SEBU7919-10 (en-us)

March 2017

Operation and
Maintenance
Manual
C4.4 Marine Generator Set
J1Z 1-UP (Engine)
MMC 1-UP (Generator Set)
S1M 1-UP (Generator Set)
D1K 1-UP (Engine)
L1K 1-UP (Generator Set)

SAFETY.CAT.COM
 i06558969

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.
SEBU7919-10 3
Table of Contents

Table of Contents Engine Stopping .............................................. 94

Foreword ........................................................... 4 Maintenance Section

Refill Capacities............................................. 100

Safety Section
Maintenance Recommendations .................. 107
Safety Messages............................................... 5
Maintenance Interval Schedule......................112
Additional Messages ....................................... 18

General Hazard Information............................ 20 Reference Information Section

Burn Prevention............................................... 24 Customer Service.......................................... 159

Fire Prevention and Explosion Prevention...... 24 Reference Materials ...................................... 161

Crushing Prevention and Cutting Prevention.. 26 Index Section

Mounting and Dismounting ............................. 27 Index.............................................................. 164

Before Starting Engine .................................... 27

Engine Starting................................................ 27

Engine Stopping .............................................. 28

Electrical System............................................. 28

Generator Isolating for Maintenance............... 28

Product Information Section

General Information ........................................ 30

Product Identification Information ................... 39

Operation Section

Lifting and Storage .......................................... 40

Installation ....................................................... 44

Features and Controls..................................... 46

Engine Starting................................................ 62

Engine Operation ............................................ 70

Generator Operation ....................................... 75

Cold Weather Operation ................................. 93

4 SEBU7919-10
Foreword

Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This frequent lubrication and maintenance than is
manual should be stored in or near the engine area in specified in the Maintenance Interval Schedule may
a literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design Maintenance Intervals
may have caused changes to your engine which are
not included in this manual. Whenever a question Perform maintenance on items at multiples of the
arises regarding your engine, or this manual, please original requirement. Each level and/or individual
consult with your Cat dealer for the latest available items in each level should be shifted ahead or back
information. depending upon your specific maintenance practices,
operation and application. We recommend that the
maintenance schedules be reproduced and
Safety displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
This safety section lists basic safety precautions. In maintained as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, “Maintenance Records” for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more
efficiently and economically. Skill and techniques Major engine overhaul details are not covered in the
develop as the operator gains knowledge of the Operation and Maintenance Manual except for the
engine and its capabilities. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
The operation section is a reference for operators. authorized Cat dealer. Your Cat dealer offers a
variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.

Maintenance California Proposition 65 Warning

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped Diesel engine exhaust and some of its constituents
by fuel consumption, service hours and/or calendar are known to the State of California to cause cancer,
time maintenance intervals. Items in the maintenance birth defects, and other reproductive harm.
schedule are referenced to detailed instructions that
follow. Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
Use fuel consumption or service hours to determine after handling.
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
SEBU7919-10 5
Safety Section
Safety Messages

Safety Section
i06787419

Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your generator set. The exact location and a
description of the safety messages are reviewed in
this section. Become familiar with all safety
messages.
Ensure that all the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off the
generator set.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the generator set that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
6 SEBU7919-10
Safety Section
Safety Messages

Illustration 1 g01317561
Side view of the generator set
SEBU7919-10 7
Safety Section
Safety Messages

Illustration 2 g06124701
Top view of the C4.4 generator set
8 SEBU7919-10
Safety Section
Safety Messages

Illustration 3 g01156220
Rear view of the C4.4 generator set
SEBU7919-10 9
Safety Section
Safety Messages

Illustration 4 g06124760
10 SEBU7919-10
Safety Section
Safety Messages

Illustration 5 g01317566
Side view of the C4.4 radiator equipped generator set.
SEBU7919-10 11
Safety Section
Safety Messages

Illustration 6 g01320748
Side view of the C4.4 radiator equipped generator set.
12 SEBU7919-10
Safety Section
Safety Messages

Illustration 7 g01316626
Typical C4.4 enclosure
SEBU7919-10 13
Safety Section
Safety Messages

Illustration 8 g06122301
View of the premium control panel
(2) Do not operate film (6) Auto start film (7) Electrical shock film
14 SEBU7919-10
Safety Section
Safety Messages

Illustration 9 g06122276
View of the MCS control panel and safety films
(1) Electrocution film (2) Do not operate film (6) Auto start film

Electrocution (1)
This safety message is positioned on both sides of
the generator.
SEBU7919-10 15
Safety Section
Safety Messages

Illustration 10 g01392482 Illustration 11 g01370904

DANGER: Shock/Electrocution Hazard-Do not Do not operate or work on this equipment unless
operate this equipment or work on this you have read and understand the instructions
equipment unless you have read and understand and warnings in the Operation and Maintenance
the instructions and warnings in the Operation Manuals. Failure to follow the instructions or
and Maintenance Manual. Failure to follow the heed the warnings could result in serious injury
instructions or heed the warnings will result in or death.
serious injury or death.

Lifting the Genset (3)

Do Not Operate (2)
This safety message for lifting the generator set is on
This safety message is on the control panel. the frame of the generator set.
16 SEBU7919-10
Safety Section
Safety Messages

Illustration 12 g01433231 Illustration 13 g01157717

Crushing Hazard! Improper lifting could cause Crushing Hazard! Improper lifting could cause
serious injury or death. Follow the lifting instruc- serious injury or death. Follow the lifting instruc-
tions in the Operation and Maintenance Manual tions in the Operation and Maintenance Manual
for safe lifting procedures. for safe lifting procedures.

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

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

Illustration 14 g01372254

If equipped with an air inlet heater (AIH) for cold

weather starting, do not use aerosal types of
starting aids such as ether. Such use could result
in an explosion and personal injury.
SEBU7919-10 17
Safety Section
Safety Messages

Refer to Operation and Maintenance Manual, “Fire

Prevention and Explosion Prevention” for more
information.

Automatic Starting (6)

The safety message for automatic starting is on the
control panel and the electrical box with the
disconnect switch.

Illustration 16 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.
Illustration 15 g01392484

Hot Fluid Under Pressure (8)

When the engine is in the AUTOMATIC mode, the The safety message for hot fluid under pressure is on
engine can start at any moment. To avoid person- the top of the header tank by the filler neck .
al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode.

Electrical Shock (7)

The safety message for electrical shock is on the
control panel.
18 SEBU7919-10
Safety Section
Additional Messages

Refer to Operation and Maintenance Manual, “Fire

Prevention and Explosion Prevention” for more
information.

i02630825

Additional Messages
SMCS Code: 1000; 7405
There are several specific messages on this
machine. The exact location of the messages and the
description of the messages are reviewed in this
section. Please become familiarized with all
messages.

Illustration 17 g01371640 Make sure that all of the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
messages, use a cloth, water and soap. Do not use
Pressurized system! Hot coolant can cause seri- solvent, gasoline, or other harsh chemicals to clean
ous burns, injury or death. To open the cooling the messages. Solvents, gasoline, or harsh
system filler cap, stop the engine and wait until chemicals could loosen the adhesive that secures the
the cooling system components are cool. Loosen messages. Loose adhesive will allow the messages
the cooling system pressure cap slowly in order to fall.
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before per- Replace any message that is damaged, or missing. If
forming any cooling system maintenance. a message is attached to a part that is replaced,
install a message on the replacement part. Any
Caterpillar dealer can provide new messages.
Fire (9)
This safety message is positioned on the side of the
enclosure.

Illustration 18 g01948611

Fire Hazard! Stop the Engine. Do not open the

service doors if a fire exists. Opening the service
doors if a fire exists could result in personal in-
jury or death. Read and understand the instruc-
tions in the Operation and Maintenance Manual.
SEBU7919-10 19
Safety Section
Additional Messages

Illustration 19 g01319430
Typical example
C4.4 is shown.

Port for Fire Extinguisher (1)

This message is located on the side of the enclosure.
20 SEBU7919-10
Safety Section
General Hazard Information

Illustration 20 g01319438

In case of fire, break through the hole with the spray Cautiously remove the following parts. To help
nozzle of the fire extinguisher. prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
i06300340
• Filler caps
General Hazard Information • Grease fittings
SMCS Code: 1000; 4450; 7405
• Pressure taps

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

Illustration 21 g03838041

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,
Illustration 22 g00702020
or around the engine when the engine is being
serviced.
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
SEBU7919-10 21
Safety Section
General Hazard Information

• When work is performed around an engine that is When pressurized air and/or pressurized water is
operating, wear protective devices for ears in used for cleaning, wear protective clothing, protective
order to help prevent damage to hearing. shoes, and eye protection. Eye protection includes
goggles or a protective face shield. Always wear eye
• Do not wear loose clothing or jewelry that can protection for cleaning the cooling system.
snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers

are secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform
the maintenance under the following conditions:

• The engine is stopped. Ensure that the engine

cannot be started.

• The protective locks or the controls are in the

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

• When starting a new engine, 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.
• 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).
22 SEBU7919-10
Safety Section
General Hazard Information

Avoid direct spraying of water on electrical Static Electricity Hazard when

connectors, connections, and components. When
using air for cleaning, allow the machine to cool to Fueling with Ultra-low Sulfur Diesel
reduce the possibility of fine debris igniting when Fuel
redeposited on hot surfaces.
The removal of sulfur and other compounds in ultra-
Fluid Penetration low sulfur diesel fuel (ULSD fuel) decreases the
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 23 g00687600
Avoid static electricity risk when fueling. Ultra-
Always use a board or cardboard when you check for low sulfur diesel fuel (ULSD fuel) poses a greater
a leak. Leaking fluid that is under pressure can static ignition hazard than earlier diesel formula-
penetrate body tissue. Fluid penetration can cause tions with a higher sulfur contents. Avoid death
serious injury and possible death. A pin hole leak can or serious injury from fire or explosion. Consult
cause severe injury. If fluid is injected into your skin, with your fuel or fuel system supplier to ensure
you must get treatment immediately. Seek treatment the delivery system is in compliance with fueling
from a doctor that is familiar with this type of injury. standards for proper grounding and bonding
practices.
Containing Fluid Spillage
NOTICE Lines, Tubes, and Hoses
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Do not bend or strike high-pressure lines. Do not
nance, testing, adjusting, and repair of the product. install lines, tubes, or hoses that are damaged.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Repair any fuel lines, oil lines, tubes, or hoses that
bling any component containing fluids. are loose or damaged. Leaks can cause fires.

Refer to Special Publication, NENG2500, “Cat Dealer Inspect all lines, tubes, and hoses carefully. Do not
Service Tool Catalog” or refer to Special Publication, use bare hands to check for leaks. Always use a
PECJ0003, “Cat Shop Supplies and Tools Catalog” board or cardboard for checking engine components
for tools and supplies suitable to collect and contain for leaks. Tighten all connections to the
fluids on Cat products. recommended torque.

Dispose of all fluids according to local regulations Check for the following conditions:
and mandates.
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering
SEBU7919-10 23
Safety Section
General Hazard Information

Ensure that all of the clamps, the guards, and the • A vacuum cleaner that is equipped with a high
heat shields are installed correctly. Correct efficiency particulate air filter (HEPA) can also be
installation of these components will help to prevent used.
these effects: vibration, rubbing against other parts
and excessive heat during operation. • Use exhaust ventilation on permanent machining
jobs.
Inhalation • Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.

• Stay away from areas that might have asbestos

particles in the air.

Softwrap
Illustration 24 g02159053
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
Exhaust approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
Use caution. Exhaust fumes can be hazardous to protective clothing in order to minimize direct contact.
your health. If you operate the equipment in an Use good hygiene practices and wash hands
enclosed area, adequate ventilation is necessary. thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Asbestos Information Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
Cat equipment and replacement parts that are up debris.
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
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:

• 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.
24 SEBU7919-10
Safety Section
Burn Prevention

Reference: The applicable material safety data Ensure that the filler cap is cool before removing the
sheets can be found at the following web site by filler cap. The filler cap must be cool enough to touch
searching using part number or the name: with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
https://catmsds.cat.com/MSDSSearch/servlet/
cat.cis.ecs. Cooling system conditioner contains alkali. Alkali can
msdsSearch.controller. cause personal injury. Do not allow alkali to contact
UserIdentificationDisplayServlet the skin, the eyes, or the mouth.

Dispose of Waste Properly Oils

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

Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for
servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is
recommended.

i05326156

Illustration 25 g00706404 Fire Prevention and Explosion

Improperly disposing of waste can threaten the Prevention
environment. Potentially harmful fluids should be
disposed of according to local regulations. SMCS Code: 1000; 4450; 7405

Always use leakproof containers when you drain

fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.

i01480768

Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the hydraulic system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings or related items are
Illustration 26 g00704000
disconnected.
Use of personal protection equipment (PPE) may be
Coolant needed.
When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
Any contact with hot coolant or with steam can cause product when a fire hazard exists. Contact your
severe burns. Allow cooling system components to Caterpillar dealer for service.
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
SEBU7919-10 25
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause a deterioration. Properly route all hoses. The lines and
fire. Fire may cause personal injury and property hoses must have adequate support and secure
damage. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an Properly install all oil filters and all fuel filters. The
emergency shutdown. filter housings must be tightened to the proper
torque.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Caterpillar dealer for
additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
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 Illustration 27 g00704059
storing flammable materials.
Use caution when you are refueling an engine. Do
Do not expose the engine to any flame. not smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
Exhaust shields (if equipped) protect hot exhaust stop the engine before refueling.
components from oil or fuel spray from a failed line,
tube, or seal. Exhaust shields must be installed Note: Avoid static electricity risk when fueling. Ultra-
correctly. low sulfur diesel fuel (ULSD fuel) poses a greater
Do not weld on lines or tanks that contain flammable static ignition hazard than earlier diesel formulations
fluids. Do not flame cut lines or tanks that contain with a higher sulfur content. Avoid death or serious
flammable fluid. Clean any such lines or tanks injury from fire or explosion. Consult your fuel or fuel
thoroughly with a nonflammable solvent prior to system supplier to ensure that the delivery system is
welding or flame cutting. in compliance with fueling standards for proper
grounding and bonding practices.
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.
26 SEBU7919-10
Safety Section
Crushing Prevention and Cutting Prevention

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.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
Illustration 28 g02298225 repair or for replacement parts.
Gases from a battery can explode. Keep any open Check lines, tubes, and hoses carefully. Do not use
flames or sparks away from the top of a battery. Do your bare hand to check for leaks. Use a board or
not smoke in battery charging areas. cardboard to check for leaks. Tighten all connections
to the recommended torque.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a Replace the parts if any of the following conditions
hydrometer. are present:
Improper jumper cable connections can cause an • End fittings are damaged or leaking.
explosion that can result in injury. Refer to the
Operation Section of this manual for specific • Outer coverings are chafed or cut.
instructions.
• Wires are exposed.
Do not charge a frozen battery. Charging a frozen
battery may cause an explosion. • Outer coverings are ballooning.
The batteries must be kept clean. The covers (if • Portions of the hoses are kinked.
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box • Outer covers have embedded armoring.
covers when the engine is operated.
• 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.
SEBU7919-10 27
Safety Section
Mounting and Dismounting

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, Engine exhaust contains products of combustion
reinstall the guards.
which may be harmful to your health. Always
Keep objects away from moving fan blades. The fan start and operate the engine in a well ventilated
blades will throw objects or cut objects. area and, if in an enclosed area, vent the exhaust
to the outside.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes. Inspect the engine for potential hazards.

Chips or other debris may fly off objects when objects Do not start the engine or move any of the controls if
are struck. Before objects are struck, ensure that no there is a “DO NOT OPERATE” warning tag or similar
one will be injured by flying debris. warning tag attached to the start switch or to the
controls.
i01372247 Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
Mounting and Dismounting area is free of personnel.
SMCS Code: 1000; 4450; 7405 If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
Inspect the steps, the handholds, and the work area lights work properly, if equipped.
before mounting the engine. Keep these items clean
and keep these items in good repair. All protective guards and all protective covers must
be installed if the engine must be started in order to
Mount the engine and dismount the engine only at perform service procedures. To help prevent an
locations that have steps and/or handholds. Do not accident that is caused by parts in rotation, work
climb on the engine, and do not jump off the engine. around the parts carefully.
Face the engine in order to mount the engine or Do not bypass the automatic shutoff circuits. Do not
dismount the engine. Maintain a three-point contact disable the automatic shutoff circuits. The circuits are
with the steps and handholds. Use two feet and one provided in order to help prevent personal injury. The
hand or use one foot and two hands. Do not use any circuits are also provided in order to help prevent
controls as handholds. engine damage.
Do not stand on components which cannot support See the Service Manual for repairs and for
your weight. Use an adequate ladder or use a work adjustments.
platform. Secure the climbing equipment so that the
equipment will not move. i02207232

Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand Engine Starting
line to raise and lower tools or supplies.
SMCS Code: 1000
i03560601

Before Starting Engine Do not use aerosol types of starting aids such as
SMCS Code: 1000 ether. Such use could result in an explosion and
personal injury.
NOTICE If a warning tag is attached to the engine start switch
For initial start-up of a new or rebuilt engine, and for or to the controls, DO NOT start the engine or move
start-up of an engine that has been serviced, make the controls. Consult with the person that attached
provision to shut the engine off should an overspeed the warning tag before the engine is started.
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine. All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operator's compartment or
from the engine start switch.
28 SEBU7919-10
Safety Section
Engine Stopping

Always start the engine according to the procedure i02176668

that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation Electrical System
Section. Knowing the correct procedure will help to
prevent major damage to the engine components. SMCS Code: 1000; 1400
Knowing the procedure will also help to prevent
personal injury. Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
To ensure that the jacket water heater (if equipped) is operating. A spark can cause the combustible
and/or the lube oil heater (if equipped) is working gases that are produced by some batteries to ignite.
correctly, check the water temperature gauge and the
oil temperature gauge during the heater operation. To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
Engine exhaust contains products of combustion negative “−” jump start cable should be connected
which can be harmful to your health. Always start the last from the external power source to the negative
engine and operate the engine in a well ventilated “−” terminal of the starting motor. If the starting motor
area. If the engine is started in an enclosed area, is not equipped with a negative “−” terminal, connect
vent the engine exhaust to the outside. the jump start cable to the engine block.

Note: The engine is equipped with an automatic Check the electrical wires daily for wires that are
device for cold starting for normal conditions of loose or frayed. Tighten all loose electrical wires
operation. If the engine will be operated in very cold before the engine is started. Repair all frayed
conditions, then an extra cold starting aid may be electrical wires before the engine is started. See the
required. Normally, the engine will be equipped with Operation and Maintenance Manual for specific
starting instructions.
the correct type of starting aid for your region of
operation.
Grounding Practices
The engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake air Correct grounding for the engine electrical system is
in order to improve starting. necessary for optimum engine performance and
reliability. Incorrect grounding will result in
i02590389 uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Engine Stopping Uncontrolled electrical circuit paths can result in
SMCS Code: 1000 damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine Engines that are installed without engine-to-frame
according to this Operation and Maintenance ground straps can be damaged by electrical
Manual, “Engine Stopping” topic (Operation Section). discharge.

Use the Emergency Stop Button (if equipped) ONLY To ensure that the engine and the engine electrical
in an emergency situation. DO NOT use the systems function correctly, an engine-to-frame
Emergency Stop Button for normal engine stopping. ground strap with a direct path to the battery must be
After an emergency stop, DO NOT start the engine used. This path may be provided by way of a direct
until the problem that caused the emergency stop engine ground to the frame.
has been corrected.
All grounds should be tight and free of corrosion. The
On the initial start-up of a new engine or an engine engine alternator must be grounded to the negative
that has been serviced, make provisions to stop the “-” battery terminal with a wire that is adequate to
engine if an overspeed condition occurs. This may be handle the full charging current of the alternator.
accomplished by shutting off the fuel supply and/or
the air supply to the engine. i03491163

If equipped, in order to stop an electronically

controlled engine, cut the power to the engine. Generator Isolating for
Maintenance
SMCS Code: 4450

Note: If the rated output voltage of the generator

is greater than 600 volts, the generator and
connected load cable capacitances must be
discharged prior to servicing the generator.
SEBU7919-10 29
Safety Section
Generator Isolating for Maintenance

When you service an electric power generation set or 9. Determine that the generator is in a de-energized
when you repair an electric power generation set, condition. Ensure that any power source is in this
follow the procedure below: condition: removed, disabled, locked state, tagged
1. Stop the engine. out and tested out. Add ground straps to the
conductors or terminals. Connect the ground
straps to the electrical distribution system's
common grounding location or to the ground
system. During the entire work period, these
ground straps must remain connected to the
conductors and generator terminals.

Illustration 29 g00104545

2. Attach a “DO NOT OPERATE” or similar warning

tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
3. Disconnect the generator from the distribution
system.
4. Lock out the circuit breaker. Attach a “DO NOT
OPERATE” or similar warning tag to the circuit
breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have
been locked out.
5. For the following circuitry, remove the
transformer's fuses:

• Power

• Sensing

• Control

6. Attach a “DO NOT OPERATE” or similar warning

tag to the generator excitation controls.
7. Remove the cover of the generator's terminal box.
8. Use an audio/visual proximity tester in order to
verify that the generator is de-energized. This
tester must be insulated for the proper voltage
rating. Follow all guidelines in order to verify that
the tester is operational.
30 SEBU7919-10
Product Information Section
General Information

Product Information
Section

General Information
i06787470

Model View Illustrations

SMCS Code: 1000
The model views show a typical arrangement for a
C4.4 Marine Generator Set that is turbocharged and
aftercooled. The model views also show a typical
Marine Generator Set enclosure. Due to individual
applications, your generator set and your enclosure
may appear different from the illustrations.

Illustration 30 g06125681
Side view of a generator set with a turbocharged aftercooled engine
(1) Header Tank (6) Air Cleaner Service Indicator
(2) Coolant Filler Cap (7) Control Panel
(3) Fuel Filter (8) Frame
(4) Closed Crankcase Breather (9) Lifting Eye
(5) Engine Air Cleaner (10) Sea Water Outlet
SEBU7919-10 31
Product Information Section
Model View Illustrations

(11) Heat Exchanger (14) Engine Oil Level Gauge (Dipstick) (17) Engine Oil Filler
(12) Fuel Inlet (15) Engine Oil Filter
(13) Fuel Outlet (16) Sea Water Inlet

Illustration 31 g06125742
Top view of a generator set with a turbocharged aftercooled engine
(18) Oil Filler Cap (19) Aftercooler
32 SEBU7919-10
Product Information Section
Model View Illustrations

Illustration 32 g01153670
Side view of a generator set with a turbocharged aftercooled engine
(20) Terminal Box on the Generator (22) Starting Motor
(21) Exhaust Outlet (23) Generator
SEBU7919-10 33
Product Information Section
Model View Illustrations

Illustration 33 g01321275
Side view of a generator set and engine with radiator cooling
(24) Turbocharger (26) Radiator Top Tank (28) Lifting Eye
(25) Exhaust Outlet (27) Radiator

Note:
34 SEBU7919-10
Product Information Section
Model View Illustrations

Illustration 34 g01321288
Side view of an MCS generator set and engine with radiator cooling
(29) Closed Crankcase Breather (32) Fuel Inlet (35) Engine Oil Filler
(30) Fuel Outlet (33) Duplex Oil Filter
(31) Duplex Fuel Filter (34) Engine Oil Level Gauge (Dipstick)

Note: The following callouts are included in the MCS

generator set only: (30), (31), (32) and (33)
SEBU7919-10 35
Product Information Section
Model View Illustrations

Illustration 35 g01321955
Side view of a generator enclosure
(36) Lifting Eyes (37) Control Panel
36 SEBU7919-10
Product Information Section
Model View Illustrations

Illustration 36 g01321973
Rear view of a generator enclosure
(38) Exhaust Outlet (39) Ports for Raw Water, Fuel, and
Electrical Power Supply
SEBU7919-10 37
Product Information Section
Product Description

Illustration 37 g01322020
Top view of a generator enclosure
(40) Exhaust Outlet (41) Siphon Breaks

i04497152 The engines are powered with direct fuel injection. A

mechanical governor controls the fuel injection pump
Product Description output. Engine speed is controlled by the electronic
speed control. In the event of a malfunction with the
SMCS Code: 1000; 4450; 4491 electronic speed control, the mechanical speed
control will prevent an engine overspeed condition
The brushless generator is used for various marine and resulting in mechanical damage.
applications. The elimination of brushes in the field
circuit reduces maintenance with increased reliability. Fuel is metered and pumped by the fuel injection
Also, the elimination of brushes provides a higher pump under high pressure to the fuel injection
degree of protection in potentially hazardous nozzles (one per cylinder). The automatic timing
atmospheres. The generator set packages can be advance provides the best fuel injection timing over
utilized for prime power generation or standby power the full range of engine speed.
generation.
The cooling system consists of the following
The generators can be configured for three-phase components:
power or single-phase power. The generators have
full-wave excitation and regulation. The generators • A centrifugal pump that is driven by a gear
have 12 leads that can be connected in various
configurations. The generators may produce • One water temperature regulator which regulates
electrical power in either 50 Hz or 60 Hz applications. the engine coolant temperature
• Heat exchanger for the closed water circuit
38 SEBU7919-10
Product Information Section
Product Description

• Auxiliary water pump (Table 1, contd)

Number of Cylinders 4 (In-Line)
• Expansion tank
Bore 105.0 mm (4.13 inch)
• Radiator (If equipped)
Stroke 127.0 mm (5.00 inch)
The engine lubricating oil is supplied by a gear type
pump. The engine lubricating oil is cooled on models NA(2)
that are equipped with the optional oil cooler. Bypass Aspiration T(3)
valves provide unrestricted flow of lubrication oil to TA(4)
the engine parts when oil viscosity is high. Bypass Displacement 4 L (243 in3)
valves can also provide unrestricted flow of
lubrication oil to the engine parts if the oil cooler Firing Order 1, 3, 4, 2
should become plugged or if the oil filter element
should become plugged. Rotation that is viewed from the
Counterclockwise
flywheel
Engine efficiency, efficiency of emission controls, and (1) The operating rpm is dependent on the engine rating and the
engine performance depend on adherence to proper application.
operation and maintenance recommendations. (2) Naturally Aspirated
Engine performance and efficiency also depend on (3) Turbocharged
(4) Turbocharged Aftercooled
the use of recommended fuels, lubrication oils, and
coolants. Refer to the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information on maintenance items.

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

C4.4 Marine Generator Set Engine

Illustration 38 g01156157
(E) Exhaust valves
(I) Inlet valves
(R) Rear of the engine
(F) Front of the engine

Table 1
C4.4 Marine Generator Set Engine Specifications

Operating Range (rpm) 1500 to 1800(1)

(continued)
SEBU7919-10 39
Product Information Section
Product Identification Information

Product Identification The following information is stamped on the Serial

Number Plate: engine serial number, model, and
Information arrangement number.

i06787478 Generator Identification Plate

Plate Locations and Film
Locations
SMCS Code: 1000; 4450

Serial Number Plate

Illustration 41 g01157912

The identification plate (2) for the generator is on the

front of the terminal box for the generator.

Illustration 39 g06125778

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

engine near the fuel injection pump.

Illustration 42 g01157915
Typical generator identification plate

Illustration 40 g00123229
Typical serial number plate
40 SEBU7919-10
Operation Section
Lifting and Storage

Operation Section

Lifting and Storage

i02472970

Product Lifting Illustration 43 g01034418

SMCS Code: 7000; 7002 The lifting labels are located on the lifting eyes.
These labels designate the proper lifting locations for
Lifting of Generator Sets the generator set. Some generator sets may be lifted
at the base of the generator set and other generator
sets may have a single lifting point on top of the
NOTICE generator set.
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re-
member that the capacity of an eyebolt is less as the Engine Lifting with a Fuel Tank
angle between the supporting members and the ob-
ject becomes less than 90 degrees. Do not lift the unit with fuel in the fuel tank.

