G3516C

SEBU7681-22 (en-us)
November 2016
Operation and
Maintenance
Manual
G3500 Generator Sets
CWW 1-UP (Generator Set) F6F 1-UP (Generator Set)
CWY 1-UP (Generator Set) F6G 1-UP (Generator Set)
TJB 1-UP (Generator Set) FZA 1-UP (Generator Set)
TJC 1-UP (Generator Set) FZB 1-UP (Generator Set)
B9P 1-UP (Generator Set) FZC 1-UP (Generator Set)
MAD 1-UP (Generator Set) FZD 1-UP (Generator Set)
HAT 1-UP (Generator Set) FZE 1-UP (Generator Set)
HAL 1-UP (Generator Set) FZF 1-UP (Generator Set)
SLY 1-UP (Generator Set) FZG 1-UP (Generator Set)
SXY 1-UP (Generator Set) SB3 1-UP (Generator Set)
GZN 1-UP (Generator Set) F6M 1-UP (Generator Set)
GZM 1-UP (Generator Set) NWD 1-UP (Engine)
GZL 1-UP (Generator Set)
GZZ 1-UP (Generator Set)
GSB 1-UP (Generator Set)
GAS 1-UP (Generator Set)
GZK 1-UP (Generator Set)
GZJ 1-UP (Generator Set)
GZH 1-UP (Generator Set)
GZG 1-UP (Generator Set)
RLP 1-UP (Generator Set)
LGS 1-UP (Generator Set)
GZA 1-UP (Generator Set)
GZB 1-UP (Generator Set)
GZC 1-UP (Generator Set)
GYM 1-UP (Engine)
NGS 1-UP (Generator Set)
F6D 1-UP (Generator Set)
F6E 1-UP (Generator Set)
SAFETY.CAT.COM
i06558969
Important Safety Information

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

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

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7681-22 3
Table of Contents
Table of Contents Engine Stopping .............................................. 57
Foreword ........................................................... 4 Maintenance Section
Refill Capacities............................................... 59
Safety Section
Maintenance Recommendations .................... 62
Safety Messages............................................... 5
Maintenance Interval Schedule (Prime).......... 68
General Hazard Information.............................. 8
Maintenance Interval Schedule (Standby)...... 70
Burn Prevention................................................11
Maintenance Interval Schedule....................... 72
Fire Prevention and Explosion Prevention...... 12
Crushing Prevention and Cutting Prevention.. 13
Mounting and Dismounting ............................. 14
Ignition Systems .............................................. 14 Reference Information Section
Before Starting Engine .................................... 14 Customer Service.......................................... 138
Engine Starting................................................ 14 Reference Materials ...................................... 140
Engine Stopping .............................................. 15 Index Section
Electrical System............................................. 15 Index.............................................................. 148
Generator Isolating for Maintenance............... 15
Product Information Section
General Information ........................................ 17
Product Identification Information ................... 20
Operation Section
Lifting and Storage .......................................... 23
Installation ....................................................... 25
Features and Controls..................................... 27
Engine Diagnostics ......................................... 40
Engine Starting................................................ 42
Engine Operation ............................................ 47
Generator Operation ....................................... 48

4 SEBU7681-22
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This frequent lubrication and maintenance than is
manual should be stored in or near the engine area in specified in the Maintenance Interval Schedule may
a literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design Maintenance Intervals
may have caused changes to your engine which are
not included in this manual. Whenever a question Perform maintenance on items at multiples of the
arises regarding your engine, or this manual, please original requirement. Each level and/or individual
consult with your Cat dealer for the latest available items in each level should be shifted ahead or back
information. depending upon your specific maintenance practices,
operation and application. We recommend that the
maintenance schedules be reproduced and
Safety displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
This safety section lists basic safety precautions. In maintained as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, Maintenance Records for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more
efficiently and economically. Skill and techniques Major engine overhaul details are not covered in the
develop as the operator gains knowledge of the Operation and Maintenance Manual except for the
engine and its capabilities. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
The operation section is a reference for operators. authorized Cat dealer. Your Cat dealer offers a
variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.
Maintenance California Proposition 65 Warning

