SEBU9041-03

December 2013

Operation and
Maintenance
Manual
C32 Marine Generator Set
RTK 1-Up (Generator Set)

SAFETY.CAT.COM
 i05296198

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury 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.
SEBU9041 3
Table of Contents

Table of Contents Maintenance Section

Foreword.............................. ............................. 4 Refill Capacities....................... ....................... 72

Maintenance Recommendations.......... .......... 80

Safety Section
Maintenance Interval Schedule ........... ........... 86
Safety Messages....................... ....................... 5

General Hazard Information ............... .............. 9

Warranty Section

Burn Prevention....................... ....................... 12 Warranty Information .................. .................. 152

Fire Prevention and Explosion Prevention ... .. 13 Reference Information Section

Crushing Prevention and Cutting Prevention . 15 Engine Ratings ....................... ...................... 153

Mounting and Dismounting............... .............. 15 Engine Performance and Performance Analysis

Report (PAR)........................ ....................... 154
Before Starting Engine ................. .................. 15
Customer Service ..................... .................... 155
Engine Starting ........................ ....................... 16
Reference Materials .................. ................... 158
Engine Stopping ....................... ...................... 16
Index Section
Electrical System ...................... ...................... 16
Index............................... .............................. 162
Engine Electronics..................... ..................... 18

Generator Isolating for Maintenance ....... ....... 19

Product Information Section

General Information.................... .................... 20

Product Identification Information.......... ......... 25

Operation Section

Lifting and Storage..................... ..................... 27

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

Engine Starting ........................ ....................... 54

Engine Operation...................... ...................... 57

Generator Operation.................... ................... 58

Cold Weather Operation................. ................ 66

Engine Stopping ....................... ...................... 70

4 SEBU9041
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 Cat
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Cat 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 and
approximate the indicated service meter reading.
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 Cat
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 Cat dealer. Your Cat 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 Cat dealer. Consult with your dealer for
information regarding these options.
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.
SEBU9041 5
Safety Section
Safety Messages

Safety Section
i05228975

Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Become familiar with all of the 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 for cleaning 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 the
engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Cat dealer
can provide new safety messages.

Illustration 1 g03339811
View of the right side of a C32 Marine Generator Set
6 SEBU9041
Safety Section
Safety Messages

Illustration 2 g03339815
View of the left side of a C32 Marine Generator Set
SEBU9041 7
Safety Section
Safety Messages

Universal Warning (1)

Illustration 3 g01370904

One safety message is located on the valve cover

base towards the front of each side of the engine. A
universal warning is located on each side of the
terminal box. Illustration 4 g01384734

Do not operate or work on this equipment unless

you have read and understand the instructions Hot parts or hot components can cause burns or
and warnings in the Operation and Maintenance personal injury. Do not allow hot parts or compo-
Manual. Failure to follow the instructions or heed nents to contact your skin. Use protective cloth-
the warnings could result in injury or death. Con- ing or protective equipment to protect your skin.
tact any Cat dealer for replacement manuals.
Proper care is your responsibility.
Hot Fluid Under Pressure (3)
Hot Surface (2)
One message is located on each side of the barrel of
the generator.

Illustration 5 g01371640

One safety message is located on the top of each

expansion tank.
8 SEBU9041
Safety Section
Safety Messages

Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before per-
forming any cooling system maintenance.

Electrical Shock (4)

The safety message for electrical shock is located on
Illustration 7 g01392484
the sides of the terminal box and the rear of the
terminal box.

When the engine is in the AUTOMATIC mode, the

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

Lifting the Genset (6)

This safety message for lifting the genset is located
on the side panels of the terminal box.

Illustration 6 g01372247

WARNING! Shock/Electrocution Hazard! Read

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

Automatic Starting (5)

The safety message for automatic starting is located
on the sides of the terminal box.

Illustration 8 g01433231

Crushing Hazard! Improper lifting could cause

serious injury or death. Follow the lifting instruc-
tions in the Operation and Maintenance Manual
for safe lifting procedures.
SEBU9041 9
Safety Section
General Hazard Information

i05334609

General Hazard Information

SMCS Code: 1000; 4450; 7405

Illustration 10 g00702020

• Wear a hard hat, protective glasses, and other

Illustration 9 g00104545
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
serviced.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
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:

• Grease fittings

• Pressure taps
• Breathers

• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two bolts
or nuts that are located at opposite ends of the cover
plate or the device. Before removing the last two bolts
or nuts, pry the cover loose in order to relieve any
spring pressure or other pressure.
10 SEBU9041
Safety Section
General Hazard Information

• The engine is stopped. Ensure that the engine Fluid Penetration

cannot be started.

• The protective locks or the controls are in the

applied position.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• When starting a new engine, make provisions to

stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine. Illustration 11 g00687600

• 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.
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).
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. Always wear eye
protection for cleaning the cooling system.
Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when
redeposited on hot surfaces.
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 con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component 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.
SEBU9041 11
Safety Section
General Hazard Information

Static Electricity Hazard when Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct installation
Fueling with Ultra-low Sulfur Diesel of these components will help to prevent these
Fuel effects: vibration, rubbing against other parts and
excessive heat during operation.
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the Inhalation
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.

Illustration 12 g02159053

Avoid static electricity risk when fueling. Ultra-low

sulfur diesel fuel (ULSD fuel) poses a greater stat-
ic ignition hazard than earlier diesel formulations
with a higher sulfur contents. Avoid death or seri-
ous injury from fire or explosion. Consult with
your fuel or fuel system supplier to ensure the de-
livery system is in compliance with fueling stand-
ards for proper grounding and bonding practices.
Lines, Tubes, and Hoses
Do not bend or strike high-pressure lines. Do not
install lines, tubes, or hoses that are damaged.
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
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
Cat 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.
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 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:

• 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
12
Safety Section
Burn Prevention
• 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 Softwrap material. 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.
Reference: The applicable material safety data
sheets can be found at the following web site by
searching using part number or the name:
http://dsf2ws.cat.com/msds/servlet/
cat.cis.ecs.msdsSearch.controller.
UserIdentificationDisplayServlet
SEBU9041
Dispose of Waste Properly
Illustration 13 g00706404
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.
i02088921
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the
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.
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 or hot
components to contact the skin.
SEBU9041
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
i05326156
Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 4450; 7405
Illustration 14 g00704000
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.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
13
Safety Section
Fire Prevention and Explosion Prevention
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your 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.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray from a failed line,
tube, or seal. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and 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.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
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.
14
Safety Section
Fire Prevention and Explosion Prevention
Illustration 15 g00704059
Use caution when you are refueling an engine. Do not
smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Note: Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formulations
with a higher sulfur content. Avoid death or serious
injury from fire or explosion. Consult your fuel or fuel
system supplier to ensure that the delivery system is
in compliance with fueling standards for proper
grounding and bonding practices.
SEBU9041
Illustration 16 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.
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.
SEBU9041
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.
i01359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
15
Safety Section
Crushing Prevention and Cutting Prevention
i01372247
Mounting and Dismounting
SMCS Code: 1000; 4450; 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.
Face 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 overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
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.
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.
16
Safety Section
Engine Starting
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.
i03941639
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine with the engine start switch.
Always start the engine according to the procedure
that is described in this Operation and Maintenance
Manual, “Starting the Engine” for information about
starting the engine. Know the correct procedure to
prevent major damage to the engine components.
Know the correct procedure to prevent personal
injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
Engine exhaust contains products of combustion that
can be harmful to your health. Always start the engine
and operate the engine in a ventilated area. If the
engine is started in an enclosed area, vent the engine
exhaust to the outside.
SEBU9041
i01462046
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in the
Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.
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.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
To stop an electronically controlled engine, cut the
power to the engine.
i05187136
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 may cause the combustible
gasses that are produced by some batteries to ignite.
Connect the negative jump-start cable last from the
external power source to the negative terminal of the
starting motor. This connection sequence helps to
prevent sparks from igniting any combustible gasses
which batteries may produce. 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 operated. Repair all frayed
electrical wires before the engine is started. See this
Operation and Maintenance Manual, “Engine
Starting” for specific starting instructions.
Grounding Practices
Properly ground the electrical system for the vessel
and the engine. Proper grounding is necessary for
optimum engine performance and reliability. Improper
grounding will result in uncontrolled or unreliable
electrical circuit paths.
SEBU9041 17
Safety Section
Electrical System

Uncontrolled or unreliable electrical circuit paths may

result in damage to main bearings, crankshaft bearing
journal surfaces, and aluminum components.
Uncontrolled electrical circuit paths may also cause
electrical noise. Electrical noise may degrade the
performance of the vessel and of the radio.
Connect the starting motor directly to the negative
battery terminal. Connect the alternator to the
negative battery or negative terminal for the starting
motor. The alternator and the starting motor must
meet marine isolation requirements.

Note: All electrical connections must meet or exceed

the American Boat and Yacht Council Standard E-11.
Use a bus bar with a direct path to the negative
battery terminal for low current components that
require a negative battery connection. Connect the
bus bar directly to the negative battery terminal.
Note: All return paths to the negative battery must be
able to carry any likely fault currents.
The use of a bus bar ensures that the electronic
control module (ECM) and the components
connected to the ECM have a common reference
point.
Refer to Special Instruction, REHS1187, “Marine
Engine Electronic Installation Guide” for additional
information on grounding procedures.
18 SEBU9041
Safety Section
Engine Electronics

Negative Battery Connection for Multiple Engines

Illustration 17 g03324810

(1) Engines (8) Direct current (DC) main negative bus bar (14) Zinc bar
(2) Parallel switch (9) Alternating current (AC) grounding bus (15) Electronics ground plate
(3) Customer miscellaneous vessel loads bar (16) Chain plates
(4) Overcurrent protection (10) Strainer (17) Grounding bus bar
(5) Battery (11) Cathodic protection bus bar (18) Engine negative terminal
(6) Battery disconnect switches (12) Lightening protection ground point (19) Battery
(7) Battery (13) Immersed ground plate

Install the battery disconnect switches as close as i02784356

possible to the battery positive (+) but outside of the
battery enclosure. Engine Electronics
Note: If multiple bus bars are used to connect SMCS Code: 1000; 1900
components to the negative battery, a common
reference should be provided. All bus bars must be
wired together for proper engine synchronization for
multiple engine operations.
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
SEBU9041 19
Safety Section
Generator Isolating for Maintenance

This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be monitored
as a part of the Engine Monitoring System:
Illustration 18 g00104545
• Operating Altitude
2. Attach a “DO NOT OPERATE” or similar warning
• Engine Coolant Level tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
• Engine Coolant Temperature

• Engine Oil Pressure 3. Disconnect the generator from the distribution

system.
• Engine Speed
4. Lock out the circuit breaker. Attach a “DO NOT
• Fuel Temperature OPERATE” or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify that
• Intake Manifold Air Temperature all points of possible reverse power flow have been
• System Voltage locked out.

The Engine Monitoring package can vary for different 5. For the following circuitry, remove the transformer's
engine models and different engine applications. fuses:
However, the monitoring system and the engine
monitoring control will be similar for all engines. • power

Note: Many of the engine control systems and • sensing

display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.
i01593543
Generator Isolating for
Maintenance
SMCS Code: 4450
When you service an electric power generation set or
when you repair an electric power generation set,
follow the procedure below:
1. Stop the engine.
• control
6. Attach a “DO NOT OPERATE” or similar warning
tag to the generator excitation controls.
7. Remove the cover of the generator's terminal box.
8. Use an audio/visual proximity tester in order to
verify that the generator is de-energized. This
tester must be insulated for the proper voltage
rating. Follow all guidelines in order to verify that
the tester is operational.
9. Determine that the generator is in a de-energized
condition. Add ground straps to the conductors or
terminals. During the entire work period, these
ground straps must remain connected to the
conductors and to the terminals.
20 SEBU9041
Product Information Section
Model View Illustrations

Product Information General Information

Section
i05229168

Model View Illustrations

SMCS Code: 1000

Illustration 19 g03340389
View of the right side of a C32Marine Generator Set
(1) Generator (8) Electronic control module (ECM) (13) Selector valve for the oil filters
(2) Control panel (9) Expansion tank for the jacket water (14) Oil filler tube
(3) Turbocharger system (15) S·O·S sampling valve
(4) Water-cooled exhaust (10) Fuel priming pump (16) Lifting eyes for the generator set
(5) Air cleaner (11) Selector valve for the secondary fuel (17) Secondary fuel filters
(6) Aftercooler filter (18) Oil sampling valve
(7) Fumes disposal filter (12) Secondary fuel filters (19) Air starting motor
SEBU9041 21
General Information
Model View Illustrations

Illustration 20 g03340390
View of the left side of a C32Marine Generator Set
(20) Expansion tank for the separate circuit (21) Jacket water heater
aftercooled system (SCAC system)
22 SEBU9041
General Information
Model View Illustrations

Illustration 21 g03340395
View of the front of a C32Marine Generator Set
(22) Heat exchanger for the jacket water (24) Water pump for the SCAC cooling (26) Water pump for the jacket water cooling
cooling system system system
(23) Heat exchanger for the SCAC cooling (25) Damper
system

Illustration 22 g03340393
View of the top of a C32Marine Generator Set
(27) Lifting eye for the generator (28) Lifting eyes for the engine
SEBU9041 23
General Information
Product Description

i05026054 C32Marine Engines

Product Description
SMCS Code: 1000; 4450; 4491
These Cat C32 Marine Generator Sets have the
following characteristics:
• Four-stroke cycle

• Direct fuel injection

• Mechanically actuated electronic unit injection

• Turbocharging
• Separate circuit aftercooling (SCAC)
The Mechanical Electronic Unit Injector (MEUI) fuel Illustration 23 g00531921
system eliminates many of the mechanical Cylinder and valve locations
components that are used in a pump-and-line (A) Inlet valves
system. The electronic control and mechanical (B) Exhaust valves
actuation also provide increased control of the timing (C) Front of the engine
and increased control of the fuel injection pressure.
The timing advance is achieved by precise control of Table 1
the unit injector timing. Engine speed is controlled by
adjusting the injection duration. A special speed- C32 Marine Engine Specifications
timing wheel provides information to the Electronic Cylinders and Arrangement 12 cylinder vee block
Control Module (ECM) for detection of cylinder
position and engine speed. Bore 145 mm (5.7 inch)

The C32 Marine Engine uses a low emission system
which is integrated into the engine air cleaner. This
system eliminates the venting of oil vapors into the
engine room. The closed crankcase ventilation
system is completely enclosed. This system requires
a minimum amount of maintenance.
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left side and the right
side of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
Stroke 162 mm (6.4 inch)
Compression Ratio 15:1
Aspiration Twin Turbocharged Aftercooled
Aspiration
Displacement 32 L (1953 in3)
Firing Order 1-10-9-6-5-12-11-4-3-8-7-2
Rotation (flywheel end) Counterclockwise
Electronic Engine Features
The engine has built-in diagnostics in order to ensure
that all of the components are operating properly. In
the event of a system component failure, the operator
will be alerted to the condition via the diagnostic lamp
located on the control panel. Cat Electronic
Technician (ET) can be used to read the numerical
code of the faulty component or condition. Intermittent
faults are also logged and stored in memory.
These Cat Marine Engines are designed with
electronic controls. The integral on board computer
controls the operation of the engine. Current
operating conditions are monitored. The Electronic
Control Module (ECM) controls the response of the
engine to these conditions and to the demands of the
operator. These conditions and operator demands
determine the precise control of fuel injection by the
ECM. The electronic engine control system provides
the following features:
24
General Information
Product Description
• Engine monitoring
• Electronic engine speed governing
• Automatic air/fuel ratio control
• Torque rise shaping
• Injection timing control
• System diagnostics
The engine ECM will automatically provide the
correct amount of fuel in order to start the engine. Do
not hold the throttle down while the engine is
cranking. If the engine fails to start in 20 seconds,
release the starting switch. Allow the starting motor to
cool for 2 minutes before using the starting motor
again.
For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section).
Engine Cooling and Lubrication
The engines have water-cooled exhaust manifolds,
risers, and turbochargers. These components will
minimize the heat that is radiated into the engine
room. Changes to the cooling system of these
engines minimize the weight and the size of the
engine. These changes also improve the engine
performance. The cooling system heat exchangers,
the expansion tanks, and the deaerator help to
prevent cavitation of the water pumps. Water pumps
that work properly help maintain the performance of
the jacket water pump.
The cooling system consists of the following
components:
• Centrifugal jacket water pump that is driven by
gears
• Two water temperature regulators which regulate
the engine coolant temperature
• Oil cooler
• Auxiliary water pump and a SCAC water pump
• Deaerators that remove air from the coolant
• Treated water aftercooling
The engine lubricating oil, which is supplied by a
gear-type pump, is cooled. The engine lubricating oil
is also filtered. Bypass valves provide unrestricted
flow of lubrication oil to the engine components during
the following conditions:
• High oil viscosity
• Plugged oil cooler or plugged oil filter elements
(paper cartridge)
SEBU9041
Engine Service Life
Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
application guidelines and operation and
maintenance recommendations. In addition, use
recommended fuels, coolants, and lubricants. Use
this Operation and Maintenance Manual as a guide
for required engine maintenance.
Expected engine life is generally predicted by the
average power that is demanded. The average power
that is demanded is based on fuel consumption of the
engine over time. Reduced hours of operation at full
throttle and/or operating at reduced throttle settings
result in a lower average power demand. Reduced
hours of operation will increase the length of
operating time before an engine overhaul is required.
For more information, refer to the Operation and
Maintenance Manual, “Overhaul Considerations”
topic.
Description of the Generator
These brushless generators are used with the
following loads: mixed loads of motors and lights,
SCR-controlled equipment, computer centers,
installations of communications and petroleum drilling
applications. The elimination of the brushes in the
field circuit reduces maintenance. The elimination of
the brushes in the field circuit increases reliability.
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
generator set packages can be used in land-based
applications or marine applications.
The generators have four poles. The generators have
six lead configurations. The generators can produce
electrical power in either 50 Hz or 60 Hz applications.
SEBU9041 25
Product Identification Information
Plate Locations and Film Locations

Product Identification
Information
i05048259

Plate Locations and Film

Locations
SMCS Code: 1000; 4450
Cat engines are identified by serial numbers and by
arrangement numbers. These numbers are shown on
the Engine Serial Number Plate and on the Engine
Identification Plate. Cat dealers need these numbers
in order to determine the components that were Illustration 25 g00123229
included with the engine. This permits accurate Typical serial number plate
identification of replacement part numbers.

Engine Serial Number (1) Engine Identification Plate (2)

The Engine Serial Number Plate is located on the left The Engine Identification Plate is located on the
side of the engine block near the front at the bottom of exhaust manifold on the side of the engine that is
the water jacket. used for service.

Illustration 24 g03217620 Illustration 26 g03217622

Location of the Engine Serial Number Plate Location of the Engine Identification Plate
26 SEBU9041
Product Identification Information
Emissions Certification Film

Modification Number
Engine Low Idle Speed
Engine Full Load Speed
Performance Specification Number
Primary Fuel Filter Element
Secondary Fuel Filter Element
Engine Oil Filter Element
Auxiliary Oil Filter Element
Supplemental Coolant Additive Maintenance Element
Illustration 27 g00102789
Typical information plate Engine Oil Capacity
The following information is stamped on the Engine Total Cooling System Capacity
Identification Plate.
Air Cleaner Element
Engine Serial Number
Fan Drive Belt
Engine Arrangement Number
Alternator Belt
Engine Modification Number
Generator Arrangement Number
The engine identification plate also contains other
important information about the engine. Generator Set Serial Number
Generator Frame Size
i04019095
Voltage Rating
Emissions Certification Film kW Rating
SMCS Code: 1000; 7405
Excitation System
Note: This information is pertinent in the United AREP
States, in Canada and in Europe.
Self-Excited
Consult your Cat dealer for an Emission Control
Warranty Statement. Permanent Magnet
This label is located on the engine.

i04397923

Reference Information
SMCS Code: 1000; 4450
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.

Record for Reference

Engine Model
Engine Serial Number
Engine Arrangement Number
SEBU9041 27
Operation Section
Product Lifting

Operation Section

Lifting and Storage

i05235663

Product Lifting
SMCS Code: 7000; 7002

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.
Illustration 28 g03341050

Use a hoist to remove heavy components. Use an Lifting the Entire Package
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting fixtures in order to
obtain proper balance. Lifting fixtures also help to
provide safety.
Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure that
proper lifting devices are provided. Consult your Cat
dealer for information regarding fixtures for proper
engine lifting.
Illustration 29 g03341055

Do NOT use the engine lifting eyes or the

generator lifting eyes to lift the entire package.
Lifting points have been provided on the base rails of
the generator set for lifting the entire package.
However, lifting the engine and the generator together
requires special equipment and procedures. Consult
your Cat dealer for information regarding fixtures for
proper lifting of your complete package.
28
Lifting and Storage
Product Storage
Lifting the Engine or Lifting the
Generator
Illustration 30 g03341053
To remove the engine, use the lifting eyes that are on
the engine. To remove the generator, use the lifting
eyes that are on the generator.
i04556994
Product Storage
SMCS Code: 7002
Note: If storage for more than 1 year is necessary,
contact your local Cat dealer for the procedure
specific to your product.
Engine
Storage (Less Than One Year)
If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft and gears.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.
When the engine is started again, metal to metal
contact will cause wear before the surfaces receive
oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge,
start the engine.
1. Clean the engine of any dirt, rust, grease, and oil.
Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.
2. Remove any dirt from any air cleaner. Check all
seals, gaskets, and the filter element for damage.
SEBU9041
3. Apply lubricant to all points in this Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
4. Drain the crankcase oil. Replace the crankcase oil
and change any oil filters. For the proper
procedure, refer to this Operation and
Maintenance Manual.
5. If the engine is equipped with an air starting motor,
fill the reservoir with 50 percent volatile corrosion
inhibitor oil (<nomen>VCI oil</nomem> ) and 50
percent engine oil.
6. Add VCI oil to the crankcase oil. The volume of VCI
oil in the crankcase oil should be 3 to 4 percent.
Note: If the engine crankcase is full, drain enough
engine oil so the mixture can be added.
7. Remove any air filter elements. Turn the engine at
cranking speed with the throttle control in FUEL
OFF position. Use a sprayer to add a mixture of 50
percent VCI oil and 50 percent engine oil into the
air inlet or turbocharger inlet.
Note: The mixture of VCI oil can be added to the inlet
by removing the plug for checking turbocharger boost
pressure. The minimum application rate for the VCI
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement.
8. Use a sprayer to apply a mixture of 50 percent VCI
oil and 50 percent crankcase oil into the exhaust
openings. The minimum application rate for the oil
mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement. Seal the exhaust pipe and
seal any drain holes in the muffler.
9. Remove the fuel from the secondary fuel filter
housing. Alternately, empty and reinstall the spin-
on fuel filter element in order to remove any dirt
and water. Drain any sleeve metering fuel pump.
Clean the primary fuel filter. Fill with calibration
fluid or kerosene. Install the primary fuel filter and
operate the priming pump. This procedure will
send clean oil to the secondary filter and the
engine.
Open the fuel tank drain valve in order to drain any
water and dirt from the fuel tank. Apply a spray of
calibration fluid or kerosene at the rate of
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
capacity in order to prevent rust in the fuel tank.
Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel.
Apply a small amount of oil to the threads on the
fuel tank filler neck and install the cap. Seal all
openings to the tank in order to prevent
evaporation of the fuel and as a preservative.
SEBU9041
10. Remove the fuel nozzles or spark plugs. Apply
30 mL (1 oz) of the mixture of oils (50 percent VCI
oil and 50 percent engine oil) into each cylinder.
Use a bar or a turning tool in order to turn over the
engine slowly. This procedure puts the oil on the
cylinder walls. Install all fuel nozzles or spark plugs
and tighten to the correct torque.
11. Spray a thin amount of the mixture of oil (50
percent VCI oil and 50 percent engine oil) onto the
flywheel, ring gear teeth and starter pinion. Install
the covers in order to prevent evaporation of the
vapors from the VCI oil.
12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move,
such as rod threads, ball joints, linkage.
Note: Install all covers. Ensure that tape has been
installed over the following components: openings, air
inlets, exhaust openings, flywheel housing,
crankcase breathers, dipstick tubes and any other
necessary components.
Ensure that all covers are airtight and
weatherproof. Use a waterproof weather resistant
tape such as Kendall No. 231 or an equivalent.
Do not use duct tape. Duct tape will only seal for a
short period.
13. Remove the batteries. As an alternative, place the
batteries in storage. As needed, periodically
charge the batteries while the batteries are in
storage.
If the batteries are not removed, wash the tops of
the batteries until the tops are clean. Apply an
electrical charge to the batteries in order to obtain
a specific gravity of 1.225.
Disconnect the battery terminals. Place a plastic
cover over the batteries.
Note: For additional information, refer to Special
Instruction, SEHS7633, “Battery Test Procedure”.
14. Loosen all belts.
15. Place a waterproof cover over the engine. Ensure
that the engine cover is secure. The cover should
be loose enough to allow air to circulate around the
engine in order to prevent damage from
condensation.
16. Attach a tag with the storage date to the engine.
17. Remove the waterproof cover at 2 month or 3
month intervals in order to check the engine for
corrosion. If the engine has signs of corrosion,
repeat the protection procedure.
29
Lifting and Storage
Product Storage
Conventional Coolant System
Completely fill the cooling system before storage.
Water or water mixed with supplemental coolant
additive (SCA) is not approved for use with Cat C7-
C32 Marine Engines which are cooled with heat
exchangers. Cat C7-C32 Marine Engines which are
cooled with heat exchangers require a minimum of 30
percent glycol to prevent cavitation of cooling system
components. A minimum of 50 percent glycol is very
strongly recommended.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for more information about
coolants.
Raw Water System
Completely drain the raw water system by removing
all the drain plugs from the raw water pump, water
shielded manifolds, heat exchanger bonnets and
aftercooler.
After the system has been drained, inspect all zinc
plugs (normally painted red) for damage from
corrosion.
Note: To ensure complete drainage and evaporation
during storage, DO NOT install the drain plugs and
zinc plugs. Place all removed plugs in a cloth bag and
fasten the bag to the engine for storage.
Removal from Storage
1. Remove all outside protective covers.
2. Change the oil and filters.
3. Check the condition of the fan and alternator belts.
Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts -
Inspect/Adjust/Replace” for the correct procedure.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner
elements.
6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.
30
Lifting and Storage
Product Storage
8. Pressure- lubricate the engine before starting the
engine. Pressure lubricating the engine ensures
immediate lubrication and prevents damage to the
engine during the first few minutes of engine
operation. If the engine is not equipped with a
prelube pump, contact your Cat dealer about
lubricating the engine before starting the engine.
9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.
10. Before start-up, test the cooling system for a 3 to
6 percent concentration of coolant conditioner. Add
liquid coolant conditioner or a coolant conditioner
element, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
11. If the engine is equipped with a fresh water
system, ensure that the system is clean. Ensure
that the system is full. Ensure that the system has
the correct amount of supplemental cooling system
conditioner.
If the engine is equipped with a raw water system,
install all of the drain plugs and zinc plugs. Fill the
system. It may be necessary to prime the raw
water system pumps before operation.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.
13. If the engine was removed from storage in which
temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Maintenance”.
Generator
Storage (Less Than One Year)
When a generator is in storage, moisture condenses
in the windings. To minimize condensation, always
place the generator in a dry storage area. Seal all
openings with tape.
If a brush-type generator (SRCR) is stored, lift the
brushes off the slip ring to prevent chemical action
damage to the slip ring. Attach a tag to the generator
which states that the brushes have been lifted.
Perform a resistance check of the windings. Record
this reading. This check is done in order to provide a
base line for determining whether moisture or winding
deterioration occurs during storage.
SEBU9041
Removal From Storage
Remove all protective covers. Reseat the brushes on
the slip ring for SRCR generators.
Before start-up of a generator, use a megohmmeter to
check insulation resistance for moisture and/or
foreign material. Refer to this Operation and
Maintenance Manual, “Generator Start-up Check List”
for the procedure. A resistance reading of 1 megohm
or less indicates that the winding has absorbed too
much moisture.
Use one of the following methods for drying the
generator in order to remove moisture which is
caused by high humidity or dampness:
1. Place the generator in an oven which is no hotter
than 85°C (185°F) for 4 hours.
2. Use a canvas enclosure around the generator and
heating lamps to increase the ambient
temperature. Provide an opening in the top of the
canvas in order to release the moisture.
3. Send a low voltage current through the windings in
order to increase the temperature of the windings
to 85°C (185°F).
Megohmmeter Checks
Test the main stator windings with a megohmmeter in
the following situations:
1. Before the initial start-up of the generator set
2. Every 3 months if the generator operates in a
humid environment
3. If the generator has not been run under load for 3
months or more
These intervals are only recommendations. Perform a
megohmmeter test more frequently if the environment
is extremely humid, salty, or if the last megohmmeter
test was close to 1 megohm.
Additional Information
For additional information about storage procedures,
refer to Special Instruction, SEHS9031, “Storage
Procedure for Cat Products”.
SEBU9041 31
Features and Controls
Alarms and Shutoffs

Features and Controls Testing the Alarm System and the

Shutoff System
i04423643
NOTICE
Alarms and Shutoffs During testing, abnormal operating conditions must
be simulated. Perform the tests correctly in order to
SMCS Code: 7400 help prevent possible engine damage.
Alarms and shutoffs are one of the three following
types: Refer to the System Operation, Testing and Adjusting
Manual for more information on testing procedures, or
• Switches consult your Cat dealer.
• Transducers
i03646563
• Differential pressure sensors
Battery Disconnect Switch
Alarms
(If Equipped)
Engines may be equipped with alarms that are used
to alert the operator when undesirable operating SMCS Code: 1411
conditions occur.
The battery disconnect switch and the engine start
switch perform different functions. Turn off the battery
NOTICE disconnect switch in order to disable the entire
When an alarm is activated, corrective measures electrical system. The battery remains connected to
must be taken before the situation becomes an emer- the electrical system when you turn off the engine
gency in order to avoid possible engine damage. start switch.
Turn the battery disconnect switch to the OFF
The alarm will remain active until the condition is position and remove the key when you service the
corrected. electrical system or any other components.

Shutoffs Also turn the battery disconnect switch to the OFF

position and remove the key when the engine will not
NOTICE be used for an extended period of a month or more.
This will prevent drainage of the battery.
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart
the engine. NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
Shutoffs are set at critical levels for the following age to the electrical system could result.
conditions:

• Coolant temperature To ensure that no damage to the engine occurs, verify

• Oil pressure
• Overspeed
A particular shutoff may need to be acknowledged at
the control panel before the engine will start.
Make sure that you are familiar with the following
items:
• Types and locations of shutoff sensors
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.

• Conditions that cause each shutoff to function 2. Turn the battery disconnect switch to the OFF
position.
• Resetting procedure for engine restart
32 SEBU9041
Features and Controls
Control Panel

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.

i05226309

Control Panel
(Marine Generator Set Engine
Control Panel 3 (MGECP 3))
SMCS Code: 7451
Refer to Special Instruction, REHS4817, “Overview
and Configuration of the Marine Classification Society
(MCS) Alarm and Protection (A&P), MCS Controller
and Remote Equipment Interface (REI)”.

