4 Air Cleaner Clean or replace elements, more often if needed. 43 Batteries Clean ~ check electrolyte level. 46 ‘Alternator, Fan and Accessory Drive Belts Check — adjust. a7 PM 2 Every 1200 Service Hours or One Year, Whichever Occurs First Engine Valve Lash Check and adjust. 48 Flywheel Clutch (Heavy Duty) Change olf, co 48 Water Separator Repiace element. 49 PCV Valve ‘Check diaphragms. Replace if necessary. 49 Thermostats Replace thermostats, gaskets and seals. 60 Turbocharger (If Equipped) ‘Check - repair or replace if necessary. 51 Vibration Damper Check — replace if necessary. 51 Engine Protective Devices (If Equipped) Cheok by authorized personnel only. 51 Every 2400 Service Hours or Two Years, Whichever Occurs First PM3 Cooling System Clean, add conditioner precharge. 52 Coolant and PCV Hoses Replace. 53 Fuel injection Nozzles Test - replace if necessary. 54 Governor ‘Check full ioad speed (set point) and low idle rpm. 58 Every 4000 Service Hours Generator Bearing Lubricate. [mPa | 59 When Required Voltage Regulator and Generator Clean and inspect, check space heaters, [ winding resistance checks. 60 NOTE: Items identified by PM-1, PM-2 and PM-3 are organized for a Preventive Maintenance Program. 30 Daily Walk-Around Inspection Inspect Engine 1. Make sure lines are properly clamped and tight. Check for loose fittings or leaks. 2. All guards must be in place. Repair or replace missing or damaged guards. 3. Disconnect any battery chargers that are not protected against the starter current drain. Check condition of batteries and the level of electrolyte. 4. Check tor coolant, fuel or oil leaks on or below engine. 5. Drain water from the water separator daily before starting the engine 6. Check condition of all belts. Replace if necessary. 7. Check condition of gauges. Replace if cracked or if gauges can not be calibrated to zero (‘'0"). 31 Engine Crankcase (Engine Stopped) Measure Oif Level (Engine Stopped) WARNING Hot oil and components can cause person- al injury. Do not allow hot oil or components to contact skin. 1. Measure the oil level. 2. Maintain the oil level between the FULL and ADD marks on the dipstick. Do not fill the crankcase above the FULL mark. 3. Add oil it necessary Daily Replacing NOTE: The water separator is not a filter. It separates water from the fuel. Change element anytime the water separator becomes contaminated enough that water level cannot be seen through the transparent cover. 1. Close the fuel supply valve, if equipped. 2. Remove all dirt from the separator and surrounding area. 3. Open vent valve @) and drain valve @®. Allow water to drain. Close valves @) and @). 4. To remove. the water separator element, depress the extended tab @ with the heel of the hand. Then lift the siotted tab from the locking slot, at the top of the base, with the fingers. Remove the clamp. 5. Remove element © from base © and discard it. 34 6. Clean the three sealing surfaces © on base ©) before installing a new element. 7. Align outlet hole @ and roll pin and push new element () into position on the base. 8. The clamp must be installed with the hand and finger tabs in the UP position. 9. Engage lower tab of clamp in siot at bottom of separator base. While depressing clamp, with heel of hand, push upper tab into locking slot at top of base. 10. Open the fuel supply valve, if equipped. 11. Prime the fuel system. See “Priming the System’ under item '‘Fuel Filters.”’ 12. start the engine and check for fuel leaks, First Oil Change Interval Only — New, Rebuilt or Remanufactured Engines Engine Valve Lash Check and Adjust tn . ee Initial valve lash adjustment on new, rebuilt or remanufactured engines is recommended at the first scheduled oil change interval, due to initial wear and seating of valve train components. For the procedure, see topic, “Engine Vaive Lash”' in “Every 1200 Service Hours or 1 Year, Whichever Occurs First.” 35 Every 100 Service Hours or Two Weeks, Whichever Occurs First Clutch Control Lever Pilot Bearing (Heavy Duty Clutch) Lubricate Fitting a ‘4. Lubricate 2 fittings; 1 fitting on each 1. Remove plug from main shaft. side of the clutch housing. 2. insert grease fitting and lubricate bearing. Pilot Bearing (Standard Clutch) 3. Remove grease fitting and install plug. NOTE: Some clutches are furnished with a Lubricate Fitting prelubricated pilot bearing, therefore no % lubrication will be required. f shaft Lubricate 1 fitting at the end o' NOTE: Some clutches are furnished with a prelubricated pilot bearing, therefore no lubrication will be required. 