When it is necessary to remove a component at an i04871589

angle, only use a link bracket that is properly rated for
the weight. Product Storage
Use a hoist to remove heavy components. Use an SMCS Code: 7002
adjustable lifting beam, if necessary. All supporting
members (chains and cables) should be parallel to Note: If storage for more than 1 year is necessary,
each other. The chains and cables should be contact your local Cat dealer for the procedure
perpendicular to the top of the object that is being specific to your product.
lifted.
Some removals require lifting the fixtures in order to Engine
obtain proper balance and safety. Consult your
Caterpillar dealer for information regarding fixtures Storage (Less Than One Year)
for proper lifting of your complete package.
Lifting eyes are designed and installed for the If an engine is not used, oil can run off the following
specific arrangement. Alterations to the lifting eyes parts that normally receive lubrication: cylinder walls,
and/or the engine make the lifting eyes and the lifting piston rings, main bearings, connecting rod bearings,
fixtures obsolete. If alterations are made, ensure that crankshaft and gears.
proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures This lack of lubricant allows corrosion to begin to
for proper engine lifting. appear on the metal. This condition is worse in areas
of high humidity.
On some enclosed generator sets, it may be
necessary to remove a top panel of the enclosure in When the engine is started again, metal to metal
order to access the lifting eye. 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.
3. Apply lubricant to all points in this Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
SEBU7919-10 41
Operation Section
Product Storage

4. Drain the crankcase oil. Replace the crankcase oil 10. Remove the fuel nozzles or spark plugs. Apply
and change any oil filters. For the proper 30 mL (1 oz) of the mixture of oils (50 percent VCI
procedure, refer to this Operation and oil and 50 percent engine oil) into each cylinder.
Maintenance Manual.
Use a bar or a turning tool in order to turn over the
5. If the engine is equipped with an air starting motor, engine slowly. This procedure puts the oil on the
fill the reservoir with 50 percent volatile corrosion cylinder walls. Install all fuel nozzles or spark plugs
inhibitor oil (<nomen>VCI oil</nomen>) and 50 and tighten to the correct torque.
percent engine oil. 11. Spray a thin amount of the mixture of oil (50
6. Add VCI oil to the crankcase oil. The volume of percent VCI oil and 50 percent engine oil) onto the
VCI oil in the crankcase oil should be 3 to 4 flywheel, ring gear teeth and starter pinion. Install
percent. the covers in order to prevent evaporation of the
vapors from the VCI oil.
Note: If the engine crankcase is full, drain enough
engine oil so the mixture can be added. 12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move,
7. Remove any air filter elements. Turn the engine at such as rod threads, ball joints, linkage.
cranking speed with the throttle control in FUEL
Note: Install all covers. Ensure that tape has been
OFF position. Use a sprayer to add a mixture of 50
installed over the following components: openings,
percent VCI oil and 50 percent engine oil into the air inlets, exhaust openings, flywheel housing,
air inlet or turbocharger inlet. crankcase breathers, dipstick tubes and any other
necessary components.
Note: The mixture of VCI oil can be added to the inlet
by removing the plug for checking turbocharger boost Ensure that all covers are airtight and
pressure. The minimum application rate for the VCI weatherproof. Use a waterproof weather resistant
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of tape such as Kendall No. 231 or an equivalent. Do
engine displacement. not use duct tape. Duct tape will only seal for a
short period.
8. Use a sprayer to apply a mixture of 50 percent VCI
oil and 50 percent crankcase oil into the exhaust 13. Remove the batteries. As an alternative, place
openings. The minimum application rate for the oil the batteries in storage. As needed, periodically
mixture is 5.5 mL per L (3 oz per 1000 cu in) of charge the batteries while the batteries are in
engine displacement. Seal the exhaust pipe and storage.
seal any drain holes in the muffler. If the batteries are not removed, wash the tops of
9. Remove the fuel from the secondary fuel filter the batteries until the tops are clean. Apply an
electrical charge to the batteries in order to obtain
housing. Alternately, empty and reinstall the spin- a specific gravity of 1.225.
on fuel filter element in order to remove any dirt
and water. Drain any sleeve metering fuel pump. Disconnect the battery terminals. Place a plastic
cover over the batteries.
Clean the primary fuel filter. Fill with calibration
fluid or kerosene. Install the primary fuel filter and Note: For additional information, refer to Special
operate the priming pump. This procedure will Instruction, SEHS7633, “Battery Test Procedure”.
send clean oil to the secondary filter and the
engine. 14. Loosen all belts.
Open the fuel tank drain valve in order to drain any 15. Place a waterproof cover over the engine. Ensure
water and dirt from the fuel tank. Apply a spray of that the engine cover is secure. The cover should
calibration fluid or kerosene at the rate of be loose enough to allow air to circulate around
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. the engine in order to prevent damage from
Add 0.15 mL per L (.02 oz per 1 gal US) of condensation.
commercial biocide such as Biobor JF to the fuel. 16. Attach a tag with the storage date to the engine.
Apply a small amount of oil to the threads on the 17. Remove the waterproof cover at 2 month or 3
fuel tank filler neck and install the cap. Seal all
openings to the tank in order to prevent month intervals in order to check the engine for
evaporation of the fuel and as a preservative. corrosion. If the engine has signs of corrosion,
repeat the protection procedure.
42 SEBU7919-10
Operation Section
Product Storage

Cooling System 12. If the engine was removed from storage in which
temperatures of less than -12°C (10°F) were
Completely fill the cooling system before storage. encountered, refer to Service Manual, SEBU5898,
Refer to this Operation and Maintenance Manual, “Cold Weather Recommendations Operation and
“Fluid Recommendations” for more information about Maintenance”.
coolants.
Generator
Removal from Storage
Storage (Less Than One Year)
1. Remove all outside protective covers.
2. Change the oil and filters. When a generator is in storage, moisture condenses
in the windings. To minimize condensation, always
3. Check the condition of the fan and alternator belts. place the generator in a dry storage area. Seal all
Replace the belts, if necessary. Refer to this openings with tape.
Operation and Maintenance Manual, “Belts - If a brush-type generator (SRCR) is stored, lift the
Inspect/Adjust/Replace” for the correct procedure. brushes off the slip ring to prevent chemical action
damage to the slip ring. Attach a tag to the generator
4. Replace the fuel filter elements. which states that the brushes have been lifted.
5. Remove the plastic covers from the air cleaner Perform a resistance check of the windings. Record
elements. this reading. This check is done in order to provide a
6. Use a bar or a turning tool in order to turn the base line for determining whether moisture or
winding deterioration occurs during storage.
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or Removal From Storage
resistance exist.
7. Before starting the engine, remove the valve cover Remove all protective covers. Reseat the brushes on
the slip ring for SRCR generators.
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in Before start-up of a generator, use a megohmmeter
order to prevent damage to the mechanism. to check insulation resistance for moisture and/or
foreign material. Refer to this Operation and
8. Pressure- lubricate the engine before starting the Maintenance Manual, “Generator Start-up Check
engine. Pressure lubricating the engine ensures List” for the procedure. A resistance reading of 1
immediate lubrication and prevents damage to the megohm or less indicates that the winding has
engine during the first few minutes of engine absorbed too much moisture.
operation. If the engine is not equipped with a Use one of the following methods for drying the
prelube pump, contact your Cat dealer about generator in order to remove moisture which is
lubricating the engine before starting the engine. caused by high humidity or dampness:
9. Check the condition of all rubber hoses. Replace 1. Place the generator in an oven which is no hotter
any worn hoses. Replace any damaged hoses. than 85°C (185°F) for 4 hours.
10. Before start-up, test the cooling system for a 3 to 2. Use a canvas enclosure around the generator and
6 percent concentration of coolant conditioner. heating lamps to increase the ambient
Add liquid coolant conditioner or a coolant temperature. Provide an opening in the top of the
conditioner element, if equipped. canvas in order to release the moisture.
Test the coolant mixture for proper nitrite level. If 3. Send a low voltage current through the windings in
necessary, adjust the coolant mixture. order to increase the temperature of the windings
to 85°C (185°F).
Prime the engine with clean diesel fuel before
starting.
Megohmmeter Checks
11. On the first day of operation, check the entire
engine several times for leaks and correct Test the main stator windings with a megohmmeter in
operation. 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
SEBU7919-10 43
Operation Section
Product Storage

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”.
44 SEBU7919-10
Operation Section
Installation

Installation The hoist and the hoist cables should have a rating
that is greater than the weight of the generator. When
the unit is moved, ensure that the generator is
i06244540 supported by the lift trucks fork tines. Also ensure
that the generator is balanced on the lift trucks fork
Product Installation tines. Slide the fork tines beneath the attached skid in
order to lift the generator, if equipped.
SMCS Code: 1000; 1404; 4450; 7002
Location
Receiving Inspection
The location of the generator must comply with all
If the generator is received during cold weather, allow local regulations. The location of the generator must
the unit to reach room temperature before you also comply with all special industrial regulations.
remove the protective packing material. Warming the Locate the generator in an area that meets the
generator to room temperature will prevent the following requirements:
following problems:
• Clean
• Water condensation on cold surfaces
• Dry
• Early failures due to wet windings
• Sufficient ventilated
• Early failures due to wet insulating materials
• Easily accessible for inspection and maintenance
Unpacking Ensure that there is sufficient space in front and
behind of any exhaust or inlet vent, including the
Moving the Generator following:

Unpack the equipment with care in order to avoid • Fire / heavy weather hatches should be able to
scratching painted surfaces. open fully away from the vent.
• Placing the vent such that a bulkhead is not
immediately in front or behind the opening.
Improper lift rigging can allow unit to tumble • A suggested clearance between the vent and any
causing injury and damage. bulkhead or otherwise is at least the longest of the
height or width of the vent.

NOTICE Do not obstruct air inlet openings. Do not obstruct

Do not use the engine lifting eyes to remove the en- discharge openings. Coolant flow must reach these
gine and generator together. openings. If the generator is exposed to harsh
environmental conditions, the generator can be
modified in the field in order to add filters and space
Move the unit to the mounting location. The unit can heaters. In addition, a more rigid periodic
be moved by either of the following methods: maintenance schedule should be established.
• Attach an overhead crane to the eyebolts that are
installed on the generator frame. Electrical Measurements
• Use a lift truck in order to lift the generator. Measure the insulation resistance of each winding if
the generator was exposed to the following
Refer to the Operation and Maintenance Manual, conditions:
“Product Lifting” section.
• Rapid changes in temperature
• Freezing

• Wet climate during shipment

• Wet climate during storage
Note: These tests should be conducted prior to any
power connections that are being made. These tests
should be conducted prior to any control connections
that are being made.
SEBU7919-10 45
Operation Section
Product Installation

Refer to the Generator Maintenance section of this

manual in order to measure the following items:
• Exciter field (stator)

• Exciter armature (rotor)

• Generator field (rotor)

• Generator armature (stator)

Protective Devices
The output to the load of the generator should always
be protected with an overload protection device such
as a circuit breaker or fuses. Fuses should be sized
by using the lowest possible current rating. However,
this rating must be above the current rating for full
load. A common recommendation is 115 percent of
rated current. Determine the size of fuses or
determine the size of circuit breakers in accordance
with NEMA, IEC, and Local Electrical Codes.
46 SEBU7919-10
Operation Section
Features and Controls

Features and Controls i06787483

i03646563
Control Panel
(Protection and Paralleling Unit
Battery Disconnect Switch (PPU) Control Panel (if
(If Equipped) equipped))
SMCS Code: 1411
SMCS Code: 7451
The battery disconnect switch and the engine start
switch perform different functions. Turn off the battery S/N: MMC
disconnect switch in order to disable the entire Generator Sets
electrical system. The battery remains connected to
the electrical system when you turn off the engine There are three types of control panels that are
start switch. available for the generator set. The control panels
are the Protection and Paralleling Unit (PPU) Control
Turn the battery disconnect switch to the OFF Panel, the Standard Control Panel, and the Premium
position and remove the key when you service the Control Panel. The Protection and Paralleling Unit
electrical system or any other components. (PPU) Control Panel is discussed in this section. The
Standard Control Panel and the Premium Control
Also turn the battery disconnect switch to the OFF Panel are discussed in this Operation and
position and remove the key when the engine will not Maintenance Manual, “Control Panel (Standard
be used for an extended period of a month or more. Control Panel and the Premium Control Panel) (if
This will prevent drainage of the battery. equipped))”.

NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.

To ensure that no damage to the engine occurs,

verify that the engine is fully operational before
cranking the engine. Do not crank an engine that is
not fully operational.
Perform the following procedure in order to check the
battery disconnect switch for proper operation:
1. With the battery disconnect switch in the ON
position, verify that electrical components are
functioning. Verify that the hour meter is displaying
information. Verify that the engine will crank.
2. Turn the battery disconnect switch to the OFF
position.
3. Verify that the following items are not functioning:
electrical components, hour meter and engine
cranking. If any of the items continue to function
with the battery disconnect switch in the OFF
position, consult your Caterpillar dealer.
SEBU7919-10 47
Operation Section
Protection and Paralleling Unit (PPU) Control Panel (if equipped)

Protection and Paralleling Unit (PPU)

Control Panel

Illustration 44 g06122202
Protection and Paralleling Unit (PPU) Control Panel
(1) Emergency stop push button (3) Warning lamps
(2) PPU (4) Control panel housing

Emergency Stop Push Button (1) – The emergency

stop push button (ESPB) is used to shutdown the
engine during an emergency situation. The ESPB
shuts off the fuel and the ESPB trips the air shutoff.
PPU (2) – The PPU controls the functions of the
generator set.
Warning Lamps (3) –
48 SEBU7919-10
Operation Section
Protection and Paralleling Unit (PPU) Control Panel (if equipped)

Illustration 45 g06121613
PPU
(5) Alarm Indicator (14) “MODE” key (22) Indicate light for alarm inhibit
(6) Information key (15) Indicator light for control in remote (23) Controller status indicator light
(7) “JUMP” key mode (24) Controller power indicator light
(8) “START” key (16) Menu navigation key for LEFT (25) Menu navigation key for UP
(9) “STOP” key (reset) (17) “BACK” key (26) “LOG” key
(10) Engine operating indicator (18) Menu navigation key for DOWN (27) “VIEW” key
(11) Generator status indicator (19) “Lamp Test Key” (28) Display area
(12) Circuit breaker indicator (20) Select Key
(13) Circuit breaker key (if equipped) (21) Menu navigation key for RIGHT

The PPU is operated by keys on the panel. Three mode in order for the “START” key to function. The
keys (8, 9, and 14) control the starting and the remote indicator light (15) cannot be illuminated. To
stopping of the generator set. Keys (6, 7, 16, 17, 18, switch off the remote indicator light, press “MODE”
19, 20, 21, 24, 25, 26, and 27) allow operator to key (14).
access additional information about the generator
set. This information is shown on the display (28). “ STOP”” Key (reset) (9) – The “STOP” key shuts
down the engine when the engine is running.
Alarm Indicator (5) – A flashing LED indicates that Pressing the “ STOP”” key bypasses the cooldown
alarms that have not been acknowledged are still period.
present. A fixed LED light indicates that all alarms are
acknowledged. A RED LED is for Shutdown. A Engine operating indicator (10) – Light indicates
GREEN LED is for an Alarm. that the generator is running.

“ INFO”” Key (6) – This shifts the display to show the Generator Status Indicator (11) – This light
list of alarms. The list has a maximum of 30 alarms. indicates that the voltage and frequency is present
and OK.
“ JUMP”” Key (7) – The “JUMP” key is used to enter a
number to select a menu. Every setting has a specific Circuit Breaker Indicator (12) – The light indicates
number. Use the “JUMP” key to select any setting that the breaker is closed.
and display any setting without navigating all the way Circuit Breaker Key (13) (if equipped) – The circuit
through the menus. breaker key opens the circuit breaker and the circuit
“ START”” Key (8) – The “START” key begins the breaker key closes the circuit breaker.
starting sequence. The PPU must be in manual
SEBU7919-10 49
Operation Section
Protection and Paralleling Unit (PPU) Control Panel (if equipped)

“ MODE”” Key (14) – The “MODE” key switches the Use the following procedure to access the Service
system between LOCAL START/STOP and Menu.
“REMOTE START/STOP” . Light (15) is illuminated
for “REMOTE” control. 1. Press the “JUMP” key.

Indicator Light for Control In Remote Mode (15) – 2. Use the Menu Navigation Key for UP and the
The indicator illuminated through operation of Mode Menu Navigation Key for DOWN In order to step to
key. (14) channel 4980.
Menu Navigation Key for LEFT (16) – This key 3. Press the “SEL” key.
moves the cursor to the left for maneuvering in the
menus. 4. Choose the desired functions, timers, inputs, or
outputs by moving the cursor and pressing the
“ BACK”” Key (17) – The “BACK” key jumps one step “SEL” key.
backward in the menu to previous display or to the
entry screen.
Alarms
Menu Navigation Key for DOWN (18) – This key
decreases the value of the selected set point in the The following steps describe the function of the
setting menus. This key is also used for scrolling to alarm.
the second line that displays the values for the
generator in the display for daily use. 1. An alarm occurs. The alarm light starts flashing.

“ SEL”” Key (20) – This key is used to select the 2. The display automatically shows the alarm
function that has been chosen. The function that has information.
been chosen is the underlined selection in the lower
line of the display. 3. Move the cursor to “ACK” and press the “SEL” key
to acknowledge the alarm. Take the necessary
Menu Navigation Key for RIGHT (21) – This key action for the alarm.
moves the cursor to the right to maneuver in the
menus. 4. The alarm will disappear when the condition that
Indicator Light for “ Alarm Inhibit”” (22) – This light caused the alarm is no longer present.
indicates that the “inhibit input” is on. 5. Alarms that have not been acknowledged are still
Indicator for Status of the Controller (23) – This present if the alarm light flashes.
light indicates that the unit is running a self-check and
the unit is functioning properly. 6. Use the menu navigation keys to step through the
list of alarms.
Power Indicator (24) – This light indicates that the
auxiliary DC battery supply circuit is switched on. Warnings
Menu Navigation Key for UP (25) – This key
increases the value of the selected set point in the “ WARNING BATTERY VOLTAGE”” – If the control
module detects voltage from the alternator that is
setting menus. This key is also used for scrolling to below the setting for low voltage, the display will
the second line that displays the values for the show “BATTERY LOW V” . The alarm indicator
generator in the display for daily use. illuminates, and an audible alarm is activated.
“ LOG”” Key (26) – This key shifts the display to the “ FAIL TO STOP”” – If the control module determines
three lower lines to show the event and a list of that the signal from the engine speed sensor
alarms. The list holds 100 events. These events are indicates that the engine is running but the engine
erased when the main unit is switched off. should not be running, the display will show “STOP
“ VIEW”” Key (27) – Enter a menu number selection. FAIL” . The alarm indicator illuminates, and an
All settings have a specific number. The “VIEW” key audible alarm is activated.
enables the user to select any setting. The “VIEW” “ WARNING LOW OIL PRESSURE”” – If the control
key enables the user to display any setting without module detects engine oil pressure that has fallen
navigating through all the menus. below the setting for low oil pressure (warning), the
display will show “LOW OIL PRESS” . The alarm
Display Area (28) – The display area shows indicator illuminates, and an audible alarm is
information about the generator set. activated. This warning is only active after the engine
has exceeded the Safety On Timer.
Service Menu “ WARNING HIGH COOLANT TEMP”” – If the control
module detects engine coolant temperature that has
Accessing the Service Menu can only be exceeded the setting for high coolant temperature
accomplished by using the “JUMP” key. (warning), the display will show “HIGH ENGINE
TEMP” . The alarm indicator illuminates, and an
50 SEBU7919-10
Operation Section
Protection and Paralleling Unit (PPU) Control Panel (if equipped)

audible alarm is activated. This warning is only active “ HIGH EXHAUST TEMPERATURE ALARM
after the engine has exceeded the “Safety On” Timer. OPTIONAL”” – If the control module detects a high
exhaust temperature (warning), the display will show
“ WARNING OVERSPEED”” – If the engine speed “HIGH EXH TEMP” . The alarm indicator illuminates,
exceeds the setting for engine overspeed (warning), and an audible alarm is activated.
the display will show “OVERSPEED” . The alarm
indicator illuminates, and an audible alarm is “ HIGH PRESSURE FUEL LEAK ALARM
activated. OPTIONAL”” – If the control module detects a high-
pressure fuel leak (warning), the display will show “H
“ WARNING GENERATOR HIGH FREQUENCY”” – If P FUEL LEAK” . The alarm indicator illuminates, and
the control module detects an output frequency for an audible alarm is activated.
the generator that exceeds the setting for high
generator frequency (warning), the display will show “ WATER IN FUEL ALARM OPTIONAL”” – If the
“F/U FAILURE” . The alarm indicator illuminates, and control module detects a signal for water in fuel
an audible alarm is activated. (warning), the display will show “WATER IN FUEL” .
The alarm indicator illuminates, and an audible alarm
“ WARNING GENERATOR LOW FREQUENCY”” – If is activated.
the control module detects an output frequency for
the generator that is below the setting for low
generator frequency (warning), the display will show Shutdowns
“F/U FAILURE” . The alarm indicator illuminates, and
an audible alarm is activated. “ SHUTDOWN FAIL TO START”” – If the engine does
not start after a preset number of attempts, the
“ GENERATOR HIGH VOLTAGE WARNING”” – If the display will show “F/U FAIL” . The alarm indicator will
control module detects an output voltage for the
flash, and an audible alarm is activated.
generator that exceeds the setting for high generator
voltage (warning), the display will show “OVER “ SHUTDOWN EMERGENCY STOP”” – If the voltage
VOLTAGE” . The alarm indicator illuminates, and an signal at the input for the emergency stop is
audible alarm is activated. disconnected, the display will show “E-STOP” . The
“ GENERATOR LOW VOLTAGE WARNING”” – If the generator set will not start until the emergency stop
control module detects an output voltage for the push button has been reset. Power is removed from
generator that is less than the setting for low the fuel solenoid and the starter solenoid. The alarm
generator voltage (warning), the display will show indicator will flash, and an audible alarm is activated.
“UNDER VOLTAGE” . The alarm indicator “ SHUTDOWN LOW OIL PRESSURE”” – If the control
illuminates, and an audible alarm is activated. module detects engine oil pressure that has fallen
“ LUB OIL HIGH TEMPERATURE ALARM”” – If the below the setting for low oil pressure (shutdown), the
control module detects a high lube oil temperature display will show “LOW O P S/DOWN” . The alarm
more than 120 degrees celsius for four cylinder indicator will flash, and an audible alarm is activated.
engines and more than 130 degrees celsius for six This warning is only active after the engine has
cylinder engines (warning), the display will show exceeded the Safety On Timer.
“LUB OIL HIGH” . The alarm indicator illuminates. “ SHUTDOWN HIGH COOLANT TEMPERATURE”” –
If the control module detects engine coolant
“ SHUTDOWN OVERRIDE”” – If the control module
detects an override for engine shutdown and the temperature that has exceeded the setting for high
switch is set to OVERRIDE, the display will show “S/ coolant temperature (shutdown), the display will
D OVERRIDE” . The alarm indicator illuminates, and show “HET S/DOWN” . The alarm indicator will flash,
an audible alarm is activated. and an audible alarm is activated. This warning is
only active after the engine has exceeded the “Safety
“ STARTING AIR PRESSURE LOW ALARM On” Timer.
OPTIONAL”” – If the control module detects low
starting air pressure (warning), the display will show “ SHUTDOWN OVERSPEED”” – If the engine speed
“START AIR P LOW” . The alarm indicator exceeds the setting for engine overspeed
illuminates, and an audible alarm is activated. (shutdown), the display will show “F/U FAIL” . The
alarm indicator will flash, and an audible alarm is
“ GENERATOR WINDING OR BEARING OVER activated.
TEMPERATURE ALARM OPTIONAL”” – If the
control module detects a generator bearing over “ SHUTDOWN UNDERSPEED”” – If the engine speed
temperature (warning), the display will show “GEN falls below the setting for engine underspeed
BRG OVER TEMP” . The alarm indicator illuminates, (shutdown), the display will show “F/U FAIL” . The
and an audible alarm is activated. alarm indicator will flash, and an audible alarm is
activated. This warning is only active after the engine
“ EXTERNAL FUEL TANK LEVEL ALARM has exceeded the “Safety On” Timer.
OPTIONAL”” – If the control module detects a low fuel
level in an external fuel tank, the display will show “ SHUTDOWN GENERATOR HIGH FREQUENCY”” –
“EXT FUEL T LOW” . The alarm indicator illuminates, If the control module detects an output frequency for
and an audible alarm is activated. the generator that exceeds the setting for high
generator frequency (shutdown), the display will
SEBU7919-10 51
Operation Section
Control Panel

show “F/U FAIL” . The alarm indicator will flash, and

an audible alarm is activated.
“ SHUTDOWN GENERATOR LOW FREQUENCY”” –
If the control module detects an output frequency for
the generator that is below the setting for low
generator frequency (shutdown), the display will
show “F/U FAIL” . The alarm indicator will flash, and
an audible alarm is activated.
“ GENERATOR HIGH VOLTAGE SHUTDOWN”” – If
the control module detects an output voltage for the
generator that exceeds the setting for high generator
voltage (shutdown), the display will show “HIGH
VOLT S/D” . The alarm indicator will flash, and an
audible alarm is activated.
“ GENERATOR LOW VOLTAGE SHUTDOWN”” – If
the control module detects an output voltage for the
generator that is less than the setting for low
generator voltage (shutdown), the display will show
“LOW VOLT S/D” . The alarm indicator will flash, and
an audible alarm is activated.
“ ELECTRONIC GOVERNOR FAILURE
SHUTDOWN”” – If the control module detects an
electronic governor failure (shutdown), the display
will show “GOV FAIL S/DOWN” . The alarm indicator
illuminates, and an audible alarm is activated.

i06787484

Control Panel
(Premium Control Panel, and
MCS Control Panel)
SMCS Code: 7451

S/N: L1K; S1M

Generator Sets
The premium control panel does not have any
mechanical gauges. The premium control panel and
the MCS control panel have digital displays. The
gauges are included in the electronic control and the
gauges are digital.
52 SEBU7919-10
Operation Section
Premium Control Panel, and MCS Control Panel

Premium Control Panel

Illustration 46 g06121792
Premium control panel
(1) Control module with display (2) Horn (3) Emergency stop button

Premium Control Module With Display(1) – The

control module controls the functions of the generator
set.
Horn (2) – The horn activates when one of the fault
indicators is illuminated. The horn can be silenced by
pressing the alarm silence switch.
Emergency Stop Push Button (3) – The emergency
stop push button (ESPB) is used to shutdown the
engine during an emergency situation. The ESPB
shuts off the fuel.
SEBU7919-10 53
Operation Section
Premium Control Panel, and MCS Control Panel

Premium Control Module With Display

Illustration 47 g06121764
Premium control module with display
(5) UP key (11) Modes select key (17) Stop key (reset)
(6) DOWN key (12) Indicator for the information mode (18) Start key
(7) Display area (13) Indicator for the alarm mode (19) Manual mode key
(8) Programmable indicators (14) Indicator for the engine status mode (20) Automatic mode key
(9) Indicator for alarm (15) Indicator for the generator status mode (21) Lamp test key
(10) Indicator for the configuration mode (16) Indicator for the event log mode

The control module with a display is operated by keys

on the panel. The four keys at the bottom of the Programmable Indicators (8) – The programmable
module (17), (18), (19), and (20) control the starting indicators are available for use by the customer. See
and the stopping of the generator set. Three smaller Systems Operation, RENR5855 for more information
keys (5), (6), and (11) allow the operator to access on programming the indicators.
additional information about the generator set. This
information is shown on the display (7). Alarm Indicator (9) – The alarm indicator lights for
several different reasons. When the alarm indicator is
UP Key (5) – When the UP key is pressed, the ON, the problem is a warning. When the alarm
display area will scroll upward. indicator is flashing, the problem is a shutdown fault.
When any alarm occurs, the display changes to the
DOWN Key (6) – When the DOWN key is pressed, Alarm Mode.
the display will scroll downward.
Operator Configuration Mode Indicator (10) – The
Display Area (7) – The display area shows operation configuration mode indicator illuminates
information about the generator set. when the module is in the configuration mode. When
54 SEBU7919-10
Operation Section
Premium Control Panel, and MCS Control Panel

the UP key and the DOWN key are pressed together, Warnings
the module enters the configuration mode. The
language can be changed. The contrast of the “ WARNING CHARGE ALT FAILURE”” – If the control
display can be adjusted. module does not detect voltage from the alternator,
the display will show “WARNING CHARGE ALT
Mode Select Key (11) – The modes select key FAILURE” . The alarm indicator will illuminate.
changes the mode of the display area. When a mode
is active, the indicator above the appropriate symbol “ WARNING LOW BATTERY VOLTAGE”” – If the
(12), (13), (14), (15), or (16) is illuminated. control module detects voltage from the alternator
that is below the setting for low voltage, the display
Indicator for Information Mode (12) – The will show “WARNING LOW BATTERY VOLTAGE” .
information mode is active when the indicator for The alarm indicator illuminates.
information mode is illuminated. The information
mode is the normal mode for the display area. The “ WARNING HIGH BATTERY VOLTAGE”” – If the
display indicates the status of the generator. An control module detects voltage from the alternator
example is “GENERATOR AT REST” . If the display that is above the setting for high voltage, the display
is in another mode, the display will automatically will show “WARNING HIGH BATTERY VOLTAGE” .
change back to the information mode after a set The alarm indicator illuminates.
period of inactivity. “ FAIL TO STOP”” – If the signal from the oil pressure
Indicator for Alarm Mode (13) – The alarm mode is sender indicates that the engine is running but the
active when the indicator for alarm mode is engine should not be running, the display will show
illuminated. The display shows the information for “FAIL TO STOP” . The alarm indicator illuminates.
any active alarms. An example is “SHUTDOWN LOW The control module can be configured in order for the
OIL PRESSURE” . engine to start only if the signal from the oil pressure
sender indicates that the pressure is low.
Indicator for Engine Status Mode (14) – The
engine status mode is active when the indicator for “ WARNING LOW OIL PRESSURE”” – If the control
engine status mode is illuminated. The display shows module detects engine oil pressure that has fallen
the information regarding the engine. An example is below the setting for low oil pressure (warning), the
“ENGINE SPEED” and “OIL PRESSURE” . display will show “WARNING LOW OIL PRESSURE”
. The alarm indicator illuminates. This warning is only
Indicator for Generator Status Mode (15) – The active after the engine has exceeded the Safety On
generator status mode is active when the indicator Timer.
for generator status mode is illuminated. The display
“ WARNING HIGH COOLANT TEMP”” – If the control
shows the information regarding the generator. An module detects engine coolant temperature that has
example is “GENERATOR VOLTAGE” and exceeded the setting for high coolant temperature
“GENERATOR CURRENT” . (warning), the display will show “WARNING HIGH
Indicator for Event Log Mode (16) – The event log COOLANT TEMP” . The alarm indicator illuminates.
mode is active when the indicator for event log mode This warning is only active after the engine has
is illuminated. The display shows the information exceeded the Safety On Timer.
regarding the last 25 alarms (shutdown). In the “ WARNING OVERSPEED”” – If the engine speed
memory, older alarms are replaced by newer alarms. exceeds the setting for engine overspeed (warning),
Stop/Reset Key (17) – The stop key shuts down the the display will show “WARNING OVERSPEED” .
engine when the engine is running. The alarm indicator illuminates.