Illustration 31 g03339009
Cat Marine Generator Set Engine Control Panel III (MGECP III)
(1) Display control unit (DCU) (6) Context-sensitive switches
(2) “POWER” indicator (7) “LOCAL STOP” switch
(3) “ALARMS” list (8) “LOCAL START” switch
(4) “START” switch (9) “DIGITAL THROTTLE RAISE/LOWER”
(5) “STOP” switch switch
SEBU9041 33
Features and Controls
Control Panel

(10) “IDLE/RATED” selector
(11) “MANUAL SPEED ADJUST” control
(12) “THROTTLE MODE SELECTOR”
switch
(13) “FAULT RESET” switch
(14) “VOLTAGE ADJUST” switch (19) “SCROLL UP”
(15) “EMERGENCY STOP” switch (20) “MENU” list
(16) “MODE SELECTOR” switch
(17) LCD Screen
(18) “SCROLL DOWN” switch

• The “L” symbol indicated that the control unit is in

local mode. Remote commands are not permitted
when the control unit is in local mode.

• The “M” symbol indicates that the control unit is in

manual mode. The “Automatic Start/Stop”
function is not permitted when the control unit is in
manual mode.
• The “SO” symbol indicates that the control unit is
in shutdown override mode.

• The green “OK” symbol indicates that the

following events are not present on the alarms list:
warning, alarm and shutdown. The green “OK”
Illustration 32 g03341433
symbol indicates that no yellow diagnostic
messages and no red diagnostic message are
Inside of panel door present on the alarms list.
(21) “CRANK OVERRIDE” switch
(22) “SHUTDOWN OVERRIDE” switch • The wrench symbol indicates that a maintenance
interval which has been programmed into the
Controlling the Generator Set Using control unit is overdue.
the DCU (1)
The control unit has switches for the following
functions:
• Engine starting

• Engine stopping
• Alarm list

• Menu
• Up arrow and down arrow

• Four Context-sensitive switches with varying

functionality
The LCD screen is divided into three main sections:

Status Bar
The status bar is the top line on the screen. The
status bar is reserved for the engine state and status
symbols.
34 SEBU9041
Features and Controls
Control Panel

Main Screen (Instrument Screen)

Illustration 33 g02176582

All instruments and menu items are displayed on the Context Sensitive Switches
main screen. The screen for the control unit may
have multiple instrument screens. Press the “UP The bottom line on the screen is for the four Context-
ARROW” switch and press the “DOWN ARROW” sensitive switches. The functions of the Context-
switch in order to navigate between the instrument sensitive switches vary.
screens. If there is only one instrument screen,
pressing the switches does not change the screen.
Pressing the same switch repeatedly will eventually
scroll back to the first screen.
The following symbols and icons may be displayed
on the instrument screen:

Yellow Triangle
The “YELLOW TRIANGLE” is the warning symbol.
When the “YELLOW TRIANGLE” flashes above an
instrument, a new warning exists for that channel.
The “YELLOW TRIANGLE” stops flashing when the
operator acknowledges the warning.

Red Triangle
The “RED TRIANGLE” is the alarm symbol or the
shutdown symbol. When the “RED TRIANGLE”
flashes above an instrument, a new alarm exists for
that channel or the channel is responsible for an
engine shutdown. The “RED TRIANGLE” stops
flashing when the operator acknowledges the alarm.
SEBU9041 35
Features and Controls
Control Panel

Start Engine and Stop Engine

36 SEBU9041
Features and Controls
Control Panel

Starting the Engine

Illustration 34 g02176581

The “START” switch may be configured as

LATCHED or as HOLD. The values for the “START”
switch and the values for the “STOP” switch always
match.
Start the engine with one of two methods:

• If the “START” switch is configured as LATCHED,

perform the following sequence in order to start the
engine: press the “START” switch, observe the
confirmation dialog and press “YES” . The control
unit will complete the starting sequence.

• If the “START” switch is configured as HOLD,

press and hold the “START” switch until the
engine starts.
SEBU9041 37
Features and Controls
Control Panel

Stopping the Engine

Illustration 35 g02176599

The “STOP” switch may be configured as LATCHED

or as HOLD. The values for the “STOP” switch and
the values for the “START” switch always match.
Stop the engine with one of two methods:
• If the “STOP” switch is configured as LATCHED,
perform the following sequence in order to start the
engine: press the “STOP” switch, observe the
confirmation dialog and press “YES” . The control
unit will complete the stopping sequence.
• If the “STOP” switch is configured as HOLD,
press and hold the “STOP” switch until the engine
stops.
38
Features and Controls
Control Panel
List of Alarms
Illustration 36
Enter the Alarms List
Press the “ALARMS LIST” switch in order to view
the alarm list. Press the “ALARMS LIST” switch
again in order to leave the alarms list. The “EXIT”
switch may be pressed in order to leave the alarms
list.
Alarms are displayed in several colors and texts.
• The following entries are displayed in red text:
alarm entries, shutdown entries and automatic
stop entries.
• Warnings are displayed on a yellow background.
• New alarms (unacknowledged alarms) are
displayed in bold text.
• Acknowledged alarms are displayed in normal
text.
• An alarm that is not acknowledged before
becoming inactive is displayed in normal text on a
gray background.
• An inactive alarm that is displayed on a yellow
background was either an alarm or a shutdown.
• An inactive alarm that is displayed on a yellow
background was a warning.
SEBU9041
g02176135
Filter Alarms
The alarm list filters alarms into three groups:
• All alarms (all alarms and all diagnostics)
• Panel alarms (all alarms and no diagnostics)
• Diagnostics (diagnostics only)
Use the second Context-sensitive switch and the third
Context-sensitive switch in order to choose between
the three groups.
Silence the Buzzer
If the buzzer sounds, press the “ALARMS LIST”
switch in order to silence the buzzer.
• If the alarm list is not displayed before the
“ALARMS LIST” switch is pressed, press the
“ALARMS LIST” switch to display the alarms list.
• If the alarms list is displayed when the buzzer
sounds, pressing the “ALARMS LIST” switch will
silence the buzzer.
SEBU9041 39
Features and Controls
Control Panel

Acknowledge Alarms

Acknowledge a Single Alarm

Use the arrow switches in order to select an alarm for
acknowledgment. The selected alarm line will expand
to reveal any additional information.
Press the “ACKNOWLEDGE” switch in order to
acknowledge the selected alarm.

Acknowledge All Alarms

Press and hold the “ACKNOWLEDGE” switch for
one second in order to acknowledge all alarms.

Note: An active alarm is displayed until the active

alarm becomes inactive.
40 SEBU9041
Features and Controls
Control Panel

Menu

Illustration 37 g02163221

The menu screen displays the following items:

• Settings
• Counters

• Generator
• Display

• Configuration
• Help
SEBU9041 41
Features and Controls
Control Panel

Settings

Illustration 38 g02176304

Automatic/Manual Start Disabled

When the control unit is set to the AUTOMATIC
mode,the control unit may be started from a remote
signal and the control unit may be stopped from a
remote signal. When the control unit is set to the
MANUAL position,the control unit may not be started
from a remote signal and the control unit may not be
stopped from a remote signal. When the control unit
is In the MANUAL position, the M symbol is visible in
the status bar.
Select the “START DISABLED” switch in order to
disable the starting mechanism for the engine.
Note: Caterpillar recommends the removal of the
connection to the battery before any maintenance on
the engine is performed.
Prelube Override

Note: The control terminal 88 (Automatic mode)
overrides a MANUAL setting in the menu. When the
controller is in automatic mode, either the menu or the
remote signal can issue commands.
If the engine is configured for prelube, the
“PRELUBE OVERRIDE” function can cancel the
procedure. If the “PRELUBE OVERRIDE” function is
chosen during the prelube, the prelube is stopped
and the control unit continues the start procedure.

Local/Remote
In LOCAL mode, the control unit cannot be operated
remotely. An “L” symbol is visible in the status bar.
Communications commands are not operable in the
LOCAL mode.
Hard wired commands are not operable in LOCAL
mode.
42 SEBU9041
Features and Controls
Control Panel

Counters

Illustration 39 g02177046

The “COUNTERS” screen displays the service Since Restart

hours for the engine.
The “SINCE RESTART” screen displays the service
Three options may be selected from the hours which have accumulated since the reset
“COUNTERS” screen: function was last used. Press the “RESET” switch in
order to return the service hours which have
• Counters accumulated after the last reset to zero.

• Event Log
• Service Interval for the Engine

Total
The “TOTAL” screen displays the total service hours.
The operator may not reset the service hours.

Since Start
The “SINCE START” counter starts at ZERO each
time the engine is started. The “SINCE START”
counter continues to accumulate service hours until
the engine is stopped. The operator may not reset the
service hours.
SEBU9041 43
Features and Controls
Control Panel

Events Log

Illustration 40 g02176307

Use the “UP” arrow and the “DOWN” arrow in order
to navigate the event log.
An event may be any of the following items:
diagnostic event, warning alarm, shutdown and use
of a switch.
The control unit maintains a log of all events. The
latest 500 logged entries may be displayed. When the
number of events is larger than 500, the oldest events
are lost.
The event log may be sorted in four ways:
• The oldest entry is displayed first.
Service Intervals for the Engine
Service intervals for four maintenance procedures
may be programmed into the control unit. When a
programmed interval occurs, the alarms list displays a
wrench key beside the maintenance procedure.
When the maintenance is completed, select the
maintenance procedure and press “SERVICE
DONE” . This action restarts the counter for the
service hours for the service interval.

• The most severe entry is displayed first.

• The least severe entry is displayed first.

• Count
Timestamp – The selected event will be expanded.
The second line displays the service hour at which
the event occurred. For alarms, the second line also
displays the service hours for an acknowledged
inactive situation.
44 SEBU9041
Features and Controls
Control Panel

Generator

Illustration 41 g02177054

A Power Analyzer Module (PAM) may be connected

to the control unit to allow the control unit to read the
parameters for the generator. The connection is
shown by a “GENERATOR” symbol which is
displayed on the generator screen.

Note: Press the “UP” switch or press the “DOWN”

switch from the normal instrument view to display the
values for the generator.
SEBU9041 45
Features and Controls
Control Panel

Display

Illustration 42 g02176308

Screen Backlight Language

Select between the following settings for the screen
backlight:
• 10 percent backlighting for the darkest setting.
• 50 percent backlighting for the medium setting.
• 100 percent backlighting for the setting with the
most backlighting.
• The automatic setting uses an ambient light
detector in order to vary the backlighting between
10 percent and 100 percent.
Select the language which will be displayed on the
panel from the following languages: English, French,
Spanish, Italian, German, Dutch, Russian, Norwegian
and Chinese.
Note: Text for the configured instruments must be
manually translated during the installation process.
Selecting a language which has no manual
translation causes the default language to be used.
Use the Context-sensitive switches while viewing an
instrument screen to adjust the preferred language.

Units of Measure
Select the unit of measure:

• “METRIC”
• “US” (English)
46 SEBU9041
Features and Controls
Control Panel

Configuration

Illustration 43 g02176309

Test for Engine Overspeed

When the DCU is in the “ENGINE OVERSPEED
TEST” mode, the automatic procedure for shutting
down the engine due to an overspeed condition may
be tested. Lower the overspeed setpoint to the
nominal speed and use the following procedure to
perform this test:

1. Make sure that the engine is not running. The

“ENGINE OVERSPEED TEST” mode cannot be
entered if the engine is running.

2. Observe the red arc on the “RPM METER” in

order to make sure that the overspeed setpoint has
been lowered.
3. Start the engine and adjust the rpm until the rpm
rises above the overspeed setpoint.

4. Observe the engine shutdown.

The test for engine overspeed is timed out after 5
minutes or when an actual overspeed situation
occurs. The test can be stopped by selecting the
“Engine Overspeed Test” again.
SEBU9041 47
Features and Controls
Control Panel

Help

Illustration 44 g02176580

A number of troubleshooting screens exist for the

DCU.
48 SEBU9041
Features and Controls
Control Panel

Illustration 45 g02176619

Supply • Value

The two power supplies are listed. Information about • Faulty circuit
voltage and information about supply selection may
be viewed. • Channel use

Switch Channels COM (Communications)

Each of the eight switch channels may be viewed for
information about whether the switch is open ( “OV” )
or closed ( “24v INPUT” ).
4-20mA Channels
The following information may be displayed for each
of the 4-20mA channels:
• Current, 2-25mA which is indicated in mA
This section lists the communication status for
communication ports 1, 2, 3, 4 and 6.
Output
This section lists the output status on terminals 63
through 84 for the DCU.
Input

• Broken wire (<2mA) This section lists the input status on terminals 86
through 97 for the DCU.
• Short circuit (>25mA)
Run Indication Sources
• Channel use
A number of different sources may be configured to
PT100 Channels indicate engine operation. The “RUN INDICATION”
page indicates which source is providing the
The following information may be displayed for each information about engine operation to the DCU.
of the four PT100 channels:
SEBU9041 49
Features and Controls
Control Panel

Switch Test
This section allows all DCU switches to be tested. To
exit the “SWITCH TEST” tab, press and hold the
second Context-sensitive switch. Press the fourth
Context-sensitive switch to exit. Press the first
Context-sensitive switch to change tabs.
50
Features and Controls
Control Panel
Version Information
Illustration 46
This section displays the following information:
• Hardware version
• Software version
• ECM version (if applicable)
• Internet Protocol (IP) number of the DCU
Operating the Generator Set Using
the Control Panel
“ LOCAL STOP”” Switch (7)
The “LOCAL STOP” switch may be used to stop the
engine when a fault with other systems exists. The
“LOCAL STOP” switch may be used in a non-critical
situation when other stop methods have failed. Use of
the “LOCAL STOP” switch activates a direct request
circuit to the engine fuel control. No cool down delay
will occur.
The “LOCAL STOP” switch is always available to
stop fuel injection and stop the engine.
SEBU9041
g02176577
“ LOCAL START”” (Manual Start) Switch
(8)
Note: The engine may only be started with the
“LOCAL START” switch when the “MODE
SELECTION” switch is in the CENTER position.
Use the “LOCAL START” switch to bypass the
automatic start and the remote start of the engine by
the DCU.
1. Place the “MODE SELECTION” switch in the
CENTER position before using the “LOCAL
START” switch.
2. Push the “LOCAL START” switch and hold down
the “LOCAL START” switch to crank the engine.
Release of the “LOCAL START” switch
disengages the engine starting motor.
The helm is notified of the LOCAL START position by
network message.
SEBU9041
“ DIGITAL THROTTLE RAISE/LOWER””
Switch (9)
When the “THROTTLE MODE SELECTOR” switch
(12) is in the DIGITAL position, the “DIGITAL
THROTTLE RAISE/LOWER” switch may be used to
make minor adjustments to the speed. Holding the
“THROTTLE MODE SELECTOR” switch in the UP
position will continue to increase the speed of the
engine until the selector switch is released. Holding
the “THROTTLE MODE SELECTOR” switch in the
DOWN position will continue to decrease the speed
of the engine until the selector switch is released.
“ IDLE RATED”” Switch (10)
The “IDLE RATED” switch is used to select the IDLE
position or the RATED position for the engine.
“ MANUAL SPEED ADJUST”” Switch (11)
The “THROTTLE MODE” selector must be in the
“MANUAL” mode for the “MANUAL SPEED
ADJUST” switch to be operable. Never leave this
control unattended when using the control to operate
the generator set.
“ THROTTLE MODE”” Selector Switch (12)
“ MANUAL”” Mode
When the “THROTTLE MODE” selector is in the
“MANUAL” mode, the operator may quickly change
the speed of the generator set.
“ DIGITAL”” Mode
When the “THROTTLE MODE SELECTOR” switch
is in the “DIGITAL” mode, the throttle may be
controlled by the “DIGITAL THROTTLE RAISE/
LOWER” switch (9)
“ FAULT RESET”” Switch (13)
The “ FAULT RESET” switch is used to clear active
faults from the engine control and from the voltage
regulator.
“ VOLTAGE ADJUST”” Switch (14)
The “VOLTAGE ADJUST” switch is used to raise or
to lower the generator system voltage by regulator
control.
“ EMERGENCY STOP (E STOP) ” Switch
(15)
The “EMERGENCY STOP” switch is used for a hard
stop and for stopping the engine because of an
emergency event. Use as a last option or during
limited access engine service actions.
51
Features and Controls
Gauges and Indicators
The activation of the “EMERGENCY STOP” switch
removes power to the engine control module (ECM)
whichstops fuel injection and stops the engine in the
most forceful manner.
“ MODE SELECTION”” Switch (16)
RIGHT (AUTOMATED REMOTE) Position
The “MODE SELECTION” switch is in the RIGHT
position during normal remote engine operation and
monitoring. A lock or disposable tie may be installed
to prevent casual mode change. The “LOCAL
START” switch (8) and the “LOCAL STOP” switch
(7) are not operable when the “MODE SELECTION”
switch is in the RIGHT position.
CENTER (MANUAL) Position
Note: Never work on the engine without installing the
safety lock-out.
For limited diagnostic operation or for local operation,
the following conditions must be met:
• The “MODE SELECTION” switch in the CENTER
position
• The engine may be operated with the remote start
disabled
Some monitoring features are bypassed in this mode.
LEFT (OFF) Position
Note: Always lock-out power before entering the
engine work space.
When the “MODE SELECTION” switch is in the
LEFT (OFF) position, the key switch input to the
engine control is removed. Fuel and engine cranking
are prevented.
“ CRANK OVERRIDE”” Switch (21)
Activating the “CRANK OVERRIDE” switch
bypasses all start logic in the panel and immediately
engages the starting motor.
“ SHUTDOWN OVERRIDE”” Switch (22)
Activating the “SHUTDOWN OVERRIDE” switch
bypasses all shutdown conditions except overspeed.
i02706567
Gauges and Indicators
SMCS Code: 7450
Your engine may not have the same gauges or all of
the gauges that are described.
52
Features and Controls
Gauges and Indicators
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time. Noticeable changes
in gauge readings indicate potential gauge or engine
problems. Problems may also be indicated by gauge
readings that change even if the readings are within
specifications. Determine and correct the cause of
any significant change in the readings. Consult your
Caterpillar dealer for assistance.
NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
Engine Coolant Temperature – This
gauge indicates the engine coolant
temperature. The temperature may vary
according to the load. Do not allow the
temperature to exceed the boiling temperature of
the pressurized cooling system.
The sensor for engine coolant temperature must be
fully submerged in order to detect the temperature
correctly. If the engine is operating above the normal
temperature range, perform the following procedure:
1. Reduce the load and/or the engine rpm.
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load and/or rpm.
Engine Load – This gauge indicates a
percentage of the engine's full rated
torque. The calculation of the
percentage is based on these factors: flow of fuel,
engine rpm, fuel energy content and fuel
correction factor. This gauge flashes if the torque
exceeds the maximum limit that is programmed
into the control strategy.
Engine Oil Pressure – The oil pressure
should be greatest after a cold engine is
started. The pressure will decrease as
the engine warms up. The pressure will increase
when the engine rpm is increased. The pressure
will stabilize when the engine rpm is stable.
A lower oil pressure is normal at low idle. If the load is
stable and the gauge reading changes, perform the
following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
3. Check and maintain the oil level.
SEBU9041
Engine Oil Temperature – This gauge
indicates the engine oil temperature
after the oil has passed through the oil
cooler. The oil cooler is thermostatically
controlled.
Exhaust Temperature – This gauge
indicates the exhaust temperature at the
exhaust inlets to the turbochargers. The
two exhaust temperatures may vary slightly.
The exhaust temperatures at the exhaust inlets to the
turbochargers provide a good indication of engine
performance. For engines with dry exhaust manifolds,
the temperatures are representative of the actual
temperatures of the valves. Monitor this parameter
frequently.
NOTICE
Severe damage to the engine can result if the exhaust
temperature at the inlet to the turbocharger exceeds
the extreme limit.
Fuel Level – This gauge indicates the
fuel level in the fuel tank. Normally, the
fuel level gauge will register the fuel
level only when the switch is in the ON position.
Fuel Pressure – This gauge indicates
fuel pressure to the fuel injection pump
from the fuel filter. A decrease in fuel
pressure usually indicates a dirty fuel filter or a
plugged fuel filter. As the fuel filter becomes
plugged, there will be a noticeable reduction in
the engine's performance.
Fuel Temperature – This gauge indicates
the temperature of the fuel. A high fuel
temperature can adversely affect
performance. If the temperature of the fuel is too
low, the fuel filter may begin to plug. See this
Operation and Maintenance Manual, “Fuel and the
Effect from Cold Weather” for more information.
Fuel Usage – This gauge indicates the
rate of fuel usage.
Inlet Manifold Air Pressure – This gauge
indicates the air pressure (turbocharger
boost pressure) in the air inlet manifold
after the aftercooler. The inlet manifold air
pressure depends on the engine rating, the load,
and the operating conditions. To establish the
normal inlet manifold air pressure, compare the
data from the gauge to the data from the engine
commissioning and look for trends.
SEBU9041 53
Features and Controls
Gauges and Indicators

Inlet Manifold Air Temperature – This

gauge indicates the inlet manifold air
temperature after the aftercooler. As the
inlet air increases in temperature the following
conditions occur: expansion of the air, less
oxygen in the cylinders and less power. If the
temperature of the inlet air is too high during full
speed and load operation, the engine may
consume excessive fuel.

Service Hour Meter – This gauge

indicates the total number of clock hours
on the engine.

System Voltage – This gauge indicates

the voltage of the electrical system.

Tachometer – This gauge indicates

engine speed (rpm). When the throttle
control lever is moved to the full throttle
position without load, the engine is running at
high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
throttle position with maximum rated load.

NOTICE
To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated at
high idle without damage, but should never be al-
lowed to exceed high idle rpm.

Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.
For more information, refer to Specifications, Systems
Operation, and Troubleshooting, SENR5002,
“Installation Guide for Marine Engine Electronic
Displays”.
54
Engine Starting
Before Starting Engine
Engine Starting
i01486758
Before Starting Engine
SMCS Code: 1000; 1400; 1450
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.
• For the maximum service life of the engine, make
a thorough inspection before the engine is started.
Look for the following items: oil leaks, coolant
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed.
• Inspect the cooling system hoses for cracks and
for loose clamps.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage.
• Inspect the wiring for loose connections and for
worn wires or frayed wires.
• Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply
valve.
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.
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.
SEBU9041
• Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.
• Ensure that the areas around the rotating parts are
clear.
• All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair any
damaged guards. Replace damaged guards and/
or missing guards.
• Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor (if
equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
corrosion.
• Reset all of the shutoffs or alarm components.
• Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
the coolant level to the “FULL” mark on the
coolant recovery tank.
• If the engine is not equipped with a coolant
recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain
the coolant level in the sight glass.
• Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.
• Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
i04409253
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
When using starting fluid (ether), follow the manu-
facturer's instructions carefully. Use the starting
fluid sparingly and spray only while cranking the
engine. Failure to do so could result in an explo-
sion and/or fire and personal injury.
SEBU9041
NOTICE
The optional ether starting aid is the only starting fluid
system that is recommended on the engine.
The engine is designed to start without starting aids
at temperatures greater than 13° C (55° F)
When No. 2 diesel fuel is used, the following items
provide a means of minimizing starting problems and
fuel problems in cold weather: starting aids, engine oil
pan heaters, jacket water heaters, fuel heaters and
fuel line insulation.
For temperatures below −18° C (0° F), consult your
Cat dealer.
Use the procedure that follows for cold weather
starting.
Note: If the engine has not been run for several
weeks, fuel may have drained. Air may have moved
into the filter housing. Also, when fuel filters have
been changed, some air will be left in the filter
housing. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to al-
low the starting motor to cool before attempting to
start the engine again.
1. Turn the ignition switch to the RUN position.
Advance the throttle in order to supply fuel to the
engine.
NOTICE
Excessive ether can cause piston and piston ring
damage. Use ether for cold starting purposes only.
Do not use excessive starting fluid while starting the
engine. Do not use starting fluid after the engine is
running.
2. If equipped, press the “STARTING AID” switch in
order to improve cold weather starting. Release
the “STARTING AID” switch when the engine
starts. Use the starting fluid sparingly. Carefully
follow the instructions of the OEM.
55
Engine Starting
Starting the Engine
NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine speed until the
oil pressure gauge indicates normal. If oil pressure is
not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investi-
gate and correct the cause.
3. Increase the engine rpm to approximately 1/4 of
the full load rpm.
4. Allow the engine to idle for 3 to 5 minutes, or allow
the engine to idle until the water temperature
indicator begins to rise. The engine should run at
low idle smoothly until speed is gradually
increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation.
5. Operate the engine at low load until all systems
reach operating temperature. Check the gauges
during the warm-up period.
i05243408
Starting the Engine
SMCS Code: 1000; 1450
Note: Do not start the engine if a “DO NOT
OPERATE” warning tag or a similar warning tag is
attached to any of the controls.
Refer to this Operation and Maintenance Manual,
“Control Panel” for the starting procedure for the
generator set.
i01042616
After Starting Engine
SMCS Code: 1000
Note: In temperatures from 0 to 60 °C (32 to 140 °F),
the warm-up time is approximately five minutes. In
temperatures below 0 °C (32 °F), additional warm-up
time may be required.
Note: Ensure that the self-test for the monitoring
system is completed before you operate the engine
under load.
1. Operate the engine at low idle rpm for five minutes.
Perform these checks during the warm-up:
• Check for any fluid leaks and for any air leaks.
• Check all the gauges.
56 SEBU9041
Engine Starting
After Starting Engine

Observe the gauges and record the data frequently

while the engine is operating. Comparing the data
over time will help to determine normal readings for
each gauge. This will also help detect abnormal
operating developments. Investigate any
significant changes in the readings.

2. After the engine has idled for five minutes and the
inspections have been made, increase the engine
speed to 1/2 rated rpm.

NOTICE
To avoid engine overheating and possible engine
damage, ensure that water discharge is visible at the
sea water outlet and/or the water flow is not
restricted.
If the water flow is restricted and/or water discharge is
not visible at the sea water outlet, follow the recom-
mended procedure.

3. Observe the water discharge at the sea water

outlet. If water discharge is not visible or the water
flow is restricted, perform the following procedure:

a. Stop the engine immediately.

b. Inspect the inlet screen and the sea water

strainer for debris. Remove any debris that is
found.
c. Inspect the cooling system and the auxiliary
water pumps for evidence of leaks.

4. Check for any fluid leaks and for any air leaks.

5. Perform any necessary repairs before you operate

the engine.

6. After the inspections have been made, move the

throttle control to the idle position and proceed with
operation.
SEBU9041 57
Engine Operation
Engine Operation

Engine Operation
i01646252
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 of the engine.
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.
i04289968
Fuel Conservation Practices
SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. The design and technology used
byCaterpillar 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.
• Observe the service indicator for the air cleaner
frequently, if equipped. Keep the air cleaner
elements clean.
• Do not remove the cover for the air cleaner unless
the air filter service indicator indicates the need for
cleaning of the filter.
• Maintain a good electrical system.
One bad battery cell will overwork the alternator. This
will consume excess power and excess fuel.
• Ensure that the belts are properly adjusted. The
belts should be in good condition.
• Ensure that all of the connections of the hoses are
tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. Keep cooling
system components clean and keep cooling
system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
• Settings for the fuel system and the limits for the
operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a higher
altitude, the settings must be changed by a Cat
dealer. Changing the settings will help to provide
the maximum efficiency for the engine. Engines
can be operated safely at higher altitudes, but the
engines will deliver less horsepower. The fuel
settings should be changed by a Cat dealer in
order to obtain the rated horsepower.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.

• Be aware of the properties of the different fuels.

Use only the recommended fuels.

• Avoid unnecessary operation at no load.

Shut off the engine instead of operating the engine at
no load for long periods of time.
58
Generator Operation
Generator Operation
Generator Operation
i04010770
Generator Operation
SMCS Code: 4450
Loading of the Generator
When a generator is installed or reconnected, be sure
that the total current in one phase does not exceed
the nameplate rating. Each phase should carry the
same load, allowing the engine to work at the rated
capacity. If one phase current exceeds the nameplate
amperage, an electrical unbalance can result in an
electrical overload and overheating.
Allowable combinations of unbalanced loads are
shown in Illustration 47 . When you operate with
significant single-phase loads, the combinations of
single-phase load and three-phase load may be
used. Such combinations should be located below
the line on the graph.
Illustration 47 g00627416
Allowable Combinations of Unbalanced Loads
SEBU9041
Block Loading
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
• Percent of load before the block load is applied
If derating for the block load is required, refer to ISO
3046 Standards 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 represents the efficiency of the load.
Power factor is the ratio of apparent power to total
power. The power factor is expressed as a decimal.
The power factor represents that portion of the
current which is doing useful work. The portion of
current which is not doing useful work is absorbed in
maintaining the magnetic field in motors or other
devices.
In most applications, electric motors and transformers
determine the power factor of the system. Induction
motors usually have a 0.8 or smaller power factor.
Incandescent lighting is a resistive load of about 1.0
power factor, or unity.
The power factor of a system may be determined by a
power factor meter or by calculations. Determine the
power requirement in kW by multiplying the power
factor by the kVA that is supplied to the system. As
the power factor increases, the total current supplied
to a constant power demand will decrease. For
example, a 100 kW load at a 0.8 power factor will
draw more current than a 100 kW load at 0.9 power
factor. high-power factor will result in full engine load
at less than the rated amperage of the generator. A
lower power factor increases the possibility of
overloading the generator.
Note: Caterpillar generators are designed for a 0.8
power factor unless otherwise specified.
SEBU9041
Excitation System
Permanent Magnet Pilot Excited
Generators
Permanent Magnet Pilot Excited (PMPE) generators
receive power for the voltage regulator from a pilot
exciter, rather than the main armature. The pilot
exciter consists of a permanent magnet rotor and a
permanent magnet stator. The pilot exciter operates
independently from the generator output voltage.
Constant excitation during a large load application is
possible because the irregularities that occur in
generator output voltage are not fed back into the
exciter. Such irregularities can be caused by load
conditions. The independent operation also allows
the generator to better sustain an overload for a short
duration. The pilot exciter also ensures that the
generator will start properly even if the rotating field
becomes completely demagnetized.
Low Idle Adjustment
Generator sets normally have a higher low idle setting
than industrial engines. Low idle will be approximately
66% of the full load speed of 60 Hz units. Low idle will
be approximately 80% of the full load speed of 50 Hz
units.
Note: Operating the generator set at low idle speed
for an extended time will cause some voltage
regulators to shut off. The generator set must be
completely shut down and restarted in order for the
voltage regulator to operate.
Standby Generator Sets
Most standby units are installed with controls that will
start the unit automatically. Standby units start, pick
up the load, run, and stop without an operator in
attendance.
Standby units cannot automatically change the
governor control. Standby units cannot automatically
change the voltage settings. The governor speed and
voltage level must be preset for the proper operation
of the standby unit. Whenever the set is operated
manually, be sure that the governor speed and
voltage levels are correct for automatic operation.
Check all switches for the proper setting. The start
select switch should be in the AUTOMATIC position.
Emergency Stop Switches should be in RUN position.
Generator Options
Space Heaters
All Cat Marine Generators are provided with space
heaters. These space heaters are installed for
operation in high humidity conditions. For more
information on space heaters, refer to this Operation
and Maintenance Manual, “Space Heater - Check”.
59
Generator Operation
Single Unit Operation
Embedded Temperature Detectors
All Cat Marine Generators are available with
embedded resistance type temperature detectors
(RTDs). The detectors are installed in the slots of the
main armature. The main armature is also called a
stator. If the Marine Classification Society control
panel (MCS Control Panel) is installed, the detectors
are connected to the RIO and are monitored by the
MCS controller. Otherwise, the detectors are used
with the equipment that is provided by the customer.
Bearing Temperature Detectors
Bearing temperature detectors are standard
equipment. If an MCS system is installed, the
detectors are connected to the RIO and are
monitored by the MCS controller. Otherwise, the
bearing temperature detectors are used with the
equipment that is provided by the customer. Thus, the
temperature of the bearing can be measured or
monitored. Bearing temperature measurements may
help to prevent premature bearing failure. Contact
your Cat dealer for more information.
i04010972
Single Unit Operation
SMCS Code: 4450
Initial Start-Up
Before the initial start-up, perform the megohmmeter
test on the main stator winding. Refer to the Special
Instruction, SEHS9124, “Cleaning and Drying of
Electric Set Generators” for the procedure.
Starting
1. Make all of the preliminary checks listed in this
Operation and Maintenance Manual, “Before
Starting Engine” topic.
2. Be sure that the main circuit breaker or the line
circuit breaker is open.
3. Start the engine according to this Operation and
Maintenance Manual, “Starting the Engine” topic.
Allow the engine to warm up.
4. Adjust to the full-load engine speed.
5. Close the main circuit breaker.
6. Apply the load. Apply the load in increments in
order to maintain system frequency and voltage at
a constant level.
7. Readjust the governor for rated frequency.
60 SEBU9041
Generator Operation
Parallel Operation

Stopping
Refer to this Operation and Maintenance Manual,
“Manual Stop Procedure” for the required procedures
for stopping the generator set.

i04010991

Parallel Operation
SMCS Code: 4450

Initial Start-Up
Preparing a generator for parallel operation requires
special attention. Before you attempt to parallel units Illustration 48 g00695380
for the first time, check all the units for the following
three conditions.

