Caterpillar C2.2 Generator Set

⚠ Ensure the engine cannot be started while this maintenance is performed.

⚠ Hot engine components can cause burns.

1. Ensure the engine cannot be started and is stopped.
2. Measure the inlet valve lash; specification 0.20 mm.
3. Measure the exhaust valve lash; specification 0.20 mm.
4. Adjust valves per Systems Operation, Testing and Adjusting sequence.

1. If the engine is equipped with fan guards, remove the fan guards.
2. Loosen bolt (1) and bolt (2) on the adjuster link.
3. Loosen nut (4) and bolt (5).
4. Push the alternator toward the engine and remove the belt.
5. Position the new belt onto the alternator, water pump and crankshaft pulleys.
6. Slide the alternator away from the engine to tighten the belt.
7. Tighten bolt (1) and bolt (2) to a torque of 25 N·m.
8. Tighten nut (4) and bolt (5) to a torque of 25 N·m.
9. Install the fan guards.
10. Check the belt tension again after 20 hours of engine operation.

⚠ Batteries give off combustible gases which can explode.

1. Switch the engine to the OFF position and remove all electrical loads.
2. Turn off and disconnect any battery chargers.
3. Disconnect the NEGATIVE '-' cable from the battery terminal.
4. Disconnect the POSITIVE '+' cable from the battery terminal.
5. Remove the used battery and recycle it.
6. Install the new battery.
7. Connect the cable from the starting motor to the POSITIVE '+' terminal.
8. Connect the NEGATIVE '-' cable to the NEGATIVE '-' terminal.

⚠ Pressurized System: Hot coolant can cause serious burns.

1. Stop the engine and allow it to cool; loosen the filler cap slowly to relieve pressure.
2. Remove the engine drain plug and the radiator drain plug; drain the coolant.
3. Flush the cooling system with clean water to remove debris.
4. Close the drain valve and install the drain plugs.
5. Fill the cooling system with clean water and install the filler cap.
6. Run the engine at low idle until temperature reaches 49 °C to 66 °C.
7. Stop the engine and allow it to cool; drain and flush with clean water.
8. Fill the cooling system with Extended Life Coolant (ELC).
9. Run the engine at high idle for 1 minute to purge air; stop the engine.
10. Maintain coolant at the maximum mark and install the filler cap.

⚠ Hot oil and hot components can cause personal injury.

1. Ensure dirt cannot enter the breather assembly and place a container under it.
2. Remove clip (3) and hose (4) from cap (2); remove cap (2) from body (1).
3. Remove filter element (5) and O ring seal (6); discard.
4. Install a new O ring seal (6) and a new filter element (5) into cap (2).
5. Install the cap assembly into the main body and tighten to 10 N·m.
6. Install hose (4) and clip (3); clean away any split fluid.

⚠ Hot oil and hot components can cause personal injury.

⚠ Do not fill the oil filters with oil before installing them.

Tools: 1U-8760 Chain Wrench, 175-7546 Oil Filter Cutter Gp

1. Drain the crankcase with the engine stopped and the oil warm.
2. Remove the oil filter with a 1U-8760 Chain Wrench.
3. Cut the oil filter open with a 175-7546 Oil Filter Cutter Gp to inspect debris.
4. Clean the sealing surface of the cylinder block.
5. Apply clean engine oil to the new oil filter seal.
6. Install the oil filter and tighten by hand per the filter instructions.
7. Fill the crankcase with the correct amount of oil.
8. Crank the engine with the fuel OFF to fill the oil filters.
9. Start the engine and run at LOW IDLE for 2 minutes.
10. Stop the engine and allow oil to drain back for a minimum of 10 minutes.
11. Check the oil level between the ADD and FULL marks.

⚠ Do not loosen the high-pressure fuel lines to purge air.

1. Ensure the fuel tank is full and any fuel valve is in the ON position.
2. For gravity feed systems, loosen the vent screw and allow fuel to flow.
3. When air-free fuel comes from the vent screw, tighten it by hand.
4. Loosen the vent screw on the secondary fuel filter.
5. Turn the keyswitch to RUN to operate the electric priming pump.
6. When air-free fuel comes from the vent screw, tighten it to 24 N·m.
7. Operate the electric priming pump for 2 minutes.
8. Turn the keyswitch to the OFF position.
9. Crank the engine and run at low idle for a minimum of 5 minutes.
10. Ensure the fuel system is free from leaks.

⚠ Do not use aerosol types of starting aids such as ether.

⚠ Do not start the engine under load.

1. Disengage any equipment that is driven by the engine.
2. Turn the keyswitch to RUN and wait until the glow plug lamp extinguishes.
3. Turn the keyswitch to START; the starter motor cranks the engine.
4. If the engine fails to start within 30 seconds, wait two minutes before retrying.
5. Allow the keyswitch to return to RUN after the engine starts.
6. Allow constant speed engines to reach operating speed with no load; run 2 minutes before load.

⚠ Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear.

1. Remove the load from the engine and reduce the engine speed to low idle.
2. Allow the engine to idle for 5 minutes to cool the engine.
3. Turn the ignition keyswitch to the OFF position.

⚠ Do not use ECM or ECM sensors or their grounding points for grounding the welder.

1. Stop the engine and remove the electrical power from the ECM.
2. Ensure that the fuel supply to the engine is turned off.
3. Disconnect the negative battery cable; open the battery disconnect switch if installed.
4. Disconnect all electronic components from the wiring harnesses.
5. Connect the welder ground clamp directly to the component being welded, close to the weld.
6. Protect the wiring harnesses from welding debris and spatter.
7. Use standard welding procedures to weld the materials together.