SEBU8013-01

August 2010

Operation and
Maintenance
Manual
C18 Marine Generator Set
GBM1-Up (Generator Set)

SAFETY.CAT.COM
 i03991620

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8013-01 3
Table of Contents

Table of Contents Maintenance Section

Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 6
General Hazard Information .................................. 11
Burn Prevention .................................................... 14
Fire Prevention and Explosion Prevention ............ 14
Crushing Prevention and Cutting Prevention ........ 16
Mounting and Dismounting ................................... 17
Refill Capacities .................................................... 96
Maintenance Recommendations ........................ 104
Maintenance Interval Schedule ........................... 110
Warranty Section
Warranty Information .......................................... 182
Reference Information Section
Engine Ratings ................................................... 183
Engine Performance and Performance Analysis
Report (PAR) ..................................................... 185

Before Starting Engine .......................................... 17 Customer Service ............................................... 186

Engine Starting ..................................................... 17 Reference Materials ............................................ 189

Engine Stopping ................................................... 18 Index Section

Electrical System .................................................. 18 Index ................................................................... 193

Engine Electronics ................................................ 18

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

Product Information Section

Model Views ......................................................... 20

Product Identification Information ........................ 27

Operation Section
Lifting and Storage ................................................ 34

Installation ............................................................. 38

Gauges and Indicators .......................................... 40

Features and Controls .......................................... 42

Engine Diagnostics ............................................... 74

Engine Starting ..................................................... 78

Engine Operation .................................................. 82

Engine Stopping ................................................... 83

Cold Weather Operation ....................................... 85

Generator Operation ............................................. 90

4 SEBU8013-01
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
follow.
Use fuel consumption or service hours to determine
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
if they provide more convenient schedules and
approximate the indicated service meter reading.
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequent lubrication and maintenance than is
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance
Manual, Maintenance Records for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
SEBU8013-01 5
Foreword

California Proposition 65 Warning

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

Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
6 SEBU8013-01
Safety Section
Safety Messages

Safety Section
i03726700

Safety Messages
SMCS Code: 1000; 7405

g02009714
Illustration 1
View of the right side of a GS388 Marine Genset
SEBU8013-01 7
Safety Section
Safety Messages

g02009494
Illustration 2
View of the left side of a GS388 Marine Genset

Universal Warning (1)

These safety messages are located on each side of
the terminal box.

g01370904

Do not operate or work on this product unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
8 SEBU8013-01
Safety Section
Safety Messages

Hot Surface (2) Hot Surface (3)

These messages are located on each side of the These safety messages are located on each side of
barrel of the generator. the engine.

g01372256

Hot parts or hot components can cause burns or

personal injury. Do not allow hot parts or compo-
g01384734 nents to contact your skin. Use protective clothing
or protective equipment to protect your skin.

Hot parts or hot components can cause burns or

personal injury. Do not allow hot parts or compo-
nents to contact your skin. Use protective clothing
or protective equipment to protect your skin.
SEBU8013-01
Explosion Hazard (4)
This safety message is located on the air cleaner
element.
g02010075
Explosion Hazard! Spraying uncontrolled ether in-
to the air inlet system can cause explosions or fire
that may result in personal injury or death. Read
and follow the starting procedures in the Opera-
tion and Maintenance Manual.
9
Safety Section
Safety Messages
Hot Fluid Under Pressure (5)
This safety message is located next to the cap on
the heat exchanger.
g01378799
Pressurized system! Hot coolant can cause seri-
ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order to
relieve the pressure. Read and understand the Op-
eration and Maintenance Manual before perform-
ing any cooling system maintenance.
10 SEBU8013-01
Safety Section
Safety Messages

Lifting the Genset (6) Automatic Starting (7)

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

g01392484

When the engine is in the AUTOMATIC mode, the

engine can start at any moment. To avoid personal
g01433231 injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.

Crushing Hazard! Improper lifting could cause se-

rious injury or death. Follow the lifting instruc-
tions in the Operation and Maintenance Manual for
safe lifting procedures.
SEBU8013-01
Shock/Electrocution (8)
The safety message for electrical shock is located
on the sides of the terminal box and the rear of the
terminal box.
g01392482
Do not connect the generator to a utility electrical
distribution system unless it is isolated from the
system. Electrical feedback into the distribution
system can occur and could cause personal injury
or death.
Open and secure the main distribution switch, or
if the connection is permanent, install a double
throw switch to prevent electrical feedback. Some
generators are specifically approved by a utility
to run in parallel with the distribution system and
isolation may not be required. Always check with
your utility for the applicable circumstances.
i03704500
General Hazard Information
SMCS Code: 1000; 7405
g00104545
Illustration 3
11
Safety Section
General Hazard Information
Attach a Do Not Operate warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to
each operator control station. When it is appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
g00702020
Illustration 4
Wear a hard hat, protective glasses, and other
protective equipment, as required.
When work is performed around an engine that is
operating, wear protective devices for ears in order
to help prevent damage to hearing.
12 SEBU8013-01
Safety Section
General Hazard Information

Do not wear loose clothing or jewelry that can snag Fluid Penetration
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.
For initial start-up of a new engine or for starting an
engine that has been serviced, make provisions to
stop the engine if an overspeed occurs. This may
be accomplished by shutting off the fuel supply
and/or the air supply to the engine.
Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This 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. This could result in
personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
g00687600
Illustration 5
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi) when the air nozzle
is deadheaded. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
SEBU8013-01
Asbestos Information
Illustration 6
g00702022
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
Never use compressed air for cleaning.
Avoid brushing materials that contain asbestos.
Avoid grinding materials that contain asbestos.
Use a wet method in order to clean up asbestos
materials.
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
Use exhaust ventilation on permanent machining
jobs.
Wear an approved respirator if there is no other
way to control the dust.
13
Safety Section
General Hazard Information
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.
Lines, Tubes, and Hoses
Do not bend or strike high pressure lines. Do not
install lines, tubes, or hoses that are damaged.
Repair any fuel lines, oil lines, tubes, or hoses that
are loose or damaged. Leaks can cause fires.
Inspect all lines, tubes and hoses carefully. Do
not use bare hands to check for leaks. Always
use a board or cardboard for checking engine
components for leaks. Tighten all connections to the
recommended torque.
Check for the following conditions:
End fittings that are damaged or leaking
Outer covering that is chafed or cut
Wire that is exposed in reinforced hose
Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed
Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. This will help to
prevent these effects: vibration, rubbing against other
parts, and excessive heat during operation.
14 SEBU8013-01
Safety Section
Burn Prevention

Dispose of Waste Properly Oils

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

If the application has a makeup tank, remove the cap

for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.

g00706404
Illustration 7
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
i03941492

i02088921 Fire Prevention and Explosion

Burn Prevention Prevention
SMCS Code: 1000; 7405 SMCS Code: 1000; 7405

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the Illustration 8
g00704000
cooling system is drained.
Use of personal protection equipment (PPE) may be
Check the coolant level after the engine has stopped needed.
and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler All fuels, most lubricants, and some coolant mixtures
cap. The filler cap must be cool enough to touch with are flammable.
a bare hand. Remove the filler cap slowly in order
to relieve pressure. Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate
Cooling system conditioner contains alkali. Alkali can a product when a fire hazard exists. Contact your
cause personal injury. Do not allow alkali to contact Caterpillar dealer for service.
the skin, the eyes, or the mouth.
SEBU8013-01 15
Safety Section
Fire Prevention and Explosion Prevention

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

A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines
and hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Properly install all oil filters and all fuel filters. The
filter housings must be tightened to the proper torque.

If the application involves the presence of combustible

gases, consult your Caterpillar dealer for additional
information about suitable protection devices.

Remove all flammable materials such as fuel, oil, and

debris from the engine. Do not allow any flammable
materials to accumulate on the engine.

All fluids that are captured in the fluid spill

containment basin should be cleaned up immediately.
Failure to clean up spilled fluids can cause a fire. Fire
may cause personal injury and property damage.

Store fuels and lubricants in properly marked

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

Do not expose the engine to any flame. g00704059

Illustration 9

Exhaust shields (if equipped) protect hot exhaust

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

Wiring must be kept in good condition. Properly

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

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
16
Safety Section
Crushing Prevention and Cutting Prevention
g00704135
Illustration 10
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. Charging a frozen
battery may cause an explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Do not use ether as a starting aid. Refer to this
Operation and Maintenance Manual, Starting the
Engine for information about starting the engine.
SEBU8013-01
Lines, Tubes, and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
End fittings are damaged or leaking.
Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are ballooning.
Portions of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
rubbing against other parts, and excessive heat.
i01359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
SEBU8013-01
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
i01372247
Mounting and Dismounting
SMCS Code: 1000; 7405
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i03560601
Before Starting Engine
SMCS Code: 1000
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
Inspect the engine for potential hazards.
17
Safety Section
Mounting and Dismounting
Do not start the engine or move any of the controls
if there is a DO NOT OPERATE warning tag or
similar warning tag attached to the start switch or to
the controls.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
See the Service Manual for repairs and for
adjustments.
i03941639
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine with the engine start switch.
Always start the engine according to the procedure
that is described in this Operation and Maintenance
Manual, Starting the Engine for information about
starting the engine. Know the correct procedure to
prevent major damage to the engine components.
Know the correct procedure to prevent personal
injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
18
Safety Section
Engine Stopping
Engine exhaust contains products of combustion
that can be harmful to your health. Always start the
engine and operate the engine in a ventilated area.
If the engine is started in an enclosed area, vent the
engine exhaust to the outside.
i01462046
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in
the Operation and Maintenance Manual, Engine
Stopping (Operation Section) in order to avoid
overheating of the engine and accelerated wear of
the engine components.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
To stop an electronically controlled engine, cut the
power to the engine.
i02456933
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative jump start cable should be connected
last from the external power source to the negative
terminal of the starting motor. If the starting motor
is not equipped with a negative terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual, Engine
Starting for specific starting instructions.
SEBU8013-01
Grounding Practices
The electrical system for the vessel and the engine
must be properly grounded. Proper grounding
is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Uncontrolled electrical circuit paths can also cause
electrical noise. Electrical noise may degrade the
performance of the vessel and of the radio.
The alternator, the starting motor, and all of the
electrical systems MUST be grounded to the negative
battery terminal. The alternator must meet marine
isolation requirements. The starting motor must also
meet marine isolation requirements.
For engines which have an alternator that is grounded
to an engine component, a ground strap MUST
connect that component to the negative battery
terminal and the component MUST be electrically
isolated from the engine.
A bus bar with a direct path to the negative - battery
terminal is permissible and recommended for use
for all components that require a negative - battery
connection. The bus bar should be directly connected
to the negative - battery terminal. A bonding cable
should also be connected from the cylinder block to
the bus bar on the negative - battery connection.
Use of a bus bar ensures that the Electronic Control
Module (ECM) and all of the components that are
connected to the ECM have a common reference
point.
Refer to Special Instruction, REHS1187, Marine
Engine Electronic Installation Guide for additional
information on grounding procedures.
i04009632
Engine Electronics
SMCS Code: 1000; 1400; 1900
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
SEBU8013-01 19
Safety Section
Generator Isolating for Maintenance

This engine has a comprehensive, programmable

engine monitoring system. The engine control module
(ECM), Marine Classification Society controller (MCS
controller), and the Cat Digital Voltage Regulator
(CDVR) are able to monitor the operating conditions
of the engine and the generator. If any of the engine
parameters extend outside an allowable range,
appropriate action is taken by the engine monitoring
system.

The following actions are available for engine

monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes are
able to limit engine speed and/or the engine power.
g00104545
Many of the parameters that are monitored by the Illustration 11
ECM can be programmed for the engine monitoring
functions. The following parameters can be monitored 2. Attach a DO NOT OPERATE or similar warning
as a part of the Engine Monitoring System: tag to the engine prime mover starting circuit.
Disconnect the engine starting circuit.
Operating Altitude
3. Disconnect the generator from the distribution
Engine Coolant Level system.

Engine Coolant Temperature 4. Lock out the circuit breaker. Attach a DO NOT
OPERATE or similar warning tag to the circuit
Engine Oil Pressure breaker. Refer to the electrical diagram. Verify that
all points of possible reverse power flow have
Engine Speed been locked out.

Fuel Temperature 5. For the following circuitry, remove the transformer's

Intake Manifold Air Temperature
System Voltage
The engine monitoring system can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and display
modules that are available for Caterpillar Engines
will work in unison with the Engine Monitoring
System. Together, the two controls will provide the
engine monitoring function for the specific engine
application. Refer to the Troubleshooting Manual for
more information.
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.

i01489970 9. Determine that the generator is in a de-energized

condition. Add ground straps to the conductors
Generator Isolating for or terminals. During the entire work period, these
Maintenance ground straps must remain connected to the
conductors and to the terminals.
SMCS Code: 4450

When you service an electric power generation set

or when you repair an electric power generation set,
follow the procedure below:

1. Stop the engine.

20 SEBU8013-01
Product Information Section
Model Views

Product Information
Section

Model Views
i03593727

Model View Illustrations

SMCS Code: 1000

g01922058
Illustration 12
Typical example
(1) Terminal strip (5) Fuel priming pump (9) Water pump (jacket water)
(2) Engine oil filler (6) Expansion tank filler cap (10) Fuel filter
(3) Engine oil cooler (7) Expansion tank (11) Isolators
(4) Engine oil level gauge (dipstick) (8) Heat exchanger (12) Engine oil filter
SEBU8013-01 21
Product Information Section
Model Views

g01922193
Illustration 13
Typical example
(12) Filter change indicator (16) Air filter restriction indicator (20) Electronic control module (ECM)
(13) Aftercooler (17) Sea water pump (21) Junction box
(14) Aftercooler condensate drain valve (18) Fuel transfer pump
(15) Air cleaner (19) Filter for crankcase ventilation system
22 SEBU8013-01
Product Information Section
Model Views

i04036313

Model View Illustrations

SMCS Code: 1000

g02234413
Illustration 14
Typical example (right-hand service)
Cooled with a heat exchanger
(1) Aftercooler (5) Aftercooler condensate drain valve (9) Fuel transfer pump
(2) Air cleaner (6) Electronic control module (ECM) (10) Sea water pump
(3) Air filter restriction indicator (7) Filter for crankcase ventilation system
(4) Flywheel housing (8) CCV filter change indicator
SEBU8013-01 23
Product Information Section
Model Views

g02234353
Illustration 15
Typical example (right-hand service)
Keel cooled system
(11) Rear lifting eye (16) Water pump (jacket water) (21) Engine oil filter
(12) Water temperature regulator housing (17) Crankshaft vibration damper (22) Engine oil cooler
(13) Deaerator housing (18) Water inlet (23) Engine oil level gauge
(14) Front lifting eye (19) Fuel filter (24) Engine oil filler
(15) Water outlet (20) Fuel priming pump (25) Starting motor
24 SEBU8013-01
Product Information Section
Model Views

Illustration 16
Typical example (left-hand service)
Keel cooled system
(26) Aftercooler
(27) Air cleaner
(28) Air filter restriction indicator
(29) Aftercooler condensate drain valve
(30) Duplex oil filter assembly
g02234357
(31) Filter for crankcase ventilation system (36) Sea water pump
(32) CCV filter change indicator (37) Fuel transfer pump
(33) Fuel filter (38) Engine oil filler
(34) Fuel priming pump
(35) Engine oil level gauge

i03593358 Four cycle

Product Description Direct fuel injection
SMCS Code: 1000; 4450; 4491; 7000 Electronic unit injection
Engine Description Turbocharged
The Caterpillar C18 Marine Auxiliary Generator Set Raw/Sea water aftercooler or separate circuit
Engine provides the following features: aftercooler (SCAC)
SEBU8013-01
The electronic engine control system provides the
following features:
Engine monitoring
Electronic governing
Automatic air/fuel ratio control
Torque rise shaping
Injection timing control
System diagnostics
Electronic unit injectors combine the metering of
fuel (duration and timing) and the injection of fuel.
Electronic unit injectors produce very high injection
pressures.
The Electronic Control Module (ECM) controls the
amount of fuel that is injected by varying the signals to
the electronic unit injectors. High injection pressures
help to reduce fuel consumption and emissions.
The use of this type of electronic unit injector
helps to provide precise control of injection timing.
The injection timing varies with engine operating
conditions. This optimizes the engine's performance
for starting, emissions, noise, and fuel consumption.
The timing advance is achieved through the precise
control of the firing of the electronic unit injector.
Engine rpm is controlled by adjusting the firing
duration. A speed/timing sensor provides information
to the ECM for detection of cylinder position and
engine rpm.
The engine has built-in diagnostics that are used in
order to ensure that all of the components function
properly.
The cooling system consists of the following
components:
Gear-driven centrifugal pump
One water temperature regulator which regulates
the engine coolant temperature
Oil cooler
Auxiliary water pump or a separate circuit
aftercooler (SCAC)
Raw/Sea water aftercooler
The engine lubricating oil that is supplied by a
gear-type pump is cooled. The engine lubricating oil
is also filtered. Bypass valves provide unrestricted
flow of lubrication oil to the engine components
during the following conditions:
25
Product Information Section
Model Views
High oil viscosity
Plugged oil cooler or plugged oil filter elements
(paper cartridge)
Note: Most illustrations represent typical right hand
service. The C18 Marine Auxiliary Generator Set
Engine is also available with left hand service. The
following items will be located on the left side for left
hand service:
Fuel filter
Oil filter
Oil level gauge
Engine Service Life
Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Expected engine life is generally predicted by
the average power demand, based on the fuel
consumption of the engine over a period of time.
Reduced hours of operation at full throttle and/or
operating at reduced throttle settings result in a lower
average power demand. Reduced hours of operation
will increase the length of operating time before
an engine overhaul is required. See this Operation
and Maintenance Manual, Maintenance Interval
Schedule (Maintenance Section).
Engine Specifications
g00904617
Illustration 17
Cylinder and valve locations
(A) Exhaust valve
(B) Inlet valve
26 SEBU8013-01
Product Information Section
Model Views

Table 1
C18 Marine Engine Specifications
Item Single Dual
Turbocharger Turbocharger
Cylinders and 6 In-Line
Arrangement
Bore 145 mm (5.7 inch)

Stroke 183 mm (7.2 inch)

Compression Ratio 16.5:1 14.5:1

Aspiration TA(1)

Displacement 18 L (1098 in3)

Firing Order 1-5-3-6-2-4

Rotation (viewed from Counterclockwise

flywheel)
(1) Turbocharged Aftercooled

Description of the Generator

These brushless generators are used with the
following loads: mixed loads of motors and lights,
SCR-controlled equipment, computer centers,
installations of communications, and petroleum
drilling applications. The elimination of the brushes in
the field circuit reduces maintenance. The elimination
of the brushes in the field circuit increases reliability.
The elimination of brushes provides a higher degree
of protection in potentially hazardous atmospheres.

The generator set packages can be utilized for prime

power generation or standby power generation. The
generator set packages can be used in land based
applications or marine applications.

The generators have four poles. The generators

have twelve lead configurations. The generators are
capable of producing electrical power in either 50 Hz
or 60 Hz applications.
SEBU8013-01 27
Product Information Section
Product Identification Information

Product Identification
Information
i03596940

Plate Locations and Film

Locations
SMCS Code: 1000

g01922402
Illustration 18

Serial Number Plate for the The Engine Serial Number Plate contains the
Generator (1) following information:

The generator identification is located on the side of
the generator.
The generator identification film includes the following
information:
Engine serial number __________________________________
Engine model number _________________________________
Arrangement number __________________________________

Serial number for the generator _____________________ Engine Information (3)

Generator model number _____________________________ The Engine Information Plate is on the valve cover.

The Engine Information Plate contains the following

Engine Serial Number (2) information:
The Engine Serial Number Plate is on the lower right
side of the cylinder block near the rear of the engine. Engine serial number __________________________________
Arrangement number __________________________________
28 SEBU8013-01
Product Information Section
Product Identification Information

Compression ratio ______________________________________

Aftercooler temperature _______________________________
Power _____________________________________________________
Full load RPM ___________________________________________

i00610276

Reference Numbers
SMCS Code: 1000

Information for the following items may be needed to

order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.

Record for Reference

Engine Model _______________________________________________

Engine Serial No. __________________________________________

Engine Arrangement No. _________________________________

Modification No. ____________________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Performance Specification No. _________________________

Primary Fuel Filter No. ____________________________________

Water Separator Element No. ___________________________

Secondary Fuel Filter Element No. ____________________

Lubrication Oil Filter Element No. ______________________

Auxiliary Oil Filter Element No. _________________________

Supplemental Coolant Additive Maintenance Element

No. (Optional) _______________________________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element No. _________________________________

Fan Drive Belt No. _________________________________________

Alternator Belt No. _________________________________________

SEBU8013-01 29
Product Information Section
Product Identification Information

i02469186

Declaration of Conformity
SMCS Code: 1000

g01231339
Illustration 19
30 SEBU8013-01
Product Information Section
Product Identification Information

i04019095 Wye Configuration Diagrams

Emissions Certification Film 12 Lead
SMCS Code: 1000; 7405

Note: This information is pertinent in the United

States, in Canada and in Europe.

Consult your Cat dealer for an Emission Control

Warranty Statement.

This label is located on the engine.

i03578360

Generator Lead Connections

SMCS Code: 4450

Lead Numbering
The Wye configurations and the Delta configurations
are the most common generator lead connections. g00611608
The following three-phase connection diagrams Illustration 20
illustrate the proper connection and lead identification. 12 Lead Wye Configuration
Low Voltage
The leads are numbered clockwise from the top Terminals T10, T11, and T12 become neutral connections when
and from the outside. The diagrams that are the terminals are tied together.
contained in the Wye Configuration Diagrams
section show lead numbering for the twelve lead Delta Configuration Diagrams
generators. The diagrams that are contained in the
Delta Configuration Diagrams section show lead 12 Lead
numbering for the twelve lead generators.

g00669312
Illustration 21
12 Lead Delta Configuration
Terminals T6 and T9 become the neutral connections when the
terminals are tied together and when the terminals are grounded.
This reflects the terminal T2 and T10 connection as the high phase.
SEBU8013-01
Grounding the Frame
In any generator set installation, the frame of the
generator must be positively connected to an earth
ground or the frame of the generator must be
positively connected to the hull of a vessel. This
connection is the first connection that should be
made at the installation. This connection is the last
connection that should be removed. If the generator
set is on flexible pads or resilient pads, the ground
connection must be flexible in order to avoid possible
breakage in later operation.
Ground connection cables or straps should have
at least the current carrying capacity of the largest
line lead to the connected load. Joints in cables or
straps must be clean, free of electrical resistance,
and protected from possible oxidation. Bolted ground
connection joints eventually oxidize. These joints are
also frequent sources of radio frequency interference
(RFI). Joints should be silver soldered and joints
should also be bolted. These bolts will be electrically
reliable and mechanically reliable.
Neutral Connections
On Wye Configuration Generators, the neutral lead
should be attached to ground. This connection should
be made at installation. The neutral lead is grounded
in order to prevent load-side equipment damage.
If the neutral wire is grounded and one of the phase
leads becomes grounded, the excessive current
will open a load circuit breaker. In addition, this
excessive current will cause the generator voltage to
collapse. The result depends on the following factors:
the particular generator's electrical characteristics,
type of fault, and trip rating of the circuit breaker. An
undervoltage device may be required in order to
provide an adequate short circuit protection.
There are some instances when the neutral wire
should not be grounded. An ungrounded generator
neutral lead is acceptable when measures have
been taken in order to prevent grounds to the
phase leads. An example of such measures are
ground fault protective circuits. When ground fault
protective circuits are used, the entire group of
distribution circuits should be studied. The entire
group of distribution circuits should then be treated
as a system. If a new distribution system is being
developed, the owner should confer with a consultant
that is certified and registered. If an existing system
should be modified for ground fault protection, the
owner should also confer with a consultant that is
certified and registered.
Single Units
In a three-phase, four-wire system, the neutral wire
should be grounded according to local wiring codes.
31
Product Information Section
Product Identification Information
When definite measures need to be taken in order to
prevent grounds to the load leads, an ungrounded
neutral can be used. Be sure to check your local
wiring codes.
Multiple Units
When multiple generators are operated in parallel,
all the neutral connections may be grounded. In
this case, there may be circulating current through
the neutral connections. In order to eliminate the
possibility of circulating currents, ground the neutral
of only one generator. If multiple generators are
alternated on a line, a switch should be installed in
each generator's neutral ground circuit. In this case,
all neutral ground circuits except one can be opened.
Be sure that one of the neutral ground circuits is
closed.
Parallel to a Utility
There will be occasions when a Wye connected
generator is paralleled with a utility system (infinite
bus). On these occasions, the utility system's
step-down transformer may also have a Wye
connection. The grounding of both of the Wye neutral
connections may result in circulating currents through
the neutral connections. The coordination of ground
fault protection requires a study of the entire system.
This study should be done by a consultant that is
familiar with generator systems. This consultant
should be registered and certified. This study will
determine the grounding method that should be used.
i03578355
Voltage Connections
SMCS Code: 4450
Three-Phase Voltage Connections
The Wye Configuration and the Delta Configuration
are given in the following diagrams.
The terminals must be connected securely. The
terminals must also be insulated with a good quality
electrical tape.
If a Delta Configuration is being used, the generator
winding pitch must be two-thirds. If the generator
winding pitch is not two-thirds, there will be circulating
current within the Delta. This circulating current will
cause additional heat in the generator stator. In such
cases, the generator must be derated.
32 SEBU8013-01
Product Information Section
Product Identification Information

Wye Configuration Diagrams Delta Configuration Diagrams

12 Lead Generators 12 Lead Generators

g00637319 g00626130
Illustration 22 Illustration 24
Typical twelve lead Wye configuration (60 Hz) Typical twelve lead Delta configuration (60 Hz)
This configuration is only for use with 3406E, 3412C, 3500 series,
and C18 generator sets.
Single-Phase Current From a
This is a typical high voltage connection.
Three-Phase Generator
Three-phase current and single-phase current
can be taken simultaneously from a generator
that is connected for three-phase service. In
the Wye Configuration, connect the load to the
three-phase leads (any two of the three leads). In
the Delta Configuration, connect the load to the
three-phase leads (any two of the three leads). In
both configurations, this will provide single-phase
voltage at the same voltage as three-phase voltage.

Connect the load to any phase lead and neutral lead

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

In a Delta Configuration (240 Volts, 60 Hz, and

three-phase power), the following voltages will be
present: 208 Volts between the high phase and
neutral and 240 Volts between either of the low
phases and neutral.
g00637320
Illustration 23 Refer to Operation Section, Generator Operation
Typical twelve lead parallel Wye configuration (60 Hz) for allowable single-phase loading unbalance.
This configuration is only for use with 3406E, 3412C, 3500 series,
and C18 generator sets. Single-phase power that is taken from a three-phase
This is a typical low voltage connection. source can be a problem. Ensure that the
single-phase loading is equally distributed.

Do not exceed the nameplate current rating for any

one phase.
SEBU8013-01 33
Product Information Section
Product Identification Information

Wye Configuration Diagrams

12 Lead Generators

g00637321
Illustration 25
Single-phase voltage with twelve lead Wye configuration
This configuration is only for use with 3406E, 3412C, 3500 series,
and C18 generator sets.

Delta Configuration Diagrams

12 Lead Generators

g00626136
Illustration 26
Single-phase voltage with twelve lead Delta configuration
34
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
i03677044
Product Lifting
SMCS Code: 1000; 1404; 7002
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting fixtures in order to
obtain proper balance. Lifting fixtures also help to
provide safety.
Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
Lifting the Entire Package
Do NOT use the engine lifting eyes or the
generator lifting eyes to lift the entire package.
Lifting points have been provided on the base rails
of the generator set for lifting the entire package.
However, lifting the engine and the generator together
requires special equipment and procedures. Consult
your Caterpillar dealer for information regarding
fixtures for proper lifting of your complete package.
Lifting the Engine Only
To remove the engine ONLY, use the lifting eyes that
are on the engine.
SEBU8013-01
Lifting the Generator Only
To remove the generator ONLY, use the lifting eyes
that are on the generator.
i03585220
Product Storage
SMCS Code: 1000; 1404; 7002
Note: If long term storage for a period of time which
exceeds one year is necessary, contact your local
Caterpillar dealer for the preferred procedure to use
in your specific case.
Engine
Storage (Less Than One Year)
If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft, and gears.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.
When the engine is started again, metal to metal
contact will cause wear before the surfaces receive
oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge,
start the engine.
1. Clean the engine of any dirt, rust, grease, and oil.
Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.
2. Remove any dirt from the air cleaner(s). 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.
4. Drain the crankcase oil. Replace the crankcase
oil and change the oil filter(s). For the
proper procedure, refer to this Operation and
Maintenance Manual.
5. If the engine is equipped with an air starting motor,
fill the reservoir with a mixture of 50 percent
volatile corrosion inhibitor oil (<nomen>VCI
oil</nomen>) and 50 percent engine oil.
6. Add VCI oil to the crankcase oil. The volume
of VCI oil in the crankcase oil should be 3 to 4
percent.
SEBU8013-01
Note: If the engine crankcase is full, drain enough
engine oil so the mixture can be added.
7. Remove the air filter element(s). Turn the engine
at cranking speed with the throttle control in FUEL
OFF position. Use a sprayer to add a mixture of
50 percent VCI oil and 50 percent engine oil into
the air inlet or turbocharger inlet.
Note: The mixture of VCI oil can be added to the
inlet by removing the plug for checking turbocharger
boost pressure. The minimum application rate for the
VCI oil mixture is 5.5 mL per L (3 oz per 1000 cu in)
of engine displacement.
8. Use a sprayer to apply a mixture of 50 percent VCI
oil and 50 percent crankcase oil into the exhaust
openings. The minimum application rate for the oil
mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement. Seal the exhaust pipe and
seal any drain holes in the muffler.
9. Remove the fuel from the secondary fuel filter
housing. Alternately, empty and reinstall the
spin-on fuel filter element in order to remove any
dirt and water. Drain any sleeve metering fuel
pump.
Clean the primary fuel filter. Fill with calibration
fluid or kerosene. Install the primary fuel filter and
operate the priming pump. This will send clean oil
to the secondary filter and the engine.
Open the fuel tank drain valve in order to drain
any water and dirt from the fuel tank. Apply a
spray of calibration fluid or kerosene at the rate
of 30 mL per 30 L (1 oz per 7.50 gal US) of fuel
tank capacity in order to prevent rust in the fuel
tank. Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel.
Apply a small amount of oil to the threads on
the fuel tank filler neck and install the cap. Seal
all openings to the tank in order to prevent
evaporation of the fuel and as a preservative.
10. Remove the fuel nozzles or spark plugs. Apply
30 mL (1 oz) of the mixture of oils (50 percent VCI
oil and 50 percent engine oil) into each cylinder.
Use a bar or a turning tool in order to turn over
the engine slowly. This puts the oil on the cylinder
walls. Install all fuel nozzles or spark plugs and
tighten to the correct torque.
11. Spray a thin amount of the mixture of oil (50
percent VCI oil and 50 percent engine oil) onto
the flywheel, the ring gear teeth, and the starter
pinion. Install the covers in order to prevent
evaporation of the vapors from the VCI oil.
35
Operation Section
Lifting and Storage
12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move,
such as rod threads, ball joints, linkage, etc.
Note: Install all covers. Ensure that tape has been
installed over all openings, air inlets, exhaust
openings, the flywheel housing, the crankcase
breather(s), the dipstick tubes, etc.
Ensure that all covers are airtight and
weatherproof. Use a waterproof weather resistant
tape such as Kendall No. 231 or an equivalent.
Do not use duct tape. Duct tape will only seal for
a short period of time.
13. Under most conditions, it is best to remove the
batteries. As an alternative, place the batteries
in storage. As needed, periodically charge the
batteries while the batteries are in storage.
If the batteries are not removed, wash the tops
of the batteries until the tops are clean. Apply an
electrical charge to the batteries in order to obtain
a specific gravity of 1.225.
Disconnect the battery terminals. Place a plastic
cover over the batteries.
Note: For additional information, refer to Special
Instruction, SEHS7633, Battery Test Procedure.
14. Loosen all belts.
15. Place a waterproof cover over the engine. Ensure
that the engine cover is secure. The cover should
be loose enough to allow air to circulate around
the engine in order to prevent damage from
condensation.
16. Attach a tag with the storage date to the engine.
17. Remove the waterproof cover at two or three
month intervals in order to check the engine for
corrosion. If the engine has signs of corrosion,
repeat the protection procedure.
Conventional Coolant System
Completely fill the cooling system before storage.
Water or water mixed with supplemental coolant
additive (SCA) is not an approved coolant for use with
Caterpillar C7-C32 Marine Engines which are cooled
with heat exchangers. Caterpillar C7-C32 Marine
Engines which are cooled with heat exchangers
require a minimum of 30 percent glycol in order to
prevent cavitation of cooling system components.
A minimum of 50 percent glycol is very strongly
recommended.
36
Operation Section
Lifting and Storage
Refer to this Operation and Maintenance Manual,
Refill Capacities and Recommendations for more
information about coolants.
Raw Water System
Completely drain the raw water system by removing
all the drain plugs from the raw water pump, the
water shielded manifolds, heat exchanger bonnets,
and the aftercooler.
After the system has been drained, inspect all
zinc plugs (normally painted red) for damage from
corrosion.
Note: To ensure complete drainage and evaporation
during storage, DO NOT install the drain plugs and
zinc plugs. Place all removed plugs in a cloth bag
and fasten the bag to the engine for storage.
Removal from Storage
1. Remove all outside protective covers.
2. Change the oil and filters.
3. Check the condition of the fan and alternator
belts. Replace the belts, if necessary. Refer to
this Operation and Maintenance Manual, Belts -
Inspect/Adjust/Replace for the correct procedure.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner
elements.
6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.
8. Pressure lubricate the engine before starting the
engine. Pressure lubricating the engine ensures
immediate lubrication and prevents damage to
the engine during the first few minutes of engine
operation. If the engine is not equipped with a
prelube pump, contact your Caterpillar dealer for
information about lubrication of the engine before
the engine is started.
9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.
SEBU8013-01
10. Before start-up, test the cooling system for a
three to six percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
11. If the engine is equipped with a fresh water
system, ensure that the system is clean. Ensure
that the system is full. Ensure that the system
has the correct amount of supplemental cooling
system conditioner.
If the engine is equipped with a raw water system,
install all of the drain plugs and zinc plugs. Fill
the system. It may be necessary to prime the raw
water system pumps before operation.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.
13. If the engine was removed from storage in which
temperatures of less than -12C (10F) were
encountered, refer to Service Manual, SEBU5898,
Cold Weather Recommendations Operation and
Maintenance.
Generator
Storage (Less Than One Year)
When a generator is in storage, moisture condenses
in the windings. To minimize condensation, always
place the generator in a dry storage area. Seal all
openings with tape.
If a brush-type generator (SRCR) is to be in storage,
lift the brushes off the slip ring in order to prevent
damage to the slip ring by chemical action. Attach a
tag to the generator which states that the brushes
have been lifted.
Perform a resistance check of the windings. Record
this reading. This check is done in order to provide a
base line for determining whether moisture or winding
deterioration occurs during storage.
Removal From Storage
Remove all protective covers. Reseat the brushes on
the slip ring for SRCR generators.
SEBU8013-01 37
Operation Section
Lifting and Storage

Before start-up of a generator, use a megohmmeter

to check insulation resistance for moisture and/or
foreign material. Refer to this Operation and
Maintenance Manual, Generator Start-up Check
List for the procedure. A resistance reading of one
megohm or less indicates that the winding has
absorbed too much moisture.

Use one of the following methods for drying the

generator in order to remove moisture which is
caused by high humidity or dampness:

1. Place the generator in an oven which is no hotter

than 85C (185F) for four hours.

2. Use a canvas enclosure around the generator

and heating lamps to increase the ambient
temperature. Provide an opening in the top of the
canvas in order to release the moisture.

3. Send a low voltage current through the windings in

order to increase the temperature of the windings
to 85C (185F).

Megohmmeter Checks
Test the main stator windings with a megohmmeter in
the following situations:

1. Before the initial start-up of the generator set

2. Every three months if the generator operates in a

humid environment

3. If the generator has not been run under load for

three months or more

These intervals are only recommendations. It may

be necessary to perform a megohmmeter test more
frequently if the environment is extremely humid,
salty, or if the last megohmmeter test was close to
one megohm.