• Same phase rotation

When servicing or repairing electric power gen-
• Same alternating current frequency eration equipment:

• Same winding pitch Make sure the unit is off-line (disconnected

• Same voltage adjustment
1. Check the phase rotation.
Units that operate in parallel must have the same
phase rotation. Two methods may be used to
determine if the incoming unit and the unit that is
on-line have the same phase rotation. These
methods are listed below:
from utility and/or other generators power serv-
ice), 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.

• 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.
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.
• 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 generator leads 1 and 3,
thus reversing the direction of phase
rotation. Terminal 2 should always be
connected to line 2.

• 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. Verify that the
generator set is programmed to run at the correct
frequency.

3. Adjust the voltage.

SEBU9041
Refer to this 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.
Note: Do not change the voltage settings after this
step.
b.
4. Check the winding pitch.
The units that operate in parallel must have the
same winding pitch to reduce the effect of
circulating currents. It is possible to parallel units
with different winding pitches after the amount of
circulating current flow between each of the units
has been determined. Contact your Cat dealer for
further information.
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. After the engine has run a few minutes, bring the
engine 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. Very quickly close the breaker while
the lights are out.
61
Generator Operation
Parallel Operation
6. Use governor controls in order to share kW load
between engines.
7. Generator temperature will be stabilized in
approximately 1 hour. After the generator
temperature has been stabilized, adjust the
voltage droop rheostat of each generator. This
adjustment will share the reactive load and thus
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 share of the
kW load for each unit 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
Illustration 49 g00630841
Load Sharing Module (Typical Example)
62
Generator Operation
Parallel Operation
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 unit in a parallel operation will result
in the same change in engine power for each unit
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 5 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, 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:
SEBU9041
• Each governor should have a 5 percent speed
droop 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 5 minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes very
important when the units are paralleled. 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.
SEBU9041 63
Generator Operation
Voltage Regulators

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.

i05264083

Voltage Regulators
SMCS Code: 4467

Cat Digital Voltage Regulator (Cat

DVR )

The Cat Digital Voltage Regulator presents an

electrical shock/electrocution hazard. This hazard
will cause serious injury or death.
Service by trained personnel only.
The terminals and heat sinks are live at
hazardous voltages when power is applied and
for up to 8 minutes after power is removed.
Illustration 50 g01115009
The Cat DVR is a microprocessor-based voltage
regulator. Control power for the Cat DVR is supplied
from an external source of 24 VDC. The power stage
of the Cat DVR is supplied from a multiple pole high
frequency permanent magnet generator which is
mounted on the end of the generator shaft.
Connections to the Cat DVR are made through three
connectors. The communication between the Cat
DVR and the service tool is accomplished by using a
CANBUS protocol.
The Cat DVR has the following features:
• Three control modes:
1. Automatic voltage regulation (AVR)

2. Power factor (PF) regulation

3. Reactive power (VAR) regulation

64 SEBU9041
Generator Operation
Generator Lead Connections

• Programmable stability settings Wye Configuration Diagrams

• Soft start control with an adjustable time setting in
AVR mode 12 Lead

• Dual slope voltage versus frequency (V/Hz)

characteristic

• Three-phase or single-phase voltage sensing

• Single-phase current sensing

• Field current sensing and field voltage sensing

• Ten protection functions

Adjusting the Cat DVR

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

i05018410
Illustration 51 g00611608
Generator Lead Connections 12 Lead Wye Configuration
SMCS Code: 4450 Low Voltage
Terminals T10, T11, and T12 become neutral
Lead Numbering connections when the terminals are tied together.

The Wye configurations and the Delta configurations

are the most common generator lead connections.
The following three-phase connection diagrams
illustrate the proper connection and lead
identification.
The leads are numbered clockwise from the top and
from the outside. The diagrams that are contained in
the “Wye Configuration Diagrams” section show lead
numbering for the 12 lead generators. The diagrams
that are contained in the “Delta Configuration
Diagrams” section show lead numbering for the 12
lead generators.
SEBU9041
Delta Configuration Diagrams
12 Lead
Illustration 52 g00669312
12 Lead Delta Configuration
Terminals T6 and T9 become the neutral connections
when the terminals are tied together and when the
terminals are grounded. This reflects the terminal T2
and T10 connection as the high phase.
Grounding the Frame
In any generator set installation, the frame of the
generator must be positively connected to an earth
ground or the frame of the generator must be
positively connected to the hull of a vessel. This
connection is the first connection that should be made
at the installation. This connection is the last
connection that should be removed. If the generator
set is on flexible pads or resilient pads, the ground
connection must be flexible in order to avoid possible
breakage in later operation.
Ground connection cables 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. These joints are
also frequent sources of radio frequency interference
(RFI). Joints should be silver soldered and joints
should also be bolted. These bolts will be electrically
reliable and mechanically reliable.
Neutral Connections
On Wye Configuration Generators, the neutral lead
should be attached to ground. This connection should
be made at installation. The neutral lead is grounded
in order to prevent load-side equipment damage.
65
Generator Operation
Generator Lead Connections
If the neutral wire is grounded and one of the phase
leads becomes grounded, the excessive current will
open a load circuit breaker. In addition, this excessive
current will cause the generator voltage to collapse.
The result depends on the following factors: the
electrical characteristics of the generator, type of fault
and trip rating of the circuit breaker. An undervoltage
device may be required in order to provide an
adequate short circuit protection.
There are some instances when the neutral wire
should not be grounded. An ungrounded generator
neutral lead is acceptable when measures have been
taken in order to prevent grounds to the phase leads.
An example of such measures is a ground fault
protective circuits. When ground fault protective
circuits are used, the entire group of distribution
circuits should be studied. The entire group of
distribution circuits should then be treated as a
system. If a new distribution system is being
developed, the owner should confer with a consultant
that is certified and registered. If an existing system
should be modified for ground fault protection, the
owner should also confer with a consultant that is
certified and registered.
Single Units
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
When definite measures need to be taken in order to
prevent grounds to the load leads, an ungrounded
neutral can be used. Be sure to check your local
wiring codes.
Multiple Units
When multiple generators are operated in parallel, all
the neutral connections may be grounded. In this
case, there may be circulating current through the
neutral connections. In order to eliminate the
possibility of circulating currents, ground the neutral
of only one generator. If multiple generators are
alternated on a line, a switch should be installed in
the neutral ground circuit of each generator. In this
case, all neutral ground circuits except one can be
opened. Be sure that one of the neutral ground
circuits is closed.
Parallel to a Utility
There will be occasions when a Wye connected
generator is paralleled with a utility system (infinite
bus). On these occasions, the utility system step-
down transformer may also have a Wye connection.
The grounding of both of the Wye neutral connections
may result in circulating currents through the neutral
connections. The coordination of ground fault
protection requires a study of the entire system. This
study should be done by a consultant that is familiar
with generator systems. This consultant should be
registered and certified. This study will determine the
grounding method that should be used.
66
Cold Weather Operation
Cold Weather Operation
Cold Weather Operation
i04557066
Cold Weather Operation
SMCS Code: 1000; 1250
Cat Diesel Engines can operate effectively in cold
weather. The starting and the operation of the diesel
engine is dependent on the following items in cold
weather:
• The type of fuel that is used
• The viscosity of the oil
• Optional starting aids
• Optional warm-up aids
Refer to Special Publication, SEBU5898, “Cold
Weather Recommendations for Cat Machines”.
The purpose of this section will cover the following
information:
• Explain potential problems that are caused by
cold-weather operation.
• Suggest steps which can be taken in order to
minimize starting problems and operating
problems when the ambient air temperature is
colder than 0 to −55 °C (32 to −67 °F).
The operation and maintenance of an engine in
freezing temperatures is complex because of the
following conditions: the unlimited differences in
weather conditions, engine applications and the
supplies that are available in your area. These
factors, recommendations from your Cat dealer, past
proven practices, and the information that is
contained in this section should be combined to
provide guidelines for cold-weather operation.
SEBU9041
Hints for Cold Weather Operation
• If the engine is started, operate the engine until a
minimum operating temperature of 71 °C (160 °F)
is achieved. Achieving operating temperature will
help prevent the intake valves and exhaust valves
from sticking.
• The cooling system and the lubrication system for
the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
down for a few hours and the engine will start
readily. If the engine is shut down for at least
8hours, the engine should be considered cooled to
outside temperature.
• Install the correct lubricant in each compartment
before the beginning of cold weather.
• Check all rubber parts (hoses, fan drive belts, and
so on) weekly.
• Check all electrical wiring and connections for any
fraying or damaged insulation.
• Keep all batteries fully charged and warm.
• Fill the fuel tank at the end of each shift.
• Check the air cleaners and the air intake daily.
Check the air intake more often when you operate
in snow.
Personal injury or property damage can result
from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable
and toxic and if improperly stored could result in
injury or property damage.
DO NOT USE ETHER (starting fluids) unless spe-
cifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.
NOTICE
The optional automatic ether injection system is the
only starting fluid system that is recommended. Ex-
cessive starting fluid can cause piston and ring dam-
age. Use starting fluid for cold starting purposes only.
SEBU9041
• Inject starting fluid only when the engine is
cranking.
• Dryers for the air system may be effective in
reducing moisture condensation and the formation
of ice in air systems.
• The injection of alcohol may prevent moisture from
freezing the air compressor governor and other
components of the air system.
• For jump starting with cables in cold weather, refer
to the Operation and Maintenance Manual for jump
starting instructions.
Viscosity of the Engine Lubrication
Oil
Proper engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to crank
the engine. Refer to the Operation and Maintenance
Manual, “Fluid Recommendations” for the
recommended viscosity of oil.
Lubricating Oil Heaters
Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure the
compatibility of the components, only use equipment
that is recommended by Caterpillar.
NOTICE
Heating elements that are in direct contact with the lu-
bricating oil can cause coking of the oil.
To aviod coking of the oil when the oil is heated, follow
these recommendations:
The temperature of the heating surface must not ex-
ceed 150 °C (300 °F). The maximum heat density of
the heating surface must not exceed 1.24 w/cm2
(8W/in2).
Engine oil pan heaters are useful devices that provide
the following functions:
• Assist in reducing the cold cranking amperage that
is needed to start the engine.
• Improve the flow of oil at start-up.
• The time that is needed to warm up the engine is
reduced.
• The service life of bearings is increased.
Engine oil pan heaters can reduce the minimum
ambient temperatures that are normally
recommended for multigrade oil. Consult your dealer
for more information.
67
Cold Weather Operation
Cold Weather Operation
Recommendations for the Coolant
Provide cooling system protection for the lowest
expected outside temperature. Refer to the Operation
and Maintenance Manual, “Fluid Recommendations”
for the recommended coolant mixture.
In cold weather, check the coolant often for the proper
glycol concentration in order to ensure adequate
freeze protection.
Jacket Water Heater
A jacket water heater heats the coolant that
surrounds the combustion chamber providing the
following functions:
• Startability is improved.
• Warm up time is reduced.
• The required temperature for ether is reduced.
An electric jacket water heater can be activated once
the engine is stopped. An effective jacket water
heater is typically a 1500 W unit. Consult your marine
dealer for more information.
Idling the Engine
While the engine is idling, the application of a light
load (parasitic load) will assist in maintaining the
minimum operating temperature. The minimum
operating temperature is 71 °C (160 °F). Maintaining
an elevated low idle speed for extended periods will
be easier with the installation of a hand throttle. An
idle speed of 1200 rpm is preferred for all engines.
Recommendations for Coolant
Warm Up
Warm up any system that has cooled below normal
operating temperatures due to inactivity. The warm-
up should be performed before the engine is returned
to full operation. During operation in very cold
temperature conditions, damage to engine valve
mechanisms can result from engine operation for
short intervals. This damage can happen if the engine
is started and the engine is stopped many times
without being operated in order to warm up
completely.
When the engine is operated below normal operating
temperatures, fuel and oil are not completely burned
in the combustion chamber. This fuel and oil causes
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and
the deposits are burned off during operation at normal
engine operating temperatures.
When the engine is started and stopped without
operating long enough to warm up completely, the
carbon deposits become thicker. The carbon deposits
will cause the following problems:
68
Cold Weather Operation
Fuel and the Effect from Cold Weather
• Free operation of the valves is prevented.
• Valves become stuck.
• Pushrods are bent.
• Other damage to valve train components can
result.
For this reason, when the engine is started, the
engine must be operated until the coolant
temperature is 71 °C (160 °F) minimum. Carbon
deposits on the valve stems are kept at a minimum
and the free operation of the valves and the valve
components are maintained.
Warm the engine thoroughly to keep other engine
parts in better condition. The service life of the engine
will be extended. Lubrication will be improved. There
will be less acid and less sludge in the oil. The better
condition of the oil will provide longer service life for
the engine bearings, the piston rings, and other parts.
However, limit unnecessary idle time to 10 minutes.
Engine wear is greatest at low idle and unnecessary
idling wastes fuel.
On/Off Fan Clutch
Viscous fans continuously rotate in cold weather,
which creates unnecessary movement of the air. For
better control of the operation of the fan, an ON/OFF
fan clutch may be used. ON/OFF fan clutches can
help prevent excessive cooling in cold weather. In the
“OFF” position, the fan is kept stationary by the ON/
OFF fan clutch. The unnecessary movement of the
air is reduced in order to maintain adequate engine
operating temperatures in cold weather.
Purge Valve and Insulated Heater Lines
During periods of operations with a light load, The
coolant must bypass the radiator in order to help
prevent excessive cooling of the engine. Coolant that
passes through the radiator must be minimized in
order to maintain the engine operating temperature in
cold weather.
Excessive cooling of the engine is prevented by a
“jiggle” valve that performs two functions. The valve
allows the flow of air and the valve prevents the flow
of coolant. These valves prevent the unnecessary
coolant flow, which may be diverted around the water
temperature regulator to the radiator.
Insulated cab heater lines for very cold weather are
also beneficial. These lines provide more available
heat from the coolant to the cab and less heat is lost
to the outside air.
SEBU9041
Insulating the Air Inlet and Engine
Compartment
When temperatures below −18 °C (−0 °F) will be
frequently encountered, an air cleaner inlet that is
located in the engine compartment may be specified.
The special air cleaner inlet is sometimes referred to
as a snow valve. An air cleaner that is located in the
engine compartment may also minimize the snow
that is packed in the air cleaner. Heat that is rejected
by the engine warms the inlet air.
Additional heat can be retained around the engine by
insulating the engine compartment.
i04408649
Fuel and the Effect from Cold
Weather
SMCS Code: 1000; 1250; 1280
The following fuels are the grades that are available
for Cat engines:
• No. 1
• No. 2
• 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.
SEBU9041
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.
When No. 2 diesel fuel is used, the following
components provide a means of minimizing problems
in cold weather:
• Starting aids
• Engine oil pan heaters
• Engine coolant heaters
• Fuel line insulation
For more information on cold-weather operation, see
Special Publication, SEBU5898, “Cold Weather
Recommendations”.
i04369188
Fuel Related Components in
Cold Weather
SMCS Code: 1000; 1250; 1280
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after operating the engine.
Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
Some fuel tanks use supply lines that 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.
Draining the fuel tank will help prevent water and/or
sediment from being pumped from the fuel storage
tank and into the engine fuel tank. Drain the water
and sediment from any fuel storage tank at the
following intervals:
• Weekly
• Oil changes
• Refueling of the fuel tank
69
Cold Weather Operation
Fuel Related Components in Cold Weather
Fuel Filters
NOTICE
Do not fill the fuel filters with fuel before installing
them. The fuel would not be filtered and could be con-
taminated. Contaminated fuel will cause accelerated
wear to fuel system parts.
NOTICE
Caterpillar requires the use of a 4 micron(c) secon-
dary fuel filter for the following reasons: to maximize
fuel system life and to prevent premature wear out
from abrasive particles in the fuel. Cat high efficiency
fuel filters meet these requirements. Consult your Cat
dealer for the proper part numbers.
When the engine is equipped with a primary filter/
water separator, the primary filter/water separator
must use a 10 micron filter to a 15 micron filter. The
filters are becoming more critical as fuel injection
pressures increase to 209 MPa (30000 psi) and
higher psi. For more information on priming the fuel
system, see the Operation and Maintenance Manual,
“Fuel System - Prime” topic.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater with
a large heating surface. The fuel heater should be
practical in size. Small heaters can be too hot due to
the limited surface area.
Disconnect the fuel heater in warm weather.
Note: Only use fuel heaters that are controlled by the
water temperature regulator or fuel heaters that are
self-regulating. Fuel heaters that are not controlled by
the water temperature regulator can heat the fuel in
excess of 65° C (149° F). A loss of engine power can
occur if the fuel supply temperature exceeds 37° C
(100° F).
Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel when the engine operates in warm weather.
For further information on fuel heaters, consult your
Cat dealer.
70
Engine Stopping
Emergency Stopping
Engine Stopping
i03893229
Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices
or controls for normal stopping procedure.
Ensure that any components for the external system
that support the engine operation are secured after
the engine is stopped.
Illustration 53 g00104303
Typical emergency stop button
The emergency stop button is in the OUT position for
normal engine operation. For an emergency stop,
push the emergency stop button. This shuts off the
fuel to the engine. This also activates the air shutoff (if
equipped).
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.
The engine control switch and the emergency stop
button must be reset before the engine can be
restarted. The air shutoff (if equipped) must be reset
before the engine can be restarted. Reset the engine
control switch before resetting the emergency stop
button.
To reset the engine control switch, turn the switch to
the “OFF/RESET” position.
To reset the emergency stop button, turn the button
clockwise. The spring-loaded button will return to the
OUT position. The button may also be pulled to the
OUT position.
SEBU9041
i05237815
Manual Stop Procedure
SMCS Code: 1000; 7418
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 be-
fore stopping the engine.
Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.
1. Reduce the engine rpm to low idle.
2. Increase the engine rpm to no more than 50
percent of the rated rpm for 3 to 5 minutes in order
to cool the engine. Reduce the engine rpm to low
idle.
3. Push the “STOP” switch.
i04137729
After Stopping Engine
SMCS Code: 1000
Note: After operation, allow 10 minutes for the engine
oil to return to the oil pan before checking the engine
oil level.
• Check the crankcase oil level. Maintain the oil level
between the “ADD” mark and the “FULL” mark
on the oil level gauge.
Note: Only use oil that is recommended in this
Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.
• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
• Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
• Fill the fuel tank to prevent accumulation of
moisture in the fuel. Do not overfill the fuel tank.
• Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
SEBU9041 71
Engine Stopping
After Stopping Engine

Note: Only use coolant that is recommended in this

Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.
• If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
72 SEBU9041
Maintenance Section
Refill Capacities

Maintenance Section Note: Keel cooled engine JW and SCAC system

volumes represent the total system volumes through
the top of the filler neck for customer auxiliary
expansion tank sizing considerations.
Refill Capacities
i05391578
i05502090
Fluid Recommendations
Refill Capacities SMCS Code: 1280; 1348; 1395; 7560
SMCS Code: 1000; 1348; 1395; 7560
Note: Refer to the emissions label on the engine to
Lubrication System determine to which emissions regulation the engine is
certified.
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump Note: The interval for changing the coolant varies
plus standard oil filters. Auxiliary oil filter systems will depending on the type of coolant being replaced.
require additional oil. Refer to the OEM specifications Refer to this article, “Coolant Recommendations”for
for the capacity of the auxiliary oil filter. the intervals.
Table 2
Note: For more information, refer to Special
Approximate Refill Capacities Publication, SEBU6251, “Cat Commercial Diesel
Engine Fluids Recommendations”.
Compartment or System Liters Quarts
Engine Crankcase(1) 138 146 Diesel Engine Oil
(1) Deep sump oil pan (500 hr)
Cat Diesel Engine Oil (Cat DEO )
Cooling System Capacity Cat oils have been developed and tested in order to
provide the full performance and service life that has
To maintain the cooling system properly, the total been designed and built into Cat engines. Cat oils
capacity of the cooling system must be determined. are currently used to fill Cat Diesel Engines at the
The capacity of the total cooling system will vary factory. These oils are offered by Cat dealers for
between individual installations. The external system continued use when the engine oil is changed.
can include the following components: expansion Consult your Cat dealer for more information on these
tank, radiator and piping. Refer to the specifications oils.
that are provided by the OEM. Record the total
cooling system capacity in the appropriate Table. Due to significant variations in the quality and in the
performance of commercially available oils,
For the recommended coolant, see this Operation Caterpillar makes the following recommendations:
and Maintenance Manual, “Fluid Recommendations”.
Table 3 Note: Cat DEO and Cat DEO-ULS multigrade oils
C32 HEX Cooled SCAC Engines
are the preferred oils for use in this Cat Diesel
Engine.
Coolant System Coolant Capacity Table 5
JW system 117.8 L (124.5 qt) Commercial
Cat Lubricants Viscosity Grade
Lubricants
SCAC system 24.3 L (25.7 qt)
SAE 15W-40
Cat DEO-ULS
Note: HEX cooled engine JW and SCAC system Diesel Engine Oil-Ul- SAE 10W-30
volumes represent the fill volumes up to the cold full tra Low Sulfur (API Cat DEO-ULS SYN SAE 5W-40
mark. CJ-4)
Cat DEO Cold
Table 4 SAE 0W-40
Weather
C32 Keel Cooled SCAC Engines
Diesel Engine Oil SAE 15W-40
Coolant System Coolant Capacity (API CI-4/CI-4 PLUS Cat DEO
and API CH-4) SAE 10W-30
JW system 106.8 L (112.9 qt)

SCAC system 19.7 L (20.8 qt)

SEBU9041
Engines which are Certified to US Marine
Environmental Protection Agency (EPA)
Tier 3 Regulations
NOTICE
An engine certified to US Environmental Protection
Agency (US EPA) Marine Tier 3 regulations which is
installed in a US flagged vessel must use ultra-low
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR
part 80.510 (c). When an engine is not installed in a
US flagged vessel, refer to applicable local or Interna-
tional Maritime Organization (IMO) regulations for fuel
requirements.
Caterpillar recommends the use of Cat DEO-ULS for
engines that use ultra-low sulfur diesel fuel (ULSD
fuel) or sulfur-free diesel fuel. Cat DEO-ULS has the
proper amount of lubricity for engines using ULSD.
The use of engine oil that meets Cat Engine
Crankcase Fluid specifications (Cat ECF-3)
specifications is acceptable. Refer to this article
“Commercial Oil” for more information.
Engines which are Not Certified to US
Marine EPA Tier 3 Regulations
Cat DEO is recommended for engines using fuels of
sulfur levels that exceed 0.2 percent (> 2000 ppm
(mg/kg) ). Cat DEO-ULS may be used in these
applications if an oil analysis program is followed. The
oil change interval may be affected by the fuel sulfur
level. Refer to this Operation and Maintenance
Manual, “Engine Oil Sample - Obtain” for more
information about the Cat S·O·S Oil Sampling
program.
Commercial Oil
Note: Non-Cat commercial oils are, as a group,
second choice oils. Within this grouping of second
choice oils there are tiered levels of performance.
NOTICE
Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids.
The three current Caterpillar ECF specifications are:
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each
higher Cat ECF specification provides increased
performance over lower Cat ECF specifications.
A commercial oil must meet the following standards
to be considered an equivalent of a Cat diesel engine
oil:
73
Refill Capacities
Fluid Recommendations
Table 6
Cat Engine Crankcase Fluids (ECF) Definitions
Cat Performance
API Oil Category
Requirement
API CJ-4 Oil Category performance
Cat ECF-3
requirements
API CI-4 / CI-4 PLUS Oil Category perform-
ance requirements and
Passing standard Cat C13 engine test per
Cat ECF-2
API requirements and
Oils of sulfated ash > 1.50 percent are not
allowed
API CH-4 Oil Category performance require-
ments and
For oils that are between 1.30 percent and
1.50 percent sulfated ash, passing one addi-
Cat ECF-1-a
tional Cat 1P SCOTE test ( “ASTM D6681”)
is required and
Oils of sulfated ash > 1.50 percent are not
allowed
Engines which are Certified to US Marine
Environmental Protection Agency (EPA)
Tier 3 Regulations
If an engine which is certified to US Marine EPA Tier 3
Regulations is installed on a US flagged vessel and is
not using Cat DEO-ULS, Caterpillar recommends the
use of an oil that meets the following standards: Cat
ECF-3 specification and API CJ-4 oil category.
Lubricant Viscosity
In selecting oil for any engine application, both of the
following must be satisfied: the oil viscosity and the
category of oil performance or the specification for oil
performance . Using only one of these parameters
will not sufficiently define oil for an engine application.
The proper SAE viscosity grade of oil is determined
by the following temperatures: minimum ambient
temperature during cold engine start-up and
maximum ambient temperature during engine
operation.
Refer to Table 7 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
engine.
Refer to Table 7 (maximum temperature) in order to
select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
74 SEBU9041
Refill Capacities
Fluid Recommendations

Note: Generally, use the highest oil viscosity that is (Table 8, contd)
available to meet the requirement for the temperature (1) Cat DEO-ULS applies to Cat DEO-ULS SAE 15W-40,

at start-up. SAE10W-30, Cat DEO-ULS SYN SAE 5W-40, and Cat DEO
Cold Weather SAE 0W-40. Cat DEO applies to Cat DEO SAE
Table 7 15W-40 and SAE 10W-30.
(2) Use of an oil analysis program to determine oil drain intervals is
Lubricant Viscosities for Ambient Temperatures for
strongly recommended if fuel sulfur is between 0.05% (500
Cat Diesel Engines ppm) and 0.5% (5000 ppm).
(3) Use of an oil analysis program to determine oil drain intervals is
Oil Type and Per- °C °F
Viscosity required if fuel sulfur is above 0.5% (5000 ppm).
formance (4) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
Grade Min Max Min Max
Requirements refer to TBN and engine oil guidelines given in this section.
(5) Cat DEO-ULS may be used if an oil analysis program is fol-
Cat Cold Weather lowed. High fuel sulfur levels may reduce the oil drain intervals.
SAE 0W-40 −40 40 −40 104
DEO-ULS
Cat DEO-ULS SYN SAE 5W-40 −30 50 −22 122
S·O·S Services Oil Analysis
Cat DEO-ULS SAE 10W-30 −18 40 0 104
Cat DEO Caterpillar has developed a maintenance tool that
SAE 15W-40 −10 50 14 122
evaluates oil degradation. the maintenance
SAE 0W-30 −40 30 −40 86 management also detects the early signs of wear on
Cat ECF-1-a, Cat internal components. The Cat tool for oil analysis is
SAE 5W-30 −30 30 −22 86 called S·O·S oil analysis and the tool is part of the
ECF-2, Cat ECF-3
SAE 10W-40 −18 50 0 122 S·O·S Services program. S·O·S oil analysis divides
oil analysis into four categories:
Note: A cold soaked start occurs when the engine • Component wear rate
has not been operated recently, allowing the oil to
become more viscous due to cooler ambient • Oil condition
temperatures. Supplemental heat is recommended
for cold soaked starts below the minimum ambient • Oil contamination
temperature. Supplemental heat may be necessary
for cold soaked starts that are above the minimum • Identification of oil
temperature depending on factors such as parasitic These four types of analysis are used to monitor the
load. condition of your equipment. The four types of
analysis will also help you identify potential problems.
Total Base Number (TBN) and Fuel Sulfur A properly administered S·O·S oil analysis program
will reduce repair costs and the program will lessen
Levels the impact of downtime.
The use of Cat S·O·S Services oil analysis is The S·O·S Oil Analysis program uses a wide range of
recommended strongly for determining oil life. tests to determine the condition of the oil and the
crankcase. Guidelines that are based on experience
The minimum required Total Base Number (TBN) for and a correlation to failures have been established for
oil depends on the fuel sulfur level. The TBN for new these tests. Exceeding one or more of these
oil is typically determined by the “ASTM D2896” guidelines could indicate serious fluid degradation or
procedure. For direct injection engines that use a pending component failure. A trained person at your
distillate fuel, the following guidelines apply: Cat dealership should make the final analysis.
Table 8
NOTICE
TBN recommendations for applications in Cat engines
Always use a designated pump for oil sampling, and
Fuel Sulfur Level per- TBN of Commercial use a separate designated pump for coolant sam-
Cat Engine Oils (1)
cent (ppm) Engine Oils pling. Using the same pump for both types of samples
may contaminate the samples that are being drawn.
0.05 percent Cat DEO-ULS This contaminate may cause a false analysis and an
Min 7
(500ppm) Cat DEO incorrect interpretation that could lead to concerns by
>0.05-0.2 percent Cat DEO both dealers and customers.
Min 10
(>500- 2000 ppm) (2) Cat DEO-ULS

Above 0.2 percent Refer to Special Publication, SEBU6251, “Cat

Cat DEO (5) Min 10
(above 2000ppm) (3) (4) Commercial Diesel Engine Fluids Recommendations”
in order to obtain additional information about S·O·S
Services oil analysis. You can also contact your local
Cat dealer.
(continued)
SEBU9041 75
Refill Capacities
Fluid Recommendations