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped Diesel engine exhaust and some of its constituents
by fuel consumption, service hours and/or calendar are known to the State of California to cause cancer,
time maintenance intervals. Items in the maintenance birth defects, and other reproductive harm.
schedule are referenced to detailed instructions that
follow. Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
Use fuel consumption or service hours to determine after handling.
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
SEBU7681-22 5
Safety Section
Safety Messages
Safety Section
i03624588
Safety Messages
SMCS Code: 1000; 7405
Illustration 1 g01944213
There are several specific safety messages on this

engine. The exact location of the safety messages
and the description of the safety messages are
reviewed in this section. Please become familiarized
with all safety messages.
6 SEBU7681-22
Safety Section
Safety Messages
Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
safety messages if the illustrations are not legible.
When you clean the safety messages, use a cloth,
water and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part that
is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
Read the Manual (1)

This safety message is located on the face of the
EMCP II. WARNING! Shock/Electrocution Hazard! Read
and understand the instructions and warnings in
the Operation and Maintenance Manual. Failure
to follow the instructions or heed the warnings
could cause serious injury or death.
Hot Surface (3)

This safety message for hot surfaces is located on
the barrel of the generator.
Do not operate or work on this engine or genera-

tor set unless you have read and understand the
instructions and warnings in the Operation and
Maintenance Manuals.
Failure to follow the warnings and instructions
could result in injury or death. Contact any Cater-
pillar dealer for replacement manuals. Proper
care is your responsibility.
Electrical Shock (2)

This safety message for electrical shock is located on
the base of the valve cover. This safety message is
also located on the face of the EMCP II.
SEBU7681-22 7
Safety Section
Safety Messages
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
Hot surfaces inside enclosure. Keep hands back. 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
Hot Surface (4) system and isolation may not be required.
Always check with your utility for the applicable
This safety message for hot surfaces is located on circumstances.
the valve cover.
Automatic Starting (6)

This safety message for automatic starting is located
on the covers of the generator.
Hot surface! Do not touch!
Electrical Distribution (5)

This safety message for electrical distribution
(generator) is located on the covers of the generator.
8 SEBU7681-22
Safety Section
General Hazard Information
When the engine is in the AUTOMATIC mode, the

engine can start at any moment. To avoid person-
al injury, always remain clear of the the engine Illustration 9 g01433231
when the engine is in the AUTOMATIC mode.
Lifting the Genset (7) Crushing Hazard! Improper lifting could cause
serious injury or death. Follow the lifting instruc-
This safety message for lifting the genset is located tions in the Operation and Maintenance Manual
on the side panels of the generator. for safe lifting procedures.
i04076154

SMCS Code: 1000; 4450; 7405
.Attach a Do Not Operate warning tag to the start

switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to
each operator control station. When appropriate,
disconnect the starting controls.
SEBU7681-22 9
Safety Section
Do not allow unauthorized personnel on the engine, Report all necessary repairs.
or around the engine when the engine is being
serviced. Unless other instructions are provided, perform
the maintenance under the following conditions:
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the The engine is stopped. Ensure that the engine
engine and operate the engine in a well ventilated cannot be started.
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside. The protective locks or the controls are in the
applied position.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids, Disconnect the batteries when maintenance is
hold a rag over the part that is being removed. performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Filler caps Tape the leads in order to help prevent sparks.
Grease fittings When starting a new engine or an engine which
Pressure taps has not been started since service has been
performed, make provisions to stop the engine if
Breathers an overspeed occurs. Shutting down the engine
may be accomplished by shutting off the fuel
Drain plugs supply and/or the air supply to the engine.
Use caution when cover plates are removed. Do not attempt any repairs that are not
Gradually loosen, but do not remove the last two understood. Use the proper tools. Replace any
bolts or nuts that are located at opposite ends of the equipment that is damaged or repair the
cover plate or the device. Before removing the last equipment.
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure. Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
California Proposition 65 Warning
Some engine exhaust constituents are known to the
State of California to cause cancer, birth defects, and
other reproductive harm.
Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.
When pressurized air and/or pressurized water is
Wear a hard hat, protective glasses, and other used for cleaning, wear protective clothing, protective
protective equipment, as required. shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
When work is performed around an engine that is
operating, wear protective devices for ears in
order to help prevent damage to hearing.
Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine.
Ensure that all protective guards and all covers

are secured in place on the engine.
Never put maintenance fluids into glass
containers. Glass containers can break.
Use all cleaning solutions with care.
10 SEBU7681-22
Safety Section
The maximum air pressure for cleaning purposes Repair any fuel lines, oil lines, tubes, or hoses that
must be reduced to 205 kPa (30 psi) when the air are loose or damaged. Leaks can cause fires.
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective Inspect all lines, tubes, and hoses carefully. Do not
equipment. The maximum water pressure for use bare hands to check for leaks. Always use a
cleaning purposes must be below 275 kPa (40 psi). board or cardboard for checking engine components
Always wear eye protection for cleaning the cooling for leaks. Tighten all connections to the
system. recommended torque.
Check for the following conditions:
Fluid Penetration
End fittings that are damaged or leaking
Outer covering that is chafed or cut
Wire that is exposed in reinforced hose

Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed

Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct
installation of these components will help to prevent
these effects: vibration, rubbing against other parts
and excessive heat during operation.
Inhalation
Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids. Illustration 13 g02159053
Refer to Special Publication, NENG2500, Cat Dealer

Service Tool Catalog or refer to Special Publication, Exhaust
PECJ0003, Cat Shop Supplies and Tools Catalog
for tools and supplies suitable to collect and contain Use caution. Exhaust fumes can be hazardous to
fluids on Cat products. your health. If you operate the equipment in an
enclosed area, adequate ventilation is necessary.
Dispose of all fluids according to local regulations
and mandates. Asbestos Information
Caterpillar equipment and replacement parts that are
Lines, Tubes, and Hoses shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
Do not bend or strike high-pressure lines. Do not replacement parts. Use the following guidelines when
install lines, tubes, or hoses that are damaged. you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
SEBU7681-22 11
Safety Section
Burn Prevention
Use caution. Avoid inhaling dust that might be Reference: The applicable material safety data
generated when you handle components that contain sheets can be found at the following web site by
asbestos fibers. Inhaling this dust can be hazardous searching by the part number or the name of the
to your health. The components that may contain product:
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The http://dsf2ws.cat.com/msds/servlet/
asbestos that is used in these components is usually cat.cis.ecs.msdsSearch.controller.
bound in a resin or sealed in some way. Normal UserIdentificationDisplayServlet
handling is not hazardous unless airborne dust that
contains asbestos is generated.
Dispose of Waste Properly
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. Illustration 14 g00706404
Wear an approved respirator if there is no other Improperly disposing of waste can threaten the
way to control the dust. environment. Potentially harmful fluids should be
disposed of according to local regulations.
Comply with applicable rules and regulations for
the work place. In the United States, use Always use leakproof containers when you drain
Occupational Safety and Health Administration fluids. Do not pour waste onto the ground, down a
(OSHA) requirements. These OSHA requirements drain, or into any source of water.
can be found in 29 CFR 1910.1001.
i01480768
Obey environmental regulations for the disposal of
asbestos. Burn Prevention
Stay away from areas that might have asbestos SMCS Code: 1000; 4450; 7405
particles in the air.
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
Softwrap performed on the engine. Relieve all pressure in the
air system, in the hydraulic system, in the lubrication
Keep the engine room ventilation operating at full system, in the fuel system, or in the cooling system
capacity. Wear a National Institute of Occupational before any lines, fittings or related items are
Safety and Health (NIOSH) approved particulate disconnected.
respirator. Wear appropriate protective clothing in
order to minimize direct contact. Use good hygiene
practices and wash hands thoroughly after handling Coolant
Softwrap. Do not smoke until washing hands
When the engine is at operating temperature, the
thoroughly after handling Softwrap. Clean up debris
engine coolant is hot. The coolant is also under
with a vacuum or by wet sweeping. Do not use
pressure. The radiator and all lines to the heaters or
pressurized air to clean up debris. to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
12 SEBU7681-22
Safety Section
Fire Prevention and Explosion Prevention
Ensure that the filler cap is cool before removing the Determine whether the engine will be operated in an
filler cap. The filler cap must be cool enough to touch environment that allows combustible gases to be
with a bare hand. Remove the filler cap slowly in drawn into the air inlet system. These gases could
order to relieve pressure. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact If the application involves the presence of
the skin, the eyes, or the mouth. combustible gases, consult your Cat dealer for
additional information about suitable protection
Oils devices.
Remove all flammable materials such as fuel, oil, and
Hot oil and hot lubricating components can cause debris from the engine. Do not allow any flammable
personal injury. Do not allow hot oil to contact the materials to accumulate on the engine.
skin. Also, do not allow hot components to contact
the skin. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
Batteries oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
Electrolyte is an acid. Electrolyte can cause personal storing flammable materials.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for Do not expose the engine to any flame.
servicing batteries. Wash hands after touching the Exhaust shields (if equipped) protect hot exhaust
batteries and connectors. Use of gloves is components from oil or fuel spray in a line, a hose, or
recommended. a seal failure. Exhaust shields must be installed
correctly.
i04823690
Do not weld on lines or tanks that contain flammable
Fire Prevention and Explosion fluids. Do not flame cut lines that contain flammable
fluid. Clean any such lines thoroughly with a
Prevention nonflammable solvent prior to welding or flame
cutting.
SMCS Code: 1000; 4450; 7405
Wiring must be kept in good condition. Ensure that all
electrical wires are properly routed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
All fuels, most lubricants, and some coolant mixtures hoses must have adequate support and secure
are flammable. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a Properly install all oil filters and fuel filters. The filter
fire. Fire may cause personal injury and property housings must be tightened to the proper torque.
damage.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
SEBU7681-22 13
Safety Section
Crushing Prevention and Cutting Prevention
Check lines, tubes, and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
End fittings are damaged or leaking.