Additional Information
For additional information about storage procedures,
refer to Special Instruction, SEHS9031, Storage
Procedure for Caterpillar Products.
38
Operation Section
Installation
Installation
i03651261
Generator Set Installation
SMCS Code: 7002
For additional information about the installation of
your Caterpillar C18 Generator Set, refer to the
Application and Installation Guide or contact your
Caterpillar dealer.
Receiving Inspection
If the generator is received during cold weather,
allow the unit to reach room temperature before you
remove the protective packing material. Warming
the generator to room temperature will prevent the
following problems:
Water condensation on cold surfaces
Early failures due to wet windings
Early failures due to wet insulating materials
Unpacking and Storage
Moving the Generator
Improper lift rigging can allow unit to tumble caus-
ing injury and damage.
NOTICE
Do not use the engine lifting eyes to remove the en-
gine and generator together.
Unpack the equipment with care in order to avoid
scratching painted surfaces. Move the unit to the
mounting location. The unit can be moved by either
of the following methods:
Attach an overhead crane to the lifting eyes that
are installed on the generator package.
Use a lift truck in order to lift the generator.
The hoist and the hoist cables should have a rating
that is greater than the weight of the generator.
When the unit is moved, ensure that the generator
is completely supported by the lift truck's fork tines.
Also ensure that the generator is balanced on the
lift truck's fork tines. Slide the fork tines beneath the
attached skid in order to lift the generator.
SEBU8013-01
Storage
Short Time Storage
If the generator is not installed immediately, store
the generator in a clean area. This area should also
have the following conditions: low humidity, stable
humidity, and stable temperature. Space heaters
must be energized in order to keep condensation
from the windings. All accessory equipment that
is supplied with the unit should be stored with the
generator. The combined unit should be covered
with a durable cover in order to protect against the
following contaminants:
Dust
Dirt
Moisture
Long Time Storage
A storage period in excess of six months should be
preceded by the following preparation:
1. Install desiccant bags inside the exciter's cover
and install desiccant bags inside the screen of
the fan.
2. Seal the unit in a covering of plastic or other
material that has been designed for that purpose.
3. Adequately tag the generator. This will ensure
that preservative greases and desiccant bags are
removed before the unit is placed in operation.
Bearing Inspection
Ball bearing generators use grease. This grease is
subject to deterioration. If the generator is stored
longer than one year, new ball bearings should be
installed. These bearings should be greased to
the proper level prior to being put into operation. If
inspection indicates that bearings are free of rust or
corrosion, and no noise or excessive vibration appear
on start-up, replacement is not necessary.
Location
The location of the generator must comply with all
local regulations. The location of the generator must
also comply with all special industrial regulations.
Locate the generator in an area that meets the
following requirements:
Clean
Dry
SEBU8013-01 39
Operation Section
Installation

Well ventilated Protective Devices

Easily accessible for inspection and maintenance
Do not obstruct air inlet openings. Do not obstruct
discharge openings. Coolant flow must reach these
openings. If the generator is exposed to harsh
environmental conditions, the generator can be
modified in the field in order to add filters and
space heaters. In addition, a more rigid periodic
maintenance schedule should be established.
The output to the load of the generator should always
be protected with an overload protection device such
as a circuit breaker or fuses. Fuses should be sized
by using the lowest possible current rating. However,
this rating must be above the current rating for full
load. A common recommendation is 115 percent
of rated current. Determine the size of fuses or
determine the size of circuit breakers in accordance
with NEMA, IEC, and Local Electrical Codes.

Electrical Measurements
Measure the insulation resistance of each winding
if the generator was exposed to the following
conditions:

Rapid changes in temperature

Freezing
Wet climate during shipment
Wet climate during storage
Note: These tests should be conducted prior to any
power connections that are being made. These tests
should be conducted prior to any control connections
that are being made.

Refer to the Generator Maintenance section of this

manual in order to measure the following items:

Exciter field (stator)

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

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

Special Instruction, SEHS7654, Alignment -

General Instructions

Special Instruction, SEHS7259, Alignment of

Single-Bearing Generators
40
Operation Section
Gauges and Indicators
Gauges and Indicators
i02706567
Gauges and Indicators
SMCS Code: 1900; 7450
Your engine may not have the same gauges or all of
the gauges that are described.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time. Noticeable changes
in gauge readings indicate potential gauge or engine
problems. Problems may also be indicated by gauge
readings that change even if the readings are within
specifications. Determine and correct the cause of
any significant change in the readings. Consult your
Caterpillar dealer for assistance.
NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
Engine Coolant Temperature This
gauge indicates the engine coolant
temperature. The temperature may vary
according to the load. Do not allow the temperature
to exceed the boiling temperature of the pressurized
cooling system.
The sensor for engine coolant temperature must be
fully submerged in order to detect the temperature
correctly. If the engine is operating above the normal
temperature range, perform the following procedure:
1. Reduce the load and/or the engine rpm.
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load and/or rpm.
Engine Load This gauge indicates a
percentage of the engine's full rated torque.
The calculation of the percentage is based
on these factors: flow of fuel, engine rpm, fuel
energy content, and fuel correction factor. This gauge
flashes if the torque exceeds the maximum limit that
is programmed into the control strategy.
SEBU8013-01
Engine Oil Pressure The oil pressure
should be greatest after a cold engine is
started. The pressure will decrease as
the engine warms up. The pressure will increase
when the engine rpm is increased. The pressure will
stabilize when the engine rpm is stable.
A lower oil pressure is normal at low idle. If the load
is stable and the gauge reading changes, perform
the following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
3. Check and maintain the oil level.
Engine Oil Temperature This gauge
indicates the engine oil temperature after
the oil has passed through the oil cooler.
The oil cooler is thermostatically controlled.
Exhaust Temperature This gauge
indicates the exhaust temperature at the
exhaust inlets to the turbochargers. The
two exhaust temperatures may vary slightly.
The exhaust temperatures at the exhaust inlets
to the turbochargers provide a good indication of
engine performance. For engines with dry exhaust
manifolds, the temperatures are representative of
the actual temperatures of the valves. Monitor this
parameter frequently.
NOTICE
Severe damage to the engine can result if the exhaust
temperature at the inlet to the turbocharger exceeds
the extreme limit.
Fuel Level This gauge indicates the fuel
level in the fuel tank. Normally, the fuel level
gauge will register the fuel level only when
the switch is in the ON position.
Fuel Pressure This gauge indicates fuel
pressure to the fuel injection pump from
the fuel filter. A decrease in fuel pressure
usually indicates a dirty fuel filter or a plugged fuel
filter. As the fuel filter becomes plugged, there will be
a noticeable reduction in the engine's performance.
SEBU8013-01 41
Operation Section
Gauges and Indicators

For more information, refer to Specifications,

Fuel Temperature This gauge indicates Systems Operation, and Troubleshooting,
the temperature of the fuel. A high SENR5002, Installation Guide for Marine Engine
fuel temperature can adversely affect Electronic Displays.
performance. If the temperature of the fuel is too low,
the fuel filter may begin to plug. See this Operation
and Maintenance Manual, Fuel and the Effect from
Cold Weather for more information.

Fuel Usage This gauge indicates the

rate of fuel usage.

Inlet Manifold Air Pressure This gauge

indicates the air pressure (turbocharger
boost pressure) in the air inlet manifold
after the aftercooler. The inlet manifold air pressure
depends on the engine rating, the load, and the
operating conditions. To establish the normal inlet
manifold air pressure, compare the data from the
gauge to the data from the engine commissioning
and look for trends.

Inlet Manifold Air Temperature This

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

Service Hour Meter This gauge

indicates the total number of clock hours
on the engine.

System Voltage This gauge indicates

the voltage of the electrical system.

Tachometer This gauge indicates engine

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

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

Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.
42 SEBU8013-01
Operation Section
Features and Controls

Features and Controls

i03899941

Control Panel
(Marine Classification Society
Control Panel (MCS Control
Panel) (Standard Panel, if
Equipped))
SMCS Code: 7451

General Information
The control unit has buttons for the following
functions:

Engine starting
Engine stopping
Alarm list
Menu
Up arrow and down arrow
Four soft buttons with varying functionality
SEBU8013-01 43
Operation Section
Features and Controls

g02177059
Illustration 27
(1) Power indicator (6) Voltage adjust (11) Scroll down
(2) Alarm list (7) Frequency (12) Scroll up
(3) Start (8) Emergency stop (13) Menu
(4) Stop (9) Idle/Rated (14) LCD screen
(5) context-sensitive menu buttons (10) Power switch (Lockout/tagout)

The screen is divided into three main sections: The wrench symbol indicates that a maintenance
interval which has been programmed into the
Status Bar control unit is overdue.

The status bar is the top line on the screen. The

status bar is reserved for the engine state and status
symbols.

The L symbol indicated that the control unit is in

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

The M symbol indicates that the control unit is in

manual mode. The Automatic Start/Stop function
is not permitted when the control unit is in manual
mode.

The SO symbol indicates that the control unit is in

shutdown override mode.

The greenOK symbol indicates that the following

events are not present on the alarms list: warning,
alarm, and shutdown. The greenOK symbol
indicates that no yellow diagnostic messages and
no red diagnostic message are present on the
alarms list.
44 SEBU8013-01
Operation Section
Features and Controls

Main Screen (Instrument Screen)

g02176582
Illustration 28

All instruments and menu items are displayed on the Soft Buttons
main screen. The screen for the control unit may
have multiple instrument screens. Press the UP The bottom line on the screen is for the four soft
ARROW button and press the DOWN ARROW buttons. The functions of the soft buttons vary.
button in order to navigate between the instrument
screens. If there is only one instrument screen,
pressing the buttons does not change the screen.
Pressing the same button repeatedly will eventually
scroll back to the first screen.

The following symbols and icons may be displayed

on the instrument screen:

Yellow Triangle

The YELLOW TRIANGLE is the warning symbol.

When the YELLOW TRIANGLE flashes above an
instrument, a new warning exists for that channel.
The YELLOW TRIANGLE stops flashing when the
operator acknowledges the warning.

Red Triangle

The RED TRIANGLE is the alarm symbol or the

shutdown symbol. When the RED TRIANGLE
flashes above an instrument, a new alarm exists
for that channel or the channel is responsible for
an engine shutdown. The RED TRIANGLE stops
flashing when the operator acknowledges the alarm.
SEBU8013-01 45
Operation Section
Features and Controls

Start Engine and Stop Engine

Starting the Engine

g02176581
Illustration 29

The START button may be configured as LATCHED

or as HOLD. The values for the START button and
the values for the STOP button always match.

Start the engine with one of two methods:

If the START button is configured as LATCHED,

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

If the START button is configured as HOLD, press

and hold the START button until the engine starts.
46 SEBU8013-01
Operation Section
Features and Controls

Stopping the Engine

g02176599
Illustration 30

The STOP button may be configured as LATCHED

or as HOLD. The values for the STOP button and
the values for the START button always match.
Stop the engine with one of two methods:

If the STOP button is configured as LATCHED,

perform the following sequence in order to start
the engine: press the STOP button, observe the
confirmation dialog, and press YES . The control
unit will complete the stopping sequence.

If the STOP button is configured as HOLD, press

and hold the STOP button until the engine stops.
SEBU8013-01
List of Alarms
Illustration 31
Enter the Alarms List
Press the ALARMS LIST button in order to view the
alarm list. Press the ALARMS LIST button again in
order to leave the alarms list. The EXIT button may
be pressed in order to leave the alarms list.
Alarms are displayed in several colors and texts.
The following entries are displayed in red text:
alarm entries, shutdown entries, and automatic
stop entries.
Warnings are displayed on a yellow background.
New alarms (unacknowledged alarms) are
displayed in bold text.
Acknowledged alarms are displayed in normal text.
An alarm that is not acknowledged before
becoming inactive is displayed in normal text on a
gray background.
An inactive alarm that is displayed on a yellow
background was either an alarm or a shutdown.
An inactive alarm that is displayed on a yellow
background was a warning.
47
Operation Section
Features and Controls
g02176135
Filter Alarms
The alarm list filters alarms into three groups:
All alarms (all alarms and all diagnostics)
Panel alarms (all alarms and no diagnostics)
Diagnostics (diagnostics only)
Use the second soft button and the third soft button
in order to choose between the three groups.
Silence the Buzzer
If the buzzer sounds, press the ALARMS LIST
button in order to silence the buzzer.
If the alarm list is not displayed before the
ALARMS LIST button is pressed, press the
ALARMS LIST button to display the alarms list.
If the alarms list is displayed when the buzzer
sounds, pressing the ALARMS LIST button will
silence the buzzer.
48 SEBU8013-01
Operation Section
Features and Controls

Acknowledge Alarms
Acknowledge a Single Alarm

Use the arrow buttons in order to select an alarm for

acknowledgment. The selected alarm line will expand
to reveal any additional information.

Press the ACKNOWLEDGE button in order to

acknowledge the selected alarm.

Acknowledge All Alarms

Press and hold the ACKNOWLEDGE button for one

second in order to acknowledge all alarms.

Note: An active alarm is displayed until the active

alarm becomes inactive.

Menu

g02163221
Illustration 32

The menu screen displays the following items: Help

Settings
Counters
Generator
Display
Configuration
SEBU8013-01 49
Operation Section
Features and Controls

Settings

g02176304
Illustration 33

Automatic/Manual Note: Caterpillar recommends the removal of the

When the control unit is set to the AUTOMATIC
mode, the control unit may be started from a remote
signal and the control unit may be stopped from a
remote signal. When the control unit is set to the
MANUAL position, the control unit may not be started
from a remote signal and the control unit may not be
stopped from a remote signal. When the control unit
is In the MANUAL position, the M symbol is visible in
the status bar.
connection to the battery before any maintenance on
the engine is performed.
Prelube Override
If the engine is configured for prelube, the PRELUBE
OVERRIDE function can cancel the procedure. If the
PRELUBE OVERRIDE function is chosen during
the prelube, the prelube is stopped and the control
unit continues the start procedure.

Note: The control terminal 88 (Automatic mode)

overrides a MANUAL setting in the menu. When the
controller is in automatic mode, either the menu or
the remote signal can issue commands.

Local/Remote

In LOCAL mode, the control unit cannot be operated

remotely. An L symbol is visible in the status bar.
Communications commands are not operable in the
LOCAL mode.

Hard wired commands are not operable in LOCAL

mode.

Start Disabled

Select the START DISABLED button in order to

disable the starting mechanism for the engine.
50 SEBU8013-01
Operation Section
Features and Controls

Counters

g02177046
Illustration 34

The COUNTERS screen displays the service hours Since Restart

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

Event Log
Service Interval for the Engine
Total

The TOTAL screen displays the total service hours.

The operator may not reset the service hours.

Since Start

The SINCE START counter starts at ZERO each

time the engine is started. The SINCE START
counter continues to accumulate service hours until
the engine is stopped. The operator may not reset
the service hours.
SEBU8013-01 51
Operation Section
Features and Controls

Events Log

g02176307
Illustration 35

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

The event log may be sorted in four ways:

The oldest entry is displayed first.

The most severe entry is displayed first.
The least severe entry is displayed first.
Count
Timestamp The selected event will be expanded.
The second line displays the service hour at which
the event occurred. For alarms, the second line also
displays the service hours for an acknowledged
inactive situation.
52 SEBU8013-01
Operation Section
Features and Controls

Generator

g02177054
Illustration 36

A Power Analyzer Module (PAM) may be connected

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

Note: The page which displays the values for the

generator may be accessed by pressing the UP
button or by pressing the DOWN button from the
normal instrument view.
SEBU8013-01 53
Operation Section
Features and Controls

Display

g02176308
Illustration 37

Screen Backlight Note: Text for the configured instruments must

Select between the following settings for the screen
backlight:
10 percent backlighting for the darkest setting.
be manually translated during the installation
process. Selecting a language which has no manual
translation causes the default language to be used.
Use the soft buttons while viewing an instrument
screen to adjust the preferred language.

50 percent backlighting for the medium setting.

100 percent backlighting for the setting with the
most backlighting.

The automatic setting uses an ambient light

detector in order to vary the backlighting between
10 percent and 100 percent.

Units of Measure

Select the unit of measure:

METRIC
US (English)

Language
Select the language which will be displayed on
the panel from the following languages: English,
French, Spanish, Italian, German, Dutch, Russian,
Norwegian, and Chinese.
54 SEBU8013-01
Operation Section
Features and Controls

Configuration

g02176309
Illustration 38

Test for Engine Overspeed

When the control unit is in the ENGINE

OVERSPEED TEST mode, the automatic procedure
for shutting down the engine due to an overspeed
condition may be tested by lowering the overspeed
setpoint to the nominal speed. Use the following
procedure to perform this test:

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

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

2. Observe the red arc on the RPM METER in

order to make sure that the overspeed setpoint
has been lowered.

3. Start the engine and adjust the rpm until the rpm
rises above the overspeed setpoint.

4. Observe the engine shutdown.

The test for engine overspeed is timed out after

5 minutes or when an actual overspeed situation
occurs. The test can be stopped by selecting the
Engine Overspeed Test again.
SEBU8013-01 55
Operation Section
Features and Controls

Help

g02176580
Illustration 39

A number of troubleshooting screens exist for the

control unit.

g02176619
Illustration 40
56 SEBU8013-01
Operation Section
Features and Controls

Supply Button Test

The two power supplies are listed. Information about
voltage and information about supply selection may
be viewed.
Switch Channels
This section allows all control unit buttons to be
tested. To exit the BUTTON TEST tab, press and
hold the second soft button. Press the fourth soft
button to exit. Press the first soft button to change
tabs.

Each of the eight switch channels may be viewed for

information about whether the switch is open (OV)
or closed (24v INPUT).

4-20mA Channels
The following information may be displayed for each
of the 4-20mA channels:

Current, 2-25mA which is indicated in mA

Broken wire (<2mA)
Short circuit (>25mA)
Channel use
PT100 Channels
The following information may be displayed for each
of the four PT100 channels:

Value
Faulty circuit
Channel use

COM (Communications)
This section lists the communication status for
communication ports 1, 2, 3, 4, and 6.

Output
This section lists the output status on terminals 63
through 84 for the control unit.

Input
This section lists the input status on terminals 86
through 97 for the control unit.

Run Indication Sources

A number of different sources may be configured to
indicate engine operation. The RUN INDICATION
page indicates which source is providing the
information about engine operation to the control unit.
SEBU8013-01 57
Operation Section
Features and Controls

Version Information

g02176577
Illustration 41

This section displays the following information:

Hardware version
Software version
ECM version (if applicable)
Internet Protocol (IP) number of the control unit
58 SEBU8013-01
Operation Section
Features and Controls

i04001712

Control Panel
(Marine Classification Society
Remote Control Panel (MCS
Remote Control Panel) (If
Equipped))
SMCS Code: 7451

g02177257
Illustration 42
MCS Remote Panel
(1) LCD display (4) Alarms list (7) Soft keys
(2) Status bar (5) Start button
(3) Home (6) Stop button

The four buttons have the following functions: The SOFT BUTTON line is reserved for soft
buttons whose meaning varies depending on the
The START button starts one or more engines selected display.

TheSTOP button stops one or more engines

TheALARMS LIST button displays the alarms list
The HOME button displays the top-level
instrument display

The display is divided into three main sections:

The STATUS BAR is reserved for status symbols.

The instruments and menu icons are displayed
SEBU8013-01
Illustration 43
Symbols and Indication Icons
Status Bar
Local Mode (L)
When the symbol L is displayed, the corresponding
MCS Controller engine panel is in local mode. The
remote panel cannot acknowledge alarms or activate
the start or stop functions. The LOCAL/REMOTE
setting may be used to activate the remote function.
Manual Mode (M)
When the symbol M is displayed, the corresponding
MCS Controller engine control unit is in manual
mode. The automatic start and automatic stop
functions are inactive when the MCS Controller is in
the manual mode.
Shutdown Override (SO)
When the symbol SO is displayed, the
corresponding MCS Controller engine panel is in
shutdown override mode. The automatic shutdown
function is inactive when the MCS Controller is in the
shutdown override mode. The following functions are
not affected by the shutdown override mode:
Overspeed shutdown functions
59
Operation Section
Features and Controls
g02163222
Oil mist detection
Service and Diagnostics (Service Wrench Icon)
The service wrench symbol is displayed in the status
bar during the following circumstances:
Scheduled service is due.
A white diagnostic from the engine control module
(ECM) is active.
Active Station (Rectangular Symbol)
One active station symbol is a large rectangular
symbol in the top right corner of the display. Three
meanings are possible when the rectangular active
station symbol is displayed:
If the symbol is black and the text Inactive Station
is displayed, the remote panel is not an active
station for any engine.
If the symbol is orange and black and the text
Active Station is displayed, the remote panel is
the active station for one or more engines, but not
for all engines in the network.
If the symbol is orange and the text Active Station
is displayed, the remote panel is the active station
for all of the engines in the network.
60
Operation Section
Features and Controls
Active Station (Star Symbol)
One active station symbol is star shaped. An orange
star is displayed when the display is for a single
engine and the remote panel is the active station for
the engine. When the display is divided into two or
four quadrants, the active station star is displayed in
the name and engine status banner.
Warning and Alarm Triangles
A yellow triangle is displayed when a warning exists
on this channel. If the triangle flashes, the warning is
unacknowledged. A red triangle is displayed when an
alarm or a shutdown situation exists on this channel.
If the triangle flashes, the alarm or shutdown situation
is unacknowledged.
Press the ALARMS LIST button for details of the
warning or the alarm.
Start and Stop Engines
Start One or More Engines
Use the following procedure to start one or more
engines:
1. Press the START button.
2. Select one or more engines to start by pressing
the touch display. Each selected engine icon will
be displayed inside a white rectangle.
3. Press the OK button again to start the selected
engines.
Stop One or More Engines
Multiple engines may be stopped at the same time.
1. Press the STOP button
2. Select one or more engines to start by pressing
the touch display. Each selected engine icon will
be displayed inside a white rectangle.
3. Press the OK button again to stop the selected
engines.
Alarms List
Press the ALARMS LIST button to enter the alarm
list. All current alarms will be visible on the display.
Press the ALARMS LIST button again to leave the
alarms list.
Alarms are displayed in several colors and texts.
SEBU8013-01
The following entries are displayed in red text:
alarm entries, shutdown entries, and automatic
stop entries.
Warnings are displayed in yellow text.
New alarms (unacknowledged alarms) are
displayed in bold text.
Acknowledged alarms are displayed in normal text.
An alarm that is not acknowledged before
becoming inactive is displayed in normal text on a
gray background.
An inactive alarm that is displayed on a red
background was either an alarm or a shutdown.
An inactive alarm that is displayed on a yellow
background was a warning.
Silence the Alarm
If the alarm sounds, press the ALARMS LIST button
to silence the alarm. If the alarms list is not displayed
when the alarm sounds, pressing the ALARMS
LIST button will display the alarms list.
Acknowledge an Alarm
When a star is displayed before an engine name, the
remote panel is the active station of that engine. An
alarm with a star displayed before the engine name
may be acknowledged with the remote panel. An
alarm without a star before the engine name may
not be acknowledged with the remote panel unless
the remote panel become the active station for that
engine.
Acknowledge a Single Alarm
Touch the alarm that you want to acknowledge.
The alarm line will expand to reveal any additional
information. Press the ACKNOWLEDGE . button to
acknowledge the selected alarm
Acknowledge All Alarms
In the alarm list, press and hold for at least one
second the ACKNOWLEDGE button. This action
acknowledges all alarms.
Note: Alarms that are still active remain displayed
until the alarms become inactive. The active
acknowledged alarms are displayed with a gray
background.
SEBU8013-01
Filter Alarms
The remote panel may receive alarms from up to
eight different MCS Controller engine panels (MCS
Controller engine panels) at one time. Two buttons
may be used for filtering the alarms:
The ENGINE VIEWS button (soft button 2)
The ALARM VIEWS soft button 3
Note: A yellow dot in the center of the button
indicates that a filter is applied.
Engine Views
Press ENGINE VIEWS for a selection of engine
filters. All engines connected to the remote panel
appear on the list. The list also includes the
following selections: THIS STATION and ALL.
Selecting THIS STATION only displays alarms
built into the remote panel. Selecting an only engine
name displays alarms from the selected engine.
SelectingALL displays all alarms from all sources.
Alarm Views
Press ALARM VIEWS to filter alarm types from
the MCS Controller engine panels. Select PANEL
ALARMS to display only panel alarms and not
alarms from the ECM. Select ECM DIAGNOSTICS
to display only the diagnostic messages and alarms
from the ECM. Select ALL to display all alarms from
all sources.
Home Button
Press the HOME button to display the top-level
engine instruments. Press and hold the HOME
button for 1 second to display the menu.
Menu
The menu may be accessed by the following
methods:
Press the HOME button then press soft button 1.
Press and hold the HOME button for 1 second.
Active Station
The ACTIVE STATION selection is useful when
there are multiple remote panel stations in the
installation. Press ACTIVE STATION to bring up
the active station dialog.
61
Operation Section
Features and Controls
Camera
An Internet Protocol camera (IP camera) may be
connected to the ethernet network. The image may
be displayed on the remote panel display. As many as
four cameras may be connected to one remote panel.
All four images may be displayed simultaneously.
The image update rate is 4 to 5 frames per second.
Touch any small image to enlarge the image or touch
any full sized image to reduce the image to one fourth
of the display.
Backlight
Select between the following settings for the display
backlight:
10 percent backlighting for the darkest setting.
50 percent backlighting for the medium setting.
100 percent backlighting for the setting with the
most backlighting.
The automatic setting uses an ambient light
detector in order to vary the backlighting between
10 percent and 100 percent.
In the AUTOMATIC mode, an ambient light
detector is used to determine the correct amount
of backlighting. In the NIGHT mode, the display
is turned off when no activity is present for 10
seconds. The display will activate upon an alarm or
an operator action. The display will stay lit as long as
unacknowledged alarms exist.
Generator
Any generator images or values are displayed when
the MCS Controller engine panel is reading generator
parameters from the PAM.
Languages
Select the operator language for the remote control
panel . The instruments text descriptions reside in the
MCS Controller engine panel and must be translated
for each language during the installation of the MCS
Controller engine panel. If a language is selected
for which no translation exists, the default language
is used.
Counters
The counters page displays service hours for all
engines.
62
Operation Section
Features and Controls
Illustration 44
Information
The information page displays IP addresses and
revision numbers. The MCS Controller engine panel
section displays the IP addresses of the connected
engine panels.
Configuration
Pressing CONFIGURATION opens the
configuration sub-menu section. The configuration
page is not password protected.
Wallpaper
The wallpaper is the background image for the
instrument displays. The following wallpaper options
are available:
A wallpaper may be selected from the selection
of available wallpapers.
A personal wallpaper may be uploaded using an
internet web site interface.
Button Beep
Select the ON position to enable sound to
accompany each button activity and each touch
display activity. SelectOFF to turn off the sound.
SEBU8013-01
g02176297
Sound Configuration
The remote panel includes two speakers for sound
and a buzzer. Use this function to choose the source
for sound.
Note: The speaker sound is also available on the
3.5 mm (0.14 inch) standard minijack output on the
rear of the panel.
Home Page Layout
Press the HOME button to access the home page.
The home page displays engine instrument screens.
The following configurations are available.
Selecting SINGLE SCREEN displays the engine
with the lowest IP number. Any other engines may
be accessed with the PREVIOUS button and the
NEXT button.
Selecting DUALSCREEN displays the engine
with the lowest IP number on the left side of the
display and the engine with the next IP number on
the right side. Any other engines ay be accessed
with the PREVIOUS button and the NEXT
button.
SEBU8013-01 63
Operation Section
Features and Controls

Selecting QUAD SCREEN displays the engine

with the lowest IP number on the top left portion of
the display. The engine with the next IP number is
displayed on the top right portion of the display.
The engine with the next IP number is displayed on
the lower left portion of the display. The information
for as many as five additional engines may be
accessed on the lower right portion of the display
with the PREVIOUS and NEXT buttons.

Calibrate Touch Screen

The touch display may be recalibrated. If the touch

function is not operational, press and hold the
HOME button for 10 seconds and the calibration
screen will be displayed.

Units

Use this function to choose the preferred units of

measure.

Troubleshooting

Selecting TROUBLESHOOTING displays the

troubleshooting information.

System Configuration

The system configuration submenu is password

protected. The password in a four-digit number. If an
incorrect password is entered, the panel issues an
encrypted code. This code is used by the factory to
revert to the original password.
64 SEBU8013-01
Operation Section
Features and Controls

i04033308

Electronic Modular Control

Panel 3 (EMCP 3)
(If Equipped)
SMCS Code: 4490

Electronic Control Module 3

(ECMP3)

g01045431
Illustration 45
(1) Display screen (7) Lamp test key (13) Right key
(2) AC overview key (8) Run key (14) Enter key
(3) Engine overview key (9) Auto key (15) Down key
(4) Yellow warning lamp (10) Stop key (16) Left key
(5) Red shutdown lamp (11) Up key
(6) Acknowledge key (12) Escape key

Navigation Keys Acknowledge Key (6) Pressing the

AC Overview (2) The AC OVERVIEW key
will navigate the display to the first screen of AC
information. The AC OVERVIEW information
contains various AC parameters that summarize the
electrical operation of the generator set.
Engine Overview (3) The ENGINE OVERVIEW
key will navigate the display to the first screen of
engine information. The ENGINE OVERVIEW
information contains various engine parameters that
summarize the operation of the generator set.
ACKNOWLEDGE key will cause the horn
relay to turn off and will silence the horn. Pressing
this key may also cause the red flashing light
or yellow flashing light to turn off. Pressing this
key may also cause the red flashing light or the
yellow flashing lights to come on continuously. The
ACKNOWLEDGE key may be configured to send
a global alarm silence signal on the J1939data link
which will silence the horns on the annunciators.
SEBU8013-01
Lamp Test Key (7) Pressing and holding the
LAMP TEST key will cause each LED and the
display screen pixels to turn on continuously until the
key is released.
RUN Key (8) Pressing the RUN key will start
the engine.
AUTO Key (9) Pressing the AUTO key will cause
the engine to enter the AUTO mode. The engine
will start if the module receives a start command from
a remote source.
STOP Key (10) Pressing the STOP key will stop
the engine.
Up Key (11) The UP key is used to navigate
through the various menus and monitoring screens.
The UP key is also used when a setpoint is entered.
When numeric data is entered, the UP key is used
in order to increment the digits (0-9). If the setpoint
requires selection from a list, the UP key is used to
navigate UP through the list.
Escape Key (12) The ESCAPE key is used in
order to navigate through the menus. When the key
is pressed, the user moves backward or the user
moves upward through the menus. The ESCAPE
key is also used to exit out of entering data when the
user is programming the setpoints. If the ESCAPE
key is pressed during setpoint adjustment, changes
that are made on the screen will not be saved.
Right Key (13) The RIGHT key is used during
setpoint adjustment. The RIGHT key is used to
select a digit that will be edited as numeric data is
entered. The RIGHT key is also used to select a
check box as setpoint adjustments are made. The
RIGHT key is also used to unselect a check box as
setpoint adjustments are made. If a check box has a
check mark, the function has been enabled. Pressing
the RIGHT key will disable the function. Pressing
the RIGHT key will also cause the check mark to
disappear. If the check box does not have a check
mark, the function is disabled. Pressing the RIGHT
key will enable the function. Pressing the RIGHT
key will also cause a check mark to appear.
Enter Key (14) The ENTER key is used in order
to navigate through the menus. When the key is
pressed, the user moves forward or the user moves
downward through the menus. The ENTER key is
also used to save any changes while the setpoints
are being programmed. Pressing the ENTER
key during programming the setpoints causes the
changes to be saved to memory.
65
Operation Section
Features and Controls
Down Key (15) The DOWN key is used to
navigate downward through the various menus or
screens. The DOWN key is also used to program
the setpoints. The DOWN key is used to decrease
the digits as numeric data is entered. If the setpoint
requires selection from a list, the DOWN key is
used to navigate DOWN through the list.
Left Key (16) The LEFT key is used during
setpoint adjustment. The LEFT key is used to select
the digit that is edited during the entry of numeric
data. The LEFT key is also used during some of
the setpoint adjustments to select a check box. The
key is also used to unselect a check box. If a check
box has a check mark, pressing the LEFT key
will disable the function. Pressing the key will also
remove the check mark. Pressing the LEFT key
will also cause the check mark to disappear. If the
check box does not have a check mark, pressing
the LEFT key will enable the function. Pressing the
LEFT key will also cause a check mark to appear.
Alarm Indicators
Yellow Warning Lamp (4) A flashing yellow light
indicates that there are active warnings that have
not been acknowledged. A continuous yellow light
indicates that there are acknowledged warnings that
are active. If there are any active warnings, the yellow
light will change from flashing yellow to continuous
yellow after the ACKNOWLEDGE key is pressed. If
there are no longer any active warnings, the yellow
light will turn off after the ACKNOWLEDGE key is
pressed.
Red Shutdown Lamp (5) A flashing red light
indicates that there are active shutdowns that
have not been acknowledged. A continuous red
light indicates that there are active shutdowns that
have been acknowledged. If there are any active
shutdowns, the red light will change from flashing red
to continuous red after the ACKNOWLEDGE key is
pressed. Any condition that has caused a shutdown
must be manually reset. If there are no longer any
active shutdowns, the red light will turn off.
Digital Inputs
Note: There are eight digital inputs on EMCP 3.2
and EMCP 3.3. There are six digital inputs on
EMCP 3.1.
66 SEBU8013-01
Operation Section
Features and Controls

Digital Input 1 Digital Input 1 is used for the Rear bearing temperature
emergency stop. This input should be wired to
GROUND through an Emergency Stop switch. Right exhaust temperature
The input can be set to activate on an active high
(normally closed contact) or an active low (normally Left exhaust temperature
open contact). Activating the emergency stop input
will cause the generator set to stop immediately. The Levels
emergency stop input will also prevent the generator
set from starting. As Digital Input 1 is activated, the Engine coolant level
engine will not start until the event has been cleared.
Refer to System Operation, Troubleshooting, Testing Engine oil level
and Adjusting, RENR7902, Digital Input Resetting.
Fuel level
Digital Input 2 Digital Input 2 is used for remotely
starting and stopping the generator set. This input External fuel tank level
should be wired to GROUND through a switch that
can be initiated remotely. The input can be set to Other
activate on an active high (normally closed contact)
or an active low (normally open contact). If the input Closed air damper
is active and the engine is in AUTO, the engine will
attempt to start. If the input is inactive, the engine will ATS in normal position
enter cooldown mode and the engine will stop.
ATS in emergency position
The remainder of the inputs can be configured. The
DIGITAL input adds additional monitoring of the Battery charger failure
engine and generator. The inputs can be configured
by going to the EVENT I/P FUNCTIONS parameter Closed breaker
under the SETPOINTS menu. The DIGITAL
INPUTS parameter can only be set to ACTIVE Closed utility breaker
HIGH or ACTIVE LOWto initiate a High Warning,
Low Warning, High Shutdown, Low Shutdown, or Detected fuel leak
Status.
Custom event
The inputs can be programmed to monitor the
following parameters or components. Refer to For detailed information about the electronic control
System Operation, Troubleshooting, Testing and module, see Systems Operation, Troubleshooting,
Adjusting, RENR7902, Digital Input Programming. Testing and Adjusting, RENR7902, EMCP3.

Pressures
Annunciator Module
Air filter differential pressure
Engine oil pressure
Fire extinguishing system
Fuel filter differential pressure
Oil filter differential pressure
Starting air pressure
Temperatures

Ambient air temperature

Engine coolant temperature
Engine oil temperature
Exhaust temperature g01101388
Illustration 46
SEBU8013-01 67
Operation Section
Features and Controls

General Information For detailed information about the annunciator

module, see Systems Operation, Troubleshooting,
The annunciator module is used to indicate various Testing and Adjusting, RENR7902, EMCP3.
system events and conditions. The annunciator
module uses indicator lights and an audible horn
to give the operator information about the current
status of the system. The annunciator module can
be used to announce faults and/or status signals to
the operator. The annunciator module allows the
operator to silence the horn. The annunciator module
also allows the operator to acknowledge faults to the
system.

There are 17 pairs of LED indicators on the front

panel of the annunciator. Sixteen pairs of LED
indicators are used to announce events, diagnostics,
and ready signals. The seventeenth pair of led
indicators is used as a combined network operation
and module information. The seventeenth pair of LED
indicators alerts the operator if there is a problem
with the J1939 data link connection.

Basic Operation
Each pair of LED indicators on the annunciator
consists of two of the following three colors: green,
yellow, and red. For example, a pair of red and
yellow LED indicators may be configured for engine
oil pressure. If a low engine oil pressure condition
is read over the data link, the annunciator will flash
the yellow LED and the audible horn will sound. If
the low oil pressure shutdown is read over the data
link, the annunciator will flash the red LED and the
audible horn will sound.

Press the Alarm Acknowledge key in order to

acknowledge a shutdown condition. Press the
Alarm Acknowledge key to acknowledge an alarm
condition . In order to silence the horn, press the
Alarm Acknowledge key that is located near the
middle of the annunciator.

Test the led indicators by pressing the Lamp Test

key near the top of the annunciator. Test the horn
when the data link is connected by holding in the
Lamp Test key. Test the horn when the data link is
disconnected by pressing the Lamp Test key that is
located near the top of the annunciator.

Configuration
The annunciator module can be customized in order
to signal many different conditions that are related
to the system. Each pair of LED lights must be
configured by using the appropriate service tool.
Once the service tool has been connected to the
annunciator, the user must enter the Configuration
screen. Each pair of LED lights has four settings:
SPN, Trigger Type, Trigger Severity Level, and
Failure Mode Identifier (FMI).
68 SEBU8013-01
Operation Section
Features and Controls

i03996173

Sensors and Electrical

Components
(Engines Equipped with MCS
Control Unit)
SMCS Code: 1439; 1900; 7400

g02173989
Illustration 47
View of the left side of a C18 Marine Engine with left side service
(1) Low oil pressure alarm (6) Oil pressure (pre-filter) (9) Fuel pressure (after filter)
(2) Low coolant level alarm (7) Low air pressure for starting motor (10) Fuel pressure (pre-filter)
(3) Low oil pressure shutdown alarm (engines equipped with air starting
(4) High coolant temperature shutdown motor)
(5) Oil pressure (after filter) (8) Low oil level alarm
SEBU8013-01 69
Operation Section
Features and Controls

g02173990
Illustration 48
View of the right side of a C18 Marine Engine with left side service
(11) High oil temperature alarm (12) Low coolant pressure alarm

g02173991
Illustration 49
View of the left side of a C18 Marine Engine with right side service
(1) Low oil pressure alarm (3) Low oil pressure shutdown (7) Low air pressure for starting motor alarm
(2) Low coolant level alarm (4) High coolant temperature shutdown (8) Low oil level alarm
70 SEBU8013-01
Operation Section
Features and Controls

g02173993
Illustration 50
View of the right side of a C18 Marine Engine with right side service
(5) Oil pressure (after filter)
(6) Oil pressure (pre-filter)
(9) Fuel pressure (after filter)
(10) Fuel pressure (pre-filter)
(11) High oil temperature alarm
(12) Low coolant pressure alarm
SEBU8013-01 71
Operation Section
Features and Controls

i03646563 i01097127

Battery Disconnect Switch Engine Shutoffs and Engine

(If Equipped) Alarms
SMCS Code: 1411-B11; 1411 SMCS Code: 1900; 7400; 7418

The battery disconnect switch and the engine start

switch perform different functions. Turn off the battery
Shutoffs
disconnect switch in order to disable the entire Shutoffs and alarms are one of two types:
electrical system. The battery remains connected to
the electrical system when you turn off the engine
start switch. Electrical

Turn the battery disconnect switch to the OFF Mechanical

position and remove the key when you service the All electric shutoffs and all electronic alarms operate
electrical system or any other components.
through components that actuate switches in a
sensing unit.
Also turn the battery disconnect switch to the OFF
position and remove the key when the engine will not
Shutoffs are set at critical levels for the following
be used for an extended period of a month or more.
conditions:
This will prevent drainage of the battery.
Operating temperature
NOTICE
Never move the battery disconnect switch to the OFF Operating pressure
position while the engine is operating. Serious dam-
age to the electrical system could result. Operating level

To ensure that no damage to the engine occurs,

Operating rpm
verify that the engine is fully operational before A particular shutoff may need to be reset before the
cranking the engine. Do not crank an engine that is engine will start.
not fully operational.