Fuel • Ultra-low Sulfur Diesel Fuel (ULSD fuel). ULSD

Note: Caterpillar strongly recommends the filtration of
fuel through a fuel filter with a rating of four microns(c)
absolute or less. This filtration should be located on
the device that dispenses the fuel to the fuel tank for
the engine. This filtration should also be located on
the device that dispenses fuel from the bulk storage
tank. Series filtration is recommended.
NOTICE
In order to meet expected fuel system component life,
4 micron(c) absolute or less secondary fuel filtration is
required for all Cat Diesel Engines that are equipped
with unit injected fuel systems. All current Cat Diesel
Engines are factory equipped with Cat Advanced Ef-
ficiency 4 micron(c) absolute fuel filters.
Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids and filters.
Fuel for Cat Marine Diesel Engines
which are certified to United States
Environmental Protection Agency Tier 3
Standards (US EPA Tier 3 Standards)
NOTICE
An engine certified to US Environmental Protection
Agency (US EPA) Marine Tier 3 regulations which is
installed in a US flagged vessel must use ultra-low
sulfur diesel fuel (ULSD fuel) as defined by 40 CFR
part 80.510 (c). When an engine is not installed in a
US flagged vessel, refer to applicable local or Interna-
tional Maritime Organization (IMO) regulations for fuel
requirements.
Cat Marine Diesel Engines which are certified to US
EPA Tier 3 Standards are designed to operate with
the following types of fuel:
fuel contains ≤0.0015 percent (≤15 ppm (mg/kg) of
sulfur.
• Approved blends of biodiesel fuel. Refer to the
“Biodiesel” topic in this article for more information.
The use of diesel fuel that contains >0.0050 percent
(>50 ppm (mg/kg)) of sulfur may cause the aftercooler
to foul. Fouling of the aftercooler may result in engine
damage.
Note: If the engine operates in an area outside of US
EPA jurisdiction and where fuel quality is unknown,
refer to EPA regulations for instructions on obtaining
a migratory exemption. In order to operate a Cat
Marine Diesel Engine which is certified to US EPA
Marine Tier 3 Standards with fuel that contains >50
ppm (mg/kg) of sulfur, modifications to the crankcase
ventilation system (CCV system) must be made to
prevent fouling of the aftercooler. Crankcase fumes
cannot be routed back into the engine air intake when
the engine is operating with fuel that contains >50
ppm (mg/kg) of sulfur. Contact your Cat dealer for
more information.
Specifications for Distillate Diesel Fuel
Note: Diesel fuel used to operate a Cat Marine
Diesel Engine which is certified to US EPA Tier 3
Standards must also meet the “Cat Specification for
Distillate Diesel Fuel for Off-Highway Diesel
Engines”. The acceptability of these fuels for use is
determined on a case by case basis. A complete fuel
analysis is required. Consult your Cat dealer for
further information.
NOTICE
The footnotes are a key part of the “Caterpillar Speci-
fication for Distillate Diesel Fuel for Off-Highway Die-
sel Engines” Table. Read ALL of the footnotes.
Table 9
Caterpillar Specification for Distillate Fuel for Nonroad
Diesel Engines

Specifications Requirements ASTM ISO Test

Test
Aromatics 35% maximum “D1319” “ISO 3837”
0.01% maximum
Ash “D482” “ISO 6245”
(weight)

Carbon Residue on 0.35% maximum

“D524” “ISO 4262”
10% Bottoms (weight)

“D613”
40 minimum (DI
Cetane Number (1) or “ISO 5165”
engines)
“D6890”
Illustration 54 g02157153
NACD Film
(continued)
76 SEBU9041
Refill Capacities
Fluid Recommendations

(Table 9, contd) (Table 9, contd)

Caterpillar Specification for Distillate Fuel for Nonroad Caterpillar Specification for Distillate Fuel for Nonroad
Diesel Engines Diesel Engines

Specifications Requirements ASTM ISO Test Specifications Requirements ASTM ISO Test
Test Test
35 minimum (PC 0.05% maximum
Sediment “D473” “ISO 3735”
engines) (weight)

The cloud point Gums and Resins 10 mg per 100 mL

“D381” “ISO 6246”
must not exceed (4) maximum
Cloud Point the lowest ex- “D2500” “ISO 3015” (1) Alternatively, to ensure a minimum cetane number of 35 (PC en-
pected ambient
gines), and 40 (DI engines), distillate diesel fuel should have a
temperature. minimum cetane index of 37.5 (PC engines), and 44.2 (DI en-
gines) when the “ASTM D4737-96a” test method is used. A fuel
Copper Strip with a higher cetane number may be required for operation at a
No. 3 maximum “D130” “ISO 2160”
Corrosion higher altitude or in cold weather.
10% at 282 °C
(2) Via standards tables, the equivalent kg/m3 (kilograms per cubic
meter) using the “ASTM D287” test method temperature of
(540 °F)
15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/
maximum m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
Distillation “D86” “ISO 3405” (3)
90% at 360 °C Certain Cat fuel systems and engine components can operate
(680 °F) on fuel with a maximum sulfur content of 3%. Contact your Cat
dealer for guidance about appropriate maintenance intervals
maximum
and fluids for engines operating on fuel with sulfur levels be-
Flash Point legal limit “D93” “ISO 2719” tween 0.1% and 3%.
(4) Follow the test conditions and procedures for gasoline (motor).
Minimum of 80%
reflectance after
Thermal Stability aging for 180 mi- “D6468”
No equiva- Biodiesel
lent test
nutes at 150 °C
(302 °F) A biodiesel blend of up to 20 percent may be used in
the engine when the fuel blend meets the
30 minimum No equiva- recommendations in table 10 and meets the
API Gravity (2) “D287”
lent test
recommendations in Special Publication, SEBU6251,
45 maximum “Biodiesel”. A blend of greater than 20 percent
6 °C (10 °F) mini- biodiesel may be acceptable in some cases. See
Pour Point mum below ambi- “D97” “ISO 3016” your Cat dealer for more information.
ent temperature
Note: A complete Cat S·O·S Services oil analysis
“D5453” ISO 20846 program is recommended strongly when using
Sulfur (3) or or biodiesel blends above 5 percent.
“D2622” ISO 20884
Table 10
1.4 cSt minimum
Biodiesel Blends for Cat Commercial Diesel Engines
and 20.0 cSt maxi-
mum as delivered Distillate diesel fuel
to the fuel injection Biodiesel blend stock Final blend
used for blend
pumps
Kinematic Viscosity - - Caterpillar distillate
Caterpillar biodiesel B20: “ASTM
1.4 cSt minimum diesel fuel specifica-
specification, “ASTM D7467” and “API”
and 4.5 cSt maxi- tion, “ASTM D975” or
D6751” or “EN14214” gravity 30-45
mum as delivered “EN590”
to the rotary fuel
injection pumps

“D1796”
Water and
0.05% maximum or “ISO 3734”
Sediment
“D2709”
No equiva-
Water 0.05% maximum “D6304”
lent test

(continued)
SEBU9041 77
Refill Capacities
Fluid Recommendations

Cooling System

The cooling system operates under pressure

which is controlled by the pressure cap. Remov-
ing the cap while the system is hot may allow the
escape of hot coolant and steam, causing serious
burns.
Before you remove the pressure cap, allow the
system to cool. Use a thick cloth and turn the
pressure cap slowly to the first stop to allow pres-
sure to escape before fully removing the cap.
Avoid contact with coolant.

NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.

NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper-
ature or drained completely in order to prevent dam-
age caused by freezing coolant.

Never operate an engine without water temperature

regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system
problems can develop without water temperature
regulators. Removing the regulators allows some
coolant to bypass the radiator, potentially causing
overheating.
78 SEBU9041
Refill Capacities
Fluid Recommendations

Coolant Recommendations
Table 11
Coolant Recommendations for use in Cat Diesel Engines
Service Required
Recommendations Product
Hours(1) (2) (3) Maintenance

Add Cat ELC Extend-

12000 hours er at 6000 service
Cat ELC (Cat Extended Life Coolant)
or 6 years hours or one half of
service life
Preferred
Add Cat ELC Extend-
12000 hours er at 6000 service
Cat ELI (Cat Extended Life Inhibitor)
or 6 years hours or one half of
service life
Cat EC-1 specification and “ASTM D6210” and
Organic Additive Technology (OAT) based on a combination of a mono-
Add Extender at 3000
carboxylic acid and a dicarboxylic acid 6000 hours
Min requirements service hours or one
Phosphate, borate, and silicate free or 6 years
half of service life
Tolyltriazole: minimum typical concentration of 900 ppm (mg/kg)
Nitrite: minimum typical concentration of 500 ppm (mg/kg) in new coolants

SCA (Supplemental
3000 hours
Acceptable Cat DEAC (Cat Diesel Engine Antifreeze/Coolant) coolant additive) at
or 3 years
maintenance intervals
“ASTM D6210” and
Min requirements for fully for- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US gal)
3000 hours SCA at maintenance
mulated Heavy Duty Com- and maximum of 2400 ppm (140 grains/US gal)
or 2 years intervals
mercial coolants Silicon concentration: minimum of 100 ppm (mg/kg) and maximum of 275
ppm (mg/kg)

“ASTM D4985” and(1)

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US gal) SCA at initial fill and
3000 hours
mercial coolants requiring and maximum of 2400 ppm (140 grains/US gal) SCA at maintenance
or 1 year
SCA precharge Silicon concentration: minimum of 100 ppm (mg/kg) and maximum of 275 intervals
ppm (mg/kg)
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets Re-
agent 4 “ASTM D1193” requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.

Table 12
Special Requirements for Cat C7 through C32Separate Circuit Aftercooled (SCAC) Marine Engines (1) (2)

Maximum of 20% glycol is allowed in the aftercooler circuit (not applicable to the jacket water circuit which is capable of 50% glycol).
Water mixed with ELI or water mixed with SCA are not recommended for use in applications that require freeze protection.(3) (4)
(1) Heat exchanger cooled and keel cooled configurations
(2) For freezing protection of −5° C (23° F) temperatures and lower, consult your Cat dealer for guidance.
(3) For applications that allow the use of Cat ELI and water, a minimum of 7.5% of Cat ELI is recommended.
(4) For applications that allow the use of SCA and water, a minimum of 6% to a maximum of 8% concentration of Cat SCA is recommended.
SEBU9041
NOTICE
Use Only Approved SCAs and Extenders
Conventional coolants require the maintenance addi-
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless
approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring com-
patibility and acceptable performance.
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex-
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en-
suring compatibility and acceptable performance.
Failure to follow these recommendations can result in
shortened cooling system component life.
Cat ELC can be recycled into conventional coolants.
S·O·S Services Coolant Analysis
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and
freezing. S·O·S coolant analysis can be done at your
Cat dealer. Cat S·O·S coolant analysis is the best
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program
that is based on periodic samples.
Table 13
Recommended Interval
Type of Level 1 Level 2
Coolant
Cat DEAC
Conventional Heavy- Every 250 hours Yearly(1)
Duty Coolants
Cat ELC
Cat ELI
Optional Yearly(1)
Commercial EC-1
Coolants
(1)
The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
Note: Check the SCA (Supplemental Coolant
Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at
the interval that occurs first.
S·O·S Services Coolant Analysis (Level
1)
A coolant analysis (Level 1) is a test of the properties
of the coolant.
79
Refill Capacities
Fluid Recommendations
The following properties of the coolant are tested:
• Glycol concentration for freeze protection and boil
protection
• Ability to protect from erosion and corrosion
• pH
• Conductivity
• Visual analysis
• Odor analysis
The results are reported, and appropriate
recommendations are made.
S·O·S Services Coolant Analysis (Level 2)
A coolant analysis (Level 2) is a comprehensive
chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
system.
The S·O·S coolant analysis (Level 2) has the
following features:
• Full coolant analysis (Level 1)
• Identification of metal corrosion and of
contaminants
• Identification of buildup of the impurities that cause
corrosion
• Identification of buildup of the impurities that cause
scaling
• Determination of the possibility of electrolysis
within the cooling system of the engine
The results are reported, and appropriate
recommendations are made.
For more information on S·O·S coolant analysis,
consult your Cat dealer.
Greases
If it is necessary to choose a single grease, always
choose a grease that meets or exceeds the
requirements of the most demanding application.
Remember that the products which barely meet the
minimum performance requirements can be expected
to barely produce the minimum lives of your parts.
False economy is being used if a grease is purchased
with the lowest cost as the only consideration.
Instead, use the grease that yields the lowest total
operating cost. The cost should be based on an
analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
is required.
80
Maintenance Recommendations
General Maintenance Information
Maintenance
Recommendations
i05264090
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 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
• experience level of the operator
• philosophy of the operator
A regular maintenance program is strongly
recommended. This program would involve the
following steps:
SEBU9041
• periodic disassembly
• 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 Cat dealer.
i02909163
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050
Coolant System
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)
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
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:
SEBU9041
• The high pressure fuel lines are constantly
charged with high pressure.
• 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.
i05264113
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 Cat dealer regarding welding on a chas-
sis frame or rail.
Proper welding procedures are necessary in order to
avoid damage to the engine 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 Cat
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.
81
Maintenance Recommendations
Welding on Engines with Electronic Controls
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 move back accidentally,
and contact any of the ECM pins.
82 SEBU9041
Maintenance Recommendations
Welding on Engines with Electronic Controls

6. Use standard welding practices to weld the

materials.

Illustration 55 g01075639
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage 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.
SEBU9041 83
Maintenance Recommendations
Generator Start-up Checklist

i03860683

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:

Main Stator Megohmmeter Reading: Before Storage: After Storage:

Generator dried for 24 hours prior to startup? (Y/N) Drying method:

SPACE HEATERS Yes No Comments

Space heaters operating properly?

Space heater operated 48 hours before startup?

MEGOHMMETER TEST Special Instruction, 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments
SEHS9124 reading reading corrected corrected temp.

Main Stator
Main Rotor
Beginning of
Exciter Stator
Storage
Exciter Rotor
PMG Stator
Main Stator
Main Rotor
Start-up Exciter Stator
Exciter Rotor
PMG Stator

Table 15
GENERATOR START-UP CHECKLIST (CONT.)

Regulator Voltage Amps Comments

F1 to F2 DC
E1 to E2 AC
All Frames
E1 to E3 AC
No Load
E2 to E3 AC
2400, 2500, PM1 to PM4 AC
2800, and 2900
Frames

(continued)
84 SEBU9041
Maintenance Recommendations
Generator Start-up Checklist

(Table 15, contd)

PM1 to PM2 AC
2600 Frame PM1 to PM3 AC
PM2 to PM3 AC
Generator Excitation DC Compare with F1 to F2
Name Plate Information:
F1 to F2 DC
All Frames
E1 to E2 AC
E1 to E3 AC
E2 to E3 AC
Full Load
2400, 2500, PM1 to PM4 AC
2800, and 2900
Frames
PM1 to PM2 AC
2600 Frame PM1 to PM3 AC
PM2 to PM3 AC

Table 16
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

Table 17
GENERATOR START-UP CHECKLIST (CONT.)

MECHANICAL Data Comments

Bearing temperature readings at full load Front __________ Rear ___________

Stator temperature readings at full load A0 _______ B0 _______ C0 _______

Air gap on main stator Top __________ Bottom __________

Air gap on exciter stator Top __________ Bottom __________

Air gap of PMG Top __________ Bottom __________

Ambient air to generator at full load Temperature ____________________

Supplier air opening to generator Size of Opening _________________

SWITCH GEAR/PARALLEL OPERATION

Manufacturer:
Setting 1 Setting 2 Setting 3 Comments

(continued)
SEBU9041 85
Maintenance Recommendations
Generator Start-up Checklist

(Table 17, contd)

Type of Circuit breaker

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.
86
Maintenance Recommendations
Maintenance Interval Schedule
i05599877
Maintenance Interval Schedule
SMCS Code: 1000; 4450; 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 which includes the following items:
performing all adjustments, using proper lubricants,
fluids, and filters and replacing old components with
new components due to normal wear and aging .
Failure to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
Choose the interval that occurs first in order to
determine the correct maintenance interval: fuel
consumption, service hours and calendar time .
Products that operate in severe operating conditions
may require more frequent maintenance.
All of the following will affect the oil change interval:
operating conditions, fuel type, oil type and size of the
oil sump . Scheduled oil sampling analyzes used oil in
order to determine if the oil change interval is suitable
for your specific engine.
Refer to this Operation and Maintenance Manual,
“Engine Oil and Filter - Change” in order to determine
the oil change interval that is suitable for your specific
engine.
To determine the maintenance intervals for the
overhauls, refer to this Operation and Maintenance
Manual, “Maintenance Recommendations” .
When Required
“Aftercooler Core - Clean/Test”................................88
“Aftercooler Core - Inspect” .....................................89
“Battery - Recycle” ...................................................90
“Battery - Replace”...................................................90
“Battery or Battery Cable - Disconnect”...................91
“Coolant - Change” ..................................................93
“Coolant Extender (ELC) - Add” ..............................95
“Engine - Clean”.................................................... 101
“Engine Oil Level Gauge - Calibrate”.................... 105
“Engine Storage Procedure - Check” ....................110
SEBU9041
“Fuel System - Prime”............................................111
“Generator - Dry”....................................................119
“Generator Bearing - Lubricate”............................ 122
“Generator Set - Test” ........................................... 127
“Generator Set Alignment - Check” ...................... 128
“Generator Winding - Test” ................................... 129
“Heat Exchanger - Inspect”................................... 134
“Heat Exchanger - Clean/Test” ............................. 134
“Maintenance Recommendations” ....................... 137
“Rotating Rectifier - Check” .................................. 145
“Sea Water Strainer - Clean/Inspect” ................... 146
“Varistor - Inspect”................................................. 149
Daily
“Coolant Level - Check”...........................................96
“Electrical Connections - Check” .......................... 101
“Engine Air Cleaner Service Indicator - Inspect” .. 102
“Engine Oil Level - Check”.................................... 104
“Fuel System Primary Filter/Water Separator -
Drain” .....................................................................114
“Generator Bearing Temperature - Test/Record”.. 126
“Generator Load - Check”..................................... 126
“Power Factor - Check”......................................... 145
“Walk-Around Inspection” ..................................... 150
Every Week
“Generator - Inspect” ............................................120
“Generator Set Vibration - Inspect”....................... 128
“Standby Generator Set Maintenance
Recommendations” .............................................. 146
“Stator Winding Temperature - Test”..................... 148
“Voltage and Frequency - Check”......................... 150
Every 50 Service Hours or Weekly
“Aftercooler Condensate Drain Valve - Inspect/
Clean” ......................................................................88
“Engine Cooling System Corrosion Protection System
- Inspect”............................................................... 102
“Sea Water Strainer - Clean/Inspect” ................... 146
SEBU9041
Every 250 Service Hours
“Battery Charger - Check”........................................90
“Battery Electrolyte Level - Check” ..........................91
“Belts - Inspect/Adjust/Replace” ..............................92
“Coolant Sample (Level 1) - Obtain”........................97
“Cooling System Supplemental Coolant Additive
(SCA) - Test/Add”.....................................................99
“Engine Oil Sample - Obtain”................................ 105
“Fuel Tank Water and Sediment - Drain” ...............118
“Hoses and Clamps - Inspect/Replace”................ 135
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)
“Coolant Sample (Level 2) - Obtain”........................98
“Engine Valve Lash - Check” .................................110
“Engine Valve Rotators - Inspect”..........................110
“Fuel Injector - Check” ...........................................111
Every 500 Service Hours
“Engine Crankcase Breather - Clean” .................. 103
“Fuel System Primary Filter (Water Separator)
Element - Replace”................................................112
“Fuel System Secondary Filter - Replace” ............114
Every 750 Service Hours
“Engine Oil and Filter - Change”........................... 106
Initial 1000 Service Hours
“Aftercooler Core - Inspect” .....................................89
“Heat Exchanger - Inspect”................................... 134
Every 1000 Service Hours
“Engine Air Cleaner Element (Single Element) -
Inspect/Replace”................................................... 101
“Generator Winding Insulation - Test”................... 130
“Turbocharger - Inspect” ....................................... 148
Every 2000 Service Hours
“Fumes Disposal Filter Element - Replace”...........118
“Stator Lead - Check” ........................................... 148
87
Maintenance Recommendations
Maintenance Interval Schedule
Every Year
“Coolant Sample (Level 2) - Obtain”........................98
“Varistor - Check”.................................................. 149
Every 3000 Service Hours
“Auxiliary Water Pump (Bronze Impeller) - Inspect/
Replace” ..................................................................89
“Bolts (Fuel Filter Base) - Inspect/Replace” ............93
“Coolant Temperature Regulator - Replace” ...........98
“Crankshaft Vibration Damper - Inspect”.............. 100
“Engine Mounts - Inspect” .................................... 104
“Engine Speed/Timing Sensor - Clean/Inspect”... 109
“Engine Valve Lash - Check” .................................110
“Engine Valve Rotators - Inspect”..........................110
“Fuel Injector - Check” ........................................... 111
“Starting Motor - Inspect” ...................................... 147
Every 5000 Service Hours
“Water Pump - Inspect”......................................... 151
Every 8000 Service Hours
“Rotating Rectifier - Check” .................................. 145
Overhaul
“Aftercooler Core - Clean/Test”................................88
“Generator Bearing - Inspect/Replace” ................ 121
“Heat Exchanger - Clean/Test” ............................. 134
“Maintenance Recommendations” ....................... 137
“Overhaul (Major)” ................................................ 141
Overhaul (Top End)
“Aftercooler Core - Inspect” .....................................89
“Heat Exchanger - Inspect”................................... 134
“Maintenance Recommendations” ....................... 137
“Oil Cooler Core - Check/Clean/Test”................... 141
“Overhaul (Top End)” ............................................144
88
Maintenance Recommendations
Aftercooler Condensate Drain Valve - Inspect/Clean
i05215845
Aftercooler Condensate Drain
Valve - Inspect/Clean
SMCS Code: 1063-042-DN
Illustration 56 g03336909
Aftercooler condensate drain valves
(1) Drain valves
(2) Valve seats
(3) Plungers
The engine boost pressure forces the plunger to
move down to the valve seat. The plunger must close
against the seat at a pressure of 27.5 kPa (4 psi).
When the engine stops, the absence of boost
pressure allows the plunger to rise to the open
position, allowing condensation from the aftercooler
to drain.
The plunger must be able to move freely in order to
close the system when the engine is running. The
plunger must be able to move freely in order to allow
condensation to drain from the aftercooler when the
engine is stopped. Residue from normal engine
operation could cause the plunger to stick.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component 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.
SEBU9041
1. Remove the valve from the adapter. Check the
valve in order to determine if the plunger moves
freely. If the plunger does not move easily, clean
the valve with solvent.
2. Reassemble the aftercooler condensate drain
valve. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
information on the proper torques.
i04363377
Aftercooler Core - Clean/Test
SMCS Code: 1064-070; 1064-081
Note: An aftercooler that circulates fresh water or
treated water may require cleaning less often than an
aftercooler which circulates salt water. The
maintenance interval for an aftercooler which
circulates fresh water or treated water should be
evaluated when the aftercooler is cleaned and tested
after the first 1000 hours of engine operation. The
interval will vary depending on operating conditions.
Clean the Aftercooler Core
Remove the core. Refer to the Disassembly and
Assembly Manual, “Aftercooler - Remove” for the
procedure.
1. Turn the aftercooler core on one side in order to
remove debris. Remove the debris that is
accessible.
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 concen-
tration of cleaner.
2. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 18 lists Hydrosolv liquid
cleaners that are available from your Cat dealer.
Table 18
Hydrosolv Liquid Cleaners(1)
Description
Part Number Size
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 temper-
atures up to 93°C (200°F). Consult your Cat dealer for more
information.
SEBU9041
3. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside
and from the outside of the core.
Note: Do not use high pressure when the fins are
cleaned. High pressure can damage the fins.
4. Wash the core with hot, soapy water.
5. Flush the core thoroughly in order to remove
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear and free of debris.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Test the Aftercooler Core
1. Inspect the core for trapped debris and cleanliness.
If necessary, remove the debris and repeat the
cleaning procedure.
2. Inspect the core for damage and perform a
pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform
pressure tests.
3. Plug both ends of the aftercooler core and
pressurize the core to 205 kPa (30 psi). Submerge
the core in water. Look for bubbles which are being
emitted from the core. The bubbles are evidence of
leaks.
4. If any leaks are found, do not attempt to repair the
core.
Install a core that is clean and a core that passes the
pressure test in step 3. Refer to the Disassembly and
Assembly Manual, “Aftercooler - Install” for the
procedure.
For more information on cleaning the core, consult
your Cat dealer.
89
Maintenance Recommendations
Aftercooler Core - Inspect
i05194761
Aftercooler Core - Inspect
SMCS Code: 1064-040
The interval for the maintenance of the aftercooler
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 of the aftercooler
• Effectiveness of the aftercooler
Operating in water that contains silt, sediment, salt,
algae, and so on, will adversely affect the aftercooler
system. In addition, intermittent use of the vessel will
adversely affect the aftercooler.
The following items indicate that the aftercooler 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 aftercooler are
required if the engine is overheating.
Your Cat dealer has the equipment and the trained
personnel that are needed in order to measure the
pressure drop across the aftercooler.
Refer to the Operation and Maintenance Manual,
“Aftercooler Core - Clean/Test”. For more information
on servicing the aftercooler, consult your Cat dealer.
i03091745
Auxiliary Water Pump (Bronze
Impeller) - Inspect/Replace
SMCS Code: 1371-510
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).
90
Maintenance Recommendations
Battery - Recycle
Refer to Disassembly and Assembly, “Auxiliary Water
Pump - Remove” in order to remove the auxiliary
water pump. Refer to Disassembly and Assembly,
“Auxiliary Water Pump - Disassemble” in order to
disassemble the auxiliary water pump.
Inspect 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 Disassembly and Assembly, “Auxiliary Water
Pump - Assemble” in order to assemble the auxiliary
water pump. Refer to Disassembly and Assembly,
“Auxiliary Water Pump - Install” in order to install the
auxiliary water pump.
i00993589
Battery - Recycle
SMCS Code: 1401-005; 1401-510; 1401-535; 1401-
561; 1401
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
• A battery supplier
• An authorized battery collection facility
• Recycling facility
i02153996
Battery - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can
explode. A spark can cause the combustible
gases to ignite. This can result in severe personal
injury 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.
SEBU9041
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
charger.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane.
Disconnect the cable from the NEGATIVE “-”
battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to 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 key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
8. Connect the cable from the ground plane 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.
SEBU9041 91
Maintenance Recommendations
Battery Electrolyte Level - Check

The batteries may not fully recharge when the engine i01492654
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
Battery or Battery Cable -
the battery from freezing. Disconnect
SMCS Code: 1401; 1402-029
i02601752

Battery Electrolyte Level -

Check
SMCS Code: 1401-535-FLV
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.

1. Turn the start switch to the OFF position. Turn the

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.
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.

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.
92 SEBU9041
Maintenance Recommendations
Belts - Inspect/Adjust/Replace

i05224104 Adjust
Belts - Inspect/Adjust/Replace The belt tension does not require adjustment.

SMCS Code: 1357-025; 1357-040; 1357-510 Replace

1. Remove the front cover.
2. Insert a ratchet with a square drive into the square
hole that is located in the tensioner for the fan drive
belt. Rotate the tensioner clockwise in order to
relieve tension on the fan drive belt. Remove the
fan drive belt.
3. Then insert a ratchet with a square drive into the
square hole that is located in the tensioner for the
alternator belt.
4. Rotate the tensioner counterclockwise in order to
relieve tension on the alternator belt. Remove the
alternator belt.
5. Install the new belt correctly, as shown. Be sure
that the belt is fully seated on the pulleys. The
correct tension will automatically be applied when
the ratchet is removed.
6. Replace the front cover.
Illustration 57 g03338555
(1) Belt tensioner
(2) Square drive used for belt replacement

Inspect
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
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.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
If the belts are too tight, unnecessary stresses are
placed on the pulley bearings and on the belts. These
stresses may shorten the service life of the
components.
Remove the belt guard, if equipped. Inspect the
condition and adjustment of the alternator belts and
accessory drive belts (if equipped).
If the belt does not require replacement, install the
belt guard. If the belt requires adjustment or
replacement, follow the procedure below.
SEBU9041 93
Maintenance Recommendations
Bolts (Fuel Filter Base) - Inspect/Replace

i05238809 i04538352

Bolts (Fuel Filter Base) - Coolant - Change

Inspect/Replace SMCS Code: 1350-044; 1352; 1395-044; 1395
SMCS Code: 1262-040-BC; 1262-510-BC; 7553- Refer to this Operation and Maintenance Manual,
040; 7553-510 “Fluid Recommendations” for the correct intervals for
changing the coolant.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.

Drain the Cooling System

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.

NOTICE
Care must be taken to ensure that fluids are con-
Illustration 58 g03320213
tained during performance of inspection, mainte-
Mounting bolts for the secondary fuel filter base nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Three bolts are used to mount the base for the ers before opening any compartment or disassem-
secondary fuel filter to the mounting bracket. Inspect
the bolts for the following conditions: bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
• Wear
Service Tool Catalog” or refer to Special Publication,
• Corrosion PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
• Cracking fluids on Cat products.
Dispose of all fluids according to local regulations and
• Sagging
mandates.
• Crushing
1. Stop the engine and allow the engine to cool.
Replace any damaged bolts. Refer to Disassembly
and Assembly, UENR3257, “Fuel Filter Base - Ensure that the engine will not start when the
Remove and Install” for the procedure. cooling system is drained.

2. Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling
system filler cap.
94
Maintenance Recommendations
Coolant - Change
3. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
Note: If equipped, be sure to drain the heater and any
related supply and return lines.
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 Cat dealer or
consult Cat Dealer Service Tool Group :
Inside USA 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
International 1-309-578-7372
Flush
Systems Filled with Cat ELC, Cat ELI, or a
Conventional Coolant that Meets the Cat
EC-1 Requirements and the Standards of
ASTM D6210
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the drain
plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
SEBU9041
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. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
information on the proper torques.
Systems Filled with Cat DEAC ,
Conventional Coolant which does not
Meet the Cat EC-1 Requirements, or
Supplemental Coolant Additive (SCA)
and Water
3. Flush the cooling system with clean water in order
to remove any debris.
4. Close the drain valve (if equipped). Clean the drain
plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
5. Fill the cooling system with a mixture of clean water
and Cat Fast Acting Cooling System Cleaner.
6. Choose 1 of the following options.
• Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity.
• For cooling systems with heavy deposits or
plugging, add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling
system capacity.
7. Install the cooling system filler cap.
8. Start and run the engine at low idle for a minimum
of 30 minutes. For cooling systems with heavy
deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at
least 82 °C (180 °F).
SEBU9041
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
cleaning agent are gone.
9. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in order
to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to
flush the heater and any related supply and return
lines. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
Fill the Cooling System
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system. Refer to this Operation and
Maintenance Manual, “Fluid Recommendations”
for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
information about the capacity of the cooling
system. Do not install the cooling system filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high idle
for 1 minute in order to purge the air from the
cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
95
Maintenance Recommendations
Coolant Extender (ELC) - Add
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. Only
install the used filler cap if the gasket is not
damaged. Use a 9S-8140 Pressurizing Pump to
pressure test a reinstalled 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. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i04862631
Coolant Extender (ELC) - Add
SMCS Code: 1352-544-NL
Note: Refer to this Operation and Maintenance
Manual, “Fluid Recommendations” (Cooling System)
for the maintenance interval for the addition of the
coolant extender.
Cat ELC (Extended Life Coolant) and Cat ELI
(Extended Life Inhibitor) do not require the frequent
additions of any supplemental cooling additives. The
Cat ELC Extender will only be added one time.
Note: Do not use conventional supplemental coolant
additive (SCA) with Cat ELC or with Cat ELI.
Check the cooling system only when the engine is
stopped and cool.
Personal injury can result from hot coolant, steam
and alkali.
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.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
96 SEBU9041
Maintenance Recommendations
Coolant Level - Check

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component 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.
Illustration 59 g00103638
(1) Filler cap
1. Loosen the cooling system filler cap slowly in order (2) “COLD FULL” mark
(3) “LOW ADD” mark
to relieve pressure. Remove the cooling system
filler cap.
1. Observe the coolant level in the coolant recovery
2. If necessary, drain enough coolant from the cooling tank. Maintain the coolant level to “COLD FULL”
system in order to add the Cat ELC Extender . mark (2) on the coolant recovery tank.