36 6. install the new fitter elements by hand until the gasket contacts the base. Tighten the filters 3/4 of a turn more with a filter wrench, Do not overtighten. * 7. Fill the crankcase. See “Refill Capacities.”’ NOTICE If equipped with auxiliary oil filters, extra oil must be added when filling the crankcase. If the extra oil is not added, the auxiliary oil filter will take priority and the engine may starve for oil. 39 8. Before starting the engine, check the oil level. The oil level should be at or above the FULL mark on the dipstick. 9. Start and run the engine at tow idle for two minutes. Inspect for oil leaks. Stop the engine. 10. wait 10 minutes to allow the oil to drain back into the crankcase. Check the oil level. Maintain the oil level to the FULL mark on the dipstick. Oil and Filter Change Interval - Every Occurs First Cooling System Add Conditioner or Replace Element ARNING At operating temperature, the engine cool- ant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the en- gine has been stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve Pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to Prevent personal injury. NOTICE All water is corrosive at engine operating temperature. Use Caterpillar liquid cooling system conditioner or Caterpillar cooling system conditioner element to treat either plain water or ethylene glycol antifreeze solution. Never use both the liquid cooling system con- ditioner and the conditioner element at the same time. NOTE: See “Know Your Cooling System” Form SEBDO518 and your Caterpillar dealer for more detailed specifications. Service Hours or Three Months, Whichever Liquid Conditioner 1. Loosen the filler cap slowly to relieve pressure and remove the cap. 2, tt may be necessary to drain enough coolant from the radiator to allow for the addition of the liquid cooling system conditioner. 3. Add 0.24 liters (1/2 pint) of Caterpillar liquid cooling system conditioner for every 38 liters (10 U.S. gallons) of cooling system capacity. NOTE: On new, rebuilt or remanufactured engines only or when changing the coolant, add enough liquid conditioner for a 3% to 6% concentration of conditioner. Add 0.95 liters (1 quart) for every 30 liters (8 U.S. gallons) of cooling system capacity. fagttdy gota gy teee ee ve Stesriesas iiss: 4. Inspect the filler cap gaskets. Replace the cap if the gaskets are damaged. Install the filler cap. 40 Conditioner Element (If Equipped) ‘1. Close the coolant conditioner element inlet and outlet valves. 2. Remove and discard the conditioner element. 3. Clean the element mounting base. Make sure ali of the old gasket is removed. 4, Coat the gasket of a new maintenance conditioner element with a thin film of engine oil. Install the new conditioner element. NOTE: On a new, rebuilt or remanufactured engine, use a precharge conditioner element for original fill of the cooling system. 5, Open the inlet and outlet valves. 6. Remove the filler cap. 7. Start the engine and check for leaks. Allow the coolant level to stabilize. 8. Add coolant if necessary to bring the cootant to within 13 mm (1/2 inch} below the bottom of the fill pipe or to the proper level on the sight glass, if so equipped. 9. Inspect the filler cap. Replace the cap if the gasket is damaged. Install the cap. 41 Fuel Filters Replace Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Turn the disconnect switch OFF or discon- nect the battery when changing fuel filters. 1. Stop the engine. 2. Shut off the fue! tank supply valve. Primary Filter (If Equipped) sO ° —© 1. Loosen bolt @ on the filter housing and remove filter case @ 2. Remove element @® and wash it in clean, nonflammable solvent. 3. install element © and case @. Tighten bolt @). Oit and Filter Change Interval - Every Oceurs First 3. Clean the inside of the cover. 4. Remove the tape covering the inlet opening. Install either a new or cleaned filter element with the larger gasket on top. 5. install the air cleaner cover and tighten the rod assembly. 6. Reset the service indicator by pushing on the piston plunger. Cleaning Air Cleaner Elements Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective cloth- ing and protective shoes. Maximum air pressure must be less than 205 kPa (30 psi) for cleaning purposes. Service Hours or Three Months, Whichever 44 NOTICE Do not clean filter elements by bumping or tapping. Do not use filter elements with damaged pleats, gaskets or seals. NOTE: Air cleaner filter elements can be cleaned with either air, water or detergent. Have spare elements on hand to use while cleaning used elements. Pressure Air — 205 kPa (30 psi) Maximum Pressure - 1. Direct air inside of the element along the length of the pleats.  