Outer coverings are chafed or cut.
Wires are exposed.

Outer coverings are ballooning.
Flexible parts 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 to prevent vibration, rubbing
against other parts, and excessive heat.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do i01359666
not smoke in battery charging areas.
Crushing Prevention and
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a Cutting Prevention
hydrometer.
SMCS Code: 1000; 4450; 7405
Improper jumper cable connections can cause an Support the component properly when work beneath
explosion that can result in injury. Refer to the the component is performed.
Operation Section of this manual for specific
instructions. Unless other maintenance instructions are provided,
Do not charge a frozen battery. Charging a frozen never attempt adjustments while the engine is
battery may cause an explosion. running.
The batteries must be kept clean. The covers (if Stay clear of all rotating parts and of all moving parts.
equipped) must be kept on the cells. Use the Leave the guards in place until maintenance is
recommended cables, connections, and battery box performed. After the maintenance is performed,
covers when the engine is operated. reinstall the guards.
Keep objects away from moving fan blades. The fan
Fire Extinguisher blades will throw objects or cut objects.
Make sure that a fire extinguisher is available. Be When objects are struck, wear protective glasses in
familiar with the operation of the fire extinguisher. order to avoid injury to the eyes.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations Chips or other debris may fly off objects when objects
on the instruction plate. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
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 Cat dealer for repair or
for replacement parts.
14 SEBU7681-22
Safety Section
Mounting and Dismounting
i01377941 Before starting the engine, ensure that no one is on,