Perform the following procedure in order to check the NOTICE

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.
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart
the engine.
Make sure that you are familiar with the following
items:
Types and locations of shutoff

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.
Conditions that cause each shutoff to function
Resetting procedure for engine restart
Alarms
Engines may be equipped with alarms that are used
to alert the operator when undesirable operating
conditions occur.

NOTICE
When an alarm is activated, corrective measures must
be taken before the situation becomes an emergency
in order to avoid possible engine damage.
72 SEBU8013-01
Operation Section
Features and Controls

Once an alarm is activated, corrective measures

need to be taken within a reasonable amount of
time, or engine damage could result. The alarm will
continue until the condition is corrected. The alarm
may need to be reset.

A switch may be installed in the alarm for silencing.

This may be installed while the engine is stopped for
repairs. Check for this switch before you start the
engine. Make sure that the switch is moved to the
ON position and that the warning lights are flashing.
The engine will not be protected if the switch is left
in the OFF position.

Testing the Shutoff and Alarm

System
Most control panels are equipped with a lamp test
switch. Turn the switch to the ON position in order
to check the indicator lights for proper operation.
Replace defective bulbs immediately.

NOTICE
During testing, abnormal operating conditions must be
simulated. Perform the tests correctly in order to help
prevent possible engine damage.
Refer to the Service Manual for more information on
testing procedures, or consult your Caterpillar dealer.
i04009894
Voltage Regulators
SMCS Code: 4467
Cat Digital Voltage Regulator (Cat
DVR)
g01115009
Illustration 51
The Cat DVR is a microprocessor-based voltage
regulator. Control power for the Cat DVR is supplied
from an external source of 24 VDC. The power
stage of the Cat DVR is supplied from a multiple
pole high frequency permanent magnet generator
which is mounted on the end of the generator shaft.
Connections to the Cat DVR are made through three
connectors. The communication between the Cat
DVR and the service tool is accomplished by using a
CANBUS protocol.
The Cat DVR has the following features:

Three control modes:

The Cat Digital Voltage Regulator presents an
electrical shock/electrocution hazard. This hazard
will cause serious injury or death.
Service by trained personnel only.
The terminals and heat sinks are live at hazardous
voltages when power is applied and for up to 8
minutes after power is removed.
1. Automatic voltage regulation (AVR)
2. Power factor (PF) regulation
3. Reactive power (VAR) regulation
Programmable stability settings
Soft start control with an adjustable time setting
in AVR mode

Dual slope voltage versus frequency (V/Hz)

characteristic

Three-phase or single-phase voltage sensing

Single-phase current sensing
SEBU8013-01 73
Operation Section
Features and Controls

Field current sensing and field voltage sensing

Ten protection functions
Adjusting the Cat DVR
In order to view and configure the parameters of the
Cat DVR, a PC with the Caterpillar DVR software is
required.

Refer to Specifications, Systems Operation, Testing

and Adjusting, RENR7941, Cat Digital Voltage
Regulator for complete information.
74 SEBU8013-01
Operation Section
Engine Diagnostics

Engine Diagnostics
i03568753

Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902

System configuration parameters are parameters

that are configured to specify the engine's emissions
levels, the power rating, and the specific application.
Default values for the parameters are programmed
at the factory. Some parameters may be changed in
order to equip the engine for a specific application.
The system configuration parameters must be
reprogrammed if the electronic control module (ECM)
is replaced. It is not necessary to reprogram the
system configuration parameters if you update the
ECM flash file. Certain configuration parameters are
stamped into the engine information plate.

Note: If the parameters that are protected with

the factory passwords are changed, the Caterpillar
warranty may be voided.

Table 2
Parameter Worksheet
Security Access Parameters
Equipment ID
ECM Serial Number
Software Group Part Number
Software Group Release Date
Software Group Description
Selected Engine Rating
Rating Number
Rated Frequency
Rated Engine Speed
Rated Real Genset Power
Rated Apparent Genset Power
Rating Configuration
Test Spec
Engine/Gear Parameters
Engine Acceleration Rate
Low Idle Speed
Engine Speed Droop
Droop/Isochronous Switch Enable
Droop mode selection
Remote Emergency Stop (E-Stop) Switch Input Type Configuration
(continued)
SEBU8013-01 75
Operation Section
Engine Diagnostics

(Table 2, contd)
Parameter Worksheet
I/O Configuration Parameters
Desired Speed Input Configuration
Secondary Desired Speed Input Configuration(2)
Fuel Enable Input Configuration
Secondary Fuel Enable Input Configuration
Coolant Level Installation Status
Maintenance Parameters
Engine Oil Capacity
Maintenance Indicator Mode
PM1 Interval
System Settings
Governor Gain Factor
Governor Minumum Stability Factor
Governor Maximum Stability Factor
Injector Serial Numbers
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
Cylinder 5
Cylinder 6
Information from the Engine Information Plate
Engine Serial Number
FLS
FTS
(2) The configuration of this parameter is dependent on the configuration of the throttle controls for the application. Refer to Troubleshooting,
Speed Control - Test for additional information.

Parameter Descriptions ECM Serial Number

Equipment ID The serial number of the ECM that is stored in the

ECM memory
This parameter allows the customer to enter a
description into the electronic control module (ECM) Software Group Part Number
in order to identify the engine's application. A
maximum of 17 characters can be entered in the field. The part number of the flash file that is currently
installed in the ECM
Engine Serial Number
Software Group Release Date
The engine serial number must be programmed to
match the engine serial number that is stamped The release date of the flash file that is currently
on the engine information plate. The engine serial installed in the ECM
number is not preprogrammed into a replacement
ECM.
76 SEBU8013-01
Operation Section
Engine Diagnostics

Software Group Description Engine Acceleration Rate

The description of the application for the flash file that This parameter defines the maximum rate of engine
is currently installed in the ECM acceleration.

Rating Number Low Idle Speed

The rating number corresponds to the selected set
of performance maps that has been selected for
this application. There may be more than one set of
performance maps that are available for this engine.
All of the maps are resident in the flash file for the
engine.
This parameter defines the low idle rpm of the engine.
Engine Speed Droop
This parameter enables the engine to be operated
in a load sharing system.

Rated Frequency Droop/Isochronous Switch Enable

The line frequency of the generator set This parameter defines the installation status of a
switch that is used to select droop or isochronous
Rated Engine Speed mode.

The optimum speed of the engine Droop Mode Selection

Rated Real Genset Power
The output power of the generator set in kilowatts
Rated Apparent Genset Power
The kVA rating of the generator set
Rating Configuration
The performance maps in the software
Test Spec
This is the engine's Test Specifiction Number. Use
this number to retrieve data that is related to the
engine's specifications from the Technical Marketing
Information System (TMI). The following information
can be retrieved from TMI:
This parameter allows the customer to select droop
or isochronous mode.
Remote Emergency Stop (E-Stop) Switch
Input Type Configuration
This parameter sets the installation status and the
configuration of the emergency stop switch.
Desired Speed Input Configuration
This parameter defines the type of signal that is used
for throttle control. This parameter will be used while
a valid signal is present at the expected input.
The following input types are available:
PWM A Pulse Width Modulated signal (PWM) is
received via terminal P1-66 at the ECM connector.

As shipped consists CAN Input A J1939 signal is received via the CAN
data link.
Engine test specifications
0 - 5 VDC An analog signal is received via terminal
Systems data P1-15 at the ECM connector.

Physical data Secondary Desired Speed Input

Configuration
Gasket kit data
This parameter defines the type of signal that is used
Reman parts as a secondary throttle control. If the signal for this
input becomes unavailable, the ECM will revert to
Performance data this type of signal for the throttle control. Refer to
Desired Speed Input Configuration for the input
A link to TMI Web can be found on the web site for
types that are available.
the Service Information System (SIS).
SEBU8013-01 77
Operation Section
Engine Diagnostics

Fuel Enable Input Configuration FLS

This parameter allows the selection for the type of This parameter represents the fuel system
input that is used to enable the fuel for the engine. adjustment that was made at the factory in order to
fine tune the fuel system to the engine. The correct
Secondary Fuel Enable Input Enable value for this parameter is stamped on the engine
information plate. Only change this value if the engine
Status is rerated or if a new ECM has been installed. Factory
passwords are required to change this parameter.
This parameter sets the installation status of a
secondary switch that can be used to enable the fuel
for the engine. FTS
This parameter is another parameter that represents
Coolant Level Sensor a fuel system adjustment that was performed at
the factory in order to fine tune the fuel system to
This parameter can be set to either Installed or Not
this engine. Only change this value if the engine is
Installed. rerated or if a new ECM has been installed. Factory
passwords are required to change this parameter.
Engine Oil Capacity
Total Tattletale
Program this parameter to the capacity of engine oil
for the engine.
The total tattletale counts the number of changes to
system parameters.
Maintenance Indicator Mode
The ECM records data that is related to equipment
maintenance. The ECM will activate the maintenance
indicator lamp when scheduled maintenance is
due. The maintenance indicator lamp can be reset
by actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.

PM1 Interval
This parameter allows the customer to define the
maintenance interval if Maintenance Indicator Mode
is programmed to one of the manual options. Refer
to the Operation and Maintenance Manual for more
information.

Governor Gain Factor

This parameter is used in determining the engine's
rate of response to an engine load.

Governor Minimum Stability Factor

This parameter is used by the ECM to offset the
steady state speed error when the steady state
speed error is less than 20 rpm.

Governor Maximum Stability Factor

This parameter is used by the ECM to offset the
steady state speed error when the steady state
speed error is greater than 20 rpm.
78
Operation Section
Engine Starting
Engine Starting
i01486758
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, Maintenance
Interval Schedule for more information.
For the maximum service life of the engine, make
a thorough inspection before the engine is started.
Look for the following items: oil leaks, coolant
leaks, loose bolts, and trash buildup. Remove trash
buildup and arrange for repairs, as needed.
Inspect the cooling system hoses for cracks and
for loose clamps.
Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage.
Inspect the wiring for loose connections and for
worn wires or frayed wires.
Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply valve.
NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when fuel
filters have been changed, some air pockets will be
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Manual, Fuel System - Prime for more information
on priming the fuel system.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
SEBU8013-01
Do not start the engine or move any of the controls
if there is a DO NOT OPERATE warning tag or
similar warning tag attached to the start switch or
to the controls.
Ensure that the areas around the rotating parts are
clear.
All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.
Disconnect any battery chargers that are not
protected against the high current drain that
is created when the electric starting motor (if
equipped) is engaged. Check electrical cables
and check the battery for poor connections and
for corrosion.
Reset all of the shutoffs or alarm components.
Check the engine lubrication oil level. Maintain the
oil level between the ADD mark and the FULL
mark on the oil level gauge.
Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
the coolant level to the FULL mark on the coolant
recovery tank.
If the engine is not equipped with a coolant
recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain
the coolant level in the sight glass.
Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.
Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
SEBU8013-01 79
Operation Section
Engine Starting

i02377318 i03900529

Starting the Engine Starting the Engine

(EMCP 3 (If Equipped)) (If Equipped with Marine
SMCS Code: 1000; 1450
Classification Society Control
Unit (MCS Control Unit))
1. Start the engine by one of these three methods.
SMCS Code: 1000; 1450
The operator presses the RUN Key.
The control is in AUTO and the remote initiate
contact (IC) becomes active.

The operator presses the AUTO Key and a

start command is sent via the RS-485 SCADA
Data Link.

2. The EMCP 3 checks the system before the crank

cycle begins. The EMCP 3 checks that no system
faults are present. The EMCP 3 checks that all
previous shutdown faults have been reset. The
EMCP 3 also checks that the engine is not already
running. If the engine is equipped with prelube,
the EMCP 3 checks the status of the prelube. If
the prelube is not complete, the EMCP 3 will not
crank the engine.
3. The EMCP 3 begins the crank cycle.
4. The EMCP 3 cranks the engine until the crank
cycle time reaches the setpoint for total crank time
or until the engine starts.
5. The EMCP 3 deactivates the starting motor
relay (SMR) when the engine speed reaches the
setpoint for crank terminate speed.
g02174258
Illustration 52
MCS Control Unit
(1) START button
(2) STOP button
The START button may be configured as LATCHED
or as HOLD. The values for the START button and
the values for the STOP button always match.
Start the engine with one of two methods:
If the START button is configured as LATCHED,
perform the following sequence in order to start the
engine: press the START button., observe the
confirmation dialog, and press YES . The control
unit will complete the starting sequence.

If the START button is configured as HOLD, press

and hold the START button until the engine starts.

i02706577

Cold Weather Starting

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

Refer to the Owner's Manual of the OEM for your

type of controls. Use the following procedure in order
to start the engine.
80
Operation Section
Engine Starting
DO NOT USE ETHER (starting fluids) unless
specifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.
Startability will be improved at temperatures below
10C (50F) from the use of a cylinder block coolant
heater or from other means that are used to heat
the crankcase oil. Some engine applications use a
jacket water heater to improve startability. This will
help reduce white smoke and misfire during start-up
in cold weather.
NOTICE
When using ether (starting fluid), follow the manufac-
turer's instructions carefully, use it sparingly and spray
it only while cranking the engine. Excessive ether can
cause piston and ring damage. Use ether (starting flu-
id) for cold weather starting purposes only.
For engines that are not equipped with an Air Inlet
Heater, use ether when temperatures are below 0C
(32F). If the engine is equipped with an injection
system for starting fluid, crank the engine. Depress
the ether switch for three seconds. Additional
injections may be necessary in order to start the
engine.
Note: If the engine has not been run for several
weeks, fuel may have drained. Air may have moved
into the filter housing. Also, when fuel filters have
been changed, some air will be left in the filter
housing. Refer to the Operation and Maintenance
Manual, Fuel System - Prime (Maintenance Section)
for more information on priming the fuel system.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
1. Turn the ignition switch to the ON position.
SEBU8013-01
The CHECK ENGINE/DIAGNOSTIC lamp will
flash while the engine is cranking. The lamp
should turn off after proper engine oil pressure
is achieved. If the lamp fails to flash, notify your
authorized Caterpillar dealer. If the lamp continues
to flash, the Electronic Control Module (ECM) has
detected a problem in the system. Refer to the
Operation and Maintenance Manual, Diagnostic
Flash Code Retrival for more information.
2. Push the start button or turn the ignition switch to
the START position in order to crank the engine.
Do not push down or hold the throttle down
while the engine is cranked. The system will
automatically provide the correct amount of fuel
that is needed to start the engine.
3. If the engine fails to start within 30 seconds,
release the start button, or the ignition switch. Wait
for two minutes in order to allow the starting motor
to cool before attempting to start the engine again.
NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine speed until the
oil pressure gauge indicates normal. If oil pressure
is not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investi-
gate and correct the cause.
Note: The CHECK ENGINE/DIAGNOSTIC lamp
may come on after the engine is started. If this
occurs, the Electronic Control Module (ECM) has
detected a problem with the system. Refer to the
Operation and Maintenance Manual, Diagnostic
Flash Code Retrival for more information.
4. Allow the engine to idle for approximately
three minutes. Idle the engine until the water
temperature gauge has begun to rise. Check all
gauges during the warm-up period.
Note: The oil pressures and fuel pressures should
be in the normal range on the instrument panel. Do
not apply a load to the engine or increase engine rpm
until the oil pressure gauge indicates at least normal
pressure. Inspect the engine for leaks and/or unusual
noises.
i04009931
After Starting Engine
SMCS Code: 1000
Note: In temperatures from 0 to 60 C (32 to 140 F),
the warm-up time is approximately 5 minutes. In
temperatures below 0 C (32 F), additional warm-up
time may be required.
SEBU8013-01 81
Operation Section
Engine Starting

Note: Ensure that the self-test for the monitoring i00627907

system is completed before you operate the engine
under load. Air Starting
1. Operate the engine at low idle rpm for 5 minutes. SMCS Code: 1451
Perform these checks during the warm-up:
For good life of the air starting motor, the air supply
Check for any fluid leaks and for any air leaks. must be free from dirt and water.

Check all the gauges.
Observe the gauges and record the data frequently
while the engine is operating. Comparing the
data over time will help to determine normal
readings for each gauge and will help to detect
abnormal operating developments. Investigate
any significant changes in the readings.
1. Open the drain valve and close the drain valve in
order to drain condensation and oil carryover. This
drain valve is located on the bottom of the air tank.
2. Check the air supply pressure. The air starting
motor requires a minimum of 620 kPa (90 psi) air
pressure to operate properly. The maximum air
pressure must not exceed 1034 kPa (150 psi).

2. After the engine has idled for 5 minutes and the

inspections have been made, increase the engine
speed to the rated rpm.

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

If the water flow is restricted and/or water discharge

is not visible at the sea water outlet, follow the recom-
mended procedure.

g00104406
3. Observe the water discharge at the sea water Illustration 53
outlet. If water discharge is not visible or the water Air Valve
flow is restricted, perform the following procedure:
3. Press the air valve or press the start button for
a. Stop the engine immediately. the engine in order to crank the engine. After the
engine starts, release the air valve or release the
b. Inspect the inlet screen and the sea water start button.
strainer for debris. Remove any debris that is
found.

c. Inspect the cooling system and the auxiliary

water pumps for evidence of leaks.

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

5. Perform any necessary repairs before you operate

the engine.

6. After the inspections have been made, move the

throttle control to the rated position and proceed
with operation.
82
Operation Section
Engine Operation
Engine Operation
i01646252
Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors
in obtaining the maximum life and economy of
the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
The time that is needed for the engine to reach
normal operating temperature can be less than the
time taken for a walk-around inspection of the engine.
The engine can be operated at the rated rpm after
the engine is started and after the engine reaches
operating temperature. The engine will reach normal
operating temperature sooner during a low engine
speed (rpm) and during a low power demand. This
procedure is more effective than idling the engine
at no load. The engine should reach operating
temperature in a few minutes.
Gauge readings should be observed and the data
should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
SEBU8013-01
i01316674
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. Repair the fuel lines, if necessary.
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.
Ensure that all of the connections of the hoses are
tight. The connections should not leak.
Keep heat exchangers, and water pumps clean.
Keep the components in good repair.
Ensure that all of the accessory pumps are
repaired. The pumps should operate efficiently.
Do not exceed the maximum oil level.
Never operate without water temperature
regulators.
Water temperature regulators regulate heat. Water
temperature regulators help to provide efficient
operating temperatures. Cold engines consume
excessive fuel. Water temperature regulators also
help prevent engine overheating.
SEBU8013-01 83
Operation Section
Engine Stopping

Engine Stopping i03900530

Manual Stop Procedure

i03353845 (If Equipped with Marine
Emergency Stopping Classification Society Control
SMCS Code: 1000; 7418 Unit (MCS Control Unit))
SMCS Code: 1000
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

Ensure that any components for the external system

that support the engine operation are secured after
the engine is stopped.

Emergency Stop Button (If

Equipped)

g02174258
Illustration 55
MCS Control Unit
(1) START button
(2) STOP button

The STOP button may be configured as LATCHED

or as HOLD. The values for the STOP button and
the values for the START button always match.
Stop the engine with one of two methods:

If the STOP button is configured as LATCHED,

perform the following sequence in order to start
Illustration 54
g00104303 the engine: press the STOP button, observe the
confirmation dialog, and press YES . The control
Typical emergency stop button
unit will complete the stopping sequence.
The emergency stop button is in the OUT position for
normal engine operation. Push the emergency stop
If the STOP button is configured as HOLD, press
and hold the STOP button until the engine stops.
button. The engine will not start when the button is
locked. Turn the button clockwise in order to reset.

Refer to Operation and Maintenance Manual,

Features and Controls for the location and the
operation of the emergency stop button.
84
Operation Section
Engine Stopping
i04010070
Manual Stop Procedure
SMCS Code: 1000
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
Excessive temperatures in the turbocharger center-
housing will cause oil coking problems. Excessive
temperatures in the turbocharger centerhousing may
damage the turbocharger bearing/shaft system and
significantly shorten the life of the turbocharger.
Allow the engine to gradually cool before stopping the
engine
Open the main circuit breaker in order to disengage
the driven equipment.
Note: If the cooldown feature is not utilized, operate
the engine for a cooldown period before stopping the
engine. After the driven equipment is disengaged,
allow the engine to operate at rated rpm for 5 minutes.
Stop the engine by pressing the STOP key on the
control panel.
The engine will coast to a stop. Ensure that any
system that provides external support to the engine
is secured after the engine is stopped.
Automatic Stopping
Automatic stopping will occur when the engine is
operating in the automatic mode and the remote
start/stop initiate contact opens. If the cooldown
feature is utilized, the engine will operate for a
programmed period before the engine stops.
Otherwise, the engine will immediately shut off.
SEBU8013-01
i02702528
After Stopping Engine
SMCS Code: 1000
Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
Check the crankcase oil level. Maintain the oil level
between the ADD mark and the FULL mark on
the oil level gauge.
If necessary, repair any leaks.
If necessary, perform minor adjustments or tighten
loose bolts.
Note the service hour meter reading. Perform
the maintenance that is in the Operation and
Maintenance Manual.
Fill the fuel tank in order to help prevent
accumulation of moisture in the fuel. Do not overfill
the fuel tank.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Refill Capacities and Recommendations topic that
is in this Operation and Maintenance Manual. Failure
to do so can cause engine damage.
Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling. The cooling
system can also be maintained between the
COLD FULL mark and the LOW ADD mark on
the coolant recovery bottle (if equipped).
If freezing temperatures are expected, check
the coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
If freezing temperatures are expected, drain the
keel cooling system (if equipped).
Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU8013-01
Cold Weather Operation
i04010071
Cold Weather Operation
SMCS Code: 1000; 1250
Cat Diesel Engines can operate effectively in cold
weather. The starting and the operation of the diesel
engine is dependent on the following items in cold
weather:
The type of fuel that is used
The viscosity of the oil
Optional starting aids
Optional warm-up aids
Refer to Special Publication, SEBU5898, Cold
Weather Recommendations for Cat Machines.
The purpose of this section will cover the following
information:
Explain potential problems that are caused by
cold-weather operation.
Suggest steps which can be taken in order to
minimize starting problems and operating problems
when the ambient air temperature is colder than
0 to 55 C (32 to 67 F).
The operation and maintenance of an engine in
freezing temperatures is complex because of the
following conditions: the unlimited differences in
weather conditions, engine applications, and the
supplies that are available in your area. These
factors, recommendations from your Caterpillar
dealer, past proven practices, and the information
that is contained in this section should be combined
in order to provide guidelines for cold-weather
operations.
Hints for Cold Weather Operation
If the engine is started, operate the engine until a
minimum operating temperature of 71 C (160 F)
is achieved. Achieving operating temperature will
help prevent the intake valves and exhaust valves
from sticking.
85
Operation Section
Cold Weather Operation
The cooling system and the lubrication system
for the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
down for a few hours and the engine will start
readily. If the engine is shut down for at least
8hours, the engine should be considered cooled
to outside temperature.
Install the correct lubricant in each compartment
before the beginning of cold weather.
Check all rubber parts (hoses, fan drive belts, and
so on) weekly.
Check all electrical wiring and connections for any
fraying or damaged insulation.
Keep all batteries fully charged and warm.
Fill the fuel tank at the end of each shift.
Check the air cleaners and the air intake daily.
Check the air intake more often when you operate
in snow.
Personal injury or property damage can result
from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable and
toxic and if improperly stored could result in injury
or property damage.
DO NOT USE ETHER (starting fluids) unless
specifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.
NOTICE
The optional automatic ether injection system is the
only starting fluid system that is recommended. Ex-
cessive starting fluid can cause piston and ring dam-
age. Use starting fluid for cold starting purposes only.
Inject starting fluid only when the engine is
cranking.
Dryers for the air system may be effective in
reducing moisture condensation and the formation
of ice in air systems.
The injection of alcohol may prevent moisture from
freezing the air compressor governor and other
components of the air system.
86
Operation Section
Cold Weather Operation
For jump starting with cables in cold weather, refer
to the Operation and Maintenance Manual for jump
starting instructions.
Viscosity of the Engine Lubrication
Oil
Proper engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to crank
the engine. Refer to the Operation and Maintenance
Manual, Refill Capacities and Recommendations
for the recommended viscosity of oil.
Lubricating Oil Heaters
Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure the
compatibility of the components, only use equipment
that is recommended by Caterpillar.
NOTICE
Heating elements that are in direct contact with the
lubricating oil can cause coking of the oil.
To aviod coking of the oil when the oil is heated, follow
these recommendations:
The temperature of the heating surface must not ex-
ceed 150 C (300 F). The maximum heat density
of the heating surface must not exceed 1.24 w/cm2
(8W/in2).
Engine oil pan heaters are useful devices that provide
the following functions:
Assist in reducing the cold cranking amperage
that is needed to start the engine.
Improve the flow of oil at start-up.
The time that is needed to warm up the engine
is reduced.
The service life of bearings is increased.
Engine oil pan heaters can reduce the minimum
ambient temperatures that are normally
recommended for multigrade oil. Consult your dealer
for more information.
Recommendations for the Coolant
Provide cooling system protection for the lowest
expected outside temperature. Refer to the Operation
and Maintenance Manual, Refill Capacities and
Recommendations for the recommended coolant
mixture.
SEBU8013-01
In cold weather, check the coolant often for the proper
glycol concentration in order to ensure adequate
freeze protection.
Jacket Water Heater
A jacket water heater heats the coolant that
surrounds the combustion chamber providing the
following functions:
Startability is improved.
Warm up time is reduced.
The required temperature for ether is reduced.
An electric jacket water heater can be activated
once the engine is stopped. An effective jacket water
heater is typically a 1500 W unit. Consult your marine
dealer for more information.
Idling the Engine
While the engine is idling, the application of a light
load (parasitic load) will assist in maintaining the
minimum operating temperature. The minimum
operating temperature is 71 C (160 F). Maintaining
an elevated low idle speed for extended periods will
be easier with the installation of a hand throttle. An
idle speed of 1200 rpm is preferred for all engines.
Recommendations for Coolant
Warm Up
Warm up any system that has cooled below normal
operating temperatures due to inactivity. The
warm-up should be performed before the engine is
returned to full operation. During operation in very
cold temperature conditions, damage to engine
valve mechanisms can result from engine operation
for short intervals. This damage can happen if the
engine is started and the engine is stopped many
times without being operated in order to warm up
completely.
When the engine is operated below normal operating
temperatures, fuel and oil are not completely burned
in the combustion chamber. This fuel and oil causes
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and
the deposits are burned off during operation at
normal engine operating temperatures.
When the engine is started and stopped without
operating long enough to warm up completely, the
carbon deposits become thicker. The carbon deposits
will cause the following problems:
Free operation of the valves is prevented.
SEBU8013-01
Valves become stuck.
Pushrods are bent.
Other damage to valve train components can
result.
For this reason, when the engine is started,
the engine must be operated until the coolant
temperature is 71 C (160 F) minimum. Carbon
deposits on the valve stems are kept at a minimum
and the free operation of the valves and the valve
components are maintained.
Warm the engine thoroughly to keep other engine
parts in better condition. The service life of the engine
will be extended. Lubrication will be improved. There
will be less acid and less sludge in the oil. The better
condition of the oil will provide longer service life for
the engine bearings, the piston rings, and other parts.
However, limit unnecessary idle time to 10 minutes.
Engine wear is greatest at low idle and unnecessary
idling wastes fuel.
On/Off Fan Clutch
Viscous fans continuously rotate in cold weather,
which creates unnecessary movement of the air. For
better control of the operation of the fan, an ON/OFF
fan clutch may be used. ON/OFF fan clutches can
help prevent excessive cooling in cold weather. In
the OFF position, the fan is kept stationary by the
ON/OFF fan clutch. The unnecessary movement
of the air is reduced in order to maintain adequate
engine operating temperatures in cold weather.
Purge Valve and Insulated Heater Lines
During periods of operations with a light load, The
coolant must bypass the radiator in order to help
prevent excessive cooling of the engine. Coolant that
passes through the radiator must be minimized in
order to maintain the engine operating temperature
in cold weather.
Excessive cooling of the engine is prevented by a
jiggle valve that performs two functions. The valve
allows the flow of air and the valve prevents the flow
of coolant. These valves prevent the unnecessary
coolant flow, which may be diverted around the water
temperature regulator to the radiator.
Insulated cab heater lines for very cold weather are
also beneficial. These lines provide more available
heat from the coolant to the cab and less heat is lost
to the outside air.
87
Operation Section
Cold Weather Operation
Insulating the Air Inlet and Engine
Compartment
When temperatures below 18 C (0 F) will be
frequently encountered, an air cleaner inlet that is
located in the engine compartment may be specified.
The special air cleaner inlet is sometimes referred to
as a snow valve. An air cleaner that is located in the
engine compartment may also minimize the snow
that is packed in the air cleaner. Heat that is rejected
by the engine warms the inlet air.
Additional heat can be retained around the engine by
insulating the engine compartment.
i02237624
Fuel and the Effect from Cold
Weather
SMCS Code: 1000; 1250
The following fuels are the grades that are available
for Caterpillar 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.
88
Operation Section
Cold Weather Operation
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
Engine oil pan heaters
Engine coolant heaters
Fuel heaters
Fuel line insulation
For more information on cold weather operation,
see Special Publication, SEBU5898, Cold Weather
Recommendations.
i03353862
Fuel Related Components in
Cold Weather
SMCS Code: 1000; 1250
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after operating the engine.
Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
SEBU8013-01
Drain the water and sediment from any fuel storage
tank at the following intervals:
Weekly
Oil changes
Refueling of the fuel tank
This will help prevent water and/or sediment from
being pumped from the fuel storage tank and into
the engine fuel tank.
Fuel Filters
NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contami-
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
four micron[c] absolute high efficiency fuel filter is re-
quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer
for the proper part numbers.
When the engine is equipped with a primary
filter/water separator, the primary filter/water
separator must use a 10 micron filter to a 15 micron
filter. The filters are becoming more critical as fuel
injection pressures increase to 209 MPa (30000 psi)
and higher psi. For more information on priming the
fuel system, see the Operation and Maintenance
Manual, Fuel System - Prime topic (Maintenance
Section).
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater
with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
to the limited surface area.
Disconnect the fuel heater in warm weather.
SEBU8013-01 89
Operation Section
Cold Weather Operation

Note: Fuel heaters that are controlled by the water

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

Note: Heat exchanger type fuel heaters should have

a bypass provision in order to prevent overheating of
the fuel in warm weather operation.

For further information on fuel heaters, consult your

Caterpillar dealer.
90 SEBU8013-01
Operation Section
Generator Operation

Generator Operation
i04010770

Generator Operation
SMCS Code: 4450

Loading of the Generator

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

Allowable combinations of unbalanced loads are

shown in Illustration 56. When you operate with
significant single-phase loads, the combinations of
single-phase load and three-phase load may be
used. Such combinations should be located below
the line on the graph.

g00627416
Illustration 56
Allowable Combinations of Unbalanced Loads

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

The block loading capability of a generator set

depends on the following factors.

Engine transient response

Voltage regulator response
Type of the voltage regulator
Altitude of operation of the generator set
Type of load
Percent of load before the block load is applied
SEBU8013-01
If derating for the block load is required, refer to ISO
3046 Standards or SAE J1349 Standards. Also,
reference Engine Data Sheet, LEKX4066, Loading
Transient Response and Engine Data Sheet,
LEKX4067, Block and Transient Response.
Note: ISO stands for International Standards
Organization.
Power Factor
The power factor represents the efficiency of the
load. Power factor is the ratio of apparent power
to total power. The power factor is expressed as a
decimal. The power factor represents that portion of
the current which is doing useful work. The portion of
current which is not doing useful work is absorbed
in maintaining the magnetic field in motors or other
devices.
In most applications, electric motors and transformers
determine the power factor of the system. Induction
motors usually have a 0.8 or smaller power factor.
Incandescent lighting is a resistive load of about 1.0
power factor, or unity.
The power factor of a system may be determined by
a power factor meter or by calculations. Determine
the power requirement in kW by multiplying the power
factor by the kVA that is supplied to the system. As
the power factor increases, the total current supplied
to a constant power demand will decrease. For
example, a 100 kW load at a 0.8 power factor will
draw more current than a 100 kW load at 0.9 power
factor. high-power factor will result in full engine load
at less than the rated amperage of the generator.
A lower power factor increases the possibility of
overloading the generator.
Note: Caterpillar generators are designed for a 0.8
power factor unless otherwise specified.
91
Operation Section
Generator Operation
Excitation System
Permanent Magnet Pilot Excited
Generators
Permanent Magnet Pilot Excited (PMPE) generators
receive power for the voltage regulator from a pilot
exciter, rather than the main armature. The pilot
exciter consists of a permanent magnet rotor and a
permanent magnet stator. The pilot exciter operates
independently from the generator output voltage.
Constant excitation during a large load application
is possible because the irregularities that occur in
generator output voltage are not fed back into the
exciter. Such irregularities can be caused by load
conditions. The independent operation also allows
the generator to better sustain an overload for a
short duration. The pilot exciter also ensures that the
generator will start properly even if the rotating field
becomes completely demagnetized.
Low Idle Adjustment
Generator sets normally have a higher low idle
setting than industrial engines. Low idle will be
approximately 66% of the full load speed of 60 Hz
units. Low idle will be approximately 80% of the full
load speed of 50 Hz units.
Note: Operating the generator set at low idle speed
for an extended time will cause some voltage
regulators to shut off. The generator set must be
completely shut down and restarted in order for the
voltage regulator to operate.
Standby Generator Sets
Most standby units are installed with controls that
will start the unit automatically. Standby units start,
pick up the load, run, and stop without an operator
in attendance.
Standby units cannot automatically change the
governor control. Standby units cannot automatically
change the voltage settings. The governor speed and
voltage level must be preset for the proper operation
of the standby unit. Whenever the set is operated
manually, be sure that the governor speed and
voltage levels are correct for automatic operation.
Check all switches for the proper setting. The start
select switch should be in the AUTOMATIC position.
Emergency Stop Switches should be in RUN position.
92
Operation Section
Generator Operation
Generator Options
Space Heaters
All Cat Marine Generators are provided with space
heaters. These space heaters are installed for
operation in high humidity conditions. For more
information on space heaters, refer to this Operation
and Maintenance Manual, Space Heater - Check.
Embedded Temperature Detectors
All Cat Marine Generators are available with
embedded resistance type temperature detectors
(RTDs). The detectors are installed in the slots of
the main armature. The main armature is also called
a stator. If the Marine Classification Society control
panel (MCS Control Panel) is installed, the detectors
are connected to the RIO and are monitored by the
MCS controller. Otherwise, the detectors are used
with the equipment that is provided by the customer.
Bearing Temperature Detectors
Bearing temperature detectors are standard
equipment. If an MCS system is installed, the
detectors are connected to the RIO and are
monitored by the MCS controller. Otherwise, the
bearing temperature detectors are used with the
equipment that is provided by the customer. Thus,
the temperature of the bearing can be measured or
monitored. Bearing temperature measurements may
help to prevent premature bearing failure. Contact
your Cat dealer for more information.
SEBU8013-01
i04010972
Single Unit Operation
SMCS Code: 4450
Initial Start-Up
Before the initial start-up, perform the megohmmeter
test on the main stator winding. Refer to the Special
Instruction, SEHS9124, Cleaning and Drying of
Electric Set Generators for the procedure.
Starting
1. Make all of the preliminary checks listed in this
Operation and Maintenance Manual, Before
Starting Engine topic.
2. Be sure that the main circuit breaker or the line
circuit breaker is open.
3. Start the engine according to this Operation and
Maintenance Manual, Starting the Engine topic.
Allow the engine to warm up.
4. Adjust to the full-load engine speed.
5. Close the main circuit breaker.
6. Apply the load. Apply the load in increments in
order to maintain system frequency and voltage
at a constant level.
7. Readjust the governor for rated frequency.
Stopping
Refer to this Operation and Maintenance Manual,
Manual Stop Procedure for the required procedures
for stopping the generator set.
i04010991
Parallel Operation
SMCS Code: 4450; 4480
Initial Start-Up
Preparing a generator for parallel operation requires
special attention. Before you attempt to parallel units
for the first time, check all the units for the following
three conditions.
Same phase rotation
Same alternating current frequency
Same winding pitch
SEBU8013-01
Same voltage adjustment
1. Check the phase rotation.
Units that operate in parallel must have the same
phase rotation. Two methods may be used to
determine if the incoming unit and the unit that
is on-line have the same phase rotation. These
methods are listed below:
Using a phase rotation meter
Using a set of three light bulbs
Use the procedure below to determine the proper
phase rotation by using three light bulbs.
g00695380
Illustration 57
When servicing or repairing electric power gener-
ation equipment:
Make sure the unit is off-line (disconnected from
utility and/or other generators power service), and
either locked out or tagged DO NOT OPERATE.
Remove all fuses.
a. Connect the light bulbs with rated voltage
between the generator leads and the
corresponding line phase. For example,
connect terminal 1 to line 1 across the open
circuit breaker.
b. Start the units that will be in operating in
parallel. Bring the units up to speed. As the
units approach the same speed, the lights will
start to blink.
93
Operation Section
Generator Operation
If the lights blink in sequence, one of the
units is connected backward. In order to
correct the problem, stop the units. Remove
generator leads 1 and 3 at the circuit breaker.
Exchange generator leads 1 and 3, thus
reversing the direction of phase rotation.
Terminal 2 should always be connected to
line 2.
Both generators have the same phase
rotation when the lights blink in unison. The
first condition of Initial Start-Up has been
met.
2. Adjust the frequency.
The units that will be operating in parallel must
operate at the same speed. Speed is proportional
to the alternating current frequency. Verify that the
generator set is programmed to run at the correct
frequency.
3. Adjust the voltage.
Refer to this Operation and Maintenance Manual,
Voltage Regulators.
Note: Make sure that the speed droop is identical for
all of the engines before adjustments are made to
the generator.
a.
Note: Do not change the voltage settings after this
step.
b.
4. Check the winding pitch.
The units that operate in parallel must have
the same winding pitch to reduce the effect of
circulating currents. It is possible to parallel units
with different winding pitches after the amount of
circulating current flow between each of the units
has been determined. Contact your Cat dealer for
further information.
Starting Multiple Units
Use the procedure for starting single units in order
to start multiple units. Refer to Operation Section,
Single Unit Operation.
Paralleling Multiple Units
Units may be paralleled at no load. Units may also
be paralleled with units under load. After the initial
conditions for start-up are satisfied, verify for the
following requirements:
94
Operation Section
Generator Operation
One of the governors can be an isochronous
governor. Electronic load sharing governors are
an exception.
Generators must have voltage droop compensation
or cross current compensation.
1. Start the unit which will be paralleled.
2. Turn on the synchronizer lights.
3. After the engine has run a few minutes, bring the
engine up to synchronous speed. This means
that the frequency of the incoming unit will be the
same frequency as the unit that is on-line. The
synchronizing lights will begin to blink.
Note: The frequency of the incoming unit should be
slightly greater than the line frequency. This will allow
the incoming unit to assume some of the load instead
of adding to the system load.
4. By using the governor control, adjust the engine
speed until the lights blink very slowly.
5. The lights are off when the voltages of the two
units are in-phase. Very quickly close the breaker
while the lights are out.
6. Use governor controls in order to share kW load
between engines.
7. Generator temperature will be stabilized in
approximately 1 hour. After the generator
temperature has been stabilized, adjust the
voltage droop rheostat of each generator. This
adjustment will share the reactive load and thus
will limit the circulating currents. Less droop
increases the reactive current that is carried by the
generator. Adjusting the voltage droop rheostat
in a counterclockwise direction will decrease the
droop. Adjusting the voltage droop rheostat in a
clockwise direction will increase droop.
Load Division and Speed Droop (If
Equipped)
Once two units have been paralleled, the share of the
kW load for each unit is determined by the governor
control setting. If two units of the same capacity and
the same governor characteristics have the same
governor control settings, the units will share the load
equally. The total load must not exceed the capacity
of the one engine.
In order to transfer the load from one engine to
another engine, use the following procedure:
1. Increase the governor speed control of one unit in
order to increase the load.
SEBU8013-01
2. Reduce the governor speed control of the other
unit in order to decrease the load on that unit.
3. Raise the governor speed control or lower the
governor speed control of both units in order to
change system frequency.
Parallel Operation Of Governors
Illustration 58
g00630841
Load Sharing Module (Typical Example)
The generator set load sharing module provides
either the droop load sharing or the isochronous load
sharing for parallel applications. The load sharing
module has a synchronizing parallel module SPM-A
input. The module provides the proportional load
sharing. More information is available in the System
Operation, Testing and Adjusting, SENR6565,
Generator Set Load Sensor and Generator Load
Sharing Module.
Function of The Engine Governor
This section describes the function of the engine
governor in relation to load division between parallel
electric sets.
It is very important to understand two basic facts
about load division between generator sets which
are operating in parallel.
1. The power which is supplied to the generator
and to the load is a function of the engine. The
setting of the engine governor and the position
of the engine governor control determine the
amount of power that is delivered by the engine.
Therefore, the governor setting and the position
of the governor control determine the kW load
which is carried by the generator. A change in the
engine power of any unit in a parallel operation
will result in the same change in engine power for
each unit in that parallel operation. In other words,
the units that are in parallel operation will stay in
parallel operation.
SEBU8013-01 95
Operation Section
Generator Operation

2. The division of power is not determined by
generator excitation or terminal voltage. The
excitation will determine the power factor for a
generator when the generator is operating in
parallel with other generators.
Governors that are used with Caterpillar powered
electric sets can be of two types:
Governors with fixed speed droop
Governors with adjustable speed droop
The values of speed droop which are commonly
used are 5 percent. Governors with adjustable speed
droop can be adjusted so the characteristics match
closely with the characteristics of governors with
fixed speed droop. If the governor is adjusted for 0
percent speed droop or isochronous operation, the
same speed from no load to full load can be obtained.
Summary on Governor Operation
The preceding discussion of governor operation can
be summarized below:
2. Be sure that the neutral of one of the remaining
units is grounded.
3. Remove the load from the outgoing unit. See
the Parallel Operation, Load Division - Speed
Droop. The amperage may never go to zero due
to circulating currents.
4. Open the circuit breaker.
5. Allow the engine to cool for 5 minutes.
6. Stop the engine.
Circulating Currents
Understanding the circulating currents becomes
very important when the units are paralleled. These
circulating currents are flowing between generators
in parallel operation. The circulating currents
are caused by voltage differences between the
generators. The circulating currents are not doing
useful work. The amount of the circulating current can
be determined by subtracting the amperage which is
going to the load from the total generator amperage.