2. Direct air on the outside of the element aiong the length of the pleats. Direct air on the inside along the pleats. Inspect the efement for any rips, tears or damage. Pressure Water — 280 kPa (40 psi) Maximum Pressure 1. Direct water on the inside of the element, along the length of the pleats. 45 2. Direct water on the outside of the element along the length of the pleats. Air dry thoroughly before using and inspect the element. Detergent 1. Wash the element in warm water and nonsudsing detergent. 2. Rinse the element with clean water. See instruction for cleaning with water. 3. Air dry it thoroughly before using and inspect the element. Oil and Filter Change interval - Every Occurs First Inspecting Element 1. Insert a light inside of the cleaned and dry element. Inspect it for rips and tears. Discard the element if damaged. 2. Wrap and store good cleaned elements in a clean, dry place. Service Hours or Three Months, Whichever 46 Batteries Clean — Check Electrolyte Level WAR Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause per- sonal injury if it contacts skin or eyes. Always wear protective glasses when working with batteries. 1. Ciean the top of the batteries. 2. Remove the filler caps. Maintain the electrolyte level to the bottom of the filler openings. if an addition of water is necessary, use distilled water. If not available, use clean water, low in minerals. Do not use artificially softened water. At proper charging rate, batteries should not require more than 30 cc (1 ounce) of water per ceil per week. 3. install filler caps. Water Separator Replace Element It is recommended that the water separator element be replaced at this Preventive Maintenance interval. Refer to Water Separator in the Daily Preventive Maintenance section of this guide for the proper procedure. PCV Valve Check Diaphragms - Replace If Necessary 1. Ciean the outside of the PCV valve(s) and the area around it. Inspect PCV hoses for deterioration or damage, replace if necessary. 2. Remove the screws and washers that hold cover (1) in place. 49 3. Remove cover @ and the spring. 4. Remove the diaphragm assembly, inner sieeve @ and gasket @) from housing ©). 5. Disassemble the diaphragm assembly. 6. Clean and inspect all parts. Replace any part that is worn or damaged. Always install a new gasket and diaphragm when the PCV valve is disassembled. 7. Assemble the diaphragm assembly using a new diaphragm ©). 8. To prevent diaphragm ©) from distorting and tearing during assembly, coat both flange sides of the diaphragm with gasket cement. Install it with the side marked “piston face” towards piston 9. Coat new gasket @) with gasket cement and install it against the rear face of inner sieeve (2). 10. Install the diaphragm assembly in housing 1 1 » install the spring and cover @) with the washers and screws that hold cover @) in place. Every 1200 Service Hours or One Year Whichever Occurs First Thermostats Replace Thermostats, Gaskets and Seals FECL At operating temperature, the engine cool- ant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the en- gine has been stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure, Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to Prevent personal injury. 1. Loosen the filler cap slowly to relieve any pressure and remove the cap. 2. Drain the coolant from the cooling system to a level below the thermostat housing 3. Loosen the hase clamps and remove the radiator hose from the thermostat housing. 4, Remove the thermostat housing from the engine block 50 5. Remove the thermostats and gasket from the engine block. Remove thermostat and seal from thermostat housing 6. Replace thermostats and gasket. NOTE: The thermostats should begin opening (bench test in atmospheric pressure) at approximately 80°C to 84°C (176°F to 183°F). The thermostats should be fully open at approximately 90°C to 94°C (194°F to 201°F) 7, Install new thermostats in the engine block. NOTE: Former thermostats may be reused, if they meet test specifications above and are not damaged or have excessive buildup of deposits 8. install a new gasket and the thermostat housing on the engine block. 9, install the radiator hose and tighten the hose clamps 10. Add coolant to the cooling system to bring it to the proper level. 11. Start the engine and inspect for leaks and proper operating temperature. Turbocharger (If Equipped) Check — Repair or Repiace lf Necessary 1. Remove the exhaust outlet piping from the turbocharger. 2. Turn the turbine and compressor wheel by hand. The assembly should turn freely. 