underneath, or close to the engine. Ensure that the
Mounting and Dismounting area is free of personnel.
SMCS Code: 1000; 4450; 7405 Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure that
Generator sets in permanent installations may all lights work properly.
require the use of a ladder or a work platform in order
to provide access for normal maintenance. The All protective guards and all protective covers must
owner and/or the user is responsible for providing be installed if the engine must be started in order to
safe access that conforms to SAE J185 and/or local perform service procedures. To help prevent an
building codes. accident that is caused by parts in rotation, work
around the parts carefully.
Inspect the steps, the handholds, and the work area
before mounting the generator set. Keep these items Do not bypass the automatic shutoff circuits. Do not
clean and keep these items in good repair. disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
Mount the generator set and dismount the generator circuits are also provided in order to help prevent
set only at locations that have steps and/or engine damage.
handholds. Do not climb on the generator set, and do
not jump off the generator set. On the initial start-up of a new engine or an engine
that has been serviced, be prepared to stop the
Face the generator set in order to mount the engine if an overspeed condition occurs. This may be
generator set or dismount the generator set. Maintain accomplished by shutting off the fuel supply to the
a three-point contact with the steps and handholds. engine, or shutting off the ignition system.
Use two feet and one hand or use one foot and two
hands. Do not use any controls as handholds. See the Service Manual for repairs and for
adjustments.
Do not jump from an elevated platform. Do not jump
from a ladder or stairs.
i02136012
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work Engine Starting
platform. Secure the climbing equipment so that the
equipment will not move. SMCS Code: 1000
Do not carry tools or supplies when you mount the If a warning tag is attached to the engine start switch
generator set or when you dismount the generator or to the controls, DO NOT start the engine or move
set. Use a hand line to raise and lower tools or the controls. Consult with the person that attached
supplies. the warning tag before the engine is started.
All protective guards and all protective covers must
i00702251
be installed if the engine must be started in order to
perform service procedures. To help prevent an
Ignition Systems accident that is caused by parts in rotation, work
SMCS Code: 1550 around the parts carefully.
Ignition systems can cause electrical shocks. Avoid If there is a possibility that unburned gas remains in
contacting the ignition system components and the exhaust system, refer to the purge procedure in
wiring. this Operation and Maintenance Manual, Engine
Starting topic in the Operation Section.
Do not attempt to remove the valve covers when the
engine is operating. The transformers are grounded Start the engine from the operator's compartment or
to the valve covers. Personal injury or death may from the engine start switch.
result and the ignition system will be damaged if the
valve covers are removed during engine operation. Always start the engine according to the procedure
The engine will not operate without the valve covers. that is described in the Operation and Maintenance
Manual, Engine Starting topic in the Operation
Section. Knowing the correct procedure will help to
i00659904 prevent major damage to the engine components.
Knowing the procedure will also help to prevent
Before Starting Engine personal injury.
SMCS Code: 1000 To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Inspect the engine for potential hazards. properly, check the water temperature and the oil
temperature during heater operation.
SEBU7681-22 15
Safety Section
Engine Stopping
Engine exhaust contains products of combustion Ground the engine block with a ground strap that is
which can be harmful to your health. Always start the furnished by the customer. Connect this ground strap
engine and operate the engine in a well ventilated to the ground plane.
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside. Use a separate ground strap to ground the battery
negative terminal for the control system to the ground
i00659907
plane.
Rubber couplings may connect the steel piping of the
Engine Stopping cooling system and the radiator. This causes the
piping and the radiator to be electrically isolated.
SMCS Code: 1000
Ensure that the piping and the radiator is
To avoid overheating of the engine and accelerated continuously grounded to the engine. Use ground
wear of the engine components, stop the engine straps that bypass the rubber couplings.
according to the instructions in this Operation and
Ensure that all grounds are secure and free of
Maintenance Manual, Engine Stopping topic
corrosion.
(Operation Section).
Use the Emergency Stop Button (if equipped) ONLY i06795266
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping. Generator Isolating for
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop Maintenance
has been corrected. SMCS Code: 4450
On the initial start-up of a new engine or an engine When you service an electric power generation set or
that has been serviced, make provisions to stop the when you repair an electric power generation set,
engine if an overspeed occurs. This may be
follow the procedure below:
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system. 1. Stop the engine.
i02896515
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started.
Grounding Practices Illustration 17 g00104545
Proper grounding is necessary for optimum engine 2. Attach a DO NOT OPERATE or similar warning
performance and reliability. Improper grounding will tag to the engine prime mover starting circuit.
result in uncontrolled electrical circuit paths and in Disconnect the engine starting circuit.
unreliable electrical circuit paths.
3. Disconnect the generator from the distribution
Uncontrolled electrical circuit paths can result in system.
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components. 4. Lock out the circuit breaker. Attach a DO NOT
Uncontrolled electrical circuit paths can also cause OPERATE or similar warning tag to the circuit
electrical activity that may degrade the engine breaker. Refer to the electrical diagram. Verify that
electronics and communications. all points of possible reverse power flow have
Use a ground strap to ground the case of all control been locked out.
panels to the engine block.
5. For the following circuitry, remove the
transformer's fuses:
16 SEBU7681-22
Safety Section
Generator Isolating for Maintenance
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 to verify that
the generator is de-energized. This tester must be
insulated for the proper voltage rating. Follow all
guidelines to verify that the tester is operational.
9. Determine that the generator is in a de-energized
condition. Add ground straps to the conductors or
terminals. During the entire work period, these
ground straps must remain connected to the
conductors and to the terminals.
SEBU7681-22 17
General Information
Product Information
Section
General Information
i03676402
Model View Illustrations

SMCS Code: 1000
The illustrations show various typical features of
G3500C and G3500E Generator Sets. The
illustrations do not show all of the options that are
available.
18 SEBU7681-22
Product Description
Typical Example
(1) Oil filler (6) Throttle (11) Fuel inlet

