SEBU8468-06-00-ALL - 3500 Manual O&M

SEBU8468-06
February 2013
Operation and
Maintenance
Manual
3500 Generator Sets
YAM 1-Up (3512
Generator Set)
YAN 1-Up (3512
Generator Set)
YAP 1-Up (3516
Generator Set)
YAR 1-Up (3516
Generator Set)
YAT 1-Up (3516
Generator Set)
YBT 1-Up (3516
Generator Set)
YAW 1-Up (3516
Generator Set)
YBW 1-Up (3516
Generator Set)
YAY 1-Up (3512
Generator Set)
YAZ 1-Up (3512
Generator Set)
SAFETY.CAT.COM
i05086812
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury
or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8468 3
Table of Contents
Table of Contents Generator Operation.................... ................... 67
Foreword.............................. ............................. 4 Cold Weather Operation................. ................ 76
Engine Stopping ....................... ...................... 78

Safety Section
Safety Messages....................... ....................... 5

Maintenance Section
Refill Capacities....................... ....................... 81

General Hazard Information .............. ..............11
Burn Prevention....................... ....................... 14 Maintenance Recommendations.......... .......... 90
Fire Prevention and Explosion Prevention ... .. 14 Maintenance Interval Schedule (Prime) ..... .... 97
Crushing Prevention and Cutting Prevention . 16 Maintenance Interval Schedule (Standby)... ... 99
Mounting and Dismounting............... .............. 16 Maintenance Interval Schedule (High

Displacement)....................... ...................... 101
Sound Information ..................... ..................... 17
Warranty Section
Sound Information ..................... ..................... 17
Warranty Information .................. .................. 179
Before Starting Engine ................. .................. 18
Reference Information Section
Engine Starting ........................ ....................... 18
Engine Ratings ....................... ...................... 180
Engine Stopping ....................... ...................... 19
Customer Service ..................... .................... 182
Electrical System ...................... ...................... 19
Reference Materials .................. ................... 184
Generator Isolating for Maintenance ....... ....... 19
Index Section
Product Information Section
Index............................... .............................. 194
General Information.................... .................... 21
Product Identification Information.......... ......... 24
Operation Section
Lifting and Storage..................... ..................... 33
Installation ........................... ........................... 35
Features and Controls .................. .................. 37
Engine Diagnostics..................... .................... 52
Engine Starting ........................ ....................... 61
Engine Operation...................... ...................... 66

4 SEBU8468
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This manual frequent lubrication and maintenance than is
should be stored in or near the engine area in a specified in the Maintenance Interval Schedule may
literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing Maintenance Intervals
improvement and advancement of product design
may have caused changes to your engine which are Perform maintenance on items at multiples of the
not included in this manual. Whenever a question original requirement. Each level and/or individual
arises regarding your engine, or this manual, please items in each level should be shifted ahead or back
consult with your Cat dealer for the latest available depending upon your specific maintenance practices,
information. operation and application. We recommend that the
maintenance schedules be reproduced and displayed
Safety near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
This safety section lists basic safety precautions. In as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, Maintenance Records for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more Major engine overhaul details are not covered in the
efficiently and economically. Skill and techniques Operation and Maintenance Manual except for the
develop as the operator gains knowledge of the interval and the maintenance items in that interval.
engine and its capabilities. Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers a
The operation section is a reference for operators. variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.
Maintenance California Proposition 65 Warning
The maintenance section is a guide to engine care. Diesel engine exhaust and some of its constituents
The illustrated, step-by-step instructions are grouped are known to the State of California to cause cancer,
by fuel consumption, service hours and/or calendar birth defects, and other reproductive harm.
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that Battery posts, terminals and related accessories
follow. contain lead and lead compounds. Wash hands after
Use fuel consumption or service hours to determine handling.
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
SEBU8468 5
Safety Section
Safety Messages
Safety Section
i03308796
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all safety messages.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off of
the engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
Illustration 1 g01689256
View of the right side of a typical Caterpillar 3500 or 3500BGenerator Set
6 SEBU8468
Safety Section
Safety Messages
View of the left side of a typical Caterpillar 3500 or 3500BGenerator Set
SEBU8468 7
Safety Section
Safety Messages
1 Universal Warning
WARNING! Shock/Electrocution Hazard! Read
and understand the instructions and warnings in
the Operation and Maintenance Manual. Failure to
follow the instructions or heed the warnings could
cause serious injury or death.
3 Electrocution
One safety message is located on the control panel.
Do not operate or work on this engine or genera-

tor set unless you have read and understand the
instructions and warnings in the Operation and
Maintenance Manuals. Illustration 5 g01392482
Failure to follow the warnings and instructions One safety message is located on the rear of the
could result in injury or death. Contact any Cater- terminal box. One safety message is located on each
pillar dealer for replacement manuals. Proper side of the terminal box.
care is your responsibility.
2 Shock
Do not connect the generator to a utility electrical
distribution system unless it is isolated from the
system. Electrical feedback into the distribution
system can occur and could cause personal
injury or death.
Open and secure the main distribution switch, or
if the connection is permanent, install a double
throw switch to prevent electrical feedback. Some
generators are specifically approved by a utility to
run in parallel with the distribution system and
isolation may not be required. Always check with
your utility for the applicable circumstances.
One safety message is located on the control panel.

One safety message may be located on the oil cooler
and one safety message may be located on the left
side of the engine.
8 SEBU8468
Safety Section
Safety Messages
4 Auto Start
Crushing Hazard! Improper lifting could cause
serious injury or death. Follow the lifting instruc-
tions in the Operation and Maintenance Manual
for safe lifting procedures.
6 Hot Surface
One safety message is located on the rear of the

terminal box. One safety message is located on each
side of the terminal box.
When the engine is in the AUTOMATIC mode, the

engine can start at any moment. To avoid person-
al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode.
5 Crushing
One safety message is located on the oil cooler. One

safety message is located on the left side of the
crankcase cover. One safety message is located on
each side of the barrel of the generator. One safety
message is located on each side of the radiator.
Hot parts or hot components can cause burns or

personal injury. Do not allow hot parts or compo-
nents to contact your skin. Use protective cloth-
ing or protective equipment to protect your skin.
One safety message is located on each side of the

terminal box.
SEBU8468 9
Safety Section
Safety Messages
7 Vapor Explosion (Oil Filter) 9 Canadian Standards Association
Illustration 9 g01407639 Illustration 11 g01667111
One safety message is located on each side of the If applicable, this safety message is located on the
duplex oil filter. right side of the barrel of the generator.
Warning: Vapor Explosion. May cause serious in- Separate protection and control must be provided
jury or death. Read the Operation and Mainte- in accordance with the Canadian Electrical Code,
nance Manual before conducting any part 1.
maintenance on the duplex oil filter.
10 Lifting the Product (Not

8 Vapor Explosion (Fuel Filter) Including the Radiator)

duplex fuel filter. terminal box.
Warning: Vapor Explosion. Could cause serious

injury or death. Read the Operation and Mainte-
nance Manual before conducting any mainte-
nance on the duplex fuel filter.
10 SEBU8468
Safety Section
Safety Messages
12 Hot Fluid Under Pressure

Before lifting the product, read this Operation and
Maintenance Manual, Product Lifting in the Op-
eration Section.
If improper equipment is used to lift the product,
injury and damage can occur. Use cables which
are properly rated for the weight. Use a spreader
bar and attach the cables according to the infor-
mation on the safety message.
11 Lifting the Product (Including the

Radiator)
One safety message is located next to the radiator

cap.
Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. 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. Read and understand the
Operation and Maintenance Manual before per-
Illustration 13 g01411378 forming any cooling system maintenance.

terminal box. 13 Lifting the Engine
Before lifting the product, read this Operation and

Maintenance Manual, Product Lifting in the Op-
eration Section.
This safety message may be located on the lifting bail

for the engine.
SEBU8468 11
Safety Section
General Hazard Information
Use caution when cover plates are removed.

Gradually loosen, but do not remove the last two bolts
or nuts that are located at opposite ends of the cover
Before lifting the product, read this Operation and plate or the device. Before removing the last two bolts
Maintenance Manual, Product Lifting in the Op- or nuts, pry the cover loose in order to relieve any
eration Section. spring pressure or other pressure.
i05223775

SMCS Code: 1000; 4450; 7405
Wear a hard hat, protective glasses, and other

protective equipment, as required.
When work is performed around an engine that is

operating, wear protective devices for ears in order
to help prevent damage to hearing.
Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.
Ensure that all protective guards and all covers are

secured in place on the engine.
Never put maintenance fluids into glass

Attach a Do Not Operate warning tag to the start
switch or controls before the engine is serviced or containers. Glass containers can break.
repaired. These warning tags (Special Instruction,
Use all cleaning solutions with care.
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each Report all necessary repairs.
operator control station. When appropriate,
disconnect the starting controls. Unless other instructions are provided, perform
the maintenance under the following conditions:
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugs
12 SEBU8468
Safety Section
The engine is stopped. Ensure that the engine Fluid Penetration

cannot be started.
The protective locks or the controls are in the

applied position.
Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
When starting a new engine, make provisions to

stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine. Illustration 18 g00687600
Do not attempt any repairs that are not Always use a board or cardboard when you check for
understood. Use the proper tools. Replace any a leak. Leaking fluid that is under pressure can
equipment that is damaged or repair the penetrate body tissue. Fluid penetration can cause
equipment. serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
Start the engine with the operator controls. Never you must get treatment immediately. Seek treatment
short across the starting motor terminals or the from a doctor that is familiar with this type of injury.
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the Containing Fluid Spillage
electrical system could be damaged.
NOTICE
Pressurized Air and Water Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Pressurized air and/or water can cause debris and/or nance, testing, adjusting, and repair of the product.
hot water to be blown out which could result in Be prepared to collect the fluid with suitable contain-
personal injury.
ers before opening any compartment or disassem-
The maximum air pressure for cleaning purposes bling any component containing fluids.
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip Refer to Special Publication, NENG2500, Cat Dealer
guarding (if applicable) and personal protective Service Tool Catalog or refer to Special Publication,
equipment. The maximum water pressure for PECJ0003, Cat Shop Supplies and Tools Catalog
cleaning purposes must be below 275 kPa (40 psi). for tools and supplies suitable to collect and contain
fluids on Cat products.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective Dispose of all fluids according to local regulations and
shoes, and eye protection. Eye protection includes mandates.
goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.
Lines, Tubes, and Hoses
Avoid direct spraying of water on electrical
connectors, connections, and components. When Do not bend or strike high-pressure lines. Do not
using air for cleaning, allow the machine to cool to install lines, tubes, or hoses that are damaged.
reduce the possibility of fine debris igniting when
redeposited on hot surfaces. Repair any fuel lines, oil lines, tubes, or hoses that
are loose or damaged. Leaks can cause fires.
Inspect all lines, tubes, and hoses carefully. Do not
use bare hands to check for leaks. Always use a
board or cardboard for checking engine components
for leaks. Tighten all connections to the
recommended torque.
Check for the following conditions:
SEBU8468 13
Safety Section
End fittings that are damaged or leaking If dust that may contain asbestos is present, there are
several guidelines that should be followed:
Outer covering that is chafed or cut
Never use compressed air for cleaning.
Wire that is exposed in reinforced hose
Avoid brushing materials that contain asbestos.
Outer covering that is ballooning locally
Avoid grinding materials that contain asbestos.
Flexible part of the hose that is kinked or crushed
Use a wet method in order to clean up asbestos
Armoring that is embedded in the outer covering materials.
Ensure that all of the clamps, the guards, and the A vacuum cleaner that is equipped with a high
heat shields are installed correctly. Correct installation efficiency particulate air filter (HEPA) can also be
of these components will help to prevent these used.
effects: vibration, rubbing against other parts and
excessive heat during operation. Use exhaust ventilation on permanent machining
jobs.
Inhalation
Wear an approved respirator if there is no other
way to control the dust.
Comply with applicable rules and regulations for
the work place. In the United States , use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA
requirements can be found in 29 CFR 1910.1001.
Obey environmental regulations for the disposal of
asbestos.
Stay away from areas that might have asbestos

particles in the air.
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
Exhaust approved by the National Institute of Occupational
Safety and Health (NIOSH) . Wear appropriate
Use caution. Exhaust fumes can be hazardous to protective clothing in order to minimize direct contact.
your health. If you operate the equipment in an Use good hygiene practices and wash hands
enclosed area, adequate ventilation is necessary. thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Asbestos Information Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
Cat equipment and replacement parts that are up debris.
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat Reference: The applicable material safety data
replacement parts. Use the following guidelines when sheets can be found at the following web site by
you handle any replacement parts that contain searching using part number or the name:
asbestos or when you handle asbestos debris.
http://dsf2ws.cat.com/msds/servlet/
Use caution. Avoid inhaling dust that might be cat.cis.ecs.msdsSearch.controller.
generated when you handle components that contain UserIdentificationDisplayServlet
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
14 SEBU8468
Safety Section
Burn Prevention
Dispose of Waste Properly If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
i04090689
Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be Fire Prevention and Explosion
disposed of according to local regulations. Prevention
Always use leakproof containers when you drain SMCS Code: 1000; 4450; 7405
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i02088921
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the Illustration 21 g00704000
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or Use of personal protection equipment (PPE) may be
to the engine contain hot coolant. Any contact with needed.
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the All fuels, most lubricants, and some coolant mixtures
cooling system is drained. are flammable.
Check the coolant level after the engine has stopped Always perform a Walk-Around Inspection, which
and the engine has been allowed to cool. Ensure that may help you identify a fire hazard. Do not operate a
the filler cap is cool before removing the filler cap. product when a fire hazard exists. Contact your Cat
The filler cap must be cool enough to touch with a dealer for service.
bare hand. Remove the filler cap slowly in order to Flammable fluids that are leaking or spilled onto hot
relieve pressure. surfaces or onto electrical components can cause a
Cooling system conditioner contains alkali. Alkali can fire. Fire may cause personal injury and property
cause personal injury. Do not allow alkali to contact damage.
the skin, the eyes, or the mouth. A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
Oils emergency shutdown.
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot
components to contact the skin.
SEBU8468 15
Safety Section
Fire Prevention and Explosion Prevention
Determine whether the engine will be operated in an

environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Cat dealer for
additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
All fluids that are captured in the fluid spill
containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
may cause personal injury and property damage.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials. Illustration 22 g00704059
Do not expose the engine to any flame. Use caution when you are refueling an engine. Do not
smoke while you are refueling an engine. Do not
Exhaust shields (if equipped) protect hot exhaust refuel an engine near open flames or sparks. Always
components from oil or fuel spray in a line, a tube, or stop the engine before refueling.
a seal failure. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure Gases from a battery can explode. Keep any open
clamps. Tighten all connections to the recommended flames or sparks away from the top of a battery. Do
torque. Leaks can cause fires. not smoke in battery charging areas.
Properly install all oil filters and fuel filters. The filter Never check the battery charge by placing a metal
housings must be tightened to the proper torque. object across the terminal posts. Use a voltmeter or a
hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
16 SEBU8468
Safety Section
Crushing Prevention and Cutting Prevention
Do not charge a frozen battery. Charging a frozen End fittings are damaged or leaking.
battery may result in an explosion.
Outer coverings are chafed or cut.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the Wires are exposed.
recommended cables, connections, and battery box
covers when the engine is operated. Outer coverings are ballooning.
Fire Extinguisher Flexible parts of the hoses are kinked.
Make sure that a fire extinguisher is available. Be Outer covers have embedded armoring.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire End fittings are displaced.
extinguisher regularly. Obey the recommendations on
the instruction plate. Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
rubbing against other parts, and excessive heat.
Ether
Ether is flammable and poisonous. i01359666
Use ether in well ventilated areas. Do not smoke

while you are replacing an ether cylinder or while you Crushing Prevention and
are using an ether spray. Cutting Prevention
Do not store ether cylinders in living areas or in the SMCS Code: 1000; 4450; 7405
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49 C Support the component properly when work beneath
(120 F). Keep ether cylinders away from open the component is performed.
flames or sparks.
Unless other maintenance instructions are provided,
Dispose of used ether cylinders properly. Do not never attempt adjustments while the engine is
puncture an ether cylinder. Keep ether cylinders away running.
from unauthorized personnel.
Stay clear of all rotating parts and of all moving parts.
Do not spray ether into an engine if the engine is Leave the guards in place until maintenance is
equipped with a thermal starting aid for cold weather performed. After the maintenance is performed,
starting. reinstall the guards.
Lines, Tubes, and Hoses Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent or When objects are struck, wear protective glasses in
damaged. order to avoid injury to the eyes.
Repair any lines that are loose or damaged. Leaks Chips or other debris may fly off objects when objects
can cause fires. Consult your Cat dealer for repair or are struck. Before objects are struck, ensure that no
for replacement parts. one will be injured by flying debris.
Check lines, tubes, and hoses carefully. Do not use i01377941

your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque. Mounting and Dismounting
SMCS Code: 1000; 4450; 7405
Replace the parts if any of the following conditions
are present: Generator sets in permanent installations may require
the use of a ladder or a work platform in order to
provide access for normal maintenance. The owner
and/or the user is responsible for providing safe
access that conforms to SAE J185 and/or local
building codes.
Inspect the steps, the handholds, and the work area
before mounting the generator set. Keep these items
clean and keep these items in good repair.
SEBU8468 17
Safety Section
Sound Information
Mount the generator set and dismount the generator Refer to the following for factors that influence the
set only at locations that have steps and/or level of exposure:
handholds. Do not climb on the generator set, and do
not jump off the generator set. The characteristics of the area around the
generator set
Face the generator set in order to mount the
generator set or dismount the generator set. Maintain Other sources of noise
a three-point contact with the steps and handholds.
Use two feet and one hand or use one foot and two The number of machines and other adjacent
hands. Do not use any controls as handholds. processes
Do not jump from an elevated platform. Do not jump The length of time of exposure to the noise
from a ladder or stairs.
This information will enable the user of the machine to
Do not stand on components which cannot support evaluate the hazard and the risk.
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move. i03736987
Do not carry tools or supplies when you mount the Sound Information
generator set or when you dismount the generator
set. Use a hand line to raise and lower tools or SMCS Code: 1000
supplies.
S/N: YAT1Up
i03690560 S/N: YAN1Up; CTH1Up
Sound Information S/N: YAZ1Up; CTH1Up

SMCS Code: 1000 S/N: YAP1Up; DDJ1Up
Note: Information of the sound level is for machines S/N: YAR1Up; DDM1Up
in European Union countries and in countries that S/N: YAM1Up; 1GZ1Up
adopt the directives of the European Union.
S/N: YAY1Up; 1GZ1Up
NOTICE
Hearing protection may be needed when working Note: Information of the sound level is for machines
near an operating generator set. in European Union countries and in countries that
adopt the directives of the European Union.
Sound levels will vary depending on the configuration NOTICE

of the generator set and the final installation of the Hearing protection may be needed when working
generator set. near an operating generator set.
Refer to the following for sound levels:
Sound levels will vary depending on the configuration
The sound pressure level of a complete generator of the generator set and the final installation of the
set (including the radiator) at 1 meter is 111 dB(A) generator set.
for the noisiest configuration when ISO 8528-
10:1998(E) clause 14 is used at 75 percent of the Refer to the following for sound levels:
rated power.
The sound pressure level of a complete generator
The sound power level of a complete generator set set (including the radiator) at 1 meter is 111 dB(A)
(including the radiator) is 125 dB(A) for the noisiest for the noisiest configuration when ISO 8528-
configuration when ISO 8528-10:1998(E) clause 10:1998(E) clause 14 is used at 75 percent of the
13 is used at 75 per cent of the rated power. rated power.
Note: The preceding sound levels are emission The sound power level of a complete generator set
levels. The preceding sound levels are not (including the radiator) that is not covered by the
necessarily safe sound levels. There is a correlation European Union Directive 2000/14/EC is 125 dB
between the emission levels and the level of (A) for the noisiest configuration when ISO 8528-
exposure. The correlation between emission levels 10:1998(E) clause 13 is used at 75 percent of the
and the level of exposure can not be used to rated power.
determine if further precautions are required.
18 SEBU8468
Safety Section
Before Starting Engine
Note: The preceding sound levels are emission All protective guards and all protective covers must
levels. The preceding sound levels are not be installed if the engine must be started in order to
necessarily safe sound levels. There is a correlation perform service procedures. To help prevent an
between the emission levels and the level of accident that is caused by parts in rotation, work
exposure. The correlation between emission levels around the parts carefully.
and the level of exposure can not be used to
Do not bypass the automatic shutoff circuits. Do not
determine if further precautions are required. disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
Refer to the following for factors that influence the circuits are also provided in order to help prevent
level of exposure: engine damage.
The characteristics of the area around the See the Service Manual for repairs and for
generator set adjustments.
Other sources of noise
i01103904
The number of machines and other adjacent
processes Engine Starting
The length of time of exposure to the noise SMCS Code: 1000
This information will enable the user of the machine to If a warning tag is attached to the engine start switch
evaluate the hazard and the risk. or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
i03560601
All protective guards and all protective covers must
Before Starting Engine be installed if the engine must be started in order to
perform service procedures. To help prevent an
SMCS Code: 1000 accident that is caused by parts in rotation, work
around the parts carefully.
NOTICE
For initial start-up of a new or rebuilt engine, and for Start the engine from the operator's compartment or
from the engine start switch.
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed Always start the engine according to the procedure
occur. This may be accomplished by shutting off the that is described in this Operation and Maintenance
air and/or fuel supply to the engine. Manual, Engine Starting topic (Operation Section).
Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing
the procedure will also help to prevent personal injury.
To ensure that the jacket water heater (if equipped)
Engine exhaust contains products of combustion and/or the lube oil heater (if equipped) is working
which may be harmful to your health. Always start properly, check the water temperature gauge and the
and operate the engine in a well ventilated area oil temperature gauge during the heater operation.
and, if in an enclosed area, vent the exhaust to the
outside. Engine exhaust contains products of combustion that
can be harmful to your health. Always start the engine
and operate the engine in a well ventilated area. If the
Inspect the engine for potential hazards. engine is started in an enclosed area, vent the engine
exhaust to the outside.
Do not start the engine or move any of the controls if
there is a DO NOT OPERATE warning tag or Ether
similar warning tag attached to the start switch or to
the controls. Ether is poisonous and flammable.
Before starting the engine, ensure that no one is on, Do not inhale ether, and do not allow ether to contact
underneath, or close to the engine. Ensure that the the skin. Personal injury could result.
area is free of personnel.
Do not smoke while ether cylinders are changed.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all Use ether in well ventilated areas.
lights work properly, if equipped.
Use ether with care in order to avoid fires.
SEBU8468 19
Safety Section
Engine Stopping
Keep ether cylinders out of the reach of unauthorized Grounding Practices

persons.
The electrical systems for the generator, the engine
Store ether cylinders in authorized storage areas and the control systems must be properly grounded.
only. Proper grounding is necessary for optimum
performance and reliability. Improper grounding will
Do not store ether cylinders in direct sunlight or at result in uncontrolled electrical circuit paths and in
temperatures above 49 C (120 F). unreliable electrical circuit paths.
Discard the ether cylinders in a safe place. Do not Uncontrolled electrical circuit paths can result in
puncture the ether cylinders. Do not burn the ether damage to main bearings, to the surface of
cylinders. crankshaft journals, and to aluminum components.
Uncontrolled electrical circuit paths can also cause
i01032808 electrical activity that may degrade the performance
of the generator set's electronics.
Engine Stopping The charging alternator and the starting motor must
SMCS Code: 1000 be bonded to the negative battery terminal.
To avoid overheating of the engine and accelerated For engines with an alternator that is grounded to an
wear of the engine components, stop the engine engine component, a ground strap must connect that
according to this Operation and Maintenance Manual, component to the negative battery terminal. Also,
Engine Stopping topic (Operation Section). that component must be electrically isolated from the
engine.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. DO NOT use the The ground strap for the charging alternator must be
Emergency Stop Button for normal engine stopping. of a size that is adequate for carrying the full charging
After an emergency stop, DO NOT start the engine current of the alternator.
until the problem that caused the emergency stop has
been corrected. i01226491
On the initial start-up of a new engine or an engine

that has been serviced, make provisions to stop the Generator Isolating for
engine if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply and/or
Maintenance
the air supply to the engine. SMCS Code: 4450
When you service an electric power generation set or
i02347814 when you repair an electric power generation set,
follow the procedure below:
Electrical System
1. Stop the engine.
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit is
operating. A spark can cause the combustible gases
that are produced by some batteries to ignite.
When the engine is started from an external source,
follow this procedure: first, connect the positive +
jump start cable from the external power source to the
positive + battery terminal of the engine that is
being started. Then connect the negative jump
start cable from the external power source to the
negative terminal of the starting motor. This will
help to prevent sparks from igniting combustible
gases that are produced by some batteries.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires Illustration 24 g00104545
before the engine is operated. Repair all frayed
electrical wires before the engine is started. 2. Attach a DO NOT OPERATE or similar warning
tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
20 SEBU8468
Safety Section
Generator Isolating for Maintenance
3. Disconnect the generator from the distribution

system.
4. Lock out the circuit breaker. Attach a DO NOT

OPERATE or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have been
locked out.
5. Remove the fuses for the transformers for the
following circuitry:
power
sensing
control
6. Attach a DO NOT OPERATE or similar warning
tag to the generator excitation controls.
7. Remove the cover of the generator's terminal box.
8. Use an audio/visual proximity tester in order to

verify that the generator is de-energized. This
tester must be insulated for the proper voltage
rating. Follow all guidelines in order to verify that
the tester is operational.
9. Determine that the generator is in a de-energized

condition. Add ground straps to the conductors or
terminals. During the entire work period, these
ground straps must remain connected to the
conductors and to the terminals.
SEBU8468 21
Product Information Section
Model View Illustrations
Product Information
Section
General Information
i02362285
Model View Illustrations

SMCS Code: 1000
The illustrations show typical features of the 3500
SeriesGenerator Set Engines . The illustrations do
not show all of the options that are available.
(1) Control panel (3) Oil sampling valve

(2) Terminal strip (4) Air cleaner
22 SEBU8468
General Information
Product Description
(5) Air inlet (13) Radiator cap (21) Water inlet

(6) Lifting eye (14) Engine control module (ECM) (22) Oil drain valve
(7) Oil filler (15) Coolant drain (23) Separate circuit water inlet
(8) Exhaust (16) Oil level gauge (24) Separate circuit water outlet
(9) Excess fuel return (17) Water outlet (25) Fumes disposal tube
(10) Fuel priming pump (18) Fuel inlet (26) Starting motor
(11) Fuel filter (19) Water drain (27) Oil drain
(12) Oil filter (20) Oil screen
i03741320 The generators are utilized in three-phase full-wave

excitation and regulation. The generators are either
Product Description four pole or six pole design with six lead configuration
or twelve lead configuration. The generators are
SMCS Code: 1000; 4450; 4491 capable of producing electrical power in either 50 Hz
or 60 Hz applications.
S/N: YAT1Up
S/N: YAN1Up; CTH1Up i03730540
S/N: YAZ1Up; CTH1Up Product Description

S/N: YAP1Up; DDJ1Up SMCS Code: 1000; 4450; 4491
S/N: YAR1Up; DDM1Up The 3500B and the 3500CGenerator Sets consist of
an engine, a generator and control systems.
S/N: YAM1Up; 1GZ1Up
S/N: YAY1Up; 1GZ1Up Intended Use
The 3500BGenerator Sets consist of an engine, a This Power Generator is intended to be used to
generator and control systems. generate electrical power.
Intended Use Engine Description

This Power Generator is intended to be used to 3500BGenerator SetEngines and the
generate electrical power. 3500CGenerator SetEngines are electronically
controlled diesel engines. The engines have
Engine Description electronic fuel injectors. The engines can be
equipped with either jacket water aftercooling or
3500BGenerator SetEngines are electronically separate circuit aftercooling. The engine is offered in
controlled diesel engines. The engines have a 12 cylinder engine and a 16 cylinder engine.
electronic fuel injectors. The engines can be
equipped with either jacket water aftercooling or Engine efficiency and engine performance depend on
separate circuit aftercooling. The engine is offered in adherence to proper operation and maintenance
an 8 cylinder engine, a 12 cylinder engine, and a 16 recommendations. Use the recommended fuels,
cylinder engine. lubrication oils, and coolant. Pay special attention to
the air cleaner, to the fuel system, to the lubrication
Engine efficiency and engine performance depend on system, and to the cooling system maintenance.
adherence to proper operation and maintenance Refer to this Operation and Maintenance Manual,
recommendations. Use the recommended fuels, Maintenance Interval Schedule for more information
lubrication oils, and coolant. Pay special attention to on maintenance items.
the air cleaner, to the fuel system, to the lubrication
system, and to the cooling system maintenance. Generator Description
Refer to the Operation and Maintenance Manual,
Maintenance Interval Schedule for more information The brushless generator can be used with the
on maintenance items. following loads: mixed loads of motors and lights,
SCR-controlled equipment, computer centers,
Generator Description installations of communications and petroleum drilling
applications.
The brushless generator can be used with the
following loads: mixed loads of motors and lights, The generator set packages can be utilized for prime
SCR-controlled equipment, computer centers, power generation or standby power generation.
installations of communications and petroleum drilling
applications.
The generator set packages can be utilized for prime
power generation or standby power generation.
SEBU8468 23
General Information
Product Description
The generators are utilized in three-phase full-wave

excitation and regulation. The generators are either
four pole or six pole design with six lead configuration
or twelve lead configuration. The generators are
capable of producing electrical power in either 50 Hz
or 60 Hz applications.
24 SEBU8468
Product Identification Information
Plate Locations and Film Locations
Product Identification Information Plate

Information
i03728143
Plate Locations and Film

Locations
SMCS Code: 1000; 4450
S/N: YAT1Up
S/N: YAN1Up; CTH1Up
S/N: YAZ1Up; CTH1Up
S/N: YAP1Up; DDJ1Up Illustration 27 g01659054
S/N: YAR1Up; DDM1Up The information plate is on the left side top surface of
S/N: YAM1Up; 1GZ1Up the cylinder block in front of the front cylinder head.
S/N: YAY1Up; 1GZ1Up The following information is stamped on the

information plate: maximum altitude of the engine,
horsepower, high idle, full load rpm, fuel settings and
Engine Identification other information.
Caterpillar dealers need the information from the
serial number plate and from the information plate in Identification of the Generator Set
order to determine the components that were
included with the engine. This permits accurate
identification of replacement part numbers.
Serial Number Plate
The identification plate for the generator set is located

on the right side of the barrel of the generator.
When service is required, the information that is given
on this plate should be used. The identification plate
for the generator set includes the following
The serial number plate is on the left side of the information: serial number, model number and the
cylinder block near the rear of the engine. rating of the generator set. The generator set consists
of the engine and the generator. All pertinent
The following information is stamped on the serial generator data is also included on the plate in order to
number plate: engine serial number, model and provide the information that is necessary to order
arrangement number. parts.
SEBU8468 25
Serial Number Plate for the Engine Power for Primary Engine (kW)
Generator Engine Power for Additional Engine (If Equipped)
Typical Machine Operating Weight for European

Market (kg)
Year of Construction
Machine Type
The serial number for the generator is located on the

left side of the front of the generator.
Output Lead Wiring

All generator lead wiring information can be found on
a decal that is located on the side panel of the Illustration 31 g01120192
generator's terminal box. If the generator is equipped
with a circuit breaker, the decal may be found on the This plate is positioned on the bottom left side of the
sheet metal of the circuit breaker panel. plate for the PIN.
Note: The CE plate is on machines that are certified

European Union to the European Union requirements that were
effective at that time.
For machines that are compliant to 1998/42/EC , the
following information is stamped onto the CE plate.
For quick reference, record this information in the
spaces that are provided below.
Engine Power for Primary Engine (kW)

Market (kg)
Year
For the name and the address of the manufacturer,
and the country of origin of the machine, refer to the
PIN plate.
For the name, the address and the country of origin of
This plate is positioned on the bottom left side of the the manufacturer, see the PIN plate.
plate for the PIN.
to the European Union requirements that were
26 SEBU8468
i03690640 Information Plate

Plate Locations and Film
Locations
SMCS Code: 1000; 4450
Engine Identification
Caterpillar dealers need the information from the
serial number plate and from the information plate in
order to determine the components that were
included with the engine. This permits accurate
identification of replacement part numbers.
Serial Number Plate

The information plate is on the left side top surface of

the cylinder block in front of the front cylinder head.
The serial number plate is on the left side of the

cylinder block near the rear of the engine.
Typical information plate
The following information is stamped on the

information plate: maximum altitude of the engine,
horsepower, high idle, full load rpm, fuel settings and
other information.
Typical serial number plate for the engine
The following information is stamped on the serial

number plate: engine serial number, model and
arrangement number.
SEBU8468 27
Identification of the Generator Set Serial Number Plate for the

Generator
The identification plate for the generator set is located
on the right side of the barrel of the generator.
The serial number for the generator is located on the
left side of the front of the generator.
Typical serial number plate for the generator
Output Lead Wiring

All generator lead wiring information can be found on
Typical identification plate a decal that is located on the side panel of the
generator's terminal box. If the generator is equipped
When service is required, the information that is given with a circuit breaker, the decal may be found on the
on this plate should be used. The identification plate sheet metal of the circuit breaker panel.
for the generator set includes the following
information: serial number, model number and the
rating of the generator set. The generator set consists
of the engine and the generator. All pertinent
generator data is also included on the plate in order to
provide the information that is necessary to order
parts.
28 SEBU8468
European Union Note: The CE plate is on machines that are certified

Market (kg)
Year
For the name and the address of the manufacturer,
and the country of origin of the machine, refer to the
Illustration 40 g01880193 PIN plate.
This plate is positioned on the bottom left side of the

plate for the PIN.
Engine Power for Additional Engine (If Equipped)

Market (kg)
Year of Construction
Machine Type
This plate is positioned on the bottom left side of the

plate for the PIN.
SEBU8468 29
Declaration of Conformity
i05031096
SMCS Code: 1000
S/N: YAT1Up
S/N: YAN1Up; CTH1Up
S/N: YAZ1Up; CTH1Up
S/N: YAP1Up; DDJ1Up
S/N: YAR1Up; DDM1Up
S/N: YAM1Up; 1GZ1Up
S/N: YAY1Up; 1GZ1Up
30 SEBU8468
Table 1
An EC Declaration of Conformity document was provided with the product if it was manufactured to comply with specific requirements for the
European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with
the product. The extract shown below from an EC Declaration of Conformity for product that are declared compliant to 2006/42/EC applies only
to those products originally CE marked by the manufacturer listed and which have not since been modified.
EC DECLARATION OF CONFORMITY OF MACHINERY
Manufacturer:CATERPILLAR INC . 100 N.E. ADAMS STREET PEORIA, IL 61629 USA
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:
Standards & Regulations Manager,Caterpillar France S.A.S 40 ,

Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France
I, the undersigned, _________, hereby certify that the construction equipment specified hereunder
Description: Generic Denomination: Power Generation Equipment
Function: Power Generator

Model/Type: 3512B or 3516B
Serial Number:
Commercial Name: Caterpillar
Fulfills all the relevant provisions of the following Directives
Directives Notified Body Document No.
2006/42/EC N/A
2006/95/EC N/A
2004/108/EC N/A
2000/14/EC amended by 2005/88/EC, Note (1) Note (2)
Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)
Representative Equipment Type Sound Power Level - _____dB (A)
Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File
Note (2) Notified body name and address
Done at: Signature
Date: Name/Position
Note: The above information was correct as of October, 2009, but may be subject to change. Refer to the individual declaration of conformity is-
sued with the machine for exact details.
SEBU8468 31
i03690833
SMCS Code: 1000
Table 2
An EC Declaration of Conformity document was provided with the product if it was manufactured to comply with specific requirements for the
European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with
the product. The extract shown below from an EC Declaration of Conformity for product that are declared compliant to 2006/42/EC applies only
to those product originally CE marked by the manufacturer listed and which have not since been modified.
EC DECLARATION OF CONFORMITY OF MACHINERY
Manufacturer:CATERPILLAR INC . 100 N.E. ADAMS STREET PEORIA, IL 61629 USA
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:
Standards & Regulations Manager,Caterpillar France S.A.S 40 ,

Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France
I, the undersigned, _________, hereby certify that the construction equipment specified hereunder
Description: Generic Denomination: Power Generation Equipment
Function: Power Generator

Model/Type: 3500B
Serial Number:
Commercial Name: Caterpillar
Fulfils all the relevant provisions of the following Directives
Directives Notified Body Document No.
2006/42/EC N/A
2006/95/EC N/A
2004/108/EC N/A
2000/14/EC amended by 2005/88/EC, Note (1) Note (2)
Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)
Representative Equipment Type Sound Power Level - _____dB (A)
Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File
Note (2) Notified body name and address
Done at: Signature
Date: Name/Position
Note: The above information was correct as of October, 2009, but may be subject to change, please refer to the individual declaration of con-
formity issued with the machine for exact details.
32 SEBU8468
Emissions Certification Film
i04605109
Emissions Certification Film

SMCS Code: 1000; 7405
Note: This information is pertinent in the United

States , in Canada and in Europe .
Consult your Cat dealer for an Emission Control
Warranty Statement.
This label is located on the engine.
i01400354
Reference Information
SMCS Code: 1000; 4450
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.
Record for Reference

Engine Model
Engine Serial Number
Engine Arrangement Number
Packaging Arrangement Number
Modification Number
Engine Low Idle rpm
Engine Power Rating
Engine Full Load rpm
Performance Specification Number
Governor Group Number
Turbocharger
Primary Fuel Filter
Secondary Fuel Filter Element
Lubrication Oil Filter Element
Air Cleaner Element
Alternator Belt
Fan Drive Belt Set
Lubrication System Capacity
Total Cooling System Capacity
SEBU8468 33
Operation Section
Product Lifting
Operation Section NOTICE

Unless otherwise noted, factory shipped loose radia-
tors are not designed to be lifted or hoisted while in-
Lifting and Storage stalled on a generator package. Shipped loose
radiators must be installed on site after the packages
(engine, generator, rails) are set in place. Radiators
i02772114
that are factory installed but shipped without coolant
cannot be lifted while installed on a generator pack-
Product Lifting age if they are filled with coolant. Only those pack-
SMCS Code: 7000; 7002 ages that are shipped from the factory filled with
coolant can be lifted or hoisted while filled with cool-
ant. Refer to the shipping consist to determine if cool-
ant was included on the order prior to lifting the
generator set package.
Lifting the Entire Package

Do NOT use only the engine lifting eyes or only
the generator lifting eyes to lift the entire package.
The procedure for lifting the package utilizes a three-
point lifting method. These lifting points are the front
engine lifting eye (4) and the two lifting eyes (5) that
are located on the sides of the rails toward the rear of
the package.
Lifting the Engine Only

To remove the engine ONLY, use lifting eyes (3) and
(4) that are on the engine.
NOTICE
Never bend the eyebolts and the brackets. Only load Lifting the Generator Only
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle Note: The control panel and the terminal box will
between the supporting members and the object be- need to be removed before attempting to lift the
comes less than 90 degrees. generator.
When it is necessary to remove a component at an To remove the generator ONLY, use lifting eyes (1)
angle, only use a link bracket that is properly rated for and (2) that are on the generator.
the weight.
i03203660
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the entire package. Use Product Storage
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be SMCS Code: 7002
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being Short Time Storage
lifted.
Some removals require lifting fixtures in order to If the generator is not installed immediately, store the
obtain proper balance. Lifting fixtures also help to generator in a clean area. This area should also have
provide safety. the following conditions: low humidity, stable humidity
and stable temperature. Space heaters must be
Lifting eyes are designed and installed for each energized in order to keep condensation from the
package. Alterations to the lifting eyes and/or the windings. All accessory equipment that is supplied
package make the lifting eyes and the lifting fixtures with the unit should be stored with the generator. The
obsolete. If alterations are made, ensure that proper combined unit should be covered with a durable
lifting devices are provided. Consult your Caterpillar cover in order to protect against the following
contaminants:
dealer for information regarding fixtures for proper
lifting.
34 SEBU8468
Lifting and Storage
Product Storage
Dust Bearing Inspection

Dirt New bearings are greased at the manufacturer. This
grease is designed for long life, but the grease may
Moisture deteriorate under certain conditions in storage.
Other airborne abrasive substances Ball bearing generators use synthetic grease. This
grease is subject to deterioration. If the generator is
Long Time Storage stored more than one year and the bearings are not
turned during the year, new ball bearings may be
required.
Engine Storage
If the engine will not be started for several weeks, the
Electrical Measurements
lubricating oil will drain from the cylinder walls and Measure the insulation resistance of each winding if
from the piston rings. Rust can form on the cylinder the generator was exposed to the following
liner surface, which will increase engine wear which conditions:
can reduce engine service life.
Rapid changes in temperature
To help prevent excessive engine wear, use the
following guidelines: Freezing
Complete all of the lubrication recommendations Wet climate during storage
that are listed in this Operation and Maintenance
Manual, Maintenance Interval Schedule Note: These tests should be conducted prior to any
(Maintenance Section). power connections that are being made. These tests
should be conducted prior to any control connections
If freezing temperatures are expected, check the that are made.
cooling system for adequate protection against
freezing. See this Operation and Maintenance Refer to the Generator Maintenance section of this
Manual, Refill Capacities and Recommendations manual in order to measure the following items:
(Maintenance Section). Exciter Field (Stator)
If an engine is out of operation and if use of the
engine is not planned, special precautions should be Exciter Armature (Rotor)
made. If the engine will be stored for more than one
Generator Field (Rotor)
month, a complete protection procedure is
recommended. Generator Armature (Stator)
Your Caterpillar dealer will have instructions for
preparing the engine for extended storage periods. For additional information on generator storage,
consult your Caterpillar dealer for assistance.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, Storage Procedure
for Caterpillar Products.
Generator Storage
A storage period in excess of six months should be
preceded by the following preparation:
1. Install desiccant bags inside the exciter's cover.

For generators that have 1800 frames, install
desiccant bags inside the screen of the fan.
2. Seal the unit in a covering of plastic or other

material that has been designed for that purpose.
3. Adequately tag the generator. This will ensure that

preservative greases and desiccant bags are
removed before the generator is placed in
operation.
SEBU8468 35
Installation
Product Installation
Installation Storage
i03690838 Short Time Storage
Product Installation If the generator is not installed immediately, store the

generator in a clean area. This area should also have
SMCS Code: 1000; 1404; 4450; 7002 the following conditions: low humidity, stable humidity
and stable temperature. Space heaters must be
energized in order to keep condensation from the
Receiving Inspection windings. All accessory equipment that is supplied
with the unit should be stored with the generator. The
If the generator is received during cold weather, allow combined unit should be covered with a durable
the unit to reach room temperature before you cover in order to protect against the following
remove the protective packing material. Warming the contaminants:
generator to room temperature will prevent the
following problems: Dust
Water condensation on cold surfaces Dirt
Early failures due to wet windings Moisture
Early failures due to wet insulating materials Other airborne abrasive material
Unpacking and Storage Long Time Storage
Moving the Generator A storage period in excess of six months should be
preceded by the following preparation:
1. Install desiccant bags inside the exciter's cover and

install desiccant bags inside the screen of the fan.
Improper lift rigging can allow unit to tumble
causing injury and damage. 2. Seal the unit in a covering of plastic or other
material that has been designed for that purpose.
NOTICE 3. Adequately tag the generator. This will ensure that
Do not use the engine lifting eyes to remove the en- preservative greases and desiccant bags are
gine and generator together. removed before the unit is placed in operation.
Unpack the equipment with care in order to avoid Bearing Inspection

scratching painted surfaces. Move the unit to the
mounting location. The unit can be moved by either of Ball bearing generators use grease. This grease is
the following methods: subject to deterioration. If the generator is stored
longer than one year, new ball bearings should be
Attach an overhead crane to the eyebolts that are installed. These bearings should be greased to the
installed on the generator frame. proper level prior to being put into operation. If
inspection indicates that bearings are free of rust or
Use a lift truck in order to lift the generator. corrosion, and no noise or excessive vibration appear
on start-up, replacement is not necessary.
The hoist and the hoist cables should have a rating
that is greater than the weight of the generator. When Location
the unit is moved, ensure that the generator is
completely supported by the lift truck's fork tines. Also The location of the generator must comply with all
ensure that the generator is balanced on the lift local regulations. The location of the generator must
truck's fork tines. Slide the fork tines beneath the also comply with all special industrial regulations.
attached skid in order to lift the generator. Locate the generator in an area that meets the
following requirements:
Clean
Dry
Well ventilated
Easily accessible for inspection and maintenance
36 SEBU8468
Installation
Product Installation
Access to the radiator filler cap is on the roof of

the enclosure. There must be safe access to the
roof of the enclosure. There must be sufficient
clearance above the roof of the enclosure.
Do not obstruct air inlet openings. Do not obstruct
discharge openings. Air flow must reach these
openings. If the generator is exposed to harsh
environmental conditions, the generator can be
modified in the field in order to add filters and space
heaters. In addition, a more rigid periodic
maintenance schedule should be established.
Electrical Measurements
Measure the insulation resistance of each winding if
the generator was exposed to the following
conditions:
Rapid changes in temperature
Freezing
Wet climate during shipment

Wet climate during storage
Note: These tests should be conducted prior to any

power connections that are being made. These tests
should be conducted prior to any control connections
that are being made.
Refer to this Operation and Maintenance Manual,
Rotating Rectifier - Test in order to measure the
following items:
Exciter field (stator)

Exciter armature (rotor)
Generator field (rotor)

Generator armature (stator)
Note: For further information concerning the

installation of this generator set, see the appropriate
Application and Installation Guide.
Protective Devices
The output to the load of the generator should always
be protected with an overload protection device such
as a circuit breaker or fuses. Fuses should be sized
by using the lowest possible current rating. However,
this rating must be above the current rating for full
load. A common recommendation is 115 percent of
rated current. Determine the size of fuses or
determine the size of circuit breakers in accordance
with NEMA , IEC, and Local Electrical Codes.
SEBU8468 37
Features and Controls
Alarms and Shutoffs
Features and Controls NOTICE

Never move the battery disconnect switch to the OFF
i02755536 position while the engine is operating. Serious dam-
age to the electrical system could result.
Alarms and Shutoffs
SMCS Code: 7400 To ensure that no damage to the engine occurs, verify
that the engine is fully operational before cranking the
This section contains some general information about engine. Do not crank an engine that is not fully
the function of typical engine protective devices. operational.
Alarms and shutoffs are electronically controlled. The Perform the following procedure in order to check the
operation of all alarms and shutoffs utilize battery disconnect switch for proper operation:
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating 1. With the battery disconnect switch in the ON
temperatures, pressures, or speeds in order to position, verify that electrical components are
protect the engine from damage.
functioning. Verify that the hour meter is displaying
The alarms function in order to warn the operator information. Verify that the engine will crank.
when an abnormal operating condition occurs. The
shutoffs function in order to shut down the engine 2. Turn the battery disconnect switch to the OFF
when a more critical abnormal operating condition position.
occurs. The shutoffs help to prevent damage to the
equipment. 3. Verify that the following items are not functioning:
electrical components, hour meter and engine
If an engine protective device shuts off the engine,
always determine the cause of the shutoff. Make the cranking. If any of the items continue to function
necessary repairs before attempting to start the with the battery disconnect switch in the OFF
engine. position, consult your Caterpillar dealer.
Become familiar with the following information:
Types of the alarm and shutoff controls
Locations of the alarm and shutoff controls
Conditions which cause each control to function

Resetting procedure that is required before starting
the engine
i03646563
Battery Disconnect Switch

(If Equipped)
SMCS Code: 1411
The battery disconnect switch and the engine start
switch perform different functions. Turn off the battery
disconnect switch in order to disable the entire
electrical system. The battery remains connected to
the electrical system when you turn off the engine
start switch.
Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other components.
Also turn the battery disconnect switch to the OFF
position and remove the key when the engine will not
be used for an extended period of a month or more.
This will prevent drainage of the battery.
38 SEBU8468
Electronic Modular Control Panel 3 (EMCP 3)
i02369871

