XQ400 Power Module Caterpillar

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance.

Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

When Required

Air Inlet Filter - Inspect/Clean/Test
Battery - Recycle
Battery - Replace
Circuit Breakers - Reset
Coolant - Change
Engine - Clean
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Generator - Dry
Generator Bearing - Lubricate
Generator Set - Test
Generator Set Alignment - Check
Generator Winding - Test
Heat Exchanger - Inspect
Ignition System Timing - Check/Adjust
Maintenance Recommendations
Stator Winding Temperature - Test
Varistor - Check

Daily

Air Prelube Pump Lubricator Oil Level - Check
Air Tank Moisture and Sediment - Drain
Control Panel - Inspect/Test
Coolant Level - Check
Electrical Connections - Check
Engine Air Cleaner Service Indicator - Inspect
Engine Air Precleaner - Check/Clean
Engine Oil Level - Check
Fuel Filter Differential Pressure - Check
Generator - Inspect
Generator Bearing Temperature - Test/Record
Generator Load - Check
Power Factor - Check
Voltage and Frequency - Check
Walk-Around Inspection

Every 170 400 L (45 000 US gal) of Fuel or 3000 Service Hours

Heat Exchanger - Inspect

Every 8000 Service Hours

Catalytic Converter Substrate - Replace
Exhaust Bypass - Inspect
Gas Pressure Regulator - Test
Gas Pressure Regulator - Test
Ignition System Transformer Resistance - Test
Rotating Rectifier - Check
Turbocharger - Inspect

Between 8000 and 12 000 Service Hours

Overhaul (Top End)

Between 12 000 and 22 000 Service Hours

Valve Stem Projection - Measure/Record

Between 18 000 and 24 000 Service Hours

Overhaul (Major)
Overhaul Considerations

Every Week

Automatic Start/Stop - Inspect
Battery Charger - Check
Generator Lead - Check
Jacket Water Heater - Check
Space Heater - Test
Standby Generator Set Maintenance Recommendations

Every 250 Service Hours

Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Engine Oil Sample - Obtain

Every 750 Service Hours

Aftercooler Core - Inspect/Clean/Test
Battery Electrolyte Level - Check
Belts - Inspect/Adjust/Replace
Coolant Sample (Level 1) - Obtain
Crankshaft Vibration Damper - Inspect
Engine Crankcase Breather - Clean
Engine Oil and Filter - Change
Engine Valve Rotators - Inspect
Fan Drive Bearing - Lubricate
Gas Pressure Regulator Condensation - Drain
Hoses and Clamps - Inspect/Replace
Spark Plugs - Inspect/Adjust/Replace

Initial 750 Service Hours

Valve Stem Projection - Measure/Record

Every 750 Service Hours Before Initial 3000 Hours

Carburetor Air/Fuel Ratio - Check/Adjust

Every 1500 Service Hours

Crankcase Blowby - Test/Record
Cylinder Pressure - Test/Record
Engine Protective Devices - Check
Engine Speed/Timing Sensor - Clean/Inspect
Engine Speed/Timing Sensor - Clean/Inspect
Engine Valve Lash - Check
Exhaust Piping - Check
Valve Stem Projection - Measure/Record

Every 1500 Service Hours After Initial 3000 Hours

Carburetor Air/Fuel Ratio - Check/Adjust

Every Year

Catalytic Converter Pressure - Test
Catalytic Converter Substrate - Inspect
Catalytic Converter Temperature - Test
Engine Mounts - Inspect
Generator Winding Insulation - Test
Varistor - Check

Every 3000 Service Hours

Air Prelube Pump Lubricator Bowl - Clean
Alternator - Inspect
Coolant Sample (Level 2) - Obtain
Coolant Temperature Regulator - Replace
Driven Equipment - Check
Engine Performance - Test
Generator Set Vibration - Test/Record
Inlet Air System - Check
Starting Motor - Inspect
Stator Lead - Check
Water Pump - Inspect

Every 3000 Service Hours or 3 Years

Starting Motor - Inspect

Commissioning

Valve Stem Projection - Measure/Record