Each governor should have a 5 percent speed The circulating current may be as high as 25
droop to provide the simplest combination of percent of rated amperes with cold generator sets.
governors for electric sets that are connected in Such current may not even be considered harmful.
parallel. If a constant frequency from no load to full The total generator current should not exceed the
load is required, one governor can be adjusted for amperage rating.
isochronous operation. This isochronous unit will
be called a lead unit. As the generators warm, the circulating currents will
decrease. The ammeter readings should decrease
In order for all paralleled units to accept the slightly, but the voltage meter readings should remain
full share of the load, the following governor constant.
adjustments are required. The governors should
have the same full load speed. The governors
should have the same high idle speed in the case
of governors which are adjusted for speed droop
operation. Governor controls should be set to
the high idle position so that the full range of the
governor is available.

Operating an isochronous governor in parallel

with a speed droop governor requires special
techniques.

Any number of electric sets can be operated in

parallel. However, only one governor of the group
can be adjusted for isochronous operation. The
exception will be some special cases of electronic
governors with automatic load sharing.

Stopping
In order to remove a generator from the line, perform
the following procedure.

1. Check the load. The load must be less than the

rated capacity of the remaining units.
96
Maintenance Section
Refill Capacities
Maintenance Section
Refill Capacities
i04039453
Refill Capacities and
Recommendations
SMCS Code: 1348; 1395; 7560
NOTICE
Every attempt is made to provide accurate, up-to-date
information. By use of this document you agree that
Caterpillar Inc. is not responsible for errors or omis-
sions.
NOTICE
These recommendations are subject to change with-
out notice. Contact your local Cat dealer for the most
up-to-date recommendations.
Note: Instructions for the installation of the filter are
printed on the side of each Cat spin-on filter. For
non-Cat filters, refer to the installation instructions
that are provided by the supplier of the filter.
For more information, refer to Special Publication,
SEBU6251, Caterpillar Commercial Engine Fluids
Recommendations.
Diesel Engine Oil
NOTICE
Faulty engine coolant temperature regulators, or op-
erating with light loads, short operation cycles, exces-
sive idling, or operating in applications were normal
operating temperature is seldom reached can con-
tribute to excessive water in the crankcase oil. Cor-
rosive damage, piston deposits and increased oil con-
sumption can result. If a complete oil analysis program
is not followed or if the results are ignored, the poten-
tial for corrosive damage and piston deposits increas-
es.
Cat Diesel Engine Oil (Cat DEO)
Cat oils have been developed and tested in order to
provide the full performance and service life that has
been designed and built into Cat engines. Cat oils
are currently used to fill diesel engines at the factory.
These oils are offered by Cat dealers for continued
use when the engine oil is changed. Consult your Cat
dealer for more information on these oils.
SEBU8013-01
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:
Cat DEO (Diesel Engine Oil) (10W-30)
Cat DEO (Diesel Engine Oil) (15W-40)
Cat DEO-ULS (Diesel Engine Oil - Ultralow
Sulfur) (10W-30)
Cat DEO-ULS (Diesel Engine Oil - Ultralow
Sulfur) (15W-40)
Note: Cat DEO-ULS multigrade is the preferred
oil for use in all Cat diesel engines for which SAE
15W-40 is the preferred viscosity grade.
Commercial Oil
Note: Non-Cat commercial oils are not the best oils
for your engine.
NOTICE
Caterpillar does not warrant the quality or perfor-
mance of non-Cat fluids.
The three current Cat ECF specifications are:
Cat ECF-1-a, Cat ECF-2, and Cat ECF-3. Each
higher Cat ECF specification provides increased
performance over lower Cat ECF specifications.
Note: The Cat ECF-1-a and Cat ECF-2 specifications
replaced the Cat ECF-1 specification on 1 March
2007.
Note: If Cat DEO multigrade or DEO-ULS multigrade
oils are not used, use only commercial oils that meet
the following categories/specifications:
Commercial oils that meet the requirements of the
Cat ECF-1-a, Cat ECF-2, and/or the Cat ECF-3
specification are acceptable. API category of oils
that have not met the requirements of at least one
Cat ECF specification may cause reduced engine
life.
The preferred commercial oils meet at least one of
the following requirements: Cat ECF-3 specification
and API CJ-4.
Oils that meet the requirements of the API CJ-4
category are compliant with the Cat ECF-3
specification.
The following categories of oils are not approved for
use in your Cat Engine:API CF, API CF-4, and API
CG-4.
SEBU8013-01 97
Maintenance Section
Refill Capacities

In selecting oil for any engine application, both of Cat SOS Services Oil Analysis
the following must be satisfied: the oil viscosity and
the oil performance category or the oil performance Caterpillar has developed a maintenance tool
specification. Using only one of these parameters will that evaluates oil degradation. the maintenance
not sufficiently define oil for an engine application. management also detects the early signs of wear
on internal components. The Caterpillar tool for oil
The proper SAE viscosity grade of oil is determined analysis is called SOS oil analysis and the tool
by the minimum ambient temperature during is part of the SOS Services program. SOS oil
cold engine start-up, and the maximum ambient analysis divides oil analysis into four categories:
temperature during engine operation.
Component wear rate
Refer to Table 3 (minimum temperature) in order to
determine the required oil viscosity for starting a cold Oil condition
engine.
Oil contamination
Refer to Table 3 (maximum temperature) in order to
select the oil viscosity for engine operation at the Identification of oil
highest ambient temperature that is anticipated.
These four types of analysis are used to monitor
Note: Generally, use the highest oil viscosity that is the condition of your equipment. The four types of
available to meet the requirement for the temperature analysis will also help you identify potential problems.
at start-up. A properly administered SOS oil analysis program
will reduce repair costs and the program will lessen
If ambient temperature conditions at engine start-up the impact of downtime.
require the use of multigrade SAE 0W oil, SAE
0W-40 viscosity grade is generally preferred over The SOS oil analysis program uses a wide range of
SAE 0W-30. tests to determine the condition of the oil and of the
lubricated compartment. Guidelines that are based
Table 3 on experience and a correlation to failures have
Lubricant Viscosities for Ambient Temperatures been established for these tests. Exceeding one
for DI Diesel Engines or more of these guidelines could indicate serious
fluid degradation or a pending component failure. A
Ambient Temperature trained person at your Cat dealership should make
Viscosity Grade Minimum Maximum the final analysis.
SAE 0W-30 40 C (40 F) 30 C (86 F)
NOTICE
SAE 0W-40 40 C (40 F) 40 C (104 F) Always use a designated pump for oil sampling, and
SAE 5W-30 30 C (22 F) 30 C (86 F) use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
SAE 5W-40 30 C (22 F) 50 C (122 F) contaminate the samples that are being drawn. This
SAE 10W-30 18 C (0 F) 40 C (104 F) contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
SAE 10W-40 18 C (0 F) 50 C (122 F) dealers and customers.
SAE 15W-40 9.5 C (15 F) 50 C (122 F)
Refer to Special Publication, SEBU6251, Caterpillar
Note: Supplemental heat is recommended for Commercial Engine Fluids Recommendations in
cold soaked starts below the minimum ambient order to obtain additional information about SOS
temperature. Supplemental heat may be necessary Services oil analysis. You can also contact your local
for cold soaked starts that are above the minimum Cat dealer.
temperature that is stated, depending on the parasitic
load and other factors. Cold soaked starts occur Refill Capacities
when the engine has not been operated recently. The
idle period allows the oil to become more viscous due The refill capacities for the engine crankcase reflect
to cooler ambient temperatures. the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter.
98 SEBU8013-01
Maintenance Section
Refill Capacities

Table 4 Table 5
Approximate Refill Capacities Caterpillar Specification for Distillate Fuel for
Off-Highway Diesel Engines
Compartment or System Liters Quarts
Specifications Requirements ASTM ISO Test
Engine Crankcase 68.1 72 Test
ISO
Aromatics 35% maximum D1319
Fuel 3837
0.01%
Filter the fuel coming into the bulk storage fuel tank ISO
Ash maximum D482
to 20 microns(c) absolute or less. 6245
(weight)

Caterpillar strongly recommends the filtration of Carbon 0.35%

ISO
Residue on maximum D524
distillate fuel and/or biodiesel/biodiesel blends 4262
10% Bottoms (weight)
through a fuel filter with a rating of four microns(c)
absolute or less. The filtration should be located on 40 minimum
the device dispensing fuel to the fuel tank for the (DI engines) D613
Cetane ISO
engine, and on the devise dispensing fuel from the or
Number (1)
35 minimum 5165
D6890
bulk storage tank. Series filtration is recommended. (PC engines)

Diesel engines may burn a wide variety of fuels. The cloud

These fuels are divided into two general groups. The point must
two groups are called the preferred fuels and the not exceed
ISO
Cloud Point the lowest D2500
permissible fuels. expected
3015
ambient
The preferred fuels provide maximum engine service temperature.
life and performance. The preferred fuels are distillate
fuels. These fuels are commonly called diesel Copper Strip No. 3 ISO
D130
fuel, furnace oil, gas oil, or kerosene. These fuels Corrosion maximum 2160
must meet the Caterpillar specification for distillate 10% at 282 C
diesel fuel that is found in Special Publication, (540 F)
SEBU6251, Caterpillar Commercial Engine Fluids maximum ISO
Recommendations. Distillation D86
90% at 360 C 3405
(680 F)
Note: The permissible fuels are some crude oils, maximum
some blends of crude oil with distillate fuel, some
biodiesel, and some marine diesel fuel. These fuels ISO
Flash Point legal limit D93
are not suitable for use in all engine applications. 2719
The acceptability of these fuels for use is determined Minimum
on an individual basis. A complete fuel analysis of 80%
is required. Consult your Cat dealer for further reflectance No
Thermal
information. Stability
after aging for D6468 equivalent
180 minutes test
There are many different types of fuel additives that at 150 C
are available to use. Caterpillar does not generally (302 F)
recommend the use of fuel additives. 30 minimum No
API Gravity (2) D287 equivalent
45 maximum test
Distillate Diesel Fuel
6 C (10 F)
Caterpillar recommends that all distillate diesel fuel, minimum ISO
Pour Point D97
including ULSD fuel (fuel 15 ppm sulfur using ASTM below ambient 3016
D5453, ASTM D2622 or ISO 20846, ISO 20884) temperature
meet the requirements of the Caterpillar Specification ISO
for Distillate Diesel Fuel that are specified in Table 5. D5453 20846
Sulfur (3) or or
Note: ULSD has less electrical conductivity than D2622 ISO
LSD. Follow all grounding and safety practices that 20884
are standard for the industry. (continued)
SEBU8013-01 99
Maintenance Section
Refill Capacities

(Table 5, contd) Biodiesel

Caterpillar Specification for Distillate Fuel for
Off-Highway Diesel Engines Biodiesel that meets the requirements that are
listed in the Caterpillar specification for biodiesel,
Specifications Requirements ASTM ISO Test ASTM D6751, or EN 14214 are acceptable blending
Test stock. Biodiesel may be blended in amounts up
1.4 cSt to a maximum of 30 percent with an acceptable
minimum diesel fuel. This blend is acceptable if the biodiesel
and 20.0 cSt constituent meets the requirements that are outlined
maximum in Table 6 prior to blending. In addition, the final blend
as delivered must meet the requirements for distillate diesel fuel
to the fuel that are listed in the Caterpillar Specification for
injection Distillate Diesel Fuel, Table 5.
Kinematic pumps
- -
Viscosity 1.4 cSt Note: A complete Cat SOS Services oil analysis
minimum program is strongly recommended when using
and 4.5 cSt biodiesel blends above 5 percent.
maximum as
delivered to
the rotary
fuel injection
pumps
Water and 0.05% ISO
D1796
Sediment maximum 3734
No
0.05%
Water D1744 equivalent
maximum
test
0.05%
ISO
Sediment maximum D473
3735
(weight)
Gums and 10 mg per 100 ISO
D381
Resins (4) mL maximum 6246
0.52 mm
No
(0.0205 inch)
Lubricity D6079 equivalent
maximum at
test
60 C (140 F)
(1) Alternatively, to ensure a minimum cetane number of 35 (PC
engines), and 40 (DI engines), distillate diesel fuel should have
a minimum cetane index of 37.5 (PC engines), and 44.2 (DI
engines) when the ASTM D4737-96a test method is used. A
fuel with a higher cetane number may be required for operation
at a higher altitude or in cold weather.
(2) Via standards tables, the equivalent kg/m 3 (kilograms per cubic
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/m3, and for the maximum API gravity of 45 is 801.3 kg/m 3.
(3) Follow the federal, state, local, and other governing authorities
for guidance concerning the fuel requirements in your area.
Follow the engine Operation and Maintenance Manual and
the details provided in this Fuel section. ULSD 0.0015% (<15
ppm S) is required by law for Tier 4 engines and engines
with aftertreatment devices. ULSD and LSD 0.05% (500
ppm S) are strongly recommended for pre-Tier 4 engines.
Diesel fuel with > 0.05% (>500 ppm) sulfur is acceptable for
use where allowed by law. Consult your Caterpillar dealer for
guidance when sulfur levels are above 0.1% (1000 ppm).
Certain Caterpillar fuel systems and engine components can
operate on fuel with a maximum sulfur content of 3%. Refer to
the specific engine Operation and Maintenance Manual and
consult your Caterpillar dealer.
(4) Follow the test conditions and procedures for gasoline (motor).
100 SEBU8013-01
Maintenance Section
Refill Capacities

Table 6
Caterpillar Specification for Biodiesel Fuel(1)
Property Test Method Test Method Units Limits
Specific
United States International Properties of Fuel
Density at 15C ASTM D1298 ISO 3675 g/cm3 0.86-0.90
Viscosity at 40C ASTM D445 ISO 3104 mm /s
2
4.0-6.0
Flash Point ASTM D93 ISO 3679 C 130 minimum
Cold Filter Plugging
- Summer ASTM D4539 DIN EN 116 C 0
- Winter 6 below ambient
Pour Point
- Summer ASTM D97 ISO 3016 C -9 maximum
- Winter -20 maximum
Sulfur Content ISO 20846 0.0015 maximum
ASTM D5453 % weight
ISO 20884
Distillation
- 10% Evaporation ASTM D1160 C To Be Determined
- 90% Evaporation 345
Carbon Residue, Conradson
ASTM D4530 ISO 10370 % weight 0.05 maximum
(CCR)
Cetane Number ASTM D613 ISO 5165 45 minimum
Sulfated Ash ASTM D874 ISO 3987 % weight 0.02 maximum
Water/Sediment Content ASTM D2709 ISO 12937 g/m 3
500 maximum
Copper Corrosion ASTM D130 ISO 2160 No. 1
Oxidation Stability ASTM D2274 EN 14112 mg/100mL 15 maximum
Esterification EN 14103 % volume 98.0 minimum
Acid Value ASTM D664 EN 14104 mg NaOH/g 0.5 maximum
Methanol Content GC Method EN 14110 % weight 0.2 maximum
Monoglycerides ASTM D6584 EN 14105 % weight 0.8 maximum
Diglycerides ASTM D6584 EN 14105 % weight 0.2 maximum
Triglycerides ASTM D6584 EN 14105 % weight 0.2 maximum
Free Glycerine ASTM D6584 EN 14105 % weight 0.02 maximum
Total Glycerine ASTM D6584 EN 14105 % weight 0.240 maximum
Iodine Number EN 14111 cg I2/g 110 maximum
Phosphorus Content ASTM D4951 EN 14107 mg/kg 0.001
(1) The final blend of biodiesel as used in the engine must meet the requirements that are stated in the Caterpillar Specification for Distillate
Diesel Fuel for Diesel Engines in Table 5.

Note: Fuels that meet ASTM D6751 or EN 14214

may be used for blending with an acceptable distillate
fuel. The conditions, recommendations, and limits
that are noted in this biodiesel section apply.
SEBU8013-01 101
Maintenance Section
Refill Capacities

Cooling System Coolants which only meet the requirements of

ASTM D6210
Coolant Recommendations
Cat DEAC
NOTICE
The following coolant require treatment with SCA on
Never operate an engine without water temperature
a maintenance basis:
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob- Cat DEAC
lems can develop without water temperature regula-
tors. Removing the regulators allows some coolant to Coolants which only meet the requirements of
ASTM D4985
bypass the radiator, potentially causing overheating.
Coolants which only meet the requirements of
The following two types of coolants may be used in ASTM D6210
Cat Diesel Engines:

Preferred Cat ELC (Extended Life Coolant) or

a commercial extended life coolant that meets the
Caterpillar EC-1 (Engine Coolant -1) specification

Acceptable Cat DEAC (Diesel Engine

Antifreeze/Coolant) or a commercial heavy-duty
antifreeze/coolant that meets ASTM D4985 or
ASTM D6210 specifications

NOTICE
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 or equivalent specification.
This type of coolant/antifreeze is made for light duty
automotive applications.

Use only the coolant/antifreeze that is recommended.

NOTICE
Water alone and/or water mixed with SCA are not ap-
proved coolants for use with C7-C32 Heat Exchanger
cooled marine engines. C7-C32 heat exchanger
cooled marine engines require a minimum of 30
percent glycol to prevent cavitation of cooling system
components, with a minimum of 50 percent glycol
very strongly recommended. Use only glycol based
coolants that meet one or more of the coolant speci-
fications that are defined as preferred or acceptable
in Special Publication, SEBU6251, Caterpillar Com-
mercial Diesel Engine Fluids Recommendations and
that also comply with any additional requirements
that are stated in Special Publication, SEBU6251,
Caterpillar Commercial Diesel Engine Fluids Rec-
ommendations (i.e. chemical composition, the use of
SCA, the use of Extender, etc.).

The following coolant require a treatment of SCA at

the initial fill:

Coolants which only meet the requirements of

ASTM D4985

The following coolant do not require a treatment of

SCA at the initial fill:
102 SEBU8013-01
Maintenance Section
Refill Capacities

Table 7
Coolant Service Life
Coolant Type Service Life (1)(2)

Cat ELC 12000 Service Hours or Six Years(3)

Commercial coolant that meets the
6000 Service Hours or Six Years(4)(5)
Caterpillar EC-1 Specification
Cat DEAC 3000 Service Hours or Three Years
Commercial Heavy-Duty
Coolant/Antifreeze that meets 3000 Service Hours or Two Years
ASTM D6210
Commercial Heavy-Duty
Coolant/Antifreeze that meets 3000 Service Hours or One Year
ASTM D4985
Cat SCA(6) and water(7) 3000 Service Hours or Two Years
Commercial supplemental coolant
3000 Service Hours or One Year
additive(8) and water(6)(7)
(1) Use the interval that occurs first.
(2) Refer to the engine's Operation and Maintenance Manuals, Maintenance Interval
Schedule for the correct interval for replacement of the cooling system water
temperature regulator.
(3) Cat ELC Extender must be added at 6000 service hours or one half of the service
life of the Cat ELC.
(4) An extender must be added at 3000 service hours or one half of the service life of
the coolant.
(5) In order to be used in Cat diesel engines in accordance with the service interval for EC-1
coolants that is listed in this Special Publication, commercial EC-1 coolants must also
pass/conform to the additional requirements for EC-1 specification coolants as stated in
the coolant section of this Special Publication.
(6) The concentration of Cat SCA in a cooling system that uses Cat SCA and water should
be from 6% to 8% by volume.
(7) Refer to this Special Publication, General Coolant Information under the section that
discusses the requirements for water.
(8) Consult the supplier for the commercial SCA for instructions on usage. Also, refer to
this Special Publication, Water/Supplemental Coolant Additive topic for additional
information.

Note: These coolant change intervals are only
achievable with annual SOS Services Level 2
coolant sampling and analysis.
Cat ELC can be recycled into conventional coolants.
Cat SOS Coolant Analysis
Testing the engine coolant is important to ensure
that the engine is protected from internal cavitation
and corrosion. The analysis also tests the ability of
the coolant to protect the engine from boiling and
freezing. SOS coolant analysis can be done at your
Cat dealer. Caterpillar SOS coolant analysis is the
best way to monitor the condition of your coolant
and your cooling system. SOS coolant analysis is a
program that is based on periodic samples.
Cat SOS Coolant Analysis (Level 1)
Glycol concentration for freeze protection and boil
protection
Ability to protect from erosion and corrosion
pH
Conductivity
Visual analysis
Odor analysis
For information about performing this maintenance,
refer to this Operation and Maintenance Manual,
Coolant System Coolant Sample (Level 1) - Obtain.
For information about performing this maintenance,
refer to this Operation and Maintenance Manual,
Maintenance Interval Schedule.

A coolant analysis (Level 1) is a test of the following

properties of the coolant:
SEBU8013-01 103
Maintenance Section
Refill Capacities

Cat SOS Coolant Analysis (Level 2)
A coolant analysis ( Level 2) is a comprehensive
chemical evaluation of the coolant. The SOS coolant
analysis ( Level 2) has the following features:
Note: Always choose grease that meets or exceeds
the recommendations that are specified by the
equipment manufacturer for the application.

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

Contact your local Cat dealer for additional

information concerning the SOS Coolant Analysis
program.

Refill Capacity (Coolant)

Table 8

Approximate Refill Capacities for Coolant

Compartment or System Liters Quarts
Engine and Expansion Tank(1) 45 48
(1) The following capacities are for engines that have heat
exchangers and expansion tanks that are installed in the
factory. Cooling systems which are installed by the OEM for the
vessel may differ. Refer to the OEM specifications.

Grease
NOTICE
These recommendations are subject to change with-
out notice. Contact your local Cat dealer for the most
up-to-date recommendations.

Caterpillar provides various greases that vary in

performance from a moderate performance to an
extremely high performance. Cat greases service
the entire line of Cat products in the wide variety of
climates throughout the world. From this variety of
Cat grease products, you can find a Cat grease that
will meet or exceed the performance requirements of
most on-highway trucks.

The performance requirements of your engine must

be determined before you select any Cat grease.
Consult the recommendations for greases that are
made by the OEM for the equipment. Then, consult
with your Cat dealer for a list of greases that have the
performance specifications and the available sizes of
containers.
104
Maintenance Section
Maintenance Recommendations
Maintenance
Recommendations
i01179728
General Maintenance
Information
SMCS Code: 4450; 7000
Note: Read the warnings and read the instructions
that are contained in the Safety Section of this
manual. These warnings and instructions must be
understood before you perform any operation or any
maintenance procedures.
Rotating electric machines are complex structures
that are exposed to the following forms of stress:
mechanical
electrical
thermal
environmental
These stresses may be of varying magnitudes. The
electrical insulation systems are very susceptible to
damage that is caused by the stresses that are listed
above. Exposure to these stresses may shorten
the effective life of the electrical insulation system.
Therefore, the service life of an electric machine will
largely depend on the serviceability of the electrical
insulation systems. An inspection program and a
testing procedure are recommended. An inspection
program and a testing procedure will ensure that the
equipment is maintained in satisfactory condition.
This will increase field reliability.
A regular maintenance and inspection program can
provide an evaluation of the present condition of
the equipment. A regular maintenance program
and a regular inspection program can also reveal
future problems. The frequency of this maintenance
program will depend on the following factors:
application
environmental conditions
operator's experience
operator's philosophy
A regular maintenance program is strongly
recommended. This program would involve the
following steps:
periodic disassembly
SEBU8013-01
knowledgeable visual examination of the
equipment
the application of electrical tests
Never perform a test over the rated potential. These
tests can damage insulation that is contaminated
or insulation that is in marginal condition. For more
information, refer to I.E.E.E. Standard 432-1992 or
consult a Caterpillar dealer.
i02909163
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050
Coolant System
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
To relieve the pressure from the coolant system, turn
off the engine. Allow the cooling system pressure cap
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure.
Fuel System
To relieve the pressure from the fuel system, turn off
the engine.
High Pressure Fuel Lines (If Equipped)
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
The high pressure fuel lines are the fuel lines that
are between the high pressure fuel pump and the
high pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
systems.
This is because of the following differences:
The high pressure fuel lines are constantly charged
with high pressure.
SEBU8013-01
The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks:
1. Stop the engine.
2. Wait for ten minutes.
Do not loosen the high pressure fuel lines in order to
remove air pressure from the fuel system.
Engine Oil
To relieve pressure from the lubricating system, turn
off the engine.
i03642798
Welding on Engines with
Electronic Controls
SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Proper welding procedures are necessary in order
to avoid damage to the engine's ECM, sensors,
and associated components. When possible,
remove the component from the unit and then
weld the component. If removal of the component
is not possible, the following procedure must be
followed when you weld on a unit that is equipped
with a Caterpillar Electronic Engine. The following
procedure is considered to be the safest procedure to
weld on a component. This procedure should provide
a minimum risk of damage to electronic components.
105
Maintenance Section
Maintenance Recommendations
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train, the bearings, hy-
draulic components, electrical components, and other
components.
Do not ground the welder across the centerline of the
package. Improper grounding could cause damage to
the bearings, the crankshaft, the rotor shaft, and other
components.
Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.
Note: Perform the welding in areas that are free from
explosive hazards.
1. Stop the engine. Turn the switched power to the
OFF position.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
3. Disconnect the J1/P1 and J2/P2 connectors from
the ECM. Move the harness to a position that will
not allow the harness to accidentally move back
and make contact with any of the ECM pins.
106 SEBU8013-01
Maintenance Section
Maintenance Recommendations

g01075639
Illustration 59
Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder

4. Connect the welding ground cable directly to the

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

Note: If electrical/electronic components are used

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

5. Protect the wiring harness from welding debris

and spatter.

6. Use standard welding practices to weld the

materials.
SEBU8013-01 107
Maintenance Section
Maintenance Recommendations

i03860683

Generator Start-up Checklist

SMCS Code: 4450

Table 9
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________
Generator Serial Number: _________________________________ Arrangement Number: ___________________
GENERATOR NAME PLATE INFORMATION
Voltage: ___________________ Package (prime, continuous, standby): _________________
Amperage: _________________ Kilowatts: ________________________________________
Storage Location:
Main Stator Megohmmeter Reading: Before Storage: After Storage:
Generator dried for 24 hours prior to startup? (Y/N) Drying method:
SPACE HEATERS Yes No Comments
Space heaters operating properly?
Space heater operated 48 hours before
startup?
MEGOHMMETER TEST Special 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments
Instruction, SEHS9124 reading reading corrected corrected temp.
Main Stator
Main Rotor
Beginning
Exciter Stator
of Storage
Exciter Rotor
PMG Stator
Main Stator
Main Rotor
Start-up Exciter Stator
Exciter Rotor
PMG Stator
108 SEBU8013-01
Maintenance Section
Maintenance Recommendations

Table 10
GENERATOR START-UP CHECKLIST (CONT.)

Regulator Voltage Amps Comments

F1 to F2 DC
E1 to E2 AC
All Frames
E1 to E3 AC
E2 to E3 AC

No Load 2400, 2500, PM1 to PM4 AC

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

Table 11

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
SEBU8013-01 109
Maintenance Section
Maintenance Recommendations

Table 12
GENERATOR START-UP CHECKLIST (CONT.)
MECHANICAL Data Comments
Bearing temperature readings at full load Front __________ Rear
___________
Stator temperature readings at full load A0 _______ B0 _______
C0 _______
Air gap on main stator Top __________ Bottom
__________
Air gap on exciter stator Top __________ Bottom
__________
Air gap of PMG Top __________ Bottom
__________
Ambient air to generator at full load Temperature
____________________
Supplier air opening to generator Size of Opening
_________________
SWITCH GEAR/PARALLEL OPERATION
Manufacturer:
Setting 1 Setting 2 Setting 3 Comments
Type of Circuit breaker
Overload setting
Reverse power relay
VAR/PF Controller
Load share
INSTALLATION & LOAD INFORMATION
Neutral grounding system UPS
Enclosure type - Size
Motor: Other loads:
- Total SKVA - Lighting
- Total HP - Computers
- Welding
- Non-linear
- Other

FULL LOAD DATA

Voltage Amps KW KVARS P.F.
110
Maintenance Section
Maintenance Interval Schedule
i03634531
Maintenance Interval Schedule
SMCS Code: 1000; 7500
Ensure that all safety information, warnings,
and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for
the performance of maintenance including all
adjustments. The user is responsible for the
use of proper lubricants, fluids, and filters. The
user is responsible for the installation of new
components due to normal wear and aging. The
performance of this product may be diminished if
proper maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Note: Use whichever of the following that occurs
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
Products that operate in severe operating conditions
may require more frequent maintenance.
When Required
Battery - Recycle ................................................. 114
Battery - Replace ................................................. 114
Battery or Battery Cable - Disconnect ................. 115
Engine - Clean .................................................... 130
Engine Oil Level Gauge - Calibrate .................... 134
Engine Storage Procedure - Check .................... 140
Fuel System - Prime ........................................... 142
Generator - Dry ................................................... 151
Generator Set - Test ........................................... 156
Generator Set Alignment - Check ....................... 157
Heat Exchanger - Inspect ................................... 158
Maintenance Recommendations ........................ 165
Sea Water Strainer - Clean/Inspect .................... 173
Varistor - Test ...................................................... 176
Winding - Test ..................................................... 178
Zinc Rods - Inspect/Replace ............................... 179
Daily
Closed Crankcase Ventilation (CCV) Filter Service
Indicator - Inspect .............................................. 117
Cooling System Coolant Level - Check .............. 125
Engine Air Cleaner Service Indicator - Inspect ... 131
Engine Oil Level - Check .................................... 134
Fuel System Primary Filter/Water Separator -
Drain ................................................................. 145
Generator Load - Check ..................................... 155
Power Factor - Check ......................................... 171
Walk-Around Inspection ...................................... 177
SEBU8013-01
Initial 20 to 40 Service Hours
Belts - Inspect/Adjust/Replace ............................. 116
Every Week
Electrical Connections - Check ........................... 130
Generator Bearing Temperature - Measure/
Record .............................................................. 155
Power Factor - Check ......................................... 171
Standby Generator Set Maintenance
Recommendations ............................................ 173
Stator Winding Temperature - Measure/Record .. 175
Voltage and Frequency - Check ......................... 177
Every 50 Service Hours or Weekly
Aftercooler Condensate Drain Valve -
Inspect/Clean ..................................................... 112
Sea Water Strainer - Clean/Inspect .................... 173
Zinc Rods - Inspect/Replace ............................... 179
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 127
Every 500 Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ............................................................... 126
Every 1000 Service Hours
Insulation - Test ................................................... 162
Every 2000 Service Hours
Generator - Inspect ............................................. 153
Generator Set Vibration - Inspect ....................... 157
Stator Lead - Check ............................................ 174
Every 2000 Service Hours or 1 Year
Generator Bearing - Lubricate ............................ 155
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 127
Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .. 124
Every 8000 Service Hours
Rotating Rectifier - Check ................................... 171
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ........... 122
SEBU8013-01 111
Maintenance Section
Maintenance Interval Schedule

First 14 400 L (3750 US gal) of Fuel or 250 Water Pump - Inspect ......................................... 178
Service Hours
Overhaul
Engine Valve Lash - Inspect/Adjust .................... 141
Engine Valve Rotators - Inspect ......................... 141 Generator Bearing - Inspect/Replace ................. 154
Fuel Injector - Inspect/Adjust .............................. 142 Maintenance Recommendations ........................ 165
Overhaul (Major) ................................................. 167
Every 14 400 L (3750 US gal) of Fuel or 250 Overhaul (Top End) ............................................. 170
Service Hours or 1 Year
Commissioning
Auxiliary Water Pump (Rubber Impeller) -
Inspect ............................................................... 114 Generator Set Alignment - Check ....................... 157
Battery Charger - Check ...................................... 115
Battery Electrolyte Level - Check ......................... 115
Belts - Inspect/Adjust/Replace ............................. 116
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ............................................... 127
Engine - Clean .................................................... 130
Engine Air Cleaner Element - Clean/Replace ..... 130
Engine Crankcase Breather - Clean ................... 133
Engine Oil Sample - Obtain ................................ 135
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 144
Fuel System Secondary Filter - Replace ............ 146
Fuel Tank Water and Sediment - Drain ............... 150
Hoses and Clamps - Inspect/Replace ................ 159

Every 28 500 L (7500 US gal) of Fuel or 500

Service Hours or 1 Year
Engine Oil and Filter - Change ........................... 136

Every 57 000 L (15 000 US gal) of Fuel or

1000 Service Hours
Aftercooler Core - Clean/Test .............................. 112
Closed Crankcase Ventilation (CCV) Fumes Disposal
Filter - Replace ................................................... 117
Heat Exchanger - Inspect ................................... 158
Turbocharger - Inspect ........................................ 175

Every 170 400 L (45 000 US gal) of Fuel or

3000 Service Hours
Auxiliary Water Pump (Bronze Impeller) -
Inspect ............................................................... 113
Cooling System Coolant (DEAC) - Change ......... 119
Cooling System Water Temperature Regulator -
Replace ............................................................. 128
Crankshaft Vibration Damper - Inspect ............... 129
Engine Mounts - Inspect ..................................... 133
Engine Speed/Timing Sensor - Clean/Inspect .... 139
Engine Valve Lash - Inspect/Adjust .................... 141
Engine Valve Rotators - Inspect ......................... 141
Fuel Injector - Inspect/Adjust .............................. 142
Starting Motor - Inspect ...................................... 174

Every 284 000 L (75 000 US gal) of Fuel or

5000 Service Hours
Alternator - Inspect .............................................. 113
Oil Cooler Core - Check/Clean/Test .................... 167
112 SEBU8013-01
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean

i02098179 i03635591

Aftercooler Condensate Drain Aftercooler Core - Clean/Test

Valve - Inspect/Clean SMCS Code: 1064-070; 1064-081
SMCS Code: 1063-042-DN, VL
Note: An aftercooler that circulates fresh water
or treated water may require cleaning less often
than an aftercooler which circulates salt water.
The maintenance interval for an aftercooler which
circulates fresh water or treated water should be
evaluated when the aftercooler is cleaned and tested
after the first 1000 hours of engine operation. The
interval will vary depending on operating conditions.