3. Add Cat ELC Extender according to the
requirements for the cooling system capacity.
Refer to this Operation and Maintenance Manual,
“Refill Capacities” for the coolant capacity.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
For further information, refer to this Operation and
Maintenance Manual, , “Fluid Recommendations”.
i04550124
Coolant Level - Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
Engines That Are Equipped with a
Coolant Recovery Tank
2. Loosen filler cap (1) slowly in order to relieve any
pressure. Remove the filler cap.
3. Pour the proper coolant mixture into the tank. Refer
to this Operation and Maintenance Manual, “Refill
Capacities” for information about coolants. Do not
fill the coolant recovery tank above “COLD FULL”
mark (2).
4. Clean filler cap (1) and the receptacle. Reinstall the
filler cap and inspect the cooling system for leaks.
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
and cool, the coolant will return to the engine.
Engines That Are Not Equipped
with a Coolant Recovery Tank
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.

1. Remove the cooling system filler cap slowly in

order to relieve pressure.
SEBU9041 97
Maintenance Recommendations
Coolant Sample (Level 1) - Obtain

2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
For additional information about coolant analysis and
about other coolants, see this Operation and
Maintenance Manual, “Fluid Recommendations” or
consult your Cat dealer.
Sampling Conditions
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.
If the engine is not equipped with a sampling port, the
coolant should be warm.
Use the following guidelines for proper sampling of
the coolant:

• Complete the information on the label for the

sampling bottle before you begin to take the
samples.

• Keep the unused sampling bottles stored in plastic

Illustration 60 g00103639
Typical filler cap gaskets
3. Clean the cooling system filler cap and inspect the
condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
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.

4. Inspect the cooling system for leaks. • Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
i04333559

• Never collect samples from expansion bottles.

Coolant Sample (Level 1) -
• Never collect samples from the drain for a system.
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Timing of the Sampling
Testing the engine coolant is important to ensure that Table 19
the engine is protected from internal cavitation and
corrosion. The analysis also tests the ability of the Recommended Interval
coolant to protect the engine from boiling and
freezing. S·O·SSystems Coolant Analysis can be
Type of Level 1 Level 2
done at your Cat dealer. Cat S·O·S coolant analysis Coolant
is the best way to monitor the condition of your Cat DEAC
coolant and your cooling system. S·O·S coolant Cat SCA
analysis is a program that is based on periodic Conventional Heavy-
Every 250 hours Yearly(1)
samples. Duty Coolants

Note: Obtaining a Coolant Sample (Level 1) is Cat ELC

optional if the cooling system is filled with one of Cat ELI
Optional(1) Yearly(1)
the following coolants: Cat ELC (Extended Life Commercial EC-1
Coolant)., Cat ELI (Extended Life Inhibitor) and Coolants
Conventional Heavy-Duty Coolant. (1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any of the following Note: Check the SCA (Supplemental Coolant
coolants: Cat DEAC, Cat SCA and Conventional Additive) of the conventional coolant at every oil
Heavy-Duty Coolants. change or at every 250 hours. Perform this check at
the interval that occurs first.
98
Maintenance Recommendations
Coolant Sample (Level 2) - Obtain
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 Cat
dealer.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. 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
incorrect interpretation that could lead to concerns by
both dealers and customers.
Submit the sample for Level 1 analysis.
Note: Level 1 results may indicate a need for Level 2
Analysis.
i04638756
Coolant Sample (Level 2) -
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
An S·O·S Coolant Analysis (Level 2) is a
comprehensive chemical evaluation of the coolant.
This analysis is also a check of the overall condition
of the cooling system. The S·O·S Coolant Analysis
(Level 2) has the following features:
• Full coolant analysis (Level 1)
• Identification of metal corrosion and contaminants
• Identification of buildup of the impurities that cause
corrosion and scaling
• Determination of the possibility of electrolysis
within the cooling system of the engine
The results are reported and appropriate
recommendations are made.
Obtaining the Sample
Refer to Operation and Maintenance Manual,
“Coolant Sample (Level 1) - Obtain” for the guidelines
for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For further information, refer to this Operation and
Maintenance Manual, “Fluid Recommendations”.
SEBU9041
i04240223
Coolant Temperature
Regulator - Replace
SMCS Code: 1355-510
Replace the water temperature regulator before the
water temperature regulator fails. Replacing the water
temperature regulator reduces the chances for
unscheduled downtime.
A water temperature regulator that fails in a partially
opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
the cylinder liner.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cool-
ing 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 tempera-
ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is
open.
Do not use liquid gasket material on the gasket or cyl-
inder head surface.
SEBU9041
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component 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.
Note: If replacing only the water temperature
regulator, only drain the coolant to a level that is
below the water temperature regulator housing.
Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulator -
Remove and Water Temperature Regulator - Install”
for the replacement procedure or consult your Cat
dealer.
i05053052
Cooling System Supplemental
Coolant Additive (SCA) - Test/
Add
SMCS Code: 1352-045; 1395-081
Note: This maintenance is NOT required for
cooling systems that are filled with Extended Life
Coolant.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact
with the skin and eyes. Do not drink cooling sys-
tem coolant additive.
99
Maintenance Recommendations
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” and to Special Publica-
tion, GECJ0003, “Cat Shop Supplies and Tools” for
tools and supplies suitable to collect and contain flu-
ids on Caterpillar products.
Dispose of all fluids according to applicable regula-
tions and mandates.
Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1).
Cooling Systems that Use
Conventional Coolant
Test the Concentration of the SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Test the concentration of the SCA with the 4C-9301
Coolant Conditioner Test Kit.
100 SEBU9041
Maintenance Recommendations
Crankshaft Vibration Damper - Inspect

Add the SCA, If Necessary

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.

1. Remove the cooling system filler cap slowly.

2. If necessary, drain some coolant in order to allow

space for the addition of the SCA.

3. Add the proper amount of SCA. For the proper

amount of SCA, refer to this Operation and
Maintenance Manual, “Refill Capacities and
Recommendations” or refer to this Operation and
Maintenance Manual, “Fluid Recommendations”. Illustration 61 g01134779

The proper concentration of SCA depends on the Viscous vibration damper

type of coolant that is used. For the proper
concentration of SCA, refer to Special Publication,
SEBU6251, “Caterpillar Commercial Diesel Engine
Fluids Recommendations”.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
i03175962
Crankshaft Vibration Damper -
Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to the
crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train
noise at variable points in the speed range.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.
Typical example
(1) Crankshaft pulley
(2) Weight
(3) Case
Inspection
Inspect the damper for the following conditions:
• The damper is dented, cracked, or fluid is leaking
from the damper.
• The paint on the damper is discolored from
excessive heat.
• The damper is bent.
• The bolt holes are worn or there is a loose fit for
the bolts.
• The engine has had a crankshaft failure due to
torsional forces.
Replace the damper if any of these conditions exist.
Removal and Installation
Refer to this Operation and Maintenance Manual,
“Belts - Inspect/Adjust/Replace” for information on
removing and on installing the belt. Refer to the
Disassembly and Assembly Manual, “Vibration
Damper and Pulley - Remove and Install” for
information on removing and installing the damper.
SEBU9041 101
Maintenance Recommendations
Electrical Connections - Check

i01595880 i05024170

Electrical Connections - Check Engine Air Cleaner Element

SMCS Code: 4459-535 (Single Element) - Inspect/
Check all exposed electrical connections for Replace
tightness. SMCS Code: 1051; 1054-040; 1054-510
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.

i01646701

Engine - Clean Illustration 62 g03195697

SMCS Code: 1000-070 Typical air cleaner installation
(1) Cover for the air cleaner cannister
(2) Latches for the air cleaner
(3) Air cleaner cannister

Personal injury or death can result from high

voltage. NOTICE
Never run the engine without an air cleaner element
Moisture can create paths of electrical installed. Never run the engine with a damaged air
conductivity. cleaner element. Do not use air cleaner elements with
Make sure that the electrical system is OFF. Lock damaged pleats, gaskets, or seals. Dirt entering the
out the starting controls and tag the controls “ DO engine causes premature wear and damage to en-
NOT OPERATE”” . gine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.

NOTICE If the air cleaner element becomes plugged, the air

Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
lates on the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Cat dealer has the proper air cleaner
elements for your application. Consult your Cat dealer
for the correct air cleaner element.
NOTICE
Never service the air cleaner element with the engine
running. Operating the engine without an air cleaner
allows dirt to enter the engine.
Replacing the Air Cleaner Element
1. Open the four latches on the air cleaner.
2. Remove the used air cleaner. Properly dispose of
the air cleaner according to local standards. Wipe
the inside of the air cleaner canister to remove any
accumulated dirt and debris.
102
Maintenance Recommendations
Engine Air Cleaner Service Indicator - Inspect
3. Install a new air cleaner.
4. Close the four latches.
5. Reset the service indicator.
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
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.
Illustration 63 g00103777
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
Service indicators are important instruments.
SEBU9041
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
• 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 plugged.
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 of
2 N·m (18 lb in).
i05303334
Engine Cooling System
Corrosion Protection System -
Inspect
SMCS Code: 1388-040
Galvanic corrosion may harm components that cool
the engine. Corrosion is caused when dissimilar
metals are in contact and the dissimilar metals are
immersed in salt water. The voltage potential from
salt water to the engine must be tested on a regular
basis to protect the cooling components.
SEBU9041 103
Maintenance Recommendations
Engine Crankcase Breather - Clean

Location of the Corrosion Testing the Voltage Potential

Protection Post Operate the engine for at least 30 minutes, then stop
the engine. Disconnect the engine from the shore
C18SCACMarine Engine power connection. Use a 257-9140 Multimeter and
a 244-1536 Cable Group to test the voltage
potential from the salt water to the engine. A silver-
silver chloride half cell probe is widely available if the
Cat tools are not available.
1. Connect a #8 American Wire Gauge (AWG) cable
from the sacrificial anode to the bonding system of
the vessel.
2. Test the voltage at the bonding stud.

3. Test the voltage at the bonding connector.

Results of the Test

The voltage potential must be between -0.500 mV
and -0.800 mV.
Note: A value near or greater than 0.0 mV is
extremely corrosive.
Measure the galvanic potential of the system and
apply zinc or other less noble metal to divert
corrosion. Contact your Cat dealer for more
Illustration 64 g03252916
information.
(1) Bonding connector
(2) Bonding stud i02263740
(3) Vessel zinc
Engine Crankcase Breather -
C32SCACMarine Engine Clean
SMCS Code: 1317-070

NOTICE
Perform this maintenance with the engine stopped.

If the crankcase breather is not maintained on a

regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.

Illustration 65 g03267159
(4) Bonding connector
(5) Vessel zinc
(6) Bonding stud
104 SEBU9041
Maintenance Recommendations
Engine Mounts - Inspect

i04948069

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Illustration 67 g00110310
Illustration 66 g01136454 (Y) “ADD” mark
Typical example (X) “FULL” mark
(1) Hose clamp
(2) Breather assembly
(3) Retaining clamp
NOTICE
(4) Seal Perform this maintenance with the engine stopped.

1. Loosen hose clamp (1) and remove the hose from
breather assembly (2).
2. Loosen retaining clamp (3). Remove the breather
assembly and seal (4).
1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the oil level gauge .
Do not fill the crankcase above the “FULL” mark
(X).

3. Wash the breather element in solvent that is clean NOTICE

and nonflammable. Allow the breather element to
dry before installation.
4. Install a breather element that is clean and dry.
Install the seal, the breather assembly, and the
clamp. Refer to the Specifications, SENR3130 in
order to locate the proper torques.
5. Install the hose. Install the hose clamp. Refer to the
Specifications, SENR3130 in order to locate the
proper torques.
i02456872
Engine Mounts - Inspect
SMCS Code: 1152-040; 1152
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused 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,
“Torque Specifications” for the recommended
torques. Refer to the OEM recommendations for
more information.
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge
(dipstick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylinder
liner.
If the oil level is above the “FULL” mark on the oil lev-
el gauge, drain some of the oil immediately.
2. Remove the oil filler cap and add oil, if necessary.
For the correct oil to use, see this Operation and
Maintenance Manual, “Fluid Recommendations”
topic. Do not fill the crankcase above the “FULL”
mark (X) on the oil level gauge. Clean the oil filler
cap. Install the oil filler cap.
3. Record the amount of oil that is added. For the next
oil sample and analysis, include the total amount of
oil that has been added since the previous sample.
SEBU9041
i04548759
Engine Oil Level Gauge -
Calibrate
SMCS Code: 1326-524; 1326
The engine is shipped with an engine oil level gauge
that is marked with “ADD” and “FULL” marks. This
procedure should only be performed when the
generator set is not installed in a perfectly horizontal
plane.
The engine oil level gauge may only be calibrated
after the generator set is installed in the vessel.
Note: The engine may be equipped with auxiliary
engine oil filters. The extra filters require more engine
oil than the standard amounts. Refer to the
specifications of the original equipment manufacturer
(OEM).
Use the following procedure in order to calibrate and
mark the engine oil level gauge.
1. Ensure that the generator set is properly aligned
and that the vessel is in the design trim. The
generator set must be installed properly in the
vessel.
Note: If the engine is being filled with oil for the first
time, perform Step 2. If the engine contained oil
before this calibration procedure, skip Step 2 and
proceed to Step 3.
2. Use the information in this Operation and
Maintenance Manual, “Fluid Recommendations” in
order to select the correct oil for the engine. Add
engine oil to the crankcase by using the procedure
in this Operation and Maintenance Manual,
“Engine Oil and Filter - Change”. Fill the crankcase
with 138 L (146 qt) of the recommended oil.
3. Operate the engine until normal operating
temperature is achieved. Stop the engine. Drain
the engine oil by using the procedure in this
Operation and Maintenance Manual, “Engine Oil
and Filter - Change”.
4. If needed, replace the engine oil filters using the
procedure in this Operation and Maintenance
Manual, “Engine Oil and Filter - Change”.
5. Clean the engine oil level gauge and install the
engine oil level gauge.
6. Use the information in Operation and Maintenance
Manual, “Fluid Recommendations” in order to
select the correct oil for the engine.
105
Maintenance Recommendations
Engine Oil Level Gauge - Calibrate
7. Add engine oil to the crankcase using the
procedure in this Operation and Maintenance
Manual, “Engine Oil and Filter - Change”. Add
110 L (116 qt) of the recommended oil if the oil
filters were changed. If the filters were not
changed, subtract 2 L (2.1 qt) of oil from the total
for each filter.
8. Start the engine. Ensure that the lubrication system
and the new engine oil filters are filled. Inspect the
lubrication system for leaks.
9. Stop the engine and allow the engine oil to drain
into the engine crankcase for approximately 20
minutes.
10. Check the engine oil level. Use a marking tool in
order to engrave the new “ADD” mark (Y) to the
correct location on the gauge assembly.
11. Add 28 L (30 qt) of the recommended oil grade
and weight of engine oil to the crankcase. Allow
the oil to drain into the sump for approximately 20
minutes.
12. Check the engine oil level. Use a marking tool in
order to engrave the new “FULL” mark (X) onto
the correct location on the gauge assembly.
Illustration 68 g00110310
Oil Level Gauge “ADD” mark (Y) and “FULL” mark
(X)
i04237495
Engine Oil Sample - Obtain
SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
106
Maintenance Recommendations
Engine Oil and Filter - Change
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order to
help obtain the most accurate analysis, provide the
following information:
• Engine model
• Service hours on the engine
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve in
order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. 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
incorrect interpretation that could lead to concerns by
both dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion into
the sump.
SEBU9041
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.
i04405896
Engine Oil and Filter - Change
SMCS Code: 1318-510
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.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component 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.
Drain the Engine Oil
After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
SEBU9041 107
Maintenance Recommendations
Engine Oil and Filter - Change

• If the engine is equipped with a drain valve, turn

the drain valve knob counterclockwise in order to
drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the
drain valve.
• If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil to
drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
After the oil has drained, the oil drain plugs should be
cleaned and installed.

Replace the Oil Filter With the

Engine Stopped (Standard Oil
Filters)
NOTICE
Caterpillar oil filters are built to Caterpillar specifica-
tions. Use of an oil filter not recommended by Cater-
pillar 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 recom-
mended 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 Gp. 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 Cat dealer in order to
arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
Illustration 69 g00103713
Typical filter mounting base and 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.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
nated. 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.
Replacing the Engine Oil Filters
During Engine Operation (Duplex
Oil Filters)
This filter contains hot, pressurized oil that can
cause burns and fire hazards, which may result in
bodily injury or death. Follow the instructions giv-
en in this Operation and Maintenance Manual and
stop the engine if rapid air movement exists to
blow the oil.
108
Maintenance Recommendations
Engine Oil and Filter - Change
Illustration 70 g01426431
If the engine is equipped with duplex oil filters, the
engine oil filter elements can be changed while the
engine is in operation. This is useful if the oil filter
elements require more frequent replacement than the
engine oil.
Illustration 71 g01034883
1. Open the “FILL” valve for a minimum of 5 minutes
in order to fill the oil filter elements that will not be
serviced. The oil filters that will not be serviced
must be full of engine oil. Close the FILL valve.
2. Move the control valve to the “AUX RUN” position
in order to change the main oil filter elements.
Move the selector valve to the “MAIN RUN”
position in order to change the auxiliary oil filter
elements.
3. Allow the oil pressure gauge for the oil filter that is
being changed to reach a “ZERO” pressure
reading.
SEBU9041
4. Perform Step 1 through Step 5 of “Replace the Oil
Filter With the Engine Stopped (Standard Oil
Filters)”.
5. Open the “FILL” valve for a minimum of 5 minutes
in order to fill the new oil filter elements.
6. Close the “FILL” valve. Rotate the control valve to
the “RUN” position for the oil filter that was
serviced.
Fill the Engine Crankcase
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.
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge
(dipstick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylinder
liner.
If the oil level is above the “FULL” mark on the oil lev-
el gauge, drain some of the oil immediately.
Use the following procedure in order to fill the
crankcase if the engine oil filters were replaced during
engine operation.
1. If the engine oil filters were replaced during engine
operation, operate the engine at low idle. Ensure
that the oil level is at the “FULL” mark on the
“LOW IDLE” side of the oil level gauge.
2. Add oil, if necessary. Remove the oil filler cap. Fill
the crankcase through the oil filler tube only.
SEBU9041 109
Maintenance Recommendations
Engine Speed/Timing Sensor - Clean/Inspect

Use the following procedure in order to fill the
crankcase if the engine oil filters were replaced with
the engine stopped. Refer to this Operation and
Maintenance Manual, “Fluid Recommendations” for
information about choosing the oil for the engine.
, Small amounts of debris may be found in the oil filter
element due to normal wear and friction. If an
excessive amount of debris is found in the oil filter
element, consult your Caterpillar dealer in order to
arrange for further oil analysis.

1. Remove the oil filler cap. Fill the crankcase through i04602232
the oil filler tube only. Clean the oil filler cap. Install
the oil filler cap. Engine Speed/Timing Sensor -
Clean/Inspect
NOTICE SMCS Code: 1905-040; 1905-070; 1907-040; 1907-
To prevent crankshaft or bearing damage, crank en- 070
gine with fuel off to fill all filters before starting.
Do Not crank engine for more than 30 seconds.

2. Close the fuel supply line and crank the engine

until the oil pressure gauge indicates 70 kPa
(10 psi). Open the fuel supply line. Allow the
starting motor to cool for 2 minutes before cranking
again.

3. Start the engine according to this Operation and

Maintenance Manual, “Starting The Engine”
procedure (Operation Section). Operate the engine
at low idle for 2 minutes. in order to ensure that the
lubrication system has oil and that the oil filters are
filled with oil. Inspect the engine for oil leaks.
Ensure that the oil level is at the “FULL” mark on
the “LOW IDLE” side of the oil level gauge.

4. Stop the engine and allow the oil to drain back into
the sump for a minimum of 10 minutes.
Illustration 72 g01137086
5. Remove the oil level gauge and check the oil level.
Maintain the oil level to the “FULL” mark on the Front view
“ENGINE STOPPED” side of the oil level gauge. (1) Secondary speed/timing sensor
(2) Primary speed/timing sensor
Inspect the Used Oil Filter Elements
1. Remove the speed/timing sensors from the front
Cut the used oil filter element open with a utility knife. housing. Check the condition of the plastic end of
Remove the metal wrap. Cut the filter element free the speed/timing sensors for wear and/or
from the end caps. Spread apart the pleats and
inspect the element for metal debris. An excessive contaminants.
amount of debris in the element may indicate early
wear or a pending failure. 2. Clean the metal shavings and other debris from the
face of the speed/timing sensors. Use the
Use a magnet to differentiate between the ferrous procedure in the Troubleshooting Manual, “Speed/
metals and the nonferrous metals that are found in Timing Sensor - Calibrate” in order to calibrate the
the element. Ferrous metals may indicate wear on the speed/timing sensors.
steel and the cast iron parts of the engine. Nonferrous
metals may indicate wear on the aluminum parts, the
brass parts, or the bronze parts of the engine. Parts
that may be affected include the following
components: main bearings, rod bearings,
turbocharger bearings and cylinder heads.
Aluminum debris may indicate problems with the
bearings of the front gears. If you find aluminum
debris, inspect the crankshaft vibration damper and
the idler gear bearings.
110
Maintenance Recommendations
Engine Storage Procedure - Check
i01458399
Engine Storage Procedure -
Check
SMCS Code: 1000-535
The oil change interval may be extended to 12
months for a vehicle that is operated seasonally and
placed in storage for the remainder of the year by
using the required storage procedures and the
required start-up procedures. This extension is
permitted if the following categories for oil change
intervals in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” have not been
reached:
• Mileage
• Operating hours
• Fuel consumption
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 three
months, a complete protection procedure is
recommended. For more detailed information on
engine storage, see Special Instruction, SEHS9031,
“Storage Procedure For Caterpillar Products”.
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. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the use
of volatile corrosion inhibitor (VCI) oil in order to
prevent internal engine damage due to moisture
during storage. These inhibitors in the VCI oil act by
evaporating inside the engine. The inhibitors then
condense over the inside surfaces of the engine. The
evaporation process and the condensing process
offers full protection to surfaces that cannot be
reached with preservatives. 0.9 L (1.0 qt) of
4C-6792 VCI oil will treat 28.4 L (30.0 qt) of engine
oil. This will give a 3 percent concentration of VCI oil.
The engine must be completely sealed when the
engine is stored in order for the VCI oil to function
properly. The VCI oil is easily cleaned from the engine
when you remove the engine from storage. The
volatile vapors are removed by simply running the
engine to operating temperature. A mineral oil base is
left behind after the volatile vapors are removed.
SEBU9041
i04242309
Engine Valve Lash - Check
SMCS Code: 1105-535
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of the
valve train components and to the seating of the
valve train components.
The maintenance is recommended by Caterpillar as
part of a lubrication and preventive maintenance
schedule to help provide maximum engine life.
Note: Only qualified service personnel should
perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve
bridge, see System Systems Operation/Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
Consult your Cat dealer for assistance.
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 meas-
uring/adjusting valve lash clearance.
i01597115
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
When inspecting the valve rotators, protective
glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
Engine valve rotators rotate the valves when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
1. Start the engine according to Operation and
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
2. Operate the engine at low idle.
SEBU9041 111
Maintenance Recommendations
Fuel Injector - Check

3. Observe the top surface of each valve rotator. The i02728734

valve rotators should turn slightly when the valves
close. Fuel System - Prime
SMCS Code: 1250-548; 1258-548
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not re-
placed, valve face guttering could result and cause Fuel leaked or spilled onto hot surfaces or electri-
pieces of the valve to fall into the cylinder. This can cal components can cause a fire. To help prevent
cause piston and cylinder head damage. possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
If a valve fails to rotate, consult your Caterpillar
dealer.
The fuel system should be primed after a unit injector
i04841177
is changed or when the fuel system is totally dry.

Note: The fuel system does not typically need to be

Fuel Injector - Check primed when the primary fuel filters or secondary fuel
SMCS Code: 1290-535 filters are changed or when an Electronic Control
Module (ECM) is replaced. When the engine is
started under these circumstances, the engine may
momentarily run rough until the air is purged from the
system.
Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos-
NOTICE
sible injury, do not use the starting motor to turn
Do not allow dirt to enter the fuel system. Thoroughly
the flywheel.
clean the area around a fuel system component that
Hot engine components can cause burns. Allow will be disconnected. Fit a suitable cover over any dis-
additional time for the engine to cool before meas- connected fuel system components.
uring/adjusting the unit injectors.
The electronic unit injectors use high voltage. Dis-
connect the unit injector enable circuit connector
in order to prevent personal injury. Do not come
in contact with the injector terminals while the en-
gine is running.

The operation of Cat engines with improper

adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.
Only qualified service personnel should perform this
maintenance. Refer to the following topics for your
engine for the correct procedure: Refer to the
Systems Operation, Testing and Adjusting, “Fuel
System” for the maintenance procedure.

NOTICE
The camshafts must be correctly timed with the crank-
shaft before an adjustment of the lash for the fuel in-
jector is made. The timing pins must be removed from
the camshafts before the crankshaft is turned or dam-
age to the cylinder block will be the result.
112 SEBU9041
Maintenance Recommendations
Fuel System Primary Filter (Water Separator) Element - Replace

1. Turn the priming pump plunger (4)

counterclockwise in order to unlock the plunger.
Manually pump the plunger in order to fill the fuel
lines and the fuel filters with fuel.
2. As the air is purged from the fuel system, fuel
pressure will increase. This will create resistance
in the plunger. Continue to pump the plunger until a
strong resistance is felt. The number of strokes will
vary with the amount of air in the fuel lines.

3. After resistance is felt in the plunger, push in the

plunger. Lock the plunger by turning the plunger
clockwise.
4. Start the engine at low idle.

5. If the engine runs rough, continue to run the engine

at low idle until the engine runs smoothly.

NOTICE
Illustration 73 g01373601 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.

i05354209

Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. If a vacuum gauge is installed, the primary
filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).

Replace the Element

Illustration 74 g01368408 Fuel leaked or spilled onto hot surfaces or electri-

(1) Fuel priming pump cal components can cause a fire. To help prevent
(2) Fuel filter base possible injury, turn the start switch off when
(3) Secondary fuel filter changing fuel filters or water separator elements.
Clean up fuel spills immediately.
Follow the procedure below in order to prime the
engine with fuel.
SEBU9041 113
Maintenance Recommendations
Fuel System Primary Filter (Water Separator) Element - Replace

4. Remove the O-ring from the gland of the bowl.

NOTICE
Clean the following components:
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
• Bowl
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- • O-ring
ers before opening any compartment or disassem-
bling any component containing fluids. • Mounting base
Refer to Special Publication, NENG2500, “Dealer Inspect the O-ring for damage and for
Service Tool Catalog” for tools and supplies suitable deterioration. Replace the O-ring, if necessary.
to collect and contain fluids on Cat products.
5. Lubricate the O-ring with clean diesel fuel.
Dispose of all fluids according to local regulations and
mandates.
6. Install bowl (2) on a new element. Tighten the bowl
by hand. Do not use tools in order to tighten the
NOTICE bowl.
Do not allow dirt to enter the fuel system. Thoroughly 7. Lubricate the top seal of element (1) with clean
clean the area around a fuel system component that diesel fuel. Install the new element on the
will be disconnected. Fit a suitable cover over discon-
mounting base. Tighten the element by hand.
nected fuel system component.

NOTICE
Do not fill fuel filters with fuel before installing
them. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts. The fuel system
should be primed prior to starting the engine.
1. Close the main fuel supply valve.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the
fuel system.
8. Open the main fuel supply valve.
9. Start the engine and check for leaks. Run the
engine for 1 minute. Stop the engine and check for
leaks again.
Detecting leaks is difficult while the engine is
running. The primary filter/water separator is under
suction. A leak will allow air to enter the fuel. The
air in the fuel can cause low power due to aeration
of the fuel. Ensure that the components are
correctly installed to prevent air from entering the
fuel system.

Illustration 75 g01453091
(1) Element
(2) Bowl
(3) Drain

2. Remove element (1) from the element mounting

base while bowl (2) is attached.

3. Dispose of the contents of the filter. Remove bowl

(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
114 SEBU9041
Maintenance Recommendations
Fuel System Primary Filter/Water Separator - Drain

i01463757
NOTICE
Care must be taken to ensure that fluids are con-
Fuel System Primary Filter/ tained during performance of inspection, mainte-
Water Separator - Drain nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
SMCS Code: 1260-543; 1263-543 ers before opening any compartment or disassem-
bling any component 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.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 76 g00668636
(1) Bowl
(2) Element Note: If the engine is equipped with duplex fuel filters,
(3) Drain
the fuel filter elements can be replaced while the
Bowl (1) should be monitored daily for signs of water. engine is in operation. Refer to “Replacing the Fuel
If water is present, drain the water from the bowl. Filter Elements During Engine Operation For Engines
That Are Equipped With Duplex Fuel Filters”.
1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Dispose of the water properly.

2. Close drain (3).

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.

i05303381

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. Clean up fuel
spills immediately.
SEBU9041 115
Maintenance Recommendations
Fuel System Secondary Filter - Replace

4. Unlock the fuel priming pump in order to relieve

residual pressure in the fuel system.

5. Remove the used fuel filter. Use a cloth or use a

container in order to catch excess fuel.
6. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.

7. Apply clean diesel fuel to the new fuel filter gasket.

NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.

8. Install the new fuel filter. Tighten the fuel filter until
the gasket contacts the base. Tighten the fuel filter
by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.

Note: Do not remove the plug in the fuel filter base to

release the air from the fuel system during periodic
service of the fuel filter. Periodic removal of the plug
Illustration 77 g03140296 will result in increased wear of the threads in the fuel
Typical secondary fuel filter filter base.
(1) Priming pump 9. Operate the fuel priming pump plunger until a
(2) Fuel shutoff strong resistance is felt and until the check valve
(3) Drain valve
(4) Fuel indicators clicks. This procedure will require considerable
(5) Auxiliary secondary fuel filter strokes. Lock the fuel priming pump.
(6) Main secondary fuel filter
(7) Fuel selector valve 10. Open the fuel tank supply valve.

Replacing the Fuel Filter Elements
with the Engine Stopped
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.
1. Stop the engine.
2. Turn off the start switch or disconnect the battery
(starting motor) when maintenance is performed
on fuel filters.
3. Shut off the fuel tank supply valve to the engine.
11. Start the engine according to the normal operating
procedures. Immediately increase the engine rpm
between 1000 to 1200 rpm with no load. The
engine will begin to misfire briefly until air from the
fuel filter is purged. No damage to the engine will
occur.
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.
12. If the engine stalls during the purging of the air,
refer to the Operation and Maintenance Manual,
“Fuel System - Prime” for more information.

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
116 SEBU9041
Maintenance Recommendations
Fuel System Secondary Filter - Replace

Replacing the Fuel Filter Elements

During Engine Operation For
Engines That Are Equipped With
Duplex Fuel Filters
Note: The engine must be at IDLE in order to replace
the fuel filter elements during engine operation.