SMCS Code: 4490
Electronic Control Module (Generator Set)
(1) Display screen (7) Lamp test key (13) Right key
(2) AC overview key (8) Run key (14) Enter key
(3) Engine overview key (9) Auto key (15) Down key
(4) Yellow warning lamp (10) Stop key (16) Left key
(5) Red shutdown lamp (11) Up key
(6) Alarm acknowledge key (12) Escape key
SEBU8468 39
Navigation Keys check box does not have a check mark, the function
is disabled. Pressing the RIGHT key will enable the
AC Overview (2) The AC OVERVIEW key will function. Pressing the RIGHT key will also cause a
navigate the display to the first screen of AC check mark to appear.
information. The AC OVERVIEW information
contains various AC parameters that summarize the Enter Key (14) The ENTER key is used in order
electrical operation of the generator set. to navigate through the menus. When the key is
pressed, the user moves forward or the user moves
Engine Overview (3) The ENGINE OVERVIEW downward through the menus. The ENTER key is
key will navigate the display to the first screen of also used to save any changes while the setpoints
engine information. The ENGINE OVERVIEW are being programmed. Pressing the ENTER key
information contains various engine parameters that during programming the setpoints causes the
summarize the operation of the generator set. changes to be saved to memory.
Acknowledge Key (6) Pressing the Down Key (15) The DOWN key is used to
ACKNOWLEDGE key will cause the horn relay to navigate downward through the various menus or
turn off. This will silence the horn. Pressing this key screens. The DOWN key is also used to program
will also cause any red or yellow flashing lights to the setpoints. The DOWN key is used to decrease
either turn off or to come on continuously, depending the digits when entering numeric data. If the setpoint
on the active status of the alarms. The requires selection from a list, the DOWN key is
ACKNOWLEDGE key may also be configured to used to navigate DOWN through the list.
send out a global alarm silence signal on the J1939
Data Link, which will silence the horns on the Left Key (16) The LEFT key is used during
annunciators. setpoint adjustment. The LEFT key is used to
select the digit that is edited during the entry of
Lamp Test Key (7) Pressing and holding the numeric data. The LEFT key is also used during
LAMP TEST key will cause each LED and the some of the setpoint adjustments to select a check
display screen pixels to turn on continuously until the box. The key is also used to unselect a check box. If
key is released. a check box has a check mark, pressing the LEFT
key will disable the function. Pressing the key will also
RUN Key (8) Pressing the RUN key will start the remove the check mark. Pressing the LEFT key
engine. will also cause the check mark to disappear. If the
AUTO Key (9) Pressing the AUTO key will cause check box does not have a check mark, pressing the
the engine to enter the AUTO mode. The engine LEFT key will enable the function. Pressing the
will start if the module receives a start command from LEFT key will also cause a check mark to appear.
a remote source.
STOP Key (10) Pressing the STOP key will stop Alarm Indicators
the engine.
Yellow Warning Lamp (4) A flashing yellow light
Up Key (11) The UP key is used to navigate indicates that there are active warnings that have not
through the various menus and monitoring screens. been acknowledged. A continuous yellow light
The UP key is also used when a setpoint is indicates that there are acknowledged warnings that
entered. When entering numeric data, the UP key are active. If there are any active warnings, the yellow
is used in order to increment the digits (0-9). If the light will change from flashing yellow to continuous
setpoint requires selection from a list, the UP key is yellow after the ACKNOWLEDGE key is pressed.
used to navigate UP through the list. If there are no longer any active warnings, the yellow
Escape Key (12) The ESCAPE key is used in light will turn off after the ACKNOWLEDGE key is
order to navigate through the menus. When the key is pressed.
pressed, the user moves backward or the user moves Red Shutdown Lamp (5) A flashing red light
upward through the menus. The ESCAPE key is indicates that there are active shutdowns that have
also used to exit out of entering data when the user is not been acknowledged. A continuous red light
programming the setpoints. If the ESCAPE key is indicates that there are active shutdowns that have
pressed while the user is programming the setpoints, been acknowledged. If there are any active
none of the changes made on the screen will be shutdowns the red light will change from flashing red
saved to memory. to continuous red after the ACKNOWLEDGE key is
pressed. Any condition that has caused a shutdown
Right Key (13) The RIGHT key is used during must be manually reset. If there are no longer any
setpoint adjustment. The RIGHT key is used to active shutdowns, the red light will turn off.
select which digit is edited while entering numeric
data. The RIGHT key is also used during some
setpoint adjustments in order to select or to unselect
a check box. If a check box has a check mark, the
function has been enabled. Pressing the RIGHT
key will disable the function. Pressing the RIGHT
key will also cause the check mark to disappear. If the
40 SEBU8468
Digital Inputs Engine oil temperature
Note: There are 8 digital inputs on EMCP 3.2 and Exhaust temperature
EMCP 3.3 . There are 6 digital inputs on EMCP
3.1 . Rear bearing temperature
Digital Input 1 Digital Input 1 is used for the Right exhaust temperature
emergency stop. This input should be wired to
GROUND through an Emergency Stop switch. The Left exhaust temperature
input can be set to activate on an active high
(normally closed contact) or an active low (normally Levels
open contact). Activating the emergency stop input
will cause the generator set to stop immediately. The Engine coolant level
emergency stop input will also prevent the generator
set from starting. Once Digital Input 1 goes active, the Engine oil level
engine will not start until the event has been cleared.
Fuel level
Refer to System Operation, Troubleshooting, Testing
and Adjusting, RENR7902, Digital Input Resetting. External fuel tank level
Digital Input 2 Digital Input 2 is used for remotely Other
starting and stopping the generator set. This input
should be wired to GROUND through a switch that Air damper closed
can be initiated remotely. The input can be set to
activate on an active high (normally closed contact) or ATS in normal position
an active low (normally open contact). If the input is
active and the engine is in AUTO, the engine will ATS in emergency position
attempt to start. Once the input becomes inactive the
engine will enter into cooldown mode (if programmed) Battery charger failure
and then the engine will stop.
Generator breaker closed
The remainder of the inputs can be configured. The
main purpose for the other DIGITAL inputs is to Utility breaker closed
add additional monitoring capabilities of the
Fuel leak detected
parameters for the engine or generator. The inputs
can be configured by going to the EVENT I/P Custom event
FUNCTIONS parameter under the SETPOINTS
menu. The DIGITAL INPUTS parameter can only For detailed information about the electronic control
be set to ACTIVE HIGH or ACTIVE LOW in module, see Systems Operation, Troubleshooting,
order to initiate a High Warning, Low Warning, High Testing and Adjusting, RENR7902, EMCP3 .
Shutdown, Low Shutdown, or Status.
The inputs can be programmed to monitor the Control Panel
following parameters or components. Refer to
System Operation, Troubleshooting, Testing and
Adjusting, RENR7902, Digital Input Programming.
Pressures
Air filter differential pressure
Engine oil pressure

Fire extinguisher pressure
Fuel filter differential pressure

Oil filter differential pressure
Starting air pressure

Temperatures This is a typical view. The shape of this panel will
differ from installation to installation.
Ambient air temperature (1) Starting aid auto/manual switch (optional)
(2) Panel light switch
Engine coolant temperature (3) Emergency stop push button
(4) Voltage adjust switch
SEBU8468 41
(5) Speed potentiometer (optional) module uses indicator lights and an audible horn to
give the operator information about the current status
Note: Your application may not have all of these of the system. The annunciator module can be used
features. to announce faults and/or status signals to the
operator. The annunciator module allows the operator
Starting Aid Auto/Manual Switch (1) The starting to silence the horn. The annunciator module also
aid switch is optional. The starting aid switch is used allows the operator to acknowledge faults to the
to inject ether into the engine when you are starting system.
the engine in cold weather conditions. When the
starting aid switch is in the ON position, the switch There are seventeen pair of LED indicators on the
energizes the starting aid solenoid valve and the annunciator's front panel. Sixteen pair of LED
switch meters a specific amount of ether into a indicators are used to announce events, diagnostics,
holding chamber. When the starting aid switch is and ready signals. The seventeenth pair of LED
released, the solenoid releases the ether to the indicators is used as a combined network/module
engine. status LED. The seventeenth pair of LED indicators
can tell the operator if there is a problem with the
Panel Light Switch (2) The panel lights switch J1939 data link connection.
turns on or the panel lights switch turns off the panel
lights. Basic Operation
Emergency Stop Push Button (3) The emergency
stop push button (ESPB) is used to shut down the Each pair of LED indicators on the annunciator
engine during an emergency situation. If equipped, consists of two of the following three colors: green,
the ESPB shuts off the fuel and the ESPB activates yellow and red. For example, a pair of red and yellow
the optional air shutoff. LED indicators may be configured for engine oil
pressure. If a low engine oil pressure warning is read
Voltage Adjust Switch (4) This switch can be used over the data link, the annunciator will flash the yellow
to raise the voltage. The switch can also be used to LED and the audible horn will sound. If the low engine
lower the voltage. oil pressure shutdown is read over the data link, the
annunciator will flash the red LED and the audible
Speed Potentiometer (5) The speed potentiometer horn will sound.
is optional. The speed potentiometer can be used
with the generator set that has an electronic governor. To acknowledge the shutdown and alarm conditions
or to silence the horn, press the Alarm
Acknowledge button that is located near the middle
Annunciator Module of the annunciator.
To test the LED indicators or to test the horn when the
data link is connected or the data link is
disconnected, hold in the Lamp Test button that is
located near the top of the annunciator.
Configuration
The annunciator module can be customized in order
to signal many different conditions that are related to
the system. Each pair of LEDs must be configured by
using the appropriate service tool. Once the service
tool has been connected to the annunciator, the user
must enter the Configuration screen. Each pair of
LEDs has four settings: SPN, Trigger Type, Trigger
Severity Level and Failure Mode Identifier (FMI).
For detailed information about the annunciator
module, see Systems Operation, Troubleshooting,
Testing and Adjusting, RENR7902, EMCP3 .
General Information
The annunciator module is used to indicate various
system events and conditions. The annunciator
42 SEBU8468
i03983091

(EMCP 4.1/4.2 If equipped)
SMCS Code: 4490
Electronic Control Module (Generator Set)
EMCP 4 Control System Panel
(1) Display screen (7) Event log (13) Right key
(2) AC overview key (8) Run key (14) OK key
(3) Engine overview key (9) Auto key (15) Down key
(4) Main menu key (10) Stop key (16) Left key
(5) Alarms acknowledge key (11) Escape key
(6) Reset shut down Key (12) Up key
SEBU8468 43
Navigation Keys data. The RIGHT key is also used during some
setpoint adjustments in order to select or to unselect
AC Overview (2) The AC OVERVIEW key will a check box. If a check box has a check mark, the
navigate the display to the first screen of AC function has been enabled. Pressing the RIGHT
information. The AC OVERVIEW information key will disable the function. Pressing the RIGHT
contains various AC parameters that summarize the key will also cause the check mark to disappear. If the
electrical operation of the generator set. check box does not have a check mark, the function
is disabled. Pressing the RIGHT key will enable the
Engine Overview (3) The ENGINE OVERVIEW function. Pressing the RIGHT key will also cause a
key will navigate the display to the first screen of check mark to appear.
engine information. The ENGINE OVERVIEW
information contains various engine parameters that Enter Key (14) The ENTER key is used in order
summarize the operation of the generator set. to navigate through the menus. When the key is
pressed, the user moves forward or the user moves
Main Menu Key (4) The MAIN MENU key will downward through the menus. The ENTER key is
navigate the display to the main menu directly without also used to save any changes while the setpoints
having to navigate out of menus. are being programmed. Pressing the OK key
during programming the setpoints causes the
Acknowledge Key(5) Pressing the changes to be saved to memory.
ACKNOWLEDGE key will cause the horn relay to
turn off. The horn relay being turned off will silence Down Key (15) The DOWN key is used to
the horn. Pressing the ACKNOWLEDGE key will navigate downward through the various menus or
also cause any red or yellow flashing lights to either screens. The DOWN key is also used to program
turn off or to come on continuously. The the setpoints. The DOWN key is used to decrease
ACKNOWLEDGE key may also be configured to the digits when entering numeric data. If the setpoint
send out a global alarm silence signal on the J1939 requires selection from a list, the DOWN key is
Data Link. Sending out a global alarm silence signal used to navigate DOWN through the list.
on the J1939 Data Link will silence the horns on the
annunciators. Left Key (16) The LEFT key is used during
setpoint adjustment. The LEFT key is used to
Reset Key (6) Pressing the RESET key will reset select the digit that is edited during the entry of
various events. numeric data. The LEFT key is also used during
some of the setpoint adjustments to select a check
Event Log Key (7) Pressing the EVENT LOG box. The key is also used to unselect a check box. If
key will navigate the display to the event log. a check box has a check mark, pressing the LEFT
RUN Key (8) Pressing the RUN key will start the key will disable the function. Pressing the key will also
engine. remove the check mark. Pressing the LEFT key
will also cause the check mark to disappear. If the
AUTO Key (9) Pressing the AUTO key will cause check box does not have a check mark, pressing the
the engine to enter the AUTO mode. The engine LEFT key will enable the function. Pressing the
will start if the module receives a start command from LEFT key will also cause a check mark to appear.
a remote source.
STOP Key (10) Pressing the STOP key will stop
the engine. Alarm Indicators
Escape Key (11) The ESCAPE key is used in Yellow Warning Lamp A yellow warning lamp is
order to navigate through the menus. When the key is located above the ACKNOWLEDGE key. A
pressed, the user moves backward or the user moves flashing yellow light indicates that there are active
upward through the menus. The ESCAPE key is warnings that have not been acknowledged. A
also used to exit out of entering data when the user is continuous yellow light indicates that there are
programming the setpoints. If the ESCAPE key is acknowledged warnings that are active. If there are
pressed while the user is programming the setpoints, any active warnings, the yellow light will change from
changes made on the screen will not be saved to flashing yellow to continuous yellow after the
memory. ACKNOWLEDGE key is pressed. If there are no
longer any active warnings, the yellow light will turn
Up Key (12) The UP key is used to navigate off after the ACKNOWLEDGE key is pressed.
through the various menus and monitoring screens.
The UP key is also used when a setpoint is Red Shutdown Lamp A red shutdown lamp is
entered. When entering numeric data, the UP key located above the RESET key. A flashing red light
is used in order to increment the digits (0-9). If the indicates that there are active shutdowns that have
setpoint requires selection from a list, the UP key is not been acknowledged. A continuous red light
used to navigate UP through the list. indicates that there are active shutdowns that have
been acknowledged. If there are any active
Right Key (13) The RIGHT key is used during shutdowns, the red light will change from flashing red
setpoint adjustment. The RIGHT key is used to to continuous red after the ACKNOWLEDGE key is
select which digit is edited while entering numeric pressed. Any condition that has caused a shutdown
44 SEBU8468
must be manually reset. If there are no longer any with the generator set that has an electronic governor.
active shutdowns, the red light will turn off.
Customer Connection (6) The customer
connection is a 9-pin connector for connecting the
Caterpillar Electronic Technician .
Digital Inputs
Horn (7) The horn provides an audible alarm.
There are several digital inputs and outputs on
EMCP 4.1 and EMCP 4.2 . For detailed Pump Run Switch (if equipped)(8) Under normal
information about the inputs on this electronic control circumstances, the fuel transfer process is automatic.
module, see Systems Operation, Troubleshooting, In some instances, a manual operation may be
Testing, and Adjusting, UENR1209, EMCP4.1/4.2 . required. Press the pump run switch once in order to
start the pump manually.
Control Panel Pump Stop Switch (if equipped)(9) The pump
stop switch is a push-button switch that locks into
position. The pump stop switch will stop the pump if
the switch is locked into position. Releasing the
switch will place the pump back into the run mode.
Annunciator Module
(1) Starting aid auto/manual switch (if equipped)
(3) Emergency stop push button
(4) Voltage adjust switch (if equipped)
(5) Speed potentiometer (if equipped)
(6) Customer connection (if equipped)
(7) Horn (if equipped)
(8) Pump run switch (if equipped)
(9) Pump stop switch (if equipped)
Starting Aid Auto/Manual Switch (1) The starting

aid switch is optional. The starting aid switch is used
to inject ether into the engine when you are starting
the engine in cold-weather conditions. When the
starting aid switch is in the ON position, the solenoid
valve is energized. The switch then meters a specific
amount of ether into a holding chamber. When the
starting aid switch is released, the solenoid releases
the ether to the engine.
Panel Light Switch (2) The panel lights switch
lights.
Emergency Stop Push Button (3) The emergency
stop push button (ESPB) is used to shut down the
engine during an emergency situation. If equipped,
the ESPB shuts off the fuel and the ESPB activates
the optional air shutoff.
Voltage Adjust Switch (4) This switch can be used
to raise the voltage. The switch can also be used to
lower the voltage.
Speed Potentiometer (5) The speed potentiometer
is optional. The speed potentiometer can be used
SEBU8468 45
(20) Alarm acknowledge button
General Information
The annunciator module is used to indicate various
module uses indicator lights and an audible horn to
give the operator information about the status of the
system. The annunciator module can be used to
announce faults and/or status signals to the operator.
The annunciator module allows the operator to
silence the horn. The annunciator module also allows
the operator to acknowledge faults to the system.
There are 17 pairs of LED indicators on the front
panel of the annunciator. The 16 pairs of LED
indicators are used to announce events, diagnostics,
and ready signals. The 17th pair of LED indicators is
used as a combined network/module status LED. The
17th pair of LED indicators can tell the operator if
there is a problem with the J1939 data link
connection.
Basic Operation
Each pair of LED indicators on the annunciator
consists of two of the following three colors: green,
yellow and red. For example, a pair of red and yellow
LED indicators may be configured for engine oil
pressure. If a low engine oil pressure warning is read
over the data link, the annunciator will flash the yellow
LED. The audible horn will then sound. If the low
engine oil pressure shutdown is read over the data
link, the annunciator will flash the red LED. The
audible horn will then sound.
To acknowledge the shutdown and alarm conditions
or to silence the horn, press the Alarm
Acknowledge button (20).
To test the LED indicators or the horn when the data
link is either connected or disconnected, hold the
Lamp Test button in.
Configuration
The annunciator module can be customized in order
the system. Each pair of LEDs must be configured by
using the appropriate service tool. Once the service
tool has been connected to the annunciator, the user
must enter the Configuration screen. Each pair of
LEDs has four settings: SPN, Trigger Type, Trigger
Severity Level and Failure Mode Identifier (FMI).
For detailed information about the annunciator
Testing, and Adjusting, UENR1209, EMCP4.1/4.2 .
46 SEBU8468
i04197190

(EMCP 4.3/4.4)
SMCS Code: 4490
(1) Display screen (9) Main menu (16) Auto key

(2) F4 Soft key (10) Warning Indicator lamp (yellow) (17) Stop key
(3) F3 Soft key (11) Alarms acknowledge key and silence (18) Escape key
(4) F2 Soft key key (19) Up key
(5) F1 Soft key (12) Shutdown Indicator lamp (red) (20) Right key
(6) Control key (13) Event reset key (21) OK key
(7) AC overview key (14) Event log key (22) Down key
(8) Engine overview key (15) Run key (23) Left key
SEBU8468 47
General Information Displaying event codes from other modules

The main component of the Electronic Modular Programming the display preferences of the
Control Panel 4.3/4.4 (EMCP 4.3/4.4) is the electronic EMCP 4.3/4.4
control module (ECM). This section discusses the
display, keys, and indicators on the control system Changing password levels of the EMCP 4.3/4.4
panel of the ECM. The EMCP 4.3/4.4 panel is used
for monitoring and controlling many of the generator
set functions. Some of the functions include: Alarm Acknowledge/Silence Key
Sending start and stop signals to the engine (10) Alarm Acknowledge/Silence Key Pressing
the alarm acknowledge/silence key will cause the
Providing visual and audible indications when horn relay output to turn off and silence the horn.
warning or shutdown events occur Pressing the key will also cause any yellow or red
flashing lights to turn off or to become solid
Displaying engine information and AC generator depending on the active status of the alarms. The
set information alarm acknowledge/silence key may also be
configured to send out a global alarm silence on the
Displaying Suspect Parameter Number (SPN) and J1939Data Link which will silence horns on
Failure Mode Identifier (FMI) information for events annunciators. However, other modules must be
configured in order to listen to the global
Programming set points for the standard EMCP acknowledge.
4.3/4.4 (The set points for optional modules are set
with the use of Cat ET .)
Event Reset Key
Annunciator configuration is done within the EMCP
4.3/4.4 (11) Event Reset Key The event reset button will
clear all inactive fault conditions.
ECM Front Panel Components
The following components can be found on the front Alarm Indicators
panel of the ECM:
Yellow Warning Light The yellow warning light
Information Display (10) is located directly above the alarm acknowledge/
silence key (11). A flashing yellow light indicates that
Alarm Indicators there are unacknowledged active warnings. A solid
yellow light indicates that there are acknowledged
Alarm Acknowledge/Silence Key warnings active. If there are any active warnings, the
yellow light will change from flashing yellow to solid
Event Reset Key yellow after the alarm acknowledge/silence key is
pressed. If there are no longer any active warnings,
Function Keys the yellow light will turn off after the alarm
acknowledge/silence key is pressed.
Navigation Keys
System Overview Keys Red Shutdown Light The red shutdown (12) light
is located directly above the event reset key (13). A
Information Display flashing red light indicates that there are
unacknowledged active shutdown events. A solid red
light indicates that there are acknowledged shutdown
(1) Display Screen Information from the EMCP 4 events active. If there are any active shutdown
is displayed on the display screen. This screen is events, the red light will change from flashing red to
used for the following programming and display solid red after the alarm acknowledge/silence key is
functions. pressed. Any condition that has caused a shutdown
event must be manually reset. If there are no longer
Displaying AC parameter information of the any active shutdown events, the red light will turn off.
generator set
Displaying engine parameter information of the Function Keys
generator set
(2)F4 Pressing the F4 key will enable the function
Programming set points for the generator that is described on the screen directly above this
key. When this key is defined on screen to scroll up or
Displaying engine event information down, the Scroll Up and Scroll Down keys will also
function the same.
48 SEBU8468
increment the digits (0-9). If the set point requires

selection from a list, then the key is used to navigate
(3)F3 Pressing the F3 key will enable the function up through the list.
that is described on the screen directly above this
key. When this key is defined on screen to scroll up or (20) Right Key The right key is used during set
down, the Scroll Up and Scroll Down keys will also point adjustment. During numeric data entry, the key
function the same. is used in order to choose which digit is being edited.
The key is also used during certain set point
adjustments in order to select a check box or to
(4)F2 Pressing the F2 key will enable the function deselect a check box. If a box has a check mark
that is described on the screen directly above this inside, then pressing the key will cause the check
key. When this key is defined on screen to scroll up or mark to disappear. If the box does not have a check
down, the Scroll Up and Scroll Down keys will also mark inside, then pressing the key will cause a check
function the same. mark to appear inside.
(22) Down Key The down key is used in order to
(5) F1 Pressing the F1 key will enable the function navigate down through the various menus or
that is described on the screen directly above this monitoring screens. The key is also used during set
key. When this key is defined on screen to scroll up or point entry. During numeric data entry, the key is used
down, the Scroll Up and Scroll Down keys will also in order to decrement the digits (0-9). If the set point
function the same. requires selection from a list, then the key is used to
(15) RUN Pressing the RUN key causes the navigate down through the list.
EMCP 4.3/4.4 to enter the run mode. (23) Left Key The left key is used during set point
(16) AUTO Pressing the AUTO key causes the adjustment. During numeric data entry, the key is
used in order to choose which digit is being edited.
EMCP 4.3/4.4 to enter the auto mode.
The key is also used during certain set point
(17) STOP Pressing the STOP key causes the adjustments in order to select a check box or to
EMCP 4.3/4.4 to enter the stop mode or the cool deselect a check box. If a box has a check mark
down mode. inside, then pressing the key will cause the check
mark to disappear. If the box does not have a check
(18) Escape Key The escape key is used during mark inside, then pressing the key will cause a check
menu navigation in order to navigate up through the mark to appear inside.
menu/submenu structure. Each key press causes the
user to move backward (upward) through the menus.
The escape key is also used in order to cancel of data System Overview Keys
entry screens during set point programming. If the
escape key is pressed during set point programming, (7) AC Overview Pressing the AC overview key
then none of the changes displayed on the screen will displays the first screen of AC information for the
be saved to memory. generator set. This initial information page contains
(21) OK Key The OK key is used during menu various AC parameters that summarize the electrical
navigation in order to move forward (downward) operation of the generator set. Additional AC
through the menu/submenu structure. The key is also parameters can be viewed by pressing the down key
used during set point programming in order to save multiple times.
set points changes. Pressing the OK key during set (8) Engine Overview Pressing the engine overview
point programming causes set point changes to be key displays the first screen of engine information.
saved to memory. This initial information page contains various engine
parameters that summarize the operation of the
engine. Additional engine parameters can be viewed
Navigation Keys by pressing the down key multiple times.
(6) Control Key The control key will navigate the

display to the screen that allows the user to monitor Control Panel
and/or adjust various special control features.
(9) Main Menu Key The main menu will navigate
the display to the main menu directly without having
to navigate out of menus.
(14) Event Log The event log button will navigate
the display to the event log.
(19) Up Key The up key is used in order to navigate
up through the various menus or monitoring screens.
The key is also used during set point entry. During
numeric data entry, the key is used in order to
SEBU8468 49
stop switch is a push-button switch that locks into

position. The pump stop switch will stop the pump if
the switch is locked into position. Releasing the
switch will place the pump back into the run mode.
Annunciator Module
(1) Starting aid auto/manual switch (if equipped)
(3) Emergency stop push button
(4) Voltage adjust switch (if equipped)
(5) Speed potentiometer (if equipped)
(6) Customer connection (if equipped)
(7) Horn (if equipped)
(8) Pump run switch (if equipped)
(9) Pump stop switch (if equipped)
Starting Aid Auto/Manual Switch (1) The starting

aid switch is optional. The starting aid switch is used
to inject ether into the engine when you are starting
the engine in cold-weather conditions. When the
starting aid switch is in the ON position, the switch
energizes the starting aid solenoid valve. The starting
aid solenoid valve meters a specific amount of ether Illustration 51 g01101388
into a holding chamber. When the starting aid switch
is released, the solenoid releases the ether to the General Information
engine.
Panel Light Switch (2) The panel lights switch The annunciator module is used to indicate various
module uses indicator lights and an audible horn to
lights.
give the operator information about the status of the
Emergency Stop Push Button (3) The emergency system. The annunciator module can be used to
stop push button (ESPB) is used to shut down the announce faults and/or status signals to the operator.
engine during an emergency situation. If equipped, The annunciator module allows the operator to
the ESPB shuts off the fuel and the ESPB activates silence the horn. The annunciator module also allows
the optional air shutoff. the operator to acknowledge faults to the system.
Voltage Adjust Switch (4) This switch can be used There are 17 pairs of LED indicators on the front
to raise the voltage. The switch can also be used to panel of the annunciator. 16 pairs of LED indicators
lower the voltage. are used to announce events, diagnostics, and ready
signals. The 17th pair of LED indicators is used as a
Speed Potentiometer (5) The speed potentiometer combined network/module status LED. The 17th pair
is optional. The speed potentiometer can be used of LED indicators can tell the operator if there is a
with the generator set that has an electronic governor. problem with the J1939 data link connection.
Customer Connection (6) The customer
connection is a 9-pin connector for connecting the Basic Operation
Caterpillar Electronic Technician .
Each pair of LED indicators on the annunciator
Horn (7) The horn provides an audible alarm. consists of two of the following three colors: green,
yellow and red. For example, a pair of red and yellow
Pump Run Switch (if equipped)(8) Under normal LED indicators may be configured for engine oil
circumstances, the fuel transfer process is automatic. pressure. If a low engine oil pressure warning is read
In some instances, a manual operation may be over the data link, the annunciator will flash the yellow
required. Press the pump run switch once in order to LED and the horn will sound. If the low engine oil
start the pump manually. pressure shutdown is read over the data link, the
Pump Stop Switch (if equipped)(9) The pump annunciator will flash the red LED and the horn will
sound.
50 SEBU8468
Gauges and Indicators
To acknowledge the shutdown and alarm conditions Oil Filter Differential Pressure This
or to silence the horn, press the Alarm gauge indicates the difference in
Acknowledge button that is located on the pressure between the inlet side and the
annunciator. outlet side of the engine oil filters. As the oil filter
Test the LED indicators or the horn when the data link elements become plugged, oil filter differential
is connected or disconnected, by pushing Lamp pressure will increase. Replace the engine oil
Test button located on the annunciator. filter elements when the oil filter differential
pressure reaches 105 kPa (15 psi).
Configuration Jacket Water Coolant Temperature
This gauge indicates the temperature of
The annunciator module can be customized in order the engine coolant at the outlet for the
the system. Each pair of LEDs must be configured by jacket water. The jacket water coolant
using the appropriate service tool. Once the service temperature may vary according to the load. The
tool has been connected to the annunciator, the user jacket water coolant temperature should never be
must enter the Configuration screen. Each pair of allowed to exceed the boiling temperature of the
LEDs has four settings: SPN, Trigger Type, Trigger pressurized cooling system. The operating range
Severity Level and Failure Mode Identifier (FMI). for jacket water coolant temperature is
88 to 100 C (190 to 210 F). Higher temperatures
For detailed information about the annunciator may occur under certain conditions.
Testing and Adjusting, UENR1210, EMCP4.3/4.4 . The engine should operate within the normal
temperature range. The sensor for jacket water
i02755534 coolant temperature must be fully submerged in order
to detect the temperature correctly. If the engine is
Gauges and Indicators operating above the normal temperature range,
perform the following procedure:
SMCS Code: 7450
1. Reduce the load and the engine rpm.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order. 2. Inspect the cooling system for leaks.
Determine the normal operating range by observing
the gauges over a period of time. 3. Determine if the engine must be shut down
Noticeable changes in gauge readings can indicate immediately or if the engine can be cooled by
potential gauge or engine problems. Problems may reducing the load and rpm.
also be indicated by gauge readings that change
even if the readings are within specifications. NOTICE
Determine and correct the cause of any significant High inlet manifold air temperature increases the risk
change in the readings. Consult your Caterpillar of engine damage. Maximum inlet air temperature is
dealer for assistance. 115 C (235 F).
Your engine may not have the same gauges or all of
the gauges that are described below.
Inlet Manifold Air Temperature This
gauge indicates the inlet manifold air
NOTICE temperature to the cylinders. The sensor
If no oil pressure is indicated, STOP the engine. The for inlet manifold air temperature is located after
engine will be damaged from operating without oil the aftercooler.
pressure.
Maintain the aftercooler in good condition. Ensure
that the inlet manifold air temperature of an engine at
Engine Oil Pressure This gauge operating temperature does not vary by more than
indicates the pressure of the engine oil. 4 C (7 F) from the maximum inlet manifold air
The engine oil pressure will be highest temperature.
after a cold engine is started. The engine oil
pressure will decrease as the engine warms up. Inlet Manifold Air Pressure This gauge
The engine oil pressure will increase when the indicates the air pressure (turbocharger
engine rpm is increased. The engine oil pressure boost pressure) in the air plenum (air
will stabilize when the engine rpm is stable. The inlet manifold) after the aftercooler. The inlet
typical range for engine oil pressure at low idle manifold air pressure depends on the engine
rpm is 186 to 344 kPa (27 to 50 psi). The typical rating, the load, and the operating conditions.
range for engine oil pressure at rated rpm is
Pyrometer The pyrometer indicates the exhaust
275 to 600 kPa (40 to 87 psi). stack temperature at the exhaust elbows. For engines
SEBU8468 51
Gauges and Indicators
with two exhaust stacks, the two exhaust stack Air Cleaner Differential Pressure This
temperatures may vary slightly. This may be due to gauge indicates the difference in air
variation of the sensitivity of the two thermocouples. pressure between the inlet side and the
Maximum exhaust stack temperature can vary from engine side of the air filter element. The air
480 to 590 C (900 to 1100 F). cleaner differential pressure is measured from the
air inlet to the turbocharger. As the air filter
The pyrometer also indicates the temperature of the element becomes plugged, the difference in
exhaust gas of each individual cylinder. These pressure between the two sides of the air cleaner
temperatures are measured at the exhaust port of element will increase. For optimum engine
each cylinder head. The exhaust temperature will performance, clean the air cleaner elements or
vary slightly between the cylinders. replace the air cleaner elements when the air
cleaner differential pressure reaches 3.75 kPa
Tachometer This gauge indicates the (15 inches of H2O). Maximum air cleaner
engine rpm. differential pressure is 7.5 kPa (30 inches of H2O).
NOTICE Ammeter This gauge indicates the

To help prevent engine damage, never exceed the amount of charge or discharge in the
high idle rpm. An overspeed can result in serious battery charging circuit. Operation of the
damage to the engine. The engine can be operated at indicator should be to the right side of 0 (zero).
high idle without damage, but the engine should Engine Oil Temperature This gauge
never be allowed to exceed the high idle rpm. indicates the engine oil temperature
after the oil has passed through the oil
Note: The high idle rpm and the full load rpm are cooler. The oil cooler is thermostatically
stamped on the engine Information Plate. controlled. The oil temperature is controlled by an
82 C (180 F) temperature regulator that is in
Service Hour Meter The service hour contact with the oil. The maximum oil temperature
meter indicates the total number of clock at rated rpm and rated load is 104 C (220 F).
hours on the engine.
Cranking Timers There is a cranking
Fuel Pressure This meter indicates fuel timer which may be used on an
pressure to the fuel injection pump from Automatic Start/Stop mode. The timer
the fuel filter. The normal fuel pressure allows the engine to crank for 30 seconds. If the
range is 345 kPa (50 psi) to 520 kPa (75 psi). engine does not start within the 30 second
Minimum fuel pressure is 275 kPa (40 psi) at the interval the Status Control Module will not
rated speed. activate. This condition indicates a failure to start.
A decrease in fuel pressure usually indicates a dirty Coolant Pressure This gauge can be
fuel filter or a plugged fuel filter. As the fuel filter used for jacket water pressure or
becomes plugged, there will be a noticeable auxiliary water pressure.
reduction in the engine's performance.
Fuel Filter Differential Pressure This

gauge indicates the difference in fuel
pressure between the inlet side and the
outlet side of the fuel filter. As the fuel filter
element becomes plugged, the difference in
pressure between the two sides of the fuel filter
increases. Service the fuel filter when the fuel
filter differential pressure reaches 105 kPa
(15 psi).
52 SEBU8468
Engine Diagnostics
Configuration Parameters
Engine Diagnostics (Table 3, contd)

Typical Configuration Parameters
i03259690 Parameter Programmability
Configuration Parameters Engine Rated Speed Software dependent
SMCS Code: 1000; 1900; 1901; 1902 Air Shutoff (ON/OFF) (If Programmable
equipped)
Configuration parameters concern various engine
Ether Control (ON/OFF) Programmable
features. Some parameters can affect the
performance of the engine. Most of the parameters Total Tattletale Unprogrammable
may be programmed with an Electronic Technician
(ET) service tool. Some of the parameters require a Pilot House EMS Status (ON/ Programmable
password in order to be programmed. OFF)
Note: For information on programming the Cold Mode Cylinder Cutout Programmable
parameters, use the appropriate ET service tool and
see the Service Manual, Troubleshooting module. For generator set engines with switchgear
conversions and for marine auxiliary engines, the
Some parameters may not be available on all following parameters are programmed at the factory
applications. If a parameter is not available the ET to 0:crank duration and maximum number of crank
service tool will indicate that the parameter is cycles.
unavailable when the parameter is selected.
Crank duration
Table 3 is a list of typical configuration parameters.
Table 3 Maximum number of crank cycles
Typical Configuration Parameters The 0 settings prevent the Electronic Control
Parameter Programmability
Module (ECM) from engaging the starting motors.
The settings must be reprogrammed before the
Vehicle ID Programmable engine will crank.
Engine Serial Number Programmable Engines that are equipped with a generator set
control panel do not require reprogramming for
Fuel Ratio Control Offset Programmable Crank Duration and for Maximum Number Of
Crank Cycles . These parameters are programmed
ECM Serial Number Unprogrammable
in the generator set control panel.
Personality Module Part Software dependent
Number Ensure that the Air Shutoff and the Ether Control
parameters are Enabled/ON (if equipped) . If the
Personality Module Release Software dependent engine does not have these options, ensure that
Date these two parameters are DISABLED/OFF .
Rated Fuel Position Programmable
If the engine is equipped with a prelube pump, the
Acceleration Delay Time Programmable Engine Prelube Duration must be programmed to a
value that is greater than 0 seconds. Otherwise, the
Engine Acceleration Rate Programmable prelube pump will not cycle. If the engine is not
equipped with a prelube pump, the parameter must
Low Idle Speed Programmable be programmed to 0.
Cooldown Speed Programmable
No password is required for programming a new ECM
Engine Cooldown Duration Programmable during the first 100 hours of service life. This 100 hour
free configuration feature enables the customer to
Engine Prelube Duration Programmable tailor the programmable setpoints to the requirements
of the installation. Exceptions are the following
Crank Duration Programmable
parameters: Fuel Limit , Personality Module
Maximum Number Of Crank Programmable Mismatch , ECM Hours and ECM Total Fuel
Cycles Consumption .
Crank Terminate Speed Programmable
Engine Rotation Software dependent
(continued)
SEBU8468 53
Engine Diagnostics
Caterpillar Monitoring System The ECM will log the event if any response is made
by the Caterpillar Monitoring System. A parameter
The engine is equipped with a programmable may be programmed OFF : the ECM will log the
Caterpillar Monitoring System. The ECM monitors the event if the setpoint for the parameter is exceeded.
operating parameters of the engine. The ECM can
initiate responses if a specific engine parameter Any failure of a sensor will result in disabling the
exceeds an acceptable range. Three possible corresponding portion of the Caterpillar Monitoring
responses may be available for each parameter: System. The failure of a sensor will cause an
WARNING , DERATE and SHUTDOWN . ACTIVE diagnostic code for the sensor.
Some of the responses are not available for some of
the parameters. An ET service tool is used to perform All of the derating is cumulative. A derating of five
the following activities: percent followed by a derating of two percent results
in a total derating of seven percent. If the conditions
Select the available responses. that cause the derating are not corrected, the derating
will continue. The process will continue until the
Program the level for monitoring. engine is at low idle with no load.
Program delay times for each response.
Voltage
The settings for the parameters are programmed at
the factory. If the application requires the settings for The ECM automatically warns the operator of low
the parameters to be reprogrammed, then the system voltage. The default settings that are
parameter must be programmed with an ET service programmed at the factory are listed in Table 4 .
tool. Table 4
The screens of the ET service tool provide guidance Voltage Monitoring

for the programming. The following options can be Parameter Default Setting
programmed: ON/OFF , WARNING , DERATE
and SHUTDOWN . Warning setpoint 20 volts
The screens of the ET service tool also provide Warning delay 10 seconds
guidance for changing setpoints. For information on
programming the Caterpillar Monitoring System, use Hysteresis 2 volts
the appropriate ET service tool and see the Service Security level No password is required.
Manual, Troubleshooting module.
Default Settings for the Caterpillar If the voltage is below 20 volts for 10 seconds, a
warning will occur. To deactivate the warning, the
Monitoring System voltage must rise above 22 volts.
Derate This is a reduction of engine horsepower in The setpoint can be programmed to a value between
response to an abnormal operating condition. 20 and 22 volts.
Setpoint This is a specific value which can activate
the following responses: warning, deration and Engine Oil Pressure
shutdown. The setpoint can be a pressure, a speed, a
temperature, or a voltage. The ECM automatically performs the following
functions for low engine oil pressure:
Hysteresis This is the change in the signal from a
sensor that is tolerated by the ECM. This is the Warning
difference between the setpoint that activates a
response and the setpoint that deactivates the Shutdown
response. For example, a warning for low voltage can
activate if a value below 20 volts is detected by the The strategy is based on a map of the engine oil
ECM. The voltage must rise to 22 volts in order to pressure versus the engine rpm. See Illustration 52 .
clear the warning. The hysteresis is the 2 volts that The default settings that are programmed at the
are above the 20 volts. factory are listed in Table 5 .
Table 5
The Caterpillar Monitoring System is enabled after Engine Oil Pressure
the engine is started. When the engine rpm exceeds
50 rpm below low idle, the ECM begins checking Parameter Default Settings
parameters. The ECM monitors the parameters in
Hysteresis 40 kPa (5.8 psi)
order to determine if the parameters exceed the
setpoints.
(continued)
54 SEBU8468
Engine Diagnostics
(Table 5, contd) Warning

Activation delay 10 seconds
Derating
Security level A password is required.
Shutdown
Warning setpoint Map
The default settings that are programmed at the
Warning delay 4 seconds factory are listed in Table 6 .
Shutdown setpoint Map Table 6
High Coolant Temperature
Shutdown delay 9 seconds
Parameter Default Setting
Warning setpoint 102 C (216 F)
Warning delay 5 seconds
Derate setpoint 107 C (225 F)
Derate delay 30 seconds
Maximum time for a derate 480 seconds

Hysteresis 5 C (9 F)
Maximum derate 25%

Shutdown setpoint 107 C (225 F)
Shutdown delay 5 seconds
If the coolant temperature is above 102 C (216 F)

for five seconds, a warning will occur. The coolant
temperature must be below 97 C (207 F) in order to
deactivate the warning.
If the coolant temperature is above 107 C (225 F)
for 30 seconds, derating will occur. A continuous 25
percent derating is reached in 480 seconds. When
the coolant temperature is less than 102 C (216 F),
the percent of the derating decreases. The percent of
the derating decreases until the capability of
providing full power is restored. However, if the
coolant temperature rises above the setpoint again,
the derating will resume.
Map of the engine oil pressure versus the engine rpm
(Y) Engine oil pressure in kPa If the coolant temperature is above 107 C (225 F)
(X) Engine rpm for five seconds, a shutdown will occur.
(1) Hysteresis
(2) Minimum engine oil pressure Note: The default setting for the delay of the derating
is programmed to the maximum value of 30 seconds.
If the engine oil pressure is below the minimum The delay for the shutdown is five seconds. These
pressure for four seconds, a warning will occur. To settings result in a shutdown that occurs before a
deactivate the warning, the engine oil pressure must derating. These settings are programmed because
rise to 40 kPa (5.8 psi) above the minimum pressure.
most customers prefer a shutdown for high coolant
If the engine oil pressure is below the minimum temperature. The settings can be programmed to
pressure for nine seconds, a shutdown will occur. different values.
The map cannot be reprogrammed. The setpoint can be programmed in the range of
90 to 102 C (194 to 215 F).
High Coolant Temperature
The ECM will automatically perform the following
functions for high coolant temperature:
SEBU8468 55
Engine Diagnostics
Low Coolant Temperature Note: The default settings for the warning and for the
shutdown are equal. Therefore, the warning and the
The ECM will automatically warn the operator of low shutdown occur simultaneously. These settings were
coolant temperature. The default settings that are selected in order to log both a warning and a
programmed at the factory are listed in Table 7 . shutdown: furthermore, an overspeed condition can
Table 7 occur rapidly.
Low Coolant Temperature The setpoints can be programmed to a value
Parameter Default Setting between 1200 and 2400 rpm.
Warning setpoint 80 C (176 F)

Inlet Air Restriction
Activation delay 10 minutes functions if a high inlet air restriction occurs:
Hysteresis 5 C (9 F) Warning
Derating
The engine must operate for a minimum of ten The strategy is applied to the right side air filter and/or
minutes in order to activate this strategy. If the coolant the left side air filter. The default settings that are
temperature is below 80 C (176 F) for five seconds, programmed at the factory are listed in Table 9 .
a warning will occur. To deactivate the warning, the Table 9
coolant temperature must rise above 85 C (185 F).
Inlet Air Restriction
The setpoint can be programmed in the range of Parameter Default Setting
63 to 85 C (145 to 185 F).
Warning setpoint 7 kPa (1 psi)
Note: The low coolant temperature is monitored in
order to detect a failure of the water temperature
regulators. This feature is not intended to monitor Derate setpoint 7 kPa (1 psi)
the operation of jacket water heaters.
Overspeed Security level A password is required.
The ECM will automatically perform the following Derate per 1 kPa (.15 psi) 2%
functions if an engine overspeed occurs: Maximum restriction 25 kPa (3.6 psi)
Warning
If the inlet air restriction is above 7 kPa (1 psi) for five
Shutdown seconds, both a warning and a derating will occur.
The continuous schedule of the derating is two
Different setpoints are based on the engine percent per 1 kPa (0.15 psi). The maximum derating
application and the engine rating. The default settings is 50 percent at 25 kPa (3.6 psi). The derating
that are programmed at the factory are listed in Table remains at the maximum level until the situation is
8. corrected.
Table 8
Overspeed Altitude
Parameter Default Setting The ECM automatically compensates for engine
Warning setpoint 1.18 times rated rpm operation at higher elevations. The ECM derates the
fuel delivery according to the barometric pressure.
Warning delay 0 seconds The barometric pressure is sensed by the
atmospheric pressure sensor. The atmospheric
Shutdown setpoint 1.18 times rated rpm pressure has an effect on the performance of the
Shutdown delay
engine. Derating the fuel delivery maintains the
0 seconds
temperatures of the exhaust gas within acceptable
Hysteresis 100 rpm limits.
If the engine speed exceeds the setpoint rpm, a

warning and a shutdown will occur.
56 SEBU8468
Engine Diagnostics
The derating of the engine starts at a specific The derating reduces the power by two percent. This
barometric pressure. The barometric pressure is is followed by a 15 second delay. If the exhaust
equal to the atmospheric pressure of an elevation. temperature is not reduced below the setpoint after
The atmospheric pressure is specific for the engine the 15 second delay, the engine is derated another
and for the engine rating. The default settings that are two percent.
programmed at the factory are listed in Table 10 .
Table 10
When the exhaust temperature is reduced to less
than the setpoint, two percent of the power is restored
Altitude for every 15 seconds. This continues until full power
Default Setting
is restored. However, if the exhaust temperature rises
Parameter
above the setpoint again, the derating resumes.
Derate setpoint 2T specification

Oil Filter Differential Pressure
Derate per 305 m (1000 ft) of The ECM automatically warns the operator of high oil
3% filter differential pressure. The default settings that are
altitude
programmed at the factory are listed in Table 11 .
Maximum derate 35% of the rated power
Table 12
Oil Filter Differential Pressure
If the barometric pressure is below the setpoint, a
warning and a derating will occur. The continuous Parameter Default Setting
schedule of the derating is three percent per 1 kPa
(.15 psi) of pressure below the setpoint. The Warning setpoint 105 kPa (15 psi)
maximum derating is 35 percent. Warning delay 5 seconds
Exhaust Temperature Hysteresis 10 kPa (1.5 psi)
Security level No password is required.

functions if a high exhaust temperature occurs:
If the oil filter differential pressure is above 105 kPa
Warning (15 psi) for five seconds, a warning will occur. To
deactivate the warning, the oil filter differential
Derating pressure must be below 95 kPa (13.5 psi).
The strategy is applied to the right side exhaust
manifold and/or the left side exhaust manifold. The Fuel Filter Differential Pressure
default settings that are programmed at the factory
are listed in Table 11 . The ECM automatically warns the operator of high
fuel filter differential pressure. The default settings
Table 11
that are programmed at the factory are listed in Table
Exhaust Temperature 13 .
Table 13
Fuel Filter Differential Pressure
Warning setpoint 2T specification
Warning setpoint 105 kPa (15 psi)
Derate setpoint 2T specification
Hysteresis 10 kPa (1.5 psi)
Derate delay setpoint 15 seconds
Security level No password is required.
Hysteresis 10 C (18 F)
Security level A password is required. If the fuel filter differential pressure is above 105 kPa
(15 psi) for five seconds, a warning will occur. To
Percent of derate per step 2% per step deactivate the warning, the fuel filter differential
pressure must be below 95 kPa (13.8 psi).
If the exhaust temperature is above the setpoint for
the warning for five seconds, a warning will occur. Crankcase Pressure
If the exhaust temperature is above the setpoint for The ECM will automatically perform the following
derating for five seconds, derating will occur. functions if high crankcase pressure occurs:
SEBU8468 57
Engine Diagnostics
Warning Warning
Derating Derating
Shut down Shut down

The default settings that are programmed at the The default settings that are programmed at the
factory are listed in Table 14 . factory are listed in Table 15 .
Table 14 Table 15
Crankcase Pressure Aftercooler Coolant Temperature
Parameter Default Setting Parameter Default Setting
Warning setpoint 2 kPa (.3 psi) Warning Setpoint 102 C (215 F)
Warning delay 3 seconds Warning delay 5 seconds
Derate setpoint 6 kPa (.9 psi) Derate setpoint 107 C (225 F)
Derate delay 10 seconds Derate delay 5 seconds
Maximum time for a derate 480 seconds Maximum time for a derate 480 seconds
Hysteresis 0.25 kPa (.036 psi) Hysteresis 3 C (5.4 F)
Security level A password is required. Security level A password is required.