Start Key (18) – The start key begins the starting “ WARNING UNDERSPEED”” – If the engine speed is
sequence. The control module must be in the manual below the setting for the engine underspeed
mode in order for the start key to function. (warning), the display will show “WARNING
UNDERSPEED” . The alarm indicator illuminates.
Manual Mode Key (19) – The manual mode key is This warning is only active after the engine has
used to start the generator. After the manual mode exceeded the Safety On Timer.
key is pressed, the generator will be in the manual “ WARNING GENERATOR HIGH FREQUENCY”” – If
mode. In this mode, when the start key is pressed the the control module detects an output frequency for
engine will start. the generator that exceeds the setting for high
Automatic Mode Key (20) – The auto key places the generator frequency (warning), the display will show
generator in the automatic mode. When the “WARNING GENERATOR HIGH FREQUENCY” .
The alarm indicator illuminates.
generator is in the automatic mode, the engine will
start after receiving a signal for remote starting. “ WARNING GENERATOR LOW FREQUENCY”” – If
the control module detects an output frequency for
Alarm Mute Key (21) – The alarm mute key turns off the generator that is below the setting for low
the alarm. generator frequency (warning), the display will show
“WARNING GENERATOR LOW FREQUENCY” .
The alarm indicator illuminates.
SEBU7919-10 55
Operation Section
Premium Control Panel, and MCS Control Panel

“ GENERATOR HIGH VOLTAGE WARNING”” – If the show “SHUTDOWN GENERATOR HIGH

control module detects an output voltage for the FREQUENCY” . The alarm indicator will flash.
generator that exceeds the setting for high generator
voltage (warning), the display will show “ SHUTDOWN GENERATOR LOW FREQUENCY”” –
“GENERATOR HIGH VOLTAGE WARNING” . The If the control module detects an output frequency for
alarm indicator illuminates. the generator that is below the setting for low
generator frequency (shutdown), the display will
“ GENERATOR LOW VOLTAGE WARNING”” – If the show “SHUTDOWN GENERATOR LOW
control module detects an output voltage for the FREQUENCY” . The alarm indicator will flash.
generator that is less than the setting for low
generator voltage (warning), the display will show “ GENERATOR HIGH VOLTAGE SHUTDOWN”” – If
“GENERATOR LOW VOLTAGE WARNING” . The the control module detects an output voltage for the
alarm indicator illuminates. generator that exceeds the setting for high generator
voltage (shutdown), the display will show
“ MAINTENANCE DUE ALARM”” – Maintenance “GENERATOR HIGH VOLTAGE SHUTDOWN” . The
intervals can be programmed into the control module. alarm indicator will flash.
When the hour meter reaches a maintenance setting,
the display will show “MAINTENANCE DUE ALARM” “ GENERATOR LOW VOLTAGE SHUTDOWN”” – If
. The alarm indicator illuminates. the control module detects an output voltage for the
generator that is less than the setting for low
generator voltage (shutdown), the display will show
Shutdowns “GENERATOR LOW VOLTAGE SHUTDOWN” . The
alarm indicator will flash.
“ SHUTDOWN FAIL TO START”” – If the engine does
“ OIL PRESSURE SENDER OPEN CIRCUIT”” – If the
not start after a preset number of attempts, the control module detects an open circuit in the wiring
display will show “SHUTDOWN FAIL TO START” . for the oil pressure sender, the display will show “OIL
The alarm indicator will flash. PRESSURE SENDER OPEN CIRCUIT” . The alarm
indicator will flash. The shutdown is immediate.
“ SHUTDOWN EMERGENCY STOP”” – If the voltage
signal at the input for the emergency stop is “ GENERATOR EARTH FAULT”” – If the control
disconnected, the display will show “SHUTDOWN module detects current that exceeds a limit that has
EMERGENCY STOP” . The generator set will not been programmed and the control module
start until the emergency stop push button has been determines that a short to ground exists, the display
reset. Power is removed from the fuel solenoid and will show “GENERATOR EARTH FAULT” . The alarm
the starter solenoid. The alarm indicator will flash. indicator will flash.
“ SHUTDOWN LOW OIL PRESSURE”” – If the control “ GENERATOR PHASE SEQUENCE WRONG”” – If
module detects engine oil pressure that has fallen the control module detects a problem with the phase
below the setting for low oil pressure (shutdown), the rotation of the generator, the display will show
display will show “SHUTDOWN LOW OIL “GENERATOR PHASE SEQUENCE WRONG” . The
PRESSURE” . The alarm indicator will flash. This alarm indicator will flash.
warning is only active after the engine has exceeded
the Safety On Timer. “ AUXILIARY INPUTS”” – If an auxiliary input has
been configured to shutdown the engine, the display
“ SHUTDOWN HIGH COOLANT TEMP”” – If the will show the message that has been programmed.
control module detects engine coolant temperature The alarm indicator will flash.
that has exceeded the setting for high coolant
temperature (shutdown), the display will show
“SHUTDOWN HIGH COOLANT TEMP” . The alarm
indicator will flash. This warning is only active after
the engine has exceeded the Safety On Timer.
“ SHUTDOWN OVERSPEED”” – If the engine speed
exceeds the setting for engine overspeed
(shutdown), the display will show “SHUTDOWN
OVERSPEED” . The alarm indicator will flash.
“ SHUTDOWN UNDERSPEED”” – If the engine speed
falls below the setting for the engine underspeed
(shutdown), the display will show “SHUTDOWN
UNDERSPEED” . The alarm indicator will flash. This
warning is only active after the engine has exceeded
the Safety On Timer.
“ SHUTDOWN GENERATOR HIGH FREQUENCY”” –
If the control module detects an output frequency for
the generator that exceeds the setting for high
generator frequency (shutdown), the display will
56 SEBU7919-10
Operation Section
Premium Control Panel, and MCS Control Panel

MCS Control Panel

Illustration 48 g06121731

(1) Engine shutdown override switch (2) Emergency stop push button (4) Alarm/Display module
(located inside control box) (3) Warning Lamps
SEBU7919-10 57
Operation Section
Premium Control Panel, and MCS Control Panel

Illustration 49 g06121706
Location label inside the MCS cover
(1) Power supply relay (8) USP service port (15) 10 x terminal blocks
(2) Generator running relay (9) Display screen cable connection (16) 6A diode
(3) Alternator charging relay (10) Battery connection (17) Shutdown override
(4) Circuit breakers (11) 5A fuse (18) Back up start/stop
(5) Capacitor (12) 150 ohm resistor (19) Back up start/stop
(6) End stop terminal (13) 5k ohm resistor
(7) MCS 3 controller (14) Diodes
58 SEBU7919-10
Operation Section
Premium Control Panel, and MCS Control Panel

MCSDisplay

Illustration 50 g06121613

(5) Alarm Indicator (14) Mode key (22) Indicator light for alarm inhibit
(6) Information key (15) Indicator light for control in remote (23) Controller status indicator light
(7) “JUMP” key mode (24) Controller power indicator light
(8) “START” key (16) Menu navigation key for LEFT (25) Menu navigation key forLEFT
(9) “STOP” key (reset) (17) Back Key (26) LOG key
(10) Engine operating indicator (18) Menu navigation for DOWN key (27) VIEW key
(11) Generator status indicator (19) Lamp test (28) Display area
(12) Circuit breaker indicator (20) Select key
(13) Circuit breaker key (if fitted) (21) Menu navigation key forRIGHT

The MCS is operated by keys on the panel. Three

keys (8, 9, and 14) control the starting and the “ START”” Key (8) – The “START” key begins the
stopping of the generator set. Keys 6, 7, 14, 16, 17, starting sequence. The PPU must be in manual
18, 19, 20, 21, 25, 26, and 27 allow the operator to mode in order for the “START” key to function. The
access information about the generator set. This remote indicator light (15) cannot be illuminated. To
information is shown on the display (28). switch off the remote indicator light, press “MODE”
key (14).
Alarm Indicator (5) – A flashing LED indicates that
alarms that have not been acknowledged are still “ STOP”” Key (reset) (9) – The “STOP” key shuts
present. A fixed LED light indicates that all alarms are down the engine when the engine is running.
acknowledged. A RED LED is for Shutdown. A Pressing the “ STOP”” key bypasses the cooldown
GREEN LED is for an Alarm. period.

“ INFO”” Key (6) – The info key shifts the display to Engine operating indicator (10) – Light indicates
show the list of alarms. The list has a maximum of 30 that the generator is running.
alarms.
Generator Status Indicator (11) – This light
“ JUMP”” Key (7) – The “JUMP” key is used to enter a indicates that the voltage and frequency is present
number to select a menu. Every setting has a specific and OK.
number. Use the “JUMP” key to select any setting
and display any setting without navigating all the way “ MODE”” Key (12) – The “MODE” key switches the
through the menus. system between LOCAL START/STOP and
SEBU7919-10 59
Operation Section
Premium Control Panel, and MCS Control Panel

“REMOTE START/STOP” . Light (13) is illuminated Note: Keep a record of the password. If the
for “REMOTE” control. password is forgotten, entering the menus will not be
possible.
Indicator Light for Control In Remote Mode (13) –
The indicator illuminated through operation of Mode Use the following procedure to change the password.
key. (12)
1. Press the “JUMP” key.
Menu key for LEFT (14) – This key moves the
cursor to the left for maneuvering in the menus. 2. Use the Menu key for UP and the Menu key for
DOWN In order to step to channel 4976.
“ BACK”” Key (15) – The “BACK” key jumps one step
backward in the menu to previous display or to the 3. Press the “SEL” key.
entry screen.
Note: The password must be reentered when the
Menu key for DOWN (16) – This key decreases the display has not been used for 3 minutes.
value of the selected set point in the setting menus.
This key is also used for scrolling to the second line
that displays the values for the generator in the Service Menu
display for daily use.
Accessing the Service Menu can only be
“ SEL”” Key (17) – This key is used to select the accomplished by using the “JUMP” key.
function that has been chosen. The function that has
been chosen is the underlined selection in the lower Use the following procedure to access the Service
line of the display. Menu.
Menu key for RIGHT (18) – This key moves the 1. Press the “JUMP” key.
cursor to the right to maneuver in the menus.
2. Use the Menu key for UP and the Menu key for
Indicator Light for “ Alarm Inhibit”” (19) – This light DOWN In order to step to channel 4980.
indicates that the “inhibit input” is on.
3. Press the “SEL” key.
Indicator for Status of the Controller (20) – This
light indicates that the unit is running a self-check and 4. Choose the desired functions, timers, inputs, or
the unit is functioning properly. outputs by moving the cursor and pressing the
“SEL” key.
Power Indicator (21) – This light indicates that the
auxiliary DC battery supply circuit is switched on.
Language Selection
Menu key for UP (22) – This key increases the value
of the selected set point in the setting menus. This The MCS can be configured for the following
key is also used for scrolling to the second line that languages: English, Spanish, German and French.
displays the values for the generator in the display for The language may be chosen when the system is set
daily use. up. The language may be chosen by using the
“JUMP” key.
“ VIEW”” Key (23) – Enter a menu number selection.
All settings have a specific number. The “VIEW” key Use the following procedure to change the language.
enables the user to select any setting. The “VIEW”
key enables the user to display any setting without 1. Press the “JUMP” key.
navigating through all the menus.
2. Use the Navigation Key for UP and the Navigation
“ LOG”” Key (24) – This key shifts the display to the Key for DOWN In order to step to channel 4231.
three lower lines to show the event and a list of
alarms. The list holds 100 events. These events are 3. Press the “SEL” key.
erased when the main unit is switched off.
4. Choose the password by using the Navigation Key
Lamp test switch (25) – The lamp test switch is for UP and the Navigation Key for DOWN and
used to test indicators on the control panel. press the “SEL” key.
Display Area (26) – The display area shows 5. Use the Navigation Key for UP and the Navigation
information about the generator set.
Key for DOWN and select the desired language.
6. Press the “SEL” key.
Setting the Password
Note: The password must be reentered when the
Setting the password can only be accomplished by display has not been used for 3 minutes.
using the “JUMP” key.
60 SEBU7919-10
Operation Section
Premium Control Panel, and MCS Control Panel

Alarms “ WARNING GENERATOR LOW FREQUENCY”” – If

the control module detects an output frequency for
The following steps describe the function of the the generator that is below the setting for low
alarm. generator frequency (warning), the display will show
“F/U FAILURE” . The alarm indicator illuminates, and
1. An alarm occurs. The alarm light starts flashing. an audible alarm is activated.
2. The display automatically shows the alarm “ GENERATOR HIGH VOLTAGE WARNING”” – If the
information. control module detects an output voltage for the
generator that exceeds the setting for high generator
3. Move the cursor to “ACK” and press the “SEL” key voltage (warning), the display will show “OVER
to acknowledge the alarm. Take the necessary VOLTAGE” . The alarm indicator illuminates, and an
action for the alarm. audible alarm is activated.

4. The alarm will disappear when the condition that “ GENERATOR LOW VOLTAGE WARNING”” – If the
control module detects an output voltage for the
caused the alarm is no longer present. generator that is less than the setting for low
5. Alarms that have not been acknowledged are still generator voltage (warning), the display will show
“UNDER VOLTAGE” . The alarm indicator
present if the alarm light flashes. illuminates, and an audible alarm is activated.
6. Use the navigation keys to step through the list of “ LUB OIL HIGH TEMPERATURE ALARM”” – If the
alarms. control module detects a high lube oil temperature
more than 120 degrees celsius for four cylinder
Warnings engines and more than 130 degrees celsius for six
cylinder engines (warning), the display will show
“ WARNING BATTERY VOLTAGE”” – If the control “LUB OIL HIGH” . The alarm indicator illuminates.
module detects voltage from the alternator that is
below the setting for low voltage, the display will “ SHUTDOWN OVERRIDE”” – If the control module
detects an override for engine shutdown and the
show “BATTERY LOW V” . The alarm indicator switch is set to OVERRIDE, the display will show “S/
illuminates, and an audible alarm is activated.
D OVERRIDE” . The alarm indicator illuminates, and
“ FAIL TO STOP”” – If the control module determines an audible alarm is activated.
that the signal from the engine speed sensor
indicates that the engine is running but the engine “ STARTING AIR PRESSURE LOW ALARM
OPTIONAL”” – If the control module detects low
should not be running, the display will show “STOP starting air pressure (warning), the display will show
FAIL” . The alarm indicator illuminates, and an “START AIR P LOW” . The alarm indicator
audible alarm is activated. illuminates, and an audible alarm is activated.
“ WARNING LOW OIL PRESSURE”” – If the control “ GENERATOR WINDING OR BEARING OVER
module detects engine oil pressure that has fallen TEMPERATURE ALARM OPTIONAL”” – If the
below the setting for low oil pressure (warning), the control module detects a generator bearing over
display will show “LOW OIL PRESS” . The alarm temperature (warning), the display will show “GEN
indicator illuminates, and an audible alarm is BRG OVER TEMP” . The alarm indicator illuminates,
activated. This warning is only active after the engine and an audible alarm is activated.
has exceeded the Safety On Timer.
“ EXTERNAL FUEL TANK LEVEL ALARM
“ WARNING HIGH COOLANT TEMP”” – If the control OPTIONAL”” – If the control module detects a low fuel
module detects engine coolant temperature that has level in an external fuel tank, the display will show
exceeded the setting for high coolant temperature “EXT FUEL T LOW” . The alarm indicator illuminates,
(warning), the display will show “HIGH ENGINE and an audible alarm is activated.
TEMP” . The alarm indicator illuminates, and an
audible alarm is activated. This warning is only active “ HIGH EXHAUST TEMPERATURE ALARM
after the engine has exceeded the “Safety On” Timer. OPTIONAL”” – If the control module detects a high
exhaust temperature (warning), the display will show
“ WARNING OVERSPEED”” – If the engine speed “HIGH EXH TEMP” . The alarm indicator illuminates,
exceeds the setting for engine overspeed (warning), and an audible alarm is activated.
the display will show “OVERSPEED” . The alarm
indicator illuminates, and an audible alarm is “ HIGH PRESSURE FUEL LEAK ALARM
activated. OPTIONAL”” – If the control module detects a high-
pressure fuel leak (warning), the display will show “H
“ WARNING GENERATOR HIGH FREQUENCY”” – If P FUEL LEAK” . The alarm indicator illuminates, and
the control module detects an output frequency for an audible alarm is activated.
the generator that exceeds the setting for high
generator frequency (warning), the display will show “ WATER IN FUEL ALARM OPTIONAL”” – If the
control module detects a signal for water in fuel
“F/U FAILURE” . The alarm indicator illuminates, and (warning), the display will show “WATER IN FUEL” .
an audible alarm is activated.
The alarm indicator illuminates, and an audible alarm
is activated.
SEBU7919-10 61
Operation Section
Premium Control Panel, and MCS Control Panel

“ GENERATOR LOW VOLTAGE SHUTDOWN”” – If

the control module detects an output voltage for the
Shutdowns generator that is less than the setting for low
generator voltage (shutdown), the display will show
“ SHUTDOWN FAIL TO START”” – If the engine does “LOW VOLT S/D” . The alarm indicator will flash, and
not start after a preset number of attempts, the an audible alarm is activated.
display will show “F/U FAIL” . The alarm indicator will “ ELECTRONIC GOVERNOR FAILURE
flash, and an audible alarm is activated. SHUTDOWN”” – If the control module detects an
electronic governor failure (shutdown), the display
“ SHUTDOWN EMERGENCY STOP”” – If the voltage will show “GOV FAIL S/DOWN” . The alarm indicator
signal at the input for the emergency stop is illuminates, and an audible alarm is activated.
disconnected, the display will show “E-STOP” . The
generator set will not start until the emergency stop
push button has been reset. Power is removed from
the fuel solenoid and the starter solenoid. The alarm
indicator will flash, and an audible alarm is activated.
“ SHUTDOWN LOW OIL PRESSURE”” – If the control
module detects engine oil pressure that has fallen
below the setting for low oil pressure (shutdown), the
display will show “LOW O P S/DOWN” . The alarm
indicator will flash, and an audible alarm is activated.
This warning is only active after the engine has
exceeded the Safety On Timer.
“ SHUTDOWN HIGH COOLANT TEMPERATURE”” –
If the control module detects engine coolant
temperature that has exceeded the setting for high
coolant temperature (shutdown), the display will
show “HET S/DOWN” . The alarm indicator will flash,
and an audible alarm is activated. This warning is
only active after the engine has exceeded the “Safety
On” Timer.
“ SHUTDOWN OVERSPEED”” – If the engine speed
exceeds the setting for engine overspeed
(shutdown), the display will show “F/U FAIL” . The
alarm indicator will flash, and an audible alarm is
activated.
“ SHUTDOWN UNDERSPEED”” – If the engine speed
falls below the setting for engine underspeed
(shutdown), the display will show “F/U FAIL” . The
alarm indicator will flash, and an audible alarm is
activated. This warning is only active after the engine
has exceeded the “Safety On” Timer.
“ SHUTDOWN GENERATOR HIGH FREQUENCY”” –
If the control module detects an output frequency for
the generator that exceeds the setting for high
generator frequency (shutdown), the display will
show “F/U FAIL” . The alarm indicator will flash, and
an audible alarm is activated.
“ SHUTDOWN GENERATOR LOW FREQUENCY”” –
If the control module detects an output frequency for
the generator that is below the setting for low
generator frequency (shutdown), the display will
show “F/U FAIL” . The alarm indicator will flash, and
an audible alarm is activated.
“ GENERATOR HIGH VOLTAGE SHUTDOWN”” – If
the control module detects an output voltage for the
generator that exceeds the setting for high generator
voltage (shutdown), the display will show “HIGH
VOLT S/D” . The alarm indicator will flash, and an
audible alarm is activated.
62 SEBU7919-10
Operation Section
Engine Starting

Engine Starting • Ensure that any driven equipment has been

disengaged. Minimize electrical loads or remove
any electrical loads.
i04522810

Before Starting Engine

SMCS Code: 1000; 1400; 1450

Engine exhaust contains products of combustion

which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust
to the outside.
Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more
information.
• Before you start the engine, refer to this Operation
and Maintenance Manual, “Walk-Around
Inspection” .
• Before you start the engine, refer to this Operation
and Maintenance Manual, “Engine Oil Level -
Check” for the procedure to ensure that the oil
supply is adequate.
• Ensure that the engine has an adequate fuel
supply.
• Open the fuel supply valve (if equipped).

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

If the engine has not been started for several weeks,

fuel may have drained from the fuel system. Air may
have entered the filter housing. Also, when fuel filters
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
• Do not start the engine if there is a “DO NOT
OPERATE” warning tag or similar warning tag
attached to the start switch.
• Do not move any of the controls if there is a “DO
NOT OPERATE” warning tag or similar warning
tag attached to the controls.
• Reset all of the shutoffs or alarm components.
SEBU7919-10 63
Operation Section
Starting the Engine

i06789491

Starting the Engine

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

Illustration 51 g06121117
PPU Control Panel
(1) Protection and Paralleling Unit (PPU) (2) Horn (3) Emergency Stop Push Button

Protection and Paralleling Unit (PPU) (1) – The Emergency Stop Push Button (3) – The emergency
module controls the functions of the generator set. stop push button (ESPB) is used to shutdown the
engine during an emergency situation.
Horn (2) – The horn activates when a fault (alarm or
shutdown signal) is received by the controller. The
fault is indicated with text on the controller display.
Move the cursor to “ACK” . Press the “SEL” key to
acknowledge the alarm and silence the horn.
64 SEBU7919-10
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Illustration 52 g06121052
MCS Control panel
(1) Emergency stop push button (2) Alarm/Display module (3) Warning lamps

Emergency Stop Push Button (1) – The emergency

stop push button (ESPB) is used to shutdown the
engine during an emergency situation.
Alarm/Display module(2) – The display module
controls the functions of the generator set.
Warning lamps(3) – The alarm module controls the
alarm functions of the generator set.
SEBU7919-10 65
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Illustration 53 g06120730
Location label inside the MCS cover
(1) Power supply relay (7) MCS 3 controller (13) 5k ohm resistor
(2) Generator running relay (8) USP service port (14) Diodes
(3) Alternator charging relay (9) Display screen cable connection (15) 10 x terminal blocks
(4) Circuit breakers (10) Battery connection (16) 6A diode
(5) Capacitor (11) 5A fuse (17) Shutdown override
(6) End stop terminal (12) 150 ohm resistor (18) Back up start/stop
66 SEBU7919-10
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Illustration 54 g06117703
PPU display module
(19) Start key (20) Stop/reset key (21) Mode key
SEBU7919-10 67
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Illustration 55 g06117491
MCS display module
(1) Start Key (2) Stop Key (3) Mode Key

Local Operation If “V3” is selected, the display will indicate the

status in the start/run cycle. The display will show
Use the following procedure to start the engine. “start prepare” and “start relay on” .
1. Turn the power supply for the Generator Set to the a. If the timer (preheat) is configured, then the
ON position. timer (preheat) will be initiated. After the timer
(preheat) has expired, the engine will begin to
The “Power” LED will illuminate immediately. The
“Self check ok” LED will illuminate after a few crank.
seconds. The Generator Set is now ready to start.
Note: When the engine starts, the starting motor is
Line 4 on the display will read “SETUP V3 V2 V1” . disengaged and the starting motor is locked out.

The view that is being displayed is underlined. Use b. If the engine did not start, then the control
the left arrow button and the right arrow button to
module will permit the starting motor to cool
scroll between the 4 screens of the display.
down for a predetermined amount of time. Once
2. Make sure that the “Auto” LED is off. If the “Auto” the cooldown timer has expired, the engine will
LED is on, press the “Mode” key once to crank.
extinguish the “Auto” LED and gain local control.
3. Press the “Start” key.
68 SEBU7919-10
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Note: The “Failed to Start” fault will be displayed in Note: When the engine starts, the starting motor is
“V3” after 3 failed attempts to start the engine. The disengaged and the starting motor is locked out.
“Alarm” LED indicator will flash. If the
aforementioned event occurs, move the cursor to b. If the engine did not start, then the control
“ACK” and press the “SEL” key to reset the alarm. module will permit the starting motor to cool
Determine the reason that the engine failed to start down for a predetermined amount of time. Once
before making further attempts.
the cooldown timer has expired, the engine will
crank.
c. After the engine has started, the timer (safety) is
activated, unless the timer has been set to 0. Note: The “Failed to Start” fault will be displayed in
This function allows the engine to warmup so “V3” after 3 failed attempts to start the engine. The
that no faults will occur. Once the timer (safety) “Alarm” LED indicator will flash. If the
has expired, fault protection is available. The aforementioned event occurs, move the cursor to
generator load may now be applied to the “ACK” and press the “SEL” key to acknowledge the
engine. alarm. Determine the reason that the engine failed
to start before making further attempts.
4. To stop the engine, open the circuit breaker and
remove the load from the generator. Press and c. After the engine has started, the timer (safety) is
release the “STOP” key. activated.
Note: Pressing the “Stop” key will bypass the This function allows the engine to warmup so
cooldown period. that no faults will occur. Once the timer
(safety) has expired, fault protection is
available.
Remote Operation
d. The PPU will automatically apply the generator
Use the following procedure to start the engine. load. The PPU will synchronize the generator
1. Turn the power supply for the Generator Set to the with other generators that are operating in
ON position. parallel. The PPU will bring the generator on the
line after the generator is synchronized.
The “Power” LED will illuminate. The “Self check
ok” LED will illuminate after a few seconds. The 4. To stop the engine, open the circuit breaker and
generator set is now ready to start. remove the load from the generator.
Line 4 on the display will show “SETUP V3 V2 V1”
. Engine Shutdown Override Switch
The view that is displayed is underlined. Use the
left arrow button and the right arrow button to
scroll between the 4 screens of the display.
2. Ensure that the “Remote” LED is on.
If the “Remote” LED is off, press the “Mode” key
once and illuminate the “Remote” LED to gain
remote control of the genset.
3. Initiate a remote start on the customer connection.
Initiating a remote start on the customer
connection would be done with a remote mounted
switch on the vessel.
Note: If “V3” is selected, the display will indicate the
status in the start/run cycle. The display will read
“start prepare” and “start relay on” .

a. If the timer (preheat) is configured, the timer

(preheat) will be initiated.
After the timer (preheat) has stopped timing,
the engine will begin cranking. Illustration 56 g06116597
MCS
(1) Engine shutdown override switch (located inside control box)
SEBU7919-10 69
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Personal injury or death can result from high

voltage.
When power generation equipment must be in
operation to make tests and/or adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
The engine shutdown override switch is located in
the electrical box for the controller. The automatic
shutdown system may be disabled if the unit is used
in emergency situations. When the generator set is in
this mode, any fault will give an indication but the
fault will not stop the engine.
Turn the latch for the cover on the electrical box to
open the electrical box and access the override
switch.
Enable the shutdown on the MCS controller by
turning the switch to A. Disable the shutdown by
turning the switch to B.
70 SEBU7919-10
Operation Section
Engine Operation

Engine Operation
i04521149

Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors in
obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
The time that is needed for the engine to reach
normal operating temperature can be less than the
time taken for a walk-around inspection.
The engine can be operated at the rated rpm after
the engine is started and after the engine reaches
operating temperature. The engine will reach normal
operating temperature sooner during a low engine
speed (rpm) and during a low-power demand. This
procedure is more effective than idling the engine at
no load. The engine should reach operating
temperature in a few minutes.
Gauge readings should be observed and the data
should be recorded frequently while the engine is
operating. Comparing the data over time will help to
determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
SEBU7919-10 71
Operation Section
Engine Operation

Cooling System

Illustration 57 g01232494

(1) Header tank assembly (remote mounted) (4) Adaptor (7) Hose
(2) Hose (PVC) (5) Hose end-push in (8) Hose clip
(3) Plug (6) Hose (9) -T- Fitting
72 SEBU7919-10
Operation Section
Engine Operation

Illustration 58 g01232466

Illustration 59 g01232483

Keel-Cooled Engine with an

Aftercooler
Note: The cooling system for the generator set is a
keel-cooled system which uses engine coolant.
SEBU7919-10 73
Operation Section
Engine Operation

Illustration 60 g01230513
Turbocharged
(1) Aftercooler (5) Exhaust manifold (9) Fresh water pump
(2) Purge line (6) Engine (10) Auxiliary water pump
(3) Purge line (7) Water temperature regulator housing (11) Keel cooler
(4) Remote tank (8) Engine oil cooler (12) Keel cooler for aftercooler

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

• Exhaust manifold (5)

• Cylinder head
74 SEBU7919-10
Operation Section
Fuel Conservation Practices

The coolant flows forward through the cylinder head • Keep keel coolers, heat exchangers, and water
and into water temperature regulator housing (7). If pumps clean. Keep the components in good
the water temperature regulator is closed, the coolant repair.
goes directly through a bypass to the inlet side of
water pump (9). If the water temperature regulator is • Ensure that all of the accessory pumps are
open, the bypass is closed and the coolant flows to repaired. The pumps should operate efficiently.
keel cooler (11) in order to be cooled. After the
coolant flows through the keel cooler, the coolant is • Do not exceed the maximum oil level.
mixed with coolant that is returning from exhaust
manifold (5). • Never operate without water temperature
regulators.
An auxiliary water pump (10) is also used in order to
supply coolant flow to aftercooler (1). The coolant Water temperature regulators regulate the
flows through the aftercooler in order to cool the hot temperature of the coolant. Water temperature
inlet air. From the aftercooler, the coolant flows to a regulators help to provide efficient operating
second keel cooler (12) in order to be cooled. temperatures. Cold engines consume excessive fuel.
Water temperature regulators also help prevent
i02305196 engine overheating.

Fuel Conservation Practices

SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life of
the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. The fuel lines should be repaired if there is
evidence of failure.
• Be aware of the properties of the different fuels.
Use only the recommended fuels.

• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods of
time.
• Observe the service indicator frequently. Keep the
air cleaner elements clean.
• Ensure that the turbochargers are operating
correctly so that the proper air/fuel ratio is
maintained. Clean exhaust indicates proper
functioning.
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator.
This will consume excess power and excess fuel.
• Ensure that the belts are properly adjusted. The
belt should be in good condition.

• Ensure that all of the connections of the hoses are

tight. The connections should not leak.
SEBU7919-10 75
Operation Section
Generator Operation

Generator Operation
i02290569

Generator Operation
SMCS Code: 4450

Loading of the Generator

When a generator is installed or reconnected, be
sure that the total current in one phase does not
exceed the nameplate rating. Each phase should
carry the same load. This allows the engine to work
at the rated capacity. An electrical unbalance can
result in an electrical overload and overheating if one
phase current exceeds the nameplate amperage.
Allowable combinations of unbalanced loads are
shown in Illustration 61 . 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 61 g00627416
Allowable Combinations of Unbalanced Loads

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

• Engine transient response

• Voltage regulator response

• Type of the voltage regulator

• Altitude of operation of the generator set

• Type of load
• The amount of load
76 SEBU7919-10
Operation Section
Generator Operation

If derating is required in order to block load, refer to Note: The Caterpillar generators are rated at a power
ISO 3046 or SAE J1349 Standards. Also, reference factor of 0.8 unless the generator is specified
Engine Data Sheet, LEKX4066, “Loading Transient otherwise.
Response” and Engine Data Sheet, LEKX4067,
“Block and Transient Response”.
Excitation System
Note: ISO stands for International Standards
Organization. The generator uses the AREP excitation system.
This system does not use a permanent magnet. The
voltage regulator is powered by two auxiliary
Power Factor windings. These windings are independent of the
circuit for detecting voltage. The first winding is
The power factor is the ratio of apparent power to labelled as “X1” and “X2” . This winding has a voltage
total power. The power factor is expressed as a that is proportional to the output voltage of the
decimal. The power factor represents that portion of generator. The second winding is labelled as “Z1”
the current which is doing useful work. The portion of
and “Z2” . This winding has a voltage that is
current which is not doing useful work is absorbed in proportional to the current of the stator. The voltage
maintaining the magnetic field in motors or other
from the power supply is rectified and filtered before
devices. This current is called the reactive load. This being used by the regulator monitoring transistor.
current does not require engine power to be
maintained. This principle ensures that regulation is not affected
by interference that is generated by the load.
In most applications, electric motors and
transformers determine the power factor of the Standby Electric Sets
system. Induction motors usually have a power factor
of 0.8 or less. Incandescent lighting is a resistive load Most standby units are installed with controls for
of about 1.0 power factor, or unity. automatic starting. Standby units start without an
The power factor of a system may be determined by operator in attendance.
a power factor meter or by calculations. Determine Standby units can not automatically change the
the power requirement in kW by multiplying the governor speed. Standby units can not automatically
power factor by the kVA that is supplied to the change the setting of the voltage level. The governor
system. As the power factor goes up, the total current speed and voltage level must be preset for the proper
that is supplied to a constant power demand will go operation of that unit. Whenever the generator is
down. A 100 kW load that is at 0.8 power factor will operated manually, ensure that the settings for
draw more current than a 100 kW load that is at 0.9
power factor. A high power factor will result in a full governor speed and voltage level are correct for
engine load at less than the generator rated automatic operation. Check all switches on the
amperage. A lower power factor increases the Standard Control Panel for the proper setting. Check
possibility of overloading the generator. all push buttons on the Premium Control Panel for
the proper setting. On the Standard Control Panel,
the Start Selector Switch should be in the
AUTOMATIC position. On the Premium Control
Panel, the “AUTO” push button is pressed.

Generator Options
Battery Disconnect Switch
This switch is a single-pole switch. This switch
cannot be used with dual electric starters.

Space Heaters
The generator can be equipped with space heaters.
The space heater is installed for operation in high
humidity conditions. 120 volt and 240 volt space
heaters are available.

Radio Frequency Interference (RFI) Filter

This filter is available for applications that require a
filter.
SEBU7919-10 77
Operation Section
Generator Lead Connections

Instrumentation
Three different remote start/stop panels are
available. Extensions for the wiring harness are Accidental engine starting can cause injury or
available in order to mount the panels. Contact your death to personnel working on the equipment.
Caterpillar dealer for more information. To avoid accidental engine starting, disconnect
the battery cable from the negative (−) battery ter-
i06249761 minal. Completely tape all metal surfaces of the
disconnected battery cable end in order to pre-
Generator Lead Connections vent contact with other metal surfaces which
could activate the engine electrical system.
SMCS Code: 4450
Place a Do Not Operate tag at the Start/Stop
switch location to inform personnel that the
equipment is being worked on.
DANGER: Shock/Electrocution Hazard-Do not
operate this equipment or work on this
equipment unless you have read and understand Grounding the Frame
the instructions and warnings in the Operation
and Maintenance Manual. Failure to follow the In any generator set installation, the frame of the
instructions or heed the warnings will result in
generator must be positively connected to an earth
serious injury or death.
ground. This connection is the first connection that is
made at the installation. This connection is the last
connection that should be removed. If the generator
set is on flexible mounting pads, the ground
connection must be flexible in order to avoid possible
Personal injury or death can result from high breakage in later operation.
voltage.
Ground connection cable or straps should have at
When power generation equipment must be in least the current carrying capacity of the largest line
operation to make tests and/or adjustments, high lead to the connected load. Joints in cables or straps
voltage and current are present. must be clean, free of electrical resistance, and
protected from possible oxidation. Bolted ground
Improper test equipment can fail and present a connection joints eventually oxidize. The joints are
high voltage shock hazard to its user. frequent sources of radio frequency interference
(RFI). Joints that are silver soldered and bolted are
Make sure the testing equipment is designed for preferred.
and correctly operated for high voltage and cur-
rent tests being made. Neutral Connections
When servicing or repairing electric power gener-
ation equipment: The generators with a Wye Configuration usually
have the neutral ground when the generator is
• Make sure the unit is off-line (disconnected installed. Grounding the neutral is for preventing
from utility and/or other generators power damage to equipment.
service) , and either locked out or tagged DO If the neutral wire is grounded and one of the phase
NOT OPERATE. leads becomes grounded, the excessive current will
open a load circuit breaker. Also, the excessive
• Remove all fuses. current will cause the generator voltage to collapse.
The result depends on the following items: electrical
• Make sure the generator engine is stopped. characteristics of the generator , type of fault and trip
rating of the circuit breaker. An undervoltage device
• Make sure all batteries are disconnected. may be required in order to provide an adequate
short circuit protection.
• Make sure all capacitors are discharged.
Failure to do so could result in personal injury or
death. Make sure residual voltage in the rotor,
stator and the generator is discharged.
78 SEBU7919-10
Operation Section
Generator Lead Connections

There are some cases when the neutral wire is not Wiring Code A for Three-Phase
grounded. An ungrounded generator neutral lead is
acceptable when the possibility of grounds to the
Configuration
phase leads has been eliminated. An example of
such measures is a ground fault protective circuit.
Ground fault protection requires the entire group of
distribution circuits to be treated as a system. The
owner should contact a certified consultant if a new
distribution system is being developed. The owner
should also contact a certified consultant if an
existing system should be modified for the ground
fault protection.