3. if the assembly does not turn freely, refer to the Service Manual or consult your Caterpillar dealer. 51 Vibration Damper Check 1. Inspect for separation of the rubber ring, between the inner hud and the outer ring. 2. Replace the vibration damper if there is separation or damage to the rubber ring. Engine Protective Devices (If Equipped) Check By Authorized Personnel Only It is important that the shut-off switches be in good working order because they operate only in time of a mechanical emergency, it is impossible to tell if they are in good working order through normal operation. Have them checked at regular intervals by your Caterpillar dealer. Every 2400 Service Hours or Two Years Whichever Occurs First 3. Loosen the hose clamps and remove the oi! cooler hoses and discard. 4. Loosen the hose clamps and remove the hoses from PCV vaives on both sides of the engine. 5. install all new coolant and PCV hoses and tighten the clamps. 6. Add the coolant to the cooling system, 7. Start and run the engine with the filler cap off. Allow the coolant to warm and stabilize 8. Ada coolant if necessary to bring the coolant level to the proper level. Install the filler cap. 9. Check for coolant leaks at the oil cooler connections. Stop the engine. 54 Fuel Injection Nozzles Test — Replace If Necessary Whenever the engine performs in such a manner that a fuel injection nozzle is suspected of causing irregular running, smoking or knocking, isolate each fuel injection nozzle, one at a time, to determine the malfunctioning nozzle. NOTE: For complete fuel injection nozzle testing and cleaning, consult your authorized Caterpillar engine dealer, 1. Loosen the fuel injection line nut at the cylinder head, one at a time, with the engine running. Be sure to tighten each fuel line nut after the test, before the next fuel line nut is loosened. 2. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance or smoking, have that cylinder injection nozzle tested. To Remove Injection Nozzles 1. Clean the area around the valve cover. 2. Loosen the hose clamp and disconnect the hose from the PCV valve(s). 3. Remove the valve cover. NOTE: On later engines it is NOT NECESSARY to loosen the valve adjusting locknuts or to remove the rocker arm assemblies (steps 4 and 5). These later engines have a different type of nozzle with the fuel line routed OVER the rocker arm assembly. These nozzles may be removed without disturbing the valve mechanism, DO NOT REMOVE the fuel line from these nozzles, Engines with these new nozzles aiso have new fuel injection lines with a larger inside diameter. They can be identified by the notched nuts on the fuel injection lines. The new nozzles and fuel injection lines were effective with 9ON65055, 294789, 323472 (except Sperry-New Holland TR95 Combine which was effective with 323923), and 30A1176 (except engine arrangement 7W8603 which does not use the new nozzles and lines). The new nozzles require a 6V6976 Puller Group for nozzle removal. Nozzle and fuel line are removed and tested as an assembly. To remove nozzle and fuel line assembly proceed to step 6. 55 4. Loosen the valve adjusting screw locknuts ©). Turn adjusting screw @) counterclockwise until there is some clearance between the push rod end and the adjusting screw @). Remove six bolts @). 5. Remove rocker arm assembly (). 6. Thoroughly clean the area around each fuel line connection. Disconnect fuel line @) from adapter ©). 7. Disconnect injection nozzle line @) from adapter ©). Slide adapter © out of the cylinder head. 8. Remove clamp and the spacer that holds the fuel injection nozzle in place. Every 2400 Service Hours or Two Years Whicnever Occurs First NOTICE Never use force to remove the fuel injection nozzles. Turn and pull the fuel injection noz- zles straight out by hand. Never pry with a screwdriver or similar tool. Use 6V4061 Noz- zie Pulling Group for difficult to remove nozzles. 9. Remove tuel injection nozzles @) from the cylinder head. 10. Have fuel injection nozzles @) tested by an authorized Caterpillar engine dealer, To Install Injection Nozzles NOTICE Never install an injector that has been dropped without first testing it. Examine the tip to be sure it is not broken or cracked. Us- ing the Caterpillar 6V3020, 20X scope, provides a close examination of the nozzie tip and orifices. 56 ae fed ieereeres ori= ae Bi Paw p e ‘eee, GIR oSe. BGG hdd se eee * 1. install a new seal washer and carbon dam (@ with 6V4979 Carbon Seal Too! @ on fuel injection nozzle @). 2. Make sure the bore in the cylinder head and the fuel iniet fittings are clean. 