Maximum derate 25% Maximum derate 25%
Shutdown setpoint 3.5 kPa (.51 psi) Shutdown setpoint 107 C (225 F)
Shutdown delay 3 seconds Shutdown delay 5 seconds
If the crankcase pressure is above 2 kPa (.3 psi) for If the aftercooler coolant temperature is above 102 C
three seconds, a warning will occur. To deactivate the (215 F) for five seconds, a warning will occur. To
warning, the crankcase pressure must be below deactivate the warning, the aftercooler coolant
1.75 kPa (.254 psi). temperature must be below 99 C (209.6 F).
If the crankcase pressure is above 6 kPa (.9 psi) for If the aftercooler coolant temperature is above 107 C
10 seconds, derating will occur. The continuous (225 F) for five seconds, derating will occur. The
schedule of the derating will reach 25 percent in 480 continuous schedule of the derating will reach 25
seconds. percent in 480 seconds.
When the crankcase pressure is less than 5.75 kPa When the aftercooler coolant temperature is less than
(.39 psi), the percent of the derating is decreased until 104 C (219.6 F), the percent of the derating is
full power is restored. However, if the crankcase decreased until full power is restored. However, if the
pressure rises above the setpoint again, the derating aftercooler coolant temperature rises above the
resumes. setpoint again, the derating resumes.
If the crankcase pressure is above 3.5 kPa (.51 psi)
If the aftercooler coolant temperature is above 107 C
for three seconds, a shutdown will occur.
(225 F) for five seconds, a shutdown will occur.
Note: The default settings result in a shutdown that
occurs before a derating. These settings were Data Link Features
selected for the reason that high crankcase pressure
can occur rapidly. The settings can be CAT Data Link Flash
reprogrammed.
Flash This is a method of downloading or
programming electronic information.
Aftercooler Coolant Temperature
The ECM will automatically perform the following The CAT Data Link Flash provides the capability to
functions when high aftercooler coolant temperature flash the software that controls the engine through the
occurs: use of the CAT Data Link.
58 SEBU8468
Engine Diagnostics
CAT Secondary Data Link The air shutoff uses a plate that rotates on a shaft in
order to shut off inlet air to the aftercooler. The engine
The CAT Secondary Data Link provides the ability for stops because of the restricted air supply to the
each ECM to have a CAT Data Link that is local to combustion chamber. The air shutoff only actuates for
that engine. This feature also enables a global CAT the following conditions:
Data Link to connect to other engine controls through
a common data link. This enables the operator to The Emergency Stop button is pressed.
communicate through a single Customer
Communication Module (CCM) or through a An overspeed shutdown occurs.
telephone line with all of the engines that are in an
engine room. Cold Cylinder Cutout
The CAT Secondary Data Link provides the capability Note: This is an optional feature.
for as many as eight generator set engines to
communicate via a remote display or a control panel. The Cold Cylinder Cutout strategy is used so that the
The CAT Secondary Data Link is for use with the ECM may perform the following functions:
following systems: switchgear, remote monitoring and
control systems. Reduce the white smoke for cold starting.
Switching between data links requires the use of the Minimize the duration of advanced timing (cold
Cat ET software. Refer to Systems Operation, mode).
Troubleshooting, Testing and Adjusting, RENR7902,
Electronic Modular Control Panel 3 (EMCP 3) for Reduce the use of ether injection.
more information.
The ECM automatically turns off one electronic unit
Ether Injection System injector at a time during the following occurrences:
Note: This is an optional feature. Cold start-up
The ECM automatically injects ether into the air inlet Extended time at low idle
manifold when the following conditions are met:
The ECM monitors the change of the fuel rack in
The engine rpm is between 50 and 400 rpm. order to determine if a cylinder is firing. If the cylinder
is firing the ECM activates the electronic unit injector.
The jacket water coolant temperature is less than If the cylinder is not firing the electronic unit injector
21 C (70 F). remains deactivated. This reduces white smoke.
The duration of ether injection varies linearly with the The following conditions must be met in order to
jacket water coolant temperature. The duration of activate the Cold Cylinder Cutout strategy:
ether injection varies within the following range:
The Cold Cylinder Cutout parameter is
15 seconds at the maximum temperature of 21 C programmed to ENABLE .
(70 F)
The engine rpm is equal to high idle rpm or less
130 seconds at the minimum temperature of than high idle rpm.
40 C (40 F)
The fuel rack is less than 13 mm (.5 inch).
The longest duration of ether injection is 130 seconds
even if the jacket water coolant temperature is less The jacket water coolant temperature is less than
than 40 C (40 F). A switch enables the operator 63 C (145 F).
to inject ether manually. This can occur when the
following conditions are met: The Cold Cylinder Cutout strategy is activated under
either of the following conditions:
The switch for ether injection is in the manual
Ten seconds after the engine reaches the low idle
position.
rpm
The engine rpm is more than 50 rpm.
Three seconds after ether injection is completed
The jacket water coolant temperature is less than The following conditions will deactivate the Cold
21 C (70 F). Cylinder Cutout strategy:
Air Shutoff
Note: This is an optional feature.
SEBU8468 59
Engine Diagnostics
The Cold Cylinder Cutout parameter is Adjusting the Calculation of Fuel

programmed to DISABLED .
Consumption
The jacket water coolant temperature is more than
70 C (158 F). When the engine is shipped from the factory, an
estimate of the engine's fuel consumption is
The ET service tool is used for the cold cylinder programmed into the ECM. The estimate is based
cutout test. upon the engine's performance specifications. The
actual fuel consumption can be determined with a
The ether injection system is used. meter that measures the flow of the fuel. Customers
are likely to find a slight difference between the
estimate of fuel consumption that was programmed
The coolant temperature sensor has failed.
and the actual fuel consumption. The customer can
If the engine speed varies more than 50 rpm from use an ET service tool to program the ECM for the
actual fuel consumption. No password is required in
the start of the Cold Cylinder Cutout, the Cold order to change this parameter.
Cylinder Cutout deactivates for three seconds. A
new engine speed is established when the Cold To program the ECM for the actual fuel consumption,
Cylinder Cutout reactivates. change the Fuel Correction Factor that is already
programmed into the ECM. The Fuel Correction
If the engine is operated at low idle for ten seconds Factor can be programmed in increments of 0.5
before the engine speed is reduced by more than percent between 25 percent.
50 rpm, the Cold Cylinder Cutout deactivates for
30 seconds. The new Fuel Correction Factor must be calculated.
The following variables must be known in order to
If the engine rpm exceeds the high idle rpm, the perform the calculation:
Cold Cylinder Cutout deactivates for ten minutes.
The actual fuel consumption
If the fuel rack is greater than 13 mm (.5 inch), the
Cold Cylinder Cutout deactivates for three The fuel consumption that has been calculated by
seconds. the ECM
The original Fuel Correction Factor that was
Display of Engine Performance programmed into the ECM
Histogramming A factor for error must be calculated first. Use the

formula in Table 16 .
The ET service tool can display the trends of the Table 16
engine performance. The information can be used to Error Calculation For the Fuel Correction Factor
improve the overall performance of the engine. The
historical information is stored in a format that can be e = [(a s) a] 100
used to construct histograms. Data is available for the
e is the factor for error.
following parameters:
a is the actual fuel consumption.
Engine rpm
s is the fuel consumption that is calculated by the ECM.(1)
Engine load (1) The fuel consumption that is calculated by the ECM is based on
the original Fuel Correction Factor.
Left side exhaust temperatures
To determine the new Fuel Correction Factor, use the
Right side exhaust temperatures formula in Table 17 .
Table 17
Incrementing the Hours of the ECM Calculation For The Fuel Correction Factor
A new ECM that is installed on an engine can be N = O + [(100 + O) e] 100

programmed to display the correct total number of N is the new Fuel Correction Factor.
operating hours for that engine. The hour meter can
only be increased. An ET service tool and a factory O is the original Fuel Correction Factor.
level security password are required.
e is the error that was calculated with the equation in Table 16 .
60 SEBU8468
Engine Diagnostics
Adjusting the Total Fuel Consumption for

the ECM
A new ECM that is installed on an engine can be
programmed to display the correct total fuel
consumption for that engine. The total fuel
consumption can only be increased. An ET service
tool and a factory level security password are
required.
SEBU8468 61
Engine Starting
Before Starting Engine
Engine Starting Cooling System

Inspect the cooling system for leaks or loose
i02590960 connections.
Before Starting Engine Inspect the cooling system hoses for cracks and
for loose clamps.
SMCS Code: 1000; 1400; 1450
Inspect the water pumps for evidence of leaks.
Inspect the fan drive belts for cracks and for
deterioration.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start Check the coolant level. Add coolant, if necessary.
and operate the engine in a well ventilated area For information on the proper coolant to use, see
and, if in an enclosed area, vent the exhaust to the this Operation and Maintenance Manual, Refill
outside. Capacities and Recommendations.
Perform the required daily maintenance and other Driven Equipment

periodic maintenance before starting the engine.
Inspect the engine room. This inspection can help Perform any maintenance that is required for the
prevent major repairs at a later date. See this driven equipment. Refer to the Operation and
Operation and Maintenance Manual (Maintenance Maintenance Manual for the generator.
Section), Maintenance Interval Schedule.
Ensure that the main circuit breaker is open.
Walk-Around Inspection
Electrical System
NOTICE
For any type of leak (coolant, lube, or fuel) clean up Inspect the wiring for the following conditions:
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu- Loose connections
id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is Wiring that is worn or frayed
proved to be unwarranted.
Inspect the alternator belt for cracks and for
deterioration.
To obtain maximum service life for your engine, make
a thorough inspection before starting the engine. Ensure that the grounds are secure.
Make a walk-around inspection of the installation.
Look for items such as oil or coolant leaks, loose Fuel System
bolts and trash buildup. Remove any trash. Arrange
for repairs, as needed.
NOTICE
The guards must be in the proper place. Repair All valves in the fuel return line must be open before
damaged guards or replace missing guards. and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
Ensure that the areas around the rotating parts are failure or other damage.
clear.
Air Inlet System Inspect the fuel lines for loose fittings and leaks.
Ensure that the fuel lines are properly clamped.
Ensure that the air inlet piping and the air filters are
in place. Ensure that the fuel is supplied to the engine.
If the engine has not been started for several weeks,
Ensure that all clamps and connections are fuel may have drained from the fuel system. Air may
secure. have entered the filter housing. Also, when fuel filters
have been changed, some air space will be left in the
Observe the air cleaner service indicator. Service housing. In these instances, prime the fuel system.
the air cleaner when the yellow diaphragm enters See this Operation and Maintenance Manual
the red zone, or when the red piston locks in the (Maintenance Section), Fuel System-Prime for
visible position. information on priming the fuel system.
62 SEBU8468
Engine Starting
Cold Weather Starting
Lubrication System i00735665
Cold Weather Starting

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Note: Oil pan immersion heaters are not

recommended for heating the lube oil. To ensure the
compatibility of the components, only use equipment
that is recommended by Caterpillar .
Startability will be improved at temperatures below
16 C (60 F) with a starting aid. A jacket water
heater may be needed and/or the crankcase oil may
need to be warmed.
A jacket water heater is available as an option for
starting in temperatures as low as 0 C (32 F). The
jacket water heater can maintain the water
temperature at approximately 32 C (90 F). The
Oil level gauge heated water will help to keep the oil in the engine
(1) ADD mark block warm enough to flow when the engine is
(2) FULL mark started.
Check the engine crankcase oil level. Maintain the Maintain the proper level of electrolyte in the
oil level between the ADD and FULL marks batteries. Keep the batteries fully charged.
on the ENGINE STOPPED side of the oil level
To maximize the battery power, heat the battery
gauge. For information on the proper oil to use, compartment or store the batteries in a warm location.
see this Operation and Maintenance Manual, Typically, batteries only have 50 percent of the
Refill Capacities and Recommendations. capability at 10 C (14 F) versus 27 C (80 F).
Check for leaks at the following components: Extra battery capacity may be necessary for very cold
crankshaft seals, crankcase, oil filters, oil gallery temperatures.
plugs, sensors and valve covers.
When No. 2 diesel fuel is used, a fuel heater will
Inspect the tubes, tee pieces, and clamps on the maintain the temperature of the fuel above the cloud
crankcase breathers. point. Fuel line insulation will help to maintain the fuel
temperature.
Inspect the Closed Crankcase Ventilation (CCV)
Consult your Caterpillar dealer for more information
filter, if equipped. If the restriction indicator is on the starting aids that are available for cold weather
visible, service the CCV. starting.
Starting System Starting With the Starting Aid

Disconnect any battery chargers that are not
Switch
protected against the high current drain that is
created when the electric starting motor is
engaged.
Personal injury or property damage can result
Inspect the battery cables for good connections from alcohol or starting fluids.
and for corrosion.
Alcohol or starting fluids are highly flammable
Inspect the gauges and the control panel for good and toxic and if improperly stored could result in
condition. injury or property damage.
Reset the shutoff and alarm components.

SEBU8468 63
Engine Starting
Starting the Engine
NOTICE
Automatic Starting
Excessive starting fluid can cause piston and ring
damage.
Use starting fluid for cold starting purposes only. When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid person-
Do not use excessive starting fluid during starting or
after the engine is running. al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode.
The optional ether starting aid which is located on

the control panel is the only system that is To enable automatic starting, the EMCP 3 control
recommended for the injection of starting fluid. panel must be in AUTO mode. To place the control
panel into auto mode, press the AUTO key. The
Perform the procedures that are described in this engine will automatically start when the remote start/
Operation and Maintenance Manual (Operation stop initiate contact closes.
Section), Before Starting Engine.
Manual Starting
1. Turn the Engine Control Switch to the MAN.
START position. The engine will crank. NOTICE
For initial start-up of a new or rebuilt engine, and for
2. Ether will automatically be injected if the following start-up of an engine that has been serviced, make
conditions are met: provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
a. The STARTING AID switch is in the air and/or fuel supply to the engine.
AUTOMATIC position.
b. The jacket water temperature is less than Do not start the engine or move any of the controls if
21 C (70 F). there is a DO NOT OPERATE warning tag or a
similar warning tag attached to the start switch or to
the controls.
Note: Additional injections may be necessary in order
Ensure that no one will be endangered before the
to start the engine. Additional injections may also be engine is started and when the engine is started.
necessary in order to achieve low idle.
3. If additional injection is necessary, toggle the 1. Perform all of the procedures that are described in
STARTING AID switch to the MANUAL position. this Operation and Maintenance Manual, Before
For additional injection, the jacket water Starting Engine (Operation Section).
temperature must be less than 21 C (70 F).
4. The STARTING AID switch is a momentary NOTICE

switch. To stop the injection, release the Do not engage the starting motor when flywheel is
STARTING AID switch. turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
i02310064
the starter switch or button and wait two minutes to al-
low the starting motor to cool before attempting to
Starting the Engine start the engine again.
SMCS Code: 1000; 1450
2. To start an engine with an EMCP 3 control panel,
press the RUN key.
Engine exhaust contains products of combustion

which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
64 SEBU8468
Engine Starting
Starting with Jump Start Cables
i03204322 2. Connect the end of one jump start cable to the

positive + terminal of the battery for the engine
Starting with Jump Start that is being started. Connect the other end to the
Cables positive + terminal of the power source.
SMCS Code: 1000; 1401; 1402; 1900 3. Connect one end of the second jump start cable to
the negative terminal of the power source.
Connect the other end to the negative ground
of the starting motor.
Improper jump start cable connections can cause
an explosion resulting in personal injury. 4. Press the RUN button .
Prevent sparks near the batteries. Sparks could 5. After the engine starts, disconnect the cable from
cause vapors to explode. Do not allow jump start the negative ground of the starting motor.
cable ends to contact each other or the engine. Disconnect the other end of the cable from the
negative terminal of the power source.
If the installation is not equipped with a backup
6. Disconnect the cable from the positive + terminal
battery system, then it may be necessary to start the
engine from an external electrical source. of the battery for the engine that was started.
Disconnect the other end of the cable from the
Many batteries which are considered unusable are positive + terminal of the power source.
still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that are
severely discharged. The batteries must be charged i00736680
to the proper voltage with a battery charger. For
information on testing and charging, refer to the After Starting Engine
Special Instruction, SEHS7633, Battery Test
Procedure. SMCS Code: 1000
Note: After the engine has been installed or rebuilt,

NOTICE carefully monitor the engine in order to detect any
Using a battery source with the same voltage as the unusual engine performance.
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage Warm-up
the electrical system.
Do not reverse the battery cables. The alternator can 1. Operate the engine at low idle for two to three
be damaged. Attach ground cable last and remove minutes. Allow the jacket water temperature to
first. begin to rise before increasing the engine rpm to
rated rpm.
When using an external electrical source to start the
engine, turn the generator set control switch to the Note: More warm-up time may be necessary when
OFF position. Turn all electrical accessories OFF the ambient temperature is below 18 C (0 F).
before attaching the jump start cables.
Ensure that the main power switch is in the OFF posi- 2. Check all of the gauges during the warm-up period.
tion before attaching the jump start cables to the en-
gine being started. 3. Make another walk-around inspection. Inspect the
engine for fluid leaks and air leaks.
Turn off all auxiliary power and accessories of the The time that is needed for the engine to reach the
engine. Otherwise, these components will operate normal mode of operation is usually less than the
when the power source is connected. time that is needed for a walk-around inspection.
Before attaching the jump start cables, ensure that The engine will reach normal operating temperature
the control switch for the generator set is in the OFF faster when the engine is operated at rated rpm and
position. low power demand. This procedure is more effective
than idling the engine with no load. The engine
1. Perform all of the procedures in this Operation and should reach normal operating temperature in a few
Maintenance Manual (Operation Section), Before minutes.
Starting Engine.
Engaging the Driven Equipment
SEBU8468 65
Engine Starting
After Starting Engine
1. Ensure that the gauges are in the normal ranges

for the engine rpm.
2. Increase the engine rpm to rated rpm. Always

increase the engine speed to rated rpm before
applying the load.
3. Adjust the voltage and the frequency, if necessary.
4. Close the main circuit breaker in order to apply the

load.
5. Continue to check the gauges and the driven
equipment.
66 SEBU8468
Engine Operation
Engine Operation
Engine Operation Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
i02154674
Be aware of the properties of the different fuels.
Engine Operation Use only the recommended fuels.
SMCS Code: 1000 Avoid unnecessary idling.
Proper operation and maintenance are key factors in Shut off the engine rather than idle for long periods of
attaining the maximum service life and economy for time.
the engine. Follow the instructions in this Operation
and Maintenance Manual in order to minimize Observe the service indicator frequently. Keep the
operating costs and maximize the service life of the air cleaner elements clean.
engine.
Ensure that the turbochargers are operating
Observe the gauges frequently while the engine is correctly so that the proper air/fuel ratio is
operating. Record the data from the gauges in a log maintained. Clean exhaust indicates proper
regularly. Compare the data to the specifications for
normal engine operation. Comparing the data over functioning.
time will help to detect changes in engine
Maintain a good electrical system.
performance.
One defective battery cell will overwork the alternator.
Investigate any significant change in the gauge
This will consume excess power and excess fuel.
readings. Monitor the engine operation and take
action when discrepancies are found. Ensure that the belts are properly adjusted. The
belts should be in good condition.
Operating the Engine and the
Driven Equipment Ensure that all of the connections of the hoses are
tight. The connections should not leak.
Check the gauges and the driven equipment
frequently while the engine is operating under a load. Ensure that the driven equipment is in good
The engine can be operated for extended periods of working order.
time at full load.
Cold engines consume excess fuel. Utilize heat
Partial Load Operation from the jacket water system and the exhaust
system, when possible. Keep cooling system
Extended operation at reduced load (less than 30%) components clean and keep cooling system
may cause increased oil consumption and carbon components in good repair. Never operate the
buildup in the cylinders. Extended operation at engine without water temperature regulators. All of
reduced load may also cause fuel to slobber through these items will help maintain operating
the exhaust system. This may result in a loss of temperatures.
power and/or poor performance.
Settings for the fuel system and the limits for the
To maintain engine efficiency and performance, apply
operating altitude are stamped on the Engine
a full load to the engine on an hourly basis, or operate
the engine at a load level that is greater than 30%. Information Plate. If an engine is moved to a higher
This will burn excess carbon from the cylinders. altitude, the settings must be changed by a
Caterpillar dealer. Changing the settings will help
prevent damage to the turbocharger. Changing the
i00165110 settings will help to provide the maximum
efficiency for the engine. Engines can be operated
Fuel Conservation Practices safely at higher altitudes, but the engines will
SMCS Code: 1000; 1250 deliver less horsepower. The fuel settings should
be changed by a Caterpillar dealer in order to
The efficiency of the engine can affect the fuel obtain the rated horsepower.
economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency in all
applications. Follow the recommended procedures in
order to attain optimum performance for the life of the
engine.
Avoid spilling fuel.

SEBU8468 67
Generator Operation
Generator Operation
Generator Operation Block Loading

Block loading is the instantaneous application of an
i03205781 electrical load to a generator set. This load may be
anywhere from a moderate percentage of the rated
Generator Operation load up to the rated load.
SMCS Code: 4450 The block loading capability of a generator set
depends on the following factors.
Loading of the Generator Engine transient response
When a generator is installed or reconnected, be sure Voltage regulator response
that the total current in one phase does not exceed
the nameplate rating. Each phase should carry the Type of the voltage regulator
same load. This allows the engine to work at the rated
capacity. If one phase current exceeds the nameplate Altitude of operation of the generator set
amperage, an electrical unbalance can result in an
electrical overload and overheating. Type of load (power factor for the load)
Allowable combinations of unbalanced loads are The percentage of load before the application of
shown in Illustration 54 . When you operate with
significant single-phase loads, the combinations of the block load
single-phase load and three-phase load may be If derating for the block load is required, refer to ISO
used. Such combinations should be located below 3046 Standards or SAE J1349 Standards. Also,
the line on the graph. reference Engine Data Sheet, LEKX4066, Loading
Transient Response and Engine Data Sheet,
LEKX4067, Block and Transient Response.
Note: ISO stands for International Standards
Organization.
Power Factor
The power factor represents the efficiency of the load.
Power factor is the ratio of apparent power to total
power. The power factor is expressed as a decimal.
The power factor represents that portion of the
current which is doing useful work. The portion of
current which is not doing useful work is absorbed in
maintaining the magnetic field in motors or other
devices.
In most applications, electric motors and transformers
determine the power factor of the system. Induction
motors usually have a 0.8 or smaller power factor.
Incandescent lighting is a resistive load of about 1.0
power factor, or unity.
The power factor of a system may be determined by a
power factor meter or by calculations. Determine the
power requirement in kW by multiplying the power
factor by the kVA that is supplied to the system. As
the power factor increases, the total current that is
supplied to a constant power demand will decrease.
For example, a 100 kW load at a 0.8 power factor will
draw more current than a 100 kW load at 0.9 power
factor. High power factor will result in full engine load
at less than the rated amperage of the generator. A
lower power factor increases the possibility of
overloading the generator.
Note: If no other power factor is specified, Caterpillar

generators are designed for a 0.8 lagging power
factor.
Allowable Combinations of Unbalanced Loads
68 SEBU8468
Generator Operation
Generator Operation
Excitation Systems Low Idle Adjustment

Permanent Magnet Pilot Excited Generator sets normally have a higher low idle setting
than industrial engines. Low idle will be approximately
Generators 66% of the full load speed of 60 Hz units. Low idle will
be approximately 80% of the full load speed of 50 Hz
Note: The standard generator is designed with units.
internal excitation. The PMPE generator is an option. There is no low idle stop on generator sets with
Permanent Magnet Pilot Excited (PMPE) generators electronic governors. On generator sets with
receive power for the voltage regulator from a pilot mechanical governors and natural gas generator
exciter, rather than the main armature. The pilot sets, the low idle is set at the factory. The low idle
exciter consists of a permanent magnet rotor and a should only be adjusted by your Caterpillar dealer if
permanent magnet stator. The pilot exciter operates adjustment is required.
independently from the generator output voltage.
Constant excitation during a large load application is Note: Operating the generator set at low idle speed
possible because the irregularities that occur in for an extended time will cause some voltage
generator output voltage are not fed back into the regulators to shut off. The generator set must be
exciter. Such irregularities can be caused by load completely shut down. Then, the generator set must
conditions. The independent operation also allows be restarted. This will allow the voltage regulator to
the generator to better sustain an overload for a short again produce an output.
duration. The pilot exciter also ensures that the
generator will start properly even if the rotating field Standby Generator Sets
becomes completely demagnetized.
Most standby units are installed with controls that will
Internal Excitation Generators start the unit automatically. Standby units perform the
following tasks without an operator in attendance:
The Internal Excitation generator consists of two start, pick up the load, run and stop.
special sets of coils that are wound to fit in carefully
selected slots of the main stator. The wire coils Standby units can not change the governor control
provide total separation from the main winding of the automatically. Standby units can not change the
stator. The wire coils provide isolation from the main voltage settings automatically. The governor speed
winding of the stator. The coils can only be fit to the and voltage level must be preset for the proper
main stator while the main stator is being wound. operation of the standby unit. Whenever the set is
operated manually, be sure that the governor speed
The two auxiliary windings are designed in order to and voltage levels are correct for automatic operation.
provide power to the voltage regulator. The two coils Check all switches for the proper setting. The start
are connected in series and the two coils are select switch should be in the AUTOMATIC position.
connected to the three-phase power input of the Emergency Stop Switches should be in RUN position.
voltage regulator.
Generator Options
One auxiliary winding produces a voltage which is
proportional to the output voltage of the generator.
The other auxiliary winding acts as a current Space Heaters
transformer. The other auxiliary winding produces a
voltage that is proportional to the output current of the A customer may choose to install a space heater.
generator. These space heaters are installed for operation in
high humidity conditions. For more information on
The outputs from the two coils are combined on the space heaters, refer to Maintenance Section, Space
inside of the voltage regulator. the outputs from the Heater - Check.
two coils provide a constant power source.
When the engine starts turning the Rotating Field
Embedded Temperature Detectors
Assembly (RFA), the residual magnetism that is in
the exciter stator (L1) and the embedded permanent The generators are available with embedded
magnets that are in the exciter causes a small temperature detectors. The detectors are installed in
the slots of the main armature. The main armature is
amount of AC voltage to be generated in exciter rotor also called a stator. The detectors are used with the
(L2). Induced voltage causes current to flow. The equipment that is provided by the customer. Thus, the
current that is caused by the induced voltage is temperature of the main armature winding can be
present in the exciter armature. measured or monitored. Three types of temperature
detectors are available. Contact your Caterpillar
The AC is then rectified by a three-phase full-wave dealer for more information.
bridge rectifier circuit. Flashing of the field is not
required in order to start the generator.
SEBU8468 69
Generator Operation
Single Unit Operation
Bearing Temperature Detectors i03266287
Bearing temperature detectors are available as an Parallel Operation

option on the generators. Bearing temperature
detectors measure main bearing temperature. SMCS Code: 4450
Bearing temperature detectors are used with the
equipment that is provided by the customer. Thus, the Initial Start-Up
temperature of the bearing can be measured or
monitored. Bearing temperature measurements may Preparing a generator for parallel operation requires
help to prevent premature bearing failure. special attention. Before you attempt to parallel units
for the first time, check all the units for the following
i01490164 three conditions.
same phase rotation

Single Unit Operation
SMCS Code: 4450 same alternating current frequency
same voltage adjustment

Initial Start-Up
Several methods may be used in order to parallel
Before the initial start-up, perform the megohmmeter generators. The preferred method is the utilization of
test on the main stator winding. Refer to the Special a switchgear that uses automatic paralleling.
Instruction, SEHS9124, Cleaning and Drying of
Electric Set Generators for the procedure. A method of manually paralleling generators which
requires thorough understanding of the process is
Starting outlined below.
1. Make all preliminary engine starting checks. 1. Check the phase rotation.
Units that operate in parallel must have the same
2. Be sure that the main circuit breaker or the line phase rotation. There are two methods that may
circuit breaker is open. be used in order to determine if the incoming unit
and the unit that is on-line have the same phase
3. Start the engine. Allow the engine to warm up. rotation. These methods are listed below:
4. Adjust to the full load engine speed. using a phase rotation meter
5. Close the main circuit breaker. using a set of three light bulbs
6. Apply the load. Do not try to apply the full load. Use the procedure below to determine the proper
Apply the load in increments in order to maintain phase rotation by using three light bulbs.
system frequency at a constant level.
7. Readjust the governor for rated frequency.
Stopping
1. Remove the load in increments.
2. Open the circuit breaker.
3. Allow the engine to run for five minutes in order to

cool.
4. Stop the engine.
70 SEBU8468
Generator Operation
Parallel Operation
b. Adjust the control in order to give the rated

frequency at full load.
c. Remove the load and check the high idle

speed. The high idle speed should be
approximately 2 to 5 percent above full load
speed for generators that are equipped with
droop. If these speeds can not be obtained,
contact your Caterpillar dealer.
d. For the most consistent results, repeat 2.b.

and 2.c. until the second condition of Initial
Start-Up has been met.
3. Adjust the voltage. The generator voltage
regulator should be programmed to the nominal
values. Refer to Operation and Maintenance
When servicing or repairing electric power gen- Manual, Voltage Regulators.
eration equipment: Note: Make sure that the speed droop is identical
for all of the engines before adjustments are made
Make sure the unit is off-line (disconnected
from utility and/or other generators power serv- to the generator.
ice), and either locked out or tagged DO NOT a. Program the reactive droop for the voltage
OPERATE. Remove all fuses. regulator to approximately 2%. Initially
program the same value on all generators
a. Connect the light bulbs with rated voltage which will be paralleled.
between the generator leads and the
corresponding line phase. For example, b. The no-load voltages should be identical for all
connect terminal 1 to line 1 across the open the generators that are operating in parallel.
circuit breaker. Connect the generators in parallel. Try to
obtain a 0 kW power exchange by adjusting
b. Start the units that will be in operating in
the speed of the generator. Try to minimize the
parallel. Bring the units up to speed. As the
circulating currents between generators by
units approach the same speed, the lights will
altering the voltage setting on one of the
start to blink.
generators.
If the lights blink in sequence, one of the Note: Do not change the voltage settings after
units is connected backward. In order to this step.
correct the problem, stop the units. Remove c. Apply the available load. The setting is correct
generator leads 1 and 3 at the circuit only if a reactive load is available. Equalize the
breaker. Exchange these generator leads. Kilowatts or divide the rated power of the units
This reverses the direction of phase proportionally by altering the speed. Alter the
rotation. Terminal 2 should always be voltage droop in order to equalize the currents
connected to line 2. Go to 5. or divide the currents.
Both generators have the same phase Starting Multiple Units
rotation when the lights blink in unison. The
first condition of Initial Start-Up has been Use the procedure for starting single units in order to
met. start multiple units. Refer to Operation Section,
Single Unit Operation.
2. Adjust the frequency.
Paralleling Multiple Units
The units that will be operating in parallel must
operate at the same speed. Speed is proportional Units may be paralleled at no load. Units may also be
to the alternating current frequency. paralleled with units under load. After the initial
conditions for start-up are satisfied, verify for the
a. Allow each electric set to run under load for following requirements:
about 30 minutes.
SEBU8468 71
Generator Operation
Voltage Regulators
Generators must have voltage droop Stopping

compensation or cross current compensation.
In order to remove a generator from the line, perform
1. Start the unit which will be paralleled. the following procedure.
2. Turn on the synchronizer lights. 1. Check the load. The load must be less than the
rated capacity of the remaining units.
3. After the engine has run a few minutes, bring the
engine up to synchronous speed. This means that 2. Be sure that the neutral of one of the remaining
the frequency of the incoming unit will be the same units is grounded.
frequency as the unit that is on-line. The
synchronizing lights will begin to blink. 3. Remove the load from the outgoing unit. See the
Parallel Operation, Load Division - Speed Droop.
Note: The frequency of the incoming unit should be The amperage may never go to zero due to
slightly greater than the line frequency. This will allow circulating currents.
the incoming unit to assume some of the load instead
of adding to the system load. 4. Open the circuit breaker.
4. By using the control, adjust the engine speed until 5. Allow the engine to cool for five minutes.
the lights blink very slowly.
6. Stop the engine.
5. The lights are off when the voltages of the two units
are in-phase. At this point, very quickly close the Circulating Currents
breaker while the lights are out.
Understanding the circulating currents becomes very
important when you parallel the units. These
6. Use the controls in order to share kW load between circulating currents are flowing between generators in
engines. parallel operation. The circulating currents are
caused by voltage differences between the
7. Generator temperature will be stabilized in generators. The circulating currents are not doing
approximately one hour. After the generator useful work. The amount of the circulating current can
temperature has been stabilized, adjust the be determined by subtracting the amperage which is
voltage droop rheostat of each generator. This will going to the load from the total generator amperage.
share the reactive load and this will limit the The circulating current may be as high as 25 percent
circulating currents. Less droop increases the of rated amperes with cold generator sets. Such
reactive current that is carried by the generator. current may not even be considered harmful. The
total generator current should not exceed the
Load Division and Speed Droop (If amperage rating.
Equipped) As the generators warm, the circulating currents will
decrease. The ammeter readings should decrease
Once two units have been paralleled, the unit's share slightly, but the voltage meter readings should remain
of the kW load is determined by the control setting. If constant.
two units of the same capacity and the same
characteristics have the same control settings, the
units will share the load equally. The total load must i04009894
not exceed the capacity of the engines.
Voltage Regulators
In order to transfer more of the load from one engine
to another engine, use the following procedure: SMCS Code: 4467
1. Increase the speed control of one unit in order to Cat Digital Voltage Regulator (Cat
increase the load.
DVR )
2. Reduce the speed control of the other unit in order
to decrease the load on that unit.
3. Raise the speed control or lower the speed control The Cat Digital Voltage Regulator presents an
of both units in order to change system frequency. electrical shock/electrocution hazard. This hazard
will cause serious injury or death.
Service by trained personnel only.
72 SEBU8468
Generator Operation
Generator Lead Connections
The terminals and heat sinks are live at Programmable stability settings
hazardous voltages when power is applied and
for up to 8 minutes after power is removed. Soft start control with an adjustable time setting in
AVR mode
Dual slope voltage versus frequency (V/Hz)
characteristic
Three-phase or single-phase voltage sensing

Single-phase current sensing
Field current sensing and field voltage sensing

Ten protection functions
Adjusting the Cat DVR

In order to view and configure the parameters of the
Cat DVR, a PC with the Caterpillar DVR software is
required.
Refer to Specifications, Systems Operation, Testing
and Adjusting, RENR7941, Cat Digital Voltage
Regulator for complete information.
i04535324

SMCS Code: 4450
Lead Numbering
The Wye (Star) configurations and the Delta
The Cat DVR is a microprocessor-based voltage configurations are the most common generator lead
regulator. Control power for the Cat DVR is supplied connections. The following three-phase connection
from an external source of 24 VDC. The power stage diagrams illustrate the proper connection and lead
of the Cat DVR is supplied from a multiple pole high identification.
frequency permanent magnet generator which is
mounted on the end of the generator shaft. The leads are numbered clockwise from the top and
Connections to the Cat DVR are made through three from the outside inward. The diagrams show lead
connectors. The communication between the Cat numbering for the six and twelve lead generators.
DVR and the service tool is accomplished by using a
CANBUS protocol.
The Cat DVR has the following features:
Three control modes:
1. Automatic voltage regulation (AVR)
2. Power factor (PF) regulation
3. Reactive power (VAR) regulation

SEBU8468 73
Generator Operation
Wye Configuration Diagrams
6 Lead
12 Lead Wye Configuration - Low Voltage
Terminals T10, T11, andT12 become neutral
connection when the terminals are tied together.
6 Lead Wye Configuration Delta Configuration Diagrams
Terminals T4, T5, andT6 become neutral connection
when the terminals are tied together. 6 Lead
12 Lead
6 Lead Delta Configuration
12 Lead Wye Configuration - High Voltage
Terminals T10, T11, andT12 become neutral
connection when the terminals are tied together.
74 SEBU8468
Generator Operation
12 Lead If the neutral wire is grounded and one of the phase

leads becomes grounded, the excessive current will
open a load circuit breaker to isolate the fault. The
excessive current will collapse the generator voltage,
if the circuit breaker does not trip first. The result
depends on the particular generator electrical
characteristics, type of fault and trip rating of the
circuit breaker. An undervoltage device may be
required in order to provide an adequate short circuit
protection.
There are some instances in which grounding the
neutral wire is undesirable. An ungrounded generator
neutral lead is acceptable in applications in which
definite measures have been taken to prevent
grounds to the phase leads. Examples of such
measures are ground fault protective circuits. Ground
fault protection requires that the entire group of
distribution circuits should be studied and treated as a
system. The owner should engage a certified and
registered consultant if a new distribution system is
being developed. The owner should also engage a
certified and registered consultant if an existing
system should be modified for the ground fault
protection.
Illustration 61 g00669312 Neutral resistors and reactors may be added to the
12 Lead Delta Configuration system for two reasons: to provide protection during
Terminals T6 and T9 become the neutral connection faults and to limit neutral currents.
when the terminals are tied together and grounded.
This position reflects the terminal T2 and T10 Single Units
connection as the high phase.
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
Grounding the Frame
In applications, in which definite measures are taken
In any generator set installation, the frame of the in order to prevent grounds to the load leads, an
generator is positively connected to an earth ground. ungrounded neutral can be used. Be sure to check
This connection is the first one that is made at the your local wiring codes.
installation. This connection is the last one that
should be removed. The ground connection must be Multiple Units
flexible in order to avoid possible breakage in later
operation. Operation of multiple generators in parallel, having all
neutrals grounded, may result in the circulating
Ground connection cable or straps should have at
current through the neutral connections. In order to
least the current carrying capacity of the largest line
lead to the connected load. Joints in cables or straps eliminate the possibility of circulating currents, ground
must be clean, free of electrical resistance, and the neutral of only one generator. If multiple
protected from possible oxidation. Bolted ground generators are alternated on line, a switch should be
connection joints eventually oxidize. The joints are installed in the neutral ground circuit of each
frequent sources of radio frequency interference generator. In this case all neutral ground circuits
(RFI). Silver soldered and bolted joints are electrically except one can be opened. Be sure that one of the
and mechanically sound. neutral ground circuits is closed.
Neutral Connections
The generators with grounded configuration usually
have the neutral grounded when the generator is
installed. However, there are some cases when
definite measures can be taken in order to prevent
ground faults on the load side. The purpose of the
grounding of the neutral is to prevent load side
equipment damage. The purpose of the grounding of
the neutral is also to prevent harm to personnel.
SEBU8468 75
Generator Operation
Parallel to Utility
When a Wye (Star) connected generator is going to
operate in parallel with a utility system (infinite bus)
and when the secondary of the step-down
transformer in the utility system is also a Wye
connection, the following may happen. The grounding
of both Wye neutrals may result in circulating currents
through the neutrals. Also, the coordination of ground
fault protection requires an entire system study. A
study should be done by a certified and registered
consultant who is familiar with generator systems.
The study will determine which grounding method
should be used.
76 SEBU8468
Cold Weather Operation
Fuel and the Effect from Cold Weather
Cold Weather Operation Starting aids

Engine oil pan heaters
i02237624
Engine coolant heaters
Fuel and the Effect from Cold Fuel heaters
Weather
Fuel line insulation
SMCS Code: 1000; 1250; 1280
For more information on cold weather operation, see
The following fuels are the grades that are available Special Publication, SEBU5898, Cold Weather
for Caterpillar engines: Recommendations.
No. 1
i01250450
No. 2
Fuel Related Components in
Blend of No. 1 and No. 2
Cold Weather
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2 SMCS Code: 1000; 1250; 1280
is best suited for cold weather operation.
Quantities of No. 1 diesel fuel are limited. No. 1 diesel
Fuel Tanks
fuels are usually available during the months of the Condensation can form in partially filled fuel tanks.
winter in the colder climates. During cold weather Top off the fuel tanks after you operate the engine.
operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary. Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
There are three major differences between No. 1 and Some fuel tanks use supply pipes that allow water
No. 2 diesel fuel. No. 1 diesel fuel has the following and sediment to settle below the end of the fuel
properties: supply pipe.
Lower cloud point Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
Lower pour point equipped with this system, regular maintenance of
the fuel system filter is important.
Lower rating of kJ (BTU) per unit volume of fuel
Drain the water and sediment from any fuel storage
When No. 1 diesel fuel is used, a decrease in power tank at the following intervals: weekly, oil changes
and in fuel efficiency may be noticed. Other operating and refueling of the fuel tank. This will help prevent
effects should not be experienced. water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
The cloud point is the temperature when a cloud of
wax crystals begins to form in the fuel. These crystals Fuel Filters
can cause the fuel filters to plug. The pour point is the
temperature when diesel fuel will thicken. The diesel It is possible that a primary fuel filter is installed
fuel becomes more resistant to flow through fuel between the fuel tank and the engine fuel inlet. After
pumps and through fuel lines. you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
Be aware of these values when diesel fuel is system. Refer to the Operation and Maintenance
purchased. Anticipate the average ambient Manual in the Maintenance Section for more
temperature of the area. Engines that are fueled in information on priming the fuel system.
one climate may not operate well if the engines are
moved to another climate. Problems can result due to The micron rating and the location of a primary fuel
changes in temperature. filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
Before troubleshooting for low power or for poor common components that are affected by cold fuel.
performance in the winter, check the type of fuel that
is being used.
When No. 2 diesel fuel is used the following
components provide a means of minimizing problems
in cold weather:
SEBU8468 77
Cold Weather Operation
Fuel Related Components in Cold Weather
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
two micron absolute high efficiency fuel filter is re-
quired for all Caterpillar Electronic Unit Injectors.
Caterpillar High Efficiency Fuel Filters meet these re-
quirements. Consult your Caterpillar dealer for the
proper part numbers.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the primary fuel
filter.
The following fuel heaters are recommended for
Caterpillar engines:
7C-3557 Fuel Heater Group
7C-3558 Heater Kit

For further information on fuel heaters, consult your
Caterpillar dealer.
Disconnect the fuel heater in warm weather.
Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65C (149F). A loss of
engine power can occur if the fuel supply temperature
exceeds 37C (100F).
Note: Heat exchanger type fuel heaters should have

a bypass provision in order to prevent overheating of
the fuel in warm weather operation.
78 SEBU8468
Engine Stopping
Emergency Stopping
Engine Stopping
i03292463
Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices
or controls for normal stopping procedure.
Ensure that any components for the external system

that aid the engine operation are secured after the
engine is stopped.
Emergency Stop Button

Use of the emergency stop will shut off the fuel. If the
engine is equipped with air shutoffs, the air shutoffs
will also be activated.
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.
It may be necessary to reset the emergency stop

button before the engine can be restarted.
If the emergency stop button is used, both of the air
shutoffs must be reset before the engine can be
restarted.
The power for the ECM must be cycled before the
engine can be restarted.
Air Shutoffs (If Equipped)

The reset mechanisms for the air shutoffs in your
3500Engine may look like one of the following reset
mechanisms.
SEBU8468 79
Engine Stopping
Manual Stop Procedure
The air shutoffs are activated by oil pressure when i03205685

energy to a solenoid is interrupted. Each air shutoff
uses a plate that rotates on a shaft in order to shut off
inlet air to the aftercooler. The engine stops because
Manual Stop Procedure
of the restricted air supply to the combustion SMCS Code: 1000; 7418
chamber. The air shutoffs will actuate for the following
conditions:
NOTICE
The emergency stop button is pressed. Stopping the engine immediately after it has been
working under load can result in overheating and ac-
The air shutoff is activated. celerated wear of engine components.
An overspeed shutdown occurs. Excessive temperatures in the turbocharger center-

housing will cause oil coking problems. Excessive
The electronic control module loses power. temperatures in the turbocharger centerhousing may
damage the turbocharger bearing/shaft system and
To reset the air shutoff on earlier models, turn the significantly shorten the life of the turbocharger.
reset knob to the OPEN position. To reset the air
shutoff on later models, turn the hex until the indicator Allow the engine to gradually cool before stopping the
is at the OPEN position. engine
Ensure that both of the air shutoffs are resetbefore
starting the engine. Ensure that the cause of the 1. Open the main circuit breaker in order to disengage
emergency stop is repaired before starting the the driven equipment.
engine.
2. Turn the engine control switch to the OFF/
RESET position. The engine will immediately
shut off.
3. Press the red STOP button on the EMCP3
controller. If the setpoint for the duration of the
cooldown period is set to a value that is greater
than zero, the engine will operate for a
programmed period of time before the engine
stops. Otherwise, the engine will immediately shut
off.
80 SEBU8468
Engine Stopping
After Stopping Engine
Automatic Stopping
Automatic stopping will occur when the engine is
operating in the automatic mode and the remote start/
stop initiate contact opens. If the cooldown feature is
utilized, the engine will operate for a programmed
period of time before the engine stops. Otherwise, the
engine will immediately shut off.
i02237586
After Stopping Engine

SMCS Code: 1000
Check the engine crankcase oil level. Maintain the

oil level between the ADD and FULL marks
on the ENGINE STOPPED side of the oil level
gauge. Complete all of the lubrication
recommendations that are listed in Special
Publication, SEBU6251, Caterpillar Commercial
Diesel Engine Fluids Recommendations.
If necessary, perform minor adjustments. Repair

any leaks and tighten loose bolts.
Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, Maintenance Interval
Schedule.
Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not overfill
the fuel tank.
Note: Only use the antifreeze coolant solutions that

are recommended in Special Publication, SEBU6251,
Caterpillar Commercial Diesel Engine Fluids
Recommendations. Failure to follow the
recommendations in Special Publication, SEBU6251,
Recommendations can cause engine damage.
Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. See
Special Publication, SEBU6251, Caterpillar
Commercial Diesel Engine Fluids
Recommendations. Add the proper coolant/water
mixture, if necessary.
Perform all required periodic maintenance on the

generator. The generator maintenance is outlined
in the Operation and Maintenance Manual that is
supplied with the generator.
SEBU8468 81
Maintenance Section
Refill Capacities
Maintenance Section (Table 19, contd)

3516BEngine (3) 233 L 247 L
(61.5 US (65.3 US gal)
Refill Capacities gal)
3516BEngine (4) 233 L 330 L

(61.5 US (87.2 US gal)
i04594970 gal)
Refill Capacities (1)

(2)
60 Hz engine with 43 C
50 Hz engine with 50 C
(109 F) ambient capability
(122 F) ambient capability
(3) 60 Hz engine with 43 C (109 F) ambient capability
SMCS Code: 1000; 1348; 1395; 7560 (4) 60 Hz engine with 50 C (122 F) ambient capability
Lubricant Capacities i04327132
The capacity of the engine lubrication system

includes the capacity of the oil filters that are installed Fluid Recommendations
at the factory. Auxiliary oil filter systems (if equipped) SMCS Code: 1280; 1348; 1395; 7560
will require additional oil. Refer to the specifications
that are provided by the OEM of the auxiliary oil filter Refer to this Operation and Maintenance Manual,
system. Severe Service Application for information about
Table 18 operating an engine in a severe service application.
Approximate Refill Capacities for 3500BEngine Lubrication
Note: The interval for changing the coolant varies
Systems
depending on the type of coolant being replaced.
Compartment or System 3512BEngines 3516BEngines Refer to this article, Coolant Recommendations, for
the intervals for changing the coolant.
Engine crankcase 318 L 405 L
(84 US gal) (107 US gal)
Diesel Engine Oil
For more information, refer to Special Publication,
Coolant Capacities SEBU6251, Cat Commercial Engine Fluids
Recommendations.
To maintain the cooling system, the total cooling
system capacity must be determined. The total
cooling system capacity will vary between individual Cat Diesel Engine Oil (Cat DEO )
installations. The total cooling system capacity can
include the following components: engine, expansion Cat oils have been developed and tested in order to
tank, heat exchanger, radiator and piping. provide the full performance and service life that has
been designed and built into Cat engines. Cat oils
Refer to the specifications that are provided by are currently used to fill Cat Diesel Engines at the
Caterpillar or the OEM of the installation. Record the factory. These oils are offered by Cat dealers for
total cooling system capacity in the appropriate Table. continued use when the engine oil is changed.
Table 19 Consult your Cat dealer for more information on
these oils.
Approximate Refill Capacities for 3500BGenerator Set Cool-
ing Systems Due to significant variations in the quality and in the
performance of commercially available oils,
Engine Radiator Total cool- Caterpillar makes the following recommendations:
ing system
Table 20
3512BEngine 157 L 244 L
Cat Lubricants Viscosity Grade
(41.5 US (64.5 US gal)
gal) SAE 15W-40
Cat DEO-ULS
3512BEngine (1) 233 L 203 L SAE 10W-30
Diesel Engine
(61.5 US (53.6 US gal)
Oil-Ultra Low Cat DEO-ULS SYN SAE 5W-40
gal)
Sulfur
233 L 247 L Cat Cold Weather
3516BEngine (2) SAE 0W-40
(61.5 US (65.3 US gal) DEO-ULS
gal) SAE 15W-40
Diesel Engine Cat DEO
SAE 10W-30
Oil
(continued) Cat DEO SYN SAE 5W-40
82 SEBU8468
Refill Capacities
Fluid Recommendations
Note: Cat DEO and Cat DEO-ULS multigrade oils Refer to Table 22 (maximum temperature) in order to
are the preferred oils for use in this Cat Diesel select the oil viscosity for engine operation at the
Engine . highest ambient temperature that is anticipated.
Note: Generally, use the highest oil viscosity that is
Commercial Oil available to meet the requirement for the temperature
at start-up.
Note: Non-Cat commercial oils are second choice
Table 22
oils for your engine.
Lubricant Viscosities for Ambient Temperatures
NOTICE for Cat Diesel Engines
Caterpillar does not warrant the quality or perform- Oil Type and Per- C F
ance of non-Cat fluids. formance
Viscosity
Grade Min Max Min Max
Requirements
The three current Caterpillar ECF specifications are: Cat ECF-1-a
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each Cat ECF-2 SAE 0W-30 40 30 40 86
higher Cat ECF specification provides increased Cat ECF-3
performance over lower Cat ECF specifications.
Cat Cold Weather
A commercial oil must meet the following standards DEO-ULS
to be considered an equivalent of a Cat Diesel Cat ECF-1-a SAE 0W-40 40 40 40 104
Engine Oil : Cat ECF-2
Cat ECF-3
Table 21
Cat Engine Crankcase Fluids (ECF) Definitions Cat DEO-ULS
Cat ECF-1-a
SAE 5W-30 30 30 22 86
Cat Performance Cat ECF-2
Cat ECF Specifications Requirements
Requirement Cat ECF-3
API CJ-4 Oil Category performance Cat DEO-ULS SYN

Cat ECF-3 Cat DEO
requirements
Cat ECF-1-a SAE 5W-40 30 50 22 122
API CI-4 / CI-4 PLUS Oil Category per- Cat ECF-2
formance requirements Cat ECF-3
Passing standard Cat C13 engine test Cat ECF-1-a

Cat ECF-2 Cat ECF-2 SAE 10W-30 18 40 0 104
per API requirements
Cat ECF-3
Oils of sulfated ash > 1.50 percent are
not allowed Cat DEO-ULS SAE 10W-40 18 50 0 122
Cat DEO SAE 15W-40 9.5 50 15 122
API CH-4 Oil Category performance
requirements
For oils that are between 1.30 percent Note: A cold soaked start occurs when the engine
and 1.50 percent sulfated ash, passing has not been operated recently, allowing the oil to
Cat ECF-1-a become more viscous due to cooler ambient
one additional Cat 1P SCOTE test
(ASTM D6681) is required temperatures. Supplemental heat is recommended
for cold soaked starts below the minimum ambient
Oils of sulfated ash > 1.50 percent are
temperature. Supplemental heat may be necessary
not allowed
for cold soaked starts that are above the minimum
temperature depending on factors such as parasitic
In selecting oil for any engine application, both of the load.
following must be satisfied: the oil viscosity and the
category of oil performance or the specification for oil
performance . Using only one of these parameters Total Base Number (TBN) and Fuel Sulfur
will not sufficiently define oil for an engine application. Levels
The proper SAE viscosity grade of oil is determined The use of Cat SOS Services oil analysis is
by the following temperatures: minimum ambient recommended strongly for determining oil life.
temperature during cold engine start-up and
maximum ambient temperature during engine The minimum required Total Base Number (TBN) for
operation. oil depends on the fuel sulfur level. The TBN for new
oil is typically determined by the ASTM D2896
Refer to Table 22 (minimum temperature) in order to procedure. For direct injection engines that use
determine the required oil viscosity for starting a cold distillate fuel, the following guidelines apply:
engine.
SEBU8468 83
Refill Capacities
Table 23
NOTICE
TBN recommendations for applications in Cat engines Always use a designated pump for oil sampling, and
(1)
use a separate designated pump for coolant sam-
TBN of Com- pling. Using the same pump for both types of samples
Fuel Sulfur Level per- may contaminate the samples that are being drawn.
Cat Engine Oils mercial Engine
cent (ppm)
Oils This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by
0.05 percent (500 Cat DEO-ULS
Min 7 both dealers and customers.
ppm) Cat DEO
0. 1- 0.05 percent Cat DEO-ULS