This filter contains pressurized fuel that can

cause a fire hazard, which may result in bodily in-
jury or death. Follow the instructions given in this
Operation and Maintenance Manual and stop the
Illustration 78 g03409950
engine if rapid air movement exists to blow the
fuel.
1. Move the fuel selector valve to the AUX RUN
position as marked on the indicator plate.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication, Illustration 79 g03329518
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain 2. Once the lever has been moved to the AUX RUN
fluids on Cat products. position, the fuel gauge for the auxiliary filter
Dispose of all fluids according to local regulations and should indicate full pressure and the fuel gauge for
mandates. the main filter should indicate no pressure.

3. Slowly open the drain valve and purge any

Replacing the Main Fuel Filter
Use the following procedure to replace the main fuel
filter while the engine is in operation.
remaining pressure from the main filter. Some fuel
may also drain from the fuel drain. The fuel
indicator for the auxiliary filter should indicate full
pressure and the fuel indicator for the main filter
should indicate no pressure.

4. Remove the used main fuel filter.

5. Clean the gasket sealing surface of the main fuel
filter base. Ensure that all of the old gasket is
removed.
6. Apply clean diesel fuel to the new main fuel filter
gasket.
SEBU9041 117
Maintenance Recommendations
Fuel System Secondary Filter - Replace

7. Install a new main fuel filter. Tighten the fuel filter

until the gasket contacts the base. Tighten the fuel
filter by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.
8. Move the lever to the RH FLOW - LH FILL position.
The indicator for the main filter should indicate
slight pressure. Purge the air from lines for the
main filter through the drain valve. Close the drain
valve when the fuel starts flowing through the drain
valve.
9. Move the fuel selection lever to the FLOW BOTH
position and monitor the main filter for leaks.
Illustration 81 g03410043
Uninstall and reinstall the main filter if necessary.
2. Once the lever has been moved to the MAIN RUN
Replacing the Auxiliary Fuel Filter
position, the fuel gauge for the main filter should
Use the following procedure to replace the auxiliary indicate full pressure and the fuel gauge for the
fuel filter while the engine is in operation. auxiliary filter should indicate no pressure.

3. Slowly open the drain valve and purge any

remaining pressure from the auxiliary filter. Some
fuel may also drain from the fuel drain. The fuel
indicator for the main filter should indicate full
pressure and the fuel indicator for the auxiliary filter
should indicate no pressure.

4. Remove the used auxiliary filter.

5. Clean the gasket sealing surface of the auxiliary

Illustration 80
1. Move the fuel selector valve to the MAIN RUN
position as marked on the indicator plate.
fuel filter base. Ensure that all of the old gasket is
removed.
6. Apply clean diesel fuel to the new auxiliary fuel
filter gasket.
g03409976
7. Install a new auxiliary fuel filter. Tighten the fuel
filter until the gasket contacts the base. Tighten the
fuel filter by hand according to the instructions that
are shown on the fuel filter. Do not overtighten the
fuel filter.
8. Move the fuel selection lever to the “LH FLOW -
RH FILL” position. The indicator for the auxiliary
filter should indicate slight pressure. Purge the air
from the lines for the auxiliary filter through the
drain valve. Close the drain valve when the fuel
starts to flow through the valve.

9. Move the fuel selection lever to the FLOW BOTH

position and monitor the auxiliary filter for leaks.
Uninstall and reinstall the auxiliary filter if
necessary.
118
Maintenance Recommendations
Fuel Tank Water and Sediment - Drain
i05111531
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component 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 close the drain can allow air into the
system, which could have detrimental results to
performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.
Fill the fuel tank after operating the engine in order to
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
SEBU9041
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
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.
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Oil change
• Refill of the tank
This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
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.
i05019230
Fumes Disposal Filter Element
- Replace
SMCS Code: 1074
Replacement of the fumes disposal filter is affected
by the following items:
• Engine load
• Soot concentration
• Condition of the engine
Replacing the Fumes Disposal
Filter
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
SEBU9041 119
Maintenance Recommendations
Generator - Dry

Illustration 83 g01292899
(4) Plastic cover
(5) Service indicator

1. Remove the plastic cover.

Illustration 82 g03123321 2. Push down on the service indicator.

Typical installation 3. Replace the cover.
(1) Latches for the canister
(2) Service indicator
(3) Cap for the canister i03642821
(4) Engine air cleaner
(5) Canister Generator - Dry
Note: When possible, perform the maintenance while SMCS Code: 4450-569
the engine is off.
NOTICE
1. Release the latches that hold the canister to the Do not operate the generator if the windings are wet.
cap. If the generator is operated when the windings are
wet, damage can occur due to insulation breakdown.
Note: Removal of the canister may be difficult while
the engine is operating. The canister has negative air When moisture is present or when moisture is
pressure while the engine is operating which creates suspected in a generator, the generator must be dried
a vacuum. before being energized.
2. Lower the canister in order to expose the element.
There may be oil in the bottom of the canister. If the drying procedure does not restore the insulation
resistance to an acceptable value, the winding should
Avoid spilling the oil. be reconditioned.
3. Remove the filter element by pulling down. Dispose Note: For additional information, refer to Special
of the used element properly. Instruction, SEHS9124 .
4. Replace the canister and align the canister with the Drying Methods
boss on the filter base assembly.
The following methods can be used for drying a
5. Clamp the latches in the closed position. generator:

Resetting the Service Indicator (If • Self-circulating air method

Equipped) • Oven method

NOTICE
Do not allow the winding temperature to exceed
85 °C (185.0 °F). Temperatures that are greater than
85 °C (185.0 °F) will damage the winding insulation.
120
Maintenance Recommendations
Generator - Inspect
Self-Circulating Air Method
Note: Disable the excitation before using this method.
Run the engine and disconnect the generator load.
This will help circulate air. Operate the generator
space heaters.
Oven Method
Place the entire generator inside a forced air drying
oven for four hours at 65 °C (149 °F).
NOTICE
Use a forced air type oven rather than a radiant type
oven.
Radiant type ovens can cause localized overheating.
i05264189
Generator - Inspect
SMCS Code: 4450-040
Personal injury or death can result from improper
troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
Refer to Safety Section, “Generator Isolating for
Maintenance” for information regarding the procedure
to isolate the generator safely.
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
SEBU9041
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, various
cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
the items on the following list:
• The extent of the cleaning procedure that is being
attempted
• The type of enclosure of the generator
• The voltage rating of the generator
• The type of dirt that is being removed
Cleaning (Assembled Generators)
Cleaning may be required at the point of installation. If
complete disassembly of the generator is not
necessary or feasible, 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.
If necessary, connect a small nonconductive tube
may to the vacuum cleaner. This will allow the
vacuum cleaner to clean the surfaces that are not
exposed. After most of the dust has been removed, a
small brush may be attached to the vacuum hose in
order to loosen dirt that is more firmly attached to the
surface.
After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure should
be a maximum of 210 kPa (30 psi) in order to prevent
mechanical damage to the insulation. If the above
cleaning procedures are not effective, consult a Cat
dealer.
SEBU9041
Cleaning (Disassembled
Generators)
An initial insulation resistance check should be made
on the generator in order to confirm electrical integrity.
A minimum reading of 1 megohm would be expected
with severely contaminated generators. A zero
megohm reading may indicate an insulation
breakdown. An insulation breakdown requires more
than cleaning. An insulation breakdown requires
repair.
A high-pressure wash is normally an effective way to
clean windings. This includes windings that have
been exposed to flooding or windings that have been
contaminated by salt. A solution of hot water and
detergent is used for this method of cleaning.
A high-pressure wash sprays a high velocity fluid
stream of this solution over the generator that is being
cleaned. This detergent washing is followed by
multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean
water is used in order to dilute the detergent.
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation
resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It may
be necessary to use solvents if the generator is
contaminated with oil or if the generator is
contaminated with grease.
Note: For more information on drying methods, refer
to Special Instructions, SEHS9124, “Cleaning and
Drying of Electric Set Generators”.
i03099722
Generator Bearing - Inspect/
Replace
(SR4 Generator)
SMCS Code: 4471-040; 4471-510
The following maintenance procedure for generator
bearings should be followed at every major engine
overhaul:
Inspect
121
Maintenance Recommendations
Generator Bearing - Inspect/Replace
1. Remove the bearing bracket. Inspect the following
items: bracket bore, bearing outer race and rolling
elements. On standby power units, the bearing
must be inspected and the grease must be
replaced at three year intervals. The sleeve in the
bearing bracket should be inspected for out of
roundness, excessive wear, and a bracket step
that is less than 0.0762 mm (0.0030 inch). If there
is no sleeve in the bearing bracket, inspect the
bore of the bearing bracket. The bearing should be
inspected for damage to the outer race, severe
fretting, and smoothness of operation. When
possible, the bearing elements should be
inspected. Some double shielded ball bearings
prevent visual inspection of the elements of the
bearing. Other double shielded ball bearings have
a retaining ring. This retaining ring can be removed
in order to allow access for a visual inspection of
the elements of the bearing.
On two-bearing generators, the front bearing can
only be removed after the drive coupling is
removed. Refer to the Systems Operation Testing
and Adjusting Disassembly and Assembly,
“Coupling - Remove” for the generator for
instructions for removing the drive coupling.
Replace
1. All ball bearings should be cleaned. The cavity in
the bracket should be repacked with 2S-3230
Grease. Pack the ball bearings (one-third to one-
half of the volume of the cavity).
2. Use an induction heater to heat the ball bearings to
107 °C (224.6 °F) for ten minutes in order to install
either of the following bearings: ball bearings that
are new and ball bearings that have been
inspected. Mount the bearings on the shaft. To
reinstall the hub, heat the hub to 400 °C (752.0 °F)
for three hours. Mount the hub to the shaft.
3. Ensure that the tube of the grease gun is filled with
grease.
4. Remove the bracket drain plug and operate the
generator for one hour. This will allow the grease to
expand. The expanding grease will force the
excess grease from the cavity. When the excess
grease is forced from the cavity, the internal
pressure will be reduced. The generator should
continue to operate until the grease stops purging.
5. Stop the engine. Install the bracket drain plug.
Wipe off the excess grease.
122 SEBU9041
Maintenance Recommendations
Generator Bearing - Lubricate

6. For greasing intervals, follow the recommendations

on the lubrication plate (if equipped) or refer to
Maintenance Schedule, “Generator Bearing -
Lubricate”. Whenever the bearings are greased,
repeat Step 1. DO NOT MIX GREASES.
i05032881
Generator Bearing - Lubricate
SMCS Code: 4471-086
Procedure for Bearing Service
Perform periodic bearing lubrication at the intervals
that are shown in Table 20 . Use the following
instructions as the suggested procedure in order to
service the bearings of the generator.
Note: If the generator already has a visible grease
point, go to Step 4.
1. Stop the generator set. Remove the required
external cover plates, grills, and louvers of the
generator in order to access the bearings.
2. Remove the top grease pipe plug and the lower
grease pipe plug. If no grease pipes can be found,
then locate the insert for the grease pipe. The
insert is located on the bearing brackets. Remove
the inserts. Install the grease pipes.
6. Operate the generator set at rated speed for
approximately 1 hour. When running the engine
more than 30 minutes, the recommended engine
load to apply is a minimum of 50%. The procedure
will allow the grease to expand. The expanding
grease will force the excess grease from the cavity.
The internal pressure will be reduced as the
excess grease is forced from the cavity. Operate
the generator until no grease is forced out of the
cavity.
7. Stop the generator set. Inspect the generator
windings, grease tubes, and bearing housings.
Wipe off any excess grease. If a grease pipe plug
was removed in Step 2, install the plug in the
bottom grease pipe. Wipe off any excess grease.
Note: Do not allow grease to drip on the stator
windings of the generator. The stator windings that
are exposed to grease could suffer degraded
insulation. The degraded insulation would cause a
reduction in the life of the windings.
8. Install all of the external cover plates, grills, and
louvers of the generator that were removed in
order to access the bearings.

3. Install a grease fitting in the top grease pipe.

4. Use a Cat ® 8F-9866 Grease Gun or equivalent

grease gun to grease the bearings. Use the
appropriate type of grease and the quantity that is
listed in Table 20 . Avoid the use of alternate types
of grease. Usage of alternate types of grease
could cause premature bearing failure.

Note: Add only the amount of grease listed in Table

20 . Do not continue to add grease until purging is
observed. Purging of grease will not always be
observed.
5. If grease fittings are permanently installed, ensure
that the protective caps for the grease fittings are
installed on the fittings when finished. If a grease
fitting was installed in Step 2, remove the top
grease fitting and install the plug that was
removed. If applicable, do not install the plug on
the bottom grease location yet. Wipe off the
excess grease.

Note: Do not allow grease to drip on the stator

windings of the generator. The stator windings that
are exposed to grease could suffer degraded
insulation. The degraded insulation would cause a
reduction in the life of the windings.
SEBU9041 123
Maintenance Recommendations
Generator Bearing - Lubricate

Table 20
Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Number Type Size Maximum(1) Part Number Diameter
5P-2448 315 BC 580 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 75 mm (3 inch)
Ball Bearing 160 mm 590 ing Lubricant service hours (1.8 oz)
(6.3 inch) or 12 months
OD
75 mm
(3 inch) ID

6Y-3955 220 BC 450 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 100 mm
Ball Bearing 180 mm ing Lubricant service hours (1.8 oz) (3.9 inch)
(7.1 inch) or 12 months
OD
100 mm
(3.9 inch)
ID
6Y-6488 318 BC 597 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 90 mm (3.5 inch)
Ball Bearing 190 mm ing Lubricant service hours (1.8 oz)
(7.5 inch) or 12 months
OD
90 mm
(3.5 inch)

108-1760 321 BC 680 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 105 mm
Ball Bearing 225 mm ing Lubricant service hours (1.8 oz) (4.1 inch)
(8.9 inch) or 12 months
OD
105 mm
(4.1 inch)
ID
108-1761 322 BC 690 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 110 mm
Ball Bearing 240 mm 800 ing Lubricant service hours (1.8 oz) (4.3 inch)
(9.4 inch) or 12 months
OD
110 mm
(4.3 inch)
ID
109-7687 316 BC 580 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 80 mm
Ball Bearing 170 mm ing Lubricant service hours (1.8 oz) (3.15 inch)
(6.7 inch) or 12 months
OD
80 mm
(3.15 inch)
ID
139-0349 Roller 2900 85° C (185° F) 1p0808 Every 250 2.8 g N/A 127 mm (5 inch)
Roller Bearing 2800 service (0.1 oz)
hours
139-0350 Roller 2900 85° C (185° F) 1p0808 Every 250 2.8 g N/A 127 mm (5 inch)
Roller Bearing 2800 service (0.1 oz)
hours
154-3032 326 BC 820 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 130 mm
Ball Bearing 280 mm 1800 (2) (3) 95° C (203° F) ing Lubricant service hours (1.8 oz) (5.1 inch)
(11 inch) 2600(3) 85° C (185° F) or 12 months
OD 2700(3) 85° C (185° F)
130 mm
(5.1 inch)
ID

(continued)
124 SEBU9041
Maintenance Recommendations
Generator Bearing - Lubricate

(Table 20, contd)

Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Number Type Size Maximum(1) Part Number Diameter
193-4070 018 BC 498 85° C (185° F) 2S-3230 Bear- Every 2000 51.2 g 59 mL (2 oz) 90 mm (3.5 inch)
Ball Bearing 140 mm 499 ing Lubricant service hours (1.8 oz)
(5.5 inch) or 12 months
OD
90 mm
(3.5 inch)
ID
241-4644 320 BC LC7 95° C (203° F) UNIREX N3 Every 4500 60 g N/A 100 mm
Bearing 215 mm service hours (2.1 oz) (3.9 inch)
(8.5 inch) or 12 months
OD
100 mm
(3.9 inch)
ID
243-5220 315 BB LC6100 95° C (203° F) UNIREX N3 Sealed(4) Sealed Sealed 75 mm (3.0 inch)
Bearing 160 mm LC5000
(6.3 inch)
OD
75 mm
(3.0 inch)
ID
253-9789 320 BC 1400 85° C (185° F) UNIREX N3 Grease can- N/A N/A 100 mm
Bearing 215 mm not be added (3.9 inch)
(8.5 inch) to this
OD bearing.
100 mm
(3.9 inch)
ID
253-9792 226BC 1400 95° C (203° F) EA6 Grease can- Grease Grease can- 140 mm
Bearing 230 mm not be added cannot be not be added (5.5 inch)
(9.05 inch) to this added to to this
OD bearing. this bearing.
130 mm bearing.
(5.12 inch)
ID
261-3545 307 BB LC2000 95° C (203° F) UNIREX N3 Sealed(4) Sealed Sealed 35 mm (1.4 inch)
Bearing 80 mm
(3.1 inch)
OD
35 mm
(1.4 inch)
ID
262-5921 307 BC LC2000 95° C (203° F) UNIREX N3 Sealed(4) Sealed Sealed 35 mm (1.4 inch)
Bearing 80 mm
(3.1 inch)
OD
35 mm
(1.4 inch)
ID

(continued)
SEBU9041 125
Maintenance Recommendations
Generator Bearing - Lubricate

(Table 20, contd)

Bearing Bearing Frame Temperature Grease Interval Weight Volume Shaft
Part Number Type Size Maximum(1) Part Number Diameter
263-0161 309 BC LC3000 95° C (203° F) UNIREX N3 Sealed(4) Sealed Sealed 45 mm (1.8 inch)
Bearing 100 mm
(3.9 inch)
OD
45 mm
(1.8 inch)
ID
281-3091 328 BC 3010(2) 95° C (203° F) EA6 Grease can- Grease Grease can- 140 mm
Ball Bearing 300 mm 3020(2) not be added cannot be not be added (5.5 inch)
(11.8 inch) 3042(2) to this added to to this
OD 3044(2) bearing. this bearing.
140 mm 3045(2) bearing.
(5.5 inch)
ID
311-0843 326 BC 1800(2) 95° C (203° F) EA6 Grease can- N/A N/A 130 mm
Ball Bearing 280 mm not be added (5.1 inch)
(11 inch) to this
OD bearing.
130 mm
(5.1 inch)
ID
311-0844 322 BC 1600 95° C (203° F) EA6 Grease can- N/A N/A 110 mm
Ball Bearing 240 mm not be added (4.3 inch)
(9.4 inch) to this
OD bearing.
110 mm
(4.3 inch)
ID
341-7383 330 BC 3055 (5) 95° C (203° F) Exxon Polyrex Every 1800 51.2 g 14.9 mL 150 mm
Ball Bearing 320 mm 3066(5) EM Base materi- service hours (1.8 oz) (0.5 oz) (5.9 inch)
(12.6 inch) 3068(5) al is Polyurea. or 12 months
OD
150 mm
(5.9 inch)
ID
375-3715 328 BC 3010(2) (3) 95° C (203° F) 2S-3230 Bear- Every 2400 51.2 g 59 mL (2 oz) 140 mm
Ball Bearing 300 mm 3020(2) (3) ing Lubricant service hours (1.8 oz) (5.5 inch)
(11.8 inch) 3042(2) (3) or 12 months
OD 3044(2) (3)
140 mm 3045(2) (3)
(5.5 inch)
ID
(1) Indicates the alarm temperature set point that the bearing should be continuously operated at on the specified generator frame size. Shutdown
set points are typically 10° C (18° F) higher.
(2) 1800 frame generators and 3000 frame generators shipped before 2012 use double-shielded bearings with EA6 grease. There are no
threaded holes in the bearing brackets for the grease tubes that are used to add grease. Therefore, no grease can be added to the bearings.
Beginning in 2012, 1800 frame generators and 3000 frame generators that are shipped will use a single-shielded bearing with 2S-3230 grease.
The front and rear brackets contain factory installed grease fittings, therefore, single-shielded bearings must be lubricated periodically. Refer-
ence the Parts Manual with package serial number to identify the bearing part number and to determine bearing lubrication requirements.
(3) All 2600, 2700, 1800 and 3000 frame generators shipped beginning in 2012, use a single-shielded bearing design. Replacement bearings re-
ceived from the Parts Division will have a shield on each side of the bearing. The shield facing the outside of the generator must be removed
when the new bearing is installed.
(4) Grease cannot be added to this bearing. Refer to the Operation and Maintenance Manual, “Generator Bearing - Replace” article for information
concerning the replacement of these bearings.
(5) The generator uses a non-shielded bearing design. Although replacement bearings may have a shield on each side, both shields must be re-
moved when the new bearing is installed. Replacement bearings are shipped as dry bearings and must be packed to 50% grease fill at time of
installation.
126
Maintenance Recommendations
Generator Bearing Temperature - Test/Record
Bearing Replacement
Refer to the appropriate publication for each specific
generator for bearing replacement procedures.
Replace both bearings of a two-bearing generator.
Replace any bearing wear sleeves and lip seals when
the bearings are replaced.
Except for the 341-7383 Ball Bearing, replacement
bearings are pre-lubricated. The pre-lubricated
bearings do not require additional grease at time of
replacement. The 341-7383 Ball Bearing is shipped
as a dry bearing. The 341-7383 Ball Bearing must
be packed to 50% grease fill at time of installation.
Old grease must be removed at the time of bearing
replacement from the bearing bracket cavity. After the
bearing bracket cavity is cleaned, the bearing bracket
cavity must be packed with new grease from one-
third to one-half full.
Note: Generator set alignment is required after the
bearings are replaced.
Additional Information
Refer to Special Instruction, REHS4892, “Generator
Bearing Service” for further information.
i05264199
Generator Bearing
Temperature - Test/Record
SMCS Code: 4471-081-TA
The monitoring of bearing temperature may prevent
premature bearing failure. A generator set should
never operate above the recommended set points.
Keep records in order to monitor the changes in the
temperature of the bearing.
Note: Measure the bearing temperature after the
generator reaches normal operating temperature.
Resistive Temperature Detectors
(RTDs)
Cat Generators may be equipped with resistance
temperature detectors for generator bearings. These
detectors are 100 ohm resistance temperature
detectors. A resistance temperature detector may be
monitored by the optional monitor for the EMCP 3.2/
3.3 resistance temperature detector. A resistance
temperature detector may be monitored by
equipment that is provided by the customer. Consult
with your Cat dealer about other methods of
measuring the bearing temperature.
SEBU9041
The EMCP 3.2/3.3 may be configured to “ALARM”
or the EMCP 3.2/3.3 may be configured to
“SHUTDOWN” . An alarm is activated if the
temperature of the bearing reaches 85 °C (185 °F). A
shutdown occurs if the temperature of the bearing
reaches 95 °C (203 °F).
Infrared Thermometers
Bearing temperatures can also be recorded with the
use of an infrared thermometer. Refer to Special
Publication, NENG2500, “Cat Dealer Service Tools
Catalog” for various infrared thermometers. Follow
the instructions that come with your infrared
thermometer.
i05264201
Generator Load - Check
SMCS Code: 4450-535-LA
During normal operation, monitor the power factor
and monitor generator loading.
When a generator is installed or when a generator is
reconnected, ensure that the total current in any one
phase does not exceed the nameplate rating. Each
phase should carry the same load, which allows the
generator to work at the rated capacity. If one phase
current exceeds the nameplate amperage, an
electrical imbalance will occur. An electrical
imbalance can result in an electrical overload and an
electrical imbalance can result in overheating.
The power factor can be referred to as the efficiency
of the load, which 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.
Generator sets normally have a low idle setting that is
higher than industrial engines. Low idle will be
approximately 66 percent of the full speed that is
achieved by 60 Hz units. This would be equal to 80
percent of the full speed that is achieved by 50 Hz
units.
Some generator sets are equipped with Woodward
governors and some generator sets are equipped
with Cat electronic governors. These generator sets
have no low idle stop. On generator sets with
mechanical governors and generators that are natural
gas, the low idle is set at the factory. Adjustment of
the low idle on these machines should only be done
by a Cat dealer.
SEBU9041
Note: Operating the generator set at low idle speed
for an extended time will cause some voltage
regulators to shut off. The generator set must be
completely shut down and the generator set must be
restarted. This will allow the voltage regulator to
produce an output again.
i03292462
Generator Set - Test
SMCS Code: 4450-081
Personal injury or death can result from high
voltage.
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 serv-
ice), 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.
DANGER: Shock/Electrocution Hazard-Do not
operate this equipment or work on this equipment
unless you have read and understand the
instructions and warnings in the Operation and
Maintenance Manual. Failure to follow the
instructions or heed the warnings will result in
serious injury or death.
Table 21
Tools Needed
Part Number Part Quantity
237-5130 Digital Multimeter 1
(continued)
127
Maintenance Recommendations
Generator Set - Test
(Table 21, contd)
12 VDC Battery 1
Potential
1
Transformer
The generator set functional test is a simplified test
that can be performed in order to determine if the
generator is functional. The generator set functional
test should be performed on a generator set that is
under load.
The generator set functional test determines if the
following statements happen:
• A phase voltage is being generated.
• The phase voltages are balanced.
• The phase voltages change relative to engine
speed.
The generator set functional test consists of the
following steps:
1. Stop the generator. Connect the potential
transformer's high voltage winding to the generator
terminals (T1) and (T2). Connect the voltmeter to
the low voltage winding. If two transformers are
available, connect the high voltage winding of the
second transformer to the generator terminals (T1)
and (T3). Connect the secondary terminals that
correspond to generator terminal (T2) of both
transformers together.
2. Disconnect wires “F1+” and “F2-” from the
voltage regulator. Disconnect the generator from
the load.
3. Connect a 12 VDC automotive battery to wires “F1
+” and “F2-” .
NOTICE
Do not operate the generator set at a speed that is
higher than one-half of the rated speed.
Higher speeds under these test conditions can cause
damage to the system.
4. Operate the generator set at half the rated speed.
5. Measure the AC voltage across the low voltage
terminals of the transformer that correspond to the
following generator terminals: “T1” and “T2” ,
“T2” and “T3” and “T3” and “T1” . Record the
voltages.
128 SEBU9041
Maintenance Recommendations
Generator Set Alignment - Check

6. Monitor the voltage between any two of the i02291365

locations in step 5. Decrease the generator set
speed by 10 percent. Increase the generator set
speed by 10 percent.
7. The voltages that were measured in Step 5 should
be nearly equal. These voltages should measure a
minimum of 85 VAC.
8. When the generator set speed is decreased by 10
percent, the voltages that were measured in Step 6
should decrease by 10 percent. When the
generator set speed is increased by 10 percent,
the voltages that were measured in Step 6 should
increase by 10 percent.
i03956450
Generator Set Alignment -
Check
(Generator Sets)
SMCS Code: 7002-024
Generator Set Vibration -
Inspect
SMCS Code: 4450-040-VI
Excessive vibration will indicate a problem with the
generator set. The vibration may be caused by the
following:
• 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.
• There is a short circuit in the stator.
Check for vibration damage. Vibration may cause the
following problems:

The genset must be aligned when the genset is • loose fittings

installed or moved into a different position. If the
generator set is run at the full continuous rating, the • loose bolts
alignment of the generator to the engine must be
checked annually. • excessive noise

Properly maintain the alignment between the engine • cracked insulation

and the driven equipment in order to minimize the
following problems: The following areas are susceptible to vibration
damage:
• Bearing problems
• stator output leads
• Vibration of the engine crankshaft
• protective sleeving
• Vibration of the driven equipment
• insulation
Refer to the following information for more information
about the alignment of the generator set: • exposed electrical connections

• Special Instruction, SEHS7654, “Alignment - • transformers

General Instructions”
• fuses
• Special Instruction, SEHS7259, “Alignment of
• capacitors
Single Bearing Generators”
Check the generator set's vibration level by using a
• Special Instruction, REHS0177, “Alignment of the broad spectrum analyzer.
Close Coupled Two Bearing Generators”
Keep a record of the measurement of the alignment.
The record may be used to check the trend of the
alignment. The record may be used to analyze the
trend of the alignment.
SEBU9041 129
Maintenance Recommendations
Generator Winding - Test

i03736530 Table 22
Quantity Needed Tool
Generator Winding - Test
1 Low ohmmeter
SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
081
Measure the resistance of the following windings:
(L1), (L2), (L3), (L4) and (L5). The winding that is
being tested must be disconnected from the other
components before the resistance can be measured.

Note: The winding temperature affects the

resistance. When the winding temperature increases,
the winding resistance increases. When the winding
temperature decreases, the winding resistance
decreases. Therefore, a correct measurement can be
performed only when the winding is at room
temperature.
The following resistance measurements are
approximations. If the measured value is not near the
listed approximation, the winding is probably
damaged. For a more precise resistance value,
consult the Technical Marketing Information (TMI).
Refer to the generator arrangement that is in
question.
The following windings have very little resistance:
(L2), (L4) and (L5). The resistance of these windings
will measure near 0 ohms. Use a milliohmmeter to
measure the resistance of the windings.
Exciter rotor (L2) – Refer to Table 23 .
Main stator (L4) – less than 0.1 ohm
Pilot exciter stator (L5) – less than 0.1 ohm

Use a multimeter in order to measure the resistance

of field windings (L1) and (L3).
Exciter field (stator) (L1) – Refer to table 23 .
Main field (rotor) (L3) – approximately 0.35 ohms to
1.2 ohms
Illustration 84 g01388839
PMPE Generator wiring diagram for the family of Note: There should be no continuity between any
1800 frames
winding and ground. There should be no continuity
(CR1-C6) Diodes between any winding and another winding.
(CR7) Varistor Table 23
(L1) Exciter stator
L2 Exciter Main Field for
(L2) Exciter rotor L1 Exciter Field
Rotor the Rotor
(L3) Main rotor
1800 Frame 10.9 ohms 0.05 ohms .9 ohms
(L4) Main stator
1600 Frame 10 ohms 0.06 ohms .5 ohms
(L5) Permanent magnet generator stator
(PM) Permanent magnet 1400 Frame 11 ohms 0.06 ohms .35 ohms

(RFA) Rotating field assembly

(CT1) Optional voltage droop transformer
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
130
Maintenance Recommendations
Generator Winding Insulation - Test
i03736629
Generator Winding Insulation -
Test
SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
081
Recommended Periodic Insulation
Tests
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”” po-
sition. Attach “ DO NOT OPERATE”” tags to all
starting controls. Disconnect the batteries or dis-
able the starting system. Lock out all switchgear
and automatic transfer switches that are associ-
ated with the generator.
Table 24
Tools Needed
Part Number Part Name Quantity
300-8648 Insulation Testing Gp 1 For additional information, refer to Special Instruction,
Periodically, use an insulation tester to check the
insulation resistance of the generator's main stator
winding. The frequency of this test is determined by
the generator's environment. Previous insulation
tester readings will also determine the frequency of
this test.
Test the main stator windings with an insulation tester
in the following situations:
SEBU9041
• The generator set is started for the first time.
• The generator set is removed from storage.
• The generator set is operating in a humid
environment. Test every three months.
• The generator set is not protected from the
elements in an enclosed area. Test every three
months.
• The generator set is installed in an enclosed area.
This area needs to be low in humidity and this area
needs to have steady temperatures. Test every
twelve months (minimum).
• The generator set has not been run under load for
three months. Test the generator set weekly. Use
space heaters around the generator set if the
generator is exposed to a sea water environment
or if the humidity is above 75 percent. Also use
space heaters if a test result was below 3
megohms.
Space heaters must be used whenever the generator
set is not under load. Space heaters must also be
used whenever salt is present or whenever high
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester
readings above one megohm. Use space heaters
only when the generator is not running.
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
Recommended Procedure for the
Insulation Test
Personal injury or death can result from
electrocution.
The megohmmeter is applying a high voltage to
the circuit.
To avoid electrocution, do not touch the instru-
ment leads without first discharging them. When
finished testing also discharge the generator
windings.
1. Take the generator out of service.
2. Visually inspect the generator for moisture. If
moisture exists, do not perform this insulation test.
Dry the unit first. Refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
SEBU9041 131
Maintenance Recommendations
Generator Winding Insulation - Test

4. Discharge the capacitance of the windings.

5. Disconnect “T0” from ground.

6. Disconnect the sensing lead wires for the regulator.

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

9. Connect the insulation tester's RED lead to “T0” .

10. Set the voltage to the rated voltage of the
generator.

11. Use the 30/60 Time Resistance Method:

a. Apply voltage.

b. Observe the readings at 30 seconds. Observe

the readings at 60 seconds.

c. Record the 60 second reading. This reading

must be corrected for temperature.

d. Record temperature.

e. Record humidity.

f. Remove voltage.