Single Units
Each unit should be connected to a common ground.
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
Be sure to check your local wiring codes.

Connection Diagrams

Illustration 63 g00952030

Illustration 62 g01154944
The generator lead connections are located in the
terminal box on the generator.

The generator lead connections are located in the Illustration 64 g00952058

terminal box on the generator or in the enclosure for Factory connection for “A” wiring code
the control panel.
Table 2
Change the position of the wire terminals in order to
L-L Voltage for Wiring Code A
modify the connection. The code for the winding is
specified on the nameplate. Winding 50 Hz 60 Hz

6 190-208 190-240
7 220-230 -

8 - 190-208
SEBU7919-10 79
Operation Section
Generator Lead Connections

R 220 voltage sensing – 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing – 0 => (T3) / 220 V =>
(T2)

Wiring Code B for Single-Phase

Configuration or Three-Phase
Configuration

NOTICE
This configuration is not possible for LSA 44.2 gener-
ator models.

Illustration 65 g00952097

Illustration 66 g00952196
Factory connection for “B” wiring code

Table 3
L-L Voltage for Wiring Code B

Winding 50 Hz 60 Hz

6 110-120 120
7 120-130 -

8 - 110-120

R 220 voltage sensing – 0 => (T8) / 110 V => (T11)

80 SEBU7919-10
Operation Section
Generator Lead Connections

R 438 LS voltage sensing – 0 => (T3) / 110 V => Table 4

(T2) L-L Voltage for Wiring Code D

Winding 50 Hz 60 Hz
Wiring Code D for Three-Phase
6 380-415 380-480
Configuration
7 440-460 -

8 - 380-416

R 220 voltage sensing – 0 => (T8) / 110 V => (T11)

R 438 LS voltage sensing – 0 => (T3) / 380 V =>
(T2)

Wiring Code F for Single-Phase

Configuration or Three-Phase
Configuration

Illustration 67 g00952201

Illustration 69 g00952381
Voltage LM equals one half of voltage LL.

Illustration 68 g00952365
Factory connection for “D” wiring code
SEBU7919-10 81
Operation Section
Generator Lead Connections

Illustration 70 g00952390 Illustration 72 g00952430

Factory connection for “F” wiring code Factory connection for “FF” wiring code

Table 5 Table 6
L-L Voltage for Wiring Code F L-L Voltage for Wiring Code FF

Winding 50 Hz 60 Hz Winding 50 Hz 60 Hz

6 220-240 220-240 6 220-240 220-240

7 250-260 - 7 250-260 -

8 200 220-240 8 200 220-240

R 220 voltage sensing – 0 => (T8) / 110 V => (T11) R 220 voltage sensing – 0 => (T1) / 110 V => (T4)
R 438 LS voltage sensing – 0 => (T3) / 220 V => R 438 LS voltage sensing – 0 => (T10) / 220 V =>
(T2) (T1)

Wiring Code FF for Single-Phase

Configuration

Illustration 71 g00952416
Voltage LM equals one half of voltage LL.
82 SEBU7919-10
Operation Section
Single Unit Operation

Connections for Exciter Field R 791 T Interference Suppression

Connections for Series (SHUNT)

Illustration 75 g00953025
Connect the interference suppression, as shown.
Illustration 73 g03871392 The letters in the circles represent the wiring codes
(WHT) White for the generators.
(BLU) Blue (BLK) Black
(BLK) Black (BLU) Blue
(RED) Red (WHT) White
(A) Wiring code “A”
Parallel Connection for Auxiliary Winding (B) Wiring code “B”
Regulation Excitation Principle (AREP) and (D) Wiring code “D”
(F) Wiring code “F”
Permanent Magnet Generator (PMG) (FF) Wiring code “FF”

i02292263

Single Unit Operation

SMCS Code: 4450

Initial Start-Up
Measure the insulation resistance of each winding if
the generator was exposed to the following
conditions:
• Rapid changes in temperature

• Freezing
Illustration 74 g01147978
(WHT) White
• Wet climate during shipment
(BLU) Blue
(BLK) Black • Wet climate during storage
(RED) Red
Refer to this Operation and Maintenance Manual,
“Insulation - Test”.
Note: These tests should be conducted prior to any
power connections or control connections that are
being made.

Starting
1. Make all preliminary engine starting checks.
2. Be sure that the main circuit breaker or the line
circuit breaker is open.
SEBU7919-10 83
Operation Section
Parallel Operation

3. Start the engine. Allow the engine to warm up. 11. Turn potentiometer (P4) slowly counterclockwise
until there is a significant voltage drop. The
4. Adjust to the full load engine speed.
voltage drop should be approximately 15 %.
5. Close the main circuit breaker.
12. Vary the frequency around 48 Hz or 58 Hz
6. Apply the load. Do not try to apply the full load. according to the operating frequency. Check the
Apply the load in increments in order to maintain change in the voltage that was previously
system frequency at a constant level. observed.
7. Readjust the governor for rated frequency.
Stopping
Adjust the Voltage 1. Remove the load in increments.
Adjust the voltage regulator in order to obtain the 2. Open the circuit breaker.
proper voltage. Refer to Operation and
Maintenance Manual, “Voltage Regulators” for 3. Allow the engine to run for five minutes in order to
more information about the voltage regulator. cool.
1. Turn the remote adjustment potentiometer to the 4. Stop the engine.
center position, if equipped.
i02668538
2. Connect an analog voltmeter that is calibrated for
100 VDC on terminal E+ and terminal E-. Parallel Operation
3. Connect a voltmeter that is calibrated for 300 VAC SMCS Code: 4450
to 500 VAC or 1000 VAC to the output terminals of
the generator.
Initial Start-Up
4. Make sure that the ST3 wire is positioned on the
desired frequency. Also, the engine speed must be Preparing a generator for parallel operation requires
changed from the factory setting in order to special attention. Before you attempt to parallel units
for the first time, check all the units for the following
change the frequency of the generator. three conditions.
5. Turn voltage potentiometer (P2) to a full
• Same phase rotation
counterclockwise position.
6. Turn frequency potentiometer (P4) to a full • Same alternating current frequency
clockwise position. • Same voltage adjustment
7. Turn stability potentiometer (P3) counterclockwise
to about 1/3 of the total rotation for the 1. Check the phase rotation.
potentiometer. Units that operate in parallel must have the same
8. Start the engine and set the engine speed to a phase rotation. There are two methods that may
be used in order to determine if the incoming unit
frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz. and the unit that is on-line have the same phase
9. Adjust the output voltage to the correct value with rotation. These methods are listed below:
potentiometer P2. This voltage should be the rated
• Using a phase rotation meter
voltage UN for single operation or UN plus 2% to
4% for parallel operation with a current • Using a set of three light bulbs
transformer. Use potentiometer P3 to make
adjustments if the voltage oscillates. Adjust Use the procedure below to determine the proper
potentiometer P3 in both directions while you phase rotation by using three light bulbs.
observe the voltage between E+ and E-. The
voltage between E+ and E- should be
approximately 10 VDC. The best response times
are obtained at the limit of the instability. Try
cutting or replacing the wire ST2 if no stable
position can be obtained.
10. Check the LAM operation. ST5 must be closed.
84 SEBU7919-10
Operation Section
Parallel Operation

b. Adjust the governor control in order to give the

rated frequency at full load.

c. Remove the load and check the high idle speed.

The high idle speed should be approximately 2
to 5 percent above full load speed for governors
that are equipped with droop. If these speeds
can not be obtained, contact your Caterpillar
dealer.
d. For the most consistent results, repeat 2.b and
2.c until the second condition of “Initial Start-Up”
has been met.
3. Adjust the voltage.The potentiometers should be
Illustration 76 g00695380
at the initial settings. Refer to Operation and
Maintenance Manual, “Voltage Regulators”.
Note: Make sure that the speed droop is identical
When servicing or repairing electric power gen- for all of the engines before adjustments are made
eration equipment: to the generator.
Make sure the unit is off-line (disconnected
from utility and/or other generators power serv- a. Preset the unit for parallel operation by
ice), and either locked out or tagged DO NOT connecting the current transformer to S1 and S2
OPERATE. Remove all fuses. of the connector J2. Set potentiometer P1 for
quadrature droop in the center position. Apply
a. Connect the light bulbs with rated voltage the rated load. The voltage should drop for 2%
between the generator leads and the to 3%. Switch the positions of the two incoming
corresponding line phase. For example, connect secondary wires of the current transformer if the
terminal 1 to line 1 across the open circuit voltage increases.
breaker.
b. The no-load voltages should be identical for all
b. Start the units that will be in operating in the generators that are operating in parallel.
parallel. Bring the units up to speed. As the units Connect the generators in parallel. Try to obtain
approach the same speed, the lights will start to a 0 kW power exchange by adjusting the speed
blink. of the generator. Try to minimize the circulating
currents between generators by altering the
• If the lights blink in sequence, one of the
voltage setting with potentiometer P2 or Rhe on
units is connected backward. In order to
one of the generators.
correct the problem, stop the units. Remove
generator leads 1 and 3 at the circuit Note: Do not change the voltage settings after
breaker. Exchange these generator leads. this step.
This reverses the direction of phase
rotation. Terminal 2 should always be c. Apply the available load. The setting is correct
connected to line 2. Go to 5. only if a reactive load is available. Equalize the
Kilowatts or divide the rated power of the units
• Both generators have the same phase proportionally by altering the speed. Alter the
rotation when the lights blink in unison. The
first condition of “Initial Start-Up” has been
met.

2. Adjust the frequency.

The units that will be operating in parallel must
operate at the same speed. Speed is proportional
to the alternating current frequency.

a. Allow each electric set to run under load for

about 30 minutes.
SEBU7919-10 85
Operation Section
Parallel Operation

quadrature droop potentiometer (P1) in order to 7. Generator temperature will be stabilized in

equalize the currents or divide the currents. approximately one hour. After the generator
temperature has been stabilized, adjust the
Starting Multiple Units voltage droop rheostat of each generator. This will
share the reactive load and this will limit the
Use the procedure for starting single units in order to circulating currents. Less droop increases the
start multiple units. Refer to Operation Section, reactive current that is carried by the generator.
“Single Unit Operation”. Adjusting the voltage droop rheostat in a
counterclockwise direction will decrease the
Paralleling Multiple Units droop. Adjusting the voltage droop rheostat in a
clockwise direction will increase droop.
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 Load Division and Speed Droop (If
following requirements: Equipped)
• One of the governors can be an isochronous
Once two units have been paralleled, the unit's share
governor. Electronic load sharing governors are of the kW load is determined by the governor control
an exception. setting. If two units of the same capacity and the
same governor characteristics have the same
• Generators must have voltage droop governor control settings, the units will share the load
compensation or cross current compensation. equally. The total load must not exceed the capacity
of the one engine.
1. Start the unit which will be paralleled.
In order to transfer the load from one engine to
2. Turn on the synchronizer lights. another engine, use the following procedure:
3. After the engine has run a few minutes, bring the 1. Increase the governor speed control of one unit in
engine up to synchronous speed. This means that order to increase the load.
the frequency of the incoming unit will be the same
frequency as the unit that is on-line. The 2. Reduce the governor speed control of the other
synchronizing lights will begin to blink. unit in order to decrease the load on that unit.

Note: The frequency of the incoming unit should be 3. Raise the governor speed control or lower the
slightly greater than the line frequency. This will allow governor speed control of both units in order to
the incoming unit to assume some of the load instead change system frequency.
of adding to the system load.
Parallel Operation Of Governors
4. By using the governor control, adjust the engine
speed until the lights blink very slowly.
5. The lights are off when the voltages of the two
units are in-phase. At this point, very quickly close
the breaker while the lights are out.
6. Use governor controls in order to share kW load
between engines.

Illustration 77 g00630841
Load Sharing Module (Typical Example)
86 SEBU7919-10
Operation Section
Parallel Operation

The generator set load sharing module provides • Each governor should have a three percent speed
either the droop load sharing or the isochronous load droop in order to provide the simplest combination
sharing for parallel applications. The load sharing of governors for electric sets that are connected in
module has a synchronizing parallel module SPM-A parallel. If a constant frequency from no load to full
input. The module provides the proportional load load is required, one governor can be adjusted for
sharing. More information is available in the System isochronous operation. This isochronous unit will
Operation, Testing and Adjusting, SENR6565, be called a “lead unit” .
“Generator Set Load Sensor and Generator Load
Sharing Module”. • In order for all paralleled units to accept the full
share of the load, the following governor
Function of The Engine Governor adjustments are required. The governors should
have the same full load speed. The governors
This section describes the function of the engine should have the same high idle speed in the case
governor in relation to load division between parallel of governors which are adjusted for speed droop
electric sets.
operation. Governor controls should be set to the
It is very important to understand two basic facts high idle position so that the full range of the
about load division between generator sets which are governor is available.
operating in parallel.
• Operating an isochronous governor in parallel with
1. The power which is supplied to the generator and a speed droop governor requires special
to the load is a function of the engine. The setting techniques.
of the engine governor and the position of the
engine governor control determine the amount of • Any number of electric sets can be operated in
power that is delivered by the engine. Therefore, parallel. However, only one governor of the group
can be adjusted for isochronous operation. The
the governor setting and the position of the
exception will be some special cases of electronic
governor control determine the kW load which is governors with automatic load sharing.
carried by the generator. A change in the engine
power of any one of the units in a parallel
operation will result in the same change in engine
Stopping
power for each of the other units in that parallel In order to remove a generator from the line, perform
operation. In other words, the units that are in the following procedure.
parallel operation will stay in parallel operation.
1. Check the load. The load must be less than the
2. The division of power is not determined by rated capacity of the remaining units.
generator excitation or terminal voltage. The
excitation will determine the power factor for a 2. Be sure that the neutral of one of the remaining
generator when the generator is operating in units is grounded.
parallel with other generators. 3. Remove the load from the outgoing unit. See the
Governors that are used with Caterpillar powered Parallel Operation, “Load Division - Speed Droop”.
electric sets can be of two types: The amperage may never go to zero due to
circulating currents.
• Governors with fixed speed droop
4. Open the circuit breaker.
• Governors with adjustable speed droop 5. Allow the engine to cool for five minutes.
The values of speed droop which are commonly used 6. Stop the engine.
are 3 percent and 0 percent. Governors with
adjustable speed droop can be adjusted so the
characteristics match closely with the characteristics Circulating Currents
of governors with fixed speed droop. If the governor
is adjusted for 0 percent speed droop or isochronous Understanding the circulating currents becomes very
operation, then the same speed from no load to full important when you parallel the units. These
load can be obtained. circulating currents are flowing between generators
in parallel operation. The circulating currents are
Summary on Governor Operation caused by voltage differences between the
generators. The circulating currents are not doing
The preceding discussion of governor operation can useful work. The amount of the circulating current
be summarized below: can be determined by subtracting the amperage
which is going to the load from the total generator
amperage.
SEBU7919-10 87
Operation Section
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 Accidental engine starting can cause injury or
total generator current should not exceed the death to personnel working on the equipment.
amperage rating.
To avoid accidental engine starting, disconnect
As the generators warm, the circulating currents will the battery cable from the negative (−) battery ter-
decrease. The ammeter readings should decrease minal. Completely tape all metal surfaces of the
slightly, but the voltage meter readings should remain disconnected battery cable end in order to pre-
constant.
vent contact with other metal surfaces which
could activate the engine electrical system.
i05318299
Place a Do Not Operate tag at the Start/Stop
Voltage Regulators switch location to inform personnel that the
equipment is being worked on.
SMCS Code: 4467
The voltage regulator is located in the terminal box
on the generator.

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.

Personal injury or death can result from high

voltage.
When power generation equipment must be in
operation 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- Illustration 78 g01155079
rent tests being made. The voltage regulator is located in the terminal box
on the generator.
When servicing or repairing electric power gener-
(1) Terminal Box on the Generator
ation equipment:
• Make sure the unit is off-line (disconnected The voltage regulator is powered by two auxiliary
from utility and/or other generators power windings. These windings are independent from the
circuit for detection of voltage. The first winding is
service) , and either locked out or tagged DO
Labeled as “X1” and “X2” . This winding has a
NOT OPERATE. voltage that is proportional with the output voltage of
the generator. The second winding is Labeled as “Z1”
• Remove all fuses.
and “Z2” . This winding has a voltage that is
• Make sure the generator engine is stopped. proportional to the current of the stator. The voltage
from the power supply is rectified and filtered before
• Make sure all batteries are disconnected. being used by the regulator monitoring transistor.
This principle ensures that regulation is not affected
• Make sure all capacitors are discharged. by interference that is generated by the load.

Failure to do so could result in personal injury or

death. Make sure residual voltage in the rotor,
stator and the generator is discharged.
88 SEBU7919-10
Operation Section
Voltage Regulators

These voltage regulators may have an optional

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

R438 Adjustments
NOTICE
ST9 must be closed for AREP excitation.

Table 7
R438 Automatic Voltage Regulator

Maximum current for short 3 x In for 10 seconds

circuit
Standard power supply Two auxiliary windings

Supply for shunt max 48 VAC at 50/60 Hz

Rated overload current 8 amperes for 10 seconds

Electronic protection for over- Excitation ceiling current for 10

load and short circuit opening seconds and return to approxi-
on voltage sensing mately 1 ampere
THE GENERATOR MUST BE
STOPPED IN ORDER TO RE-
SET THE PROTECTION.
Fuse “F1” on input side “X1” and “X2”

Fuse “F2” on output side “E+” and “E-”

Voltage sensing 5 VAC that is isolated by the

transformer
Terminals for 0 to 110 VAC 95 to 140 VAC
Terminals for 0 to 220 VAC 170 to 260 VAC
Terminals for 0 to 380 VAC 340 to 520 VAC
Voltage regulation ±1%

Rapid response time or normal response time from the location of

jumper “ST2”

Voltage adjustment via potentiometer “P2” (other voltages via the

step down transformer)

Underspeed protection and adjustment of frequency threshold via

potentiometer “P4”

Maximum adjustment for excitation via potentiometer “P5” (4.5 to

10 amperes)

50 Hz or 60 Hz selection with jumper “ST3” (1).

(1) The engine speed setting must be changed in order to change
the frequency of the generator set.
SEBU7919-10 89
Operation Section
Voltage Regulators

Illustration 79 g00952512
R438 Voltage Regulator
90 SEBU7919-10
Operation Section
Voltage Regulators

10. Turn potentiometer (P4) slowly counterclockwise

until there is a significant voltage drop. The
voltage drop should be approximately 15 %.
11. Vary the frequency of both parts between 48 Hz
or 58 Hz according to the operating frequency.
Check the change in the voltage that was
previously observed.
Use the following procedure in order to run the
generator set in parallel operation.
1. Preset the unit for parallel operation by connecting
the current transformer to S1 and S2 of the
connector J2. Set potentiometer P1 for quadrature
Illustration 80 g01153904 droop in the center position. Apply the rated load.
R438 power supply connections for AREP excitation The voltage should drop for 2% to 3%. Switch the
(YEL) Yellow positions of the two incoming secondary wires of
(RED) Red the current transformer if the voltage increases.
(GRN) Green
(BLK) Black 2. The no-load voltages should be identical for all the
(AUX) Auxiliary Windings generators that are operating in parallel. Connect
(EX) Exciter Field
the generators in parallel. Try to obtain a 0 kW
Use the following procedure to adjust the R438 power exchange by adjusting the speed of the
voltage regulator. generator. Try to minimize the circulating currents
between generators by altering the voltage setting
1. Remove wire ST4. with potentiometer P2 or Rhe on one of the
2. Connect an analog voltmeter that is calibrated for generators.
50 VDC on terminal E+ and terminal E-.
Note: Do not change the voltage settings after
3. Connect a voltmeter that is calibrated for 300 VAC this step.
to 500 VAC or 1000 VAC.
4. Turn potentiometer (P2) to a full counterclockwise
position.
5. Turn potentiometer (P4) to a full clockwise
position.
6. Turn potentiometer (P3) counterclockwise to about
1/3 of the total rotation for the potentiometer.
7. Start the engine and set the engine speed to a
frequency of 48 Hz for 50 Hz or 58 Hz for 60 Hz.
8. Adjust the output voltage to the correct value with
potentiometer P2. This voltage should be the rated
voltage UN for single operation or UN plus 2% to
4% for parallel operation. Use potentiometer P3 to
make adjustments if the voltage oscillates. Adjust
potentiometer P3 in both directions while you
observe the voltage between E+ and E-. The
voltage between E+ and E- should be
approximately 10 VDC. The best response times
are obtained at the limit of the instability. Try
cutting or replacing the wire ST2 if no stable
position can be obtained.
9. Check the LAM operation. ST5 must be closed.
SEBU7919-10 91
Operation Section
Voltage Regulators

3. Apply the available load. The setting is correct only 1. Open switch D. The excitation current should
if a reactive load is available. Equalize the increase up to the preset maximum value and the
Kilowatts or divide the rated power of the units excitation current should remain at the preset
proportionally by altering the speed. Equalize or maximum value for approximately 10 seconds.
divide the currents by altering the quadrature The current will decrease to less than 1 Amp.
droop potentiometer.
2. Open switch A in order to reset the internal
protection.
R438 Adjustment for Maximum
Excitation Note: The voltage must be adjusted after the
maximum excitation current has been set.

Special Use

Illustration 81 g00952800

The factory setting corresponds to an excitation

current that is required to obtain a three-phase short Illustration 82 g00952821
circuit current of 3 X IN at 50 Hz for industrial power,
unless this is specified otherwise. The exciter is switched off by disconnecting the
power supply to the voltage regulator. The
The maximum level of excitation may be reduced by connection is identical for resetting the internal
a static method. The static method is safer for the protection for the voltage regulator.
generator and the network. Use the following steps to
reduce the maximum excitation level.
1. Disconnect the power supply wires X1, X2, Z1, and
Z2.
2. Disconnect sensing leads 0V, 110V, 220V, and
380V on the generator.
3. Connect the main power supply 200V-240V, as
shown. X1,X2:120V
4. Install a 10 Amp DC ammeter in series with the
exciter field.
5. Turn potentiometer P5 to a full counterclockwise
position and activate the power supply. If there is
no output current from the voltage regulator, turn Illustration 83 g00952830

potentiometer P2 clockwise until the ammeter

Use a 12 VDC power source in order to energize the
indicates a stable current. field, if necessary. Refer to the following table.
6. Switch off the power supply. Switch on the power Table 8
supply. Turn potentiometer P5 until the required Applications B Volts Time
maximum current is obtained. The maximum
Voltage buildup 12 (1A) 1 - 2 seconds
current must not be greater than 10 Amperes.
Use the following steps in order to check the internal
protection. (continued)
92 SEBU7919-10
Operation Section
Voltage Regulators

(Table 8, contd)
De-energized parallel
12 (1A) 1 - 2 seconds
operation

Standby parallel operation 24 (2A) 5 - 10 seconds

Battery starting 48 (4A) 5 - 10 seconds

Voltage that is sustained at

48 (4A) 5 - 10 seconds
overload
SEBU7919-10 93
Operation Section
Cold Weather Operation

Cold Weather Operation • Engine oil pan heaters

• Engine coolant heaters
i05264084
• Fuel heaters
Fuel and the Effect from Cold • Fuel line insulation
Weather For more information on cold-weather operation, see
SMCS Code: 1000; 1250; 1280 Special Publication, SEBU5898, “Cold Weather
Recommendations”.
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.
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
94 SEBU7919-10
Operation Section
Engine Stopping

Engine Stopping
i06789502

Stopping the Engine

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

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.

Emergency Stop Push Button (1) – The emergency

stop push button (ESPB) is used to shutdown the
engine during an emergency situation. The ESPB
shuts off the fuel.
Horn (23) – The horn activates when a fault (alarm or
shutdown signal) is received by the controller. The
fault is indicated with text on the controller display.
Move the cursor to “ACK” and press the “SEL” key to
reset the alarm.
PPU (3) – The PPU controls the functions of the
generator set.
SEBU7919-10 95
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Illustration 84 g06116540
Close up of the PPU
(1) Emergency stop push button (2) Horn (3) Protection and Paralleling Unit (PPU)
96 SEBU7919-10
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Illustration 85 g06116510
Close up of the PPU
(4) Start key (5) Stop/Reset key (6) Mode key
SEBU7919-10 97
Operation Section
Protection and Paralleling Unit (PPU) Control Panel and Marine Certification Society (MCS) Control Panel (if
equipped)

Illustration 86 g06116462
MCS control panel
(1) Engine shutdown override switch (3) Warning lamps
(2) Emergency stop push button (4) Alarm/Display module
98 SEBU7919-10
Operation Section
Emergency Stopping

Illustration 87 g06116358
MCS control module
(5) Start key (6) Stop key (7) Mode key

Manual Operation 2. Once the operator opens the circuit breaker, the
PPU will automatically go into the cool down
1. Open the circuit breaker and remove the load from mode.
the generator.
3. The cool down timer will start. The cool down
2. Allow the engine to operate at low idle for at least 3 mode will allow the engine to cool down properly.
minutes so the engine can cool down. The LCD display will indicate “COOL DOWN” .
Note: Pressing the stop key bypasses the 4. The LCD display will indicate “STOPPING” .
cooldown period.
Note: If the engine fails to stop running, the LCD
3. Press and release the “Stop” key(6). display will indicate “STOP FAILURE” . The alarm will
sound.
4. The LCD display will indicate “STOPPING” .
5. Once the engine has stopped, the LCD display will
Note: If the engine fails to stop running, the LCD indicate “STOPPED” .
display will indicate “STOP FAILURE” . The alarm will
sound. i06825474

5. Once the engine has stopped, the LCD display will

indicate “STOPPED” .
Emergency Stopping
SMCS Code: 1000; 7418
Remote Operation
Emergency Stop Procedure
1. Open the circuit breaker and remove the load from
the generator. To emergency stop perform the following steps
below:
SEBU7919-10 99
Operation Section
Emergency Stopping

NOTICE
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices
or controls for normal stopping procedure.

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

Illustration 89 g06129844

1. The engine will not start when the emergency stop

button (1) is locked.
2. Turn the button clockwise in order to reset.
3. For routine stopping, use the standard designed
system.

Illustration 88 g06129863
(1) Emergency Button
(2) Battery Isolation Switch

1. Push the emergency button (1).

2. Turn the battery isolation switch (2) to lock out the Illustration 90 g06129867
unit. Ensure that the engine has stopped.
3. Rotate the emergency stop button clockwise to 4. For safety reasons, when the engine has stopped,
return it to normal function. always turn the battery isolation switch (2). This
will prevent the engine from restarting and will also
4. Ensure that any components for the external prevent electrical damage and injury that may
system that support the engine operation are result.
secured after the engine is stopped.
5. During maintenance of the engine, isolate the
Emergency Stop Reset battery power before working on the machine. Do
not operate the emergency stop.
Note: After activating the emergency stop, the button
must be returned to the normal running position.
Neglecting this procedure may cause the fuel stop
solenoid to foul.
Failure to follow this procedure may void the
warranty.
100 SEBU7919-10
Maintenance Section
Refill Capacities

Maintenance Section (Table 10, contd)

(2) Add the capacity for the engine only to the capacity for the ex-
ternal system. Enter the total in this row.

Refill Capacities i04862012

i04856732 Fluid Recommendations

SMCS Code: 1280; 1348; 1395; 7560
Refill Capacities
SMCS Code: 1000; 1348; 1395; 7560 Diesel Engine Oil
Lubrication Capacities Cat Diesel Engine Oil (Cat DEO)
The refill capacities for the engine crankcase reflect Cat oils have been developed and tested in order to
the approximate capacity of the crankcase or sump provide the full performance and service life that has
plus standard oil filters. Auxiliary oil filter systems will been designed and built into Cat engines. Cat oils
require additional oil. Refer to the OEM specifications are currently used to fill Cat Diesel Engines at the
for the capacity of the auxiliary oil filter. factory. These oils are offered by Cat dealers for
Table 9 continued use when the engine oil is changed.
Consult your Cat dealer for more information on
C4.4 Marine Generator Set Engine these oils.
Approximate Refill Capacity of the Lubrication
System Due to significant variations in the quality and in the
performance of commercially available oils,
Compartment or System Liters Quarts Caterpillar makes the following recommendations:
Standard Sump(1) 8.0 8.5 Table 11

(1) These values are the approximate capacities for the crankcase Cat Lubricants Viscosity Grade
oil sump which include the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer SAE 15W-40
Diesel Engine Cat DEO-ULS
to the OEM specifications for the capacity of the auxiliary oil SAE 10W-30
filter. Oil-Ultra Low
Sulfur Cat Cold Weather DEO-
SAE 0W-40
ULS
Coolant Capacities
Diesel Engine SAE 15W-40
Cat DEO
To maintain the cooling system, the total cooling Oil SAE 10W-30
system capacity must be known. The approximate
capacity for the engine cooling system is listed.
External system capacities will vary among Note: Cat DEO-ULS and Cat DEO multigrade oils
applications. Refer to the OEM specifications for the are the preferred oils for use in this Cat Diesel
external system capacity. This capacity information Engine.
will be needed in order to determine the amount of
coolant/antifreeze that is required for the total cooling Commercial Oil
system.
Table 10 Note: Non-Cat commercial oils are second choice
C4.4 Marine Generator Set Engine oils for your engine.
Approximate Refill Capacity of the Cooling System

Compartment or System Liters Quarts NOTICE

Caterpillar does not warrant the quality or perform-
Engine only 13 13.7 ance of non-Cat fluids.
External system(1) 18 19 The three current Caterpillar ECF specifications are:
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each
Total cooling system(2) higher Cat ECF specification provides increased
(1) The external system includes an expansion tank with the fol- performance over lower Cat ECF specifications.
lowing components: heat exchanger, aftercooler, piping and
keel cooling system. A commercial oil must meet the following standards
to be considered an equivalent of a Cat Diesel
Engine Oil:
(continued)
SEBU7919-10 101
Maintenance Section
Fluid Recommendations

Table 12
Cat Engine Crankcase Fluids (ECF) Definitions Table 13
Cat Performance Lubricant Viscosities for Ambient Temperatures
Cat ECF Specifications Requirements
Requirement
Oil Type and Per- °C °F
API CJ-4 Oil Category performance formance Oil Viscos-
Cat ECF-3 ities
requirements Requirements Min Max Min Max
API CI-4 / CI-4 PLUS Oil Category per- Cat DEO-ULS Cold
formance requirements SAE 0W-40 −40 40 −40 104
Weather
Passing standard Cat C13 engine test Cat DEO-ULS SAE 10W-30 −18 40 0 104
Cat ECF-2
per API requirements Cat DEO SAE 15W-40 −10 50 14 122
Oils of sulfated ash > 1.50 percent are
SAE 0W-40 −40 40 −40 104
not allowed
SAE 5W-30 −30 30 −22 86
API CH-4 Oil Category performance
requirements SAE 0W-30 −40 30 −40 86
Commercial Oils
For oils that are between 1.30 percent ECF-1a, ECF-2, SAE 5W-40 −30 50 −22 122
and 1.50 percent sulfated ash, passing ECF-3
Cat ECF-1-a SAE 10W-30 −18 40 0 104
one additional Cat 1P SCOTE test
(“ASTM D6681”) is required SAE 10W-40 −18 50 0 122
Oils of sulfated ash > 1.50 percent are SAE 15W-40 −9.5 50 15 122
not allowed

Note: A cold soaked start occurs when the engine

In selecting oil for any engine application, both of the has not been operated recently, allowing the oil to
following must be satisfied: the oil viscosity and the become more viscous due to cooler ambient
category of oil performance or the specification for oil temperatures. Supplemental heat is recommended
performance . Using only one of these parameters for cold soaked starts below the minimum ambient
will not sufficiently define oil for an engine
application. temperature. Supplemental heat may be necessary
for cold soaked starts that are above the minimum
The proper SAE viscosity grade of oil is determined temperature depending on factors such as parasitic
by the following temperatures: minimum ambient load.
temperature during cold engine start-up and
maximum ambient temperature during engine Total Base Number (TBN) and Fuel Sulfur
operation. Levels
Refer to Table 13 (minimum temperature) in order to
determine the required oil viscosity for starting a cold The use of Cat S·O·S Services oil analysis is
engine. recommended strongly for determining oil life.