3. Install new O-ring seals on adapter © and fuel injection nozzle @) Every 4000 Service Hours Generator Bearing Lubricate 1. Remove the cow! cover from the rear of the generator housing. 2. Remove the right side and lower grease pipe plugs. 3. install a grease fitting in the right side threaded grease pipe. 4. Lubricate all small frame generators with a grease gun using two (2) pumps of grease. Use Multipurpose-type Grease (MPG). NLGi No. 2 Grade is suitable for most temperatures. Use NLGI No. 1 or 0 Grade for extremely low temperatures. 59 5. Install the lower plug. Wipe off excess grease. 6. Remove the fitting from the right side grease pipe. 7. Start the engine and allow the grease to expand, 8. Stop the engine. Install the plug in the right side grease pipe and wipe off excess grease. 9. Install the cowl cover. Voltage Regulator and Generator Clean and Inspect 7 NCU Before working inside the generator, make sure that the starter motor can not be activat- ed by any automatic or manual signal. When the engine-generator is operating, volt- ages up to 600V are present in these areas near or 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 part of the body or any conductive materi- al. Loss of life or injury could result from electrical shock or injury from molten metal. An electrical shock can be received from the regulator 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. NOTICE Electronic components in the regulator can be damaged during generator operation if contact is made between the part and ground. 60 If moisture is allowed to remain in contact with an electrical winding, some of the moisture will eventually be absorbed. This will lower the resistance of the winding insulation. The insulation used on the windings of Caterpillar generators is moisture resistant, but constant exposure to moisture will gradually lower the insulation's resistance. Dirt can make the problem worse because it can hold the moisture in contact with the insulation, Salt (from sea air) can also make the problem much worse. This is because salt tends to absorb moisture from the air. When the salt and moisture combine, they make a good electrical conductor. Clean the voltage regulator and generator of dirt and debris. Use a brush to loosen accumulations of dirt and a vacuum system for removal. Use of compressed air is not recommended, because of moisture present in the form of condensate. Carbon tracking on insulators can be caused by dirt or loose connections. These carbon paths must be cleaned or the insulators replaced. Failure to correct a carbon tracking problem will eventually resuit in a short in the electrical circuit. Visually check for loose or broken wires and connections. Check the wires and connections on the regulator assembly. Check that all circuit boards are fully plugged in their sockets, Check all wires and connections in the generator. Make any necessary repairs to the wiring as required. Refer to the “Electric Set Generator Service Manual" for testing and adjusting or disassembly and assembly procedures. Space Heaters The SR4 generator can operate in high humidity conditions without problems. However, problems can occur when the generator is idle and the surrounding air is warmer than the generator. Moisture can form on the windings and result in poor performance and even result in damage to the windings. Whenever the generator is not in use, insure that the space heaters are in operation. An external source of either 115 or 230 (200 v at 50 Hz) volts A.C. is required to operate the space heaters. Space Heater Connection to External Source H1, H2, H3, H4. Terminal Strip Terminals ' usyac if 115 VAC source is available, connect both heaters in parallel across the source (L1-L2). If 230 VAC source is available, connect both heaters in series across the source {L1-L2). 61 Recommended Periodic Insulation Resistance Checks Use a megohmmeter to check generator winding insulation resistance periodically. The frequency of the megohmmeter test is determined by the generators environment and by previous megohmmeter test indications. Megohmmeter test every 6 months if the generator is installed in an enclosed area with relatively low humidity and minimal temperature variations. Megohmmeter test every 3 months if the generator is not protected from the elements by an enclosed area, Megohmmeter test every week and use space heaters if the generator is exposed to a sea water environment or if the surrounding conditions are very humid (relative humidity above 75%) or if a recent megohmmeter test treading was less than 3megohms. In applications where salt and high hunidity are present, space heaters must be operated