Caterpillar 3044C Generator Set

⚠ Only qualified service personnel should perform.

⚠ Hot engine components can cause burns.

1. Initial valve lash adjustment recommended at first scheduled oil change.
2. Ensure engine cannot be started. Do not use starting motor to turn flywheel.
3. Allow engine to cool before measuring/adjusting valve lash.
4. Ensure engine is stopped before measuring.
5. Refer to Service Manual for complete procedure.

⚠ If belts too loose, vibration causes wear and slipping may cause overheating.

Tools: 45 N force gauge

1. Inspect belts for wear and cracking. Replace worn or damaged belts.
2. For multiple drive belts, replace in matched sets.
3. Check belt tension: apply 45 N force midway between pulleys; deflection should be 10 mm.
4. Adjust: loosen mounting bolts (1).
5. Move alternator (4) to increase or decrease tension.
6. Tighten mounting bolts (1).
7. Replace: refer to Disassembly and Assembly, V-Belts - Remove and Install.
8. After new belts, check tension again after 20 hours.

⚠ Batteries give off combustible gases which can explode. Ensure proper ventilation. Do not smoke.

⚠ Do not remove battery cables or batteries with battery cover in place.

1. Switch engine OFF. Remove all electrical loads.
2. Turn off and disconnect any battery chargers.
3. Disconnect NEGATIVE "-" cable from NEGATIVE battery terminal.
4. Disconnect POSITIVE "+" cable from POSITIVE battery terminal.
5. Remove used battery.
6. Install new battery.
7. Ensure engine start switch is OFF before connecting cables.
8. Connect POSITIVE "+" cable to POSITIVE terminal.
9. Connect NEGATIVE "-" cable to NEGATIVE terminal.

⚠ Do not remove with battery cover in place.

1. Turn start switch OFF. Turn ignition switch OFF and remove key.
2. Disconnect negative battery terminal at battery that goes to start switch. Ensure cable cannot contact terminal.
3. When four 12 volt batteries are involved, disconnect negative side of two batteries.
4. Tape leads to prevent accidental starting.
5. Proceed with repairs. Reverse steps to reconnect.

⚠ Pressurized System: Hot coolant can cause serious burns.

Tools: 9S-8140 Pressurizing Pump

1. Drain: stop engine, loosen filler cap, remove cap. Open drain cock or remove drain plug on engine and radiator. Allow coolant to drain.
2. Flush: flush with clean water. Close drain. Fill with mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner (0.5 L per 15 L capacity). Install cap.
3. Run engine at low idle for at least 30 minutes. Coolant temperature at least 82 °C.
4. Stop engine, drain, flush with clean water.
5. Fill: close drain. Fill with coolant/antifreeze. Do not install cap.
6. Start and run engine at low idle then high idle for one minute to purge air. Stop engine.
7. Check coolant level within 13 mm below bottom of filler pipe.
8. Inspect filler cap gasket; pressure test with 9S-8140 if not damaged. Install cap.
9. Start engine and inspect for leaks.

⚠ Pressurized System: Hot coolant can cause serious burns.

Tools: 9S-8140 Pressurizing Pump

1. Drain: stop engine, loosen filler cap, remove cap. Open drain cock or remove drain plug on engine and radiator. Allow coolant to drain.
2. Flush: flush with clean water. Close drain. Fill with clean water. Install cap.
3. Run engine at low idle until temperature reaches 49 to 66 °C.
4. Stop engine, drain, flush with clean water.
5. Fill: close drain. Fill with Extended Life Coolant (ELC). Do not install cap.
6. Start and run engine at low idle then high idle for one minute to purge air. Stop engine.
7. Check coolant level within 13 mm below bottom of filler pipe.
8. Inspect filler cap gasket; pressure test with 9S-8140 if not damaged. Install cap.
9. Start engine and inspect for leaks.

⚠ Cooling system coolant additive contains alkali.

1. Loosen filler cap slowly to relieve pressure. Remove cap.
2. Drain enough coolant to add Cat ELC Extender.
3. Add Cat ELC Extender according to cooling system capacity.
4. Clean filler cap. Inspect gaskets. Replace if damaged. Install cap.

⚠ Pressurized System: Hot coolant can cause serious burns.

1. Check coolant level when engine stopped and cool.
2. With recovery tank: observe level, maintain to COLD FULL mark.
3. Loosen filler cap, remove. Pour proper coolant mixture into tank. Do not fill above COLD FULL mark.
4. Clean filler cap and receptacle. Reinstall and inspect for leaks.
5. Without recovery tank: remove filler cap slowly. Maintain coolant level within 13 mm of bottom of filler pipe.
6. Clean filler cap, check gaskets, replace if damaged. Reinstall. Inspect for leaks.

⚠ Always use designated pump for oil sampling and separate for coolant sampling.

1. Complete label before sampling.
2. Keep unused bottles in plastic bags.
3. Obtain sample directly from coolant sample port. Do not sample from expansion bottles or drains.
4. Keep lids on empty bottles until ready.
5. Place sample in mailing tube immediately.
6. Submit for Level 1 analysis.

1. Refer to Level 1 guidelines for proper sampling.
2. Submit sample for Level 2 analysis.

⚠ Cooling system coolant additive contains alkali.

Tools: 8T-5296 Coolant Conditioner Test Kit, 4C-9301 Coolant Conditioner Test Kit

1. Test SCA concentration using 8T-5296 or 4C-9301 Coolant Conditioner Test Kit.
2. Do not exceed 6% SCA with coolant or 8% with water.
3. To add: slowly loosen filler cap, remove.
4. Drain some coolant to make space.
5. Add proper amount of SCA.
6. Clean filler cap, inspect gaskets, replace if damaged. Install cap.

⚠ Failure to replace on regular schedule could cause severe engine damage.

⚠ If installed incorrectly, engine may overheat causing cylinder head damage.

1. Replace before failure as preventive maintenance.
2. Drain coolant to below regulator housing.
3. Refer to Service Manual for replacement procedure.
4. Ensure new regulator installed in original position and vent hole open.
5. Do not use liquid gasket material on gasket or cylinder head surface.