Refer to Table 13 (maximum temperature) in order to The minimum required Total Base Number (TBN) for
select the oil viscosity for engine operation at the oil depends on the fuel sulfur level. The TBN for new
highest ambient temperature that is anticipated. oil is typically determined by the “ASTM D2896”
procedure. For direct injection engines that use
Note: Generally, use the highest oil viscosity that is distillate fuel, the following guidelines apply:
available to meet the requirement for the temperature Table 14
at start-up. TBN recommendations for applications in Cat
Engines
Fuel Sulfur Level TBN of Commercial
Cat Engine Oils (1)
percent (ppm) Engine Oils

0.05 percent Cat DEO-ULS

Min 7
(500ppm) Cat DEO

(continued)
102 SEBU7919-10
Maintenance Section
Fluid Recommendations

(Table 14, contd)

NOTICE
TBN recommendations for applications in Cat Always use a designated pump for oil sampling, and
Engines use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
>0.05-0.2 percent Cat DEO-ULS ples may contaminate the samples that are being
Min 10
(>500- 2000 ppm) (2) Cat DEO drawn. This contaminate may cause a false analysis
Above 0.2 percent and an incorrect interpretation that could lead to con-
(above 2000ppm) (3) Cat DEO (5) Min 10 cerns by both dealers and customers.
(4)

(1) Cat DEO-ULS applies to Cat DEO-ULS SAE 15W-40, Refer to Special Publication, SEBU6251, “Cat
SAE10W-30 and Cat DEO Cold Weather SAE 0W-40. Cat Commercial Diesel Engine Fluids
DEO applies to Cat DEO SAE 15W-40 and SAE 10W-30. Recommendations” in order to obtain additional
(2) Use of an oil analysis program to determine oil drain intervals is information about S·O·S Services oil analysis. You
strongly recommended if fuel sulfur is between 0.05% (500
ppm) and 0.5% (5000 ppm).
can also contact your local Cat dealer.
(3) Use of an oil analysis program to determine oil drain intervals is

(4)
required if fuel sulfur is above 0.5% (5000 ppm).
For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
Fuel
refer to TBN and engine oil guidelines given in Special Publica-
tion, SEBU6251, “Cat Commercial Diesel Engine Fluids Rec- Note: Caterpillar strongly recommends the filtration
ommendations” “Engine Oil”. of fuel through a fuel filter with a rating of four
(5) Cat DEO-ULS may be used if an oil analysis program is fol- microns(c) absolute or less. This filtration should be
lowed. High fuel sulfur levels may reduce the oil drain intervals. located on the device that dispenses the fuel to the
fuel tank for the engine. This filtration should also be
S·O·S Services Oil Analysis located on the device that dispenses fuel from the
bulk storage tank. Series filtration is recommended.
Caterpillar has developed a maintenance tool that
evaluates oil degradation. the maintenance
NOTICE
management also detects the early signs of wear on In order to meet expected fuel system component life,
internal components. The Caterpillar tool for oil 4 micron (c) absolute or less secondary fuel filtration
analysis is called S·O·S oil analysis and the tool is is required for all Cat Diesel Engines that are
part of the S·O·S Services program. S·O·S oil equipped with unit injected fuel systems. All current
analysis divides oil analysis into four categories: Cat Diesel Engines are factory equipped with Cat Ad-
vanced Efficiency 4 micron(c) absolute fuel filters.
• Component wear rate
Caterpillar does not warrant the quality or perform-
• Oil condition ance of non-Cat fluids and filters.
• Oil contamination For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
• Identification of oil Recommendations” or consult your Cat dealer for
These four types of analysis are used to monitor the further information.
condition of your equipment. The four types of
analysis will also help you identify potential problems. Specifications for Distillate Diesel Fuel
A properly administered S·O·S oil analysis program
will reduce repair costs and the program will lessen Note: Diesel fuel used to operate a Cat Marine
the impact of downtime. Diesel Engine which is certified to US EPA Tier 3
Standards must also meet the “Cat Specification for
The S·O·S Oil Analysis program uses a wide range Distillate Diesel Fuel for Off-Highway Diesel
of tests to determine the condition of the oil and the Engines”. The acceptability of these fuels for use is
crankcase. Guidelines that are based on experience
and a correlation to failures have been established determined on a case by case basis. A complete fuel
for these tests. Exceeding one or more of these analysis is required. Consult your Cat dealer for
guidelines could indicate serious fluid degradation or further information.
a pending component failure. A trained person at
your Cat dealership should make the final analysis. 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.
SEBU7919-10 103
Maintenance Section
Fluid Recommendations

Table 15
Caterpillar Specification for Distillate Fuel for Nonroad (Table 15, contd)
Diesel Engines
Caterpillar Specification for Distillate Fuel for Nonroad
ASTM Diesel Engines
Specifications Requirements Test ISO Test
ASTM
Aromatics 35% maximum “D1319” “ISO 3837” Specifications Requirements Test ISO Test
0.01% maximum “D1796”
Ash “D482” “ISO 6245” Water and
(weight) 0.05% maximum or “ISO 3734”
Sediment
“D2709”
Carbon Residue 0.35% maximum
“D524” “ISO 4262”
on 10% Bottoms (weight) No equiva-
Water 0.05% maximum “D6304”
lent test
40 minimum (DI
engines) “D613” 0.05% maximum
Sediment “D473” “ISO 3735”
Cetane Number (1) or “ISO 5165” (weight)
35 minimum (PC “D6890”
engines) Gums and Resins 10 mg per 100 mL
(5) “D381” “ISO 6246”
maximum
The cloud point
(1) Alternatively, to ensure a minimum cetane number of 35 (PC
must not exceed
engines), and 40 (DI engines), distillate diesel fuel should have
Cloud Point the lowest ex- “D2500” “ISO 3015” a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en-
pected ambient gines) when the “ASTM D4737-96a” test method is used. A fuel
temperature. with a higher cetane number may be required for operation at a
higher altitude or in cold weather.
Copper Strip (2) Via standards tables, the equivalent kg/m3 (kilograms per cubic
No. 3 maximum “D130” “ISO 2160”
Corrosion meter) using the “ASTM D287” test method temperature of
15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/
10% at 282 °C
m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
(540 °F) (3) Certain Cat fuel systems and engine components can operate
maximum on fuel with a maximum sulfur content of 3%. Contact your Cat
Distillation “D86” “ISO 3405” dealer for guidance about appropriate maintenance intervals
90% at 360 °C
and fluids for engines operating on fuel with sulfur levels be-
(680 °F)
tween 0.1% and 3%.
maximum (4) An engine which operates on fuel with 0.1% (1000 ppm) of sul-
legal limit fur or more is operating in a severe service application. Refer to
Flash Point “D93” “ISO 2719”
this Operation and Maintenance Manual, “Severe Service Ap-
Minimum of 80% plication” for information about operating an engine in a severe
service application.
reflectance after (5)
No equiva- Follow the test conditions and procedures for gasoline (motor).
Thermal Stability aging for 180 mi- “D6468”
lent test
nutes at 150 °C
(302 °F) Biodiesel
30 minimum No equiva- A biodiesel blend of up to 20 percent may be used in
API Gravity (2) “D287”
45 maximum lent test the engine when the fuel blend meets the
recommendations in table 16 and meets the
6 °C (10 °F) mini- recommendations in Special Publication, SEBU6251,
Pour Point mum below ambi- “D97” “ISO 3016” “Biodiesel”. A blend of greater than 20 percent
ent temperature biodiesel may be acceptable in some cases. See
your Cat dealer for more information.
“D5453” ISO 20846
Sulfur (3)(4) or or Note: A complete Cat S·O·S Services oil analysis
“D2622” ISO 20884
program is recommended strongly when using
1.4 cSt minimum biodiesel blends above 5 percent.
and 20.0 cSt max-
imum as delivered Table 16
to the fuel injec- Biodiesel Blends for Cat Commercial Diesel Engines
Kinematic tion pumps
- - Distillate diesel fuel
Viscosity 1.4 cSt minimum Biodiesel blend stock Final blend
used for blend
and 4.5 cSt maxi-
mum as delivered Caterpillar distillate
Caterpillar biodiesel B20: “ASTM
to the rotary fuel diesel fuel specifica-
specification, “ASTM D7467” and “API”
injection pumps tion, “ASTM D975” or
D6751” or “EN14214” gravity 30-45
“EN590”

(continued)
104 SEBU7919-10
Maintenance Section
Fluid Recommendations

Fuel Additives Never operate an engine without water temperature

regulators in the cooling system. Water temperature
Cat Diesel Fuel Conditioner regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system
Refer to Special Publication, SEBU6251, “Cat problems can develop without water temperature
Commercial Diesel Engine Fluids regulators. Removing the regulators allows some
Recommendations” for further information. coolant to bypass the radiator, potentially causing
overheating.
Cat Diesel Fuel System Cleaner
Coolant Recommendations
Refer to Special Publication, SEBU6251, “Cat
Commercial Diesel Engine Fluids Note: A Cat Diesel Engine equipped with air-to-air
Recommendations” for further information. aftercooling (ATAAC) requires a minimum of 30
percent glycol to help prevent water pump cavitation.
Aftermarket Fuel Additives

There are many different types of fuel additives that NOTICE

are available to use. Caterpillar does not generally Do not use a commercial coolant/antifreeze that only
recommend the use of fuel additives. meets the ASTM “D3306” specification. This type of
coolant/antifreeze is made for light duty automotive
Note: For best results, your fuel supplier should treat applications.
the fuel when additives are needed.
Use only the coolant/antifreeze that is recommended.
Refer to Special Publication, SEBU6251, “Cat
Commercial Diesel Engine Fluids
Recommendations” for further information. Note: A mixture of SCA and water is not
recommended for use in the cooling system of the
Cooling System C4.4 marine auxiliary generator. The use of SCA
and water in the cooling system could result in
Note: Refer to Special Publication , SEBU6251, “Cat damage to the aluminum components.
Commercial Diesel Engine Fluids
Recommendations” for complete information about
the proper fluids for use in the cooling system.

The cooling system operates under pressure

which is controlled by the radiator pressure cap.
Removing the cap while the system is hot may al-
low the escape of hot coolant and steam, causing
serious burns.
Before you remove the radiator cap, allow the
system to cool. Use a thick cloth and turn the ra-
diator 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 tem-
perature or drained completely in order to prevent
damage caused by freezing coolant.
SEBU7919-10 105
Maintenance Section
Fluid Recommendations

Table 17
Coolant Recommendations for use in Cat Diesel Engines
Service Hours Required
Recommendations Product (1)(2)(3) Maintenance

Add Cat ELC Extender

12000 hours or at 6000 service hours
Cat ELC (Cat Extended Life Coolant)
6 years or one half of service
life
Preferred
Add Cat ELC Extender
12000 hours or at 6000 service hours
Cat ELI (Cat Extended Life Inhibitor)
6 years 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 or
Min requirements service hours or one
Phosphate, borate, and silicate free 6 years
half of service life
Tolyltriazole: minimum typical concnetration of 900 ppm
Nitrite: minimum typical concentration of 500 ppm in new coolants

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

“ASTM D4985” and(1)

Min requirements for Com- SCA at initial fill and
Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US 3000 hours or
mercial coolants requiring SCA at maintenance
gal) and maximum of 2400 ppm (140 grains/US gal) 1 year
SCA precharge intervals
Silicon concentration: minimum of 100 ppm and maximum of 275 ppm
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 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.

S·O·S Services Coolant Analysis

NOTICE
Use Only Approved SCAs and Extenders
Testing the engine coolant is important to ensure that
Conventional coolants require the maintenance addi- the engine is protected from internal cavitation and
tion of SCA throughout the expected life of the cool- corrosion. The analysis also tests the ability of the
ants. Do NOT use an SCA with a coolant unless coolant to protect the engine from boiling and
approved specifically by the coolant supplier. The freezing. S·O·S coolant analysis can be done at your
coolant manufacturer is responsible for ensuring Cat dealer. Cat S·O·S coolant analysis is the best
compatibility and acceptable performance. way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program
To help ensure expected performance, EC-1 coolants that is based on periodic samples.
require the one time maintenance addition of an ex- Table 18
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been Recommended Interval
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en- Type of
suring compatibility and acceptable performance. Level 1 Level 2
Coolant
Failure to follow these recommendations can result in
shortened cooling system component life.
(continued)
Cat ELC can be recycled into conventional coolants.
For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
106 SEBU7919-10
Maintenance Section
Fluid Recommendations

(Table 18, contd) The results are reported, and appropriate

Cat DEAC
recommendations are made.
Conventional Heavy- Every 250 hours Yearly(1) For more information on S·O·S coolant analysis,
Duty Coolants
consult your Cat dealer.
Cat ELC
Cat ELI
Optional Yearly(1) Greases
Commercial EC-1
Coolants If it is necessary to choose a single grease, always
(1) The Level 2 Coolant Analysis should be performed sooner if a choose a grease that meets or exceeds the
problem is suspected or identified. requirements of the most demanding application.
Remember that the products which barely meet the
Note: Check the SCA (Supplemental Coolant minimum performance requirements can be
Additive) of the conventional coolant at every oil expected to barely produce the minimum lives of your
change or at every 250 hours. Perform this check at parts. False economy is being used if a grease is
the interval that occurs first. purchased with the lowest cost as the only
consideration. Instead, use the grease that yields the
S·O·S Services Coolant Analysis (Level 1) lowest total operating cost. The cost should be based
on an analysis that includes the costs of parts, labor,
A coolant analysis (Level 1) is a test of the properties downtime, and the cost of the amount of grease that
of the coolant. is required.

The following properties of the coolant are tested: For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
• Glycol concentration for freeze protection and boil Recommendations”.
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
SEBU7919-10 107
Maintenance Section
Maintenance Recommendations

Maintenance • the application of electrical tests

Recommendations 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
i05264090 information, refer to “I.E.E.E. Standard 432-1992” or
consult a Cat dealer.
General Maintenance
Information i02909163

SMCS Code: 4450; 7000 System Pressure Release

Note: Read the warnings and read the instructions SMCS Code: 1250; 1300; 1350; 5050
that are contained in the Safety Section of this
manual. These warnings and instructions must be Coolant System
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: Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
• mechanical diator is cool. Then loosen cap slowly to relieve
the pressure.
• electrical
To relieve the pressure from the coolant system, turn
• thermal off the engine. Allow the cooling system pressure cap
to cool. Remove the cooling system pressure cap
• environmental slowly in order to relieve pressure.
These stresses may be of varying magnitudes. The
electrical insulation systems are susceptible to Fuel System
damage that is caused by the stresses that are listed
above. Exposure to these stresses may shorten the To relieve the pressure from the fuel system, turn off
effective life of the electrical insulation system. the engine.
Therefore, the service life of an electric machine will
largely depend on the serviceability of the electrical High Pressure Fuel Lines (If Equipped)
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. Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
A regular maintenance and inspection program can spray may cause a fire hazard. Failure to follow
provide an evaluation of the present condition of the these inspection, maintenance and service in-
equipment. A regular maintenance program and a structions may cause personal injury or death.
regular inspection program can also reveal future
problems. The frequency of this maintenance The high pressure fuel lines are the fuel lines that are
program will depend on the following factors: between the high pressure fuel pump and the high
pressure fuel manifold and the fuel lines that are
• application between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
• environmental conditions systems.
• experience level of the operator This is because of the following differences:
• philosophy of the operator • The high pressure fuel lines are constantly
charged with high pressure.
A regular maintenance program is strongly
recommended. This program would involve the • The internal pressures of the high pressure fuel
following steps: lines are higher than other types of fuel system.
• periodic disassembly Before any service or repair is performed on the
engine fuel lines, perform the following tasks:
• knowledgeable visual examination of the
equipment 1. Stop the engine.
108 SEBU7919-10
Maintenance Section
Welding on Engines with Electronic Controls

2. Wait for ten minutes. 3. Disconnect the J1/P1 and J2/P2 connectors from
the ECM. Move the harness to a position that will
Do not loosen the high pressure fuel lines in order to
remove air pressure from the fuel system. not allow the harness to move back accidentally,
and contact any of the ECM pins.
Engine Oil 4. Disconnect any component with a microprocessor
from the engine harness, such as:
To relieve pressure from the lubricating system, turn
off the engine. • Engine ECM

i05909227 • Product Link

Welding on Engines with • Cell/Sat Radio

Electronic Controls • DOC Identity Modules

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 correct procedure must be followed.
When welding on a unit that is equipped with a Cat
Electronic Engine, the following is considered to be
the safest procedure:

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,
hydraulic 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.
Illustration 91 g01075639
Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close Use the example above. The current flow from the
as possible to the weld. This will help reduce the pos- welder to the ground clamp of the welder will not
sibility of damage. damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
Note: Perform the welding in areas that are free from (4) Battery disconnect switch in the open position
explosive hazards. (5) Disconnected battery cables
(6) Battery
1. Stop the engine. Turn the switched power to the (7) Electrical/Electronic component
OFF position. (8) Minimum distance between the component that is being
welded and any electrical/electronic component
2. Disconnect the negative battery cable from the (9) The component that is being welded
(10) Current path of the welder
battery. If a battery disconnect switch is provided, (11) Ground clamp for the welder
open the switch.
SEBU7919-10 109
Maintenance Section
Generator Start-up Checklist

5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld. This location will
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, current flow from the welder
could severely damage the component. Current flow
from the welder could also severely damage
electrical/electronic components that are located
between the welder ground and the weld.

6. Protect the wiring harness from welding debris and

spatter.
7. Use standard welding practices to weld the
materials.

i03643560

Generator Start-up Checklist

SMCS Code: 4450

Table 19
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________

Generator Serial Number: _________________________________ Arrangement Number: ___________________

GENERATOR NAME PLATE INFORMATION

Voltage: ___________________ Package (prime, continuous, standby): _________________

Amperage: _________________ Kilowatts: ________________________________________

Storage Location:

Generator Alignment:

Main Stator Megohmmeter Reading: Before Storage: After Storage:

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

SPACE HEATERS Yes No Comments

Space heaters operating properly?

Space heater operated 48 hrs. before start-up?

MEGOHMMETER TEST (SEHS9124) 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments

reading reading corrected corrected temp.

Beginning of Main Stator

Storage
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator

(continued)
110 SEBU7919-10
Maintenance Section
Generator Start-up Checklist

(Table 19, contd)

GENERATOR START-UP CHECKLIST
Start-up Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Regulator Voltage Amps Comments

No Load F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
Full Load Generator Excitation Name Plate DC Compare with F1 to F2
Information:
F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC

Table 20
GENERATOR START-UP CHECKLIST (CONT.)

ELECTRICAL Yes No Comments

Unit properly grounded

Check diodes
Over current protection

Over voltage protection

Check for loose wiring

Adjust voltage

Adjust frequency

Verify kilowatt transducer (if applicable)

MECHANICAL Data Comments

Bearing temperature readings at full load Front __________ Rear ___________

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

Air gap on main stator Top __________ Bottom __________

(continued)
SEBU7919-10 111
Maintenance Section
Generator Start-up Checklist

(Table 20, contd)

Air gap on exciter stator Top __________ Bottom __________

Air gap of PMG Top __________ Bottom __________

Ambient air to generator at full load Temperature ____________________

Supplier air opening to generator Size of Opening _________________

SWITCH GEAR/PARALLEL OPERATION

Manufacturer:
Setting 1 Setting 2 Setting 3 Comments

Circuit breaker type

Overload setting

Reverse power relay

VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system UPS

Enclosure type Size

Motor: Other loads:

- Total SKVA - Lighting

- Total HP - Computers

- Welding

- Non-linear
- Other

FULL LOAD DATA

Voltage Amps kW KVARS P.F.
112 SEBU7919-10
Maintenance Section
Maintenance Interval Schedule

i06830067 “ Engine Air Cleaner Service Indicator -

Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Maintenance Interval Schedule “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 132
SMCS Code: 1000; 4450; 7500
“ Generator Load - Check”. . . . . . . . . . . . . . . . . . . 142
Ensure that all safety information, warnings, and
instructions are read and understood before any “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . 157
operation or any maintenance procedures are
performed. Every Week
The user is responsible for the performance of “ Automatic Start/Stop - Inspect” . . . . . . . . . . . . . . 115
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement “ Space Heater - Test” . . . . . . . . . . . . . . . . . . . . . . 154
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and “ Stator Winding Temperature - Test” . . . . . . . . . . 155
procedures may result in diminished performance of
the product and/or accelerated wear of components. “ Voltage and Frequency - Check” . . . . . . . . . . . . 157
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, to Every 250 Service Hours
determine the maintenance intervals. Products that
operate in severe operating conditions may require “ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . 122
more frequent maintenance.
Note: Before each consecutive interval is performed, Initial 500 Hours (for New Systems,
all maintenance from the previous interval must be Refilled Systems, and Converted
performed.
Systems)
When Required “ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . 123
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . 115
Every 500 Service Hours or 1 Year
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 115
“ Engine Air Cleaner Element (Single Element) -
“ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . . . . . Inspect/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . 127
“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . 118
Every 2000 Service Hours or 6
“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . 120 Months
“ Enclosure - Inspect”. . . . . . . . . . . . . . . . . . . . . . . 124 “ Stator Lead - Check” . . . . . . . . . . . . . . . . . . . . . . 155
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Every Year
“ Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . 125 “ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . 123
“ Engine Air Cleaner Element (Single Element) - “ Varistor - Check” . . . . . . . . . . . . . . . . . . . . . . . . . 157
Inspect/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . 127
“ Varistor - Inspect”. . . . . . . . . . . . . . . . . . . . . . . . . 157
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 135
“ Generator - Dry”. . . . . . . . . . . . . . . . . . . . . . . . . . 140 Every 6900 L (1820 US gal) of Fuel
or 500 Service Hours or 1 Year
“ Generator Set - Test” . . . . . . . . . . . . . . . . . . . . . . 143
“ Auxiliary Water Pump (Rubber Impeller) -
“ Generator Winding Insulation - Test” . . . . . . . . . 144 Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Daily “ Battery Electrolyte Level - Check” . . . . . . . . . . . . . . .

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . 116 “ Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . 125
“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . 121
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . 131
“ Electrical Connections - Check” . . . . . . . . . . . . . 124
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 132
SEBU7919-10 113
Maintenance Section
Maintenance Interval Schedule

“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 133

“ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 138
“ Fuel System Secondary Filter - Replace”. . . . . . 138
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 139
“ Heat Exchanger - Inspect”. . . . . . . . . . . . . . . . . . 145
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . 146
“ Sea Water Strainer - Clean/Inspect”. . . . . . . . . . 153

Every 14 200 L (3750 US gal) of

Fuel or 500 Service Hours
“ Battery Charger - Check” . . . . . . . . . . . . . . . . . . 116

Every 13 800 L (3650 US gal) of

Fuel or 1000 Service Hours or 1
Year
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 134

Every 27 600 L (7290 US gal) of

Fuel or 2000 Service Hours or 2
Years
“ Aftercooler Core - Inspect/Clean/Test” . . . . . . . . 114
“ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 114
“ Coolant Temperature Regulator - Replace” . . . . 123
“ Generator - Inspect”. . . . . . . . . . . . . . . . . . . . . . . 141
“ Generator Set Vibration - Test/Record” . . . . . . . 143
“ Rotating Rectifier - Inspect/Test”. . . . . . . . . . . . . 151
“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . 155
“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . 155
“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . 158

Every 110 400 L (29 160 US gal) of

Fuel or 8000 Service Hours
“ Engine Crankcase Breather - Replace” . . . . . . . . . . .

Every 165 600 L (43 750 US gal) of

Fuel or 12 000 Service Hours
“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 149
114 SEBU7919-10
Maintenance Section
Aftercooler Core - Inspect/Clean/Test

i04862171 Caterpillar recommends the use of Hydrosolv

liquid cleaner. Table 21 lists Hydrosolv liquid
Aftercooler Core - Inspect/ cleaners that are available from your Cat dealer.
Table 21
Clean/Test
Hydrosolv Liquid Cleaners(1)
SMCS Code: 1064-040; 1064-081; 1064-070
Part Number Description Size
The interval for the cleaning of the aftercooler core
depends on the operating environment of the vessel 1U-5490 Hydrosolv 4165 19 L (5 US gallon)
and on the operating time. The sea water that is Hydrosolv 100 19 L (5 US gallon)
174-6854
circulated through the aftercooler and the amount of
operating time of the vessel affects the following (1) Use a two to five percent concentration of the cleaner at tem-
items: peratures up to 93°C (200°F). Refer to Application Guide,
NEHS0526 or consult your Cat dealer for more information.
• Cleanliness of the tubes for the aftercooler
5. Steam clean the core in order to remove any
• Effectiveness of the aftercooler residue. Flush the tubes of the heat exchanger
Operating in water that contains the following will core. Remove any other trapped debris.
adversely affect the aftercooler: silt, sediment, salt 6. Wash the core with hot, soapy water. Rinse the
and algae.
core thoroughly with clean water.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.

NOTICE Personal injury can result from air pressure.

Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Personal injury can result without following prop-
nance, testing, adjusting, and repair of the product. er procedure. When using pressure air, wear a
Be prepared to collect the fluid with suitable contain- protective face shield and protective clothing.
ers before opening any compartment or disassem-
bling any component containing fluids. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication, 7. Dry the core with compressed air. Direct the air in
PECJ0003, “Cat Shop Supplies and Tools Catalog” the reverse direction of the normal flow.
for tools and supplies suitable to collect and contain
fluids on Cat products. 8. Inspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service
Dispose of all fluids according to local regulations radiators are equipped to perform pressure tests.
and mandates.
If necessary, repair the core.
9. Install the aftercooler. Refer to the Disassembly
1. Drain the aftercooler.
and Assembly Manual, “Aftercooler - Remove and
2. Remove the aftercooler. Refer to the Disassembly Install” article for the installation procedure.
and Assembly Manual, “Aftercooler - Remove and
Install” article for the aftercooler removal For more information on cleaning the core, consult
your Cat dealer.
procedure.
3. Turn the aftercooler core upside-down in order to i02676048
remove debris.
Alternator - Inspect
NOTICE SMCS Code: 1405-040
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic Caterpillar recommends a scheduled inspection of
cleaner can attack the internal metals of the core and the alternator. Inspect the alternator for loose
cause leakage. Only use the recommended concen-
tration of cleaner. connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
4. Back flush the core with cleaner. proper performance of the electrical system. Make
repairs, as required.
SEBU7919-10 115
Maintenance Section
Automatic Start/Stop - Inspect

Check the alternator and the battery charger for If wear or damage is found, replace the components
proper operation. If the batteries are properly which are worn or damaged. Use the proper repair kit
charged, the ammeter reading should be very near for the pump. Refer to the Disassembly and
zero. All batteries should be kept charged. The Assembly for more information on servicing the
batteries should be kept warm because temperature auxiliary water pump.
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will i02039199
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time or
if the engine is run for short periods, the batteries Battery - Recycle
may not fully charge. A battery with a low charge will SMCS Code: 1401-005; 1401-535; 1401-510; 1401-
freeze more easily than a battery with a full charge. 561; 1401

i01942284 Always recycle a battery. Never discard a battery.

Return used batteries to one of the following
Automatic Start/Stop - Inspect locations:

SMCS Code: 4462 • A battery supplier

The generator set must be ready to operate under a • An authorized battery collection facility
load at any time. After performing maintenance on
the generator set, inspect the position of the control • A recycling facility
switches. Ensure the following conditions:
i01878164
• The starting system is enabled.

• The control switches are in the correct position for Battery - Replace
automatic starting. SMCS Code: 1401-510
• The switchgear and the automatic transfer
switches that are associated with the generator
are enabled.
Batteries give off combustible gases which can
explode. A spark can cause the combustible
i06638162 gases to ignite. This can result in severe personal
injury or death.
Auxiliary Water Pump (Rubber
Ensure proper ventilation for batteries that are in
Impeller) - Inspect an enclosure. Follow the proper procedures in or-
SMCS Code: 1371-040 der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
Impellers and seals require periodic inspection. serviced.
Impellers have a service life that is limited. The
service life depends on the engine operating
conditions.
Inspect the components more frequently when the The battery cables or the batteries should not be
pump is exposed to debris, sand, or other abrasive removed with the battery cover in place. The bat-
materials. Inspect the components if the pump is tery cover should be removed before any servic-
operating at a differential pressure less than 103 kPa ing is attempted.
(15 psi).
Removing the battery cables or the batteries with
Check the following components for wear or damage: the cover in place may cause a battery explosion
resulting in personal injury.
• Bearings

• Impeller 1. Switch the engine to the OFF position. Remove all

• Seals electrical loads.
2. Turn off any battery chargers. Disconnect any
• Wear plate
battery chargers.
116 SEBU7919-10
Maintenance Section
Battery Charger - Check

3. The NEGATIVE “-” cable connects the NEGATIVE Ensure that the electrolyte level is 13 mm (0.5 inch)
“-” battery terminal to the NEGATIVE “-” terminal above the top of the separators.
on the starter motor. Disconnect the cable from the
NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE All lead-acid batteries contain sulfuric acid which
“+” battery terminal to the POSITIVE “+” terminal can burn the skin and clothing. Always wear a
on the starting motor. Disconnect the cable from face shield and protective clothing when working
the POSITIVE “+” battery terminal. on or near batteries.

Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate 1. Remove the filler caps. Maintain the electrolyte
recycling facility. level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
5. Remove the used battery.
water. If distilled water is not available, use clean
6. Install the new battery. water that is low in minerals. Do not use artificially
softened water.
Note: Before the cables are connected, ensure that 2. Check the condition of the electrolyte with the
the engine start switch is OFF.
245-5829 Coolant Battery Tester Refractometer.
7. Connect the cable from the starting motor to the 3. Keep the batteries clean.
POSITIVE “+” battery terminal.
Clean the battery case with one of the following
8. Connect the cable from the NEGATIVE “-” terminal cleaning solutions:
on the starter motor to the NEGATIVE “-” battery
terminal. • A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
i01942625
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
Battery Charger - Check (1 qt) of clean water
SMCS Code: 1401-535 Thoroughly rinse the battery case with clean
water.
Check the battery charger for proper operation. If the
batteries are properly charged, the needle of the Use the 1U-9921 Battery Service Tool to clean
ammeter will register near “0” (zero). the battery terminals. Use a wire brush to clean
the cable clamps. Clean the items until the
The batteries should be kept warm, when possible. surfaces are bright or shiny. DO NOT remove
The temperature of the battery will affect cranking material excessively. Excessive removal of
power. A battery that is too cold will not crank the material can cause the clamps to fit improperly.
engine, even if the engine is warm. Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
The batteries may not fully recharge when the engine
is not run for long periods of time. The batteries may
i04521280
not fully recharge if the engine only runs for short
periods. Ensure a full charge in order to help prevent
the battery from freezing. Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
i06845102

Battery Electrolyte Level - Fan Drive Belt

Check Inspection
SMCS Code: 1401-535-FLV
To maximize the engine performance, inspect the
When the engine has not run for long or short periods belts for wear and for cracking. Check the belt
of time, the batteries may not fully recharge. Ensure a tension. Adjust the belt tension in order to minimize
full charge to help prevent the battery from freezing. belt slippage. Belt slippage will decrease the life of
the belts.
In warmer climates, check the electrolyte level more
frequently.
SEBU7919-10 117
Maintenance Section
Belts - Inspect/Adjust/Replace

Adjustment
If the belts are too loose, the belts will vibrate. This
vibration is enough to cause unnecessary wear on
the belts and on the pulleys.
If the belts are too tight, unnecessary stresses are
placed upon the pulley bearings and upon the belts.
These stresses will shorten the life of the belts and of
the pulley bearings.
If new belts are installed, check the tension again
after 30 minutes of engine operation at the rated rpm.
For the correct tension on the belt, refer to
Specifications, “Belt Tension Chart”.
Illustration 92 g01157422
Replacement The belt cover must be removed for inspection,
adjustment, and replacement.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only one (1) Mounting bolt
(2) Adjustment bolt
belt of a matched set will cause the new belt to carry (3) Adjustment bolt
more load because the older belt is stretched. The
additional load on the new belt could cause the new
belt to break. To maximize the engine performance, inspect the
belt for wear and for cracking. Check the belt tension.
Refer to the Service Manual for more information on Adjust the belt tension in order to minimize belt
the procedures for the following topics: belt removal slippage. Belt slippage will decrease the life of the
and belt installation procedure. belt.
For the correct tension on the belt, refer to
Alternator Belt Specifications, “Belt Tension Chart”.

Inspection Adjustment
1. Remove the belt cover.
2. Loosen mounting bolts (1) and adjusting bolts (2)
The high voltage that is produced by an operating and (3).
generator set can cause severe injury or death.
Before performing any maintenance or repairs, 3. Slide the alternator in the direction that will give the
ensure that the generator will not start. correct tension.
Place the engine control switch in the “ OFF”” posi- 4. Tighten adjusting bolts (2) and (3). Tighten
tion. Attach “ DO NOT OPERATE”” tags to all start- mounting bolt (1).
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and 5. Reinstall the belt cover, if equipped.
automatic transfer switches that are associated
with the generator.
118 SEBU7919-10
Maintenance Section
Circuit Breakers - Reset

If new belts are installed, check the belt adjustment Drain

again after 30 minutes of engine operation at the
rated rpm.

i06789504 Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
Circuit Breakers - Reset stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
SMCS Code: 1417-529; 1420-529 pressure cap slowly in order to relieve the
pressure.

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.
Illustration 93 g06124838 Dispose of all fluids according to local regulations
and mandates.
Push in on the circuit breaker to reset the circuit
breaker.
(A) 80 Amp Circuit Breaker – This circuit breaker is
for the battery charger and the circuit for the
alternator.
(B) 10 Amp Circuit Breaker – This circuit breaker is
for the control panel.

i06789506

Coolant - Change
SMCS Code: 1350-044; 1352; 1395-044; 1395

NOTICE
Keep all parts clean from contaminants. Illustration 94 g03870695

Contaminants may cause rapid wear and shortened Typical example

component life. (1) Header tank
(2) Cooling system filler cap

Note: Inspect the water pump and the water 1. Stop the engine and allow the engine to cool.
temperature regulator after the cooling system has Loosen cooling system filler cap (2) slowly to
been drained. If necessary, replace the water pump, relieve any pressure. Remove cooling system filler
the water temperature regulator, and the hoses. cap (2).
SEBU7919-10 119
Maintenance Section
Coolant - Change

Illustration 97 g01341440
Illustration 95 g01156304
2. Remove the drain plug (4) from the cylinder block.
Remove the drain plug (3) from the water-cooled
exhaust manifold . Remove drain plug (5) from the
heat exchange . Remove drain plug (6) from the
radiator (if equipped). Allow the coolant to drain.

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

For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
Group:

Inside USA 1-800-542-TOOL

Inside Illinois 1-800-541-8TOOL
Canada 1-800-523-TOOL
International 1-309-578-7372

Illustration 96 g06124851 Flush

1. Flush the cooling system with clean water to
remove any debris.
2. Clean the drain plugs. Install the drain plugs. For
the proper torque, refer to the Specifications
Manual, SENR3130, “Torque Specifications”.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
120 SEBU7919-10
Maintenance Section
Coolant Extender (ELC) - Add

1. Make sure that all the plugs that were removed in

the previous steps have been installed. Remove
plug (6). Remove filler cap and begin filling the
system with the proper mixture of ELC and water.
Refer to this Operation and Maintenance Manual,
“Fluid 9sRecommendations” for proper coolant.
Install plug (6) as the coolant begins to run out of
the hole for plug (6). For the proper torque, refer to
the Specifications Manual, SENR3130, “Torque
Specifications”. After the plugs are installed, fill the
system until the coolant level is approximately
12 mm (0.5 inch) below the neck of the filler tube.
Install the cooling system filler cap.

Illustration 98 g03870762
2. Start and run the engine until the engine reaches
normal operating temperature. Stop the engine
3. Make sure that all the plugs that were removed in and allow the engine to cool.
the previous steps have been installed. Remove 3. Remove the filler cap. Maintain the coolant level
plug (6). Remove filler cap and begin filling the 12 mm (0.5 inch) below the neck of the filler tube.
system with clean water. Install plug (6) as the
water begins to run out of the hole for plug (6). For 4. Clean the cooling system filler cap. Inspect the
the proper torque, refer to the Specifications gasket for the cooling system filler cap. If the
Manual, SENR3130, “Torque Specifications”. After gasket for the cooling system filler cap is
the plugs are installed, fill the system until the damaged, discard the cap and install a new
water level is approximately 12 mm (0.5 inch) cooling system filler cap. If the gasket for the
below the neck of the filler tube. Install the cooling cooling system filler cap is not damaged, use a
system filler cap. 9S-8140 Pressurizing Pump to pressure test the
cooling system filler cap. The correct pressure for
4. Start and run the engine until the temperature the cooling system filler cap is stamped on the
reaches 49 to 66°C (120 to 150°F). face of the cooling system filler cap. If the cooling
5. Stop the engine and allow the engine to cool. system filler cap does not retain the correct
Loosen the cooling system filler cap slowly to pressure, install a new cooling system filler cap.
relieve any pressure. Remove the cooling system 5. Pour the ELC into the recovery tank until the
filler cap. Remove the drain plugs (3), (4), and (5). coolant reaches the “COLD FULL” mark, if
Allow the water to drain. Flush the cooling system equipped. Do not fill the tank above the “COLD
with clean water. Clean the drain plugs. Install the FULL” mark.
drain plugs. For the proper torque, refer to the
Specifications Manual, SENR3130, “Torque 6. Clean the cooling system filler cap. Install the
Specifications”. cooling system filler cap. Start the engine. Inspect
the cooling system for leaks and for proper
Fill operating temperature.

i04862631
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. 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.
SEBU7919-10 121
Maintenance Section
Coolant Level - Check

Note: Do not use conventional supplemental coolant For further information, refer to this Operation and
additive (SCA) with Cat ELC or with Cat ELI. Maintenance Manual, , “Fluid Recommendations”.

Check the cooling system only when the engine is i06248801

stopped and cool.
Coolant Level - Check
SMCS Code: 1395-082
Personal injury can result from hot coolant, Check the coolant level when the engine is stopped
steam and alkali. and cool.
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. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Remove cooling system pressure cap slowly to stop the engine and wait until the cooling system
relieve pressure only when engine is stopped and components are cool. Loosen the cooling system
cooling system pressure cap is cool enough to pressure cap slowly in order to relieve the
touch with your bare hand. pressure.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

NOTICE
Care must be taken to ensure that fluids are con-
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 99 g03871129

1. Loosen the cooling system filler cap slowly in order Typical header tank
to relieve pressure. Remove the cooling system
1. Loosen filler cap slowly in order to relieve any
filler cap.
pressure. Remove the filler cap.
2. If necessary, drain enough coolant from the
2. Pour the proper coolant mixture into the tank until
cooling system in order to add the Cat ELC
the coolant reaches the baffle (1). Refer to this
Extender.
Operation and Maintenance Manual, “Coolant -
3. Add Cat ELC Extender according to the Change” for additional information in filling the
requirements for the cooling system capacity. cooling system. Refer to the Operation and
Refer to this Operation and Maintenance Manual, Maintenance Manual, “Fluid Recommendations”
“Refill Capacities” for the coolant capacity. for information on the correct mixture and type of
coolant. Refer to the Operation and Maintenance
4. Clean the cooling system filler cap. Inspect the
Manual, “Refill Capacities” for the cooling system
gaskets on the cooling system filler cap. Replace
capacity.
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
122 SEBU7919-10
Maintenance Section
Coolant Sample (Level 1) - Obtain

3. Clean filler cap and the receptacle. Reinstall the • Obtain coolant samples directly from the coolant
filler cap and inspect the cooling system for leaks. sample port. You should not obtain the samples
from any other location.
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional • Keep the lids on empty sampling bottles until you
volume will be forced into the coolant tank during are ready to collect the sample.
engine operation. When the engine is stopped and
cool, the coolant will return to the engine. • 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 22
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·S Systems Coolant Analysis can be Type of
done at your Cat dealer. Cat S·O·S coolant analysis Level 1 Level 2
is the best way to monitor the condition of your Coolant
coolant and your cooling system. S·O·S coolant Cat DEAC
analysis is a program that is based on periodic Cat SCA
samples. Every 250 hours Yearly(1)
Conventional Heavy-
Duty Coolants
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with one of Cat ELC
the following coolants: Cat ELC (Extended Life Cat ELI
Optional(1) Yearly(1)
Coolant)., Cat ELI (Extended Life Inhibitor) and Commercial EC-1
Coolants
Conventional Heavy-Duty Coolant.
(1) The Level 2 Coolant Analysis should be performed sooner if a
Note: Obtain a Coolant Sample (Level 1) if the problem is suspected or identified.
cooling system is filled with any of the following
coolants: Cat DEAC, Cat SCA and Conventional Note: Check the SCA (Supplemental Coolant
Heavy-Duty Coolants. Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at
For additional information about coolant analysis and the interval that occurs first.
about other coolants, see this Operation and
Maintenance Manual, “Fluid Recommendations” or Obtain the sample of the coolant as close as possible
consult your Cat dealer. 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
Sampling Conditions pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
If the engine is equipped with a sampling port, the collecting samples can be obtained from your Cat
engine should be running at operating temperature dealer.
when the sample is obtained.
If the engine is not equipped with a sampling port, the NOTICE
Always use a designated pump for oil sampling, and
coolant should be warm.
use a separate designated pump for coolant sam-
Use the following guidelines for proper sampling of pling. Using the same pump for both types of sam-
the coolant: ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
• Complete the information on the label for the and an incorrect interpretation that could lead to con-
sampling bottle before you begin to take the cerns by both dealers and customers.
samples.

• Keep the unused sampling bottles stored in plastic Submit the sample for Level 1 analysis.
bags.
SEBU7919-10 123
Maintenance Section
Coolant Sample (Level 2) - Obtain

Note: Level 1 results may indicate a need for Level 2 For further information, refer to this Operation and
Analysis. Maintenance Manual, “Fluid Recommendations”.

i04638756 i06103506

Coolant Sample (Level 2) - Coolant Temperature

Obtain Regulator - Replace
SMCS Code: 1350-008; 1395-554; 1395-008; 7542 SMCS Code: 1355-510

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 Illustration 100 g00944247
recommendations are made. Top view of the expansion tank

Obtaining the Sample Replace the water temperature regulator before the
water temperature regulator fails. Replacing the
Refer to Operation and Maintenance Manual, water temperature regulator reduces the chances for
“Coolant Sample (Level 1) - Obtain” for the guidelines unscheduled downtime.
for proper sampling of the coolant.
A water temperature regulator that fails in a partially
Submit the sample for Level 2 analysis. opened position can cause overheating or over
cooling 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.
124 SEBU7919-10
Maintenance Section
Electrical Connections - Check

• lightning arrestors
NOTICE
Failure to replace your water temperature regulator Check all lead wires and electrical connections for
on a regularly scheduled basis could cause severe proper clearance.
engine damage.
Cat engines incorporate a shunt bypass design cool- i02659941
ing system and require operating the engine with a
water temperature regulator installed. Enclosure - Inspect
If the water temperature regulator is installed incor- SMCS Code: 7263-040; 7274-040
rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera- NOTICE
ture regulator is installed in the original position. En- Do not spray or splash water into the generator air in-
sure that the water temperature regulator vent hole is let or exhaust openings. Ensure that the openings
open. are covered in order to prevent water from entering
Do not use liquid gasket material on the gasket or cyl- the electrical windings and bearings.
inder head surface. The interior of the enclosure package and the
exterior of the enclosure package should be kept
clean. Wash the interior of the enclosure package
NOTICE and the exterior of the enclosure package with soap
Care must be taken to ensure that fluids are con- and water.
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. Ensure that the air discharge for the exhaust duct is
Be prepared to collect the fluid with suitable contain- clear. Clean debris, twigs, and leaves away from the
ers before opening any compartment or disassem- enclosure package, as needed.
bling any component containing fluids.
Lubricate the hinges on the door, as needed. Use
Refer to Special Publication, NENG2500, “Cat Dealer Caterpillar Multipurpose Lithium Complex Grease
Service Tool Catalog” or refer to Special Publication, (MPGL). If Caterpillar Multipurpose Lithium Complex
PECJ0003, “Cat Shop Supplies and Tools Catalog” Grease (MPGL) is not available, use a similar
for tools and supplies suitable to collect and contain multipurpose grease.
fluids on Cat products.
Note: Only chrome hinges require lubrication.
Dispose of all fluids according to local regulations Powder black door hinges do not require lubrication.
and mandates.
i02668687
Note: If replacing only the water temperature
regulator, only drain the coolant to a level that is Engine - Clean
below the water temperature regulator housing. SMCS Code: 1000-070
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 Personal injury or death can result from high
dealer. voltage.

i01595880
Moisture could create paths of electrical
conductivity.
Electrical Connections - Check Make sure the unit is off line (disconnected from
SMCS Code: 4459-535 utility and/or other generators), locked out and
tagged "Do Not Operate".
Check all exposed electrical connections for
tightness.
NOTICE
Check the following devices for loose mounting or for Water or condensation can cause damage to genera-
physical damage: tor components. Protect all electrical components
from exposure to water.
• transformers

• fuses
• capacitors
SEBU7919-10 125
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

• The air cleaner element should be replaced at

NOTICE
Accumulated grease and oil on an engine is a fire least one time per year. This replacement should
hazard. Keep the engine clean. Remove debris and be performed regardless of the number of
fluid spills whenever a significant quantity accumu- cleanings.
lates on the engine.
Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation,
thoroughly check the air cleaner elements for tears
Note: Do not steam clean the generator. Water may
and/or holes in the filter material. Inspect the gasket
damage the generator. or the seal of the air cleaner element for damage.
A clean engine provides the following benefits: Maintain a supply of suitable air cleaner elements for
replacement purposes.
• Easy detection of fluid leaks
Dual Element Air Cleaners
• Maximum heat transfer characteristics
The dual element air cleaner contains a primary air
• Ease of maintenance cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
i04322011 used up to six times if the element is properly
cleaned and inspected. The primary air cleaner
element should be replaced at least one time per
Engine Air Cleaner Element year. This replacement should be performed
(Dual Element) - Inspect/Clean/ regardless of the number of cleanings.
Replace The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
SMCS Code: 1051; 1054-510; 1054-040; 1054-070 should be removed and discarded for every three
cleanings of the primary air cleaner element. When
NOTICE the engine is operating in environments that are
Never run the engine without an air cleaner element dusty or dirty, air cleaner elements may require more
installed. Never run the engine with a damaged air frequent replacement.
cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.

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

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element. Illustration 101 g00736431
Unfiltered air will drastically accelerate internal
(1) Cover
engine wear. Your Cat dealer has the proper air (2) Primary air cleaner element
cleaner elements for your application. Consult your (3) Secondary air cleaner element
Cat dealer for the correct air cleaner element. (4) Turbocharger air inlet

• Check the precleaner (if equipped) daily for 1. Remove the cover. Remove the primary air cleaner
accumulation of dirt and debris. Remove any dirt element.
and debris, as needed.
2. The secondary air cleaner element should be
• Operating conditions (dust, dirt, and debris) may removed and discarded for every three cleanings
require more frequent service of the air cleaner of the primary air cleaner element.
element.
Note: Refer to “Cleaning the Primary Air Cleaner
• The air cleaner element may be cleaned up to six Elements”.
times if the element is properly cleaned and
inspected.
126 SEBU7919-10
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

3. Cover the turbocharger air inlet with tape in order There are two common methods that are used to
to keep out dirt. clean primary air cleaner elements:

4. Clean the inside of the air cleaner cover and body • Pressurized air
with a clean, dry cloth.
• Vacuum cleaning
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a Pressurized Air
primary air cleaner element that is new or cleaned.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator. Personal injury can result from air pressure.
Personal injury can result without following prop-
Cleaning the Primary Air Cleaner er procedure. When using pressure air, wear a
Elements protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
NOTICE than 205 kPa (30 psi) for cleaning purposes.
Caterpillar recommends certified air filter cleaning
services that are available at Cat dealers. The Cat Pressurized air can be used to clean primary air
cleaning process uses proven procedures to assure cleaner elements that have not been cleaned more
consistent quality and sufficient filter life. than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
Observe the following guidelines if you attempt to maximum pressure of 207 kPa (30 psi).
clean the filter element:
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets,
or seals. Dirt entering the engine will cause damage
to engine components.
Illustration 102 g00281692
The primary air cleaner element can be used up to
six times if the element is properly cleaned and Note: When the primary air cleaner elements are
inspected. When the primary air cleaner element is cleaned, always begin with the clean side (inside) in
cleaned, check for rips or tears in the filter material. order to force dirt particles toward the dirty side
The primary air cleaner element should be replaced (outside).
at least one time per year. This replacement should
be performed regardless of the number of cleanings. To help prevent damage to the paper pleats, aim the
hose so that the air flows inside the element along
Use clean primary air cleaner elements while dirty the length of the filter. Do not aim the stream of air
elements are being cleaned. directly at the primary air cleaner element. Dirt could
be forced further into the pleats.
NOTICE
Do not clean the air cleaner elements by bumping or Note: Refer to “Inspecting the Primary Air Cleaner
tapping. This could damage the seals. Do not use el- Elements”.
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.

Visually inspect the primary air cleaner elements

before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
SEBU7919-10 127
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace

Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.

Inspecting the Primary Air Cleaner

Elements
Illustration 104 g00281694

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

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box for
storage. For identification, mark the outside of the
box and mark the primary air cleaner element.
Include the following information:
• Date of cleaning

• Number of cleanings
Illustration 103 g00281693
Store the box in a dry location.
Inspect the clean, dry primary air cleaner element.
Use a 60W blue light in a dark room or in a similar i04871243
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears and/
Engine Air Cleaner Element
or holes. Inspect the primary air cleaner element for (Single Element) - Inspect/
light that may show through the filter material. If
necessary, compare the primary air cleaner element Replace
to a new primary air cleaner element that has the SMCS Code: 1051; 1054-510; 1054-040
same part number.
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged The high voltage that is produced by an operating
pleats, gaskets, or seals. Discard damaged primary generator set can cause severe injury or death.
air cleaner elements. Before performing any maintenance or repairs,
ensure that the generator will not start.
Storing Primary Air Cleaner Elements
Place the engine control switch in the “ OFF”” posi-
If a primary air cleaner element that passes tion. Attach “ DO NOT OPERATE”” tags to all start-
inspection will not be used, the primary air cleaner ing controls. Disconnect the batteries or disable
element can be stored for future use. the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Perform the Operation and Maintenance Manual,
“Engine Air Cleaner Service Indicator-Inspect”
procedure before performing the following procedure.
128 SEBU7919-10
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace

NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.

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

Note: This type of air cleaner is only available on

open generator sets.

Illustration 106 g01197952

2. Remove air cleaner element (3).

3. Inspect the replacement element for the following
items:damage, dirt and debris. Install a clean,
undamaged air filter element (3). Make sure that
the element is properly seated in the air cleaner
housing.

Illustration 105 g01197946

1. Unfasten latches (1). Remove cover (2).

Illustration 107 g01197946

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

SEBU7919-10 129
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

i06103548 If the service indicator does not reset easily, or if the

core does not latch at the greatest vacuum, the
Engine Air Cleaner Service service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Indicator - Inspect indicator may be plugged.
(If Equipped) If necessary, replace the service indicator more
frequently in environments that are severely dusty.
SMCS Code: 7452-040
Replace the service indicator annually regardless of
Some engines may be equipped with a different the operating conditions. Replace the service
service indicator. indicator when the engine is overhauled, and
whenever major engine components are replaced.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet Note: When a new service indicator is installed,
air pressure displays the difference in the pressure excessive force may crack the top of the service
that is measured before and after the air cleaner indicator. Tighten the service indicator to a torque of
element. As the air cleaner element becomes dirty, 2 N·m (18 lb in).
the pressure differential rises. If your engine is
equipped with a different type of service indicator, i06789513
follow the OEM recommendations in order to service
the air cleaner service indicator.
Engine Crankcase Breather -
The service indicator may be mounted on the clean
side of the air cleaner housing or in a remote Replace
location. SMCS Code: 1317-510

Turbocharged Engines and

Naturally Aspirated Engines
Note: The housing for the crankcase ventilator filter
must also be replaced on engines that are
turbocharged. Refer to “Replace the Housing of the
Crankcase Ventilator Filter and the Crankcase
Ventilator Filter”.

Replace the Breather on the Valve Cover

Illustration 108 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.

• Check for ease of resetting. The service indicator

should reset in less than three pushes.
• Check the movement of the service indicator core
when the engine is run at full load speed. The core
should latch approximately at the greatest vacuum Illustration 109 g01158025
that is attained. The crankcase breather is on the valve cover.
130 SEBU7919-10
Maintenance Section
Engine Crankcase Breather - Replace

Illustration 110 g01158031 Illustration 112 g01158042

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

Illustration 111 g01158039

(2) Screws
(3) Cover

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

SEBU7919-10 131
Maintenance Section
Engine Mounts - Inspect

4. Installation is the reverse of removal.

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

Illustration 114 g03046976

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

2. Turn lid in a counterclockwise direction for

approximately 15 degrees. Remove the Lid.
3. Remove crankcase ventilator filter.
Illustration 113 g06124866
4. Remove O-ring.
1. Disconnect the hoses from the housing (1) for the
5. Install a new O-ring.
crankcase ventilator filter. Remove the housing
(1). 6. Install a new crankcase ventilator filter.
7. Install lid (2).

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.
132 SEBU7919-10
Maintenance Section
Engine Oil Level - Check

i00623423 Obtain the Sample and the

Engine Oil Level - Check Analysis
SMCS Code: 1348-535-FLV

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
Hot oil and hot components can cause personal contact the skin.
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
Illustration 115 g00110310
• The amount of oil that has been added since the
(Y) “ADD” mark. (X) “FULL” mark.
last oil change

NOTICE To ensure that the sample is representative of the oil

Perform this maintenance with the engine stopped. in the crankcase, obtain a warm, mixed oil sample.
To avoid contamination of the oil samples, the tools
1. Maintain the oil level between “ADD” mark (Y) and and the supplies that are used for obtaining oil
“FULL” mark (X) on oil level gauge (1). Do not fill samples must be clean.
the crankcase above “FULL” mark (X). Caterpillar recommends using the sampling valve in
order to obtain oil samples. The quality and the
NOTICE consistency of the samples are better when the
Operating your engine when the oil level is above the sampling valve is used. The location of the sampling
“FULL” mark could cause your crankshaft to dip into valve allows oil that is flowing under pressure to be
the oil. The air bubbles created from the crankshaft obtained during normal engine operation.
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power. The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
2. Remove the oil filler cap and add oil, if necessary.
needed for obtaining oil samples. Instructions are
Clean the oil filler cap. Install the oil filler cap. also provided.

i04237495 NOTICE
Always use a designated pump for oil sampling, and
Engine Oil Sample - Obtain use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
SMCS Code: 1348-554-SM ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
In addition to a good preventive maintenance and an incorrect interpretation that could lead to con-
program, Caterpillar recommends using S·O·S oil cerns by both dealers and customers.
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels. 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.
SEBU7919-10 133
Maintenance Section
Engine Oil and Filter - Change

For instructions, see Special Publication, PEGJ0047, Drain Valve (If Equipped)
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.

i02307330

Engine Oil and Filter - Change

SMCS Code: 1318-510

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
Illustration 116 g01155733
oil to be drained properly.
Drain valve for the engine oil
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through 1. The oil drain valve may be connected to the used
the engine lubrication system with the new oil. oil tank for the vessel. The drain valve may have a
plug that is threaded into the end of the valve or
Drain the Engine Oil the fittings on the valve. If there is a plug, remove
the plug.
NOTICE 2. Open the drain valve and allow the oil to drain into
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- a suitable container or the piping for used oil on
nance, testing, adjusting and repair of the product. the vessel. Dispose of the used oil in accordance
Be prepared to collect the fluid with suitable contain- with local regulations.
ers before opening any compartment or disassem-
bling any component containing fluids.
Replace the Oil Filter
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup- NOTICE
plies suitable to collect and contain fluids on Caterpil- Caterpillar oil filters are built to Caterpillar specifica-
lar products. tions. Use of an oil filter not recommended by Cater-
pillar could result in severe engine damage to the
Dispose of all fluids according to local regulations engine bearings, crankshaft, etc., as a result of the
and mandates. larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom-
Remove the oil drain plug from the oil pan or use one
mended by Caterpillar.
of the following methods in order to drain the engine
oil into a suitable container. Dispose of the used oil in
accordance with local regulations. 1. Remove the oil filter with a 1U-8760 Chain
Wrench.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter. Break apart the pleats and inspect the oil
filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear
or a pending failure.
134 SEBU7919-10
Maintenance Section
Engine Valve Lash - Check

Use a magnet to differentiate between the ferrous 5. Install the oil filter. Tighten the oil filter until the oil
metals and the nonferrous metals that are found in filter gasket contacts the base. Tighten the oil filter
the oil filter element. Ferrous metals may indicate by hand according to the instructions that are
wear on the steel and cast iron parts of the engine.
shown on the oil filter. Do not overtighten the oil
Nonferrous metals may indicate wear on the filter.
aluminum parts, brass parts or bronze parts of the
engine. Parts that may be affected include the Fill the Engine Crankcase
following items: main bearings, rod bearings,
turbocharger bearings and cylinder heads.
1. Remove the oil filler cap. Refer to the Operation
Due to normal wear and friction, it is not and Maintenance Manual, “Refill Capacitites and
uncommon to find small amounts of debris in the Recommendations” for more information on the
oil filter. Consult your Caterpillar dealer in order to proper type of oil. Fill the crankcase with the
arrange for a further analysis if an excessive
amount of debris is found in the oil filter. proper amount of oil. Refer to the Operation and
Maintenance Manual, “Refill Capacitites and
Recommendations” for the proper amount of oil.

NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or
overfilling the crankcase with oil can cause engine
damage.

NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
Illustration 117 g00741009
Typical mounting base for the oil filter and oil filter 2. Start the engine and run the engine for two
gasket minutes. Perform this procedure in order to ensure
that the lubrication system has oil and that the oil
3. Clean the sealing surface of the filter mounting filters are filled. Inspect the oil filter for oil leaks.
base. Ensure that all of the old oil filter gasket is
removed. 3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes.
4. Apply clean engine oil to the new oil filter gasket.
4. Remove the oil level gauge in order to check the oil
NOTICE level. Maintain the oil level between the “ADD” and
Do not fill the oil filters with oil before installing them. “FULL” marks on the oil level gauge.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear i04242309
to engine components.
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.
SEBU7919-10 135
Maintenance Section
Fuel System - Prime

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
measuring/adjusting valve lash clearance.

i06789522

Fuel System - Prime

Illustration 118 g03868235
SMCS Code: 1250-548; 1258-548 (1) Vent screw
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be 1. Slacken the vent screw (1).
started. Air can enter the fuel system when the
following events occur:

• The fuel tank is empty or the fuel tank has been

partially drained.

• The low-pressure fuel lines are disconnected.

• A leak exists in the low-pressure fuel system.

• The fuel filter is replaced.

• A new injection pump is installed.
Use the following procedure to remove air from the
fuel system:

Fuel system - Prime (Non-Marine

Classification Society)
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.
136 SEBU7919-10
Maintenance Section
Fuel System - Prime

Illustration 119 g03869655

2. Remove the starter solenoid wire (2) and press

NOTICE
start. Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
Note: The control panel will run through the start minutes before cranking the engine again.
sequence but will not crank. The fuel lift pump will
operate during crank cycle until the system is bled.
The fuel pump operation can be heard during this
period.

Note: Perform bleeding of system for no longer than

30 seconds, then allow the lift pump to cool down for
a minimum of 2 minutes.

3. Press the Stop button and tighten the vent screw.

4. Start the engine in the normal way.

Fuel System - Prime ( Marine

Classification Society 1)
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:

• The fuel tank is empty or the fuel tank has been

partially drained.
• The low-pressure fuel lines are disconnected. Illustration 120 g03869666
(1) Vent screws
• A leak exists in the low-pressure fuel system. (2) Lever

• The fuel filter is replaced.

1. Slacken the vent screws (1), starting with the first
• A new injection pump is installed. one in the system, turn the lever (2) to one side.

Use the following procedure to remove air from the

fuel system:
SEBU7919-10 137
Maintenance Section
Fuel System - Prime

Illustration 122 g01003929

Injector nuts

Note: Damage to the following components may

occur if the starting motor is used excessively to
purge the air from the fuel system: fuel injection
Illustration 121 g06116331
pump, the battery, and the starting motor.
(4) E STOP button 4. Loosen the flare nuts (1) for the high-pressure fuel
lines on all the fuel injectors.
2. Allow the engine to crank and press the 'E STOP'
button (4), the fuel will start to fill the fuel canister. NOTICE
Do not crank the engine continuously for more than
3. Start the engine in the normal way.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
NOTICE
Perform this for no longer than 30 seconds, then al-
low the lift pump to cool down for a minimum of 2 5. Observe the connection at the flare nut. Operate
minutes. the starting motor and crank the engine until the
fuel is free of air.