Clean the Aftercooler Core

Remove the core. Refer to the Disassembly and
Assembly Manual, Aftercooler - Remove for the
procedure.
g01069660
Illustration 60 1. Turn the aftercooler core on one side in order
(1) Adapter to remove debris. Remove the debris that is
(2) Valve accessible.
(3) Plunger
(4) Valve seat
NOTICE
The engine boost pressure forces the plunger to Do not use a high concentration of caustic cleaner to
move down to the valve seat. The plunger must clean the core. A high concentration of caustic cleaner
close against the seat at a pressure of 27.5 kPa can attack the internal metals of the core and cause
(4 psi). When the engine is stopped, the absence leakage. Only use the recommended concentration of
of boost pressure allows the plunger to rise to the cleaner.
open position, which allows condensation from the
aftercooler to drain out. 2. Back flush the core with cleaner.

The plunger must be able to move freely in order to Caterpillar recommends the use of Hydrosolv
close the system when the engine is running. The liquid cleaner. Table 13 lists Hydrosolv liquid
plunger must be able to move freely in order to allow cleaners that are available from your Caterpillar
condensation to drain from the aftercooler when dealer.
the engine is stopped. Residue from normal engine
operation could cause the plunger to stick. Table 13
Hydrosolv Liquid Cleaners(1)
1. Remove the valve from the adapter. Check the
valve in order to determine if the plunger moves Part
Description Size
freely. If the plunger does not move easily, clean Number
the valve with solvent. 1U-5490 Hydrosolv 4165 19 L (5 US gallon)

2. Reassemble the aftercooler condensate drain 174-6854 Hydrosolv 100 19 L (5 US gallon)

valve. Refer to the Operation and Maintenance (1) Use a two to five percent concentration of the cleaner
Manual for more information on the proper at temperatures up to 93C (200F). Refer to Application
torques. Guide, NEHS0526 or consult your Caterpillar dealer for more
information.

3. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside
and from the outside of the core.

Note: Do not use high pressure when the fins are

cleaned. High pressure can damage the fins.

4. Wash the core with hot, soapy water.

SEBU8013-01
5. Flush the core thoroughly in order to remove
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear and free of debris.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Test the Aftercooler Core
1. Inspect the core for trapped debris and
cleanliness. If necessary, remove the debris and
repeat the cleaning procedure.
2. Inspect the core for damage and perform a
pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform
pressure tests.
3. Plug both ends of the aftercooler core and
pressurize the core to 205 kPa (30 psi). Submerge
the core in water. Look for bubbles which are
being emitted from the core. The bubbles are
evidence of leaks.
4. If any leaks are found, do not attempt to repair the
core.
Install a core that is clean and a core that passes the
pressure test in step 3. Refer to the Disassembly
and Assembly Manual, Aftercooler - Install for the
procedure.
For more information on cleaning the core, consult
your Caterpillar dealer.
113
Maintenance Section
Alternator - Inspect
i02676048
Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
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
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
i01042055
Auxiliary Water Pump (Bronze
Impeller) - Inspect
SMCS Code: 1371-040
Impellers and seals require periodic inspection.
Impellers have a service life that is limited. The
service life depends on the engine operating
conditions.
Inspect the components more frequently when the
pump is exposed to debris, sand, or other abrasive
materials. Inspect the components if the pump is
operating at a differential pressure of more than
103 kPa (15 psi).
Check the following components for wear or damage:
Bearings
Impeller
Seals
Wear plate
If wear or damage is found, replace the components
which are worn or damaged. Use the proper repair
kit for the pump. Refer to the Disassembly and
Assembly for more information on servicing the
auxiliary water pump.
114 SEBU8013-01
Maintenance Section
Auxiliary Water Pump (Rubber Impeller) - Inspect

i01041983 i02156825

Auxiliary Water Pump (Rubber Battery - Replace

Impeller) - Inspect SMCS Code: 1401-510
SMCS Code: 1371-040

Impellers and seals require periodic inspection.

Impellers have a service life that is limited. The
service life depends on the engine operating
conditions.
Inspect the components more frequently when the
pump is exposed to debris, sand, or other abrasive
materials. Inspect the components if the pump is
operating at a differential pressure of more than
103 kPa (15 psi).
Check the following components for wear or damage:
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.

Bearings
Impeller The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
Seals tery cover should be removed before any servic-
ing is attempted.
Wear plate
Removing the battery cables or the batteries with
If wear or damage is found, replace the components the cover in place may cause a battery explosion
which are worn or damaged. Use the proper repair resulting in personal injury.
kit for the pump. Refer to the Disassembly and
Assembly for more information on servicing the 1. Turn the key start switch to the OFF position.
auxiliary water pump. Remove the key and all electrical loads.

i02039199 2. Turn OFF the battery charger. Disconnect the

charger.
Battery - Recycle
3. The NEGATIVE - cable connects the NEGATIVE
SMCS Code: 1401-561 - battery terminal to the ground plane. Disconnect
the cable from the NEGATIVE - battery terminal.
Always recycle a battery. Never discard a battery.
Return used batteries to one of the following 4. The POSITIVE + cable connects the POSITIVE
locations: + battery terminal to the starting motor.
Disconnect the cable from the POSITIVE +
A battery supplier battery terminal.

An authorized battery collection facility Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
A recycling facility recycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that

the key start switch is OFF.

7. Connect the cable from the starting motor to the

POSITIVE + battery terminal.
SEBU8013-01
8. Connect the cable from the ground plane to the
NEGATIVE - battery terminal.
i01942625
Battery Charger - Check
SMCS Code: 1401-535
Check the battery charger for proper operation. If
the batteries are properly charged, the needle of the
ammeter will register near 0 (zero).
The batteries should be kept warm, when possible.
The temperature of the battery will affect cranking
power. A battery that is too cold will not crank the
engine, even if the engine is warm.
The batteries may not fully recharge when the engine
is not run for long periods of time. The batteries may
not fully recharge if the engine only runs for short
periods. Ensure a full charge in order to help prevent
the battery from freezing.
i02601752
Battery Electrolyte Level -
Check
SMCS Code: 1401-535
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the FULL mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
115
Maintenance Section
Battery Charger - Check
A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
i01492654
Battery or Battery Cable -
Disconnect
SMCS Code: 1402-029
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
116 SEBU8013-01
Maintenance Section
Belts - Inspect/Adjust/Replace

i02229322 Alternator Belt Adjustment

Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510

Inspection
Inspect the alternator belt and any accessory belts
for wear and for cracking. Replace the belts if the
belts are not in good condition.

Check the belt tension according to the information in

the Service Manual, Specifications.

Slippage of loose belts can reduce the efficiency

of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components:

Belts
Pulleys Illustration 61
g00960176

(1) Adjusting nuts

Bearings (2) Mounting bolt
(3) Mounting bolt
If the belts are too tight, unnecessary stress is placed (4) Mounting bolt
on the components. This reduces the service life of
the components. 1. Remove the drive belt guard.

Replacement 2. Loosen mounting bolts (2), (3), and (4). Loosen

For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
adjusting nuts (1).
3. Turn adjusting nuts (1) in order to increase or
decrease the drive belt tension.
4. Tighten adjusting nuts (1). Tighten mounting bolts
(2), (3), and (4).

5. Reinstall the drive belt guard.

If new drive belts are installed, check the drive belt

tension again after 30 minutes of engine operation at
the rated rpm.
SEBU8013-01 117
Maintenance Section
Closed Crankcase Ventilation (CCV) Filter Service Indicator - Inspect

i01852860

Closed Crankcase Ventilation

(CCV) Filter Service Indicator
- Inspect
SMCS Code: 1317-040-FI

g01637464
Illustration 63
g00744250
Illustration 62
(1) Plastic cover
(2) Service indicator

The Closed Crankcase Ventilation system (CCV)

is equipped with a service indicator. If the fumes
disposal filter becomes plugged prior to the normal
service interval, increased restriction of the filter will
cause the crankcase pressure to become positive.
When the pressure continues to rise, the service
indicator will show through the plastic cover. The
service indicator indicates the need for the fumes
disposal filter to be changed. Refer to the Operation
and Maintenance Manual, Closed Crankcase
Ventilation (CCV) Fumes Disposal Filter - Replace
topic for more information.

Note: Check the service indicator when the engine is

running at low idle.

i03615046 g01637466
Illustration 64
Closed Crankcase Ventilation (1) Crankcase breather
(2) Filter base and filter for fumes disposal
(CCV) Fumes Disposal Filter - (3) Air cleaner

Replace The Closed Crankcase Ventilation system (CCV)

requires the replacement of the fumes disposal filter.
SMCS Code: 1317-510-FI The service interval of the CCV will be affected by
the following items:
The engine may look like one of the engines which
are pictured below.
Engine load
Soot concentration
Condition of the engine
118 SEBU8013-01
Maintenance Section
Closed Crankcase Ventilation (CCV) Fumes Disposal Filter - Replace

The CCV is equipped with a service indicator. If the

fumes disposal filter becomes plugged prior to the
normal service interval, increased restriction of the
filter will cause the vacuum to become positive. When
the pressure continues to rise, the service indicator
will show through the cap. The service indicator
indicates the need for the fumes disposal filter to be
changed. Reset the service indicator by using the
following procedure:

Resetting the Service Indicator

g01938796
Illustration 66
(6) Filter base assembly
(7) Latches
(8) Canister

1. Release the latches that hold the canister to the

filter base assembly .

Note: Removal of the canister may be difficult while

the engine is operating. The canister has negative air
pressure while the engine is operating. This creates
a vacuum.
g01292899
Illustration 65
(4) Plastic cover 2. Lower the canister in order to expose the element.
(5) Service indicator There may be oil in the bottom of the canister.
Avoid spilling the oil.
1. Remove the plastic cover.
3. Remove the filter element by pulling down.
2. Push down on the service indicator. Dispose of the used element properly.

3. Replace the cover. 4. Remove the O-ring assembly on the top end cap
of the used element.
Replacing the Fumes Disposal 5. Replace the O-ring seal on the bottom of the filter
Filter base assembly.

6. Install the new O-ring on the top end cap of the

element. Install the element into the correct place.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to 7. Replace the canister and align the canister with
contact the skin. the boss on the filter base assembly.

8. Clamp the latches in the closed position.

Note: When possible, perform the maintenance while
the engine is off.
SEBU8013-01 119
Maintenance Section
Cooling System Coolant (DEAC) - Change

i03211768 Note: Inspect the water pump and the water

temperature regulator after the cooling system has
Cooling System Coolant been drained. This is a good opportunity to replace
(DEAC) - Change the water pump, the water temperature regulator and
the hoses, if necessary.
SMCS Code: 1350-070; 1395-044
Drain

Personal injury can result from hot coolant, steam

and alkali.

At operating temperature, engine coolant is hot

and under pressure. The heat exchanger and all
lines to heaters or the engine contain hot coolant
or steam. Any contact can cause severe burns.

Remove the filler cap slowly to relieve pressure

only when the engine is stopped and the filler cap
for the heat exchanger is cool enough to touch
with your bare hand.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01355994
Illustration 67
1. Stop the engine and allow the engine to cool.
Loosen expansion tank filler cap (1) slowly in order
to relieve any pressure. Remove the expansion
tank filler cap.
2. Open the cooling system drain valve (if equipped).
3. In order to fully drain the coolant, remove the
following plugs:

Refer to Special Publication, NENG2500, Caterpillar a. Remove plug (2) in order to vent the water near
Dealer Service Tool Catalog for tools and supplies the water temperature regulator.
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:

The engine overheats frequently.

Foaming of the coolant
The oil has entered the cooling system and the
coolant is contaminated.

The fuel has entered the cooling system and the

coolant is contaminated.

g01355995
Illustration 68
Commercial application
120 SEBU8013-01
Maintenance Section
Cooling System Coolant (DEAC) - Change

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

For information regarding the disposal and the

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

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Flush

g01637916
NOTICE
Illustration 69 Use of commercially available cooling system clean-
Pleasure craft ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
b. Remove drain plug (3) from the bottom heat proved for Caterpillar engines.
exchanger.
1. Flush the cooling system with clean water in order
to remove any debris.

2. Close the drain valve (if equipped). Clean the

drain plugs. Reinstall the drain plugs. Refer to
the Operation and Maintenance Manual for more
information on the proper torques.

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

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the expansion tank filler cap.

4. Start the engine and run the engine for a minimum

of 30 minutes with a coolant temperature of at
g01355996
Illustration 70 least 82C (180F).

c. Remove drain plug (4) from the bottom of the
water cooled exhaust manifold.
d. Remove drain plugs (5) from the bottom of the
jacket water pump inlet.
e. Remove drain plug (6) from the bottom of the
oil cooler.
4. Allow coolant to drain.
5. Stop the engine and allow the engine to cool.
Loosen the expansion tank filler cap slowly
in order to relieve any pressure. Remove the
expansion tank filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Reinstall the
drain plugs. Refer to the Specifications Manual for
more information on the proper torques.
SEBU8013-01
Cooling Systems with Heavy
Deposits or Plugging
Note: For the following procedure to be effective,
there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Reinstall the drain plugs. Refer to
the Operation and Maintenance Manual for more
information on the proper torques.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the expansion tank filler cap.
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
at least 82C (180F).
5. Stop the engine and allow the engine to cool.
Loosen the expansion tank filler cap slowly in order
to relieve any pressure. Remove the expansion
tank filler cap. Open the drain valve (if equipped)
or remove the cooling system drain plugs. Allow
the water to drain. Flush the cooling system with
clean water. Close the drain valve (if equipped).
Clean the drain plugs. Reinstall the drain plugs.
Refer to the Operation and Maintenance Manual
for more information on the proper torques.
Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Engines That Are Equipped with a
Coolant Recovery Tank
1. Fill the system to the top with the mixture of
coolant/antifreeze that is recommended. Refer to
the Operation and Maintenance Manual for more
information on cooling system specifications.
2. Reinstall the filler cap on the coolant recovery
tank.
3. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at 1500
rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
4. Remove filler cap from the coolant recovery tank.
121
Maintenance Section
Cooling System Coolant (DEAC) - Change
5. Pour the coolant/antifreeze into the tank until the
coolant reaches the COLD FULL mark. Do not
fill the tank above the COLD FULL mark.
6. Clean the filler cap. Install the filler cap onto
the recovery tank. Start the engine. Inspect the
cooling system for leaks and for proper operating
temperature.
Engines That Are Not Equipped with a
Coolant Recovery Tank
1. Fill the expansion tank with the coolant/antifreeze.
Do not install the expansion tank filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at 1500
rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
4. Clean the expansion tank filler cap. Inspect the
gasket on the filler cap for the expansion tank.
If the gasket for the filler cap for the expansion
tank is damaged, discard the old filler cap and
install a new filler cap for the expansion tank. If
the gasket for the filler cap for the expansion tank
is not damaged, use a 9S-8140 Pressurized
Pump Group in order to pressure test the filler cap
for the expansion tank. The correct pressure for
the filler cap of the expansion tank is stamped on
the face of the filler cap for the expansion tank. If
the expansion tank filler cap does not retain the
correct pressure, install a new expansion tank
filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
122 SEBU8013-01
Maintenance Section
Cooling System Coolant (ELC) - Change

i03211792 Note: Inspect the water pump and the water

temperature regulator after the cooling system has
Cooling System Coolant (ELC) been drained. This is a good opportunity to replace
- Change the water pump, the water temperature regulator and
the hoses, if necessary.
SMCS Code: 1350-070; 1395-044
Drain

Personal injury can result from hot coolant, steam

and alkali.

At operating temperature, engine coolant is hot

and under pressure. The heat exchanger and all
lines to heaters or the engine contain hot coolant
or steam. Any contact can cause severe burns.

Remove the filler cap slowly to relieve pressure

only when the engine is stopped and the filler cap
for the heat exchanger is cool enough to touch
with your bare hand.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01355994
Illustration 71
1. Stop the engine and allow the engine to cool.
Loosen expansion tank filler cap (1) slowly in order
to relieve any pressure. Remove the expansion
tank filler cap.
2. Open the cooling system drain valve (if equipped).
3. In order to fully drain the coolant, remove the
following plugs:

Refer to Special Publication, NENG2500, Caterpillar a. Remove plug (2) in order to vent the water near
Dealer Service Tool Catalog for tools and supplies the water temperature regulator.
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:

The engine overheats frequently.

Foaming of the coolant
The oil has entered the cooling system and the
coolant is contaminated.

The fuel has entered the cooling system and the

coolant is contaminated.

Note: When the cooling system is cleaned, only g01355995

clean water is needed when the ELC is drained and Illustration 72
replaced. Commercial application
SEBU8013-01 123
Maintenance Section
Cooling System Coolant (ELC) - Change

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

For information regarding the disposal and the

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

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Flush
1. Flush the cooling system with clean water in order
g01637916
Illustration 73 to remove any debris.
Pleasure craft
2. Close the drain valve (if equipped). Clean the
b. Remove drain plug (3) from the bottom heat drain plugs. Reinstall the drain plugs. Refer to
exchanger. the Operation and Maintenance Manual for more
information on the proper torques.

3. Fill the cooling system with clean water. Reinstall

the expansion tank filler cap. Operate the
engine until the temperature reaches 49 to 66C
(120 to 150F).

4. Stop the engine and allow the engine to cool.

Loosen the expansion tank filler cap slowly
in order to relieve any pressure. Remove the
expansion tank filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water.

5. If necessary, repeat step 2 through step 4.

Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
g01355996
Illustration 74 per minute to avoid air locks.

c. Remove drain plug (4) from the bottom of the

water cooled exhaust manifold.
d. Remove drain plugs (5) from the bottom of the
jacket water pump inlet.
e. Remove drain plug (6) from the bottom of the
oil cooler.
Engines That Are Equipped with a
Coolant Recovery Tank
1. Fill the expansion tank to the top with the
ELC. Refer to the Operation and Maintenance
Manual for more information on cooling system
specifications.

4. Allow coolant to drain. 2. Reinstall the filler cap for the recovery tank.
124
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
3. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at 1500
rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
4. Loosen the filler cap of the recovery tank slowly in
order to relieve any pressure. Remove the filler
cap from the recovery tank.
5. Pour the ELC into the tank until the coolant
reaches the COLD FULL mark. Do not fill the
tank above the COLD FULL mark.
6. Clean the filler cap of the recovery tank. Reinstall
the filler cap onto the recovery tank. Start
the engine. Inspect the coolant recovery tank
for coolant leaks and for proper operating
temperature.
Engines That Are Not Equipped with a
Coolant Recovery Tank
1. Fill the expansion tank with the ELC. Do not
reinstall the expansion tank filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at 1500
rpm for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
4. Clean the expansion tank filler cap. Inspect the
gasket of the filler cap for the expansion tank. If
the gasket is damaged, discard the old expansion
tank filler cap and install a new expansion tank
filler cap. If the gasket is not damaged, use a
9S-8140 Pressurized Pump Group in order to
pressure test the expansion tank filler cap. The
correct pressure for the filler cap of the expansion
tank is stamped on the face of the filler cap for
the expansion tank. If the expansion tank filler cap
does not retain the correct pressure, install a new
expansion tank filler cap.
5. Start the engine. Inspect the engine for coolant
leaks and for proper operating temperature.
SEBU8013-01
i02482066
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
additives which are associated with the present
conventional coolants. The Cat ELC Extender only
needs to be added once.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.
Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
tional coolants and/or conventional SCA reduces the
Cat ELC service life.
Check the cooling system only when the engine is
stopped and cool.
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
SEBU8013-01
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant from
the cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the
requirements for your engine's cooling system
capacity. Refer to the Operation and Maintenance
Manual, Refill Capacities and Recommendations
article for more information.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
i02456586
Cooling System Coolant Level
- Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
125
Maintenance Section
Cooling System Coolant Level - Check
Engines That Are Equipped with a
Coolant Recovery Tank
g00103638
Illustration 75
(1) Filler cap
(2) COLD FULL mark
(3) LOW ADD mark
1. Observe the coolant level in the coolant recovery
tank. Maintain the coolant level to COLD FULL
mark (2) on the coolant recovery tank.
2. Loosen filler cap (1) slowly in order to relieve any
pressure. Remove the filler cap.
3. Pour the proper coolant mixture into the tank.
Refer to this Operation and Maintenance Manual,
Refill Capacities and Recommendations for
information about coolants. Do not fill the coolant
recovery tank above COLD FULL mark (2).
4. Clean filler cap (1) and the receptacle. Reinstall
the filler cap and inspect the cooling system for
leaks.
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
and cool, the coolant will return to the engine.
Engines That Are Not Equipped
with a Coolant Recovery Tank
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Remove the cooling system filler cap slowly in
order to relieve pressure.
126 SEBU8013-01
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

2. Maintain the coolant level within 13 mm (0.5 inch) Table 14

of the bottom of the filler pipe. If the engine is Recommended Interval
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass. Type of Coolant Level 1 Level 2
Every 500 Initial 500 Hours
Cat DEAC
Hours(1) and Yearly(1)(2)
Initial 500 Hours
Cat ELC Optional(2)
and Yearly(2)
(1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the
recommended interval for coolant samples of commercial
coolants that meet the Cat EC-1 specification for engine
coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.

g00103639
Illustration 76
Typical filler cap gaskets
3. Clean the cooling system filler cap and inspect
the condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.

i03619060

Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems that
are filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval
that is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants:

Commercial long life coolants that meet the Illustration 77

g01942100
Caterpillar Engine Coolant Specification -1
Coolant sampling valve on bottom of the inlet bonnet for the oil
(Caterpillar EC-1) cooler

Cat DEAC (Diesel Engine Antifreeze/Coolant) The coolant sampling valve for the engine coolant is
located on the right side of the engine on the inlet
Commercial heavy-duty coolant/antifreeze bonnet for the oil cooler.
SEBU8013-01
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:
Complete the information on the label for the
sampling bottle before you begin to take the
samples.
Keep the unused sampling bottles stored in plastic
bags.
Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
Keep the lids on empty sampling bottles until you
are ready to collect the sample.
Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
Never collect samples from expansion bottles.
Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis,
see this Operation and Maintenance Manual, Refill
Capacities and Recommendations or consult your
Caterpillar dealer.
127
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i01987714
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Refer to Operation and Maintenance Manual,
Cooling System Coolant Sample (Level 1) - Obtain
for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For additional information about coolant
analysis, see Special Publication, SEBU6251,
Caterpillar Commercial Diesel Engines Fluids
Recommendations or consult your Caterpillar dealer.
i03509177
Cooling System Supplemental
Coolant Additive (SCA) -
Test/Add
SMCS Code: 1352-045; 1395-081
Note: This maintenance is NOT required for
cooling systems that are filled with Extended Life
Coolant.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
128
Maintenance Section
Cooling System Water Temperature Regulator - Replace
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog and to Special Publica-
tion, GECJ0003, Cat Shop Supplies and Tools for
tools and supplies suitable to collect and contain flu-
ids on Caterpillar products.
Dispose of all fluids according to applicable regula-
tions and mandates.
Note: Caterpillar recommends an SOS coolant
analysis (Level 1).
Cooling Systems that Use
Conventional Coolant
Test the Concentration of the SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Test the concentration of the SCA with the 4C-9301
Coolant Conditioner Test Kit.
SEBU8013-01
Add the SCA, If Necessary
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Remove the cooling system filler cap slowly.
2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
3. Add the proper amount of SCA. For the
proper amount of SCA, refer to this Operation
and Maintenance Manual, Refill Capacities
and Recommendations topic. The proper
concentration of SCA depends on the type of
coolant that is used. For the proper concentration
of SCA, refer to Special Publication, SEBU6251,
Caterpillar Commercial Diesel Engine Fluids
Recommendations.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
i03645060
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime. Refer to this
Operation and Maintenance Manual, Maintenance
Interval Schedule for the proper maintenance
interval.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
SEBU8013-01 129
Maintenance Section
Crankshaft Vibration Damper - Inspect

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.

NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.

Caterpillar engines incorporate a shunt design cooling

system and require operating the engine with a water
temperature regulator installed.

If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
g01134779
ulator is installed in the original position. Ensure that Illustration 78
the water temperature regulator vent hole is open. Viscous vibration damper
Typical example
Do not use liquid gasket material on the gasket or (1) Crankshaft pulley
cylinder head surface. (2) Weight
(3) Case

Refer to two articles in the Disassembly and

Assembly Manual, Water Temperature Regulators
- Remove and Water Temperature Regulators -
Install for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i03175962
Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to
the crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train
noise at variable points in the speed range.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.
Inspection
Inspect the damper for the following conditions:
The damper is dented, cracked, or fluid is leaking
from the damper.
The paint on the damper is discolored from
excessive heat.
The damper is bent.
The bolt holes are worn or there is a loose fit for
the bolts.
The engine has had a crankshaft failure due to
torsional forces.
Replace the damper if any of these conditions exist.
Removal and Installation
Refer to this Operation and Maintenance Manual,
Belts - Inspect/Adjust/Replace for information
on removing and on installing the belt. Refer to
the Disassembly and Assembly Manual, Vibration
Damper and Pulley - Remove and Install for
information on removing and installing the damper.
130 SEBU8013-01
Maintenance Section
Electrical Connections - Check

i01595880 Note: Caution must be used in order to prevent

electrical components from being damaged by
Electrical Connections - Check excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
SMCS Code: 4459-535 starter, and the ECM.
Check all exposed electrical connections for
tightness. i01756656

Check the following devices for loose mounting or Engine Air Cleaner Element -
for physical damage: Clean/Replace
transformers SMCS Code: 1054-070; 1054-510

fuses NOTICE
Never run the engine without an air cleaner element
capacitors installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
lightning arrestors damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
Check all lead wires and electrical connections for
components. Air cleaner elements help to prevent air-
proper clearance.
borne debris from entering the air inlet.

i01646701
Type 1
Engine - Clean
Note: Use the 102-9720 Cleaning Kit. This product
SMCS Code: 1000-070 contains the detergent and oil that is made specifically
for the maintenance of the air cleaner elements.

Personal injury or death can result from high volt-

age.

Moisture can create paths of electrical conductiv-

ity.

Make sure that the electrical system is OFF. Lock

out the starting controls and tag the controls DO
NOT OPERATE.

NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
Easy detection of fluid leaks
Maximum heat transfer characteristics
Ease of maintenance
g00898593
Illustration 79
(1) Air cleaner element
Note: This type of air cleaner element should be
replaced after three cleanings.
1. Remove the air cleaner element (1). Tap the air
cleaner element in order to dislodge dirt particles.
Gently brush the air cleaner element with a soft
bristle brush.
SEBU8013-01 131
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Type 2
NOTICE
Do not use gasoline, steam, caustic or unapproved
detergents, or parts cleaning solvents. Do not use high
pressure water or air to clean the air cleaner element.
Any of those liquids or methods can cause air cleaner
element damage.

2. Spray the air cleaner element with the cleaning

solution. Allow the air cleaner element to stand
for 10 minutes.

3. Rinse the air cleaner element with low water

pressure. The maximum water pressure for this
procedure is 275 kPa (40 psi). Tap water is
acceptable. Start to rinse the air cleaner element Illustration 80
g00898590
from the clean side (inside). Next, clean the dirty
side (outside) in order to flush out dirt. Inspect the 1. Disconnect latches (1).
air cleaner element for tears and/or holes after
the air cleaner element is cleaned. Do not reuse 2. Remove cover (2).
damaged air cleaner elements.
3. Remove the air cleaner element.
NOTICE
Do not use compressed air, open flame, or hot air to Note: This type of air cleaner element may be
dry the air cleaner element. Excess heat shrinks cot- cleaned up to six times.
ton fiber, and compressed air may blow holes in the
material. Allow the air cleaner element to air dry. 4. Refer to Guideline for Reusable Parts and Salvage
Operations, SEBF8062 for cleaning instructions or
replace the air cleaner element.
4. Shake excess water off the air cleaner element ,
and allow the air cleaner element to air dry. Drying 5. Install the air cleaner element.
the air cleaner element in the sun speeds the
process. 6. Install cover (2).

NOTICE 7. Fasten cover (2) with latches (1).

Do not use transmission fluid, engine oil, diesel fuel,
or other lubricant to oil the air cleaner element. The i00641711
air cleaner element can not function correctly if im-
proper oil is used. Never operate an engine with a Engine Air Cleaner Service
dry air cleaner element. The air cleaner element can
not function correctly without oil. Always saturate the Indicator - Inspect
clean air cleaner element with the recommended oil.
SMCS Code: 7452-040
5. The dry air cleaner element should be oiled before
installation. Apply small amounts of oil across the
top of each pleat. Allow the oil to soak into the air
cleaner element for 20 minutes. Oil any remaining
white spots.

6. Inspect the housing and the clamp for air cleaner

element (1). Install the clean, oiled air cleaner
element. Replace the housing and the clamp, if
necessary. Refer to Specifications, SENR3130,
Torque Specifications for the proper torque of
the clamp.

g00291942
Illustration 81
Typical air cleaner service indicator that is mounted on the air
cleaner housing
132
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
An air cleaner service indicator may be mounted on
the air cleaner element or in a remote location.
Some vessels are equipped with a low air pressure
indicator that monitors the inlet air pressure. This
indicator measures air pressure before the air is
drawn through the air cleaner element. Then, the
indicator monitors the pressure level after the air
has passed through the air cleaner element. As the
air cleaner element becomes dirty, this air cleaner
pressure differential rises.
Some vessels may be equipped with a different air
cleaner indicator.
If your vessel is equipped with a different type of air
cleaner indicator, follow the recommendations for the
vessel. You can also follow the recommendations in
the air cleaner OEM in order to service the air cleaner
element.
g00103777
Illustration 82
Typical Air Cleaner Service Indicator
Observe the air cleaner service indicator. You should
clean the air cleaner element, or you should replace
the air cleaner element under two conditions:
The yellow diaphragm enters the red zone.
The service indicator displays the red color at any
time.
The red piston locks in the visible position.
Test the Air Cleaner Service
Indicator
Air cleaner service indicators are important,
inexpensive instruments. Two methods can be used
to test the service indicator.
Check for ease of resetting. The service indicator
should reset in less than three pushes.
SEBU8013-01
Check the movement of the yellow core when the
engine is accelerated to the engine rated rpm.
The yellow core should latch at the approximate
greatest vacuum that is attained.
The air cleaner service indicator should be replaced
under certain conditions and at certain times:
The service indicator does not reset easily.
The yellow core does not latch at the greatest
vacuum.
The engine is used for a year.
The engine is overhauled.
Major engine components are replaced.
Note: Replace the air cleaner service indicator
often whenever you operate in a severely dusty
environment.
If the new service indicator will not reset, the hole for
the service indicator may be plugged.
Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in).
Service the Air Cleaner Service
Indicator
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
If the air cleaner element becomes plugged, the
air can split the filter material. Unfiltered air will
drastically accelerate internal engine wear. Your
Caterpillar dealer has air filter elements for this unit.
Consult your Caterpillar dealer for the correct air
cleaner element.
If the air cleaner service indicator appears red at any
time, clean the air cleaner element or install a new air
cleaner element. At 250 hour intervals, clean the air
cleaner element or replace the air cleaner element .
SEBU8013-01 133
Maintenance Section
Engine Crankcase Breather - Clean

Refer to the Operation and Maintenance Manual

(Maintenance Section) for more information on
servicing the air cleaner element.

i02751871

Engine Crankcase Breather -

Clean
SMCS Code: 1317-070

NOTICE
Perform this maintenance with the engine stopped.
g01377736
Illustration 84
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become 3. Wash breather (4) in solvent that is clean and
plugged. A plugged crankcase breather will cause nonflammable. Allow the breather to dry before
excessive crankcase pressure that may cause installation.
crankshaft seal leakage.
4. Install the valve cover. Refer to the Disassembly
and Assembly Manual.

5. Install the breather hose on the valve cover. Install

the hose clamp.

i02456872

Engine Mounts - Inspect

SMCS Code: 1152-040

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
Illustration 83
g01377732 replaced. Refer to Special Publication, SENR3130,
Torque Specifications for the recommended
1. Loosen hose clamp (1) and remove breather hose torques. Refer to the OEM recommendations for
(2) from valve cover (3). more information.

2. Remove valve cover (3). Refer to the Disassembly

and Assembly Manual.
134 SEBU8013-01
Maintenance Section
Engine Oil Level - Check

i02703852 i02703804

Engine Oil Level - Check Engine Oil Level Gauge -

SMCS Code: 1348-535-FLV Calibrate
SMCS Code: 1326-524

The engine is shipped with an engine oil level gauge

that is not marked. The engine oil level gauge is
not marked because the following features can be
different for each engine:

Angle of the installation

Side for service
The engine oil level gauge must be calibrated after
the engine is installed in the vessel.

Illustration 85
g01356472 Note: The engine may be equipped with auxiliary
Right hand service shown
engine oil filters. The extra filters require more engine
oil than the standard amounts. Refer to the OEM
1. Stop the engine and allow the engine oil to drain specifications.
into the crankcase for approximately ten minutes.
Use the following procedure in order to calibrate and
mark the engine oil level gauge.

1. Ensure that the engine is properly aligned and that

the engine is in the design trim. The engine must
be installed properly in the vessel.

Note: If the engine has oil in the crankcase, skip step

g00110310
2 and proceed to step 3.
Illustration 86
Oil level gauge 2. If there is no oil in the engine, use information in
(Y) ADD mark this Operation and Maintenance Manual, Refill
(X) FULL mark Capacities and Recommendations in order to
select the correct oil for the engine. Add engine oil
2. Check the engine oil. Maintain the engine oil level to the crankcase by using the procedure in this
between ADD mark (Y) and FULL mark (X) on Operation and Maintenance Manual, Engine Oil
engine oil level gauge (2). Do not fill the crankcase and Filter - Change . Choose the appropriate
above FULL mark (X). amount of oil from the following types of sumps:

NOTICE Standard Oil Sump: Fill the crankcase with

Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
3. Remove engine oil filler cap (1) and add oil, if
necessary. Clean the engine oil filler cap. Reinstall
the engine oil filler cap.
45.4 L (48 qt) of the recommended oil.
Deep Oil Sump: Fill the crankcase with 64.3 L
(68 qt) of the recommended oil.
Clean the engine oil level gauge and install the
engine oil level gauge.
Note: If the engine contains oil, perform steps 3
through 7. Skip steps 3 through 7 if you are filling the
engine with oil for the first time.

3. Operate the engine until normal operating

temperature is achieved. Stop the engine. Drain
the engine oil by using the procedure in this
Operation and Maintenance Manual, Engine Oil
and Filter - Change .
SEBU8013-01
4. Replace the engine oil filter by using the procedure
in this Operation and Maintenance Manual,
Engine Oil and Filter - Change .
5. Clean the engine oil level gauge and install the
engine oil level gauge.
6. Use the information in Operation and Maintenance
Manual, Refill Capacities and Recommendations
in order to select the correct oil for the engine.
7. Add engine oil to the crankcase by using the
procedure in this Operation and Maintenance
Manual, Engine Oil and Filter - Change . Choose
the appropriate amount of oil from the following
two sumps:
Standard Oil Sump: Fill the crankcase with
45.4 L (48 qt) of the recommended oil.
Deep Oil Sump: Fill the crankcase with 64.3 L
(68 qt) of the recommended oil.
8. Start the engine. Ensure that the lubrication
system and the new engine oil filter are filled.
Inspect the lubrication system for leaks.
9. Stop the engine and allow the engine oil to drain
into the engine crankcase for approximately ten
minutes.
10. Check the engine oil level. Use a marking tool in
order to engrave the ADD mark (Y) to the correct
location on the gauge assembly.
11. Add 3.8 L (4 qt) of the recommended oil grade
and weight of engine oil to the crankcase. Add this
amount for both standard sumps and deep sumps.
12. Check the engine oil level. Use a marking tool in
order to engrave FULL mark (X) onto the correct
location on the gauge assembly.
g00110310
Illustration 87
Oil Level Gauge ADD mark (Y) and FULL mark (X)
135
Maintenance Section
Engine Oil Sample - Obtain
i03542996
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. SOS oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Engine model
Service hours on the engine
The number of hours that have accumulated since
the last oil change
The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
136
Maintenance Section
Engine Oil and Filter - Change
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEgj0047,
How To Take A Good SOS Oil Sample. Consult 1. After the engine has been operated at normal
your Caterpillar dealer for complete information and
assistance in establishing an SOS program for your
engine.
i02683617
Engine Oil and Filter - Change
SMCS Code: 1318-510; 1348-044
Hot oil and components can cause personal in-
jury.
Do not allow hot oil or components to contact
skin.
If the engine is equipped with duplex oil filters, the
engine oil filter elements can be changed while the
engine is in operation. This is useful if the oil filter
elements require more frequent replacement than the
engine oil. Refer to Replacing the Engine Oil Filters
During Engine Operation.
The oil change interval can be affected by several
factors:
Air/fuel ratio
Ambient air conditions
Engine application
Fuel type
Oil type
Size of the oil sump
SEBU8013-01
The SOS oil analysis program analyzes used oil in
order to determine if the oil change interval is suitable
for your specific engine.
Drain the Oil
Do not drain the oil when the engine is cold. As the
oil cools, waste particles settle on the bottom of the
oil pan. The waste particles are not removed when
the cold oil is drained. Drain the crankcase when the
oil is warm. This method allows proper draining of the
waste particles that are suspended in the oil.
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.
operating temperature, STOP the engine.
2. Drain the oil according to the equipment on the
engine.
Note: Drain the oil into a suitable container. DO NOT
drain the oil into the bilge sump. Dispose of the oil
according to local regulations.
Illustration 88
g01348195
Oil drain plug
Note: If a suction device is used in order to remove
the oil from the oil pan, ensure that the suction device
is clean. This will prevent dirt from entering into the
oil pan. Be careful not to strike the engine oil suction
tubes or the piston cooling jets.
a. If the engine does not have a drain valve or a
pump, remove an oil drain plug. Allow the oil to
drain. After the oil has drained, clean the drain
plug and clean the fitting for the drain plug.
Install the drain plug. Tighten the drain plug to
70 15 Nm (52 11 lb ft).
b. If the engine has an oil drain valve, open the
valve. After the oil has drained, close the valve.
SEBU8013-01 137
Maintenance Section
Engine Oil and Filter - Change

c. If the engine has a pump for removing dirty oil, Replacing the Engine Oil Filters With the
connect a hose to the outlet of the pump. Place Engine Stopped (Standard Oil Filters)
the hose in a suitable container. Open the valve
for the drain line. The two marks on the valve
must be turned so that one mark points to the
pump and the second mark points to the drain
line. Operate the pump until the crankcase
is empty. Close the valve to the drain line.
Disconnect the hose.

d. If the oil drain valve has a quick connect

coupling, attach the coupling. Open the drain
valve in order to drain the crankcase. After
the oil has drained, close the drain valve.
Disconnect the coupling.

