BOLT 8T0644 - Caterpillar

The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start.Place the engine control switch in the "OFF" position. Attach "DO NOT OPERATE" tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Generator Sets with Coolant Recovery Tanks
Note: The coolant will expand as the coolant heats up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool, the coolant will return to the engine.
Check the coolant level when the engine is stopped and cool.
Observe the coolant level in the coolant recovery tank. Maintain the coolant level at the "COLD" mark.
Pour the proper coolant mixture into the coolant recovery tank. Refer to the Operation and Maintenance Manual, "Cooling System Specifications" for information on the correct mixture and type of coolant. Refer to the Operation and Maintenance Manual, "Refill Capacities" for the cooling system capacity. Do not fill the coolant recovery tank above "COLD FULL" mark.Generator Sets without Coolant Recovery Tanks
Note: The coolant will expand as the coolant heats up during normal engine operation. The additional volume will be forced out of the heat exchanger during engine operation.
Check the coolant level when the engine is stopped and cool.
Loosen filler cap on the heat exchanger slowly in order to relieve any pressure. Remove the filler cap.
Maintain the coolant level within 13 mm (0.5 inch) of the top of the heat exchanger.
Pour the proper coolant mixture into the heat exchanger, if necessary. Refer to the Operation and Maintenance Manual, "Cooling System Specifications" for information on the correct mixture and type of coolant. Refer to the Operation and Maintenance Manual, "Refill Capacities" for the cooling system capacity.
Clean filler cap and the filler neck. Reinstall the filler cap.