Priming the Fuel System with the 6. Tighten the flare nuts (1) to a torque of 30 N·m
(22 lb ft).
“ START”” Switch
7. The engine is now ready to start. Operate the
1. Remove the cover for the fuel injectors. Refer to engine at low idle for a minimum of 5 minutes
the Disassembly and Assembly Manual. immediately after air has been removed from the
fuel system.
2. Turn the key switch to the RUN position. Leave the
key switch in the RUN position for 3 minutes.
3. Turn the key switch to the OFF position.
138 SEBU7919-10
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

Note: Running the engine for this period will help Note: The fuel level in element (3) should be reduced
ensure that the pump is free of air. before removal of the element. Remove cap (1) if the
element is not equipped with a drain on the bottom.
i02214246 Remove the nylon insert in order to reduce the level
of fuel in the element. A reduction in the level of fuel
Fuel System Primary Filter in the element will help prevent fuel from being spilled
when the element is removed.
(Water Separator) Element -
Replace NOTICE
Do not use a tool in order to remove the fuel filter. At-
SMCS Code: 1260-510-FQ; 1263-510-FQ tempting to remove the fuel filter with a filter wrench
or a filter strap could damage the locking ring.

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

Fuel leaked or spilled onto hot surfaces or electri- counterclockwise. Remove locking ring (2). The
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when used element should be removed and discarded.
changing fuel filters or water separator elements.
Clean up fuel spills immediately. Note: If the element is equipped with a sediment
bowl, remove the sediment bowl from the element.
Thoroughly clean the sediment bowl. Inspect the O-
ring seals for wear or damage. Install new O-ring
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly seals, if necessary. Install the sediment bowl onto the
clean the area around a fuel system component that new element. Hand tighten the sediment bowl. Hand
will be disconnected. Fit a suitable cover over discon- tightening is the only method that should be used.
nected fuel system component.
NOTICE
Turn the fuel supply valve to the OFF position before Do not fill fuel filters with fuel before installing them.
performing this maintenance. Place a tray under the Contaminated fuel will cause accelerated wear to fuel
fuel filter in order to catch any fuel that might spill. system parts.
Clean up any spilled fuel immediately.

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

element fully into the filter head.
5. Hold the element in place. Fit locking ring (2) into
position. Rotate the locking ring clockwise in order
to fasten the element to the filter head.

Note: If the nylon insert was removed, install the

nylon insert and install cap (1).

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

Maintenance Manual, “Fuel System - Prime” for
more information.

i01713207
Illustration 123 g00741109
(1) Cap Fuel System Secondary Filter -
(2) Locking ring
(3) Element Replace
(4) Water separator bowl
(5) Drain SMCS Code: 1261-510-SE

1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly. Drain Fuel leaked or spilled onto hot surfaces or electri-
the fuel into a suitable container by using the fuel cal components can cause a fire. To help prevent
drain on the bottom of element (3). Drain the water possible injury, turn the start switch off when
from water separator (4) into a suitable container. changing fuel filters or water separator elements.
Not all engines are equipped with a water Clean up fuel spills immediately.
separator.
SEBU7919-10 139
Maintenance Section
Fuel Tank Water and Sediment - Drain

Note: If the element is equipped with a sediment

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly bowl, remove the sediment bowl from the element.
clean the area around a fuel system component that Thoroughly clean the sediment bowl. Inspect the O-
will be disconnected. Fit a suitable cover over discon- ring seals. Install new O-ring seals, if necessary.
nected fuel system component. Install the sediment bowl to the new element. Hand
tighten the sediment bowl. Hand tightening is the only
Turn the fuel supply valve to the OFF position before method that should be used.
performing this maintenance. Place a tray under the
fuel filter in order to catch any fuel that might spill.
Clean up any spilled fuel immediately. NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.

4. Ensure that the fuel filter base is clean. Push a

new fuel filter fully into the fuel filter base.
5. Hold the fuel filter in place. Fit locking ring (3) into
position. Rotate the locking ring clockwise in order
to fasten the fuel filter to the fuel filter base.
Note: If the nylon insert was removed, install the
nylon insert and install cap (1).

6. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System - Prime”.
Illustration 124 g00802952
(1) Cap i06104305
(2) Fuel filter base
(3) Quick release collar
(4) Fuel filter
Fuel Tank Water and Sediment
(5) Drain valve for fuel filter - Drain
1. Close the fuel supply valve. SMCS Code: 1273-543-M&S

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

NOTICE
drain valve (5) and drain the fuel and water from Care must be taken to ensure that fluids are con-
fuel filter (4) into a suitable container. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Note: If the fuel filter element is not equipped with a Be prepared to collect the fluid with suitable contain-
drain, remove cap (1). Remove the nylon insert in ers before opening any compartment or disassem-
order to reduce the level of fuel in the fuel filter bling any component containing fluids.
element. A reduction in the level of fuel in the fuel
filter element will help prevent fuel from being spilled Refer to Special Publication, NENG2500, “Cat Dealer
when the element is removed. Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
NOTICE fluids on Cat products.
Do not use a tool in order to remove the fuel filter. At-
tempting to remove the fuel filter with a filter wrench Dispose of all fluids according to local regulations
or a filter strap could damage the locking ring. and mandates.

3. Hold fuel filter (4) and rotate quick release collar

(3) counterclockwise. Remove quick release collar
(3). The used element should be removed and
discarded.
140 SEBU7919-10
Maintenance Section
Generator - Dry

Fuel Tank If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
Fuel quality is critical to the performance and to the settle before filling the engine fuel tank. Internal
service life of the engine. Water in the fuel can cause baffles in the bulk storage tank will also help trap
excessive wear to the fuel system. Condensation sediment. Filtering fuel that is pumped from the
occurs during the heating and cooling of fuel. The storage tank helps to ensure the quality of the fuel.
condensation occurs as the fuel passes through the When possible, water separators should be used.
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining i03642821
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. The
fuel tank utilizes a fuel tank vent to prevent an air lock Generator - Dry
or vacuum. Ensure that the vent is free of debris and SMCS Code: 4450-569
not damaged.

Drain the Water and the Sediment NOTICE

Do not operate the generator if the windings are wet.
If the generator is operated when the windings are
Fuel tanks should contain some provision for draining
wet, damage can occur due to insulation breakdown.
water and draining sediment from the bottom of the
fuel tanks. When moisture is present or when moisture is
Prepare to catch water and sediment in an suspected in a generator, the generator must be
appropriate container. Connect a hose (if necessary) dried before being energized.
to the valve prior to opening the valve.
If the drying procedure does not restore the insulation
Open the drain valve on the bottom of the fuel tank in resistance to an acceptable value, the winding should
order to drain the water and the sediment. Close the be reconditioned.
drain valve.
Note: For additional information, refer to Special
Note: Failure to close the drain properly could result Instruction, SEHS9124 .
in fuel leakage, which could have detrimental results
to performance. Drying Methods
Check the fuel daily. Drain the water and sediment The following methods can be used for drying a
from the fuel tank after operating the engine. Drain generator:
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure. • Self-circulating air method

Fill the fuel tank after operating the engine in order to • Oven method
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel NOTICE
expands as the fuel gets warm. The tank may Do not allow the winding temperature to exceed
overflow. 85 °C (185.0 °F). Temperatures that are greater than
85 °C (185.0 °F) will damage the winding insulation.
Some fuel tanks use stand pipes that allow water and
sediment to settle below the end of the fuel stand
pipe. Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is Self-Circulating Air Method
equipped with this system, regular maintenance of
the fuel system filter is important. Note: Disable the excitation before using this
method.
Fuel Storage Tanks Run the engine and disconnect the generator load.
This will help circulate air. Operate the generator
Drain the water and the sediment from the fuel space heaters.
storage tank during the following conditions:

• Weekly Oven Method

• Refill of the tank Place the entire generator inside a forced air drying
oven for four hours at 65 °C (149 °F).
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.
SEBU7919-10 141
Maintenance Section
Generator - Inspect

These contaminants will develop a conductive path

NOTICE which may produce shorts. Cleaning is advisable if
Use a forced air type oven rather than a radiant type
oven. heavy accumulations of dirt can be seen or if heavy
accumulations of dust can be seen. If excess dirt is
Radiant type ovens can cause localized overheating. the cause of a restriction in the ventilation, cleaning is
also advisable. Restricted ventilation will cause
excessive heating.
i06639212
NOTICE
To avoid the possibility of deterioration to the genera-
Generator - Inspect tor windings, do not clean the generator unless there
SMCS Code: 4450-040 is visual, electrical, or thermal evidence that dirt is
present.

If harmful dirt accumulations are present, various

Personal injury or death can result from improper cleaning techniques are available. The cleaning
troubleshooting and repair procedures. procedure that is used may be determined by one of
the items on the following list:
The following troubleshooting and repair proce-
dures should only be performed by qualified per- • The extent of the cleaning procedure that is being
sonnel familiar with this equipment. attempted
• The type of enclosure of the generator

• The voltage rating of the generator

The high voltage that is produced by an operating • The type of dirt that is being removed
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start. Cleaning (Assembled Generators)
Place the engine control switch in the “ OFF”” posi-
NOTICE
tion. Attach “ DO NOT OPERATE”” tags to all start- Do not use water to clean the generator.
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator. NOTICE
Do not use trichloroethane, perchloroethylene, tri-
Refer to Safety Section, “Generator Isolating for chloroethane, or any alkaline products to clean the
Maintenance” for information regarding the generator.
procedure to isolate the generator safely.
Cleaning may be required at the point of installation.
Proper maintenance of electrical equipment requires Complete disassembly of the generator may not be
periodic visual examination of the generator and necessary or feasible. In this case, a vacuum cleaner
periodic visual examination of the windings. Proper should be used to pick up the following items: dry dirt,
maintenance of electrical equipment also requires dust, and carbon. Cleaning the generator will prevent
appropriate electrical checks and appropriate thermal the spreading of these contaminants.
checks. Insulation material should be examined for
cracks. The insulation material should be examined A small nonconductive tube may need to be
for accumulations of dirt and dust. If there is an connected to the vacuum cleaner. The small
insulation resistance value that is below normal, a nonconductive tube will allow the vacuum cleaner to
conductive path may be present. This conductive clean the surfaces that are not exposed. After dust is
path may be made of one of the following materials: removed, use a small brush attached to the vacuum
hose to remove dirt that is firmly attached to the
• Carbon surface.

• Salt

• Metal dust
• Dirt that is saturated with moisture
142 SEBU7919-10
Maintenance Section
Generator Load - Check

After the initial cleaning with a vacuum, compressed Note: For more information on drying methods, refer
air may be used to remove the remaining dust and to Special Instructions, SEHS9124, “Cleaning and
dirt. Compressed air that is used for cleaning should Drying of Electric Set Generators”.
be free of moisture and free of oil. Air pressure
should be a maximum of 210 kPa (30 psi) to prevent i01878834
mechanical damage to the insulation. If the above
cleaning procedures are not effective, consult a
Caterpillar dealer. Generator Load - Check
SMCS Code: 4450-535-LA
Cleaning (Disassembled
Generators)
Personal injury or death can result from high
NOTICE voltage.
Do not use water to clean the generator.
When power generation equipment must be in
operation to make tests and/or adjustments, high
NOTICE voltage and current are present.
Do not use trichloroethane, perchloroethylene, tri-
chloroethane, or any alkaline products to clean the Improper test equipment can fail and present a
generator. high voltage shock hazard to its user.

An initial insulation resistance check should be made Make sure the testing equipment is designed for
on the generator to confirm electrical integrity. A and correctly operated for high voltage and cur-
minimum reading of 1megohm would be expected rent tests being made.
with severely contaminated generators. A zero
megohm reading may indicate an insulation During normal operation, monitor the power factor
breakdown. An insulation breakdown requires more and monitor generator loading.
than cleaning. An insulation breakdown requires
repair. When a three-phase generator is installed or when a
three-phase generator is reconnected, ensure that
Use the following for cleaning the stator, the rotor, the the total current in any one phase does not exceed
exciter, and the diode bridge: the nameplate rating. Each phase should carry the
same load. This allows the three-phase generator to
• Unleaded Gasoline work at the rated capacity. If one phase current
exceeds the nameplate amperage, an electrical
• Toluene imbalance will occur. An electrical imbalance can
result in an electrical overload and an electrical
• Benzene imbalance can result in overheating on three-phase
generators. This is not applicable to single-phase
• Cyclohexane generators.

Avoid permitting the solvent to run into the slots. The power factor can be referred to as the efficiency
Apply the solvent with a brush. Use a sponge on the of the load. This can be expressed as the ratio of kVA
windings frequently to remove the debris. Dry the to actual kW. The power factor can be calculated by
winding with a dry cloth. Allow the solvent to dividing kW by kVA. Power factor is expressed as a
evaporate before reassembling the generator. decimal. Power factor is used to mean the portion of
current that is supplied to a system that is doing
Allow the generator to dry at room temperature. useful work. The portion of the current that is not
Check the insulation resistance. The insulation doing useful work is absorbed in maintaining the
resistance should now be normal. If the insulation magnetic field in motors. This current (reactive load)
resistance is not normal, repeat the procedure. can be maintained without engine power.
SEBU7919-10 143
Maintenance Section
Generator Set - Test

i05731121 1. Stop the generator. Connect the potential

transformer high voltage winding to the generator
Generator Set - Test terminals (T1) and (T2). Connect the voltmeter to
SMCS Code: 4450-081 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
Personal injury or death can result from high correspond to generator terminal (T2) of both
voltage. transformers together.

When power generation equipment must be in 2. Disconnect wires “E+” and “E-” from the voltage
operation to make tests and/or adjustments, high regulator. Disconnect the generator from the load.
voltage and current are present.
3. Connect a 12 VDC automotive battery to wires “E
Improper test equipment can fail and present a +” and “E-” .
high voltage shock hazard to its user.
4. Measure the AC voltage across the low voltage
Make sure the testing equipment is designed for terminals of the transformer that correspond to the
and correctly operated for high voltage and cur- following generator terminals: “T1” and “T2” , “T2”
rent tests being made. and “T3” and “T3” and “T1” . Record the voltages.
When servicing or repairing electric power gener-
ation equipment: i04497390

• Make sure the unit is off-line (disconnected Generator Set Vibration - Test/
from utility and/or other generators power
service), and either locked out or tagged DO Record
NOT OPERATE. SMCS Code: 4450-081-VI
• Make sure the generator engine is stopped. Excessive vibration will indicate a problem with the
generator set. The vibration may be caused by the
• Make sure all batteries are disconnected. following:
• Make sure all capacitors are discharged. • Misalignment of the coupling between the engine
and the generator
Table 23 • Faulty mounting or play in the coupling
Required Tools
• Incorrect balancing of the generator shaft or
Part Number Part Description Qty engine crankshaft
6V-7070 Digital Multimeter 1 • A three-phase generator has too much load on a
- 12 VDC Battery 1
single phase.

- Potential Transformer 1 • There is a short circuit in the stator.

Check for vibration damage. Vibration may cause the
The generator set functional test is a simplified test following problems:
that can be performed in order to determine if the
generator is functional. The generator set functional • loose fittings
test should be performed on a generator set that is
under load. • loose bolts
The generator set functional test determines if the • excessive noise
following statements happen:
• cracked insulation
• A phase voltage is being generated.
The following areas are susceptible to vibration
• The phase voltages are balanced. damage:
• The phase voltages change relative to engine • stator output leads
speed.
• protective sleeving
The generator set functional test consists of the
following steps: • insulation
144 SEBU7919-10
Maintenance Section
Generator Winding Insulation - Test

• exposed electrical connections The insulation tester (megohmmeter) produces a

high potential voltage between the test leads. During
• transformers the test, a small amount of current flows. The tester
converts this current to a resistance reading.
• fuses
The insulation test is performed as part of periodic
• capacitors maintenance in order to detect the deterioration of
the winding insulation. When there is a rapid
Check the vibration level of the generator set by decrease in the insulation resistance in a short
using a broad spectrum analyzer. Record the results. amount of time, the generator needs to be cleaned.

Note: For information on generator cleaning, refer to

i04863034
Special Instruction, SEHS9124.
Generator Winding Insulation - When generators have not been used recently,
moisture can accumulate. Therefore, the insulation
Test test should be performed on generators that have
SMCS Code: 4453-081; 4454-081; 4457-081; 4470- been idle. If moisture is known to exist, the windings
081 must be dried prior to testing. Refer to Testing and
Adjusting, “Generator - Dry”.
The insulation test should be performed on
generators that are being used for the first time. The
The high voltage that is produced by an operating insulation test should be performed more frequently
generator set can cause severe injury or death. in the following cases:
Before performing any maintenance or repairs,
ensure that the generator will not start. • The generator set is operating in a humid
environment.
Place the engine control switch in the “ OFF”” posi-
tion. Attach “ DO NOT OPERATE”” tags to all start- • The generator set is not protected from the
ing controls. Disconnect the batteries or disable elements in an enclosed area.
the starting system. Lock out all switchgear and
automatic transfer switches that are associated • The generator set has not been run under load for
with the generator. 3 months.
Table 24 Note: The use of space heaters may be needed
TOOLS NEEDED around the generator set in the following cases:
Part Number Tool Quantity • The generator set has not been run under load for
3 months.
142-5055 Insulation Tester 1
Megohmmeter
• The generator set is exposed to a sea water
environment.

• The humidity is above 75 percent.

Personal injury or death can result from • A test result was below 3 megohms.
electrocution.
Recondition or replace the winding in the following
The megohmmeter is applying a high voltage to cases:
the circuit.
• The measured insulation resistance falls below the
To avoid electrocution, do not touch the instru- specified amount. The cleanup procedure does
ment leads without first discharging them. When
finished testing also discharge the generator not correct the discrepancy.
windings.
• The measured insulation resistance falls below the
The following materials will cause the winding specified amount. The drying procedure does not
insulation to deteriorate:moisture, dust, grease and correct the discrepancy.
other foreign matter within the generator.
The specified insulation resistance is an approximate
This deterioration reduces the resistance of the value. The generator may be operated with less than
insulation. This test will measure the resistance of the the specified value. However, a generator that has a
winding insulation. low winding insulation resistance will be more likely
to have a failure.
SEBU7919-10 145
Maintenance Section
Heat Exchanger - Inspect

4. Measure the resistance of the exciter field winding

insulation to ground. The insulation resistance
Personal injury or death can result from improper must be a minimum of 0.25 megohm (250000
troubleshooting and repair procedures. ohms).
The following troubleshooting and repair proce-
dures should only be performed by qualified per- Exciter Armature (Rotor L2)
sonnel familiar with this equipment.
1. Isolate exciter armature (L2) from the rectifier
circuit. Disconnect the three wires of the exciter
The insulation test gives accurate results only when armature from the rectifier blocks.
the generator windings are free of moisture and the
generator windings are at room temperature. 2. Connect one test lead of the insulation tester
(megohmmeter) to the rotor shaft.
Each winding must have a minimum insulation
resistance of 1 megohm. 3. Connect one test lead of the insulation tester
(megohmmeter) to any one exciter field lead.
Main Armature (Stator L4) 4. The insulation resistance must be a minimum of
0.25 megohm (250000 ohms).
1. Remove the load from the generator by either of
the following:
i01592749

• Open the line circuit breaker.

Heat Exchanger - Inspect
• Open the following load connections: T1, T2, SMCS Code: 1379-040
T3 and T0.
The interval for the maintenance of the tube type heat
Prevent these wires from coming into contact with exchanger depends on the operating environment of
each other and prevent these wires from the vessel and on the operating time. The sea water
contacting ground. that is circulated through the heat exchanger and the
2. Isolate the main armature (L4) from the voltage amount of operating time of the vessel affects the
regulator by disconnecting the wires for voltage following items:
sensing. If generator lead (T0) is connected to the • Cleanliness of the tubes for the heat exchanger
generator frame or ground, open the connection.
• Effectiveness of the heat exchanger system
3. Connect one test lead of the insulation tester
(megohmmeter) to the generator enclosure Operating in water that contains silt, sediment, salt,
(ground). algae, etc will adversely affect the heat exchanger
system. In addition, intermittent use of the vessel will
4. Connect the other test lead of the insulation tester adversely affect the heat exchanger system.
(megohmmeter) to generator lead (T0).
The following items indicate that the heat exchanger
5. The insulation resistance must be 1 megohm or may require cleaning:
more.
• Increased coolant temperature
Exciter Field (Stator L1) • Engine overheating
1. Isolate exciter field (L1) from the voltage regulator • Excessive pressure drop between the water inlet
by disconnecting wires 5+ and 6-. Prevent these and the water outlet
wires from coming into contact with each other
An operator that is familiar with the normal operating
and prevent these wires from contacting ground. temperature of the coolant can determine when the
2. Connect one test lead of the insulation tester coolant temperature is out of the normal range.
(megohmmeter) to the generator enclosure Inspection and maintenance of the heat exchanger
are required if the engine is overheating.
(ground).
3. Connect one test lead of the insulation tester Cleaning the Heat Exchanger
(megohmmeter) to exciter field lead (5+ or 6-).
1. Remove the heat exchanger. Refer to the Service
Manual for the procedure.
146 SEBU7919-10
Maintenance Section
Hoses and Clamps - Inspect/Replace

2. Turn the heat exchanger core upside-down in For more information on cleaning the core, consult
order to remove debris. your Caterpillar dealer.

NOTICE i06825542
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
Hoses and Clamps - Inspect/
cause leakage. Only use the recommended concen- Replace
tration of cleaner.
SMCS Code: 7554-510; 7554-040

3. Back flush the core with cleaner. Hoses and clamps must be inspected periodically
and replaced at the recommended interval to ensure
Caterpillar recommends the use of Hydrosolv safe and continuous operation of the engine. Failure
liquid cleaner. Table 25 lists Hydrosolv liquid to replace a fuel hose at the recommended change
cleaners that are available from your Caterpillar interval may result in a hazardous situation. Take
dealer. proper safety precautions before inspecting or
Table 25 replacing hoses and clamps.
Hydrosolv Liquid Cleaners(1) Note: Always use a board or cardboard when the
Part Number Description Size engine components are checked for leaks. Leaking
fluid that is under pressure can cause serious injury
1U-5490 Hydrosolv 4165 19 L (5 US gallon) or possible death. Leaks that are the size of a pin
Hydrosolv 100 19 L (5 US gallon)
hole are included. Refer to Operation and
174-6854
Maintenance Manual, “General Hazard Information”
(1) Use a two to five percent concentration of the cleaner at tem- for more information.
peratures up to 93°C (200°F). Refer to Application Guide,
NEHS0526 or consult your Caterpillar dealer for more Note: Ensure that the hose is compatible with the
information.
application.
4. Steam clean the core in order to remove any
residue. Flush the tubes of the heat exchanger Inspect Tubes, Hoses, Bellows, and
core. Remove any other trapped debris. Clamps
5. Wash the core with hot, soapy water. Rinse the Inspect all tubes and hoses for leaks that are caused
core thoroughly with clean water. by the following conditions. Replace any tube or hose
which exhibits any of the following conditions. Failure
to replace a tube or hose which exhibits any of the
following conditions may result in a hazardous
Personal injury can result from air pressure. situation.

Personal injury can result without following prop- • Hoses which are cracked
er procedure. When using pressure air, wear a
protective face shield and protective clothing. • Hoses which are soft

Maximum air pressure at the nozzle must be less • Outer covering that is chafed or cut
than 205 kPa (30 psi) for cleaning purposes.
• Exposed wire that is used for reinforcement
6. Dry the core with compressed air. Direct the air in • Outer covering that is ballooning locally
the reverse direction of the normal flow.
• Flexible part of the hose that is kinked or crushed
7. Inspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service • Armoring that is embedded in the outer covering
radiators are equipped to perform pressure tests.
If necessary, repair the core. • Exhaust bellows for leaks or damage

8. Install the heat exchanger. Refer to the Service • Hoses which exhibit signs of leakage which are
Manual for the procedure. 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
SEBU7919-10 147
Maintenance Section
Hoses and Clamps - Inspect/Replace

• Looseness
• Damage
Personal injury can result from removing hoses
Inspect all couplings for leaks. Replace any coupling or fittings in a pressure system.
which exhibits signs of leaks.
Failure to relieve pressure can cause personal
Each installation application can be different. The injury.
differences depend on the following factors:
Do not disconnect or remove hoses or fittings un-
• Type of hose til all pressure in the system has been relieved.

• Type of fitting material 1. Stop the engine.

• Anticipated expansion and contraction of the hose 2. Allow the engine to cool.
• Anticipated expansion and contraction of the 3. Before servicing a coolant hose, slowly loosen the
fittings filler cap for the cooling system to relieve any
pressure.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen 4. Remove the filler cap for the cooling system.
which can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. 5. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
Replace hoses that are cracked or soft. Replace Drain the coolant into a suitable clean container.
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps The coolant can be reused.
that are cracked or damaged. Tighten or replace 6. Remove the hose clamps.
hose clamps which are loose.
7. Disconnect the old hose.
Replace the Hoses and the Clamps 8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or
NOTICE
Care must be taken to ensure that fluids are con- install new hose clamps. Refer to Specifications,
tained during performance of inspection, mainte- SENR3130, “Torque Specifications” “Hose
nance, testing, adjusting, and repair of the product. Clamps” for information about selecting and
Be prepared to collect the fluid with suitable contain- installing the proper hose clamps.
ers before opening any compartment or disassem-
bling any component containing fluids. 10. Refill the cooling system.
Refer to Special Publication, NENG2500, “Cat Dealer 11. Clean the coolant filler cap. Inspect the gaskets
Service Tool Catalog” or refer to Special Publication, on the filler cap. Inspect the gasket seat. Inspect
PECJ0003, “Cat Shop Supplies and Tools Catalog” the vacuum valve and seat for debris or damage.
for tools and supplies suitable to collect and contain Replace the filler cap if the gaskets are damaged.
fluids on Cat products.
Install the filler cap.
Dispose of all fluids according to local regulations 12. Start the engine. Inspect the cooling system for
and mandates.
leaks.

Cooling System Fuel System

Pressurized System: Hot coolant can cause seri- Personal injury can result from removing hoses
ous burns. To open the cooling system filler cap, or fittings in a pressure system.
stop the engine and wait until the cooling system Failure to relieve pressure can cause personal
components are cool. Loosen the cooling system injury.
pressure cap slowly in order to relieve the
pressure. Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
148 SEBU7919-10
Maintenance Section
Hoses and Clamps - Inspect/Replace

7. Refill the fuel system. Refer to this Operation and

Maintenance Manual, “Fuel System - Prime” for
Contact with high pressure fuel may cause fluid information about priming the engine with fuel.
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow 8. Start the engine. Inspect the fuel system for leaks.
these inspection, maintenance and service in-
structions may cause personal injury or death. Lubrication System

NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
any loose or damaged fuel and oil lines, tubes and
contact the skin.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
recommended torque. 1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
NOTICE 2. Remove the hose clamps.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that 3. Disconnect the old hose.
will be disconnected. Fit a suitable cover over any
disconnected fuel system components. 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,
Note: High-pressure fuel lines may be installed
between the high-pressure fuel pump and the fuel SENR3130, “Torque Specifications” “Hose
injectors. High-pressure fuel lines are constantly Clamps” for information about selecting and
charged with high pressure. Do not check the high- installing the proper hose clamps.
pressure fuel lines with the engine or the starting 6. Refill the lubrication system. Refer to this
motor in operation. Wait for 10 minutes after the
Operation and Maintenance Manual, “Engine Oil
engine stops before you perform any service or
repair on high-pressure fuel lines. Waiting for 10 Level - Check” to ensure that the lubrication
minutes will allow the pressure to be purged. system is filled with the proper amount of engine
oil.
1. Drain the fuel from the fuel system to a level that is
7. Start the engine. Inspect the lubrication system for
below the hose that is being replaced.
leaks.
2. Remove the hose clamps.
Air System
3. Disconnect the old hose.
Note: When servicing fuel system, use cap/s or 1. Remove the hose clamps.
cover/s as required to protect the system and 2. Disconnect the old hose.
maintain fuel system cleanliness.
3. Replace the old hose with a new hose.
4. Replace the old hose with a new hose.
4. Install hose clamps which have been inspected or
5. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications,
install new hose clamps. Refer to Specifications, SENR3130, “Torque Specifications” “Hose
SENR3130, “Torque Specifications” “Hose Clamps” for information about selecting and
Clamps” for information about selecting and installing the proper hose clamps.
installing the proper hose clamps.
Note: The bellows and the V-clamps that are used on
6. Carefully inspect the engine for any spilled fuel. the exhaust bellows should never be reused.
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.
SEBU7919-10 149
Maintenance Section
Overhaul Considerations

5. Start the engine. Inspect the air lines for leaks. • Many original parts can be reused according to the
standards for reusable parts.
i01585907
• The engine's service life can be extended without
the risk of a major catastrophe due to engine
Overhaul Considerations failure.
SMCS Code: 7595-043
• The best cost/value relationship per hour of
Reduced hours of operation at full load will result in a extended life can be attained.
lower average power demand. A decreased average
power demand should increase both the engine After Failure Overhaul
service life and the overhaul interval.
If a major engine failure occurs and the engine must
The need for an overhaul is generally indicated by be removed from the hull, many options are
increased fuel consumption and by reduced power. available. An overhaul should be performed if the
engine block or the crankshaft needs to be repaired.
The following factors are important when a decision
is being made on the proper time for an engine If the engine block is repairable and/or the crankshaft
overhaul: is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
• The need for preventive maintenance with a similar exchange core.
• The quality of the fuel that is being used This lower cost can be attributed to three aspects:
• The operating conditions • Specially designed Caterpillar engine features
• The results of the S·O·S analysis • Caterpillar dealer exchange components

Oil Consumption as an Overhaul • Caterpillar remanufactured exchange components

Indicator Overhaul Recommendation
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total To minimize downtime, Caterpillar recommends a
operating cost for your Caterpillar engine. Oil scheduled engine overhaul by your Caterpillar dealer
consumption can also be used to estimate the before the engine fails. This will provide you with the
required capacity of a makeup oil tank that is suitable best cost/value relationship.
for the maintenance intervals.
Note: Overhaul programs vary according to the
Oil consumption is in proportion to the percentage of engine application and according to the dealer that
the rated engine load. As the percentage of the performs the overhaul. Consult your Caterpillar
engine load is increased, the amount of oil that is dealer for specific information about the available
consumed per hour also increases. overhaul programs and about overhaul services for
extending the engine life.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per If an overhaul is performed without overhaul service
bhp). The brake specific oil consumption (BSOC) from your Caterpillar dealer, be aware of the following
depends on the engine load. Consult your Caterpillar maintenance recommendations.
dealer for assistance in determining the typical oil
consumption rate for your engine. Rebuild or Exchange
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal Cylinder Head Assembly, Oil Pump, and Fuel
wear, an engine overhaul should be scheduled. Transfer Pump
There may be a corresponding increase in blowby
and a slight increase in fuel consumption. These components should be inspected according to
the instructions that are found in various Caterpillar
Overhaul Options reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
Before Failure Overhaul
If the parts comply with the established inspection
A planned overhaul before failure may be the best specifications that are expressed in the reusable
value for the following reasons: parts guideline, the parts should be reused.
• Costly unplanned downtime can be avoided.
150 SEBU7919-10
Maintenance Section
Overhaul Considerations

Parts that are not within the established inspection • Main bearings
specifications should be dealt with in one of the
following manners: Note: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check
• Salvaging for cracks in the crankshaft.
• Repairing Inspect the camshaft for damage to the journals and
to the lobes.
• Replacing
Note: If the camshaft is removed for any reason, use
Using out-of-spec parts can result in the following the magnetic particle inspection process to check for
problems: cracks in the camshaft.
• Unscheduled downtime Inspect the following components for signs of wear or
for signs of scuffing:
• Costly repairs
• Camshaft bearings
• Damage to other engine parts
• Camshaft followers
• Reduced engine efficiency
Caterpillar recommends replacing the crankshaft
• Increased fuel consumption vibration damper.

Reduced engine efficiency and increased fuel Oil Cooler Core and Heat Exchanger Core
consumption translates into higher operating costs.
Therefore, Caterpillar recommends repairing out-of- During an overhaul, Caterpillar recommends the
spec parts or replacing out-of-spec parts. removal of the oil cooler core and the heat
exchanger. Clean the cores. Then, pressure test the
Inspection and/or Replacement cores.

