Caterpillar 3054C Generator Set

⚠ Personal injury can result from air pressure.

⚠ Do not use a high concentration of caustic cleaner to clean the core.

Tools: pressurized air, pressurized water, light bulb

1. Remove the core.
2. Turn the core upside-down to remove debris.
3. Direct pressurized air (less than 205 kPa) opposite the fan airflow, holding the nozzle about 6 mm from the fins.
4. Use pressurized water (less than 275 kPa) to soften mud; clean the core from both sides.
5. Back flush the core with a suitable cleaner.
6. Steam clean the core and flush the fins.
7. Wash the core with hot soapy water and rinse thoroughly.
8. Dry the core with compressed air in the reverse direction of normal flow.
9. Inspect the core for cleanliness and pressure test it; repair if necessary.
10. Install the core.
11. Start the engine and accelerate to high idle, then inspect with a light bulb.

⚠ Loose belts may slip enough to cause overheating.

Tools: 144-0235 Belt Tension Gauge

1. Inspect belts for wear and cracking; replace worn or damaged belts.
2. Replace belts in matched sets for multiple drive belt applications.
3. Install the 144-0235 Belt Tension Gauge at the center of the longest free length.
4. Correct tension is 535 N (120 lb); adjust the belt if tension is below 250 N (56 lb).
5. Loosen the alternator pivot bolt and the link bolt.
6. Move the alternator to increase or decrease belt tension.
7. Tighten the alternator pivot bolt and link bolt to 22 N·m (16 lb ft).

⚠ Batteries give off combustible gases which can explode.

⚠ The battery cover should be removed before any servicing is attempted.

1. Turn the key start switch to OFF. Remove the key and all electrical loads.
2. Turn OFF the battery charger and disconnect it.
3. Disconnect the NEGATIVE '-' cable from the NEGATIVE '-' battery terminal.
4. Disconnect the POSITIVE '+' cable from the POSITIVE '+' battery terminal.
5. Remove the used battery.
6. Install the new battery.
7. Connect the cable from the starting motor to the POSITIVE '+' battery terminal.
8. Connect the cable from the ground plane to the NEGATIVE '-' battery terminal.

⚠ All lead-acid batteries contain sulfuric acid which can burn the skin and clothing.

Tools: 245-5829 Coolant Battery Tester Refractometer, fine grade sandpaper

1. Remove the filler caps and maintain the electrolyte to the 'FULL' mark.
2. Add distilled water if necessary; do not use artificially softened water.
3. Check the electrolyte condition with the 245-5829 Coolant Battery Tester Refractometer.
4. Keep the batteries clean.
5. Clean the battery case with baking soda and water or ammonia and water.
6. Rinse the battery case with clean water.
7. Clean terminals and clamps with fine grade sandpaper until bright.
8. Coat clamps and terminals with 5N-5561 Silicone Lubricant, petroleum jelly, or MPGM.

⚠ Removing the battery cables with the cover in place may cause a battery explosion.

Tools: fine grade sandpaper

1. Turn the start switch OFF and the ignition switch OFF (if equipped). Remove the key and all electrical loads.
2. Disconnect the negative battery terminal so the cable cannot contact the terminal.
3. Remove the positive connection.
4. Clean all disconnected connections and battery terminals.
5. Clean terminals and clamps with fine sandpaper until bright.
6. Coat clamps and terminals with silicone lubricant or petroleum jelly.
7. Tape the cable connections to help prevent accidental starting.
8. Connect the positive connection before the negative connection.

⚠ Pressurized system: hot coolant can cause serious burns.

Tools: 9S-8140 Pressurizing Pump

1. Stop the engine, allow it to cool, loosen the filler cap slowly, and remove it.
2. Open the cooling system drain valve or remove a drain plug; allow the coolant to drain.
3. Flush the cooling system with clean water to remove debris.
4. Close the drain valve, clean and install the drain plugs.
5. Fill with clean water and Caterpillar Fast Acting Cooling System Cleaner (0.5 L per 15 L).
6. Start and run the engine at low idle for at least 30 minutes at 82 °C (180 °F).
7. Stop the engine, drain, and flush with clean water until all cleaning agent is gone.
8. Fill the cooling system with coolant/antifreeze.
9. Run the engine at low idle, increase to 1500 rpm, and run at high idle for one minute.
10. Check the coolant level within 13 mm (0.5 inch) below the bottom of the fill pipe.
11. Clean and inspect the filler cap gasket; pressure test with a 9S-8140 Pressurizing Pump.

⚠ Pressurized system: hot coolant can cause serious burns.

Tools: 9S-8140 Pressurizing Pump

1. Stop the engine, allow it to cool, loosen the filler cap slowly, and remove it.
2. Open the drain valve or remove the drain plugs and allow the coolant to drain.
3. Flush the cooling system with clean water and drain.
4. Close the drain valve, clean and install the drain plugs.
5. Fill with clean water, install the filler cap, and run until 49 to 66 °C (120 to 150 °F).
6. Stop the engine, drain, and flush with clean water.
7. Fill with Extended Life Coolant (ELC); do not install the filler cap.
8. Run the engine at low idle for 5 minutes, then at high idle for one minute.
9. Check the coolant level within 13 mm (0.5 inch) below the bottom of the fill pipe.
10. Clean the filler cap and inspect the gasket; pressure test with a 9S-8140 Pressurizing Pump.

⚠ Do NOT use conventional supplemental coolant additive (SCA) with Cat ELC.

1. Loosen the cooling system filler cap slowly to relieve pressure, then remove it.
2. Drain enough coolant to add the Cat ELC Extender, if necessary.
3. Add Cat ELC Extender according to the engine's cooling system capacity.
4. Clean the filler cap, inspect the gaskets, replace the cap if damaged, and install it.

⚠ Pressurized system: hot coolant can cause serious burns.

1. Check the coolant level when the engine is stopped and cool.
2. Observe the coolant level in the coolant recovery tank; maintain to the 'COLD FULL' mark.
3. Loosen the filler cap slowly to relieve pressure, then remove it.
4. Pour the correct coolant mixture into the tank; do not fill above the 'COLD FULL' mark.
5. Clean the filler cap and receptacle, reinstall the cap, and inspect for leaks.

⚠ Cooling system coolant additive contains alkali; avoid contact with skin and eyes.

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

1. Test the SCA concentration with the 8T-5296 or 4C-9301 Coolant Conditioner Test Kit.
2. Do not exceed six percent SCA concentration for coolant and SCA.
3. Do not exceed eight percent SCA concentration for water and SCA.
4. Slowly loosen the filler cap to relieve pressure, then remove it.
5. Drain some coolant to allow space for the extra SCA.
6. Add the proper amount of SCA.
7. Clean the filler cap, inspect gaskets, replace if damaged, and install.

⚠ If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage.

1. Replace the water temperature regulator before it fails as preventive maintenance.
2. Drain coolant to a level below the water temperature regulator housing if only regulators are replaced.
3. Refer to the Disassembly and Assembly Manual for removal and installation.
4. Ensure the new regulator is installed in the original position with the vent hole open.
5. Do not use liquid gasket material on the gasket or cylinder head surface.

⚠ Never run the engine without an air cleaner element installed.

⚠ Never service the air cleaner element with the engine running.

Tools: tape, clean dry cloth

1. Remove the cover and the primary air cleaner element.
2. Remove and discard the secondary element for every three cleanings of the primary element.
3. Cover the turbocharger air inlet with tape to keep dirt out.
4. Clean the inside of the air cleaner cover and body with a clean, dry cloth.
5. Remove the tape and install the secondary element and a new or cleaned primary element.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.