3. Replace the engine oil filter elements before filling

the crankcase with new oil. Illustration 89
g01356351

Standard Oil Filters

Replace the Oil Filter Elements Right hand service

Replace the engine oil filters when any of the Perform the following procedure after the oil has
following conditions occur: been drained.

Every oil change 1. Remove used oil filters and properly discard the
used oil filters.
The engine oil filter differential pressure reaches
103 kPa (15 psi).

The oil filter elements have been used for 1000

service hours.

Note: Do not attempt to clean the used oil filters.

Used oil filters will retain waste particles. The used oil
filters would not filter the oil properly.

Service tools are available to aid in the service of oil

filters. Consult your Caterpillar dealer for the part
names and the part numbers. Follow the instructions
that are supplied with the service tools. If the service
tools are not used, perform the following appropriate
g00103713
procedure. Illustration 90
Typical filter mounting base and filter gasket

2. Clean the sealing surface of the filter mounting

base. Make sure that the former oil filter gaskets
are removed.

3. Apply a thin film of clean engine oil to the seal of

each new filter gasket.

NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
138 SEBU8013-01
Maintenance Section
Engine Oil and Filter - Change

4. Install the filters by hand. Tighten each filter until

the sealing surface contacts the base. Note the
position of the index marks on each filter in relation
to a fixed point on the filter base.

Note: Caterpillar filters have rotation index marks

that are spaced 90 or 1/4 of a turn away from each
other. When you tighten the filters, use the rotation
index marks as a guide.

5. Tighten each filter according to the instructions

that are printed on the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filters to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filters. Do not overtighten the oil filter.

Replacing the Engine Oil Filters During

Engine Operation (Duplex Oil Filter
System Only)
This filter contains hot, pressurized oil that can
cause burns and fire hazards, which may result
in bodily injury or death. Follow the instructions
given in this Operation and Maintenance Manual
and stop the engine if rapid air movement exists
to blow the oil.
g01034883
Illustration 92
1. Open the FILL valve for a minimum of five
minutes in order to fill the oil filter elements that
will not be serviced. The oil filters that will not be
serviced must be full of engine oil. Close the FILL
valve.
2. Move the control valve to the AUX RUN position
in order to change the main oil filter elements.
Move the selector valve to the MAIN RUN
position in order to change the auxiliary oil filter
elements.

3. Allow the oil pressure gauge for the oil filter that
is being changed to reach a ZERO pressure
reading.

4. Perform Step 1 through Step 5 of Replacing the

Engine Oil Filters With the Engine Stopped.

5. Open the FILL valve for a minimum of five

minutes in order to fill the new oil filter elements.

6. Close the FILL valve. Rotate the control valve

to the RUN position for the oil filter that was
g01356340 serviced.
Illustration 91
Duplex Oil Filter System 7. Inspect the oil filters for oil leaks. If any leaks exist,
Left hand service stop the engine and make any necessary repairs.

If the engine is equipped with duplex oil filters, the
engine oil filter elements can be changed while the
engine is in operation. This is useful if the oil filter
elements require more frequent replacement than
the engine oil.
8. If the engine oil filters were replaced without
changing the crankcase oil, maintain the oil level
between the FULL mark and the ADD mark on
the oil level gauge. If necessary, add oil.
SEBU8013-01
Fill the Crankcase
NOTICE
Only use oils that are recommended by Caterpillar.
For the proper oil to use, refer to this Operation and
Maintenance Manual, Engine Oil topic (Maintenance
Section).
NOTICE
If the engine is equipped with an auxiliary oil filter
system, extra oil must be added when filling the
crankcase. If equipped with an auxiliary oil filter
system that is not supplied by Caterpillar, follow the
recommendations of the OEM.
NOTICE
Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge (dip-
stick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the FULL mark on the oil level
gauge, drain some of the oil immediately.
1. Remove the oil filler cap. Fill the crankcase
through the oil filler tube only. For the amount
of oil and type of oil to use, refer to Operation
and Maintenance Manual, Refill Capacities and
Recommendations (Maintenance Section). Clean
the oil filler cap. Install the oil filler cap.
NOTICE
To prevent crankshaft or bearing damage, crank en-
gine with fuel off to fill all filters before starting.
Do Not crank engine for more than 30 seconds.
2. Close the fuel supply line and crank the engine
until the oil pressure gauge indicates 70 kPa
(10 psi). Open the fuel supply line. Allow the
starting motor to cool for two minutes before
cranking again.
139
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect
3. Ensure that the oil level is to the FULL mark on
the oil level gauge. Start the engine and operate
the engine at low idle for two minutes. This will
ensure that the lubrication system has oil and that
the oil filters are filled with oil. Inspect the engine
and the oil filters for oil leaks. If any leaks exist,
stop the engine and make any necessary repairs.
4. Stop the engine and allow the oil to drain back into
the sump for a minimum of ten minutes.
5. Remove the oil level gauge and check the oil
level. Maintain the oil level between the FULL
mark and the ADD mark on the oil level gauge. If
necessary, add oil.
Inspect the Used Oil Filter Elements
Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the oil
filter for metal debris. An excessive amount of metal
debris in the oil filter may indicate early wear or a
pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found
in the element. Ferrous metals may indicate wear
on the steel and the cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Aluminum debris may indicate problems with the
bearings of the front gears. If you find aluminum
debris, inspect the crankshaft vibration damper and
the idler gear bearings.
Due to normal wear and friction, it is not uncommon
to find small amounts of debris in the oil filter element.
If an excessive amount of debris is found in the oil
filter element, consult your Caterpillar dealer in order
to arrange for further oil analysis.
i03572058
Engine Speed/Timing Sensor -
Clean/Inspect
SMCS Code: 1905-040; 1905-070; 1907-040;
1907-070
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
140 SEBU8013-01
Maintenance Section
Engine Storage Procedure - Check

3. Connect the harness assembly.

NOTICE
Care must be taken to ensure that fluids are contained Crankshaft Speed/Timing Sensor
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

g01900805
Illustration 94
Camshaft Speed/Timing Sensor (4) Bolt
(5) Sensor
(6) Harness

Removal Procedure
1. Disconnect the harness assembly.

2. Remove the bolt and the sensor.

3. Remove the O-ring seal from the sensor.

Procedure for Cleaning and Inspecting

Check the condition of the plastic end of the sensor
Illustration 93
g01368433 for wear and for contaminants. Clean the metal
(1) Bolt
shavings and other debris from the face of the sensor.
(2) Sensor
(3) Harness assembly Installation Procedure
Removal Procedure 1. Install a new O-ring seal on the sensor. Lubricate
the O-ring seal with clean engine oil.
1. Disconnect the harness assembly.
2. Install the position sensor in the front housing and
2. Remove the bolt and the sensor. install the bolt.

3. Remove the O-ring seal from the sensor. 3. Connect the harness assembly.

Procedure for Cleaning and Inspecting i03585580

Check the condition of the plastic end of the sensor Engine Storage Procedure -
for wear and for contaminants. Clean the metal
shavings and other debris from the face of the sensor. Check
SMCS Code: 1000-535
Installation Procedure
See your Caterpillar dealer for the storage procedure
1. Install a new O-ring seal on the sensor. Lubricate if the engine will be stored for more than one year.
the O-ring seal with clean engine oil.

2. Position the sensor in the housing and install the

bolt.
SEBU8013-01
Refer to this Operation and Maintenance Manual,
Product Storage if the engine will be stored for less
than one year.
i03126876
Engine Valve Lash -
Inspect/Adjust
SMCS Code: 1102-025
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
initial adjustment is necessary due to initial wear of
the valve train components and seating of the valve
train components.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
Adjustment of the Electronic Unit
Injector
Adjust the electronic unit injector (preload) at the
same interval as the valve lash adjustment. The
operation of Caterpillar engines with improper valve
adjustments and with improper adjustments of the
electronic unit injector can reduce engine efficiency.
This reduced efficiency could result in excessive fuel
usage and/or shortened engine component life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, Valve Lash and Valve Bridge
Adjustment article or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
141
Maintenance Section
Engine Valve Lash - Inspect/Adjust
i01597115
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
When inspecting the valve rotators, protective
glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
Engine valve rotators rotate the valves when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
1. Start the engine according to Operation and
Maintenance Manual, Engine Starting (Operation
Section) for the procedure.
2. Operate the engine at low idle.
3. Observe the top surface of each valve rotator. The
valve rotators should turn slightly when the valves
close.
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
If a valve fails to rotate, consult your Caterpillar
dealer.
142
Maintenance Section
Fuel Injector - Inspect/Adjust
i03534881
Fuel Injector - Inspect/Adjust
SMCS Code: 1290-025
Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos-
sible injury, do not use the starting motor to turn
the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring/adjusting the unit injectors.
The electronic unit injectors use high voltage. Dis-
connect the unit injector enable circuit connector
in order to prevent personal injury. Do not come
in contact with the injector terminals while the en-
gine is running.
The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.
Only qualified service personnel should perform
this maintenance. Refer to the Systems Operation,
Testing and Adjusting, Electronic Unit Injector -
Test for the test procedure, and Systems Operation,
Testing and Adjusting, Electronic Unit Injector -
Adjust for the adjustment procedure for the injectors.
i03570039
Fuel System - Prime
SMCS Code: 1258-548
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SEBU8013-01
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Note: Refer to this Operation and Maintenance
Manual, Fuel System Secondary Filter - Replace for
information on replacing the filter.
g01096972
Illustration 95
Hand priming pump
(1) Air purge screw
(2) Fuel pressure regulating valve
The Secondary Fuel Filter Has
Been Replaced
1. Turn the ignition switch to the OFF position.
2. Open the air purge screw for the fuel filter by three
full turns. Do not remove the air purge screw.
SEBU8013-01
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.
3. Start the engine. The engine should start and the
engine should run smoothly. If the engine does
not start after 30 seconds, allow the starting motor
to cool for two minutes before attempting to start
the engine again.
Note: You may use the hand priming pump for the
fuel filter (if equipped) instead of starting the engine
and running the engine.
4. While the engine is running, observe the air purge
screw. When a small drop of fuel appears at the
threads of the air purge screw, close and tighten
air purge screw.
Note: There may be a noticeable change in the
sound of the running engine when the air purge
screw is tightened. The change in the sound of the
engine is normal.
Note: Failure to tighten all fittings could result in
serious fuel leaks.
5. Clean any residual fuel from the engine
components.
The Engine Has Been Run Out of
Fuel
1. Turn the ignition switch to the OFF position.
2. Fill the fuel tank(s) with clean diesel fuel.
3. Open the fuel pressure regulating valve by two
and one half turns. The regulating valve is located
in the integral fuel filter base.
Note: Do not remove the regulating valve completely.
Open the valve enough to allow the air that is trapped
in the cylinder head to be purged from the fuel
system.
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.
4. Crank the engine for 30 seconds. Use a suitable
container to catch the fuel while you crank the
engine. Allow the starting motor to cool for two
minutes.
143
Maintenance Section
Fuel System - Prime
Note: You may use the hand priming pump for the
fuel filter (if equipped) instead of cranking the engine.
5. Crank the engine for 30 seconds. Allow the
starting motor to cool for two minutes.
6. Close and tighten the fuel pressure regulating
valve.
7. Crank the engine for 30 seconds. Allow the
starting motor to cool for two minutes.
8. Repeat Step 7 until the engine starts and the
engine runs.
Note: Failure to tighten all fittings could result in
serious fuel leaks.
9. Clean any residual fuel from the engine
components.
The Engine Has Been Rebuilt
1. Turn the ignition switch to the OFF position.
2. Fill the fuel tank (s) with clean diesel fuel.
3. Open the the air purge screw for the fuel filter by
three full turns. Do not remove the air purge screw.
4. Open the fuel pressure regulating valve by two
and one half turns. The regulating valve is located
in the integral fuel filter base.
Note: Do not remove the regulating valve completely.
Open the valve enough to allow the air that is trapped
in the cylinder head to be purged from the fuel
system.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
5. Crank the engine for 30 seconds. Use a suitable
container to catch the fuel while you crank the
engine. Allow the starting motor to cool for two
minutes.
Note: You may use the hand priming pump for the
fuel filter (if equipped) instead of cranking the engine.
6. Crank the engine for 30 seconds. Allow the
starting motor to cool for two minutes.
7. Close and tighten the air purge screw.
8. Crank the engine for 30 seconds. Allow the
starting motor to cool for two minutes.
144
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
9. Close and tighten the fuel pressure regulating
valve.
Note: Failure to tighten all fittings could result in
serious fuel leaks.
10. Crank the engine for 30 seconds. Allow the
starting motor to cool for two minutes.
11. Repeat Step 10 until the engine starts and runs.
12. Clean any residual fuel from the engine
components.
i02049797
Fuel System Primary Filter
(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. Install a vacuum gauge. Change the
element for the primary filter/water separator if the
pressure is at 50 to 70 kPa (15 to 20 inches Hg).
Replace the Element
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SEBU8013-01
g00668636
Illustration 96
(1) Bowl
(2) Element
(3) Drain
1. Stop the engine.
2. Turn the start switch to the OFF position.
3. Shut off the fuel tank supply valve to the engine.
4. If the primary fuel filter is equipped with a drain
valve (3), open the drain valve in order to drain any
fuel from the filter case. Close the drain valve (3).
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
5. Remove the fuel filter bowl (1) and wash the fuel
filter bowl with clean diesel fuel.
6. Remove the fuel filter (2).
7. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
8. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel,
use Caterpillar fuel filters.
Consult your Caterpillar dealer for proper part num-
bers.
9. Install the new fuel filter (2). Spin the fuel filter
onto the fuel filter base until the gasket contacts
the base. Use the rotation index marks on the
filters as a guide for proper tightening. Tighten the
filter for an additional 3/4 turn by hand. Do not
overtighten the filter.
SEBU8013-01
NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contami-
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.
10. Install the clean fuel filter bowl (1) on the new fuel
filter.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.
11. Open the fuel tank supply valve.
12. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and check
the engine for leaks again.
Detection of leaks is very difficult especially if
the engine is running. The primary filter/water
separator is under suction. A leak will allow air to
enter the fuel. The air in the fuel can cause low
power due to aeration of the fuel. If air enters the
fuel, check the components for overtightening or
undertightening.
i02927285
Fuel System Primary
Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
145
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
g01453091
Illustration 97
(1) Element
(2) Bowl
(3) Drain
Bowl (2) should be monitored daily for signs of water.
If water is present, drain the water from the bowl.
1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Dispose of the water properly.
2. Close drain (3).
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.
146
Maintenance Section
Fuel System Secondary Filter - Replace
i03572801
Fuel System Secondary Filter -
Replace
SMCS Code: 1261-510-SE
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. Clean up fuel
spills immediately.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: If the engine is equipped with duplex fuel
filters, the fuel filter elements can be replaced while
the engine is in operation. Refer to Replacing the
Fuel Filter Elements During Engine Operation For
Engines That Are Equipped With Duplex Fuel Filters.
Replacing the Fuel Filter Elements
with the Engine Stopped
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
SEBU8013-01
Illustration 98
g01902879
Right hand service
(1) Fuel priming pump
(2) Fuel filter
1. Stop the engine.
2. Turn off the start switch or disconnect the battery
(starting motor) when maintenance is performed
on fuel filters.
3. Shut off the fuel tank supply valve to the engine.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
4. Unlock the fuel priming pump in order to relieve
residual pressure in the fuel system.
5. Remove the used fuel filter. Use a cloth or use a
container in order to catch excess fuel.
6. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
7. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
8. Install the new fuel filter. Tighten the fuel filter until
the gasket contacts the base. Tighten the fuel
filter by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.
Note: DO NOT remove the plug in the fuel filter base
in order to release the air from the fuel system during
periodic service of the fuel filter. Periodic removal of
the plug will result in increased wear of the threads in
the fuel filter base.
SEBU8013-01 147
Maintenance Section
Fuel System Secondary Filter - Replace

9. Operate the fuel priming pump plunger until a Replacing the Main Fuel Filter
strong resistance is felt and until the check valve
clicks. This procedure will require considerable
strokes. Lock the fuel priming pump.

10. Open the fuel tank supply valve.

11. Start the engine according to the normal operating

procedures. Immediately increase the engine rpm
between 1000 to 1200 rpm with no load. The
engine will begin to misfire briefly until air from
the fuel filter is purged. No damage to the engine
will occur.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

12. If the engine stalls during the purging of the air,

refer to the Operation and Maintenance Manual,
Fuel System - Prime for more information. g01902892
Illustration 99
Duplex fuel filters
Replacing the Fuel Filter Elements Engines are shipped from the factory with the control valve in the
During Engine Operation For MAIN RUN position.

Engines That Are Equipped With (3)

(4)
Fuel pressure gauge for the main fuel filter
Plate that shows the position of the valve
Duplex Fuel Filters (5) Fuel pressure gauge for the auxiliary fuel filter
(6) Control valve
(7) Auxiliary fuel filter
If the engine is equipped with duplex fuel filters, the (8) Main fuel filter
fuel filters can be replaced while the engine is in
operation. Use the following procedure in order to replace the
main fuel filter while the engine is in operation.

This filter contains pressurized fuel that can cause

a fire hazard, which may result in bodily injury or
death. Follow the instructions given in this Opera-
tion and Maintenance Manual and stop the engine
if rapid air movement exists to blow the fuel.

g01902917
Illustration 100

1. Move the control valve to the LH FLOW - RH FILL

position as marked on plate. The fuel pressure
gauge for the main fuel filter should indicate
full pressure. The fuel pressure gauge for the
auxiliary fuel filter should indicate slight pressure.
Five minutes may be required in order to fill the
auxiliary fuel filter. The auxiliary fuel filter must
become full of fuel.
148 SEBU8013-01
Maintenance Section
Fuel System Secondary Filter - Replace

g01902918 g01902918
Illustration 101 Illustration 102

2. Move the control valve to the AUX RUN position.
The fuel pressure gauge for the auxiliary fuel filter
should indicate full pressure. The fuel pressure
gauge for the main fuel filter should indicate no
pressure.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
7. Move the control valve to the RH FLOW - LH
FILL position. The fuel pressure gauge for the
auxiliary fuel filter should indicate full pressure.
The fuel pressure gauge for the main fuel filter
should indicate slight pressure. Five minutes may
be required in order to fill the main fuel filter. The
main filter must become full of fuel.

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

3. Remove the used main fuel filter. Use a cloth or

use a container in order to catch excess fuel.

4. Clean the gasket sealing surface of the main fuel

filter base. Ensure that all of the old gasket is
removed.
5. Apply clean diesel fuel to the new main fuel filter
gasket.
6. Install a new main fuel filter. Tighten the fuel filter
until the gasket contacts the base. Tighten the fuel
filter by hand according to the instructions that are
shown on the fuel filter. Do not overtighten the fuel
filter.
g01902917
Illustration 103
8. Move the control valve to the MAIN RUN position.
The fuel pressure gauge for the main fuel filter
should indicate full pressure. The fuel pressure
gauge for the auxiliary fuel filter should indicate
no pressure.
replacing the Auxiliary Fuel Filter
The procedure for replacing the auxiliary fuel filter is
similar to the procedure for replacing the main fuel
filter.
SEBU8013-01 149
Maintenance Section
Fuel System Secondary Filter - Replace

g01902917
Illustration 106

2. Move the control valve to the MAIN RUN position.

The fuel pressure gauge for the main fuel filter
should indicate full pressure. The fuel pressure
gauge for the auxiliary fuel filter should indicate
g01902892 no pressure.
Illustration 104
Duplex fuel filters
NOTICE
The engine is operating with the control valve in the AUX RUN
position. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
(3) Fuel pressure gauge for the main fuel filter
(4) Plate that shows the position of the valve will be disconnected. Fit a suitable cover over discon-
(5) Fuel pressure gauge for the auxiliary fuel filter nected fuel system component.
(6) Control valve
(7) Auxiliary fuel filter
(8) Main fuel filter NOTICE
Use a suitable container to catch any fuel that might
Use the following procedure in order to replace the spill. Clean up any spilled fuel immediately.
auxiliary fuel filter while the engine is in operation.

3. Remove the used auxiliary fuel filter. Use a cloth

or use a container in order to catch excess fuel.

4. Clean the gasket sealing surface of the auxiliary

fuel filter base. Ensure that all of the old gasket
is removed.

5. Apply clean diesel fuel to the new auxiliary fuel

filter gasket.

6. Install a new auxiliary fuel filter. Tighten the fuel

filter until the gasket contacts the base. Tighten
the fuel filter by hand according to the instructions
that are shown on the fuel filter. Do not overtighten
Illustration 105
g01902918 the fuel filter.

1. Move the control valve to the RH FLOW - LH FILL

position. The fuel pressure gauge for the auxiliary
fuel filter should indicate full pressure. The fuel
gauge for the main fuel filter should indicate
slight pressure. Five minutes may be required for
filling the main fuel filter. The main fuel filter must
become full of fuel.
150
Maintenance Section
Fuel Tank Water and Sediment - Drain
g01902917
Illustration 107
7. Move the control valve to the LH FLOW - RH FILL
position. The fuel pressure gauge for the main
fuel filter should indicate full pressure. The fuel
pressure gauge for the auxiliary fuel filter should
indicate slight pressure. Allow five minutes in
order to fill the auxiliary fuel filter. The auxiliary
fuel filter must become full of fuel.
Illustration 108
g01902918
8. Move the control valve to the AUX RUN position.
The fuel pressure gauge for the auxiliary fuel filter
should indicate full pressure. The fuel pressure
gauge for the main fuel filter should indicate no
pressure.
Move the control valve to the FLOW BOTH position
after both fuel filters are replaced.
SEBU8013-01
i03645042
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Note: Failure to properly close the drain can allow air
into the system, which could have detrimental results
to performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
SEBU8013-01 151
Maintenance Section
Generator - Dry

Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Refer to Special Instruction, REHS9124, Cleaning
and Drying of the Generator for further necessary
information.
Of the following methods for drying the generator, the
use of external heat is preferred.
External heat
Internal heat
Combination of external and internal heat

Fuel Storage Tanks Circulating current

Drain the water and the sediment from the fuel
storage tank during the following conditions:
Weekly
Oil change
Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended. Refer
to Special Publication, SENR9620, Improving Fuel
System Durablity.
External heat is the most preferable method.
Insulation drying time can vary from a few hours
to several days. The drying time depends on the
moisture content and the process for drying that is
used.
Note: Drying sometimes does not produce the
required results. The use of a qualified rebuild
shop may be necessary for dipping and drying the
generator.

If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.

i03997990

Generator - Dry
SMCS Code: 4450-569

g02175752
Illustration 109
Typical curves of the resistance in the insulation that is drying
Personal injury or death can result from improper
(1) Curve of the temperature in the windings
troubleshooting and repair procedures. (2) Heat turned off.
(3) Drying time in hours
The following troubleshooting and repair proce- (4) Temperature in degrees celsius
dures should only be performed by qualified per- (5) Curve of insulation resistance during drying process
sonnel familiar with this equipment. (6) Insulation resistance in megohms

Refer to this Operation and Maintenance Manual,

Generator Isolating for Maintenance for information
regarding the procedure to isolate the generator in
a safe manner.
152 SEBU8013-01
Maintenance Section
Generator - Dry

Note: When new insulation or very damp insulation

is being dried, the resistance will probably fall
rapidly. The rapid fall in resistance is the result of the
temperature being raised to a value for drying. After
reaching a minimum for a given temperature, the
resistance will again rise as moisture is driven out of
the insulation. The actual values will vary with each
situation. Refer to Illustration 110.

If the windings or insulation are wet during the

resistance measurement, use a 5 megohm resistor
for protection in series with red positive lead. This
procedure limits the voltage across the circuit
under the test. Use this method until drying is well
in progress and the resistance has reached an
acceptable level.
Check the windings after every 4 hours when either
external or internal heat is used to dry the generator.
Check the windings very hour when circulating
current is used to dry the generator. Refer to Special
Instruction, REHS9124, Cleaning and Drying of the
Generator for more information.
Drying is complete when the tests show no increase
in resistance and the resistance is above the
minimum. Record these readings and compare these
readings. Keep these records for future reference.
g01697074
Illustration 111
Curve of insulation resistance for windings that are wet or dirty
(1) Resistance after 30 seconds
(2) Resistance after 60 seconds
Illustration 111 indicates the curve of the resistance
that is decaying over a period of 60 seconds. If the
insulation resistance after 60 seconds is not higher
than the resistance after 30 seconds , clean the
windings and thoroughly dry the windings. Refer
to Special Instruction, REHS9124, Cleaning and
Drying of the Generator for more information.
Note: Caterpillar recommends a minimum acceptable
insulation resistance of 1 megohm for generators
which operate with less than 1000 V of operating or
rated voltage. Generators which operate at 1000 V
of operating or rated voltage should have a minimum
insulation resistance as determined by the following
equation:

R = (V/1000) + M

R is the minimum insulation resistance.

V is the rated voltage.

M is 1 megohm.
g01696934
Illustration 110
Curve of insulation resistance for windings in good condition These values are approximate. It may be possible to
(1) Resistance after 30 seconds
operate a generator with less resistance.
(2) Resistance after 60 seconds
External Heat
Illustration 110 indicates the curve of the resistance
of a normal high resistance in the windings over
a period of 60 seconds. The resistance after 60
Ovens
seconds will be greater than the resistance or equal
The best oven is a forced air drying oven for drying
to the resistance after 30 seconds .
electrical equipment. Radiant ovens sometimes
cause localized overheating.
Note: If the insulation resistance after 60 seconds is
not higher than the resistance after 30 seconds , the
insulation may be weak. NOTICE
Do not heat the generator too quickly. Try to limit the
rise in temperature of the insulation and windings to
11.11 C (20 F) per hour. Failure to do so may cause
equipment damage.
SEBU8013-01
Note: Many electrical shops are equipped with
baking ovens.
Heat the generator to approximately 75 C (167 F).
Never exceed 75 C (167 F) until the insulation
tester tests correctly for insulation resistance (at least
4 hours).
Alternate Method
A tent formed by a tarp or a canvas with heated
lamps or a portable space heater may be used as
an alternate method.
A hole should be left in the top of the tarp for
ensuring proper circulation through the generator
and for permitting the moisture to exhaust. Heat the
generator to approximately 75 C (167 F). Never
exceed 75 C (167 F) until the insulation tester tests
correctly for insulation resistance (at least 4 hours).
Internal Heating
If generators operate under one of the following
conditions, the electric space heaters should be
installed as part of the generator:
Generators are in damp environments and go for
long periods of time without operation.
Generators operate regularly in an environment
with moisture laden air.
Circulating Current
Drying can be accomplished by circulating low
voltage current through the windings. Since the
voltage is low, the breakdown of the insulation will not
occur as the breakdown might have occurred with
normal operation and wet insulation. Refer to Special
Instruction, REHS9124, Cleaning and Drying of the
Generator for this procedure.
i01880220
Generator - Inspect
SMCS Code: 4450-040
Personal injury or death can result from improper
troubleshooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
153
Maintenance Section
Generator - Inspect
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the OFF posi-
tion. Attach DO NOT OPERATE tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Refer to Safety Section, Generator Isolating for
Maintenance for information regarding the procedure
to safely isolate the generator.
Proper maintenance of electrical equipment requires
periodic visual examination of the generator and
periodic visual examination of the windings. Proper
maintenance of electrical equipment also requires
appropriate electrical checks and appropriate thermal
checks. Insulation material should be examined for
cracks. The insulation material should be examined
for accumulations of dirt and dust. If there is an
insulation resistance value that is below normal, a
conductive path may be present. This conductive
path may be made of one of the following materials:
Carbon
Salt
Metal dust
Dirt that is saturated with moisture
These contaminants will develop a conductive path
which may produce shorts. Cleaning is advisable if
heavy accumulations of dirt can be seen or if heavy
accumulations of dust can be seen. If excess dirt is
the cause of a restriction in the ventilation, cleaning
is also advisable. Restricted ventilation will cause
excessive heating.
NOTICE
To avoid the possibility of deterioration to the genera-
tor windings, do not clean the generator unless there
is visual, electrical, or thermal evidence that dirt is
present.
If harmful dirt accumulations are present, a variety
of cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
the items on the following list:
The extent of the cleaning procedure that is being
attempted
154
Maintenance Section
Generator Bearing - Inspect/Replace
The type of enclosure of the generator
The voltage rating of the generator
The type of dirt that is being removed
Cleaning (Assembled Generators)
Cleaning may be required at the point of installation.
At this point, complete disassembly of the generator
may not be necessary or feasible. In this case,
a vacuum cleaner should be used to pick up the
following items: dry dirt, dust, and carbon. This will
prevent the spreading of these contaminants.
A small nonconductive tube may need to be
connected to the vacuum cleaner. This will allow the
vacuum cleaner to clean the surfaces that are not
exposed. After most of the dust has been removed,
a small brush may be attached to the vacuum hose
in order to loosen dirt that is more firmly attached to
the surface.
After the initial cleaning with a vacuum, compressed
air may be used to remove the remaining dust and
dirt. Compressed air that is used for cleaning should
be free of moisture and free of oil. Air pressure
should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the
above cleaning procedures are not effective, consult
a Caterpillar dealer.
Cleaning (Disassembled
Generators)
An initial insulation resistance check should be
made on the generator in order to confirm electrical
integrity. A minimum reading of one megohm would
be expected with severely contaminated generators.
A zero megohm reading may indicate an insulation
breakdown. An insulation breakdown requires more
than cleaning. An insulation breakdown requires
repair.
A high pressure wash is normally an effective way
to clean windings. This includes windings that have
been exposed to flooding or windings that have been
contaminated by salt. A solution of hot water and
detergent is used for this method of cleaning.
A high pressure wash sprays a high velocity fluid
stream of this solution over the generator that is
being cleaned. This detergent washing is followed by
multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean
water is used in order to dilute the detergent.
SEBU8013-01
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation
resistance should now be normal. If the insulation
resistance is not normal, repeat the procedure. It
may be necessary to use solvents if the generator
is contaminated with oil or if the generator is
contaminated with grease.
Note: For more information on drying methods, refer
to Special Instructions, SEHS9124, Cleaning and
Drying of Electric Set Generators.
i03099722
Generator Bearing -
Inspect/Replace
(SR4 Generator)
SMCS Code: 4471-040; 4471-510
The following maintenance procedure for generator
bearings should be followed at every major engine
overhaul:
Inspect
1. Remove the bearing bracket. Inspect the following
items: bracket bore, bearing outer race, and
rolling elements. On standby power units, the
bearing must be inspected and the grease must
be replaced at three year intervals. The sleeve
in the bearing bracket should be inspected for
out of roundness, excessive wear, and a bracket
step that is less than 0.0762 mm (0.0030 inch). If
there is no sleeve in the bearing bracket, inspect
the bore of the bearing bracket. The bearing
should be inspected for damage to the outer race,
severe fretting, and smoothness of operation.
When possible, the bearing elements should be
inspected. Some double shielded ball bearings
prevent visual inspection of the elements of the
bearing. Other double shielded ball bearings
have a retaining ring. This retaining ring can be
removed in order to allow access for a visual
inspection of the elements of the bearing.
On two-bearing generators, the front bearing
can only be removed after the drive coupling
is removed. Refer to the Systems Operation
Testing and Adjusting Disassembly and Assembly,
Coupling - Remove for the generator for
instructions for removing the drive coupling.
Replace
1. All ball bearings should be cleaned. The cavity
in the bracket should be repacked with 2S-3230
Grease. Pack the ball bearings (one-third to
one-half of the volume of the cavity).
SEBU8013-01
2. Use an induction heater to heat the ball bearings to
107 C (224.6 F) for ten minutes in order to install
either of the following bearings: ball bearings
that are new and ball bearings that have been
inspected. Mount the bearings on the shaft. To
reinstall the hub, heat the hub to 400 C (752.0 F)
for three hours. Mount the hub to the shaft.
3. Ensure that the tube of the grease gun is filled
with grease.
4. Remove the bracket drain plug and operate the
generator for one hour. This will allow the grease
to expand. The expanding grease will force the
excess grease from the cavity. When the excess
grease is forced from the cavity, the internal
pressure will be reduced. The generator should
continue to operate until the grease stops purging.
5. Stop the engine. Install the bracket drain plug.
Wipe off the excess grease.
6. For greasing intervals, follow the recommendations
on the lubrication plate (if equipped) or refer to
Maintenance Schedule, Generator Bearing -
Lubricate. Whenever the bearings are greased,
repeat Step 1. DO NOT MIX GREASES.
i04011489
Generator Bearing - Lubricate
SMCS Code: 4471-086
Lubricating Process (If Applicable)
Note: If the generator already has a visible grease
point, go to Step 4.
1. Remove either the louver assembly or the rear
plate from the rear of the generator housing.
2. Remove the top grease pipe plug and remove the
lower grease pipe plug.
3. Install a grease fitting in the grease pipe.
4. Grease the bearings with 2S-3230 Bearing
Lubricant.
5. Wipe off the excess grease. Remove the top
grease fitting. Install the plug.
6. Operate the generator for 1 hour. This process
will allow the grease to expand. The expanding
grease will force the excess grease from the
cavity. When the excess grease is forced from
the cavity, the internal pressure will be reduced.
The generator should continue to operate until the
grease stops purging.
155
Maintenance Section
Generator Bearing - Lubricate
7. Stop the engine. Install the plug in the bottom
grease pipe. Wipe off the excess grease.
8. Install the louver assembly or install the rear plate.
Additional Information
Refer to Special Instruction, REHS4892, Generator
Bearing Service for further information.
i04011510
Generator Bearing
Temperature - Measure/Record
SMCS Code: 4471-082-TA
If a Marine Classification Society system (MCS
system) is not available, bearing temperature
detectors are used with equipment that has been
provided by the customer. Bearing temperature
detectors may help to prevent premature bearing
failure.
A bearing temperature that is 50 C (122 F) above
the ambient temperature may require a change in
operation. The unit should be shut down in order to
prevent damage if the bearing temperature is 50 C
(122 F) above the ambient temperature.
i01878834
Generator Load - Check
SMCS Code: 4450-535-LA
Personal injury or death can result from high volt-
age.
When power generation equipment must be in op-
eration to make tests and/or adjustments, high
voltage and current are present.
Improper test equipment can fail and present a
high voltage shock hazard to its user.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur-
rent tests being made.
During normal operation, monitor the power factor
and monitor generator loading.
156 SEBU8013-01
Maintenance Section
Generator Set - Test

When a three-phase generator is installed or when

a three-phase generator is reconnected, ensure that
the total current in any one phase does not exceed
Personal injury or death can result from high volt-
the nameplate rating. Each phase should carry the
age.
same load. This allows the three-phase generator
to work at the rated capacity. If one phase current
When power generation equipment must be in op-
exceeds the nameplate amperage, an electrical
eration to make tests and/or adjustments, high
imbalance will occur. An electrical imbalance can
voltage and current are present.
result in an electrical overload and an electrical
imbalance can result in overheating on three-phase
Improper test equipment can fail and present a
generators. This is not applicable to single-phase
high voltage shock hazard to its user.
generators.
Make sure the testing equipment is designed for
The power factor can be referred to as the efficiency
and correctly operated for high voltage and cur-
of the load. This can be expressed as the ratio of kVA
rent tests being made.
to actual kW. The power factor can be calculated by
dividing kW by kVA. Power factor is expressed as a
When servicing or repairing electric power gener-
decimal. Power factor is used to mean the portion
ation equipment:
of current that is supplied to a system that is doing
useful work. The portion of the current that is not
doing useful work is absorbed in maintaining the Make sure the unit is off-line (disconnected
from utility and/or other generators power
magnetic field in motors. This current (reactive load)
service), and either locked out or tagged DO
can be maintained without engine power.
NOT OPERATE.

i02377583 Make sure the generator engine is stopped.

Generator Set - Test Make sure all batteries are disconnected.
SMCS Code: 4450-081 Make sure all capacitors are discharged.

Table 15

DANGER: Shock/Electrocution Hazard-Do not op- Tools Needed

erate this equipment or work on this equipment Part Number Part Quantity
unless you have read and understand the instruc-
tions and warnings in the Operation and Mainte- Digital
237-5130 1
Multimeter
nance Manual. Failure to follow the instructions or
heed the warnings will result in serious injury or 12 VDC battery 1
death.
Potential
1
Transformer

The generator set functional test is a simplified test

that can be performed in order to determine if the
generator is functional. The generator set functional
test should be performed on a generator set that is
under load.

