SEBU7681-03

February 2004

Operation and
Maintenance
Manual
G3500C and G3500E Generator Sets
TJB1-Up (Generator Set)
TJC1-Up (Generator Set)
HAL1-Up (Generator Set)
B9P1-Up (Generator Set)
CWW1-Up (Generator Set)
CWY1-Up (Generator Set)
SLY1-Up (Generator Set)
 i01658146

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. 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 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.
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. 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
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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. Caterpillar dealers have the most current information available.

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, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents Maintenance Recommendations .......................... 66

Maintenance Interval Schedule ............................ 70

Foreword ................................................................. 4
Reference Information Section
Safety Section
Customer Service ............................................... 127
Safety Messages .................................................... 6
Reference Materials ............................................ 129
General Hazard Information ................................... 9
Index Section
Burn Prevention .................................................... 12
Index ................................................................... 135
Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 14

Mounting and Dismounting ................................... 14

Ignition Systems ................................................... 14

Before Starting Engine .......................................... 15

Engine Starting ..................................................... 15

Engine Stopping ................................................... 15

Electrical System .................................................. 15

Generator Isolating for Maintenance .................... 16

Product Information Section

General Information .............................................. 17

Model Views and Specifications ........................... 18

Product Identification Information ........................ 22

Operation Section
Lifting and Storage ................................................ 27

Installation ............................................................. 29

Features and Controls .......................................... 31

Engine Starting ..................................................... 45

Engine Operation .................................................. 50

Engine Stopping ................................................... 51

Generator Operation ............................................. 53

Voltage Regulators ............................................... 60

Maintenance Section
Refill Capacities .................................................... 62
4
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
Use service hours to determine 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.
Recommended service should always be
performed at the service hour interval. The actual
operating environment of the engine also governs
the maintenance schedule. Therefore, under
extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
maintenance than is specified in the maintenance
schedule may be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine’s permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
California Proposition 65 Warning
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.
 5
Foreword

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
6
Safety Section
Safety Messages

Safety Section
i01974889

Safety Messages
SMCS Code: 1000; 7405

g01005329
Illustration 1

g01025011
Illustration 2

There are several specific safety messages on this

engine. The exact location of the safety messages
and the description of the safety messages are
reviewed in this section. Please become familiarized
with all safety messages.
 7
Safety Section
Safety Messages

Make sure that all of the safety messages are legible. Electrical Shock (2)
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the This safety message for electrical shock is located on
safety messages if the illustrations are not legible. the base of the valve cover. This safety message is
When you clean the safety messages, use a cloth, also located on the face of the EMCP II.
water and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.

Replace any safety message that is damaged, or

missing. If a safety message is attached to a part
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.

Read the Manual (1)

This safety message is located on the face of the g00920549
EMCP II.

WARNING! Shock/Electrocution Hazard! Read and

understand the instructions and warnings in the
Operation and Maintenance Manual. Failure to fol-
low the instructions or heed the warnings could
cause serious injury or death.

Hot Surface (3)

This safety message for hot surfaces is located on
the barrel of the generator.

g00928086

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.

Failure to follow the warnings and instructions

could result in injury or death. Contact any
Caterpillar dealer for replacement manuals. Prop-
er care is your responsibility.

g00928084

Hot surfaces inside enclosure. Keep hands back.

8
Safety Section
Safety Messages

Hot Surface (4) Electrical Distribution (5)

This safety message for hot surfaces is located on This safety message for electrical distribution
the valve cover. (generator) is located on the covers of the generator.

g01025010 g01025010

Hot surface! Do not touch! 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.
 9
Safety Section
General Hazard Information

Automatic Starting (6) Lifting the Genset (7)

This safety message for automatic starting is located This safety message for lifting the genset is located
on the covers of the generator. on the side panels of the generator.

g00928083

When the engine is in the AUTOMATIC mode, the

engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when g00928085
the engine is in the AUTOMATIC mode.

Crushing Hazard! Improper lifting could cause se-

rious injury or death. Follow the lifting instruc-
tions in the Operation and Maintenance Manual for
safe lifting procedures.

i01359759

General Hazard Information

SMCS Code: 1000; 4450; 7405

g00104545
Illustration 3
10
Safety Section
General Hazard Information
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to
each operator control station. When it is appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
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
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 plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
g00702020
Illustration 4
• 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 containers.
Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• 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.
• Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
California Proposition 65 Warning
Some engine exhaust constituents are known to the
State of California to cause cancer, birth defects, and
other reproductive harm.
Pressure Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
When pressure air and/or pressure water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).

Fluid Penetration
g00687600
Illustration 5
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Tools and
Shop Products Guide” for the following items:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
11
Safety Section
General Hazard Information
Asbestos Information
g00702022
Illustration 6
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
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 usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
12
Safety Section
Burn Prevention

• 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.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.

Dispose of Waste Properly Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.

Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.

g00706404
Illustration 7
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i01372262

Always use leakproof containers when you drain Fire Prevention and Explosion
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
Prevention
SMCS Code: 1000; 4450; 7405
i01480768

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 air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.

Coolant Illustration 8
g00704000

When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
 13
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. The filter housings must be tightened to the proper
torque.
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 Caterpillar 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.

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.

Do not expose the engine to any flame.

g00704135
Illustration 9
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
Gases from a battery can explode. Keep any open
a hose, or a seal failure. Exhaust shields must be
flames or sparks away from the top of a battery. Do
installed correctly.
not smoke in battery charging areas.
Do not weld on lines or tanks that contain flammable
Never check the battery charge by placing a metal
fluids. Do not flame cut lines that contain flammable
object across the terminal posts. Use a voltmeter or
fluid. Clean any such lines thoroughly with a
a hydrometer.
nonflammable solvent prior to welding or flame
cutting.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
Wiring must be kept in good condition. All electrical
the Operation Section of this manual for specific
wires must be properly routed and securely attached.
instructions.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
Do not charge a frozen battery. This may cause an
engine. Clean all electrical connections and tighten
explosion.
all electrical connections.
The batteries must be kept clean. The covers
Eliminate all wiring that is unattached or unnecessary.
(if equipped) must be kept on the cells. Use the
Do not use any wires or cables that are smaller than
recommended cables, connections, and battery box
the recommended gauge. Do not bypass any fuses
covers when the engine is operated.
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure Fire Extinguisher

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
14
Safety Section
Crushing Prevention and Cutting Prevention
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
i01359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
i01377941
Mounting and Dismounting
SMCS Code: 1000; 4450; 7405
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.
Mount the generator set and dismount the generator
set only at locations that have steps and/or
handholds. Do not climb on the generator set, and do
not jump off the generator set.
Face the generator set in order to mount the
generator set or dismount the generator set. Maintain
a three-point contact with the steps and handholds.
Use two feet and one hand or use one foot and two
hands. Do not use any controls as handholds.
Do not jump from an elevated platform. Do not jump
from a ladder or stairs.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
generator set or when you dismount the generator
set. Use a hand line to raise and lower tools or
supplies.
i00702251
Ignition Systems
SMCS Code: 1550
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.
Do not attempt to remove the valve covers when the
engine is operating. The transformers are grounded
to the valve covers. Personal injury or death may
result and the ignition system will be damaged if the
valve covers are removed during engine operation.
The engine will not operate without the valve covers.

i00659904
Before Starting Engine
SMCS Code: 1000
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure that
all lights work properly.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
On the initial start-up of a new engine or an engine
that has been serviced, be prepared to stop the
engine if an overspeed condition occurs. This may
be accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
See the Service Manual for repairs and for
adjustments.
i01932295
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch
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.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operator’s compartment or
from the engine start switch.
15
Safety Section
Before Starting Engine
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the 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)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil
temperature during heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
i00659907
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to the instructions in this Operation and
Maintenance Manual, “Engine Stopping” topic
(Operation Section).
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
i00887114
Electrical System
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.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started.
16
Safety Section
Generator Isolating for Maintenance
Grounding Practices
Proper grounding is necessary for optimum engine
performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
unreliable electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft journal
surfaces, and to aluminum components. Uncontrolled
electrical circuit paths can also cause electrical
activity that may degrade the engine electronics and
communications.
For the starting motor, do not attach the battery
negative terminal to the engine block.
Use a ground strap to ground the case of all control
panels to the engine block.
Ground the engine block with a ground strap that is
furnished by the customer. Connect this ground strap
to the ground plane.
Use a separate ground strap to ground the battery
negative terminal for the control system to the ground
plane.
Rubber couplings may connect the steel piping of
the cooling system and the radiator. This causes the
piping and the radiator to be electrically isolated.
Ensure that the piping and the radiator is continuously
grounded to the engine. Use ground straps that
bypass the rubber couplings.
Ensure that all grounds are secure and free of
corrosion.
i01489970
Generator Isolating for
Maintenance
SMCS Code: 4450
When you service an electric power generation set
or when you repair an electric power generation set,
follow the procedure below:
1. Stop the engine.
g00104545
Illustration 10
2. Attach a “DO NOT OPERATE” or similar warning
tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
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. For the following circuitry, remove the
transformer’s fuses:
• 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.
 17
Product Information Section
General Information

Product Information
Section

General Information
i01472899

Welding on Engines with

Electronic Controls
SMCS Code: 1000

NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.

To help avoid damage to the electronic controls,

proper welding procedures are necessary. Before
you weld on equipment with electronic controls,
observe the following precautions:

1. Turn off the engine. Place the engine control

switch in the OFF position.

2. If the engine has a battery disconnect switch, open

the switch. Otherwise, disconnect the negative “-”
battery cable from the battery of the equipment.

NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp
as close as possible to the weld.

4. Protect wiring harnesses from welding debris and

from spatter. Use proper welding procedures.
18
Product Information Section
Model Views and Specifications

Model Views and

Specifications
i01996291

Model View Illustrations

SMCS Code: 1000; 4450

The illustrations show various typical features

of G3500C and G3500E Generator Sets. The
illustrations do not show all of the options that are
available.

50 Hz Model Views

g01007697
Illustration 11
(1) Oil filler (6) ProAct throttle (11) Fuel inlet
(2) Engine control module (7) Aftercooler drains (12) Fuel metering valve
(3) Lifting eyes (8) Oil filters (13) Air inlet
(4) Jacket water outlet (9) Oil level gauge (dipstick) (14) Exhaust stack
(5) Aftercooler (10) Jacket water inlet (15) Oil drain
 19
Product Information Section
Model Views and Specifications

60 Hz Model Views

g01007788
Illustration 12
(1) Oil filler (6) ProAct throttle (11) Oil level gauge (dipstick)
(2) Engine control module (7) Lifting eye (1 of 2) (12) Air inlet
(3) Jacket water outlet (8) Aftercooler drains (13) Exhaust stack
(4) Aftercooler (9) Jacket water inlet (14) Fuel metering valve
(5) Fuel inlet (10) Oil filters (15) Oil drain

i01972289 • Inlet Manifold Pressure Sensor

Generator Set Description • Load Signal
SMCS Code: 7002 • Inlet manifold temperature sensor
The Generator Set consists of an engine, a generator, The fuel metering valve controls the flow of fuel to
and a control system. the engine. The ECM determines the requirement for
the mixture of air and fuel. The ECM sends a signal
Engine Description to the fuel metering valve. The fuel metering valve
controls the volume of the gas flow to the engine.
Fuel System (Air/Fuel Ratio Control)
The fuel flows through the fuel metering valve into
The fuel system includes these components: the air inlet elbow. The mixture of air and fuel flows
through the turbocharger compressor. The air/fuel
mixture is cooled in the aftercooler. The mixture
• Fuel metering valve enters the manifold through a throttle which is
electronically controlled.
• Engine control module (ECM)
20
Product Information Section
Model Views and Specifications

The ECM sends an electronic throttle signal to the
electronic actuator. The throttle is controlled by the
actuator.
Ignition System
The engine is equipped with an electronic ignition
system. The system provides dependable firing
and low maintenance. The system provides precise
control of the spark and the ignition timing for each
cylinder.
The system also provides diagnostic capability that
enhances troubleshooting.
The engines are equipped with protection from
detonation. A detonation sensor is located between
every two cylinders. The ignition timing is retarded
for a cylinder when excessive detonation is sensed
in that cylinder. If the maximum retarded position is
attained and detonation continues to occur, the ECM
shuts down the engine.
Description of the Generator
The SR4B brushless generator can be used with the
following loads: mixed loads of motors and lights,
SCR-controlled equipment, computer centers, and
petroleum drilling applications.
The generator set packages can be utilized for prime
power generation or standby power generation.
SR4B generators are utilized in three-phase full-wave
excitation and regulation. The generators are either
four pole or six pole design. The generators have six
lead configuration or twelve lead configuration. The
generators are capable of producing electrical power
in either 50 Hz or 60 Hz applications.
i01964958
Specifications
SMCS Code: 1000

The engines are equipped with flame arresters. The Table 1

flame arresters are located at the entrance of each G3500C Engine Specifications
inlet port. If the engine backfires, the flame arresters
prevent the fire from entering the air/fuel mixture. Item G3516C Engine G3520C Engine

Lubrication System Cylinders and 60 degree V 16 60 degree V 20

arrangement
The engine lubrication oil is circulated by a Bore 170 mm (6.7 inch)
gear-driven pump. The oil is cooled and filtered. A
bypass valve provides unrestricted flow of lubrication Stroke 190 mm (7.5 inch)
oil to the engine parts if the oil filter elements become Total 69 L (4210 in 3 ) 86.2 L (5262 in 3 )
plugged. displacement
Compression 11.7:1 11.3:1
Cooling System ratio

The cooling system uses a water pump. The cooling Aspiration TA with SCAC (1)

system has temperature regulators that regulate Rotation Counterclockwise

the temperature of the coolant. The temperature (flywheel end)
depends on the application.
Firing order 1-2-5-6-3-4-9- 1-2-11-12-3-4-
10-15-16-11-12- 15-16-7-8-19-
The turbocharged engine has a Separate Circuit
13-14-7-8 20-9-10-17-18-
Aftercooler (SCAC). The temperature depends on 5-6-13-14
the engine rating and the application.
(1) Turbocharged Aftercooled with Separate Circuit Aftercooling
The circuit for the aftercooler may be combined
or the circuit for the aftercooler may be separate
circuits. In the combined system, a pump circulates
water through both the aftercooler and oil cooler
cores. The combined system uses a thermostatic
control to regulate the oil temperature. This prevents
overcooling.

For a more detailed description, refer to the Systems

Operation/Testing and Adjusting manual.
 21
Product Information Section
Model Views and Specifications

Table 2
G3500E Engine Specifications

Item G3516E Engine G3520E Engine

Cylinders and 60 degree V 16 60 degree V 20
arrangement
Bore 170 mm (6.7 inch)
Stroke 190 mm (7.5 inch)
Total 69 L (4210 in 3 ) 86.2 L (5262 in 3 )
displacement
Compression
ratio
g00881273
Illustration 14
Aspiration TA with SCAC (1)
G3520C and G3520E Engine design
Rotation Counterclockwise (A) Inlet valves
(flywheel end) (B) Exhaust valves
(C) Flywheel
Firing order 1-2-5-6-3-4-9- 1-2-11-12-3-4-
10-15-16-11-12- 15-16-7-8-19-
13-14-7-8 20-9-10-17-18-
5-6-13-14
(1) Turbocharged Aftercooled with Separate Circuit Aftercooling

g01020798
Illustration 13
G3516C and G3516E Engine design
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
22
Product Information Section
Product Identification Information

Product Identification Engine Serial Number (2)

Information The Engine Serial Number Plate is on the left side of
the cylinder block near the rear of the engine.
i02022372 The Engine Serial Number Plate contains the
Plate Locations and Film following information:

Locations • Engine serial number __________________________________

SMCS Code: 1000; 4450 • Engine model number _________________________________
• Arrangement number __________________________________

Generator Identification (3)

The generator identification is located on the left side
of the generator.

The generator identification film includes the following

information:

• Generator serial number ______________________________

• Generator model number _____________________________
• Generator set rating ____________________________________

i01934436

Reference Information
SMCS Code: 1000; 4450

Identification of the items in Table 3 may be needed

Illustration 15
g01044252
Engine Information (1)
The Engine Information Plate is on the left side of
the engine near the front of the block between the
number 2 cylinder and the front housing.
The Engine Information Plate contains the following
information:
• Engine serial number __________________________________
• Arrangement number __________________________________
• Compression ratio ______________________________________
• Aftercooler temperature _______________________________
• Power _____________________________________________________
• Full load RPM ___________________________________________
in order to obtain parts and service. Some of the
numbers are on the engine Serial Number Plate
and/or Information Plate. Locate the information
for your engine. Record the information on the
appropriate space in Table 3. Make a copy of this
list for a record. Retain the information for future
reference.
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement
number.
The packaging arrangement may also be called a
pricing arrangement or a customer arrangement. This
is the total package with attachments and options
that are not included in the engine arrangement.
The performance specification can be used by
your Caterpillar dealer with the Technical Marketing
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed
performance data is recorded. The performance
specification number can be used for obtaining the
data.
 23
Product Information Section
Product Identification Information

Table 3 Wye Configuration Diagram

Reference Numbers
6 Lead
Engine Model
Generator Set Serial
Number
Engine Serial Number
Generator Serial Number
Arrangement Number
Packaging Arrangement
Turbocharger
Fuel Filter Element
Fuel Pressure Regulator
Oil Filter Element
Air Cleaner Element
Alternator Belt
Capacity of the Lubrication
System
g00611486
Capacity of the Cooling Illustration 16
System 6 Lead Wye Configuration
Performance Specification Terminals T4, T5 and T6 become neutral connections when the
Number terminals are tied together.

Low Idle rpm

Delta Configuration Diagram
High Idle rpm
6 Lead
Power Rating

i01688836

Generator Lead Connections

SMCS Code: 4450

Lead Numbering
The Wye configuration and the Delta configuration are
the most common generator lead connections. The
following three-phase connection diagrams illustrate
the proper connection and lead identification.

g00669319
Illustration 17
6 Lead Delta Configuration
24
Product Information Section
Product Identification Information
Grounding the Frame
In any generator set installation, the frame of the
generator must be positively connected to an
earth ground. This connection should be the first
connection that is made during installation. This
connection should be the last connection that is
removed. The ground connection must be flexible in
order to avoid breakage during operation.
Ground connection cable or straps should have at
least the current carrying capacity of the largest
line lead to the connected load. Joints in cables or
straps must be clean, free of electrical resistance,
and protected from possible oxidation. Bolted ground
connection joints eventually oxidize. The joints are
frequent sources of radio frequency interference
(RFI). Bolted connections should be silver soldered
for the best performance.
Neutral Connections
Generators with grounded configurations usually
have a neutral that is grounded when the generator
is installed. Ground the neutral in order to prevent
equipment damage and personal injury.
If the neutral wire is grounded and one of the phase
leads becomes grounded, the excessive current will
open a load circuit breaker in order to isolate the
fault. If the circuit breaker does not open, then the
excessive current will reduce the generator voltage
to zero. The result depends on the characteristics of
the generator, the type of fault, and the trip rating of
the circuit breaker. An undervoltage device may be
required in order to provide an adequate short circuit
protection.
Some installations do not require the neutral wire
to be grounded. Ungrounded neutral leads are
acceptable if measures have been taken in order to
prevent grounds to the phase leads. An example of
such measures are ground fault protective circuits.
All of the distribution circuits must be treated as a
system in order to ensure ground fault protection.
The operator should contact 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.
Neutral resistors and reactors may be added to the
system for two reasons: to provide protection during
faults and to limit neutral currents.
Single Units
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
In applications where definite measures are taken
in order to prevent grounds to the load leads, an
ungrounded neutral can be used. Be sure to check
your local wiring codes.
Multiple Units
Operation of multiple generators in parallel, having
all neutrals grounded, may result in the circulating
current through the neutral connections. In order
to eliminate the possibility of circulating currents,
ground the neutral of only one generator. If multiple
generators are alternated on line, a switch should
be installed in the neutral ground circuit of each
generator. In this case all neutral ground circuits
except one can be opened. Be sure that one of the
neutral ground circuits is closed.
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.
i01689047
Voltage Connections
SMCS Code: 4450
Three-Phase Voltage Connections
The Wye (Star) Configuration for a 480 V generator
and the Delta Configuration for a 240 V generator are
given in the following diagrams.
The terminals must be connected securely. The
terminals must also be insulated with a good quality
electrical tape.
 25
Product Information Section
Product Identification Information

If a Delta Configuration is used, a two-thirds winding Delta Configuration Diagram

pitch is recommended and is required with 590 frame
size generators and above. If the generator winding 6 Lead Generators
pitch is not two-thirds, third harmonics will cause
a high circulating current. The generator will need
to be derated. This current can exceed the winding
current rating causing generator overheating and
damage which may pose a fire hazard. A Wye (Star)
connected generator may require a two-thirds pitch
winding if the neutral is solidly grounded. Refer
to the Specifications, LEBX6693, “Generator Set
Installation Drawings” for more information. A floating
neutral does not require a two-thirds pitch winding.

Wye (Star) Configuration Diagram

6 Lead Generators

g00626129
Illustration 19
Typical Delta Configuration (60 Hz, 6 Lead)

Single-Phase Current From a

Three-Phase Generator
Three-phase current and single-phase current
can be taken simultaneously from a generator
that is connected for three-phase service. In the
Wye (Star) Configuration, connect the load to the
three-phase leads (any two of the three leads). In
the Delta Configuration, connect the load to the
three-phase leads (any two of the three leads). In
Illustration 18
g00626053 both configurations, this will provide single-phase
Typical Wye (Star) Configuration (60 Hz, 6 Lead)
voltage at the same voltage as three-phase voltage.

Connect the load to any phase lead and neutral lead

of the Wye (Star) Configuration. This will produce
voltage at 58% of three-phase voltage.

Refer to Operation Section, “Generator Operation”

for allowable single-phase loading unbalance.

Single-phase power that is taken from a three-phase

source can be a problem. Ensure that the
single-phase loading is equally distributed.

Do not exceed the nameplate current rating for any

one phase.
26
Product Information Section
Product Identification Information

Wye (Star) Configuration Diagram

6 Lead Generators

g00626132
Illustration 20
Single-Phase Voltage Diagram with 6 Lead Wye (Star)
Configuration

Delta Configuration Diagram

6 Lead Generators

g00626135
Illustration 21
Single-Phase Voltage Diagram with 6 Lead Delta Configuration

Operation Section
Lifting and Storage
i01934462
Generator Set Lifting
SMCS Code: 7002
Engine Only
g00103219
Illustration 22
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting fixtures in order to
obtain proper balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Note: The lifting eyes must be removed before
the engine is operated.
27
Operation Section
Lifting and Storage
Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
Generator Set
NOTICE
Do not use the engine lifting eyes to remove the en-
gine and generator together.
A lifting plate is provided with the package generator
set. Instructions for lifting the package generator set
are stamped on the lifting plate.
Consult your Caterpillar dealer for information
regarding proper fixtures and lifting devices.
Generator sets will not be level if you lift the unit
from a single lifting point. A counterweight can be
added between the package frame rails whenever
the application requires frequent relocation of the
unit. For complete information about adding the
counterweight, consult your Caterpillar dealer.
The single point lifting eye is secured from the factory
before being shipped. The correct orientation of the
single point lifting eye will allow you to look through
the eye when you stand at the side of the enclosure.
The lifting eye may stretch when the package is
lifted. This may cause the locking nuts to loosen.
This could cause the lifting eye to swivel. Ensure that
the lifting eye is correctly oriented on the packaged
generator set. Ensure that the lifting eye is tightened
to the correct torque before you lift the packaged
generator set.
28
Operation Section
Lifting and Storage

i01615882

Generator Set Storage

SMCS Code: 7002

If the engine will not be started for several weeks, the

lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface, which will increase engine wear which
can reduce engine service life.

To help prevent excessive engine wear, use the

following guidelines:

• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).

• If freezing temperatures are expected, check

the cooling system for adequate protection
against freezing. Refer to this Operation
and Maintenance Manual, “General Coolant
Information” (Maintenance Section).

If an engine is out of operation and if use of the engine

is not planned, special precautions should be made.
If the engine will be stored for more than one month,
a complete protection procedure is recommended.

Your Caterpillar dealer will have instructions for

preparing the engine for extended storage periods.

For more detailed information on engine storage,

refer to Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”.

Generator Storage
For information on generator storage, refer to this
Operation and Maintenance Manual, “Generator Set
Installation” (Operation Section).

Installation
i01856938
Generator Set Installation
SMCS Code: 7002
Receiving Inspection
If the generator is received during cold weather,
allow the unit to reach room temperature before you
remove the protective packing material. Warming
the generator to room temperature will prevent the
following problems:
• Water condensation on cold surfaces
• Early failures due to wet windings
• Early failures due to wet insulating materials
Unpacking and Storage
Moving the Generator
Improper lift rigging can allow unit to tumble caus-
ing injury and damage.
NOTICE
Do not use the engine lifting eyes to remove the en-
gine and generator together.
Unpack the equipment with care in order to avoid
scratching painted surfaces. Move the unit to the
mounting location. The unit can be moved by either
of the following methods:
• Attach an overhead crane to the lifting eyes that
are installed on the generator package.
• Use a lift truck in order to lift the generator.
The hoist and the hoist cables should have a rating
that is greater than the weight of the generator.
When the unit is moved, ensure that the generator
is completely supported by the lift truck’s fork tines.
Also ensure that the generator is balanced on the
lift truck’s fork tines. Slide the fork tines beneath the
attached skid in order to lift the generator.
29
Operation Section
Installation
Storage
Short Time Storage
If the generator is not installed immediately, store
the generator in a clean area. This area should also
have the following conditions: low humidity, stable
humidity, and stable temperature. Space heaters
must be energized in order to keep condensation
from the windings. All accessory equipment that
is supplied with the unit should be stored with the
generator. The combined unit should be covered
with a durable cover in order to protect against the
following contaminants:
• Dust
• Dirt
• Moisture
Long Time 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
and 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 unit is placed in operation.
Bearing Inspection
Ball bearing generators use grease. This grease is
subject to deterioration. If the generator is stored
longer than one year, new ball bearings should be
installed. These bearings should be greased to
the proper level prior to being put into operation. If
inspection indicates that bearings are free of rust or
corrosion, and no noise or excessive vibration appear
on start-up, replacement is not necessary.
Location
The location of the generator must comply with all
local regulations. The location of the generator must
also comply with all special industrial regulations.
Locate the generator in an area that meets the
following requirements:
• Clean
• Dry
30
Operation Section
Installation

• Well ventilated Protective Devices

• Easily accessible for inspection and maintenance
Do not obstruct air inlet openings. Do not obstruct
discharge openings. Coolant 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.
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.