Crankshaft Bearings, Crankshaft Seals, Thrust NOTICE

Do not use caustic cleaners to clean the core.
Bearings, Main Bearings, and Rod Bearings
Caustic cleaners can attack the internal metals of the
The following components may not last until the core and cause leakage.
second overhaul.

• Thrust bearings Note: Use this cleaning procedure to clean the oil
cooler core and the heat exchanger core.
• Main bearings
1. Remove the oil cooler core and the heat
• Rod bearings exchanger core.
• Crankshaft seals 2. Remove any debris from the cores. To remove
Caterpillar recommends the installation of new parts debris from the oil cooler core, turn the oil cooler
at each overhaul period. core onto one end. To remove debris from the heat
exchanger core, turn the heat exchanger core onto
Inspect these parts while the engine is disassembled one end.
for an overhaul.
3. Flush the cores internally with cleaner in order to
Inspect the crankshaft for any of the following loosen foreign substances. This will also help to
conditions:
remove oil from the oil cooler core.
• Deflection
Note: Caterpillar recommends the use of Hydrosolv
• Damage to the journals Liquid Cleaners. Table 26 lists the Hydrosolv Liquid
Cleaners that are available from your Caterpillar
• Bearing material that has seized to the journals dealer.
Check the journal taper and the profile of the Table 26
crankshaft journals. Check these components by Hydrosolv Liquid Cleaners(1)
interpreting the wear patterns on the following
components: Part Number Description Size

• Rod bearing
(continued)
SEBU7919-10 151
Maintenance Section
Rotating Rectifier - Inspect/Test

(Table 26, contd) Caterpillar recommends an S·O·S Coolant Analysis

1U-5490 Hydrosolv 4165 19 L (5 US gallon)
(Level II).

174-6854 Hydrosolv 100 19 L (5 US gallon) S·O·S Coolant Analysis (Level II)

(1) Use a two to five percent concentration of the cleaner at tem-
peratures up to 93°C (200°F). Refer to Application Guide,
An S·O·S Coolant Analysis (Level II) is a
NEHS0526 or consult your Caterpillar dealer for more comprehensive coolant analysis which completely
information. analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level II)
4. Use steam to clean the cores. This removes any provides the following information:
remaining residue from the cleaner. Flush the fins • Complete S·O·S Coolant Analysis (Level I)
of each of the cores. Remove any other trapped
debris. • Visual inspection of properties
5. Wash the cores with hot, soapy water. Rinse the • Identification of metal corrosion
cores thoroughly with clean water.
• Identification of contaminants

• Identification of built up impurities (corrosion and

scale)
Personal injury can result from air pressure.
S·O·S Coolant Analysis (Level II) provides a report of
Personal injury can result without following prop- the results of both the analysis and the maintenance
er procedure. When using pressure air, wear a recommendations.
protective face shield and protective clothing.
For more information about coolant analysis, see
Maximum air pressure at the nozzle must be less your Caterpillar dealer.
than 205 kPa (30 psi) for cleaning purposes.
i06249787
6. Dry the cores with compressed air. Direct the air in
the reverse direction of the normal flow. Rotating Rectifier - Inspect/
7. Inspect the components in order to ensure Test
cleanliness. The oil cooler core and the heat
exchanger core should be pressure tested. Repair SMCS Code: 4465-081; 4465-040
cores, if necessary. Install the oil cooler core and
the heat exchanger core. Inspect
For more information about cleaning the cores, Check the exciter armature. Ensure that the rotating
consult your Caterpillar dealer. rectifier is tight. If a failure of a rectifier is suspected,
refer to the “Test” section below.
Obtain Coolant Analysis
Test
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level I). Further
coolant analysis is recommended when the engine is
overhauled. The high voltage that is produced by an operating
generator set can cause severe injury or death.
For example, considerable deposits are found in the Before performing any maintenance or repairs,
water jacket areas on the external cooling system, ensure that the generator will not start.
but the concentrations of coolant additives were
carefully maintained. The coolant water probably Place the engine control switch in the “ OFF”” posi-
contained minerals that were deposited on the tion. Attach “ DO NOT OPERATE”” tags to all start-
engine over time. ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
A coolant analysis can be conducted in order to verify automatic transfer switches that are associated
the condition of the water that is being used in the with the generator.
cooling system. A full water analysis can be obtained
by consulting your local water utility company or an There are two assemblies that can be used to test
agricultural agent. Private laboratories are also the rotating rectifier. Use either of the following
available for water analysis. procedures in order to test the rotating rectifier.
152 SEBU7919-10
Maintenance Section
Rotating Rectifier - Inspect/Test

Note: There are two ways of creating an assembly Note: For further information, contact your Cat
with separate excitation. Both assemblies should dealer.
have characteristics which are compatible with the
field excitation power of the machine Assembly B
Assembly A Note: Ensure that the alternator is disconnected from
any external load and inspect the terminal box to
Note: Ensure that the alternator is disconnected from check that the connections are fully tightened.
any external load and inspect the terminal box to
check that the connections are fully tightened. 1. Stop the generator set. Disconnect the wires for
the AVR and isolate the wires for the AVR.
1. Stop the generator set. Disconnect the wires for
the AVR and isolate the wires for the AVR.

Illustration 126 g03870192

Illustration 125 g03870185 2. Connect a "Variac" variable power supply and a

(1) Exciter field wire (6-) diode bridge on both exciter field wires (5+) and
(2) Exciter field wire (5+) (6-).
2. Connect a 12 V battery in series with a rheostat of Note: The assembly should have characteristics that
approximately 50 ohms - 300 W and a diode on are compatible with the power for the field excitation
both exciter field wires (5+) and (6-). of the generator.
3. Connect a variable power supply and a diode 3. Operate the generator set at rated speed.
bridge to both of the wires for the exciter field (5+)
and (6-). 4. Gradually increase the current of the exciter field
by adjusting the rheostat or the variable power
Note: The assembly should have characteristics that supply. Measure the output voltage and the
are compatible with the power for the field excitation current at no load. Measure the output voltage and
of the generator. measure the current at no load.
4. Operate the generator set at rated speed. Note: The generator is operating properly when the
output voltage is at the rated value and the output
5. Gradually increase the current of the exciter field voltage is balanced within 1 percent for the rated
by adjusting the rheostat or the variable power level of excitation.
supply. Measure the output voltage and the
current at no load. Measure the output voltage and
measure the current at no load.

Note: The generator is operating properly when the

output voltage is at the rated value and the output
voltage is balanced within 1 percent for the rated
level of excitation.
SEBU7919-10 153
Maintenance Section
Sea Water Strainer - Clean/Inspect

Note: For further information, contact your Cat

dealer.

i02312204

Sea Water Strainer - Clean/

Inspect
SMCS Code: 1371-070; 1371-040
The sea water strainer must be clean in order to
allow proper engine cooling. 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. The sea water strainer
protects the aftercooler from debris. The sea water
strainer will catch pieces of the rubber impeller from
the raw water pump due to a failure from debris. The
sea water strainer is installed on turbocharged
engines only.

Drain the Sea Water Cooling

System Illustration 128 g00751786

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

Turbocharged Engines
the heat exchanger (4). Ensure that the drain hole
1. Close the valve for the sea water. is not plugged.
4. Use the turning tool on the front of the crankshaft
in order to rotate the engine. This will ensure that
all of the water has drained from the sea water
pump.

Clean the Sea Water Strainer

Turbocharged Engines
1. Ensure that the sea water cooling system is
drained. Refer to “Drain the Sea Water Cooling
System” for the procedure.

Illustration 127 g00751785

Typical example of a sea water pump

2. Disconnect both hoses (2) from the sea water

pump (1).
154 SEBU7919-10
Maintenance Section
Space Heater - Test

Illustration 129 g00752040

2. Remove the hose clamp (2) for the sea water

strainer. Remove the sea water strainer (1) and
clean the screen. Use clean water to clean the
screen. Remove any dirt and debris.
Illustration 131 g00751786
3. Install the sea water strainer (1). Install the hose
and the hose clamp (2). Fill the sea water strainer
2. Install the drain plug (3) in the front cover of the
and the suction line for the auxiliary water pump
heat exchanger (4).
with water.
3. Open the valve for the sea water.
Filling the Sea Water Cooling
System i04865112

Turbocharged Engines
Space Heater - Test
SMCS Code: 4450-081-HTR
A Caterpillar generator can operate in high humidity
conditions without problems. However, problems can
occur when the generator is idle and the surrounding
air is warmer than the generator. Moisture can form
on the windings that will result in poor performance
from the windings. Moisture can also result in
damage to the windings. Whenever the generator is
not active, ensure that the space heaters are in
operation.
Table 27
Tools Needed

Part Number Part Quantity

237-5130 Digital Multimeter 1

1. Stop the generator set.

2. Remove the panels in order to allow access to the
regulator and control terminal strips. Locate
terminal strip “TS1” .
Illustration 130 g00751785

1. Connect the hoses (2) at the sea water pump (1).

SEBU7919-10 155
Maintenance Section
Starting Motor - Inspect

3. For 240 V systems, use the multimeter to i03725200

measure the voltage between terminal “H1” and
terminal “H4” . If voltage is not present, disconnect Stator Winding Temperature -
the power source to terminal “H1” and terminal
“H4” , and check for 3 to 12 ohms resistance. If
Test
there is no resistance, check the generator service SMCS Code: 4453-081-TA
manual for further information. For 120 V systems, Some generators are provided with optional 100
use the multimeter to measure the voltage Ohm Resistance Temperature Detectors (RTD).
between terminal “H1” and terminal “H2” . If When the temperature of the stator winding is
voltage is not present, disconnect the power suspected to be high, measure the temperature. If
source to terminal “H1” , terminal “H2” , terminal the generator is furnished with Resistance
“H3” , and terminal “H4” . Check for 3 to 12 ohms Temperature Detectors, the detectors are installed in
the slots of the main armature (stator). The detectors
resistance. If there is no resistance, check the are used with equipment that is available from the
generator service manual for further information. factory. This equipment is used in order to measure
the main armature's winding temperature.
i00651416
i04871070
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040 Turbocharger - Inspect
SMCS Code: 1052-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the Periodic inspection and cleaning are recommended
engine may not start in an emergency situation. for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
Check the starting motor for proper operation. Check the air inlet system. Therefore, by-products from oil
the electrical connections and clean the electrical and from combustion can collect in the turbocharger
connections. Refer to the Service Manual for more
information on the checking procedure and for compressor housing. Over time, this buildup can
specifications or consult your Caterpillar dealer for contribute to loss of engine power, increased black
assistance. smoke and overall loss of engine efficiency.
If the turbocharger fails during engine operation,
i03230840
damage to the turbocharger compressor wheel and/
or to the engine may occur. Damage to the
Stator Lead - Check turbocharger compressor wheel may result in
damage to the pistons, the valves, and the cylinder
SMCS Code: 4459-535 head.
Ensure that the stator output leads are routed out of
the generator in a manner that prevents the leads
from rubbing against metal objects.
Disconnect batteries before performance of any
Visually inspect the following areas for cracking and service work.
physical damage:
• stator output leads

• protective sleeving
Hot engine components can cause injury from
• insulation burns. Before performing maintenance on the en-
gine, allow the engine and the components to
cool.
156 SEBU7919-10
Maintenance Section
Turbocharger - Inspect

NOTICE
Keep all parts clean from contaminants.
Personal injury can result from rotating and mov-
ing parts. Contaminants may cause rapid wear and shortened
component life.
Stay clear of all rotating and moving parts.
Never attempt adjustments while the machine is
moving or the engine is running unless otherwise Removal and Installation
specified.
Refer to Disassembly and Assembly, “Turbocharger -
The machine must be parked on a level surface Remove” for the removal procedure. Refer to
and the engine stopped. Disassembly and Assembly, “Turbocharger - Install”
for the installation procedure. Consult with your
Caterpillar dealer for further information.
NOTICE
Turbocharger bearing failures can cause large quan- Cleaning and Inspecting
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine 1. Remove the exhaust outlet piping and remove the
damage. air inlet piping from the turbocharger. Visually
Minor leakage of a turbocharger housing under ex- inspect the piping for the presence of oil.
tended low idle operation should not cause problems 2. Turn the compressor wheel and the turbine wheel
as long as a turbocharger bearing failure has not
occurred. by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
When a turbocharger bearing failure is accompanied contact with the turbocharger housing. There
by a significant engine performance loss (exhaust should not be any visible signs of contact between
smoke or engine rpm up at no load), do not continue the turbine wheel or compressor wheel and the
engine operation until the turbocharger is repaired or
replaced. turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
NOTICE the turbocharger must be reconditioned.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 3. Check the compressor wheel for cleanliness. If
nance, testing, adjusting, and repair of the product. only the blade side of the wheel is dirty, dirt and/or
Be prepared to collect the fluid with suitable contain- moisture is passing through the air filtering
ers before opening any compartment or disassem- system. If oil is found only on the back side of the
bling any component containing fluids. wheel, there is a possibility of a failed turbocharger
Refer to Special Publication, NENG2500, “Cat Dealer oil seal.
Service Tool Catalog” or refer to Special Publication,
The presence of oil may be the result of extended
PECJ0003, “Cat Shop Supplies and Tools Catalog”
engine operation at low idle. The presence of oil
for tools and supplies suitable to collect and contain
may also be the result of a restriction of the line for
fluids on Cat products.
the inlet air (plugged air filters). This restriction
Dispose of all fluids according to local regulations causes the turbocharger to slobber.
and mandates. 4. Use a dial indicator to check the end clearance on
the shaft. If the measured end play is greater than
An inspection of the turbocharger can minimize the Service Manual specifications, the
unscheduled downtime. An inspection of the turbocharger should be repaired or replaced. An
turbocharger can also reduce the chance for potential end play measurement that is less than the
damage to other engine parts. minimum Service Manual specifications could
Note: Turbocharger components require precision indicate carbon buildup on the turbine wheel. The
clearances. The turbocharger cartridge must be turbocharger should be disassembled for cleaning
balanced due to high rpm. Severe Service and for inspection if the measured end play is less
Applications can accelerate component wear. Severe than the minimum Service Manual specifications.
Service Applications require more frequent
inspections of the cartridge. 5. Inspect the bore of the turbine housing for
corrosion.
SEBU7919-10 157
Maintenance Section
Varistor - Check

6. Clean the turbocharger housing and clean the • The guards must be in the proper place. Repair
backing plate of the cartridge with standard shop damaged guards or replace missing guards.
solvents and a soft bristle brush.
• Wipe all caps and plugs before the engine is
7. Fasten the air inlet piping and the exhaust outlet serviced in order to reduce the chance of system
piping to the turbocharger housing. contamination.

i03291822 NOTICE
For any type of leak (coolant, lube, or fuel) clean up
Varistor - Check the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu-
SMCS Code: 4466-535 id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is
The varistor must be checked at regular intervals. proved to be unwarranted.
Refer to Systems Operation/Testing and Adjusting,
KENR5284, “Varistor - Test” for instructions.
NOTICE
i03291802 Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean-
Varistor - Inspect ing or high pressure water.

SMCS Code: 4466-040

• Inspect the radiator cores for cleanliness.
The varistor must be visually inspected at regular
intervals. For generator sets with 1400 or with 1600 • Ensure that cooling lines are properly clamped
frames, discoloration of the varistor indicates that and that cooling lines are tight. Check for leaks.
replacement of the varistor is necessary. For Check the condition of all pipes.
generator sets with 1800 frames, physical signs of
failure indicate that replacement of the varistor is • Inspect the water pumps for coolant leaks.
necessary.
Note: The water pump seal is lubricated by coolant in
i01491868 the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
Voltage and Frequency - parts contract.
Check Excessive coolant leakage may indicate the need to
SMCS Code: 4450-535-EL replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
Check for the proper voltage setting and check for or seals, refer to the Service Manual for the engine or
the proper frequency setting. Check for stability. consult your Caterpillar dealer.

For the correct voltage and frequency, refer to the • Inspect the lubrication system for leaks at the front
generator set's Serial Plate. crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
i02489875
• Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Walk-Around Inspection
SMCS Code: 1000-040 • Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
Inspect the Engine for Leaks and • Inspect the alternator belt and the accessory drive
for Loose Connections belts for cracks, breaks or other damage.

A walk-around inspection should only take a few Belts for multiple groove pulleys must be replaced as
minutes. When the time is taken to perform these matched sets. If only one belt is replaced, the belt will
checks, costly repairs and accidents can be avoided. carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
For maximum engine service life, make a thorough the new belt could cause the belt to break.
inspection of the engine compartment before starting
• Drain the water and the sediment from fuel tanks
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose on a daily basis in order to ensure that only clean
connections and trash buildup. Make repairs, as fuel enters the fuel system.
needed:
158 SEBU7919-10
Maintenance Section
Water Pump - Inspect

• 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.

• 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 or any gauges that can
not 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.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Disassemble and Water Pump - Assemble” for the
disassembly and assembly procedure. If necessary
to remove the water pump, refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Remove and Water Pump - Install”.
Inspect the water pump for wear, cracks, pin holes,
and proper operation. Refer to the Parts Manual for
the correct part numbers for your engine or consult
your Cat dealer if repair is needed or replacement is
needed.
SEBU7919-10 159
Reference Information Section
Customer Service

Reference Information Europe, Africa, and Middle East

Caterpillar Overseas S.A.
Section 76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Customer Service Switzerland
Phone: 22-849-4444
Fax: 22-849-4544
i05875990
Far East
Customer Assistance Caterpillar Asia Pte. Ltd.
7 Tractor Road
SMCS Code: 1000; 4450 Jurong, Singapore 627968
Republic of Singapore
USA and Canada Phone: 65-662-8333
Fax: 65-662-8302
When a problem arises concerning the operation or
the service of a Marine engine, the problem will China
normally be managed by the dealer in your area. Caterpillar China Ltd.
37/F., The Lee Gardens
Your satisfaction is a primary concern to Caterpillar 33 Hysan Avenue
and to Cat dealers. If you have a problem that has Causeway Bay
not been handled to your complete satisfaction,
follow these steps: G.P.O. Box 3069
Hong Kong
1. Discuss your problem with a manager from the Phone: 852-2848-0333
dealership. Fax: 852-2848-0440
2. If your problem cannot be resolved at the dealer Japan
level, use the phone number that is listed below to Shin Caterpillar Mitsubishi Ltd.
talk with a Field Service Coordinator: SBS Tower
10-1, Yoga 4-Chome
877-228-9900 Setagaya-Ku, Tokyo 158-8530
Japan
The normal hours are from 7:00 AM to 6:00 PM Phone: 81-3-5717-1150
Monday through Friday Central Standard Time.
Fax: 81-3-5717-1177
3. If your needs have not been met still, submit the
matter in an email to the following email Japan
addresses: https://marine.cat.com/contact-us or Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
www.marine.cat.com.
4-10-1, Yoga
Keep in mind: probably, your problem will Setagaya-Ku, Tokyo 158-0097
ultimately be solved at the dealership, using the Phone: 81-3-5797-4300
dealership facilities, equipment, and personnel. Fax: 81-3-5797-4359
Therefore, follow the steps in sequence when a
problem is experienced.

Outside of the USA and of Canada

If a problem arises outside the USA and outside
Canada, and if the problem cannot be resolved at the
dealer level, consult the appropriate Caterpillar office.
Latin America, Mexico, Carribean
Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
160 SEBU7919-10
Reference Information Section
Ordering Replacement Parts

Australia and New Zealand

Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366

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 speci-
fications including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
• Part number

• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU7919-10 161
Reference Information Section
Reference Materials

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
162 SEBU7919-10
Reference Information Section
Maintenance Log

i01176304

Maintenance Log
SMCS Code: 1000; 4450

Table 28
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU7919-10 163
Reference Information Section
Reference Material

i05975063

Reference Material
SMCS Code: 1000; 4450
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
www.cat.com. Use the product name, sales model,
and serial number in order to obtain the correct
information for your product.

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.
164 SEBU7919-10
Index Section

Index
A Customer Assistance .................................... 159
Outside of the USA and of Canada ........... 159
Additional Messages ....................................... 18
USA and Canada....................................... 159
Aftercooler Core - Inspect/Clean/Test ............114
Customer Service.......................................... 159
Alternator - Inspect .........................................114
Automatic Start/Stop - Inspect .......................115
Auxiliary Water Pump (Rubber Impeller) - D
Inspect ..........................................................115 Decommissioning and Disposal.................... 163

B E
Battery - Recycle ............................................115 Electrical Connections - Check ..................... 124
Battery - Replace............................................115 Electrical System............................................. 28
Battery Charger - Check.................................116 Grounding Practices .................................... 28
Battery Disconnect Switch (If Equipped)......... 46 Emergency Stopping....................................... 98
Battery Electrolyte Level - Check ...................116 Emergency Stop Procedure ........................ 98
Before Starting Engine .............................. 27, 62 Emergency Stop Reset................................ 99
Belts - Inspect/Adjust/Replace .......................116 Enclosure - Inspect........................................ 124
Alternator Belt .............................................117 Engine - Clean............................................... 124
Fan Drive Belt .............................................116 Engine Air Cleaner Element (Dual Element)
Burn Prevention............................................... 24 - Inspect/Clean/Replace .............................. 125
Batteries....................................................... 24 Cleaning the Primary Air Cleaner
Coolant ........................................................ 24 Elements .................................................. 126
Oils............................................................... 24 Servicing the Air Cleaner Elements........... 125
Engine Air Cleaner Element (Single
C Element) - Inspect/Replace ......................... 127
Engine Air Cleaner Service Indicator -
Circuit Breakers - Reset .................................118
Inspect (If Equipped) ................................... 129
Cold Weather Operation ................................. 93
Test the Service Indicator .......................... 129
Control Panel (Premium Control Panel, and
Engine Crankcase Breather - Replace ......... 129
MCS Control Panel)....................................... 51
Turbocharged Engines .............................. 131
MCS Control Panel ...................................... 56
Turbocharged Engines and Naturally
Premium Control Panel ............................... 52
Aspirated Engines.................................... 129
Control Panel (Protection and Paralleling
Engine Mounts - Inspect................................ 131
Unit (PPU) Control Panel (if equipped)) ........ 46
Engine Oil and Filter - Change ...................... 133
Protection and Paralleling Unit (PPU) Control
Drain the Engine Oil................................... 133
Panel .......................................................... 47
Fill the Engine Crankcase.......................... 134
Coolant - Change ...........................................118
Replace the Oil Filter ................................. 133
Drain ...........................................................118
Engine Oil Level - Check............................... 132
Fill .............................................................. 120
Engine Oil Sample - Obtain........................... 132
Flush ...........................................................119
Obtain the Sample and the Analysis ......... 132
Coolant Extender (ELC) - Add ...................... 120
Engine Operation ............................................ 70
Coolant Level - Check ................................... 121
Cooling System............................................ 71
Coolant Sample (Level 1) - Obtain................ 122
Keel-Cooled Engine with an Aftercooler...... 72
Sampling Conditions.................................. 122
Engine Starting.......................................... 27, 62
Timing of the Sampling .............................. 122
Engine Stopping ........................................ 28, 94
Coolant Sample (Level 2) - Obtain................ 123
Engine Valve Lash - Check ........................... 134
Obtaining the Sample ................................ 123
Coolant Temperature Regulator - Replace ... 123
Crushing Prevention and Cutting Prevention.. 26
SEBU7919-10 165
Index Section

F Drying Methods.......................................... 140

Generator - Inspect ....................................... 141
Features and Controls..................................... 46
Cleaning (Assembled Generators) ............ 141
Fire Prevention and Explosion Prevention...... 24
Cleaning (Disassembled Generators) ....... 142
Ether ............................................................ 26
Generator Isolating for Maintenance............... 28
Fire Extinguisher.......................................... 26
Generator Lead Connections .......................... 77
Lines, Tubes, and Hoses ............................. 26
Connection Diagrams .................................. 78
Fluid Recommendations ............................... 100
Grounding the Frame .................................. 77
Cooling System.......................................... 104
Neutral Connections .................................... 77
Diesel Engine Oil ....................................... 100
Single Units.................................................. 78
Fuel ............................................................ 102
Generator Load - Check................................ 142
Greases ..................................................... 106
Generator Operation ....................................... 75
Foreword ........................................................... 4
Block Loading .............................................. 75
California Proposition 65 Warning ................. 4
Excitation System ........................................ 76
Literature Information .................................... 4
Generator Options ....................................... 76
Maintenance .................................................. 4
Loading of the Generator............................. 75
Maintenance Intervals ................................... 4
Power Factor ............................................... 76
Operation ....................................................... 4
Standby Electric Sets .................................. 76
Overhaul ........................................................ 4
Generator Set - Test ...................................... 143
Safety............................................................. 4
Generator Set Vibration - Test/Record.......... 143
Fuel and the Effect from Cold Weather ........... 93
Generator Start-up Checklist......................... 109
Fuel Conservation Practices ........................... 74
Generator Winding Insulation - Test.............. 144
Fuel System - Prime ...................................... 135
Exciter Armature (Rotor L2)....................... 145
Fuel System - Prime ( Marine Classification
Exciter Field (Stator L1) ............................. 145
Society 1) ................................................. 136
Main Armature (Stator L4) ......................... 145
Fuel system - Prime (Non-Marine
Classification Society).............................. 135
Priming the Fuel System with the “START” H
Switch ...................................................... 137 Heat Exchanger - Inspect.............................. 145
Fuel System Primary Filter (Water Cleaning the Heat Exchanger.................... 145
Separator) Element - Replace..................... 138 Hoses and Clamps - Inspect/Replace........... 146
Fuel System Secondary Filter - Replace ...... 138 Inspect Tubes, Hoses, Bellows, and
Fuel Tank Water and Sediment - Drain ......... 139 Clamps..................................................... 146
Drain the Water and the Sediment ............ 140 Replace the Hoses and the Clamps .......... 147
Fuel Storage Tanks.................................... 140
Fuel Tank ................................................... 140
I

G Important Safety Information............................. 2

Installation ....................................................... 44
General Hazard Information............................ 20
Containing Fluid Spillage............................. 22
L
Dispose of Waste Properly .......................... 24
Fluid Penetration ......................................... 22 Lifting and Storage .......................................... 40
Inhalation ..................................................... 23
Lines, Tubes, and Hoses ............................. 22 M
Pressurized Air and Water........................... 21
Softwrap....................................................... 23 Maintenance Interval Schedule......................112
Static Electricity Hazard when Fueling with Daily ............................................................112
Ultra-low Sulfur Diesel Fuel ....................... 22 Every 110 400 L (29 160 US gal) of Fuel or
General Information ........................................ 30 8000 Service Hours ..................................113
General Maintenance Information................. 107 Every 13 800 L (3650 US gal) of Fuel or 1000
Generator - Dry.............................................. 140 Service Hours or 1 Year............................113
166 SEBU7919-10
Index Section

Every 14 200 L (3750 US gal) of Fuel or 500 Location ....................................................... 44

Service Hours ...........................................113 Protective Devices....................................... 45
Every 165 600 L (43 750 US gal) of Fuel or 12 Receiving Inspection ................................... 44
000 Service Hours ....................................113 Unpacking.................................................... 44
Every 2000 Service Hours or 6 Months......112 Product Lifting ................................................. 40
Every 250 Service Hours ............................112 Engine Lifting with a Fuel Tank .................... 40
Every 27 600 L (7290 US gal) of Fuel or 2000 Lifting of Generator Sets.............................. 40
Service Hours or 2 Years ..........................113 Product Storage .............................................. 40
Every 500 Service Hours or 1 Year ............112 Additional Information.................................. 43
Every 6900 L (1820 US gal) of Fuel or 500 Engine.......................................................... 40
Service Hours or 1 Year ............................112 Generator..................................................... 42
Every Week ................................................112
Every Year ..................................................112 R
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) ..........112 Reference Information Section ..................... 159
When Required...........................................112 Reference Material ........................................ 163
Maintenance Log........................................... 162 Reference Materials ...................................... 161
Maintenance Recommendations .................. 107 Refill Capacities............................................. 100
Maintenance Records ................................... 161 Coolant Capacities .................................... 100
Maintenance Section..................................... 100 Lubrication Capacities ............................... 100
Model View Illustrations .................................. 30 Rotating Rectifier - Inspect/Test .................... 151
Mounting and Dismounting ............................. 27 Assembly A................................................ 152
Assembly B................................................ 152
Inspect ....................................................... 151
O
Test ............................................................ 151
Operation Section............................................ 40
Ordering Replacement Parts......................... 160 S
Overhaul Considerations............................... 149
Oil Consumption as an Overhaul Safety Messages............................................... 5
Indicator ................................................... 149 Automatic Starting (6).................................. 17
Overhaul Recommendation....................... 149 Do Not Operate (2) ...................................... 15
Electrical Shock (7)...................................... 17
Electrocution (1)........................................... 14
P
Fire (9) ......................................................... 18
Parallel Operation............................................ 83 Hot Fluid Under Pressure (8)....................... 17
Circulating Currents..................................... 86 Lifting the Genset (3) ................................... 15
Initial Start-Up .............................................. 83 Lifting the Genset (4) ................................... 16
Load Division and Speed Droop (If No Ether In Air Inlet (5) ................................ 16
Equipped)................................................... 85 Safety Section ................................................... 5
Parallel Operation Of Governors ................. 85 Sea Water Strainer - Clean/Inspect .............. 153
Paralleling Multiple Units ............................. 85 Clean the Sea Water Strainer.................... 153
Starting Multiple Units.................................. 85 Drain the Sea Water Cooling System........ 153
Stopping....................................................... 86 Filling the Sea Water Cooling System ....... 154
Plate Locations and Film Locations ................ 39 Single Unit Operation ...................................... 82
Generator Identification Plate...................... 39 Adjust the Voltage........................................ 83
Serial Number Plate..................................... 39 Initial Start-Up .............................................. 82
Product Description ......................................... 37 Starting ........................................................ 82
Engine Specifications .................................. 38 Stopping....................................................... 83
Product Identification Information ................... 39 Space Heater - Test....................................... 154
Product Information Section............................ 30 Starting Motor - Inspect ................................. 155
Product Installation.......................................... 44 Starting the Engine (Protection and
Electrical Measurements ............................. 44 Paralleling Unit (PPU) Control Panel and
SEBU7919-10 167
Index Section

Marine Certification Society (MCS)

Control Panel (if equipped)) .......................... 63
Engine Shutdown Override Switch.............. 68
Local Operation ........................................... 67
Remote Operation ....................................... 68
Stator Lead - Check ...................................... 155
Stator Winding Temperature - Test ............... 155
Stopping the Engine (Protection and
Paralleling Unit (PPU) Control Panel and
Marine Certification Society (MCS)
Control Panel (if equipped)) .......................... 94
Manual Operation ........................................ 98
Remote Operation ....................................... 98
System Pressure Release............................. 107
Coolant System ......................................... 107
Engine Oil .................................................. 108
Fuel System............................................... 107

T
Table of Contents .............................................. 3
Turbocharger - Inspect .................................. 155
Cleaning and Inspecting ............................ 156
Removal and Installation ........................... 156

V
Varistor - Check ............................................. 157
Varistor - Inspect............................................ 157
Voltage and Frequency - Check.................... 157
Voltage Regulators .......................................... 87
R438 Adjustment for Maximum Excitation .. 91
R438 Adjustments ....................................... 88
Special Use.................................................. 91

W
Walk-Around Inspection ................................ 157
Inspect the Engine for Leaks and for Loose
Connections ............................................. 157
Water Pump - Inspect.................................... 158
Welding on Engines with Electronic
Controls ....................................................... 108
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
SEBU7919 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2017 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

170 March 2017