The generator set functional test determines if the

following statements happen:

A phase voltage is being generated.

The phase voltages are balanced.
The phase voltages change relative to engine
speed.

The generator set functional test consists of the

following steps:
SEBU8013-01 157
Maintenance Section
Generator Set Alignment - Check

1. Stop the generator. Connect the potential Keep a record of the measurement of the alignment.
transformer's high voltage winding to the The record may be used to check the trend of the
generator terminals (T1) and (T2). Connect alignment. The record may be used to analyze the
the voltmeter to the low voltage winding. If two trend of the alignment.
transformers are available, connect the high
voltage winding of the second transformer to the
i03112463
generator terminals (T1) and (T3). Connect the
secondary terminals that correspond to generator
terminal (T2) of both transformers together.
Generator Set Vibration -
Inspect
2. Disconnect wires E+ and E- from the voltage
regulator. Disconnect the generator from the load. SMCS Code: 4450-040-VI

3. Connect a 12 VDC automotive battery to wires Check for vibration damage. Vibration may cause the
E+ and E-. following problems:

4. Measure the AC voltage across the low voltage Loose fittings

terminals of the transformer that correspond to the
following generator terminals: T1 and T2, T2 Loose belts
and T3, and T3 and T1. Record the voltages.
i03956450
Generator Set Alignment -
Check
(Generator Sets)
SMCS Code: 7002-024
The genset must be aligned when the genset is
installed or moved into a different position. If the
generator set is run at the full continuous rating, the
alignment of the generator to the engine must be
checked annually.
Properly maintain the alignment between the engine
and the driven equipment in order to minimize the
following problems:
Bearing problems
Vibration of the engine crankshaft
Vibration of the driven equipment
Refer to the following information for more information
about the alignment of the generator set:
Special Instruction, SEHS7654, Alignment -
General Instructions
Special Instruction, SEHS7259, Alignment of will meet your needs.
Single Bearing Generators
Excessive noise
Cracked insulation
The following areas are susceptible to vibration
damage:
Stator output leads
Protective sleeving
Insulation
Exposed electrical connections
Transformers
Fuses
Capacitors
Lightning arresters
When a generator set is installed a vibration plot
should be recorded in order to assist in diagnosing
potential problems. This vibration plot should be
updated yearly. The vibration plot should also be
updated when the generator set is moved. Refer to
Data Sheet, LEKQ4023, Linear Vibration for the
allowable limits of vibration.
Contact the Caterpillar Dealer Service Tools group
for information on ordering a vibration analyzer that

Special Instruction, REHS0177, Alignment of the

Close Coupled Two Bearing Generators
158
Maintenance Section
Heat Exchanger - Inspect
i03712080
Heat Exchanger - Inspect
SMCS Code: 1379-040
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The heat exchanger and all
lines to heaters or the engine contain hot coolant
or steam. Any contact can cause severe burns.
Remove the filler cap slowly to relieve pressure
only when the engine is stopped and the filler cap
for the heat exchanger is cool enough to touch
with your bare hand.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
The interval for the maintenance of the plate type heat
exchanger depends on the operating environment of
the vessel and on the operating time. The sea water
that is circulated through the heat exchanger and the
amount of operating time of the vessel affects the
following items:
Cleanliness of the heat exchanger plates
Effectiveness of the heat exchanger system
SEBU8013-01
Operating in water that contains the following will
adversely affect the heat exchanger system: silt,
sediment, salt, and algae. In addition, intermittent use
of the vessel will adversely affect the heat exchanger
system.
The following items indicate that the heat exchanger
may require cleaning:
Increased coolant temperature
Engine overheating
Excessive pressure drop between the water inlet
and the water outlet
An operator that is familiar with the normal operating
temperature of the coolant can determine when
the coolant temperature is out of the normal range.
Inspection of the heat exchanger and maintenance
of the heat exchanger are required if the engine is
overheating.
Your Caterpillar dealer has the equipment and the
personnel in order to measure the pressure drop
across the heat exchanger.
Cleaning Procedure
Removal and Disassembly of the Heat
Exchanger
Drain the heat exchanger. Refer to the Disassembly
and Assembly Manual, Heat Exchanger - Remove
for the removal procedure.
Refer to the Disassembly and Assembly Manual,
Heat Exchanger - Disassemble for the disassembly
procedure. Keep the plates in order..
Cleaning the Heat Exchanger
Refer to Choosing the Correct Cleaning Fluid for
the correct cleaning fluid for your heat exchanger.
Clean the plates with a cleaning solution and a soft
brush. Pressurized water may also be used. Do not
use steel wool or a wire brush, which may scratch the
plate. Any iron scratches on the plates can lead to
corrosion of the plates. Rinse the plates with water.
Choosing the Correct Cleaning Fluid
Refer to 16 for the correct cleaning fluid for the heat
exchanger.
SEBU8013-01 159
Maintenance Section
Hoses and Clamps - Inspect/Replace

Table 16 i03847809

Problem Source Cleaners(1)(2)(3)(4) Hoses and Clamps -

Calcium
carbonate
Inspect/Replace
Scaling
Calcium sulfate
Silicates SMCS Code: 7554-040; 7554-510

Corrosion Hoses and clamps must be inspected periodically

products Nitric acid in order to ensure safe operation and continuous
Metal oxides Sulfamic acid operation of the engine. Take proper safety
Sediment(5)
Silt Citric acid precautions before inspecting or replacing hoses and
Diatomic Phosphoric acid
organisms
clamps.
Complexing
Seaweed agents Note: Always use a board or cardboard when the
Chips of wood Sodium
polyphosphates
engine components are checked for leaks. Leaking
Gross fouling and fibers fluid that is under pressure can cause serious
Mussels injury or possible death. This includes leaks that
Barnacles
are the size of a pin hole. Refer to Operation and
Bacteria Maintenance Manual, General Hazard Information
Biological growth Nematodes for more information.
Protozoa

Oily films
Paraffinic or Inspect the Hoses and the Clamps
Naphtha based
Residue Asphalt
solvent such as Inspect all hoses for leaks that are caused by the
Fats
Kerosene.(6)(7) following conditions. Replace any hose which exhibits
(1) Cleaners should be mixed at a maximum concentration of 4 any of the following conditions. Failure to replace a
percent by weight. The temperature of the cleaning solution hose which exhibits any of the following conditions
should be less than 60 C (140 F). may result in a hazardous situation.
(2) Do not use water that contains more than 300 ppm of chlorine
in the preparation of cleaning solutions.
(3) Do not use hydrochloric acid to clean stainless steel plates. Do Hoses which are cracked
not use hydrofluoric acid to clean titanium plates.
(4) Do not use a type of ketone such as acetone and Hoses which are soft
methyletyketone. Do not use aromatics such as benzene
and toluene. Do not use esters such as ethylacetate and
butylacetate. Do not use halogenated hydrocarbons such as
Outer covering that is chafed or cut
chlorothene and carbon tetrachloride.
(5) The addition of surfactants to the cleaning solution may ease Exposed wire that is used for reinforcement
cleaning.
(6) Do not mix the solvent with water for cleaning. Dry the plates
Outer covering that is ballooning locally
with a cloth or rinse the plates with water.
(7) Gaskets that are made from natural rubber, butyl rubber and
EPDM rubber will swell in these solvents. Do not allow the
Flexible part of the hose that is kinked or crushed
solvent to contact the gasket more than half an hour.
Armoring that is embedded in the outer covering
Assembly and Installation of the Heat Hoses which exhibit signs of leakage which are not
Exchanger the result of loose couplings or clamps

Refer to the Disassembly and Assembly Manual, Inspect all clamps for the following conditions.
Heat Exchanger - Assemble for the assembly Replace any clamp which exhibits signs of any of the
procedure. following conditions.

Refer to the Disassembly and Assembly Manual, Cracking

Heat Exchanger - Install for the installation
procedure. Looseness
Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.

Each installation application can be different. The

differences depend on the following factors:
160
Maintenance Section
Hoses and Clamps - Inspect/Replace
Type of hose
Type of fitting material
Anticipated expansion and contraction of the hose
Anticipated expansion and contraction of the
fittings
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
hose clamps which are loose.
Replace the Hoses and the Clamps
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog or refer to Special Pub-
lication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
Cooling System
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
SEBU8013-01
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
1. Stop the engine.
2. Allow the engine to cool.
3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system in order to relieve
any pressure.
4. Remove the filler cap for the cooling system.
5. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
Drain the coolant into a suitable clean container.
The coolant can be reused.
6. Remove the hose clamps.
7. Disconnect the old hose.
8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, Torque Specifications, Hose
Clamps for information about selecting and
installing the proper hose clamps.
10. Refill the cooling system.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap
if the gaskets are damaged. Install the filler cap.
12. Start the engine. Inspect the cooling system for
leaks.
Fuel System
Personal injury can result from removing hoses or
fittings in a pressure system.
Failure to relieve pressure can cause personal in-
jury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
SEBU8013-01 161
Maintenance Section
Hoses and Clamps - Inspect/Replace

Lubrication System

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol- Hot oil and hot components can cause personal
low these inspection, maintenance and service in- injury. Do not allow hot oil or hot components to
structions may cause personal injury or death. contact the skin.

NOTICE 1. Drain the oil from the lubrication system to a level

Do not bend or strike high pressure lines. Do not in- that is below the hose that is being replaced.
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and 2. Remove the hose clamps.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 3. Disconnect the old hose.
ommended torque.
4. Replace the old hose with a new hose.

NOTICE 5. Install hose clamps which have been inspected or

Do not allow dirt to enter the fuel system. Thoroughly install new hose clamps. Refer to Specifications,
clean the area around a fuel system component that SENR3130, Torque Specifications, Hose
will be disconnected. Fit a suitable cover over any dis- Clamps for information about selecting and
connected fuel system components. installing the proper hose clamps.

6. Refill the lubrication system. Refer to this

Note: High pressure fuel lines may be installed
Operation and Maintenance Manual, Engine
between the high pressure fuel pump and the fuel
Oil Level - Check in order to ensure that the
injectors. High pressure fuel lines are constantly
lubrication system is filled with the proper amount
charged with high pressure. Do not check the high
of engine oil.
pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
7. Start the engine. Inspect the lubrication system
engine stops before you perform any service or repair
for leaks.
on high pressure fuel lines in order to allow pressure
to be purged.
Air System
1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced. 1. Remove the hose clamps.

2. Remove the hose clamps. 2. Disconnect the old hose.

3. Disconnect the old hose. 3. Replace the old hose with a new hose.

4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, Torque Specifications, Hose
Clamps for information about selecting and
installing the proper hose clamps.
4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, Torque Specifications, Hose
Clamps for information about selecting and
installing the proper hose clamps.
5. Start the engine. Inspect the air lines for leaks.

6. Carefully inspect the engine for any spilled fuel.

Make sure that no fuel remains on or close to the
engine.

Note: Fuel must be added to the fuel system ahead

of the fuel filter.

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

Maintenance Manual, Fuel System - Prime for
information about priming the engine with fuel.

8. Start the engine. Inspect the fuel system for leaks.

162
Maintenance Section
Insulation - Test
i03642858
Insulation - Test
SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081
Recommended Periodic Insulation
Tests
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the OFF posi-
tion. Attach DO NOT OPERATE tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Table 17
Tools Needed
Part Number Part Name Quantity
300-8648 Insulation 1
Testing Gp
Periodically, use an insulation tester to check the
insulation resistance of the generator's main stator
winding. The frequency of this test is determined by
the generator's environment. Previous insulation
tester readings will also determine the frequency of
this test.
Test the main stator windings with an insulation tester
in the following situations:
The generator set is started for the first time.
The generator set is removed from storage.
The generator set is operating in a humid
environment. Test every three months.
The generator set is not protected from the
elements in an enclosed area. Test every three
months.
The generator set is installed in an enclosed area.
This area needs to be low in humidity and this area
needs to have steady temperatures. Test every
twelve months (minimum).
SEBU8013-01
The generator set has not been run under load
for three months. Test the generator set weekly.
Use space heaters around the generator set if the
generator is exposed to a sea water environment or
if the humidity is above 75 percent. Also use space
heaters if a test result was below 3 megohms.
Space heaters must be used whenever the generator
set is not under load. Space heaters must also be
used whenever salt is present or whenever high
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester
readings above one megohm. Use space heaters
only when the generator is not running.
For additional information, refer to Special Instruction,
SEHS9124, Cleaning and Drying of Electric Set
Generators.
Recommended Procedure for the
Insulation Test
Personal injury or death can result from electro-
cution.
The megohmmeter is applying a high voltage to
the circuit.
To avoid electrocution, do not touch the instru-
ment leads without first discharging them. When
finished testing also discharge the generator
windings.
1. Take the generator out of service.
2. Visually inspect the generator for moisture. If
moisture exists, do not perform this insulation
test. Dry the unit first. Refer to Special Instruction,
SEHS9124, Cleaning and Drying of Electric Set
Generators.
3. Inspect the installation. Determine the equipment
that will be tested by the insulation tester.
4. Discharge the capacitance of the windings.
5. Disconnect T0 from ground.
6. Disconnect the sensing lead wires for the
regulator. This may be accomplished by
unplugging the harness connectors.
7. Disconnect the PT leads of the load share module.
8. Connect the insulation tester's Black lead to
ground.
9. Connect the insulation tester's RED lead to T0.
SEBU8013-01 163
Maintenance Section
Insulation - Test

10. Set the voltage to the rated voltage of the

generator.

11. Use the 30/60 Time Resistance Method:

a. Apply voltage.

b. Observe the readings at 30 seconds. Observe

the readings at 60 seconds.

c. Record the 60 second reading. This reading

must be corrected for temperature.

d. Record temperature.

e. Record humidity.

f. Remove voltage.

12. Evaluate the readings. The actual value of the

resistance may vary greatly between generators.
For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
between the 60 second resistance readings and
the readings that were taken on previous dates.
These two readings must be taken under similar
conditions. If a 60 second resistance reading
has a 50 percent reduction from the previous
reading, the insulation may have absorbed too
much moisture.

Switch the insulation tester to the OFF position.

This will discharge the insulation tester's leads.
Disconnect the insulation tester's leads.

Note: The results from the insulation resistance

checks indicate when cleaning and/or repairing is
becoming critical. Generally, insulation resistance
will vary greatly with temperature. Therefore, always
test at the same temperature and humidity. Refer to
Illustration 112.

Engine Serial Number_____________________________________

Serial Number for the Generator________________________

164 SEBU8013-01
Maintenance Section
Insulation - Test

g00633226
Illustration 112
SEBU8013-01 165
Maintenance Section
Maintenance Recommendations

i03958771 The following factors can contribute to severe

operation: environment, improper operating
Maintenance procedures, and improper maintenance practices.
Recommendations
Environmental Factors
SMCS Code: 1000
Extreme Ambient Temperatures
Maintenance Information Extended operation in environments that are
The operating conditions of an engine affect the extremely cold or hot can damage components. Valve
components can be damaged by carbon buildup if
maintenance intervals and the time between
the engine is frequently started and stopped in very
overhauls for the engine. The following conditions
affect the maintenance intervals and the expected cold temperatures. Extremely hot inlet air reduces
the performance capabilities of the engine.
overhaul interval for the engine.
Note: See this Operation and Maintenance Manual,
Severe Operation Cold Weather Operation topic (Operation Section),
or see Supplement, SEBU5898, Cold Weather
Severe operation is the use of an engine that Recommendations.
exceeds current published standards for the engine.
Caterpillar maintains standards for the following Cleanliness
engine parameters:
Unless the equipment is cleaned regularly, extended
Horsepower operation in a dirty environment and in a dusty
environment can damage components. Built up mud,
Range of rpm dirt, and dust can encase components. This operating
environment can make maintenance difficult. The
Fuel consumption buildup can contain corrosive chemicals. Corrosive
chemicals and salt can damage some components.
Fuel quality
Improper Operating Procedures
Altitude
Maintenance intervals Extended operation at low idle

Selection of oil Minimum cool down periods after high load factor
operation
Selection of coolant
Operating the engine beyond the guidelines for the
engine rating
Environmental qualities
Installation Operating the engine at loads that are greater than
the rated load
Refer to the standards for your engine or consult your
Caterpillar dealer in order to determine if your engine Operating the engine at speeds that are greater
than the rated speed
is operating within the defined parameters.

Severe operation can accelerate component wear.
Engines that are operating under severe conditions
may need more frequent maintenance intervals for
the following reasons:
Use of the engine for an application that is not
approved
Improper Maintenance Practices

Maximum reliability Extension of maintenance intervals

Retention of full service life Not using recommended fuel, lubricants, and
antifreeze/coolant solutions
Because of individual applications, it is not possible
to identify all of the factors which can contribute to
severe operation. Consult your Caterpillar dealer
about the maintenance that is needed for your
specific engine.
166
Maintenance Section
Maintenance Recommendations
Overhaul Information
Caterpillar makes the following recommendations for
the timing of the overhaul procedures for your engine.
The intervals may be extended based on individual
application and load factors. Contact your Caterpillar
dealer for further information about the optimal
maintenance interval for the overhaul procedures.
Table 18
Overhaul
Recommended Interval
Procedure
Top End Every 284000 L (750000 US gal)
Overhaul or 5000 SH
Every 570000 L (150000 US gal)
Major Overhaul
or 10000 SH
Note: Refer to this Operation and Maintenance
Manual, Overhaul (Top) for further information
about the top overhaul.
Note: Refer to this Operation and Maintenance
Manual, Overhaul (Major) for further information
about the major overhaul.
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
The need for preventive maintenance
The quality of the fuel that is being used
The operating conditions
The results of the SOS analysis
Oil Consumption as an Overhaul
Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
SEBU8013-01
The oil consumption rate (brake-specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake-specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
When te engine oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
To minimize downtime, Caterpillar Inc. recommends a
scheduled engine overhaul by your Caterpillar dealer
before the engine fails. The scheduled overhaul will
provide you with the best cost/value relationship.
Note: Overhaul programs vary according to the
engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
A planned overhaul before failure may be the best
value for the following reasons:
Costly unplanned downtime can be avoided.
Many original parts can be reused according to the
standards for reusable parts.
The service life of the engine can be extended
without the risk of a major catastrophe due to
engine failure.
The best cost/value relationship per hour of
extended life can be attained.
After Failure Overhaul
If a major engine failure occurs and the engine must
be removed from the hull, many options are available.
An overhaul should be performed if the engine block
or the crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
with a similar exchange core.
This lower cost can be attributed to three aspects:
Specially designed Caterpillar engine features
Caterpillar dealer exchange components
SEBU8013-01 167
Maintenance Section
Oil Cooler Core - Check/Clean/Test

Caterpillar Inc. remanufactured exchange

components
Personal injury can result from air pressure.
i03634803
Personal injury can result without following prop-
Oil Cooler Core - er procedure. When using pressure air, wear a pro-
Check/Clean/Test tective face shield and protective clothing.

(If Equipped) The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
SMCS Code: 1378-070; 1378-081; 1378-535 nozzle is deadheaded.

Clean the Oil Cooler Core
Remove the core. Refer to the Disassembly and
Assembly Manual, Oil Cooler - Remove for the
procedure.
1. Turn the oil cooler core on one side in order
to remove debris. Remove the debris that is
accessible.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Test the Oil Cooler Core
1. Inspect the core for trapped debris and
cleanliness. If necessary, remove the debris and
repeat the cleaning procedure.

2. Inspect the core for damage and perform a

NOTICE pressure test in order to detect leaks. Many shops
Do not use a high concentration of caustic cleaner to that service radiators are equipped to perform
clean the core. A high concentration of caustic cleaner pressure tests.
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of 3. Plug both ends of the oil cooler core and
cleaner. pressurize the core to 205 kPa (30 psi). Submerge
the core in water. Look for bubbles which are
2. Back flush the core with cleaner. being emitted from the core. The bubbles are
evidence of leaks.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 19 lists Hydrosolv liquid 4. If any leaks are found, do not attempt to repair the
cleaners that are available from your Caterpillar core.
dealer.
Install a core that is clean and a core that passes the
Table 19 pressure test in step 3. Refer to the Disassembly
Hydrosolv Liquid Cleaners(1) and Assembly Manual, Oil Cooler - Install for the
procedure.
Part
Description Size
Number For more information on cleaning the core, consult
1U-5490 Hydrosolv 4165 19 L (5 US gallon) your Caterpillar dealer.
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) i03962492
Use a two to five percent concentration of the cleaner
at temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more Overhaul (Major)
information.
SMCS Code: 7595-020-MJ
3. Steam clean the core in order to remove any
residue. Flush the fins of the oil cooler core. Note: Refer to this Operation and Maintenance
Remove any other trapped debris from the inside Manual, Maintenance Recommendations for
and from the outside of the core. information about the optimal maintenance interval
for the major overhaul.
4. Wash the core with hot, soapy water.
The need for a major overhaul is determined by
5. Flush the core thoroughly in order to remove several factors.
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the An increase of oil consumption
core is clear and free of debris.
An increase of crankcase blowby
168 SEBU8013-01
Maintenance Section
Overhaul (Major)

The total amount of fuel consumption Aftercooler core

The service hours of the engine International Convention for Safety of
Life at Sea (SOLAS)
The wear metal analysis of the lube oil
Caterpillar recommends replacing the following:
An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates All shields that have been installed to cover up fuel
and oil line connections per (SOLAS) regulations
that the bearings and the surfaces that wear may
need service. An increase in the levels of noise and
vibration indicates that rotating parts require service. All marine certification society approved tapes are
installed in order to cover up fuel line connections
Note: An oil analysis may indicate a decrease of and oil line connections according to the SOLAS
regulations.
wear metals in the lube oil. The cylinder liners may be
worn so that polishing of the bore occurs. Also, the
increased use of lube oil will dilute the wear metals. Inspection, Reconditioning, or
Monitor the engine as the engine accumulates
Exchanging of Components
service hours. Consult your Caterpillar dealer about
Inspect the following components according to
scheduling a major overhaul.
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Note: The driven equipment may also require service
Parts and Salvage Operations, SEBF8029, Index
when the engine is overhauled. Refer to the literature
of Publications on Reusability or Salvage of Used
that is provided by the OEM of the driven equipment. Parts.
For the major overhaul, all of the bearings,
Recondition the worn components or exchange the
seals, gaskets, and components that wear are components, if necessary. Your Caterpillar dealer can
disassembled. The parts are cleaned and inspected.
provide these services and components.
If necessary, the parts are replaced. The crankshaft
is measured for wear. The crankshaft may require
regrinding. Alternatively, the crankshaft may be Camshaft followers
replaced with a Caterpillar replacement part.
Camshaft thrust washers
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure Connecting rods
that the components are operating within the
appropriate specifications. Crankshaft vibration damper
Cylinder head assembly
Replacement of Components
Cylinder liners
Replace the following components during the major
overhaul: Engine mounts
Camshaft bearings Scavenge oil pump
Connecting rod bearings Engine wiring harness
Crankshaft seals Exhaust manifold seals
Crankshaft thrust washers Exhaust manifold bellows
Electronic unit injectors Fuel pressure regulating valve
Gear train bushings Fuel priming pump
Gear train bearings Fuel transfer pump
Main bearings Inlet manifold gaskets
Piston rings Inlet manifold seals
SEBU8013-01 169
Maintenance Section
Overhaul (Major)

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

Software update Engine failure due to a broken crankshaft

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

Camshaft Unusual fit

Crankshaft Unusual wear

In addition to the inspection of components, inspect
Driven equipment (alignment) the alignment of the driven equipment. See the
Application and Installation Guide for the engine or
Engine cylinder block see the literature that is provided by the OEM of the
driven equipment.
Engine control module
Flywheel Cleaning of Components
Front gear train (gears) Clean the oil suction screen. Also, remove side
covers in order to clean the oil sump. For instructions
Oil suction screen on removal and installation of components, see
the Service Manual, Disassembly and Assembly
Rear gear train module.

Inspect the camshaft for damage to the journals and Obtain a Coolant Analysis
the lobes.
For conventional heavy-duty coolant or antifreeze,
Inspect the crankshaft for any of the following check the concentration of supplemental coolant
conditions:
additive (SCA) regularly. The concentration of SCA
can be checked with an SOS coolant analysis (Level
Deflection 1). A more detailed coolant analysis is recommended
periodically.
Damage to the journals
Bearing material that has seized to the journals
170
Maintenance Section
Overhaul (Top End)
For example, considerable deposits are found in the
water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained. The coolant water probably
contained minerals which were deposited on the
engine over time.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis may be obtained
from the following sources:
Caterpillar dealer
Local water utility company
Agricultural agent
Independent laboratory
Caterpillar recommends an SOS coolant analysis
(Level II). This analysis is a comprehensive chemical
evaluation of the coolant. This analysis is also a
check of the overall condition of the inside of the
cooling system. The following services are provided:
Full Level 1 analysis
Identification of the source of metal corrosion and
of contaminants
Identification of buildup of the impurities that cause
corrosion
Identification of buildup of the impurities that cause
scaling
Determination of possible electrolysis within the
engine cooling system
A report of the results of the analysis is provided.
Maintenance recommendations are based on the
results.
For more information about SOS coolant analysis,
consult your Caterpillar dealer.
i03962489
Overhaul (Top End)
SMCS Code: 7595-020-TE
Note: Refer to this Operation and Maintenance
Manual, Maintenance Recommendations for
information about the optimal maintenance interval
for the top overhaul.
SEBU8013-01
A top end overhaul involves the removal, the
inspection, and the rework of the cylinder head
components. A few additional components are
replaced and serviced.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.
The following definitions explain the terminology for
the services that are performed during an overhaul:
Inspect Inspect the components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, Specifications module.
Rebuild The component is reconditioned in order
to comply with reusability guidelines.
Replace The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer for a
credit on replacement parts. Consult your Caterpillar
dealer about repair options for your engine.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
recommendations in Table 20.
SEBU8013-01 171
Maintenance Section
Power Factor - Check

Table 20 Testing A Brushless Exciter

Recommendations for Top End Overhauls (1) Rotating Rectifier With An
Service Top End Overhaul Ohmmeter
Inspect Cylinder head assemblies Table 21
Rebuild
Replace Valves Tools Needed
Rocker arms Part Number Part Name Quantity
Inspect 6V-7070 Digital 1
Valve bridges
Replace Multimeter
Fuel Injectors
9U-7330 Multimeter 1
Clean/Test Oil cooler core(2)
Aftercooler core (Fresh water or 146-4080 Digital 1
treated water system)(3) Multimeter
(RS-232)
Replace Cylinder head gaskets
Aftercooler core (salt water system) 7X-1710 Multimeter Probe 1
(1)
Group
For instructions on removal and installation of components,
see the Service Manual, Disassembly and Assembly module.
(2) Refer to this Operation and Maintenance Manual, Oil Cooler
Core - Check/Clean/Test for the procedure.
(3) Refer to this Operation and Maintenance Manual, Aftercooler
Core - Clean/Test for the procedure.

i01216962

Power Factor - Check

SMCS Code: 4450-535-PWR

The power factor of a system can be determined by

a power factor meter or by calculations. The power
factor can be calculated by dividing kW by kVA.
Power factor is expressed as a decimal. g00555106
Illustration 113

If the failure of a rectifier is suspected, use the

i02331392
following procedure.
Rotating Rectifier - Check 1. Remove the cover from the exciter.
SMCS Code: 4465-535
2. Remove the nut that secures the rectifier to the
Check the exciter armature. Ensure that the rotating heat sink.
rectifier is tight. If a failure of a rectifier is suspected,
refer to Testing A Brushless Exciter Rotating 3. Remove the diode lead.
Rectifier With An Ohmmeter.
4. Lift the rectifier from the heat sink.

5. Refer to Illustration 113. Connect the ohmmeter's

leads across the rectifier. Note the meter reading.

6. Reverse the ohmmeter leads. Note the meter

reading.

The ohmmeter should indicate a low resistance

when the ohmmeter leads are across the rectifier in
one direction. The ohmmeter should indicate a high
resistance when the leads are reversed.

If the ohmmeter indicates a low resistance in both

directions, the rectifier is shorted. A high resistance
in both directions indicates an open rectifier.
172 SEBU8013-01
Maintenance Section
Rotating Rectifier - Check

Replace any faulty rectifiers with rectifiers that have 2. Touch the black ohmmeter lead to the rectifier
comparable operating characteristics. Include the terminals that have the following labels: AC1,
following information when a rectifier is being ordered AC2, and AC3. The meter should indicate an
for replacement: open circuit or high resistance for each rectifier
terminal. If the meter does not indicate an open
Part Number of the rectifier circuit or high resistance, the rectifier is bad.
Replace the rectifier.
Model number of the exciter
3. Touch the black ohmmeter lead to the rectifier
Type of the exciter terminal that is marked +.

Serial number of the generator 4. Touch the red ohmmeter lead to the rectifier
terminals that have the following labels: AC1,
AC2, and AC3. The meter should indicate a
Rectifier Block Test good diode or low resistance. If the meter does
not indicate a good diode or low resistance, the
rectifier is bad. Replace the rectifier.

5. Touch the black ohmmeter lead to the rectifier

terminal that is marked .

6. Touch the red ohmmeter lead to the rectifier

terminals that have the following labels: AC1,
AC2, and AC3. The meter should indicate an
open circuit or high resistance for each rectifier
terminal. If the meter does not indicate an open
circuit or high resistance, the rectifier is bad.
Replace the rectifier.

7. Touch the red ohmmeter lead to the rectifier

terminal that is marked .

8. Touch the black ohmmeter lead to the rectifier

terminals that have the following labels: AC1,
AC2, and AC3. The meter should indicate a
good diode or low resistance. If the meter does
not indicate a good diode or low resistance, the
rectifier is bad. Replace the rectifier.

Replace any faulty rectifiers with rectifiers that have

comparable operating characteristics. Include the
following information when a rectifier is being ordered
Illustration 114
g00775020 for replacement:
Rectifier Block
Part Number of the rectifier
(1) AC1 terminal
(2) AC2 terminal
(3) AC3 terminal Model number of the exciter
(4) Negative terminal
(5) Positive terminal Type of the exciter
Perform the following steps in order to test the rectifier Serial number of the generator
block. When possible, use the diode test scale. If
there is no diode test scale, use the resistance scale.

1. Touch the red ohmmeter lead to the rectifier

terminal that is marked +.
SEBU8013-01
i00905687
Sea Water Strainer -
Clean/Inspect
SMCS Code: 1371-040; 1371-070
The sea water strainer must be clean in order to
allow proper engine cooling. Check the sea water
strainer for plugging. Inspect the sea water strainer
more frequently if the vessel is being operated
in water which is shallow or dirty. Refer to the
OEM recommendations for more information about
inspecting and cleaning the sea water strainer.
Ensure that the auxiliary water pump is primed and
that the suction line is open.
1. Remove the sea water strainer and clean the
screen. Remove any dirt and debris.
2. Install the sea water strainer. Fill the sea water
strainer and the suction line for the auxiliary water
pump with water.
i03108463
Standby Generator
Set Maintenance
Recommendations
SMCS Code: 4450-041
A standby generator set may not need to be used
very often. However, the generator set is usually
needed for operation in an emergency situation.
Maintenance of the standby generator set is very
important for the following reasons:
The generator set must always be in excellent
operating condition.
The generator set must be ready to work under
load at any time.
Establishing a Preventive Maintenance Program will
provide these benefits:
Maximum availability of the standby generator set
Longer service life for the generator set
Minimum of expensive repairs
Your Caterpillar dealer can help you to establish an
effective Preventive Maintenance Program for your
generator set. Consult your Caterpillar dealer for
details.
173
Maintenance Section
Sea Water Strainer - Clean/Inspect
Maintenance and Operation
Procedures
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the OFF posi-
tion. Attach DO NOT OPERATE tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
The recommended maintenance for the generator set
is listed in this Operation and Maintenance Manual,
Maintenance Interval Schedule (Standby Generator
Sets) (Maintenance Section).
Maintenance and Repair
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the
subsequent maintenance intervals must be
performed by an authorized service technician or by
your Caterpillar dealer.
Unless other instructions are provided, perform
maintenance and repairs under the following
conditions:
The engine is stopped.
The starting system is disabled.
The generator does not pose an electrical shock
hazard.
The generator is disconnected from the load.
Operation
To ensure proper operation, the generator set must be
exercised regularly. For instructions on operating the
generator set, see the Operation and Maintenance
Manual for the generator set control panel.
For these operation procedures, follow the
instructions that are provided in this Operation and
Maintenance Manual, Operation Section: starting
the engine, engine operation, and stopping the
engine.
174
Maintenance Section
Starting Motor - Inspect
Record Keeping
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems, and repairs.
Space Heaters
Moisture causes damage to generators and other
electrical equipment. Make every effort to keep the
generator set as dry as possible.
Generators can operate without problems in humid
environments. However, problems can occur when
the generator is inactive. Moisture can condense on
the windings. This can result in poor performance.
Also, damage to the windings can occur.
Use space heaters in order to help keep the windings
dry. When the generator is not active, ensure that the
space heaters are operating. When the generator is
operating, turn OFF the space heaters.
i01113939
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
the starting motor is recommended.
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
to start properly. The engine will not start if the
starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
the flywheel ring gear can be damaged because of
irregular engagement.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth. Look
for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
ring gear must be replaced.
Electric Starting Motor
Note: Problems with the electric starting motor can
be caused by the following conditions: malfunction of
the solenoid and malfunction of the electric starting
system.
Inspect the electrical system for the following
conditions:
Loose connections
SEBU8013-01
Corrosion
Wires that are worn or frayed
Cleanliness
Make repairs, if necessary.
Air Starting Motor
Personal injury or death can result from improp-
erly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
connections for leaks.
If the teeth of the starting motor pinion and/or the
flywheel ring gear are damaged, the air circuit for
the starting motor must be examined in order to
determine the cause of the problem.
Removal and Installation of the
Starting Motor
Refer to the Service Manual, Disassembly and
Assembly module for information on removing the
starting motor and installing the starting motor.
Consult your Caterpillar dealer for assistance.
i03230840
Stator Lead - Check
SMCS Code: 4459-535
Ensure that the stator output leads are routed out of
the generator in a manner that prevents the leads
from rubbing against metal objects.
Visually inspect the following areas for cracking and
physical damage:
stator output leads
protective sleeving
SEBU8013-01
insulation
i04011511
Stator Winding Temperature -
Measure/Record
SMCS Code: 4453-082-TA
SR4B generators are provided with embedded
temperature detectors. The detectors are installed
in the slots of the main armature (stator) and in the
bearing housing. If the Marine Classification Society
system (MCS system) is not installed, the detectors
are used with equipment that is provided by the
customer. This equipment is used in order to measure
the winding temperature of the main armature. This
equipment is also used in order to monitor the main
winding temperature of the armature.
Note: If the main stator winding temperature is
150 C (302 F), the alarm fault will appear.
i01539769
Turbocharger - Inspect
SMCS Code: 1052-040; 1052
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.
175
Maintenance Section
Stator Winding Temperature - Measure/Record
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.
Removal and Installation
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the
procedure and specifications.
Cleaning and Inspecting
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
from entering during reassembly.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned.
176 SEBU8013-01
Maintenance Section
Varistor - Test

3. Check the compressor wheel for cleanliness. i01494879

If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering Varistor - Test
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger SMCS Code: 4466-081
oil seal.

The presence of oil may be the result of extended

engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.

4. Use a dial indicator to check the end clearance

on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.

5. Inspect the bore of the turbine housing for

corrosion.