12. Evaluate the readings. The actual value of the

resistance may vary greatly between generators.
For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
the readings that were taken on previous dates.
These two readings must be taken under similar
conditions. If a 60 second resistance reading has a
50 percent reduction from the previous reading,
the insulation may have absorbed too much
moisture.
Switch the insulation tester to the “OFF” position.
This will discharge the insulation tester's leads.
Disconnect the insulation tester's leads.
Note: The results from the insulation resistance
checks indicate when cleaning and/or repairing is
becoming critical. Generally, insulation resistance will
vary greatly with temperature. Therefore, always test
at the same temperature and humidity. Refer to
Illustration 85 .
Engine Serial Number
Serial Number for the Generator
132 SEBU9041
Maintenance Recommendations
Generator Winding Insulation - Test
SEBU9041 133
Maintenance Recommendations
Generator Winding Insulation - Test

Illustration 85 g00633226
134
Maintenance Recommendations
Heat Exchanger - Inspect
i05194157
Heat Exchanger - Inspect
SMCS Code: 1379-040
The interval for the maintenance of the 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 of the heat exchanger
• Effectiveness of the heat exchanger system
Operating in water that contains silt, sediment, salt,
algae, and so on, 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.
Your Cat dealer has the equipment and the trained
personnel that are needed in order to measure the
pressure drop across the heat exchanger.
Refer to this Operation and Maintenance Manual,
“Heat Exchanger - Clean/Test”. For more information
on servicing the heat exchanger, consult your Cat
dealer.
i05194829
Heat Exchanger - Clean/Test
SMCS Code: 1379-070; 1379-081
Clean the Heat Exchanger
1. Remove the heat exchanger from the engine.
Refer to the Disassembly and Assembly Manual,
“Heat Exchanger - Remove” for the procedure.
2. Remove the heat exchanger core from the heat
exchanger. Refer to the Disassembly and
Assembly Manual, “Heat Exchanger -
Disassemble” for the procedure.
SEBU9041
3. Turn the heat exchanger core onto one side in
order to remove debris. Remove the debris that is
accessible.
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 concen-
tration of cleaner.
4. Back flush the heat exchanger core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 25 lists Hydrosolv liquid
cleaners that are available from your Cat dealer.
Table 25
Hydrosolv Liquid Cleaners(1)
Part Number Description Size
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a 2 to 5 percent concentration of the cleaner at tempera-
tures up to 93°C (200°F). Consult your Cat dealer for more
information.
5. Clean the heat exchanger core with steam to
remove any residue. Flush the fins of the heat
exchanger. Remove any other trapped debris from
the inside and from the outside of the core.
6. Wash the heat exchanger core with hot, soapy
water.
7. Flush the heat exchanger core thoroughly in order
to remove residue and remaining debris. Flush the
heat exchanger core with clean, fresh water until
the water that is exiting the core is clear and free of
debris.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
8. Dry the heat exchanger core with compressed air.
Direct the air in the reverse direction of the normal
flow.
Test the Heat Exchanger Core
SEBU9041 135
Maintenance Recommendations
Hoses and Clamps - Inspect/Replace

1. Inspect the heat exchanger core for trapped debris • Hoses which are cracked
and cleanliness. If necessary, remove the debris
and repeat the cleaning procedure. • Hoses which are soft

• Outer covering that is chafed or cut

2. Inspect the heat exchanger core for damage and
perform a pressure test in order to detect leaks. • Exposed wire that is used for reinforcement
Many shops that service radiators are equipped to
perform pressure tests. • Outer covering that is ballooning locally

3. Plug both ends of the heat exchanger core and
pressurize the core to 100 kPa (14.5 psi).
Submerge the core in water. Look for bubbles
which are being emitted from the core. The
bubbles are evidence of leaks.
4. If any leaks are found, do not attempt to repair the
core.
5. Install a core that is clean and that passes the
pressure test in step 3. Refer to the Disassembly
and Assembly Manual, “Heat Exchanger -
Assemble” for the procedure.
6. Install the heat exchanger onto the engine. Refer to
the Disassembly and Assembly Manual, “Heat
Exchanger - Install” for the procedure.
• 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.

For more information on cleaning the core, consult Each installation application can be different. The
your Cat dealer. differences depend on the following factors:

• Type of hose
i05373687
• Type of fitting material
Hoses and Clamps - Inspect/
• Anticipated expansion and contraction of the hose
Replace
SMCS Code: 7554-040; 7554-510 • Anticipated expansion and contraction of the
fittings
Hoses and clamps must be inspected periodically
and replaced at the recommended interval to ensure Due to extreme temperature changes, the hose will
safe and continuous operation of the engine. Failure heat set. Heat setting causes hose clamps to loosen
to replace a fuel hose at the recommended change which can result in leaks. A constant torque hose
interval may result in a hazardous situation. Take clamp will help to prevent loose hose clamps.
proper safety precautions before inspecting or
replacing hoses and clamps. Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses
Note: Always use a board or cardboard when the that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace hose
engine components are checked for leaks. Leaking
clamps which are loose.
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.
136
Maintenance Recommendations
Hoses and Clamps - Inspect/Replace
Replace the Hoses and the Clamps
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component 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
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
Personal injury can result from removing hoses
or fittings in a pressure system.
Failure to relieve pressure can cause personal
injury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
1. Stop the engine.
2. Allow the engine to cool.
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.
SEBU9041
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
Personal injury can result from removing hoses
or fittings in a pressure system.
Failure to relieve pressure can cause personal
injury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
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
recommended 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.
SEBU9041
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.
Lubrication System
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,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
137
Maintenance Recommendations
Maintenance Recommendations
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,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose 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.
i03658149
Maintenance
Recommendations
SMCS Code: 1000
Relationship of Fuel Consumption
to Service Hours
Experience has shown that maintenance intervals are
most accurately based on fuel consumption. Fuel
consumption corresponds more accurately to the
engine load. Table 26 lists average ranges of fuel
consumption and service hours for the C32 engine.
138 SEBU9041
Maintenance Recommendations
Maintenance Recommendations

Table 26
Maintenance Interval Schedule
Fuel Consumption for C32 ACERT Commercial Diesel Engines(1)

Rating
Interval
A B C D
25,000 L 33,000 L 40,000 L 50,000 L
250 Service Hours (6,600 US gal) (8,800 US gal) (10,500 US gal) (13,200 US gal)

50,000 L 66,000 L 80,000 L 100,000 L

500 Service Hours (13,200 US gal) (17,600 US gal) (21,000 US gal) (26,400 US gal)

100,000 L 132,000 L 160,000 L 200,000 L

1,000 Service Hours
(26,400 US gal) (35,200 US gal) (42,000 US gal) (52,800 US gal)

200,000 L 264,000 L 320,000 L 400,000 L

2,000 Service Hours
(52,800 US gal) (70,400 US gal) (84,000 US gal) (105,600 US gal)

300,000 L 396,000 L 480,000 L 600,000 L

3,000 Service Hours
(79,200 US gal) (105,600 US gal) (126,000 US gal) (158,400 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.

Maintenance intervals must be reduced for engines
that operate in a severe service application and for
engines that operate in a different engine rating
definition.
Severe Service Application
Severe service operation can accelerate component
wear. An engine which operates in a severe service
application may need more frequent maintenance
intervals for the following reasons:
• Maximum reliability
Refer to the standards for your engine or consult your
Caterpillar dealer in order to determine if your engine
is operating within the defined parameters.
Because of individual applications, it is not possible to
identify all of the factors which can contribute to
severe operation. Consult your Caterpillar dealer
about the maintenance that is needed for your
specific engine.
The following factors can contribute to severe
operation: environment, improper operating
procedures and improper maintenance practices.

• Retention of full service life Extreme Ambient Temperatures

A severe service application is an application which Extended operation in environments that are
exceeds the current published standards for that extremely cold or hot can damage components. Valve
engine. Caterpillar maintains standards for the components can be damaged by carbon buildup if the
following engine parameters: engine is frequently started and stopped in very cold
temperatures. Extremely hot inlet air reduces the
• Horsepower performance capabilities of the engine.
• Range of rpm Note: See this Operation and Maintenance Manual,
“Cold Weather Operation” topic (Operation Section),
• Fuel consumption or see Supplement, SEBU5898, “Cold Weather
Recommendations”.
• Fuel quality
• Altitude Cleanliness
• Maintenance intervals Unless the equipment is cleaned regularly, extended
operation in a dirty environment and in a dusty
• Selection of oil environment can damage components. Built up mud,
dirt, and dust can encase components. This can
• Selection of coolant make maintenance difficult. The buildup can contain
corrosive chemicals. Corrosive chemicals and salt
• Environmental qualities can damage some components.

• Installation
SEBU9041 139
Maintenance Recommendations
Maintenance Recommendations

Improper Operating Procedures • The total amount of fuel consumption

• Extended operation at low idle • The service hours of the engine

• Minimum cool down periods after high load factor • An increase of oil consumption
operation
• An increase of crankcase blowby
• Operating the engine beyond the guidelines for the
engine rating • The wear metal analysis of the lube oil

• Operating the engine at loads that are greater than • An increase in the levels of noise and vibration
the rated load An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
• Operating the engine at speeds that are greater need to be serviced. An increase in the levels of
than the rated speed noise and vibration indicates that rotating parts
require service.
• Use of the engine for an application that is not
approved Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
Improper Maintenance Practices liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
• Extension of maintenance intervals the wear metals.
Monitor the engine as the engine accumulates
• Not using recommended fuel, lubricants, and service hours. Consult your Caterpillar dealer about
coolant scheduling a major overhaul.
Overhaul Considerations Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
Some factors that are important for determining the
overhaul intervals include the following that is provided by the OEM of the driven equipment.
considerations:
Overhaul Intervals Which are Based on
• Performance of preventive maintenance
Fuel Consumption
• Use of recommended lubricants
Experience has shown that the interval for an
• Use of recommended coolants overhaul is most accurately based on fuel
consumption. Fuel consumption corresponds more
• Use of recommended fuels accurately to the engine load.

• Proper installation

• Operating conditions
• Operation within acceptable limits

• Engine load
• Engine speed
• Use of S·O·S Services Fluids Analyses
Generally, engines that are operated at a reduced
load and/or speed achieve more service life before an
overhaul. However, this is for engines that are
properly operated and maintained.
Other factors must also be considered for determining
a major overhaul:
Table 27
Overhaul Intervals
Top End Overhaul Fuel Consumption 1000000 L (264000 US gal)

Major Overhaul Fuel Consumption 2000000 L (528000 US gal)

140
Maintenance Recommendations
Maintenance Recommendations
Overhaul Intervals Which are Based on
Oil Consumption
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). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the 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:
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
standards for reusable parts.
• The engine 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.
After Failure Overhaul
If a major engine failure occurs and the engine must
be removed, many options are available. An overhaul
should be performed if the engine block or the
crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft
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:
SEBU9041
• Specially designed Caterpillar engine features
• Caterpillar dealer exchange components
• Caterpillar Inc. remanufactured exchange
components
Coolant Analysis
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine is
overhauled.
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 Inc. recommends an S·O·S Coolant
Analysis (Level 2).
S·O·S Coolant Analysis (Level 2)
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2)
provides the following information:
• Complete S·O·S Coolant Analysis (Level 2)
• 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 2) provides a report of
the results of both the analysis and the maintenance
recommendations.
For more information, refer to Special Publication,
SEBU6251, “Caterpillar Commercial Diesel Engine
Fluids Recommendations” or contact your Caterpillar
dealer.
Engine Components
Refer to this Operation and Maintenance Manual,
“Overhaul (Top End)” for a list of components which
are affected by a top end overhaul. Refer to this
Operation and Maintenance Manual, “Overhaul
(Major)” for a list of components which are affected by
a major overhaul.
SEBU9041
i03751386
Oil Cooler Core - Check/Clean/
Test
SMCS Code: 1378-070; 1378-081; 1378-535
This maintenance procedure shall be performed
when the top end overhaul is performed. Refer to this
Operation and Maintenance Manual, “Maintenance
Recommendations” article for information about the
maintenance interval for the top end overhaul.
Clean the Oil Cooler Core
Remove the core. Refer to the Disassembly and
Assembly Manual, “Oil Cooler - Remove” for the
procedure.
1. Turn the oil cooler core on one side in order to
remove debris. Remove the debris that is
accessible.
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 concen-
tration of cleaner.
2. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 28 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.
Table 28
Hydrosolv Liquid Cleaners(1)
Part Number Description Size
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 temper-
atures up to 93°C (200°F). Refer to Application Guide,
NEHS0526 or consult your Caterpillar dealer for more
information.
3. Steam clean the core in order to remove any
residue. Flush the fins of the oil cooler core.
Remove any other trapped debris from the inside
and from the outside of the core.
4. Wash the core with hot, soapy water.
5. Flush the core thoroughly in order to remove
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear and free of debris.
141
Maintenance Recommendations
Oil Cooler Core - Check/Clean/Test
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Test the Oil Cooler Core
1. Inspect the core for trapped debris and cleanliness.
If necessary, remove the debris and repeat the
cleaning procedure.
2. Inspect the core for damage and perform a
pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform
pressure tests.
3. Plug both ends of the oil cooler core and pressurize
the core to 205 kPa (30 psi). Submerge the core in
water. Look for bubbles which are being emitted
from the core. The bubbles are evidence of leaks.
4. If any leaks are found, do not attempt to repair the
core.
Install a core that is clean and a core that passes the
pressure test in step 3. Refer to the Disassembly and
Assembly Manual, “Oil Cooler - Install” for the
procedure.
For more information on cleaning the core, consult
your Caterpillar dealer.
i05239037
Overhaul (Major)
SMCS Code: 7595-020-MJ
Refer to this Operation and Maintenance Manual,
“Maintenance Recommendations” in order to
determine the maintenance interval for a major
overhaul.
The need for a major overhaul is determined by
several factors.
142
Maintenance Recommendations
Overhaul (Major)
• An increase of oil consumption
• An increase of crankcase blowby
• The total amount of fuel consumption
• The service hours of the engine
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
need service. An increase in the levels of noise and
vibration indicates that rotating parts require service.
Note: An oil analysis may indicate a decrease of
wear metals in the lube oil. The cylinder liners may be
worn so that polishing of the bore occurs. Also, the
increased use of lube oil will dilute the wear metals.
Monitor the engine as the engine accumulates
service hours. Consult your Cat dealer about
scheduling a major overhaul.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
A major overhaul includes all of the work that is done
for the top end overhaul. A major overhaul includes
additional parts and labor. Additional parts and labor
are required in order to completely rebuild the engine.
For the major overhaul, all of the bearings, seals,
gaskets, and components that wear are
disassembled. The parts are cleaned and inspected.
If necessary, the parts are replaced. The crankshaft is
measured for wear. The crankshaft may require
regrinding. Alternatively, the crankshaft may be
replaced with a Cat replacement part.
Your Cat dealer can provide these services and
components. Your Cat dealer can ensure that the
components are operating within the appropriate
specifications.
Replacement of Components
Replace the following components during the major
overhaul:
SEBU9041
• Camshaft bearings
• Connecting rod bearings
• Crankshaft seals
• Crankshaft thrust washers
• Electronic unit injectors
• Gear train bushings
• Gear train bearings
• Main bearings
• Mounting bolts for the secondary fuel filter base
• Piston rings
International Convention for Safety of Life
at Sea (SOLAS)
Caterpillar recommends replacing the following:
• All shields that have been installed to cover up fuel
and oil line connections per (SOLAS) regulations
• All marine certification society approved tapes are
installed in order to cover up fuel line connections
and oil line connections according to the SOLAS
regulations.
Inspection, Reconditioning, or
Exchanging of Components
Inspect the following components according to the
instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
Parts”.
Recondition the worn components or exchange the
components, if necessary. Your Cat dealer can
provide these services and components.
SEBU9041 143
Maintenance Recommendations
Overhaul (Major)

• Camshaft followers • Camshaft

• Camshaft thrust washers • Crankshaft

• Connecting rods • Driven equipment (alignment)

• Crankshaft vibration damper • Engine cylinder block

• Cylinder head assembly • Engine control module

• Cylinder liners • Flywheel

• Engine mounts • Front gear train (gears)

• Scavenge oil pump • Oil suction screen
• Engine wiring harness • Rear gear train

• Exhaust manifold seals Inspect the camshaft for damage to the journals and
the lobes.
• Exhaust manifold bellows
Inspect the crankshaft for any of the following
• Fuel pressure regulating valve conditions:

• Fuel priming pump • Deflection

• Fuel transfer pump • Damage to the journals

• Inlet manifold gaskets • Bearing material that has seized to the journals

• Inlet manifold seals Check the journal taper and the profile of the
crankshaft journals. Check these components by
• Oil cooler core interpreting the wear patterns on the following
components:
• Oil pump
• Rod bearing
• Pistons
• Main bearings
• Piston pins
Note: If the crankshaft or the camshaft are removed
• Prelube pump for any reason, use the magnetic particle inspection
process to check for cracks.
• Pushrods
Replace the crankshaft vibration damper if any of the
• Rocker arms following conditions occur:

• Spacer plate • Engine failure due to a broken crankshaft

• Software update • Excessive wear of the front bearing for the

crankshaft
• Turbocharger
• Excessive wear of the gear train that is not caused
Inspection of Components by a lack of lubrication

Inspect the following components according to the
instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
Parts”.
Inspect the gears of the gear train and inspect the
gear train bushings for the following conditions:
• Worn gear teeth
• Unusual fit

• Unusual wear
144
Maintenance Recommendations
Overhaul (Top End)
In addition to the inspection of components, inspect
the alignment of the driven equipment. See the
Application and Installation Guide for the engine or
see the literature that is provided by the OEM of the
driven equipment.
Cleaning of Components
Clean the oil suction screen. Also, remove side
covers in order to clean the oil sump. For instructions
on removal and installation of components, see the
Service Manual, “Disassembly and Assembly”
module.
Cleaning and Pressure Testing of
Components
Clean and pressure test the aftercooler core. Refer to
this Operation and Maintenance Manual, “Aftercooler
Core - Clean/Test” for the procedure.
Clean and pressure test the heat exchanger. Refer to
this Operation and Maintenance Manual, “Heat
Exchanger - Clean/Test” for the procedure.
Obtain a Coolant Analysis
For conventional heavy-duty coolant or antifreeze,
check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA
can be checked with an S·O·S coolant analysis
(Level I). A more detailed coolant analysis is
recommended periodically.
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 which 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 may be obtained
from the following sources:
• Cat dealer
• Local water utility company
• Agricultural agent
• Independent laboratory
Caterpillar recommends an S·O·S coolant analysis
(Level II) which is a comprehensive chemical
evaluation of the coolant. This analysis is also a
check of the overall condition of the inside of the
cooling system. The following services are provided:
SEBU9041
• Full Level I analysis
• Identification of the source of metal corrosion and
of contaminants
• Identification of buildup of the impurities that cause
corrosion
• Identification of buildup of the impurities that cause
scaling
• Determination of possible electrolysis within the
engine cooling system
A report of the results of the analysis is provided.
Maintenance recommendations are based on the
results.
For more information about S·O·S coolant analysis,
consult your Cat dealer.
i05195216
Overhaul (Top End)
SMCS Code: 7595-020-TE
Refer to this Operation and Maintenance Manual,
“Maintenance Recommendations” article for
information about the maintenance interval for the top
end overhaul.
A top end overhaul involves the removal, the
inspection, and the rework of the cylinder head
components. A few additional components are
replaced and serviced.
Your Cat dealer can provide these services and
components. Your Cat dealer can ensure that the
components are operating within the appropriate
specifications.
The following definitions explain the terminology for
the services that are performed during an overhaul:
Inspect – Inspect the components according to the
instructions that are in Cat reusability publications.
Refer to Guidelines for Reusable Parts and Salvage
Operations, SEBF8029, “Index of Publications on
Reusability or Salvage of Used Parts”. The guidelines
were developed in order to help Cat dealers and
customers to avoid unnecessary expenditures. New
parts are not required if the existing parts can still be
used, reconditioned, or repaired. If the components
are not in the reusability guidelines, refer to the
Service Manual, “Specifications” module.
Rebuild – The component is reconditioned in order to
comply with reusability guidelines.
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement part
may be a new part, a CAT remanufactured part, a
rebuilt part, or a used part. Some worn components
may be exchanged with your Cat dealer for a credit
SEBU9041 145
Maintenance Recommendations
Power Factor - Check

on replacement parts. Consult your Cat dealer about Testing a Three-Diode Rectifier
repair options for your engine.
Block
If you elect to perform an overhaul without the
services of a Cat dealer, be aware of the
recommendations in Table 29 .
Table 29
Recommendations for Top End Overhauls (1)

Service Top End Overhaul

Inspect Cylinder head assemblies

Rebuild
Replace Valves

Aftercooler core(2)
Inspect
Heat exchanger(3)

Inspect Rocker arms

Replace Valve bridges

Clean/Test Oil cooler core(4)

Cylinder head gaskets

Replace
Fuel Injectors

Illustration 86 g00610240
(1) For instructions on removal and installation of components, see
the Service Manual, “Disassembly and Assembly” module.
(2) Refer to this Operation and Maintenance Manual, “Aftercooler
Core - Inspect” for the procedure.
(3) Refer to this Operation and Maintenance Manual, “Heat Ex-
changer - Inspect” for the procedure.
(4) Refer to this Operation and Maintenance Manual, “Oil Cooler
Core - Check/Clean/Test” for the procedure.

i01216962

Power Factor - Check

SMCS Code: 4450-535-PWR
The power factor of a system can be determined by a
power factor meter or by calculations. The power
factor can be calculated by dividing kW by kVA.
Power factor is expressed as a decimal.

i05072489

Rotating Rectifier - Check

SMCS Code: 4465-535 Illustration 87 g00613971

Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
proceed to the “Testing a Three-Diode Rectifier
Block” section.
Three-Diode Rectifier Block (two pieces)
The following procedure tests all three diodes within a
block. Check the positive rectifier block and the
negative rectifier block. If any meter reading does not
fall within the given ranges, replace the rectifier block.

1. Set the digital multimeter on the diode range.

Remove all leads from the rectifier block.
2. To test the negative rectifier block, follow these
steps:
146
Maintenance Recommendations
Sea Water Strainer - Clean/Inspect
a. Place the red test lead on the negative “-”
terminal. Place the black test lead on the
following rectifier terminals: “AC1” (3), “AC2”
(4) and “AC3” (5). All readings on the meter
should be between 0.4 and 1.0.
b. Place the black test lead on the negative “-”
terminal. Place the red test lead on the
following rectifier terminals: “AC1” (3), “AC2”
(4) and “AC3” (5). 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. Place the black test lead on
the following rectifier terminals: “AC1” (3),
“AC2” (4) and “AC3” (5). In all cases, the
meter should read “OL” (overload).
b. Place the black test lead on the positive “+”
rectifier terminal. Place the red test lead on the
following rectifier terminals: “AC1” (3), “AC2”
(4) and “AC3” (5). All readings on the meter
should be between 0.4 and 1.0.
Note: A shorted diode can damage the exciter rotor. If
a diode is shorted, check the exciter rotor. Refer to
the Testing and Adjusting, “Winding - Test” and
Testing and Adjusting, “Insulation - Test”. Perform
these tests.
Note: This rectifier block also contains varistor “CR7”
. “CR7” can be checked by measuring the resistance
between the positive “+” rectifier terminal and the
negative “-” rectifier terminal. The resistance should
be a minimum of 15000 ohms.
i04277901
Sea Water Strainer - Clean/
Inspect
SMCS Code: 1371-040; 1371-070
The sea water strainer must be clean in order to allow
proper engine cooling and component life. The sea
water strainer is located before the sea water pump
impeller and filters out debris. Check the sea water
strainer for plugging. Inspect the sea water strainer
more frequently if the vessel is being operated in
water which is shallow or dirty. Refer to the OEM
recommendations for more information about
inspecting and cleaning the sea water strainer.
SEBU9041
i04524988
Standby Generator Set
Maintenance
Recommendations
SMCS Code: 4450-041
A standby generator set may be intermittently used.
However, the generator set is needed for operation in
an emergency situation. Maintenance of the standby
generator set is important for the following reasons:
• The generator set must always be in excellent
operating condition.
• The generator set must be ready to work under
load at any time.
Establishing a Preventive Maintenance Program will
provide these benefits:
• Maximum availability of the standby generator set
• Longer service life for the generator set
• Minimum of expensive repairs
Your Cat dealer can help you to establish an
effective Preventive Maintenance Program for your
generator set. Consult your Cat dealer for details.
Maintenance and Operation
Procedures
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the “ OFF”” po-
sition. Attach “ DO NOT OPERATE”” tags to all
starting controls. Disconnect the batteries or dis-
able the starting system. Lock out all switchgear
and automatic transfer switches that are associ-
ated with the generator.
The recommended maintenance for the generator set
is listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule (Standby Generator
Sets)” (Maintenance Section).
Maintenance and Repair
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the
subsequent maintenance intervals must be
performed by an authorized service technician or by
your Cat dealer.
SEBU9041
Unless other instructions are provided, perform
maintenance and repairs under the following
conditions:
• The engine is stopped.
• The starting system is disabled.
• The generator does not pose an electrical shock
hazard.
• The generator is disconnected from the load.
Operation
To ensure proper operation, the generator set must
be exercised regularly. For instructions on operating
the generator set, see the Operation and
Maintenance Manual for the generator set control
panel.
For these operation procedures, follow the
instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting
the engine, engine operation and stopping the
engine.
Record Keeping
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems and repairs.
Space Heaters
Moisture can damage generators and other electrical
equipment. Make every effort to keep the generator
set as dry as possible.
Generators can operate without problems in humid
environments. However, problems can occur when
the generator is inactive. Moisture can condense on
the windings. This condition can result in poor
performance. Also, damage to the windings can
occur.
Use space heaters in order to help keep the windings
dry. When the generator is not active, ensure that the
space heaters are operating. When the generator is
operating, turn OFF the space heaters.
i05264216
Starting Motor - Inspect
(If equipped)
SMCS Code: 1451-040; 1453-040
Air Starting Motor
If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
the starting motor is recommended.
147
Maintenance Recommendations
Starting Motor - Inspect
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine to
start properly. The engine will not start if the starting
motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the flywheel
ring gear can be damaged because of irregular
engagement.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel ring
gear. Look for patterns of wear on the teeth. Look for
teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
ring gear must be replaced.
Personal injury or death can result from improp-
erly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Inspect all of the components in the air circuit for the
starting motor. Inspect all of the air lines and
connections for leaks.
If damaged teeth are found, the air circuit for the
starting motor must be examined in order to
determine the cause of the problem.
Electric Starting Motor
If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
the starting motor is recommended.
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine to
start properly. The engine will not start if the starting
motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the flywheel
ring gear can be damaged because of irregular
engagement.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel ring
gear. Look for patterns of wear on the teeth. Look for
teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
ring gear must be replaced.
Problems with the electric starting motor can be
caused by the following conditions: malfunction of the
solenoid and malfunction of the electric starting
system.
148
Maintenance Recommendations
Stator Lead - Check
Inspect the electrical system for the following
conditions:
• Loose connections
• Corrosion
• Wires that are worn or frayed
• Cleanliness
Removal and Installation of the
Starting Motor
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the
starting motor and installing the starting motor.
Consult your Cat dealer for assistance and/or for
options on replacement of the starting motor.
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
i03725200
Stator Winding Temperature -
Test
SMCS Code: 4453-081-TA
Some generators are provided with optional 100 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.
SEBU9041
i05264219
Turbocharger - Inspect
SMCS Code: 1052-040
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.
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.
NOTICE
Turbocharger bearing failures can cause large quanti-
ties 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
occurred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. 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.
Removal and Installation
For options regarding the removal, installation, repair
and replacement, consult your Cat dealer. Refer to
the Service Manual for this engine for the procedure
and specifications.
Cleaning and Inspecting
SEBU9041 149
Maintenance Recommendations
Varistor - Check

1. Remove the exhaust outlet piping and remove the i04140312

air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean the Varistor - Inspect
interior of the pipes in order to prevent dirt from SMCS Code: 4466-040
entering during reassembly.

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 result 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
Illustration 88 g00677004
turbocharger should be repaired or replaced. An
end play measurement that is less than the PMPE Generator Wiring Diagram
minimum Service Manual specifications could (CR1-CR6) Diodes
(CR7) Varistor
indicate carbon buildup on the turbine wheel. The (L1) Exciter field (stator)
turbocharger should be disassembled for cleaning (L2) Exciter armature (rotor)
and for inspection if the measured end play is less (L3) Main field (rotor)
(L4) Main armature (stator)
than the minimum Service Manual specifications. (L5) Pilot exciter armature
(PM) Permanent magnet
5. Inspect the bore of the turbine housing for (RFA) Rotating field assembly
corrosion. (CST) Customer supplied transformer

6. Clean the turbocharger housing with standard shop

solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i03291822
Ohmmeter
An ohmmeter can be used to check a varistor (CR7).
Place an ohmmeter across the varistor. The
resistance should be a minimum of 15000 ohms. If
the resistance is less than 15000 ohms, the varistor is
faulty.

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.
150
Maintenance Recommendations
Voltage and Frequency - Check
Test Light
Illustration 89 g00555113
Test Light
Refer to the test light that is shown in Illustration 89 .
Follow these steps in order to test the varistor:
1. Disconnect either lead of the varistor (CR7).
2. Place the test light across the varistor.
3. Observe the results. The lamp should not light.
4. Reverse the test light.
5. Observe the results. The lamp should not light.
If the test light illuminates in either direction, there is a
short in the varistor. Replace any faulty varistors with
varistors that have comparable operating
characteristics. Include the following information
when a varistor is being ordered for replacement:
• Part number of the varistor
• Serial number of the generator
After the varistor has been replaced, verify that the
strapping of the field winding lead is securely wound
on the shaft. Also, verify that the strapping of the field
winding lead is securely tied.
i01189996
Voltage and Frequency - Check
SMCS Code: 4450-535-EL
Check for proper voltage and frequency setting.
Check for stability.
Refer to the generator set Serial Plate for correct
voltage and frequency.
SEBU9041
i05193156
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only require a few
minutes. When the time is used 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 you
start the engine. Look for items such as: oil leaks,
coolant leaks, loose bolts, worn belts and loose
connections. 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 flu-
id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
• Ensure that the cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
• Check the marine transmission oil level. Refer to
the OEM specification for the marine transmission
or refer to the OEM specification for the vessel.
• Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant in
the cooling system. A small amount of leakage to
occur as the engine cools down is normal.
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 Cat dealer.
SEBU9041 151
Maintenance Recommendations
Water Pump - Inspect

• Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. If leaking of
crankshaft seal, the rear crankshaft seal, the oil the water pump seals is observed, replace all of the
pan, the oil filters, and the valve cover. water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
• Inspect the fuel system for leaks. Disassemble and Water Pump - Assemble” for the
disassembly and assembly procedure. If necessary
• Inspect the piping for the air inlet system and the to remove the water pump, refer to two articles in the
elbows for cracks and for loose clamps. Disassembly and Assembly Manual, “Water Pump -
Remove and Water Pump - Install”.
• Inspect the alternator belt and the accessory drive
belts for cracks, breaks, or other damage. Inspect the water pump for wear, cracks, pin holes,
and proper operation. Refer to the Parts Manual for
Belts for multiple groove pulleys must be replaced as the correct part numbers for your engine or consult
matched sets. If only one belt is replaced, the belt will your Cat dealer if repair is needed or replacement is
carry more load than the belts that are not replaced. needed.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection
and for good condition.
• Inspect the ECM ground strap for a good
connection and for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.