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 the Generator Maintenance section of this

manual in order to measure the following items:

• Exciter field (stator)

• Exciter armature (rotor)
• Generator field (rotor)
• Generator armature (stator)

Alignment
After the generator set has been placed in the final
position, the generator must be aligned. Refer to
these publications:

• Special Instruction, SEHS7654, “Alignment -

General Instructions”

• Special Instruction, SEHS7259, “Alignment of

Single-Bearing Generators”

• Special Instruction, REHS0177, “Alignment of the

Close Coupled Two-Bearing Generators”

Features and Controls
i01934479
Performance Parameters
SMCS Code: 1000
Air/Fuel Ratio
The correct air/fuel ratio is very important for the
following considerations:
• Detonation Margin
• Control of emissions
• Achieving optimum service life for the engine
• Environmental Regulations
If the air/fuel ratio is not appropriate for the fuel and
the operating conditions, a failure of the engine may
occur. The service life of the turbocharger, the valves,
and other components may be reduced.
Any changes to the air/fuel ratio will affect the exhaust
emissions. After adjustment, use an emissions
analyzer to measure the exhaust emissions. Ensure
that the engine is in compliance with local regulations
for emissions.
Installation Before the Fuel Control Valve
The fuel flows from the main gas supply through
the fuel filter. Usually, the fuel filter is a component
of the design at the particular site. The customer
is responsible for supplying clean, dry fuel to the
engine. The fuel filter may be supplied by Caterpillar
or by the customer. To prevent particles from entering
the engine, a one micron filter is required. The filter
must be properly sized for the required gas pressure.
For installation of the fuel filter, the recommended
location is close to the engine before the engine’s
gas pressure regulator. Pressure gauges in the gas
lines on each side of the fuel filter are recommended
in order to monitor the filter’s differential pressure. A
manual shutoff valve in the gas line before the fuel
filter will facilitate servicing of the filter.
The filtered fuel flows to the Gas Shutoff Valve
(GSOV). The GSOV may be supplied by Caterpillar
or by the customer. The solenoid for the GSOV may
be connected to engine’s wiring harness or to a
harness that is supplied by the customer. In either
case, the customer may install a switch that can
interrupt the circuit.
31
Operation Section
Features and Controls
The control system is configured for a GSOV that is
energize-to-run. This means that the GSOV must be
energized in order for the engine to run. To enable
the fuel flow, the ECM provides +Battery voltage to
the solenoid for the GSOV. The valve opens and the
fuel flows to the engine. When the control system
shuts down the engine, the voltage is removed from
the solenoid. The valve closes and the fuel is shut off.
The fuel flows through the GSOV to the gas
pressure regulator. The regulator may be supplied by
Caterpillar or by the customer. A regulated pressure
of 7 to 35 kPa (1 to 5 psi) is recommended. Less
pressure may result in reduced power. More pressure
may result in instability.
Fuel Temperature
The system is designed for fuel temperatures less
than 60 °C (140 °F). For optimum performance, the
maximum recommended differential temperature for
the fuel and air is 2.8 °C (5 °F).
Temperature of the Air Supply
To avoid hot air from a generator, use ducting. For
more information, refer to Application and Installation
Guide, LEKQ7250, “Air Intake”. Consult your
Caterpillar dealer for assistance.
Oil Consumption
The rate of oil consumption is called Brake Specific
Oil Consumption (BSOC). The unit of measure is
grams per brake kilowatt hour or pounds per brake
horsepower hour. The BSOC depends on the engine
model, the aspiration, the operating load, and the
oil that is used. For information on calculating the
BSOC, refer to Engine Data Sheet 96.2, LEKQ4028,
“Oil Consumption Data”.
Table 4 lists the normal mid-life BSOC for G3500
Engines under the following conditions:
• Load factor of 100 percent
• Maintenance is performed according to this
Operation and Maintenance Manual, “Maintenance
Interval Schedule”.
• Caterpillar NGEO is used.
Table 4
BSOC for G3500 Engines
Turbocharged Aftercooled Engine 0.426 g/bkw h
(.0007 lb/bhp h)
32
Operation Section
Features and Controls

i01934489 • Monitoring of engine operation

Sensors and Electrical Governing of the Engine RPM
Components
The ECM receives a signal from the speed/timing
SMCS Code: 1900; 7400 sensor. The ECM maintains the desired engine rpm
through electrical control of the Proact actuator. The
Note: This section contains some general information actuator regulates the throttle plate.
about the engine electronic system and sensors. For
more information, refer to Systems Operation/Testing Control of Ignition
and Adjusting.
Each cylinder has an ignition transformer that
Electronic System is located on top of the valve cover. To initiate
combustion in each cylinder, the ECM sends a pulse
The Caterpillar Electronic System is a complete to the primary coil of the ignition transformer. The
electronic control system for gas engines. The transformer increases the voltage which creates a
following benefits are the most significant advantages spark across the spark plug electrode.
of the electronic system:
The transformers are grounded through the valve
• Air/Fuel ratio control cover. Use caution when a valve cover is removed.

• Extensive system diagnostics
• Precise control of engine operation
• Protection from detonation
Always disconnect the ignition harness from the
transformer when a valve cover is removed.
An ignition harness connects each transformer to the
ECM.

• Timing control of individual cylinders Control of Air and Fuel

The ECM determines the desired volume for the
flow rates of the air and fuel. The determination is
based on the components: actual engine speed,
actual load, MAP, MAT, and internal maps. Next, the
ECM sends information on the desired fuel flow to
the fuel metering valve via the CAN data link. The
ECM adjusts the signal to the fuel metering valve in
order to maintain emissions. The process is repeated
continuously during engine operation.

g00882978
Illustration 23
Junction box
Most of the functions of the electronic system are
provided by the Engine Control Module (ECM). The
ECM is a sealed unit that is located inside a junction
box at the rear of the engine.
Five primary functions are supported by the ECM:
• Governing of the engine rpm
• Control of ignition
• Control of the air/fuel ratio
• Start/stop control
Start/Stop Control
The ECM contains the logic and the inputs
for controlling the starting and stopping of the
engine. The logic for starting and stopping can be
programmed by the customer. The ECM supplies
positive “+” battery voltage to the starting motor relay
and the gas shutoff valve.
The engine uses an energize-to-run system. The
gas shutoff valve must remain energized in order to
supply fuel to the engine. If power is removed from
the gas shutoff valve, the fuel is shut off. The gas
shutoff valve may be controlled by the customer.
 33
Operation Section
Features and Controls

Monitoring Engine Operation

Sensors are used in order to monitor engine
operation. Wiring harnesses connect the sensors to
the ECM. The ECM uses the information from the
sensors in order to monitor the engine. The ECM
also uses the information from the sensors in order
to control the engine. The information is also used
to generate event codes, and diagnostic codes.
The codes can be read with a Caterpillar Electronic
Technician (ET).

Event – An event is a result of abnormal engine

operation. If abnormal engine operation is detected,
the ECM generates an event code. The ECM can
generate an alarm or a shutdown for abnormal engine
operation. These conditions are some examples of
events: high inlet air temperature, low oil pressure,
and engine overspeed.

Diagnostic – A diagnostic code is a result of a

problem with the operating system or with the
monitoring system. The ECM uses sensors and
internal circuitry to monitor the system components.
If a problem develops in a component or a wiring
harness, the control system will sense the problem.
The control system will notify the operator by creating
a diagnostic code. Some examples of conditions
that activate diagnostics are a short in a circuit for a
sensor, an open circuit, or a noisy signal.

Note: For detailed information on event codes and

diagnostic codes, refer to Troubleshooting.

Sensors
Sensors provide information to the ECM. The
information enables the ECM to control the engine as
efficiently as possible over a wide range of operating
conditions. The information is used for monitoring
engine operation and for protecting the engine.

Illustration 24 shows the locations of the sensors.

34
Operation Section
Features and Controls

Illustration 24
(1) Engine oil temperature sensor
(2) Jacket water pressure switch (inlet)
(3) Pressure sensor for unfiltered oil
(4) Pressure sensor for filtered oil
(5) Manifold air temperature sensor
g00946720
(6) Jacket water pressure sensor (outlet)
(7) Manifold air pressure sensor
(8) Jacket water temperature sensor
(9) Detonation sensor
(10) Speed/timing sensor

The functions of the sensors are described below.


Engine oil temperature sensor (1) – An oil
temperature sensor monitors the engine oil
temperature. A high oil temperature will activate an
alarm or a shutdown. The ECM compares the oil
temperature to the engine coolant temperature. A
high difference between the two temperatures will
activate an alarm or a shutdown.
Jacket water pressure switch (2) – A pressure
switch is located at the outlet of the oil cooler. The
jacket water pressure switch is a limit switch for the
coolant that is entering the block.
Oil pressure sensors (3) and (4) – The engine
oil pressure is measured before the oil filters and
after the oil filters. An alarm or a shutdown can be
activated by any of the following occurrences: low
filtered oil pressure, low oil filter differential pressure,
and high oil filter differential pressure.
Manifold air temperature sensor (5) – A sensor
for monitoring the air inlet temperature is located in
the elbow after the number twenty cylinder head.
Excessive inlet air temperature can activate an alarm
or a shutdown.
Jacket water pressure sensor (6) – A pressure
sensor is located at the outlet for the engine jacket
water. If the outlet pressure is too low, the ECM will
activate a shutdown.
Manifold air pressure sensor (7) – A sensor
for monitoring the air inlet pressure is located in
the elbow before the number one cylinder head.
Excessive inlet air temperature can activate an alarm
or a shutdown.
Engine coolant temperature sensor (8) –
The temperature sensor is located in the water
temperature regulator housing. To monitor the
coolant temperature, the element must be in contact
with the coolant. If overheating occurs due to low
coolant level, the sensor will not function properly.
A high coolant temperature will activate an alarm
or a shutdown. A low coolant temperature will only
activate an alarm. The setpoints for the activation can
be programmed with the Cat ET. The engine can be
restarted after a shutdown due to high engine coolant
temperature. However, another shutdown will occur
after one minute if the temperature remains high.
Detonation sensors (9) – The detonation sensors
monitor the engine for detonation in each cylinder. To
eliminate detonation, the ECM retards the timing of
the cylinder. If excessive detonation continues, the
ECM will shut down the engine.
35
Operation Section
Features and Controls
Speed/timing sensor (10) – The engine
speed/timing sensor is located on the rear end of
the left camshaft. The engine speed/timing sensor
provides accurate information to the ECM about the
position of the crankshaft and the engine rpm. The
ECM uses the position of the crankshaft in order to
determine ignition timing.
Integrated Temperature Sensing Module
(ITSM)
The ITSM monitors thermocouples that are located
at the exhaust port of each cylinder. Thermocouples
are also mounted at the inlets and outlets to the
turbochargers. The temperatures are broadcast over
the Caterpillar data link for use with other modules.
The ITSM calculates the average temperature for
each bank. Event codes are generated if the following
conditions occur:
• The temperature is higher than the limit that is
programmed.
• The temperature of a cylinder deviates significantly
from the average temperature for all of the
cylinders.
i01934516
Alarms and Shutdowns
SMCS Code: 7400
This section contains some general information about
the function of typical engine protective devices.
The alarms and shutdowns are set at critical
operating temperatures, pressures, or speeds in
order to protect the engine from damage.
An alarm warns the operator when an abnormal
operating condition occurs. The shutdowns stop the
engine if a more critical operating condition occurs.
The shutdowns help to prevent damage to the engine.
If an engine protective device shuts down the engine,
always determine the cause of the shutdown. Always
make the necessary repairs before attempting to start
the engine. Refer to Troubleshooting.
Become familiar with the following information:
• Types of the alarms and shutdowns
• Locations of the alarm and shutdown controls
• Conditions which cause each control to function
• Resetting procedure that is required before starting
the engine
36
Operation Section
Features and Controls

Testing Alarms and Shutdowns i01814162

Alarms must function properly in order to provide Electronic Modular Control

timely warning to the operator. Shutdowns help Panel II+ (EMCP II+)
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are SMCS Code: 4490
in good working order during normal operation.
Malfunctions must be simulated in order to test the Note: Your machine may not be equipped with all
engine protective devices. of the following controls.

NOTICE
During testing, abnormal operating conditions must be
simulated.

The tests must be performed correctly in order to pre-

vent possible damage to the engine.

Periodic testing of engine protective devices for

proper operation is recommended maintenance.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.

Prevention of Start-up
The engine will not start if any of the conditions that
cause a shutoff are present. The following conditions
will also prevent starting of the engine:

• No input from the driven equipment prevents

starting.

• An overcrank occurs.
• Emergency stop is pressed.
If any of these situations occur, the following
conditions must be met before the engine can be
started:

• The condition that prevented starting is not present.

• The engine control switch is turned to the
“OFF/RESET” position.

Setpoints for Alarms and Shutoffs

Some of the setpoints for the alarms and shutoffs
can be programmed with a Caterpillar Electronic
Technician (ET). Some of the parameters cannot be
programmed.

The setpoints are programmed at the factory. The

status for most of the parameters is ON. Refer to
Troubleshooting for the default setpoints of the
warnings and shutoffs for G3520C Engines.

For information on programming of parameters, refer

to the Systems Operation/Testing and Adjusting
manual.
 37
Operation Section
Features and Controls

Illustration 25
Electronic Modular Control Panel II+ (EMCP II+)
(1) Generator set control + (GSC+)
(2) Engine control switch (ECS)
(3) Start aid switch (SAS)
(4) Panel lights (PL)
(5) Alarm module (ALM)
g00781900
(6) Synchronizing lights module or Custom (9) Emergency stop push button (ESPB)
alarm module (CAM) (10) Panel light switch (PLS)
(7) Speed potentiometer (SP) or Governor
switch
(8) Voltage adjust rheostat (VAR)

The electronic modular control panel II+ (EMCP II+) is
located above the generator distribution housing. The
control panel consists of the following components:
a main panel with indicators, meters, and control
switches. This control panel may be equipped with
optional modules in order to match the customers’
needs and requirements.
The left side of the control panel contains the
Generator Set Control + (GSC+). This is the main
component of the system. The GSC+ displays
the following information: generator output, fault
conditions, and key engine parameters. The center
section of the control panel contains switches and an
optional alarm module. The right side of the control
panel may be blank, or the right side of the control
panel may contain the Synchronizing Lights Module
or the Custom Alarm Module.
Some components are optional. The optional
components may not be required for your particular
application.
Generator Set Control + (1) – The generator set
control + (GSC+) is the main component of the
EMCP II+. See the topic “Generator Set Control +
(GSC+)” in this section.
Engine Control Switch (2) – The engine control
switch (ECS) determines the status of the control
panel. In the AUTOMATIC position, the engine will
start automatically when a remote initiated contact
is closed. The engine will be shutdown after the
contact opens. The engine will be shutdown after a
cooldown period that is programmable has elapsed.
The cooldown period can be programmed to give a
0 to 30 minute cooldown period before the engine
shuts down.
In the MANUAL START position, the engine will start.
In the MANUAL START position, the engine will run
when ECS remains in the MANUAL START position.
In the STOP position, the engine is shutdown by the
fuel solenoid after a programmable cool down time
period has elapsed.
38
Operation Section
Features and Controls

In the OFF/RESET position (12 o’clock), the Panel Light Switch (10) – The panel lights switch
fault lights are reset and the engine shuts down turns on or the panel lights switch turns off the panel
immediately. lights (4).

Start Aid Switch (3) – The start aid switch (SAS) Below, you can find the descriptions of the following
is optional. The SAS is used to inject ether into main modules of the EMCP II+:
the engine when you are starting the engine in
cold weather conditions. When the SAS is in the • Generator Set Control + (GSC+)
ON position, the switch energizes the starting aid
solenoid valve (SASV) and the switch meters a • Alarm Module (ALM)
specific amount of ether into a holding chamber.
When the SAS is released, the solenoid releases the • Custom Alarm Module (CAM)
ether to the engine.
• Synchronizing Lights Module
NOTICE
The engine must be cranking before using the start Generator Set Control + (GSC+)
aid switch. Damage to the engine is possible if ether
is released to the engine but not exhausted or burned Functions and features of the GSC+
by the engine when cranking.

Panel Lights (4) – Panel lights (PL) are controlled

by panel lights switch (10). The panel lights switch
(10) is an ON/OFF switch.

Alarm Module (5) – The alarm module (ALM)

is optional. The ALM provides a visual warning.
The ALM provides an audible warning of engine
conditions before these conditions become severe.
Engine conditions that are severe may cause the
engine to shutdown. Engine conditions that are
severe may cause the engine not to start.

Synchronizing Lights Module (6) or Custom g00781917

Alarm Module (6) – The synchronizing lights module
uses synchronizing lights for paralleling the generator
sets. The synchronizing lights module is optional.
The custom alarm module (CAM) may be installed in
the same opening on the control panel. The CAM
annunciates faults, alarms or other conditions from
customer supplied inputs.
Speed Potentiometer (7) – The speed
potentiometer (SP) is optional. The SP can be
used with the generator set that has an electronic
governor. When the governor is equipped with a
speed adjusting motor, the governor switch (GS) can
be mounted instead of the SP. The GS is used in
order to raise the engine speed and the frequency.
The GS is used in order to lower the engine speed
and the frequency. The GS is also an option.
Voltage Adjust Rheostat (8) – The voltage adjust
rheostat (VAR) is used to adjust the generator output
voltage to the desired level.
Emergency Stop Push Button (9) – 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.
Illustration 26
The location of the GSC+ on the control panel for the EMCP II+
The left side of the control panel contains the
generator set control + (GSC+). The GSC+ is the
main component of the system. The GSC+ displays
the following information: generator output, generator
set functions, fault conditions, and key engine
parameters. The GSC+ accepts information from the
following sources: operator, speed sensor, engine
oil pressure sensor, water temperature sensor, and
optional remote sources. This information is used
to determine the following parameters: the “on/loff”
state of the air for the engine , the “on/off” state of the
diesel fuel, and the “on/off” state of the starter.
In the very basic operating conditions, the GSC+
receives a signal in order to run the generator set.
The GSC+ turns on the engine’s fuel. The GSC+
turns on the engine’s starter. When the engine speed
reaches the crank termination speed, the starter is
disengaged. When the GSC+ receives a signal to
stop the engine, the GSC+ shuts off the fuel and the
GSC+ shuts off the ignition.
The functions of the GSC+ are listed below:
 39
Operation Section
Features and Controls

• The GSC+ controls the normal starting and Fault indicators

stopping of the engine.

• The GSC+ shows engine conditions and generator

output information on two displays. The displays
also show the fault codes and the programming
information for the GSC+.

• The GSC+ monitors the system for faults. If a

fault occurs, the GSC+ performs a controlled fault
shutdown or the GSC+ provides a fault alarm
annunciation. The GSC+ uses indicators and
displays in order to describe the fault.

• The GSC+ contains programmable features

for certain applications or requirements for the
customer.

The features of the GSC+ are listed below:

• Cycle Crank: The GSC+ can be programmed to

crank for adjustable time periods.
g00786766
Illustration 27
• Governor Control: When the engine oil pressure Display area of the GSC+
increases past the low oil pressure setpoint, the
GSC+ indicates that the governor should increase (13) Low oil pressure indicator
(14) Emergency stop indicator
the engine speed from idle rpm to rated RPM. (15) High water temperature indicator
(16) Engine overspeed indicator
• Cooldown: When the GSC+ receives a signal to (17) Overcrank indicator
perform a shutdown, there is a time delay before (18) Spare 1 indicator
(19) Spare 2 indicator
the engine will stop running. (20) Spare 3 indicator
(21) Fault shutdown indicator
• Automatic Operation: When the GSC+ is in (22) Fault alarm indicator
automatic mode, the GSC+ can be started by a (23) Dedicated shutdown indicators
remote initiate signal (contact closure). Upon loss (24) Spare fault indicators
(25) Upper display
of the signal (contact opening), the GSC+ will (26) The key for the alarm codes
perform a normal shutdown.
The fault indicators are used in order to show a fault
• Alarm Module Communication: The GSC+ can that is present. The fault indicators are used in order
transmit fault conditions and alarm conditions to an to describe a fault that is present. The fault indicators
alarm module (AM). The GSC+ can also transmit are divided into four groups. The four groups are
the fault conditions and the alarm conditions to a listed below:
Customer Communication Module (CCM).
• Fault alarm indicator (22)
• Powerdown: The EMCP II+ system is designed to
remove power from the GSC+ when the engine • Fault shutdown indicator (21)
control switch (ECS) is in the OFF/RESET mode
and when the proper jumper wire is removed. • Spare fault indicators (24)
The GSC+ allows powerdown when the crank
termination relay is off for 70 seconds and the fuel • Dedicated shutdown indicators (23)
control relay is off for 70 seconds. If the wire is not
removed, the GSC+ will remain powered. Refer The yellow fault alarm indicator (22) FLASHES when
to Technical Information Bulletin, TIBU3508 for the GSC+ detects an alarm fault. The alarm fault does
additional information on powerdown. not cause the engine status to change. The engine
can be started. The engine will continue operating
• Fuel Solenoid Type: The GSC+ can be only if the engine is running at the time of the alarm
programmed in order to work with a fuel system fault. Fault alarm indicator (22) is accompanied by an
that is energized to run. The GSC+ can also be alarm fault code that is shown on the upper display
programmed in order to work with a fuel system (25) when the key for the alarm codes (26) is pressed.
that is energized to shutdown.
40
Operation Section
Features and Controls

The red fault shutdown indicator (21) FLASHES when
the GSC+ detects a shutdown fault. The engine will
be shut down if the engine is running. The engine will
not be allowed to start. Fault shutdown indicator (21)
is accompanied by a fault code that is immediately
shown on the upper display (25).
Engine Overspeed – The engine speed exceeds
the setpoint for engine overspeed that is programmed
into the GSC+. When the fault for engine overspeed
occurs, the engine overspeed indicator flashes. The
engine is shutdown and the engine is not allowed to
start until the fault is corrected.

The yellow spare fault indicators (24) FLASH when
the conditions that are associated with that spare fault
are active. The three spare faults can be programmed
to show coolant loss, engine oil temperature, spare
fault condition or no assignment. The spare fault
condition may be a customer generated switch input.
The yellow fault alarm indicator (22) or the red fault
shutdown indicator (21) will accompany the spare
fault indicators (24). The spare fault indicators will tell
whether the spare fault input is programmed to be an
alarm condition or a shutdown condition.
The red dedicated shutdown indicators (23) represent
the following shutdown faults: low engine oil pressure,
emergency stop, high water temperature, engine
overspeed, and engine overcrank. When the GSC+
detects a fault in one of these areas, the dedicated
shutdown indicator flashes. The engine is shutdown
if the engine is running, and the engine is not
allowed to start. No fault codes are associated with
the dedicated shutdown indicators because each
indicator has a descriptive label.
Many of the dedicated shutdown faults depend on
certain setpoints in the GSC+.
The conditions that are required to activate the
dedicated fault shutdowns and the results of each
dedicated fault are in the following list.
Overcrank – The engine does not start within the
setpoint for total cycle crank time that is programmed
into the GSC+. When the overcrank fault occurs, the
overcrank indicator FLASHES. The engine is not
allowed to start until the fault is corrected.
Note: The GSC+ can be programmed to override
the shutdown for low oil pressure and high water
temperature faults. When the operator overrides the
shutdown faults, the GSC+ responds to the faults
as though the faults are alarm faults. The dedicated
shutdown indicator is on continuously, and the
indicator will not be flashing. The engine continues
to run and the engine can be restarted. When the
dedicated shutdown indicator is ON continuously,
the setpoint for shutdown has been exceeded, but
the GSC+ is programmed to override the shutdown
fault. The GSC+ does not treat the shutdown fault
as a shutdown fault. The GSC+ treats the shutdown
fault as an alarm fault. At the factory, the GSC+ is
programmed to treat a low oil pressure fault and a
high water temperature fault as shutdown faults. The
operator or the service technician must decide to
override these shutdown faults. The operator or the
service technician must program the GSC+ to treat
the shutdown faults as alarm faults.

Low Oil Pressure – The engine oil pressure drops

below the setpoints for low oil pressure shutdown
that are programmed into the GSC+. There are two
low oil pressure setpoints. One setpoint is used when
the engine is at idle speed. The other setpoint is used
when the engine is at rated speed. When a low oil
pressure fault occurs, the low oil pressure indicator
FLASHES, and the engine is shut down. The engine
is not allowed to start until the fault is corrected.

Emergency Stop – The operator presses the

emergency stop push button (ESPB) on the front
panel. When an emergency stop condition occurs,
the emergency stop indicator FLASHES and the
engine is shut down. The engine is not allowed to
start until the condition is corrected.

High Water Temperature – The engine coolant

temperature rises above the setpoint for high water
temperature shutdown that is programmed into the
GSC+. When the high water temperature fault occurs,
the high water temperature indicator FLASHES. The
engine is shutdown and the engine is not allowed to
start until the fault is corrected.
 41
Operation Section
Features and Controls

Display Note: Line to neutral voltages are not shown when

the setpoint P032 is set to 1 for delta generator sets.

Lower display

The lower display (27) shows values for power

metering, engine parameters and the relay status.

The left side of the lower display (27) serves as a

power meter for the generator set. The following
functions will scroll automatically:

• Total real power (kW)

• Total reactive power (KVAR)
• Percentage of rated power (%kW)
• Power factor (average)
• Total energy output (kW/h)
g00786776 The display will stop scrolling when the operator
Illustration 28
presses the power meter key for less than five
Display area of the GSC+ seconds. The display will show a particular parameter
(25) Upper display continuously. Additional power meter functions will
(27) Lower display scroll, if the power meter key (28) is held for more
(28) The power meter key
(29) The AC meter key than five seconds and then released. The additional
(30) The engine meter key functions are shown below:

The display consists of the upper display and • Total real power (kW)
the lower display. Both displays are used for
programming functions when the display is in the • Real power phase A (kW)
service mode.
• Real power phase B (kW)
Upper display
• Real power phase C (kW)
The upper display (25) shows: AC voltage, current,
and frequency. Several options are available on the • Total apparent power (kVA)
upper display for AC metering. These options can be
viewed one at a time by pressing the AC meter key • Total reactive power (KVAR)
(29) on the keypad. The options are listed below:
• Percentage of rated power (%kW)
• Average voltage, generator frequency, and total
current • Power factor (average)
• Line to line voltage, generator frequency, and line • Power factor phase A
current for any one phase
• Power factor phase B
• Line to line voltage for all three phases
• Power factor phase C
• Line current for all three phases
• Total energy output (kW/h)
Note: When total current increases above “9999A”,
the GSC+ will show current in “kA” units. • Total reactive energy output (kVAR/Hr)

• Line to neutral voltage for all three phases Note: All real power values are signed with a “+” or a
“−”. A negative value indicates reverse power.
Upper display (25) is also used to show the various
fault codes for system faults.
42
Operation Section
Features and Controls

Note: The Real power phase and the power factor Keypad
phase are not shown when setpoint P032 is set to 1
for delta generator sets.

Note: Total energy output that is greater than 999,999

kW/h will be shown as MW/h in two steps in order to
maintain a resolution of 1 kW/h. The first step will
show MW/h as a whole number up to six places. The
second step will show MW/h as a decimal to three
places.

The right side of lower display (27) shows the value

of certain engine parameters. The parameters are
listed below:

• Engine oil temperature (if equipped)

• System battery voltage
• Engine hours
• Engine speed
g00786777
Illustration 29
• Engine oil pressure
Keypad area of the GSC+
• Engine coolant temperature (21) Fault shutdown indicator
(22) Fault alarm indicator
(25) Upper display
The value for one of these conditions is shown on (26) Key for the alarm codes
display (27) for two seconds. The display then scrolls (27) Lower display
to the value for the next condition. A small pointer (28) Power meter key
identifies the engine condition that corresponds to the (29) AC meter key
(30) Engine meter key
value that is showing. When the engine meter key (31) Lamp test key
(30) is pressed, the lower display (27) stops scrolling. (32) Exit key
The lower display continuously shows one particular (33) Service mode key
value. The pointer flashes above the value that is (34) Keypad
showing on the display. When the engine meter key
(30) is pressed for the second time, the lower display Keypad (34) is used to control the information that is
will return to scrolling. shown on the upper display (25) and lower display
(27). The seven keys have two sets of functions:
The relay status indicators are on the bottom of the normal functions and service functions. The normal
lower display (27). When a relay for the GSC+ is functions of the keys are described in the following
activated, the corresponding indicator is shown on paragraphs.
the lower display (27). When a relay is not activated,
the corresponding indicator is not shown. Power Meter Key (28) – This key controls the
viewing of power meter information. This information
is shown on the lower display. Pressing the key for at
least five seconds causes all the power meter data
to scroll once. The default power meter data then
resumes scrolling. If the key is pressed for less than
five seconds, the display stops scrolling.

AC Meter Key (29) – The AC meter key controls

the viewing of the AC parameters on the upper
display. Pressing the key causes the display to show
a different set of parameters.