(1000-500 ppm) Cat DEO
Min 7 Refer to Special Publication, SEBU6251, Cat
Commercial Engine Fluids Recommendations in
Above 0.1 percent order to obtain additional information about SOS
Cat DEO(3) Min 10 Services oil analysis. You can also contact your local
(above 1000 ppm)(2)
Cat dealer.
(1) When using fuel with 0.10% sulfur (1000 ppm) or higher, refer to
this Operation and Maintenance Manual, Severe Service Appli-
cation for more information. Fuel
(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
refer to TBN and engine oil guidelines given in this section. Note: Caterpillar strongly recommends the filtration
(3) Cat DEO-ULS may be used if an oil analysis program is fol- of fuel through a fuel filter with a rating of four microns
lowed. Base the oil change interval on the analysis. (c) absolute or less. This filtration should be located
on the device that dispenses the fuel to the fuel tank
SOS Services Oil Analysis for the engine. This filtration should also be located
on the device that dispenses fuel from the bulk
Caterpillar has developed a maintenance tool that storage tank. Series filtration is recommended.
evaluates oil degradation. the maintenance
management also detects the early signs of wear on NOTICE
internal components. The Caterpillar tool for oil In order to meet expected fuel system component life,
analysis is called SOS oil analysis and the tool is 4 micron(c) absolute or less secondary fuel filtration is
part of the SOS Services program. SOS oil required for all Caterpillar Diesel Engines that are
analysis divides oil analysis into four categories: equipped with unit injected fuel systems. Note that all
current Caterpillar Diesel Engines are factory
Component wear rate
equipped with Caterpillar Advanced Efficiency 4 mi-
Oil condition cron(c) absolute fuel filters.
Oil contamination Caterpillar does not warrant the quality or perform-

ance of non-Caterpillar fluids and filters.
Identification of oil
These four types of analysis are used to monitor the Diesel engines can burn a wide variety of fuels.
condition of your equipment. The four types of These fuels are divided into two general groups. The
analysis will also help you identify potential problems. two groups are called the preferred fuels and the
A properly administered SOS oil analysis program permissible fuels.
will reduce repair costs and the program will lessen
the impact of downtime. Note: The permissible fuels are some crude oils,
some blends of crude oil with distillate fuel, some
The SOS Oil Analysis program uses a wide range biodiesel, and some marine diesel fuel. These fuels
of tests to determine the condition of the oil and the are not suitable for use in all engine applications. The
crankcase. Guidelines that are based on experience acceptability of these fuels for use is determined on
and a correlation to failures have been established for an individual basis. A complete fuel analysis is
these tests. Exceeding one or more of these
guidelines could indicate serious fluid degradation or required.
a pending component failure. A trained person at your For more information, refer to Special Publication,
Cat dealership should make the final analysis. SEBU6251, Cat Commercial Engine Fluids
Recommendations or consult your Cat dealer for
further information.
Diesel Distillate Fuel

Diesel engines may burn a wide variety of fuels.
These fuels are divided into two general groups. The
two groups are called the preferred fuels and the
permissible fuels.
84 SEBU8468
Refill Capacities
The preferred fuels provide maximum engine (Table 24, contd)

service life and performance. The preferred fuels Caterpillar Specification for Distillate Fuel for Nonroad
are distillate fuels. These fuels are commonly called Diesel Engines
diesel fuel, furnace oil, gas oil, or kerosene. These
fuels must meet the Cat Specification for Distillate Specifications Requirements ASTM ISO Test
Diesel Fuel for Off-Highway Diesel Engines found in Test
this Special Publication, Distillate Diesel Fuel article.
Minimum of 80%
Note: The permissible fuels are some crude oils, reflectance after
No equiva-
some blends of crude oil with distillate fuel, some Thermal Stability aging for 180 mi- D6468
lent test
nutes at 150 C
biodiesel, and some marine diesel fuel. These fuels
(302 F)
are not suitable for use in all engine applications.
The acceptability of these fuels for use is determined 30 minimum No equiva-
on a case by case basis. A complete fuel analysis is API Gravity (2) D287
45 maximum lent test
required. Consult your Cat dealer for further
information. 6 C (10 F) mini-
Pour Point mum below ambi- D97 ISO 3016
NOTICE ent temperature
The footnotes are a key part of the Caterpillar Speci- D5453 ISO 20846
fication for Distillate Diesel Fuel for Off-Highway Die- Sulfur (3) (4) (5) or or
sel Engines Table. Read ALL of the footnotes. D2622 ISO 20884
1.4 cSt minimum
Table 24
and 20.0 cSt maxi-
Caterpillar Specification for Distillate Fuel for Nonroad mum as delivered
Diesel Engines to the fuel injection
pumps
Specifications Requirements ASTM ISO Test Kinematic Viscosity - -
Test 1.4 cSt minimum
and 4.5 cSt maxi-
Aromatics 35% maximum D1319 ISO 3837 mum as delivered
0.01% maximum to the rotary fuel
Ash D482 ISO 6245 injection pumps
(weight)
Water and D1796 or
Carbon Residue on 0.35% maximum 0.05% maximum ISO 3734
D524 ISO 4262 Sediment D2709
10% Bottoms (weight)
No equiva-
40 minimum (DI Water 0.05% maximum D6304
lent test
engines) D613
Cetane Number (1) or ISO 5165 0.05% maximum
35 minimum (PC D6890 Sediment D473 ISO 3735
(weight)
engines)
Gums and Resins 10 mg per 100 mL
The cloud point (6) D381 ISO 6246
maximum
must not exceed
Cloud Point the lowest ex- D2500 ISO 3015 0.52 mm
pected ambient (0.0205 inch) max- No equiva-
Lubricity D6079
temperature. imum at 60 C lent test
(140 F)
Copper Strip
No. 3 maximum D130 ISO 2160 (1) Alternatively, to ensure a minimum cetane number of 35 (PC en-
Corrosion
gines), and 40 (DI engines), distillate diesel fuel should have a
10% at 282 C minimum cetane index of 37.5 (PC engines), and 44.2 (DI en-
(540 F) gines) when the ASTM D4737-96a test method is used. A fuel
maximum with a higher cetane number may be required for operation at a
Distillation D86 ISO 3405 higher altitude or in cold weather.
90% at 360 C (2) Via standards tables, the equivalent kg/m3 (kilograms per cubic
(680 F) meter) using the ASTM D287 test method temperature of
maximum 15.56 C (60 F) for the minimum API gravity of 30 is 875.7 kg/
m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
Flash Point legal limit D93 ISO 2719 (3) ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 en-
gines and engines with aftertreatment devices.
(continued)
(continued)
SEBU8468 85
Refill Capacities
(Table 24, contd) Refer to Special Publication, SEBU6251, Cat

(4) Certain Cat fuel systems and engine components can operate Commercial Diesel Engine Fluids Recommendations
on fuel with a maximum sulfur content of 3%. Contact your Cat for information about the use of Cat Diesel Fuel
dealer for guidance about appropriate maintenance intervals Conditioner .
and fluids for engines operating on fuel with sulfur levels be-
tween 0.1% and 3%.
(5) An engine which operates on fuel with 0.1% (1000 ppm) of sul- Cat Diesel Fuel System Cleaner
fur or more is operating in a severe service application. Refer to
this Operation and Maintenance Manual, Severe Service Appli- Note: Cat Diesel Fuel System Cleaner is the only
cation for information about operating an engine in a severe
service application.
fuel system cleaner available to the end user that is
(6) Follow the test conditions and procedures for gasoline (motor). tested and approved by Caterpillar for use in Cat
Diesel Engines.
Biodiesel Cat Diesel Fuel System Cleaner is a proven high
performance detergent product designed specifically
A biodiesel blend of up to 20 percent may be used in for cleaning deposits that form in the fuel system.
the engine when the fuel blend meets the Deposits in the fuel system reduce system
recommendations in table 25 and meets the performance and can increase fuel consumption. Cat
recommendations in Special Publication, SEBU6251, Diesel Fuel System Cleaner addresses the deposits
Biodiesel. formed due to the use of degraded diesel fuel, poor
quality diesel fuel, and diesel fuel containing high
Note: A complete Cat SOS Services oil analysis quantities of high molecular weight compounds. Cat
program is recommended strongly when using Diesel Fuel System Cleaner addresses deposits
biodiesel blends above 5 percent. formed due to the use of biodiesel, biodiesel blends,
Table 25 and biodiesel that does not meet the appropriate
quality specifications. Continued use of Cat Diesel
Biodiesel Blends for Cat Commercial Engines Fuel System Cleaner is proven to inhibit the growth
Distillate diesel fuel
of new deposits.
Biodiesel blend stock Final blend
used for blend
Caterpillar strongly recommends that Cat Diesel
Caterpillar distillate Fuel System Cleaner be used with biodiesel and
Caterpillar biodiesel B20: ASTM D7467
diesel fuel specifica- biodiesel blends. Cat Diesel Fuel System Cleaner is
specification, ASTM and API gravity 30-
tion, ASTM D975 or suitable for use with biodiesel/biodiesel blends that
D6751 or EN14214 45 meet Caterpillar biodiesel recommendations and
EN590
requirements. Not all fuel cleaners are suitable for
use with biodiesel/biodiesel blends. Read and follow
Fuel Additives all applicable label usage instructions. Also, refer to
Special Publication, SEBU6251, Cat Commercial
Diesel Engine Fluids Recommendations, Distillate
Cat Diesel Fuel Conditioner Diesel Fuel, article and also refer to the Biodiesel
article, which includes Caterpillar biodiesel
Cat Diesel Fuel Conditioner is a proprietary recommendations and requirements.
formulation that has been extensively tested for use
with distillate diesel fuels for use in Cat Diesel Aftermarket Fuel Additives
Engines. Cat Diesel Fuel Conditioner is a high
performance diesel fuel conditioner for use with lower There are many different types of fuel additives that
quality fuels that do not meet the minimum are available to use. Caterpillar does not generally
requirements of any of the following: recommend the use of fuel additives.
Caterpillar Specification for Distillate Diesel Fuel In special circumstances, Caterpillar recognizes the
need for fuel additives. Use fuel additives with
National Conference on Weights and Measures caution. The additive may not be compatible with the
(NCWM) Premium Diesel definition (refer to the fuel. Some additives may precipitate. This action
2004 or newer National Institute of Standards & causes deposits in the fuel system. The deposits may
Technology (NIST) Handbook). cause seizure. Some additives may plug fuel filters.
Some additives may be corrosive, and some
EN590 (non-arctic) additives may be harmful to the elastomers in the fuel
system. Some additives may damage emission
ASTM D975 control systems. Some additives may raise fuel sulfur
levels above the maximum levels that are allowed by
Cat Diesel Fuel Conditioner is the only fuel the following agencies: EPA and other regulatory
conditioner/additive available to the end user that is agencies. Contact your fuel supplier for those
tested and approved by Caterpillar for use in Cat circumstances when fuel additives are required. Your
Diesel Engines. fuel supplier can make recommendations for
additives to use and for the proper level of treatment.
86 SEBU8468
Refill Capacities
Note: For best results, your fuel supplier should treat

the fuel when additives are needed.
Cooling System
Note: Refer to Special Publication, SEBU6251, Cat
Commercial Diesel Engine Fluids Recommendations
for complete information about the proper fluids for
use in the cooling system.
The cooling system operates under pressure

which is controlled by the radiator pressure cap.
Removing the cap while the system is hot may al-
low the escape of hot coolant and steam, causing
serious burns.
Before you remove the radiator cap, allow the sys-
tem to cool. Use a thick cloth and turn the radiator
cap slowly to the first stop to allow pressure to es-
cape before fully removing the cap.
Avoid contact with coolant.
NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.
NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper-
ature or drained completely in order to prevent dam-
age caused by freezing coolant.
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors. Removing the regulators allows some coolant to
bypass the radiator, potentially causing overheating.
SEBU8468 87
Refill Capacities
Coolant Recommendations
A Cat Diesel Engine equipped with air-to-air
aftercooling (ATAAC) requires a minimum of 30
percent glycol to help prevent water pump cavitation.
Table 26
Coolant Recommendations for Cat Diesel Engines
Recommendations Product Service Hours(1) (2) (3) Required Maintenance
Add Cat ELC Extender at

Preferred Cat ELC and Cat ELI 12000 hours or 6 years 6000 service hours or one half
of service life
Cat EC-1 specification and ASTM D6210 and
Organic Additive Technology (OAT) based on a
combination of a monocarboxylic acid and a dicar-
boxylic acid
Add Extender at 3000 service
Min requirements Phosphate, borate, and silicate free 6000 hours or 6 years
hours or one half of service life
Tolyltriazole: minimum typical concnetration of 900
ppm
Nitrite: minimum typical concentration of 500 ppm
in new coolants
Cat DEAC 3000 hours or 3 years SCA at maintenance intervals

Acceptable
Cat SCA in water 3000 hours or 2 years SCA at maintenance intervals
ASTM D6210 and

Nitrite (as NO2) concentration: Minimum of 1200
Min requirements for fully for-
ppm (70 grains/US gal) and maximum of 2400 ppm
mulated Heavy Duty Commer- 3000 hours or 2 years SCA at maintenance intervals
(140 grains/US gal)
cial coolants
Silicon concentration: minimum of 100 ppm and
maximum of 275 ppm
ASTM D4985 and(1)

Nitrite (as NO2) concentration: Minimum of 1200
Min requirements for Commer-
ppm (70 grains/US gal) and maximum of 2400 ppm SCA at initial fill and SCA at
cial coolants requiring SCA 3000 hours or 1 year
(140 grains/US gal) maintenance intervals
precharge
Silicon concentration: minimum of 100 ppm and
maximum of 275 ppm
Min requirements for SCA and Commercial supplemental coolant additive and Per manufacturer
3000 hours or 1 year
water water recommendations
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets Re-
agent 4 ASTM D1193 requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual SOS
Services Level 2 coolant sampling analysis.
Table 27
Special Requirements
Cat C7-C32 Marine Engines with heat exchangers
Minimum of 30% glycol is required. 50% Glycol is recommended. Water
Cat diesel engines equipped with air-to-air aftercooling (ATAAC) alone or water with SCA or with ELI is NOT allowed.
88 SEBU8468
Refill Capacities
NOTICE
SOS Services Coolant Analysis (Level
Use Only Approved SCAs and Extenders 1)
Conventional coolants require the maintenance addi- A coolant analysis (Level 1) is a test of the properties
tion of SCA throughout the expected life of the cool- of the coolant.
ants. Do NOT use an SCA with a coolant unless
approved specifically by the coolant supplier. The The following properties of the coolant are tested:
coolant manufacturer is responsible for ensuring com-
patibility and acceptable performance. Glycol concentration for freeze protection and boil
protection
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- Ability to protect from erosion and corrosion
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been pH
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en- Conductivity
suring compatibility and acceptable performance.
Visual analysis
Failure to follow these recommendations can result in
shortened cooling system component life. Odor analysis
The results are reported, and appropriate
Cat ELC can be recycled into conventional coolants. recommendations are made.
SEBU6251, Cat Commercial Engine Fluids SOS Services Coolant Analysis (Level
Recommendations.
2)
SOS Services Coolant Analysis A coolant analysis (Level 2) is a comprehensive
chemical evaluation of the coolant. This analysis is
Testing the engine coolant is important to ensure that also a check of the overall condition of the cooling
the engine is protected from internal cavitation and system.
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and The SOS coolant analysis (Level 2) has the
freezing. SOS coolant analysis can be done at your following features:
Cat dealer. Cat SOS coolant analysis is the best
way to monitor the condition of your coolant and your Full coolant analysis (Level 1)
cooling system. SOS coolant analysis is a program
that is based on periodic samples. Identification of metal corrosion and of
Table 28 contaminants
Recommended Interval Identification of buildup of the impurities that cause

corrosion
Type of Level 1 Level 2 Identification of buildup of the impurities that cause
Coolant scaling
Cat DEAC
Cat SCA Determination of the possibility of electrolysis
Every 250 hours Yearly(1)
Conventional Heavy- within the cooling system of the engine
Duty Coolants
The results are reported, and appropriate
Cat ELC recommendations are made.
Cat ELI
Optional(1) Yearly(1)
Commercial EC-1 For more information on SOS coolant analysis,
Coolants consult your Cat dealer.
(1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
Note: Check the SCA (Supplemental Coolant

Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at
the interval that occurs first.
SEBU8468 89
Refill Capacities
Greases
If it is necessary to choose a single grease, always
choose a grease that meets or exceeds the
requirements of the most demanding application.
Remember that the products which barely meet the
minimum performance requirements can be expected
to barely produce the minimum lives of your parts.
False economy is being used if a grease is purchased
with the lowest cost as the only consideration.
Instead, use the grease that yields the lowest total
operating cost. The cost should be based on an
analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
is required.
SEBU6251, Cat Commercial Engine Fluids
Recommendations.
90 SEBU8468
Maintenance Recommendations
General Maintenance Information
Maintenance periodic disassembly
Recommendations knowledgeable visual examination of the

equipment
i01179728 the application of electrical tests
General Maintenance Never perform a test over the rated potential. These
tests can damage insulation that is contaminated or
Information insulation that is in marginal condition. For more
SMCS Code: 4450; 7000 information, refer to I.E.E.E. Standard 432-1992 or
consult a Caterpillar dealer.
Note: Read the warnings and read the instructions
that are contained in the Safety Section of this i02909163
manual. These warnings and instructions must be
understood before you perform any operation or any System Pressure Release
maintenance procedures.
SMCS Code: 1250; 1300; 1350; 5050
Rotating electric machines are complex structures
that are exposed to the following forms of stress: Coolant System
mechanical
electrical
Pressurized system: Hot coolant can cause seri-
thermal ous burn. To open cap, stop engine, wait until ra-
environmental diator is cool. Then loosen cap slowly to relieve
the pressure.
These stresses may be of varying magnitudes. The
electrical insulation systems are very susceptible to
damage that is caused by the stresses that are listed To relieve the pressure from the coolant system, turn
above. Exposure to these stresses may shorten the off the engine. Allow the cooling system pressure cap
effective life of the electrical insulation system. to cool. Remove the cooling system pressure cap
Therefore, the service life of an electric machine will slowly in order to relieve pressure.
largely depend on the serviceability of the electrical
insulation systems. An inspection program and a Fuel System
testing procedure are recommended. An inspection
program and a testing procedure will ensure that the To relieve the pressure from the fuel system, turn off
equipment is maintained in satisfactory condition. the engine.
This will increase field reliability.
A regular maintenance and inspection program can
High Pressure Fuel Lines (If Equipped)
provide an evaluation of the present condition of the
equipment. A regular maintenance program and a
regular inspection program can also reveal future
problems. The frequency of this maintenance
program will depend on the following factors: Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
application spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
environmental conditions structions may cause personal injury or death.
operator's experience
The high pressure fuel lines are the fuel lines that are
operator's philosophy between the high pressure fuel pump and the high
pressure fuel manifold and the fuel lines that are
A regular maintenance program is strongly between the fuel manifold and cylinder head. These
recommended. This program would involve the fuel lines are different from fuel lines on other fuel
following steps: systems.
This is because of the following differences:
SEBU8468 91
Welding on Engines with Electronic Controls
The high pressure fuel lines are constantly

NOTICE
charged with high pressure.
Do not ground the welder to electrical components
The internal pressures of the high pressure fuel such as the ECM or sensors. Improper grounding can
lines are higher than other types of fuel system. cause damage to the drive train, the bearings, hy-
draulic components, electrical components, and other
Before any service or repair is performed on the components.
engine fuel lines, perform the following tasks:
Do not ground the welder across the centerline of the
1. Stop the engine. package. Improper grounding could cause damage to
the bearings, the crankshaft, the rotor shaft, and other
2. Wait for ten minutes. components.
Do not loosen the high pressure fuel lines in order to Clamp the ground cable from the welder to the com-
remove air pressure from the fuel system. ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
Engine Oil sibility of damage.
To relieve pressure from the lubricating system, turn

off the engine. Note: Perform the welding in areas that are free from
explosive hazards.
i03642798 1. Stop the engine. Turn the switched power to the
OFF position.
Welding on Engines with
Electronic Controls 2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
SMCS Code: 1000 open the switch.
NOTICE 3. Disconnect the J1/P1 and J2/P2 connectors from

Because the strength of the frame may decrease, the ECM. Move the harness to a position that will
some manufacturers do not recommend welding onto not allow the harness to accidentally move back
a chassis frame or rail. Consult the OEM of the equip- and make contact with any of the ECM pins.
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Proper welding procedures are necessary in order to

avoid damage to the engine's ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
possible, the following procedure must be followed
when you weld on a unit that is equipped with a
Caterpillar Electronic Engine . The following
procedure is considered to be the safest procedure to
weld on a component. This procedure should provide
a minimum risk of damage to electronic components.
92 SEBU8468
Welding on Engines with Electronic Controls
6. Use standard welding practices to weld the

materials.
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
cause damage to any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
4. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.
Note: If electrical/electronic components are used as
a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
5. Protect the wiring harness from welding debris and

spatter.
SEBU8468 93
Generator Start-up Checklist
i03211424

SMCS Code: 4450
Table 29
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: Arrangement Number:
Serial Number for the Generator: Arrangement Number:
GENERATOR NAME PLATE INFORMATION

Voltage: Package (prime, continuous, standby):
Amperage: Kilowatts:
Storage Location:
Megohmmeter Reading for the Main Stator: Before Storage: After Storage :
The generator was dried for 24 hours prior to start-up. (Y/N) Drying method:
SPACE HEATERS Yes No Comments

The space heaters are operating properly.
The space heater was operated 48 hours before

start-up.
MEGOHMMETER TEST(1) 30 second 60 second 30 second 60 second Ambient Comments

reading reading corrected corrected temperature
Beginning of Main Stator

Storage
Main Rotor
Exciter Stator
Exciter Rotor
PMG(2) Stator
Start-up Main Stator

Main Rotor
Exciter Stator
Exciter Rotor
Stator for the PMG
Regulator Voltage Amperage Comments
No Load T1 to T2 AC
T1 to T3 AC
T2 to T3 AC
PMG1 to PMG2 AC
PMG2 to PMG3 AC
PMG1 to PMG3 AC
Full Load T1 to T2 AC
T1 to T3 AC
(continued)
94 SEBU8468
(Table 29, contd)

GENERATOR START-UP CHECKLIST
T2 to T3 AC
PMG1 to PMG2 AC
PMG2 to PMG3 AC
PMG1 to PMG3 AC
(1) Special Publication, SEHS9124, Cleaning and Drying of Electric Set Generators
(2) Permanent Magnet Exciter
Table 30
GENERATOR START-UP CHECKLIST (CONTINUED)
ELECTRICAL Yes No Comments

The unit is properly grounded.
Check diodes and check the varistor.

Overcurrent protection
Overvoltage protection
Check for loose wiring.
Adjust voltage.
Adjust frequency.
MECHANICAL Data Comments

Bearing temperature readings at full load Front __________ Rear ___________
Temperature reading of the stator at full load A0 _______ B0 _______ C0 _______
Air gap on main stator Top __________ Bottom __________
Air gap on exciter stator Top __________ Bottom __________
Air gap of PMG Top __________ Bottom __________
Ambient air to generator at full load Temperature ____________________
Supplier air opening to generator set Size of Opening _________________
SWITCH GEAR/PARALLEL OPERATION

Manufacturer:
Setting 1 Setting 2 Setting 3 Comments
Circuit breaker type
Overload setting
Reverse power relay
VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system UPS
Enclosure type - Size
Motor: Other loads:
(continued)
SEBU8468 95
Severe Service Application
(Table 30, contd)

- Total SKVA - Lighting
- Total HP - Computers
- Welding
- Non-linear
- Other
FULL LOAD DATA

Voltage Amps KW KVARS P.F.
i05083249 Severe Operating Conditions

Severe Service Application Frequent operation with inlet air which has a
corrosive content
SMCS Code: 1000
Operation with inlet air which has a combustible
An engine which operates outside of normal content
conditions is operating in a severe service
application. Operation which is outside of the intended
application
An engine that operates in a severe service
application may need more frequent maintenance Operation with a plugged fuel filter
intervals in order to maximize the following
conditions: Extended operation at low idle (more than 20% of
hours)
Reliability
Frequent cold starts at temperatures below 0 C
Service life
(32 F)
The number of individual applications cause the
impossibility of identifying all of the factors which may Frequent dry starts (starting after more than 72
contribute to severe service operation. Consult your hours of shutdown)
Caterpillar dealer for the unique maintenance that
may be necessary for your engine. Frequent hot shutdowns (shutting down the engine
without the minimum of 2 minutes to 5 minutes of
An application is a severe service application if any of cool down time)
the following conditions apply:
Operation above the engine rated speed
Severe Environmental Factors
Operation below the peak torque speed
Frequent operation in dirty air
Operating with fuel which does not meet the
Frequent operation at an altitude which is above standards for distillate diesel fuel as stated in
1525 m (5000 ft) Special Publication, SEBU6251, Caterpillar
Frequent operation in ambient temperatures which Recommendations, Distillate Diesel Fuel
are above 32 C (90 F)
Operating with fuel which contains greater than
Frequent operation in ambient temperatures which 1000 ppm (0.1%) sulfur
are below 0 C (32 F)
Operating with a blend of distillate fuel which
contains more than 5 percent biodiesel
96 SEBU8468
Severe Service Application
Improper Maintenance Procedures

(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
Inadequate maintenance of fuel storage tanks from
causes such as excessive water, sediment, and
microorganism growth.
Extending maintenance intervals beyond the

recommended intervals
Using fluids which are not recommended in

Special Publication, SEBU6251, Caterpillar
Recommendations
Extending maintenance intervals for changing the

engine oil and engine coolant without SOS
validation
Extending maintenance intervals for changing air
filters, oil filters, and fuel filters
Failure to use a water separator

Using filters which are not recommended by
Special Publication, PEWJ0074, 2008 Cat Filter
and Fluid Application Guide
Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
refer to Special Publication, SEHS9031, Storage
Procedure for Caterpillar Products)
Storing the engine for 1 yr to 2 years (For

information about engine storage, refer to Special
Instruction, REHS5001, The Long Term Storage
and Recovery of Certain Commercial Engines)
SEBU8468 97
Maintenance Interval Schedule
i05242083 The starting system is disabled.
Maintenance Interval Schedule The engine is stopped.
(Prime) The generator does not pose an electrical shock

hazard.
SMCS Code: 1000; 4450; 7500
The generator is disconnected from the load.
S/N: YAT1Up
When Required
S/N: YBT1Up
Air Inlet Filter - Inspect/Clean/Test ..................... 103
S/N: YAP1Up; DDJ1Up
S/N: YAM1Up; 1GZ1Up Battery - Recycle ................................................ 109
S/N: YAY1Up; 1GZ1Up Battery - Replace................................................ 109
Ensure that all safety information, warnings, and Battery or Battery Cable - Disconnect.................111
instructions are read and understood before any
operation or any maintenance procedures are Circuit Breakers - Reset ......................................112
performed. Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace ........................................ 123
An authorized operator may perform the maintenance
items with daily intervals. An authorized operator may Engine Air Cleaner Element (Single Element) -
perform the maintenance items with intervals of every Inspect/Clean/Replace ........................................ 125
week. The maintenance that is recommended for all
other maintenance intervals must be performed by an Fuel System - Prime........................................... 137
authorized service technician or by your Cat dealer.
Fuel System Primary Filter/Water Separator -
The user is responsible for the performance of all Drain .................................................................... 139
maintenance which includes the following items:
performing all adjustments, using proper lubricants, Generator - Dry................................................... 142
fluids, and filters and replacing old components with
new components due to normal wear and aging . Generator Bearing - Lubricate............................ 145
Failure to adhere to proper maintenance intervals and Generator Set - Test ........................................... 151
procedures may result in diminished performance of
the product and/or accelerated wear of components. Generator Set Alignment - Check ...................... 152
Before each consecutive interval is performed, all Generator Winding - Test ................................... 153
maintenance from the previous intervals must be
performed. Maintenance Recommendations ....................... 160
Choose the interval that occurs first in order to Varistor - Inspect................................................. 177
determine the correct maintenance interval: fuel
consumption, service hours and calendar time . Daily
Products that operate in severe operating conditions
may require more frequent maintenance. Air Starting Motor Lubricator Oil Level - Check.. 108
All of the following will affect the oil change interval: Air Tank Moisture and Sediment - Drain ............ 108
operating conditions, fuel type, oil type and size of the
oil sump . Scheduled oil sampling analyzes used oil in Control Panel - Inspect/Test ................................113
order to determine if the oil change interval is suitable
for your specific engine. Coolant Level - Check.........................................117
Engine Air Cleaner Service Indicator - Inspect .. 128
Engine Oil and Filter - Change in order to determine Engine Air Precleaner - Check/Clean ................ 129
the oil change interval that is suitable for your specific
engine. Engine Oil Level - Check.................................... 130
To determine the maintenance intervals for the Fuel Tank Water and Sediment - Drain .............. 141
overhauls, refer to this Operation and Maintenance
Manual, Maintenance Recommendations . Generator Bearing Temperature - Test/Record.. 149
Unless other instructions are provided, perform Generator Load - Check..................................... 150
maintenance and perform repairs under the following
conditions: Jacket Water Heater - Check ............................. 160
98 SEBU8468
Power Factor - Check......................................... 171 Generator Winding Insulation - Test................... 154

Voltage and Frequency - Check......................... 177 Rotating Rectifier - Inspect/Test ......................... 172
Walk-Around Inspection..................................... 177 Every 2000 Service Hours
Every Week Air Starting Motor Lubricator Bowl - Clean......... 107
Battery Charger - Check......................................110 Crankshaft Vibration Damper - Inspect.............. 121
Electrical Connections - Check .......................... 122 Engine Mounts - Inspect .................................... 130
Generator - Inspect ............................................ 143 Generator Set Vibration - Test/Record............... 152
Generator Lead - Check..................................... 150 Stator Lead - Check ........................................... 175
Space Heater - Test............................................ 173 Turbocharger - Inspect .......................................176
Stator Winding Temperature - Test..................... 175 Every Year
Initial 250 Service Hours Generator Bearing - Inspect............................... 144
Engine Valve Lash - Check ................................ 136 Varistor - Check.................................................. 176
Fuel Injector - Inspect/Adjust.............................. 137 Varistor - Inspect................................................. 177
Every 250 Service Hours Every 3000 Service Hours or 3
Battery Electrolyte Level - Check ........................110 Years
Belts - Inspect/Adjust/Replace ............................111 Coolant (DEAC) - Change...................................113
Coolant Sample (Level 1) - Obtain......................118 Every 4000 Service Hours

Cooling System Supplemental Coolant Additive Engine Valve Lash - Check ................................ 136
(SCA) - Test/Add.................................................. 120
Fuel Injector - Inspect/Adjust.............................. 137
Engine Oil Sample - Obtain................................ 131
Every 6000 Service Hours or 3
Fan Drive Bearing - Lubricate ............................ 137
Years
Fuel Injector - Inspect/Adjust.............................. 137
Coolant Extender (ELC) - Add ............................116
Hoses and Clamps - Inspect/Replace................ 158
Radiator - Clean ................................................. 171
Years
Every 500 Service Hours Air Shutoff Damper - Remove/Check................. 106
Air Shutoff - Test ................................................. 104 Alternator - Inspect ............................................. 109
Engine Oil and Filter - Change........................... 132 Coolant Temperature Regulator - Replace .........119
Every 1000 Service Hours Engine Speed/Timing Sensor - Clean/Inspect... 136
Coolant Sample (Level 2) - Obtain......................119 Prelube Pump - Inspect...................................... 171
Engine - Clean.................................................... 122 Starting Motor - Inspect ...................................... 174
Engine Crankcase Breather - Clean/Replace.... 129 Water Pump - Inspect......................................... 178
Engine Protective Devices - Check.................... 136 Every 12 000 Service Hours or 6
Fuel System Primary Filter (Water Separator) Years
Element - Replace............................................... 138
Coolant (ELC) - Change......................................115
Fuel System Secondary Filter - Replace ........... 139
SEBU8468 99
Overhaul Refer to this Operation and Maintenance Manual,

Engine Oil and Filter - Change in order to determine
Aftercooler Core - Inspect/Clean/Test ................ 103 the oil change interval that is suitable for your specific
engine.
Generator Bearing - Replace ............................. 149
To determine the maintenance intervals for the
Overhaul (Major) ................................................ 163 overhauls, refer to this Operation and Maintenance
Manual, Maintenance Recommendations .
Overhaul (Top End) ............................................ 165
Unless other instructions are provided, perform
Overhaul Considerations ................................... 169 maintenance and perform repairs under the following
conditions:
Commissioning
The starting system is disabled.
Generator Bearing Temperature - Test/Record.. 149
The engine is stopped.
Generator Set Alignment - Check ...................... 152
The generator does not pose an electrical shock
hazard.
i05242225
When Required
(Standby)
SMCS Code: 1000; 4450; 7500
Battery - Recycle ................................................ 109
Ensure that all safety information, warnings, and
instructions are read and understood before any Battery - Replace................................................ 109
operation or any maintenance procedures are
performed. Battery or Battery Cable - Disconnect.................111
An authorized operator may perform the maintenance Circuit Breakers - Reset ......................................112
items with daily intervals. An authorized operator may
perform the maintenance items with intervals of every Fuel System - Prime........................................... 137
other maintenance intervals must be performed by an Fuel System Primary Filter/Water Separator -
authorized service technician or by your Cat dealer. Drain .................................................................... 139
The user is responsible for the performance of all Generator - Dry................................................... 142
performing all adjustments, using proper lubricants, Generator Bearing - Lubricate............................ 145
new components due to normal wear and aging . Generator Set - Test ........................................... 151
Failure to adhere to proper maintenance intervals and Generator Set Alignment - Check ...................... 152
procedures may result in diminished performance of Generator Winding - Test ................................... 153
the product and/or accelerated wear of components.
Varistor - Inspect................................................. 177
Before each consecutive interval is performed, all
performed. Daily
Choose the interval that occurs first in order to Coolant Level - Check.........................................117
consumption, service hours and calendar time . Every Week
oil sump . Scheduled oil sampling analyzes used oil in Battery Charger - Check......................................110
for your specific engine. Battery Electrolyte Level - Check ........................110
Control Panel - Inspect/Test ................................113
Electrical Connections - Check .......................... 122
100 SEBU8468
Engine Air Cleaner Service Indicator - Inspect .. 128 Engine Speed/Timing Sensor - Clean/Inspect... 136
Engine Air Precleaner - Check/Clean ................ 129 Engine Valve Lash - Check ................................ 136
Engine Oil Level - Check.................................... 130 Fan Drive Bearing - Lubricate ............................ 137
Fuel Tank Water and Sediment - Drain .............. 141 Fuel Injector - Inspect/Adjust.............................. 137
Generator - Inspect ............................................ 143 Fuel System Primary Filter (Water Separator)
Element - Replace............................................... 138
Generator Lead - Check..................................... 150
Generator Bearing - Inspect............................... 144
Generator Load - Check..................................... 150
Generator Set Vibration - Test/Record............... 152
Jacket Water Heater - Check ............................. 160
Generator Winding Insulation - Test................... 154
Power Factor - Check......................................... 171
Space Heater - Test............................................ 173 Hoses and Clamps - Inspect/Replace................ 158
Standby Generator Set Maintenance Prelube Pump - Inspect...................................... 171

Recommendations .............................................. 173 Radiator - Clean ................................................. 171
Stator Winding Temperature - Test..................... 175 Rotating Rectifier - Inspect/Test ......................... 172
Voltage and Frequency - Check......................... 177 Starting Motor - Inspect ...................................... 174
Walk-Around Inspection..................................... 177
Stator Lead - Check ........................................... 175
Every 6 Months Varistor - Check.................................................. 176
Coolant Sample (Level 1) - Obtain......................118 Varistor - Inspect................................................. 177
Every Year Water Pump - Inspect......................................... 178
Air Shutoff - Test ................................................. 104 Every 3 Years

Air Starting Motor Lubricator Bowl - Clean......... 107 Air Shutoff Damper - Remove/Check................. 106
Alternator - Inspect ............................................. 109 Coolant (DEAC) - Change...................................113
Belts - Inspect/Adjust/Replace ............................111 Coolant Temperature Regulator - Replace .........119
Coolant Sample (Level 2) - Obtain......................119 Turbocharger - Inspect .......................................176
Cooling System Supplemental Coolant Additive Every 6 Years
(SCA) - Test/Add.................................................. 120
Crankshaft Vibration Damper - Inspect.............. 121
Engine - Clean.................................................... 122
Engine Air Cleaner Element (Dual Element) - Every 10 Years
Generator Bearing - Replace ............................. 149
Engine Air Cleaner Element (Single Element) -
Inspect/Clean/Replace ........................................ 125 Commissioning
Engine Crankcase Breather - Clean/Replace.... 129 Generator Bearing Temperature - Test/Record.. 149
Engine Mounts - Inspect .................................... 130 Generator Set Alignment - Check ...................... 152
Engine Oil and Filter - Change........................... 132
Engine Protective Devices - Check.................... 136
SEBU8468 101
i05242269 The starting system is disabled.
Maintenance Interval Schedule The engine is stopped.
(High Displacement) The generator does not pose an electrical shock

hazard.
SMCS Code: 1000; 4450; 7500
S/N: YAW1Up
When Required
S/N: YBW1Up
S/N: YAN1Up; CTH1Up
S/N: YAZ1Up; CTH1Up Battery - Recycle ................................................ 109
S/N: YAR1Up; DDM1Up Battery - Replace................................................ 109
Ensure that all safety information, warnings, and Battery or Battery Cable - Disconnect.................111
instructions are read and understood before any
operation or any maintenance procedures are Circuit Breakers - Reset ......................................112
performed. Engine Air Cleaner Element (Dual Element) -
An authorized operator may perform the maintenance
items with daily intervals. An authorized operator may Engine Air Cleaner Element (Single Element) -
perform the maintenance items with intervals of every Inspect/Clean/Replace ........................................ 125
other maintenance intervals must be performed by an Fuel System - Prime........................................... 137
authorized service technician or by your Cat dealer.
Fuel System Primary Filter/Water Separator -
The user is responsible for the performance of all Drain .................................................................... 139
performing all adjustments, using proper lubricants, Generator - Dry................................................... 142
new components due to normal wear and aging . Generator Bearing - Lubricate............................ 145
Failure to adhere to proper maintenance intervals and Generator Set - Test ........................................... 151
procedures may result in diminished performance of
the product and/or accelerated wear of components. Generator Set Alignment - Check ...................... 152
Before each consecutive interval is performed, all Generator Winding - Test ................................... 153
performed. Maintenance Recommendations ....................... 160
Choose the interval that occurs first in order to Varistor - Inspect................................................. 177
consumption, service hours and calendar time . Daily
oil sump . Scheduled oil sampling analyzes used oil in Control Panel - Inspect/Test ................................113
for your specific engine. Coolant Level - Check.........................................117
Engine Air Cleaner Service Indicator - Inspect .. 128
Engine Oil and Filter - Change in order to determine Engine Air Precleaner - Check/Clean ................ 129
the oil change interval that is suitable for your specific
engine. Engine Oil Level - Check.................................... 130
To determine the maintenance intervals for the Fuel Tank Water and Sediment - Drain .............. 141
overhauls, refer to this Operation and Maintenance
Manual, Maintenance Recommendations . Generator Bearing Temperature - Test/Record.. 149
Unless other instructions are provided, perform Generator Load - Check..................................... 150
maintenance and perform repairs under the following
conditions: Jacket Water Heater - Check ............................. 160
102 SEBU8468
Power Factor - Check......................................... 171 Rotating Rectifier - Inspect/Test ......................... 172

Voltage and Frequency - Check......................... 177 Every 2000 Service Hours
Walk-Around Inspection..................................... 177 Air Starting Motor Lubricator Bowl - Clean......... 107
Every Week Crankshaft Vibration Damper - Inspect.............. 121
Battery Charger - Check......................................110 Engine Mounts - Inspect .................................... 130
Electrical Connections - Check .......................... 122 Generator Set Vibration - Test/Record............... 152
Generator - Inspect ............................................ 143 Stator Lead - Check ........................................... 175
Generator Lead - Check..................................... 150 Turbocharger - Inspect .......................................176
Space Heater - Test............................................ 173 Every Year
Stator Winding Temperature - Test..................... 175 Generator Bearing - Inspect............................... 144
Initial 250 Service Hours Varistor - Check.................................................. 176
Engine Valve Lash - Check ................................ 136 Varistor - Inspect................................................. 177
Fuel Injector - Inspect/Adjust.............................. 137 Every 3000 Service Hours or 3
Every 250 Service Hours Years
Battery Electrolyte Level - Check ........................110 Coolant (DEAC) - Change...................................113
Belts - Inspect/Adjust/Replace ............................111 Every 4000 Service Hours

Coolant Sample (Level 1) - Obtain......................118 Engine Valve Lash - Check ................................ 136
Cooling System Supplemental Coolant Additive Fuel Injector - Inspect/Adjust.............................. 137
(SCA) - Test/Add.................................................. 120
Years
Fan Drive Bearing - Lubricate ............................ 137
Hoses and Clamps - Inspect/Replace................ 158
Radiator - Clean ................................................. 171
Years
Every 500 Service Hours Air Shutoff Damper - Remove/Check................. 106
Air Shutoff - Test ................................................. 104 Alternator - Inspect ............................................. 109
Engine Oil and Filter - Change........................... 132 Coolant Temperature Regulator - Replace .........119
Every 1000 Service Hours Engine Speed/Timing Sensor - Clean/Inspect... 136
Coolant Sample (Level 2) - Obtain......................119 Prelube Pump - Inspect...................................... 171
Engine - Clean.................................................... 122 Starting Motor - Inspect ...................................... 174
Engine Crankcase Breather - Clean/Replace.... 129 Water Pump - Inspect......................................... 178
Engine Protective Devices - Check.................... 136 Every 12 000 Service Hours or 6
Fuel System Primary Filter (Water Separator) Years
Element - Replace............................................... 138
Overhaul
Generator Winding Insulation - Test................... 154
Aftercooler Core - Inspect/Clean/Test ................ 103
SEBU8468 103
Aftercooler Core - Inspect/Clean/Test
Generator Bearing - Replace ............................. 149 Note: Do not use high pressure when the fins are
cleaned. High pressure can damage the fins.
Overhaul (Major) ................................................ 163
6. Wash the core with hot, soapy water.
Overhaul (Top End) ............................................ 165
Overhaul Considerations ................................... 169 7. Flush the core thoroughly in order to remove
residue and remaining debris. Flush the core with
Commissioning clean, fresh water until the water that is exiting the
core is clear and free of debris.
Generator Set Alignment - Check ...................... 152
i03967390 Personal injury can result from air pressure.

Personal injury can result without following prop-
Aftercooler Core - Inspect/ er procedure. When using pressure air, wear a
Clean/Test protective face shield and protective clothing.
SMCS Code: 1064-040; 1064-070; 1064-081 Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
1. Remove the core. Refer to the Disassembly and
Assembly Manual, Aftercooler - Remove and 8. Dry the core with compressed air. Direct the air in
Install for the procedure. the reverse direction of the normal flow.
2. Place the aftercooler core on one side in order to 9. Prior to installation, inspect any O-rings or seals for
remove debris. Remove the debris that is damage. If necessary, replace the O-rings or seals.
accessible. 10. Inspect the core for trapped debris and
cleanliness. If necessary, remove the debris and
NOTICE repeat the cleaning procedure.
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic 11. Inspect the core for damage and perform a
cleaner can attack the internal metals of the core and pressure test in order to detect leaks. Many shops
cause leakage. Only use the recommended concen- that service radiators are equipped to perform
tration of cleaner. pressure tests.
12. Install the core. Refer to Disassembly and

3. Back flush the core with cleaner. Assembly Manual, Aftercooler - Remove and
Caterpillar recommends the use of Hydrosolv Install for the procedure.
liquid cleaner. Table 31 lists Hydrosolv liquid
cleaners that are available from your Caterpillar For more information on cleaning the core, consult
dealer. your Caterpillar dealer.
Table 31
Hydrosolv Liquid Cleaners(1) i03967430
Part Number Description Size Air Inlet Filter - Inspect/Clean/

1U-5490 Hydrosolv 4165 19 L (5 US gallon) Test
174-6854 Hydrosolv 100 19 L (5 US gallon) SMCS Code: 1051-040; 1051-070; 1051-081
(1) Use a 2 to 5 percent concentration of the cleaner at tempera-
tures up to 93C (200F). Consult your Caterpillar dealer for Monitor the connector contacts of the differential
more information. pressure switch for the air inlet filter. If the differential
pressure rises above 15.2 mm (0.6 inch) of water,
clean the filter with a solution of soap and water. Be
4. Remove the drain plug. sure that the filter is thoroughly dry before the start-
up. Replace the filter, if necessary.
5. Use steam to clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside
and from the outside of the core.
104 SEBU8468
Air Shutoff - Test
i03291912
Air Shutoff - Test

(Engines That Are Equipped with
ADEM II or ADEM III Engine
Control Modules (If equipped))
SMCS Code: 1078-081
The reset mechanisms for the air shutoffs in your
3500Engine may look like one of the following reset
mechanisms.
Refer to the Troubleshooting Guide, Air Shutoff

System information in your Service Manual for
further information about the electrical system for the
air shutoff system.
Engines That Are Equipped with

ADEM II Engine Control Modules
Note: Do not start the engine. Ensure that the engine
control is in the OFF position.
SEBU8468 105
Air Shutoff - Test
1. Ensure that both air shutoff gates are latched in the

1. Ensure that both air shutoff gates are latched in the OPEN position. Ensure that both air shutoff
OPEN position and ensure that both air shutoff switches are connected. Turn the power for the
switches are connected. Turn on the power to the engine control panel to the ON position. The air
engine control panel. Both air shutoff gates should shutoff gates should remain in the OPEN positions.
remain open. If both air shutoff gates do not remain If the air shutoff gates do not remain in the OPEN
open, check the wiring for the air shutoff switches. positions, check the wiring for the air shutoffs.
When step 1 has been successfully completed,
2. With the power for the engine control panel in the proceed to step 2.
ON position, activate the EMERGENCY STOP
switch. Both of the air shutoff gates should close. If 2. While the power for the engine control panel is in
both air shutoff gates close, proceed to step 3. If the ON position, activate the EMERGENCY
both air shutoff gates do not close, check the STOP switch . Both air shutoff gates should
wiring for the air shutoff switches and check the close. If the air shutoff gates do not close, check
wiring for the solenoids. Activate the the wiring for the air shutoffs and the wiring for the
EMERGENCY STOP switch again. When both solenoids. Both air shutoff gates must close before
air shutoff gates close, proceed to step 3. proceeding to step 3.
3. Turn the power to the engine control panel to the 3. Turn the power for the engine control panel to the
OFF position. Ensure that the EMERGENCY OFF position. Reset the EMERGENCY STOP
STOP switch is in the RUN position. Latch only switch to the RUN position. Reset the right side air
the right side air shutoff gate to the OPEN position. shutoff to the OPEN position. Turn the power for
Turn the power for the engine control panel to the the engine control panel to the ON position. Select
ON position. The right side air shutoff gate should Run/Start on the engine control panel. The
close. If the right side air shutoff closes, proceed to engine should fail to start. If the engine does not
step 4. If the right side air shutoff gate does not start, proceed to 4. If the engine starts, turn off the
close, check the air shutoff switch for the right side engine. Check the right side air shutoff. Check the
air shutoff and check the wiring for the right side air wiring for the right side air shutoff. Retest the air
shutoff . When the right side air shutoff closes, shutoff. When the procedure in 3 is followed and
proceed to step 4. the engine fails to start, proceed to 4.
4. Turn the power for the engine control panel to the 4. Reset the EMERGENCY STOP switch to the
OFF position. Latch only the left side air shutoff RUN position. Set the power for the engine control
gate to the OPEN position. Turn the power for the panel to the ON position. Activate the
engine control panel to the ON position. The left EMERGENCY STOP switch . Both air shutoff
side air shutoff gate should close. If the left side air gates should close. Set power for the engine
shutoff gate closes the test is complete. If the left control panel to the OFF position. Reset the
side air shutoff gate does not close, check the EMERGENCY STOP switch to the RUN
switch and the wiring for the left side air shutoff . position. Reset the left side air shutoff to the OPEN
position. Turn the power for the engine control
Note: Testing is only complete when the engine panel to the ON position. Select START/RUN on
successfully passes step 1 through step 4.
the engine control panel. The engine should fail
5. Operate the engine normally. Ensure that the air to start. If the engine does not start, proceed to 5.
shutoff gates continue to be latched. If the engine starts, turn off the engine. Check the
left side air shutoff. Check the wiring for the left
Engines That Are Equipped with side air shutoff. Retest the left side air shutoff.
When the procedure in step 4 is followed and the
ADEM III Engine Control Modules engine fails to start, proceed to 5.
Note: Do not start the engine. Ensure that the engine
control is in the OFF position.
106 SEBU8468
Air Shutoff Damper - Remove/Check
5. Turn the power for the engine control panel to the SMCS Code: 1078-011; 1078-535
ON position. Reset both air shutoffs. Start the
engine. Disconnect only the right side air shutoff.
Both air shutoff gates should close. The engine
should shut down. If the engine does not shut
down, use the EMERGENCY STOP switch to
stop the engine. Check the wiring for both air
shutoffs. Use the above procedure in order to
retest the right side air shutoff. When the
procedure in step 5 is followed and results of the
test are successful, reconnect the right side air
shutoff. Reset both air shutoffs.
6. Turn the power for the engine control panel to the
ON position. Reset both air shutoffs. Start the
engine. Disconnect only the left side air shutoff.
Both air shutoff gates should close. The engine Illustration 67 g01286554
should shut down. If the engine does not shut Typical air shutoff (back view)
down, use the EMERGENCY STOP switch to (1) Air shutoff gate
stop the engine. Check the wiring for both air (2) Damper assembly
shutoffs. Use the above procedure in order to
retest the left side air shutoff. When the procedure The vibration damper on the air shutoff minimizes the
in 6 is followed and the results of the test are vibration of the air shutoff gate when the engine is
successful, reconnect the right side air shutoff. operating and the air shutoff gate is in the LATCHED
Reset both air shutoffs. position. The components of the damper assembly
must be removed in order to ensure correct
7. Testing is complete only when the engine performance of the damper.
successfully passes steps 1 through 6.
8. Reset both air shutoffs. Ensure that the

EMERGENCY STOP switch has been reset.
Operate the engine normally.
i02622938
Air Shutoff Damper - Remove/

Check
(if equipped)
Damper assembly
(3) Plug
(4) Seal ring
(5) Housing
(6) Spring
(7) Plunger
1. The body of the damper should not be loosened or

removed from the air shutoff when the plunger is
removed. In order to remove the plunger without
loosening or removing the damper, unscrew the
plug with the following tools: a 6.35 mm
(0.25 inch) Allen wrench and an open end wrench .
2. Check the seal ring for damage or wear. If

necessary, replace the seal ring.
SEBU8468 107
Air Starting Motor Lubricator Bowl - Clean
3. Inspect the internal parts of the vibration damper

for wear or damage. Clean the components with
138-8440 component cleaner.
Damper plunger
4. Remove the plunger from the spring. Visually (1) Filler plug
inspect the exposed end of the plunger for dirt, (2) Bowl
fouling, damage, and wear. If distance A is less (3) Drain valve
than 18.3 mm (0.72 inch) or if a visual inspection
reveals dirt, fouling, damage, or wear on the active 2. Slowly loosen filler plug (1) in order to release the
end of the plunger, replace the plunger. Insert the pressure from the lubricator.
tapered end of a clean, undamaged plunger into
the spring. Install the open end of the spring into
NOTICE
the plug. Apply 9S-3263 thread lock or apply Care must be taken to ensure that fluids are con-
9S-4030 thread lock onto the threads of the plug. tained during performance of inspection, mainte-
Screw the assembly into the damper body. The nance, testing, adjusting and repair of the product. Be
thread lock should cure for a minimum of 1 hour prepared to collect the fluid with suitable containers
before the air shutoff is used. before opening any compartment or disassembling
any component containing fluids.
i02987710
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
Air Starting Motor Lubricator suitable to collect and contain fluids on Caterpillar
Bowl - Clean products.
(If Equipped) Dispose of all fluids according to local regulations and

mandates.
SMCS Code: 1451-070
If the engine is equipped with an air starting motor, 3. Place a suitable container under bowl (2) and open
use the following procedure: drain valve (3) in order to drain the oil from the
bowl.
4. Remove bowl (2). Clean the bowl with warm water.
Personal injury can result from removing hoses 5. Dry the bowl. Inspect the bowl for cracks. If the
or fittings in a pressure system. bowl is cracked, replace the damaged bowl with a
new bowl. Inspect the gasket. If the gasket is
Failure to relieve pressure can cause personal damaged, replace the gasket.
injury.
Do not disconnect or remove hoses or fittings un- 6. Install the bowl.
til all pressure in the system has been relieved.
7. Make sure that drain valve (3) is closed.
1. Ensure that the air supply to the lubricator is OFF. 8. For instructions on filling the lubricator, see this
Operation and Maintenance Manual, Air Starting
Motor Lubricator Oil Level - Check topic.
108 SEBU8468
Air Starting Motor Lubricator Oil Level - Check
i02987736 Adjust the Lubricator

Air Starting Motor Lubricator Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
Oil Level - Check oil in proportion to variations of the air flow.
(If Equipped) 1. Ensure that the fuel supply to the engine is OFF.
SMCS Code: 1451-535
NOTICE
NOTICE
Do not crank the engine continuously for more than
Never allow the lubricator bowl to become empty. The
30 seconds. Allow the starting motor to cool for two
air starting motor will be damaged by a lack of lubrica-
minutes before cranking the engine again.
tion. Ensure that sufficient oil is in the lubricator bowl.
2. Operate the air starting motor. Observe the drops

of oil that are released in dome (1).
Note: Some lubricators have an adjustment screw

rather than a knob.
3. If necessary, adjust the lubricator in order to
release from one to three drops of oil per second.
To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the
knob clockwise.
i04534752
Air Tank Moisture and

Sediment - Drain
1. Observe the oil level in sight gauge (3). If the oil SMCS Code: 1466-543-M&S
level is less than 1/2, add oil to the lubricator bowl.
Moisture and sediment in the air starting system can
cause the following conditions:
Freezing
Personal injury can result from removing hoses Corrosion of internal parts
or fittings in a pressure system.
Malfunction of the air starting system
Failure to relieve pressure can cause personal
injury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved. When opening the drain valve, wear protective
gloves, a protective face shield, protective cloth-
2. Ensure that the air supply to the lubricator is OFF. ing, and protective shoes. Pressurized air could
Slowly loosen filler plug (4) in order to release cause debris to be blown and result in personal
pressure from the lubricator bowl. injury.
3. Remove filler plug (4). Pour oil into the lubricator

bowl. Use nondetergent SAE 10W oil for
temperatures that are greater than 0 C (32 F).
Use air tool oil for temperatures that are below
0 C (32 F).
4. Install filler plug (4).

SEBU8468 109
Alternator - Inspect
A battery supplier
NOTICE
Care must be taken to ensure that fluids are con- An authorized battery collection facility
nance, testing, adjusting, and repair of the product. Recycling facility
Be prepared to collect the fluid with suitable contain-
i03967451
bling any component containing fluids.
Refer to Special Publication, NENG2500, Cat Dealer Battery - Replace
Service Tool Catalog or refer to Special Publication, SMCS Code: 1401-510
PECJ0003, Cat Shop Supplies and Tools Catalog
for tools and supplies suitable to collect and contain
Dispose of all fluids according to local regulations and Batteries give off combustible gases which can
mandates. explode. A spark can cause the combustible
gases to ignite. This can result in severe personal
1. Open the drain valve that is on the bottom of the air injury or death.
tank. Allow the moisture and sediment to drain. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
2. Close the drain valve. der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
i02676048 serviced.
Alternator - Inspect 1. Turn the key start switch to the OFF position.
SMCS Code: 1405-040 Remove the key and all electrical loads.
Caterpillar recommends a scheduled inspection of 2. Turn OFF the battery charger. Disconnect the
the alternator. Inspect the alternator for loose charger.
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in 3. The NEGATIVE - cable connects the NEGATIVE
order to ensure proper battery performance and/or - battery terminal to the ground plane.
proper performance of the electrical system. Make
repairs, as required. Disconnect the cable from the NEGATIVE -
battery terminal.
Check the alternator and the battery charger for
proper operation. If the batteries are properly 4. The POSITIVE + cable connects the POSITIVE
charged, the ammeter reading should be very near + battery terminal to the starting motor.
zero. All batteries should be kept charged. The Disconnect the cable from the POSITIVE +
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold, battery terminal.
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm. Note: Always recycle a battery. Never discard a
When the engine is not run for long periods of time or battery. Return used batteries to an appropriate
if the engine is run for short periods, the batteries may
not fully charge. A battery with a low charge will recycling facility.
freeze more easily than a battery with a full charge. 5. Remove the used battery.
6. Install the new battery.

i00993589
Battery - Recycle Note: Before connecting the cables, ensure that the
key start switch is OFF.
SMCS Code: 1401-005; 1401-510; 1401-535; 1401- 7. Connect the cable from the starting motor to the
561; 1401
POSITIVE + battery terminal.
Always recycle a battery. Never discard a battery.
8. Connect the cable from the ground plane to the
Always return used batteries to one of the following NEGATIVE - battery terminal.
locations:
110 SEBU8468
Battery Charger - Check
i01039758 Perform one of the following procedures if the battery

shows symptoms of overcharging:
Battery Charger - Check Reduce the rate of charging by a significant
SMCS Code: 1401-535 amount. Complete the charging at the reduced
rate.
Checking Before Start-Up Turn OFF the charger.
Check the battery charger for proper operation. If the
batteries are properly charged, the needle of the Table 32 describes the effects of overcharging on
ammeter will register near 0 (zero). different types of batteries.
Table 32
The battery charger must not produce excessive Effects of Overcharging Batteries
current during start-up. Alternatively, the charger must
be automatically disconnected for start-up. If the Type of Battery Effect
engine has an alternator, the charger must be
automatically disconnected during start-up and during Caterpillar General Service All of the battery cells have a
engine operation. Batteries low level of electrolyte.
Caterpillar Premium High Out-
put Batteries When the plates of the battery
Charging the Battery are inspected through the filler
holes, the plates may appear to
be warped. This is caused by an
excessive temperature.
The battery may not pass a load

Never disconnect any charging unit circuit or bat-
test.
tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an Caterpillar Maintenance Free The battery may not accept a
explosion from the flammable vapor mixture of Batteries charging current.
hydrogen and oxygen that is released from the The battery may not pass a load
electrolyte through the battery outlets. Injury to test.
personnel can be the result.
Perform the following procedure to charge the Checking After Stopping

battery:
Ensure that the battery charger is connected properly.
Observe the meter of the charger. Record the
1. Ensure that the charger is turned OFF. amperage.
2. Adjust the voltage of the charger in order to match
the voltage of the battery. i02601752
3. Connect the POSITIVE + lead of the charger to Battery Electrolyte Level -

the POSITIVE + battery terminal. Connect the Check
NEGATIVE - lead of the charger to the
NEGATIVE - battery terminal. SMCS Code: 1401-535-FLV
When the engine is not run for long periods of time or
4. Turn ON the battery charger.
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
Overcharging of Batteries to help prevent the battery from freezing.
Overcharging reduces the service life of batteries.

Use a battery charger that will not overcharge the
battery. DO NOT charge the battery if the meter of the
battery charger is in the RED zone. All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a
Overcharging is indicated by the following symptoms: face shield and protective clothing when working
on or near batteries.
The battery is very warm to the touch.
A strong odor of acid is present. 1. Remove the filler caps. Maintain the electrolyte
level to the FULL mark on the battery.
The battery emits smoke or a dense vapor (gas).
SEBU8468 111
Battery or Battery Cable - Disconnect
If the addition of water is necessary, use distilled 4. Proceed with necessary system repairs. Reverse
water. If distilled water is not available use clean the steps in order to reconnect all of the cables.
water that is low in minerals. Do not use artificially
softened water.
i02667833
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer. Belts - Inspect/Adjust/Replace
3. Keep the batteries clean. SMCS Code: 1357-025; 1357-040; 1357-510
Clean the battery case with one of the following Inspection

cleaning solutions:
Inspect the alternator belt and the fan drive belts for
A mixture of 0.1 kg (0.2 lb) of baking soda and wear and for cracking. Replace the belts if the belts
1 L (1 qt) of clean water are not in good condition.
A mixture of 0.1 L (0.11 qt) of ammonia and 1 L Check the belt tension according to the information in
(1 qt) of clean water the Service Manual, Specifications.
Thoroughly rinse the battery case with clean water. Slippage of loose belts can reduce the efficiency of
the driven components. Vibration of loose belts can
Use a fine grade of sandpaper to clean the cause unnecessary wear on the following
terminals and the cable clamps. Clean the items components:
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal of Belts
material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561 Pulleys
Silicone Lubricant, petroleum jelly or MPGM.
Bearings
i01492654 If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
Battery or Battery Cable - the components.
Disconnect Adjusting the Alternator Belt

SMCS Code: 1401; 1402-029
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the

battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
Typical alternator
3. Tape the leads in order to help prevent accidental (1) Mounting bolt
starting. (2) Adjusting nuts
(3) Mounting bolt
112 SEBU8468
Circuit Breakers - Reset
1. Remove the drive belt guard. i02107779
2. Loosen mounting bolt (1), adjusting nuts (2) and Circuit Breakers - Reset
mounting bolt (3).
SMCS Code: 1417-529; 1420-529
3. Turn adjusting nuts (2) in order to increase or
decrease the drive belt tension.
4. Tighten adjusting nuts (2). Tighten mounting bolt
(3). Tighten mounting bolt (1). For the proper
torque, see the Service Manual, Specifications
module.
5. Reinstall the drive belt guard.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation at
the rated rpm.
Adjusting the Fan Drive Belt

1. Loosen the mounting bolt for the pulley.
2. Loosen the adjusting nut for the pulley.
3. Move the pulley in order to adjust the belt tension.
4. Tighten the adjusting nut to the proper torque.

5. Tighten the mounting bolt to the proper torque. The circuit breaker is located behind the front left
access door.
For the proper torque specifications, refer to the
Service Manual, Specifications module.
Main Circuit (1) This circuit breaker is
designed to protect the wires between
Replacement the batteries and the fuses. If the wires
For applications that require multiple drive belts, are shorted to the machine's body, this circuit
replace the drive belts in matched sets. Replacing breaker would minimize the damage to the wires.
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive The main circuit breaker has a capacity of 80 Amp.
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail. Alternator Circuit (2) This circuit
breaker is designed to protect the
alternator. If the batteries are installed
with reversed polarity, the circuit breaker would
prevent the alternator from damaging the rectifier.
The circuit breaker for the alternator has a capacity of
105 Amp.
Circuit Breaker Reset Push in the button in order
to reset the circuit breaker. If the electrical system is
working properly, the button will remain depressed. If
the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical
circuit, if necessary.
SEBU8468 113
Control Panel - Inspect/Test
i04506312 Annunciator Panel

Control Panel - Inspect/Test
SMCS Code: 4490-040; 4490-081; 7451-040; 7451-
081
Inspect the condition of the panel. If a component is
damaged, ensure that the component is repaired or
that the component is replaced. If equipped, ensure
that the electronic displays are operating properly.
Inspect the wiring for good condition. Ensure that the
wiring connections are secure.
Electronic Modular Control Panel

4.2 (EMCP 4.2)
Test the LED indicators and the horn when the data
link is connected and when the data link is not
connected. The Lamp Test button is located near the
top of the annunciator panel. Test both the horn and
the indicators by pressing and holding the Lamp Test
button. Replace any faulty components before
starting the engine.
i04535457
Coolant (DEAC) - Change

SMCS Code: 1350-070; 1395-044
Clean the cooling system before the recommended
For detailed information on this electronic control maintenance interval if the following conditions exist:
panel, see Systems Operation, Troubleshooting,
Testing and Adjusting, UENR1209, EMCP4.1/4.2. The engine overheats frequently.
The coolant is foaming.
Switch Panel
The Panel Lights switch should turn on the panel Oil or fuel has entered the cooling system and the
lights. Toggle the switch in order to ensure that the coolant is contaminated.
panel lights are working.
Drain the Cooling System
1. Stop the engine and allow the engine to cool.
Close the water inlet for the separate circuit
aftercooler (if equipped). Ensure that the engine
will not start when the cooling system is drained.
2. Loosen the radiator filler cap slowly in order to

relieve any pressure. Remove the radiator filler
cap.
114 SEBU8468
Coolant (DEAC) - Change
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean water

and Cat Fast Acting Cooling System Cleaner .
Add .5 L (1 pt) of cleaner per 15 L (4 US gal) of
the cooling system capacity. Install the radiator
filler cap.
4. Open the water inlet for the separate circuit

aftercooler (if equipped). Start the engine. Operate
the engine for a minimum of 30 minutes with a
coolant temperature of at least 82 C (180 F).
(1) Coolant drain 5. Stop the engine and allow the engine to cool.
Note: If the engine has a jacket water heater, drain
aftercooler (if equipped). Loosen the radiator filler
the coolant from the heater.
cap slowly in order to relieve any pressure.
3. Open the coolant drain. Allow the coolant to drain.
Remove the radiator filler cap. Open the coolant
NOTICE drain. Remove the cooling system drain plugs.
Dispose of used engine coolant properly or recycle. Allow the water to drain.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full NOTICE
distillation procedure is the only method acceptable Improper or incomplete rinsing of the cooling system
by Caterpillar to reclaim the used coolant. can result in damage to copper and other metal
components.
For information regarding the disposal and the
recycling of used coolant, consult your Cat dealer or To avoid damage to the cooling system, make sure to
consult Cat Dealer Service Tools : completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
Inside U.S.A. 1-800-542-TOOL cleaning agent are gone.
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL 6. Flush the cooling system with clean water until the
EAME phone ++41-22-849 40 56 water that drains is clean. Close the coolant drain.
EAME fax ++41-22-849 49 29 Clean the cooling system drain plugs and install
the cooling system drain plugs. Open the water
Clean the Cooling System inlet for the separate circuit aftercooler (if
NOTICE equipped).
Use of commercially available cooling system
cleaners may cause damage to cooling system com- Cleaning a Cooling System that has
ponents. Use only cooling system cleaners that are Heavy Deposits or Plugging
approved for Caterpillar engines.
Note: For the following procedure to be effective,
there must be an active flow through the cooling
1. After the cooling system has been drained, flush system components.
the cooling system with clean water in order to
remove any debris. 1. After the cooling system has been drained, flush
the cooling system with clean water in order to
2. Close the cooling system drain. Clean the cooling remove any debris.
system drain plugs and install the cooling system
drain plugs. 2. Close the coolant drain. Clean the cooling system
drain plugs and install the cooling system drain
plugs.
SEBU8468 115
Coolant (ELC) - Change
3. Fill the cooling system with a mixture of clean water 3. Check the coolant level. Maintain the coolant to the
and Cat Fast Acting Cooling System Cleaner . proper level on the sight gauge (if equipped). If a
Add .5 L (1 pt) of cleaner per 3.8 to 7.6 L sight gauge is not equipped, maintain the coolant
(1 to 2 US gal) of the cooling system capacity. within 13 mm (.5 inch) below the bottom of the
Install the radiator filler cap. filler pipe.
4. Open the water inlet for the separate circuit 4. Clean the radiator filler cap. Inspect the gaskets of
aftercooler (if equipped). Start the engine. Operate the radiator filler cap. If the gaskets of the radiator
the engine for a minimum of 90 minutes with a filler cap are damaged, discard the old radiator
coolant temperature of at least 82 C (180 F). filler cap and install a new radiator filler cap. If the
gaskets of the radiator filler cap are not damaged,
5. Stop the engine and allow the engine to cool. use a 9S-8140 Pressurizing Pump in order to
Close the water inlet for the separate circuit pressure test the radiator filler cap. The correct
aftercooler (if equipped). Loosen the radiator filler pressure is stamped on the face of the radiator
cap slowly in order to relieve any pressure. filler cap. If the radiator filler cap does not maintain
Remove the radiator filler cap. Open the coolant the correct pressure, install a new radiator filler
drain. Remove the cooling system drain plugs. cap.
Allow the water to drain.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal i04535467
components.
Coolant (ELC) - Change
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water. SMCS Code: 1350-070; 1395-044
Continue to flush the system until all signs of the
cleaning agent are gone. Use only clean water to flush the cooling system
when Extended Life Coolant (ELC) is drained and
replaced.
6. Flush the cooling system with clean water until the
water that drains is clean. Close the cooling Drain the Cooling System
system drain. Clean the cooling system drain plugs
and install the cooling system drain plugs. 1. Stop the engine and allow the engine to cool.
Fill the Cooling System aftercooler (if equipped). Ensure that the engine
will not start when the cooling system is drained.
Note: For information about the proper coolant to
use, and for the capacity of the cooling system, see 2. Loosen the radiator filler cap slowly in order to
this Operation and Maintenance Manual, Refill relieve any pressure. Remove the radiator filler
Capacities and Recommendations. cap.
NOTICE
1. Fill the cooling system with coolant/antifreeze. After

filling the cooling system, do not install the radiator
filler cap.
2. Open the water inlet for the separate circuit

aftercooler (if equipped). Start the engine. Operate
the engine in order to purge the air from the
cavities of the engine block. Allow the coolant to
warm and allow the coolant level to stabilize. Stop
the engine.
(1) Coolant drain
116 SEBU8468
Coolant Extender (ELC) - Add
3. Open coolant drain (1). 1. Fill the cooling system with Extended Life Coolant
(ELC). For the correct capacity of the cooling
NOTICE system, see this Operation and Maintenance
Dispose of used engine coolant properly or recycle. Manual, Refill Capacities. Do not install the
Various methods have been proposed to reclaim used radiator filler cap.
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable 2. Open the water inlet for the separate circuit
by Caterpillar to reclaim the used coolant. aftercooler (if equipped). Start the engine. Operate
the engine in order to purge the air from the
For information regarding the disposal and the cavities of the engine block. Allow the ELC to
recycling of used coolant, consult your Cat dealer or warm and allow the coolant level to stabilize. Stop
consult Caterpillar Dealer Service Tools : the engine.
Outside Illinois 1-800-542-TOOL 3. Check the coolant level. Maintain the coolant to the
Inside Illinois 1-800-541-TOOL proper level on the sight gauge (if equipped). If a
Canada 1-800-523-TOOL sight gauge is not equipped, maintain the coolant
EAME phone ++41-22-849 40 56
within 13 mm (.5 inch) below the bottom of the
EAME fax ++41-22-849 49 29
filler pipe.
Clean the Cooling System 4. Clean the radiator filler cap. Inspect the gaskets of
1. After the cooling system has been drained, flush the radiator cap. If the gaskets of the radiator filler
the cooling system with clean water in order to cap are damaged, discard the old radiator filler cap
remove any debris. and install a new radiator filler cap. If the gaskets
of the radiator filler cap are not damaged, use a
2. Close the coolant drain. 9S-8140 Pressurizing Pump in order to pressure
test the radiator filler cap. The correct pressure is
stamped on the face of the radiator filler cap. If the
NOTICE radiator filler cap does not maintain the correct
pressure, install a new radiator filler cap.
3. Open the water inlet for the separate circuit leaks and for proper operating temperature.
aftercooler (if equipped). Fill the cooling system
with clean water. Install the radiator filler cap. i03966297
Operate the engine until the temperature reaches
49 C (120 F) to 66 C (150 F). Coolant Extender (ELC) - Add
4. Stop the engine and allow the engine to cool. SMCS Code: 1352-544-NL
Close the water inlet for the separate circuit Cat ELC (Extended Life Coolant) does not require
aftercooler (if equipped). Ensure that the engine the frequent additions of any supplemental cooling
will not start when the cooling system is drained. additives which are associated with the present
Loosen the radiator filler cap slowly in order to conventional coolants. The Cat ELC Extender is
only added once.
relieve any pressure. Remove the radiator filler
cap.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
5. Open the coolant drain. Allow the coolant to drain.
with Cat ELC .
Flush the cooling system with clean water. Close
the coolant drain. Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with con-
6. Repeat Steps 3, 4, and 5. ventional coolants and/or conventional SCA reduces
the Cat ELC service life.
Fill the Cooling System
Check the cooling system only when the engine is
NOTICE stopped and cool.
SEBU8468 117
Coolant Level - Check
i04535484
Personal injury can result from hot coolant, steam Coolant Level - Check
and alkali. SMCS Code: 1395-082
At operating temperature, engine coolant is hot Check the coolant level when the engine is stopped
and under pressure. The radiator and all lines to and cool.
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are con- Illustration 78 g00285520
tained during performance of inspection, mainte- Cooling system filler cap

nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
Pressurized System: Hot coolant can cause seri-
Refer to Special Publication, NENG2500, Caterpillar ous burns. To open the cooling system filler cap,
Dealer Service Tool Catalog for tools and supplies stop the engine and wait until the cooling system
suitable to collect and contain fluids on Caterpillar components are cool. Loosen the cooling system
products. pressure cap slowly in order to relieve the
pressure.
Dispose of all fluids according to local regulations and
mandates.
1. Remove the cooling system filler cap slowly in
order to relieve pressure.
1. Loosen the cooling system filler cap slowly in order
to relieve pressure. Remove the cooling system 2. Maintain the coolant level within 13 mm (0.5 inch)
filler cap. of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
2. Drain enough coolant from the cooling system in
level to the proper level in the sight glass.
order to add the Cat ELC Extender .
3. Add Cat ELC Extender according to the
requirements for your engine cooling system
capacity. Refer to the Operation and Maintenance
Manual, Refill Capacities and Recommendations
article for more information.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
118 SEBU8468
Coolant Sample (Level 1) - Obtain
Sampling Conditions
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.
If the engine is not equipped with a sampling port, the
coolant should be warm.
Use the following guidelines for proper sampling of
the coolant:
Complete the information on the label for the

sampling bottle before you begin to take the
samples.
Keep the unused sampling bottles stored in plastic

bags.
Typical filler cap gaskets
Obtain coolant samples directly from the coolant
3. Clean the cooling system filler cap and check the sample port. You should not obtain the samples
condition of the filler cap gaskets. Replace the from any other location.
cooling system filler cap if the filler cap gaskets are
Keep the lids on empty sampling bottles until you
damaged. Reinstall the cooling system filler cap.
are ready to collect the sample.
4. Inspect the cooling system for leaks. Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
i04333559 contamination.
Coolant Sample (Level 1) - Never collect samples from expansion bottles.

Obtain Never collect samples from the drain for a system.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Timing of the Sampling
Testing the engine coolant is important to ensure that Table 33
the engine is protected from internal cavitation and
corrosion. The analysis also tests the ability of the Recommended Interval
coolant to protect the engine from boiling and
freezing. SOS Systems Coolant Analysis can be Type of Level 1 Level 2
done at your Cat dealer. Cat SOS coolant analysis Coolant
is the best way to monitor the condition of your
coolant and your cooling system. SOS coolant Cat DEAC
analysis is a program that is based on periodic Cat SCA
Every 250 hours Yearly(1)
samples. Conventional Heavy-
Duty Coolants
Note: Obtaining a Coolant Sample (Level 1) is
Cat ELC
optional if the cooling system is filled with one of
Cat ELI
the following coolants: Cat ELC (Extended Life Commercial EC-1
Optional(1) Yearly(1)
Coolant)., Cat ELI (Extended Life Inhibitor) and Coolants
Conventional Heavy-Duty Coolant. (1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any of the following
coolants: Cat DEAC, Cat SCA and Conventional Note: Check the SCA (Supplemental Coolant
Heavy-Duty Coolants. Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at
For additional information about coolant analysis and the interval that occurs first.
about other coolants, see this Operation and
Maintenance Manual, Fluid Recommendations or
consult your Cat dealer.
SEBU8468 119
Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible Submit the sample for Level 2 analysis.
to the recommended sampling interval. In order to
receive the full effect of SOS analysis, establish a For additional information about coolant analysis, see
consistent trend of data. In order to establish a Special Publication, SEBU6251, Caterpillar
pertinent history of data, perform consistent Commercial Diesel Engines Fluids
samplings that are evenly spaced. Supplies for Recommendations or consult your Cat dealer.
collecting samples can be obtained from your Cat
dealer.
i04535903
NOTICE
Always use a designated pump for oil sampling, and
Coolant Temperature
use a separate designated pump for coolant sam- Regulator - Replace
pling. Using the same pump for both types of samples
may contaminate the samples that are being drawn. SMCS Code: 1355-510
This contaminate may cause a false analysis and an Replace the water temperature regulator before the
incorrect interpretation that could lead to concerns by water temperature regulator fails. This procedure is a
both dealers and customers. recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime. Refer to this
Submit the sample for Level 1 analysis. Operation and Maintenance Manual, Maintenance
Interval Schedule for the proper maintenance
Note: Level 1 results may indicate a need for Level 2 interval.
Analysis.
A water temperature regulator that fails in a partially
opened position can cause overheating or
i04535891
overcooling of the engine.
Coolant Sample (Level 2) - A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
Obtain overheating could result in cracking of the cylinder
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 head or piston seizure problems.
A water temperature regulator that fails in the open
NOTICE position will cause the engine operating temperature
Always use a designated pump for oil sampling, and to be too low during partial load operation. Low
use a separate designated pump for coolant sam- engine operating temperatures during partial loads
pling. Using the same pump for both types of samples could cause an excessive carbon buildup inside the
may contaminate the samples that are being drawn. cylinders. This excessive carbon buildup could result
This contaminate may cause a false analysis and an in an accelerated wear of the piston rings and wear of
the cylinder liner.
both dealers and customers.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
NOTICE
engine damage.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Caterpillar engines incorporate a shunt design cool-
nance, testing, adjusting, and repair of the product. ing system and require operating the engine with a
Be prepared to collect the fluid with suitable contain- water temperature regulator installed.
bling any component containing fluids. If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder
Refer to Special Publication, NENG2500, Cat Dealer head damage. Ensure that the new water tempera-
Service Tool Catalog or refer to Special Publication, ture regulator is installed in the original position. En-
PECJ0003, Cat Shop Supplies and Tools Catalog sure that the water temperature regulator vent hole is
for tools and supplies suitable to collect and contain open.
Do not use liquid gasket material on the gasket or cyl-
Dispose of all fluids according to local regulations and inder head surface.
mandates.
Refer to Operation and Maintenance Manual,

Cooling System Coolant Sample (Level 1) - Obtain
for the guidelines for proper sampling of the coolant.
120 SEBU8468
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Refer to two articles in the Disassembly and

Assembly Manual, Water Temperature Regulators - NOTICE
Remove and Water Temperature Regulators - Install Care must be taken to ensure that fluids are con-
for the replacement procedure of the water tained during performance of inspection, mainte-
temperature regulator. For additional information refer nance, testing, adjusting and repair of the product. Be
to this Operation and Maintenance Manual, Fluid prepared to collect the fluid with suitable containers
Recommendations or consult your Cat dealer. before opening any compartment or disassembling
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to Refer to Special Publication, NENG2500, Caterpillar
a level that is below the water temperature regulator Dealer Service Tool Catalog and to Special Publica-
housing. tion, GECJ0003, Cat Shop Supplies and Tools for
tools and supplies suitable to collect and contain flu-
ids on Caterpillar products.
i02839449
Dispose of all fluids according to applicable regula-
Cooling System Supplemental tions and mandates.
Coolant Additive (SCA) - Test/
Note: Caterpillar recommends an SOS coolant
Add analysis (Level 1).
SMCS Code: 1352-045; 1395-081
Cooling Systems that Use
Conventional Coolant
Cooling system coolant additive contains alkali. This maintenance procedure is required for
conventional coolants such as DEAC.This
To help prevent personal injury, avoid contact maintenance is NOT required for cooling systems
with the skin and eyes. Do not drink cooling sys- that are filled with Extended Life Coolant.
tem coolant additive.
Test the Concentration of the SCA
NOTICE
Excessive supplemental coolant additive concentra- NOTICE
tion can form deposits on the higher temperature sur- Do not exceed the recommended six percent supple-
faces of the cooling system, reducing the engine's mental coolant additive concentration.
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components. Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang- Add the SCA, If Necessary
er, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration. Pressurized System: Hot coolant can cause seri-
ous 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.
1. Remove the cooling system filler cap slowly.
2. If necessary, drain some coolant in order to allow

space for the addition of the SCA.
SEBU8468 121
Crankshaft Vibration Damper - Inspect
3. Add the proper amount of SCA. For the proper 3. Add the proper amount of SCA. For the proper
amount of SCA, refer to this Operation and amount of SCA, refer to this Operation and
Maintenance Manual, Refill Capacities and Maintenance Manual, Refill Capacities and
Recommendations topic. The proper Recommendations topic. For the proper
concentration of SCA depends on the type of concentration of SCA, refer to Special Publication,
coolant that is used. For the proper concentration SEBU6251, Caterpillar Commercial Diesel Engine
of SCA, refer to Special Publication, SEBU6251, Fluids Recommendations.
Recommendations. 4. Clean the cooling system filler cap. Install the
cooling system filler cap.
4. Clean the cooling system filler cap. Install the
cooling system filler cap. i04397909
Cooling Systems that Use Water Crankshaft Vibration Damper -

and SCA Inspect
Test the Concentration of the SCA SMCS Code: 1205-040
Test the concentration of the SCA with a 298-5311 The crankshaft vibration damper limits the torsional
Coolant Nitrite Test Kit for SCA or perform an SOS vibration of the crankshaft. The visconic damper has
Coolant Analysis . The test kit includes the following a weight that is located inside a fluid filled case.
items: a tool for the testing, 30 ampoules for testing
nitrite, instructions and a case. 294-7420 Test Kit Damage to the crankshaft vibration damper or failure
contains the refill ampoules for the 298-5311 of the damper can increase torsional vibrations. This
Coolant Nitrite Test Kit. Use the instructions that are vibration can result in damage to the crankshaft and
included with the test kit in order to properly conduct to other engine components. A deteriorating damper
the testing. can cause excessive torsional vibrations.
Refer to this Operation and Maintenance Manual, A damper that is hot may be the result of excessive
Maintenance Interval Schedule for the times at torsional vibration, worn bearings, or damage to the
which the procedures should be conducted. Test the damper. Use an infrared thermometer to monitor the
concentration of the SCA more frequently if more temperature of the damper during operation. Follow
frequent testing is indicated by the results of the the instructions that are included with the infrared
SOS Coolant Analysis . thermometer. If the temperature reaches 100C
(212 F), consult your Cat dealer.
NOTICE Inspect the damper for evidence of dents, cracks, and
Do not exceed the recommended eight percent sup- leaks of the fluid.
plemental coolant additive concentration.
If a fluid leak is found, determine the type of fluid. The
fluid in the damper is silicone. Silicone has the
following characteristics: transparent, viscous and
Add the SCA, If Necessary smooth.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace all of the seals.
Pressurized System: Hot coolant can cause seri- Inspect the damper and repair or replace the damper
ous burns. To open the cooling system filler cap, for any of the following reasons.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system The damper is dented, cracked, or leaking.
pressure cap slowly in order to relieve the The paint on the damper is discolored from heat.
pressure.
The engine has had a failure because of a broken
1. Remove the cooling system filler cap slowly. crankshaft.
The crankshaft bearings are showing excessive
2. If necessary, drain some coolant in order to allow
wear.
space for the addition of the SCA.
There is a large amount of gear train wear that is
not caused by a lack of oil.
122 SEBU8468
Electrical Connections - Check
Dampers With Sampling Ports Removal and Installation

Refer to the Disassembly and Assembly Manual,
Vibration Damper - Remove and Install article or
consult your Cat dealer for information about damper
replacement.
i01217164
Electrical Connections - Check

SMCS Code: 4459-535
Check all exposed electrical connections for
tightness.
Check the following devices for loose mounting or
physical damage:
transformers
fuses
capacitors
Illustration 80 g00819045 lightning arrestors
Some dampers have ports for fluid samples. If the Check all lead wires and electrical connections for
damper has no external damage, collect a sample of proper clearance.
the damper fluid. The fluid should be analyzed in
order to check for a loss of viscosity. Use the results i02062908
of the analysis to determine if the damper should be
rebuilt or replaced. Kits for fluid samples are available
from the address that follows. Return the kits to the Engine - Clean
same address for analysis. SMCS Code: 1000-070
Hasse & Wrede GmbH
Georg-Knorr-Strae 4
12681 Berlin
Germany Personal injury or death can result from high
Phone +49 30 9392-3135 voltage.
Fax +49 30 9392-7-3135
Alternate phone +49 30 9392-3156 Moisture could create paths of electrical
conductivity.
Alternate fax +49 30 9392-7-3156
The typical limit for the degradation of the damper Make sure the unit is off line (disconnected from
fluid viscosity that is used by Hasse & Wrede GmbH utility and/or other generators), locked out and
is 20 percent for most applications. The reports from tagged "Do Not Operate".
Hasse & Wrede should indicate that the fluid
samples meet this viscosity limit.
NOTICE
Dampers Without Sampling Ports Water or condensation can cause damage to genera-
tor components. Protect all electrical components
Some dampers do not have a port for a fluid sample. from exposure to water.
These dampers must be rebuilt or the dampers must
be replaced when one of the following criteria has
been met: NOTICE
The damper has been operated for 20000 hours. Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
The engine is undergoing a major overhaul. fluid spills whenever a significant quantity accumu-
lates on the engine.
SEBU8468 123
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Steam cleaning the engine will remove accumulated Check the precleaner (if equipped) daily for
oil and grease. A clean engine provides the following accumulation of dirt and debris. Remove any dirt
benefits: and debris, as needed.
Easy detection of fluid leaks Operating conditions (dust, dirt, and debris) may
require more frequent service of the air cleaner
Maximum heat transfer characteristics element.
Ease of maintenance The air cleaner element may be cleaned up to six
times if the element is properly cleaned and
NOTICE inspected.
Water and/or condensation can cause damage to
electrical components. Protect all electrical compo- The air cleaner element should be replaced at
nents from exposure to water. least one time per year. This replacement should
be performed regardless of the number of
cleanings.
Note: For more information on cleaning and drying
electric generators, refer to Special Instruction, Replace the dirty paper air cleaner elements with
SEHS9124, Cleaning and Drying of Electric Set clean air cleaner elements. Before installation,
Generators. thoroughly check the air cleaner elements for tears
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
i04564842 Maintain a supply of suitable air cleaner elements for
replacement purposes.
Engine Air Cleaner Element
(Dual Element) - Inspect/Clean/ Dual Element Air Cleaners
Replace The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner
SMCS Code: 1051; 1054-040; 1054-070; 1054-510 element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
NOTICE and inspected. The primary air cleaner element
Never run the engine without an air cleaner element should be replaced at least one time per year. This
installed. Never run the engine with a damaged air replacement should be performed regardless of the
cleaner element. Do not use air cleaner elements with number of cleanings.
damaged pleats, gaskets or seals. Dirt entering the The secondary air cleaner element is not serviceable
engine causes premature wear and damage to en- or washable. The secondary air cleaner element
gine components. Air cleaner elements help to pre- should be removed and discarded for every three
vent airborne debris from entering the air inlet. cleanings of the primary air cleaner element. When
the engine is operating in environments that are dusty
or dirty, air cleaner elements may require more
NOTICE frequent replacement.
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Cat dealer has the proper air cleaner
elements for your application. Consult your Cat
dealer for the correct air cleaner element.
(1) Cover
(2) Primary air cleaner element
(3) Secondary air cleaner element
(4) Turbocharger air inlet
124 SEBU8468
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
NOTICE
1. Remove the cover. Remove the primary air cleaner
Do not clean the air cleaner elements by bumping or
element. tapping. This could damage the seals. Do not use ele-
2. The secondary air cleaner element should be ments with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
removed and discarded for every three cleanings
damage could result.
of the primary air cleaner element.
Note: Refer to Cleaning the Primary Air Cleaner Visually inspect the primary air cleaner elements
Elements. before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
3. Cover the turbocharger air inlet with tape in order to Discard any damaged air cleaner elements.
keep out dirt.
There are two common methods that are used to
4. Clean the inside of the air cleaner cover and body clean primary air cleaner elements:
with a clean, dry cloth.
Pressurized air
5. Remove the tape for the turbocharger air inlet.
Vacuum cleaning
Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
Pressurized Air
6. Install the air cleaner cover.
Pressurized air can be used to clean primary air
7. Reset the air cleaner service indicator. cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
Cleaning the Primary Air Cleaner maximum pressure of 207 kPa (30 psi).
Elements
NOTICE
Caterpillar recommends certified air filter cleaning
services that are available at Cat dealers. The Cat
cleaning process uses proven procedures to assure
consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove Illustration 82 g00281692
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the Note: When the primary air cleaner elements are
pleats and down the pleats from the inside of the filter cleaned, always begin with the clean side (inside) in
element. Take extreme care in order to avoid damage
order to force dirt particles toward the dirty side
to the pleats.
(outside).
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to Aim the hose so that the air flows inside the element
along the length of the filter. This procedure will
engine components. prevent damage to the paper pleats. Do not aim the
stream of air directly at the primary air cleaner
The primary air cleaner element can be used up to six element. Dirt could be forced further into the pleats.
times if the element is properly cleaned and
inspected. When the primary air cleaner element is Note: Refer to Inspecting the Primary Air Cleaner
cleaned, check for rips or tears in the filter material. Elements.
The primary air cleaner element should be replaced
at least one time per year. This replacement should
be performed regardless of the number of cleanings.
Use clean primary air cleaner elements while dirty
elements are being cleaned.
SEBU8468 125
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Note: Refer to Inspecting the Primary Air Cleaner

Elements.
Inspecting the Primary Air Cleaner

Elements
Typical example
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Illustration 83 g00281693 Place the primary air cleaner element into a box for
storage. For identification, mark the outside of the box
Inspect the clean, dry primary air cleaner element. and mark the primary air cleaner element. Include the
Use a 60 W clear light in a dark room or in a similar following information:
facility. Place the light in the primary air cleaner
element. Rotate the primary air cleaner element. Date of cleaning
Inspect the primary air cleaner element for tears and/
or holes. Inspect the primary air cleaner element for Number of cleanings
light that may show through the filter material. If
necessary, to confirm the result, compare the primary Store the box in a dry location.
air cleaner element to a new air cleaner element that
has the same part number. i04564858
Do not use a primary air cleaner element that has any

tears and/or holes in the filter material. Do not use a Engine Air Cleaner Element
primary air cleaner element with damaged pleats,
gaskets, or seals. Discard damaged primary air (Single Element) - Inspect/
cleaner elements. Clean/Replace
SMCS Code: 1051; 1054-040; 1054-070; 1054-510
Storing Primary Air Cleaner Elements
If a primary air cleaner element that passes NOTICE
inspection will not be used, the primary air cleaner Never run the engine without an air cleaner element
element can be stored for future use. installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to en-
gine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
126 SEBU8468
2. Cover the air inlet with tape in order to keep out

NOTICE
dirt.
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine. 3. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
Servicing the Air Cleaner Elements 4. Remove the tape for the air inlet. Install an air
If the air cleaner element becomes plugged, the air cleaner element that is new or cleaned.
can split the material of the air cleaner element. 5. Install the air cleaner cover.
Unfiltered air will drastically accelerate internal engine
wear. Your Cat dealer has the proper air cleaner 6. Reset the air cleaner service indicator.
elements for your application. Consult your Cat
dealer for the correct air cleaner element. Cleaning the Air Cleaner Elements
Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt NOTICE
and debris, as needed. Caterpillar recommends certified air filter cleaning
services that are available at Caterpillar dealers. The
Operating conditions (dust, dirt, and debris) may Caterpillar cleaning process uses proven procedures
require more frequent service of the air cleaner to assure consistent quality and sufficient filter life.
element.
Observe the following guidelines if you attempt to
The air cleaner element may be cleaned up to six clean the filter element:
times if the element is properly cleaned and Do not tap or strike the filter element in order to re-
inspected. move dust.
The air cleaner element should be replaced at Do not wash the filter element.
least one time per year. This replacement should
be performed regardless of the number of Use low pressure compressed air in order to remove
cleanings. the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
Replace the dirty paper air cleaner elements with pleats and down the pleats from the inside of the filter
clean air cleaner elements. Before installation, element. Take extreme care in order to avoid damage
thoroughly check the air cleaner elements for tears to the pleats.
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage. Do not use air filters with damaged pleats, gaskets, or
Maintain a supply of suitable air cleaner elements for seals. Dirt entering the engine will cause damage to
replacement purposes. engine components.
The air cleaner element can be used up to six times if

the element is properly cleaned and inspected. When
the air cleaner element is cleaned, check for rips or
tears in the filter material. The air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
Use clean air cleaner elements while dirty elements
are being cleaned.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
(1) Cover
(2) Air cleaner element
damage could result.
(3) Turbocharger air inlet
Visually inspect the air cleaner elements before
1. Remove the air cleaner cover. Remove the air cleaning. Inspect the air cleaner elements for damage
cleaner element. to the seal, the gaskets, and the outer cover. Discard
any damaged air cleaner elements.
Note: Refer to Cleaning the Air Cleaner Elements.
SEBU8468 127
There are two common methods that are used to Inspecting the Air Cleaner Elements
clean air cleaner elements:
Pressurized air
Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean air cleaner
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Inspect the clean, dry air cleaner element. Use a 60

W clear light in a dark room or in a similar facility.
Place the light in the air cleaner element. Rotate the
air cleaner element. Inspect the air cleaner element
for tears and/or holes. Inspect the air cleaner element
for light that may show through the filter material. If
necessary, to confirm the result, compare the air
cleaner element to a new air cleaner element that has
the same part number.
Illustration 86 g00281692 Do not use an air cleaner element that has any tears
and/or holes in the filter material. Do not use an air
Note: When the air cleaner elements are cleaned, cleaner element with damaged pleats, gaskets, or
seals. Discard damaged air cleaner elements.
always begin with the clean side (inside) in order to
force dirt particles toward the dirty side (outside).
Storing Air Cleaner Elements
Aim the hose so that the air flows inside the element
along the length of the filter. This procedure will If an air cleaner element that passes inspection will
prevent damage to the paper pleats. Do not aim the not be used, the air cleaner element can be stored for
stream of air directly at the air cleaner element. Dirt future use.
could be forced further into the pleats.
Note: Refer to Inspecting the Air Cleaner Elements.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning air
cleaner elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
Note: Refer to Inspecting the Air Cleaner Elements.
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
128 SEBU8468
Engine Air Cleaner Service Indicator - Inspect
Place the air cleaner element into a box for storage. Some engines may be equipped with a different
For identification, mark the outside of the box and service indicator.
mark the air cleaner element. Include the following
information: Observe the service indicator. Clean the air cleaner
element or replace the air cleaner element when the
Date of cleaning following conditions occur:
Number of cleanings The yellow diaphragm enters the red zone.
Store the box in a dry location. The red piston locks in the visible position.
The air restriction reaches 6 kPa

i03212992 (25 inches of H2O).
Engine Air Cleaner Service Test the Service Indicator
Indicator - Inspect Service indicators are important instruments.
SMCS Code: 7452-040
Check for ease of resetting. The service indicator
A service indicator may be mounted on the air should reset in less than three pushes.
cleaner element or in a remote location.
Check the movement of the yellow core when the
engine is accelerated to the engine rated rpm. The
yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the fitting for the
service indicator may be plugged.
A typical location for the air cleaner service indicators
Porous filter
A porous filter is part of a fitting that is used for

mounting of the service indicator. Inspect the filter for
cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced.
Typical air cleaner service indicator
SEBU8468 129
Engine Air Precleaner - Check/Clean
Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque of
2 Nm (18 lb in).
i04836571
Engine Air Precleaner - Check/

Clean
SMCS Code: 1055-070; 1055-535
1. Loosen clamp (1). Slide the clamp down on tube

(2).
2. Loosen clamps (3). Remove both breathers as a

unit.
1. Unfasten latches (1).
2. Remove cup (2). Illustration 94 g00597465
3. Clean and inspect cup and seal. 3. Remove O-ring seals (4) from the valve covers.
Inspect the O-ring seals for good condition. Obtain
4. Reinstall cup. new O-ring seals, if necessary.
5. Fasten latches.
i04598009
Engine Crankcase Breather -

Clean/Replace
SMCS Code: 1317-070; 1317-510
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
130 SEBU8468
Engine Mounts - Inspect
i04605029
Engine Mounts - Inspect

SMCS Code: 1152-040; 1152
Misalignment of the engine and the driven equipment
will cause extensive damage. Excessive vibration can
lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by
the following conditions:
Improper mounting
Loose bolts
Deterioration of the isolators
Ensure that the mounting bolts are tightened to the
4. Remove two clamps (6). Remove both breathers proper torque. For standard torques, see
(5) from hose tee (7). Specifications, SENR3130, Torque Specifications.
Inspect the hose tee for cracks. If the tee is Ensure that the isolators are free of oil and
cracked, discard the old tee and obtain a new tee contamination. Inspect the isolators for deterioration.
for installation. Ensure that the bolts for the isolators are tightened to
the proper torque.
5. Turn the breathers upside-down in order to inspect
Replace any isolator that shows deterioration. For
the condition of the breather elements.
more information, see the literature that is provided by
Clean the breather elements with clean, the OEM of the isolators. Also see the Application
nonflammable solvent. If the breather elements and Installation Guide for the engine. Consult your
remain contaminated after the cleaning, discard Cat dealer for assistance.
the breathers and obtain new breathers. Do not
attempt to disassemble the breathers.
i02064762
Allow the breather elements to dry before
installation. Engine Oil Level - Check
SMCS Code: 1348-535-FLV
Note: Coat the rubber parts with clean engine oil or
petroleum jelly in order to make installation easier. The most accurate check of the oil level is performed
6. Place clamps (6) over the parts of hose tee (7) that when the engine is stopped. Perform this
maintenance on a surface that is as level as possible.
will receive breathers (5). Install the breathers into
the tee. Tighten the clamps to the torque that is
listed in the Service Manual, Specifications.
7. Coat O-ring seals (4) with clean engine oil. Place

the O-ring seals on the valve covers.
8. Place clamps (3) around the parts of the breathers

that will be attached to the valve covers. Install
both breathers as a unit. Tighten the clamps.
9. Place clamp (1) on the part of the hose tee that will
receive tube (2). Install the tube into the hose tee.
Tighten the clamp to the torque that is listed in the
Service Manual, Specifications.
(1) Oil filler cap
(2) Oil level gauge
SEBU8468 131
Engine Oil Sample - Obtain
i04237495
Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals. SOS oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
(3) ENGINE STOPPED side. (4) LOW IDLE side. Hot oil and hot components can cause personal
(5) ADD mark. (6) FULL mark. injury. Do not allow hot oil or hot components to
contact the skin.
1. Ensure that oil level gauge (2) is seated.
Before you take the oil sample, complete the Label,
a. If the engine is stopped, remove oil level PEEP5031 for identification of the sample. In order to
gauge (2). Observe the oil level on ENGINE help obtain the most accurate analysis, provide the
STOPPED side (3). The oil level should be following information:
between ADD mark (5) and FULL mark Engine model
(6).
Service hours on the engine
b. If the engine is operating, reduce the engine
speed to low idle. Remove oil level gauge (2) The number of hours that have accumulated since
and observe the oil level on LOW IDLE side the last oil change
(4). The oil level should be between ADD
The amount of oil that has been added since the
mark (5) and FULL mark (6).
last oil change
To ensure that the sample is representative of the oil
NOTICE in the crankcase, obtain a warm, mixed oil sample.
Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into To avoid contamination of the oil samples, the tools
the oil. The air bubbles created from the crankshaft and the supplies that are used for obtaining oil
dipping into the oil reduces the oil's lubricating char- samples must be clean.
acteristics and could result in the loss of power.
Caterpillar recommends using the sampling valve in
order to obtain oil samples. The quality and the
2. If necessary, remove oil filler cap (1) and add oil. consistency of the samples are better when the
For the correct oil to use, see this Operation and sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
Maintenance Manual, Refill Capacities and obtained during normal engine operation.
Recommendations topic in the Maintenance
Section. Do not fill the crankcase above FULL The 169-8373 Fluid Sampling Bottle is
mark (6). Clean the oil filler cap. Install the oil filler recommended for use with the sampling valve. The
cap. fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
132 SEBU8468
Engine Oil and Filter - Change
(Table 34, contd)

NOTICE
Always use a designated pump for oil sampling, and 3512 625 L (165 US gal)
use a separate designated pump for coolant sam- 3512B Every 1000 Service
pling. Using the same pump for both types of samples 3516 807 L (213 US gal) Hours
may contaminate the samples that are being drawn. 3516B
This contaminate may cause a false analysis and an
both dealers and customers.
Hot oil and hot components can cause personal

If the engine is not equipped with a sampling valve, injury. Do not allow hot oil or hot components to
use the 1U-5718 Vacuum Pump. The pump is contact the skin.
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion into
the sump.
Drain the Oil
For instructions, see Special Publication, PEGJ0047,
How To Take A Good SOS Oil Sample. Consult Do not drain the oil when the engine is cold. As the oil
your Cat dealer for complete information and cools, suspended waste particles settle on the bottom
assistance in establishing an SOS program for your of the oil pan. The waste particles are not removed
engine. when the cold oil is drained. Drain the crankcase
when the oil is warm. This method allows proper
draining of the waste particles that are suspended in
i03195322 the oil.
Failure to follow this recommended procedure will
Engine Oil and Filter - Change allow the waste particles to be recirculated through
SMCS Code: 1318-510 the engine lubrication system with the new oil.
The oil change interval will be affected by the 1. After the engine has been operated at normal
following items: operating temperature, STOP the engine.
Engine application
NOTICE
Size of the oil sump Care must be taken to ensure that fluids are con-
Fuel type
Oil type prepared to collect the fluid with suitable containers
Ambient air conditions any component containing fluids.
Air/fuel ratio Refer to Special Publication, NENG2500, Caterpillar

The SOS oil analysis program analyzes used oil in suitable to collect and contain fluids on Caterpillar
order to determine if the oil change interval is suitable products.
for your specific engine. In the absence of SOS oil
analysis, change the engine oil and engine oil filters Dispose of all fluids according to local regulations and
according to the interval that is listed in Table 34 . mandates.
Table 34
3500 and 3500BGenerator Set Oil Change Intervals 2. Drain the oil according to the equipment on the
engine.
Engine Sump Capacity Oil Change Interval
Engines With a Standard Sump
3512 318 L (84 US gal)

3512B Every 500 Service
3516 405 L (107 US gal) Hours
3516B
Engines With a Deep Sump
(continued)
SEBU8468 133
Service tools are available to aid in the service of oil

filters. Consult your Caterpillar dealer for the part
names and the part numbers. Follow the instructions
that are supplied with the service tools. If the service
tools are not used, perform the following appropriate
procedure.
Replacing the Engine Oil Filters With the

Engine Stopped
Perform the following procedure after the oil has been
drained.
Note: Use this procedure if the engine oil filters do
not have a control valve.
(1) Oil drain
a. Open oil drain (1). After the oil has drained,

close the oil drain.
b. If a suction device is inserted into the oil pan,
ensure that the suction device is clean. This
will prevent dirt from entering into the oil pan.
Be careful not to strike the engine oil suction
tubes or the piston cooling jets.
c. If a suction device that attaches to the oil drain

is used, ensure that the suction device is
clean. Attach the suction device to the oil
drain. Open the oil drain. After the oil has
(2) Bolts
drained, close the oil drain and remove the (3) Cover
suction device. (4) Plug
(5) Drain valve
d. If the oil drain valve has a quick connect
coupling, attach the coupling. Open the drain
valve in order to drain the crankcase. After the Note: Drain the oil into a suitable container. Dispose
oil has drained, close the drain valve. of the oil according to local regulations.
Disconnect the coupling. 1. Connect a hose to drain (1). Place the other end of
the hose into a suitable container in order to collect
3. Replace the engine oil filter elements before you fill the oil.
the crankcase with new oil.
2. Open drain valve (5). Remove plug (4). Allow the
Replace the Oil Filter Elements oil to drain. Clean the plug and install the plug.
Close the drain valve. Remove the hose from the
Replace the engine oil filters when any of the drain.
following conditions occur:
Every oil change Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
The engine oil filter differential pressure reaches when cover (3) is removed. Prepare to catch the oil in
103 kPa (15 psi). a suitable container. Clean up any spilled oil with
absorbent towels or pillows. DO NOT use absorbent
Note: Do not attempt to clean the used oil filters. particles to clean up the oil.
Used oil filters will retain waste particles. The used oil
filters would not filter the oil properly.
134 SEBU8468
7. Inspect the O-ring seal (7). Ensure that the

Personal injury can result from parts and/or cov- surfaces for the O-ring seal are clean. Install a new
ers under spring pressure. O-ring seal if the old O-ring seal is damaged or
deteriorated.
Spring force will be released when covers are
removed. 8. Install retainer (9), spring (8) and cover (6). Ensure
that the retainer and the spring are properly seated
Be prepared to hold spring loaded covers as the
bolts are loosened. between the oil filter elements and the cover.
9. Start the engine according to this Operation and
3. The oil filter may contain a spring behind the cover. Maintenance Manual, Starting The Engine
Be alert to the spring force. Gradually loosen but procedure (Operation Section). Check for oil leaks.
do not remove bolts (2). Before you remove the
bolts, pry the cover (3) loose or tap the cover with a Replacing the Engine Oil Filters During
rubber mallet in order to relieve any spring
pressure. Remove cover (3). Engine Operation
If the engine is equipped with duplex oil filters, the
engine oil filter elements can be changed while the
engine is operation. This is useful if the oil filter
elements require more frequent replacement than the
engine oil.
If the filter is changed during rapid air movement,

an explosive vapor may be created. The explosive
vapor may result in personal injury or in death.
If rapid air movement exists, stop the engine in or-
der to change the filter.

Section view of the engine oil filter
(6) Cover
(7) O-ring seal
Filter contains hot pressurized fluid when engine
(8) Spring is running.
(9) Retainer
(10) Oil filter element Follow instructions on control valve to avoid per-
sonal injury.
4. Remove cover (6) and spring (8). Remove O-ring
seal (7), retainer (9), and oil filter elements (10). 1. Move the control valve to the AUX RUN position
in order to change the main oil filter elements.
5. Clean cover (6), spring (8), O-ring seal (7), and Move the selector valve to the MAIN RUN
retainer (9). Clean the inside of the oil filter position in order to change the auxiliary oil filter
housing. elements.
2. Allow the oil pressure gauge for the oil filter that is
NOTICE being changed to reach a ZERO pressure
Caterpillar oil filters are built to Caterpillar specifica- reading.
tions. Use of an oil filter not recommended by Cater-
pillar could result in severe engine damage to the 3. Perform Step 1 through Step 8 of Replacing the
engine bearings, crankshaft, etc., as a result of the Engine Oil Filters With the Engine Stopped.
larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom- 4. Open the FILL valve for a minimum of five
mended by Caterpillar . minutes in order to fill the new oil filter elements.
6. Ensure that the new oil filter elements are in good

condition. Install the new oil filter elements.
SEBU8468 135
5. Close the FILL valve. Rotate the control valve to

NOTICE
the RUN position for the oil filter that was
Engine damage can occur if the crankcase is filled
serviced. above the FULL mark on the oil level gauge
(dipstick).
Inspect the Used Oil Filter Elements
An overfull crankcase can cause the crankshaft to dip
Cut the used oil filter element open with a utility knife. into the oil. This will reduce the power that is devel-
Remove the metal wrap. Cut the filter element free oped and also force air bubbles into the oil. These
from the end caps. Spread apart the pleats and bubbles (foam) can cause the following problems: re-
inspect the element for metal debris. An excessive duction of the oil's ability to lubricate, reduction of oil
amount of debris in the element may indicate early pressure, inadequate cooling, oil blowing out of the
wear or a pending failure. crankcase breathers and excessive oil consumption.
Use a magnet to differentiate between the ferrous Excessive oil consumption will cause deposits to form
metals and the nonferrous metals that are found in on the pistons and in the combustion chamber. De-
the element. Ferrous metals may indicate wear on the posits in the combustion chamber lead to the follow-
steel and the cast iron parts of the engine. Nonferrous ing problems: guttering of the valves, packing of
metals may indicate wear on the aluminum parts, the carbon under the piston rings and wear of the cylinder
brass parts, or the bronze parts of the engine. Parts liner.
that may be affected include the following
components: main bearings, rod bearings, If the oil level is above the FULL mark on the oil lev-
turbocharger bearings and cylinder heads. el gauge, drain some of the oil immediately.
Aluminum debris may indicate problems with the
bearings of the front gears. If aluminum debris is 1. Remove the oil filler cap. Fill the crankcase through
found, inspect the crankshaft vibration damper and the oil filler tube only. For the amount of oil to use,
the bearings of the front idler gear. refer to this Operation and Maintenance Manual,
Due to normal wear and friction, it is not uncommon Refill Capacities and Recommendations (
to find small amounts of debris in the oil filter element. Maintenance Section). Clean the oil filler cap.
If an excessive amount of debris is found in the oil Install the oil filler cap.
filter element, consult your Caterpillar dealer in order
to arrange for further oil analysis.
NOTICE
Fill the Crankcase To prevent crankshaft or bearing damage, crank en-
gine with fuel off to fill all filters before starting.
NOTICE
Only use oils that are recommended by Caterpillar. Do Not crank engine for more than 30 seconds.
For the proper oil to use, refer to this Operation and
Maintenance Manual, Refill Capacities and Recom-
mendations topic (Maintenance Section). 2. Close the fuel supply line and crank the engine
until the oil pressure gauge indicates 70 kPa
(10 psi). Open the fuel supply line. Allow the
NOTICE starting motor to cool for two minutes before
If the engine is equipped with an auxiliary oil filter sys- cranking again.
tem, extra oil must be added when filling the crank-
case. If equipped with an auxiliary oil filter system that 3. Follow this Operation and Maintenance Manual,
is not supplied by Caterpillar , follow the recommen- Starting The Engine procedure (Operation
dations of the OEM. Section). Operate the engine at low idle for two
minutes. This will ensure that the lubrication
system has oil and that the oil filters are filled with
oil. Inspect the engine for oil leaks. Ensure that the
oil level is at the FULL mark on the LOW IDLE
side of the oil level gauge.
4. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
5. Remove the oil level gauge and check the oil level.
Maintain the oil level to the FULL mark on the
ENGINE STOPPED side of the oil level gauge.
136 SEBU8468
Engine Protective Devices - Check
i00626013 i03457267
Engine Protective Devices - Engine Speed/Timing Sensor -

Check Clean/Inspect
SMCS Code: 7400-535 SMCS Code: 1905-040; 1905-070; 1907-040; 1907-
070
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible to
determine if the engine protective devices are in good
working order during normal operation. Malfunctions
must be simulated in order to test the engine
protective devices.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate at the
setpoints. Ensure that the engine protective devices
are functioning properly.
NOTICE
During testing, abnormal operating conditions must
be simulated.
The tests must be performed correctly in order to pre- Illustration 101 g00293337
vent possible damage to the engine.
Typical speed sensor
To prevent damage to the engine, only authorized 1. Remove the speed sensor from the flywheel
service personnel or your Caterpillar dealer should
perform the tests. housing. Check the condition of the end of the
speed sensor. Check for signs of wear and
Visual Inspection contaminants.
Visually check the condition of all gauges, sensors 2. Clean the metal shavings and other debris from the
and wiring. Look for wiring and components that are face of the magnet.
loose, broken, or damaged. Damaged wiring or
components should be repaired or replaced 3. Install the speed sensor according to the
immediately. information in the Service Manual, Specifications.
i04202808
Engine Valve Lash - Check

SMCS Code: 1105-535
Note: For procedures on adjusting the valve lash and

adjusting the valve bridge, see System Systems
Operation/Testing and Adjusting, Valve Lash and
Valve Bridge Adjustment. Consult your Cat dealer
for assistance.
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of the
valve train components and to the seating of the
valve train components.
SEBU8468 137
Fan Drive Bearing - Lubricate
Ensure that the engine cannot be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before meas-
uring/adjusting valve lash clearance.
Valve Bridge
Check the valve bridge and adjust the valve bridge, if
necessary. Perform the procedure for both valve Illustration 102 g00736668
bridges for each cylinder. After the valve bridge is
(1) Grease fittings for the fan bearings
checked for each cylinder, proceed with the valve
lash adjustment, if necessary.
Note: If the engine is operated in hot environments,
Engine Valve Lash dirty environments, or humid environments, lubricate
the fan bearings more frequently.
NOTICE 2. Lubricate the grease fittings for the fan bearings
Only qualified service personnel should perform this with Bearing Lubricant , or with an equivalent
maintenance. Refer to the Systems Operation/Testing grease.
and Adjusting Manual, Valve Lash and Valve Bridge
Adjustment article or consult your Caterpillar dealer i01565926
for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve Fuel Injector - Inspect/Adjust
adjustments can reduce engine efficiency. This re- SMCS Code: 1290-025; 1290-040
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. Note: Perform this procedure when the engine valve
lash is inspected.
The valve bridge adjustment must be performed
before making a valve lash adjustment. If the valve NOTICE
lash is within the tolerance, an adjustment of the The camshafts must be correctly timed with the crank-
valve lash is NOT necessary. shaft before an adjustment of the lash for the fuel in-
jector is made. The timing pins must be removed from
For the valve lash setting, see the engine the camshafts before the crankshaft is turned or dam-
Specifications manual. For the procedure to set the age to the cylinder block will be the result.
valve lash, see the engine Systems Operation/
Testing and Adjusting manual.
Inspect the adjustment of the lash for the fuel injector
according to the Testing And Adjusting, Fuel Injector
i01552621
Adjustment. Adjust the lash for the fuel injector, if
necessary.
Fan Drive Bearing - Lubricate
SMCS Code: 1359-086-BD i01398238
1. Inspect the fan drive pulley assembly. If the shaft is Fuel System - Prime
loose, an inspection of the internal components
SMCS Code: 1250-548; 1258-548
should be made.
1. Open the fuel supply valve. Ensure that the engine
will not start during the priming procedure. Turn the
start switch to the OFF position.
138 SEBU8468
Fuel System Primary Filter (Water Separator) Element - Replace
1. Stop the engine. Ensure that the engine will not

start during this procedure.
2. Shut off the fuel supply valve to the engine.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
Use a suitable container to catch any fuel that might
Illustration 103 g00736817 spill. Clean up any spilled fuel immediately.
(1) Fuel priming pump plunger
2. Turn the fuel priming pump plunger

counterclockwise in order to release the lock plate
from the retainer.
3. Operate the fuel priming pump until the air in the
fuel system has been pumped through the fuel
return line back to the fuel tank.
4. Press the fuel priming pump plunger to the locking
position. Turn the fuel priming pump plunger
clockwise in order to engage the lock plate in the
retainer.
Note: Enable the starting system only after all
maintenance has been completed.
Priming Procedure for Dry Starting

If the air cannot be completely purged from the fuel
system and the engine will not start, see Special
Instruction, SEHS9586, 3500 EUI Fuel Priming
Procedure. Illustration 104 g01103365
(1) Filter case
i02180086 (2) Nut
Fuel System Primary Filter 3. Loosen nut (2). Hold filter case (1) and remove nut
(Water Separator) Element - (2). Prepare to catch the fuel that is inside of the
filter case with a suitable container. Remove the
Replace filter case from the mounting bolt.
SMCS Code: 1260-510-FQ; 1263-510-FQ
4. Remove the element and wash the element in
clean, nonflammable solvent. Allow the element to
dry. Inspect the element. Install a new element if
the old element is damaged or deteriorated.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 5. Clean the inside of the filter case. Allow the filter
possible injury, turn the start switch off when case to dry.
changing fuel filters or water separator elements.
Clean up fuel spills immediately. 6. Inspect the O-ring seals. Obtain new seal rings if
the old seal rings are damaged or deteriorated.
Ensure that the sealing surfaces for the seals are
clean. Install the seals.
SEBU8468 139
Fuel System Primary Filter/Water Separator - Drain
NOTICE
The water separator is under suction during normal
NOTICE
engine operation. Ensure that the drain valve is tight-
Do not fill the fuel filters with fuel before installing the
ened securely to help prevent air from entering the
fuel filters. The fuel will not be filtered and could be fuel system.
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
i02829105
7. Place the element in the filter case. Slide the filter
case over the mounting bolt. Fuel System Secondary Filter -
8. Install the nut. Replace
SMCS Code: 1261-510-SE
9. Open the fuel supply valve.
Note: If the engine is equipped with duplex fuel filters,
10. Prime the fuel system. See this Operation and
the fuel filter elements can be changed while the
Maintenance Manual, Fuel System - Prime topic. engine is in operation. Refer to Replacing the Fuel
Filter Elements During Engine Operation.
i02310280
Fuel System Primary Filter/

Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
SMCS Code: 1260-543; 1263-543 possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
prepared to collect the fluid with suitable containers
Refer to Special Publication, NENG2500, Caterpillar
suitable to collect and contain fluids on Caterpillar
products.
mandates.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
Illustration 105 g01157156 clean the area around a fuel system component that
(1) Bowl will be disconnected. Fit a suitable cover over discon-
(2) Drain nected fuel system component.
Bowl (1) should be monitored daily for signs of water.
If water is present, drain the water from the bowl. Replace the secondary fuel filter elements whenever
the following conditions occur:
1. Open drain (2). The drain is a self-ventilated drain.
Catch the draining water in a suitable container. The fuel filter differential pressure gauge registers
Dispose of the water properly. 103 kPa (15 psi).
2. Close the drain. The fuel filters have been used for 1000 service
hours.
140 SEBU8468
Fuel System Secondary Filter - Replace
Replacing the Fuel Filter Elements 5. Be alert to the spring force. Gradually loosen but
with the Engine Stopped do not remove bolts (1). Before removing bolts (1),
pry cover (2) loose in order to relieve any spring
1. Stop the engine. Ensure that the engine will not pressure. Remove cover (2). Remove the O-ring
start during this procedure. seal on the inside of the cover. Remove the fuel
filter elements.
2. Shut off the fuel supply valve to the engine.
6. Clean cover (2) and clean the O-ring seal. Clean
the inside of the fuel filter housing.
7. Install new fuel filter elements.

8. Inspect the O-ring seal. Ensure that the surfaces
for the O-ring seal are clean. Install a new O-ring
seal if the old O-ring seal is damaged or
deteriorated.
9. Install cover (2). Ensure that the springs are seated
properly between the cover and the fuel filter
elements.
10. Open the fuel supply valve. Reconnect the
battery.
Illustration 106 g01411122 11. Prime the fuel system. Refer to this Operation and
(1) Bolts Maintenance Manual, Fuel System - Prime topic
(2) Cover
(3) Plug
(Maintenance Section).
(4) Drain valve
(5) Drain Replacing the Fuel Filter Elements
During Engine Operation
3. Connect a hose to drain (5). Place the other end of
the hose into a suitable container in order to collect If the engine is equipped with duplex fuel filters, the
the fuel. fuel filters can be changed while the engine is in
operation.
4. Open drain valve (4). Remove plug (3). Allow the
fuel to drain. Clean the plug and install the plug.
Close the drain valve. Remove the hose from the
drain. If the filter is changed during rapid air movement,
an explosive vapor may be created. The explosive
Note: Some fuel will remain in the housing after the vapor may result in personal injury or in death.
fuel has been drained. This fuel will pour out of the
housing when cover (2) is removed. Prepare to catch If rapid air movement exists, stop the engine in or-
the fuel in a suitable container. Clean up any spilled der to change the filter.
fuel with absorbent towels or pillows. DO NOT use
absorbent particles to clean up the fuel.
Filter contains hot pressurized fluid when engine

is running.
Personal injury can result from parts and/or cov-
ers under spring pressure. Follow instructions on control valve to avoid per-
sonal injury.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the Duplex Fuel Filters
bolts are loosened.
SEBU8468 141
Fuel Tank Water and Sediment - Drain
i05111531
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
NOTICE
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Illustration 107 g01463367 Refer to Special Publication, NENG2500, Cat Dealer
(6) Control valve Service Tool Catalog or refer to Special Publication,
(7) Fill valve PECJ0003, Cat Shop Supplies and Tools Catalog
for tools and supplies suitable to collect and contain
1. Open FILL valve (5) for a minimum of five minutes fluids on Cat products.
in order to fill the fuel filters that will not be
serviced. The fuel filters that will not be serviced mandates.
must be full of fuel. Close the FILL valve.
2. If the main filter will be serviced, rotate control
valve (4) to the AUX RUN position.
Fuel Tank
Fuel quality is critical to the performance and to the
If the auxiliary filters will be serviced, rotate control service life of the engine. Water in the fuel can cause
valve (4) to the MAIN RUN position. excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
3. See Replacing the Fuel Filter Elements with the condensation occurs as the fuel passes through the
Engine Stopped. Perform Step 3 through Step 9. fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
4. Open fill valve (5) for a minimum of five minutes in the fuel tank regularly and obtaining fuel from reliable
order to fill the new elements. Close the fill valve. sources can help to eliminate water in the fuel.
After the new filter elements are full of fuel, either
the main filter or the auxiliary filter may be used.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank in
order to drain the water and the sediment. Close the
drain valve.
Note: Failure to close the drain can allow air into the
system, which could have detrimental results to
performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.
Fill the fuel tank after operating the engine in order to
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
142 SEBU8468
Generator - Dry
Some fuel tanks use supply pipes that allow water Drying Methods
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that The following methods can be used for drying a
take fuel directly from the bottom of the tank. If the generator:
engine is equipped with this system, regular
maintenance of the fuel system filter is important. Self-circulating air method
Fuel Storage Tanks Oven method
Drain the water and the sediment from the fuel Controlled current method
storage tank during the following conditions:
Energize the optional space heaters.
Weekly
NOTICE
Oil change Do not allow the winding temperature to exceed
85 C (185.0 F). Temperatures that are greater than
Refill of the tank
85 C (185.0 F) will damage the winding insulation.
This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for Self-Circulating Air Method
the breather vent on the fuel tank is also
recommended.
Run the engine and disconnect the generator load.
If a bulk storage tank has been refilled or moved This will help circulate air. Operate the generator
recently, allow adequate time for the sediment to space heaters.
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap Oven Method
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel. Place the entire generator inside a forced air drying
When possible, water separators should be used. oven for four hours at 65 C (149 F).
i03214248 NOTICE
Use a forced air type oven rather than a radiant type
Generator - Dry oven.
SMCS Code: 4450-569 Radiant type ovens can cause localized overheating.
NOTICE
Do not operate the generator if the windings are wet. Controlled Current Method
If the generator is operated when the windings are
wet, damage can occur due to insulation breakdown.
Personal injury or death can result from improper

troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
Refer to Safety Section, Generator Isolating for

Maintenance for information regarding the procedure
to safely isolate the generator. Illustration 108 g00614674
When moisture is present or when moisture is External Power Source Circuit

suspected in a generator, the generator must be dried (1) Battery (12 VDC)
before being energized. (2) Rheostat (15 ohm 25 watt)
(3) Exciter Field (Stator L1 )
If the drying procedure does not restore the insulation
resistance to an acceptable value, the winding should
be reconditioned.
SEBU8468 143
Generator - Inspect
Table 35 7. On an hourly basis, stop the drying procedure.

TOOLS NEEDED Check the insulation resistance. Repeat the above
steps until the insulation resistance is acceptable.
Quantity Part Number Description
1 225-8266 Clamp-on ammeter Guidelines for Space Heaters

(1200 amperes)
1 External power 1. Energize the space heaters when the generator is

source circuit not operating.
Heat can be used in order to dry the generator 2. Maintain the winding temperature at least 5 C
windings. This heat can be created by allowing a (9 F) over the ambient temperature. In order to
controlled current to flow through the generator. No maintain the desired temperature in some
high voltages are generated during the following conditions, a supplemental heat source or
procedure. Therefore, insulation breakdown will not temporary covers may be required.
occur.
1. Make an external power source. Refer to 3. Check the insulation resistance until the resistance
Illustration 108 . is acceptable.
2. Disconnect F1+ from the voltage regulator. Note: For more information on drying methods, refer
Disconnect F2- from the voltage regulator. to Special Instruction, SEHS9124, Cleaning and
Disconnect the generator load. Connect the Drying of Electric Set Generators.
generator output leads T0, T1, T2, and T3
together. Install the clamp-on ammeter to i01461264
generator output lead T1.
Generator - Inspect
Note: When the line current is measured on multiple
lead units, measure the current in each conductor per SMCS Code: 4450-040
phase. The currents can then be added.
3. Refer to Illustration 108 . Adjust the rheostat to the

maximum resistance value. Connect the external Personal injury or death can result from improper
power source to wires F1+ and F2-. troubleshooting and repair procedures.
4. Start the generator set. Run the generator set at The following troubleshooting and repair proce-
IDLE speed. dures should only be performed by qualified per-
NOTICE Refer to Safety Section, Generator Isolating for

Do not exceed the rated phase current that is listed Maintenance for information regarding the procedure
on the generator nameplate. Exceeding the rated to safely isolate the generator.
phase current will easily damage the generator
windings. Proper maintenance of electrical equipment requires
periodic visual examination of the generator and
periodic visual examination of the windings. Proper
5. Monitor the phase current. In order to maintain use maintenance of electrical equipment also requires
of the circuits for the protection of safety, use the appropriate electrical checks and appropriate thermal
control panel for the EMCP 3 to gradually checks. Insulation material should be examined for
cracks. The insulation material should be examined
increase the engine rpm. Increase the engine rpm for accumulations of dirt and dust. If there is an
until one of the following conditions are met: insulation resistance value that is below normal, a
conductive path may be present. This conductive
The rated phase current is obtained. path may be made of one of the following materials:
The full generator set speed is obtained. Carbon
6. If more phase current is necessary, slowly turn the Salt

rheostat. Turn the rheostat until the rated phase Metal dust
current is reached.
Dirt that is saturated with moisture
144 SEBU8468
Generator Bearing - Inspect
These contaminants will develop a conductive path Cleaning (Disassembled

which may produce shorts. Cleaning is advisable if
heavy accumulations of dirt can be seen or if heavy Generators)
accumulations of dust can be seen. If excess dirt is
the cause of a restriction in the ventilation, cleaning is An initial insulation resistance check should be made
also advisable. Restricted ventilation will cause on the generator in order to confirm electrical integrity.
excessive heating. A minimum reading of one megohm would be
expected with severely contaminated generators. A
zero megohm reading may indicate an insulation
NOTICE breakdown. An insulation breakdown requires more
To avoid the possibility of deterioration to the genera- than cleaning. An insulation breakdown requires
tor windings, do not clean the generator unless there repair.
is visual, electrical, or thermal evidence that dirt is
present. A high pressure wash is normally an effective way to
clean windings. This includes windings that have
been exposed to flooding or windings that have been
If harmful dirt accumulations are present, a variety of contaminated by salt. A solution of hot water and
cleaning techniques are available. The cleaning detergent is used for this method of cleaning.
procedure that is used may be determined by one of
the items on the following list: A high pressure wash sprays a high velocity fluid
stream of this solution over the generator that is being
The extent of the cleaning procedure that is being cleaned. This detergent washing is followed by
attempted multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean
The type of enclosure of the generator water is used in order to dilute the detergent.
The voltage rating of the generator Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation
The type of dirt that is being removed resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It may
Cleaning (Assembled Generators) be necessary to use solvents if the generator is
contaminated with oil or if the generator is
Cleaning may be required at the point of installation. contaminated with grease.
At this point, complete disassembly of the generator
may not be necessary or feasible. In this case, a Note: For more information on drying methods, refer
vacuum cleaner should be used to pick up the to Special Instructions, SEHS9124, Cleaning and
following items: dry dirt, dust and carbon. This will Drying of Electric Set Generators.
prevent the spreading of these contaminants.
i03132339
A small nonconductive tube may need to be
connected to the vacuum cleaner. This will allow the
vacuum cleaner to clean the surfaces that are not Generator Bearing - Inspect
exposed. After most of the dust has been removed, a
small brush may be attached to the vacuum hose in SMCS Code: 4471-040
order to loosen dirt that is more firmly attached to the The ball bearings that are used in LC5, LC6, and SR5
surface. generators contain grease. This grease is subject to
After the initial cleaning with a vacuum, compressed deterioration. If the generator is stored more than one
air may be used to remove the remaining dust and year, without rotating the rotor, new ball bearings may
dirt. Compressed air that is used for cleaning should be required. These bearings are greased at the
be free of moisture and free of oil. Air pressure should factory. These bearings do not require any additional
be a maximum of 210 kPa (30 psi) in order to prevent greasing in the field. Remove any necessary covers
mechanical damage to the insulation. If the above in order to inspect the rear bearings of the generators.
cleaning procedures are not effective, consult a Front bearings may be inspected through the fan
Caterpillar dealer. screen. Perform a visual inspection for obvious
damage, for corrosion, or for an excessive amount of
purged grease around the bearing sleeves. Small
amounts of purged grease are expected. Grease that
covers the brackets or the windings is excessive.
Bearing inspection should include the collection of
vibration data. Refer to this Operation and
Maintenance Manual, Generator Set Vibration - Test/
Record for further information concerning checking
the vibration levels.
SEBU8468 145
Generator Bearing - Lubricate
Bearing temperature should also be measured and Note: Do not allow grease to drip on the stator
recorded as a part of this inspection. Refer to this windings of the generator. The stator windings that
Operation and Maintenance Manual, Generator are exposed to grease could suffer degraded
Bearing Temperature - Test/Record for further insulation. The degraded insulation would cause a
information concerning checking the vibration levels. reduction in the life of the windings.
If inspection indicates that bearings are free of rust or 6. Operate the generator set at rated speed for
corrosion, and no noise or excessive vibration occur
on start-up, replacement is not necessary. approximately 1 hour. When running the engine
more than 30 minutes, the recommended engine
i05032881
load to apply is a minimum of 50%. The procedure
will allow the grease to expand. The expanding
Generator Bearing - Lubricate grease will force the excess grease from the cavity.
The internal pressure will be reduced as the
SMCS Code: 4471-086 excess grease is forced from the cavity. Operate
the generator until no grease is forced out of the
Procedure for Bearing Service cavity.
Perform periodic bearing lubrication at the intervals 7. Stop the generator set. Inspect the generator
that are shown in Table 36 . Use the following windings, grease tubes, and bearing housings.
instructions as the suggested procedure in order to
service the bearings of the generator. Wipe off any excess grease. If a grease pipe plug
was removed in Step 2, install the plug in the
bottom grease pipe. Wipe off any excess grease.
Note: If the generator already has a visible grease
point, go to Step 4. Note: Do not allow grease to drip on the stator
1. Stop the generator set. Remove the required windings of the generator. The stator windings that
external cover plates, grills, and louvers of the are exposed to grease could suffer degraded
generator in order to access the bearings. insulation. The degraded insulation would cause a
reduction in the life of the windings.
2. Remove the top grease pipe plug and the lower
grease pipe plug. If no grease pipes can be found, 8. Install all of the external cover plates, grills, and
then locate the insert for the grease pipe. The louvers of the generator that were removed in
insert is located on the bearing brackets. Remove order to access the bearings.
the inserts. Install the grease pipes.
3. Install a grease fitting in the top grease pipe.
4. Use a Cat 8F-9866 Grease Gun or equivalent

grease gun to grease the bearings. Use the
appropriate type of grease and the quantity that is
listed in Table 36 . Avoid the use of alternate types
of grease. Usage of alternate types of grease
could cause premature bearing failure.
Note: Add only the amount of grease listed in Table
36 . Do not continue to add grease until purging is
observed. Purging of grease will not always be
observed.
5. If grease fittings are permanently installed, ensure
that the protective caps for the grease fittings are
installed on the fittings when finished. If a grease
fitting was installed in Step 2, remove the top
grease fitting and install the plug that was
removed. If applicable, do not install the plug on
the bottom grease location yet. Wipe off the
excess grease.
146 SEBU8468
Table 36
Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Number Type Size Maximum(1) Part Number Diameter
5P-2448 315 BC 580 85 C (185 F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 75 mm (3 inch)
Ball Bearing 160 mm 590 ing Lubricant service hours (1.8 oz)
(6.3 inch) or 12 months
OD
75 mm
(3 inch) ID
6Y-3955 220 BC 450 85 C (185 F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 100 mm
Ball Bearing 180 mm ing Lubricant service hours (1.8 oz) (3.9 inch)
OD
100 mm
(3.9 inch)
ID
6Y-6488 318 BC 597 85 C (185 F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 90 mm (3.5 inch)
Ball Bearing 190 mm ing Lubricant service hours (1.8 oz)
OD
90 mm
(3.5 inch)
108-1760 321 BC 680 85 C (185 F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 105 mm
OD
105 mm
(4.1 inch)
ID
Ball Bearing 240 mm 800 ing Lubricant service hours (1.8 oz) (4.3 inch)
OD
110 mm
(4.3 inch)
ID
OD
80 mm
(3.15 inch)
ID
139-0349 Roller 2900 85 C (185 F) 1p0808 Every 250 2.8 g N/A 127 mm (5 inch)
Roller Bearing 2800 service (0.1 oz)
hours
139-0350 Roller 2900 85 C (185 F) 1p0808 Every 250 2.8 g N/A 127 mm (5 inch)
Roller Bearing 2800 service (0.1 oz)
hours
Ball Bearing 280 mm 1800 (2) (3) 95 C (203 F) ing Lubricant service hours (1.8 oz) (5.1 inch)
(11 inch) 2600 (3) 85 C (185 F) or 12 months
OD 2700 (3) 85 C (185 F)
130 mm
(5.1 inch)
ID
(continued)
SEBU8468 147
(Table 36, contd)

193-4070 018 BC 498 85 C (185 F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 90 mm (3.5 inch)
Ball Bearing 140 mm 499 ing Lubricant service hours (1.8 oz)
OD
90 mm
(3.5 inch)
ID
241-4644 320 BC LC7 95 C (203 F) UNIREX N3 Every 4500 60 g N/A 100 mm
Bearing 215 mm service hours (2.1 oz) (3.9 inch)
OD
100 mm
(3.9 inch)
ID
243-5220 315 BB LC6100 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 75 mm (3.0 inch)
Bearing 160 mm LC5000
(6.3 inch)
OD
75 mm
(3.0 inch)
ID
253-9789 320 BC 1400 85 C (185 F) UNIREX N3 Grease can- N/A N/A 100 mm
Bearing 215 mm not be added (3.9 inch)
(8.5 inch) to this
OD bearing.
100 mm
(3.9 inch)
ID
253-9792 226BC 1400 95 C (203 F) EA6 Grease can- Grease Grease can- 140 mm
Bearing 230 mm not be added cannot be not be added (5.5 inch)
(9.05 inch) to this added to to this
OD bearing. this bearing.
130 mm bearing.
(5.12 inch)
ID
261-3545 307 BB LC2000 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 35 mm (1.4 inch)
Bearing 80 mm
(3.1 inch)
OD
35 mm
(1.4 inch)
ID
262-5921 307 BC LC2000 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 35 mm (1.4 inch)
Bearing 80 mm
(3.1 inch)
OD
35 mm
(1.4 inch)
ID
(continued)
148 SEBU8468
(Table 36, contd)

263-0161 309 BC LC3000 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 45 mm (1.8 inch)
Bearing 100 mm
(3.9 inch)
OD
45 mm
(1.8 inch)
ID
281-3091 328 BC 3010 (2) 95 C (203 F) EA6 Grease can- Grease Grease can- 140 mm
Ball Bearing 300 mm 3020 (2) not be added cannot be not be added (5.5 inch)
(11.8 inch) 3042 (2) to this added to to this
OD 3044 (2) bearing. this bearing.
140 mm 3045 (2) bearing.
(5.5 inch)
ID
311-0843 326 BC 1800 (2) 95 C (203 F) EA6 Grease can- N/A N/A 130 mm
Ball Bearing 280 mm not be added (5.1 inch)
(11 inch) to this
OD bearing.
130 mm
(5.1 inch)
ID
311-0844 322 BC 1600 95 C (203 F) EA6 Grease can- N/A N/A 110 mm
Ball Bearing 240 mm not be added (4.3 inch)
(9.4 inch) to this
OD bearing.
110 mm
(4.3 inch)
ID
341-7383 330 BC 3055 (5) 95 C (203 F) Exxon Polyrex Every 1800 51.2 g 14.9 mL 150 mm
Ball Bearing 320 mm 3066 (5) EM Base materi- service hours (1.8 oz) (0.5 oz) (5.9 inch)
(12.6 inch) 3068 (5) al is Polyurea. or 12 months
OD
150 mm
(5.9 inch)
ID
375-3715 328 BC 3010 (2) (3) 95 C (203 F) 2S-3230 Bear- Every 2400 51.2 g 59 mL (2 oz) 140 mm
Ball Bearing 300 mm 3020 (2) (3) ing Lubricant service hours (1.8 oz) (5.5 inch)
(11.8 inch) 3042 (2) (3) or 12 months
OD 3044 (2) (3)
140 mm 3045 (2) (3)
(5.5 inch)
ID
(1) Indicates the alarm temperature set point that the bearing should be continuously operated at on the specified generator frame size. Shutdown
set points are typically 10 C (18 F) higher.
(2) 1800 frame generators and 3000 frame generators shipped before 2012 use double-shielded bearings with EA6 grease. There are no
threaded holes in the bearing brackets for the grease tubes that are used to add grease. Therefore, no grease can be added to the bearings.
Beginning in 2012, 1800 frame generators and 3000 frame generators that are shipped will use a single-shielded bearing with 2S-3230 grease.
The front and rear brackets contain factory installed grease fittings, therefore, single-shielded bearings must be lubricated periodically. Refer-
ence the Parts Manual with package serial number to identify the bearing part number and to determine bearing lubrication requirements.
(3) All 2600, 2700, 1800 and 3000 frame generators shipped beginning in 2012, use a single-shielded bearing design. Replacement bearings re-
ceived from the Parts Division will have a shield on each side of the bearing. The shield facing the outside of the generator must be removed
when the new bearing is installed.
(4) Grease cannot be added to this bearing. Refer to the Operation and Maintenance Manual, Generator Bearing - Replace article for information
concerning the replacement of these bearings.
(5) The generator uses a non-shielded bearing design. Although replacement bearings may have a shield on each side, both shields must be re-
moved when the new bearing is installed. Replacement bearings are shipped as dry bearings and must be packed to 50% grease fill at time of
installation.
SEBU8468 149
Generator Bearing - Replace
Bearing Replacement alignment
Refer to the appropriate publication for each specific environmental

generator for bearing replacement procedures.
environmental
Replace both bearings of a two-bearing generator.
exercising the generator
Replace any bearing wear sleeves and lip seals when
the bearings are replaced. temperature
Except for the 341-7383 Ball Bearing, replacement vibration
bearings are pre-lubricated. The pre-lubricated
bearings do not require additional grease at time of Standby Usage
replacement. The 341-7383 Ball Bearing is shipped
as a dry bearing. The 341-7383 Ball Bearing must The generator bearings are shielded and greased for
be packed to 50% grease fill at time of installation. the life of the bearing. Some purging of the grease
occurs normally with the bearings. Carefully adhere to
Old grease must be removed at the time of bearing the recommendations for the following conditions:
replacement from the bearing bracket cavity. After the temperature, vibration, contamination and alignment.
bearing bracket cavity is cleaned, the bearing bracket Over time, the bearing grease may deteriorate. This
cavity must be packed with new grease from one- deterioration may cause the grease to loose
third to one-half full. lubricating properties.
Note: Generator set alignment is required after the Caterpillar recommends the replacement of the
bearings are replaced. bearing after ten years of service in a standby
application in normal conditions. If the bearing is
Additional Information installed in the following conditions, Caterpillar
recommends replacement of the bearing in 5 years.
Refer to Special Instruction, REHS4892, Generator
Bearing Service for further information. High temperature environment (Refer to the
temperature chart in this Operation and
i03098183 Maintenance Manual, Generator Bearing -
Lubricate article.
Generator Bearing - Replace Condensing humidity
(SR5 Generator Bearings)
Coastal environment
SMCS Code: 4471-510
Chemical environment
Standard Usage Abrasive environment
Caterpillar recommends replacement of the
generator bearing at the major overhaul unless the i03642839
generator is installed in any of the following
conditions: Generator Bearing
High temperature environment (refer to the Temperature - Test/Record
temperature chart in this Operation and
Maintenance Manual, Generator Bearing - SMCS Code: 4471-081-TA
Lubricate article. The monitoring of bearing temperature may prevent
premature bearing failure. A generator set should
Condensing humidity never operate above the recommended set points.
Keep records in order to monitor the changes in the
Coastal environment temperature of the bearing.
Chemical environment Note: Measure the bearing temperature after the
generator reaches normal operating temperature.
Abrasive environment
If any of these conditions exist, consult your
Caterpillar dealer for the appropriate checks:
150 SEBU8468
Generator Lead - Check
Resistive Temperature Detectors When a generator is installed or when a generator is

reconnected, ensure that the total current in any one
(RTDs) phase does not exceed the nameplate rating. Each
phase should carry the same load. This allows the
Caterpillar Generators may be equipped with generator to work at the rated capacity. If one phase
resistance temperature detectors for generator current exceeds the nameplate amperage, an
bearings. These detectors are 100 ohm resistance electrical imbalance will occur. An electrical
temperature detectors. A resistance temperature imbalance can result in an electrical overload and an
detector may be monitored by the optional monitor for electrical imbalance can result in overheating.
the EMCP 3.2/3.3 resistance temperature detector. A
resistance temperature detector may be monitored by The power factor can be referred to as the efficiency
equipment that is provided by the customer. Consult of the load. This can be expressed as the ratio of kVA
with your Caterpillar dealer about other methods of to actual kW. The power factor can be calculated by
measuring the bearing temperature. dividing kW by kVA. Power factor is expressed as a
decimal. Power factor is used to mean the portion of
The EMCP 3.2/3.3 may be configured to ALARM current that is supplied to a system that is doing
or the EMCP 3.2/3.3 may be configured to useful work. The portion of the current that is not
SHUTDOWN . An alarm is activated if the doing useful work is absorbed in maintaining the
temperature of the bearing reaches 85 C (185 F). A magnetic field in motors. This current (reactive load)
shutdown occurs if the temperature of the bearing can be maintained without engine power.
reaches 95 C (203 F).
Electric sets normally have a low idle setting that is
Infrared Thermometers higher than industrial engines. Low idle will be
approximately 66 percent of the full speed that is
Bearing temperatures can also be recorded with the achieved by 60 Hz units. This would be equal to 80
use of an infrared thermometer. Refer to Special percent of the full speed that is achieved by 50 Hz
Publication, NENG2500, Caterpillar Dealer Service units.
Tools Catalog for a variety of infrared thermometers.
Follow the instructions that come with your infrared The ADEM III system functions as the governor for
thermometer. this engine.
i02517207
Note: Operating the electric set at low idle speed for
an extended time will cause some voltage regulators
to shut off. The electric set must be completely shut
Generator Lead - Check down and the electric set must be restarted. This will
SMCS Code: 4450-535 allow the voltage regulator to again produce an
output.
The generator set may have braided cables between
the generator and the breaker instead of wire cables.
Check for signs of wear along the braided cables.
Pay particular attention to the cables at the housing
for the breaker and the generator terminal box.
If the rubber mats or the insulation on the braided
cables show signs of wear at points of contact with
other surfaces, replace the mats or the cable
immediately. If your generator set does not have
rubber mats in place, contact your Caterpillar dealer.
i03215110
Generator Load - Check

SMCS Code: 4450-535-LA
During normal operation, monitor the power factor
and monitor generator loading.
SEBU8468 151
Generator Set - Test
i03292462 The generator set functional test determines if the

following statements happen:
Generator Set - Test A phase voltage is being generated.
SMCS Code: 4450-081
The phase voltages are balanced.
The phase voltages change relative to engine

speed.
Personal injury or death can result from high
voltage. The generator set functional test consists of the
following steps:
When power generation equipment must be in op-
eration to make tests and/or adjustments, high 1. Stop the generator. Connect the potential
voltage and current are present. transformer's high voltage winding to the generator
Improper test equipment can fail and present a terminals (T1) and (T2). Connect the voltmeter to
high voltage shock hazard to its user. the low voltage winding. If two transformers are
available, connect the high voltage winding of the
Make sure the testing equipment is designed for
second transformer to the generator terminals (T1)
and correctly operated for high voltage and cur-
rent tests being made. and (T3). Connect the secondary terminals that
correspond to generator terminal (T2) of both
When servicing or repairing electric power gener- transformers together.
ation equipment:
2. Disconnect wires F1+ and F2- from the
Make sure the unit is off-line (disconnected voltage regulator. Disconnect the generator from
from utility and/or other generators power serv-
the load.
ice), and either locked out or tagged DO NOT
OPERATE. 3. Connect a 12 VDC automotive battery to wires F1
+ and F2- .
Make sure the generator engine is stopped.
Make sure all batteries are disconnected. NOTICE
Make sure all capacitors are discharged. Do not operate the generator set at a speed that is
higher than one-half of the rated speed.
Higher speeds under these test conditions can cause
damage to the system.
DANGER: Shock/Electrocution Hazard-Do not

operate this equipment or work on this equipment 4. Operate the generator set at half the rated speed.
unless you have read and understand the
instructions and warnings in the Operation and 5. Measure the AC voltage across the low voltage
Maintenance Manual. Failure to follow the terminals of the transformer that correspond to the
instructions or heed the warnings will result in following generator terminals: T1 and T2 ,
serious injury or death. T2 and T3 and T3 and T1 . Record the
voltages.
Table 37
Tools Needed
6. Monitor the voltage between any two of the
locations in step 5. Decrease the generator set
Part Number Part Quantity speed by 10 percent. Increase the generator set
237-5130 Digital Multimeter 1 speed by 10 percent.
12 VDC Battery 1 7. The voltages that were measured in Step 5 should
Potential be nearly equal. These voltages should measure a
1 minimum of 85 VAC.
Transformer
The generator set functional test is a simplified test

that can be performed in order to determine if the
generator is functional. The generator set functional
test should be performed on a generator set that is
under load.
152 SEBU8468
Generator Set Alignment - Check
8. When the generator set speed is decreased by 10 Coupling wear

percent, the voltages that were measured in Step 6
should decrease by 10 percent. When the Loose fittings
generator set speed is increased by 10 percent, Fatigue of the metal components of the engine
the voltages that were measured in Step 6 should
increase by 10 percent. Cracks in the cabinet which surrounds the
generator
i03956450
Cracks in welds
Generator Set Alignment - Excessive noise
Check Cracked insulation
(Generator Sets) The following areas are susceptible to vibration
SMCS Code: 7002-024 damage:
The genset must be aligned when the genset is Coupling for the generator set
installed or moved into a different position. If the
generator set is run at the full continuous rating, the Generator bearings
alignment of the generator to the engine must be
checked annually. Stator output leads
Properly maintain the alignment between the engine Protective sleeving
and the driven equipment in order to minimize the
following problems: Insulation
Bearing problems Exposed electrical connections
Vibration of the engine crankshaft Transformers
Vibration of the driven equipment Fuses

Refer to the following information for more information Capacitors
about the alignment of the generator set:
Lightning arresters
Special Instruction, SEHS7654, Alignment -
General Instructions When a generator set is installed, a vibration plot
should be recorded in order to assist in diagnosing
Special Instruction, SEHS7259, Alignment of potential problems. This vibration plot should be
Single Bearing Generators updated yearly. The vibration plot should also be
updated when the generator set is moved and when
Special Instruction, REHS0177, Alignment of the the engine is overhauled. This will allow the trend of
Close Coupled Two Bearing Generators the vibration to be monitored and analyzed. A
potential problem may be prevented by monitoring
Keep a record of the measurement of the alignment. the trend of the vibration. If the vibration is
The record may be used to check the trend of the approaching the limit of the specification of the
alignment. The record may be used to analyze the component, the problem may be more imminent.
trend of the alignment. Refer to Data Sheet, LEKQ4023, Linear Vibration for
the allowable limits of vibration.
i03643886 Caterpillar also recommends recording the vibration
of the bearing at the generator bearing bracket.
Generator Set Vibration - Test/ If the vibration exceeds the EDS limits for vibration,
Record check the alignment. Refer to this Operation and
Maintenance Manual, Generator Set Alignment -
SMCS Code: 4450-081-VI Check for the alignment procedure.
Check for vibration damage. Contact the Caterpillar Dealer Service Tools group
for information on ordering a vibration analyzer that
Vibration may cause the following problems: will meet your needs.
SEBU8468 153
Generator Winding - Test
i03736530 Table 38
Quantity Needed Tool
Generator Winding - Test
1 Low ohmmeter
SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
081
Measure the resistance of the following windings:
(L1), (L2), (L3), (L4) and (L5). The winding that is
being tested must be disconnected from the other
components before the resistance can be measured.
Note: The winding temperature affects the

resistance. When the winding temperature increases,
the winding resistance increases. When the winding
temperature decreases, the winding resistance
decreases. Therefore, a correct measurement can be
performed only when the winding is at room
temperature.
The following resistance measurements are
approximations. If the measured value is not near the
listed approximation, the winding is probably
damaged. For a more precise resistance value,
consult the Technical Marketing Information (TMI).
Refer to the generator arrangement that is in
question.
The following windings have very little resistance:
(L2), (L4) and (L5). The resistance of these windings
will measure near 0 ohms. Use a milliohmmeter to
measure the resistance of the windings.
Exciter rotor (L2) Refer to Table 39 .
Main stator (L4) less than 0.1 ohm
Pilot exciter stator (L5) less than 0.1 ohm
Use a multimeter in order to measure the resistance

of field windings (L1) and (L3).
Exciter field (stator) (L1) Refer to table 39 .
Main field (rotor) (L3) approximately 0.35 ohms to
1.2 ohms
PMPE Generator wiring diagram for the family of Note: There should be no continuity between any
1800 frames
winding and ground. There should be no continuity
(CR1-C6) Diodes between any winding and another winding.
(CR7) Varistor Table 39
(L1) Exciter stator
L2 Exciter Main Field for
(L2) Exciter rotor L1 Exciter Field
Rotor the Rotor
(L3) Main rotor
1800 Frame 10.9 ohms 0.05 ohms .9 ohms
(L4) Main stator
1600 Frame 10 ohms 0.06 ohms .5 ohms
(L5) Permanent magnet generator stator
(PM) Permanent magnet 1400 Frame 11 ohms 0.06 ohms .35 ohms
(RFA) Rotating field assembly

(CT1) Optional voltage droop transformer
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
154 SEBU8468
Generator Winding Insulation - Test
i03736629 The generator set is started for the first time.
Generator Winding Insulation - The generator set is removed from storage.
Test The generator set is operating in a humid

environment. Test every three months.
SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
081 The generator set is not protected from the
elements in an enclosed area. Test every three
Recommended Periodic Insulation months.
Tests The generator set is installed in an enclosed area.
This area needs to be low in humidity and this area
needs to have steady temperatures. Test every
twelve months (minimum).
The high voltage that is produced by an operating
generator set can cause severe injury or death. The generator set has not been run under load for
Before performing any maintenance or repairs, three months. Test the generator set weekly. Use
ensure that the generator will not start. space heaters around the generator set if the
generator is exposed to a sea water environment
Place the engine control switch in the OFF po- or if the humidity is above 75 percent. Also use
sition. Attach DO NOT OPERATE tags to all space heaters if a test result was below 3
starting controls. Disconnect the batteries or dis- megohms.
able the starting system. Lock out all switchgear
and automatic transfer switches that are associ- Space heaters must be used whenever the generator
ated with the generator. set is not under load. Space heaters must also be
used whenever salt is present or whenever high
Table 40 humidity is present. Using a space heater in this
Tools Needed
fashion is the only way to maintain insulation tester
readings above one megohm. Use space heaters
Part Number Part Name Quantity only when the generator is not running.
300-8648 Insulation Testing Gp 1 For additional information, refer to Special Instruction,
SEHS9124, Cleaning and Drying of Electric Set
Periodically, use an insulation tester to check the Generators.
insulation resistance of the generator's main stator
winding. The frequency of this test is determined by Recommended Procedure for the
the generator's environment. Previous insulation Insulation Test
tester readings will also determine the frequency of
this test.
Test the main stator windings with an insulation tester
in the following situations: Personal injury or death can result from
electrocution.
The megohmmeter is applying a high voltage to
the circuit.
To avoid electrocution, do not touch the instru-
ment leads without first discharging them. When
finished testing also discharge the generator
windings.
1. Take the generator out of service.
2. Visually inspect the generator for moisture. If

moisture exists, do not perform this insulation test.
Dry the unit first. Refer to Special Instruction,
SEHS9124, Cleaning and Drying of Electric Set
Generators.
3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
SEBU8468 155
4. Discharge the capacitance of the windings.
5. Disconnect T0 from ground.
6. Disconnect the sensing lead wires for the regulator.

This may be accomplished by unplugging the
harness connectors.
7. Disconnect the PT leads of the load share module.
8. Connect the insulation tester's Black lead to
ground.
9. Connect the insulation tester's RED lead to T0 .

10. Set the voltage to the rated voltage of the
generator.
11. Use the 30/60 Time Resistance Method:

a. Apply voltage.
b. Observe the readings at 30 seconds. Observe

the readings at 60 seconds.
c. Record the 60 second reading. This reading

must be corrected for temperature.
d. Record temperature.
e. Record humidity.
f. Remove voltage.
12. Evaluate the readings. The actual value of the

resistance may vary greatly between generators.
For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
the readings that were taken on previous dates.
These two readings must be taken under similar
conditions. If a 60 second resistance reading has a
50 percent reduction from the previous reading,
the insulation may have absorbed too much
moisture.
Switch the insulation tester to the OFF position.
This will discharge the insulation tester's leads.
Disconnect the insulation tester's leads.
Note: The results from the insulation resistance
checks indicate when cleaning and/or repairing is
becoming critical. Generally, insulation resistance will
vary greatly with temperature. Therefore, always test
at the same temperature and humidity. Refer to
Illustration 110 .
Engine Serial Number
Serial Number for the Generator
156 SEBU8468
SEBU8468 157

158 SEBU8468
Hoses and Clamps - Inspect/Replace
i04301694 Type of hose
Hoses and Clamps - Inspect/ Type of fitting material
Replace Anticipated expansion and contraction of the hose

SMCS Code: 7554-040; 7554-510 Anticipated expansion and contraction of the
fittings
Hoses and clamps must be inspected periodically in
order to ensure safe operation and continuous Due to extreme temperature changes, the hose will
operation of the engine. Take proper safety heat set. Heat setting causes hose clamps to loosen
precautions before inspecting or replacing hoses and which can result in leaks. A constant torque hose
clamps. clamp will help to prevent loose hose clamps.
Note: Always use a board or cardboard when the Replace hoses that are cracked or soft. Replace
engine components are checked for leaks. Leaking hoses that show signs of leakage. Replace hoses
fluid that is under pressure can cause serious injury that show signs of damage. Replace hose clamps
or possible death. Leaks that are the size of a pin that are cracked or damaged. Tighten or replace hose
hole are included. Refer to Operation and clamps which are loose.
Maintenance Manual, General Hazard Information
for more information. Replace the Hoses and the Clamps
Inspect the Hoses and the Clamps NOTICE
Inspect all hoses for leaks that are caused by the tained during performance of inspection, mainte-
following conditions. Replace any hose which exhibits nance, testing, adjusting, and repair of the product.
any of the following conditions. Failure to replace a Be prepared to collect the fluid with suitable contain-
hose which exhibits any of the following conditions
may result in a hazardous situation.
Hoses which are cracked
Refer to Special Publication, NENG2500, Cat Dealer
Hoses which are soft Service Tool Catalog or refer to Special Publication,
PECJ0003, Cat Shop Supplies and Tools Catalog
Outer covering that is chafed or cut for tools and supplies suitable to collect and contain
Exposed wire that is used for reinforcement
Outer covering that is ballooning locally mandates.
Flexible part of the hose that is kinked or crushed

Cooling System
Armoring that is embedded in the outer covering
Hoses which exhibit signs of leakage which are not
the result of loose couplings or clamps
Pressurized System: Hot coolant can cause seri-
Inspect all clamps for the following conditions. ous burns. To open the cooling system filler cap,
Replace any clamp which exhibits signs of any of the stop the engine and wait until the cooling system
following conditions.
components are cool. Loosen the cooling system
Cracking pressure cap slowly in order to relieve the
pressure.
Looseness
Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks. Personal injury can result from removing hoses
or fittings in a pressure system.
Each installation application can be different. The
differences depend on the following factors: Failure to relieve pressure can cause personal
injury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
SEBU8468 159
Hoses and Clamps - Inspect/Replace
NOTICE
1. Stop the engine.
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
2. Allow the engine to cool.
any loose or damaged fuel and oil lines, tubes and
3. Before servicing a coolant hose, slowly loosen the hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
filler cap for the cooling system in order to relieve
recommended torque.
any pressure.
4. Remove the filler cap for the cooling system.

NOTICE
5. Drain the coolant from the cooling system to a level Do not allow dirt to enter the fuel system. Thoroughly
that is below the hose that is being replaced. Drain clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
the coolant into a suitable clean container. The
connected fuel system components.
coolant can be reused.
6. Remove the hose clamps.
Note: High-pressure fuel lines may be installed
7. Disconnect the old hose. between the high-pressure fuel pump and the fuel
injectors. High-pressure fuel lines are constantly
8. Replace the old hose with a new hose. charged with high pressure. Do not check the high-
pressure fuel lines with the engine or the starting
9. Install hose clamps which have been inspected or
motor in operation. Wait for 10 minutes after the
install new hose clamps. Refer to Specifications, engine stops before you perform any service or repair
SENR3130, Torque Specifications, Hose Clamps on high-pressure fuel lines. Waiting for 10 minutes will
for information about selecting and installing the to allow the pressure to be purged.
proper hose clamps. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
10. Refill the cooling system.
2. Remove the hose clamps.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap 3. Disconnect the old hose.
if the gaskets are damaged. Install the filler cap.
4. Replace the old hose with a new hose.
leaks. 5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
Fuel System SENR3130, Torque Specifications, Hose Clamps
for information about selecting and installing the
proper hose clamps.
6. Carefully inspect the engine for any spilled fuel.

Personal injury can result from removing hoses Make sure that no fuel remains on or close to the
or fittings in a pressure system. engine.
Failure to relieve pressure can cause personal
injury. Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved. 7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, Fuel System - Prime for
information about priming the engine with fuel.
8. Start the engine. Inspect the fuel system for leaks.

Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
160 SEBU8468
Jacket Water Heater - Check
Lubrication System i03230758
Jacket Water Heater - Check

SMCS Code: 1383-535
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to Jacket water heaters help to improve startability in
contact the skin. ambient temperatures that are below 21 C (70 F).
All installations that require automatic starting should
have jacket water heaters.
1. Drain the oil from the lubrication system to a level
Check the operation of the jacket water heater. Check
that is below the hose that is being replaced. the operation of the circulation pump, if equipped. For
an ambient temperature of 0 C (32 F), the heater
2. Remove the hose clamps. should maintain the jacket water coolant temperature
at approximately 32 C (90 F).
3. Disconnect the old hose.
4. Replace the old hose with a new hose. i03195329
5. Install hose clamps which have been inspected or Maintenance

SENR3130, Torque Specifications, Hose Clamps
Recommendations
for information about selecting and installing the SMCS Code: 1000
proper hose clamps.
Overhaul Intervals
6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, Engine Oil Some factors that are important for determining the
Level - Check in order to ensure that the overhaul intervals include the following
lubrication system is filled with the proper amount considerations:
of engine oil. Performance of preventive maintenance
7. Start the engine. Inspect the lubrication system for Use of recommended lubricants
leaks.
Use of recommended coolants
Air System Use of recommended fuels
1. Remove the hose clamps. Proper installation
2. Disconnect the old hose. Operating conditions
3. Replace the old hose with a new hose. Operation within acceptable limits
4. Install hose clamps which have been inspected or Engine load

Engine speed
SENR3130, Torque Specifications, Hose Clamps
for information about selecting and installing the Generally, engines that are operated at a reduced
proper hose clamps. load and/or speed achieve more service life before an
overhaul. However, this is for engines that are
Note: The bellows and the V-clamps that are used on properly operated and maintained.
the bellows should never be reused.
Other factors must also be considered for determining
5. Start the engine. Inspect the air lines for leaks. a major overhaul:
SEBU8468 161
The total amount of fuel consumption (Table 41, contd)

1000 Service 133500 L 164000 L 194000 L
The service hours of the engine Hours (35000 US gal) (43200 US gal) (51200 US gal)
of fuel of fuel
An increase of oil consumption
2000 Service 267000 L 328000 L 388000 L
An increase of crankcase blowby Hours (70000 US gal) (86400 US gal) (102400 US
of fuel gal) of fuel
The wear metal analysis of the lube oil
3000 Service 398000 L 491000 L 582000 L
An increase in the levels of noise and vibration Hours (105000 US (129600 US (153600 US
gal) gal) of fuel gal) of fuel
An increase of wear metals in the lube oil indicates 796000 L 982000 L 1164000 L
that the bearings and the surfaces that wear may 6000 Service
Hours (210000 US (259200 US (307200 US
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts gal) gal) of fuel gal) of fuel
require service. Top End 11000 Service 9000 Service 7500 Service
Overhaul Hours Hours Hours
Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder 1500000 L (395000 US gal) of fuel
liners may be worn so that polishing of the bore
Second Top 22000 Service 18000 Service 15000 Service
occurs. Also, the increased use of lube oil will dilute End Overhaul Hours Hours Hours
the wear metals.
3000000 L (790000 US gal) of fuel
Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about Major Overhaul 33000 Service 27000 Service 22500 Service
scheduling a major overhaul. Hours Hours Hours
4500000 L (1185000 US gal) of fuel
Note: The driven equipment may also require service
(1) Fuel consumption is based on a load factor of approximately 60
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment. percent.
Table 42
Using Fuel Consumption For Calculating
Service Hours and Fuel Consumption for 3516B Engines(1)
the Overhaul Intervals
Interval Rated Up To Rated 1301 to Rated 1601 to
Experience has shown that maintenance intervals are 1300 RPM 1600 RPM 1800 RPM
most accurately based on fuel consumption. Fuel 250 Service 44000 L 53000 L 64500 L
consumption corresponds more accurately to the Hours (11600 US gal) (14000 US gal) (17000 US gal)
engine load. Tables 41 , and 42 list average ranges of fuel of fuel
of fuel consumption and service hours for standard
displacement engines. Tables 43 and 44 list average 500 Service 88000 L 106000 L 129000 L
ranges of fuel consumption and service hours for high Hours (23200 US gal) (28000 US gal) (34000 US gal)
displacement engines. These tables are based on a of fuel of fuel
load factor of approximately 60 percent. 1000 Service 176000 L 212000 L 258000 L
Hours (46500 US gal) (56000 US gal) (68000 US gal)
Standard Displacement Engines of fuel of fuel
2000 Service 352000 L 424000 L 516000 L
Table 41 Hours (93000 US gal) (112000 US (136000 US
Service Hours and Fuel Consumption for 3512B Engines(1) gal) of fuel gal) of fuel
3000 Service 528700 L 636700 L 773000 L

Interval Rated Up To Rated 1301 to Rated 1601 to
Hours (139500 US (168000 US (204000 US
1300 RPM 1600 RPM 1800 RPM
250 Service 33400 L 41000 L 48500 L
Hours (8800 US gal) (10800 US gal) (12800 US gal) 6000 Service 1056000 L 1272000 L 1548000 L
of fuel of fuel Hours (279000 US (336000 US (408000 US
500 Service 66800 L 82000 L 97000 L
Hours (17600 US gal) (21600 US gal) (25600 US gal) Top End 11000 Service 9000 Service 7500 Service
of fuel of fuel Overhaul Hours Hours Hours
2000000 L (528000 US gal) of fuel
(continued)
(continued)
162 SEBU8468
(Table 42, contd) (Table 44, contd)

Second Top 22000 Service 18000 Service 15000 Service 250 Service 44000 L 53000 L 64500 L
End Overhaul Hours Hours Hours Hours (11600 US gal) (14000 US gal) (17000 US gal)
of fuel of fuel of fuel
4000000 L (1056000 US gal) of fuel
500 Service 88000 L 106000 L 129000 L
Major Overhaul 33000 Service 27000 Service 22500 Service Hours (23200 US gal) (28000 US gal) (34000 US gal)
Hours Hours Hours of fuel of fuel of fuel
6000000 L (1584000 US gal) of fuel 1000 Service 176000 L 212000 L 258000 L
(1) Hours (46500 US gal) (56000 US gal) (68000 US gal)
Fuel consumption is based on a load factor of approximately 60
percent. of fuel of fuel of fuel
2000 Service 352000 L 424000 L 516000 L
Hours (93000 US gal) (112000 US (136000 US
High Displacement Engines of fuel gal) of fuel gal) of fuel
Table 43 3000 Service 528700 L 636700 L 773000 L

Hours (139500 US (168000 US (204000 US
Service Hours and Fuel Consumption for 3512B High Dis-
gal) of fuel gal) of fuel gal) of fuel
placement Engines(1)
6000 Service 1056000 L 1272000 L 1548000 L
Interval Rated Up to Rated 1301 to Rated 1601 to
Hours (279000 US (336000 US (408000 US
1300 RPM 1600 RPM 1800 RPM
250 Service 33400 L 41000 L 48500 L
Hours (8800 US gal) (10800 US gal) (12800 US gal) Top End 11000 Service 9000 Service 7500 Service
of fuel of fuel of fuel Overhaul Hours Hours Hours
500 Service 66800 L 82000 L 97000 L 2000000 L (528000 US gal) of fuel

Major Overhaul 22000 Service 18000 Service 15000 Service
of fuel of fuel of fuel
Hours Hours Hours
1000 Service 133500 L 164000 L 194000 L
4000000 L (1056000 US gal) of fuel
of fuel of fuel of fuel (1) Fuel consumption is based on a load factor of approximately 60
percent.
2000 Service 267000 L 328000 L 388000 L
Hours (70000 US gal) (86400 US gal) (102400 US
of fuel of fuel gal) of fuel
Use the actual records of fuel consumption, when
possible. If the actual records are not available, use
3000 Service 398000 L 491000 L 582000 L the following procedure in order to estimate the fuel
Hours (105000 US (129600 US (153600 US consumption.
1. Estimate the average percent of the load for the
6000 Service 796000 L 982000 L 1164000 L
operation of the engine.
Hours (210000 US (259200 US (307200 US
2. Refer to the fuel consumption data in the Technical
Top End 11000 Service 9000 Service 7500 Service Marketing Information (TMI) for your engine. This
Overhaul Hours Hours Hours will determine the fuel consumption for the percent
1500000 L (395000 US gal) of fuel of the load that was estimated in Step 1. Use this
figure as variable F for the equation in Table 45 .
Major Overhaul 22000 Service 18000 Service 15000 Service
Hours Hours Hours
For more information about the Technical
Marketing Information (TMI) for your engine,
3000000 L (790000 US gal) of fuel consult your Caterpillar dealer.
(1) Fuel consumption is based on a load factor of approximately 60 Table 45
percent.
Equation For Calculating Overhaul Intervals
Table 44
F/R = H
Service Hours and Fuel Consumption for 3516B High Dis-
F is the estimated total amount of fuel consumption of the
placement Engines(1)
engine.
Interval Rated Up to Rated 1301 to Rated 1601 to
R is the rate of fuel consumption in liters per hour or gallons per
1300 RPM 1600 RPM 1800 RPM
hour.
H is the number of estimated hours until the overhaul interval.
(continued)
SEBU8468 163
Overhaul (Major)
Oil Consumption as an Overhaul Monitor the engine as the engine accumulates

service hours. Consult your Caterpillar dealer about
Indicator scheduling a major overhaul.
Oil consumption, fuel consumption, and maintenance Note: The driven equipment may also require service
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil when the engine is overhauled. Refer to the literature
consumption can also be used to estimate the that is provided by the OEM of the driven equipment.
required capacity of a makeup oil tank that is suitable
for the maintenance intervals. A major overhaul includes all of the work that is done
for the top end overhaul. A major overhaul includes
Oil consumption is in proportion to the percentage of additional parts and labor. Additional parts and labor
the rated engine load. As the percentage of the are required in order to completely rebuild the engine.
engine load is increased, the amount of oil that is
consumed per hour also increases. For the major overhaul, all of the bearings, seals,
gaskets, and components that wear are
The oil consumption rate (brake specific oil disassembled. The parts are cleaned and inspected.
consumption) is measured in grams per kW/h (lb per If necessary, the parts are replaced. The crankshaft is
bhp). The brake specific oil consumption (BSOC) measured for wear. The crankshaft may require
depends on the engine load. Consult your Caterpillar regrinding. Alternatively, the crankshaft may be
dealer for assistance in determining the typical oil replaced with a Caterpillar replacement part.
consumption rate for your engine.
Your Caterpillar dealer can provide these services
When an engine's oil consumption has risen to and components. Your Caterpillar dealer can ensure
three times the original oil consumption rate due that the components are operating within the
to normal wear, an engine overhaul should be appropriate specifications.
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption. Replacement of Components
Replace the following components during the major
i02624456 overhaul:
Overhaul (Major) Camshaft bearings
SMCS Code: 7595-020-MJ Connecting rod bearings
Refer to this Operation and Maintenance Manual, Crankshaft seals
Maintenance Recommendations in order to
determine the maintenance interval for a major
overhaul. Crankshaft thrust washers
The need for a major overhaul is determined by Electronic unit injectors

several factors.
Gear train bushings
An increase of oil consumption
Gear train bearings
An increase of crankcase blowby
Main bearings
The total amount of fuel consumption
Piston rings
The service hours of the engine
Inspection, Reconditioning or
The wear metal analysis of the lube oil Exchanging of Components
An increase in the levels of noise and vibration Inspect the following components according to the
An increase of wear metals in the lube oil indicates instructions that are in Caterpillar reusability
that the bearings and the surfaces that wear may publications. Refer to Guidelines for Reusable Parts
need to be serviced. An increase in the levels of and Salvage Operations, SEBF8029, Index of
noise and vibration indicates that rotating parts Publications on Reusability or Salvage of Used Parts.
require service.
Recondition the worn components or exchange the
Note: It is possible for oil analysis to indicate a components, if necessary. Your Caterpillar dealer
decrease of wear metals in the lube oil. The cylinder can provide these services and components.
liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
the wear metals.
164 SEBU8468
Overhaul (Major)
Camshaft followers Aftercooler core

Camshaft thrust washers Camshaft
Connecting rods Crankshaft

Crankshaft vibration damper Driven equipment (alignment)
Cylinder head assembly Engine cylinder block

Cylinder liners Engine control module
Engine mounts Exhaust bellow shields

Scavenge oil pump Flywheel
Engine wiring harness Front gear train (gears)
Exhaust manifold seals Oil suction screen

Exhaust manifold bellows Rear gear train
Fuel pressure regulating valve Inspect the camshaft for damage to the journals and
the lobes.
Fuel priming pump
Inspect the crankshaft for any of the following
Fuel transfer pump conditions:
Inlet manifold gaskets Deflection
Inlet manifold seals Damage to the journals
Oil cooler core Bearing material that has seized to the journals
Oil pump Check the journal taper and the profile of the
crankshaft journals. Check these components by
Pistons interpreting the wear patterns on the following
components:
Piston pins
Rod bearing
Prelube pump
Main bearings
Pushrods
Note: If the crankshaft or the camshaft are removed
Rocker arms for any reason, use the magnetic particle inspection
process to check for cracks.
Spacer plate
Replace the crankshaft vibration damper if any of the
Software update following conditions occur:
Turbocharger Engine failure due to a broken crankshaft
Inspection of Components Excessive wear of the front bearing for the

crankshaft
Inspect the following components according to the
instructions that are in Caterpillar reusability Excessive wear of the gear train that is not caused
publications. Refer to Guidelines for Reusable Parts by a lack of lubrication
and Salvage Operations, SEBF8029, Index of
Publications on Reusability or Salvage of Used Parts. Inspect the gears of the gear train and inspect the
gear train bushings for the following conditions:
Worn gear teeth

Unusual fit
Unusual wear
SEBU8468 165
Overhaul (Top End)
In addition to the inspection of components, inspect Full Level I analysis

the alignment of the driven equipment. See the
Application and Installation Guide for the engine or Identification of the source of metal corrosion and
see the literature that is provided by the OEM of the of contaminants
driven equipment.
Identification of buildup of the impurities that cause
Cleaning of Components corrosion
Clean the oil cooler core and the aftercooler core. Identification of buildup of the impurities that cause
Then, pressure test both of these cores. For scaling
instructions on cleaning the cores, see this Operation
and Maintenance Manual, Aftercooler Core - Inspect/ Determination of possible electrolysis within the
Clean topic. engines' cooling system
Clean the oil suction screen. Also, remove side A report of the results of the analysis is provided.
covers in order to clean the oil sump. For instructions Maintenance recommendations are based on the
on removal and installation of components, see the results.
Service Manual, Disassembly and Assembly
module. For more information about SOS coolant analysis,
consult your Caterpillar dealer.
Obtain a Coolant Analysis
i04041712
For conventional heavy-duty coolant/antifreeze,
check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA Overhaul (Top End)
can be checked with an SOS coolant analysis SMCS Code: 7595-020-TE
(Level I). A more detailed coolant analysis is
recommended periodically. Refer to this Operation and Maintenance Manual,
Maintenance Recommendations in order to
For example, considerable deposits are found in the determine the maintenance interval for a top end
water jacket areas on the external cooling system, but overhaul.
the concentrations of coolant additives were carefully
maintained. The coolant water probably contained A top end overhaul involves the removal, the
minerals which were deposited on the engine over inspection, and the rework of the cylinder head
time. components. Some additional components are
replaced and serviced.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the Your Caterpillar dealer can provide these services
cooling system. A full water analysis may be obtained and components. Your Caterpillar dealer can ensure
from the following sources: that the components are operating within the
appropriate specifications.
Caterpillar dealer
Note: The driven equipment may also require service
Local water utility company when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Agricultural agent
Independent laboratory
First Top End Overhaul
If you elect to perform an overhaul without the
Caterpillar recommends an SOS coolant analysis services of a Caterpillar dealer, be aware of the
(Level II). This is a comprehensive chemical following recommendations.
evaluation of the coolant. This analysis is also a
check of the overall condition of the inside of the
cooling system. The following services are provided: Cylinder Head Assembly
Inspect the cylinder head assembly according to the
instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts
Publications on Reusability or Salvage of Used Parts.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
166 SEBU8468
Overhaul (Top End)
The use of out-of-spec parts will cause unscheduled 4. Wash the screen assembly in clean nonflammable
downtime and/or costly repairs. solvent. Allow the screen assembly to dry before
installation.
Unit Injectors
5. Install the screen assembly and install new O-ring
Replace the unit injectors. Consult your Caterpillar seals according to the instructions in the Service
dealer about exchanging the unit injectors. Your Manual, Disassembly and Assembly module.
Caterpillar dealer can provide these services and
components. 6. Install the cover.
The wear of unit injectors is affected by the following 7. Remove side covers in order to gain access to the
considerations: sump. Clean the bottom of the sump with
Quality of the fuel absorbent towels or pillows. When the bottom of
the sump is clean, install the side covers.
Quality of the filtration of the fuel
Replacement of Components
The wear of the unit injectors can result in elevated
levels of exhaust emissions and/or poor engine Replace the following components during the top end
performance. The misfire of a single cylinder is not overhaul:
typically attributed to normal wear. This condition can
be repaired by replacing the faulty unit injector. Electronic unit injectors
The following lists of circumstances indicate that the
unit injectors should be inspected more frequently: Inspection, Reconditioning, or
Use of fuels that are not recommended in this Exchanging of Components
Operation and Maintenance Manual, Refill
Capacities and Recommendations Inspect the following components according to the
Extreme ambient temperatures that reduce the publications. Refer to Guidelines for Reusable Parts
ability of the fuel to provide lubrication
Frequent plugging of the fuel filters Recondition the worn components or exchange the
components, if necessary. Your Caterpillar dealer
Insufficient maintenance of the fuel tank or the fuel can provide these services and components.
storage tank that can allow excessive water,
sediment, and other foreign matter.
Insufficient maintenance of the fuel filters
Oil Suction Screen

Clean the oil suction screen after the oil has been
drained.
Note: Approximately 1 L (1 qt) of oil will remain in the

oil housing after the sump has been drained. This oil
will pour out of the oil housing when the cover is
removed. Prepare to catch the oil in a pan. Clean up
any spilled oil with absorbent towels or pillows. DO
NOT use absorbent particles to clean up the oil.
1. Remove the cover.
2. Remove the screen assembly according to the
instructions in the Service Manual, Disassembly
and Assembly module. Discard the used O-ring
seals.
3. Inspect the screen assembly. Obtain a new screen
assembly, if necessary.
SEBU8468 167
Overhaul (Top End)
Camshaft followers Cylinder Head Assembly

Cylinder head assembly Inspect the cylinder head assembly according to the
Scavenge oil pump publications. Refer to Guidelines for Reusable Parts
Engine wiring harness Publications on Reusability or Salvage of Used Parts.
Exhaust manifold seals Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
Exhaust manifold bellows that the components are operating within the
Fuel pressure regulating valve
The use of out-of-spec parts will cause unscheduled
Fuel priming pump downtime and/or costly repairs.
Fuel transfer pump
Unit Injectors
Inlet manifold gaskets
Replace the unit injectors. Consult your Caterpillar
Inlet manifold seals dealer about exchanging the unit injectors. Your
Caterpillar dealer can provide these services and
Oil pump components.
Prelube pump The wear of unit injectors is affected by the following

considerations:
Pushrods
Quality of the fuel
Rocker arms
Quality of the filtration of the fuel
Spacer plate
The wear of the unit injectors can result in elevated
Software update levels of exhaust emissions and/or poor engine
performance. The misfire of a single cylinder is not
Turbocharger typically attributed to normal wear. This condition can
be repaired by replacing the faulty unit injector.
Inspection of Components The following lists of circumstances indicate that the
unit injectors should be inspected more frequently:
instructions that are in Caterpillar reusability Use of fuels that are not recommended in this
publications. Refer to Guidelines for Reusable Parts Operation and Maintenance Manual, Refill
and Salvage Operations, SEBF8029, Index of Capacities and Recommendations
Extreme ambient temperatures that reduce the
Aftercooler core ability of the fuel to provide lubrication
Camshaft Frequent plugging of the fuel filters
Driven equipment (alignment) Insufficient maintenance of the fuel tank or the fuel
storage tank that can allow excessive water,
Engine control module sediment, and other foreign matter.
Exhaust bellow shields Insufficient maintenance of the fuel filters
Oil suction screen
Oil Suction Screen
Top End Overhaul (Second)
Clean the oil suction screen after the oil has been
If you elect to perform an overhaul without the drained.
services of a Caterpillar dealer, be aware of the
following recommendations.
168 SEBU8468
Overhaul (Top End)
Note: Approximately 1 L (1 qt) of oil will remain in the Camshaft followers

housing after the sump has been drained. This oil will
pour out of the housing when cover (1) is removed. Connecting rods
Prepare to catch the oil in a pan. Clean up any spilled
oil with absorbent towels or pillows. DO NOT use Connecting rod bearings
absorbent particles to clean up the oil.
Cylinder head assembly
1. Remove the screen assembly according to the
instructions in the Service Manual, Disassembly Cylinder liners
and Assembly module. Discard the used O-ring
seals. Scavenge oil pump
2. Wash the screen assembly in clean nonflammable Engine wiring harness

solvent. Allow the screen assembly to dry before
Exhaust manifold seals
installation.
Exhaust manifold bellows
3. Remove side covers in order to gain access to the
sump. Clean the bottom of the sump with Fuel pressure regulating valve
absorbent towels or pillows. When the bottom of
the sump is clean, install the side covers. Fuel priming pump
4. Inspect the screen assembly for good condition. Fuel transfer pump
Obtain a new screen assembly, if necessary. Install
Inlet manifold gaskets
the screen assembly. Install new O-ring seals.
Inlet manifold seals
Replacement of Components
Oil pump
Replace the following components during the top end
overhaul: Pistons
Electronic unit injectors Piston pins
Prelube pump
Inspection, Reconditioning, or
Exchanging of Components Pushrods
Rocker arms
instructions that are in Caterpillar reusability Spacer plate
and Salvage Operations, SEBF8029, Index of Software update
Turbocharger
Recondition the worn components or exchange the
components, if necessary. Your Caterpillar dealer
can provide these services and components. Inspection of Components
SEBU8468 169
Overhaul Considerations
Aftercooler core Because of individual applications, it is not possible to

identify all of the factors which can contribute to
Camshaft severe operation. Consult your Caterpillar dealer
about the maintenance that is needed for your
Crankshaft specific engine.
Driven equipment (alignment) The following factors can contribute to severe
operation: environment, improper operating
Engine control module procedures and improper maintenance practices.
Exhaust bellow shields
Environmental Factors
Oil suction screen
Extreme Ambient Temperatures
Note: Inspect only two of the components from each
cylinder bank. Inspecting only two components will Extended operation in environments that are
provide an adequate example of the condition of the extremely cold or hot can damage components. Valve
other components. components can be damaged by carbon buildup if the
engine is frequently started and stopped in very cold
i03101741
temperatures. Extremely hot inlet air reduces the
performance capabilities of the engine.
Overhaul Considerations Note: See this Operation and Maintenance Manual,
SMCS Code: 7595-043 Cold Weather Operation topic (Operation Section),
or see Supplement, SEBU5898, Cold Weather
Recommendations.
Severe Operation
Severe operation is the use of an engine that Cleanliness
exceeds current published standards for that engine.
Caterpillar maintains standards for the following Unless the equipment is cleaned regularly, extended
engine parameters: operation in a dirty environment and in a dusty
environment can damage components. Built up mud,
Horsepower dirt, and dust can encase components. This can
make maintenance difficult. The buildup can contain
Range of rpm corrosive chemicals. Corrosive chemicals and salt
can damage some components.
Fuel consumption
Improper Operating Procedures
Fuel quality
Extended operation at low idle
Altitude
Minimum cool down periods after high load factor
Maintenance intervals
operation
Selection of oil
Operating the engine beyond the guidelines for the
Selection of coolant engine rating
Environmental qualities Operating the engine at loads that are greater than
the rated load
Installation
Operating the engine at speeds that are greater
Refer to the standards for your engine or consult your than the rated speed
Caterpillar dealer in order to determine if your engine
is operating within the defined parameters. Use of the engine for an application that is not
approved
Severe operation can accelerate component wear.
Engines that are operating under severe conditions
may need more frequent maintenance intervals for Improper Maintenance Practices
the following reasons:
Extension of maintenance intervals
Maximum reliability
Not using recommended fuel, lubricants, and
Retention of full service life coolant/antifreeze
170 SEBU8468
Overhaul Considerations
Overhaul Information Delaying an overhaul until a breakdown increases

the chance of a catastrophic failure. This type of
An overhaul is replacing the major worn components failure requires more parts, labor, and cleanup.
of the engine. An overhaul interval is a maintenance
interval that is planned. The engine is rebuilt with Excessive wear means that fewer components will
certain rebuilt parts or new parts that replace the worn be reusable. More labor may be required for
parts.
salvage or repair of the components.
An overhaul also includes the following maintenance:
When all of the costs are considered, repair-before-
Inspection of all the parts that are visible during the failure is the least expensive alternative for most
disassembly components and engines.
It is not practical to wait until the engine exhibits
Replacement of the seals and gaskets that are
symptoms of excessive wear or failure. It is not less
removed costly to wait. A planned overhaul before failure may
be the best value for the following reasons:
Cleaning of the internal passages of the engine
and the engine block Costly unplanned downtime can be avoided.
Inspecting the alignment of the driven equipment Many original parts can be reused according to the
Most owners will save money by overhauling the guidelines for reusable parts.
engine at the intervals that are recommended in this
Operation and Maintenance Manual. Consider the The service life of the engine can be extended
graph in Illustration 111 . without the risk of a major catastrophe due to
engine failure.
Achieve the best cost/value relationship per hour
of extended service life.
Overhaul Inspection
Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order to
perform the required maintenance on the items that
are listed. Consult your Caterpillar dealer for
assistance.
To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
Illustration 111 g00745964 Index of Publications on Reusability or Salvage of
(Y) Cost
Used Parts.
(X) Time
(1) Cost of maintenance and repair that is planned
The Guidelines For Reusable Parts and Salvage
(2) Cost of maintenance and repair that is not planned Operations is part of an established Caterpillar parts
reusability program. These guidelines were
In Illustration 111 , line (1) represents the developed in order to assist Caterpillar dealers and
maintenance and repair costs for an owner that customers reduce costs by avoiding unnecessary
followed the recommendations for inspection, expenditures for new parts. If the engine parts comply
maintenance, and repair. The peaks represent with the established inspection specifications, the
overhauls. parts can be reused.
Line (2) represents the maintenance and repair costs The use of out-of-spec parts could result in
for an owner that chose to operate beyond the unscheduled downtime and/or costly repairs. The use
recommended intervals. The initial cost of the repair- of out-of-spec parts can also contribute to increased
after-failure philosophy is lower. Also, the first fuel consumption and reduction of engine efficiency.
overhaul was delayed. However, the peaks are New parts are not necessary if the old parts can be
significantly higher than the peaks for the customer reused, repaired, or salvaged. Otherwise, the old
that used the repair-before-failure philosophy. parts can be replaced or exchanged.
The higher peaks result from two key factors: Your Caterpillar dealer can provide the parts that are
needed to rebuild the engine at the least possible
cost.
SEBU8468 171
Power Factor - Check
Overhaul Programs Cracks
An economical way to obtain most of the parts that Pin holes

are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured Proper operation
parts are available at a fraction of the cost of new
parts. These parts have been rebuilt by Caterpillar Wear
and certified for use. The following components are
Inspect the prelube pump for leaks. Replace all of the
examples of the remanufactured parts:
seals if a leak is observed.
Cylinder heads Inspect the wiring for the following conditions:
Oil Pumps Damage
Turbochargers Fraying
Water pumps Ensure that the wiring is in good condition.
Consult your Caterpillar dealer for details and for a Inspect the electrical connections. Ensure that the
list of the remanufactured parts that are available. electrical connections are secure.
Your Caterpillar dealer may be offering a variety of If repair or replacement is necessary, refer to the
overhaul options. engine's Disassembly and Assembly manual. Consult
your Caterpillar dealer for assistance.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on Air Prelube Pump
preventive maintenance programs or major repair
options are available from many servicing dealers for Inspect all of the components in the air circuit for the
all Caterpillar engines. Consult your Caterpillar prelube pump. Inspect all of the air lines and
dealer in order to schedule a before failure overhaul. connections for leaks. Ensure that the components in
the air circuit are in good condition.
Overhaul Recommendation
Electric Prelube Pump
Caterpillar recommends a scheduled overhaul in
order to minimize downtime. A scheduled overhaul Inspect the brushes. Replace the brushes, if
will provide the lowest cost and the greatest value. necessary.
Schedule an overhaul with your Caterpillar dealer.
i04020194
Overhaul programs vary between dealers. To obtain
specific information about the types of overhaul
programs and services, consult your Caterpillar Radiator - Clean
dealer.
SMCS Code: 1353-070
i01216962 Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Power Factor - Check
Inspect the radiator for these items: damaged fins,
SMCS Code: 4450-535-PWR corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
The power factor of a system can be determined by a
power factor meter or by calculations. The power
factor can be calculated by dividing kW by kVA.
Power factor is expressed as a decimal.
Personal injury can result from air pressure.
i01612991
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
Prelube Pump - Inspect protective face shield and protective clothing.
SMCS Code: 1319-040
The maximum air pressure for cleaning purposes
Inspect the prelube pump for the following conditions: must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
172 SEBU8468
Rotating Rectifier - Inspect/Test
Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction of
the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between the
tubes.
Pressurized water may also be used for cleaning. The
maximum water pressure for cleaning purposes must
be less than 275 kPa (40 psi). Use pressurized water
in order to soften mud. Clean the core from both
sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water. Illustration 112 g00555106
After cleaning, start the engine and accelerate the If the failure of a rectifier is suspected, use the
engine to high idle rpm. This procedure will help in the following procedure.
removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to 1. Remove the cover from the exciter.
inspect the core for cleanliness. Repeat the cleaning,
if necessary. 2. Remove the nut that secures the rectifier to the
heat sink.
Inspect the fins for damage. Bent fins may be opened
with a comb. Inspect these items for good condition: 3. Remove the diode lead.
welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary. 4. Lift the rectifier from the heat sink.
5. Refer to Illustration 112 . Connect the ohmmeter's
i03724701
leads across the rectifier. Note the meter reading.
Rotating Rectifier - Inspect/ 6. Reverse the ohmmeter leads. Note the meter
Test reading.
SMCS Code: 4465-040; 4465-081 The ohmmeter should indicate a low resistance when
the ohmmeter leads are across the rectifier in one
direction. The ohmmeter should indicate a high
Testing A Brushless Exciter resistance when the leads are reversed.
Rotating Rectifier With An If the ohmmeter indicates a low resistance in both
Ohmmeter directions, the rectifier is shorted. A high resistance in
both directions indicates an open rectifier.
Table 46
Tools Needed Replace any faulty rectifiers with rectifiers that have
comparable operating characteristics. Include the
Part Number Part Name Quantity following information when a rectifier is being ordered
for replacement:
237-5130 Digital Multimeter 1
257-9140 Multimeter 1 Part Number of the rectifier

146-4080 Digital Multimeter 1 Model number of the exciter
(RS-232)
Type of the exciter
7X-1710 Multimeter Probe 1
Group
Serial number of the generator
SEBU8468 173
Space Heater - Test
Testing a Brushless Exciter i04322931
Rotating Rectifier With A Test Light

Space Heater - Test
SMCS Code: 4450-081-HTR
The space heater is attached to the rear bearing
bracket. The space heater is located in the exciter
end of the generator.

Test Light
If an ohmmeter is not available, a rectifier can be

tested by using a test light. A test light consists of two
standard flashlight batteries and a flashlight bulb. Illustration 114 g00610396
Refer to Illustration 113 .
Space Heater Connection Diagram
If the failure of a rectifier is suspected, use the
following procedure. A Cat generator can operate in high humidity
conditions without problems. The humidity can be as
1. Remove the cover from the exciter. high as 100% no condensing humidity. However,
problems can occur when the generator is idle and
2. Remove the nut that secures the rectifier to the the surrounding air is warmer than the generator.
heat sink. Moisture can form on the windings. Moisture will
result in poor performance or even damage to the
3. Remove the diode lead. windings. Whenever the generator is not active, the
optional space heaters should be operated.
4. Lift the rectifier from the heat sink.
An external source is required to operate the space
5. Connect the leads of the test light across the heaters. Both of the sources must be a single phase.
rectifier. Notice if the bulb is illuminated. This source can be either 115 VAC or 230 VAC.
When the external source is 50 Hz, 200 VAC must be
6. Reverse the leads of the test light across the used. Refer to Illustration 114 .
rectifier. Notice if the bulb is illuminated. See your Cat dealer for information on checking
The bulb should be illuminated when the leads of the your Cat generator.
test light are across the rectifier in one direction. The
bulb should not be illuminated when the leads are i04524988
reversed.
If the bulb is illuminated in both directions, the rectifier Standby Generator Set
is shorted. If the bulb is not illuminated in either
direction, the rectifier is open. Maintenance
Replace any faulty rectifiers with rectifiers that have Recommendations
comparable operating characteristics. Include the SMCS Code: 4450-041
following information when a rectifier is being ordered
for replacement: A standby generator set may be intermittently used.
However, the generator set is needed for operation in
Part Number of the rectifier an emergency situation. Maintenance of the standby
generator set is important for the following reasons:
Model number of the exciter
Type of the exciter

Serial number of the generator
174 SEBU8468
Starting Motor - Inspect
The generator set must always be in excellent Operation

operating condition.
To ensure proper operation, the generator set must
The generator set must be ready to work under be exercised regularly. For instructions on operating
load at any time. the generator set, see the Operation and
Maintenance Manual for the generator set control
Establishing a Preventive Maintenance Program will panel.
provide these benefits:
For these operation procedures, follow the
Maximum availability of the standby generator set instructions that are provided in this Operation and
Maintenance Manual, Operation Section: starting
Longer service life for the generator set the engine, engine operation and stopping the
engine.
Minimum of expensive repairs
Your Cat dealer can help you to establish an Record Keeping
effective Preventive Maintenance Program for your
generator set. Consult your Cat dealer for details. Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems and repairs.
Maintenance and Operation
Procedures Space Heaters
Moisture can damage generators and other electrical
equipment. Make every effort to keep the generator
The high voltage that is produced by an operating set as dry as possible.
generator set can cause severe injury or death.
Before performing any maintenance or repairs, Generators can operate without problems in humid
environments. However, problems can occur when
ensure that the generator will not start. the generator is inactive. Moisture can condense on
Place the engine control switch in the OFF po- the windings. This condition can result in poor
sition. Attach DO NOT OPERATE tags to all performance. Also, damage to the windings can
occur.
starting controls. Disconnect the batteries or dis-
able the starting system. Lock out all switchgear Use space heaters in order to help keep the windings
and automatic transfer switches that are associ- dry. When the generator is not active, ensure that the
ated with the generator. space heaters are operating. When the generator is
operating, turn OFF the space heaters.
The recommended maintenance for the generator set
is listed in this Operation and Maintenance Manual, i02618737
Maintenance Interval Schedule (Standby Generator
Sets) (Maintenance Section). Starting Motor - Inspect
Maintenance and Repair (If equipped)
SMCS Code: 1451-040; 1453-040
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the Air Starting Motor
subsequent maintenance intervals must be
performed by an authorized service technician or by If the starting motor fails, the engine may not start in
your Cat dealer. an emergency situation. A scheduled inspection of
the starting motor is recommended.
Unless other instructions are provided, perform
maintenance and repairs under the following The starting motor pinion and the flywheel ring gear
conditions: must be in good condition in order for the engine to
start properly. The engine will not start if the starting
The engine is stopped. motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the flywheel
The starting system is disabled. ring gear can be damaged because of irregular
engagement.
The generator does not pose an electrical shock
hazard.
SEBU8468 175
Stator Lead - Check
Inspect the starting motor for proper operation. Listen Loose connections
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel ring Corrosion
gear. Look for patterns of wear on the teeth. Look for
teeth that are broken or chipped. If damaged teeth Wires that are worn or frayed
are found, the starting motor pinion and the flywheel
ring gear must be replaced. Cleanliness
Removal and Installation of the

Starting Motor
Personal injury or death can result from improp-
erly checking for a leak. Refer to the Service Manual, Disassembly and
Assembly module for information on removing the
Always use a board or cardboard when checking starting motor and installing the starting motor.
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis- Consult your Caterpillar dealer for assistance and/or
sue causing serious injury, and possible death. for options on replacement of the starting motor.
If fluid is injected into your skin, it must be treated i03230840

immediately by a doctor familiar with this type of
injury.
Stator Lead - Check
SMCS Code: 4459-535
Inspect all of the components in the air circuit for the
starting motor. Inspect all of the air lines and Ensure that the stator output leads are routed out of
connections for leaks. the generator in a manner that prevents the leads
from rubbing against metal objects.
If damaged teeth are found, the air circuit for the
starting motor must be examined in order to Visually inspect the following areas for cracking and
determine the cause of the problem. physical damage:
Electric Starting Motor stator output leads
If the starting motor fails, the engine may not start in protective sleeving
an emergency situation. A scheduled inspection of
the starting motor is recommended. insulation
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine to i03725200
start properly. The engine will not start if the starting
motor pinion does not engage the flywheel ring gear. Stator Winding Temperature -
The teeth of the starting motor pinion and the flywheel
ring gear can be damaged because of irregular Test
engagement. SMCS Code: 4453-081-TA
Inspect the starting motor for proper operation. Listen Some generators are provided with optional 100 Ohm
for grinding when the engine is started. Inspect the Resistance Temperature Detectors (RTD). When the
teeth of the starting motor pinion and the flywheel ring temperature of the stator winding is suspected to be
gear. Look for patterns of wear on the teeth. Look for high, measure the temperature. If the generator is
teeth that are broken or chipped. If damaged teeth furnished with Resistance Temperature Detectors, the
are found, the starting motor pinion and the flywheel detectors are installed in the slots of the main
ring gear must be replaced. armature (stator). The detectors are used with
equipment that is available from the factory. This
Problems with the electric starting motor can be equipment is used in order to measure the main
caused by the following conditions: malfunction of the armature's winding temperature.
solenoid and malfunction of the electric starting
system.
Inspect the electrical system for the following
conditions:
176 SEBU8468
Turbocharger - Inspect
i01539769 1. Remove the exhaust outlet piping and remove the

air inlet piping from the turbocharger. Visually
Turbocharger - Inspect inspect the piping for the presence of oil. Clean the
SMCS Code: 1052-040 interior of the pipes in order to prevent dirt from
entering during reassembly.
Periodic inspection and cleaning is recommended for
the turbocharger compressor housing (inlet side). Any 2. Turn the compressor wheel and the turbine wheel
fumes from the crankcase are filtered through the air by hand. The assembly should turn freely. Inspect
inlet system. Therefore, by-products from oil and from the compressor wheel and the turbine wheel for
combustion can collect in the turbocharger
contact with the turbocharger housing. There
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black should not be any visible signs of contact between
smoke and overall loss of engine efficiency. the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
If the turbocharger fails during engine operation, contact between the rotating turbine wheel or the
damage to the turbocharger compressor wheel and/ compressor wheel and the turbocharger housing,
or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional the turbocharger must be reconditioned.
damage to the pistons, the valves, and the cylinder
head. 3. Check the compressor wheel for cleanliness. If
only the blade side of the wheel is dirty, dirt and/or
NOTICE moisture is passing through the air filtering system.
Turbocharger bearing failures can cause large quanti- If oil is found only on the back side of the wheel,
ties of oil to enter the air inlet and exhaust systems. there is a possibility of a failed turbocharger oil
Loss of engine lubricant can result in serious engine seal.
damage.
The presence of oil may be the result of extended
Minor leakage of a turbocharger housing under ex- engine operation at low idle. The presence of oil
tended low idle operation should not cause problems may also be the result of a restriction of the line for
as long as a turbocharger bearing failure has not the inlet air (plugged air filters), which causes the
occurred. turbocharger to slobber.
When a turbocharger bearing failure is accompanied 4. Use a dial indicator to check the end clearance on
by a significant engine performance loss (exhaust the shaft. If the measured end play is greater than
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or the Service Manual specifications, the
replaced. turbocharger should be repaired or replaced. An
end play measurement that is less than the
minimum Service Manual specifications could
An inspection of the turbocharger can minimize indicate carbon buildup on the turbine wheel. The
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential turbocharger should be disassembled for cleaning
damage to other engine parts. and for inspection if the measured end play is less
than the minimum Service Manual specifications.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must be 5. Inspect the bore of the turbine housing for
balanced due to high rpm. Severe Service corrosion.
Applications can accelerate component wear. Severe
Service Applications require more frequent 6. Clean the turbocharger housing with standard shop
inspections of the cartridge. solvents and a soft bristle brush.
Removal and Installation 7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
i03291822
Refer to the Service Manual for this engine for the
procedure and specifications.
Varistor - Check
Cleaning and Inspecting SMCS Code: 4466-535
The varistor must be checked at regular intervals.
Refer to Systems Operation/Testing and Adjusting,
KENR5284, Varistor - Test for instructions.
SEBU8468 177
Varistor - Inspect
i03291802
NOTICE
For any type of leak (coolant, lube, or fuel) clean up
Varistor - Inspect the fluid. If leaking is observed, find the source and
SMCS Code: 4466-040 correct the leak. If leaking is suspected, check the flu-
id levels more often than recommended until the leak
The varistor must be visually inspected at regular is found or fixed, or until the suspicion of a leak is
intervals. For generator sets with 1400 or with 1600 proved to be unwarranted.
frames, discoloration of the varistor indicates that
replacement of the varistor is necessary. For
generator sets with 1800 frames, physical signs of
failure indicate that replacement of the varistor is NOTICE
necessary. Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
i01189996
Voltage and Frequency - Check Ensure that cooling lines are properly clamped.
SMCS Code: 4450-535-EL Check for leaks. Check the condition of all pipes.
Check for proper voltage and frequency setting. Inspect the water pump for coolant leaks.
Check for stability.
Note: The water pump seal is lubricated by coolant in
Refer to the generator set Serial Plate for correct the cooling system. It is normal for a small amount of
voltage and frequency. leakage to occur as the engine cools down and the
parts contract.
i02591373
Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
Walk-Around Inspection water pump and the installation of water pump and/or
seals, refer to the Service Manual for the engine or
SMCS Code: 1000-040 consult your Caterpillar dealer.
Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil
Personal injury or death can result from improper pan, the oil filters and the valve cover.
troubleshooting and repair procedures.
Inspect the Closed Crankcase Ventilation (CCV)
The following troubleshooting and repair proce- filter, if equipped. If the restriction indicator is
dures should only be performed by qualified per- visible, service the CCV.
Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Inspect the Engine for Leaks and
Inspect the piping for the air inlet system and the
for Loose Connections elbows for cracks and for loose clamps.
A walk-around inspection should only take a few Inspect the alternator belt and the accessory drive
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided. belts for cracks, breaks or other damage.
For maximum engine service life, make a thorough Belts for multiple groove pulleys must be replaced as
inspection of the engine compartment before starting matched sets. If only one belt is replaced, the belt will
the engine. Look for items such as oil leaks or coolant carry more load than the belts that are not replaced.
leaks, loose bolts, worn belts, loose connections and The older belts are stretched. The additional load on
trash buildup. Make repairs, as needed: the new belt could cause the belt to break.
The guards must be in the proper place. Repair

damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system
contamination.
178 SEBU8468
Water Pump - Inspect
Drain the water and the sediment from fuel tanks Cracking Cracking of insulation may result from
on a daily basis in order to ensure that only clean mechanical stress. The structure that is used to brace
fuel enters the fuel system. the stator winding will become loose if the problem is
not corrected. Further mechanical damage or
Inspect the wiring and the wiring harnesses for electrical damage may also result.
loose connections and for worn wires or frayed
wires. Erosion Erosion can be caused when foreign
substances rub against the insulation that is on the
Inspect the ground strap for a good connection surface of the coil .
and for good condition.
Inspect the engine-to-frame ground strap for a

i03543200
good connection and for good condition.
Disconnect any battery chargers that are not Water Pump - Inspect
protected against the current drain of the starting SMCS Code: 1361-040
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is A failed water pump might cause severe engine
equipped with a maintenance free battery. overheating problems that could result in the following
conditions:
Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauges that Cracks in the cylinder head
can not be calibrated.
A piston seizure
Inspect the Generator Other potential damage to the engine
Refer to Safety Section, Generator Isolating for
Maintenance for information regarding the procedure A failed water pump might cause severe engine
to safely isolate the generator. overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
A visual inspection should be initially directed at the damage to the engine.
areas that are most prone to damage and
deterioration. The most prone areas to damage and Visually inspect the water pump for leaks. If leaking of
deterioration are listed below: the water pump seals is observed, replace all of the
water pump seals. Refer to two articles in the
Ground insulation Ground insulation is insulation Disassembly and Assembly Manual, Water Pump -
that is intended to isolate components that are Disassemble and Water Pump - Assemble for the
carrying current from components that are not disassembly and assembly procedure. If it is
carrying current. necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
Support insulation Support insulation is usually Water Pump - Remove and Water Pump - Install.
made from one of the following items: a compressed
lamination of fibrous materials, polyester, or felt pads Inspect the water pump for wear, cracks, pin holes
that have been impregnated with various types of and proper operation. Refer to the Parts Manual for
bonding agents. the correct part numbers for your engine or consult
your Caterpillar dealer if repair is needed or
replacement is needed.
There are many different types of damage that can
occur in these areas. Several of the different types of
damage are listed below:
Thermal aging Thermal aging can cause the
degradation of insulation or the deterioration of
insulation. An examination of the coils may reveal that
the insulation has expanded into the ventilation ducts.
This is the result of a loss of bond which will cause
the insulation material to separate. The insulation
material could also separate from the conductors on
the windings.
Abrasion The surfaces of coils and the surfaces of

connectors may be damaged by abrasion. These
surfaces may also be damaged by contamination
from other sources. An example of these sources
would be chemicals or abrasive substances.
SEBU8468 179
Warranty Section
Warranty Information
Warranty Section
i04342956
SMCS Code: 1000
Engine Protection Plans

Extended Warranties and Service
Contracts
A wide variety of protection plans are available for Cat
Engines . Consult your Cat dealer for detailed
information on the specific programs and coverages
that are available.
Consult your Cat dealer for information on a plan that
is tailored in order to fit your requirements.
i01237445
Emissions Warranty
Information
SMCS Code: 1000
This engine may be certified to comply with exhaust
emission standards and the engine may be covered
by an Emissions Warranty. A detailed explanation of
the Emissions Warranty that is applicable to
emissions certified engines is found in Supplement,
SMBU6981, Federal Emissions Control Warranty
Information For U.S. , Canada , and California .
Consult your authorized Caterpillar dealer in order to
determine if your engine is emissions certified and if
the engine is subject to an Emissions Warranty.
180 SEBU8468
Reference Information Section
Engine Rating Conditions
Reference Information
Section
Engine Ratings
i00727327
Engine Rating Conditions

SMCS Code: 1000
All engine ratings are in compliance with the following
standard ambient air conditions of SAE J1349:
99 kPa (29.3 inches of Hg)
30 percent relative humidity
A temperature of 25 C (77 F)
Ratings relate to the standard conditions of ISO8665,
of ISO3046/1, of DIN6271, and of BS5514.
The engine ratings are based on the following fuel
specifications:
Low heat value (LHV) of the fuel of 42 780 kJ/kg
(18,390 Btu/lb) at 29 C (84 F)
Gravity (API) of 35 degrees at 15 C (60 F)

Specific gravity of .849 at 15 C (60 F)
Density of 850 kg/m3 (7.085 lb/US gal)

The engine ratings are gross output ratings.
Gross Output Ratings The total output capability
of the engine that is equipped with standard
accessories.
Standard accessories include the following

components:
Oil pumps
Fuel pumps
Water pumps
Subtract the power that is required to drive auxiliary
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).
SEBU8468 181
Engine Ratings
Engine Rating Definitions
i02693176
Engine Rating Definitions

SMCS Code: 1000
Table 47
Power Rating
Emergency Standby Power Standby(1) Prime Continuous

(ESP)(1)
Average power output 70% of ESP rating 70% of standby power 70% of prime power rating 70% to 100% of continuous
power rating
Load(2) Varying Varying Varying Non-varying
Typical hours per year 50 200 Unlimited Unlimited
Maximum expected usage 200 500 n/a n/a

(hours per year)
Typical peak demand n/a n/a 100% of prime rated ekW 100% of continuous rated
with 10% overload capabil- ekW for 100% of operating
ity for emergency use for a hours.
maximum of 1 hour in 12.
The generator set cannot
be operated at overload
for more than 25 hours per
year.
Typical application Building service standby Standby Industrial, pumping, con- Base load, utility, or
struction, rental generator cogeneration
set, or cogeneration
(1) Power is available for the duration of an emergency outage.
(2) The typical load factor is the sum of the loads a generator set experiences while it is running under load divided by the number of hours the
generator set operates under those loads. Extended idling time does not enter into the calculation for the load factor. Time that the generator
set is not operating does not enter into the calculation for the load factor.
Operating units above these rating definitions results

in a shorter life before an overhaul.
182 SEBU8468
Customer Service
Customer Assistance
Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i05133089
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000; 4450 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
If a problem arises concerning the operation or Caterpillar Asia Pte. Ltd.
service of an engine, the problem will be managed by 7 Tractor Road
the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Cat dealers. If you have a problem that has Fax: 65-662-8302
not been handled to your complete satisfaction, follow
these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
without additional assistance, use the phone Hong Kong
number below to talk with a Field Service Phone: 852-2848-0333
Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Caterpillar Japan Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Electric Power North America Australia and New Zealand
Attn: Product Support Manager Caterpillar of Australia Ltd.
AC 6109 1 Caterpillar Drive
Mossville, Illinois 61552 Private Mail Bag 4
Keep in mind: probably, your problem will Tullamarine, Victoria 3043
ultimately be solved at the dealership, using the Australia
dealership facilities, equipment, and personnel. Phone: 03-9953-9333
Therefore, follow the steps in sequence when a Fax: 03-9335-3366
problem is experienced.
Outside of USA and of Canada

If a problem arises outside of USA and outside
Canada , and if the problem cannot be resolved at the
dealer level, consult the appropriate Caterpillar
office.
Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
SEBU8468 183
Customer Service
Ordering Replacement Parts
i01028392
Ordering Replacement Parts

SMCS Code: 4450; 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, physi-
cal dimensions, type, strength and material.
Failure to heed this warning can lead to premature
failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
Part number
Part name
Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
184 SEBU8468
Reference Materials
Maintenance Records
Reference Materials
i00912149
Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
Determine operating costs.

Establish maintenance schedules for other
engines that are operated in the same
environment.
Show compliance with the required maintenance
practices and maintenance intervals.
Maintenance records can be used for a variety of
other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.
Records should be kept for the following items:
Fuel Consumption A record of fuel consumption is
essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
Service Hours A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents These items should be easy to obtain,
and these items should be kept in the engine history
file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:
Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
Dealer work orders and itemized bills

Owner's repair costs
Owner's receipts
Maintenance log
SEBU8468 185
Reference Materials
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 48
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
186 SEBU8468
Reference Materials
Reference Material
i04564439 SOS Services

Reference Material Data Sheet, NEHP6013, SOS Fluids Analysis
Products
SMCS Code: 1000; 4450
Special Publication, PEHJ0191, Cat SOS Fluid
The following publications are available for order Analysis
through your Cat dealer.
Special Publication, PEHP7076, Understanding
Lubricants SOS Services Tests
Data Sheet, PEHJ0021, Cat DEO (SAE 10W-30
and SAE 15W-40) (Worldwide - except North
America , Egypt , and Saudi Arabia )
Data Sheet, PEHJ0059, Cat DEO (SAE 10W-30
and SAE 15W-40) (North America : Canada ,
Mexico , and United States )
Special Publication, PEHP6001, How To Take A
Good Oil Sample
Greases
Data Sheet, NEHP6010, Cat Ultra 5Moly Grease
(NLGI grades 1 and 2)
Data Sheet, NEHP6011, Cat Arctic Platinum
Grease (NLGI grade 0)
Data Sheet, NEHP6012, Cat Desert Gold Grease
(NLGI grade 2)
Data Sheet, NEHP6015, Cat High Speed Ball

Bearing Grease (NLGI grade 2)
Special Publication, PEGJ0035, Grease Selection

Guide
Data Sheet, PEHP0002, Cat Advanced 3Moly
Data Sheet, PEHJ0088, Cat Multipurpose
Coolants
Data Sheet, PEHJ0067, Cat ELC (Extended Life
Coolant) (Worldwide)
Data Sheet, PEHP9554, Cat DEAC (Diesel
Engine Antifreeze/Coolant) (Concentrate)
Special Publication, PMEP5027, Label - ELC
Radiator Label
Special Publication, SEBD0518, Knowing Your

Cooling System
SEBU8468 187
Reference Materials
Reference Material
Miscellaneous Special Instruction, REHS4892, Generator

Bearing Service
Special Publication, NENG2500, Dealer Service
Tool Catalog Additional Reference Material
Special Publication, PECP9067, One Safe The Engine Fluids Data Book can be obtained from
Source the following locations: local technological society,
local library and local college. If necessary, consult
Special Publication, PELJ0179, Caterpillar EMA at the following address:
Engine Crankcase Fluid-1 Specifications (Cat
ECF-1) (All international markets) Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
Service Manual, RENR5050, 3500B Generator Chicago, Illinois, USA 60602
Set Engines E-mail: ema@enginemanufacturers.org
(312) 827-8700
Systems Operation/Troubleshooting/Testing and Facsimile: (312) 827-8737
Adjusting, RENR7902, Electronic Modular Control
Panel 3 (EMCP3) The Society of Automotive Engineers (SAE)
Specifications can be found in your SAE handbook.
Specifications, Systems Operation, Testing and This publication can also be obtained from the
Adjusting, RENR7941, Caterpillar Digital Voltage following locations: local technological society, local
Regulator (CDVR) library and local college. If necessary, consult SAE at
the following address:
Special Publication, SEBF8029, Index to
Guidelines for Reusable Parts and Salvage SAE International
Operations 400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Special Publication, SEBF8062, Guideline for Telephone (724) 776-4841
Reusable Parts - Cleaning and Inspection of Air
Filters The American Petroleum Institute Publication No.
1509 can be obtained from the following locations:
Special Publication, SEBU5898, Cold Weather local technological society, local library and local
college. If necessary, consult API at the following
Recommendations
address:
Special Publication, SEBU7050, SR4 and SR4B
American Petroleum Institute
Generators and Control Panels
1220 L St. N.W.
Special Instruction, SEHS7259, Alignment of Washington, DC, USA 20005
Single Bearing Generators Telephone (202) 682-8000
Special Instruction, SEHS7332, Do Not Operate The International Organization for Standardization
(ISO) offers information and customer service
Tag regarding international standards and standardizing
Special Instruction, SEHS7633, Battery Test activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
Procedure national standards, regional standards, regulations,
certification and related activities. Consult the
Special Publication, SEHS7654, Alignment - member of ISO in your country.
General Instructions
International Organization for Standardization
Special Instruction, SEHS8622, Using the FT- (ISO)
1984 Air-To-Air Aftercooler Leak Test Group 1, rue de Varemb
Case postale 56
Special Instruction, SEHS9031, Storage
CH-1211 Genve 20
Procedure for Caterpillar Products
Switzerland
Special Instruction, SEHS9124, Cleaning and Telephone +41 22 749 01 11
Drying of Electric Set Generators Facsimile +41 22 733 34 30
E-mail central@iso.ch
Specifications, SENR3130, Torque Web site http://www.iso.ch
Specifications
European classifications are established by the
Special Instruction, SMHS7001, Assembly of Fan Counseil International Des Machines a Combustion
Drive Pulley Assemblies (CIMAC) (International Council on Combustion
Engines) .
188 SEBU8468
Reference Materials
Decommissioning and Disposal
CIMAC Central Secretariat

Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone +49 69 6603 1567
Facsimile +49 69 6603 1566
Emissions Warranty
This engine may be Certified and this engine may be
covered by an Emissions Warranty. The engine is
certified if the engine has a special label that states
that the engine is certified. A Caterpillar dealer can
also inform you if the engine is Certified.
i03696960
Decommissioning and
Disposal
SMCS Code: 1000
When the generator set is removed from service,
local regulations for the generator set
decommissioning will vary. Disposal of the generator
set will vary with local regulations. Consult the
nearest Caterpillar dealer for additional information.
SEBU8468 189
Reference Materials
Symbols
i02342531
Symbols
SMCS Code: 1000; 4450; 4480; 4490

The control panel and modules utilize International Graphic Symbols to identify functions.
A typical list of the symbols that are used is shown above.
i04046112
Bridge A bridge is a circuit that is used to measure

Glossary small quantities of current, voltage, or resistance.
SMCS Code: 4450
Actuate Actuation relates to putting something in Bridge Rectifier A bridge rectifier is a circuit that is
motion. used to change alternating current (AC) to direct
current (DC).
Alternating Current (AC) Alternating Current is an

electric current that reverses direction at regular Buildup A buildup is a gradual increase in voltage.
intervals (50 times per second in 50 Hz or 60 times
per second in 60 Hz). Cathode A cathode is the negative end of a diode
or a cathode is the negative end of a rectifier.
Anode An anode is the positive end of a diode or
an anode is the positive end of a rectifier. Capacitance Capacitance is the ability to store an
electrical charge.
Blocking Rectifier A blocking rectifier permits
direct current flow in only one direction. Capacitor A capacitor is a device that will store an
electrical charge.
Bolted A bolted device uses a bolt to hold two or
more parts together.
190 SEBU8468
Reference Materials
Glossary
Circuit Breaker A circuit breaker is an automatic Electrostatic Charge Electrostatic charge is

switch that is used to open a circuit. electricity that is caused by induced voltage and
stored charge.
Circulating Current Circulating current is the flow
of current between two or more generators that are Exciter An exciter supplies direct current (DC) to
working in parallel. Circulating current is also the flow the field windings of the generator.
of current between two or more generators that are
parallel with a utility line.
Field A field is a magnetic line of force that
surrounds a conductor. This force is caused by
Conduct Conducting relates to allowing the flow of current flow in the conductor.
current.
Field Windings Field windings are many turns of
Constant Voltage Regulation Constant Voltage wire that are wrapped around an iron core. When
Regulation is one of the two methods of voltage direct current (DC) flows through the field windings, a
regulation. In order to maintain the line voltage, magnetic field is produced. This magnetic field is
Constant voltage regulators allow the field to be comparable to the magnetic field of a bar magnet.
forced to the saturation point. This allows the engine
to be overloaded. On large block load applications,
the engine may not recover. Flashing Flashing is a process of putting direct
current from an external source into the field
windings. This process causes the generator to
Continuity Continuity provides a path for current produce an output voltage.
flow.
Flux Flux is magnetic lines of force.
Control A control is a device that controls another
device. A control is also a circuit that controls a
device. Frequency Frequency is the number of cycles that
are completed in a one second period. The unit of
frequency is the Hertz (Hz). 1 Hz is equal to 1 cycle
Cross Current Compensation Cross current per second.
compensation is a method that is used for reactive
power equalization.
Full-Wave Rectifier A full-wave rectifier changes
the positive phase and the negative phase of
Current Transformer (CT) A current transformer is alternating current to direct current.
used to step down higher line current.
Gain Gain relates to the ratio of input magnitude to
Direct Current (DC) Direct current is current flow output magnitude.
that moves in only one direction in a given circuit.
Gate A gate is an electronic part of a controlled
Damping Damping refers to decreasing the rectifier (thyristor).
amplitude of a signal.
Generate The production of electricity.
De-energized A de-energized input refers to
stopping the current that is going to a component.
Grounded A device is grounded by making a
connection to ground. A device could also be
Distribution Winding Distribution windings go from grounded by making a connection to a component
one end of the core to the other end of the core. that is connected to ground.
These windings are arranged in groups that are
located in several slots.
Hertz (Hz) Hertz is the unit of measurement for
frequency. 1 Hz is equal to 1 cycle per second.
Droop Droop refers to a decrease.
Humidity Humidity is the water content that is

Excitation Excitation is controlled direct current present in the air.
(DC) that is used to make a magnetic field.
Impedance Impedance is the resistance to

Energized An energized input refers to activating a alternating current.
device.
SEBU8468 191
Reference Materials
Glossary
Impulse Modulation Impulse modulation changes Lock In Lock in occurs when a contact closes in
the following characteristics of a wave: amplitude, order to keep a device in an energized state.
frequency and phase. This is accomplished by
impressing one wave on another wave that has
constant properties. Lock Out Lockout occurs when a contact opens in
order to keep a device in a de-energized state.
Induce Induce refers to the transfer of power from

one device to another device. The transfer is done via Magnetic A magnetic device is a device that has
a magnetic field or via an electric field. the characteristics of a magnet.
Interference Interference is an unwanted mixture of Magnification Magnification refers to the

electrical signals. Interference is usually associated enlargement of an item.
with electrical noise.
Module A module is an assembly of electronic
Internally Excited (IE) Is an excitation system components and electronic circuits.
based on two auxiliary windings integrated into the
main stator winding suppling power to the voltage Moisture Moisture is the presence of water.
regulator only.
Open Crankcase Ventilation (OCV) A method to

Instrumentation Instrumentation is a group of remove oil mist from engine fumes, and return the
instruments that are used for measuring a system liquid oil back to the pan. OCV uses a specific type of
function. filter
Insulated An insulated device is a device that is Oscillation Oscillation is the flow of electricity that
covered with a nonconductive material.
periodically changes direction and/or magnitude.
kVA This is the abbreviation for Kilovolt Amperes.

kVA is a term that is used when electrical devices are Permanent Magnet (PM) A permanent magnet
rated. In order to calculate the kVA rating of a device, supplies the initial magnetism that is required to start
multiply the rated output (amperes) by the rated a PMPE generator.
operating voltage.
Permanent magnet pilot excited (PMPE) A PMPE
KVAR Kilovolt Amperes Reactive is abbreviated as generator receives power for the voltage regulator
KVAR. KVAR is associated with the reactive power from a pilot exciter. A PMPE generator consists of a
that flows in a power system. Reactive power does permanent magnet and a pilot exciter.
not load the generator set's engine. Reactive power
will cause thermal loss in the generator. PF Regulation PF Regulation is one of the two
ways to regulate the reactive power output. PF
KVAR Regulation KVAR Regulation is one of the regulation is used when the generator is connected in
two methods that are used to regulate the reactive parallel with an infinite bus (utility) and it is not
power output. Regardless of the generator's real possible to control the system voltage.
power output, the voltage regulator causes the
generator to produce a constant value of KVAR. In Phase Winding A phase winding is a group of
this case, the power factor of the generator will generator stator coils. Electric power for one phase of
change when the real power output changes. KVAR the load is induced in the phase winding.
regulation is used when the generator is connected in
parallel with an infinite bus (utility) and it is not
possible to change the system voltage. Polarity Polarity is the positive characteristics or
the negative characteristics of two poles.
Kilowatts (kW) Kilowatt is the electrical rating of
the generator. 1 kW equals 1000 W. Actual power is Power Factor (PF) Power factor is the ratio of
measured in kilowatts. apparent power (kVA) to total power (kW). The power
factor represents the portion of the current that is
doing useful work. Power factor is expressed as a
Lead A lead is a wire. decimal number between 0 and 1.
Line Voltage Line voltage is the output voltage of Pulsating Pulsating relates to the characteristics of
the generator that is measured between the current that are like mechanical vibration.
generator leads (phases).
192 SEBU8468
Reference Materials
Glossary
Radio Suppression Radio suppression reduces

the amplitude of radio frequency interference.
SE An SE generator is a self-excited generator. An
SE generator uses a small part of the generator
Reactive Droop Compensation Reactive Droop output to provide excitation current back to the
Compensation is one of the two methods that are generator. An SE generator uses residual magnetic
used for reactive power equalization. In reactive field for start-up.
droop compensation, the voltage regulator causes an
individual generator output to change in proportion to
the reactive current. This reactive current is Semiconductor A semiconductor is a component
measured with a current transformer. such as one of the following components: a transistor,
a diode and a thyristor. Semiconductors have
electrical characteristics that are between a
Reactive Power Reactive power flows back and conductor and insulation.
forth between the inductive windings of the generator.
These windings are part of the electrical load. The
reactive power does not perform any useful work in Series Boost A series boost is an attachment that
the electrical load. The reactive power only applies allows generator output to continue for a short time
load to the generator. This limits the capacity of the during a line failure, which allows the circuit breaker
generator . to trip in sequence.
Reciprocating Reciprocating motion is motion that Short A short is an undesired electrical connection
first moves in a straight line in one direction. The that exists between two or more components.
direction of this motion then varies by 180 degrees. Shutdown A shutdown occurs when the engine is
Rectifier A rectifier is a diode circuit that converts stopped. This shutdown can occur manually or this
alternating current (AC) to direct current (DC). shutdown can occur automatically.
Regenerative Power Regenerative power works Simultaneous A simultaneous occurrence refers to

against primary power. two actions that happen at the same time.
Reset A reset returns a switch to a ready condition. Solid-State A solid-state component is an electrical
In addition, a reset returns a circuit to a ready component that has no moving parts.
condition.
Stator A stator is the windings of a generator that
Residual Magnetism Residual magnetism is a do not rotate.
small amount of magnetism that is remaining in a
device after excitation is removed. Surge A surge is a sudden increase in voltage or
current.
RFA An RFA is a rotating field assembly.
Tap A tap is a connection at the midpoint of a
Rotating Rectifier A rotating rectifier is mounted to circuit. From this tap, power is taken from the circuit.
a plate on a generator shaft. This plate then rotates
with the generator shaft. Transfer A transfer refers to moving something
from one point to another point. A transfer also refers
to converting something from one state to another
Rotor A rotor is the rotating windings of a
state.
generator.
Transient Peak Voltage A transient peak voltage is

Saturable Reactor A saturable reactor has
characteristics that are like a valve. As the load a high voltage condition of limited duration.
changes, a valve opens in order to give more current
to the output or a valve closes in order to give less Turn-on When a device is turned on, the device is
current to the output. activated or the device is started.
Saturated A device has been saturated when the Varistor A varistor is a device that loses resistance
device has been magnetized in excess. When as voltage increases.
saturation occurs, a large increase in current results
in a small increase in magnetic force.
Voltage Droop Resistor A voltage droop resistor is
a variable resistor. This resistor is used to control the
SCR An SCR is a silicon controlled rectifier. An change of voltage. The change of voltage can occur
SCR is a semiconductor.
SEBU8468 193
Reference Materials
Glossary
when a generator is paralleled with another

generator. The change of voltage can also occur
when the generator is paralleled with a utility.
Voltage Level Rheostat A voltage level rheostat

gives a range of control that is used when the voltage
output level is adjusted.
Voltage Regulator A voltage regulator is a circuit

that senses the output voltage of the generator . The
field coil current is automatically adjusted in order to
maintain the desired output.
Voltage Spike A voltage spike is a brief high

voltage.
Volts per Hertz Regulation Under block loading

conditions, the Volts per Hertz Regulation provides
fast recovery. This regulation maintains close voltage
control over the normal load range. This regulation
also produces a rapid response of the generator set.
This control is maintained by matching the generator
output to the engine performance.
Windings Windings are layers of wire on a core.
Wiring Wiring relates to the wires of a circuit.

Wound Wound refers to being circled.
194 SEBU8468
Index Section
Index
A C
After Starting Engine........................................ 64 Circuit Breakers - Reset..................................112
Engaging the Driven Equipment .................. 64 Cold Weather Operation.................................. 76
Warm-up ...................................................... 64 Cold Weather Starting ..................................... 62
After Stopping Engine...................................... 80 Starting With the Starting Aid Switch ........... 62
Aftercooler Core - Inspect/Clean/Test............ 103 Configuration Parameters................................ 52
Air Inlet Filter - Inspect/Clean/Test................. 103 Air Shutoff .................................................... 58
Air Shutoff - Test (Engines That Are Caterpillar Monitoring System..................... 53
Equipped with ADEM II or ADEM III Cold Cylinder Cutout.................................... 58
Engine Control Modules (If equipped)) ........ 104 Data Link Features....................................... 57
Engines That Are Equipped with ADEM II Default Settings for the Caterpillar Monitoring
Engine Control Modules........................... 104 System ....................................................... 53
Engines That Are Equipped with ADEM III Display of Engine Performance ................... 59
Engine Control Modules........................... 105 Ether Injection System ................................. 58
Air Shutoff Damper - Remove/Check (if Control Panel - Inspect/Test............................113
equipped)..................................................... 106 Annunciator Panel.......................................113
Air Starting Motor Lubricator Bowl - Clean Electronic Modular Control Panel 4.2 (EMCP
(If Equipped) ................................................ 107 4.2) ............................................................113
Air Starting Motor Lubricator Oil Level - Switch Panel ...............................................113
Check (If Equipped) ..................................... 108 Coolant (DEAC) - Change ..............................113
Adjust the Lubricator.................................. 108 Clean the Cooling System ..........................114
Air Tank Moisture and Sediment - Drain ........ 108 Cleaning a Cooling System that has Heavy
Alarms and Shutoffs ........................................ 37 Deposits or Plugging.................................114
Alternator - Inspect ........................................ 109 Drain the Cooling System ...........................113
Fill the Cooling System ...............................115
Coolant (ELC) - Change .................................115
B Clean the Cooling System ..........................116
Battery - Recycle ........................................... 109 Drain the Cooling System ...........................115
Battery - Replace........................................... 109 Fill the Cooling System ...............................116
Battery Charger - Check .................................110 Coolant Extender (ELC) - Add ........................116
Checking After Stopping .............................110 Coolant Level - Check ....................................117
Checking Before Start-Up...........................110 Coolant Sample (Level 1) - Obtain .................118
Battery Disconnect Switch (If Equipped) ......... 37 Sampling Conditions...................................118
Battery Electrolyte Level - Check ...................110 Timing of the Sampling ...............................118
Battery or Battery Cable - Disconnect ............ 111 Coolant Sample (Level 2) - Obtain .................119
Before Starting Engine ...............................18, 61 Coolant Temperature Regulator - Replace .....119
Walk-Around Inspection............................... 61 Cooling System Supplemental Coolant
Belts - Inspect/Adjust/Replace........................ 111 Additive (SCA) - Test/Add ............................ 120
Adjusting the Alternator Belt ....................... 111 Cooling Systems that Use Conventional
Adjusting the Fan Drive Belt .......................112 Coolant..................................................... 120
Inspection....................................................111 Cooling Systems that Use Water and SCA
Replacement...............................................112 ................................................................. 121
Burn Prevention............................................... 14 Crankshaft Vibration Damper - Inspect.......... 121
Batteries....................................................... 14 Dampers With Sampling Ports................... 122
Coolant......................................................... 14 Dampers Without Sampling Ports.............. 122
Oils............................................................... 14 Removal and Installation............................ 122
Crushing Prevention and Cutting Prevention .. 16
Customer Assistance..................................... 182
SEBU8468 195
Index Section
Outside of USA and of Canada ................. 182 Engine Crankcase Breather - Clean/
USA and Canada ...................................... 182 Replace........................................................ 129
Customer Service .......................................... 182 Engine Diagnostics.......................................... 52
Engine Mounts - Inspect................................ 130
Engine Oil and Filter - Change ...................... 132
D Drain the Oil ............................................... 132
Declaration of Conformity ...........................29, 31 Fill the Crankcase ...................................... 135
Decommissioning and Disposal .................... 188 Inspect the Used Oil Filter Elements.......... 135
Replace the Oil Filter Elements.................. 133
Engine Oil Level - Check ............................... 130
E Engine Oil Sample - Obtain ........................... 131
Electrical Connections - Check...................... 122 Obtain the Sample and the Analysis.......... 131
Electrical System ............................................. 19 Engine Operation............................................. 66
Grounding Practices .................................... 19 Operating the Engine and the Driven
Electronic Modular Control Panel 3 (EMCP Equipment.................................................. 66
3).................................................................... 38 Partial Load Operation................................. 66
Annunciator Module..................................... 41 Engine Protective Devices - Check ............... 136
Control Panel ............................................... 40 Visual Inspection........................................ 136
Electronic Control Module (Generator Set).. 38 Engine Rating Conditions.............................. 180
Electronic Modular Control Panel 4 (EMCP Engine Rating Definitions .............................. 181
4) (EMCP 4.1/4.2 If equipped) ....................... 42 Engine Ratings .............................................. 180
Annunciator Module..................................... 44 Engine Speed/Timing Sensor - Clean/
Control Panel ............................................... 44 Inspect ......................................................... 136
Electronic Control Module (Generator Set).. 42 Engine Starting ...........................................18, 61
Electronic Modular Control Panel 4 (EMCP Ether ............................................................ 18
4) (EMCP 4.3/4.4).......................................... 46 Engine Stopping .........................................19, 78
Annunciator Module..................................... 49 Engine Valve Lash - Check............................ 136
Control Panel ............................................... 48 Engine Valve Lash ..................................... 137
ECM Front Panel Components.................... 47 Valve Bridge............................................... 137
General Information ..................................... 47
Emergency Stopping ....................................... 78
F
Air Shutoffs (If Equipped)............................. 78
Emergency Stop Button............................... 78 Fan Drive Bearing - Lubricate........................ 137
Emissions Certification Film ............................ 32 Features and Controls ..................................... 37
Emissions Warranty Information.................... 179 Fire Prevention and Explosion Prevention ...... 14
Engine - Clean ............................................... 122 Ether ............................................................ 16
Engine Air Cleaner Element (Dual Element) Fire Extinguisher.......................................... 16
- Inspect/Clean/Replace .............................. 123 Lines, Tubes, and Hoses ............................. 16
Cleaning the Primary Air Cleaner Elements Fluid Recommendations.................................. 81
................................................................. 124 Cooling System............................................ 86
Servicing the Air Cleaner Elements ........... 123 Diesel Engine Oil ......................................... 81
Engine Air Cleaner Element (Single Fuel .............................................................. 83
Element) - Inspect/Clean/Replace ............... 125 Greases ....................................................... 89
Cleaning the Air Cleaner Elements............ 126 Foreword............................................................ 4
Servicing the Air Cleaner Elements ........... 126 California Proposition 65 Warning ................. 4
Engine Air Cleaner Service Indicator - Literature Information..................................... 4
Inspect ......................................................... 128 Maintenance .................................................. 4
Test the Service Indicator........................... 128 Maintenance Intervals.................................... 4
Engine Air Precleaner - Check/Clean............ 129 Operation ....................................................... 4
Overhaul ........................................................ 4
Safety............................................................. 4
196 SEBU8468
Index Section
Fuel and the Effect from Cold Weather............ 76 Infrared Thermometers .............................. 150
Fuel Conservation Practices............................ 66 Resistive Temperature Detectors (RTDs) .. 150
Fuel Injector - Inspect/Adjust ......................... 137 Generator Isolating for Maintenance ............... 19
Fuel Related Components in Cold Weather .... 76 Generator Lead - Check ................................ 150
Fuel Filters ................................................... 76 Generator Lead Connections .......................... 72
Fuel Heaters ................................................ 77 Grounding the Frame................................... 74
Fuel Tanks.................................................... 76 Lead Numbering .......................................... 72
Fuel System - Prime ...................................... 137 Multiple Units ............................................... 74
Priming Procedure for Dry Starting ............ 138 Neutral Connections .................................... 74
Fuel System Primary Filter (Water Parallel to Utility ........................................... 75
Separator) Element - Replace ..................... 138 Single Units.................................................. 74
Fuel System Primary Filter/Water Separator Generator Load - Check ................................ 150
- Drain .......................................................... 139 Generator Operation........................................ 67
Fuel System Secondary Filter - Replace ....... 139 Block Loading .............................................. 67
Replacing the Fuel Filter Elements During Excitation Systems....................................... 68
Engine Operation ..................................... 140 Generator Options ....................................... 68
Replacing the Fuel Filter Elements with the Loading of the Generator ............................. 67
Engine Stopped........................................ 140 Low Idle Adjustment..................................... 68
Fuel Tank Water and Sediment - Drain.......... 141 Power Factor................................................ 67
Drain the Water and the Sediment............. 141 Standby Generator Sets .............................. 68
Fuel Storage Tanks .................................... 142 Generator Set - Test ...................................... 151
Fuel Tank ................................................... 141 Generator Set Alignment - Check
(Generator Sets) .......................................... 152
Generator Set Vibration - Test/Record........... 152
G Generator Start-up Checklist ........................... 93
Gauges and Indicators .................................... 50 Generator Winding - Test............................... 153
General Hazard Information .............................11 Generator Winding Insulation - Test .............. 154
Containing Fluid Spillage ............................. 12 Recommended Periodic Insulation Tests... 154
Dispose of Waste Properly........................... 14 Recommended Procedure for the Insulation
Fluid Penetration.......................................... 12 Test........................................................... 154
Inhalation ..................................................... 13 Glossary ........................................................ 189
Lines, Tubes, and Hoses ............................. 12
Pressurized Air and Water ........................... 12
Softwrap....................................................... 13
H
General Information......................................... 21 Hoses and Clamps - Inspect/Replace ........... 158
General Maintenance Information ................... 90 Inspect the Hoses and the Clamps ............ 158
Generator - Dry.............................................. 142 Replace the Hoses and the Clamps .......... 158
Drying Methods.......................................... 142
Generator - Inspect........................................ 143
Cleaning (Assembled Generators) ............ 144 I
Cleaning (Disassembled Generators)........ 144 Important Safety Information ............................. 2
Generator Bearing - Inspect .......................... 144 Installation ....................................................... 35
Generator Bearing - Lubricate ....................... 145
Additional Information ................................ 149
Procedure for Bearing Service................... 145 J
Generator Bearing - Replace (SR5 Jacket Water Heater - Check......................... 160
Generator Bearings) .................................... 149
Standard Usage ......................................... 149
Standby Usage .......................................... 149 L
Generator Bearing Temperature - Test/ Lifting and Storage........................................... 33
Record ......................................................... 149
SEBU8468 197
Index Section
M Maintenance Section....................................... 81
Manual Stop Procedure................................... 79
Maintenance Interval Schedule (High
Automatic Stopping...................................... 80
Displacement).............................................. 101
Model View Illustrations................................... 21
Commissioning .......................................... 103
Mounting and Dismounting.............................. 16
Daily ........................................................... 101
Every 1000 Service Hours ......................... 102
Every 12 000 Service Hours or 6 Years ..... 102 O
Every 2000 Service Hours ......................... 102
Every 250 Service Hours ........................... 102 Operation Section............................................ 33
Every 3000 Service Hours or 3 Years ........ 102 Ordering Replacement Parts ......................... 183
Every 4000 Service Hours ......................... 102 Overhaul (Major)............................................ 163
Every 500 Service Hours ........................... 102 Cleaning of Components ........................... 165
Every 6000 Service Hours or 3 Years ........ 102 Inspection of Components ......................... 164
Every 6000 Service Hours or 6 Years ........ 102 Inspection, Reconditioning or Exchanging of
Every Week................................................ 102 Components............................................. 163
Every Year.................................................. 102 Obtain a Coolant Analysis.......................... 165
Initial 250 Service Hours ............................ 102 Replacement of Components .................... 163
Overhaul .................................................... 102 Overhaul (Top End)........................................ 165
When Required.......................................... 101 First Top End Overhaul .............................. 165
Maintenance Interval Schedule (Prime) .......... 97 Top End Overhaul (Second)....................... 167
Commissioning ............................................ 99 Overhaul Considerations ............................... 169
Daily ............................................................. 97 Overhaul Information ................................. 170
Every 1000 Service Hours ........................... 98 Severe Operation....................................... 169
Every 12 000 Service Hours or 6 Years ....... 98
Every 2000 Service Hours ........................... 98 P
Every 250 Service Hours ............................. 98
Every 3000 Service Hours or 3 Years .......... 98 Parallel Operation............................................ 69
Every 4000 Service Hours ........................... 98 Circulating Currents ..................................... 71
Every 500 Service Hours ............................. 98 Initial Start-Up .............................................. 69
Every 6000 Service Hours or 3 Years .......... 98 Load Division and Speed Droop (If Equipped)
Every 6000 Service Hours or 6 Years .......... 98 ................................................................... 71
Every Week.................................................. 98 Paralleling Multiple Units.............................. 70
Every Year.................................................... 98 Starting Multiple Units .................................. 70
Initial 250 Service Hours .............................. 98 Stopping....................................................... 71
Overhaul ...................................................... 99 Plate Locations and Film Locations............24, 26
When Required............................................ 97 Engine Identification................................24, 26
Maintenance Interval Schedule (Standby)....... 99 European Union ......................................25, 28
Commissioning .......................................... 100 Identification of the Generator Set ..........24, 27
Daily ............................................................. 99 Information Plate.....................................24, 26
Every 10 Years........................................... 100 Output Lead Wiring .................................25, 27
Every 3 Years............................................. 100 Serial Number Plate................................24, 26
Every 6 Months .......................................... 100 Serial Number Plate for the Generator....25, 27
Every 6 Years............................................. 100 Power Factor - Check .................................... 171
Every Week.................................................. 99 Prelube Pump - Inspect ................................. 171
Every Year.................................................. 100 Air Prelube Pump....................................... 171
When Required............................................ 99 Electric Prelube Pump ............................... 171
Maintenance Log ........................................... 185 Product Description ......................................... 22
Maintenance Recommendations............. 90, 160 Engine Description....................................... 22
Overhaul Intervals...................................... 160 Generator Description................................. 22
Maintenance Records.................................... 184 Generator Description................................. 22
Intended Use................................................ 22
198 SEBU8468
Index Section
Product Identification Information.................... 24 11 Lifting the Product (Including the Radiator)

Product Information Section ............................ 21 ................................................................... 10
Product Installation.......................................... 35 12 Hot Fluid Under Pressure........................ 10
Bearing Inspection ....................................... 35 13 Lifting the Engine .................................... 10
Electrical Measurements ............................. 36 2 Shock .......................................................... 7
Location ....................................................... 35 3 Electrocution ............................................... 7
Protective Devices ....................................... 36 4 Auto Start .................................................... 8
Receiving Inspection.................................... 35 5 Crushing...................................................... 8
Storage ........................................................ 35 6 Hot Surface ................................................. 8
Unpacking and Storage ............................... 35 7 Vapor Explosion (Oil Filter) ......................... 9
Product Lifting.................................................. 33 8 Vapor Explosion (Fuel Filter)....................... 9
Lifting the Engine Only................................. 33 9 Canadian Standards Association................ 9
Lifting the Entire Package ............................ 33 Safety Section ................................................... 5
Lifting the Generator Only ............................ 33 Severe Service Application.............................. 95
Product Storage............................................... 33 Improper Maintenance Procedures
Bearing Inspection ....................................... 34 (Maintenance Procedures Which May
Electrical Measurements ............................. 34 Contribute to a Severe Service Application)
Long Time Storage....................................... 34 ................................................................... 96
Short Time Storage...................................... 33 Severe Environmental Factors .................... 95
Severe Operating Conditions....................... 95
Single Unit Operation....................................... 69
R Initial Start-Up .............................................. 69
Radiator - Clean............................................. 171 Starting......................................................... 69
Reference Information..................................... 32 Stopping....................................................... 69
Record for Reference................................... 32 Sound Information ........................................... 17
Reference Information Section ...................... 180 Space Heater - Test ....................................... 173
Reference Material ........................................ 186 Standby Generator Set Maintenance
Additional Reference Material.................... 187 Recommendations....................................... 173
Coolants..................................................... 186 Maintenance and Operation Procedures ... 174
Emissions Warranty ................................... 188 Starting Motor - Inspect (If equipped) ............ 174
Greases ..................................................... 186 Air Starting Motor ....................................... 174
Lubricants .................................................. 186 Electric Starting Motor................................ 175
Miscellaneous ............................................ 187 Removal and Installation of the Starting Motor
SOS Services .......................................... 186 ................................................................. 175
Reference Materials ...................................... 184 Starting the Engine .......................................... 63
Refill Capacities............................................... 81 Automatic Starting........................................ 63
Coolant Capacities....................................... 81 Manual Starting............................................ 63
Lubricant Capacities .................................... 81 Starting with Jump Start Cables ...................... 64
Rotating Rectifier - Inspect/Test..................... 172 Stator Lead - Check....................................... 175
Testing a Brushless Exciter Rotating Rectifier Stator Winding Temperature - Test ................ 175
With A Test Light....................................... 173 Symbols......................................................... 189
Testing A Brushless Exciter Rotating Rectifier System Pressure Release............................... 90
With An Ohmmeter................................... 172 Coolant System............................................ 90
Engine Oil .................................................... 91
Fuel System ................................................. 90
S
Safety Messages............................................... 5
T
1 Universal Warning....................................... 7
10 Lifting the Product (Not Including the Table of Contents............................................... 3
Radiator) ...................................................... 9 Turbocharger - Inspect .................................. 176
Cleaning and Inspecting ............................ 176
SEBU8468 199
Index Section
Removal and Installation............................ 176
V
Varistor - Check ............................................. 176
Varistor - Inspect............................................ 177
Voltage and Frequency - Check .................... 177
Voltage Regulators .......................................... 71
Cat Digital Voltage Regulator (Cat DVR )... 71
W
Walk-Around Inspection ................................ 177
Inspect the Engine for Leaks and for Loose
Connections ............................................. 177
Inspect the Generator ................................ 178
Warranty Information ..................................... 179
Engine Protection Plans............................. 179
Warranty Section ........................................... 179
Water Pump - Inspect .................................... 178
Welding on Engines with Electronic Controls .. 91
200 SEBU8468
Index Section
Product and Dealer Information
Note: For
product identification plate locations, see the section Product Identification
Information in the Operation and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission
Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment
Number:
Dealer Information
Name: Branch:
Address:
Dealer Phone Hours

Contact Number
Sales:
Parts:
Service:
2013 Caterpillar CAT, CATERPILLAR, their respective logos, Caterpillar Yellow, and the POWER EDGE trade
All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

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SEBU8468-06

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Generator Operation.................... ................... 67

Foreword.............................. ............................. 4 Cold Weather Operation................. ................ 76

Engine Stopping ....................... ...................... 78

Safety Messages....................... ....................... 5

Refill Capacities....................... ....................... 81

Burn Prevention....................... ....................... 14 Maintenance Recommendations.......... .......... 90

Mounting and Dismounting............... .............. 16 Maintenance Interval Schedule (High

Product Identification Information.......... ......... 24

Lifting and Storage..................... ..................... 33

Installation ........................... ........................... 35

Features and Controls .................. .................. 37

Engine Diagnostics..................... .................... 52

Engine Starting ........................ ....................... 61

Engine Operation...................... ...................... 66

Foreword Recommended service should be performed at the

One safety message is located on the control panel.

Do not operate or work on this engine or genera-

One safety message is located on the control panel.

One safety message is located on the rear of the

When the engine is in the AUTOMATIC mode, the

One safety message is located on the oil cooler. One

Hot parts or hot components can cause burns or

One safety message is located on each side of the

7 Vapor Explosion (Oil Filter) 9 Canadian Standards Association

Illustration 9 g01407639 Illustration 11 g01667111

10 Lifting the Product (Not

One safety message is located on each side of the

Warning: Vapor Explosion. Could cause serious

12 Hot Fluid Under Pressure

11 Lifting the Product (Including the

One safety message is located next to the radiator

Pressurized system! Hot coolant can cause seri-

One safety message is located on each side of the

Before lifting the product, read this Operation and

This safety message may be located on the lifting bail

Use caution when cover plates are removed.

General Hazard Information

Wear a hard hat, protective glasses, and other

When work is performed around an engine that is

Do not wear loose clothing or jewelry that can snag

Ensure that all protective guards and all covers are

Never put maintenance fluids into glass

The engine is stopped. Ensure that the engine Fluid Penetration

The protective locks or the controls are in the

When starting a new engine, make provisions to

Stay away from areas that might have asbestos

Improperly disposing of waste can threaten the

Determine whether the engine will be operated in an

Fire Extinguisher Flexible parts of the hoses are kinked.

Use ether in well ventilated areas. Do not smoke

Check lines, tubes, and hoses carefully. Do not use i01377941

Sound Information S/N: YAZ1Up; CTH1Up

Sound levels will vary depending on the configuration NOTICE

Keep ether cylinders out of the reach of unauthorized Grounding Practices

On the initial start-up of a new engine or an engine

3. Disconnect the generator from the distribution

4. Lock out the circuit breaker. Attach a DO NOT

7. Remove the cover of the generator's terminal box.

8. Use an audio/visual proximity tester in order to