6. Clean the turbocharger housing with standard

shop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outlet

piping to the turbocharger housing.
g00677004
Illustration 115
PMPE Generator Wiring Diagram
(CR1-CR6) Diodes
(CR7) Varistor
(L1) Exciter field (stator)
(L2) Exciter armature (rotor)
(L3) Main field (rotor)
(L4) Main armature (stator)
(L5) Pilot exciter armature
(PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer

Ohmmeter
An ohmmeter can be used to check a varistor
(CR7). Place an ohmmeter across the varistor. The
resistance should be a minimum of 15000 ohms. If
the resistance is less than 15000 ohms, the varistor
is faulty.
SEBU8013-01
Test Light
Illustration 116
g00555113
Test Light
Refer to the test light that is shown in Illustration 116.
Follow these steps in order to test the varistor:
1. Disconnect either lead of the varistor (CR7).
2. Place the test light across the varistor.
3. Observe the results. The lamp should not light.
4. Reverse the test light.
5. Observe the results. The lamp should not light.
If the test light illuminates in either direction, there is
a short in the varistor. Replace any faulty varistors
with varistors that have comparable operating
characteristics. Include the following information
when a varistor is being ordered for replacement:
Part number of the varistor
Serial number of the generator
After the varistor has been replaced, verify that the
strapping of the field winding lead is securely wound
on the shaft. Also, verify that the strapping of the field
winding lead is securely tied.
i01491868
Voltage and Frequency - Check
SMCS Code: 4450-535-EL
Check for the proper voltage setting and check for
the proper frequency setting. Check for stability.
For the correct voltage and frequency, refer to the
generator set's Serial Plate.
177
Maintenance Section
Voltage and Frequency - Check
i02706582
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only require a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
The guards must be in the proper place. Repair
damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
Ensure that the cooling lines are tight and ensure
that the cooling lines are properly clamped. Check
for leaks. Check the condition of all pipes.
Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.
Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
178 SEBU8013-01
Maintenance Section
Water Pump - Inspect

Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.
Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
Inspect the ground strap for a good connection and
for good condition.
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 it is
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 Caterpillar dealer if repair is needed or
replacement is needed.
i01787397
Winding - Test
SMCS Code: 4453-081; 4454-081; 4457-081;
4470-081

Inspect the ECM to the cylinder head 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 and replace any gauges
that can not be calibrated.

i03543200

Water Pump - Inspect

SMCS Code: 1361-040; 1361

A failed water pump might cause severe engine

overheating problems that could result in the following
conditions:

Cracks in the cylinder head g00677004

Illustration 117
A piston seizure PMPE Generator Wiring Diagram
(CR1-CR6) Diodes
Other potential damage to the engine (CR7) Varistor
(L1) Exciter field (stator)
A failed water pump might cause severe engine (L2) Exciter armature (rotor)
(L3) Main field (rotor)
overheating problems that could result in cracks in (L4) Main armature (stator)
the cylinder head, a piston seizure or other potential (L5) Pilot exciter armature
damage to the engine. (PM) Permanent magnet
(RFA) Rotating field assembly
(CST) Customer supplied transformer
SEBU8013-01
Table 22
Tools Needed
Part Number Part(1)
Digital
6V-7070
Multimeter
Digital
146-4080 Multimeter
(RS232)
(1) Only one multimeter is necessary for this test. Either of the
multimeters that are shown will work.
The high voltage that is produced by an operating
generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
Place the engine control switch in the OFF posi-
tion. Attach DO NOT OPERATE tags to all start-
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and
automatic transfer switches that are associated
with the generator.
Measure the resistance of the following windings:
(L1), (L2), (L3), (L4), and (L5). The winding that
is being tested must be disconnected from the
other components before the resistance can be
measured. The following resistance measurements
are approximations. If the measured value is
not near the listed approximation, the winding is
probably damaged. For a more precise resistance
value, consult the Technical Marketing Information
(TMI). Refer to the generator arrangement that is in
question.
Note: The winding temperature affects the
resistance. When the winding temperature increases,
the winding resistance also increases. When
the winding temperature decreases, the winding
resistance also decreases. Therefore, a correct
measurement can be performed only when the
winding is at room temperature.
The following armature windings have very little
resistance: (L2), (L4), and (L5). The resistance of
these windings will measure near 0 ohms. Use a
milliohmmeter to measure the resistance of the
armature windings.
Exciter Armature (Rotor) (L2) less than 0.1 ohm
Main armature (Stator) (L4) less than 0.1 ohm
Pilot Exciter Armature (L5) less than 0.1 ohm
Use a multimeter in order to measure the resistance
of field windings (L1) and (L3).
179
Maintenance Section
Zinc Rods - Inspect/Replace
Exciter Field (Stator) (L1) approximately 3.0
ohms to 6.0 ohms
Quantity Main Field (Rotor) (L3) approximately 0.75 ohms
to 2.0 ohms
1
Note: There should be no continuity between any
winding and ground. There should be no continuity
1 between any winding and another winding.
i03996033
Zinc Rods - Inspect/Replace
SMCS Code: 1388-040; 1388-510
Caterpillar requires the inspection of the zinc
rods every 50 service hours until a wear rate is
established.
Corrosion in sea water circuits can result in premature
deterioration of system components, leaks, and
possible cooling system contamination.
Zinc rods are inserted in the sea water cooling
system of the engine in order to help prevent the
corrosive action of salt water. The reaction of the zinc
to the sea water causes the zinc rods to deteriorate.
The zinc rods deteriorate instead of engine parts
for the cooling system that are more critical. Rapid
deterioration of zinc rods may indicate the presence
of uncontrolled electrical currents from improperly
installed electrical attachments or improperly
grounded electrical attachments.
The zinc rods must be inspected at the proper
intervals. The zinc rods must be replaced when
deterioration occurs.
Inspect the zinc rods within 24 hours of initially
filling the plumbing with sea water. If no significant
corrosion is noted, inspect the zinc rods weekly or
inspect the zinc rods after each 50 hours of engine
operation. If no significant deterioration is noted,
inspect the zinc rods weekly or inspect the zinc rods
after each 50 hours of engine operation.
Locations of the Zinc Rods
The number and the location of the zinc rods may
vary between engines.
180 SEBU8013-01
Maintenance Section
Zinc Rods - Inspect/Replace

g01937139
Illustration 118
One or two zinc rods may be located in the transmission oil cooler.

g02182894
Illustration 119
One zinc rods may be located in the fuel cooler.

g01937142
Illustration 120
One zinc rod may be located on top of the auxiliary water pump.
SEBU8013-01 181
Maintenance Section
Zinc Rods - Inspect/Replace

g01937141
Illustration 121
One zinc rod may be located in the intake for the heat exchanger. One zinc rod may be located in the outlet for the heat exchanger.

Replace the Zinc Rods

g01958134
Illustration 122
View of the top of the engine g00104049
Illustration 124
One zinc rod may be located in the lines group.
1. Unscrew the old zinc rod or drill the old zinc rod
from the plug. Clean the plug.
Inspect the Zinc Rods
2. Apply 9S-3263 Compound to the shoulder of
1. Remove the zinc rod.
a new zinc rod. Apply the compound only to the
shoulder of the zinc rod. Install the zinc rod into
the plug.

3. Coat the external threads of the plug with

5P-3413 Pipe Sealant. Install the zinc rod. Refer
to the Specifications Manual for more information
on torque specifications.

g00104048
Illustration 123

2. Tap the zinc rod lightly with a hammer. If the zinc

rod has deteriorated, or if the zinc rod flakes,
install a new zinc rod.
182 SEBU8013-01
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i04011911

Emissions Warranty
Information
SMCS Code: 1000

Caterpillar Inc. (Caterpillar) warrants to the ultimate

purchaser and each subsequent purchaser that:

1. New non-road diesel engines and stationary diesel

engines less than 10 liters per cylinder operated
and serviced in the United States and Canada,
including all parts of their emission control systems
(emission related components), are:

a. Designed, built, and equipped so as to conform,

at the time of sale, with applicable emission
standards prescribed by the United States
Environmental Protection Agency (EPA) by
way of regulation.

b. Free from defects in materials and workmanship

in emission-related components that can cause
the engine to fail to conform to applicable
emission standards for the warranty period.

2. New non-road diesel engines operated and

serviced in the state of California, including all
parts of their emission control systems (emission
related components), are:

a. Designed, built, and equipped so as to conform,

at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).

b. Free from defects in materials and workmanship

which cause the failure of an emission-related
component to be identical in all material
respects to the component as described in the
Caterpillar application for certification for the
warranty period.

A detailed explanation of the Emission Control

Warranty that is applicable to new non-road and
stationary diesel engines, including the components
covered and the warranty period, is found in
supplement Special Publication, SELF9001, Federal
Emission Control Warranty and Emission Control
Warranty for California. Consult your authorized Cat
dealer to determine if your engine is subject to an
Emission Control Warranty.
SEBU8013-01
Reference Information
Section
Engine Ratings
i00727327
Engine Rating Conditions
SMCS Code: 1000
All engine ratings are in compliance with the following
standard ambient air conditions of SAE J1349:
99 kPa (29.3 inches of Hg)
30 percent relative humidity
A temperature of 25 C (77 F)
Ratings relate to the standard conditions of
ISO8665, of ISO3046/1, of DIN6271, and of demand is 100% of continuous rated ekW for 100%
BS5514.
The engine ratings are based on the following fuel
specifications:
Low heat value (LHV) of the fuel of 42 780 kJ/kg
(18,390 Btu/lb) at 29 C (84 F)
Gravity (API) of 35 degrees at 15 C (60 F)
Specific gravity of .849 at 15 C (60 F)
Density of 850 kg/m3 (7.085 lb/US gal)
The engine ratings are gross output ratings.
Gross Output Ratings The total output capability
of the engine that is equipped with standard
accessories.
Standard accessories include the following
components:
Oil pumps
Fuel pumps
Water pumps
Subtract the power that is required to drive auxiliary
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).
183
Reference Information Section
Engine Ratings
i03570771
Engine Rating Definitions
SMCS Code: 1000
Power rating definitions are in accordance with
ISO8528.
Prime Power
Output is available with varying load for an unlimited
time. The average power output is 70% of the prime
power rating. Typical peak demand of 100% of prime
rated ekW with 10% of overload capability is for
emergency use for a maximum of one hour in 12.
The engine cannot be operated at overload for more
than 25 hours per year.
Continuous Power
Output is available with varying load for an unlimited
time. The average power output is between 70% and
100% of the continuous power rating. Typical peak
of operating hours.
Standby Power
Output is available with varying load for the duration
of the interruption of the normal power source. The
average power output is 70% of the standby power
rating. The typical operation is 200 hours per year.
The maximum expected usage is 500 hours per year.
Emergency Standby Power
Output is available with varying load for the duration
of an emergency outage. The average power output
is 70% of the standby power rating. The typical
operation is 50 hours per year. The maximum
expected usage is 200 hours per year.
i00899220
Marine Classification Society
Certification Requirements
SMCS Code: 1000
The major seafaring nations have established
technical groups called marine classification
societies. Caterpillar Inc. has maintained standards
and quality under the guidelines that are set forth by
the 14 major marine classification societies that are
listed. For more information, refer to Engine Data
Sheet, 103.1 and Engine Data Sheet, 103.1.1 in the
Caterpillar Technical Manual.
184 SEBU8013-01
Reference Information Section
Engine Ratings

ABS American Bureau of Shipping (USA)

BV Bureau Veritas (France)

CCG Canadian Coast Guard (Canada)

CCRS China Corporation Register of Shipping

(Taiwan)

CCS China Classification Society (China)

CR Croatian Register of Shipping (Croatia)

DnV Det norske Veritas (Norway)

GL Germanischer Lloyd (Germany)

KR Korean Register of Shipping (Korea)

LR Lloyd's Register of Shipping (Great Britain)

NK Nippon Kaiji Kyokai (Japan)

PR Polish Register (Poland)

RINa Registro Italiano Navale (Italy)

RS Maritime Register of Shipping (Russia)

SEBU8013-01
Engine Performance and Performance Analysis Report (PAR)
Engine Performance and
Performance Analysis
Report (PAR)
i01044073
Engine Performance
SMCS Code: 1000
Today's marine operator is concerned with
performance, cost of operation and satisfactory
engine life. Traditionally, poor performance of the
vessel is believed to result from a lack of engine
performance or from a loss of engine performance. In
fact, the engine is only one of numerous factors that
influence the overall performance of a vessel.
Several factors determine the power demand on an
engine. The engine does not have control over the
demand that is caused by the vessel design. The
vessel design includes the following features:
Hull
Propeller
Drive train
Those features also affect the amount of power that
is available to perform additional work. For example,
those features affect the power that is used to drive
an auxiliary pump.
If a problem with the performance of the vessel
occurs, consider the following effects on power
demand:
Loads
Condition of the vessel
Vessel design
Condition of the drive train
Condition of the propeller
Deterioration of the engine systems decreases the
ability of the engine to produce power and vessel
speed. Engine systems include the cooling system,
the lubrication system, the fuel system, etc. The
engine is not likely to be the cause of poor fuel
economy without excessive exhaust smoke and/or
the loss of power.
If you have a valid problem with the engine's
performance, consult an authorized Caterpillar dealer
for assistance.
185
Reference Information Section
If the engine is covered by a warranty, the Caterpillar
warranty will cover the cost in order to solve a valid
deficiency of the engine's performance. However, if
the engine is not at fault, all costs that are incurred
will be the responsibility of the owner.
Note: Adjustment of the fuel system outside
Caterpillar specified limits will not improve fuel
efficiency. Adjustment of the fuel system outside
Caterpillar specified limits could also result in damage
to the engine.
Caterpillar engines are manufactured with
state-of-the-art technology. Caterpillar engines are
designed to help provide two characteristics in all
applications:
Maximum performance
Fuel efficiency
To ensure optimum performance for the service life
of the engine, follow the recommended operation
procedures that are described in this manual. Also,
follow the preventive maintenance procedures that
are described in this manual.
Performance Analysis Report
(PAR)
To verify the condition of the propulsion system,
Caterpillar has developed the Performance Analysis
Report (PAR) for marine engines.
A PAR is an in-vessel test procedure that is performed
by a Caterpillar analyst under operating conditions.
The test compares the performance of all marine
engine systems to the original testing specifications.
When a PAR is conducted at Sea Trial, an installation
of high quality can be ensured. The PAR will confirm
the matching of the following components for
optimum performance and for fuel efficiency: hull,
rudders, propeller, marine transmission, ventilation,
and cooling systems.
Caterpillar recommends scheduling a PAR in order
to maintain optimum performance.
A periodic PAR can define deterioration of the
propulsion system. A PAR can assist in repairs, in
overhauls, and in maintenance schedules. This will
help to provide the most economical, efficient cost
of operation.
186 SEBU8013-01
Reference Information Section
Customer Service

Customer Service Europe, Africa, and Middle East

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

USA and Canada Far East

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

1-800-447-4986 Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Marine Center of Excellence Japan
Manager, Customer Service Caterpillar Power Systems, Inc.
111 Southchase Blvd SBS Tower (14th floor)
Fountain Inn, SC 29644 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Please keep in mind: probably, your problem will Phone: 81-3-5797-4300
ultimately be solved at the dealership, using the Fax: 81-3-5797-4359
dealership facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Outside of the USA and of Canada Tullamarine, Victoria 3043
Australia
If a problem arises outside the USA and outside Phone: 03-9953-9333
Canada, and if the problem cannot be resolved at the Fax: 03-9335-3366
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
SEBU8013-01
i01028392
Ordering Replacement Parts
SMCS Code: 7567
When replacement parts are required for this
product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
Part number
Part name
Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
187
Reference Information Section
Customer Service
i01880104
On-Board Replacement Parts
SMCS Code: 7567
The various Marine Classification Societies require
a supply of replacement parts on vessels that
are primarily powered by diesel engines. The
replacement parts may be needed for making repairs
offshore or at remote ports. The types of replacement
parts and the numbers of parts depends on the range
of the vessel. The following two categories of vessels
are considered:
Category 1 This category includes vessels that
make short trips between ports.
Category 2 This category includes vessels in
ocean service that is unrestricted. The vessels may
travel far from ports that provide service. The list of
replacement parts for this category is more extensive.
Table 23 lists the parts that are recommended by
Caterpillar for vessels in both categories.
The requirements of individual Marine Classification
Societies may differ. Table 24 lists the requirements
of all the Marine Classification Societies. Additionally,
some items that are recommended by Caterpillar are
listed. All of the parts that are listed in Table 23 and
24 are recommended for vessels in Category 2. To
customize this list for your specific engine application,
consult your Caterpillar dealer.
Table 23
Replacement Parts for Vessels in Category
1 and Category 2
Quantity Item
4 Air cleaner element
1 Alternator belt
1 Electronic control module (ECM)
1 Electronic unit injector
- Engine oil
- Extended Life Coolant (ELC) and Extender
or
Diesel Engine Antifreeze/Coolant (DEAC)
and Supplemental Coolant Additive (SCA)
4 Fuel filter elements
1 Fluid sampling bottles
- Liquid gasket material
4 Engine oil filters
1 Service kit (electronic connector)
4 Water temperature regulators
(continued)
188 SEBU8013-01
Reference Information Section
Customer Service

(Table 23, contd) (Table 24, contd)

Replacement Parts for Vessels in Category Replacement Parts for Vessels in Category 2
1 and Category 2
System Quantity Item
Quantity Item
Piston 1 Connecting rod assembly
4 Zinc rods
1 Connecting rod bearing

Table 24 1 Cylinder liner

Replacement Parts for Vessels in Category 2 1 Filler band (cylinder liner)
System Quantity Item 1 Main bearing
Camshaft and 1 Bolt (crankshaft to 2 Cap bolt and washer (main
crankshaft flywheel) bearing)
1 Camshaft gear 1 Piston assembly
1 Crankshaft gear 1 Piston pin
1 Idler gear and balance 2 Piston pin retainer
weight gear assembly
1 Piston rings (complete set)
(water pump)
1 3 Seals (cylinder liner)
Shaft and thrust washer
(idler gear and balance Starting 1 Starting motor
weight gear assembly)
Turbocharger 1 Complete turbocharger
Cooling 1 Aftercooler core and
gasket 4 Gasket
1 Auxiliary water pump 4 Locknut
1 Jacket water pump 4 Stud (mounting)
4 Water temperature Valves 6 Exhaust valves
regulator
4 Inlet valves
Cylinder head 6 Bolt and washer
10 Valve guides
1 Bolt and nut (exhaust
24 Valve locks
manifold)
10 Valve rotators
1 Cylinder head assembly
10 Valve springs
4 Gasket (cylinder)
- Water seals for one
cylinder
Fuel 3 Electronic unit injector
1 Fuel transfer pump
3 Seal (electronic unit
injector)
Inlet air 2 Air cleaner element
Lubrication 1 Bypass valve (oil cooler)
1 Bypass valve (oil filter)
1 Gasket (oil pan)
1 Oil cooler core (engine)
1 Oil cooler core (marine
gear)
Miscellaneous 1 Gasket kit (engine)
(continued)
SEBU8013-01
Reference Materials
i04011530
Reference Material
SMCS Code: 1000
The following literature can be obtained through any
Caterpillar dealer.
Diesel Engine Oils
Data Sheet, PEHJ0021, Cat DEO (Diesel Engine
Oil) APD, EAME, LACD Only
Data Sheet, PEHJ0059, Cat DEO (for North
America)
Data Sheet, PEHJ0091, Cat DEO (Egypt and
Saudi Arabia)
Data Sheet, PEHJ0159, Cat DEO-ULS (Ultra Low
Sulfur)
Special Publication, PEHJ0192, Optimizing Oil
Change Intervals
Special Publication, PEGJ0047, How To Take A
Good SOS Oil Sample
Data Sheet, PEHP7062, Cat DEO SYN
Special Publication, PELJ0179, Caterpillar Engine
Crankcase Fluid-1 Specification (Cat ECF-1)
Special Publication, SEBD0640, Oil and Your
Engine
Special Publication, SEBU5898, Cold Weather
Recommendations
Greases
Data Sheet, NEHP6010, Cat Ultra 5Moly Grease
Data Sheet, NEHP6011, Cat Arctic Platinum
Grease
Data Sheet, NEHP6012, Cat Desert Gold Grease
Data Sheet, NEHP6015, Cat Special Purpose
Grease
Data Sheet, PEGJ0035, Grease Selection Guide
Data Sheet, PEHJ0088, Cat Multipurpose Grease
Data Sheet, PEHP0002, Cat Advanced 3Moly
Grease
189
Reference Information Section
Reference Materials
Fuels
CD-ROM, PEXT9044, Improving Fuel System
Durability
Special Publication, SEBD0717, Diesel Fuels and
Your Engine
Special Publication, SENR9620, Improving Fuel
System Component Durability
Coolants
Special Publication, PEEP5032, Engine Coolant
Label
Data Sheet, PEHP9554, Cat DEAC (Diesel
Engine Antifreeze/Coolant)
Data Sheet, PEHJ0067, Cat ELC (Extended Life
Coolant)
Labels, PMEP5027, Label - ELC Label
Special Publication, SEBD0518, Know Your
Cooling System
SOS Services
Labels, SEBU5031, SOS Oil Analysis Label
Special Publication, PEGJ0046, Cat SOS
Services: Understanding Your Results
Special Publication, PEGJ0047, How To Take A
Good SOS Oil Sample
Data Sheet, NEHP6013, SOS Fluids Analysis
Products
Special Publication, PEHJ0191, Cat SOS Fluid
Analysis
Special Publication, PEHP7052, Cat SOS
Services Management Guide
Miscellaneous
Special Publication, SEBU6251, Caterpillar
Commercial Diesel Engine Fluids
Recommendations
Special Instruction, REHS4817, Overview,
Installation, and Configuration of the Marine
Classification Society Alarm and Protection (MCS
A&P), MCS Controller and Remote Panel
Service Manual, RENR2385, C18 Marine and
Marine Auxiliary Generator Set Engines
190 SEBU8013-01
Reference Information Section
Reference Materials

Special Publication, LEBM0189, Marine Power
Display Operator's Guide
Special Publication, LEDM5615, Caterpillar
Marine Parts and Service Locations Directory U.S.,
Canada, Mexico, and Caribbean
The Society of Automotive Engineers (SAE)
Specifications can be found in your SAE handbook.
This publication can also be obtained from the
following locations: local technological society, local
library, and local college. If necessary, consult SAE
at the following address:

Special Publication, NEHS0526, Service SAE International

Technician Application Guide
Special Publication, NENG2500, Cat Dealer
Service Tool Catalog
Special Publication, PECJ0003, Cat Shop Tools
and Supplies
Special Publication, PECP9067, One Safe Source
2008 - 2009 Parts Catalog
Special Instruction, REHS0354, Charging System
Troubleshooting for All Engines
Special Instruction, REHS1187, Marine Engine
Electronic Installation Guide
Special Publication, SEBF8029, Index to
Guidelines for Reusable Parts and Salvage
Operations
Special Publication, SEBU5898, Cold Weather
Recommendations
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
The American Petroleum Institute Publication No.
1509 can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:
American Petroleum Institute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.

Special Instruction, SEHS7332, Do Not Operate International Organization for Standardization

Tag (ISO)
1, rue de Varemb
Special Instruction, SEHS7633, Battery Test Case postale 56
Procedure CH-1211 Genve 20
Switzerland
Special Instruction, SEHS9031, Storage Telephone: +41 22 749 01 11
Procedure for Caterpillar Products Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
Specifications, SENR3130, Torque Specifications Web site: http://www.iso.ch

Special Publication, SENR5002, Installation Guide European classifications are established by the
for Marine Engine Electronic Displays Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
Additional Reference Material
The Engine Fluids Data Book can be obtained from CIMAC Central Secretariat
Lyoner Strasse 18
the following locations: local technological society,
60528 Frankfurt
local library, and local college. If necessary, consult
EMA at the following address: Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
Engine Manufacturers Association
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
E-mail: ema@enginemanufacturers.org
(312) 827-8700
Facsimile: (312) 827-8737
SEBU8013-01 191
Reference Information Section
Reference Materials

i03623818 Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
Decommissioning and documents as proof of repair for warranty:
Disposal
Dealer work orders and itemized bills
SMCS Code: 1000
Owner's repair costs
When the generator set is removed from service, local
regulations for the generator set decommissioning Owner's receipts
will vary. Disposal of the generator set will vary with
local regulations. Consult the nearest Caterpillar Maintenance log
dealer for additional information.

i00912149

Maintenance Records
SMCS Code: 1000

Caterpillar Inc. recommends the retention of accurate

maintenance records. Accurate maintenance records
can be used for the following purposes:

Determine operating costs.

Establish maintenance schedules for other engines
that are operated in the same environment.

Show compliance with the required maintenance

practices and maintenance intervals.

Maintenance records can be used for a variety of

other business decisions that are related to engine
maintenance.

Maintenance records are a key element of a

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

Records should be kept for the following items:

Fuel Consumption A record of fuel consumption

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

Service Hours A record of service hours is

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

Documents These items should be easy to

obtain, and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:
192 SEBU8013-01
Reference Information Section
Reference Materials

i01176304

Maintenance Log
SMCS Code: 1000

Table 25
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
SEBU8013-01
Index
A Control Panel (Marine Classification Society Control
After Starting Engine ............................................. 80
After Stopping Engine............................................ 84
Aftercooler Condensate Drain Valve -
Inspect/Clean...................................................... 112
Aftercooler Core - Clean/Test ............................... 112
Clean the Aftercooler Core ............................... 112
Test the Aftercooler Core .................................. 113
Air Starting............................................................. 81
Alternator - Inspect ............................................... 113
Auxiliary Water Pump (Bronze Impeller) -
Inspect ................................................................ 113
Auxiliary Water Pump (Rubber Impeller) -
Inspect ................................................................ 114
B Cooling Systems with Heavy Deposits or
Battery - Recycle .................................................. 114
Battery - Replace.................................................. 114
Battery Charger - Check....................................... 115
Battery Disconnect Switch (If Equipped) ............... 71
Battery Electrolyte Level - Check ......................... 115
Battery or Battery Cable - Disconnect .................. 115
Before Starting Engine .................................... 17, 78
Belts - Inspect/Adjust/Replace.............................. 116
Alternator Belt Adjustment ................................ 116
Inspection.......................................................... 116
Replacement..................................................... 116
Burn Prevention..................................................... 14
Batteries............................................................. 14
Coolant............................................................... 14
Oils..................................................................... 14
C Cooling System Supplemental Coolant Additive
Closed Crankcase Ventilation (CCV) Filter Service
Indicator - Inspect ............................................... 117
Closed Crankcase Ventilation (CCV) Fumes Disposal
Filter - Replace ................................................... 117
Replacing the Fumes Disposal Filter ................ 118
Resetting the Service Indicator ......................... 118
Cold Weather Operation........................................ 85
Hints for Cold Weather Operation...................... 85
Idling the Engine ................................................ 86
Recommendations for Coolant Warm Up .......... 86
Recommendations for the Coolant .................... 86
Viscosity of the Engine Lubrication Oil............... 86
Cold Weather Starting ........................................... 79
Configuration Parameters...................................... 74
Parameter Descriptions ..................................... 75
193
Index Section
Panel (MCS Control Panel) (Standard Panel, if
Equipped)) ........................................................... 42
General Information ........................................... 42
Help.................................................................... 55
List of Alarms ..................................................... 47
Menu .................................................................. 48
Start Engine and Stop Engine............................ 45
Control Panel (Marine Classification Society Remote
Control Panel (MCS Remote Control Panel) (If
Equipped)) ........................................................... 58
Alarms List ......................................................... 60
Home Button ...................................................... 61
Menu .................................................................. 61
Start and Stop Engines ...................................... 60
Symbols and Indication Icons ............................ 59
Cooling System Coolant (DEAC) - Change.......... 119
Plugging ......................................................... 121
Drain ................................................................. 119
Fill .................................................................... 121
Flush ................................................................ 120
Cooling System Coolant (ELC) - Change............ 122
Drain ................................................................ 122
Fill .................................................................... 123
Flush ................................................................ 123
Cooling System Coolant Extender (ELC) - Add... 124
Cooling System Coolant Level - Check ............... 125
Engines That Are Equipped with a Coolant
Recovery Tank ............................................... 125
Engines That Are Not Equipped with a Coolant
Recovery Tank ............................................... 125
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................ 126
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................ 127
(SCA) - Test/Add................................................ 127
Cooling Systems that Use Conventional
Coolant........................................................... 128
Cooling System Water Temperature Regulator -
Replace.............................................................. 128
Crankshaft Vibration Damper - Inspect ............... 129
Inspection......................................................... 129
Removal and Installation.................................. 129
Crushing Prevention and Cutting Prevention ........ 16
Customer Assistance........................................... 186
Outside of the USA and of Canada.................. 186
USA and Canada ............................................. 186
Customer Service ................................................ 186
D
Declaration of Conformity ...................................... 29
Decommissioning and Disposal .......................... 191
194
Index Section
E F
Electrical Connections - Check............................ 130
Electrical System ................................................... 18
Grounding Practices .......................................... 18
Electronic Modular Control Panel 3 (EMCP 3) (If
Equipped) ............................................................ 64
Annunciator Module ........................................... 66
Electronic Control Module 3 (ECMP3) ............... 64
Emergency Stopping ............................................. 83
Emergency Stop Button (If Equipped) ............... 83
Emissions Certification Film .................................. 30
Emissions Warranty Information.......................... 182
Engine - Clean..................................................... 130
Engine Air Cleaner Element - Clean/Replace ..... 130
Type 1 .............................................................. 130
Type 2 .............................................................. 131
Engine Air Cleaner Service Indicator - Inspect.... 131
Service the Air Cleaner Service Indicator ........ 132
Test the Air Cleaner Service Indicator.............. 132
Engine Crankcase Breather - Clean.................... 133
Engine Diagnostics................................................ 74
Engine Electronics................................................. 18
Engine Mounts - Inspect...................................... 133
Engine Oil and Filter - Change ............................ 136
Drain the Oil ..................................................... 136
Fill the Crankcase ............................................ 139
Inspect the Used Oil Filter Elements................ 139
Replace the Oil Filter Elements ....................... 137
Engine Oil Level - Check ..................................... 134
Engine Oil Level Gauge - Calibrate ..................... 134
Engine Oil Sample - Obtain ................................. 135
Obtain the Sample and the Analysis................ 135
Engine Operation................................................... 82
Engine Performance............................................ 185
Performance Analysis Report (PAR)................ 185
Engine Performance and Performance Analysis
Report (PAR) ..................................................... 185
Engine Rating Conditions .................................... 183
Engine Rating Definitions .................................... 183
Continuous Power............................................ 183
Emergency Standby Power ............................. 183
Prime Power .................................................... 183
Standby Power................................................. 183
Engine Ratings .................................................... 183
Engine Shutoffs and Engine Alarms...................... 71
Alarms................................................................ 71
Shutoffs.............................................................. 71
Testing the Shutoff and Alarm System............... 72
Engine Speed/Timing Sensor - Clean/Inspect..... 139
Camshaft Speed/Timing Sensor ...................... 140
Crankshaft Speed/Timing Sensor .................... 140
Engine Starting ................................................ 17, 78
Engine Stopping .............................................. 18, 83
Engine Storage Procedure - Check..................... 140
Engine Valve Lash - Inspect/Adjust ..................... 141
Adjustment of the Electronic Unit Injector ........ 141
Engine Valve Rotators - Inspect .......................... 141
SEBU8013-01
Features and Controls ........................................... 42
Fire Prevention and Explosion Prevention ............ 14
Ether .................................................................. 16
Fire Extinguisher ................................................ 16
Lines, Tubes, and Hoses ................................... 16
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 5
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4
Safety................................................................... 4
Fuel and the Effect from Cold Weather ................. 87
Fuel Conservation Practices.................................. 82
Fuel Injector - Inspect/Adjust ............................... 142
Fuel Related Components in Cold Weather .......... 88
Fuel Filters ......................................................... 88
Fuel Heaters ...................................................... 88
Fuel Tanks.......................................................... 88
Fuel System - Prime ............................................ 142
The Engine Has Been Rebuilt.......................... 143
The Engine Has Been Run Out of Fuel ........... 143
The Secondary Fuel Filter Has Been
Replaced ........................................................ 142
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................. 144
Replace the Element........................................ 144
Fuel System Primary Filter/Water Separator -
Drain .................................................................. 145
Fuel System Secondary Filter - Replace ............. 146
Replacing the Fuel Filter Elements During Engine
Operation For Engines That Are Equipped With
Duplex Fuel Filters ......................................... 147
Replacing the Fuel Filter Elements with the Engine
Stopped.......................................................... 146
Fuel Tank Water and Sediment - Drain ............... 150
Drain the Water and the Sediment................... 150
Fuel Storage Tanks .......................................... 151
Fuel Tank ......................................................... 150
G
Gauges and Indicators .......................................... 40
General Hazard Information ................................... 11
Asbestos Information ......................................... 13
Containing Fluid Spillage ................................... 12
Dispose of Waste Properly ................................ 14
Fluid Penetration................................................ 12
Lines, Tubes, and Hoses ................................... 13
Pressurized Air and Water ................................. 12
General Maintenance Information ....................... 104
Generator - Dry.................................................... 151
Circulating Current ........................................... 153
External Heat ................................................... 152
Internal Heating................................................ 153
SEBU8013-01
Generator - Inspect.............................................. 153
Cleaning (Assembled Generators)................... 154
Cleaning (Disassembled Generators).............. 154
Generator Bearing - Inspect/Replace (SR4
Generator) ......................................................... 154
Inspect ............................................................. 154
Replace............................................................ 154
Generator Bearing - Lubricate ............................. 155
Additional Information ...................................... 155
Lubricating Process (If Applicable) .................. 155
Generator Bearing Temperature - Measure/
Record ............................................................... 155
Generator Isolating for Maintenance ..................... 19
Generator Lead Connections ................................ 30
Grounding the Frame......................................... 31
Lead Numbering ................................................ 30
Multiple Units ..................................................... 31
Neutral Connections .......................................... 31
Parallel to a Utility .............................................. 31
Single Units........................................................ 31
Generator Load - Check ...................................... 155
Generator Operation.............................................. 90
Block Loading .................................................... 90
Excitation System .............................................. 91
Generator Options ............................................. 92
Loading of the Generator ................................... 90
Low Idle Adjustment........................................... 91
Power Factor...................................................... 91
Standby Generator Sets .................................... 91
Generator Set - Test ............................................ 156
Generator Set Alignment - Check (Generator
Sets) .................................................................. 157
Generator Set Installation...................................... 38
Alignment ........................................................... 39
Bearing Inspection ............................................. 38
Electrical Measurements.................................... 39
Location ............................................................. 38
Protective Devices ............................................. 39
Receiving Inspection.......................................... 38
Storage .............................................................. 38
Unpacking and Storage ..................................... 38
Generator Set Vibration - Inspect ........................ 157
Generator Start-up Checklist ............................... 107
H Inspection, Reconditioning, or Exchanging of
Heat Exchanger - Inspect .................................... 158
Cleaning Procedure ......................................... 158
Hoses and Clamps - Inspect/Replace ................. 159
Inspect the Hoses and the Clamps .................. 159
Replace the Hoses and the Clamps ................ 160
Important Safety Information ................................... 2
Installation ............................................................. 38
195
Index Section
Insulation - Test ................................................... 162
Recommended Periodic Insulation Tests......... 162
Recommended Procedure for the Insulation
Test................................................................. 162
L
Lifting and Storage ................................................ 34
M
Maintenance Interval Schedule ............................ 110
Maintenance Log ................................................. 192
Maintenance Recommendations ................. 104, 165
Maintenance Information ................................. 165
Oil Consumption as an Overhaul Indicator ...... 166
Overhaul Information ....................................... 166
Maintenance Records.......................................... 191
Maintenance Section ............................................. 96
Manual Stop Procedure......................................... 84
Automatic Stopping............................................ 84
Manual Stop Procedure (If Equipped with Marine
Classification Society Control Unit (MCS Control
Unit)) .................................................................... 83
Marine Classification Society Certification
Requirements .................................................... 183
Model View Illustrations................................... 20, 22
Model Views .......................................................... 20
Mounting and Dismounting.................................... 17
O
Oil Cooler Core - Check/Clean/Test (If
Equipped) .......................................................... 167
Clean the Oil Cooler Core................................ 167
Test the Oil Cooler Core................................... 167
On-Board Replacement Parts ............................. 187
Operation Section.................................................. 34
Ordering Replacement Parts ............................... 187
Overhaul (Major).................................................. 167
Cleaning of Components ................................. 169
Inspection of Components ............................... 169
Components................................................... 168
Obtain a Coolant Analysis................................ 169
Replacement of Components .......................... 168
Overhaul (Top End) ............................................. 170
196
Index Section
P Sensors and Electrical Components (Engines
Parallel Operation.................................................. 92
Circulating Currents ........................................... 95
Initial Start-Up .................................................... 92
Load Division and Speed Droop (If Equipped)... 94
Parallel Operation Of Governors........................ 94
Paralleling Multiple Units.................................... 93
Starting Multiple Units ........................................ 93
Stopping............................................................. 95
Plate Locations and Film Locations....................... 27
Engine Information (3) ....................................... 27
Engine Serial Number (2) .................................. 27
Serial Number Plate for the Generator (1) ......... 27
Power Factor - Check.......................................... 171
Product Description ............................................... 24
Description of the Generator.............................. 26
Engine Description............................................. 24
Product Identification Information .......................... 27
Product Information Section .................................. 20
Product Lifting........................................................ 34
Lifting the Engine Only....................................... 34
Lifting the Entire Package .................................. 34
Lifting the Generator Only.................................. 34
Product Storage..................................................... 34
Additional Information ........................................ 37
Engine................................................................ 34
Generator........................................................... 36
R Cleaning and Inspecting .................................. 175
Reference Information Section ............................ 183
Reference Material .............................................. 189
Additional Reference Material.......................... 190
Coolants........................................................... 189
Diesel Engine Oils............................................ 189
Fuels ................................................................ 189
Greases ........................................................... 189
Miscellaneous .................................................. 189
SOS Services................................................. 189
Reference Materials ............................................ 189
Reference Numbers .............................................. 28
Record for Reference......................................... 28
Refill Capacities..................................................... 96
Refill Capacities and Recommendations............... 96
Cooling System................................................ 101
Diesel Engine Oil ............................................... 96
Fuel .................................................................... 98
Grease ............................................................. 103
Rotating Rectifier - Check.................................... 171
Rectifier Block Test .......................................... 172
Testing A Brushless Exciter Rotating Rectifier With
An Ohmmeter................................................. 171
S Welding on Engines with Electronic Controls ......
Safety Messages ..................................................... 6
Safety Section ......................................................... 6
Sea Water Strainer - Clean/Inspect ..................... 173
SEBU8013-01
Equipped with MCS Control Unit) ........................ 68
Single Unit Operation ............................................ 92
Initial Start-Up .................................................... 92
Starting............................................................... 92
Stopping............................................................. 92
Standby Generator Set Maintenance
Recommendations............................................. 173
Maintenance and Operation Procedures ......... 173
Starting Motor - Inspect ....................................... 174
Air Starting Motor ............................................. 174
Electric Starting Motor...................................... 174
Removal and Installation of the Starting
Motor .............................................................. 174
Starting the Engine (EMCP 3 (If Equipped)).......... 79
Starting the Engine (If Equipped with Marine
Classification Society Control Unit (MCS Control
Unit)) .................................................................... 79
Stator Lead - Check............................................. 174
Stator Winding Temperature - Measure/Record .. 175
System Pressure Release ................................... 104
Coolant System................................................ 104
Engine Oil ........................................................ 105
Fuel System ..................................................... 104
T
Table of Contents..................................................... 3
Turbocharger - Inspect ........................................ 175
Removal and Installation.................................. 175
V
Varistor - Test....................................................... 176
Ohmmeter ........................................................ 176
Test Light.......................................................... 177
Voltage and Frequency - Check .......................... 177
Voltage Connections.............................................. 31
Single-Phase Current From a Three-Phase
Generator ......................................................... 32
Three-Phase Voltage Connections .................... 31
Voltage Regulators ................................................ 72
Cat Digital Voltage Regulator (Cat DVR) ........... 72
W
Walk-Around Inspection ...................................... 177
Inspect the Engine for Leaks and for Loose
Connections ................................................... 177
Warranty Information ........................................... 182
Warranty Section ................................................. 182
Water Pump - Inspect .......................................... 178
105
Winding - Test...................................................... 178
SEBU8013-01 197
Index Section

Zinc Rods - Inspect/Replace ............................... 179

Inspect the Zinc Rods ...................................... 181
Locations of the Zinc Rods .............................. 179
Replace the Zinc Rods..................................... 181
198 SEBU8013-01
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section Product Identification Information in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
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