C32 Generator Set Caterpillar

Overhaul Considerations

Usage:

C32 K7C

Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval.

The need for an overhaul is indicated by increased fuel consumption and by reduced power.

The following factors are important when a decision is being made on the proper time for an engine overhaul:

The need for preventive maintenance
The quality of the fuel that is being used
The operating conditions
The results of the S·O·S analysis

Oil Consumption as an Overhaul Indicator

Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.

Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.

The oil consumption rate (brake-specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake-specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine.

When engine oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled. There may be a corresponding increase in blowby and a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the best value for the following reasons:

Costly unplanned downtime can be avoided.
Many original parts can be reused according to the standards for reusable parts.
The engine service life can be extended without the risk of a major catastrophe due to engine failure.
The best cost/value relationship per hour of extended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the engine must be removed, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired.

The overhaul cost should be between 40 and 50 percent of the cost of a new engine with a similar exchange core.

This lower cost can be attributed to three aspects:

Specially designed Caterpillar engine features
Caterpillar dealer exchange components
Caterpillar Inc. remanufactured exchange components

Overhaul Recommendation

To minimize downtime, a scheduled engine overhaul by your Caterpillar dealer is recommended. This scheduled overhaul will provide you with the best cost/value relationship.

Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life.

If an overhaul is performed without overhaul service from your Caterpillar dealer, be aware of the following maintenance recommendations.

Unit Fuel Injector

Clean the fuel injector body and replace the O-rings. Replace the O-rings and the gasket on the injector sleeve. Clean the area around the injector seating in the injector sleeve. Refer to the Service Manual for the complete procedure, or consult with your Caterpillar dealer for assistance.

Rebuild or Exchange

Cylinder Head Assembly, Connecting Rods, Pistons, Cylinder Liners, Turbocharger, Cylinder Packs, Oil Pump, and Fuel Transfer Pump

These components should be inspected according to the instructions that are found in various Caterpillar reusability publications. The Special Publication, SEBF8029 lists the reusability publications that are needed for inspecting the engine parts.

If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline, the parts should be reused.

Parts that are not within the established inspection specifications should be dealt with in one of the following manners:

Salvaging
Repairing
Replacing

Using out-of-spec parts can result in the following problems:

Unscheduled downtime
Costly repairs
Damage to other engine parts
Reduced engine efficiency
Increased fuel consumption

Reduced engine efficiency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Piston Rings, Crankshaft Bearings, Valve Rotators, and Crankshaft Seals

The following components may not last until the second overhaul.

Thrust bearings
Main bearings
Rod bearings
Valve rotators
Crankshaft seals
Nonmetallic fuel lines (if equipped)

Caterpillar Inc. recommends the installation of new parts at each overhaul period.

Inspect these parts while the engine is disassembled for an overhaul.

Inspect the crankshaft for any of the following conditions:

Deflection
Damage to the journals
Bearing material that has seized to the journals

Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:

Rod bearing
Main bearings

Note: If the crankshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the crankshaft.

Inspect the camshaft for damage to the journals and to the lobes.

Note: If the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the camshaft.

Inspect the following components for signs of wear or for signs of scuffing:

Camshaft bearings
Camshaft followers

Caterpillar Inc. recommends replacing the crankshaft vibration damper.

Oil Cooler Core and Aftercooler Core

During an overhaul, the removal of the oil cooler core and the aftercooler core is recommended. The oil cooler core and the aftercooler core should be cleaned and pressure tested.

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NOTICE

Do not use caustic cleaners to clean the core. Caustic cleaners can attack the internal metals of the core and cause leakage.

Note: Use this cleaning procedure to clean the oil cooler core and the aftercooler core.

Remove the oil cooler core and the aftercooler core.
Remove any debris from the oil cooler core and the aftercooler core. To remove debris from the oil cooler core, turn the oil cooler core onto one end. To remove debris from the aftercooler core, turn the aftercooler core upside-down.
Flush the oil cooler core and the aftercooler core internally with cleaner in order to loosen foreign substances. Flushing will also help to remove oil from the oil cooler core and the aftercooler core.
Note: The use of Hydrosolv Liquid Cleaners is recommended. Table 1 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer.
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Table 1
Hydrosolv Liquid Cleaners⁽¹⁾

Part Number Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Hydrosolv 100 19 L (5 US gallon)

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⁽¹⁾ Use a 2 to 5 percent concentration of the cleaner at temperatures up to 93°C (200°F). Refer to Application Guide, NEHS0526 or consult your Caterpillar dealer for more information.
Use steam to clean the oil cooler core and the aftercooler core. This cleaning removes any remaining residue from the cleaner. Flush the fins of the oil cooler core and the aftercooler core. Remove any other trapped debris.

Table 1
Hydrosolv Liquid Cleaners⁽¹⁾
Part Number	Description	Size
1U-5490	Hydrosolv 4165	19 L (5 US gallon)
174-6854	Hydrosolv 100	19 L (5 US gallon)

Wash the oil cooler core and the aftercooler core with hot, soapy water. Rinse the oil cooler core and the aftercooler core thoroughly with clean water.

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Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Dry the oil cooler core and the aftercooler core with compressed air. Direct the air in the reverse direction of the normal flow.
Inspect the components in order to ensure cleanliness. The oil cooler core and the aftercooler core should be pressure tested. Repair the oil cooler core and the aftercooler core, if necessary. Install the oil cooler core and the aftercooler core.

For more information about cleaning the cores, consult your Caterpillar dealer.

Obtain Coolant Analysis

The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits or with S·O·S Coolant Analysis (Level 1). Further coolant analysis is recommended when the engine is overhauled.

A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis.

Caterpillar Inc. recommends an S·O·S Coolant Analysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. An S·O·S Coolant Analysis (Level 2) provides the following information: