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(B.~_s jk'(A SEBU7919-03

August 2011
t; fVt;T<V~ Dt-P\ ·

Operation and
Maintenance
Manual
C4.4 Marine Generator Set
MMC1-Up (Generator Set)

SAFETY.CAT.COM
 i03991620

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.

A WARNING

The meaning of this safety alert symbol is as follows:

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

A WARNING
When replacement parts are required for this
product Caterpillar recommends using Cat re-
placement parts or ports with equivalent Eipoci
fications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7919-03 3
Table of Contents

Table of Contents Maintenance Interval Schedule ............ ............... 115

Reference Information Section

Foreword ........................................................ ... ... ... 4
Customer Service .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .... .. 162
Safety Section
Reference Materials .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. . 164
Safety Messages .................................................. .. 6
Index Section
Additional Messages ...................................... ..... _. 20
Index ..................................................... ....... ....... 168
General Hazard Information .......................... ....... 22

Burn Prevention ............................................ .... .... 25

Fire Prevention and Explosion Prevention .... .. .. .... 25

Crushing Prevention and Cutting Prevention .. ...... 27

Mounting and Dismounting ............................ ....... 28

Before Starting Engine .................................... .... .. 28

Engine Starting ...... .... ................ .... ........ .. ...... .. .. ... 28

Engine Stopping .... .. ............................................. 29

Electrical System .................................................. 29

Generator Isolating for Maintenance ............ ........ 30

Product Information Section

Model Views ......................................................... 31

Product Identification Information ................ .. ...... 41

Operation Section
Lifting and Storage ........................................ .. ...... 48

Installation .......... .... ........ .. ......... .. ................... ...... . 50

Features and Controls .................................... .. .... 52

Engine Starting ................................................... .. 80

Engine Operation ................................................ .. 88

Engine Stopping ................................................... 93

Cold Weather Operation .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 99

Generator Operation .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 100

Maintenance Section
Refill Capacities ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... 107

Maintenance Recommendations .. .. ... .. .. .. .. .. .. .... . 109

4 SEBU7919-03
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 whic_h 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 fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
follow.
Use fuel consumption or 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 a~d
approximate the indicated service meter read1ng.
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequent lubrication and maintenance than is
specified in the Maintenance Interval 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.
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.
SEBU7919-03 5
Foreword

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.

Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
6 SEBU7919-03
Safety Section
Safety Messages

Safety Section
i02626148

Safety Messages
SMCS Code: 1000; 7405

There may be several specific safety messages

on your generator set. The exact location and a
description of the safety messages are reviewed in
this section. Please become familiar with all safety
messages.

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off
of the generator set.

Replace any safety message that is damaged or

missing. If a safety message is attached to a part of
the generator set that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
SEBU7919-03 7
Safety Section
Safety Messages

g01317561
Illustration 1
Side view of the generator set
8 SEBU7919-03
Safety Section
Safety Messages

3 4

• e o

3 4
5

~
g01156075
Illustration 2
Top view of the C4.4generator set
SEBU7919-03 9
Safety Section
Safety Messages

g01156220
Illustration 3
Rear view of the C4.4 generator set
10 SEBU7919-03
Safety Section
Safety Messages

88'D:!I
• ~ g

g01320692
Illustration 4
SEBU7919-03 11
Safety Section
Safety Messages

e l-------1e

"

"

l&.[mi1
g01317566
Illustration 5
Side view of the C4.4 radiator equipped generator set.
12 SEBU7919-03
Safety Section
Safety Messages

g01320748
Illustration 6
Side view of the C4.4 radiator equipped generator set.
SEBU7919-03 13
Safety Section
Safety Messages

g01316626
Illustration 7
Typical C4.4 enclosure
14 SEBU7919-03
Safety Section
Safety Messages

6~ 6 AUTO
0

I II F?rl

.0.

0
o 1 &[@-~o;-----o-o-+---- 21~rm1

Illustration 8 g01157667

View of the standard control panel

SEBU7919-03 15
Safetye~ Section
Saf
essages

• D

g011576BB
Illustration 9
View ofth e premium control panel
16 SEBU7919-03
Safety Sectio
Safety M essages
n

Illustration 10 g01321026

View of the MCS control panel

SEBU7919-03 17
Safety Section
Safety Messages

Electrocution (1) Lifting the Genset (3)

This safety message is positioned on both sides of This safety message for lifting the generator set is
the generator. located on the frame of the generator set.

A DANGER

219-3484 2

A DANGER
DANGER: Shock/Electrocution Hazard-Do not op-
g01037912

w
erate this equipment or work on this equipment
unless you have read and understand the instruc- g0092BOB5
tions and warnings in the Operation and Mainte-
nance Manual. Failure to follow the instructions or
heed the warnings will result in serious injury or A WARNING
death.
Crushing Hazard I Improper lifting could cause se-
rious injury or death. Follow the lifting instruc-
Do Not Operate (2) tions in the Operation and Maintenance Manual for
safe lifting procedures.
This safety message is located on the control panel.

A WARNING

g01105289

A WARNING
Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
18 SEBU7919-03
Safety Section
Safety Messages

Lifting the Genset (4) No Ether In Air Inlet (5)

This safety message for lifting the genset is located This safety message for no ether in the air inlet is
on the frame of the generator set. located on the body of the air cleaner and above the
intake on the enclosure.

A WARNING

(];)
2,000 Kg
(4,400 LBS) w 224·8945

g00931562

g01157717
A WARNING
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.
A WARNING
If equipped with an air Inlet heater (AIH) for cold
weather starting, do not use aerosal types of start-
ing aids such as ether. Such use could result in an
explosion and personal injury.
Refer to Operation and Maintenance Manual, "Fire
Prevention and Explosion Prevention" for more
information.
SEBU7919-03 19
Safety Section
Safety Messages

Automatic Starting (6) Hot Fluid Under Pressure (8)

The safety message for automatic starting is located The safety message for hot fluid under pressure is
on the control panel and the electrical box with the located on the top of the header tank by the filler
disconnect switch. neck.

A WARNING A WARNING

6AUTO

g01154070 g00930639

A WARNING
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.
Electrical Shock (7)
The safety message for electrical shock is located
on the control panel.
A WARNING
Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.

.A WARNING

g01120247

A WARNING
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.
20 SEBU7919-03
Safety Section
Additional Messages

Fire (9)
This safety message is positioned on the side of the
enclosure.

A WARNING

w 233-6084

g00950811

A WARNING
Fire Hazard! Stop the Engine. Do not open the
service doors if a fire exists. Opening the service
doors if a fire exists could result in personal injury
or death. Read and understand the instructions in
the Operation and Maintenance Manual.

Refer to Operation and Maintenance Manual, "Fire

Prevention and Explosion Prevention" for more
information.

i02630825

Additional Messages
SMCS Code: 1000; 7405

There are several specific messages on this

machine. The exact location of the messages and
the description of the messages are reviewed in
this section. Please become familiarized with all
messages.

Make sure that all of the messages are legible.

Clean the messages or replace the messages if
you cannot read the words. Replace the illustrations
if the illustrations are not legible. When you clean
the messages, use a cloth, water and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.

Replace any message that is damaged, or missing .

If a message is attached to a part that is replaced,
install a message on the replacement part. Any
Caterpillar dealer can provide new messages.
SEBU7919-03 21
Safety Section
Additional Messages

g01319430
Illustration 11
Typical example
C4.4 is shown.

Port for Fire Extinguisher (1)

This message is located on the side of the enclosure.

22 SEBU7919-03
Safety Section
General Hazard Information

233-6748

g01319438
Illustration 12

In case of fire, break through the hole with the spray Cautiously remove the following parts. To help
nozzle of the fire extinguisher. prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
i04074884
• Filler caps
General Hazard Information • Grease fittings
SMCS Code: 1000; 7405
• 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.

g00104545
Illustration 13

Attach a "Do Not Operate" warning tag to the start

switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to
each operator control station. When appropriate,
disconnect the starting controls.

Do not allow unauthorized personnel on the engine,

or around the engine when the engine is being g00702020
serviced. Illustration 14
SEBU7919-03
• 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.
• The protective locks or the controls are in the
applied position.
• Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• When starting a new engine or an engine which
has not been started since service has been
performed, make provisions to stop the engine if an
overspeed occurs. Shutting down the engine may
be accomplished by shutting off the fuel supply
and/or the air supply to the engine.
• Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
• Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
Pressurized Air and Water
Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
23
Safety Section
General Hazard Information
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
Always wear eye protection for cleaning the cooling
system.
Fluid Penetration
Illustration 15 g006B7600
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
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
Dealer Service Tool Catalog" or refer to Special Pub-
lication, PECJ0003, "Caterpillar Shop Supplies and
Tools Catalog" for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
Lines, Tubes, and Hoses
Do not bend or strike high-pressure lines. Do not
install lines, tubes, or hoses that are damaged.
24
Safety Section
General Hazard Information
Repair any fuel lines, oil lines, tubes, or hoses that
are loose or damaged. Leaks can cause fires.
Inspect all lines, tubes, and hoses carefully. Do
not use bare hands to check for leaks. Always
use a board or cardboard for checking engine
components for leaks. Tighten all connections to the
recommended torque.
Check for the following conditions:
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Wire that is exposed in reinforced hose
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and
the heat shields are installed correctly. Correct
installation of these components will help to prevent
these effects: vibration, rubbing against other parts,
and excessive heat during operation.
Inhalation
g02159053
Illustration 16
Exhaust
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the equipment in an
enclosed area, adequate ventilation is necessary.
Asbestos Information
Caterpillar equipment and replacement parts that
are shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine
Cat replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
SEBU7919-03
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.
• Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in "29 CFR 1910.1001".
• Obey environmental regulations for the disposal
of asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands
thoroughly after handling Softwrapmaterial. Do not
smoke until washing hands thoroughly after handling
Softwrap material. Clean up debris with a vacuum
or by wet sweeping . Do not use pressurized air to
clean up debris.
SEBU7919-03
Reference: The applicable material safety data
sheets can be found at the following web site by
searching by the part number or the name of the
product:
http://dsf2ws.cat.com/msds/servleU
cat. cis.ecs.msdsSearch. controller.
Userldentification Display Servlet
Dispose of Waste Properly
g00706404
Illustration 17
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01480768
Burn Prevention
SMCS Code: 1000; 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
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
25
Safety Section
Burn Prevention
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.
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.
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.
i04363128
Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 7405
g00704000
Illustration 18
Use of personal protection equipment (PPE) may be
needed.
All fuels, most lubricants, and some coolant mixtures
are flammable.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate
a product when a fire hazard exists. Contact your
Caterpillar dealer for service.
26 SEBU7919-03
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot Arcing or sparking could cause a fire. Secure
surfaces or onto electrical components can cause connections, recommended wiring , and properly
a fire. Fire may cause personal injury and property maintained battery cables will help to prevent arcing
damage. or sparking.

A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
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.
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines
and hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Properly install all oil filters and all fuel filters. The
filter housings must be tightened to the proper torque.

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.

•
All fluids that are captured in the fluid spill
containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
may cause personal injury and property damage.

Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.

Do not expose the engine to any flame. g00704059

Illustration 19

Exhaust shields (if equipped) protect hot exhaust

Use caution when you are refueling an engine. Do
components from oil or fuel spray from a failed line,
not smoke while you are refueling an engine. Do not
tube, or seal. Exhaust shields must be installed
refuel an engine near open flames or sparks. Always
correctly.
stop the engine before refueling.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting

Wiring must be kept in good condition . Properly

route and securely attach all electrical wires. Check
all electrical wires daily. Repair any wires that are
loose or frayed before you operate the engine. Clean
all electrical connections and tighten all electrical
connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
SEBU7919-03
Illustration 20 g02298225
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. Charging a frozen
battery may cause an explosion .
The batteries must be kept clean . The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
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.
Ether
Do not use ether as a starting aid. Refer to this
Operation and Maintenance Manual, "Starting the
Engine" for information about starting the engine.
27
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 .
• Portions 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 in order to prevent vibration,
rubbing against other parts, and excessive heat.
101359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 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.
28
Safety Section
Mounting and Dismounting
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.
i01372247
Mounting and Dismounting
SMCS Code: 1000; 7405
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
F~ce the engine in order to mount the engine or
dismount the engine. 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 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
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i03560601
Before Starting Engine
SMCS Code: 1000
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 ove'rspeed
occur. This may be accomplished by ::;hulling off lhe
air and/or fuel supply to the engine.
A WARNING
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.
Inspect the engine for potential hazards.
SEBU7919-03
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.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped .
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.
See the Service Manual for repairs and for
adjustments.
i02207232
Engine Starting
SMCS Code: 1000
A WARNING
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
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.
SEBU7919-03
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
correctly, check the water temperature gauge and the
oil temperature gauge during the 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.
Note: The engine is equipped with an automatic
device for cold starting for normal conditions of
operation . If the engine will be operated in very cold
conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operation.
The engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake
air in order to improve starting.
i02590389
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to 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 condition occurs. This may be
accomplished by shutting off the fuel supply and/or
the air supply to the engine.
If equipped, in order to stop an electronically
controlled engine, cut the power to the engine.
29
Safety Section
Engine Stopping
i02176668
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.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative "-"jump start cable should be connected
last from the external power source to the negative
"-" terminal of the starting motor. If the starting motor
is not equipped with a negative "-" terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
starting instructions.
Grounding Practices
Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect 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 bearing
journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
"-" battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
30 SEBU7919-03
Safety Section
Generator Isolating for Maintenance

i01469970 9. Determine that the generator is in a de-energized

condition. Add ground straps to the conductors
Generator Isolating for or terminals. During the entire work period, these
Maintenance ground straps must remain connected to the
conductors and to the terminals.
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 21

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.
SEBU7919-03 31
Product Information Section
Model Views

Product Information
Section

Model Views
i02667924

Model View Illustrations

SMCS Code: 1000

The model views show a typical arrangement for a

C4.4 Marine Generator Set that is turbocharged and
aftercooled. The model views also show a typical
Marine Generator Set enclosure. Due to individual
applications, your generator set and your enclosure
may appear different from the illustrations.
32 SEBU7919-03
Product Information Section
Model Views

6 7

14 13 12 11 10
9

Illustration 22 g01153518

Side view of a generator set with a turbocharged aftercooled engine

(1) Header Tank (7) Control Panel (13) Fuel Outlet
(2) Coolant Filler Cap (8) Frame (14) l::ng1ne U1l Level Gauge (Uipstick)
(3) Fuel Filter (9) Lifting Eye (15) Engine Oil Filter
(4) Closed Crankcase Breather (10) Sea Water Outlet (16) Sea Water Inlet
(5) Engine Air Cleaner (11) Heat Exchanger (17) Engine Oil Filler
(6) Air Cleaner Service Indicator (12) Fuel Inlet
SEBU7919-03 33
Product Information Section
Model Views

18

Illustration 23 g01153557

Top view of a generator set with a turbocharged aftercooled engine

(18) Oil Filler Cap (19) Aftercooler
34 SEBU7919-03
Product Information Section
Model Views

21

20

23

g01153670
Illustration 24
Side view of a generator set with a turbocharged aftercooled engine
(20) Terminal Box on the Generator (22) Starting Motor
(21) Exhaust Outlet (23) Generator
SEBU7919-03 35
Product Information Section
Model Views

25 26

27

28 28

Illustration 25 g01321275

Side view of a generator set and engine with radiator cooling

(24) Turbocharger (26) Radiator Top Tank (28) Lifting Eye
(25) Exhaust Outlet (27) Radiator

Note:
36 SEBU7919-03
Product Information Section
Model Views

35 29

33 32

g013212BB
Illustration 26
Side view of an MCS generator set and engine with radiator cooling
(29) Closed Crankcase Breather (32) Fuel Inlet (35) Engine Oil Filler
(30) Fuel Outlet (33) Duplex Oil Filter
(31) Duplex Fuel Filter (34) Engine Oil Level Gauge (Dipstick)

Note: The following callouts are included in the MCS

generator set only: (30), (31 ), (32), and (33)
SEBU7919-03 37
Product Information Section
Model Views

37

36 36

Illustration 27 g01321955

Side view of a generator enclosure

(36) Lifting Eyes (37) Control Panel
38 SEBU7919-03
Product Information Section
Model Views

39 39

g01321973
Illustration 28
Rear view of a generator enclosure
(38) Exhaust Outlet
(39) Ports for Raw Water, Fuel, and Electrical
Power Supply
SEBU7919-03
40
Illustration 29
Top view of a generator enclosure
(40) Exhaust Outlet (41) Siphon Breaks
i04497152
Product Description
SMCS Code: 1000; 4450; 4491; 7000
The brushless generator is used for various marine
applications. The elimination of brushes in the
field circuit reduces maintenance with increased
reliability. Also, the elimination of brushes provides a
higher degree of protection in potentially hazardous
atmospheres. The generator set packages can be
utilized for prime power generation or standby power
generation.
The generators can be configured for three-phase
power or single-phase power. The generators have
full-wave excitation and regulation. The generators
have 12 leads that can be connected in various
configurations. The generators may produce
electrical power in either 50 Hz or 60 Hz applications.
39
Product Information Section
Model Views
41
g01322020
The engines are powered with direct fuel injection . A
mechanical governor controls the fuel injection pump
output. Engine speed is controlled by the electronic
speed control. In the event of a malfunct~on with
the electronic speed control, the mechanrcal speed
control will prevent an engine overspeed condition
and resulting in mechanical damage.
Fuel is metered and pumped by the fuel injection
pump under high pressure to the fuel injection
nozzles (one per cylinder). The automatic timing
advance provides the best fuel injection timing over
the full range of engine speed.
The cooling system consists of the following
components:
• A centrifugal pump that is driven by a gear
• One water temperature regulator which regulates
the engine coolant temperature
40 SEBU7919-03
Product Information Section
Model Views

• Heat exchanger for the closed water circuit Table 1

C4.4 Marine Generator Set Engine Specifications
• Auxiliary water pump
Operating Range (rpm) 1500 to 1800(1)
• Expansion tank Number of Cylinders 4 (In-Line)

• Radiator (If equipped) Bore 105.0 mm (4.13 inch)

Stroke 127.0 mm (5.00 inch)
The engine lubricating oil is supplied by a gear
type pump. The engine lubricating oil is cooled on NA(2)
models that are equipped with the optional oil cooler. Aspiration T(3l
TA(4)
Bypass valves provide unrestricted flow of lubrication
oil to the engine parts when oil viscosity is high. Displacement 4 L (243 in3 )
Bypass valves can also provide unrestricted flow
of lubrication oil to the engine parts if the oil cooler Firing Order 1, 3, 4, 2
should become plugged or if the oil filter element Rotation that is viewed
should become plugged. Counterclockwise
from the flywheel
(1) The operating rpm is dependent on the engine rating and the
Engine efficiency, efficiency of emission controls, and application.
engine performance depend on adherence to proper (2) Naturally Aspirated
operation and maintenance recommendations. (3) Turbocharged
Engine performance and efficiency also depend on (4) Turbocharged Aftercooled
the use of recommended fuels, lubrication oils, and
coolants. Refer to the Operation and Maintenance
Manual, "Maintenance Interval Schedule" for more
information on maintenance items.

Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The No. 1 cylinder is the front cylinder.

C4.4 Marine Generator Set Engine

1-

R (f;)@@~ 1-
F

•E 0

g01156157
Illustration 30
(E) Exhaust valves
(I) Inlet valves
(R) Rear of the engine
(F) Front of the engine
SEBU7919-03 41
Product Information Section
Product Identification Information

Product Identification Generator Identification Plate

Information
i02312169

Plate Locations and Film

Locations
SMCS Code: 1000

Serial Number Plate

g01157912
Illustration 33

The identification plate (2) for the generator is located

on the front of the terminal box for the generator.

g01157911
Illustration 31

The Serial Number Plate (1) is located on the left side

of the engine near the fuel injection pump.

ENGINE g01157915
MODEL Illustration 34
SERIAL Typical generator identification plate
NUMBER

oCJ.TERPILLAR ®CJ.T®o i01464579

ARRANGEMENT
NUMBER
Engine Identification
SMCS Code: 1000
(ALWAYS GIVE ALL NUMBERS)
MADE IN IJ.S.A. JN-3790 12 Caterpillar engines are identified with model numbers,
and serial numbers, with performance specification
numbers, and with arrangement numbers. These
Illustration 32 g00123229
numbers are shown on the serial number plate that is
Typical serial number plate mounted on the engine.

The following information is stamped on the Serial The numbers for fuel setting information for electronic
Number Plate: engine serial number, model, and engines are stored within the personality module.
arrangement number. These numbers can be read by using Caterpillar
electronic service tools.
42 SEBU7919-03
Product Information Section
Product Identification Information

Caterpillar dealers need these numbers in order to

determine the components that were included with A WARNING
the engine. This permits accurate identification of
replacement part numbers.
Personal injury or death can result from high volt-
age.

i02312165 When power generation equipment must be in op-

eration to make tests and/or adjustments, high
Generator Set Identification voltage and current are present.
SMCS Code: 7002 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.

• Remove all fuses.

• Make sure the generator engine is stopped.

• Make sure all batteries are disconnected.

1
g01157909
Illustration 35
(1) Location of the identification plate for the generator set
The generator set consists of the generator and the
engine. The location of the identification plate for the
generator set is shown in illustration 35.
i02303546
Generator Lead Connections
SMCS Code: 4450
A DANGER
DANGER: Shock/Electrocution Hazard-Do not op-
erate this equipment or work on this equipment
unless you have read and understand the instruc-
tions and warnings in the Operation and Mainte-
nance Manual. Failure to follow the instructions or
heed the warnings will result in serious injury or
death.
• Make sure all capacitors are discharged.
Failure to do so could result in personal injury or
death. Make sure residual voltage in the rotor, sta-
tor and the generator is discharged.
A WARNING
Accidental engine starting can cause injury or
death to personnel working on the equipment.
To avoid accidental engine starting, disconnect
the battery cable from the negative(-) battery ter-
minal. Completely tape all metal surfaces of the
disconnected battory cablo ond in order to prevent
contact with other metal surfaces which could ac-
tivate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch
location to inform personnel that the equipment is
being worked on.
SEBU7919-03 43
Product Information Section
Product Identification Information

Grounding the Frame Connection Diagrams

In any generator set installation, the frame of the
generator must be positively connected to an earth
ground. This connection is the first connection
that is made at the installation. This connection
is the last connection that should be removed. If
the generator set is on flexible mounting pads, the
ground connection must be flexible in order to avoid
possible breakage in later 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). Joints that are silver soldered and bolted are
preferred.

Neutral Connections
g01154944
Illustration 36
The generators with a Wye Configuration usually The generator lead connections are located in the terminal box
have the neutral ground when the generator is on the generator.
installed. Grounding the neutral is for preventing
damage to equipment. The generator lead connections are located in the
terminal box on the generator or in the enclosure for
If the neutral wire is grounded and one of the phase the control panel.
leads becomes grounded, the excessive current
will open a load circuit breaker. Also, the excessive Change the position of the wire terminals in order to
current will cause the generator voltage to collapse . modify the connection . The code for the winding is
The result depends on the following items: electrical specified on the nameplate.
characteristics of the generator , type of fault, and trip
rating of the circuit breaker. An undervoltage device Wiring Code A for Three-Phase
may be required in order to provide an adequate
short circuit protection. Configuration

There are some cases when the neutral wire is not L1(U)
grounded. An ungrounded generator neutral lead is
acceptable when the possibility of grounds to the
phase leads has been eliminated. An example of T1 T7
such measures are ground fault protective circuits.
Ground fault protection requires the entire group
of distribution circuits to be treated as a system.
The owner should contact a certified consultant if
a new distribution system is being developed. The N
owner should also contact a certified consultant if an
existing system should be modified for the ground
fault protection.

Single Units
Each unit should be connected to a common ground.

In a three-phase, four-wire system, the neutral wire

should be grounded according to local wiring codes.
g00952030
Be sure to check your local wiring codes. Illustration 37
44 SEBU7919-03
Product Information Section
Product Identification Information

L1(V)

T11 T8

g00952058 g00952097
Illustration 38 Illustration 39
Factory connection for "A" wiring code

Table 2

L-L Voltage for Wiring Code A

Winding 50 Hz 60Hz
6 190-208 190-240
7 220-230 -
8 - 190-208

R 230 voltage sensing - 0 => (T8) I 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) I 220 V =>

(T2)

Wiring Code B for Single-Phase

Configuration or Three-Phase
Configuration
llh 1!'\tr;:~tinn 40 g00952196
NOTICE Factory connection for "8" wiring code
This configuration is not possible for LSA 44.2 gener-
ator models. Table 3

L-L Voltage for Wiring Code B

Winding 50 Hz 60Hz
6 110-120 120
7 120-130 -
8 - 110-120

R 230 voltage sensing - 0 => (T8) I 110 V => (T11)

R 438 LS voltage sensing - 0 => (T3) I 110 V =>

(T2)
SEBU7919-03 45
Product Information Section
Product Identification Information

Wiring Code D for Three-Phase R 438 LS voltage sensing - 0 => (T3) I 380 V =>
Configuration (T2)

Wiring Code F for Single-Phase

l1(U)
Configuration or Three-Phase
T1
Configuration

T4
T7

U(W) l2(V) U(W) l2(V)

l l
Illustration 41 g00952201

g00952381
Illustration 43
Voltage LM equals one half of voltage LL.

T11

Illustration 42 g00952365

Factory connection for "D" wiring code

Table 4

L-L Voltage for Wiring Code D

g00952390
Winding 50 Hz 60Hz Illustration 44

6 380-415 380-480 Factory connection for "F" wiring code

7 440-460 -

8 . 380-416

R 230 voltage sensing -0 => (T8) I 110 V => (T11)

46 SEBU7919-03
Product Information Section
Product Identification Information

Table 5 Table 6

L-L Voltage for Wiring Code F L-L Voltage for Wiring Code FF
Winding 50 Hz 60Hz Winding 50 Hz 60Hz
6 220-240 220-240 6 220-240 220-240
7 250-260 - 7 250-260 -
8 200 220-240 8 200 220-240

R 230 voltage sensing -0 => (T8) 1110 V => (T11) R 230 voltage sensing -0 => (T1) 1110 V => (T4)

R 438 LS voltage sensing - 0 => (T3) I 220 V => R 438 LS voltage sensing - 0 => (T1 0) I 220 V =>
(T2) (T1)

Wiring Code FF for Single-Phase connections for Exciter Field

Configuration
Connections for Series (SHUNT)

WHT
BLU

- -
BlK
0 co o;J
L_to 0 Q
5+
f.--

L L R 230
+ + RED
I 6-
L--

g00952416
Illustration 45 g01153397
Illustration 47
Voltage LM equals one half of voltage LL .
(WHT) White
(BLU) Blue
(BLK) Black
(RED) Red

Parallel Connection for Auxiliary Winding

Regulation Excitation Principle (AREP) and
Permanent Magnet Generator (PMG)

g00952430
Illustration 46 g01147978
Illustration 48
Factory connection for "FF" wiring code
(WHT) White
(BLU) Blue
(BLK) Black
(RED) Red
SEBU7919-03 47
Product Information Section
Product Identification Information

R 791 T Interference Suppression

BLK - T1 T1 Tl Tl T1
BLK: T2 T2 T2 T2 T9
BLK: T3 TJ TJ T3 T3
_L _L _L
BLU _. N - N -=-
_L _L _L _L _L
WHT: - -::- - - -

g00953025
Illustration 49
Connect the interference suppression, as shown. The letters in the
circles represent the wiring codes for the generators.
(BLK) Black
(BLU) Blue
(WHT) White
(A) Wiring code "A"
(B) Wiring code "B"
(D) Wiring code "D"
(F) Wiring code "F"
(FF) Wiring code "FF"
48 SEBU7919-03
Operation Section
Lifting and Storage

Operation Section The lifting labels are located on the lifting eyes.
These labels designate the proper lifting locations for
the generator set. Some generator sets may be lifted
at the base of the generator set and other generator
Lifting and Storage sets may have a single lifting point on top of the
generator set.

i02472970
Engine Lifting with a Fuel Tank
Product Lifting
Do not lift the unit with fuel in the fuel tank.
SMCS Code: 1000; 1404; 7002

Lifting of Generator Sets

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, if necessary. 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 the fixtures in order

to obtain proper balance and safety. Consult your
Caterpillar dealer for information regarding fixtures
for proper lifting of your complete package.

Lifting eyes are designed and installed for the specific

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 t1xtures tor proper
engine lifting.

On some enclosed generator sets, it may be

necessary to remove a top panel of the enclosure in
order to access the lifting eye.

+
g01034418
Illustration 50
SEBU7919-03 49
Operation Section
Lifting and Storage

i02283885

Product Storage
SMCS Code: 1000; 1404; 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. See this Operation and Maintenance
Manual, "Refill Capacities and Recommendations"
(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, see

Special Instruction, SEHS9031, "Storage Procedure
for Caterpillar Products".

Generator Storage
Store the generator set in a dry area in order to
minimize condensation on the windings. Use space
heaters to keep the windings dry, when possible.
Wrap the genset in plastic with bags of desiccant for
extended storage. Test the insulation of the generator
when the generator is removed from storage. Refer to
this Operation and Maintenance Manual, "Insulation
- Test". Dry the generator if the insulation is not
acceptable. refer to this Operation and Maintenance
Manual, "Generator- Dry".
50
Operation Section
Installation
Installation
i03903752
Product Installation
SMCS Code: 1000; 1404; 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
Moving the Generator
Unpack the equipment with care in order to avoid
scratching painted surfaces.
A WARNING
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.
Move the unit to the mounting location. The unit can
be moved by either of the following methods:
• Attach an overhead crane to the eyebolts that are
installed on the generator frame.
• Use a lift truck in order to lift the generator.
Refer to the Operation and Maintenance Manual,
"Product Lifting" section.
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
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, if equipped .
SEBU7919-03
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
• Well ventilated
• 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 .
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)
SEBU7919-03 51
Operation Section
Installation

Protective Devices
The output to the load of the generator should always
be protected with an overload protection device such
as a circuit breaker or fuses. Fuses should be sized
by using the lowest possible current rating. However,
this rating must be above the current rating for full
load. A common recommendation is 115 percent
of rated current. Determine the size of fuses or
determine the size of circuit breakers in accordance
with NEMA, IEC, and Local Electrical Codes.
52 SEBU7919-03
Operation Section
Features and Controls

Features and Controls

i02335464

Control Panel
(Protection and Paralleling
Unit (PPU) Control Panel (if
equipped))
SMCS Code: 7451

(S/N: MMC) Generator Sets

There are three types of control panels that are

available for the generator set. The control panels
are the Protection and Paralleling Unit (PPU) Control
Panel, the Standard Control Panel and the Premium
Control Panel. The Protection and Paralleling Unit
(PPU) Control Panel is discussed in this section.
The Standard Control Panel and the Premium
Control Panel are discussed in this Operation and
Maintenance Manual, "Control Panel (Standard
Control Panel and the Premium Control Panel) (if
equipped))".
SEBU7919-03 53
Operation Section
Features and Controls

Protection and Paralleling Unit

(PPU) Control Panel

CD

'-'0
"'""'
.....
0
o""""'~~-'*o
lei
B Tache
OIIP 50 psi
1500 rpm
3.4bar
~<8®&
!J. ""m'"l O

Cool.lefllp. 131F 55C

8 SEfL.Jp
..
V3 V2
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B ·-
B ··-~
0 0 0
4
B @r~ 0

g011662B1
Illustration 51
Protection and Paralleling Unit (PPU) Control Panel
(1) Engine shutdown override switch (2) Emergency stop push button (4) PPU
(located inside electrical box) (3) Horn

Engine Shutdown Override Switch (1) - This
should be switched to the NORMAL position for
normal use. Placing the switch in the OVERRIDE
position will enable the engine to continue to run
even when a shutdown signal is received. Placing
the switch in the OVERRIDE position will not override
a shutdown that is caused by engine overspeed or a
shutdown that is caused by low engine oil pressure.
Horn (3) -The horn activates when a fault (alarm or
shutdown signal) is received by the controller and the
fault is indicated with text on the controller display.
Move the cursor to "ACK". Press the "SEL" key in
order to acknowledge the alarm and silence the horn .
PPU (4) - The PPU controls the functions of the
generator set.

Emergency Stop Push Button (2) -The emergency

stop push button (ESPB) is used to shut down the
engine during an emergency situation. The ESPB
shuts off the fuel and the ESPB trips the air shutoff.
54 SEBU7919-03
Operation Section
Features and Controls

28 27 26 25 24

5 11====1-1-------;===\===\=SJ====;-\
~m
6 ------r-1+8A~~ ~\-~
11 8 Tacho 1SOO rpm
Oil P SOpsi 3.4bar
7 ----u-u-\
A Ires
vI Tl"::/
I I uMP Cool. Temp. 131 F
SETUP V3 V2
sse
Y.1 20

19

10 11 12 13 14 15 16 17 18
g01166258
Illustration 52
PPU
(5) Alarm Indicator (14) "MODE" key (22) Controller status indicator light
(6) Information key (15) Indicator light for control in remote (23) Controller power indicator light
(7) "JUMP" key mode (24) Menu navigation key for UP
(8) "START" key (16) Menu navigation key for LEFT (25) Regulator on indicator light
(9) "STOP" key (reset) (17) "BACK" key (26) "VIEW" key
(10) Engine operating indicator (18) Menu navigation key for DOWN (27) "LOG" key
(11) Generator status indicator (19) "SEL" Key (28) Display area
(12) Circuit breaker indicator (20) Menu navigation key for RIGHT
(13) Circuit breaker key (if equipped) (21) Indicator light for alarm inhibit

The PPU is operated by keys on the panel. Three
keys (8, 9, and 14) control the starting and the
stopping of the generator set. Other keys (6, 7, 16,
17, 18, 19, 20, 24, 26 and 27) allow the operator to
access additional information about the generator
set. This information is shown on the display (28).
Alarm Indicator (5) - A flashing LED indicates that
alarms that have not been acknowledged are still
present. A fixed LED light indicates that all alarms
are acknowledged. A RED LED is for Shutdown. A
GREEN LED is for an Alarm.
"INFO" Key (6) -This shifts the display in order to
show the list of alarms. The list has a maximum of
30 alarms.
"JUMP" Key (7) -The "JUMP" key is used to enter
a number in order to select a menu. Every setting
has a specific number. Use the "JUMP" key in order
to select any setting and display any setting without
navigating all the way through the menus.
"START" Key (8) - The "START" key begins the
starting sequence. The PPU must be in manual mode
in order for the "START" key to function. The remote
indicator light (15) can not be illuminated . To switch
off the remote indicator light, press "MODE" key (14).
"STOP" Key (reset) (9) - The "STOP" key shuts
down the engine when the eng1ne IS runnmg.
Pressing the "STOP" key bypasses the cooldown
period.
Engine operating indicator (10) -Light indicates
that the generator is running.
Generator Status Indicator (11) - This light
indicates that the voltage and frequency is present
and OK.
Circuit Breaker Indicator (12) -The light indicates
that the breaker is closed.
SEBU7919-03
Circuit Breaker Key (13) (if equipped) -The circuit
breaker key opens the circuit breaker and the circuit
breaker key closes the circuit breaker.
"MODE" Key (14) - The "MODE" key switches
the system between LOCAL START/STOP and
"REMOTE START/STOP". Light (13) is illuminated
for "REMOTE" control.
Indicator Light for Control In Remote Mode (15) -
The indicator illuminated through operation of Mode
key. (12)
Menu Navigation Key for LEFT (16) -This key
moves the cursor to the left for maneuvering in the
menus.
"BACK" Key (17) -The "BACK" key jumps one
step backward in the menu to previous display or to
the entry screen.
Menu Navigation Key for DOWN (18) -This key
decreases the value of the selected set point in the
setting menus. This key is also used for scrolling
to the second line that displays the values for the
generator in the display for daily use.
"SEL" Key (19) -This key is used to select the
function that has been chosen. The function that has
been chosen is the underlined selection in the lower
line of the display.
Menu Navigation Key for RIGHT (20) - This key
moves the cursor to the right in order to maneuver
in the menus.
Indicator Light for "Alarm Inhibit" (21) -This light
indicates that the "inhibit input" is on.
Indicator for Status of the Controller (22) - This
light indicates that the unit is running a self-check
and the unit is functioning properly.
Power Indicator (23) -This light indicates that the
auxiliary DC battery supply circuit is switched on.
Menu Navigation Key for UP (24) - This key
increases the value of the selected set point in the
setting menus. This key is also used for scrolling
to the second line that displays the values for the
generator in the display for daily use.
Regulator On Indicator Light (25) - This light
indicates that the voltage regulator is functioning.
"VIEW" Key (26) - Enter a menu number selection.
All settings have a specific number. The "VIEW' key
enables the user to select any setting. The "VIEW'
key enables the user to display any setting without
navigating through all of the menus.
55
Operation Section
Features and Controls
"LOG" Key (27) - This key shifts the display to the
three lower lines in order to show the event and a list
of alarms. The list holds 100 events. These events
are erased when the main unit is switched off.
Display Area (28) - The display area shows
information about the generator set.
Setting the Password
Setting the password can only be accomplished by
using the "JUMP" key.
Note: Keep a record of the password. If the password
is forgotten, it will not be possible to enter the menus.
Use the following procedure to change the password.
1. Press the "JUMP" key.
2. Use the Menu Navigation Key for UP and the
Menu Navigation Key for DOWN In order to step
to channel 4976.
3. Press the "SEL" key.
4. Use the Menu Navigation Key for UP and the
Menu Navigation Key for DOWN in order to select
the new password and save the new password.
Note: The password must be re-entered when the
display has not been used for 3 minutes.
Service Menu
Accessing the Service Menu can only be
accomplished by using the "JUMP" key.
Use the following procedure to access the Service
Menu.
1. Press the "JUMP" key.
2. Use the Menu Navigation Key for UP and the
Menu Navigation Key for DOWN In order to step
to channel 4980.
3. Press the "SEL" key.
4. Choose the desired functions, timers, inputs or
outputs by moving the cursor and pressing the
"SEL" key.
Language Selection
The PPU can be configured for the following
languages: English, Spanish, German, and French .
The language may be chosen when the system is
set up. The language may be chosen by using the
"JUMP" key.
56
Operation Section
Features and Controls
Use the following procedure to change the language.
1. Press the "JUMP" key.
2. Use the Menu Navigation Key for UP and the
Menu Navigation Key for DOWN In order to step
to channel 4231 .
3. Press the "SEL" key.
4. Choose the password by using the Menu
Navigation Key for UP and the Menu Navigation
Key for DOWN and press the "SEL" key.
5. Use the Menu Navigation Key for UP and the
Menu Navigation Key for DOWN and select the
desired language.
6. Press the "SEL" key.
Note: The password must be re-entered when the
display has not been used for 3 minutes.
Alarms
The following steps describe the function of the
alarm.
1. An alarm occurs. The alarm light starts flashing .
2. The display automatically shows the alarm
information.
3. Move the cursor to "ACK" and press the "SEL"
key in order to acknowledge the alarm. Take the
necessary action for the alarm.
4. The alarm will disappear when the condition that
caused the alarm is no longer present.
5. Alarms that have not been acknowledged are still
present if the alarm light flashes.
6. Use the menu navigation keys in order to step
through the list of alarms.
Warnings
"WARNING BATTERY VOLTAGE" -If the control
module detects voltage from the alternator that is
below the setting for low voltage, the display will show
"BATTERY LOW V". The alarm indicator illuminates,
and an audible alarm is activated.
"FAIL TO STOP" - If the control module determines
that the signal from the engine speed sensor
indicates that the engine is running but the engine
should not be running, the display will show "STOP
FAIL". The alarm indicator illuminates, and an audible
alarm is activated.
SEBU7919-03
"WARNING LOW OIL PRESSURE" - If the control
module detects engine oil pressure that has fallen
below the setting for low oil pressure (warning),
the display will show "LOW OIL PRESS". The
alarm indicator illuminates, and an audible alarm is
activ<:~tcd. This warning is only active after the engine
has exceeded the Safety On Timer.
"WARNING HIGH COOLANT TEMP" - If the control
module detects engine coolant temperature that has
exceeded the setting for high coolant temperature
(warning}, the display will show "HIGH ENGINE
TEMP". The alarm indicator illuminates, and an
audible alarm is activated. This warning is only active
after the engine has exceeded the "Safety On" Timer.
"WARNING OVERSPEED" - If the engine speed
exceeds the setting for engine overspeed (warning),
the display will show "OVERSPEED". The alarm
indicator illuminates, and an audible alarm is
activated.
"WARNING GENERATOR HIGH FREQUENCY" -
If the control module detects a output frequency
for the generator that exceeds the setting for high
generator frequency (warning}, the display will show
"F/U FAILURE". The alarm indicator illuminates, and
an audible alarm is activated .
"WARNING GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (warning}, the display will show
"F/U FAILURE". The alarm indicator illuminates, and
an audible alarm is activated.
"GENERATOR HIGH VOLTAGE WARNING" -If
the control module detects a output voltage for the
generator that exceeds the setting for high generator
voltage (warning}, the display will show "OVER
VOLTAGE". The alarm indicator illuminates, and an
audible alarm is activated.
"GENERATOR LOW VOLTAGE WARNING" -
If the control module detects a output voltage for
the generator that is less than the settin~ for low
generator voltage (warning}, the display will show
"UNDER VOLTAGE". The alarm indicator illuminates,
and an audible alarm is activated.
"LUB OIL HIGH TEMPERATURE ALARM" - If the
control module detects a high lube oil temperature
in excess of 120 degrees celsius for four cylinder
engines and in excess of 130 degrees celsius for
six cylinder engines (warning), the display will show
"LUB OIL HIGH". The alarm indicator illuminates.
SEBU7919-03
"SHUTDOWN OVERRIDE" - If the control module
detects an override for engine shutdown and the
switch is set to OVERRIDE, the display will show
"SID OVERRIDE". The alarm indicator illuminates,
and an audible alarm is activated .
"STARTING AIR PRESSURE LOW ALARM
OPTIONAL" - If the control module detects low
starting air pressure (warning), the display will show
"START AIR PLOW'. The alarm indicator illuminates,
and an audible alarm is activated.
"GENERATOR WINDING OR BEARING OVER
TEMPERATURE ALARM OPTIONAL" - If the
control module detects a generator bearing over
temperature (warning), the display will show "GEN
BRG OVER TEMP". The alarm indicator illuminates,
and an audible alarm is activated.
"EXTERNAL FUEL TANK LEVEL ALARM
OPTIONAL" - If the control module detects a low
fuel level in an external fuel tank, the display will show
"EXT FUEL T LOW'. The alarm indicator illuminates,
and an audible alarm is activated.
"HIGH EXHAUST TEMPERATURE ALARM
OPTIONAL" - If the control module detects a high
exhaust temperature (warning), the display will show
"HIGH EXH TEMP". The alarm indicator illuminates,
and an audible alarm is activated.
"HIGH PRESSURE FUEL LEAK ALARM
OPTIONAL" - If the control module detects a high
pressure fuel leak (warning), the display will show "H
P FUEL LEAK". The alarm indicator illuminates, and
an audible alarm is activated .
"WATER IN FUEL ALARM OPTIONAL" - If the
control module detects a signal for water in fuel
(warning), the display will show "WATER IN FUEL".
The alarm indicator illuminates, and an audible alarm
is activated.
Shutdowns
"SHUTDOWN FAIL TO START" - If the engine
does not start after a preset number of attempts, the
display will show "FlU FAIL". The alarm indicator will
flash, and an audible alarm is activated.
"SHUTDOWN EMERGENCY STOP" - If the
voltage signal at the input for the emergency stop is
disconnected, the display will show "E-STOP". The
generator set will not start until the emergency stop
push button has been reset. Power is removed from
the fuel solenoid and the starter solenoid. The alarm
indicator will flash, and an audible alarm is activated .
57
Operation Section
Features and Controls
"SHUTDOWN LOW OIL PRESSURE" - If the
control module detects engine oil pressure that
has fallen below the setting for low oil pressure
(shutdown), the display will show "LOW 0 P
SIDOWN". The alarm indicator will flash, and an
audible alarm is activated. This warning is only active
after the engine has exceeded the Safety On Timer.
"SHUTDOWN HIGH COOLANT TEMPERATURE" -
If the control module detects engine coolant
temperature that has exceeded the setting for high
coolant temperature (shutdown), the display will
show "HET SIDOWN". The alarm indicator will flash ,
and an audible alarm is activated. This warning is
only active after the engine has exceeded the "Safety
On" Timer.
"SHUTDOWN OVERSPEED" - If the engine speed
exceeds the setting for engine overspeed (shutdown),
the display will show "FlU FAIL". The alarm indicator
will flash , and an audible alarm is activated.
"SHUTDOWN UNDERSPEED" - If the engine
speed falls below the setting for engine underspeed
(shutdown), the display will show "FlU FAIL". The
alarm indicator will flash , and an audible alarm is
activated. This warning is only active after the engine
has exceeded the "Safety On" Timer.
"SHUTDOWN GENERATOR HIGH
FREQUENCY" - If the control module detects a
output frequency for the generator that exceeds the
setting for high generator frequency (shutdown), the
display will show "FlU FAIL". The alarm indicator will
flash, and an audible alarm is activated.
"SHUTDOWN GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (shutdown), the display will
show "FlU FAIL". The alarm indicator will flash, and
an audible alarm is activated.
"GENERATOR HIGH VOLTAGE SHUTDOWN" -If
the control module detects a output voltage for the
generator that exceeds the setting for high generator
voltage (shutdown), the display will show "HIGH
VOLT SID". The alarm indicator will flash, and an
audible alarm is activated.
"GENERATOR LOW VOLTAGE SHUTDOWN" -
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (shutdown), the display will show
ULOW VOLT SID". The alarm indicator will flash, and
an audible alarm is activated.
58 SEBU7919-03
Operation Section
Features and Controls

"ELECTRONIC GOVERNOR FAILURE

SHUTDOWN" - If the control module detects an
electronic governor failure (shutdown), the display
will show "GOV FAILS/DOWN". The alarm indicator
illuminates, and an audible alarm is activated.

i02673732

Control Panel
{Standard Control Panel,
Premium Control Panel, and
MCS Control Panel)
SMCS Code: 7451

(S/N : L 1K; S1M) Generator Sets

The standard control panel and the premium

control panel are discussed in this section. The
standard control panel has mechanical gauges and
an electronic control with indicators. The standard
control panel does not have a digital display. The
premium control panel does not have any mechanical
gauges. The premium control panel and the MCS
control panel has digital displays. The gauges are
included in the electronic control and the gauges are
digital.
SEBU7919-03 59
Operation Section
Features and Controls

Standard Control Panel

2 3

0 0

Illustration 53
g01154139

Standard control panel

(1) Oil pressure gauge (4) DC voltmeter (7) Alarm silence switch
(2) Temperature gauge (5) Hour meter (8) Emergency stop push button
(3) Control module (generator set) (6) Horn

Oil Pressure Gauge (1) - The oil pressure gauge
(OPG) shows engine oil pressure. The oil pressure
will be greatest after a cold engine is started. Oil
pressure will decrease as the engine is idling. As
the engine speed is increased to full load speed, oil
pressure will increase and oil pressure will stabilize.
Normal operating engine oil pressure should be
290 kPa (42 psi) to 448 kPa (65 psi) when the
engine is running at rated engine speed. The SAE
10W-30 oil should be at 93 oc(199.4 °F) to 125 oc
(257 °F) operating oil temperature. The engine water
operating temperature should be normal. A lower
pressure of 186 kPa (27 psi) to 344 kPa (50 psi) is
normal at low idle speed .

If the gauge reading is fluctuating and the load has

become stable, perform the following steps:

• Remove the load.

60 SEBU7919-03
Operation Section
Features and Controls

• Check and maintain oil level.
The OPG is powered whenever the engine is
operating. The value that is shown on the OPG is
proportional to the flow of current through the OPG.
The current flow is controlled by the resistance of the
sending unit for the oil pressure. As the oil pressure
changes, there is a corresponding change In the
resistance of the OPSU . Therefore, a corresponding
change in the value is shown on the OPG.
Alarm Silence Switch (7) - The alarm silence
switch is used in conjunction with the horn. The alarm
silence switch silences the horn .
Emergency Stop Push Button (8) - The
emergency stop push button (ESPB) is used to shut
down the engine during an emergency situation. The
ESPB shuts off the fuel.

Temperature Gauge (2) - The water temperature

gauge (WTG) shows the engine water temperature.
The engine should operate within the range of 78 oc
(172 °F) to 90 oc
(194 °F). The water temperature
may vary according to load. However, the water
temperature should never exceed the boiling
temperature for the pressurized system that is being
used. The water temperature is regulated by the
engine thermostats in the system. Do not operate the
engine if no thermostats are installed on the engine.

If the engine is operating and a high water

temperature reading is observed, perform the
following steps:

• Reduce the load.

• Inspect the engine for coolant leaks.

• Inspect the engine for a plugged radiator.

• Determine if the engine should be shutdown.

The WTG is powered whenever the engine is

operating. The value which is shown on the WTG is
proportional to the flow of current through the WTG.
The current flow is controlled by the resistance of the
water temperature sender. As the water temperature
changes there is a corresponding change in the
resistance of the WTSU. A corresponding change is
shown in the value on the WTG.

Note: If the WTSU is not fully submerged because of

low wC::tt~r l~v~l. th~ l~IIIIJ~rc:~lure reading will be false.

Generator Control Module (3) -See Systems

Operation, RENR5854 or Systems Operation,
RENR5855 for more information on programming
the indicators.

DC Voltmeter (4) -The DC voltmeter (VM) shows

the voltage of the starting system.

Hour Meter (5) - The service hour meter shows

the total operating hours of the engine. The meter is
powered whenever the engine is operating.

Horn (6) - The horn activates when one of the fault

indicators is illuminated. The horn can be silenced by
pressing the alarm silence switch .
SEBU7919-03 61
Operation Section
Features and Controls

Control Module

12 13 16

15 20

g01155437
Illustration 54
Standard control module
(9) Programmable indicators (13) Indicator for engine overspeed (18) Manual start position
(1 0) Indicator for a remote start signal that (14) Indicator for engine overcrank (19) Engine control switch
is present (15) Indicator for emergency stop (20) Stop (Reset) position
(11) Indicator for oil pressure (16) Indicator for alarm
(12) Indicator for coolant temperature (17) Automatic start position

The control panel has six indicators that correspond to
certain fault conditions. An indicator illuminates when
the corresponding problem exists. Each indicator has
a label that identifies the corresponding condition.
The ECS must be turned to the OFF/RESET position
in order to turn OFF the indicators. The ECS must
be turned to the OFF/RESET position in order to
reset the control panel. The control panel has four
indicators that are spare indicators.
Programmable Indicators (9) - The control panel
has four indicators that are spare indicators. These
indicators can be programmed in order to alert the
operator to various conditions. See the Systems
Operation, RENR5854 and Systems Operations,
RENR5855 for more information on programming
the indicators.
Indicator For Remote Start Signal (10) -This
indicator is reserved. This indicates that the remote
start signal is present.
Indicator For Oil Pressure (11) -This indicator
lights when the engine oil pressure has fallen below
the low limit of the engine oil pressure switch (OPS).
Indicator For Coolant Temperature (12) -This
indicator lights when the engine water temperature
has risen above the upper limit of the water
temperature switch (WfS).
Indicator For Engine Overspeed (13) - This
indicator lights when the control board has
determined that the engine speed has exceeded the
overspeed setpoint.
62 SEBU7919-03
Operation Section
Features and Controls

Indicator For Engine Overcrank (14) -This

indicator lights when the engine fails to start after
exceeding the limit for cranking.

Indicator For Emergency Stop (15) - This indicator

lights when the control module has determined thot
the emergency stop push button has been pressed.

Indicator For Alarm (16) -This indicator lights when

the control module has received any signals that
have been programmed to light the alarm indicator.
When the alarm indicator is ON, the problem is a
warning. When the alarm indicator is flashing, the
problem is a shutdown fault.

If the circuit for the oil pressure switch has failed, the
alarm indicator will illuminate. This is not a warning
of low oil pressure. The indicator for low oil pressure
illuminates when the pressure is low.

If the generator fails to stop after the cooldown

period, the alarm indicator will illuminate. The control
module determines that the generator is stopped
when the oil pressure is low and the engine speed
sensor indicates that no speed exists.

If the signal from the speed sensor fails during

cranking, the generator will shut down. The alarm
indicator will illuminate.

Automatic Start Position (17) -When the ECS

is in the AUTOMATIC position, the engine will start
automatically whenever the remote contact closes.
When the ECS is in the AUTOMATIC position, the
engine will shut down automatically when the remote
contact opens.

Manual Start Position (18) - When the ECS is in

the MANUAL START position, the engine will start.
The engine will run while the ECS remains in this
position.

Engine Control Switch (19) -The engine control

switch (ECS) selects the status of the control panel.

Stop/Reset Position (20) - When the ECS is in the

STOP/RESET position, the fault indicators are reset
and the engine shuts down immediately.
SEBU7919-03 63
Operation Section
Features and Controls

Premium Control Panel

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Illustration 55
Premium control panel
(1) Control module with display (3) Emergency stop button
(2) Hom (4) Alarm silence switch

Premium Control Module With Display(1) - The Alarm Cancel Switch (4) -The alarm silence switch
control module controls the functions of the generator is used in conjunction with the horn. The alarm
set. silence switch silences the horn.

Horn (2) - The horn activates when one of the fault

indicators is illuminated. The horn can be silenced by
pressing the alarm silence switch.

Emergency Stop Push Button (3) - The

emergency stop push button (ESPB) is used to shut
down the engine during an emergency situation. The
ESPB shuts off the fuel.
64 SEBU7919-03
Operation Section
Features and Controls

Premium Control Module With Display

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Illustration 56
Premium control module with display
(5) UP key (11) Mode select key (17) Stop key (reset)
(6) DOWN key (17) lnnir.lltnrfnr lhP. infnrmRiinn mnrlP. (18) Start key
(7) Display area (13) Indicator for the alarm mode (19) Manual mode key
(8) Programmable indicators (14) Indicator for the engine status mode (20) Automatic mode key
(9) Indicator for alarm (15) Indicator for the generator status mode (21) Lamp test key
(1 0) Indicator for the configuration mode (16) Indicator for the event log mode

The control module with a display is operated by
keys on the panel. The four keys at the bottom of
the module (17), (18), (19), and (20) control the
starting of the generator set and the stopping of the
generator set. Three smaller keys (5), (6), and (11)
allow the operator to access additional information
about the generator set. This information is shown
on the display (7).
UP Key (5) - When the UP key is pressed, the
display area will scroll upward.
DOWN Key (6) -When the DOWN key is pressed,
the display will scroll downward.
Display Area (7) - The display area shows
information about the generator set.
Programmable Indicators (8) - The programmable
indicators are available for use by the customer. See
Systems Operation, RENR5855 for more information
on programming the indicators.
SEBU7919-03
Alarm Indicator (9) -The alarm indicator lights for
several different reasons. When the alarm indicator
is ON, the problem is a warning. When the alarm
indicator is flashing, the problem is a shutdown fault.
When any alarm occurs, the display changes to the
Alarm Mode.
Operator Configuration Mode Indicator (10) -The
operation configuration mode indicator illuminates
when the module is in the configuration mode.
When the UP key and the DOWN key are pressed
together, the module enters the configuration mode.
The language can be changed. The contrast of the
display can be adjusted.
Mode Select Key (11) -The mode select key
changes the mode of the display area. When a mode
is active, the indicator above the appropriate symbol
(12), (13), (14), (15) or (16) is illuminated.
Indicator for Information Mode (12) -The
information mode is active when the indicator for
information mode is illuminated. This is the normal
mode for the display area. The display indicates the
status of the generator. An example is "GENERATOR
AT REST". If the display is in another mode,
the display will automatically change back to the
information mode after a set period of inactivity.
Indicator for Alarm Mode (13) -The alarm mode
is active when the indicator for alarm mode is
illuminated. The display shows the information for
any active alarms. An example is "SHUTDOWN LOW
OIL PRESSURE".
Indicator for Engine Status Mode (14) -The
engine status mode is active when the indicator for
engine status mode is illuminated. The display shows
the information regarding the engine. An example is
"ENGINE SPEED" and "OIL PRESSURE".
Indicator for Generator Status Mode (15) - The
generator status mode is active when the indicator
for generator status mode is illuminated. The display
shows the information regarding the generator.
An example is "GENERATOR VOLTAGE" and
"GENERATOR CURRENT".
Indicator for Event Log Mode (16) - The event log
mode is active when the indicator for event log mode
is illuminated. The display shows the information
regarding the last 25 alarms (shutdown). In the
memory, older alarms are replaced by newer alarms.
Stop/Reset Key (17) -The stop key shuts down the
engine when the engine is running.
Start Key (18) -The start key begins the starting
sequence. The control module must be in the manual
mode in order for the start key to function.
65
Operation Section
Features and Controls
Manual Mode Key (19) - The manual mode key is
used to start the generator. After the manual mode
key is pressed, the generator will be in the manual
mode. In this mode, when the start key is pressed
the engine will start.
Automatic Mode Key (20) - The auto key places
the generator in the automatic mode. When the
generator is in the automatic mode, the engine will
start after receiving a signal for remote starting.
Alarm Mute Key (21) - The alarm mute key turns
off the alarm.
Warnings
"WARNING CHARGE ALT FAILURE" -If the
control module does not detect voltage from the
alternator, the display will show "WARNING CHARGE
ALT FAILURE". The alarm indicator will illuminate.
"WARNING LOW BAITERY VOLTAGE" - If the
control module detects voltage from the alternator
that is below the setting for low voltage, the display
will show "WARNING LOW BATTERY VOLTAGE".
The alarm indicator illuminates.
"WARNING HIGH BAITERY VOLTAGE" -If the
control module detects voltage from the alternator
that is above the setting for high voltage, the display
will show "WARNING HIGH BATTERY VOLTAGE".
The alarm indicator illuminates.
"FAIL TO STOP" - If the control module determines
that the signal from the oil pressure sender indicates
that the engine is running but the engine should not
be running, the display will show "FAIL TO STOP".
The alarm indicator illuminates. Also, the control
module can be configured in order for the engine to
start only if the signal that is from the oil pressure
sender indicates that the pressure is low.
"WARNING LOW OIL PRESSURE" - If the control
module detects engine oil pressure that has fallen
below the setting for low oil pressure (warning), the
display will show "WARNING LOW OIL PRESSURE".
The alarm indicator illuminates. This warning is only
active after the engine has exceeded the Safety On
Timer.
"WARNING HIGH COOLANT TEMP" - If the control
module detects engine coolant temperature that has
exceeded the setting for high coolant temperature
(warning), the display will show "WARNING HIGH
COOLANT TEMP". The alarm indicator illuminates.
This warning is only active after the engine has
exceeded the Safety On limer.
66
Operation Section
Features and Controls
"WARNING OVERSPEED" - If the engine speed
exceeds the setting for engine overspeed (warning),
the display will show "WARNING OVERSPEED". The
alarm indicator illuminates.
"WARNING UNDERSPEED" - If the engine speed
is below the setting for the engine underspeed
(warning), the display will show "WARNING
UNDERSPEED". The alarm indicator illuminates.
This warning is only active after the engine has
exceeded the Safety On Timer.
"WARNING GENERATOR HIGH FREQUENCY" -
If the control module detects a output frequency
for the generator that exceeds the setting for high
generator frequency (warning), the display will show
"WARNING GENERATOR HIGH FREQUENCY". The
alarm indicator illuminates.
"WARNING GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (warning), the display will show
"WARNING GENERATOR LOW FREQUENCY". The
alarm indicator illuminates.
"GENERATOR HIGH VOLTAGE WARNING" -
If the control module detects a output voltage for
the generator that exceeds the setting for high
generator voltage (warning), the display will show
"GENERATOR HIGH VOLTAGE WARNING". The
alarm indicator illuminates.
"GENERATOR LOW VOLTAGE WARNING" -
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (warning), the display will show
"GENERATOR LOW VOLTAGE WARNING". The
alarm indicator illuminates.
"MAINTENANCE DUE ALARM" - Maintenance
intervals can be programmed into the control module.
When the hour meter reaches a maintenance setting,
the display will show "MAINTENANCE DUE ALARM".
The alarm Indicator Illuminates.
Shutdowns
"SHUTDOWN FAIL TO START" - If the engine
does not start after a preset number of attempts, the
display will show "SHUTDOWN FAIL TO START".
The alarm indicator will flash.
"SHUTDOWN EMERGENCY STOP" - If the
voltage signal at the input for the emergency stop is
disconnected, the display will show "SHUTDOWN
EMERGENCY STOP". The generator set will not
start until the emergency stop push button has been
reset. Power is removed from the fuel solenoid and
the starter solenoid. The alarm indicator will flash.
SEBU7919-03
"SHUTDOWN LOW OIL PRESSURE" - If the
control module detects engine oil pressure that
has fallen below the setting for low oil pressure
(shutdown), the display will show "SHUTDOWN LOW
OIL PRESSURE". The alarm indicator will flash. This
warning is only active after the engine has exceeded
the Safety On Timer.
"SHUTDOWN HIGH COOLANT TEMP" - If the
control module detects engine coolant temperature
that has exceeded the setting for high coolant
temperature (shutdown), the display will show
"SHUTDOWN HIGH COOLANT TEMP". The alarm
indicator will flash . This warning is only active after
the engine has exceeded the Safety On Timer.
"SHUTDOWN OVERS PEED" - If the engine speed
exceeds the setting for engine overspeed (shutdown),
the display will show "SHUTDOWN OVERSPEED".
The alarm indicator will flash.
"SHUTDOWN UNDERSPEED" - If the engine
speed falls below the setting for the engine
underspeed (shutdown), the display will show
"SHUTDOWN UNDERSPEED". The alarm indicator
will flash. This warning is only active after the engine
has exceeded the Safety On Timer.
"SHUTDOWN GENERATOR HIGH
FREQUENCY" -If the control module detects a
output frequency for the generator that exceeds the
setting for high generator frequency (shutdown), the
display will show "SHUTDOWN GENERATOR HIGH
FREQUENCY". The alarm indicator will flash .
"SHUTDOWN GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (shutdown) , the display will show
"SHUTDOWN GENERATOR LOW FREQUENCY".
The alarm indicator will flash .
"GENERATOR HIGH VOLTAGE SHUTDOWN"-
If the control module detects a output voltage for
Lll~ y~n~rc:dor Lhal exceeds the setting for high
generator volta~e (shutdown), the display will show
"GENERATOR HIGH VOLTAGE SHUTDOWN". The
alarm indicator will flash.
"GENERATOR LOW VOLTAGE SHUTDOWN" -
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (shutdown), the display will show
"GENERATOR LOW VOLTAGE SHUTDOWN". The
alarm indicator will flash.
SEBU7919-03 67
Operation Section
Features and Controls

"OIL PRESSURE SENDER OPEN CIRCUIT" - If

the control module detects an open circuit in the
wiring for the oil pressure sender, the display will
show "OIL PRESSURE SENDER OPEN CIRCUIT".
The alarm indicator will flash. The shutdown is
immediate.

"GENERATOR EARTH FAULT" -If the control

module detects current that exceeds a limit that
has been programmed and the control module
determines that a short to ground exists, the display
will show "GENERATOR EARTH FAULT". The alarm
indicator will flash.

"GENERATOR PHASE SEQUENCE WRONG" -

If the control module detects a problem with the
phase rotation of the generator, the display will show
"GENERATOR PHASE SEQUENCE WRONG". The
alarm indicator will flash .

"AUXILIARY INPUTS" - If an auxiliary input has

been configured to shut down the engine, the display
wilt show the message that has been programmed.
The alarm indicator will flash .
68 SEBU7919-03
Operation Section
Features and Controls

MCS Control Panel

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Illustration 57
(1) Engine shutdown override switch (2) Emergency stop push button (4) Alarm/Display module
(located inside control box) (3) Engine shutdown module
SEBU7919-03 69
Operation Section
Features and Controls

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g01339114
Illustration 58
Location label inside the MCS cover
(1) Speed Switch (5) Engine Shutdown Override Switch (9) Receptacle Connector for DC Voltage
(2) Capacitor (6) Latching Relay (10) Audible Alarm Connector
(3) Controller (7) R2 DPCO Relay (11) Receptacle connector for AC voltage
(4) Terminal Blocks (8) R2 DPCO Relay
70 SEBU7919-03
Operation Section
Features and Controls

MCSDisplay

26 24 23 22

14 15 16

g01336578
Illustration 59
(5) Alarm Indicator (14) Menu key for LEFT (24) "LOG"
(6) Information key (15) "!:lACK" key (25) Lamp test switch
(7) "JUMP" key (16) Menu key for DOWN (26) Display area
(8) "START" key (17) "SEL" Key (27) ~eset sw1tch tor the hom
(9) "STOP" key (reset) (18) Menu key for RIGHT (28) Reset switch for the lamps
(10) Engine operating indicator (19) Indicator light for alarm inhibit (29) Lamp test switch
(11) Generator status indicator (20) Controller status indicator light
(12) "MODE" key (21) Controller power indicator light
(13) Indicator light for control in remote (22) Menu key for UP
mode (23) "VIEW"

The MCS is operated by keys on the panel. Three
keys (8, 9, and 14) control the starting and the
stopping of the generator set. Other keys (6, 7, 16,
17, 18, 19, 20, 24, 25 and 26) allow the operator to
access additional information about the generator
set. This information is shown on the display (28).
Alarm Indicator (5) -A flashing LED indicates that
alarms that have not been acknowledged are still
present. A fixed LED light indicates that all alarms
are acknowledged . A RED LED is for Shutdown. A
GREEN LED is for an Alarm.
"INFO" Key (6) -This shifts the display in order to
show the list of alarms. The list has a maximum of
30 alarms.
SEBU7919-03
"JUMP" Key (7) -The "JUMP" key is used to enter
a number in order to select a menu. Every setting
has a specific number. Use the "JUMP" key in order
to select any setting and display any setting without
navigating all the way through the menus.
"START" Key (8) -The "START" key begins the
starting sequence. The PPU must be in manual mode
in order for the "START" key to function. The remote
indicator light (15) can not be illuminated. To switch
off the remote indicator light, press "MODE" key (14).
"STOP" Key (reset) (9) -The "STOP" key shuts
down the engine when the engine is running.
Pressing the "STOP" key bypasses the cooldown
period.
Engine operating indicator (10) -Light indicates
that the generator is running.
Generator Status Indicator (11) -This light
indicates that the voltage and frequency is present
and OK.
"MODE" Key (12) -The "MODE" key switches
the system between LOCAL START/STOP and
"REMOTE START/STOP". Light (13) is illuminated
for "REMOTE" control.
Indicator Light for Control In Remote Mode (13) -
The indicator illuminated through operation of Mode
key. (12)
Menu key for LEFT (14) -This key moves the
cursor to the left for maneuvering in the menus.
"BACK" Key (15) -The "BACK" key jumps one
step backward in the menu to previous display or to
the entry screen.
Menu key for DOWN (16) -This key decreases the
value of the selected set point in the setting menus.
This key is also used for scrolling to the second
line that displays the values for the generator in the
display for daily use.
"SEL" Key (17) -This key is used to select the
function that has been chosen. The function that has
been chosen is the underlined selection in the lower
line of the display.
Menu key for RIGHT (18) -This key moves the
cursor to the right in order to maneuver in the menus.
Indicator Light for "Alarm Inhibit" (19) -This light
indicates that the "inhibit input" is on.
Indicator for Status of the Controller (20) - This
light indicates that the unit is running a self-check
and the unit is functioning properly.
71
Operation Section
Features and Controls
Power Indicator (21) -This light indicates that the
auxiliary DC battery supply circuit is switched on .
Menu key for UP (22) -This key increases the
value of the selected set point in the setting menus.
This key is also used for scrolling to the second
line that displays the values for the generator in the
display for daily use.
"VIEW" Key (23) - Enter a menu number selection.
All settings have a specific number. The "VIEW' key
enables the user to select any setting. The "VIEW'
key enables the user to display any setting without
navigating through all of the menus.
"LOG" Key (24) -This key shifts the display to the
three lower lines in order to show the event and a list
of alarms. The list holds 100 events. These events
are erased when the main unit is switched off.
Lamp test switch (25) - The lamp test switch is
used to test indicators on the control panel.
Display Area (26) - The display area shows
information about the generator set.
Horn reset switch (27) - This switch is used to
silence audible devices in the event of an alarm.
Lamp reset switch (28) - This switch is used
to reset the indicators after an alarm has been
acknowledged.
Lamp test switch (29) - This switch is used to test
all indicators on the alarm module.
Setting the Password
Setting the password can only be accomplished by
using the "JUMP" key.
Note: Keep a record of the password. If the password
is forgotten, it will not be possible to enter the menus.
Use the following procedure to change the password.
1. Press the "JUMP" key.
2. Use the Menu key for UP and the Menu key for
DOWN In order to step to channel 4976.
3. Press the "SEL" key.
Note: The password must be re-entered when the
display has not been used for 3 minutes.
Service Menu
Accessing the Service Menu can only be
accomplished by using the "JUMP" key.
72
Operation Section
Features and Controls
Use the following procedure to access the Service
Menu.
1. Press the "JUMP" key.
2. Use the Menu key for UP and the Menu key for
DOWN In order to step to channel 4980.
3. Press the "SEL" key.
4. Choose the desired functions, timers, inputs or
outputs by moving the cursor and pressing the
"SEL" key.
Language Selection
The MCS can be configured for the following
languages: English, Spanish , German, and French.
The language may be chosen when the system is
set up. The language may be chosen by using the
"JUMP" key.
Use the following procedure to change the language.
1. Press the "JUMP" key.
2. Use the Navigation Key for UP and the Navigation
Key for DOWN In order to step to channel 4231 .
3. Press the "SEL" key.
4. Choose the password by using the Navigation
Key for UP and the Navigation Key for DOWN and
press the "SEL" key.
5. Use the Navigation Key for UP and the Navigation
Key for DOWN and select the desired language.
6. Press the "SEL" key.
Note: The password must be re-entered when the
display has not been used for 3 minutes.
Alarms
The following steps describe the function of the
alarm.
1. An alarm occurs. The alarm light starts flashing .
2. The display automatically shows the alarm
information.
3. Move the cursor to "ACK" and press the "SEL"
key in order to acknowledge the alarm. Take the
necessary action for the alarm.
4. The alarm will disappear when the condition that
caused the alarm is no longer present.
SEBU7919-03
5. Alarms that have not been acknowledged are still
present if the alarm light flashes.
6. Use the navigation keys in order to step through
the list of alarms.
Warnings
"WARNING BATTERY VOLTAGE" - If the control
module detects voltage from the alternator that is
below the setting for low voltage, the display will show
"BATIERY LOW V". The alarm indicator illuminates,
and an audible alarm is activated .
"FAIL TO STOP" - If the control module determines
that the signal from the engine speed sensor
indicates that the engine is running but the engine
should not be running, the display will show "STOP
FAIL". The alarm indicator illuminates, and an audible
alarm is activated .
"WARNING LOW OIL PRESSURE" - If the control
module detects engine oil pressure that has fallen
below the setting for low oil pressure (warning),
the display will show "LOW OIL PRESS". The
alarm indicator illuminates, and an audible alarm is
activated. This warning is only active after the engine
has exceeded the Safety On Timer.
"WARNING HIGH COOLANT TEMP" -If the control
module detects engine coolant temperature that has
exceeded the setting for high coolant temperature
(warning), the display will show "HIGH ENGINE
TEMP". The alarm indicator illuminates, and an
audible alarm is activated. This warning is only active
after the engine has exceeded the "Safety On" Timer.
"WARNING OVERSPEED" - If the engine speed
exceeds the setting for engine overspeed (warning),
the display will show "OVERSPEED". The alarm
indicator illuminates, and an audible alarm is
activated.
"WARNING GENERATOR HIGH FREQUENCY" -
If the control module detects a output frequency
for the generator that exceeds the setting for high
generator frequency (warning), the display will show
"F/U FAILURE". The alarm indicator illuminates, and
an audible alarm is activated.
"WARNING GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (warning), the display will show
"F/U FAILURE". The alarm indicator illuminates, and
an audible alarm is activated.
SEBU7919-03
"GENERATOR HIGH VOLTAGE WARNING" - If
the control module detects a output voltage for the
generator that exceeds the setting for high generator
voltage (warning), the display will show "OVER
VOLTAGE". The alarm indicator illuminates, and an
audible alarm is activated.
"GENERATOR LOW VOLTAGE WARNING" -
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (warning), the display will show
"UNDER VOLTAGE". The alarm indicator illuminates,
and an audible alarm is activated.
"LUB OIL HIGH TEMPERATURE ALARM" - If the
control module detects a high lube oil temperature
in excess of 120 degrees celsius for four cylinder
engines and in excess of 130 degrees celsius for
six cylinder engines (warning), the display will show
"LUB OIL HIGH". The alarm indicator illuminates.
"SHUTDOWN OVERRIDE" - If the control module
detects an override for engine shutdown and the
switch is set to OVERRIDE, the display will show
"SID OVERRIDE". The alarm indicator illuminates,
and an audible alarm is activated.
"STARTING AIR PRESSURE LOW ALARM
OPTIONAL" - If the control module detects low
starting air pressure (warning), the display will show
"START AIR PLOW'. The alarm indicator illuminates,
and an audible alarm is activated.
"GENERATOR WINDING OR BEARING OVER
TEMPERATURE ALARM OPTIONAL" - If the
control module detects a generator bearing over
temperature (warning), the display will show "GEN
BRG OVER TEMP". The alarm indicator illuminates,
and an audible alarm is activated.
"EXTERNAL FUEL TANK LEVEL ALARM
OPTIONAL" - If the control module detects a low
fuel level in an external fuel tank, the display will show
"EXT FUEL T LOW'. The alarm indicator illuminates,
and an audible alarm is activated.
"HIGH EXHAUST TEMPERATURE ALARM
OPTIONAL" - If the control module detects a high
exhaust temperature (warning), the display will show
"HIGH EXH TEMP". The alarm indicator illuminates,
and an audible alarm is activated.
"HIGH PRESSURE FUEL LEAK ALARM
OPTIONAL" - If the control module detects a high
pressure fuel leak (warning), the display will show "H
P FUEL LEAK". The alarm indicator illuminates, and
an audible alarm is activated.
73
Operation Section
Features and Controls
"WATER IN FUEL ALARM OPTIONAL" - If the
control module detects a signal for water in fuel
(warning), the display will show "WATER IN FUEL".
The alarm indicator illuminates, and an audible alarm
is activated .
Shutdowns
"SHUTDOWN FAIL TO START" - If the engine
does not start after a preset number of attempts, the
display will show "F/U FAIL". The alarm indicator will
flash, and an audible alarm is activated.
"SHUTDOWN EMERGENCY STOP" - If the
voltage signal at the input for the emergency stop is
disconnected, the display will show "E-STOP". The
generator set will not start until the emergency stop
push button has been reset. Power is removed from
the fuel solenoid and the starter solenoid. The alarm
indicator will flash, and an audible alarm is activated .
"SHUTDOWN LOW OIL PRESSURE" - If the
control module detects engine oil pressure that
has fallen below the setting for low oil pressure
(shutdown), the display will show "LOW 0 P
S/DOWN". The alarm indicator will flash, and an
audible alarm is activated. This warning is only active
after the engine has exceeded the Safety On Timer.
"SHUTDOWN HIGH COOLANT TEMPERATURE" -
If the control module detects engine coolant
temperature that has exceeded the setting for high
coolant temperature (shutdown), the display will
show "HET S/DOWN" . The alarm indicator will flash,
and an audible alarm is activated . This warning is
only active after the engine has exceeded the "Safety
On" Timer.
"SHUTDOWN OVERSPEED" - If the engine speed
exceeds the setting for engine overspeed (shutdown),
the display will show "F/U FAIL". The alarm indicator
will flash, and an audible alarm is activated.
"SHUTDOWN UNDERSPEED" - If the engine
speed falls below the setting for engine underspeed
(shutdown), the display will show "F/U FAIL". The
alarm indicator will flash, and an audible alarm is
activated. This warning is only active after the engine
has exceeded the "Safety On" Timer.
"SHUTDOWN GENERATOR HIGH
FREQUENCY" - If the control module detects a
output frequency for the generator that exceeds the
setting for high generator frequency {shutdown), the
display will show "F/U FAIL". The alarm indicator will
flash, and an audible alarm is activated .
74
Operation Section
Features and Controls
"SHUTDOWN GENERATOR LOW FREQUENCY" -
If the control module detects a output frequency
for the generator that is below the setting for low
generator frequency (shutdown), the display will
show "F/U FAIL". The alarm indicator will flash, and
an audible alarm is activated.
"GENERATOR HIGH VOLTAGE SHUTDOWN" -If
the control module detects a output voltage for the
generator that exceeds the setting for high generator
voltage (shutdown), the display will show "HIGH
VOLT S/D". The alarm indicator will flash, and an
audible alarm is activated.
"GENERATOR LOW VOLTAGE SHUTDOWN"-
If the control module detects a output voltage for
the generator that is less than the setting for low
generator voltage (shutdown), the display will show
"LOW VOLT S/D". The alarm indicator will flash, and
an audible alarm is activated.
"ELECTRONIC GOVERNOR FAILURE
SHUTDOWN" - If the control module detects an
electronic governor failure (shutdown), the display
will show "GOV FAILS/DOWN". The alarm indicator
illuminates, and an audible alarm is activated.
SEBU7919-03
i03646563
Battery Disconnect Switch
{If Equipped)
SMCS Code: 1411-811; 1411
The battery disconnect switch and the engine start
switch perform different functions. Turn off the battery
disconnect switch in order to disable the entire
electrical system. The battery remains connected to
the electrical system when you turn off the engine
start switch.
Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other components.
Also turn the battery disconnect switch to the OFF
position and remove the key when the engine will not
be used for an extended period of a month or more.
This will prevent drainage of the battery.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
To ensure that no damage to the engine occurs,
verify that the engine is fully operational before
cranking the engine. Do not crank an engine that is
not fully operational.
Perform the following procedure in order to check the
battery disconnect switch for proper operation:
1. With the battery disconnect switch in the ON
position, verify that electrical components are
functioning . Verify that the hour meter is displaying
information . Verify that the engine will crank.
2. Turn the battery disconnect switch to the OFF
position.
3. Verify that the following items are not functioning·
electrical components, hour meter, and engine
cranking. If any of the items continue to function
with the battery disconnect switch in the OFF
position, consult your Caterpillar dealer.
SEBU7919-03 75
Operation Section
Features and Controls

i02304401
A WARNING
Voltage Regulators
Accidental engine starting can cause injury or
SMCS Code: 4467 death to personnel working on the equipment.

To avoid accidental engine starting, disconnect

A DANGER the battery cable from the negative(-) battery ter-
minal. Completely tape all metal surfaces of the
DANGER: Shock/Electrocution Hazard-Do not op-
disconnected battery cable end in order to prevent
erate this equipment or work on this equipment
contact with other metal surfaces which could ac-
unless you have read and understand the instruc-
tivate the engine electrical system.
tions and warnings in the Operation and Mainte-
nance Manual. Failure to follow the instructions or
Place a Do Not Operate tag at the Start/Stop switch
heed the warnings will result in serious injury or
location to inform personnel that the equipment is
death.
being worked on.

A WARNING The voltage regulator is located in the terminal box

on the generator.
Personal injury or death can result from high volt-
age.

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.
• Remove all fuses.
• Make sure the generator engine is stopped.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
Failure to do so could result in personal injury or
death. Make sure residual voltage in the rotor, sta-
tor and the generator is discharged.
g01155079
Illustration 60
The voltage regulator is located in the terminal box on the
generator.
(1) Terminal Box on the Generator
The voltage regulator is powered by two auxiliary
windings. These windings are independent from
the circuit for detection of voltage. The first winding
is labelled as "X1" and "X2". This winding has a
voltage that is proportional with the output voltage
of the generator. The second winding is labelled as
"Z1" and "Z2". This winding has a voltage that is
proportional to the current of the stator. The voltage
from the power supply is rectified and filtered before
being used by the regulator monitoring transistor.
This principle ensures that regulation is not affected
by interference that is generated by the load .
76 SEBU7919-03
Operation Section
Features and Controls

These voltage regulators may have an optional

remote potentiometer for voltage adjustment. This
potentiometer is 450 ohms 0.5 W minimum. The
adjustment range is 5%. The voltage range is
limited by the internal potentiometer "P2". Remove
"ST4" in order to connect the potentiometer. A 1000
ohm potentiometer can also be used to extend the
adjustment range.

R438 Adjustments

NOTICE
ST9 must be closed for AREP excitation.

Table 7
R438 Automatic Voltage Regulator
Maximum current for short 3 x In for 10 seconds
circuit
Standard power supply Two auxiliary windings
Supply for shunt max 48 VAC at 50/60 Hz
Rated overload current 8 amperes for 10 seconds
Electronic protection for Excitation ceiling current
overload and short circuit for 10 seconds and return
opening on voltage sensing to approximately 1 ampere
THE GENERATOR
MUST BE STOPPED
IN ORDER TO RESET
THE PROTECTION.
Fuse "F1" on input side "X 1" and "X2"
Fuse "F2" on output side "E+" and "E-"
Voltage sensing 5 VAC that is isolated by
the transformer
Terminals for 0 to 110 VAC 95 to 140 ACV
Terminals for 0 to 220 VAC 170 to 260 ACV
Terminals for 0 to 380 VAC 340 to 520 VAC
Voltage regulation ±1%
RFtpici re!=lponse time or normal response time from the
location of jumper "ST2"
Voltage adjustment via potentiometer "P2"(other voltages
via the step down transformer)
Underspeed protection and adjustment of frequency
threshold via potentiometer "P4"
Maximum adjustment for excitation via potentiometer
"P5" (4.5 to 10 amperes)
50 or 60Hz selection with jumper "ST3"(1l.
(1) The engine speed setting must be changed in order to change
the frequency of the generator set.
SEBU7919-03 77
Operation Section
Features and Controls

I17G-260V I
( 95-140V

g00952512
Illustration 61
R438 Voltage Regulator
78 SEBU7919-03
Operation Section
Features and Controls

10. Turn potentiometer (P4) slowly counterclockwise

until there is a significant voltage drop. The voltage
R438 drop should be approximately 15 %.
VEL
X2 11. Vary the frequency of both parts between 48 Hz or
RED 58 Hz according to the operating frequency. Check
Z1 the change in the voltage that was previously
GRN AUX
X1 observed.
RIK
Z2 Use the following procedure in order to run the
5+ 6- generator set in parallel operation.
E+
E- I 1. Preset the unit for parallel operation by connecting
EX the current transformer to 51 and 52 of the
g01153904 connector J2. Set potentiometer P1 for quadrature
Illustration 62 droop in the center position. Apply the rated load.
R438 power supply connections for AREP excitation The voltage should drop for 2% to 3%. Switch the
(YEL) Yellow positions of the two incoming secondary wires of
(RED) Red the current transformer if the voltage increases.
(GRN) Green
(BLK) Black
(AUX) Auxiliary Windings 2. The no-load voltages should be identical for all the
(EX) Exciter Field generators that are operating in parallel. Connect
the generators in parallel. Try to obtain a 0 kW
Use the following procedure to adjust the R438 power exchange by adjusting the speed of the
voltage regulator. generator. Try to minimize the circulating currents
between generators by altering the voltage setting
1. Remove wire ST4. with potentiometer P2 or Rhe on one of the
generators.
2. Connect an analog voltmeter that is calibrated for
50 VDC on terminal E+ and terminal E-. Note: Do not change the voltage settings after
this step.
3. Connect a voltmeter that is calibrated for 300 VAC
to 500 VAC or 1000 VAC. 3. Apply the available load. The setting is correct
only if a reactive load is available. Equalize the
4. Turn potentiometer (P2) to a full counterclockwise Kilowatts or divide the rated power of the units
position. proportionally by altering the speed. Equalize
or divide the currents by altering the quadrature
5. Turn potentiometer (P4) to a full clockwise droop potentiometer.
position.
R438 Adjustment for Maximum
6. Turn potentiometer (P3) counterclockwise to about
1/3 of the total rotation for the potentiometer. Excitation
7. Start the engine and set the engine speed to a
frequency of 48 Hz for 50 Hz or 58 Hz tor oU Hz.

8. Adjust the output voltage to the correct value

with potentiometer P2. This voltage should be
the rated voltage UN for single operation or
UN plus 2% to 4% for parallel operation. Use
potentiometer P3 to make adjustments if the
voltage oscillates. Adjust potentiometer P3 in both
directions while you observe the voltage between
E+ and E-. The voltage between E+ and E- should
be approximately 10 VDC. The best response
times are obtained at the limit of the instability.
Try cutting or replacing the wire ST2 if no stable g00952800
Illustration 63
position can be obtained.

9. Check the LAM operation. STS must be closed .

SEBU7919-03 79
Operation Section
Features and Controls

The factory setting corresponds to an excitation Special Use

current that is required to obtain a three-phase short
circuit current of 3 X IN at 50 Hz for industrial power,
unless this is specified otherwise.

The maximum level of excitation may be reduced by

a static method. The static method is safer for the X2 AREP/PMG
generator and the network. Use the following steps Z1
to reduce the maximum excitation level. X1
Z2 -t-i-:!J...!....QH-
1. Disconnect the power supply wires X 1, X2, Z1
E+ •
and Z2.

2. Disconnect sensing leads OV, 11 OV, 220V and

380V on the generator. '
3. Connect the main power supply 200V-240V, as g00952821
Illustration 64
shown. X1,X2:120V
The exciter is switched off by disconnecting the
4. Install a 10 Amp DC ammeter in series with the power supply to the voltage regulator. The connection
exciter field . is identical for resetting the internal protection for the
voltage regulator.
5. Turn potentiometer P5 to a full counterclockwise
position and activate the power supply. If there
is no output current from the voltage regulator,
turn potentiometer P2 clockwise until the ammeter (400 v- 10 A) J-4 Diode
indicates a stable current. X2
6. Switch off the power supply. Switch on the power
Z1
supply. Turn potentiometer P5 until the required X1
maximum current is obtained . The maximum Z2
current must not be greater than 10 Amperes. E+ -4---+--i------------,
- 10 ohms
Use the following steps in order to check the internal E·4---~~------~
Exciter field
protection.

1. Open switch D. The excitation current should

increase up to the preset maximum value and
the excitation current should remain at the preset
maximum value for approximately 10 seconds.
The current will decrease to less than 1 Amp.
g00952830
Illustration 65
Use a 12 VDC power source in order to energize the
field, if necessary. Refer to the following table.

2. Open switch A in order to reset the internal Table 8

protection. Applications B Volts Time

Note: The voltage must be adjusted after the Voltage build up 12 (1A) 1 - 2 seconds
maximum excitation current has been set. De-energized parallel
12 (1A) 1 -2 seconds
operation
Standby parallel
24 (2A) 5 - 10 seconds
operation
Battery starting 48 (4A) 5 - 10 seconds
Voltage that is sustained
48 (4A) 5 - 10 seconds
at overload
80 SEBU7919-03
Operation Section
Engine Starting

Engine Starting • Reset all of the shutoffs or alarm components.

• Ensure that any driven equipment has been

i04522810 disengaged. Minimize electrical loads or remove
any electrical loads.
Before Starting Engine
SMCS Code: 1000; 1400; 1450

A WARNING
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.

Perform the required daily maintenance and other

periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, "Maintenance
Interval Schedule" for more information.

• Before you start the engine, refer to this

Operation and Maintenance Manual, "Walk-Around
Inspection" .

• Before you start the engine, refer to this Operation

and Maintenance Manual, "Engine Oil Level -
Check" for the procedure to ensure that the oil
supply is adequate.

• Ensure that the engine has an adequate fuel

supply.

• Open the fuel supply valve (if equipped).

NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.

If the engine has not been started for several weeks,

fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when fuel
filters have been changed, some air pockets will be
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Manual, "Fuel System - Prime" for more information
on priming the fuel system.

• Do not start the engine if there is a "DO NOT

OPERATE" warning tag or similar warning tag
attached to the start switch.

• Do not move any of the controls if there is a "DO

NOT OPERATE" warning tag or similar warning
tag attached to the controls.
SEBU7919-03 81
Operation Section
Engine Starting

i02673771

Starting the Engine

(Protection and Paralleling
Unit (PPU) Control Panel
and Marine Certification
Society (MCS) Control Panel (if
equipped))
SMCS Code: 1000; 1450

Illustration 66 g01166261

PPU Control Panel

(1) Engine Shutdown Override Switch (2) Emergency Stop Push Button (4) Protection and Paralleling Unit (PPU)
(located inside electrical box) (3) Horn
82 SEBU7919-03
Operation Section
Engine Starting

Engine Shutdown Override Switc h (1) -This

should be switched to the NORMAL position for
normal use. Placing the switch in the OVERRIDE
position will enable the engine to continue to run
even when a shutdown signal is received .

Emergency Stop Push Button (2) -The emergency

stop push button (ESPB) is used to shut down the
engine during an emergency situation .

Horn (3) -The horn activates when a fault (alarm or

shutdown signal) is received by the controller and the
fault is indicated with text on the controller display.
Move the cursor to "ACK". Press the "SEL" key in
order to acknowledge the alarm and silence the horn.

Protection and Paralleling Unit (PPU) (4) - The

module controls the functions of the generator set.

A
•.
m tel ~ ~-·
f(f)

~O)ff®
( ~ I I ~'¥ I
~ • ® 0
&jO-v 0 ~(!I)~ ~
4

~3

Illustration 67 g01340855

MCS Control panel

(1) Engine shutdown override switch (2) Emergency stop push button (4) Alarm/Display module
(located inside control box) (3) Engine shutdown module

Emergency Stop Push Button (2) -The emergency Display (4) - The display module controls the
stop push button (ESPB) is used to shut down the functions of the generator set.
engine during an emergency situation .
SEBU7919-03 83
Operation Section
Engine Starting

Alarm module (3) - The alarm module controls the

alarm functions of the generator set.

~3

g01339114
Illustration 68
Location label inside the MCS cover
(1) Speed switch (5) Engine shutdown override switch (9) Receptacle connector for DC voltage
(2) Capacitor (6) Latching relay (10) Audible alarm connector
(3) Controller (7) R2 DPCO Relay (11) Receptacle connector for AC voltage
(4) Terminal blocks (8) R2 DPCO Relay
84 SEBU7919-03
Operation Section
Engine Starting

Power a
Alam•
0
0 Regulator ~ check ok o
Alarm

[8 Tacho 1SOO rpm 181 ~ ~arm lnh.o

v B
Oil P SO psi
Cool. Temp. 131F
SETUP
3.4bar

V3
sse
V2 V1
<Be&
Bl<;p
~

5~ ~.. <e> 1.1

8
Run On
0 0 0
load
BAC j

® I
6~~1
~ ------~\--------~
. I 7

Illustration 69 g01166410

PPU display module

(5) Start key (7) Mode key
(6) Stop/reset key (8) Circuit breaker button
SEBU7919-03
[}
@
@ 0
rv Q
2
Illustration 70
MCS display module
(1) Start Key (2) Stop Key
Local Operation
Use the following procedure in order to start the
engine.
1. Turn the power supply for the Generator Set to
the ON position .
The "Power" LED will illuminate immediately. The
"Self check ok" LED will illuminate after a few
seconds. The Generator Set is now ready to start.
Line 4 on the display will read "SETUP V3 V2 V1".
The view that is being displayed is underlined. Use
the left arrow button and the right arrow button to
scroll between the 4 screens of the display.
2. Make sure that the "Auto" LED is off. If the "Auto"
LED is on press the "Mode" key once in order to
extinguish the "Auto" LED and gain local control.
3. Press the "Start" key.
If "V3" is selected, the display will indicate the
current status in the start/run cycle. The display
will show "start prepare" and "start relay on".
85
Operation Section
Engine Starting
3
g01336747
(3) Mode Key
a. If the timer (preheat) is configured, then the
timer (preheat) will be initiated. After the timer
(preheat) has expired, the engine will begin to
crank.
Note: When the engine starts, the starting motor is
disengaged and the starting motor is locked out.
b. If the engine did not start, then the control
module will permit the starting motor to cool
down for a predetermined amount of time.
Once the cooldown timer has expired, the
engine will crank.
Note: The "Failed to Start" fault will be displayed in
"V3" after 3 failed attempts to start the engine. The
"Alarm" LED indicator will flash . If this occurs, move
the cursor to "ACK" and press the "SEL" key in order
to reset the alarm. Determine the reason that the
engine failed to start before making further attempts.
c. After the engine has started, the timer (safety)
is activated, unless the timer has been set to 0.
This function allows the engine to warm up so
that no faults will occur. Once the timer (safety)
has expired, fault protection is available. The
generator load may now be applied to the
engine.
86 SEBU7919-03
Operation Section
Engine Starting

4. To stop the engine, open the circuit breaker and
remove the load from the generator. Press and
release the "STOP" key.
Note: Pressing the "Stop" key will bypass the
cooldown period.
c. After the engine has started, the timer (safety)
is activated.
This function allows the engine to warm up so
that no faults will occur. Once the timer (safety)
has expired, fault protection is available.

d. The PPU will automatically apply the generator

Remote Operation
Use the following procedure in order to start the
engine.
1. Turn the power supply for the Generator Set to
the ON position.
The "Power'' LED will illuminate. The "Self check
ok" LED will illuminate after a few seconds. The
generator set is now ready to start.
load. The PPU will synchronize the generator
with other generators that are operating in
parallel. The PPU will bring the generator on
the line after the generator is synchronized.
4. To stop the engine, open the circuit breaker and
remove the load from the generator.
Engine Shutdown Override Switch

Line 4 on the display will show "SETUP V3 V2 V1".

The view that is displayed is underlined. Use the

left arrow button and the right arrow button in order
to scroll between the 4 screens of the display.

2. Ensure that the "Remote" LED is on.

If the "Remote" LED is off, press the "Mode" key

once and illuminate the "Remote" LED in order to
gain the remote control of the genset.

3. Initiate a remote start on the customer connection.

This would be done with a remote mounted switch
on the vessel.

Note: If "V3" is selected, the display will indicate the

current status in the start/run cycle. The display will
read "start prepare" and "start relay on".
g0116682B
Illustration 71
a. If the timer (preheat) is configured, the timer
(preheat) will be initiated. PPU
(1) Engine shutdown override switch (located inside control box)
After the timer (preheat) has stopped timing, (2) Latch for cover on the electrical box
the engine will begin cranking.

Note: When the engine starts, the starting motor is

disengaged and the starting motor is locked out.

b. If the engine did not start, then the control

module will permit the starting motor to cool
down for a predetermined amount of time.
Once the cooldown timer has expired, the
engine will crank.

Note: The "Failed to Start" fault will be displayed in

"V3" after 3 failed attempts to start the engine. The
"Alarm" LED indicator will flash. If this occurs, move
the cursor to "ACK" and press the "SEL" key in order
to acknowledge the alarm. Determine the reason
that the engine failed to start before making further
attempts.
SEBU7919-03 87
Operation Section
Engine Starting

Illustration 72 g01341074

MCS
(1) Engine shutdown override switch (located inside control box)
(2) Latch for cover on the control box

A WARNING
Personal injury or death can result from high volt-
age.

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.

The engine shutdown override switch is located in

the electrical box for the controller. The automatic
shutdown system may be disabled if the unit is used
in emergency situations. When the generator set is in
this mode any fault will give an indication but the fault
will not stop the engine.

Turn the latch for the cover on the electrical box

in order to open the electrical box and access the
override switch.

Enable the shutdown on the MCS controller by

turning the switch to A. Disable the shutdown by
turning the switch to B.
88 SEBU7919-03
Operation Section
Engine Operation

Engine Operation
i04521149

Engine Operation
SMCS Code: 1000

Proper operation and maintenance are key factors

in obtaining the maximum life and economy of
the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.

The time that is needed for the engine to reach

normal operating temperature can be less than the
time taken for a walk-around inspection.

The engine can be operated at the rated rpm after

the engine is started and after the engine reaches
operating temperature. The engine will reach normal
operating temperature sooner during a low engine
speed (rpm) and during a low-power demand. This
procedure is more effective than idling the engine
at no load. The engine should reach operating
temperature in a few minutes.

Gauge readings should be observed and the data

should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated .
SEBU7919-03 89
Operation Section
Engine Operation

Cooling System

Illustration 73 g01232494

(1) Header tank assembly (remote mounted) (4) Adaptor (7) Hose
(2) Hose (PVC) (5) Hose end-push in (8) Hose clip
(3) Plug (6) Hose (9) -T- Fitting
90 SEBU7919-03
Operation Section
Engine Operation

g01232466
Illustration 74

g01232463
Illustration 75

Keel-Cooled Engine with an

Aftercooler
Note: The cooling system for the generator set is a
keel-cooled system which uses engine coolant.
SEBU7919-03 91
Operation Section
Engine Operation

g01230513
Illustration 76
Turbocharged
(1) Aflercooler (5) Exhaust manifold (9) Fresh water pump
(2) Purge line (6) Engine (10) Auxiliary water pump
(3) Purge line (7) Water temperature regulator housing ( 11) Keel cooler
(4) Remote tank (8) Engine oil cooler (12) Keel cooler for aflercooler

During engine operation, water pump (9) draws
engine coolant from keel cooler (11 ). The water pump
creates coolant flow through the system. The water
pump is installed on the front of the timing case. The
water pump is gear-driven by the fuel injection pump
gear.
Water pump (9) forces the coolant through a passage
in the front of the timing case to the water jacket in
the top left side of the cylinder block. One-third of
the coolant flows around the element of oil cooler (8)
to the rear of the cylinder block. Two-thirds of the
coolant is used in order to cool the cylinder block.
The coolant continues to the rear of the cylinder block
and the coolant is diverted to the following locations:

• Exhaust manifold (5)

• Cylinder head
92 SEBU7919-03
Operation Section
Engine Operation

The coolant flows forward through the cylinder head
and into water temperature regulator housing (7). If
the water temperature regulator is closed, the coolant
goes directly through a bypass to the inlet side of
water pump (9). If the water temperature regulator
is open, the bypass is closed and the coolant flows
to keel cooler (11) in order to be cooled. After the
coolant flows through the keel cooler, the coolant
is mixed with coolant that is returning from exhaust
manifold (5).
• Be aware of the properties of the different fuels.
Use only the recommended fuels .
• Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of
time.
• Observe the service indicator frequently. Keep the
air cleaner elements clean.

An auxiliary water pump (10) is also used in order to
supply coolant flow to aftercooler ( 1). The coolant
flows through the aftercooler in order to cool the hot
inlet air. From the aftercooler, the coolant flows to a
second keel cooler (12) in order to be cooled.
i02707215
Engine Warm-up
• Ensure that the turbochargers are operating
correctly so that the proper air/fuel ratio is
maintained. Clean exhaust indicates proper
functioning.
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator.
This will consume excess power and excess fuel.

SMCS Code: 1000
1. Run the engine at low idle for three to five minutes,
or run the engine at low idle until the jacket water
coolant temperature starts to rise.
• Ensure that the belts are properly adjusted. The
belt should be in good condition.
• Ensure that all of the connections of the hoses are
tight. The connections should not leak.

More time may be necessary when the • Keep keel coolers, heat exchangers, and water
temperature is below -18°C (0°F). pumps clean . Keep the components in good repair.

2. Check all of the gauges during the warm-up • Ensure that all of the accessory pumps are
period . repaired. The pumps should operate efficiently.

3. Perform a walk-around inspection . Check the
engine for fluid leaks and air leaks.
4. Increase the rpm to the rated rpm. Check for
fluid leaks and air leaks. The engine may be
operated at full rated rpm and at full load when
the temperature of the water jacket reaches 60°C
(140°F).
i02305196
• Do not exceed the maximum oil level.
• Never operate without water temperature
regulators.
Water temperature regulators regulate the
temperature of the coolant. Water temperature
regulators help to provide efficient operating
temperatures. Cold engines consume excessive
fuel. Water temperature regulators also help prevent
engine overheating .

Fuel Conservation Practices

SMCS Code: 1000; 1250

The efficiency of the engine can affect the fuel

economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life
of the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel

may overflow from the fuel tank. Inspect fuel lines for
leaks. The fuel lines should be repaired if there is
evidence of failure.
SEBU7919-03 93
Operation Section
Engine Stopping

Engine Stopping
i02673744

Stopping the Engine

(Protection and Parallelling
Unit (PPU) Control Panel
and Marine Certification
Society (MCS) Control Panel (if
equipped))
SMCS Code: 1000; 7000

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.

If the engine has been operating at high rpm and/or

high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine.

Avoiding hot engine shutdowns will maximize tur-

bocharger shaft and bearing life.
94 SEBU7919-03
Operation Section
Engine Stopping

1 3

CD

,_,0
"""'
0

8""""' Tacho 1500 rprn

181
0 ........ ~~""" 0
(j. .._ .. , 0

<8®~
Oil P 50 psi 3.4bar
Cool. Temp. 131F 55C
B SETUP V3 V2
~w
8 '; ..
(B"o-~
0 0
4
B ~

g01166281
Illustration 77
Protection and Parallelling Unit (PPU) Control Panel
(1) Engine shutdown override switch (3) Horn
(2) Emergency stop push button (4) Protection and Paralleling Unit (PPU)

Engine Shutdown Override Switch (1) - This
should be switched to the NORMAL position for
normal use. Placing the switch in the OVERRIDE
position will enable the engine to continue to run
even when a shutdown signal is received .
Horn (3) -The horn activates when a fault (alarm or
shutdown signal) is received by the controller and the
fault is indicated with text on the controller display.
Move the cursor to "ACK" and press the "SEL" key in
order to reset the alarm.

Emergency Stop Push Button (2) - The PPU (4) - The PPU controls the functions of the
emergency stop push button (ESPB) is used to shut generator set.
down the engine during an emergency situation. The
ESPB shuts off the fuel.
SEBU7919-03 95
Operation Section
Engine Stopping

Alarm
Power o
0
Alarm
13
0 Regula lor ~~ check ok 0

6.
~
Alarm lnh.o
Tacho 1500 rpm
'A OiiP 50 psi 3.4bar
.cw ~a& A
B
Cool. Temp. 131 F
SETUP
55C
V3 V2 V1
Bl w y

5~
8
Run On

~
0 0 0
Load

8
I \I I I ®~
Remote
0
STOP

~ ''\
6
I
""
""'
7

Illustration 78 g01166439

Close up of the PPU

(5) Start key (6) Stop/Reset key (7) Mode key
96 SEBU7919-03
Operation Section
Engine Stopping

ll
cJ) #cJ)

m ~ 6)"''1>
~IDfj~
( ~ I I ~<:9 I
~ 0
~18~ ~
@l cJ)

~0-v 0
4

1 @)

:I.
I PEJr!J~ I
2
3

Illustration 79
MCS control panel
(1) Engine shutdown override switch
(2) Emergency stop push button
g01340855
(3) Engine shutdown module
(4) Alarm/Display module
SEBU7919-03 97
Operation Section
Engine Stopping

.0.
@

0
5 0
6

7
g01342849
Illustration 80
MCS control module
(5) Start key (6) Stop key (7) Mode key

Manual Operation
1. Open the circuit breaker and remove the load from
the generator.
2. Allow the engine to operate at low idle for at least
3 minutes so the engine can cool down.
Note: Pressing the stop key bypasses the
cooldown period.
3. Press and release the "Stop" key(6).
2. Once the operator opens the circuit breaker, the
PPU will automatically go into the cooldown mode.
3. The cool down timer will start. This will allow the
engine to cool down properly. The LCD display will
indicate "COOL DOWN".
4. The LCD display will indicate "STOPPING".
Note: If the engine fails to stop running, the LCD
display will indicate "STOP FAILURE". The alarm
will sound.

4. The LCD display will indicate "STOPPING". 5. Once the engine has stopped, the LCD display
will indicate "STOPPED".
Note: If the engine fails to stop running, the LCD
display will indicate "STOP FAILURE". The alarm
will sound.

5. Once the engine has stopped, the LCD display

will indicate "STOPPED".

Remote Operation
1. Open the circuit breaker and remove the load from
the generator.
98 SEBU7919-03
Operation Section
Engine Stopping

i0449B616

Emergency Stopping
SMCS Code: 1000; 7418

D EMERGENCY
~ STOP

g00104303
Illustration 81
Typical emergency stop button

The emergency stop switch is in the OUT position for

normal engine operation. For an emergency stop,
push the emergency stop switch. This action shuts
off the fuel to the engine. This action also activates
the air shutoff.

Tum the switch to the OFF/RESET position to reset

the engine control switch.

Turn the "EMERGENCY STOP" switch clockwise to

reset the switch. The spring-loaded switch will return
to the OUT position. The switch may also be pulled
to the OUT position.

Do not start the engine until the problem causing

the emergency stop has been located and
corrected.

Operation of the Air Shutoff

The air shutoff uses a plate that rotates on a shaft
to shut off inlet air. The air shutoff only actuates for
the following conditions:

• The "EMERGENCY STOP" switch is pressed

• An overspeed shutdown occurs

The air shutoff must be reset before the engine can

be restarted.
SEBU7919-03 99
Operation Section
Cold Weather Operation

Cold Weather Operation When No. 2 diesel fuel is used the following
components provide a means of minimizing problems
in cold weather:
i02237624
• Starting aids
Fuel and the Effect from Cold
Weather • Engine oil pan heaters

SMCS Code: 1000; 1250 • Engine coolant heaters

The following fuels are the grades that are available • Fuel heaters
for Caterpillar engines:
• Fuel line insulation
• No. 1
For more information on cold weather operation,
• No. 2 see Special Publication, SEBU5898, "Cold Weather
Recommendations".
• Blend of No. 1 and No. 2

No.2 diesel fuel is the most commonly used fuel.

Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold weather operation.

Quantities of No. 1 diesel fuel are limited. No. 1 diesel

fuels are usually available during the months of the
winter in the colder climates. During cold weather
operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary.

There are three major differences between No. 1 and

No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:

• Lower cloud point

• Lower pour point

• Lower rating of kJ (BTU) per unit volume of fuel

When No. 1 diesel fuel is used, a decrease in power

and in fuel efficiency may be noticed . Other operating
effects should not be experienced.

The cloud point is the temperature when a cloud of

wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is
the temperature when diesel fuel will thicken. The
diesel fuel becomes more resistant to flow through
fUel pumps and through fuel lines.

Be aware of these values when diesel fuel is

purchased . Anticipate the average ambient
temperature of the area. Engines that are fueled in
one climate may not operate well if the engines are
moved to another climate. Problems can result due
to changes in temperature.

Before troubleshooting for low power or for poor

performance in the winter, check the type of fuel that
is being used.
100 SEBU7919-03
Operation Section
Generator Operation

Generator Operation
i02290569

Generator Operation
SMCS Code: 4450

Loading of the Generator

When a generator is installed or reconnected, be D
w
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 u...
0
at the rated capacity. An electrical unbalance can
1-
result in an electrical overload and overheating if one z
phase current exceeds the nameplate amperage.

Allowable combinations of unbalanced loads are

z
shown in Illustration 82. When you operate with H

significant single-phase loads, the combinations of D

single-phase load and three-phase load may be ~ 20
-'
used. Such combinations should be located below
w
the line on the graph . (/)
<(
I
CL
I
w
~ 0 80
I
1-
SINGLE-PHASE LOAD AS A PERCENT OF
THREE-PHASE KV-A RATING

g00627416
Illustration 82
Allowable Combinations of Unbalanced Loads

Block Loading
The block loading is the instantaneous application of
an electrical load to a generator set. This load may be
anywhere from a moderate percentage of the rated
load up to the rated load.

The block loading capability of a generator set

depends on the following factors.

• Engine transient response

• Voltage regulator response

• Type of the voltage regulator

• Altitude of operation of the generator set

• Type of load

• The amount of load

SEBU7919-03
If derating is required in order to block load, refer to
ISO 3046 or SAE J1349 Standards. Also, reference
Engine Data Sheet, LEKX4066, "Loading Transient
Response" and Engine Data Sheet, LEKX4067,
"Block and Transient Response".
Note: ISO stands for International Standards
Organization .
Power Factor
The power factor is the ratio of apparent power to
total power. The power factor is expressed as a
decimal. The power factor represents that portion of
the current which is doing useful work. The portion of
current which is not doing useful work is absorbed
in maintaining the magnetic field in motors or other
devices. This current is called the reactive load.
This current does not require engine power to be
maintained .
In most applications, electric motors and transformers
determine the power factor of the system. Induction
motors usually have a power factor of 0.8 or less.
Incandescent lighting is a resistive load of about 1.0
power factor, or unity.
The power factor of a system may be determined by
a power factor meter or by calculations. Determine
the power requirement in kW by multiplying the power
factor by the kVA that is supplied to the system. As
the power factor goes up, the total current that is
supplied to a constant power demand will go down. A
100 kW load that is at 0.8 power factor will draw more
current than a 100 kW load that is at 0. 9 power factor.
A high power factor will result in a full engine load
at less than the generator rated amperage. A lower
power factor increases the possibility of overloading
the generator.
Note: The Caterpillar generators are rated at a
power factor of 0.8 unless the generator is specified
otherwise.
Excitation System
The generator uses the AREP excitation system.
This system does not use a permanent magnet.
The voltage regulator is powered by two auxiliary
windings. These windings are independent of the
circuit for detecting voltage. The first winding is
labelled as "X1" and "X2". This winding has a
voltage that is proportional to the output voltage of
the generator. The second winding is labelled as
"Z1" and "Z2". This winding has a voltage that is
proportional to the current of the stator. The voltage
from the power supply is rectified and filtered before
being used by the regulator monitoring transistor.
This principle ensures that regulation is not affected
by interference that is generated by the load.
101
Operation Section
Generator Operation
Standby Electric Sets
Most standby units are installed with controls for
automatic starting. Standby units start without an
operator in attendance.
Standby units can not automatically change the
governor speed. Standby units can not automatically
change the setting of the voltage level. The governor
speed and voltage level must be preset for the
proper operation of that unit. Whenever the generator
is operated manually, ensure that the settings for
governor speed and voltage level are correct for
automatic operation. Check all switches on the
Standard Control Panel for the proper setting. Check
all push buttons on the Premium Control Panel for the
proper setting. On the Standard Control Panel, the
Start Selector Switch should be in the AUTOMATIC
position. On the Premium Control Panel, the "AUTO"
push button is pressed.
Generator Options
Battery Disconnect Switch
This switch is a single-pole switch. This switch cannot
be used with dual electric starters.
Space Heaters
The generator can be equipped with space heaters.
The space heater is installed for operation in high
humidity conditions. 120 volt and 240 volt space
heaters are available.
Radio Frequency Interference (RFI) Filter
This filter is available for applications that require a
filter.
lnstru mentation
Three different remote starVstop panels are available.
Extensions for the wiring harness are available in
order to mount the panels. Contact your Caterpillar
dealer for more information.
i02292263
Single Unit Operation
SMCS Code: 4450
Initial Start-Up
Measure the insulation resistance of each winding
if the generator was exposed to the following
conditions:
102
Operation Section
Generator Operation
• Rapid changes in temperature
• Freezing
• Wet climate during shipment
• Wet climate during storage
Refer to this Operation and Maintenance Manual,
"Insulation - Test".
Note: These tests should be conducted prior to any
power connections or control connections that are
being made.
Starting
1. Make all preliminary engine starting checks.
2. Be sure that the main circuit breaker or the line
circuit breaker is open .
3. Start the engine. 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.
Adjust the Voltage
Adjust the voltage regulator in order to obtain
the proper voltage. Refer to Operation and
Maintenance Manual, "Voltage Regulators" for
more information about the voltage regulator.
1. Turn the remote adjustment potentiometer to the
center position, if equipped .
2. Connect an analog voltmeter that is calibrated for
100 VDC on terminal E+ and terminal E-.
3. Connect a voltmeter that is calibrated for 300 VAC
to 500 VAC or 1000 VAC to the output terminals of
the generator.
4. Make sure that the ST3 wire is positioned on the
desired frequency. Also, the engine speed must
be changed from the factory setting in order to
change the frequency of the generator.
5. Turn voltage potentiometer (P2) to a full
counterclockwise position.
6. Turn frequency potentiometer (P4) to a full
clockwise position.
SEBU7919-03
7. Turn stability potentiometer (P3) counterclockwise
to about 1/3 of the total rotation for the
potentiometer.
8. Start the engine and set the engine speed to a
frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz.
9. Adjust the output voltage to the correct value
with potentiometer P2. This voltage should be
the rated voltage UN for single operation or
UN plus 2% to 4% for parallel operation with
a current transformer. Use potentiometer P3
to make adjustments if the voltage oscillates.
Adjust potentiometer P3 in both directions while
you observe the voltage between E+ and E-.
The voltage between E+ and E- should be
approximately 10 VDC. The best response times
are obtained at the limit of the instability. Try
cutting or replacing the wire ST2 if no stable
position can be obtained .
10. Check the LAM operation. ST5 must be closed.
11. Turn potentiometer (P4) slowly counterclockwise
until there is a significant voltage drop. The voltage
drop should be approximately 15 %.
12. Vary the frequency around 48 Hz or 58 Hz
according to the operating frequency. Check
the change in the voltage that was previously
observed.
Stopping
1. Remove the load in increments.
2. Open the circuit breaker.
3. Allow the engine to run for five minutes in order
to cool.
4. Stop the engine.
i026El8538
Parallel Operation
SMCS Code: 4450; 4480
Initial Start-Up
Preparing a generator for parallel operation requires
special attention. Before you attempt to parallel units
for the first time, check all the units for the following
three conditions.
• Same phase rotation
• Same alternating current frequency
SEBU7919-03
• Same voltage adjustment
1. Check the phase rotation.
Units that operate in parallel must have the same
phase rotation. There are two methods that may
be used in order to determine if the incoming unit
and the unit that is on-line have the same phase
rotation. These methods are listed below:
• Using a phase rotation meter
• Using a set of three light bulbs
Use the procedure below to determine the proper
phase rotation by using three light bulbs.
-7~~------------~r-~------2
-7~~~----------~r-7-~---- 3
SYNCHRONIZING
LAMPS - -
FUSED KNIFE
SWITCH OR CIRCUIT 1
REAKER-OPEN
g00695380
Illustration 83
A WARNING
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.
Remove all fuses.
a. Connect the light bulbs with rated voltage
between the generator leads and the
corresponding line phase. For example,
connect terminal 1 to line 1 across the open
circuit breaker.
b. Start the units that will be in operating in
parallel. Bring the units up to speed. As the
units approach the same speed, the lights will
start to blink.
103
Operation Section
Generator Operation
• If the lights blink in sequence, one of the
units is connected backward. In order to
correct the problem, stop the units. Remove
generator leads 1 and 3 at the circuit
breaker. Exchange these generator leads.
This reverses the direction of phase rotation.
Terminal 2 should always be connected to
line 2. Go to 5.
• Both generators have the same phase
rotation when the lights blink in unison. The
first condition of "Initial Start-Up" has been
met.
2. Adjust the frequency.
The units that will be operating in parallel must
operate at the same speed. 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 the
rated frequency at full load.
c. Remove the load and check the high idle
speed. The high idle speed should be
approximately 2 to 5 percent above full load
speed for 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.The potentiometers should
be at the initial settings. Refer to Operation and
Maintenance Manual, "Voltage Regulators".
Note: Make sure that the speed droop is identical for
all of the engines before adjustments are made to
the generator.
a. Preset the unit for parallel operation by
connecting the current transformer to S1 and
S2 of the connector J2. Set potentiometer P1
for quadrature droop in the center position .
Apply the rated load. The voltage should drop
for 2% to 3%. Switch the positions of the
two incoming secondary wires of the current
transformer if the voltage increases.
104
Operation Section
Generator Operation
b. The no-load voltages should be identical for all
the generators that are operating in parallel.
Connect the generators in parallel. Try to obtain
a 0 kW power exchan~e by ad justin~ the speed
of the generator. Try to minimize the circulating
currents between generators by altering the
voltage setting with potentiometer P2 or Rhe
on one of the generators.
Note: Do not change the voltage settings after
this step.
c. Apply the available load. The setting is correct
only if a reactive load is available. Equalize the
Kilowatts or divide the rated power of the units
proportionally by altering the speed. Alter the
quadrature droop potentiometer (P1) in order
to equalize the currents or divide the currents.
Starting Multiple Units
Use the procedure for starting single units in order
to start multiple units. Refer to Operation Section,
"Single Unit Operation" .
Paralleling Multiple Units
Units may be paralleled at no load . Units may also
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. Afler the engine has run a few minutes, bring the
en~ine up to synchronous speed. This means
that the frequency of the incoming unit will be the
same frequency as 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 some of the load instead
of adding to the system load.
4. By using the governor control, adjust the engine
speed until the lights blink very slowly.
5. The lights are off when the voltages of the two
units are in-phase. At this point, very quickly close
the breaker while the lights are out.
SEBU7919-03
6. Use governor controls in order to share kW load
between engines.
7. Generator temperature will be stabilized in
approximately one hour. After the generator
temperature has been stabilized, adjust the
voltage droop rheostat of each generator. This
will share the reactive load and this will 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 the
droop. Adjusting the voltage droop rheostat in a
clockwise direction will increase droop.
Load Division and Speed Droop (If
Equipped)
Once two units have been paralleled, the unit's
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 to
another engine, use 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 the governor speed control or lower the
governor speed control of both units in order to
change system frequency.
Parallel Operation Of Governors
0
Illustration 84
g00630841
Load Sharing Module (Typical Example)
SEBU7919-03
The generator set load sharing module provides
either the droop load sharing or the isochronous load
sharing for parallel applications. The load sharing
module has a synchronizing parallel module SPM-A
input. The module provides the proportional load
sharing. 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.
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
and to the load is a function of the engine. The
setting of the engine governor and the position
of the engine governor control determine the
amount of power that is delivered by the engine.
Therefore, the governor setting and the position
of the governor control determine the kW load
which is carried by the generator. A change in the
engine power of any one of the units in a parallel
operation will result in the same change in engine
power for each of the other units in that parallel
operation. In other words, the units that are in
parallel operation will stay in parallel operation .
2. The division of power is not determined by
generator excitation or terminal voltage. The
excitation will determine the power factor for a
generator when the generator is operating in
parallel with other generators.
Governors that are used with Caterpillar powered
electric sets can be of two types:
• Governors with fixed speed droop
• 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 the
characteristics match closely with the characteristics
of governors with fixed speed droop. If the governor
is adjusted for 0 percent speed droop or isochronous
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:
105
Operation Section
Generator Operation
• Each governor should have a three percent speed
droop in order to provide the simplest combination
of governors for electric sets that are connected in
parallel. 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. Governor controls should be set to
the high idle position so that the full range of the
governor is available.
• Operating an isochronous governor in parallel
with a speed droop governor 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 automatic load sharing.
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. See
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
in parallel operation. The circulating currents
are caused by voltage differences between the
generators. The circulating currents are not doing
useful work. The amount of the circulating current can
be determined by subtracting the amperage which is
going to the load from the total generator amperage.
106 SEBU7919-03
Operation Section
Generator Operation

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.
SEBU7919-03 107
Maintenance Section
Refill Capacities

Maintenance Sect ion Table 10

Engine Oil Viscosity
Caterpillar DEO Ambient Temperature
Refill Capacities Multigrade
API CH-4
API CG-4 Minimum Maximum
i02668575 Viscosity Grade

Refill Capacities and SAE OW-20 -40 oc (-4o °F) 10 oc (50 °F)
SAE OW-30 -4o oc (-40 °F) 30 oc (86 °F)
Recommendations
SAE OW-40 -40 oc (-40 °F) 40 oc (104 °F)
SMCS Code: 1348; 1395; 7560 -3o oc (-22 °F) 30 oc (86 °F)
SAE 5W-30
SAE 5W-40 -30 oc (-22 °F) 5o oc (104 °F)
Lubrication System
SAE 10W-30 -18 oc (O °F) 40 oc (104 OF)
Lubrication Capacities SAE 15W-40 -9.5 oc (15 °F) 5o oc (122 °F)

The refill capacities for the engine crankcase reflect

the approximate capacity of the crankcase or sump For additional information on selecting an
plus standard oil filters. Auxiliary oil filter systems will oil, refer to Special Publication, SEBU6251,
require additional oil. Refer to the OEM specifications "Caterpillar Commercial Diesel Engine Fluids
for the capacity of the auxiliary oil filter. Recommendations".

Table 9 Fuel
C4.4 Marine Generator Set Engine
Approximate Refill Capacity of the Fuel Recommendations
Lubrication System
Compartment or System Liters Quarts Diesel engines have the ability to burn a wide variety
of fuels. These fuels are divided into two general
Standard Sump(1) 8.0 8.5 groups. The two groups are called the preferred fuels
(1) These values are the approximate capacities for the crankcase and the permissible fuels.
oil sump which include the standard factory installed oil filters .
Engines with auxiliary oil filters will require additional oil. Refer
The preferred fuels provide maximum engine service
to the OEM specifications for the capacity of the auxiliary oil
filter. life and performance. The preferred fuels are distillate
fuels. These fuels are commonly called diesel fuel,
furnace fuel, gas oil, or kerosene.
Lubricant Viscosity Recommendations
for Direct Injection (01) Diesel Engines The permissible fuels are crude oils or blended fuels.
Use of these fuels can result in higher maintenance
The proper SAE viscosity grade of oil is determined costs and in reduced engine service life.
by the minimum ambient temperature during
cold engine start-up, and the maximum ambient In North America, diesel fuel that is identified as No.
temperature during engine operation. 1-D or No. 2-D in "ASTM 0975" generally meet the
specifications. Diesel fuels from other sources could
Refer to Table 10 (minimum temperature) in order exhibit detrimental properties that are not defined or
to determine the required oil viscosity for starting a controlled by this specification.
cold engine.
Refer to Special Publication, SEBU6251, "Caterpillar
Refer to Table 10 (maximum temperature) in order Commercial Diesel Engine Fluids Recommendations"
to select the oil viscosity for engine operation at the for additional information that relates to diesel fuel.
highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is

available to meet the requirement for the temperature
at start-up.
108 SEBU7919-03
Maintenance Section
Refill Capacities

Cooling System Note: Caterpillar DEAC DOES NOT require a

treatment with an SCA at the initial fill. Commercial
Coolant Capacities heavy-duty antifreeze/coolant that meets "ASTM
D4985" or "ASTM D5345" specifications MAY require
To maintain the cooling system, the Total Cooling a treatment with an SCA at the initial fill. Read the
System capacity must be known . The approximate label or the instructions that are provided by the OEM
capacity for the engine cooling system is listed. of the product.
External System capacities will vary among
Table 12
applications. Refer to the OEM specifications for the
External System capacity. This capacity information Caterpillar Minimum Acceptable Water Requirements
will be needed in order to determine the amount Maximum Limit ASTM Test
Property
of coolanUantifreeze that is required for the Total
Cooling System. 40 mg/L "D512",
Chloride (CI)
(2.4 grains/US gal) "D4327"
Table 11
100 mg/L
Sulfate (S04) "D516"
C4.4 Marine Generator Set Engine (5.9 grains/US gal)
Approximate Refill Capacity of the Cooling System
170 mg/L
Total Hardness "D1126"
Compartment or System Liters Quarts (10 grains/US gal)
Engine Only 13 13.7 340 mg/L
Total Solids "D1888"
(20 grain/US gal)
External System(1) 18 19
Acidity pH of 5.5 to 9.0 "D1293"
Total Cooling System(2l
(1) The External System includes an expansion tank with the
following components: heat exchanger, aftercooler, piping, and Note: A mixture of SCA and water is not
keel cooling system. recommended for use in the cooling system of the
(2) Add the capacity for the Engine Only to the capacity for the C4.4 marine auxiliary generator. The use of SCA
External System. Enter the total in this row. and water in the cooling system could result in
damage to the aluminum components.
Coolant Recommendations
Refer to Special Publication, SEBU6251, "Caterpillar
NOTICE Commercial Diesel Engine Fluids Recommendations"
Do not use a commercial coolanUantifreeze that only for additional information that relates coolant.
meets the ASTM "D3306" specification . This type of
coolanUantifreeze is made for light duty automotive Note: The service life of coolant is limited by use
applications. of service hours. Refer to the specific engine's
Operation and Maintenance Manual, "Maintenance
Use only the coolanUantifreeze that is recommended. Interval Schedule" (Maintenance Section). To
achieve this service life, the coolants must be
properly maintained. The maintenance program
The following coolants are the primary types of includes S·O·S coolant analysis.
coolants that are used in Caterpillar Engines:
Table 13
Preferred - Cat ELC (Extended Life Coolant) or Cnnhmt Service Life
a commercial extended life coolant that meets the
Caterpillar EC-1 specification Coolant Type Service Life (1)
Caterpillar ELC Six Years
Acceptable - Cat DEAC (Diesel Engine
Antifreeze/Coolant) or a commercial heavy-duty Caterpillar DEAC Three Years
coolant that meets "ASTM D4985", or "ASTM D621 0" Commercial Heavy-Duty
specifications Coolant/Antifreeze that Two Years
meets "ASTM D5345"
Caterpillar recommends a 1:1 mixture of water and
glycol. This mixture will provide optimum heavy-duty Commercial Heavy-Duty
Coolant/Antifreeze that One Year
performance as a coolanUantifreeze. meets "ASTM D4985"
( 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" (Maintenance
Section).
SEBU7919-03
Maintenance
Recommendations
i01179728
General Maintenance
Information
SMCS Code: 4450; 7000
Note: Read the warnings and read the instructions
that are contained in the Safety Section of this
manual. These warnings and instructions must be
understood before you perform any operation or any
maintenance procedures.
Rotating electric machines are complex structures
that are exposed to the following forms of stress:
• mechanical
• electrical
• thermal
• environmental
These stresses may be of varying magnitudes. The
electrical insulation systems are very susceptible to
damage that is caused by the stresses that are listed
above. Exposure to these stresses may shorten
the effective life of the electrical insulation system.
Therefore, the service life of an electric machine will
largely depend on the serviceability of the electrical
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
the equipment. A regular maintenance program
and a regular inspection program can also reveal
future problems. The frequency of this maintenance
program will depend on the following factors:
• application
• environmental conditions
• operator's experience
• operator's philosophy
A regular maintenance program is strongly
recommended. This program would involve the
following steps:
• periodic disassembly
109
Maintenance Section
Maintenance Recommendations
• knowledgeable visual examination of the
equipment
• the application of electrical tests
Never perform a test over the rated potential. These
tests can damage insulation that is contaminated
or insulation that is in marginal condition. For more
information, refer to "I.E. E. E. Standard 432-1992" or
consult a Caterpillar dealer.
i02909163
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050
Coolant System
A WARNING
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
To relieve the pressure from the coolant system, turn
off the engine. Allow the cooling system pressure cap
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure.
Fuel System
To relieve the pressure from the fuel system, turn off
the engine.
High Pressure Fuel Lines (If Equipped)
A WARNING
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
The high pressure fuel lines are the fuel lines that
are between the high pressure fuel pump and the
high pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
systems.
This is because of the following differences:
• The high pressure fuel lines are constantly charged
with high pressure.
110
Maintenance Section
Maintenance Recommendations
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks:
1. Stop the engine.
2. Wait for ten minutes.
Do not loosen the high pressure fuel lines in order to
remove air pressure from the fuel system.
Engine Oil
To relieve pressure from the lubricating system, turn
off the engine.
i0364279B
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.
Proper welding procedures are necessary in order
to avoid damage to the engine's ECM, sensors,
and associated components. When possible,
remove the component from the unit and then
weld the component. If removal of the component
is not possible, the following procedure must be
followed when you weld on a unit that is equipped
with a Caterpillar Electronic Engine. The following
procedure is considered to be the safest procedure to
weld on a component. This procedure should provide
a minimum risk of damage to electronic components.
SEBU7919-03
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train, the bearings, hy-
draulic components, electrical components, and other
components.
Do not ground the welder across the centerline of the
package. Improper grounding could cause damage to
the bearings, the crankshaft, the rotor shaft, and other
components.
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.
Note: Perform the welding in areas that are free from
explosive hazards.
1. Stop the engine. Turn the switched power to the
OFF position.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
3. Disconnect the J1/P1 and J2/P2 connectors from
the ECM. Move the harness to a position that will
not allow the harness to accidentally move back
and make contact with any of the ECM pins.
SEBU7919-03 111
Maintenance Section
Maintenance Recommendations

g01075639
Illustration 85
Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder

4. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.

Note: If electrical/electronic components are used

as a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.

5. Protect the wiring harness from welding debris

and spatter.

6. Use standard welding practices to weld the

materials.
112 SEBU7919-03
Maintenance Section
Maintenance Recommendations

i03643560

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
r--
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)
SEBU7919-03 113
Maintenance Section
Maintenance Recommendations

(Table 14, contd)

GENERATOR START-UP CHECKLIST

Full Load Generator Excitation Name DC Compare with F1 to F2
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
114 SEBU7919-03
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
Verify kilowatt transducer (if applicable)
MECHANICAL Data Comments
Bearing temperature readings at full load Front Rear
Stator temperature readings at full load AO BO co
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.
SEBU7919-03
i04376727
Maintenance Interval Schedule
SMCS Code: 1000; 7500
Ensure that all safety information, warnings,
and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for the
performance of all maintenance including the
following procedures: all adjustments, the use of
proper lubricants, fluids, filters, and the installation
of new components due to normal wear and aging .
The performance of this product may be diminished if
proper maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed .
Note: Use whichever of the following that occurs
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed .
When Required
Battery - Recycle .. .. .. .... .. ..................................... 118
Battery - Replace ............................ .. ........ .. ......... 118
Battery or Battery Cable - Disconnect .... .. ........... 119
Circuit Breakers- Reset ................ .. .... .. .............. 121
Enclosure -Inspect ........ ........... ...... .... .... ...... ...... 127
Engine - Clean .................................. ... .. ... ...... ... . 127
Fuel System - Prime .. .. ........ .... .. .. .... .. .......... ....... 138
Generator - Dry ... .. .... ..... .. .... .. ........ .. .. . ... ... .......... 143
Generator Set - Test ... .... ... .. .. .. .... ... .. .. .. ... .. ... ..... . 145
Insulation- Test .... .. ........ .............. ........ .......... ..... 150
Rotating Rectifier - Test ... ... ........ ..... ... ............ .... 155
Daily
Belts -Inspect/Adjust/Replace ...... .. .. ............. ..... 120
Cooling System Coolant Level- Check .......... .... 124
Electrical Connections- Check ... .. .. ................ ... . 127
Engine Air Cleaner Service Indicator -Inspect ... 131
Engine Oil Level - Check .. .. .. .. .. ... .... ... .. .. .. ... .. ..... 135
Generator Load- Check ............ .... ................. .. .. 145
Walk-Around Inspection ......... .. .. .... ................ ..... 160
Every Week
Automatic Start/Stop -Inspect .. ........ ............... .... 118
Instrument Panel - Inspect ......... ... .. .. ............... .. . 150
Space Heater - Check .. .. .. .. ... ...... ..... ... ... ... .. ... .. .. 158
Stator Winding Temperature - Measure/Record .. 158
Voltage and Frequency - Check .... ..... .. ... ..... ...... 160
115
Maintenance Section
Maintenance Interval Schedule
Every 250 Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ....... ... .... ............. ...... .................. .. .......... 125
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
Obtain ................................. .............................. 126
Every 500 Service Hours or 1 Year
Engine Air Cleaner Element (Single Element) -
Replace ..................................... ........................ 130
Every 2000 Service Hours or 6 Months
Stator Lead - Check .. .. .. .. ... .. .. .. .. .. ... .. ... .. ... ... .. .. ... 158
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain .. ... ................ ... .. ... ... ................ ... ...... ...... 126
Varistor- Check ....... ..... ............ ........... .. ...... ....... 160
Varistor - Inspect ... .. .. .. .. .. .. ... .. ... .. ... .. .. .. .. .. .. .. .... ... 160
Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .. 123
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC)- Change .. ......... 121
Every 14 200 L (3750 US gal) of Fuel or 500
Service Hours
Battery Charger - Check .............................. ...... .. 119
Every 6900 L (1820 US gal) of Fuel or 500
Service Hours or 1 Year
Auxiliary Water Pump (Rubber Impeller) -
Inspect ....... ..... ................. .. ... ................ ... .. .... ... . 118
Battery Electrolyte Level - Check ............ .......... ... 119
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 127
Engine Crankcase Breather - Clean/Replace .. ... 132
Engine Crankcase Breather- Replace .. .. ... .. .. .. .. 133
Engine Mounts- Inspect .. .. ...... .............. .. ... .. .... .. 135
Engine Oil Sample - Obtain .. .. .... .. .. ... .. .. ... .. .. .. .. .. 136
Engine Oil and Filter - Change .. .. .. .. .. ... ....... .. .. .. . 136
Fuel System Primary Filter (Water Separator)
Element- Replace ............................................ 140
Fuel System Secondary Filter- Replace ... ........ . 141
Fuel Tank Water and Sediment- Drain .... ......... .. 142
Heat Exchanger- Inspect ... ..... ......... .. .... .. .... .... .. 147
Hoses and Clamps -Inspect/Replace .. ......... .. .. . 147
Sea Water Strainer- Clean/Inspect ...... .............. 156
116 SEBU7919-03
Maintenance Section
Maintenance Interval Schedule

Every 13 800 L (3650 US gal) of Fuel or 1000

Service Hours or 1 Year
Engine Valve Lash - Inspect/Adjust ..... .. ............ 138 o

Every 27 600 L (7290 US gal) of Fuel or 2000

Service Hours or 2 Years
Aftercooler Core - Inspect .......................... 117 00 . . . . . . . .

Alternator- Inspect .. .. 117

oo . . . . . oooo . . . . . . . oo . . . . . . . . . . oo . . oooooooo

Cooling System Water Temperature Regulator -

Replace .. 00 . . . . . . 0 ........ 0 0 126
.... .... .. .. .... .. 0 ........ .. 0 . . . . . . . . 00

Generator- Inspect 0000 00 143

... .... ... . . oo . o o 000000 . . . . . . . . . . . . . ooo

Generator Set Vibration - Test/Record ... 146 00 . . . 0 0 . 0 0 00 0

Rotating Rectifier - Check 155

00 . . . . . . . . . . 00 . . . . 00 . . 00 0 0 . 0 0 . . 00 . .

Starting Motor- Inspect .. ....... 158 00 . . . . . . . . . . . . . . . . . . . . . . . . . . o

Turbocharger- Inspect/Clean .... 158 00 . . . . . 00 0000 .. 00000000 00

Water Pump- Inspect 161

oo . . . . . . . . . . . . . . . . . . . . . . . . . oo . . . oo . . . . . . o

Every 165 600 L (43 750 US gal) of Fuel or

12 000 Service Hours
Overhaul Considerations ... 00 . . . . . . . . . . . . . . . . 00 00 . . . . . . 00 00 0 152
SEBU7919-03 117
Maintenance Section
Aftercooler c 'ore - Inspect

i02312068 5. Steam clean the core in order to remove any

Aftercooler Core - Inspect
SMCS Code: 1064-040
The interval for the cleaning of the aftercooler core
depends on the operating environment of the vessel
and on the operating time. The sea water that is
circulated through the aftercooler and the amount
of operating time of the vessel affects the following
items:
• Cleanliness of the tubes for the aftercooler
• Effectiveness of the aftercooler
Operating in water that contains the following will
adversely affect the aftercooler: silt, sediment, salt,
and algae.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Refer to the Disassembly and Assembly Manual for
the engine.
1. Drain the aftercooler.
2. Remove the aftercooler.
3. Turn the aftercooler core upside-down in order to
remove debris.
residue. Flush the tubes of the heat exchanger
core. Remove any other trapped debris.
6. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
A WARNING
Personal injury can result from air pressure.
Personal injury can result without following prop-
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.
7. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
8. 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.
9. Install the heat exchanger. Refer to the Service
Manual for the procedure.
For more information on cleaning the core, consult
your Caterpillar dealer.

NOTICE i02676048
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner Alternator - Inspect
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of SMCS Code: 1405-040
cleaner.
Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
4. Back flush the core with cleaner. connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
Caterpillar recommends the use of Hydrosolv order to ensure proper battery performance and/or
liquid cleaner. Table 16 lists Hydrosolv liquid proper performance of the electrical system. Make
cleaners that are available from your Caterpillar repairs, as required.
dealer.
Check the alternator and the battery charger for
Table 16 proper operation . If the batteries are properly
Hydrosolv Liquid Cleaners(1J charged, the ammeter reading should be very near
zero. All batteries should be kept charged . The
Part
Description Size batteries should be kept warm because temperature
Number
affects the cranking power. If the battery is too cold,
1U-5490 Hydrosolv 4165 19 L (5 US gallon) the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
174-6854 Hydrosolv 100 19 L (5 US gallon)
When the engine is not run for long periods of time
(1) Use a two to five percent concentration of the cleaner or if the engine is run for short periods, the batteries
at temperatures up to 93•c {200.F). Refer to Application may not fully charge. A battery with a low charge will
Guide, NEHS0526 or consult your Caterpillar dealer for more
information. freeze more easily than a battery with a full charge.
118
Maintenance Section
Automatic Start/Stop- Inspect
i019422B4
Automatic Start/Stop - Inspect
SMCS Code: 4462
The generator set must be ready to operate under a
load at any time. After performing maintenance on
the generator set, inspect the position of the control
switches. Ensure the following conditions:
• The starting system is enabled.
• The control switches are in the correct position for
automatic starting.
• The switchgear and the automatic transfer switches
that are associated with the generator are enabled .
i010419B3
Auxiliary Water Pump {Rubber
Impeller) - Inspect
SMCS Code: 1371-040
Impellers and seals require periodic inspection.
Impellers have a service life that is limited. The
service life depends on the engine operating
conditions.
Inspect the components more frequently when the
pump is exposed to debris, sand, or other abrasive
materials. Inspect the components if the pump is
operating at a differential pressure of more than
103 kPa (15 psi).
Check the following components for wear or damage:
• Bearings
• Impeller
• Seals
• Wear plate
If wear or damage is found, replace the components
which are worn or damaged. Use the proper repair
kit for the pump. Refer to the Disassembly and
Assembly for more information on servicing the
auxiliary water pump.
SEBU7919-03
i02039199
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Return used batteries to one of the following
locations:
• A battery supplier
• An authorized battery collection facility
• A recycling facility
i01B7B164
Battery - Replace
SMCS Code: 1401-510
A WARNING
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to Ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
A WARNING
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Switch the engine to the OFF position. Remove
all electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. The NEGATIVE "-" cable connects the NEGATIVE
"-" battery terminal to the NEGATIVE "-" terminal
on the starter motor. Disconnect the cable from
the NEGATIVE "-" battery terminal.
SEBU7919-03
4. The POSITIVE "+" cable connects the POSITIVE
"+" battery terminal to the POSITIVE "+" terminal
on the starting motor. Disconnect the cable from
the POSITIVE "+" battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE "+" battery terminal.
8. Connect the cable from the NEGATIVE "-" terminal
on the starter motor to the NEGATIVE"-" battery
terminal.
i01942625
Battery Charger- Check
SMCS Code: 1401-535
Check the battery charger for proper operation. If
the batteries are properly charged, the needle of the
ammeter will register near "0" (zero).
The batteries should be kept warm, when possible.
The temperature of the battery will affect cranking
power. A battery that is too cold will not crank the
engine, even if the engine is warm.
The batteries may not fully recharge when the engine
is not run for long periods of time. The batteries may
not fully recharge if the engine only runs for short
periods. Ensure a full charge in order to help prevent
the battery from freezing .
i02601752
Battery Electrolyte Level -
Check
SMCS Code: 1401-535
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.
119
Maintenance Section
Battery Charger - Check
A WARNING
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
245- 5829 Coolant Battery Tester Refractometer.
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.
i01492654
Battery or Battery Cable -
Disconnect
SMCS Code: 1402-029
A WARNING
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
120
Maintenance Section
Belts- Inspect/Adjust/Replace
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
i04521280
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Fan Drive Belt
Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking . Check the belt
tension. Adjust the belt tension in order to minimize
belt slippage. Belt slippage will decrease the life of
the belts.
Adjustment
If the belts are too loose, the belts will vibrate. This
vibration is enough to cause unnecessary wear on
the belts and on the pulleys.
If the belts are too tight, unnecessary stresses are
placed upon the pulley bearings and upon the belts.
These stresses will shorten the life of the belts and of
the pulley bearings.
If new belts are installed, check the tension again
after 30 minutes of engine operation at the rated rpm.
For the correct tension on the belt, refer to
Specifications, "Belt Tension Chart".
Replacement
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.
SEBU7919-03
Refer to the Service Manual for more information on
the procedures for the following topics: belt removal
and belt installation procedure.
Alternator Belt
Inspection
A WARNING
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.
Illustration 86
g01157422
The belt cover must be removed for inspection, adjustment, and
replacement.
(1) Mounting bolt
(2) Adjustment bolt
(3) Adjustment bolt
To maximize the engine performance, inspect the
belt for wear and for cracking . Check the belt tension .
Adjust the belt tension in order to minimize belt
slippage. Belt slippage will decrease the life of the
belt.
For the correct tension on the belt, refer to
Specifications, "Belt Tension Chart".
Adjustment
1. Remove the belt cover.
2. Loosen mounting bolts (1) and adjusting bolts (2)
and (3).
SEBU7919-03 121
Maintenance Section
Circuit Breakers - Reset

3. Slide the alternator in the direction that will give When the cooling system is cleaned, only clean water
the correct tension. is needed when the ELC is drained and replaced .

4. Tighten adjusting bolts (2) and (3). Tighten
mounting bolt (1 ).
5. Reinstall the belt cover, if equipped.
If new belts are installed, check the belt adjustment
again after 30 minutes of engine operation at the
rated rpm.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain

Circuit Breakers - Reset
SMCS Code: 1417-529; 1420-529
A B
i02456186
A WARNING
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and walt until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
c sure.

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

Dealer Service Tool Catalog" for tools and supplies
g01225779 suitable to collect and contain fluids on Caterpillar
Illustration 87
products.
Push in on the circuit breaker in order to reset the Dispose of all fluids according to local regulations and
circuit breaker. mandates.
(A) 60 Amp Circuit Breaker -This circuit breaker
is for the battery charger and the circuit for the
alternator.

(B) 15 Amp Circuit Breaker -This circuit breaker is

for the Electronic Control Module (ECM).

(C) 20 Amp Circuit Breaker - This circuit breaker is

for the control panel.

i02668738

Cooling System Coolant (ELC)

-Change Illustration 88
g01157267

SMCS Code: 1350-070; 1395-044 Typical example

(1) Header tank
(2) Cooling system filler cap
NOTICE
Keep all parts clean from contaminants.
1. Stop the engine and allow the engine to cool.
Loosen cooling system filler cap (2) slowly in order
Contaminants may cause rapid wear and shortened
to relieve any pressure. Remove cooling system
component life.
filler cap (2).
122 SEBU7919-03
Maintenance Section
Cooling System Coolant (ELC) - Change

3 4
g01156304 g01341440
Illustration 89 Illustration 91

2. Remove the drain plug (4) from the cylinder block

. Remove the drain plug (3) from the water cooled
exhaust manifold . Remove drain plug (5) from the
heat exchanger . Remove drain plug (6) from the
88'1I!l
• g g
radiator (if equipped). Allow the coolant to drain .

NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.

For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
Group:
5
Outside Illinois: 1-800-542-8665
Illustration 90
g01156305 Inside Illinois: 1-800-541-8665
Canada: 1-800-523-8665

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

2. Clean the drain plugs. Install the drain plugs.

For the proper torque, refer to the Specifications
Manual, SENR3130, "Torque Specifications".

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
SEBU7919-03
g01157269
Illustration 92
3. Make sure that all the plugs that were removed in
the previous steps have been installed. Remove
plug (6). Remove filler cap and begin filling the
system with clean water. Install plug (6) as the
water begins to run out of the hole for plug (6).
For the proper torque, refer to the Specifications
Manual, SENR3130, "Torque Specifications". After
the plugs are installed keep filling the system until
the water level is approximately 12 mm (0.5 inch)
below the neck of the filler tube. Install the cooling
system filler cap.
4. Start and run the engine until the temperature
reaches 49 to 66°C (120 to 150°F).
5. 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. Remove the drain plugs (3), (4)
and (5). Allow the water to drain. Flush the cooling
system with clean water. Clean the drain plugs.
Install the drain plugs. For the proper torque, refer
to the Specifications Manual, SENR3130, "Torque
Specifications".
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
123
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
1. Make sure that all the plugs that were removed in
the previous steps have been installed. Remove
plug (6). Remove filler cap and begin filling the
system with the proper mixture of ELC and water.
Refer to this Operation and Maintenance Manual,
"Refill Capacities and Recommendations" for
proper coolant. Install plug (6) as the coolant
begins to run out of the hole for plug (6). For the
proper torque, refer to the Specifications Manual,
SENR3130, "Torque Specifications". After the
plugs are installed keep filling the system until the
coolant level is approximately 12 mm (0.5 inch)
below the neck of the filler tube. Install the cooling
system filler cap.
2. Start and run the engine until the engine reaches
normal operating temperature. Stop the engine
and allow the engine to cool.
3. Remove the filler cap. Maintain the coolant level
12 mm (0.5 inch) below the neck of the filler tube.
4. Clean the cooling system filler cap. Inspect
the gasket for the cooling system filler cap. If
the gasket for the cooling system filler cap is
damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket for the cooling system filler cap is not
damaged, use a 9S- 8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling
system filler cap.
5. Pour the ELC into the recovery tank until the
coolant reaches the "COLD FULL" mark, if
equipped. Do not fill the tank above the "COLD
FULL" mark.
6. Clean the cooling system filler cap. Install the
cooling system filler cap. Start the engine. Inspect
the cooling system for leaks and for proper
operating temperature.
i02482066
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
additives which are associated with the present
conventional coolants. The Cat ELC Extender only
needs to be added once.
124 SEBU7919-03
Maintenance Section
Cooling System Coolant Level - Check

3. Add Cat ELC Extender according to the

NOTICE requirements for your engine's cooling system
Use only Cat Extended Life Coolant (ELC) Extender capacity. Refer to the Operation and Maintenance
with C~t ELC Manual, "Refill Capacities and Recommendations"
article for more information.
Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven- 4. Clean the cooling system filler cap. Inspect the
tional coolants and/or conventional SCA reduces the gaskets on the cooling system filler cap. Replace
Cat ELC service life. the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
Check the cooling system only when the engine is
stopped and cool. i02672704

Cooling System Coolant Level

,A WARNING -Check
Personal injury can result from hot coolant, steam
and alkali. SMCS Code: 1395-082

At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Check the coolant level when the engine is stopped
and cool.
,A WARNING
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.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

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

Dealer Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
g01342207
Illustration 93
1. Loosen the cooling system filler cap slowly in Typical header tank
order to relieve pressure. Remove the cooling
system filler cap. 1. Loosen filler cap slowly in order to relieve any
pressure. Remove the filler cap.
2. It may be necessary to drain enough coolant from
the cooling system in order tq add the Cat ELC
Extender.
SEBU7919-03 125
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

2. Pour the proper coolant mixture into the tank until Table 17
the coolant reaches the baffle (1 ). Refer to this
Recommended Interval
Operation and Maintenance Manual, "Cooling
System Coolant (ELC) - Change" for additional Type of Coolant Level 1 Level 2
information in filling the cooling system. Refer to
CatDEAC
the Operation and Maintenance Manual, "Refill
Capacities and Recommendations" for information Conventional
on the correct mixture and type of coolant. Refer heavy duty-
to the Operation and Maintenance Manual, "Refill coolant
Capacities and Recommendations" for the cooling Every 250
Commercial Every year<1l
system capacity. service hours
coolant that
meets the
3. Clean filler cap and the receptacle. Reinstall the requirements
filler cap and inspect the cooling system for leaks. of the Caterpillar
EC-1 standard
Note: The coolant will expand as the coolant heats Cat ELC or
up during normal engine operation. The additional conventional Optional Every year<1J
volume will be forced into the coolant tank during EC-1 coolant
engine operation. When the engine is stopped and
(1) The Level 2 Coolant Analysis should be performed sooner if a
cool, the coolant will return to the engine. problem is suspected or identified .

i04035949
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems filled
with Cat ELC should have a Coolant Sample (Level
2) that is obtained at the recommended interval as
stated in the maintenance interval schedule.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
instead of Cat ELC including the following
coolants:
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
• Cat DEAC (Diesel Engine Antifreeze/Coolant)
• Commercial heavy-duty coolant/antifreeze
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.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
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, 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:
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.

• Keep the unused sampling bottles stored in plastic

bags.

• Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
from any other location.

• Keep the lids on empty sampling bottles until you

are ready to collect the sample.
126
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis,
see this Operation and Maintenance Manual, "Refill
Capacities and Recommendations" or consult your
Caterpillar dealer.
i04051750
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, ~nd
use a separate designated pump for coolant sampling .
Using the same pump for both types ?f samples m~y
contaminate the samples that are bemg drawn . Th1s
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the prod~ct. Be prepared to
collect the fluid with suitable contamers before open-
ing any compartment or disassembling any compo-
nent containing fluids .
Refer to Special Publication , NENG2500, "Caterpillar
Dealer Service Tool Catalog" or refer to Special Pub-
lication, PECJ0003, "Caterpillar Shop Supplies and
TuullS Calaluy" r01 Luuls e:UJd supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
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 Special Publication, SEBU62~1,
"Caterpillar Commercial Diesel Engines Flu1ds
Recommendiiltions" or consult your Caterpillar dealer.
SEBU7919-03
i03645060
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime. Refer to this
Operation and Maintenance Manual, "Maintenance
Interval Schedule" for the proper maintenance
interval.
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. Ex~essive
overheating could result in cracking of the cylinder
head or piston seizure problems.
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 durin~ pa~ial.loads
could cause an excessive carbon buildup 1ns1de the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator 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. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.
Refer to two articles in the Disassembly and
Assembly Manual, "Water Temperature Regulators
- Remove and Water Temperature Regulators -
Install" for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer.
SEBU7919-03
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.
i01595880
Electrical Connections - Check
SMCS Code: 4459-535
Check all exposed electrical connections for
tightness.
Check the following devices for loose mounting or
for physical damage:
• transformers
• fuses
• capacitors
• lightning arrestors
Check all lead wires and electrical connections for
proper clearance.
i02659941
Enclosure - Inspect
SMCS Code: 7263-040; 727 4-040
NOTICE
Do not spray or splash water into the generator air
inlet or exhaust openings. Ensure that the openings
are covered in order to prevent water from entering
the electrical windings and bearings.
The interior of the enclosure package and the exterior
of the enclosure package should be kept clean. Wash
the interior of the enclosure package and the exterior
of the enclosure package with soap and water.
Ensure that the air discharge for the exhaust duct is
clear. Clean debris, twigs, and leaves away from the
enclosure package, as needed.
Lubricate the hinges on the door, as needed. Use
Caterpillar Multipurpose Lithium Complex Grease
(MPGL). If Caterpillar Multipurpose Lithium Complex
Grease (MPGL) is not available, use a similar
multipurpose grease.
Note: Only chrome hinges require lubrication.
Powder black door hinges do not require lubrication.
127
Maintenance Section
Electrical Connections - Check
i02668687
Engine - Clean
SMCS Code: 1000-070
_A WARNING
Personal injury or death can result from high volt-
age.
Moisture could create paths of electrical conduc-
tivity.
Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and
tagged "Do Not Operate".
NOTICE
Water or condensation can cause damage to gen-
erator components. Protect all electrical components
from exposure to water.
NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Note: Do not steam clean the generator. Water may
damage the generator.
A clean engine provides the following benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
i01553486
Engine Air Cleaner Element
(Dual Element) - Clean/Replace
SMCS Code: 1054-037; 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.
128 SEBU7919-03
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
g00736431
Illustration 94
• Check the precleaner (if equipped) daily for
(1) Cover
accumulation of dirt and debris. Remove any dirt
(2) Primary air cleaner element
and debris, as needed. (3) Secondary air cleaner element
(4) Turbocharger air inlet
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner 1. Remove the cover. Remove the primary air
element. cleaner element.

• The air cleaner element may be cleaned up to 2. The secondary air cleaner element should be
six times if the element is properly cleaned and removed and discarded for every three cleanings
inspected. of the primary air cleaner element.

• The air cleaner element should be replaced at least Note: Refer to "Cleaning the Primary Air Cleaner
one time per year. This replacement should be Elements".
performed regardless of the number of cleanings.
3. Cover the turbocharger air inlet with tape in order
Replace the dirty paper air cleaner elements with to keep dirt out.
clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked 4. Clean the inside of the air cleaner cover and body
for tears and/or holes in the filter material. Inspect with a clean, dry cloth .
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 5. Remove the tape for the turbocharger air inlet.
elements for replacement purposes. Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned .
Dual Element Air Cleaners
6. Install the air cleaner cover.
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner 7. Reset the air cleaner service indicator.
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.

The secondary air cleaner element is not serviceable

or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
SEBU7919-03 129
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air Cleaner Pressurized Air

Elements
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage g00281692
Illustration 95
to the pleats.
Note: When the primary air cleaner elements are
Do not use air filters with damaged pleats, gaskets, or cleaned, always begin with the clean side (inside)
seals. Dirt entering the engine will cause damage to in order to force dirt particles toward the dirty side
engine components. (outside).

The primary air cleaner element can be used up
to six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
at least one time per year. This replacement should
be performed regardless of the number of cleanings.
Use clean primary air cleaner elements while dirty
elements are being cleaned.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air cleaner elements
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced further into the pleats.
Note: Refer to "Inspecting the Primary Air Cleaner
Elements".
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which r~quire daily
cleaning because of a dry, dusty enVIronment. .
Cleaning with pressurized air is recommended pnor
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Note: Refer to "Inspecting the Primary Air Cleaner
Elements".

There are two common methods that are used to

clean primary air cleaner elements:

• Pressurized air

• Vacuum cleaning
130
Maintenance Section
Engine Air Cleaner Element (Single Element) - Replace
Inspecting the Primary Air Cleaner
Elements
g00281693
Illustration 96
Inspect the clean, dry primary air cleaner element.
Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Do not use a primary ~ir cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Storing Primary Air Cleaner Elements
If a primary air cleaner element that passes inspection
will not be used, the primary air cleaner element can
be stored for future use.
g00281694
Illustration 97
SEBU7919-03
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
i02398637
Engine Air Cleaner Element
(Single Element) - Replace
SMCS Code: 1051; 1054-510
A WARNING
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.
Perform the Operation and Maintenance Manual ,
"Engine Air Cleaner Service Indicator-Inspect"
procedure before performing the following procedure.
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: This type of air cleaner is only available on
open generator sets.
SEBU7919-03 131
Maintenance Section
Engine Air Cleaner Service Indicator- Inspect

Illustration 98 g01197946 g01197946

Illustration 100

1. Unfasten latches (1 ). Remove cover (2). 4. Install cover (2). Fasten latches (1).

i01900118

Engine Air Cleaner Service

Indicator - Inspect
(If Equipped)
SMCS Code: 7452-040

Some engines may be equipped with a different

service indicator.

Some engines are equipped with a differential gauge

g01197952
Illustration 99
2. Remove air cleaner element (3).
3. Inspect the replacement element for the following
items:damage, dirt, and debris. Install a clean,
undamaged air filter element (3). Make sure that
the element is properly seated in the air cleaner
housing.
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing or in a remote location.
132 SEBU7919-03
Maintenance Section
Engine Crankcase Breather - Clean/Replace

i02310275

Engine Crankcase Breather -

Clean/Replace
SMCS Code: 1317-070; ·1317-5·10

g00103777
Illustration 101
Typical service indicator

Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service Indicator Illustration 102

g01157152

(1) Breather Assembly

Service indicators are important instruments.
Use the following procedure in order to change the
• Check for ease of resetting. The service indicator
should reset in less than three pushes. crankcase ventilator filter.

• Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.

If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced . If the new
service indicator will not reset, the hole for the service
indicator may be plu~~ed .

The service indicator may need to be replaced

frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced .

Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of2 N·m (181b in) .
SEBU7919-03 133
Maintenance Section
Engine Crankcase Breather - Replace

i02312484

2--------Q Engine Crankcase Breather -

Replace

'---o SMCS Code: 1317-510

Turbocharged Engines and

Naturally Aspirated Engines

·~ Note: The housing for the crankcase ventilator

5---o
filter must also be replaced on engines that are
turbocharged. Refer to "Replace the Housing of
the Crankcase Ventilator Filter and the Crankcase
Ventilator Filter".

Replace the Breather on the Valve Cover

6

Illustration 103 g01157174

(2) Lid
(3) 0-ring
(4) Crankcase ventilator filter
(5) 0-ring
(6) Housing for the crankcase ventilator filter

1. Turn lid (2) in a counterclockwise direction for

approximately 15 degrees. Remove the Lid.

2. Remove 0-ring (3).

3. Remove crankcase ventilator filter (4). g01158025

Illustration 104
4. Remove 0-ring (5). The crankcase breather is located on the valve cover.

5. Install a new 0-ring (5).

6. Install a new crankcase ventilator filter (4).

7. Install a new 0-ring (3) .

8. Install lid (2).

134 SEBU7919-03
Maintenance Section
Engine Crankcase Breather - Replace

g0115B031 g0115B042
Illustration 105 Illustration 107
(1) Dust cover (4) diaphragm
(5) Spring
1. Remove dust cover (1 ).
3. Remove diaphragm (4) and spring (5). Replace
these parts with a new diaphragm and a new
spring.

4. Installation is the reverse of removal.

Turbocharged Engines
Replace the Housing of the Crankcase
Ventilator Filter and the Crankcase
Ventilator Filter

g0115B039
Illustration 106
(2) Screws
(3) Cover

2. Remove screws (2) and cover (3).

Illustration 108 g01156045

SEBU7919-03 135
Maintenance Section
Engine Mounts - Inspect

1. Disconnect the hoses from the housing (1) for the i02456872
crankcase ventilator filter. Remove the housing
(1 ). Engine Mounts - Inspect
SMCS Code: 1152-040

2~
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused

3----o by the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

·~
Any engine mount that shows deterioration should be
replaced. Refer to Special Publication, SENR3130,

5----o
"Torque Specifications" for the recommended
torques. Refer to the OEM recommendations for
more information.

i00623423

Engine Oil Level - Check

6
SMCS Code: 1348-535-FLV

A WARNING
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
g01158053 contact the skin.
Illustration 109
(2) Lid
(3) 0-ring

Y =-X
.-:_,-=-_-=-_-:_.,.:1
.
(4) Crankcase ventilator filter
(5)
(6)
0-ring
Housing for the crankcase ventilator filter i,_=~_-_ _ _____
2. Turn lid (2) in a counterclockwise direction for
approximately 15 degrees. Remove the Lid.
(== =
AD=D==j ======IF=UL=L~i
g00110310
3. Remove 0-ring (3). Illustration 110
(Y) "ADD" mark. (X) "FULL" mark.
4. Remove crankcase ventilator filter (4).
NOTICE
5. Remove 0-ring (5). Perform this maintenance with the engine stopped.
6. Install a new 0-ring (5).
1. Maintain the oil level between "ADD" mark (Y) and
7. Install a new crankcase ventilator filter (4). "FULL" mark (X) on oil level gauge (1 ). Do not fill
the crankcase above "FULL" mark (X).
8. Install a new 0-ring (3).
NOTICE
9. Install lid (2). Operating your engine when the oil level is above the
"FULL" mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.

Clean the oil filler cap. Install the oil filler cap.
136
Maintenance Section
Engine Oil Sample - Obtain
i04237495
Engine Oil Sample - Obtain
SMCS Code: ·1 000-008; ·1348-554-SM;
7542-554-0C, SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
A WARNING
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, 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- 83 73 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.
SEBU7919-03
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant samplinj:j .
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- 5 718 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, PEGJ0047,
"How To Take A Good S·O·S Oil Sample". Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
i02307330
Engine Oil and Filter - Change
SMCS Code: 1318-510; 1348-044
A WARNING
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
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
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
properly.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
SEBU7919-03
Drain the Engine Oil
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.
Remove the oil drain plug from the oil pan or use one
of the following methods in order to drain the engine
oil into a suitable container. Dispose of the used oil in
accordance with local regulations.
Drain Valve (If Equipped)
Illustration 111 g01155733
Drain valve for the engine oil
1. The oil drain valve may be connected to the used
oil tank for the vessel. The drain valve may have a
plug that is threaded into the end of the valve or
the fittings on the valve. If there is a plug, remove
the plug.
2. Open the drain valve and allow the oil to drain into
a suitable container or the piping for used oil on
the vessel. Dispose of the used oil in accordance
with local regulations.
137
Maintenance Section
Engine Oil and Filter - Change
Replace the 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.
1. Remove the oil filter with a 1U- 8760 Chain
Wrench.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
of metal debris in the oil filter may indicate early
wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
g00741009
Illustration 112
Typical mounting base for the oil filter and oil filter gasket
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
removed.
4. Apply clean engine oil to the new oil filter gasket.
138
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
filter.
Fill the Engine Crankcase
1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual, "Refill Capacitites
and Recommendations" for more information
on the proper type of oil. Fill the crankcase with
the proper amount of oil. Refer to the Operation
and Maintenance Manual, "Refill Capacitites and
Recommendations" for the proper amount of oil.
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine for two
minutes. Perform this procedure in order to ensure
that the lubrication system has oil and that the oil
filters are filled. Inspect the oil filter for oil leaks.
3. Stop the engine and allow the oil to drain back to
lh~ sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the "ADD"
and "FULL" marks on the oil level gauge.
i0231101B
Engine Valve Lash -
Inspect/Adjust
SMCS Code: 1102-025
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
SEBU7919-03
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.
A WARNING
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is
performed. ·
Refer to the Service Manual for more information.
i04521055
Fuel System - Prime
SMCS Code: 1258-548
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
• The fuel tank is empty or the fuel tank has been
partially drained.
• The low-pressure fuel lines are disconnected.
• A leak exists in the low-pressure fuel system.
• The fuel filter is replaced .
• A new injection pump is installed.
Use the following procedure in order to remove air
from the fuel system:
SEBU7919-03 139
Maintenance Section
Fuel System - Prime

Priming the Fuel System with the Priming the Fuel System with a
"START" Switch Protection and Paralleling Unit
1. Remove the cover for the fuel injectors. Refer to
(PPU)
the Disassembly and Assembly Manual.
Use the following procedure in order to remove air
from the fuel system:
2. Turn the key switch to the RUN position. Leave
the key switch in the RUN position for 3 minutes.

3. Turn the key switch to the OFF position.

g01003929
Illustration 113
Injector nuts

Note: Damage to the following components may

occur if the starting motor is used excessively to
purge the air from the fuel system: fuel injection
pump, the battery, and the starting motor.

4. Loosen the flare nuts (1) for the high-pressure fuel

lines on all of the fuel injectors.

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.

5. Observe the connection at the flare nut. Operate

the starting motor and crank the engine until the
fuel is free of air.

6. Tighten the flare nuts (1) to a torque of 30 N·m

(22 lb ft).

7. The engine is now ready to start. Operate the

engine at low idle for a minimum of 5 minutes
immediately after air has been removed from the
fuel system.

Note: Running the engine for this period will help

ensure that the pump is completely free of air.
140
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Illustration 114
1. Hold the toggle switch (1) in the ON position for 3
minutes to prime the system.
Note: Damage to the following components may
occur if the starting motor is used excessively to
purge the air from the fuel system: fuel injection
pump, the battery, and the starting motor.
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. The engine is now ready to start.
SEBU7919-03
g01231641
i02214246
Fuel System Primary Fi lter
(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
A WARNING
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Turn the fuel supply valve to the OFF position before
performing this maintenance. Place a tray under the
fuel filter in order to catch any fuel that might spill.
Clean up any spilled fuel immediately.
SEBU7919-03 141
Maintenance Section
Fuel System Secondary Filter - Replace

4. Ensure that the filter head is clean. Push a new

element fully into the filter head .

5. Hold the element in place. Fit locking ring (2) into

position. Rotate the locking ring clockwise in order
to fasten the element to the filter head .

Note: If the nylon insert was removed, install the

nylon insert and install cap (1 ).

6. Prime the fuel system. Refer to the Operation and

Maintenance Manual, "Fuel System - Prime" for
more information .

g00741109 i01713207
Illustration 115
(1)
(2)
Cap
Locking ring Fuel System Secondary Filter -
(3)
(4)
Element
Water separator bowl
Replace
(5) Drain
SMCS Code: 1261-510-SE
1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly. Drain

the fuel into a suitable container by using the
fuel drain on the bottom of element (3). Drain the
water from water separator (4) into a suitable
container. Not all engines are equipped with a
water separator.
A WARNING
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

Note: The fuel level in element (3) should be reduced

before removal of the element. Remove cap (1) if the
element is not equipped with a drain on the bottom.
Remove the nylon insert in order to reduce the level
of fuel in the element. A reduction in the level of fuel
in the element will help prevent fuel from being spilled
when the element is removed.
NOTICE
Do not use a tool in order to remove the fuel filter.
Attempting to remove the fuel filter with a filter wrench
or a filter strap could damage the locking ring.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Turn the fuel supply valve to the OFF position before
performing this maintenance. Place a tray under the
fuel filter in order to catch any fuel that might spill.
Clean up any spilled fuel immediately.

3. Hold element (3) and rotate locking ring (2)

counterclockwise. Remove locking ring (2). The
used element should be removed and discarded.

Note: If the element is equipped with a sediment

bowl, remove the sediment bowl from the element.
Thoroughly clean the sediment bowl. Inspect the
0-ring seals for wear or damage. Install new 0-ring
seals, if necessary. Install the sediment bowl onto the
new element. Hand tighten the sediment bowl. Hand
tightening is the only method that should be used.

NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
142
Maintenance Section
Fuel Tank Water and Sediment - Drain
g00802952
Illustration 116
(1) Cap
(2) Fuel filter base
(3) Quick release collar
(4) Fuel filter
(5) Drain valve for fuel filter
1. Close the fuel supply valve.
2. Clean the outside of the fuel filter assembly. Open
drain valve (5) and drain the fuel and water from
fuel filter (4) into a suitable container.
Note: If the fuel filter element is not equipped with
a drain, remove cap (1 ). Remove the nylon insert
in order to reduce the level of fuel in the fuel filter
element. A reduction in the level of fuel in the fuel
filter element will help prevent fuel from being spilled
when the element is removed.
NOTICE
Do not use a tool in order to remove the fuel filter.
Attempting to remove the fuel filter with a filter wrench
or a filter strap could damage the locking ring.
3. Hold fuel filter (4) and rotate quick release collar
(3) counterclockwise. Remove quick release collar
(3). The used element should be removed and
discarded.
Note: If the element is equipped with a sediment
bowl, remove the sediment bowl from the element.
Thoroughly clean the sediment bowl. Inspect the
0-ring seals. Install new 0-ring seals, if necessary.
Install the sediment bowl to the new element. Hand
tighten the sediment bowl. Hand tightening is the
only method that should be used.
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
4. Ensure that the fuel filter base is clean. Push a
new fuel filter fully into the fuel filter base.
SEBU7919-03
5. Hold the fuel filter in place. Fit locking ring (3) into
position. Rotate the locking ring clockwise in order
to fasten the fuel filter to the fuel filter base.
Note: If the nylon insert was removed, install the
nylon insert and install cap (1 ).
6. Prime the fuel system. Refer to Operation and
Maintenance Manual, "Fuel System- Prime".
i04363480
Fuel Tank Water and Sediment
-Drain
SMCS Code: 1273-543-M&S
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
opening any compartment or disassembling any com-
ponent containing fluids.
Refer to Special Publication, NENG2500, "Cat Dealer
Service Tool Catalog" or refer to Special Publication,
PECJ0003, "Cat Shop Supplies and Tools Catalog" for
tools and supplies suitable to collect and contain fluids
on Cat products.
Dispose of all fluids according to local regulations and
mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate In fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Note: Failure to properly close the drain can allow air
into the system, which could hove detrimental results
to performance.
SEBU7919-03 143
Maintenance Section
Generator - Dry

Check the fuel daily. Drain the water and sediment If the drying procedure does not restore the insulation
from the fuel tank after operating the engine or drain resistance to an acceptable value, the winding should
the water and sediment from the fuel tank after the be reconditioned.
fuel tank has been filled. Allow five to ten minutes
before performing this procedure. Note: For additional information, refer to Special
Instruction, SEHS9124 .
Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
Drying Methods
fuel expands as the fuel gets warm. The tank may
The following methods can be used for drying a
overflow.
generator:
Some fuel tanks use supply pipes that allow water
• Self-circulating air method
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
• Oven method
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important. NOTICE
Do not allow the winding temperature to exceed 85 oc
(185.0 °F). Temperatures that are greater than 85 oc
Fuel Storage Tanks (185.0 °F) will damage the winding insulation.

Drain the water and the sediment from the fuel

storage tank during the following conditions: Self-Circulating Air Method
• Weekly Note: Disable the excitation before using this method.

• Oil change Run the engine and disconnect the generator load.
This will help circulate air. Operate the generator
• Refill of the tank space heaters.

This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. A four micron( c) absolute filter for the breather
vent on the fuel tank is also recommended.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
Oven Method
Place the entire generator inside a forced air drying
oven for four hours at 65 oc (149 °F).
NOTICE
Use a forced air type oven rather than a radiant type
oven .
Radiant type ovens can cause localized overheating .

i02283395
i03642621

Generator - Dry Generator - Inspect

SMCS Code: 4450-040
SMCS Code: 4450-569

NOTICE A WARNING
Do not operate the generator if the windings are wet. If
the generator is operated when the windings are wet, Personal injury or death can result from improper
damage can occur due to insulation breakdown. troubleshooting and repair procedures.

The following troubleshooting and repair proce-

When moisture is present or when moisture is dures should only be performed by qualified per-
suspected in a generator, the generator must be sonnel familiar with this equipment.
dried before being energized.
144
Maintenance Section
Generator- Inspect
A WARNING
The high voltage that is produced by an operating
generator set can cause severe Inj ury 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 availab.le. 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
SEBU7919-03
• The type of enclosure of the generator
• The voltage rating of the generator
• The type of dirt that is being removed
Cleaning (Assembled Generators)
NOTICE
Do not use water to clean the generator.
NOTICE
Do not use trichloroethane, perchlorethylene,
trichloroethane or any alkaline products to clean the
generator.
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 clean ing procedures are not effective, consult
a Caterpillar dealer.
Cleaning (Disassembled
Generators)
NOTICE
Do not use water to clean the generator.
NOTICE
Do not use trichloroethane, perchlorethylene,
trichloroethane or any alkaline products to clean the
generator.
SEBU7919-03
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.
Use the following for cleaning the stator, the rotor, the
exciter and the diode bridge:
• Unleaded Gasoline
• Toluene
• Benzene
• Ciclohexare
Avoid permitting the solvent to run into the slots.
Apply the solvent with a brush. Use a sponge on the
windings frequently in order to remove the debris.
Dry the winding with a dry cloth. Allow the solvent to
evaporate before reassembling the generator.
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.
Note: For more information on drying methods, refer
to Special Instructions, SEHS9124, "Cleaning and
Drying of Electric Set Generators".
i01B7BB34
Generator Load - Check
SMCS Code: 4450-535-LA
A WARNING
Personal injury or death can result from high volt-
age.
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.
During normal operation, monitor the power factor
and monitor generator loading.
145
Maintenance Section
Generator Load - Check
When a three-phase generator is installed or when
a three-phase 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 three-phase 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 on three-phase
generators. This is not applicable to single-phase
generators.
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.
i01593517
Generator Set - Test
SMCS Code: 4450-081
A WARNING
Personal injury or death can result from high volt-
age.
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.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
146 SEBU7919-03
Maintenance Section
Generator Set Vibration - Test/Record

Table 18 i04497390

Tools Needed Generator Set Vibration

Part Number Part Quantity Test/Record
Digital
6V 7070 1
Multimeter SMCS Code: 4450-08 ·1-VI
12 VDC battery 1
Excessive vibration will indicate a problem with the
Potential generator set. The vibration may be caused by the
1
Transformer following:

The generator set functional test is a simplified test
that can be performed in order to determine if the
generator is functional. The generator set functional
test should be performed on a generator set that is
under load.
The generator set functional test determines if the
following statements happen:
• A phase voltage is being generated.
• Misalignment of the coupling between the engine
and the generator
• Faulty mounting or play in the coupling
• Incorrect balancing of the generator shaft or engine
crankshaft
• A three-phase generator has too much load on a
single phase.

• The phase voltages are balanced. • There is a short circuit in the stator.

• The phase voltages change relative to engine Check for vibration damage. Vibration may cause the
speed. following problems:

The generator set functional test consists of the • loose fittings

following steps:
• loose bolts
1. Stop the generator. Connect the potential
transformer's high voltage winding to the • excessive noise
generator terminals (T1) and (T2) . Connect
the voltmeter to the low voltage winding . If two • cracked insulation
transformers are available, connect the high
voltage winding of the second transformer to the The following areas are susceptible to vibration
generator terminals (T1) and (T3). Connect the damage:
secondary terminals that correspond to generator
terminal (T2) of both transformers together. • stator output leads

2. Disconnect wires "E+" and "E-" from the voltage • protective sleeving
regulator. Disconnect the generator from the load.
• insulation
3. Connect a 12 VDC automotive battery to wires
"E+" and "E-". • exposed electrical connections

4. Measure the AC voltage across the low voltage • transformers

terminals of the transformer that correspond to the
following generator terminals: "T1" and "T2", "T2" • fuses
and "T3", and "T3" and "T1". Record the voltages.
• capacitors

Check the vibration level of the generator set by

using a broad spectrum analyzer. Record the results.
SEBU7919-03
i01592749
Heat Exchanger - Inspect
SMCS Code: 1379-040
The interval for the maintenance of the tube type heat
exchanger depends on the operating environment of
the vessel and on the operating time. The sea water
that is circulated through the heat exchanger and the
amount of operating time of the vessel affects the
following items:
• Cleanliness of the tubes for the heat exchanger
• Effectiveness of the heat exchanger system
Operating in water that contains silt, sediment, salt,
algae, etc will adversely affect the heat exchanger
system. In addition, intermittent use of the vessel will
adversely affect the heat exchanger system.
The following items indicate that the heat exchanger
may require cleaning:
• Increased coolant temperature
• Engine overheating
• Excessive pressure drop between the water inlet
and the water outlet
An operator that is familiar with the normal operating
temperature of the coolant can determine when
the coolant temperature is out of the normal range.
Inspection and maintenance of the heat exchanger
are required if the engine is overheating.
Cleaning the Heat Exchanger
1. Remove the heat exchanger. Refer to the Service
Manual for the procedure.
2. Turn the heat exchanger core upside-down in
order to remove debris.
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.
3. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 19 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.
147
Maintenance Section
Heat Exchanger - Inspect
Table 19
Hydrosolv Liquid Cleaners(1)
Part
Description Size
Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner
at temperatures up to 93•c (200.F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
information .
4. Steam clean the core in order to remove any
residue. Flush the tubes of the heat exchanger
core. Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
A WARNING
Personal injury can result from air pressure.
Personal injury can result without following prop-
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.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
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 heat exchanger. Refer to the Service
Manual for the procedure.
For more information on cleaning the core, consult
your Caterpillar dealer.
i04301694
Hoses and Clamps -
Inspect/Replace
SMCS Code: 7554-040; 7554-510
Hoses and clamps must be inspected periodically
in order to ensure safe operation and continuous
operation of the engine. Take proper safety
precautions before inspecting or replacing hoses and
clamps.
148
Maintenance Section
Hoses and Clamps - Inspect/Replace
Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking
fluid that is under pressure can cause serious
injury or possible death. Leaks that are the size
of a pin hole are included. Refer to Operation and
Maintenance Manual, "General Hazard Information"
for more information.
Inspect the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which exhibits
any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
may result in a hazardous situation.
• Hoses which are cracked
• Hoses which are soft
• 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
• Hoses which exhibit signs of leakage which are not
the result of loose couplings or clamps
Inspect all clamps for the following conditions.
Replace any clamp which exhibits signs of any of the
following conditions.
• Cracking
• Looseness
• Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
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
• Anticipated expansion and contraction of the
fittings
SEBU7919-03
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen
which can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
hose clamps which are loose.
Replace the Hoses and the Clamps
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
opening any compartment or disassembling any com-
ponent containing fluids.
Refer to Special Publication, NENG2500, "Cat Dealer
Service Tool Catalog" or refer to Special Publication,
PECJ0003, "Cat Shop Supplies and Tools Catalog" for
tools and supplies suitable to collect and contain fluids
on Cat products.
Dispose of all fluids according to local regulations and
mandates.
Cooling System
A WARNING
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 WARNING
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.
1. Stop the engine.
2. Allow the engine to cool.
SEBU7919-03
3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system in order to relieve
any pressure.
4. Remove the filler cap for the cooling system.
5. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced .
Drain the coolant into a suitable clean container.
The coolant can be reused.
6. Remove the hose clamps.
7. Disconnect the old hose.
8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, "Torque Specifications", "Hose
Clamps" for information about selecting and
installing the proper hose clamps.
10. Refill the cooling system.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap
if the gaskets are damaged. Install the filler cap.
12. Start the engine. Inspect the cooling system for
leaks.
Fuel System
A WARNING
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.
A WARNING
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
149
Maintenance Section
Hoses and Clamps - Inspect/Replace
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.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
Note: High-pressure fuel lines may be installed
between the high-pressure fuel pump and the fuel
injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the
high-pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
engine stops before you perform any service or repair
on high-pressure fuel lines. Waiting for 10 minutes
will to allow the pressure to be purged.
1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced .
2. Remove the hose clamps.
3. Disconnect the old hose.
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, "Torque Specifications", "Hose
Clamps" for information about selecting and
installing the proper hose clamps.
6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
engine.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.
7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, "Fuel System - Prime" for
information about priming the engine with fuel.
8. Start the engine. Inspect the fuel system for leaks.
150
Maintenance Section
Instrument Panel- Inspect
Lubrication System
A WARNING
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
2. Remove the hose clamps.
3. Disconnect the old hose.
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SEN R3130, "Torque Specifications", "Hose
Clamps" for information about selecting and
installing the proper hose clamps.
6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, "Engine
Oil Level - Check" in order to ensure that the
lubrication system is filled with the proper amount
of engine oil.
7. Start the engine. Inspect the lubrication system
for leaks.
Air System
1. Remove the hose clamps.
2. Disconnect the old hose.
3. Replace the old hose with a new hose.
4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SFNR3130, "Tnr'lllP. SpP.cifications", "Hose
Clamps" for information about selecting and
installing the proper hu~~ clamps.
Note: The bellows and the V-clamps that are used
on the bellows should never be reused.
5. Start the engine. Inspect the air lines for leaks.
SEBU7919-03
101917577
Instrument Panel - Inspect
SMCS Code: 7451-040
Inspect the instrument panel for good condition.
Perform the self test. All of the warning lamps should
illuminate. If a warning lamp does not illuminate,
replace the bulb immediately. If the alarm does
not sound, investigate the problem and correct the
problem.
Check the condition of all of the gauges. If a gauge
is broken, repair the gauge or replace the gauge
immediately.
Frequently monitor the gauges during normal
operation.
Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing
the new data to the recorded data will help to
establish the trends of engine performance. A gauge
reading that is abnormal may indicate a problem with
operation or a problem with the gauge.
i03B7B7 16
Insulation - Test
SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081
A WARNING
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.
Table 20
TOOLS NEEDED
Part Number Tool Quantity
142-5055 Insulation Tester 1
Megohm meter
SEBU7919-03
A WARNING
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.
The following materials will cause the winding
insulation to deteriorate:
• moisture (water)
• dust
• grease
• other foreign matter within the generator
This deterioration reduces the resistance of the
insulation. This test will measure the resistance of
the winding insulation.
The insulation tester (megohmmeter) produces a
high potential voltage between the test leads. During
the test, a small current flows. The tester converts
this current to a resistance reading .
The insulation test is performed as part of periodic
maintenance in order to detect the deterioration of the
winding insulation. When there is a rapid decrease
in the insulation resistance in a short amount of time,
the generator needs to be cleaned.
Note: For information on generator cleaning, refer to
Special Instruction, SEHS9124.
When generators have not been used for a period
of time, moisture can accumulate. Therefore, the
insulation test should be performed on generators
that have been idle. If moisture is known to exist,
the windings must be dried prior to testing. Refer to
Testing And Adjusting, "Generator- Dry".
The insulation test should be performed on
generators that are being used for the first time. The
insulation test should be performed more frequently
in the following cases:
• The generator set is operating in a humid
environment.
• The generator set is not protected from the
elements in an enclosed area.
151
Maintenance Section
Insulation - Test
• The generator set has not been run under load for
three months.
Note: Space heaters may need to be used around
the generator set in the following cases:
• The generator set has not been run under load for
three months.
• The generator set is exposed to a sea water
environment.
• The humidity is above 75 percent.
• A test result was below 3 megohms.
The winding needs to be reconditioned or the winding
needs to be replaced in the following cases:
• The measured insulation resistance falls below the
specified amount. The cleanup procedure does not
correct the discrepancy.
• The measured insulation resistance falls below the
specified amount. The drying procedure does not
correct the discrepancy.
The specified insulation resistance is an approximate
value. It can be possible to operate the generator with
less than the specified value. However, a generator
that has a low winding insulation resistance will be
more likely to have a failure.
A WARNING
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 insulation test gives accurate results only when
the generator windings are free of moisture and the
generator windings are at room temperature.
Each winding must have a minimum insulation
resistance of one megohm.
Main Armature (Stator L4)
1. Remove the load from the generator by either of
the following :
• Open the line circuit breaker.
• Open the following load connections: T1, T2,
T3, and TO.
152
Maintenance Section
Overhaul Considerations
Prevent these wires from coming into contact
with each other and prevent these wires from
contacting ground .
2. Isolate the main armature (L4) from the voltage
regulator by disconnecting the wires for voltage
sensing. If generator lead (TO) is connected to the
generator frame or ground, open the connection.
3. Connect one test lead of the insulation tester
(megohmmeter) to the generator enclosure
(ground).
4. Connect the other test lead of the insulation tester
(megohmmeter) to generator lead (TO).
5. The insulation resistance must be one megohm
or more.
Exciter Field (Stator L1)
1. Isolate exciter field (L 1) from the voltage regulator
by disconnecting wires 5+ and 6-. Prevent these
wires from coming into contact with each other
and prevent these wires from contacting ground.
2. Connect one test lead of the insulation tester
(megohmmeter) to the generator enclosure
(ground).
3. Connect one test lead of the insulation tester
(megohmmeter) to exciter field lead (5+ or 6-).
4. Measure the resistance of the exciter field winding
insulation to ground. The insulation resistance
must be a minimum of 0.25 megohm (250000
ohms).
Exciter Armature (Rotor L2)
1. Isolate exciter armature (L2) from the rectifier
circuit. Disconnect the three wires of the exciter
armature from the rectifier blocks.
2. Connect one test lead of the insulation tester
(megohmmeter) to the rotor shaft.
3. Connect one test lead of the insulation tester
(megohmmeter) to any one exciter field lead.
4. The insulation resistance must be a minimum of
0.25 megohm (250000 ohms).
SEBU7919-03
i015B5907
Overhaul Considerations
SMCS Code: 7595-043
Reduced hours of operation at full load will result in a
lower average power demand . A decreased average
power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
• The need for preventive maintenance
• The quality of the fuel that is being used
• The operating conditions
• The results of the S·O·S analysis
Oil Consumption as an Overhaul
Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required,capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
bhp) ThP. hrAkA specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining tile typical oil
consumption rate for your engine.
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled .
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best
value for the following reasons:
SEBU7919-03 153
Maintenance Section
Overhaul Considerations

• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
standards for reusable parts.
• The engine's service life can be extended without
the risk of a major catastrophe due to engine
failure.
• The best cost/value relationship per hour of
extended life can be attained.
If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused .
Parts that are not within the established inspection
specifications should be dealt with in one of the
following manners:
• Salvaging
• Repairing

After Failure Overhaul • Replacing

If a major engine failure occurs and the engine must Using out-of-spec parts can result in the following
be removed from the hull, many options are available. problems:
An overhaul should be performed if the engine block
or the crankshaft needs to be repaired . • Unscheduled downtime

If the engine block is repairable and/or the crankshaft • Costly repairs

is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
with a similar exchange core.
This lower cost can be attributed to three aspects:
• Specially designed Caterpillar engine features
• Caterpillar dealer exchange components
• Caterpillar remanufactured exchange components
• Damage to other engine parts
• Reduced engine efficiency
• Increased fuel consumption
Reduced engine efficiency and increased fuel
consumption translates into higher operating
costs. Therefore, Caterpillar recommends repairing
out-of-spec parts or replacing out-of-spec parts.

Overhaul Recommendation Inspection and/or Replacement

To minimize downtime, Caterpillar recommends a Crankshaft Bearings, Crankshaft Seals, Thrust

scheduled engine overhaul by your Caterpillar dealer Bearings, Main Bearings, and Rod Bearings
before the engine fails. This will provide you with the
best cost/value relationship. The following components may not last until the
second overhaul.
Note: Overhaul programs vary according to the
engine application and according to the dealer that • Thrust bearings
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available • Main bearings
overhaul programs and about overhaul services for
extending the engine life. • Rod bearings

If an overhaul is performed without overhaul service • Crankshaft seals

from your Caterpillar dealer, be aware of the following
maintenance recommendations. Caterpillar recommends the installation of new parts
at each overhaul period.
Rebuild or Exchange
Inspect these parts while the engine is disassembled
Cylinder Head Assembly, Oil Pump, and Fuel for an overhaul.
Transfer Pump
Inspect the crankshaft for any of the following
conditions:
These components should be inspected according to
the instructions that are found in various Caterpillar
reusability publications. The Special Publication, • Deflection
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts. • Damage to the journals
154
Maintenance Section
Overhaul Considerations
• Bearing material that has seized to the journals
Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the following
components:
• Rod bearing
• Main bearings
Note: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check
for cracks in the crankshaft.
Inspect the camshaft for damage to the journals and
to the lobes.
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for
cracks in the camshaft.
Inspect the following components for signs of wear or
for signs of scuffing:
• Camshaft bearings
• Camshaft followers
Caterpillar recommends replacing the crankshaft
vibration damper.
Oil Cooler Core and Heat Exchanger Core
During an overhaul, Caterpillar recommends the
removal of the oil cooler core and the heat exchanger.
Clean the cores. Then, pressure test the cores.
NOTICE
Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
core and cause leakage.
Note: Use this cleaning procedure to clean the oil
cooler core and the heat exchanger core.
1. Remove the oil cooler core and the heat
exchanger core.
2. Remove any debris from the cores. To remove
debris from the oil cooler core, turn the oil cooler
core onto one end. To remove debris from the
heat exchanger core, turn the heat exchanger
core onto one end.
3. Flush the cores internally with cleaner in order to
loosen foreign substances. This will also help to
remove oil from the oil cooler core.
SEBU7919-03
Note: Caterpillar recommends the use of Hydrosolv
Liquid Cleaners. Table 21 lists the Hydrosolv Liquid
Cleaners that are available from your Caterpillar
dealer.
Table 21
Hydrosolv Liquid Cleaners(1)
Part
Description Size
Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner
at temperatures up to 93"C (200"F) . Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
information .
4. Use steam to clean the cores. This removes any
remaining residue from the cleaner. Flush the fins
of each of the cores. Remove any other trapped
debris.
5. Wash the cores with hot, soapy water. Rinse the
cores thoroughly with clean water.
A WARNING
Personal injury can result from air pressure.
Personal injury can result without following prop-
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.
6. Dry the cores with compressed air. Direct the air
in the reverse direction of the normal flow.
7. Inspect the components in order to ensure
cleanliness. The oil cooler core and the heat
exchanger core should be pressure tested. Repair
cores, if necessary. Install the oil cooler core and
the heat exchanger core.
For more information about cleaning the cores,
consult your Caterpillar dealer.
Obtain Coolant Analysis
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Levell). Further
coolant analysis is recommended when the engine
is overhauled.
SEBU7919-03
For example, considerable deposits are found in the
water jacket areas on the external cooling system, but
the concentrations of coolant additives were carefully
maintained. The coolant water probably contained
minerals that were deposited on the engine over time.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or
an agricultural agent. Private laboratories are also
available for water analysis.
Caterpillar recommends an S·O·S Coolant Analysis
(Level II).
S·O·S Coolant Analysis (Level II)
An S·O·S Coolant Analysis (Level II) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level II) provides
the following information:
• Complete S·O·S Coolant Analysis (Levell)
• Visual inspection of properties
• Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
S·O·S Coolant Analysis (Level II) provides a report of
the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see
your Caterpillar deafer.
155
Maintenance Section
Rotating Rectifier - Check
i01880286
Rotating Rectifier - Check
SMCS Code: 4465-535
A WARNING
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.
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".
i02290281
Rotating Rectifier - Test
SMCS Code: 4465-081
A WARNING
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.
156 SEBU7919-03
Maintenance Section
Sea Water Strainer- Clean/Inspect

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" ~nn TP.~ting and Adjusting, "Insulation -Test".
Perform these tests.
4
i02312204

Sea Water Strainer -

Clean/Inspect
SMCS Code: 1371-040; 1371-070

g00992269
The sea water strainer must be clean in order to
Illustration 117 allow proper engine cooling. Check the sea water
(1) Positive DC terminal or Negative DC terminal strainer for plugging. Inspect the sea water strainer
(2) AC terminal more frequently if the vessel is being operated in
(3) AC terminal
(4) AC terminal
water which is shallow or dirty. The sea water strainer
protects the aftercooler from debris. The sea water
The following procedure tests all three diodes within strainer will catch pieces of the rubber impeller from
a block. Check the positive rectifier block and the the raw water pump due to a failure from debris.
negative rectifier block. If any meter reading does not The sea water strainer is installed on turbocharged
fall within the given ranges, replace the rectifier block. engines only.

1. Set the digital multimeter on the diode range. Drain the Sea Water Cooling
Remove all leads from the rectifier block. System ·
2. To test the negative rectifier block, follow these
steps: Turbocharged Engines

a. Place the red test lead on the negative "-" 1. Close the valve for the sea water.
terminal (1}. Place the black test lead on the
following rectifier terminals: AC terminal (2), AC
terminal (3), and AC terminal (4). All readings
on the meter should be between 0.4 and 1.0.

b. Place the black test lead on the negative "-"

terminal (1 ). Place the red test lead on the
following rectifier terminals: AC terminal (2), AC
terminal (3), and AC terminal (4). In all cases,
the meter should read "OL" (overload).

3. To test the positive rectifier block, follow these

steps:

a. Place the red test lead on the positive "+"

rectifier terminal (1). Place the black test lead
on the following rectifier terminals: AC terminal
(2), AC terminal (3), and AC terminal (4). In all
cases, the meter should read "OL" (overload).

b. Place the black test lead on the positive "+"

rectifier terminal ( 1). Place the red test lead on g00751785
Illustration 118
the following rectifier terminals: AC terminal Typical example of a sea water pump
(2), AC terminal (3}, and AC terminal (4). All
readings on the meter should be between 0.4 2. Disconnect both hoses (2) from the sea water
and 1.0. pump (1).
SEBU7919-03 157
Maintenance Section
Sea Water Strainer- Clean/Inspect

3. Install the sea water strainer (1 ). Install the hose

and the hose clamp (2). Fill the sea water strainer
and the suction line for the auxiliary water pump
with water.

Filling the Sea Water Cooling

System
Turbocharged Engines

Illustration 119 g007517B6

3. Remove the drain plug (3) from the front cover of

the heat exchanger (4). Ensure that the drain hole
is not plugged.

4. Use the turning tool on the front of the crankshaft

in order to rotate the engine. This will ensure that
all of the water has drained from the sea water
pump.
g00751785
Illustration 121
Clean the Sea Water Strainer
1. Connect the hoses (2) at the sea water pump (1 ).
Turbocharged Engines
1. Ensure that the sea water cooling system is
drained. Refer to "Drain the Sea Water Cooling
System" for the procedure.

4
Illustration 120 g00752040
g00751766
Illustration 122
2. Remove the hose clamp (2) for the sea water
strainer. Remove the sea water strainer ( 1) and 2. Install the drain plug (3) in the front cover of the
clean the screen. Use clean water to clean the heat exchanger (4).
screen . Remove any dirt and debris.
158
Maintenance Section
Space Heater - Check
3. Open the valve for the sea water.
i02501318
Space Heater - Check
SMCS Code: 4450-535-HTR
A Caterpillar generator is capable of operating in
high humidity conditions without problems. However,
problems can occur when the generator is idle and
the surrounding air is warmer than the generator.
Moisture can form on the windings that will result in
poor performance from the windings. Moisture can
also result in damage to the windings. Whenever the
generator is not active, ensure that the space heaters
are in operation.
Table 22
Tools Needed
Part Number Part Quantity
Digital
237-5130 1
Multimeter
1. Stop the generator set.
2. Remove the panels in order to allow access to
the regulator and control terminal strips. Locate
terminal strip "TS 1II .
3. For 240 V systems, use the multi meter to measure
the voltage between terminal "H 1II and terminal
"H4". If voltage is not present, disconnect the
power source to terminal "H1" and terminal "H4",
and check for 3 to 12 ohms resistance. If there is
no resistance, check the generator service manual
for further information . For 120 V systems, use
the multimeter to measure the voltage between
terminal "H1" and terminal "H2". If voltage is not
present, disconnect the power source to terminal
11
"H1", terminal "H2", terminal "H3 and terminal
,
"H4", and check for 3 to 12 ohms resistance. If
there is no resistance, check the generator serv1ce
manual for further information.
i00651416
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation .
SEBU7919-03
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
i03230840
Stator Lead- Check
SMCS Code: 4459-535
Ensure that the stator output leads are routed out of
the generator in a manner that prevents the leads
from rubbing against metal objects.
Visually inspect the following areas for cracking and
physical damage:
• stator output leads
• protective sleeving
• insulation
i02514961
Stator Winding Temperature -
Measure/Record
SMCS Code: 4453-082-TA
Some generators are provided with optional100 Ohm
Resistance Temperature Detectors (RTD). When the
temperature of the stator winding is suspected to be
high, measure the temperature. 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.
i03543183
Turbocharger - Inspect/Clean
SMCS Code: 1052-571
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing . Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
SEBU7919-03
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 can cause additional
damage to the pistons, the valves, and the cylinder
head .
A WARNING
Disconnect batteries before performance of any
service work.
A WARNING
Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
A WARNING
Personal injury can result from rotating and mov-
ing parts.
Stay clear of all rotating and moving parts.
Never attempt adjustments while the machine is
moving or the engine is running unless otherwise
specified.
The machine must be parked on a level surface
and the engine stopped.
NOTICE
Turbocharger bearing failures can ca use 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.
159
Maintenance Section
Turbocharger - lnspecUCiean
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
Dealer Service Tool Catalog" or refer to Special Pub-
lication, PECJ0003, "Caterpillar Shop Supplies and
Tools Catalog" for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Removal and Installation
Refer to Disassembly and Assembly, "Turbocharger
- Remove" for the removal procedure. Refer to
Disassembly and Assembly, "Turbocharger -Install"
for the installation procedure. Consult with your
Caterpillar dealer for further information.
Cleaning and Inspecting
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
160
Maintenance Section
Varistor - Check
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 must be reconditioned.
3. Check the compressor wheel for cleanliness.
If only the blade 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 resu lt of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced .
An end play measurement that is Jess than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
5. Inspect the bore of the turbine housing for
corrosion .
6. Clean the turbocharger housing and clean the
backing plate of the cartridge with standard shop
solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i03291B22
Varistor - Check
SMCS Code: 4466-535
The varistor must be checked at regular intervals.
Refer to Systems Operation/Testing and Adjusting,
KENR5284, "Varistor - Test" for instructions.
SEBU7919-03
i03291BD2
Varistor - Inspect
SMCS Code: 4466-040
The varistor must be visually inspected at regular
intervals. For generator sets with 1400 or with
1600 frames, discoloration of the varistor indicates
that replacement of the varistor is necessary. For
generator sets with 1800 frames, physical signs of
failure indicate that replacement of the varistor is
necessary.
i01491B66
Voltage and Frequency -Check
SMCS Code: 4450-535-EL
Check for the proper voltage setting and check for
the proper frequency setting. Check for stability.
For the correct voltage and frequency, refer to the
generator set's Serial Plate.
i02469675
Walk-Around Inspection
SMCS Code: 1000-040
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, lnosP. r:nnnP.r.tions 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.
SEBU7919-03 161
Maintenance Section
Water Pump - Inspect

• Check the condition of the gauges. Replace any

NOTICE gauges which are cracked or any gauges that can
Accumulated grease and/or oil on an engine or deck is not be calibrated.
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
i03543200

• Inspect the radiator cores for cleanliness. Water Pump - Inspect

• Ensure that cooling lines are properly clamped and
that cooling lines are tight. Check for leaks. Check
the condition of all pipes.
• Inspect the water pumps for coolant leaks.
SMCS Code: 1361-040; 1361
A failed ~ater pump might cause severe engine
overheatmg problems that could result in the following
conditions:

• Cracks in the cylinder head

~ote: The_ water pump seal is lubricated by coolant
m the cool1ng 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 pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.
• A piston seizure
• Other potential damage to the engine
A failed ~ater pump might cause severe engine
overheatmg 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

• 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.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, "Water Pump
- Disassemble and Water Pump - Assemble" for
the disassembly and assembly procedure. If it is
necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual
"Water Pump - Remove and Water Pump - lnstaiiU:

• Inspect the alternator belt and the accessory drive Inspect the water pump for wear, cracks, pin holes
belts for cracks, breaks or other damage. and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or
consult your Caterpillar dealer if repair is needed or
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will replacement is needed .
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

lo?se connections and for worn wires or frayed
w1res.

• Inspect the 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.
 162 SEBU7919-03
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

i03910803
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544

When a problem arises concerning the operation or Far East

the service of an engine, the problem will normally be Caterpillar Asia Pte. Ltd.
managed by the dealer in your area. 7 Tractor Road
Jurong, Singapore 627968
• Your satisfaction is a primary concern to Caterpillar Republic of Singapore
and to Caterpillar dealers. If you have a problem that Phone: 65-662-8333
has not been handled to your complete satisfaction, Fax: 65-662-8302
follow these steps:
China
1. Discuss your problem with a manager from the Caterpillar China Ltd.
dealership. 37/F., The Lee Gardens
33 Hysan Avenue
2. If your problem cannot be resolved at the dealer Causeway Bay
level, use the phone number that is listed below to G.P.O. Box 3069
talk with a Field Service Coordinator: Hong Kong
Phone: 852-2848-0333
1-800-447-4986 Fax: 852-2848-0440

The normal hours are from 8:00 to 4:30 Monday Japan

through Friday Central Standard Time. Shin Caterpillar Mitsubishi Ltd.
SBS Tower
3. If your needs have not been met still, submit the 10-1, Yoga 4-Chome
matter in writing to the following address: Setagaya-Ku, Tokyo 158-8530
Japan
Caterpillar Inc. Phone: 81-3-5717-1150
Marine Center of Excellence Fax: 81-3-5717-1177
Manager, Customer Service
111 Southchase Blvd Japan
Fountain Inn, SC 29644 Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
Please keep in mind: probably, your problem will 4-10-1, Yoga
ultimately be solved at the dealership, using the Setagaya-Ku, Tokyo 158-0097
dealership facilities, equipment, and personnel. Phone: 81-3-5797-4300
Therefore, follow the steps in sequence when a Fax: 81-3-5797-4359
problem is experienced.
Australia and New Zealand
Outside of the USA and of Canada Caterpillar of Australia Ltd.
1 Caterpillar Drive
If a problem arises outside the USA and outside Private Mail Bag 4
Canada, and if the problem cannot be resolved at the Tullamarine, Victoria 3043
dealer level, consult the appropriate Caterpillar office. Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
SEBU7919-03 163
Reference Information Section
Customer Service

i01026392

Ordering Replacement Parts

SMCS Code: 7567

A WARNING
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.
164 SEBU7919-03
Reference Information Section
Reference Materials

Reference Materials • Special Publication, SEBD0970, "Coolant and Your

Engine"

i02305231 • Label, PEEP5027, "Extended Life CoolanU

Antifreeze"
Reference Material
SMCS Code: 1000 Miscellaneous
The following literature can be obtained through any • Service Manual, SENR9890, "C4.4 Marine
Caterpillar dealer. Auxiliary Genset"

• Systems Operationrresting and Adjusting,

Lubricants
• Special Publication, PEHP8038, "Data Sheet -
Caterpillar Diesel Engine Oils (DEO) (CH-4) (North
America)"
• Special Publication, PEHP9536, "Data Sheet
-Caterpillar Diesel Engine Oil (DEO) (CF-4)
(International only)"
• Special Publication, NEDG6022, "Cat Lubricating
Grease"
• Special Publication, PEHP0002, "Data Sheet -
Molybdenum (MPGM) Grease"
• Special Publication, NEHP6015, "Data Sheet-
Caterpillar Special Purpose Grease (SPG)"
• Special Publication, SEBD0640, "Oil and Your
Engine"
• Operation and Maintenance Manual, SEBU5898,
"Cold Weather Recommendations"
• Operation and Maintenance Manual, SEBU6251,
"Caterpillar Commercial Diesel Engine Fluids
Recomendations"
• Special Publication, PEHP6001, "How To Take A
Good Oil Sample"
SENR9893, "C4.4 Marine Auxiliary Genset Engine"
• Specifications, SENR9892, "C4.4 Marine Auxiliary
Genset Engine"
• Disassembly and Assembly, RENR8638, "C4.4
Marine Auxiliary Genset Engine"
• Parts Manual, SEBP4122, "C4.4 Marine Genset
Dry Manifold"
• Parts Manual, SEBP4152, "C4.4 Marine Genset"
• Parts Manual, SEBP4401, "C4.4 Marine Genset"
• Electrical Schematic, RENR8052, "C4.4 Marine
Auxiliary Generator Set Engine Electrical
Schematic"
• Specifications, SENR3130, "Torque Specifications"
• Special Publication, PECP9067, "One Safe
Source" English language for use in non NACO
and non COSA
• Special Publication, LEDM5615, "Caterpillar
Marine Parts and Service Locations Directory"
• Special Publication, SEBF8029, "Index to
Guidelines for Reusable Parts and Salvage
Operations"

Fuels • Special Publication, SEBF8062, "Procedure to

Inspect and Clean Air Filters"
• Special Publication, SEBD0717, "Diesel Fuels and
Your Engine" • Special Instruction, SEHS9031, "Storage
Procedure for Caterpillar Products"
Coolants • Special Publication, NEHS0526, "Service
Technician Application Guide"
• Special Publication, PEHP4036, "Data Sheet -
Extended Life Coolant" • Special Publication, SEBU6251, "Caterpillar
Commercial Diesel Engine Fluids Recomendations"
• Special Publication, PEHP7057, "Data Sheet-
S·O·S Coolant Analysis"
• Special Instruction, SEHS7633, "Battery Test
Procedure"
• Special Publication, SEBD0518, "Know Your
Cooling System"
• Label, SEHS7332, "Danger Do Not Operate"
SEBU7919-03 165
Reference Information Section
Reference Materials

Emissions Warranty International Organization for Standardization

(ISO)
This engine may be Certified and this engine 1, rue de Varembe
may be covered by an Emissions Warranty. A Case postale 56
detailed explanation of the Emissions Warranty CH-1211 Geneve 20
that is applicable to Certified engines is found Switzerland
in Supplement, SMBU6981, "Emissions Control Telephone: +41 22 749 01 11
Warranty Information". The engine is Certified if Facsimile: +41 22 733 34 30
the engine has a special label that verifies the E-mail: central@iso.ch
certification . A Caterpillar dealer can also inform you Web site: http://www.iso.ch
if the engine is certified.
European classifications are established by the
Counseillnternational Des Machines a Combustion
Additional Reference Material (CIMAC) (International Council on Combustion
Engines).
The "EMA Lubricating Oils Data Book" can
be obtained from the following locations: local
CIMAC Central Secretariat
technological society, local library, and local college.
Lyoner Strasse 18
If necessary, consult EMA at the following address:
60528 Frankfurt
Germany
Engine Manufacturers Associaton
Telephone: +49 69 6603 1567
401 N. Michigan Ave.
Facsimile: +49 69 6603 1566
Chicago, IL, USA 60611
Telephone: (312) 644-6610 ext. 3626
i04323034
The "Society of Automotive Engineers (SAE)
Specifications" can be found in your SAE handbook. Decommissioning and
This publication can also be obtained from the
following locations: local technological society, local
Disposal
library, and local college. If necessary, consult SAE
SMCS Code: 1000
at the following address:
When the generator set is removed from service, local
SAE International regulations for the generator set decommissioning
400 Commonwealth Drive will vary. Disposal of the generator set will vary with
Warrendale, PA, USA 15096-0001 local regulations. Consult the nearest Cat dealer for
Telephone: (724) 776-4841 additional information.
The "American Petroleum Institute Publication No.
1509" can be obtained from the following locations: i00912149
local technological society, local library, and local
college. If necessary, consult API at the following Maintenance Records
address:
SMCS Code: 1000
American Petroleum Institute
1220 L St. N.W. Caterpillar Inc. recommends the retention of accurate
Washington, DC, USA 20005 maintenance records. Accurate maintenance records
Telephone: (202) 682-8000 can be used for the following purposes:

The International Organization for Standardization • Determine operating costs.

(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.
• 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.
166 SEBU7919-03
Reference Information Section
Reference Materials

Maintenance records are a key element of a

maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption - A record of fuel consumption

is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.

Service Hours - A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.

Documents - These items should be easy to

obtain, and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner's repair costs

• Owner's receipts

• Maintenance log
SEBU7919-03 167
Reference Information Section
Reference Materials

i01176304

Maintenance Log
SMCS Code: 1000

Table 23
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Authorization
Service Item Date
Hours Of Fuel
168
Index Section
Index
A D
Additional Messages .... ...... ...... ....... ... ... ..... ........... 20
Aftercooler Core -Inspect. ... ..... ........... ..... ....... ..... 117
Alternator - Inspect.. .. ............................. .... .. .. ..... . 117
Automatic StarVStop -Inspect ........ .... .. ....... .... .. ... 118
Auxiliary Water Pump (Rubber Impeller) -
Inspect .. ............... ................ .. ............. .. ... .... .. ..... 118
B Emergency Stopping .. ...... ........ .. .. .... .......... .. ........ . 98
Battery - Recycle .. ... .. .... ... ............ ....... ..... ......... ... 118
Battery - Replace ..... ... .... ...... .......... .. .... ................ 118
Battery Charger- Check ....... ..... .......... .... ........... .. 119
Battery Disconnect Switch (If Equipped) ............... 74
Battery Electrolyte Level - Check ......... ............. ... 119
Battery or Battery Cable- Disconnect.. ............. .. . 119
Before Starting Engine ........ .... ........................ 28, 80
Belts -Inspect/Adjust/Replace .. ............ ............ .. . 120
Alternator Belt.. .. ............................ .. ................ 120
Fan Drive Belt.. .. .... ........ ...... .. .. ...... ....... ......... .. 120
Burn Prevention ....... .. .............. .. ........... ............. .... 25
Batteries .. .. ........ ..... ........ ........ ...... .. .... ........ .... ... . 25
Coolant............. ........... ... .... ... .. ... .. .... .................. 25
Oils .................... ...... ......... ... ... .......... .......... ... ..... 25
c Engine Identification .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. . 41
Circuit Breakers- Reset ...... .... .. .. ........ .... .......... .. 121
Cold Weather Operation.. .. .. ..... .... .. ...... ...... .. ......... 99
Control Panel (Protection and Paralleling Unit (PPU)
Control Panel (if equipped)) .. .. ............ .. ............ ... 52
Protection and Paralleling Unit (PPU) Control
Panel ......................... ....................................... 53
Control Panel (Standard Control Panel, Premium
Control Panel, and MCS Control Panel) ............ .. 58
MCS Control Panel .......... ...... .......... .... ........ .. .... 68
Premium Control Panel ......... ........ .......... .. .... .. .. . 63
Standard Control P<mel .. .. ..... .......... .... .............. 59
Cooling System Coolant (ELC)- Change ............ 121
Drain ..... .... ... ......... ... ... .. ... .. .... ...................... .. .. 121
Fill .......... ..... .......... .. ... .. .. .. ........ ............ ....... .... . 123
Flush .................. .. ............. .. ... .......... .... .......... .. 122
Cooling System Coolant Extender (ELC)- Add ... 123
Cooling System Coolant Level - Check .. ............. 124
Cooling System Coolant Sample (Level 1) -
Obtain ..................... ........... ...... .......... .. ............ .. 125
Cooling System Coolant Sample (Level 2) -
Obtain ...... .. .. .. .. ............. ........... .... .. .. .... ...... .. .... .. 126
Cooling System Water Temperature Regulator -
Replace... ... .......... ..... .......... .. ....... ....... ............. .. 126
Crushing Prevention and Cutting Prevention ...... .. 27
Customer Assistance .... ........ .. .... ...... ...... .... .... .. ... 162
Outside of the USA and of Canada .. .... .......... .. 162
USA and Canada .... ..................................... .... 162
Customer Service.. ........ .. .. .... .. .... .. .. .. ..... ..... ........ 162
SEBU7919-03
Decommissioning and Disposal ............. ,...... ...... 165
E
Electrical Connections- Check .... .. .... .. ....... ..... .... 127
Electrical System ....... ... ....... ..... ...... ..... ...... ... ... ..... . 29
Grounding Practices ...... .. .. ................................ 29
Operation of the Air Shutoff .... .... ....................... 98
Enclosure- Inspect.. .... ...... .......... .. ........ .. .... .. ...... 127
Engine - Clean.. .. .. .... ...... .......... .. .... .. ................. .. 127
Engine Air Cleaner Element (Dual Element) -
Clean/Replace............ .. ............ ... .. .......... ..... ..... 127
Cleaning the Primary Air Cleaner Elements .. .. 129
Servicing the Air Cleaner Elements.... .. .. .... .. .. . 128
Engine Air Cleaner Element (Single Element) -
Replace....... ..... .......... .. .............. .... ........... .... ..... 130
Engine Air Cleaner Service Indicator- Inspect (If
Equipped) .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. ... .. .. ..... 131
Test the Service Indicator................................. 132
Engine Crankcase Breather - Clean/Replace...... 132
Engine Crankcase Breather - Replace ................ 133
Turbocharged Engines ......................... ............ 134
Turbocharged Engines and Naturally Aspirated
Engines .. .. .. ... ....... .. .. .. .. ... . .. ... .. .. .... .. ... .. .. .. ...... 133
Engine Mounts - Inspect.. ......... ...... ................. .. .. 135
Engine Oil and Filter- Change .................... ,.. .. ... 136
Drain the Engine Oil ...................................... ... 137
Fill the Engine Crankcase.................. ... ....... .. .. 138
Replace the Oil Filter .. .. .. .. .. .. .. ... .. .. .. .. .. ..... .. .. .. . 137
Engine Oil Level - Check............ .... ................. .... 135
Engine Oil Sample - Obtain.. .. .. ........ ... .... ....... ..... 136
Obtain the Sample and the Analysis ...... ...... .... 136
Engine Operation ......... ... .............. .. ........... ...... ...... 88
Cooling System ...... ...... .. .. .... ........ .......... ......... .. . 89
Keel-Cooled Engine with an Aftercooler ............ 90
Engine Starting .... ...... ........ ...... .. .. .... ........ .. ...... 28, 80
Engine Stopping .......... .. ............ ..... ........ .. ....... 29, 93
Engine Valve Lash -Inspect/Adjust ......... ...... ... ... 138
Engine Warm-up .. ..... ... ...... ... ... ........ ........ .. ........ .... 92
F
Features and Controls .... ............ .... .......... ............ . 52
Fire Prevention and Explosion Prevention ... ........ . 25
Ether ... ... .............................. .. ............. ... ...... ...... 27
Fire Extinguisher ........ .. ............ .. ........... ........... .. 27
Lines, Tubes, and Hoses .... .. .. ...... ...... ....... ..... ... 27
SEBU7919-03
Foreword ........... .... ............ .... .......... ... .......... .. ... ...... 5
California Proposition 65 Warning ...... ..... .... .... .. .. 5
Literature Information ..................... .. .. ........ .... ... .. . 4
Maintenance .. ..... ........... .... .......... ..... .......... ...... ... 4
Maintenance Intervals .... .. .......... .. .. .... ..... ...... .... .. . 4
Operation ............................................................. 4
Overhaul ...... .... .. .. .. ...... ...... .......... ... ..... ...... ... .... ... 4
Safety .............. .... .......... ... ............. ... ....... .. ........ ... 4
Fuel and the Effect from Cold Weather ....... ...... .. .. 99
Fuel Conservation Practices .................................. 92
Fuel System - Prime....... ...... ......... ...... .......... .... .. 138
Priming the Fuel System with a Protection and
Paralleling Unit (PPU) .. ... .. .. .. ... .. .. .. ... .. .. .. .. .. .. . 139
Priming the Fuel System with the "START"
Switch ........... .... ............ .... ........ ...... .......... ..... . 139
Fuel System Primary Filter (Water Separator)
Element- Replace ... ...... ... .... ... .... .. .......... ...... .... 140
Fuel System Secondary Filter- Replace........ ... .. 141
Fuel Tank Water and Sediment- Drain .......... .... . 142
Drain the Water and the Sediment... ......... ...... . 142
Fuel Storage Tanks .................. .. ......... .. .. .. ....... 143
Fuel Tank ........ .... ... ....... ....... ...... ... ..... ....... ..... .. 142
G
General Hazard Information ................. ................. 22
Containing Fluid Spillage .. .. .... .... .. .. ........... ........ 23
Dispose of Waste Properly .. .. .. ... .. .. .. .. .. .. .. .. .. ... .. 25
Fluid Penetration .............................. .. ........ ........ 23
Inhalation ..................................................... ...... 24
Lines, Tubes, and Hoses .. .. .. ........ ................... .. 23
Pressurized Air and Water .. .......... ...... .. ... .. ...... .. 23
Softwrap .......... ............... ... ............. ... ..... .. .... ...... 24
General Maintenance Information ..... .. .. ............ .. 109
Generator- Dry ........ .. .... .. ..... ..... .... .. ................ .... 143
Drying Methods .... ........ ...... ......... .................. ... 143
Generator - Inspect................................... ........... 143
Cleaning (Assembled Generators) .. .. .. ............. 144
Cleaning (Disassembled Generators) ..... ......... 144
Generator Isolating for Maintenance .. .... ... .. ... .. ..... 30
Generator Lead Connections ............... ........... ..... . 42
Connection Diagrams .................... .. .. ................ 43
Grounding the Frame ..... ...... ....... .......... ............. 43
Neutral Connections ...... .... ........... .. ... ... ...... ....... 43
Single Units .... ..... ......................... ... ... .... ........ .... 43
Generator Load- Check ...... ................... .. ... ........ 145
Generator Operation ........ ... ............. .. .... ..... ..... ... . 100
Block Loading .. ... .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .... ... .. .. . 100
Excitation System .. .. .. ... .. .. .. .. .. .. .. .. ... .. .. ...... .. .. .. 101
Generator Options .. .. .. .. .. .. .. .. ... ... ... .. .. .. ... ... ... .. . 101
Loading of the Generator .. ........... ...... ........ .. .... 100
Power Factor .. ..... ............. ............ .. .... ... ... ..... .... 101
Standby Electric Sets ..... .. .. .. ............ ... ............. 101
Generator Set - Test...... .... ..... .......... ..... ........... ... 145
Generator Set Identification.................... .. ... .. .. ... ... 42
Generator Set Vibration - Test/Record .. .. .. .. .. .. .. .. 146
Generator Start-up Checklist. ............................... 112
169
Index Section
H
Heat Exchanger- Inspect.. .. ............ .............. .. .... 147
Cleaning the Heat Exchanger ........ .................. 147
Hoses and Clamps -Inspect/Replace .. .. .. ...... ..... 147
Inspect the Hoses and the Clamps ... ......... ...... 148
Replace the Hoses and the Clamps ................ 148
Important Safety Information .. ............. .. .. ...... .. ...... .. 2
Installation ...... ... .... .. ........ ..... ... .. .. ...................... .... 50
Instrument Panel - Inspect... ........... .................. ... 150
Insulation- Test ........ ............. ... ... .... ........ .. ...... .... 150
Exciter Armature (Rotor L2) .. ... .... .. .. .. .. ... .. . .. .... 152
Exciter Field (Stator L 1) .. .. .. .... .. .. .. .. ... .. .... .. .. ... . 152
Main Armature (Stator L4) .. ............... .. ... ......... 151
L
Lifting and Storage .... ... .. .... .... ..... ........... ............... 48
M
Maintenance Interval Schedule .. ..... .. ............... .... 115
Maintenance Log......................... ..... ................... 167
Maintenance Recommendations ................... .... .. 109
Maintenance Records .................. .. .. ......... ........... 165
Maintenance Section ... ... .. .......... ............... ......... . 107
Model View Illustrations ....... ....... ..................... ...... 31
Model Views .. .. .. .. .. ... .. .. .. .. .. .. ..... .. ..... .... ..... .. .... .... .. 31
Mounting and Dismounting ..... ................. ........... ... 28
0
Operation Section .... ....... ........ ................... .. .. ... ... .. 48
Ordering Replacement Parts .. .. .......... ....... .... ...... 163
Overhaul Considerations............................... .. .... 152
Oil Consumption as an Overhaul Indicator ...... 152
Overhaul Recommendation .. .. .. .. .. .. ... .. .. .. ... ... .. 153
p
Parallel Operation................................................ 102
Circulating Currents........ .. .. .............. ... ...... .. .. .. 105
Initial Start-Up ...... ... .. .. ... .. .... .. .. .. .... ........... .. .... . 102
Load Division and Speed Droop (If Equipped).. 104
Parallel Operation Of Governors....... ...... ......... 104
Paralleling Multiple Units.. ...... .. .. ........... ........... 104
Starting Multiple Units.......... .... .......... .. .. .. ....... . 104
Stopping............... ................ ............................ 105
Plate Locations and Film Locations .... .. ............ ..... 41
Generator Identification Plate .... ......... ....... ........ 41
Serial Number Plate ........... .. .... ........... .. .......... .. . 41
Product Description ................ .. .. .. ....................... .. 39
Engine Specifications .. ..... ... ....... ... .... .... ... .. ..... ... 40
170 SEBU7919-03
Index Section

Product Identification Information ........ ........ .. .... .... 41 Stopping the Engine (Protection and Parallelling
Product Information Section ..... ... ..... ... ........ ......... . 31 Unit (PPU) Control Panel and Marine Certification
Product Installation .... ........... .. .... ...... ..... ..... ...... ..... 50 Society (MCS) Control Panel (if equipped)) .... .... . 93
Electrical Measurements .... ..... ................ ........... 50 Manual Operation ... ..... ........... ..... ......... ... ... ....... 97
Location .. .. .. ... .. .. .. .. .. .. ... ... .. .. .. ... .. ... .. .. .. .. .. ... .. .. .. . 50 Remote Operation .. ........ ...... ....... ........... ... ......... 97
Protective Devices .. .. .. ...... .... .. .... ..... .. .... ...... .... .. 51 System Pressure Release ..... .. ............................ 109
Receiving Inspection ............... ................... .. ..... . 50 Coolant System .......................................... ...... 109
Unpacking ............ .. .......... .. .... .. .. ........................ 50 Engine Oil .. .. ............. ....... ........ ...... .. ....... .... ...... 11 0
Product Lifting .. .. ....... ... .. ........ ...... ... ........ ........ ....... 48 Fuel System... .......... .... ........ ..... ...... ... ... ... .... .... 109
Engine Lifting with a Fuel Tank ... .. ...... ............... 48
Lifting of Generator Sets .. ........ ................... ....... 48
Product Storage .... ..... ......... ..... .. ....... ................. .... 49 T
Generator Storage .... ... .. .. .. .. .. .. .. ... .. .... ...... ......... 49
Table of Contents............. ...... .......... .... .... .. ............ .. 3
Turbocharger- Inspect/Clean .. ........ ............... ... .. 158
R Cleaning and Inspecting .... .... .. .............. .......... 159
Removal and Installation .... ...... ................ ........ 159
Reference Information Section ... ...... ... ... .. ..... .. .. .. 162
Reference Material .. .. .. .. .. ... .. .. . .. .. .. .. .. .. ... ... ... .... ... 164
Additional Reference Material .. ......... ....... .... .... 165 v
Coolants.. ..... ....... ... ... .... ..... ... ... ... .... .... .. ...... ..... 164
Emissions Warranty .......... .... ........... ... .. .. ......... 165 Varistor- Check .. ......... ..... ........... .... ....... .. ... .... .. .. 160
Fuels .................................................. .. .. .......... 164 Varistor- Inspect.. ........................ .. .............. ........ 160
Lubricants ..... ..... .... .. .. ..... .......... ...... .... ... .... .. .... 164 Voltage and Frequency- Check ... ..... ......... ...... ... 160
Miscellaneous......... ......... ..... ..... ........ ..... .. ..... .. 164 Voltage Regulators .... .. .... .. ........ ...... .. ........... ......... 75
Reference Materials ... .. .. .. ... ... .. ... .. ... .. .. .. ... .... .. .... 164 R438 Adjustment for Maximum Excitation ......... 78
Refill Capacities ... ....... .......... ...... ......... ... ............. 107 R438 Adjustments ... ....... ....... ........ ........ .... ....... .. 76
Refill Capacities and Recommendations .... .. .... ... 107 Special Use ... ...... .... .. .. .. ..... ....... .. .. ...... ... ... ......... 79
Cooling System ..... .. .. ....... ........ ........ .. .... ..... ..... 108
Fuel ...................................................... .. ..... ..... 107
Lubrication System .. .. .. ... .. .. ... .. .. ... .. .. ..... .. ... .. .. . 107 w
Rotating Rectifier - Check.. .... .. ...... .. .... .......... ...... 155
Rotating Rectifier - Test.......... ..... ....... .... ..... ...... .. 155 Walk-Around Inspection .. ........... .... ........ .. .. ..... .... 160
Inspect the Engine for Leaks and for Loose
Connections ........ ..... ..... .... ... ... .... ........ ... .... .... 160
s Water Pump- Inspect.. .. ........ .. .. ..... ... ........... ... .. .. 161
Welding on Engines with Electronic Controls ... .... 110
Safety Messages..... .... ......... .... .......... ... .. .......... ..... . 6
Safety Section .. .. .. .. .. .. .. .. .. .. ... ... .. .. .. .. .. .. .. .. ... ... .. .. .. .. . 6
Sea Water Strainer- Clean/Inspect.. .. ..... .. ... .. .. .. . 156
Clean the Sea Water Strainer......... ..... ........... . 157
Drain the Sea Water Cooling System .. ......... ... 156
Filling the Sea Water Cooling System .. .. .. .. .. ... 157
Single Unit Operation ... ..... ........ .... ... .. ................. 101
Adjust the Voltage ... .......... ... .. .... ...... .... ...... .. ... . 102
Initial Start-Up ..... ..... ..... ......... .... ...................... 101
Starting ..... ...... .. ... ........ ..... .... ... .... ............... .. ... . 102
Stopping............................. ... ................ .. ......... 102
Space Heater - Check ......... .. .. .. .......... ...... ........ .. 158
Starting Motor - Inspect .. .. .... .. .. .... .. ........... ....... .. . 158
Starting the Engine (Protection and Paralleling
Unit (PPU) Control Panel and Marine Certification
Society (MCS) Control Panel (if equipped)) ..... ... . 81
Engine Shutdown Override Switch .. ... .. .... .... ..... 86
Local Operation .. .................... .. .. .... .. ...... ... ..... .. .. 85
Remote Operation ............. ...... ......... .... .......... .... 86
Stator Lead - Check............. ..... ........................ .. . 158
Stator Winding Temperature - Measure/Record .. 158
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: __________________________ _____________________________

Engine Serial Number: ___________________ _ _ _ ______ _______________________

Generator Serial Number: __________________________________________________

Attachment Serial Numbers: - - - - - - ------------------------- - - - - - - -- - - -

Attachment Information: - - - - -------------------- - - - - - - - - - - - - - --------------

Dealer Equipment Number: _________________________________________________

Dealer Information
Name: Branch : - -----------------------

Address:

Dealer Contact Phone Number

Sales:

Parts:

Service:
 (C):?011 C":FitP.rpillar Cat, Caterpillar, their respective logos. "Caterpillar Yellow" and the Power edge
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Catcrpillm and may not be used without permission .
....__ __