Break-In Programs for Caterpillar Generators

I actually am friends with quite a few techs who work on this sort of thing. I do understand the difficulty of convincing your boss. But I wouldn't touch it. They are very sensitive and if not repaired and calibrated within the most minute specifications, the gen and everything it works with could take a proverbial dumb. I would call a CAT tech, if I were you.

A VERY good answer. The injectors and injection pump should have been serviced (cleaned and calibrated by a qualified shop) hopefully. These are very robust engines provided they are properly operated. Gradual loading as described is strongly recommended to allow new wearing surfaces to smooth out and bed in. Modern manufacturing produces much finer tolerances and better finish on machined surfaces than that of 10 years ago, so 'break-in' is not nearly as traumatic.

Operating the engines at relatively high power loading as recommended is important for long life of the pistons and piston rings. The higher pressures in the cylinder reduces back and forth cycling of the ring in its groove and facilitates long life.

Keeping intake air extremely clean, using good fuel, good oil and good coolant, and changing filters and oil when needed are critical to achieving long life. A single teaspoon of airborne dust ingested over an 8 hour period will result in a completely worn out engine by the end of the eight hours.

Thank you, people for the contributions. The guest above and Keith Bowers have given me much of the information I sought. I shall just keep in mind all the contributions.

Why are the workshop manuals so expensive? We don't have that many dealers in Afghanistan. We'd have to fly in their techs every time we thought something needed attention. We use OEM parts, though so no worry on that side.

Thank you, people.

I am the guest from about. FYI, I had this problem in Iraq. If and when you derate your gens make sure that the reason that you are derating has not already be engineered by the OEM. Example If you are derating your gens because of fuel, such as JP8, make sure that the OEM has not already acounted for JP8 usage and allows for the use of that fuel with no derate. I had a problem letting people know that they do not need to derate newer cummins engines for JP8 and that the cooling systems for gens were rated at a 90 degree C ambient temp. CAT engines hate to be run at anything less than 65% load and even that is pushing it. Load them up, your fuel/maintenance cost will go down and your engine life will go up. Win win for all.

Just crank them over 10 or 12 times to get oil up in the engine before letting it have fuel.

I work for a Cat dealer. There really isn't a break in period for the Cat engines. The cylinder liners are honed using the "Platue" method. Most automotive manufacturers are using that method also. Platue honing is a two step process that gives the rings more surface area to ride on. The rings are lapped before they are installed. With the older one step method the rings would have to rub the peaks off of the crosshatch to break-in. Platue honing "platues" the peaks of the crosshatch so there isn't any material that has to be removed for break-in. The engines can be loaded to rated load after it reaches operating temp.