whenever the generator is not operating under load. This is the only way to maintain megohmmeter test readings above 1 megohm Refer to the Testing and Adjusting section of the ‘Electric Set Generator Service Manual” for the proper procedure to test the windings. Preventive Maintenance For Standby Generator Set Engines To Be Performed By An Authorized Mechanic Item | Service Yearly: Before Starting the Engine Walk-Around Inspection Check the engine, radiator, and generator for debris, foreign objects, loose or broken fittings, guards and components. Repair as necessary. Cooling System Check for leaks. Add coolant conditioner (if required). Fuel System Drain water and sediment from tank. Change fuel filters. Air Cleaner Element Inspect; clean or replace. Governor Check and maintain oil level (if required). Engine Crankcase Check oil level. Maintain oil level between the add and full marks on the engine stopped side of the dipstick. Engine Crankcase Breather Clean. Valve Lash Check, adjust if necessary. Refer to the engine Service Manual for proper procedure and settings. Linkages Check and adjust all linkages, if necessary. Lubricate ail linkage fittings. Alarms and Shutdown Devices Check; test for proper operation. Batteries Check electrolyte level, clean terminals and connections. Engine Wipe down; ciean as needed. Generator NOTE: Refer to the generator Service Manual for information relating to use of the me- gohmmeter and low resistance readings. Lubricate bearing; vacuum clean and check wiring of the regulator, exciter and stator. Check generator windings with megohmmeter and record readings tor reference. Check operation of space heaters. Yearly: With Engine Running Start the Engine Check all gauges, oil pressure, fuel pressure, rpm (frequency), generat- ed voltage and engine jacket water temperature, for correct readings. Radiator Louvers Check for proper operation (able to open and close freely). Leaks and Noises Check for leaks and unusual noises. NOTE: Engine must be stopped before making necessary repairs. Load Test Load the engine to minimum of 30% of rated load. Operate at this level for minimum of two hours. Gauge Readings After approximately one hour record the readings of all gauges: oil pressure, fuel pressure, oil level, rpm (frequency), generated voltage, service meter, engine jacket water temperature, exhaust temperature (if equipped) and manifold vacuum (if equipped). Yearly: After Stopping the Engine Repair or Adjust Make any repairs or adjustments to the engine and generator set as necessary. Engine Crankcase Change oil; take sample for analysis. Change filters, cut old filter open and inspect for foreign material. Fuel Level Record the fuel tank level. Fill if below three-fourths full. Battery Charger Record charging amperage reading. Automatic Switches (iH Equipped) Check that all switches are in proper position for automatic start. 64 Preventive Maintenance For Standby Generator Set Engines To Be Performed By An Authorized Mechanic Item Service Every Three Years: Before Starting the Engine Before Starting Perform all Yearly Before Starting the Engine Preventive Maintenance procedures. Cooling System Drain, clean and flush the cooling system. Replace thermostai(s). Refitt with coolant solution and conditioner. Rubber Hoses and Belts It is recommended that all hoses and belts be replaced at this time to minimize downtime and additional repair cost of component failures caused by these items. Batteries Replace all batteries at this interval. Turbocharger inspect, repair or replace if necessary to minimize additional associated component faitures. Engine Perform a complete engine adjustment and tune-up. Every Three Years: With Eng ine Running Engine Running Same as all Yearly With Engine Running Preventive Maintenance proce- dures. Exhaust System Check for leaks. Repair or replace defective components with engine stopped. Every Three Years: After Stopping the Engine After Stopping Same as ali Yearly After Stopping the Engine Preventive Maintenance Procedures. 65 Troubleshooting Troubleshooting On the following pages there is a list of possible problems. To correct a problem, make reference to the CAUSE and CORRECTION. If problems are encountered, they should be corrected promptly to maintain engine operation. This list of problems, causes, and corrections, will only give an indication of where a possible problem can be, and what repairs may be needed, Remember that a problem fs not normally caused only by one part, but by the relation of one part with other parts. This list can not give all possible problems and corrections. The serviceman must find the problem and its source, then make the necessary repairs. Your Caterpillar dealer is equipped with the necessary tools and personnel to provide assistance when necessary. 