Engine Meter Key (30) – This key controls the
viewing of engine parameters on the lower display.
Pressing the key stops the scrolling of engine
conditions. The value for one particular engine
condition will show continuously. The pointer flashes
indicating that the scrolling is stopped. The scrolling
of the engine conditions will resume when the engine
meter key is pressed again.
Lamp Test Key (31) – Pressing this key performs
a lamp test on the GSC+ and the optional alarm
module. On the GSC+, the ten fault indicators are ON
CONTINUOUSLY. Every segment of upper display
(5) and lower display (6) is ON. On the optional alarm
module, all of the indicators are ON and the horn
sounds. The function for the lamp test automatically
turns off if the operator presses the key and the
operator holds the key for ten seconds.
The Alarm Codes Key (26) – If fault alarm indicator
(22) is FLASHING, pressing this key causes the
upper display (25) to show the corresponding alarm
fault code. If this key is pressed again, the generator
AC output information will be shown on the upper
display (25). If fault alarm indicator (22) is OFF, this
key has no function.
Exit Key (32) – This key only functions when the
GSC+ is in Service Mode.
Service Mode Key (33) – Pressing this key causes
the GSC+ to enter Service Mode.
Alarm Module
g00781923
Illustration 30
The location of the Alarm Module (ALM) on the control panel for
the EMCP II+
The alarm module (ALM) is optional. The alarm
module provides a visual warning and the alarm
module provides an audible warning of engine
conditions before the conditions become severe.
43
Operation Section
Features and Controls
One basic alarm module is used to satisfy the
requirements for the following modules: standby
NFPA 99 alarm module, standby NFPA 110 alarm
module, NFPA 99 remote annunciator panel, and
prime power alarm.
The front of the alarm module consists of the
following indicators:
• Four amber indicators, which can indicate High
Coolant Temperature, Low Coolant Temperature or
Low Coolant Level, Low Oil Pressure, Generator
On Load, Charger Malfunction, Low Engine Oil
Level and Low Fuel Level
• Four red indicators, which can indicate a Low DC
Voltage, Air Damper Closed, Low Oil Pressure
Shutdown, Overcrank Shutdown, High Coolant
Temperature Shutdown, and Overspeed Shutdown
• An audible alarm and Acknowledge/Silence switch
Custom Alarm Module
g00781924
Illustration 31
The location of the Custom Alarm Module (CAM) on the control
panel for the EMCP II+
The custom alarm module (CAM) is optional. The
custom alarm module provides a visual warning
and the custom alarm module provides an audible
warning of the conditions of the customer supplied
inputs before these conditions become severe. The
CAM is equipped with the following items for the
customer: horn, alarm silence switch, lamp test
switch, and eight switched inputs
The front of the alarm module consists of the
following indicators:
• Four amber indicators, which are used to display
alarm conditions
• Four red indicators, which are used to display
shutdown conditions
44
Operation Section
Features and Controls

Synchronizing Lights Module The reverse power relay is a single phase protective
relay. This relay is energized by power in only one
direction. In a reverse power fault, the relay contacts
close and the engine shuts down. This will take the
generator off the line. The reverse power relay is
equipped with a test switch and adjustments.

g00781939
Illustration 32
The location of the Synchronizing Lights Module on the control
panel for the EMCP II+
(35) Synchronizing lamps
(36) Synchronizing switch

The optional synchronizing lights module is mounted

on the right side of the control panel. This module
is not used when the control panel is equipped with
the 2301A governor.

The synchronizing lights module contains the

synchronizing lights (35) and the synchronizing
switch (36).

Synchronizing Lights (35) – The synchronizing

lights (35) are used as an aid in paralleling units at
no load and under load. Each light is connected to
the side with the load of the generator output circuit
breaker. The lights are used to indicate when the
voltages are in-phase. Close the circuit breaker in
order to connect the generator with the load.

Synchronizing Switch (36) – The synchronizing

switch has two positions, ON and OFF. When the
switch is in the ON position, the synchronizing lights
are enabled. The generator circuit breaker can be
closed manually when the synchronizing switch is on
and the lights are synchronized.

Note: Refer to Operation Section, “Parallel

Operation” for information regarding the paralleling
of two generators.

When a reverse power relay is added to

a synchronizing lights module, the original
synchronizing lights module will change in the
following ways:

• The reverse power relay is mounted on the control

panel interior.

• A reverse power fault is indicated by the Fault

Shutdown Indicator on the front of the GSC+.

Engine Starting
i01934523
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Note: Certain procedures are required before an
engine is started for the first time. See Special
Instruction, REHS1438, “Installation and Initial
Start-UP Procedure for G3500C Engines”.
Perform the required daily maintenance and other
periodic maintenance before starting the engine. This
can prevent major repairs at a later date. See this
Operation and Maintenance Manual, “Maintenance
Interval Schedule”.
Walk-Around Inspection
NOTICE
For any type of leak, clean up the fluid. If leaking is ob-
served, find the source and correct the leak. If leaking
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until
the suspicion of a leak is proved to be unwarranted.
To obtain maximum service life for your engine, make
a thorough inspection before starting the engine.
Make a walk-around inspection of the installation.
Look for items such as oil or coolant leaks, loose
bolts and trash buildup. Remove any trash. Make
repairs, if necessary.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Ensure that the areas around the rotating parts are
clear.
Air Inlet System
• Ensure that the air inlet piping and the air filters
are in place and clean.
• Ensure that all clamps and connections are secure.
• Inspect the air cleaner service indicator (if
equipped). Service the air cleaner filter element
when the yellow diaphragm enters the red zone, or
the red piston locks in the visible position.
45
Operation Section
Engine Starting
Cooling System
• Inspect the cooling system for leaks or loose
connections. Inspect the condition of all the hoses
and pipes for the cooling system. Ensure that the
connections are properly clamped.
• Inspect the water pumps for evidence of leaks.
• Check the coolant level. Add coolant, if necessary.
For information on the proper coolant to use, see
this Operation and Maintenance Manual, “Cooling
System Specifications” (Maintenance Section).
Driven Equipment
• If necessary, check the oil levels of the driven
equipment. Perform any maintenance that is
required for the driven equipment. Refer to the
literature that is provided by the OEM of the driven
equipment.
• If the engine is equipped with a clutch, ensure that
the clutch is disengaged.
• For generator set engines, ensure that the main
circuit breaker is open.
Electrical System
Inspect the wiring for the following conditions:
• Loose connections
• Wiring that is worn or frayed
Inspect the gauge panel and the control panel
for good condition. Reset any shutoff or alarm
components.
Fuel System
NEVER use a flame to check for gas leaks. Use a
gas detector.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
• Check the fuel lines for leaks with a gas detector.
• Inspect the fuel lines for loose fittings and leaks.
Ensure that the fuel lines are properly clamped.
• Ensure that the fuel is supplied to the engine at the
correct pressure for the engine.
46
Operation Section
Engine Starting
Lubrication System
g00760044
Illustration 33
Oil level gauge (dipstick)
(1) “ADD” mark
(2) “FULL” mark
NOTICE
Excessive engine oil will increase oil consumption and
result in excessive deposits in the combustion cham-
ber. Do not overfill the engine with oil.
• Check the engine crankcase oil level. Maintain the
oil level between the “ADD” and “FULL” marks on
the “ENGINE STOPPED WITH OIL COLD” side of
the oil level gauge. For information on the proper
oil to use, see this Operation and Maintenance
Manual, “Lubricant Specifications” (Maintenance
Section).
• Check for leaks at the following components:
crankshaft seals, crankcase, oil filters, oil gallery
plugs, sensors, and valve covers.
• Inspect the tubes, tee pieces, and clamps on the
crankcase breathers.
Starting System
Note: If the engine is equipped with a system for
external support, prepare the system before starting
the engine. Ensure that all of the systems for engine
support are enabled. Perform all prestart checks for
the control system.
Air Starting Motor
• Drain moisture and sediment from the air tank and
from any other air piping.
• Check the oil level in the lubricator. Keep the
lubricator at least half full. Add oil, if necessary.
• Check the air pressure for starting. The air starting
motor requires a minimum of 690 kPa (100 psi).
The maximum allowable air pressure is 1030 kPa
(150 psi). Open the air supply valve.
Electric Starting Motor
• Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor engages.
Inspect the wiring, the electrical cables, and the
battery for the following conditions:
• Loose connections
• Wires that are worn or frayed
• Corrosion
i01934528
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
NOTICE
Oil pan immersion heaters are not recommended for
heating the lube oil. To ensure the compatibility of the
components, only use equipment that is recommend-
ed by Caterpillar.
A jacket water heater is required to maintain a
minimum starting temperature of 45 °C (113 °F).
The engine may be difficult to start if the jacket
water coolant temperature is below 43 °C (110 °F).
The spark plugs may become fouled with moisture
condensation if the engine is cranked and the jacket
water coolant temperature is below 43 °C (110 °F).
For air starting motors, a larger volume of starting
air and/or a higher air pressure may be necessary in
order to start the engine at colder temperatures.
For electric starting, extra battery capacity may be
necessary.
Consult your Caterpillar dealer for more information
on the starting aids that are available for cold weather
starting.

i01934678
Starting the Engine
SMCS Code: 1000; 1450
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.
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
fuel supply and/or the ignition to the engine.
Note: Using the “EMERGENCY STOP” button will
shut off both the fuel and the ignition.
Unburned gas in the inlet manifold and/or in the
exhaust manifold can ignite when the engine is
started. Personal injury and/or property damage
can result. Use this procedure to clear the engine
and the exhaust system of unburned gas:
Before starting an engine that was stopped by ter-
minating the ignition system, turn the gas supply
OFF. Crank the engine for approximately 15 sec-
onds in order to clear any unburned gas from the
engine and the exhaust system.
Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.
Ensure that no one will be endangered before the
engine is started and when the engine is started.
Perform the procedures that are described in this
Operation and Maintenance Manual, “Before Starting
Engine”.
47
Operation Section
Engine Starting
Automatic Starting
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.
If the engine control switch is in the “AUTO” position,
the engine will automatically start when the remote
start/stop initiate contact closes.
Parameters for the Start/Stop
Control
Driven Equipment
Start-up is delayed until the switch for the driven
equipment indicates that the driven equipment is
ready.
Purge Cycle
Note: The engine uses an energize-to-run system.
The gas shutoff valve must remain energized in order
to supply fuel to the engine.
The purge cycle allows any unburned fuel to exit
through the exhaust before the ignition system is
activated.
The purge cycle occurs under these conditions:
• The gas shutoff valve is de-energized.
• The ignition is off.
• The engine is cranked.
The purge cycle occurs before the crank cycle. The
amount of time for the purge cycle is programmable.
Cycle Crank Time
The maximum amount of time for activation of the
starting motor and the gas shutoff valve for starting
is the cycle crank time. The amount of time is
programmable.
Rest Cycle
If the engine does not start within the cycle crank
time, starting is suspended for a rest cycle. The
amount of time for the rest cycle is equal to the cycle
crank time.
48
Operation Section
Engine Starting
Overcrank Time
The overcrank time includes the total purge cycle,
the total cycle crank time, and the total rest cycle.
These functions are repeated until termination of the
overcrank time.
If the engine does not start within the overcrank time,
the engine control module generates an event code.
Manual Starting
1. Ensure that fuel is supplied to the engine.
2. Ensure that the driven equipment is ready. For
generator set engines, ensure that the main circuit
breaker is open.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
3. Start the engine.
The crank terminate speed is programmable.
When the engine rpm exceeds the crank terminate
speed, the engine control module disengages the
starting motor.
4. Allow the engine speed to stabilize at low idle
rpm. Check all of the pressure gauges. Inspect
the engine for leaks and listen for unusual noises.
When all systems are normal, the rpm may be
increased.
Table 5
Rated RPM And Low Idle RPM
Rated rpm 1500 1800
Low idle rpm 1000 1200
i01934760
Starting with Jump Start
Cables
SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause
an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
If the installation is not equipped with a backup
battery system, it may be necessary to start the
engine from an external electrical source.
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
first.
When using an external electrical source to start the
engine, turn the engine control switch to the “OFF”
position. Turn all electrical accessories OFF before
attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch to the OFF position. Turn off
all accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Start the engine.
 49
Operation Section
Engine Starting

5. Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.

Note: If there is a problem with the alternator or the

battery charger, the engine will not continue to run
after starting, unless the power to the engine control
module is supplied by a separate source.

i01934778

After Starting Engine

SMCS Code: 1000

For new installations and engines that are recently

rebuilt, carefully monitor the engine in order to detect
any unusual engine performance.

After all systems are stabilized and normal, the

engine rpm can be increased from low idle rpm to
rated rpm.

It may be necessary to apply some load in order to

attain normal operating temperatures.

Engaging the Driven Equipment

1. Increase the engine speed to rated rpm.

2. Ensure that the operating parameters are in the

normal ranges for the engine load.

3. Close the main circuit breaker in order to apply

the load.

4. Refer to Special Instruction, REHS1438,

“Installation and Initial Start-up Procedure for
G3520C Engines” in order to properly load the
engine.
50
Operation Section
Engine Operation

Engine Operation Partial Load Operation

Extended operation at low idle or at a reduced load
i01934783 will cause increased oil consumption and carbon
buildup in the cylinders. Carbon buildup results in
Engine Operation the following effects:
SMCS Code: 1000 • Narrow margin for detonation
Proper operation and maintenance are key factors in • Power loss
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation • Poor performance
and Maintenance Manual in order to minimize
operating costs and maximize the service life of the • Accelerated wear of components
engine.
Caterpillar Engines can be operated at very light
Observe the gauges or the Caterpillar Electronic loads for limited times with no harmful effects. Table 7
Technician (ET) frequently while the engine is lists the limits for hours of operation at various loads.
operating. Record the data from the gauges or the
Cat ET in a log. Include the parameters that are After the time limit for reduced load operation
listed in Table 6. Average the data that is recorded has expired, operate the engine for a minimum of
during operation and record the average values for two hours at a load that is more than 70 percent
each day. Compare the data to the specifications for of the rated load.
normal engine operation. Comparing the data over
time will help to detect trends in engine performance. For example, an engine is operating at 20 percent of
the rated load. The engine may be operated at this
Table 6
load factor for a maximum of one-half hour. After the
Engine Performance one-half hour, operate this engine for at least two
hours at a load factor of more than 70 percent.
Operator Date
Engine serial number Hour meter To help keep engine maintenance at a minimum,
follow the guidelines that are listed in Table 7.
Load RPM
Coolant temperature Oil pressure Table 7

Oil filter Air filter Time Limits For Low Load Operation
differential pressure differential pressure Engine Load Time Limit
Inlet Inlet 0 to 30 percent 1/2 hour
manifold pressure manifold temperature
31 to 50 percent 2 hours
Exhaust Exhaust
temperature pressure 51 to 100 percent Continuous (1)

(1) For continuous operation, the manifold air pressure must be

Secondary transformer Exhaust emissions
voltages greater than the atmospheric pressure.

Throttle position Fuel valve position

Investigate any significant change in the gauge or in

the Cat ET readings. Monitor the engine operation
and take action when discrepancies are found.

Operating the Engine and the

Driven Equipment
Check the gauges and the driven equipment
frequently while the engine is operating under a load.
The engine can be operated continuously at full load.
 51
Operation Section
Engine Stopping

Engine Stopping Unplanned Shutdowns

Abnormal operating conditions may cause an engine
i01934812 shutdown. The fuel will be shut off, but the ignition
may not be shut off.
Emergency Stopping
An indication of the cause will be generated by
SMCS Code: 1000; 7418 the engine control module. The event code or the
diagnostic code can be obtained with a Caterpillar
NOTICE Electronic Technician (ET). For more information
Emergency shutoff controls are for EMERGENCY use on event codes and diagnostic codes, refer to
ONLY. DO NOT use emergency shutoff devices or Troubleshooting.
controls for normal stopping procedure.

Emergency Stop Button

g00882855
Illustration 34

The emergency stop button is in the OUT position

for normal engine operation. For an emergency
stop, press the emergency stop button. This
shuts off both the fuel and the ignition.

Ensure that any system that provides external

support to the engine is secured after the engine is
stopped.

NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.

The engine will not restart when the button is locked.

To reset the button, pull the button or turn the button
clockwise. The spring-loaded button will return to the
OUT position.

The control system must also be reset before the

engine will start. Turn the engine control switch to
the “OFF/RESET” position.

The customer may also provide a remote connection

for emergency stopping. For instructions on
connecting a remote emergency stop, see Special
Instruction, REHS1438, “Installation and Initial
Start-up Procedure for G3520C Engines”.
52
Operation Section
Engine Stopping

i01934845 i00662051

Manual Stop Procedure After Stopping Engine

SMCS Code: 1000; 7418 SMCS Code: 1000

NOTICE • Check the engine crankcase oil level. Maintain

Stopping the engine immediately after the engine has the oil level between the “ADD” and “FULL” marks
been operating under a load can result in overheating on the “ENGINE STOPPED” side of the oil level
and accelerated wear of the engine components. gauge.

Allow the engine to gradually cool before stopping the • If necessary, perform minor adjustments. Repair
engine. any leaks and tighten loose bolts.

• Note the service hour meter reading. Perform the

There may be several different methods of stopping
the engine. Be sure that the engine stopping
procedure is understood. Follow the instructions that
are provided by the OEM of the control panel.
1. Reduce the load to zero.
Note: Remove the load at a rate that will avoid
detonation. Reduce the load from 100 percent to
zero percent within three minutes but not less than
two minutes.
2. For generator set applications, open the main
circuit breaker.
Note: Extended idling can cause excessive oil
consumption and related problems. Refer to
Operation and Maintenance Manual, “Engine
Operation”.
3. Stop the engine according to the instructions that
are provided by the OEM of the control panel.
maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications of this manual. Failure to do
so can cause engine damage.
• Allow the engine to cool. Check the coolant level.
• If freezing temperatures are expected, check the
coolant for protection against freezing. The cooling
system must be protected against freezing to the
lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. Refer to the instructions that are
provided by the OEM of the driven equipment.

If the cooldown feature is utilized, the engine will

operate for a programmed period of time before
the engine stops. This allows the turbochargers
to slow down. After the cooldown, the engine will
shut off.

If the cooldown feature is not utilized, operate the

engine at high idle rpm for a cooldown period
before stopping the engine. If the engine has been
operated at a high load, operate the engine at
high idle until the engine systems stabilize. For
example, wait until the speed of the turbochargers
is reduced. Under normal operating conditions,
the cooldown period should be less one minute.
 53
Operation Section
Generator Operation

Generator Operation
i01934941

Generator Operation
SMCS Code: 4450

Loading of the Generator

When a generator is installed or reconnected, be
sure that the total current in one phase does not
exceed the nameplate rating. Each phase should
carry the same load. This allows the engine to work
at the rated capacity. An electrical unbalance can
result in an electrical overload and overheating if one
phase current exceeds the nameplate amperage.

Allowable combinations of unbalanced loads are

shown in Illustration 35. When you operate with
significant single-phase loads, the combinations of
single-phase load and three-phase load may be
used. Such combinations should be located below
the line on the graph.

g00627416
Illustration 35
Allowable Combinations of Unbalanced Loads

Block Loading and Transient

Capability
The block loading capability (transient response) of
a generator set that is powered by a gas engine is
less than a generator set that is powered by a diesel
engine. Most of this difference is directly attributed
to the inherently different fuel systems of the two
engines. When the governor calls for more power, a
diesel engine reacts by adding fuel directly into the
cylinder. This method permits the diesel engine to
accept 100% block loads with acceptable voltage
dips and frequency changes. When the governor on
a gas engine calls for more power the throttle opens.
This causes a larger flow of the air/fuel mixture
to move through the aftercooler core and the air
intake manifold and into the cylinder. This time delay
reduces the gas engine’s capability for accepting
large block loads.
54
Operation Section
Generator Operation
If a block load derating is required, refer to ISO 8268
Standards or SAE J1349 Standards. Also, reference
Engine Data Sheet, LEKX4066, “Loading Transient
Response” and Engine Data Sheet, LEKX4067,
“Block and Transient Response”.
Power Factor
The power factor represents the efficiency of the
load. The power factor is the ratio of apparent power
to total power. This ratio is expressed as a decimal.
The power factor represents the 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. This
current is called the reactive load. Engine power is
not required to maintain the reactive load.
In most applications, the power factor of the system
is determined by these components: electric motors,
controls, and transformers. Induction motors usually
have a power factor that is no larger than 0.8.
Incandescent lighting is a resistive load of about 1.0
power factor, or unity. Controls can operate at any
power factor. Drivers that have variable frequency
or variable speed can operate at any power factor.
An uninterruptible power supply can operate at any
power factor. In this case, the power factor can be
between 0.4 and 1.0.
The power factor of a system may be measured
with a power factor meter or determined 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. With equal
loads, a lower power factor will draw more current. A
high power factor will result in full engine load that is
less than the generator’s rated amperage. A lower
power factor increases the possibility of overloading
the generator.
Note: Normally, Caterpillar generators are designed
for a lagging power factor of 0.8. If operation at less
than 0.7 lagging power factor is desired, consult your
Caterpillar dealer in order to check the rating of the
generator.
Excitation Systems
Permanent Magnet Pilot Excited
Generators
Permanent Magnet Pilot Excited (PMPE) generators
receive power for the voltage regulator from a pilot
exciter, rather than the main armature. The pilot
exciter consists of a permanent magnet rotor and a
stator. The pilot exciter operates independently from
the generator output voltage. Constant excitation
during a large load application is possible since
irregularities in the output voltage are not fed back
into the system. Such irregularities can be caused
by load conditions. The independent operation also
allows the generator to better sustain an overload
for a short duration.
Low Idle Adjustment
Typically, the low idle on 3500C generator sets
is 1100 rpm. On 60 Hz units, low idle will be
approximately 66 percent of the full load speed. On
50 Hz units, low idle will be approximately 80 percent
of full load speed.
There is no low idle stop on generator sets with
electronic governors. The low idle is set at the factory
on generator sets that have mechanical governors.
The low idle is also set at the factory on generator
sets that run on natural gas. The low idle should only
be adjusted by your Caterpillar dealer if adjustment
is required.
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
down. Then, the electric set must be restarted. This
will allow the voltage regulator to again produce an
output.
Standby Generator Sets
Most standby units are automatic. Without an
operator in attendance, standby units will perform the
following functions: start, pick up the load, run, and
stop.
Standby units will not change the governor speed
control or voltage level settings automatically. The
governor speed and voltage level must be preset
for the proper operation of that unit. Whenever the
generator set is operated manually, ensure that the
governor speed and the voltage level settings are set
correctly for automatic operation. Check all switches
for the proper setting. The Start Selector Switch
should be in the AUTOMATIC position. Emergency
Stop Switches should be in RUN position.
 55
Operation Section
Generator Operation

Options The phase rotation of the paralleled units must

be equal. There are two methods that are used
Space Heaters in order to determine if the phase rotation of the
incoming unit is equal to the phase rotation of the
Most of the SR4B generators are provided with on-line unit. These methods are listed below.
space heaters. These space heaters are installed
for operation in all climates. The space heaters • Phase rotation meter
are especially for use in high humidity conditions.
For more information on space heaters, refer to • Set of three light bulbs
Maintenance Section, “Space Heater - Check”.
The procedure for determining the proper phase
rotation is described below.
Embedded Temperature Detectors
SR4B generators are available with embedded
temperature detectors. The detectors are installed in
the slots of the main armature. The main armature is
also called a stator. The detectors are used with the
equipment that is provided by the customer. Thus,
the temperature of the main armature winding can be
measured or monitored. Two types of temperature
detectors are available: RTD and thermocouple.
Contact your Caterpillar dealer for more information.

Bearing Temperature Detectors

Bearing temperature detectors are available on
g00695380
generators with large frames. Bearing temperature Illustration 36
detectors measure the temperature of the main
bearing. Thus, the temperature of the bearing can
be measured or monitored. Bearing temperature
measurements may help to prevent premature When servicing or repairing electric power gener-
bearing failure. Two types of temperature detectors ation equipment:
are available. Bearing temperature detectors are
used with equipment that is provided by the customer. Make sure the unit is off-line (disconnected from
Contact your Caterpillar dealer for more information. utility and/or other generators power service), and
either locked out or tagged DO NOT OPERATE.
i01807249
Remove all fuses.

Parallel Operation a. Connect the light bulbs with rated voltage

between the generator leads and the
SMCS Code: 4450
corresponding line phase. For example,
connect terminal 1 to line 1 across the open
Initial Start-Up circuit breaker.

Preparing a generator for parallel operation requires b. Start the units. Bring the units up to speed. As
special attention. Before you attempt to parallel units the units approach the same speed, the lights
for the first time, check all the units for the following will start to blink.
three conditions.
• If the lights blink in sequence, one of the
• Same phase rotation units is connected backward. In order to
correct the problem, stop the units. Remove
• Same alternating current frequency generator leads 1 and 3 at the circuit
breaker. Exchange these generator leads.
• Same voltage adjustment This reverses the direction of phase rotation.
Terminal 2 should always be connected to
1. Check the phase rotation. line 2. Go to 5.

• When the lights flash in unison, the phase

rotation is equal. The first condition of “Initial
Start-Up” has been met.
56
Operation Section
Generator Operation
2. Adjust the frequency.
The speed of the paralleled units must be equal.
Speed is proportional to the alternating current
frequency.
a. Allow each electric set to run under load for
about 30 minutes.
b. Adjust the governor control in order to give
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 governors 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.
There are two basically different methods for
reactive power equalization.
• Reactive droop compensation
• Cross current compensation
In the reactive droop compensation, the voltage
regulator causes an individual generator output
voltage to change in proportion to the reactive
current. The reactive current is measured with a
current transformer (CT).
The reactive current can be either lagging or
leading. As the lagging reactive current increases,
the voltage regulator will cause the generator
output voltage to droop proportionally. As the
leading reactive current increases, the voltage
regulator will cause the generator output voltage
to rise proportionally.
This method will tend to reduce the reactive
current for the better KVAR sharing with other
units. The reactive droop compensation is a
standard method on the Caterpillar generator sets.
The following procedure for voltage adjustment is
for the reactive droop compensation.
In the cross current compensation, the voltage
regulator is forward biased by the difference in
reactive current outputs of the generators in
parallel. Cross current compensation is very
similar to the reactive droop compensation. In
cross current compensation, the secondary circuits
of the current transformers are connected in a
series string. When one of the generators carries
more reactive current than other generators, a net
difference voltage signal will offset the generated
voltage. This will also reduce the reactive current.
Refer to the Engine Data Sheet, LEKX8142,
“Caterpillar Zero Droop Voltage for Parallel
Operation” for the adjustment procedure.
Note: The adjustment for the voltage level and
voltage droop determine the amount of circulating
currents between the generators. The circulating
currents between the generators will be reduced
when the voltage adjustments are carefully matched.
Use the same voltmeter to make adjustments on
each unit which will be paralleled.
Note: Voltage droop is expressed as the percentage
of voltage change from no load to full load. Loads of
0.8 power factor require a voltage droop of about 5
percent. A droop adjustment that causes a 2 percent
droop in voltage to a 8 percent droop in voltage is
usually required for satisfactory division of ampere
loading.
a. Adjust the voltage. Refer to the “Initial
Start-Up” in the Operation Section, “Single Unit
Operation”.
b. While the engine is running at rated speed,
turn the voltage droop potentiometer clockwise
about 1/2 of full range.
• If the driven load has the unity power factor,
set the voltage droop potentiometer on all
generators at half of full range. Proceed to
3.g.
• If the driven load is approximately 0.8 power
factor, proceed to 3.c.
c. Readjust the voltage level rheostat until the
voltage is approximately 5 percent above
desired voltage.
d. Apply full load.
e. Readjust the voltage droop rheostat in order
to obtain desired voltage with full load at
0.8 power factor. The voltage droop of each
generator must be equal in order to divide the
reactive load.
f. Repeat 3.c, 3.d and 3.e for each generator until
the following two conditions are met.