• Check the condition of the gauges. Replace any

gauges which are cracked. Replace any gauges
that cannot be calibrated.

i05264233

Water Pump - Inspect

SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in the following
conditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

A failed water pump might cause severe engine
overheating problems. Overheating could result in
cracks in the cylinder head, a piston seizure, or other
potential damage to the engine.
152 SEBU9041
Warranty Section
Emissions Warranty Information

Warranty Section

Warranty Information
i04769870

Emissions Warranty
Information
SMCS Code: 1000
Caterpillar warrants to the ultimate purchaser and
each subsequent purchaser that new Marine Diesel
Engines up to 18.5 liters per cylinder (excluding Tier 1
and Tier 2 Marine Engines less than 50 kW) operated
and serviced in the United States, including all parts
of their emission control systems (emission-related
components), are:

• Designed, built, and equipped so as to conform, at

the time of sale, with applicable emission
standards prescribed by the United States
Enviromental Protection Agency (EPA) by way of
regulation.
• Free from defects in materials and workmanship in
emission-related components that can cause the
engine to fail to conform to applicable emission
standards for the warranty period.
A detailed explanation of the Emission Control
Warranty that is applicable to new nonroad and
stationary diesel engines, including the components
covered and the warranty period, is found in
Supplement, SELF9002, “Federal Emissions Control
Warranty”. Consult your Cat dealer to determine if
your engine is subject to an Emission Control
Warranty.
SEBU9041
Reference Information
Section
Engine Ratings
i05037610
Engine Rating Conditions
SMCS Code: 1000
Ratings are based on SAE J1128/ISO 8665 standard
ambient conditions of 100 kPa (29.5 inch mercury)
and 25° C (77° F). Ratings also apply at AS1501,
BS5514, DIN 6271 and ISO 3046/1 standard
conditions of 100 kPa (29.5 inch mercury), 27° C
(81° F), and 60% relative humidity.
Power is based on a 35° (16° C (61° F) fuel which
has Low heat value (LHV) of 42780 kJ/kg
(18390 B/lb) used at 29° C (84° F) with a density of
838.9 g/L (7.001 lb/US gal).
Engine ratings may be defined as gross output
ratings or as the total output capability of the engine
when equipped with lubrication oil, fuel, and jacket
water pumps. The power to drive auxiliary
applications must be deducted from the gross output
to arrive at the net power available for the external
(flywheel) load. Typical auxiliary applications include
cooling fans, air compressors, charging alternators,
marine gears, and seawater pumps.
i03570771
Engine Rating Definitions
SMCS Code: 1000
Power rating definitions are in accordance with
ISO8528.
Prime Power
Output is available with varying load for an unlimited
time. The average power output is 70% of the prime
power rating. Typical peak demand of 100% of prime
rated ekW with 10% of overload capability is for
emergency use for a maximum of one hour in 12. The
engine cannot be operated at overload for more than
25 hours per year.
Continuous Power
Output is available with varying load for an unlimited
time. The average power output is between 70% and
100% of the continuous power rating. Typical peak
demand is 100% of continuous rated ekW for 100%
of operating hours.
153
Reference Information Section
Engine Rating Conditions
Standby Power
Output is available with varying load for the duration
of the interruption of the normal power source. The
average power output is 70% of the standby power
rating. The typical operation is 200 hours per year.
The maximum expected usage is 500 hours per year.
Emergency Standby Power
Output is available with varying load for the duration
of an emergency outage. The average power output
is 70% of the standby power rating. The typical
operation is 50 hours per year. The maximum
expected usage is 200 hours per year.
i00899220
Marine Classification Society
Certification Requirements
SMCS Code: 1000
The major seafaring nations have established
technical groups called marine classification
societies. Caterpillar Inc. has maintained standards
and quality under the guidelines that are set forth by
the 14 major marine classification societies that are
listed. For more information, refer to Engine Data
Sheet, 103.1 and Engine Data Sheet, 103.1.1 in the
Caterpillar Technical Manual.
ABS – American Bureau of Shipping (USA)
BV – Bureau Veritas (France)
CCG – Canadian Coast Guard (Canada)
CCRS – China Corporation Register of Shipping
(Taiwan)
CCS – China Classification Society (China)
CR – Croatian Register of Shipping (Croatia)
DnV – Det norske Veritas (Norway)
GL – Germanischer Lloyd (Germany)
KR – Korean Register of Shipping (Korea)
LR – Lloyd's Register of Shipping (Great Britain)
NK – Nippon Kaiji Kyokai (Japan)
PR – Polish Register (Poland)
RINa – Registro Italiano Navale (Italy)
RS – Maritime Register of Shipping (Russia)
154
Engine Performance and Performance Analysis Report (PAR)
Engine Performance
Engine Performance and
Performance Analysis
Report (PAR)
i04537530
Engine Performance
SMCS Code: 1000
Today's marine operator is concerned with
performance, cost of operation and satisfactory
engine life. Traditionally, poor performance of the
vessel is believed to result from a lack of engine
performance or from a loss of engine performance. In
fact, the engine is only one of numerous factors that
influence the overall performance of a vessel.
Several factors determine the power demand on an
engine. The engine does not have control over the
demand that is caused by the vessel design. The
vessel design includes the following features:
• Hull
• Propeller
• Drive train
Those features also affect the amount of power that is
available to perform additional work. For example,
those features affect the power that is used to drive
an auxiliary pump.
If a problem with the performance of the vessel
occurs, consider the following effects on power
demand:
• Loads
• Condition of the vessel
• Vessel design
• Condition of the drive train
• Condition of the propeller
Deterioration of the engine systems decreases the
ability of the engine to produce power and vessel
speed. Engine systems include the cooling system,
the lubrication system, the fuel system, etc. The
engine is not likely to be the cause of poor fuel
economy without excessive exhaust smoke and/or
the loss of power.
If you have a valid problem with the engine's
performance, consult an authorized Cat dealer for
assistance.
SEBU9041
If the engine is covered by a warranty, the Cat
warranty will cover the cost in order to solve a valid
deficiency of the engine's performance. However, if
the engine is not at fault, all costs that are incurred
will be the responsibility of the owner.
Note: Adjustment of the fuel system outside
Caterpillar specified limits will not improve fuel
efficiency. Adjustment of the fuel system outside
Caterpillar specified limits could also result in
damage to the engine.
Cat engines are manufactured with state-of-the-art
technology. Cat engines are designed to help
provide two characteristics in all applications:
• Maximum performance
• Fuel efficiency
To ensure optimum performance for the service life of
the engine, follow the recommended operation
procedures that are described in this manual. Also,
follow the preventive maintenance procedures that
are described in this manual.
Performance Analysis Report (PAR)
To verify the condition of the propulsion system,
Caterpillar has developed the Performance Analysis
Report (PAR) for marine engines.
A PAR is an in-vessel test procedure that is
performed by a Caterpillar analyst under operating
conditions. The test compares the performance of all
marine engine systems to the original testing
specifications.
When a PAR is conducted at Sea Trial, an installation
of high quality can be ensured. The PAR will confirm
the matching of the following components for
optimum performance and for fuel efficiency: hull,
rudders, propeller, marine transmission, ventilation
and cooling systems.
Caterpillar recommends scheduling a PAR in order to
maintain optimum performance.
A periodic PAR can define deterioration of the
propulsion system. A PAR can assist in repairs, in
overhauls, and in maintenance schedules. This will
help to provide the most economical, efficient cost of
operation.
SEBU9041 155
Customer Service
Customer Assistance

Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i03910803
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000; 4450 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
When a problem arises concerning the operation or Caterpillar Asia Pte. Ltd.
the service of an engine, the problem will normally be 7 Tractor Road
managed by the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level, use the phone number that is listed below to Hong Kong
talk with a Field Service Coordinator: Phone: 852-2848-0333
Fax: 852-2848-0440
1-800-447-4986
Japan
The normal hours are from 8:00 to 4:30 Monday Shin Caterpillar Mitsubishi Ltd.
through Friday Central Standard Time. SBS Tower
10-1, Yoga 4-Chome
3. If your needs have not been met still, submit the
Setagaya-Ku, Tokyo 158-8530
matter in writing to the following address: Japan
Caterpillar Inc. Phone: 81-3-5717-1150
Marine Center of Excellence Fax: 81-3-5717-1177
Manager, Customer Service Japan
111 Southchase Blvd Caterpillar Power Systems, Inc.
Fountain Inn, SC 29644 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 Australia
office.
Phone: 03-9953-9333
Latin America, Mexico, Carribean Fax: 03-9335-3366
Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
156
Customer Service
Ordering Replacement Parts
i01028392
Ordering Replacement Parts
SMCS Code: 4450; 7567
When replacement parts are required for this
product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent specifi-
cations including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to premature
failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU9041
i04760831
On-Board Replacement Parts
SMCS Code: 7567
The various Marine Classification Societies require a
supply of replacement parts on vessels that are
primarily powered by diesel engines. The
replacement parts may be needed for making repairs
offshore or at remote ports. The types of replacement
parts and the numbers of parts depends on the range
of the vessel. The following two categories of vessels
are considered:
Category 1 – This category includes vessels that
make short trips between ports.
Category 2 – This category includes vessels in
ocean service that is unrestricted. The vessels may
travel far from ports that provide service. The list of
replacement parts for this category is more extensive.
Table 30 lists the parts that are recommended by
Caterpillar for vessels in both categories.
The requirements of individual Marine Classification
Societies may differ. Table 31 lists the requirements
of all the Marine Classification Societies. Additionally,
some items that are recommended by Caterpillar are
listed. All of the parts that are listed in Table 30 and
31 are recommended for vessels in Category 2. To
customize this list for your specific engine application,
consult your Cat dealer.
Table 30
Replacement Parts for Vessels in Category 1 and Cate-
gory 2
Quantity Item
4 Air cleaner element
1 Alternator belt
1 Electronic control module (ECM)
1 Electronic unit injector
- Engine oil
- Extended Life Coolant (ELC) and Extender
or
Diesel Engine Antifreeze/Coolant (DEAC) and Sup-
plemental Coolant Additive (SCA)
4 Fuel filter elements
1 Fluid sampling bottles
- Liquid gasket material
4 Engine oil filters
1 Service kit (electronic connector)
4 Water temperature regulator
4 Zinc rods
SEBU9041 157
Customer Service
On-Board Replacement Parts

Table 31 (Table 31, contd)

Replacement Parts for Vessels in Category 2 Replacement Parts for Vessels in Category 2

System Quantity Item System Quantity Item

Camshaft and 1 Bolt (crankshaft to flywheel) 2 Piston pin retainer
crankshaft
1 Camshaft gear 1 Piston rings (complete set)

1 Crankshaft gear 3 Seals (cylinder liner)

1 Idler gear and balance weight Starting 1 Starting motor

gear assembly (water pump)
Turbocharger 1 Complete turbocharger
1 Shaft and thrust washer (idler
gear and balance weight gear - Gasket
assembly) 4 Locknut
Cooling 1 Aftercooler core and gasket 4 Stud (mounting)

1 Auxiliary water pump Valves 6 Exhaust valves

1 Jacket water pump 4 Inlet valves

4 Water temperature regulator 10 Valve guides

Cylinder head 6 Bolt and washer 24 Valve locks

1 Bolt and nut (exhaust manifold) 10 Valve rotators

1 Cylinder head assembly 10 Valve springs

4 Gasket (cylinder)

- Water seals for one cylinder

Fuel 3 Electronic unit injector

1 Fuel transfer pump

3 Seal (electronic unit injector)

Inlet air 2 Air cleaner element

Lubrication 1 Bypass valve (oil cooler)

1 Bypass valve (oil filter)

1 Gasket (oil pan)

1 Oil cooler core (engine)

1 Oil cooler core (marine gear)

Miscellaneous 1 Gasket kit (engine)

Piston 1 Connecting rod assembly

1 Connecting rod bearing

1 Cylinder liner

1 Filler band (cylinder liner)

1 Main bearing

2 Cap bolt and washer (main

bearing)

1 Piston assembly

1 Piston pin

(continued)
158 SEBU9041
Reference Materials
Maintenance Records

Reference Materials
i05264255

Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other
engines that are operated in the same
environment.
• Show compliance with the required maintenance
practices and maintenance intervals.
Maintenance records can be used for various other
business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is managed. Accurate
maintenance records can help your Cat 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 repair costs
• Owner receipts

• Maintenance log
SEBU9041 159
Reference Materials
Maintenance Log

i01176304

Maintenance Log
SMCS Code: 1000; 4450

Table 32
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel
160
Reference Materials
Reference Material
i05045310
Reference Material
SMCS Code: 1000; 4450
The following literature can be obtained through any
Cat dealer.
Engine Oil
• Datasheet, PEHJ0159, “Cat DEO-ULS (SAE 15W-
40)” (North America - Canada, Mexico, and United
States)
• Datasheet, PEHJ0059, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (North America - Canada,
Mexico, and United States)
• Datasheet, PEHJ0021, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Worldwide - except North
America, Egypt, Saudi Arabia, and Brazil)
• Datasheet, PEHJ0072, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Brazil)
• Datasheet, PEHJ0091, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Egypt and Saudi Arabia)
• Datasheet, PEHJ0008, “Cat Arctic DEO (SAE 0W-
30)” (Canada and United States)
Coolants
• Special Publication, PMEP5027, “Label - Cat
ELC Radiator Label”
• Datasheet, PEHJ0067, “Cat ELC (Extended Life
Coolant)” (Worldwide)
• Datasheet, PEHP9554, “Cat DEAC (Diesel Engine
Antifreeze/Coolant) (Concentrate)”
Fuels
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine”
S·O·S Services
• Procedure for Cat Products”
SEBU9041
• Special Publication, PEHJ0191, “S·O·S Coolant
Analysis”
• Special Publication, PEGJ0047, “How To Take A
Good Oil Sample”
• Special Publications, PEDP7036, “S·O·S Fluids
Analysis Cornerstone”
• Special Publications, PEHP7076, “Understanding
S·O·S Services Tests”
• Special Publication, PEHP7052, “Making the Most
of S·O·S Services”
• Special Publication, PEGJ0045, “Reporting
Particle Count by ISO Code”
• Special Publication, PEGJ0046, “Understanding
Your S·O·S Services Results”
Miscellaneous
• Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations”
• Special Publication, PECP9067, “One Safe
Source”
• Special Instruction, REHS0354, “Charging System
Troubleshooting”
• Installation Guide, REHS1187, “Marine Engine
Electronic Installation Guide”
• Specifications, SENR3130, “Torque
Specifications”
• Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
Operations”
• Special Publication, SEBF8062, “Guideline for
Reusable Parts - Cleaning and Inspection of Air
Filters”
• Special Publication, SEBU5898, “Cold Weather
Recommendations for all Cat Machines”
• Special Instruction, SEHS9031, “Storage
• Special Instruction, SEHS8622, “Using the FT-
1984 Air-To-Air Aftercooler Leak Test Group”
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Special Instruction, SEHS7332, “Do Not Operate
Tag”
SEBU9041 161
Reference Materials
Decommissioning and Disposal

i04323034

Decommissioning and
Disposal
SMCS Code: 1000
When the generator set is removed from service,
local regulations for the generator set
decommissioning will vary. Disposal of the generator
set will vary with local regulations. Consult the
nearest Cat dealer for additional information.
162 SEBU9041
Index Section

Index
A Controlling the Generator Set Using the DCU
(1)............................................................... 33
After Starting Engine........................................ 55
Help.............................................................. 47
After Stopping Engine...................................... 70
List of Alarms ............................................... 38
Aftercooler Condensate Drain Valve -
Menu ............................................................ 40
Inspect/Clean................................................. 88
Operating the Generator Set Using the Control
Aftercooler Core - Clean/Test .......................... 88
Panel .......................................................... 50
Clean the Aftercooler Core .......................... 88
Start Engine and Stop Engine...................... 35
Test the Aftercooler Core ............................. 89
Coolant - Change............................................. 93
Aftercooler Core - Inspect................................ 89
Drain the Cooling System ............................ 93
Alarms and Shutoffs ........................................ 31
Fill the Cooling System ................................ 95
Alarms.......................................................... 31
Flush ............................................................ 94
Shutoffs........................................................ 31
Coolant Extender (ELC) - Add ......................... 95
Testing the Alarm System and the Shutoff
Coolant Level - Check ..................................... 96
System ....................................................... 31
Engines That Are Equipped with a Coolant
Auxiliary Water Pump (Bronze Impeller) -
Recovery Tank ........................................... 96
Inspect/Replace............................................. 89
Engines That Are Not Equipped with a Coolant
Recovery Tank ........................................... 96
B Coolant Sample (Level 1) - Obtain .................. 97
Sampling Conditions.................................... 97
Battery - Recycle ............................................. 90
Timing of the Sampling ................................ 97
Battery - Replace............................................. 90
Coolant Sample (Level 2) - Obtain .................. 98
Battery Charger - Check .................................. 90
Obtaining the Sample .................................. 98
Battery Disconnect Switch (If Equipped) ......... 31
Coolant Temperature Regulator - Replace ...... 98
Battery Electrolyte Level - Check .................... 91
Cooling System Supplemental Coolant
Battery or Battery Cable - Disconnect ............. 91
Additive (SCA) - Test/Add .............................. 99
Before Starting Engine ...............................15, 54
Cooling Systems that Use Conventional
Belts - Inspect/Adjust/Replace......................... 92
Coolant....................................................... 99
Adjust ........................................................... 92
Crankshaft Vibration Damper - Inspect.......... 100
Inspect ......................................................... 92
Inspection................................................... 100
Replace........................................................ 92
Removal and Installation............................ 100
Bolts (Fuel Filter Base) - Inspect/Replace ....... 93
Crushing Prevention and Cutting Prevention .. 15
Burn Prevention............................................... 12
Customer Assistance..................................... 155
Batteries....................................................... 13
Outside of the USA and of Canada............ 155
Coolant......................................................... 12
USA and Canada ....................................... 155
Oils............................................................... 12
Customer Service .......................................... 155

C D
Cold Weather Operation.................................. 66
Decommissioning and Disposal .................... 161
Hints for Cold Weather Operation................ 66
Idling the Engine .......................................... 67
Recommendations for Coolant Warm Up .... 67 E
Recommendations for the Coolant .............. 67
Electrical Connections - Check...................... 101
Viscosity of the Engine Lubrication Oil......... 67
Electrical System ............................................. 16
Cold Weather Starting ..................................... 54
Grounding Practices .................................... 16
Control Panel (Marine Generator Set
Negative Battery Connection for Multiple
Engine Control Panel 3 (MGECP 3)) ............. 32
Engines ...................................................... 18
SEBU9041 163
Index Section

Emergency Stopping ....................................... 70 F

Emissions Certification Film ............................ 26
Features and Controls ..................................... 31
Emissions Warranty Information.................... 152
Fire Prevention and Explosion Prevention ...... 13
Engine - Clean ............................................... 101
Ether ............................................................ 14
Engine Air Cleaner Element (Single
Fire Extinguisher.......................................... 14
Element) - Inspect/Replace ......................... 101
Lines, Tubes, and Hoses ............................. 14
Replacing the Air Cleaner Element............ 101
Fluid Recommendations.................................. 72
Engine Air Cleaner Service Indicator -
Cooling System............................................ 77
Inspect (If Equipped).................................... 102
Diesel Engine Oil ......................................... 72
Test the Service Indicator........................... 102
Fuel .............................................................. 75
Engine Cooling System Corrosion
Greases ....................................................... 79
Protection System - Inspect......................... 102
Foreword............................................................ 4
Location of the Corrosion Protection Post . 103
California Proposition 65 Warning ................. 4
Results of the Test...................................... 103
Literature Information..................................... 4
Testing the Voltage Potential...................... 103
Maintenance .................................................. 4
Engine Crankcase Breather - Clean.............. 103
Maintenance Intervals.................................... 4
Engine Electronics........................................... 18
Operation ....................................................... 4
Engine Mounts - Inspect................................ 104
Overhaul ........................................................ 4
Engine Oil and Filter - Change ...................... 106
Safety............................................................. 4
Drain the Engine Oil ................................... 106
Fuel and the Effect from Cold Weather............ 68
Fill the Engine Crankcase .......................... 108
Fuel Conservation Practices............................ 57
Inspect the Used Oil Filter Elements.......... 109
Fuel Injector - Check....................................... 111
Replace the Oil Filter With the Engine Stopped
Fuel Related Components in Cold Weather .... 69
(Standard Oil Filters) ................................ 107
Fuel Filters ................................................... 69
Replacing the Engine Oil Filters During Engine
Fuel Heaters ................................................ 69
Operation (Duplex Oil Filters)................... 107
Fuel Tanks.................................................... 69
Engine Oil Level - Check ............................... 104
Fuel System - Prime ....................................... 111
Engine Oil Level Gauge - Calibrate ............... 105
Fuel System Primary Filter (Water
Engine Oil Sample - Obtain ........................... 105
Separator) Element - Replace ......................112
Obtain the Sample and the Analysis.......... 106
Replace the Element...................................112
Engine Operation............................................. 57
Fuel System Primary Filter/Water Separator
Engine Performance...................................... 154
- Drain ...........................................................114
Performance Analysis Report (PAR).......... 154
Fuel System Secondary Filter - Replace ........114
Engine Performance and Performance
Replacing the Fuel Filter Elements During
Analysis Report (PAR) ................................. 154
Engine Operation For Engines That Are
Engine Rating Conditions.............................. 153
Equipped With Duplex Fuel Filters............116
Engine Rating Definitions .............................. 153
Replacing the Fuel Filter Elements with the
Continuous Power...................................... 153
Engine Stopped.........................................115
Emergency Standby Power ....................... 153
Fuel Tank Water and Sediment - Drain...........118
Prime Power .............................................. 153
Drain the Water and the Sediment..............118
Standby Power........................................... 153
Fuel Storage Tanks .....................................118
Engine Ratings .............................................. 153
Fuel Tank ....................................................118
Engine Speed/Timing Sensor - Clean/
Fumes Disposal Filter Element - Replace ......118
Inspect ......................................................... 109
Replacing the Fumes Disposal Filter ..........118
Engine Starting ...........................................16, 54
Resetting the Service Indicator (If Equipped)
Engine Stopping .........................................16, 70
..................................................................119
Engine Storage Procedure - Check................110
Engine Valve Lash - Check.............................110
Engine Valve Rotators - Inspect .....................110 G
Gauges and Indicators .................................... 51
164
Index Section
General Hazard Information .............................. 9
Containing Fluid Spillage ............................. 10
Dispose of Waste Properly........................... 12
Fluid Penetration.......................................... 10
Inhalation ......................................................11
Lines, Tubes, and Hoses ..............................11
Pressurized Air and Water ........................... 10
Softwrap....................................................... 12
Static Electricity Hazard when Fueling with
Ultra-low Sulfur Diesel Fuel.........................11
General Information......................................... 20
General Maintenance Information ................... 80
Generator - Dry...............................................119
Drying Methods...........................................119
Generator - Inspect........................................ 120
Cleaning (Assembled Generators) ............ 120
Cleaning (Disassembled Generators)........ 121
Generator Bearing - Inspect/Replace (SR4
Generator) ................................................... 121
Inspect ....................................................... 121
Replace...................................................... 121
Generator Bearing - Lubricate ....................... 122
Additional Information ................................ 126
Procedure for Bearing Service................... 122
Generator Bearing Temperature - Test/
Record ......................................................... 126
Infrared Thermometers .............................. 126
Resistive Temperature Detectors (RTDs) .. 126
Generator Isolating for Maintenance ............... 19
Generator Lead Connections .......................... 64
Grounding the Frame................................... 65
Lead Numbering .......................................... 64
Multiple Units ............................................... 65
Neutral Connections .................................... 65
Parallel to a Utility ........................................ 65
Single Units.................................................. 65
Generator Load - Check ................................ 126
Generator Operation........................................ 58
Block Loading .............................................. 58
Excitation System ........................................ 59
Generator Options ....................................... 59
Loading of the Generator ............................. 58
Low Idle Adjustment..................................... 59
Power Factor................................................ 58
Standby Generator Sets .............................. 59
Generator Set - Test ...................................... 127
Generator Set Alignment - Check
(Generator Sets) .......................................... 128
Generator Set Vibration - Inspect .................. 128
Generator Start-up Checklist ........................... 83
Generator Winding - Test............................... 129
SEBU9041
Generator Winding Insulation - Test .............. 130
Recommended Periodic Insulation Tests... 130
Recommended Procedure for the Insulation
Test........................................................... 130
H
Heat Exchanger - Clean/Test......................... 134
Clean the Heat Exchanger......................... 134
Test the Heat Exchanger Core................... 134
Heat Exchanger - Inspect .............................. 134
Hoses and Clamps - Inspect/Replace ........... 135
Inspect the Hoses and the Clamps ............ 135
Replace the Hoses and the Clamps .......... 136
I
Important Safety Information ............................. 2
L
Lifting and Storage........................................... 27
M
Maintenance Interval Schedule ....................... 86
Daily ............................................................. 86
Every 1000 Service Hours ........................... 87
Every 2000 Service Hours ........................... 87
Every 250 Service Hours ............................. 87
Every 3000 Service Hours ........................... 87
Every 50 Service Hours or Weekly .............. 86
Every 500 Service Hours ............................. 87
Every 5000 Service Hours ........................... 87
Every 750 Service Hours ............................. 87
Every 8000 Service Hours ........................... 87
Every Week.................................................. 86
Every Year.................................................... 87
Initial 1000 Service Hours ............................ 87
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)............ 87
Overhaul ...................................................... 87
Overhaul (Top End)...................................... 87
When Required............................................ 86
Maintenance Log ........................................... 159
Maintenance Recommendations............. 80, 137
Overhaul Considerations ........................... 139
Relationship of Fuel Consumption to Service
Hours........................................................ 137
Maintenance Records.................................... 158
SEBU9041
Maintenance Section....................................... 72
Manual Stop Procedure................................... 70
Marine Classification Society Certification
Requirements .............................................. 153
Model View Illustrations................................... 20
Mounting and Dismounting.............................. 15
O R
Oil Cooler Core - Check/Clean/Test .............. 141
Clean the Oil Cooler Core .......................... 141
Test the Oil Cooler Core............................. 141
On-Board Replacement Parts ....................... 156
Operation Section............................................ 27
Ordering Replacement Parts ......................... 156
Overhaul (Major)............................................ 141
Cleaning and Pressure Testing of
Components............................................. 144
Cleaning of Components ........................... 144
Inspection of Components ......................... 143
Inspection, Reconditioning, or Exchanging of
Components............................................. 142
Obtain a Coolant Analysis.......................... 144
Replacement of Components .................... 142
Overhaul (Top End)........................................ 144
P Safety Messages ............................................... 5
Parallel Operation............................................ 60
Circulating Currents ..................................... 62
Initial Start-Up .............................................. 60
Load Division and Speed Droop (If Equipped)
................................................................... 61
Parallel Operation Of Governors.................. 61
Paralleling Multiple Units.............................. 61
Starting Multiple Units .................................. 61
Stopping....................................................... 62
Plate Locations and Film Locations................. 25
Engine Identification Plate (2) ...................... 25
Engine Serial Number (1)............................. 25
Power Factor - Check .................................... 145
Product Description ......................................... 23
Description of the Generator........................ 24
Electronic Engine Features.......................... 23
Engine Cooling and Lubrication................... 24
Engine Service Life ...................................... 24
Engine Specifications .................................. 23
Product Identification Information.................... 25
Product Information Section ............................ 20
Product Lifting.................................................. 27
165
Index Section
Lifting the Engine or Lifting the Generator ... 28
Lifting the Entire Package ............................ 27
Product Storage............................................... 28
Additional Information .................................. 30
Engine.......................................................... 28
Generator..................................................... 30
Reference Information..................................... 26
Record for Reference................................... 26
Reference Information Section ...................... 153
Reference Material ........................................ 160
Coolants..................................................... 160
Engine Oil .................................................. 160
Fuels .......................................................... 160
Miscellaneous ............................................ 160
S·O·S Services .......................................... 160
Reference Materials ...................................... 158
Refill Capacities............................................... 72
Cooling System Capacity............................. 72
Lubrication System ...................................... 72
Rotating Rectifier - Check.............................. 145
Testing a Three-Diode Rectifier Block........ 145
S
Automatic Starting (5) .................................... 8
Electrical Shock (4) ........................................ 8
Hot Fluid Under Pressure (3) ......................... 7
Hot Surface (2)............................................... 7
Lifting the Genset (6)...................................... 8
Universal Warning (1) .................................... 7
Safety Section ................................................... 5
Sea Water Strainer - Clean/Inspect............... 146
Single Unit Operation....................................... 59
Initial Start-Up .............................................. 59
Starting......................................................... 59
Stopping....................................................... 60
Standby Generator Set Maintenance
Recommendations....................................... 146
Maintenance and Operation Procedures ... 146
Starting Motor - Inspect (If equipped) ............ 147
Air Starting Motor ....................................... 147
Electric Starting Motor................................ 147
Removal and Installation of the Starting Motor
................................................................. 148
Starting the Engine .......................................... 55
Stator Lead - Check....................................... 148
166 SEBU9041
Index Section

Stator Winding Temperature - Test ................ 148

System Pressure Release............................... 80
Coolant System............................................ 80
Engine Oil .................................................... 81
Fuel System ................................................. 80

T
Table of Contents............................................... 3
Turbocharger - Inspect .................................. 148
Cleaning and Inspecting ............................ 148
Removal and Installation............................ 148

V
Varistor - Check ............................................. 149
Varistor - Inspect............................................ 149
Ohmmeter.................................................. 149
Test Light.................................................... 150
Voltage and Frequency - Check .................... 150
Voltage Regulators .......................................... 63
Cat Digital Voltage Regulator (Cat DVR )... 63

W
Walk-Around Inspection ................................ 150
Inspect the Engine for Leaks and for Loose
Connections ............................................. 150
Warranty Information ..................................... 152
Warranty Section ........................................... 152
Water Pump - Inspect .................................... 151
Welding on Engines with Electronic Controls .. 81
Product and Dealer Information
Note: For
product identification plate locations, see the section “Product Identification
Information” in the Operation and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission
Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment
Number:

Dealer Information
Name: Branch:

Address:

Dealer Phone Hours

Contact Number

Sales:

Parts:

Service:
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