66 Troubleshooting Index 1. Engine Will Not Turn When Start Switch Is On 2. Engine Will Not Start 3. Starting Motor Does Not Turn 4. Air Starting Motor Turns Slowly 5. Alternator Gives No Charge §. Alternator Charge Rate Is Not Regular 7. Alternator Has Noise 8. Misfiring Or Running Rough 9. Not Enough Power 10. Stall At Low RPM 11. Sudden Changes In RPM 12. Loud Combustion Noise 13. Valve Train Noise 14, Loud Vaive Train Noise 15. Too Much Valve Lash 16. Little Or No Valve Clearance 17. Valve Spring Lock Is Free 18. Noise in Engine 19. Too Much Vibration 20. Too Much White Or Blue Smoke 21, Oil At The Exhaust 22. Too Much Lubrication Oil Used 23. Too Much Black Or Gray Smoke 24, Fuel Consumption Too High 25, Low Oil Pressure 26. Coolant In Oil 27. Oil In Cooling System 28. Coolant Is Too Hot 29. Engine Has Early Wear 30. Exhaust Temperature Is Too High 6. Alternator Charge Rate Is Not Regular Cause Correction Loose drive beit for alternator. Make an adjustment to correct tension on the drive belt. Charging or ground return circuit or battery connections are damaged. inspect all cables and connections. Clean and tighten ali connections. Replace malfunctioning parts. Aiternator regulator malfunctions. Make an adjustment or replacement of alternator regulator. 7. Alternator Has Noise Cause Correction Drive belt for alternator is worn or cracked. Install a new drive belt for the alternator. Loose alternator drive pulley. Check groove in pulley for key that holds pulley in place. If groove is worn, install a new pulley. Tighten puiley nut. Drive belt and drive pulley for alternator are not in alignment. Make an adjustment to put drive belt and drive pulley in correct alignment. Worn alternator bearings. install new bearings in the alternator. 8. Misfiring Or Running Rough Cause Correction Fuel pressure is low. Make sure there is fuel in the fuel tank. Look for leaks or bad bends in the fuel line between fuel tank and fuel transfer pump. Look fer air in the fuel system, sticking, binding or damaged fue! control vaive. Check fuel pressure. The outlet pressure of the fuel transfer pump must be a minimum of 140 kPa (20 psi) at full load speed. If fuel pressure is lower than the above pressure, install a new fuel filter element. If fuel pressure is still low, check the fuel transfer pump. Air in fuel system. Find the air leak in the fuel system and correct it. If air is in the fuel system it will generally get in on the suction side of the fuel transfer pump. 69 8. Misfiring Or Running Rough (cont’d) Cause Correction Leak or break in fuel line between fuel manifold and cylinder head. Install a new fuel line, Wrong valve clearance. Make adjustment. Wrong fuel injection timing. Make adjustment to timing. 9. Not Enough Power Cause Correction Bad quality fuel. Remove the fuel from the fuel tank. Install a new fuel filter element, Put a good grade of clean fuel in the fuel tank. Fuel pressure is iow. Make sure there is fue! in the fuel tank. Look for leaks or bad bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system, sticking, binding or damaged fuel control valve. Check fuel pressure. The outlet pressure of the fuel transfer pump must be a minimum of 140 kPa (20 psi) at full load speed. lf fuel pressure is lower than the above pressure, install a new fuel filter element. If fuel pressure is still low, check the fuel transfer pump. Leaks in air inlet system Check the pressure in the air intake manifold, Look for restrictions in the air cleaner. Governor linkage. Make adjustment to get full travel of linkage. Install new parts for those that have damage. Wrong valve clearance. Make adjustment. Wrong fuel injection timing. Make adjustment to timing. Power setting too low. Make an adjustment of the power setting to specifications shown on the engine information plate. Turbocharger has carbon deposit. Inspect and repair turbocharger as necessary. 70 10. Stall At Low RPM Cause Correction Fuel pressure is low. Make sure there is fuel in the fuel tank. Look for leaks or bad bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system, sticking, binding or damaged fuel control valve. Check fuel pressure. The outlet pressure of the fuel transfer pump must be a minimum of 140 kPa (20 psi) at full load speed. if fuel pressure is lower than the above pressure, install a new fuel filter element. If fuel pressure is still low, check the fuel transfer pump. Idle rpm too tow. Make adjustment to governor so idle rpm is the same as given on the engine information plate. Engine accessories. Check engine accessories for damage and correct adjustment. If necessary, disconnect the accessories and test the engine. 