• The line voltage is equal to the desired level
at full load.
• The voltage at no load is approximately 5
percent above the rated voltage.
g. Parallel the generators and apply the driven
load. Check the output current of the generator.
If the sum of the amperes of the individual
generator amperes exceeds the total amperes
that are going to the load by 10 percent at full
load, adjust voltage droop rheostats. This will
lead to proportional current sharing between
generators. Some circulating current is
permitted at light load. Some circulating current
can be expected when generators are cold.
NOTICE
Damage to the generator is possible. Do NOT exceed
the rated ampere load on any single generator.
h. Make the final adjustments after the generators
that are parallel have been running at full
load for one hour. Tighten the locknuts on all
controls. Install the access cover. The last
condition of “Initial Start-Up” has been met.
Starting Multiple Units
Refer to Operation Section, “Single Unit Operation”.
Paralleling Multiple Units
Units may be paralleled at no load or units may
be paralleled with units under load. After the initial
conditions for start-up are satisfied, verify for the
following requirements.
• One of the governors can be an isochronous
governor. Electronic load sharing governors are
an exception.
• Generators must have voltage droop compensation
or cross current compensation.
1. Start the unit which will be paralleled.
2. Turn on the synchronizer lights.
3. After the engine has run a few minutes, bring the
engine up to synchronous speed. Synchronous
speed means that the frequency of the incoming
unit will have the same frequency of the unit that is
on-line. The synchronizing lights will begin to blink.
Note: The frequency of the incoming unit should be
slightly greater than the line frequency. This will allow
the incoming unit to assume part of the load.
57
Operation Section
Generator Operation
4. Adjust the engine speed until the lights blink very
slowly.
5. The lights turn off when the voltages of the two
units are in-phase. At this point, very quickly close
the breaker while the lights are out.
6. Use governor controls in order to share kW load
between engines.
7. Generator temperature will be stabilized in
approximately four hours. After the generator
temperature has been stabilized, adjust the
voltage droop rheostat of each generator in
order to share the reactive load. Adjust the
voltage droop rheostat of each generator in
order to limit the circulating currents. Less droop
increases the reactive current that is carried by the
generator. Adjusting the voltage droop rheostat
in a counterclockwise direction will decrease
droop. Adjusting the voltage droop rheostat in a
clockwise direction will increase droop.
Speed Droop for the Load Division
(If Equipped)
Once the two units have been paralleled, the share
of the kW load is determined by the governor
control setting. If two units of the same capacity and
the same governor characteristics have the same
governor control settings, the units will share the load
equally. The total load must not exceed the capacity
of the one engine.
In order to transfer the load from one engine, follow
the following procedure.
1. Increase the governor speed control of one unit in
order to increase the load.
2. Reduce the governor speed control of the other
unit in order to decrease the load on that unit.
3. Raise or lower the governor speed control of both
units in order to change system frequency.
Parallel Operation Of Governors
The different governors that can be used on G3500C
generator sets are shown below.
58
Operation Section
Generator Operation
g00630841
Illustration 37
Load Sharing Module (typical example)
The generator set load sharing module provides the
droop load sharing for generators that are paralleled.
The generator set load sharing module provides the
isochronous load sharing for generators that are
paralleled. The load sharing module has an input
for the synchronizing parallel module. The module
provides the load sharing that is proportional . More
information is available in the System Operation,
Testing and Adjusting, SENR6565, “Generator Set
Load Sensor and Generator Load Sharing Module”.
Function of The Engine Governor
This section describes the function of the engine
governor in relation to load division between parallel
electric sets. For detailed information on governor
controls and adjustments, refer to the Service Manual
for additional information.
It is very important to understand two basic facts
about load division between generator sets which
are operating in parallel.
1. The power which is supplied to the generator is
a function of the engine. The engine governor
settings and the positions of the governor controls
determine the amount of power that is delivered
by the engine. Therefore, the engine governor
settings and the positions of the governor controls
determine the kW load which is carried by the
generator. If the governor control setting is
advanced, the engine and the generator will
assume more kW load. Likewise, decreasing the
governor control setting will result in a reduction
of load on the unit. Other units on the line will
gain load or other units will lose load. These other
units will assume that no change in total load or
no change in the governor settings of the other
units has taken place.
2. The division of power is not determined by
generator excitation or terminal voltage. The
generator excitation will determine the power
factor of the generator during operation when the
generator is in parallel with other generators.
Governors that are used with Caterpillar powered
electric sets can be of two types: governors with
fixed speed droop or governors with adjustable
speed droop. The values of speed droop which
are commonly used are 3 percent and 0 percent.
Governors with adjustable speed droop can be
adjusted so that the settings match the settings of
the governors with fixed speed droop. If the governor
is adjusted for 0 percent speed droop operation,
then the same speed from no load to full load can
be obtained.
Summary on Governor Operation
The preceding discussion of governor operation can
be summarized below.
• The G3520C uses two electronic control modules
in order to control engine operation.
• The simplest governor combination for parallel
generator sets is a speed droop of 3 percent
for each governor. If a constant frequency from
no load to full load is required, one governor
can be adjusted for isochronous operation. This
isochronous unit will be called a “lead unit”.
• In order for all paralleled units to accept the
full share of the load, the following governor
adjustments are required. The governors should
have the same full load speed. The governors
should have the same high idle speed in the case
of governors which are adjusted for speed droop
operation. The controls for the governor should be
set to the high idle position so that the full range of
the governor is available.
• Operation of a governor that is isochronous in
parallel with speed droop governors requires
special techniques.
• Any number of electric sets can be operated in
parallel. However, only one governor of the group
can be adjusted for isochronous operation. The
exception will be some special cases of electronic
governors with an automatic load sharing governor.
Stopping
In order to remove a generator from the line, perform
the following procedure.
1. Check the load. The load must be less than the
rated capacity of the remaining units.

2. Be sure that the neutral of one of the remaining
units is grounded.
3. Remove the load from the outgoing unit. Refer
to the Parallel Operation, “Load Division - Speed
Droop”. The amperage may never go to zero due
to circulating currents.
4. Open the circuit breaker.
5. Allow the engine to cool for five minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes
very important when you parallel the units. These
circulating currents are flowing between generators
that are paralleled. The circulating currents
are caused by voltage differences between the
generators. The amount of the circulating current can
be determined by subtracting the amperage which is
going to the load from the total generator amperage.
The circulating current may be as high as 25
percent of rated amperes with cold generator sets.
Such current may not even be considered harmful.
The total generator current should not exceed the
amperage rating.
As the generators warm, the circulating currents will
decrease. The ammeter readings should decrease
slightly, but the voltage meter readings should remain
constant.
59
Operation Section
Generator Operation
i01934959
Single Unit Operation
SMCS Code: 4450
Initial Start-Up
Before the initial start-up, perform the megohmmeter
test on the main stator winding. Refer to the Special
Instruction, SEHS9124, “Cleaning and Drying of
Electric Set Generators” for the procedure.
Starting
1. Make all of the preliminary checks listed in this
Operation and Maintenance Manual, “Before
Starting Engine” topic.
2. Be sure that the main circuit breaker or the line
circuit breaker is open.
3. Start the engine according to this Operation and
Maintenance Manual, “Starting the Engine” topic.
Allow the engine to warm up.
4. Adjust to the full-load engine speed.
5. Close the main circuit breaker.
6. Apply the load. Do not try to apply the full load.
Apply the load in increments in order to maintain
system frequency at a constant level.
7. Readjust the governor for rated frequency.
Stopping
Refer to this Operation and Maintenance Manual,
“Manual Stop Procedure” for the required procedures
for stopping the generator set.
60
Operation Section
Voltage Regulators

Voltage Regulators Adjustment Procedure for the

Voltage Regulators
i01718527
Refer to the Specifications, Systems Operation,
Voltage Regulators Testing and Adjusting, SENR5833, “Digital Voltage
Regulator”.
SMCS Code: 4467
The digital voltage regulator (DVR) can be set up
The voltage regulator controls the generator output for a specific application by using the configured
voltage. parameters. Parameters are preset at the factory.
Parameters may need to be adjusted in order to meet
the specific requirements of a site. The DVR also
detects faults. When a fault is detected, the DVR
sets the appropriate alarm or caution. Certain system
parameters can also be monitored on the display of
the DVR.

Display (1) and keypad (5) are used to select

parameter values. The display and the keypad are
also used to manipulate the parameter values that
control the operation of the digital voltage regulator.
The display of the digital voltage regulator has four
digits. When one of these digits is a colon, the
number that is showing is a parameter code. When
a colon is not present, the number that is showing is
a parameter value. A decimal point in the display is
used to indicate the precision of the parameter value.

Keypad (5) has three keys. The keys are listed below.

• Function key (2)

• Scroll down key (3)
• Scroll up key (4)
Display (1) has two modes. These modes are the
parameter code mode and the parameter value
Illustration 38
g00883469 mode. Function key (2) is used to toggle back and
forth between the two modes. Scroll down key
Digital Voltage Regulator (DVR)
(3) and scroll up key (4) are used to change the
(1) Display display’s value. The scroll down key will decrease
(2) Function key
(3) Scroll down key
the parameter number or the scroll down key will
(4) Scroll up key decrease the value. The scroll up key will increase
(5) Keypad the parameter number or the scroll up key will
(6) J1 connector increase the value.
(7) Screw terminals

The digital voltage regulator (DVR) is a

microprocessor based voltage regulator. The
parameters are preset at the factory or the
parameters can be modified in order to meet the
specific requirements on the site. Certain system
parameters can also be monitored on the display
(1) of the DVR. Keypad (5) is used to change the
information that is shown on the display. J1 connector
(6) is used to join the DVR to a personal computer.
Screw terminals (7) are used to join the DVR to the
generator and various customer options.
 61
Operation Section
Voltage Regulators

Table 8 i01809359

Parameter Code Parameter Value Voltage Regulator Options

:01 0480
SMCS Code: 4467
0481
0482 Manual Voltage Control
0483
A manual voltage control is available as an option on
:02 0001 Caterpillar generator sets. Various specifications and
0002 certifications require manual voltage control of the
generator if the automatic voltage regulator should
0003 fail. The manual voltage control for the permanent
0004 magnet excited generators is shown below.
:03 0004
0003
0002
:04 0100
0099
0100
0101

The operation of display (1) and keypad (5) is

shown in Table 8. Pressing function key (2) toggles
the display between the two columns of the table
(parameter code and parameter value). The display
is in the parameter code mode when a colon is
present. If a colon is not present, the display is in
parameter value mode.

When you press scroll up key (3), the number that

is displayed will increase to the next higher number Illustration 39
g00626639
within the column. When you press scroll down key Manual voltage control for permanent magnet excited generators
(4), the number that is displayed will decrease to the
next lower number within the column. The scroll keys
will not cause the display to change columns.

To configure a parameter code, follow the procedure

below:

1. To select the desired parameter code, press scroll

key (3) or scroll key (4).

2. Access the parameter value by pressing function

key (2).

3. Select the desired parameter value by pressing

scroll key (3) or (4).

4. In order to enter the selected value into the digital

voltage regulator’s memory, press function key (2).
62
Maintenance Section
Refill Capacities

Maintenance Section Lubricant Capacities

The capacity of the engine crankcase includes the
capacity of the oil filters that are installed at the
Refill Capacities factory.

Table 10
i01965009
Lubrication System
Refill Capacities and Approximate Refill Capacities

Recommendations Engine Liters US Gallons

G3516C
423 112
SMCS Code: 1348; 1395; 7560 G3516E
G3520C
541 141
Lubrication System G3520E

Lubricant Recommendations Fuel

Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:
• Caterpillar Natural Gas Engine Oil (NGEO)
• Caterpillar EL250 Natural Gas Engine Oil
(NGEO)
• Caterpillar EL350 Natural Gas Engine Oil
(NGEO)
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during
cold engine start-up, and the maximum ambient
temperature during engine operation. To determine
the oil viscosity that is required for starting a cold
soaked engine, refer to the minimum temperature in
Table 9. To select the oil viscosity for operation at
the highest anticipated ambient temperature, refer
to the maximum temperature in the Table. Use the
highest oil viscosity that is available in order to meet
the required temperature during start-up.
Table 9
Engine Oil Viscosity
Caterpillar Ambient Temperature
NGEO
Grade of Minimum Maximum
Viscosity
SAE 30(1) 0 °C (32 °F) 40 °C (104 °F)
SAE 40(1) 5 °C (41 °F) 50 °C (122 °F)
(1) Caterpillar NGEO is available in these grades only. Multigrade
oils are NOT recommended for use in Caterpillar Gas Engines.
If other grades of viscosity are selected, ensure that the oil
meets the requirements for Caterpillar Gas Engines.
Fuel Recommendations
Caterpillar gas engines will operate successfully on
a broad range of gaseous fuels. Pipeline natural
gas has been used for many years. Commercial
fuel gases are mixtures of gases. These fuels
consist primarily of hydrocarbons (combinations of
hydrogen and carbon) and some inert gases. The
compositions of these gas mixtures have extreme
variations. Fuels such as wellhead gas, bio-gas,
and manufactured gas need to be reviewed for
acceptability. Analyze the fuel in order to determine
the following characteristics:
• Composition
• Contaminants
• Heat value
• Methane number
• Specific gravity
Field gas can have varying characteristics of
combustion. Field gas can contain numerous
harmful impurities. The impurities can alter the BTU
content. The impurities can also alter the methane
number. The impurities include everything from
water up to complex hydrocarbons that can lead to
detonation and severe engine damage. To minimize
these effects, Caterpillar recommends the following
guidelines:
1. Evaluate the fuel with the Caterpillar Methane
Number Program, LEKQ6378.

For further information about oils, see Special

Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”.
 63
Maintenance Section
Refill Capacities

Methane values below 30 are not recommended Table 11

for use in a Caterpillar engine. Fuels with a Caterpillar Minimum Acceptable Water Requirements
methane number that is below 30 must first be
processed in order to remove harmful impurities Property Maximum Limit ASTM Test
in the fuel and raising the methane number into 40 mg/L “D512”,
the acceptable range. Chloride (Cl)
(2.4 grains per US gal) “D4327”

2. If necessary, use an engine that is configured 100 mg/L

Sulfate (SO4) “D516”
for a fuel that has a high energy. Consult the (5.9 grains per US gal)
appropriate manual for the engine in order to 170 mg/L
determine the recommended engine timing. Total Hardness “D1126”
(10 grains per US gal)

3. Reduce the oil change interval according to the 340 mg/L

Total Solids “D1888”
results of the oil analysis. (20 grains per US gal)
Acidity pH of 5.5 to 9.0 “D1293”
For further information on fuels, see Special
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”. NOTICE
Use of water that does not meet the recommendations
for the cooling system will damage the cooling system.
Cooling System
Do not use these types of water in the cooling system:
Coolant Recommendations sea water, softened water that has been conditioned
with salt, hard water, and tap water.
During shipping and storage, the engine must be
protected from damage that can be caused by Only use water that meets the recommendations for
freezing of the cooling system. If the engine is the cooling system.
shipped to a site with freezing temperatures and/or
if the engine is stored in a location with freezing
temperatures, the cooling system must contain If you are not sure about the properties of your water,
antifreeze that will withstand the lowest ambient consult one of the following sources for a water
temperature. Frequently check the concentration analysis:
of glycol in the coolant/antifreeze. Make sure that
the concentration is adequate in order to prevent • Caterpillar dealer
freezing. Otherwise, the cooling system must be
completely drained. • Local water utility company

Coolant/antifreeze is normally composed of three • Agricultural agent

elements: water, glycol, and additives. Each element
must meet specific guidelines. • Independent laboratory

Water Glycol

Deionized water or distilled water is NOTICE

recommended for use in engine cooling systems.
If distilled water or deionized water is not available,
use water with the properties that are listed in Table
11.
Do not use Extended Life Coolant (ELC) with
Caterpillar Gas Engines.
ELC was not formulated for use in Caterpillar Gas En-
gines.

Use only the coolant/antifreeze that is recommended.

Preferred – Caterpillar Natural Gas Engine Coolant

(NGEC)

Alternatively, use Caterpillar Diesel Engine

Antifreeze/Coolant (DEAC) or a commercial
heavy-duty coolant/antifreeze that meets “ASTM
D6210” or “ASTM D4985” specifications.
64
Maintenance Section
Refill Capacities

Note: A 50/50 concentration of Caterpillar

NOTICE
Do not use a commercial coolant/antifreeze that only
meets the ASTM “D3306” specification. This type of
coolant/antifreeze is made for light duty automotive
applications.
Use only the coolant/antifreeze that is recommended.
NGEC or of Caterpillar DEAC does not require a
treatment with an SCA at the initial fill. Commercial
heavy-duty coolant/antifreeze that meets “ASTM
D6210” or “ASTM D4985” specifications may require
a treatment with an SCA at the initial fill. Read the
label or the instructions that are provided by the OEM
of the product.

To ensure that the correct amount of SCA is in the

Acceptable – In applications that do not require cooling system, the concentration of SCA must be
protection from boiling or from freezing, a mixture of tested on a scheduled basis. Obtain an S·O·S coolant
Caterpillar SCA and water that meets the properties analysis (Level 1) or use a test kit to check the
that are listed in Table 11 is acceptable. concentration of the SCA according to this Operation
and Maintenance Manual, “Maintenance Interval
Note: The preferred coolant/antifreeze and the Schedule”.
acceptable mixture of SCA and water require
different concentrations of SCA. Refer to the Special For further information on coolant, see Special
Publication, SEBU6400, “Supplemental Coolant Publication, SEBU6400, “Caterpillar Gas Engine
Additive (SCA)” topic. Lubricant, Fuel, and Coolant Recommendations”.
Table 12 is a list of the coolant/antifreeze that is
recommended for Caterpillar Gas Engines. The
Coolant Capacities
service life of the coolant/antifreeze that is used in
To properly maintain the cooling system, the Total
Caterpillar Gas Engines is also listed. To achieve
Cooling System capacity must be determined. The
this service life, the coolants must be properly
Total Cooling System capacity will vary between
maintained. The maintenance program includes
individual installations. The External System
S·O·S coolant analysis.
capacity includes the following components: engine,
Table 12 expansion tank, heat exchanger, radiator, and piping.
Refer to the specifications that are provided by
Recommended Coolant/Antifreeze and Service Caterpillar or by the OEM of the equipment. Record
Life of the Coolant/Antifreeze the Total Cooling System capacity in the following
Coolant/Antifreeze Service Life (1) Table:
Caterpillar NGEC
Three Years
Caterpillar DEAC
Commercial Heavy-Duty
Coolant/Antifreeze that Two Years
meets “ASTM D6210”
Commercial Heavy-Duty
Coolant/Antifreeze that One Year
meets “ASTM D4985”
Caterpillar SCA and
Two Years
Water
Commercial SCA and
One Year
Water
(1) The service life of coolant is also limited by use (service hours).
Refer to the specific engine’s Operation and Maintenance
Manual, “Maintenance Interval Schedule”.

Additives

Preferred – Caterpillar Supplemental Coolant

Additive (SCA)

Acceptable – A commercial SCA that provides

1200 mg/L (70 grains per US gal) or 1200 ppm of
nitrites in the final mixture of coolant/antifreeze
 65
Maintenance Section
Refill Capacities

Table 13
Cooling System
Approximate Refill Capacities
G3516C G3520C
G3516E G3520E
System
US US
Liters Liters
Gallons Gallons
Jacket Water
201 53 344 91
System Only
SCAC System 47.5 12.5 47.5 12.5
Only
External System
Total Cooling
System
66
Maintenance Section
Maintenance Recommendations

Maintenance • knowledgeable visual examination of the

equipment
Recommendations
• the application of electrical tests
i01135057 Never perform a test over the rated potential. These
General Maintenance tests can damage insulation that is contaminated
or insulation that is in marginal condition. For more
Information information, refer to “I.E.E.E. Standard 432-1992” or
consult a Caterpillar dealer.
SMCS Code: 4450; 7000

Note: Read the warnings and read the instructions

Space Heaters
that are contained in the Safety Section of this
The SR4B generator is capable of operating in high
manual. These warnings and instructions must be
humidity conditions without problems. However,
understood before you perform any operation or any
problems can occur when the generator is idle and
maintenance procedures.
the surrounding air is warmer than the generator.
Moisture can form on the windings that will result in
Rotating electric machines are complex structures
poor performance from the windings. Moisture can
that are exposed to the following forms of stress:
also result in damage to the windings. Whenever the
generator is not active, ensure that the space heaters
• mechanical are in operation.
• electrical Whenever the generator is operating, ensure that the
space heaters are disconnected.
• thermal
An external source of either 115 VAC or 230 VAC is
• environmental required to operate the space heaters.
These stresses may be of varying magnitudes. The
insulation systems are very susceptible to damage
that is caused by the stresses that are listed above.
Exposure to these stresses may shorten the effective
life of the insulation system. Therefore, the service
life of an electric machine will largely depend on the
serviceability of the insulation systems. An inspection
program and a testing procedure are recommended.
An inspection program and a testing procedure
will ensure that the equipment is maintained in
satisfactory condition. This will increase field
reliability.

A regular maintenance and inspection program can

provide an evaluation of the present condition of Illustration 40
g00556903
the equipment. A regular maintenance program
Space heater connection to external source (H1), (H2), (H3), and
and a regular inspection program can also reveal (H4) terminals.
future problems. The frequency of this maintenance
program will depend on the following factors: If a 115 VAC source is available, connect both
heaters in parallel across the source. If a 230 VAC
• application source is available, connect both heaters in series
across the source. Refer to Illustration 40.
• environmental conditions
• operator’s experience
• operator’s philosophy
A regular maintenance program is strongly
recommended. This program would involve the
following steps:

• periodic disassembly
 67
Maintenance Section
Maintenance Recommendations

i01689052

Generator Start-up Checklist

SMCS Code: 4450

Table 14
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________
Generator Serial Number: _________________________________ Arrangement Number: ___________________
GENERATOR NAME PLATE INFORMATION
Voltage: ___________________ Package (prime, continuous, standby): _________________
Amperage: _________________ Kilowatts: ________________________________________
Storage Location:
Generator Alignment:
Main Stator Megohmmeter Reading: Before Storage: After Storage:
Generator dried for 24 hours prior to start-up? (Y/N) Drying method:
SPACE HEATERS Yes No Comments
Space heaters operating properly?
Space heater operated 48 hrs. before
start-up?
MEGOHMMETER TEST (SEHS9124) 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments
reading reading corrected corrected temp.
Beginning of Main Stator
Storage
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Start-up Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Regulator Voltage Amps Comments
No Load F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
(continued)
68
Maintenance Section
Maintenance Recommendations

(Table 14, contd)

GENERATOR START-UP CHECKLIST
Full Load Generator Excitation DC Compare with F1 to F2
Name Plate Information:
F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
 69
Maintenance Section
Maintenance Recommendations

Table 15
GENERATOR START-UP CHECKLIST (CONT.)
ELECTRICAL Yes No Comments
Unit properly grounded
Check diodes
Over current protection
Over voltage protection
Check for loose wiring
Adjust voltage
Adjust frequency
MECHANICAL Data Comments
Bearing temperature readings at full load Front __________ Rear ___________
Stator temperature readings 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 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:
- Total SKVA - Lighting
- Total HP - Computers
- Welding
- Non-linear
- Other

FULL LOAD DATA

Voltage Amps kW KVARS P.F.
70
Maintenance Section
Maintenance Interval Schedule
i01963536
Maintenance Interval Schedule
SMCS Code: 1000; 4450; 7500
Before performing any operation or maintenance
procedures, ensure that the safety information,
warnings, and instructions are read and
understood.
Failure to adhere to proper maintenance intervals
may result in the degradation of the engine’s
performance and/or the accelerated wear of the
engine’s components.
Before each consecutive interval is performed, all
of the maintenance requirements from the previous
interval must be performed.
When Required
Bearing (Ball) - Lubricate ...................................... 74
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 82
Engine Air Cleaner Element - Replace ................. 85
Fuel Metering Valve - Check ................................. 94
Generator - Dry ..................................................... 96
Generator Set - Test ........................................... 100
Insulation - Test ................................................... 105
Overhaul Considerations ..................................... 113
Rotating Rectifier - Test ....................................... 115
Space Heater - Check ......................................... 116
Throttle Control Valve - Check ............................. 119
Valve Stem Projection - Measure/Record ........... 120
Varistor - Test ...................................................... 122
Winding - Test ..................................................... 125
Daily
Air Starting Motor Lubricator Oil Level - Check .... 73
Air Tank Moisture and Sediment - Drain ............... 73
Bearing Temperature - Measure/Record .............. 77
Cooling System Coolant Level - Check ................ 80
Engine Air Cleaner Service Indicator - Inspect ..... 87
Engine Oil Level - Check ...................................... 91
Fuel System Fuel Filter Differential Pressure -
Check .................................................................. 94
Fumes Disposal Filter Differential Pressure -
Check .................................................................. 95
Generator - Inspect ............................................... 98
Generator Load - Check ....................................... 99
Power Factor - Check .......................................... 114
Stator Winding Temperature - Measure/Record .. 119
Voltage and Frequency - Check ......................... 122
Walk-Around Inspection ...................................... 123
Every Week
Standby Generator Set Maintenance
Recommendations ............................................. 117
Initial 250 Service Hours
Crankcase Blowby - Measure/Record .................. 83
Cylinder Pressure - Measure/Record ................... 85
Valve Stem Projection - Measure/Record ........... 120
Every 250 Service Hours
Battery Electrolyte Level - Check .......................... 74
Engine Oil Sample - Obtain .................................. 92
Fumes Disposal Filter - Drain ............................... 95
Initial 1000 Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 81
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 82
Engine Speed/Timing Sensor - Clean/Inspect ...... 93
Every 1000 Service Hours
Aftercooler Condensation - Drain ......................... 72
Alternator - Inspect ............................................... 74
Belts - Inspect/Adjust/Replace .............................. 77
Crankcase Pressure - Measure ............................ 84
Crankshaft Vibration Damper - Inspect ................. 84
Engine Crankcase Breather - Clean ..................... 87
Engine Oil - Change ............................................. 88
Engine Oil Filter - Change .................................... 90
Engine Valve Lash and Bridge - Adjust ................ 93
Gas Pressure Regulator Condensation - Drain .... 96
Hoses and Clamps - Inspect/Replace ................ 101
Ignition System Timing - Check/Adjust ............... 104
Inlet Air System - Inspect .................................... 105
Radiator - Clean ................................................... 115
Water Pump - Inspect ......................................... 124
Every 2000 Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 81
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 82
Engine Speed/Timing Sensor - Clean/Inspect ...... 93
Generator Set Vibration - Inspect ....................... 100
Stator Lead - Check ............................................. 118
Every 3000 Service Hours
Ignition System Spark Plugs - Replace .............. 102
Every 4000 Service Hours
Air Starting Motor Lubricator Bowl - Clean ........... 72
Compressor Bypass - Check ................................ 78
Crankcase Blowby - Measure/Record .................. 83
Cylinder Pressure - Measure/Record ................... 85
Engine Mounts - Check ........................................ 88
Engine Protective Devices - Check ...................... 92
Starting Motor - Inspect ....................................... 118
 71
Maintenance Section
Maintenance Interval Schedule

Every 8000 Service Hours

Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 82
Fumes Disposal Filter Element - Replace ............ 95
Rotating Rectifier - Check .................................... 115
Turbocharger - Inspect ......................................... 119
Water Temperature Regulator - Replace ............ 124

Between 10 000 and 20 000 Service Hours

Overhaul (Top End) .............................................. 111

Every 24 000 Service Hours or 3 Years

Cooling System Coolant (DEAC) - Change .......... 78

Between 30 000 and 60 000 Service Hours

Overhaul (In-Frame) ........................................... 108

Between 50 000 and 100 000 Service Hours

Bearing - Inspect ................................................... 75
Overhaul (Major) ................................................. 109
72
Maintenance Section
Aftercooler Condensation - Drain

i01721862

Aftercooler Condensation -
Personal injury can result from removing hoses or
Drain fittings in a pressure system.
SMCS Code: 1063 Failure to relieve pressure can cause personal in-
jury.
The air/fuel mixture that is compressed and warmed
by the turbocharger compressor is directed through Do not disconnect or remove hoses or fittings un-
the aftercooler core. The air/fuel mixture is cooled in til all pressure in the system has been relieved.
the aftercooler.

Condensation can form in the housing of the 1. Ensure that the air supply to the lubricator is OFF.
aftercooler. A drain plug is provided for draining the
condensation.

Note: An automatic drain is available for use with

32° C (90 °F) separate circuit aftercoolers. Consult
your Caterpillar dealer for details.

g00745554
Illustration 42
(1) Filler plug
(2) Bowl
(3) Drain valve

2. Slowly loosen filler plug (1) in order to release the

Illustration 41
g00885207 pressure from the lubricator.

Remove the drain plugs (1) from the ends of the NOTICE
plenum. Drain the moisture into a suitable container. Care must be taken to ensure that fluids are contained
Reinstall the plugs. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
i01924136
ing any compartment or disassembling any compo-
Air Starting Motor Lubricator nent containing fluids.

Bowl - Clean Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
SMCS Code: 1451-070 suitable to collect and contain fluids on Caterpillar
products.
If the engine is equipped with an air starting motor,
use the following procedure: Dispose of all fluids according to local regulations and
mandates.

3. Place a suitable container under bowl (2) and

open drain valve (3) in order to drain the oil from
the bowl.

4. Remove bowl (2). Clean the bowl with warm water.

5. Dry the bowl. Inspect the bowl for cracks. If the

bowl is cracked, replace the damaged bowl with a
new bowl.

6. Install the bowl.
7. Make sure that drain valve (3) is closed.
8. For instructions on filling the lubricator, see this
Operation and Maintenance Manual, “Air Starting
Motor Lubricator Oil Level - Check” topic.
i01924142
Air Starting Motor Lubricator
Oil Level - Check
SMCS Code: 1451-535
NOTICE
Never allow the lubricator bowl to become empty. The
air starting motor will be damaged by a lack of lubrica-
tion. Ensure that sufficient oil is in the lubricator bowl.
g00745561
Illustration 43
1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.
3. Remove filler plug (4). Pour oil into the lubricator
bowl. Use nondetergent “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).
73
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check
4. Install filler plug (4).
Adjust the Lubricator
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow.
1. Ensure that the fuel supply to the engine is OFF.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
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.
i00351324
Air Tank Moisture and
Sediment - Drain
SMCS Code: 1466-543-M&S
Moisture and sediment in the air starting system can
cause the following conditions:
• Freezing
• Corrosion of internal parts
• Malfunction of the air starting system
When opening the drain valve, wear protective
gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.
1. Open the drain valve that is on the bottom of the
air tank. Allow the moisture and sediment to drain.
2. Close the drain valve.
74
Maintenance Section
Alternator - Inspect
i01879115
Alternator - Inspect
SMCS Code: 1405-040
Inspect the alternator for the following conditions:
• Loose connections
• Clean ports for cooling airflow
• Proper charging of the battery
Observe the ammeter during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system.
Make repairs, if necessary. See the Service Manual
for service procedures. Consult your Caterpillar
dealer for assistance.
i01639002
Battery Electrolyte Level -
Check
SMCS Code: 1401-535-FLV
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
1U-7298 Coolant/Battery Tester (°C) or the
1U-7297 Coolant/Battery Tester (°F).
3. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or
MPGM grease.
i02023749
Bearing (Ball) - Lubricate
(Generator)
SMCS Code: 4471-086
The following ball bearings must be lubricated:
no shield and single shield. Double shielded ball
bearings may not require lubrication. Refer to the
instructions that are located on the machine.
For ball bearings, use Caterpillar 2S-3230 Bearing
Lubricant. This grease is an NLGI No. 2 Grade.
There is Polyurea (a thickener) in this grease. The
temperature range of Caterpillar 2S-3230 Bearing
Lubricant is −29 °C (−20.2 °F) to 177 °C (350.6 °F).
For extremely low temperatures, use either NLGI No.
1 Grade or NLGI No. 0 Grade.
Lubricating Process
1. Remove either the louver assembly or the rear
plate from the rear of the generator housing.
2. Remove the top grease pipe plug and remove the
lower grease pipe plug.
3. Install a grease fitting in the grease pipe.
4. Grease the shielded ball bearings with 2S-3230
Bearing Lubricant (53.28 mL (1.8 ounces) to
59.20 mL (2.0 ounces)). Lubricate shielded ball
bearings at 2000 hour intervals. Do not mix
greases.
Note: Some two-bearing generators have spherical
roller bearings in the front bracket and ball bearings in
the rear bracket. These units should use a common
108-8611 Grease Cartridge. This grease should be
used for the front bearing and the rear bearing.
 75
Maintenance Section
Bearing - Inspect

5. Wipe off the excess grease. Remove the top
grease fitting. Install the plug.
6. Operate the generator for one hour. This will allow
the grease to expand. The expanding grease will
force the excess grease from the cavity. When
the excess grease is forced from the cavity, the
internal pressure will be reduced. The generator
should continue to operate until the grease stops
purging.
7. Stop the engine. Install the plug in the bottom
grease pipe. Wipe off the excess grease.
8. Install the louver assembly or install the rear plate.
i01928575
To reinstall the ball bearings, use an induction
heater to heat the ball bearings to 107 °C
(224.6 °F) for ten minutes. Mount the bearings
on the shaft. To reinstall the hub, heat the hub to
400 °C (752.0 °F) for three hours. Mount the hub
to the shaft.
3. Ensure that the tube of the grease gun is filled
with grease.
4. Remove the bracket drain plug and operate the
generator for one hour. This will allow the grease
to expand. The expanding grease will force the
excess grease from the cavity. When the excess
grease is forced from the cavity, the internal
pressure will be reduced. The generator should
continue to operate until the grease stops purging.

Bearing - Inspect 5. Stop the engine. Install the bracket drain plug.
Wipe off the excess grease.
(Generator)
6. For greasing intervals, follow the recommendations
SMCS Code: 4471-040 on the lubrication plate (if equipped) or refer to
Maintenance Schedule, “Bearing - Lubricate”.
The following maintenance procedure for generator Whenever the bearings are greased, repeat Step
bearings should be followed at every major engine 4. DO NOT MIX GREASES.
overhaul:

1. Remove the bearing bracket. Inspect the following

items: bracket bore, bearing outer race, and
rolling elements. On standby power units, the
bearing must be inspected and the grease must
be replaced at three year intervals. The sleeve
in the bearing bracket should be inspected for
out of roundness, excessive wear, and a bracket
step that is less than 0.0762 mm (0.0030 inch). If
there is no sleeve in the bearing bracket, inspect
the bore of the bearing bracket. The bearing
should be inspected for damage to the outer race,
severe fretting, and smoothness of operation.
When possible, the bearing elements should be
inspected. Some double shielded ball bearings
prevent visual inspection of the elements of the
bearing. Other double shielded ball bearings
have a retaining ring. This retaining ring can be
removed in order to allow access for a visual
inspection of the elements of the bearing.

On two-bearing generators, the front bearing can

only be removed after the hub is removed. In order
to remove the hub, cut off the hub with a saw. Do
not use a torch to remove the hub. Do not pull on
the hub. Pulling the hub will damage the shaft.

Note: Bearings that are being removed for failure

analysis should not be cut off with a torch.

2. All ball bearings should be cleaned. The cavity in

the bracket should be repacked with 2S-3230
Grease. Pack the ball bearings (one-third to
one-half of the volume of the cavity). Refer to
Table 16.
76
Maintenance Section
Bearing - Inspect

Table 16
Bearing Bearing Part Generator Bearing Bore Bearing Bearing Rotor
Outside Inside Number Frame in Bracket Shield Cavity Shaft
Diameter Diameter Size mm (inch) (Type) Grease Diameter
mm (inch) mm (inch) mL (oz) mm (inch)
225 mm 105 mm 6V-0410 680(1) 225.003 mm Single 139.12 mL 105.029 mm
(8.8582 inch) (4.1338 inch) (8.8584 inch) (4.7 oz) (4.1350 inch)
to to to
225.034 mm 230.88 mL 105.034 mm
(8.8596 inch) (7.8 oz) (4.1352 inch)
225 mm 105 mm 108-1760 680(1) 225.003 mm Double 148.00 mL 105.029 mm
(8.8582 inch) (4.1338 inch) (8.8584 inch) (5.0 oz) (4.1350 inch)
to to to
225.034 mm 236.80 mL 105.034 mm
(8.8596 inch) (8.0 oz) (4.1352 inch)
240 mm 110 mm 108-1761 690(1) 240.002 mm Double 207.20 mL 110.012 mm
(9.4488 inch) (4.3307 inch) (9.4489 inch) (7.0 oz) (4.3312 inch)
to to to
240.033 mm 296.00 mL 110.028 mm
(9.4501 inch) (10.0 oz)(2) (4.3318 inch)
414.40 mL
(14.0 oz)
to
621.60 mL
(21 oz)(3)
240 mm 110 mm 6V-3310 800(1) 240.002 mm Single 145.04 mL 110.012 mm
(9.4488 inch) (4.3307 inch) (9.4489 inch) (4.9 oz) (4.3312 inch)
to to to
240.033 mm 239.76 mL 110.028 mm
(9.4501 inch) (8.1 oz) (4.3318 inch)
240 mm 110 mm 6V-6752 800(1) 240.002 mm Single 145.04 mL 110.012 mm
(9.4488 inch) (4.3307 inch) (9.4489 inch) (4.9 oz) (4.3312 inch)
to to to
240.033 mm 239.76 mL 110.028 mm
(9.4501 inch) (8.1 oz) (4.3318 inch)
240 mm 110 mm 108-1761 800(1) 240.002 mm Double 148.00 mL 110.012 mm
(9.4488 inch) (4.3307 inch) (9.4489 inch) (5.0 oz) (4.3312 inch)
to to to
240.033 mm 236.80 mL 110.028 mm
(9.4501 inch) (8.0 oz) (4.3318 inch)
280 mm 130 mm 154-3032 820 280.002 mm Double N/A 130.028 mm
(11.024 inch) (5.1181 inch) (11.0237 inch) (5.1192 inch)
to to
280.032 mm 130.051 mm
(11.0249 inch) (5.1201 inch)
(1) Inboard bearing
(2) This bearing is on the same end as the exciter.
(3) This bearing is on the drive end of the generator.
 77
Maintenance Section
Bearing Temperature - Measure/Record

i01813440 Adjusting the Alternator Belt

Bearing Temperature -
Measure/Record
SMCS Code: 4471-082-TA

Bearing temperature detectors are optional on all

SR4B generators. These detectors are 100 ohm
resistance temperature detectors. If the bearing
temperature reaches 85 °C (185 °F), the alarm for
the bearing temperature will be activated. If the
bearing temperature reaches 95 °C (203 °F), the unit
will be shutdown. Bearing temperature detectors
are used with equipment that has been provided by
the customer. Bearing temperature detectors are
used in order to measure the bearing temperature.
Bearing temperature detectors may help to prevent
premature bearing failure.

i01920141

Belts - Inspect/Adjust/Replace Illustration 44

g00741969

(1) Adjusting nuts

SMCS Code: 1357-025; 1357-040; 1357-510 (2) Mounting bolt

1. Remove the drive belt guard.

Inspection
2. Loosen mounting bolt (2) and adjusting nuts (1).
Inspect the alternator belt and the fan drive belts for
wear and for cracking. Replace the belts if the belts
3. Turn adjusting nuts (1) in order to increase or
are not in good condition.
decrease the drive belt tension.
Check the belt tension according to the information in
4. Tighten adjusting nuts (1). Tighten mounting bolt
the Service Manual, “Specifications”.
(2).
Slippage of loose belts can reduce the efficiency
5. Reinstall the drive belt guard.
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
If new drive belts are installed, check the drive belt
components:
tension again after 30 minutes of engine operation at
the rated rpm.
• Belts
• Pulleys Adjusting the Fan Drive Belt
• Bearings 1. Loosen the mounting bolt for the pulley.

If the belts are too tight, unnecessary stress is placed 2. Loosen the adjusting nut for the pulley.
on the components. This reduces the service life of
the components. 3. Move the pulley in order to adjust the belt tension.

4. Tighten the adjusting nut.

Replacement
5. Tighten the mounting bolt.
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
78
Maintenance Section
Compressor Bypass - Check

i01935590 Draining the Cooling System

Compressor Bypass - Check
NOTICE
SMCS Code: 1050-535 Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01007433 Stop the engine and allow the engine to cool. Ensure
Illustration 45
that the engine will not start when the cooling system
is drained.
Check for leaks. If necessary, remove the actuator
according to the instructions in the Disassembly and
For information regarding the disposal and the
Assembly manual. Inspect the throat for wear marks.
recycling of used coolant, consult your Caterpillar
Check for free movement of the butterfly valve. If
dealer or consult Caterpillar Service Technology
necessary, replace the bearings.
Group:
Inspect the gaskets for wear or damage. If necessary,
Outside Illinois: 1-800-542-TOOL
replace the gaskets. Reinstall the actuator according
Inside Illinois: 1-800-541-TOOL
to the instructions in the Disassembly and Assembly
Canada: 1-800-523-TOOL
manual.
NOTICE
i02052840 Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
Cooling System Coolant coolant for reuse in engine cooling systems. The full
(DEAC) - Change distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
SMCS Code: 1350-044

Clean the cooling system before the recommended Draining the Jacket Water
maintenance interval if the following conditions exist:
1. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
• The engine overheats frequently.
system filler cap.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.

• Coolant analysis indicates that the coolant has

broken down.
 79
Maintenance Section
Cooling System Coolant (DEAC) - Change

Clean the Cooling System

NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.

1. After the cooling system has been drained, flush

the cooling system with clean water in order to
remove any debris.

2. Close the cooling system drain valves. Clean the

drain plugs and install the drain plugs.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

g00885932
Illustration 46 NOTICE
Locations of the vent and drain plugs If the aftercooler circuit has been drained, the vent
(1) Coolant outlet plug must be opened to allow the aftercooler to fill
(2) Aftercooler drain plug properly. Failure to do this will cause an air lock re-
(3) Oil cooler drain plug sulting in engine damage.
(4) Cylinder block drain plug
(5) Adapter drain plug
3. When the separate circuit is filled, be sure to
2. Remove the vent plug from coolant outlet (1). remove the vent plug.
Open drain (2). Remove drain plugs (3), (4), and
(5). 4. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Draining the Separate Circuit Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap. Install vent plugs (1).

5. Start the engine. Operate the engine for a

minimum of 30 minutes with a coolant temperature
of at least 82 °C (180 °F).

6. Stop the engine and allow the engine to cool. For

the jacket water and the separate circuit, loosen
the cooling system filler cap slowly in order to
relieve any pressure. Remove the cooling system
filler cap. Open the cooling system drain valves
and remove the drain plugs. Remove the vent
plugs. Allow the cleaning solution to drain.

g00947036
Illustration 47 NOTICE
Improper or incomplete rinsing of the cooling system
1. Remove vent plugs (1). can result in damage to copper and other metal com-
ponents.
2. Open coolant drain valve (2).
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
80
Maintenance Section
Cooling System Coolant Level - Check
7. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
system drain valves. Clean the drain plugs and
install the drain plugs.
Cleaning a Cooling System that
has Heavy Deposits or Plugging
Note: For the following procedure to be effective,
there must be an active flow through the cooling
system components.
1. After the cooling system has been drained, flush
the cooling system with clean water in order to
remove any debris.
2. Close the cooling system drain valves. Clean the
drain plugs and install the drain plugs.
3. Remove the vent plugs.
4. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
Install the cooling system filler cap. Install the vent
plugs.
5. Start the engine. Operate the engine for a
minimum of 90 minutes with a coolant temperature
of at least 82 °C (180 °F).
6. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves and remove the drain plugs. Remove the
vent plugs. Allow the cleaning solution to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
7. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
system drain valves. Clean the drain plugs and
install the drain plugs.
Fill the Cooling System
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Note: For information about the proper coolant to
use, and for the capacity of the cooling system, refer
to this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Section).
1. Remove the vent plugs.
2. Fill the cooling system with coolant/antifreeze.
Install the vent plugs. Do not install the cooling
system filler cap yet.
3. 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.
4. Check the coolant level. Maintain the coolant to
the proper level on the sight gauge (if equipped).
If a sight gauge is not equipped, maintain the
coolant within 13 mm (.5 inch) below the bottom of
the filler pipe.
5. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets of the cooling system filler cap are
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap.
6. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i02017615
Cooling System Coolant Level
- Check
SMCS Code: 1350-535-FLV
Climbing equipment may be required to access
this service point. Refer to the Operation and
Maintenance Manual, “Mounting and Dismount-
ing” topic for safety information.

NOTICE
Overfilling the overflow tank (if equipped) will result in
damage to the cooling system.
If the cooling system has an overflow tank, maintain
the coolant level in the tank below 1/2 full in order to
avoid damage to the cooling system.
g00760290
Illustration 48
Normal position of the coolant in the sight gauge during rated
operation
Observe the coolant level in the sight gauge (if
equipped). When the engine is running at normal
operating temperature, the coolant should be in the
upper half of the sight gauge. If the coolant level is
low, add the proper coolant mixture.
Add Coolant
Note: For the proper coolant mixture to use, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” topic.
1. Stop the engine. Allow the engine to cool.
2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.
81
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
g00103639
Illustration 49
Filler cap gaskets
3. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
4. Start the engine. Inspect the cooling system for
leaks.
i02015769
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
For conventional heavy-duty coolant/antifreeze,
check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA
can be checked with an S·O·S coolant analysis
(Level 1).
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:
82
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
• Keep the unused sampling bottles stored in plastic
bags.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
• In order to avoid contamination, immediately place
the sample in the tube that is provided for mailing.
Submit the sample for Level 1 analysis.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
For additional information about coolant analysis,
see the Special Publication, “Caterpillar Gas Engine
Lubricant, Fuel and Coolant Recommendations” or
consult your Caterpillar dealer.
i02015770
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For additional information about coolant analysis,
see the Special Publication, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations” or
consult your Caterpillar dealer.
i02017557
Cooling System Supplemental
Coolant Additive (SCA) -
Test/Add
SMCS Code: 1352-045; 1395-081
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1).
Test the Concentration of the SCA
Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Follow the instructions
that are provided in the kit.
Water and SCA
NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Use the instructions
that follow:
1. Fill the syringe to the “1.0 ml” mark with the
coolant.
2. Dispense the 1.0 mL coolant sample from the
syringe into the empty mixing bottle.
3. Add tap water to the mixing bottle in order to bring
the level up to the “10 ml” mark. Place the cap on
the bottle and shake the bottle.
 83
Maintenance Section
Crankcase Blowby - Measure/Record

4. Add 2 to 3 drops of the “NITRITE INDICATOR

SOLUTION B” to the mixing bottle. Move the bottle NOTICE
in a circular motion in order to mix the solution. Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
5. Add 1 drop of “NITRITE TEST SOLUTION A” to faces of the cooling system, reducing the engine’s
the mixing bottle. Move the bottle in a circular heat transfer characteristics. Reduced heat transfer
motion in order to mix the solution. could cause cracking of the cylinder head and other
high temperature components.
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of Excessive supplemental coolant additive concentra-
drops of “NITRITE TEST SOLUTION A” that were tion could also result in blockage of the heat exchang-
required to cause the color change. er, overheating, and/or accelerated wear of the water
pump seal.
7. Use Table 17 to interpret the results.
Do not exceed the recommended amount of supple-
Table 17
mental coolant additive concentration.
Number of Concentration Maintenance
Drops of SCA Required
3. Add the proper amount of SCA. The concentration
Less than 25 Less than the Add SCA. of the SCA depends on the type of coolant that
recommended Retest the is used. To determine the proper amount, see
concentration of coolant. this Operation and Maintenance Manual, “Refill
SCA Capacities and Recommendations” topic.
25 to 30 The None
recommended 4. Clean the cooling system filler cap. Install the
concentration of cooling system filler cap.
SCA
More than 30 More than the Remove the i01935045
recommended coolant.
concentration of Replace with Crankcase Blowby -
SCA water only
Retest the Measure/Record
coolant.
SMCS Code: 1317

Add the SCA, If Necessary
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 pres-
sure.
1. Remove the cooling system filler cap slowly.
Note: Always dispose of fluids according to local
regulations.
2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
Measure the crankcase blowby of new engines.
Record the data. Continue to periodically measure
the blowby. Comparing the recorded data to the new
data provides information about the condition of the
engines.
Note: Crankcase blowby is one of the three factors
that help to determine the in-frame overhaul interval.
For more information, see this Operation and
Maintenance manual, “Overhaul (In-Frame)” topic.
After a new engine is used for a short time, the
blowby can decrease as the piston rings are seated.
The blowby will gradually increase as the following
components show wear:
• Piston rings
• Cylinder liners
Note: A problem with the piston rings causes the
oil to deteriorate rapidly. Information regarding the
condition of the piston rings can be obtained from
the measurement of the blowby and the results of
oil analysis.
84
Maintenance Section
Crankcase Pressure - Measure
The blowby of a worn engine may exceed the blowby
of a new engine by two times or more.
A sudden increase in blowby could indicate a broken
piston ring. The following conditions are other
potential sources of blowby:
• Worn valve guides
• A turbocharger seal that leaks
A rebuilt engine can have a high blowby due to the
following factors:
• The piston rings are not seated properly.
• Worn parts such as valve guides were not replaced.
Excessive blowby may indicate the need for an
overhaul. By keeping a record of the results, a
gradual increase in the amount of the blowby will be
noted until the amount has become excessive.
To measure the blowby, use the 1U-8860 Large
Engine Blowby Pickup Group with the 8T-2701
Blowby Indicator. For instructions, see Special
Instruction, SEHS8984, “Using the 1U-8860
Large Engine Blowby Pickup Group” and Special
Instruction, SEHS8712, “Using the 8T-2700
Blowby/Air Flow Indicator”.
For assistance, consult your Caterpillar dealer.
i01601829
Crankcase Pressure - Measure
(Engines with Fumes Disposal
Filters)
SMCS Code: 1074
Measure the crankcase pressure during normal
operation.
With a fumes disposal filter that is properly installed,
the crankcase pressure will be within 0.25 kPa
(1 inch of H2O) of the atmospheric pressure.
i01949731
Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case.
Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
engine components. A deteriorating damper can
cause excessive gear train noise at variable points
in the speed range.
A damper that is hot is due to excessive torsional
vibration. Monitor the temperature of the damper
during operation.
The 8T-2821 Temperature Indicator or the 8T-2822
Temperature Indicator are recommended for
monitoring the temperature of the damper. Evenly
space four of the adhesive indicators around the
outer diameter of the damper.
Note: If you use an infrared thermometer to monitor
the temperature of the damper, use the thermometer
during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
reduce the interval for inspecting the damper.
If the temperature of the damper reaches 110 °C
(230 °F), consult your Caterpillar dealer.
Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
If a fluid leak is found, repair the damper or
replace the damper. The fluid in the damper is
silicone. Silicone has the following characteristics:
transparent, viscous, smooth, and sticky.
Inspect the damper and repair or replace the damper
for any of the following reasons.
• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken
crankshaft.
• An analysis of the oil has revealed that the front
bearing of the crankshaft is badly worn.
• There is a large amount of gear train wear that is
not caused by a lack of oil.
Removal and Installation
Refer to the Service Manual, “Disassembly and
Assembly” or consult your Caterpillar dealer for
information about damper replacement.
 85
Maintenance Section
Cylinder Pressure - Measure/Record

i01664707

Cylinder Pressure -
Measure/Record
SMCS Code: 1223-082-CC; 1223; 7450-082

Measure the cylinder pressure of new engines.

Record the data. Continue to periodically measure
the cylinder pressure. Comparing the recorded data
to the new data provides information about the
condition of the engine.

Cylinder pressure can be measured during inspection

of the spark plugs. Use the following guidelines for
checking the cylinder pressure:

• Remove all of the spark plugs.

• Fully open the throttle plate.
• Minimize the cranking time to 3 or 4 revolutions.
This will enable a maximum consistent cranking
speed for the check. Also, the battery power will
be conserved.

A loss of cylinder pressure or a change of pressure

in one or more cylinders may indicate the following g00828960
Illustration 50
conditions. These conditions may indicate a problem
with lubrication: (Y) Cylinder pressure in kPa
(X) Compression ratio
(1) Normal range for cylinder pressure
• Excessive deposits
• Guttering of valves i01935223

• A broken valve Engine Air Cleaner Element -

• A piston ring that sticks
• A broken piston ring
• Worn piston rings
• Worn cylinder liners
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
To measure the cylinder pressure, use the 193-5859
Cylinder Pressure Gauge Gp. Follow the procedure
in the Special Instruction, NEHS0798 that is included
with the gauge group. Record the pressure for
each cylinder. Use the Operation and Maintenance
Manual, “Valve Data Sheet” (Reference Materials
Section).
Illustration 50 is a graph of typical cylinder pressures
for engines with different compression ratios.
Replace
SMCS Code: 1051-510; 1054-510
NOTICE
Never run the engine without an air cleaner element
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 engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Note: Use of a platform may be necessary to reach
the air cleaner element.
Clean the air cleaner elements or replace the air
cleaner elements when the following conditions
occur:
86
Maintenance Section
Engine Air Cleaner Element - Replace

• Inspect the air cleaner elements before the air filter Inspecting Air Cleaner Elements
restriction reaches 2.5 kPa (10 inches of H2O). A
loss of engine performance may occur when the
air filter restriction exceeds this limit.

• The air cleaner elements must be cleaned or

replaced before the air filter restriction exceeds
3.75 kPa (15 inches of H2O).

Note: The air filter restriction is measured before the

air inlet to the turbocharger compressor.

Servicing the Air Cleaner Elements

Note: If the air cleaner is not manufactured by
Caterpillar, follow the instructions that are provided g00281693
Illustration 51
by the OEM of the air cleaner.

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 Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
• Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt
and debris, as needed.
Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation,
thoroughly inspect 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.
Maintain a supply of suitable air cleaner elements
for replacement purposes.
Inspect the clean, dry air cleaner element. Use a
60 watt blue light in a dark room or in a similar
facility. Place the blue light in the element. Rotate the
element. Inspect the element for tears and/or holes.
Inspect the element for light that may show through
the filter material. If it is necessary in order to confirm
the result, compare the element to a new element
that has the same part number.
Do not use an element that has any tears and/or
holes in the filter material. Do not use an element with
damaged pleats, gaskets or seals. Discard damaged
elements.
Storing Air Cleaner Elements
If an element that passes inspection will not be used,
the element can be stored for future use.

1. Remove the air cleaner cover. Remove the air

cleaner element.

2. Cover the air inlet to the turbocharger with tape

in order to keep dirt out.

3. Clean the inside of the air cleaner cover and body

with a clean, dry cloth.

4. Remove the tape for the air inlet to the

turbocharger. Install an air cleaner element that
is new or cleaned.

5. Install the air cleaner cover. g00281694

Illustration 52

Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. Restricted air flow
may result. To protect against dirt and damage, wrap
the elements in Volatile Corrosion Inhibited (VCI)
paper.

Place the element into a box for storage. For

identification, mark the outside of the box.
 87
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Store the box in a dry location.

i01799090

Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040

A service indicator may be mounted on the air

cleaner element or in a remote location.

g00924884
Illustration 54

A porous filter is part of the 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.

Note: When service indicator is installed, excessive

tightening may crack the top of the service indicator.
Tighten the service indicator to a torque of 2 N·m
(18 lb in).
g00947059
Illustration 53 Replace the service indicator annually regardless of
the operating conditions.
Some engines may be equipped with a different
service indicator.
i01811472

Observe the service indicator. Clean the air cleaner

element or replace the element when any of the
Engine Crankcase Breather -
following conditions occur: Clean
• The yellow diaphragm enters the red zone. SMCS Code: 1317-070

• The red piston locks in the visible position.
• The air restriction reaches 3.75 kPa
(15 inch of H2O).
Test the Service Indicator
Service indicators are important instruments.
Clean the crankcase breather regularly in order
to prevent excessive crankcase pressure that will
damage the engine’s seals.
Perform this maintenance when the engine is
stopped.

• Apply vacuum (suction) to the service indicator.

• Reset the service indicator.
If the yellow core does not latch at the greatest
vacuum, or if service indicator does not reset easily,
obtain a new service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.

g00882365
Illustration 55
88
Maintenance Section
Engine Mounts - Check
1. Loosen clamps (1). Slide the clamps off tubes (2).
Remove the tubes.
2. Loosen clamps (3). Remove each breather
assembly (4) from the elbow assembly.
3. Remove O-ring seals from the elbow assembly.
Inspect the O-ring seals for good condition. Obtain
new O-ring seals, if necessary.
4. Turn the breathers upside-down in order to inspect
the condition of the breather elements.
Clean the breather elements with clean,
nonflammable solvent. If the breather elements
remain contaminated after the cleaning, discard
the breather assemblies and obtain new breather
assemblies. Do not attempt to disassemble the
breather assemblies.
Allow the breather elements to dry before
installation.
Note: Lubricate the bore of the elbow assembly with
clean engine oil and install the O-ring seals.
5. Install breather assemblies (4) and tighten clamps
(3). Install elbows (2) and clamps (1). Tighten the
clamps.
i02017664
Engine Mounts - Check
SMCS Code: 1152-535
Illustration 56
g00736591
(1) Mounting bolts for the engine
(2) Mounting bolts for the generator
(3) Levelling bolts for the isolators
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 proper torque. For standard torques, see
Specifications, SENR3130, “Torque Specifications”.
Ensure that the isolators are free of oil and
contamination. Inspect the isolators for deterioration.
Ensure that the bolts for the isolators are tightened to
the proper torque.
Replace any isolator that shows deterioration. For
more information, see the literature that is provided
by the OEM of the isolators. Also see the Application
and Installation Guide for the engine. Consult your
Caterpillar dealer for assistance.
i02017618
Engine Oil - Change
SMCS Code: 1348-044; 1348
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the
starting controls.
Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
when the cold oil is drained. Drain the crankcase with
the oil warm, immediately after the engine is stopped.
This draining method allows the waste particles
that are suspended in the oil to be drained properly.
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.
1. After the engine has been operated at normal
operating temperature, STOP the engine.
Note: Drain the oil into a suitable container. Dispose
of fluids according to local regulations.
2. Drain the oil by using one of the following
methods. Use the method that corresponds to the
equipment on the engine.