(2) Engine control module (7) Aftercooler drains (12) Fuel metering valve
(3) Jacket water outlet (8) Oil filters (13) Air inlet
(4) Lifting eyes (9) Oil level gauge (dipstick) (14) Exhaust stack
(5) Aftercooler (10) Jacket water inlet (15) Oil drain
i03676743
Product Description
SMCS Code: 1000; 4450; 4491
The Generator Set consists of an engine, a
generator, and a control system.
SEBU7681-22 19
Product Description
Intended Use Lubrication System

This Power Generator is intended to be used to The engine lubrication oil is circulated by a gear-
generate electrical power. driven pump. The oil is cooled and filtered. A bypass
valve provides unrestricted flow of lubrication oil to
Engine Description the engine parts if the oil filter elements become
plugged.
Fuel System (Air/Fuel Ratio Control)
Cooling System
The fuel system includes these components:
The cooling system uses a water pump. The cooling
Fuel metering valve system has temperature regulators that regulate the
temperature of the coolant. The temperature
Engine control module (ECM) depends on the application.
Inlet Manifold Pressure Sensor The turbocharged engine has a Separate Circuit
Aftercooler (SCAC). The temperature depends on
Load Signal the engine rating and the application.
Inlet manifold temperature sensor The circuit for the aftercooler may be combined or the
circuit for the aftercooler may be separate circuits. In
The fuel metering valve controls the flow of fuel to the the combined system, a pump circulates water
engine. The ECM determines the requirement for the through both the aftercooler and oil cooler cores. The
mixture of air and fuel. The ECM sends a signal to combined system uses a thermostatic control to
the fuel metering valve. The fuel metering valve regulate the oil temperature. This prevents
controls the volume of the gas flow to the engine. overcooling.
The fuel flows through the fuel metering valve into the For a more detailed description, refer to the Systems
air inlet elbow. The mixture of air and fuel flows Operation/Testing and Adjusting manual.
through the turbocharger compressor. The air/fuel
mixture is cooled in the aftercooler. The mixture Description of the Generator
enters the manifold through a throttle which is
electronically controlled.
The SR4B brushless generator can be used with the
The ECM sends an electronic throttle signal to the following loads: mixed loads of motors and lights,
electronic actuator. The throttle is controlled by the SCR-controlled equipment, computer centers and
actuator. petroleum drilling applications.
The generator set packages can be utilized for prime
Ignition System power generation or standby power generation.
The engine is equipped with an electronic ignition SR4B generators are utilized in three-phase full-
system. The system provides dependable firing and wave excitation and regulation. The generators are
low maintenance. The system provides precise either four pole or six pole design. The generators
control of the spark and the ignition timing for each have six lead configuration or twelve lead
cylinder. configuration. The generators are capable of
producing electrical power in either 50 Hz or 60 Hz
The system also provides diagnostic capability that applications.
enhances troubleshooting.
The engines are equipped with protection from Island Mode and Coal Mine
detonation. A detonation sensor is located between Methane (CMM) application
every two cylinders. The ignition timing is retarded for
a cylinder when excessive detonation is sensed in
that cylinder. If the maximum retarded position is Island Mode refers to an application for Generator
attained and detonation continues to occur, the ECM Sets that is not paralleled to a public utility. In this
shuts down the engine. operational state, the gas engine must maintain
torque and crankshaft speed during steady state
The engines are equipped with flame arresters. The operations.
flame arresters are located at the entrance of each
inlet port. If the engine backfires, the flame arresters The Coal Mine Methane (CMM) application is a
prevent the fire from entering the air/fuel mixture. generator package that makes use of methane gas
that is embedded in coal mines. The methane gas is
used as fuel for the Generator Sets.
20 SEBU7681-22
Product Identification Information
Product Identification Full load RPM
Information Engine Serial Number (2)

i02022372 The Engine Serial Number Plate is on the left side of
the cylinder block near the rear of the engine.
Plate Locations and Film The Engine Serial Number Plate contains the
Locations following information:
SMCS Code: 1000; 4450 Engine serial number
Engine model number
Arrangement number
Generator Identification (3)

The generator identification is located on the left side
of the generator.
The generator identification film includes the
following information:
Generator serial number

Generator model number
Generator set rating
i05819574
Engine Information (1)