11. Sudden Changes In RPM Cause Correction Failure of governor or fuel injection pump. Look for damaged or broken springs, linkage or other parts, Remove the governor. Check for free travel of the control linkages. Install new parts for those that have damage. 12, Loud Combustion Noise Cause Bad quality fuel. Correction Remove the fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank. Wrong fuel injection timing Make adjustment to timing. 71 18. Noise In Engine Cause Correction Failure of bearing for connecting rod. Inspect the bearing for the connecting rod and the bearing surface (journal) on the crankshaft. Instail new parts where necessary. Damaged gears. Install new parts where necessary. Defect in attachment. Repair or install new components. 19. Too Much Vibration Cause Correction Vibration damper or pulley is loose. Check vibration damper and pulley for damage. Tighten bolts or nuts. If vibration damper or pulley bolt holes have damage or wear, replace with new parts. Engine supports are loose, wrong, or have damage. Tighten all mounting bolts. Install new components if necessary. Driven equipment is not in alignment or is out of Check alignment and balance. Correct if needed. balance Misfiring or running rough. Make reference to ttem 8. 20. Too Much White Or Blue Smo! Cause ke Correction Too much lubrication oil in engine. Remove extra oil. Find where extra oil comes from. Put correct amount of oif in engine. Misfiring or running rough. Make reference to Item 8. Wrong fuel injection timing. Make adjustment to timing, Worn valve guides. Recondition cylinder head. Worn piston rings. Install new piston rings. Failure of turbocharger oil seal. Check inlet manifoid for oil and repair turbocharger if necessary. 74 21, Oil At The Exhaust Cause Correction Too much oil in the valve compartment. Be sure that there is a plug in the end of the rocker shaft. Worn valve guides. Reconditioning of the cylinder head is needed. Worn piston rings. Inspect and install new parts as needed. 22. Too Much Lubrication Oil Used Cause Correction Too much lubrication oil in engine. Remove extra oil. Find where extra cil comes from. Fill engine with oil to the FULL mark on the dipstick. Then, check oil evel while engine is running. Do not put too much oil in engine. Oil leaks. Find all oil leaks. Make repairs as needed. Check for dirty oil breather. Oil temperature is too high. Check operation of oil cooler. Install new parts if necessary. Clean the core of the oil cooler. Too much oil in the valve compartment. Be sure that there is a plug in the end of the rocker shaft. Worn vaive guides. Recondition the cylinder head. Worn piston rings. inspect and install new parts as needed. 23. Too Much Black Or Gray Smoke Cause Correction Not enough air for combustion. Check air cleaner for restrictions. Bad fuel injectors. Install new fuel injectors. Wrong fuel injection timing. Make adjustments of timing. 75 24. Fuel Consumption Too High Cause Fuel system leaks. Correction Replacement of parts is needed at points of leakage. Fuel and combustion noise (knock). Make reference to Item 8 and Item 9. Wrong fuel injection timing. Make adjustment to timing. Low tire pressures. Check tires periodically and maintain the correct inflation pressure. 25. Low Oil Pressure Cause Dirty oil filter or oil cooler. Correction Check the operation of bypass valve for the filter. Install new oil filter element if needed. Clean or instail new oil cooler core. Remove dirty oil from engine. Put clean oil in engine. Diesel fuel in lubrication oil. Find the place where diesel fuel gets into the lubrication oil. Make repairs as needed Drain the lubrication oil that has diesel fuel in it. Install a new oil filter element. Fill the engine with clean ail. Too much clearance between rocker arm shaft and rocker arms. Check lubrication in valve compartments. install new parts as necessary. Oil pump suction pipe has damage: Replace pipe. Pressure regulating valve does not close. Clean valve and housing. Install new parts as necessary. Oil pump has damage. Repair or repiace oil pump. Too much clearance between crankshaft and crankshaft bearings. Inspect the bearings and make replacement if necessary. Too much clearance between camshaft and camshaft bearings. Install new camshaft and camshaft bearings if necessary, Defect in oil pressure gauge. Install new gauge. 76