Note: If a suction device is used in order to remove
the oil from 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.
a. If the engine has an oil drain valve, open the
valve in order to drain the oil. After the oil has
drained, close the valve.
b. If the engine has a pump for removing dirty
oil, connect a hose to the outlet of the pump.
Place the hose in a suitable container. Open
the valve for the drain line. Operate the pump
until the crankcase is empty. Close the valve to
the drain line. Disconnect the hose.
c. 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 oil has drained, close the drain valve.
Disconnect the coupling.
d. If the engine does not have a drain valve or a
pump, remove an oil drain plug. Allow the oil to
drain. After the oil has drained, clean the drain
plug and clean the fitting for the drain plug.
Install the drain plug. Tighten the drain plug to
145 ± 15 N·m (105 ± 10 lb ft).
Note: Ensure that the dirty oil is thoroughly drained
from the pan. Caterpillar recommends a thorough
cleaning of the oil pan with a vacuum and with rags
in order to completely remove all of the old oil. This
will help prevent inaccurate oil analysis results and/or
shortened life of the oil.
3. Replace the engine oil filter elements before filling
the crankcase with new oil.
a. For the procedure to change the engine oil
filters, refer to the Operation and Maintenance
Manual, “Engine Oil Filter - Change” topic
(Maintenance Section).
89
Maintenance Section
Engine Oil - Change
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.
Note: For the appropriate oil to use, and for
the amount of oil to use, refer to this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” article (Maintenance Section).
4. Remove the oil filler cap. Fill the crankcase
through the oil filler tube only. Clean the oil filler
cap. Install the oil filler cap.
NOTICE
To prevent crankshaft damage and to prevent bearing
damage, manually operate the prelube pump or crank
the engine with the fuel supply line closed for 15 to 30
seconds. This will ensure that all of the oil filters are
filled with oil before the engine is started.
5. Close the fuel supply line. Crank the engine until
the oil pressure gauge indicates 70 kPa (10 psi).
Open the fuel supply line. Allow the starting motor
to cool for two minutes before cranking again.
6. Follow this Operation and Maintenance Manual,
“Starting The Engine” procedure (Operation
Section). Operate the engine at low idle for two
minutes. This will ensure that the lubrication
system and the oil filters are filled with oil. Inspect
the engine for oil leaks. Ensure that the oil level is
between the “ADD” and the “FULL” marks on the
“LOW IDLE” side of the oil level gauge.
7. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
8. Remove the oil level gauge and check the oil level.
Maintain the oil level between the “ADD” and the
“FULL” marks on the “ENGINE STOPPED” side of
the oil level gauge.
90
Maintenance Section
Engine Oil Filter - Change

i01935324

Engine Oil Filter - Change

SMCS Code: 1308-510; 1308

Replace the engine oil filters when any of the

following conditions are met:

• The engine oil is changed.

• The engine oil filter differential pressure reaches
100 kPa (15 psi).

• The engine oil filters have been used for 1000 g00884971
operating hours. Illustration 57

1. Remove the spin-on oil filter with a 2P-8250

Replace the Oil Filter Elements Strap Wrench As.

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.

NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the
starting controls.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
g00103713
Illustration 58
Mounting base and gasket
2. Clean the sealing surface of the mounting base.
Ensure that all of the old gasket is removed.
3. Apply clean engine oil to the gasket of the new
oil filter.
NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.

4. Place the oil filter in position. Tighten the oil

filter by hand until the gasket contacts the base.
Tighten the oil filter by hand for an additional 1 full
turn (360 degrees). Do not overtighten the oil filter.

Inspect the Used Oil Filter Elements
Cut the used oil filter element open with a 4C-5084
Oil Filter Cutter Gp.
Remove the metal wrap. Cut the filter element
free from the end caps. Spread apart the pleats
and inspect the element for metal debris. Due to
normal wear and friction, it is not uncommon to find
small amounts of debris in the oil filter element.
An excessive amount of debris in the element
may indicate early wear or a pending failure. If an
excessive amount of debris is found in the oil filter
element, consult your Caterpillar dealer in order to
arrange for further oil analysis.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear
on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
i02052792
Engine Oil Level - Check
SMCS Code: 1348-535-FLV
The most accurate check of the engine oil level is
obtained when the engine is stopped.
g00924709
Illustration 59
(1) Engine oil level gauge (dipstick)
1. Remove the filler cap (not shown) in order to
ensure that the crankcase pressure is equal to the
atmospheric pressure.
Excess pressure or a slight vacuum will affect
engine oil level that is measured.
2. Ensure that engine oil level gauge (1) is seated.
91
Maintenance Section
Engine Oil Level - Check
g00735162
Illustration 60
(3) “ENGINE STOPPED WITH OIL COLD” side
(4) “ENGINE AT LOW IDLE WITH WARM OIL” side
(5) “ADD” mark
(6) “FULL” mark
a. If the engine is stopped, remove the engine oil
level gauge. Observe the engine oil level on
“ENGINE STOPPED WITH OIL COLD” side
(3).
b. If the engine is operating, reduce the engine
speed to low idle. Remove the engine oil level
gauge and observe the engine oil level on
“ENGINE AT LOW IDLE WITH WARM OIL”
side (4).
The engine oil level should be between “ADD”
mark (5) and “FULL” mark (6).
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.
92
Maintenance Section
Engine Oil Sample - Obtain
3. If necessary, add engine oil. For the correct
engine oil to use, refer to this Operation and
Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
Do not fill the crankcase above the “FULL” mark
on the engine oil level gauge. Clean the filler cap
(2). Install the filler cap.
4. Record the amount of engine oil that is added. For
the next engine oil sample and analysis, include
the total amount of engine oil that has been added
since the previous oil change. This will help to
provide the most accurate analysis.
i01935337
Engine Oil Sample - Obtain
SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
• Engine model
• Service hours on the engine
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
i01949820
Engine Protective Devices -
Check
SMCS Code: 7400-535
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-
vent possible damage to the engine.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.

Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
i02015492
Engine Speed/Timing Sensor -
Clean/Inspect
SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070
An engine speed/timing sensor is mounted in the
flywheel housing. The speed/timing sensor provides
information about engine speed and the position of
the crankshaft to the ECM.
g00760464
Illustration 61
1. Remove engine speed/timing sensor (1). Inspect
the condition of the end of the magnet. Look for
signs of wear and contaminants.
2. Clean any debris from the face of the magnet.
g00931748
Illustration 62
3. Check the tension of the sliphead. Gently extend
sliphead (2) for a minimum of 4 mm (0.16 inch).
Then push back the sliphead.
When the sliphead has the correct tension, at
least 22 N (5 lb) of force is required to push in the
sliphead from the extended position.
93
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect
NOTICE
The sliphead must be fully extended when the speed/
timing sensor is installed so that the sensor maintains
the correct clearance with the speed-timing wheel.
If the correct clearance is not maintained, the signal
from the sensor will not be generated.
Do not install the sensor between the teeth of the
speed-timing wheel. Damage to the sensor would re-
sult. Before installing the sensor, ensure that a tooth
of the wheel is visible in the mounting hole for the sen-
sor.
4. Install the engine speed/timing sensor.
a. Ensure that a tooth on the speed-timing wheel
is visible in the mounting hole for the sensor.
b. Extend sliphead (2) by a minimum of 4 mm
(0.16 inch).
c. Coat the threads of the sensor with 4C-5597
Anti-Seize Compound.
Note: The sliphead is designed to contact a tooth
during the first revolution of the speed-timing wheel.
For the maximum allowable clearance between
the sliphead and the tooth, refer to the engine’s
Specifications manual.
d. Install the sensor. Tighten the locknut to
40 ± 5 N·m (30 ± 4 lb ft).
i01935355
Engine Valve Lash and Bridge
- Adjust
SMCS Code: 1102-025; 1102
Ignition systems can cause electrical shocks.
Avoid contacting the ignition system components
and wiring.
Do not attempt to remove the valve covers when
the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
death may result and the ignition system will be
damaged if the valve covers are removed during
engine operation. The engine will not operate
without the valve covers.
For procedures on adjusting the valve bridge and the
engine valve lash, refer to the following publications:
94
Maintenance Section
Fuel Metering Valve - Check
• Special Instruction, REHS0128, “Using the
147-5482 Indicator Gauge for Valve Lash and
Valve Bridge Adjustment”
• Service Manual, “Systems Operation/Testing and
Adjusting”
Consult your Caterpillar dealer for assistance.
Valve Bridge
Check the valve bridge and adjust the valve bridge,
if necessary. Perform the procedure for both valve
bridges for each cylinder.
After the valve bridge for each cylinder is satisfactory,
measure the valve lash.
Engine Valve Lash
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. Improper
valve lash may also lead to valve failure, and result in
catastrophic failure.
If the valve lash is within the tolerance, an adjustment
of the valve lash is NOT necessary.
Perform valve lash adjustment if the dimension is not
within the tolerance. The valve bridge adjustment
must be performed before making a valve lash
adjustment.
Perform the valve lash setting when the engine is
cold. After the engine has been shut down and the
valve covers are removed, the engine is considered
cold.
Before performing maintenance, prevent the entry of
foreign matter into the top of the cylinder head and
the valve mechanism. Thoroughly clean the area
around the valve mechanism covers.
For the valve lash setting, refer to the engine’s
Specifications manual.
i01724567
Fuel Metering Valve - Check
(Raptor)
SMCS Code: 1741-535
g00886284
Illustration 63
(1) Fuel metering valve
For information regarding the fuel metering
valve, refer to Installation and Operation Manual,
SEBU7630, “Raptor Gas Regulation and Metering
Valve/Actuator System for Caterpillar”.
i01949940
Fuel System Fuel Filter
Differential Pressure - Check
SMCS Code: 1261-535
A fuel filter differential pressure gauge must be
installed in order to determine when the fuel filter
requires service. This gauge and the fuel filter are
supplied by the customer.
A fuel filter differential pressure gauge indicates the
difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
plugged.
Operate the engine at the rated rpm and at the
rated load. Check the fuel filter differential pressure.
Service the fuel filter when the fuel filter differential
pressure reaches 1.7 kPa (0.25 psi).
For instructions, refer to Special Instruction,
SEHS9298, “Installation and Maintenance of
Gaseous Fuel Filters”. Consult your Caterpillar dealer
for assistance.
 95
Maintenance Section
Fumes Disposal Filter - Drain

i01857938 i01601766

Fumes Disposal Filter - Drain Fumes Disposal Filter

SMCS Code: 1074 Differential Pressure - Check
SMCS Code: 1074

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.

Note: Always disconnect power to the fumes

collector prior to servicing. The motor is protected by
a thermal protector. If the motor is shut down due to
excessive heat, the motor will automatically restart
when the protector resets.

1. Shut down the engine and the fumes disposal Illustration 65

g00829797
filter.
Pressure gauge on top of the filter

Check the differential pressure across the filter

element. Observe the pressure that is indicated by
the pressure gauge on top of the filter. Record the
measurement.

The restriction of a new element is approximately

1.7 kPa (7 inches of H2O).

The normal restriction of the element is approximately

5.7 to 9.95 kPa (23 to 40 inches of H2O).

• Replace the filter element when the differential

pressure reaches 11.2 kPa (45 inches of H2O).
g00947065
Illustration 64
(1) Drip leg • Replace the element after every year regardless of
(2) Condensation trap drain valve the differential pressure.

2. Open drip leg (1) and drain the fluid into a suitable i01749518
container.
Fumes Disposal Filter Element
If the filter is installed and maintained properly, no
more than 28 g (1 ounce) of fluid will be drained. - Replace
If more than one 28 g (1 ounce) is drained, make SMCS Code: 1074
sure that the filter is installed according to the
instructions in Special Instruction, REHS0883.
Ensure that the system is operating properly.
Hot oil and components can cause personal in-
3. Close the drip leg. jury.

4. Open condensation trap drain valve (2) and drain Do not allow hot oil or components to contact
the fluid into a suitable container. skin.

5. Close the condensation trap drain valve.

Resume normal operation.

96
Maintenance Section
Gas Pressure Regulator Condensation - Drain

Note: Always disconnect power to the fumes

collector prior to servicing. The motor is protected by
a thermal protector. If the motor is shut down due to
excessive heat, the motor will automatically restart
when the protector resets.

g01014926
Illustration 67
Cap on the drip leg for the gas supply line to the gas pressure
regulator

1. Close the main gas supply valve.

g00763796
Illustration 66
(1) Nuts and washers
2. Remove the caps from the drip legs.
(2) Cover
(3) Body 3. Allow the moisture to drain into a suitable
(4) Filter element container. Inspect the drip legs for debris. Clean
the drip legs, if necessary.
Note: The filter element is mounted above the
engine. A ladder or a platform will be required for 4. Clean the caps. Install the caps.
servicing the element.
5. Open the main gas supply valve.
1. Remove three nuts and washers (1) in order to
remove cover (2) from body (3).
i01730803
2. Remove element (4).
Generator - Dry
3. Clean the inside of cover (2) and body (3).
SMCS Code: 4450-569
4. Install new element (4) into body (3).

5. Place cover (2) in position and install three nuts

and washers (1). Personal injury or death can result from improper
troubleshooting and repair procedures.
i01950516 The following troubleshooting and repair proce-
Gas Pressure Regulator dures should only be performed by qualified per-
sonnel familiar with this equipment.
Condensation - Drain
SMCS Code: 1270-543 Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure
To collect condensation, drip legs should be installed to safely isolate the generator.
in the following locations:
If the insulation resistance values are less than the
recommended values, one of the following drying
• Supply line for the gas pressure regulator procedures must be selected. This decision should
be based on the following factors:
• Balance line for the gas pressure regulator
• Supply line to the gas shutoff valve • the size of the unit
• the location of the unit
• the equipment that is available
 97
Maintenance Section
Generator - Dry

• the experience of personnel Heat can be used in order to dry the generator
windings. This heat can be created by allowing a
Note: For more information on drying methods, refer controlled current to flow through the generator. No
to Special Instruction, SEHS9124, “Cleaning and high voltages are generated during the following
Drying of Electric Set Generators”. procedure. Therefore, insulation breakdown will not
occur.
Remove the voltage regulator. Cover all of the inlet
openings. Cover all of the discharge holes. Provide
an opening at the top of the machine. This opening
will allow moisture to evaporate. Preferably, this
opening will be located at the fan end. Monitor the
winding temperatures. DO NOT APPLY HEAT TOO
RAPIDLY. Winding temperature should be raised
gradually at a rate of 10 °C (50 °F) per hour up to
85 °C (185 °F). Measure insulation resistance at one
hour intervals. Typically, the insulation resistance
will slowly drop while the temperature is rising. The
insulation resistance will then start to increase at a
slow rate until the insulation resistance reaches a
constant level.

The following methods can be used for drying a

generator:

• Self-circulating air method

• Oven method
• Controlled current method

Self-Circulating Air Method

Disconnect the generator load and run the engine.
This will help circulate air. Illustration 68
g00669571

Generator Wiring Diagram

Oven Method (CR1-CR6) Diodes
(CR7) Varistor
Place the entire generator inside a forced air drying (L1) Exciter field (stator)
oven for four hours at 65 °C (149 °F). (L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
NOTICE (L5) Pilot exciter armature
(PM) Permanent magnet
Use a forced air type oven rather than a radiant type
(RFA) Rotating field assembly
oven. (CST) Customer supplied transformer

Radiant type ovens can cause localized overheating. 1. Make an external power source.

2. Refer to the above diagram. Disconnect “F1+”

Controlled Current Method from the voltage regulator. Disconnect “F2-” from
the voltage regulator. Disconnect the generator
Table 18
load. Connect the generator output leads “T0”,
Tools Needed “T1”, “T2”, and “T3”. Install the clamp-on ammeter
to generator output lead “T1”.
Part Description Qty
Number
Note: When the line current is measured on
8T-0900 Clamp on ammeter (1200 1 multiple-lead units, measure the current in each
amperes) conductor per phase. The currents can then be
External Power Source 1 added.

Rheostat 1
98
Maintenance Section
Generator - Inspect
3. Refer to the above diagram. Connect the rheostat.
Adjust the rheostat to the maximum resistance
value. Connect the external power source to wires
“F1+” and “F2-”.
4. Start the generator set. Run the generator set at
idle speed.
5. Monitor the phase current. Gradually increase the
engine RPM. Increase the engine RPM until one
of the following conditions are met:
• The rated phase current is obtained.
• The full generator set speed is obtained.
6. If more phase current is still necessary, slowly
turn the rheostat until the rated phase current is
reached.
7. On an hourly basis, stop the drying procedure.
Check the insulation resistance. Repeat the above
steps until the insulation resistance is acceptable.
i01880220
Generator - Inspect
SMCS Code: 4450-040
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.
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure
to safely isolate the generator.
Proper maintenance of electrical equipment requires
periodic visual examination of the generator and
periodic visual examination of the windings. Proper
maintenance of electrical equipment also requires
appropriate electrical checks and appropriate thermal
checks. Insulation material should be examined for
cracks. The insulation material should be examined
for accumulations of dirt and dust. If there is an
insulation resistance value that is below normal, a
conductive path may be present. This conductive
path may be made of one of the following materials:
• Carbon
• Salt
• Metal dust
• Dirt that is saturated with moisture
These contaminants will develop a conductive path
which may produce shorts. Cleaning is advisable if
heavy accumulations of dirt can be seen or if heavy
accumulations of dust can be seen. If excess dirt is
the cause of a restriction in the ventilation, cleaning
is also advisable. Restricted ventilation will cause
excessive heating.
NOTICE
To avoid the possibility of deterioration to the genera-
tor windings, do not clean the generator unless there
is visual, electrical, or thermal evidence that dirt is
present.
If harmful dirt accumulations are present, a variety
of cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
the items on the following list:
• The extent of the cleaning procedure that is being
attempted
• The type of enclosure of the generator
• The voltage rating of the generator
• The type of dirt that is being removed
Cleaning (Assembled Generators)
Cleaning may be required at the point of installation.
At this point, complete disassembly of the generator
may not be necessary or feasible. In this case,
a vacuum cleaner should be used to pick up the
following items: dry dirt, dust, and carbon. This will
prevent the spreading of these contaminants.

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
exposed. After most of the dust has been removed,
a small brush may be attached to the vacuum hose
in order to loosen dirt that is more firmly attached to
the surface.
After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the
above cleaning procedures are not effective, consult
a Caterpillar dealer.
Cleaning (Disassembled
Generators)
An initial insulation resistance check should be
made on the generator in order to confirm electrical
integrity. A minimum reading of one megohm would
be expected with severely contaminated generators.
A zero megohm reading may indicate an insulation
breakdown. An insulation breakdown requires more
than cleaning. An insulation breakdown requires
repair.
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
contaminated by salt. A solution of hot water and
detergent is used for this method of cleaning.
A high pressure wash sprays a high velocity fluid
stream of this solution over the generator that is
being cleaned. This detergent washing is followed by
multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean
water is used in order to dilute the detergent.
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation
resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It
may be necessary to use solvents if the generator
is contaminated with oil or if the generator is
contaminated with grease.
Note: For more information on drying methods, refer
to Special Instructions, SEHS9124, “Cleaning and
Drying of Electric Set Generators”.
99
Maintenance Section
Generator Load - Check
i01473721
Generator Load - Check
SMCS Code: 4450-535-LA
During normal operation, monitor the power factor
and monitor generator loading.
When a generator is installed or when a generator
is reconnected, ensure that the total current in any
one phase does not exceed the nameplate rating.
Each phase should carry the same load. This allows
the generator to work at the rated capacity. If one
phase current exceeds the nameplate amperage,
an electrical imbalance will occur. An electrical
imbalance can result in an electrical overload and an
electrical imbalance can result in overheating.
The power factor can be referred to as the efficiency
of the load. This can be expressed as the ratio of kVA
to actual kW. The power factor can be calculated by
dividing kW by kVA. Power factor is expressed as a
decimal. Power factor is used to mean the portion
of current that is supplied to a system that is doing
useful work. The portion of the current that is not
doing useful work is absorbed in maintaining the
magnetic field in motors. This current (reactive load)
can be maintained without engine power.
Electric sets normally have a low idle setting that
is higher than industrial engines. Low idle will be
approximately 66 percent of the full speed that is
achieved by 60 Hz units. This would be equal to 80
percent of the full speed that is achieved by 50 Hz
units.
Some electric sets are equipped with Woodward
governors and some electric sets are equipped
with Caterpillar electronic governors. These electric
sets have no low idle stop. On electric sets with
mechanical governors and natural gas electric sets,
the low idle is set at the factory. Adjustment of the
low idle on these machines should only be done by
a Caterpillar dealer.
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
down and the electric set must be restarted. This
will allow the voltage regulator to again produce an
output.
100
Maintenance Section
Generator Set - Test

i01754617 The generator set functional test consists of the

following steps:
Generator Set - Test
1. Stop the generator. Remove the panels in order to
SMCS Code: 4450-081 allow access to the regulator and control terminal
strips. Determine the part number for the regulator.
Record the sensing voltage of the regulator. The
sensing voltage is 120 V ± 3%, 240 V ± 3%, or
Personal injury or death can result from high volt- 480 V ± 3%. If the multimeter has the capability,
age. also record the frequency.

When power generation equipment must be in op-
eration to make tests and/or adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
When servicing or repairing electric power gener-
ation equipment:
• Make sure the unit is off-line (disconnected
from utility and/or other generators power
service), and either locked out or tagged DO
NOT OPERATE.
• Make sure the generator engine is stopped.
2. Verify that the generator set is ready to start. Start
the generator set and bring the generator set to
rated speed. Measure the sensing voltage with the
multimeter on terminals 20-22, 22-24, and 20-24.
If these voltages match the sensing voltage of the
regulator and if these voltages are nearly equal,
then the output of the generator at the bus bar
should be the correct value.
3. If the voltages do not match the sensing voltage
of the regulator, see the service manual for the
regulator for further troubleshooting instructions.
i01966154
Generator Set Vibration -
Inspect
SMCS Code: 4450-040-VI

• Make sure all batteries are disconnected. Check for vibration damage. Vibration may cause the
following problems:
• Make sure all capacitors are discharged.
• Loose fittings
Table 19
• Loose belts
Tools Needed(1)
Part Number Part Quantity • Excessive noise

6V-7070
Digital
1 • Cracked insulation
Multimeter
Digital
The following areas are susceptible to vibration
146-4080 1 damage:
Multimeter
Digital • Stator output leads
9U7330 1
Multimeter
(1) Any one of these multimeters may be used. • Protective sleeving
The generator set functional test is a simplified test • Insulation
that can be performed in order to determine if the
generator is functional. The generator set functional • Exposed electrical connections
test should be performed on a generator set that is
not under load. The generator set functional test • Transformers
determines if the generator is operating at expected
voltage and frequency levels. Perform this test at the • Fuses
regulator and terminal strips. Do not perform this test
at the output connections. • Capacitors
• Lightning arresters

When a generator set is installed a vibration plot
should be recorded in order to assist in diagnosing
potential problems. This vibration plot should be
updated yearly. The vibration plot should also be
updated when the generator set is moved. Refer to
Data Sheet, LEKQ4023, “Linear Vibration” for the
allowable limits of vibration.
Contact the Caterpillar Service Technology Group for
information on ordering a vibration analyzer.
i01819486
Hoses and Clamps -
Inspect/Replace
SMCS Code: 7554-040; 7554-510
Inspect all hoses. Leaks can be caused by the
following conditions:
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.
Check for the following conditions:
• Fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
101
Maintenance Section
Hoses and Clamps - Inspect/Replace
• Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
1. Service the hoses and clamps according to the
system:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
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 pres-
sure.
a. Before servicing a coolant hose, stop the
engine. Allow the engine to cool. Loosen the
cooling system filler cap slowly in order to
relieve any pressure. Remove the cooling
system filler cap. Drain the coolant from the
cooling system to a level that is below the hose
that is being replaced.
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
b. Before servicing an oil hose, stop the engine.
Allow the engine to cool. Drain the oil from the
system to a level that is below the hose that
is being replaced.
102
Maintenance Section
Ignition System Spark Plugs - Replace
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
c. Before servicing a pressurized air hose, stop
the engine. Ensure that the air supply to the
hose is OFF. Slowly release pressure from the
system.
2. Remove the hose clamps.
3. Disconnect the old hose. Discard the hose.
4. Install a new hose.
5. Install the hose clamps with a torque wrench.
For torques on hose clamps, see Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps”.
6. After servicing the hose, restore the system to an
operational state according to the requirements
of the system:
a. If a coolant hose was serviced, refill the cooling
system. Install the cooling system filler cap.
Start the engine. Inspect the cooling system
for leaks.
b. If an oil hose was serviced, refill the system to
the proper level. Start the engine. Inspect the
system for leaks.
Personal injury or death can result from improp-
erly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
c. If a pressurized air hose was serviced, restore
air pressure to the system. Check for air leaks.
i02023754
Ignition System Spark Plugs -
Replace
SMCS Code: 1555-510
Note: Condensation can form in spark plugs that
have precombustion chambers. This can cause
difficulty for cold start-ups. To avoid condensation,
maintain the coolant in the cylinder block at a
minimum temperature of 43 °C (110 °F) continuously.
The service life of the spark plugs is affected by
fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also
affected by voltage. Higher voltage is required
by higher inlet manifold air pressure, a higher
compression ratio, or retardation of the timing. Higher
voltage reduces the service life of components such
as spark plugs, wires, and transformers.
The service life of the spark plug is different for
different applications. The minimum service life of the
spark plug is approximately 3000 service hours. The
spark plug may be good for a considerable period
beyond 3000 service hours. To help predict the
spark plug’s service life, use Caterpillar Electronic
Technician (ET) to monitor the “Cylinder #X
Transformer Secondary Output Voltage Percentage”
parameter. The value of this parameter will increase
as the spark plug gap wears over time. Experience
at the particular site will help to determine the proper
interval for replacement of the spark plugs.
If a diagnostic code is generated for the ignition
transformer’s secondary circuit, the spark plug may
need to be replaced. Misfire and a cold cylinder are
other indications of a worn spark plug. Use Cat ET
to monitor the exhaust port temperatures in order to
locate a cold cylinder.
Removing the Spark Plug
Ignition systems can cause electrical shocks.
Avoid contacting the ignition system components
and wiring.
Do not attempt to remove the valve covers when
the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
death may result and the ignition system will be
damaged if the valve covers are removed during
engine operation. The engine will not operate
without the valve covers.
 103
Maintenance Section
Ignition System Spark Plugs - Replace

Note: Excessive buildup of oil in the spark plug

well is an indication of a damaged lip seal on the
transformer.

5. Debris may have collected in the spark plug well.

Thoroughly remove any debris. Use compressed
air. The maximum air pressure for cleaning
purposes must be below 207 kPa (30 psi). Ensure
that the area around the spark plug is clean and
free of dirt and debris.

6. Use a 216-1685 deep well socket, an extension,

and a breaker bar to loosen spark plug (5). After
the spark plug has been loosened, use the socket
and extension to remove the spark plug by hand
in order to detect problems with the threads. After
the spark plug has been removed, discard the
used spark plug gasket.

If the spark plug resists removal by hand, apply

penetrating oil to the threads. To help the oil penetrate
the threads, turn the spark plug back and forth until
the spark plug is loose.

If the spark plug could not be removed by hand,

clean the threads with a Spark Plug Seat Cleaner.
This tool scrapes debris from the seat and from the
threads in the cylinder head. Be sure to clean any
debris from the cylinder.