The Engine Information Plate is on the left side of the
engine near the front of the block between the
number 2 cylinder and the front housing.
The Engine Information Plate contains the following
information:
Engine serial number
Arrangement number
Compression ratio
Aftercooler temperature
Power
Declaration of Conformity
SEBU7681-22 21
Declaration of Conformity
SMCS Code: 1000
Table 1
An EC Declaration of Conformity document was provided with the product if the product was manufactured to comply with specific requirements
for the European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity pro-
vided with the product. The extract shown below from an EC Declaration of Conformity for product that are declared compliant to 2006/42/EC
applies only to those products originally CE marked by the manufacturer listed and which have not since been modified.
EC DECLARATION OF CONFORMITY OF MACHINERY
Manufacturer:CATERPILLAR INC. 100 N.E. ADAMS STREET PEORIA, IL 61629 USA
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:
Standards & Regulations Manager,Caterpillar France S.A.S 40,

Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France
I, the undersigned, _________, hereby certify that the construction equipment specified hereunder
Description: Generic Denomination: Power Generation Equipment
Function: Power Generator
Model/Type: G3500C
Serial Number:
Commercial Name: Caterpillar
Fulfills all the relevant provisions of the following Directives
Directives Notified Body Document No.
2006/42/EC N/A
2006/95/EC N/A
2004/108/EC N/A
2000/14/EC amended by 2005/88/EC, Note (1) Note (2)
Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)
Representative Equipment Type Sound Power Level - _____dB (A)
Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File
Note (2) Notified body name and address
Done at: Signature
Date: Name/Position
Note: The above information was correct as of October, 2009, but may be subject to change. Refer to the individual declaration of conformity is-
sued with the machine for exact details.
22 SEBU7681-22
Reference Information
i01934436
Reference Information
SMCS Code: 1000; 4450
Identification of the items in Table 2 may be needed
in order to obtain parts and service. Some of the
numbers are on the engine Serial Number Plate and/
or Information Plate. Locate the information for your
engine. Record the information on the appropriate
space in Table 2 . Make a copy of this list for a
record. Retain the information for future reference.
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement
number.
The packaging arrangement may also be called a
pricing arrangement or a customer arrangement.
This is the total package with attachments and
options that are not included in the engine
arrangement.
The performance specification can be used by your
Caterpillar dealer with the Technical Marketing
Information system. Before the engine leaves the
factory, the engine performance is tested. Detailed
performance data is recorded. The performance
specification number can be used for obtaining the
data.
Table 2
Reference Numbers
Engine Model
Generator Set Serial Number

Engine Serial Number
Generator Serial Number

Arrangement Number
Packaging Arrangement
Turbocharger
Fuel Filter Element

Fuel Pressure Regulator
Oil Filter Element

Air Cleaner Element
Alternator Belt
Capacity of the Lubrication
System
Capacity of the Cooling System
Performance Specification
Number
Low Idle rpm
High Idle rpm
Power Rating
SEBU7681-22 23
Operation Section
Lifting and Storage
Operation Section Lifting the Entire Package

Do NOT use the engine lifting eyes or the
generator lifting eyes to lift the entire package.
Lifting and Storage Lifting points (3) and (4) have been provided for lifting
the entire package. However, lifting the engine and
i03643380
the generator together requires special equipment
and procedures. Consult your Caterpillar dealer for
information regarding fixtures for proper lifting of your
Product Lifting complete package.
SMCS Code: 7000; 7002
Lifting the Engine Only
To remove the engine ONLY, use lifting eyes (2) and
(3) that are on the engine.
Lifting the Generator Only