NOTICE
Do not use a thread tap. A thread tap will remove metal
unnecessarily. The threads could be stripped and the
cylinder head could be damaged.
g00925913
Illustration 69
(1) Cover
(2) Wiring harness Inspecting the Spark Plug
(3) Transformer
(4) Seal
(5) Spark plug
(6) Valve cover

1. Remove cover (1).

2. Remove wire harness (2) from transformer (3).

3. Remove the two remaining bolts that secure Illustration 70

g00935078
transformer (3). Remove transformer (3) from (7) Terminal post
valve cover (6). (8) Insulator
(9) Shell
4. Inspect O-ring seal (4). If the seal is hard, cracked, (10) Gasket
or melted, install a new seal. (11) Hole in the spark plug’s precombustion chamber

Inspect the spark plug closely for damage. The

Pressurized air can cause personal injury. When
pressurized air is used for cleaning, wear a pro-
tective face shield, protective clothing, and pro-
tective shoes.
condition of the spark plug can indicate the operating
condition of the engine.
Terminal post (7) must not move. If the terminal post
can be moved by hand, carefully tighten the post into
the threads of the insulator. If the post cannot be
tightened, discard the spark plug.
104
Maintenance Section
Ignition System Timing - Check/Adjust
Insulator (8) is covered with Teflon. If the cover is
cracked or loose, discard the spark plug.
Faint marks may extend from shell (9) onto the
insulator. The marks may be a result of a corona
that forms at the top of the shell. The conductor will
develop a corona when a very high voltage potential
ionizes the air. This is a normal condition. This is not
an indication of leakage between the shell and the
insulator.
Inspect shell (9) for damage. Cracks can be caused
by overtightening the spark plug. Overtightening can
also yield the metal which loosens the shell. Discard
any spark plug that has a shell that is cracked or
loose.
Inspect the spark plug’s precombustion chamber
for deposits. Make sure that holes (11) in the spark
plug’s precombustion chamber are not blocked.
A light brown deposit or a beige deposit is produced
by normal operation.
Deposits that are gray or black may be caused by
the following substances:
• Excessive oil
• Use of the wrong oil
• A substance that is introduced through the fuel
system or the air system
• Poor combustion because of a rich air/fuel mixture
A spark plug can operate despite a buildup of
ash. Large deposits may retain heat which can
cause premature fuel ignition. This can lead to
uncontrollable detonation.
Cleaning the Spark Plug
Do not use glass beads to clean the spark plug.
The beads could enter the precombustion chamber
through the holes. The beads could clog the holes in
the spark plug’s precombustion chamber.
Use a brass wire brush to clean the spark plug. Be
careful not to damage the Teflon cover.
Installing the Spark Plug
Note: Do not use anti-seize compound on spark
plugs. Most of the heat is transferred through the
threads and the seat area of the spark plug. Contact
of the metal surfaces must be maintained in order to
provide the heat transfer that is required.
1. Ensure that the spark plug is clean and free of
dirt and oil.
2. Always use a new gasket when a spark plug is
installed. If a used spark plug is installed, place a
new gasket on the spark plug. Orient the tabs of
the gasket toward the spark plug’s precombustion
chamber. Otherwise, the gasket may not seat
properly. If a gasket for a spark plug is installed
incorrectly, do not increase the torque on the spark
plug in order to improve the seal. Do not reuse the
gasket. Install a new gasket.
NOTICE
Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The met-
al can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that is
between the shell and the insulator, allowing combus-
tion pressure to blow past the seal. Serious damage
to the engine can occur.
Use the proper torque.
3. Install spark plug (5) by hand until the spark plug
contacts the gasket. Torque the spark plug to
the proper specification. Refer to Specifications,
“Spark Plug” for the proper torque specification.
4. Ensure that the transformer and the extension are
clean and free from dirt and oil. Lubricate O-ring
seal (4) with one of the following lubricants:
• Dielectric Grease
• Silicone Lubricant
5. Install transformer (3). Orient the transformer
toward wiring harness (2). Connect the wiring
harness.
6. Install cover (1).
i01951964
Ignition System Timing -
Check/Adjust
SMCS Code: 1550-025; 1550-535
After maintenance has been performed on the
ignition system, check the timing of the ignition
system. Adjust the timing, if necessary.
Ignition timing for gas engines varies with the gas
chemistry. Obtain a fuel analysis in order to determine
if the timing for the ignition system is correct. Enter
the data from the fuel analysis into the Caterpillar
Software Program, LEKQ6378, “Methane Number
Program”. Alternatively, you may provide the results
of a gas analysis to your Caterpillar dealer for
assistance in determining the correct timing for your
application.
 105
Maintenance Section
Inlet Air System - Inspect

Use the Caterpillar Electronic Technician (ET) to i01689065

adjust the timing. Adjust the timing according to
the instructions in Special Instruction, REHS1438, Insulation - Test
“Installation and Initial Start-Up Procedures For
G3500C Engines”. Consult your Caterpillar dealer SMCS Code: 4453-081; 4454-081; 4457-081;
for assistance. 4470-081

i01935380
Recommended Periodic Insulation
Tests
Inlet Air System - Inspect
SMCS Code: 1058-040; 1071-040; 1087-040

Use of a platform may be necessary to inspect the The high voltage that is produced by an operating
following components of the air inlet system: generator set can cause severe injury or death.
Before performing any maintenance or repairs,
• Piping between the air cleaner and the turbocharger ensure that the generator will not start.

• Rubber hoses in the air lines Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start-
• Turbocharger ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
• Piping between the turbocharger and the automatic transfer switches that are associated
aftercooler with the generator.

• Aftercooler Note: The results from the insulation resistance

• Connection of the aftercooler to the air plenum
• Connection of the air plenum to the cylinder head
Inspect the components for the following conditions:
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 71.

• Cracks
• Leaks
• Loose connections
• Debris
Ensure that all of the connections are secure. Ensure
that the components are in good condition and free
of debris.

Make repairs, if necessary. For information regarding

removal and installation of the components, refer
to Service Manual, “Disassembly and Assembly”.
Consult your Caterpillar dealer for assistance.
106
Maintenance Section
Insulation - Test

g00633226
Illustration 71

Periodically, use an insulation tester to check the
insulation resistance of the generator’s main stator
winding. Caterpillar recommends the 142-5055
Insulation Testing Gp for testing the insulation
resistance on Caterpillar generator sets. The
frequency of this test is determined by the generator’s
environment. Previous insulation tester readings will
also determine the frequency of this test.
Test the main stator windings with an insulation tester
in the following situations:
• The generator set is started for the first time.
• The generator set is removed from storage.
• The generator set is operating in a humid
environment. Test every three months.
• The generator set is not protected from the
elements in an enclosed area. Test every three
months.
• 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 generator set has not been run under load for
three months. Test the generator set weekly.
For additional information, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
Recommended Periodic Insulation
Test Procedure
Personal injury or death can result from electro-
cution.
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”.
107
Maintenance Section
Insulation - Test
3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Disconnect “T0” from ground.
6. Disconnect the regulator sensing lead wires: “20”,
“22”, and “24”.
7. Connect the insulation tester’s RED lead to
ground.
8. Connect the insulation tester’s BLACK lead to
“T0”.
9. For units that are 600 volts or less, set the voltage
to 500 Volts. For units that are more than 600
volts, set the voltage to 1000 Volts.
10. 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.
11. 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.
Engine Serial Number_____________________________________
Generator Serial Number_________________________________
108
Maintenance Section
Overhaul (In-Frame)
i01935402
Overhaul (In-Frame)
SMCS Code: 1000-020
Scheduling an In-Frame Overhaul
Generally, an in-frame overhaul is performed for
every third top end overhaul. Scheduling an in-frame
overhaul normally depends on the following three
conditions:
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease and a variation of cylinder compression
Each individual condition may not indicate a need
for an overhaul. However, evaluating the three
conditions together is the most accurate method of
determining when an overhaul is necessary.
The engine does not require an overhaul if the
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.
Periodically measure each of the three conditions.
The first measurement should occur during the
engine commissioning. This establishes a baseline
for future measurements. Additional measurements
are scheduled at regular intervals in order to
determine a schedule for the next in-frame overhaul.
The following changes in the three conditions
normally require a scheduled overhaul:
• A 300 percent increase in oil consumption
• A 200 percent increase in crankcase blowby
• A 20 percent loss of cylinder compression
Note: These indications do not require an engine
to be shut down for service. These indications
only mean that an engine should be scheduled for
service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
requirement.
Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Usually, an in-frame overhaul does not require
removal of the engine. Instead, the service is
performed with the engine in place. If the customer
requires a minimum disruption in the production of
power, the engine can be replaced with a rebuilt
model of identical specifications.
Note: The generator or the driven equipment may
also require service when the engine overhaul is
performed. Refer to the literature that is provided by
the OEM of the driven equipment.
In-Frame Overhaul Information
An in-frame overhaul includes all of the work that is
done for a top end overhaul. Additionally, some other
components that wear are replaced. The condition
of components is inspected. Those components are
replaced, if necessary.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.
The following definitions explain the terminology for
the services that are performed during an overhaul:
Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Rebuild – The component can be reconditioned in
order to comply with reusability guidelines.
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
for your engine.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
recommendations in Table 20.
 109
Maintenance Section
Overhaul (Major)

Table 20 • Reduced oil pressure

In-Frame Overhaul
• The wear metal analysis of the lube oil
Clean Oil suction screen
Clean Aftercooler core • An increase in the levels of noise and vibration
Inspect
Test An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
Inspect Compressor bypass valve need to be serviced. An increase in the levels of
Rebuild noise and vibration indicates that rotating parts
Replace Fuel metering valve
require service.
Oil cooler
Oil pump Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
Pistons liners may be worn so that polishing of the bore
Transformers occurs. Also, the increased use of lube oil will dilute
the wear metals.
Rebuild Prelube pump
Starting motor Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
Turbochargers scheduling a major overhaul.
Water pumps
Note: The generator or driven equipment may also
Replace Connecting rod bearings require service when the engine is overhauled. Refer
Cylinder head assemblies to the literature that is provided by the OEM of the
driven equipment.
Cylinder liners
Main bearings Major Overhaul Information
Piston rings
A major overhaul includes all of the work that is
Water temperature regulators done for top end overhauls and in-frame overhauls.
Additional parts and labor are required in order to
completely rebuild the engine. In some cases, the
engine is relocated for disassembly.
i01935411
For the major overhaul, all of the bearings,
Overhaul (Major) seals, gaskets, and components that wear are
disassembled. The parts are cleaned. The parts are
SMCS Code: 7595-020-MJ
inspected. If necessary, the parts are replaced. The
crankshaft is measured for wear. The crankshaft may
Scheduling a Major Overhaul require regrinding. Alternatively, the crankshaft may
be replaced with a Caterpillar replacement part.
Generally, a major overhaul is performed for every
fifth top end overhaul. The need for a major overhaul Your Caterpillar dealer can provide these services
is determined by several factors. Some of those and components. Your Caterpillar dealer can ensure
factors are the same factors that determine the that the components are operating within the
in-frame overhaul: appropriate specifications.

• An increase of oil consumption The following definitions explain the terminology for
the services that are performed during an overhaul:
• An increase of crankcase blowby
• A decrease and variation of cylinder compression
Other factors must also be considered for determining
a major overhaul:

• Power output
• The service hours of the engine
110
Maintenance Section
Overhaul (Major)

Inspect – Inspect the components according to Table 21

the instructions that are in Caterpillar reusability Major Overhaul
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index Clean Oil suction screen
of Publications on Reusability or Salvage of Used Clean Aftercooler core
Parts”. The guidelines were developed in order to Inspect
help Caterpillar dealers and customers to avoid Test
unnecessary expenditures. New parts are not
required if the existing parts can still be used, Inspect Camshafts
reconditioned, or repaired. If the components are Rebuild
Replace Camshaft followers
not in the reusability guidelines, refer to the Service
Manual, “Specifications” module. Connecting rods
Crankshaft
Rebuild – The component can be reconditioned in
order to comply with reusability guidelines. Fuel metering valve
Gear train
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance Inlet air piping
interval. The part must be replaced with a part that Oil cooler
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part, Oil pump
a rebuilt part, or a used part. Some worn components Pistons
may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options Throttle valve
for your engine. Transformers
If you elect to perform an overhaul without the Rebuild Prelube pump
services of a Caterpillar dealer, be aware of the Starting motor
recommendations in Table 21. Your Caterpillar dealer
can provide these services and components. Turbochargers
Water pumps
Vibration damper
Replace Camshaft bearings
Connecting rod bearings
Coupling (tandem engines)
Cylinder liners
Gaskets and seals
Gear train bushings
Main bearings
Piston rings
Water temperature regulators
Wiring harnesses

i01935431
Overhaul (Top End)
SMCS Code: 7595-020-TE
Scheduling a Top End Overhaul
Top end overhauls are scheduled according to
the recession of the exhaust valve stems. This
measurement provides an accurate indication of the
rate of valve wear. This measurement can be used to
predict when a cylinder head requires replacement.
To determine a baseline, measure the projection of
the exhaust valve stems after 100 to 250 service
hours. The baseline is a reference for subsequent
measurements. Continue to periodically measure
the projection.
Plan for the top end overhaul as the valve stem
projection approaches the maximum limit. Perform
the top end overhaul when the valve stem projection
has increased by a total of 2.3 mm (.09 inch). Do
not allow the projection of the exhaust valve stems
to exceed this limit.
Note: Generally, cylinder heads wear out at different
rates. In some cases, servicing the cylinder heads at
different times may be the most economic decision.
This depends on the valve stem projection of the
individual cylinders. However, this decision must
include the costs of additional downtime that is
caused by this procedure. Perform an economic
analysis in order to determine if cylinder heads should
be serviced as a group or divided into smaller groups.
Note: The generator or the driven equipment may
also require service when the engine overhaul is
performed. Refer to the literature that is provided by
the OEM of the driven equipment.
Top End Overhaul Information
A top end overhaul involves servicing the cylinder
heads and turbochargers. Also, some other engine
components are inspected.
Top end overhauls require more tools than preventive
maintenance. The following tools are needed for
restoring the engine to factory specifications:
• Torque wrenches
• Dial indicators
• Accurate measurement tools
• Cleaning equipment
• Rebuilding equipment
111
Maintenance Section
Overhaul (Top End)
Caterpillar dealers are equipped with these tools.
Caterpillar dealers can provide a flat rate price for
a top end overhaul.
Unexpected problems may be found during a top
end overhaul. Plan to correct these problems, if
necessary.
• Buildup in the cylinders from excessive oil
consumption
• Buildup in the cylinders from contamination of the
fuel
• Plugging of the aftercooler from coolant that is
poorly maintained
• Plugging of the aftercooler from contamination of
the inlet air
• Degradation of the oil cooler from hydrogen sulfide
in the fuel
The following definitions explain the terminology for
the services that are performed during an overhaul:
Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Rebuild – The component can be reconditioned in
order to comply with reusability guidelines.
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
for your engine.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
recommendations in Table 22. Your Caterpillar dealer
can provide these services and components. Your
Caterpillar dealer can ensure that the components
are operating within the appropriate specifications.
112
Maintenance Section
Overhaul (Top End)

Table 22 4. Steam clean the core in order to remove any

Top End Overhaul
residue. Flush the fins of the core. Remove any
other trapped debris.
Clean Oil suction screen
Clean Aftercooler core
5. Wash the core with hot, soapy water. Rinse the
Inspect Oil cooler core core thoroughly with clean water.
Test
Inspect Transformers
Rebuild Prelube pump Personal injury can result from air pressure.
Starting motor
Personal injury can result without following prop-
Turbochargers er procedure. When using pressure air, wear a pro-
Water pumps tective face shield and protective clothing.
Replace Cylinder head assemblies Maximum air pressure at the nozzle must be less
Spark plugs than 205 kPa (30 psi) for cleaning purposes.

Water temperature regulators

Cleaning and Inspection of Components
Aftercooler and Oil Cooler
Clean the aftercooler core and the oil cooler
core. Pressure test the components. Replace the
components, if necessary.
Note: If the cooling system is not properly maintained,
cleaning of the aftercooler can be difficult. The tank
that is opposite of the inlet port and the outlet port
can not be removed for cleaning.
Note: This procedure may be used for cleaning both
the aftercooler core and the oil cooler core.
1. Remove the core.
2. Turn the core upside-down in order to remove
debris.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Note: The test pressure for the oil cooler is 790 kPa
(115 psi). The maximum differential pressure of water
for the aftercooler is 44 kPa (6 psi). The maximum
differential pressure of air for the aftercooler is
5.1 kPa (0.74 psi).
7. Inspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.
8. Install the core.
For more information on cleaning the cores, consult
your Caterpillar dealer.
Oil Suction Screen

NOTICE Hot oil and components can cause personal in-

Do not use a high concentration of caustic cleaner to jury.
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause Do not allow hot oil or components to contact
leakage. Only use the recommended concentration of skin.
cleaner.
Clean the oil suction screen after the engine oil pan
3. Back flush the core with cleaner. has been drained.

Caterpillar recommends the use of Hydrosolv
liquid cleaner. Consult your Caterpillar dealer for
part numbers and sizes of containers.
Use a two to five percent concentration of the
cleaner at temperatures up to 93°C (200°F).
Note: Approximately 1 L (1 qt) of engine oil will
remain in the housing after the sump has been
completely drained. This engine oil will pour out of
the housing when cover (1) is removed. Prepare to
catch the engine oil in a pan. Clean up any spills with
absorbent towels or pillows. DO NOT use absorbent
particles.

g00760655
Illustration 72
(1) Cover
(2) O-ring seal
(3) Screen assembly
1. Loosen the bolts from cover (1). Remove cover
(1) and O-ring seal (2). Discard the seal. Remove
screen assembly (3).
2. Wash screen assembly (3) in clean nonflammable
solvent. Allow the screen assembly to dry before
installation.
3. Clean the engine oil sump. Remove the side
covers in order to gain access to the sump. After
the sump is clean, install the side covers.
4. Inspect screen assembly (3) for good condition.
Obtain a new screen assembly, if necessary.
Install the screen assembly. Install a new O-ring
seal (2). Install cover (1).
Transformers
The transformers produce a voltage increase. For
good operation, the connections must be clean and
secure. Inspect the transformers for the following
conditions:
• Damaged O-rings
• Dirty insulator
• Loose connections
• Loose connector
• Moisture
Measure the voltage of the diode for the primary
circuit and measure the resistance of the secondary
circuit according to Troubleshooting, “G3500C
Engines”. Consult your Caterpillar dealer for
assistance.
113
Maintenance Section
Overhaul Considerations
i01950926
Overhaul Considerations
SMCS Code: 7595-043
Overhaul Information
An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn parts.
An overhaul also includes the following maintenance:
• Inspection of all the parts that are visible during
the disassembly
• Replacement of the seals and gaskets that are
removed
• Cleaning of the internal passages of the engine
and the engine block
Most owners will save money by overhauling the
engine at the intervals that are recommended in
the Operation and Maintenance Manual. It is not
practical to wait until the engine exhibits symptoms
of excessive wear or failure. It is not less costly to
wait. A planned overhaul before failure may be the
best value for the following reasons:
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
guidelines for reusable parts.
• The service life of the engine can be extended
without the risk of a major catastrophe due to
engine failure.
• Achieve the best cost/value relationship per hour
of extended service life.
Overhaul Intervals
Top end overhauls are determined by the projection
of exhaust valve stems. In-frame overhauls are
determined by cylinder compression, crankcase
blowby, and oil consumption. Major overhauls are
determined by the in-frame tests, and by results of
S·O·S oil analysis.
Some other factors that are important for determining
the overhaul intervals include the following
considerations:
• Performance of preventive maintenance
• Use of recommended lubricants
114
Maintenance Section
Power Factor - Check
• Use of recommended coolants
• Use of recommended fuels
• Proper installation
• Operating conditions
• Operation within acceptable limits
• Engine load
• Engine speed
Note: To avoid oil problems, engines that are
turbocharged and aftercooled must be operated at a
minimum of 60 percent of rated load.
Generally, engines that are operated at a reduced
load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
properly operated and maintained.
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,
“Index of Publications on Reusability or Salvage of
Used Parts”.
The Guidelines For Reusable Parts and Salvage
Operations is part of an established Caterpillar
parts reusability program. These guidelines were
developed in order to assist Caterpillar dealers and
customers reduce costs by avoiding unnecessary
expenditures for new parts. If the engine parts comply
with the established inspection specifications, the
parts can be reused. New parts are not necessary if
the old parts can be reused, repaired, or salvaged.
If the parts are not within the inspection specifications,
the parts should be salvaged, repaired, replaced,
or exchanged. The use of out-of-spec parts could
result in unscheduled downtime and/or costly repairs.
The use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
efficiency.
Your Caterpillar dealer can provide the parts that are
needed to rebuild the engine at the least possible
cost.
Overhaul Programs
An economical way to obtain most of the parts
that are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured
parts are available at a fraction of the cost of new
parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
examples of the remanufactured parts:
• Alternators
• Connecting rods
• Crankshafts
• Cylinder heads
• Oil Pumps
• Starting motors
• Turbochargers
• Water pumps
Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available.
Your Caterpillar dealer may be offering a variety of
overhaul options.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on
preventive maintenance programs or major repair
options are available from many servicing dealers
for all Caterpillar Engines. Consult your Caterpillar
dealer in order to schedule a before failure overhaul.
Overhaul Recommendation
Caterpillar recommends a scheduled overhaul in
order to minimize downtime. A scheduled overhaul
will provide the lowest cost and the greatest value.
Schedule an overhaul with your Caterpillar dealer.
Overhaul programs vary between dealers. To obtain
specific information about the types of overhaul
programs and services, consult your Caterpillar
dealer.
i01216962
Power Factor - Check
SMCS Code: 4450-535-PWR
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.
 115
Maintenance Section
Radiator - Clean

i01604510 i01217130

Radiator - Clean Rotating Rectifier - Check

SMCS Code: 1353-070 SMCS Code: 4465-535

Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
refer to Maintenance Procedure, “Rotating Rectifier -
Test”.
i01786943

Rotating Rectifier - Test

Personal injury can result from air pressure. SMCS Code: 4465-081

Personal injury can result without following prop- Three-Diode Rectifier Block
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
of the fan’s 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 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
g00610240
with detergent and hot water. Thoroughly rinse the Illustration 73
core with clean water.

After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.

Inspect the fins for damage. Bent fins may be opened

with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning and

inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.
116
Maintenance Section
Space Heater - Check

Note: A shorted diode can cause damage to the

exciter rotor. If a diode is shorted, check the exciter
rotor. Refer to the Testing and Adjusting, “Winding -
Test” and Testing and Adjusting, “Insulation - Test”.
Perform these tests.

Note: This rectifier block also contains varistor “CR7”.

“CR7” can be checked by measuring the resistance
between the positive “+” rectifier terminal and the
negative “-” rectifier terminal. The resistance should
be a minimum of 15000.

i01754672

Space Heater - Check

SMCS Code: 4450-535-HTR

An SR4B generator is capable of operating in high

humidity conditions without problems. However,
problems can occur when the generator is idle and
g00613971
Illustration 74 the surrounding air is warmer than the generator.
Three-Diode Rectifier Block (two pieces) Moisture can form on the windings that will result in
poor performance from the windings. Moisture can
The following procedure tests all three diodes within also result in damage to the windings. Whenever the
a block. Check the positive rectifier block and the generator is not active, ensure that the space heaters
negative rectifier block. If any meter reading does not are in operation.
fall within the given ranges, replace the rectifier block.
Table 23
1. Set the digital multimeter on the diode range. Tools Needed
Remove all leads from the rectifier block.
Part Number Part Quantity
2. To test the negative rectifier block, follow these Digital
steps: 6V-7070 1
Multimeter

a. Place the red test lead on the negative “-”

1. Stop the generator set.
terminal. Place the black test lead on the
following rectifier terminals: “AC1”(3), “AC2”(4),
2. Remove the panels in order to allow access to
and “AC3”(5). All readings on the meter should
the regulator and control terminal strips. Locate
be between 0.4 and 1.0.
terminal strip “TS1”.
b. Place the black test lead on the negative
3. For 240 V systems, use the multimeter to measure
“-” terminal. Place the red test lead on the
following rectifier terminals: “AC1”(3), “AC2”(4), the voltage between terminal “H1” and terminal
“H4”. If voltage is not present, disconnect the
and “AC3”(5). In all cases, the meter should
power source to terminal “H1” and terminal “H4”,
read “OL” (overload).
and check for 3 to 12 ohms resistance. If there is
no resistance, check the generator service manual
3. To test the positive rectifier block, follow these
for further information. For 120 V systems, use
steps:
the multimeter to measure the voltage between
terminal “H1” and terminal “H2”. If voltage is not
a. Place the red test lead on the positive “+”
present, disconnect the power source to terminal
rectifier terminal. Place the black test lead
on the following rectifier terminals: “AC1”(3), “H1”, terminal “H2”, terminal “H3”, and terminal
“H4”, and check for 3 to 12 ohms resistance. If
“AC2”(4), and “AC3”(5). In all cases, the meter
there is no resistance, check the generator service
should read “OL” (overload).
manual for further information.
b. Place the black test lead on the positive “+”
rectifier terminal. Place the red test lead on the
following rectifier terminals: “AC1”(3), “AC2”(4),
and “AC3”(5). All readings on the meter should
be between 0.4 and 1.0.

Standby Generator Set Maintenance Recommendations
i01038735
Standby Generator
Set Maintenance
Recommendations
SMCS Code: 4450-041
A standby generator set may not need to be used
very often. However, the generator set is usually
needed for operation in an emergency situation.
Maintenance of the standby generator set is very
important for the following reasons:
• The generator set must always be in excellent
operating condition.
• The generator set must be ready to work under
load at any time.
Establishing a Preventive Maintenance Program will
provide these benefits:
• Maximum availability of the standby generator set
• Longer service life for the generator set
• Minimum of expensive repairs
Your Caterpillar dealer can help you to establish an
effective Preventive Maintenance Program for your
generator set. Consult your Caterpillar dealer for
details.
Maintenance and Operation
Procedures
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
The recommended maintenance for the engine is
listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule (Standby Generator
Set Engines)” (Maintenance Section).
For the recommended generator maintenance, see
the Operation and Maintenance Manual for the
generator and the control panel.
117
Maintenance Section
Maintenance and Repair
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the
subsequent maintenance intervals must be
performed by an authorized service technician or by
your Caterpillar dealer.
Unless other instructions are provided, perform
maintenance and repairs under the following
conditions:
• The engine is stopped.
• The starting system is disabled.
• The generator does not pose an electrical shock
hazard.
Operation
To ensure proper operation, the generator set must be
exercised regularly. For instructions on operating the
generator set, see the Operation and Maintenance
Manual for the generator set control panel.
For these operation procedures, follow the
instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting
the engine, engine operation, and stopping the
engine.
Record Keeping
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems, and repairs.
Space Heaters
Moisture causes damage to generators and other
electrical equipment. Make every effort to keep the
generator set as dry as possible.
Generators can operate without problems in humid
environments. However, problems can occur when
the generator is inactive. Moisture can condense on
the windings. This can result in poor performance.
Also, damage to the windings can occur.
Use space heaters in order to help keep the windings
dry. When the generator is not active, ensure that the
space heaters are operating. When the generator is
operating, turn OFF the space heaters.
118
Maintenance Section
Starting Motor - Inspect
i01113939
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
the starting motor is recommended.
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
to start properly. The engine will not start if the
starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
the flywheel ring gear can be damaged because of
irregular engagement.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth. Look
for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
ring gear must be replaced.
Electric Starting Motor
Note: Problems with the electric starting motor can
be caused by the following conditions: malfunction of
the solenoid and malfunction of the electric starting
system.
Inspect the electrical system for the following
conditions:
• Loose connections
• Corrosion
• Wires that are worn or frayed
• Cleanliness
Make repairs, if necessary.
Air Starting Motor
Personal injury or death can result from improp-
erly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
connections for leaks.
If the teeth of the starting motor pinion and/or the
flywheel ring gear are damaged, the air circuit for
the starting motor must be examined in order to
determine the cause of the problem.
Removal and Installation of the
Starting Motor
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the
starting motor and installing the starting motor.
Consult your Caterpillar dealer for assistance.
i01218172
Stator Lead - Check
SMCS Code: 4459-535
Visually inspect the following areas for cracking and
physical damage:
• stator output leads
• protective sleeving
• insulation

i01730772
Stator Winding Temperature -
Measure/Record
SMCS Code: 4453-082-TA
Some SR4B generators are provided with optional
100 Ohm Resistance Temperature Detectors
(RTD). If the generator is furnished with Resistance
Temperature Detectors, the detectors are installed in
the slots of the main armature (stator). The detectors
are used with equipment that is available from the
factory. This equipment is used in order to measure
the main armature’s winding temperature. This
equipment is also used in order to monitor the main
armature’s winding temperature.
i01935565
Throttle Control Valve - Check
SMCS Code: 1269-535
g01007524
Illustration 75
Check the throttle for leaks. If necessary, remove
the throttle according to the instructions in the
Disassembly and Assembly manual. Inspect the
throat of the throttle for wear marks. Check for free
movement of the butterfly valve. If necessary, replace
the bearings.
Inspect the gaskets for wear or damage. If necessary,
replace the gaskets. Reinstall the throttle according
to the instructions in the Disassembly and Assembly
manual.
119
Maintenance Section
Stator Winding Temperature - Measure/Record
i01454354
Turbocharger - Inspect
SMCS Code: 1052-040
Periodic inspection and cleaning is recommended for
the turbocharger. Fouling of the turbine wheels can
contribute to loss of engine power and overall loss
of engine efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine
cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. Also, the chance for potential
damage to other engine parts is reduced.
Note: Turbocharger components require clearances
that are precise. The turbocharger cartridge must be
balanced due to high rpm.
The following conditions can cause the turbocharger
to be out-of-balance:
• The buildup of deposits
• Chipping and/or flaking of deposits
If the turbocharger must be removed for inspection,
use caution. Do not break deposits from the turbine
wheel. Do not attempt to clean the turbine wheel. For
options regarding removal, installation, repair and
replacement, see the Service Manual or consult your
Caterpillar dealer.
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
120
Maintenance Section
Valve Stem Projection - Measure/Record
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger should be reconditioned.
3. Check the compressor wheel for cleanliness.
If only the inlet side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also result from restriction of the inlet air
(plugged air filters). This causes oil to leak past
the seal for the turbocharger compressor.
If oil is found on the compressor wheel and/or
at the air inlet, the source of the oil is the fuel
compressor or the PCV system.
Note: Deposits of ash and silicone can accumulate
on the turbine wheel. Turbine wheel will become
unbalanced when the deposits flake off. The
turbocharger cartridge must be replaced when this
occurs. However, remove deposits from the housing.
This will prevent wear on the blades of the new
turbine wheel.
4. Inspect the turbine wheel and the nozzle for
deposits of ash and silicone. If deposits of 1.6 mm
(0.06 inch) thickness are found or if the turbine is
in contact with the housing, the turbocharger must
be disassembled and cleaned. Removal of the
deposits can be difficult.
5. Inspect the bore of the turbine housing for
corrosion and deposits.
6. Clean the turbocharger compressor housing with
standard shop solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i01966163
Valve Stem Projection -
Measure/Record
SMCS Code: 1105-082
Valve Recession – The valves and the valve seats
are worn over time. This causes the valves to recede
into the cylinder head. This condition is called “valve
recession”.
The exhaust valves and valve seats show the
greatest wear. The top end overhaul is scheduled
according to the recession of the exhaust valves.
It is difficult to measure the actual valve recession
in the cylinder head. A simpler method is used to
determine the valve recession:
• Measure the projection of the valve rotator above
the cylinder head. It is not necessary to remove the
rocker arms in order to obtain this measurement.
Measure the projection of the exhaust valve rotators
with a 155-1536 Valve Recession Tool Group.
Follow the instructions that are provided with the tool
group.
Record the measurements on the Operation and
Maintenance Manual, “Valve Data Sheet” (Reference
Materials Section).
• Measure the projection of the exhaust valve
rotators after 250 service hours. This measurement
is the baseline. The baseline is a reference for
subsequent measurements.
• Measure the projection of the exhaust valve
rotators at the first 1000 service hours. Illustration
76 shows schedules for determining subsequent
intervals.
• After 70 percent of the maximum limit has been
reached, measure the projection of the exhaust
valve rotators at every 1000 hours of operation.
The 70 percent is 1.60 mm (0.063 inch).
• Plan for the top end overhaul as the projection of
the valve rotator approaches the maximum limit.
Perform the top end overhaul when the projection
of the valve rotator has increased by a total of
2.3 mm (0.09 inch). Do not allow the recession
of the exhaust valves to exceed this limit. The
valve head can break. This will cause severe
damage in the combustion chamber.
 121
Maintenance Section
Valve Stem Projection - Measure/Record

g00792504
Illustration 76
(A) Schedule (X) Hours of operation
(B) Schedule (1) 0.254 mm (0.0100 inch)
(C) Schedule (2) 0.218 mm (0.0086 inch)
(Y) Valve recession in millimeters (inches) (3) 0.152 mm (0.0060 inch)

To determine intervals, use the point on the graph in

Illustration 76 that is closest to the measurement for
each cylinder.

For example, suppose that the measurement that

was obtained at the initial 1000 hours shows a valve
recession of approximately 0.152 mm (0.0060 inch).
According to Schedule (C), the next interval for
measuring that cylinder is at 5000 service hours.
Another cylinder may have a valve recession of
approximately 0.254 mm (0.0100 inch). According
to Schedule (A), the next interval for measuring that
cylinder is at 3000 service hours.

Consult your Caterpillar dealer for assistance.

122
Maintenance Section
Varistor - Test

i01494879 Test Light

Varistor - Test
SMCS Code: 4466-081

g00555113
Illustration 78
Test Light

Refer to the test light that is shown in Illustration 78.

Follow these steps in order to test the varistor:

1. Disconnect either lead of the varistor (CR7).

2. Place the test light across the varistor.

3. Observe the results. The lamp should not light.

4. Reverse the test light.

5. Observe the results. The lamp should not light.

Illustration 77
g00677004 If the test light illuminates in either direction, there is
a short in the varistor. Replace any faulty varistors
PMPE Generator Wiring Diagram
with varistors that have comparable operating
(CR1-CR6) Diodes characteristics. Include the following information
(CR7) Varistor
(L1) Exciter field (stator)
when a varistor is being ordered for replacement:
(L2) Exciter armature (rotor)
(L3) Main field (rotor) • Part number of the varistor
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
• Serial number of the generator
(RFA) Rotating field assembly
(CST) Customer supplied transformer After the varistor has been replaced, verify that the
strapping of the field winding lead is securely wound
on the shaft. Also, verify that the strapping of the field
Ohmmeter winding lead is securely tied.
An ohmmeter can be used to check a varistor
(CR7). Place an ohmmeter across the varistor. The i01189996
resistance should be a minimum of 15000 ohms. If
the resistance is less than 15000 ohms, the varistor Voltage and Frequency - Check
is faulty.
SMCS Code: 4450-535-EL

Check for proper voltage and frequency setting.

Check for stability.

Refer to the generator set Serial Plate for correct

voltage and frequency.

i01966169
Walk-Around Inspection
SMCS Code: 1000-040
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.
A visual inspection should be initially directed at
the areas that are most prone to damage and
deterioration. The most prone areas to damage and
deterioration are listed below:
Ground insulation – Ground insulation is insulation
that is intended to isolate components that are
carrying current from components that are not
carrying current.
Support insulation – Support insulation is usually
made from one of the following items: a compressed
lamination of fibrous materials, polyester, or felt pads
that have been impregnated with various types of
bonding agents.
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.
Cracking – Cracking of insulation may result from
mechanical stress. The structure that is used to brace
the stator winding will become loose if the problem
is not corrected. Further mechanical damage or
electrical damage may also result.
123
Maintenance Section
Walk-Around Inspection
Erosion – Erosion can be caused when foreign
substances rub against the insulation that is on the
surface of the coil .
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
• 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.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
• Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
• Inspect the water pump for coolant leaks.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pump and the installation of water pump and/or
seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps.
124
Maintenance Section
Water Pump - Inspect
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
• Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection and
for good condition.
• Inspect the engine-to-frame ground strap for a
good connection and for good condition.
• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauges that
can not be calibrated.
i01985173
Water Pump - Inspect
SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
for the disassembly and assembly procedure.
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Service Manual or
consult your Caterpillar dealer if repair is needed or
replacement is needed.
g01028701
Illustration 79
Some water pumps have a filter in the weephole
(1). This filter helps prevent dirt from entering the
water pump. Inspect the filter with a flashlight in order
to ensure that the filter is clean. Replace the filter
annually or replace the filter when the filter becomes
plugged.
i01023425
Water Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulators before
the water temperature regulators fail. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulators reduces
the chances for unscheduled downtime.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or a seizure of the pistons.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner. Also, a low temperature can
allow moisture to condense in the oil. This can form
damaging acids.
 125
Maintenance Section
Winding - Test

i01787397
NOTICE
Failure to replace the water temperature regulators
Winding - Test
on a regularly scheduled basis could cause severe
SMCS Code: 4453-081; 4454-081; 4457-081;
engine damage.
4470-081
Never operate the engine without the water tempera-
ture regulators installed.

If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position.

For the procedure to replace the water temperature

regulators, see the Service Manual, “Disassembly
and Assembly” module. Consult your Caterpillar
dealer for assistance.

Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.

g00677004
Illustration 80
PMPE Generator Wiring Diagram
(CR1-CR6) Diodes
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer

Table 24
Tools Needed
Part Number Part(1) Quantity
Digital
6V-7070 1
Multimeter
Digital
146-4080 Multimeter 1
(RS232)
(1) Only one multimeter is necessary for this test. Either of the
multimeters that are shown will work.
126
Maintenance Section
Winding - Test

The high voltage that is produced by an operating

generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.

Place the engine control switch in the “OFF” posi-

tion. Attach “DO NOT OPERATE” tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.

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. 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.

Note: The winding temperature affects the

resistance. When the winding temperature increases,
the winding resistance also increases. When
the winding temperature decreases, the winding
resistance also decreases. Therefore, a correct
measurement can be performed only when the
winding is at room temperature.

The following armature 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
armature windings.

Exciter Armature (Rotor) (L2) – less than 0.1 ohm

Main armature (Stator) (L4) – less than 0.1 ohm

Pilot Exciter Armature (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) – approximately 3.0

ohms to 6.0 ohms

Main Field (Rotor) (L3) – approximately 0.75 ohms

to 2.0 ohms

Note: There should be no continuity between any

winding and ground. There should be no continuity
between any winding and another winding.
 127
Reference Information Section
Customer Service

Reference Information Latin America, Mexico, Carribean

Caterpillar Americas Co.
Section 701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Customer Service Fax: 305-476-6801

Europe, Africa, and Middle East

i01706971
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East
an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has 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
level without additional assistance, use the phone Hong Kong
number that is listed below to talk with a Field Phone: 852-2848-0333
Service Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Shin Caterpillar Mitsubishi 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.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610 8F, AIG Aoyama Bldg.
Mossville, Illinois 61552-0610 2-11-16, Minami-Aoyama
Minato-ku, Tokyo 107-0062
Please keep in mind: probably, your problem will Phone: 81-3-5786-3803
ultimately be solved at the dealership, using the Fax: 81-3-5786-3809
dealership’s facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at the Phone: 03-9953-9333
dealer level, consult the appropriate Caterpillar office. Fax: 03-9335-3366
128
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications 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.

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.
 129
Reference Information Section
Reference Materials

Reference Materials • Maintenance log

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
130
Reference Information Section
Reference Materials

i01176304

Maintenance Log
SMCS Code: 1000; 4450

Table 25
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
 131
Reference Information Section
Reference Materials

i01745150

Valve Data Sheet

SMCS Code: 1000

Table 26
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator
Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Inlet Manifold
2 Pushrod Side
Inlet Manifold
3 Pushrod Side
Inlet Manifold
4 Pushrod Side
Inlet Manifold
5 Pushrod Side
Inlet Manifold
6 Pushrod Side
Inlet Manifold
7 Pushrod Side
Inlet Manifold
8 Pushrod Side
Inlet Manifold
9 Pushrod Side
Inlet Manifold
10 Pushrod Side
Inlet Manifold
11 Pushrod Side
Inlet Manifold
12 Pushrod Side
Inlet Manifold
13 Pushrod Side
Inlet Manifold
14 Pushrod Side
Inlet Manifold
15 Pushrod Side
Inlet Manifold
16 Pushrod Side
Inlet Manifold
(continued)
132
Reference Information Section
Reference Materials

(Table 26, contd)

17 Pushrod Side
Inlet Manifold
18 Pushrod Side
Inlet Manifold
19 Pushrod Side
Inlet Manifold
20 Pushrod Side
Inlet Manifold

i01966738 • Special Publication, SEBD0518, “Know Your

Reference Material
SMCS Code: 1000; 4450
The following literature can be obtained through any
Caterpillar dealer.
Lubricants
• Data Sheet, PEHP0002, “Multipurpose Lithium
Complex Grease with Molybdenum (MPGM)”
• Data Sheet, PEHP0003, “Multipurpose Lithium
Complex Grease (MPG)”
• Data Sheet, PEHP0017, “Special Purpose Grease
(SPG) Bearing Lubricant”
• Special Publication, PEDP7036, “S·O·S Fluid
Analysis”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
• Special Publication, SEBU6400, “Caterpillar Gas
Engine Lubricant Recommendations”
Fuels
Cooling System”
• Special Publication, SEBD0970, “Coolant and Your
Engine”
Miscellaneous
• Application and Installation Guide, LEKQ7250, “Air
Intake”
• Data Sheet, LEKQ4023, “Linear Vibration”
• Disassembly and Assembly, RENR5980
• Engine Performance, LEBQ6117, “G3500
Industrial”
• Engine Performance, LEBQ6169, “G3500
Generator Set”
• Installation and Operation Manual, SEBU7630,
“Raptor Gas Regulation and Metering
Valve/Actuator System for Caterpillar”
• Operation and Calibration Manual, SEBU7631,
“Tecjet Gas Control Valve”
• Schematic, RENR5955, “G3520C Engine Electrical
System”

• Application and Installation Guide, LEKQ7256, • Schematic, RENR5981, “G3520C Generator

“Fuels, Fuel Systems” Electrical System”

• Application and Installation Guide, LEKQ7260, • Schematic, RENR5982, “G3512C and G3516C
“Low Energy Fuels” Generator Set Electrical System”

Coolants • Service Manual, RENR5975, “G3500C Generator

• Data Sheet, PEHP7057, “Coolant Analysis”
• Special Publication, PEDP7036, “S·O·S Fluid
Analysis”
Sets”
• Software Program, LEKQ6378, “Methane Number
Program”
• Special Instruction, GMG00694, “Analyzing
Cylinder Condition By Measuring Air Flow”

• Special Instruction, REHS0128, “Using the
147-5482 Valve Lash Gauge Group For Valve
Lash and Valve Bridge Adjustment”
• Special Instruction, REHS0177, “Alignment of the
Close Coupled Two-Bearing Generators”
• Special Instruction, REHS1438, “Installation and
Initial Start-up Procedure for G3500C Engines”.
• Special Instruction, SEHS7259, “Alignment of
Single-Bearing Generators”
• Special Instruction, SEHS7332, “Do Not Operate
Tag”
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Special Instruction, SEHS7654, “Alignment -
General Instructions”
• Special Instruction, SEHS7768, “Use of the
6V-2150 Starting/Charging Analyzer”
• Special Instruction, SEHS8712, “Using the
8T-2700 Blowby/Air Flow Indicator”
• Special Instruction, SEHS8984, “Using the
1U-8860 Blowby Pickup Group”
• Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Special Instruction, SEHS9298, “Installation and
Maintenance of Gaseous Fuel Filters”
• Special Publication, NEHS0526, “Service
Technician Application Guide”
• Special Publication, NENG2500, “Caterpillar Tools
and Shop Products Guide”
• Special Publication, PECP9067, “One Safe
Source”
• Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
Operations”
• Special Publication, SEBF8062, “Procedure to
Inspect and Clean Air Filters”
• Specifications, RENR5977, “G3500C Engines”
• Specifications, SENR3130, “Torque Specifications”
• Systems Operation/Testing and Adjusting,
RENR5978, “G3500C Engines”
133
Reference Information Section
Reference Materials
• Systems Operation/Testing and Adjusting,
SENR5833, “Digital Voltage Regulator”
• Troubleshooting, RENR5944, “G3500C Generator
Sets”
• Troubleshooting, RENR5979, “G3500C Engines”
Additional Reference Material
The “Engine Fluids Data Book” can be obtained from
the following locations: local technological society,
local library, and local college. If necessary, consult
EMA at the following address:
Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
E-mail: ema@enginemanufacturers.org
(312) 827-8700
Facsimile: (312) 827-8737
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook.
This publication can also be obtained from the
following locations: local technological society, local
library, and local college. If necessary, consult SAE
at the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
The “American Petroleum Institute Publication No.
1509” can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:
American Petroleum Institute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.
134
Reference Information Section
Reference Materials

International Organization for Standardization

(ISO)
1, rue de Varembé
Case postale 56
CH-1211 Genève 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
Web site: http://www.iso.ch

European classifications are established by the

Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).

CIMAC Central Secretariat

Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566

Index
A Cooling System Coolant Sample (Level 2) -
After Starting Engine .............................................
Engaging the Driven Equipment ........................
After Stopping Engine............................................
Aftercooler Condensation - Drain ..........................
Air Starting Motor Lubricator Bowl - Clean ............
Air Starting Motor Lubricator Oil Level - Check .....
Adjust the Lubricator ..........................................
Air Tank Moisture and Sediment - Drain................
Alarms and Shutdowns..........................................
Prevention of Start-up ........................................
Setpoints for Alarms and Shutoffs .....................
Testing Alarms and Shutdowns..........................
Alternator - Inspect ................................................
B
Battery Electrolyte Level - Check .......................... 74
Bearing - Inspect (Generator)................................ 75
Bearing (Ball) - Lubricate (Generator) ................... 74
Lubricating Process ........................................... 74
Bearing Temperature - Measure/Record ............... 77
Before Starting Engine .................................... 15, 45
Air Inlet System.................................................. 45
Cooling System.................................................. 45
Driven Equipment .............................................. 45
Electrical System ............................................... 45
Fuel System ....................................................... 45
Lubrication System ............................................ 46
Starting System.................................................. 46
Walk-Around Inspection..................................... 45
Belts - Inspect/Adjust/Replace............................... 77
Adjusting the Alternator Belt .............................. 77
Adjusting the Fan Drive Belt .............................. 77
Inspection........................................................... 77
Replacement...................................................... 77
Burn Prevention..................................................... 12
Batteries............................................................. 12
Coolant............................................................... 12
Oils..................................................................... 12
C Obtain the Sample and the Analysis.................. 92
Cold Weather Starting ...........................................
Compressor Bypass - Check.................................
Cooling System Coolant (DEAC) - Change...........
Clean the Cooling System .................................
Cleaning a Cooling System that has Heavy
Deposits or Plugging ........................................
Draining the Cooling System .............................
Fill the Cooling System ......................................
Cooling System Coolant Level - Check .................
Add Coolant .......................................................
Cooling System Coolant Sample (Level 1) -
Obtain ..................................................................
135
Index Section
Obtain .................................................................. 82
49 Cooling System Supplemental Coolant Additive
49 (SCA) - Test/Add.................................................. 82
52 Add the SCA, If Necessary ................................ 83
72 Test the Concentration of the SCA..................... 82
72 Crankcase Blowby - Measure/Record ................... 83
73 Crankcase Pressure - Measure (Engines with Fumes
73 Disposal Filters) ................................................... 84
73 Crankshaft Vibration Damper - Inspect ................. 84
35 Removal and Installation.................................... 84
36 Crushing Prevention and Cutting Prevention ........ 14
36 Customer Assistance........................................... 127
36 Outside of the USA and of Canada.................. 127
74 USA and Canada ............................................. 127
Customer Service ................................................ 127
Cylinder Pressure - Measure/Record .................... 85
E
Electrical System ................................................... 15
Grounding Practices .......................................... 16
Electronic Modular Control Panel II+ (EMCP II+) .. 36
Alarm Module..................................................... 43
Custom Alarm Module ....................................... 43
Generator Set Control + (GSC+) ....................... 38
Synchronizing Lights Module ............................. 44
Emergency Stopping ............................................. 51
Emergency Stop Button ..................................... 51
Unplanned Shutdowns....................................... 51
Engine Air Cleaner Element - Replace.................. 85
Inspecting Air Cleaner Elements........................ 86
Servicing the Air Cleaner Elements ................... 86
Engine Air Cleaner Service Indicator - Inspect...... 87
Test the Service Indicator................................... 87
Engine Crankcase Breather - Clean...................... 87
Engine Mounts - Check ......................................... 88
Engine Oil - Change .............................................. 88
Engine Oil Filter - Change ..................................... 90
Inspect the Used Oil Filter Elements.................. 91
Replace the Oil Filter Elements ......................... 90
Engine Oil Level - Check ....................................... 91
Engine Oil Sample - Obtain ................................... 92
Engine Operation................................................... 50
46 Operating the Engine and the Driven
78 Equipment ........................................................ 50
78 Partial Load Operation ....................................... 50
79 Engine Protective Devices - Check ....................... 92
Visual Inspection................................................ 93
80 Engine Speed/Timing Sensor - Clean/Inspect....... 93
78 Engine Starting ................................................ 15, 45
80 Engine Stopping .............................................. 15, 51
80 Engine Valve Lash and Bridge - Adjust ................. 93
81 Engine Valve Lash ............................................. 94
Valve Bridge....................................................... 94
81
136
Index Section
F Generator Set Description ..................................... 19
Features and Controls ........................................... 31
Fire Prevention and Explosion Prevention ............ 12
Fire Extinguisher ................................................ 13
Lines, Tubes and Hoses .................................... 14
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 5
Safety................................................................... 4
Fuel Metering Valve - Check (Raptor) ................... 94
Fuel System Fuel Filter Differential Pressure -
Check................................................................... 94
Fumes Disposal Filter - Drain ................................ 95
Fumes Disposal Filter Differential Pressure -
Check................................................................... 95
Fumes Disposal Filter Element - Replace ............. 95
G Hoses and Clamps - Inspect/Replace ................. 101
Gas Pressure Regulator Condensation - Drain ..... 96
General Hazard Information .................................... 9
Asbestos Information .......................................... 11
Containing Fluid Spillage .................................... 11
Dispose of Waste Properly ................................ 12
Fluid Penetration................................................. 11
Pressure Air and Water...................................... 10
General Information............................................... 17
General Maintenance Information ......................... 66
Space Heaters ................................................... 66
Generator - Dry...................................................... 96
Controlled Current Method................................. 97
Oven Method ..................................................... 97
Self-Circulating Air Method ................................ 97
Generator - Inspect................................................ 98
Cleaning (Assembled Generators)..................... 98
Cleaning (Disassembled Generators)................ 99
Generator Isolating for Maintenance ..................... 16
Generator Lead Connections ................................ 23
Grounding the Frame......................................... 24
Lead Numbering ................................................ 23
Multiple Units ..................................................... 24
Neutral Connections .......................................... 24
Parallel to Utility ................................................. 24
Single Units........................................................ 24
Generator Load - Check ........................................ 99
Generator Operation.............................................. 53
Block Loading and Transient Capability............. 53
Excitation Systems............................................. 54
Loading of the Generator ................................... 53
Low Idle Adjustment........................................... 54
Options............................................................... 55
Power Factor...................................................... 54
Standby Generator Sets .................................... 54
Generator Set - Test ............................................ 100
Description of the Generator.............................. 20
Engine Description............................................. 19
Generator Set Installation...................................... 29
Alignment ........................................................... 30
Bearing Inspection ............................................. 29
Electrical Measurements.................................... 30
Location ............................................................. 29
Protective Devices ............................................. 30
Receiving Inspection.......................................... 29
Storage .............................................................. 29
Unpacking and Storage ..................................... 29
Generator Set Lifting ............................................. 27
Engine Only ....................................................... 27
Generator Set .................................................... 27
Generator Set Storage .......................................... 28
Generator Storage ............................................. 28
Generator Set Vibration - Inspect ........................ 100
Generator Start-up Checklist ................................. 67
H
Replace the Hoses and the Clamps ................ 101
I
Ignition System Spark Plugs - Replace ............... 102
Cleaning the Spark Plug .................................. 104
Inspecting the Spark Plug ................................ 103
Installing the Spark Plug .................................. 104
Removing the Spark Plug ................................ 102
Ignition System Timing - Check/Adjust ................ 104
Ignition Systems .................................................... 14
Important Safety Information ................................... 2
Inlet Air System - Inspect..................................... 105
Installation ............................................................. 29
Insulation - Test ................................................... 105
Recommended Periodic Insulation Test
Procedure....................................................... 107
Recommended Periodic Insulation Tests......... 105
L
Lifting and Storage ................................................ 27
M
Maintenance Interval Schedule ............................. 70
Maintenance Log ................................................. 130
Maintenance Recommendations ........................... 66
Maintenance Records.......................................... 129
Maintenance Section ............................................. 62
Manual Stop Procedure......................................... 52
Model View Illustrations......................................... 18
50 Hz Model Views ............................................ 18
60 Hz Model Views ............................................ 19

Model Views and Specifications ............................ 18
Mounting and Dismounting.................................... 14
O
Operation Section.................................................. 27
Ordering Replacement Parts ............................... 128
Overhaul (In-Frame) ............................................ 108
In-Frame Overhaul Information........................ 108
Scheduling an In-Frame Overhaul ................... 108
Overhaul (Major).................................................. 109
Major Overhaul Information ............................. 109
Scheduling a Major Overhaul........................... 109
Overhaul (Top End) .............................................. 111
Scheduling a Top End Overhaul ....................... 111
Top End Overhaul Information .......................... 111
Overhaul Considerations ...................................... 113
Overhaul Information ........................................ 113
P Starting Motor - Inspect ........................................ 118
Parallel Operation.................................................. 55
Circulating Currents ........................................... 59
Initial Start-Up .................................................... 55
Parallel Operation Of Governors........................ 57
Paralleling Multiple Units.................................... 57
Speed Droop for the Load Division (If
Equipped)......................................................... 57
Starting Multiple Units ........................................ 57
Stopping............................................................. 58
Performance Parameters ...................................... 31
Air/Fuel Ratio ..................................................... 31
Oil Consumption ................................................ 31
Plate Locations and Film Locations....................... 22
Engine Information (1) ....................................... 22
Engine Serial Number (2) .................................. 22
Generator Identification (3) ................................ 22
Power Factor - Check........................................... 114
Product Identification Information .......................... 22
Product Information Section .................................. 17
R Valve Stem Projection - Measure/Record............ 120
Radiator - Clean ................................................... 115
Reference Information ........................................... 22
Reference Information Section ............................ 127
Reference Material .............................................. 132
Additional Reference Material.......................... 133
Coolants........................................................... 132
Fuels ................................................................ 132
Lubricants ........................................................ 132
Miscellaneous .................................................. 132
Reference Materials ............................................ 129
Refill Capacities..................................................... 62
Refill Capacities and Recommendations............... 62
Cooling System.................................................. 63
Fuel .................................................................... 62
Lubrication System ............................................ 62
137
Index Section
Rotating Rectifier - Check..................................... 115
Rotating Rectifier - Test ........................................ 115
Three-Diode Rectifier Block .............................. 115
S
Safety Messages ..................................................... 6
Safety Section ......................................................... 6
Sensors and Electrical Components ..................... 32
Electronic System .............................................. 32
Sensors.............................................................. 33
Single Unit Operation ............................................ 59
Initial Start-Up .................................................... 59
Starting............................................................... 59
Stopping............................................................. 59
Space Heater - Check .......................................... 116
Specifications ........................................................ 20
Standby Generator Set Maintenance
Recommendations.............................................. 117
Maintenance and Operation Procedures .......... 117
Air Starting Motor .............................................. 118
Electric Starting Motor....................................... 118
Removal and Installation of the Starting Motor .. 118
Starting the Engine ................................................ 47
Automatic Starting.............................................. 47
Manual Starting.................................................. 48
Parameters for the Start/Stop Control................ 47
Starting with Jump Start Cables ............................ 48
Stator Lead - Check.............................................. 118
Stator Winding Temperature - Measure/Record ... 119
T
Table of Contents..................................................... 3
Throttle Control Valve - Check.............................. 119
Turbocharger - Inspect ......................................... 119
V
Valve Data Sheet................................................. 131
Varistor - Test....................................................... 122
Ohmmeter ........................................................ 122
Test Light.......................................................... 122
Voltage and Frequency - Check .......................... 122
Voltage Connections.............................................. 24
Single-Phase Current From a Three-Phase
Generator ......................................................... 25
Three-Phase Voltage Connections .................... 24
Voltage Regulator Options..................................... 61
Manual Voltage Control...................................... 61
Voltage Regulators ................................................ 60
Adjustment Procedure for the Voltage
Regulators........................................................ 60
138
Index Section

Walk-Around Inspection ...................................... 123

Inspect the Engine for Leaks and for Loose
Connections ................................................... 123
Water Pump - Inspect.......................................... 124
Water Temperature Regulator - Replace ............. 124
Welding on Engines with Electronic Controls ........ 17
Winding - Test...................................................... 125
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 Contact Phone Number Hours

Sales:

Parts:

Service:
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