Note: The control panel and the terminal box will
need to be removed before attempting to lift the
generator.
To remove the generator ONLY, use lifting eyes (1)
that are on the generator.
i05324948
Product Storage
SMCS Code: 7002
NOTICE
Never bend the eyebolts and the brackets. Only load If the engine will not be started for several weeks, the
the eyebolts and the brackets under tension. Re- lubricating oil will drain from the cylinder walls and
member that the capacity of an eyebolt is less as the from the piston rings. Rust can form on the cylinder
angle between the supporting members and the ob- liner surface, which will increase engine wear which
ject becomes less than 90 degrees. can reduce engine service life.
When it is necessary to remove a component at an To help prevent excessive engine wear, use the
angle, only use a link bracket that is properly rated for following guidelines:
the weight.
Complete all of the lubrication recommendations
Use a hoist to remove heavy components. Use an that are listed in this Operation and Maintenance
adjustable lifting beam to lift the entire package. Use Manual, Maintenance Interval Schedule
an adjustable lifting beam to lift the engine. All
(Maintenance Section).
supporting members (chains and cables) should be
parallel to each other. The chains and cables should If freezing temperatures are expected, check the
be perpendicular to the top of the object that is being
lifted. cooling system for adequate protection against
freezing. Refer to this Operation and Maintenance
Some removals require lifting fixtures in order to Manual, Fluid Recommendations (Maintenance
obtain proper balance. Lifting fixtures also help to Section).
provide safety.
If an engine is out of operation and if use of the
Lifting eyes are designed and installed for each engine is not planned, special precautions should be
package. Alterations to the lifting eyes and/or the made. If the engine will be stored for more than 1
package make the lifting eyes and the lifting fixtures month, a complete protection procedure is
obsolete. If alterations are made, ensure that proper recommended.
lifting devices are provided. Consult your Caterpillar
dealer for information regarding fixtures for proper Your Cat dealer will have instructions for preparing
lifting. the engine for extended storage periods.
For more detailed information on engine storage,
refer to Special Instruction, SEHS9031, Storage
Procedure for Caterpillar Products.
24 SEBU7681-22
Operation Section
Product Storage
Generator Storage
For information on generator storage, refer to this
Operation and Maintenance Manual, Generator Set
Installation (Operation Section).
SEBU7681-22 25
Operation Section
Installation
Installation The hoist and the hoist cables should have a rating
that is greater than the weight of the generator. When
the unit is moved, ensure that the generator is
i03676783 completely supported by the lift truck's fork tines.
Also ensure that the generator is balanced on the lift
Product Installation truck's fork tines. Slide the fork tines beneath the
attached skid in order to lift the generator.
SMCS Code: 1000; 1404; 4450; 7002
Storage
Receiving Inspection
If the generator is received during cold weather, allow
Short Time Storage
the unit to reach room temperature before you
remove the protective packing material. Warming the If the generator is not installed immediately, store the
generator to room temperature will prevent the generator in a clean area. This area should also have
following problems: the following conditions: low humidity, stable humidity
and stable temperature. Space heaters must be
Water condensation on cold surfaces energized in order to keep condensation from the
windings. All accessory equipment that is supplied
Early failures due to wet windings with the unit should be stored with the generator. The
combined unit should be covered with a durable
Early failures due to wet insulating materials cover in order to protect against the following
contaminants:
Unpacking and Storage Dust
Moving the Generator Dirt
Moisture
Long Time Storage

Improper lift rigging can allow unit to tumble
causing injury and damage. A storage period in excess of six months should be
preceded by the following preparation:
NOTICE 1. Install desiccant bags inside the exciter's cover

Do not use the engine lifting eyes to remove the en- and install desiccant bags inside the screen of the
gine and generator together. fan.
Unpack the equipment with care in order to avoid 2. Seal the unit in a covering of plastic or other
scratching painted surfaces. Move the unit to the material that has been designed for that purpose.
mounting location. The unit can be moved by either
of the following methods: 3. Adequately tag the generator. This will ensure that
preservative greases and desiccant bags are
Attach an overhead crane to the lifting eyes that removed before the unit is placed in operation.
are installed on the generator package.
Use a lift truck in order to lift the generator. 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:
26 SEBU7681-22
Operation Section
Product Installation
Clean Special Instruction, REHS0177, Alignment of the

Close Coupled Two-Bearing Generators
Dry
Well ventilated Protective Devices

Easily accessible for inspection and maintenance The output to the load of the generator should always
be protected with an overload protection device such
Do not obstruct air inlet openings. Do not obstruct as a circuit breaker or fuses. Determine the size of
discharge openings. Coolant flow must reach these fuses or determine the size of circuit breakers in
accordance with NEMA, IEC, and Local Electrical
openings. If the generator is exposed to harsh Codes.
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.
Note: For further information concerning the

installation of this generator set, see the appropriate
Application and Installation Guide.
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
SEBU7681-22 27
Operation Section
Features and Controls
Features and Controls Testing Alarms and Shutoffs

Alarms must function properly in order to provide
i03898667
timely warning to the operator. Shutoffs help to
prevent damage to the engine. It is impossible to
Alarms and Shutoffs determine if the engine protective devices are in
SMCS Code: 7400 good working order during normal operation.
Malfunctions must be simulated in order to test the
Engines may be equipped with optional engine engine protective devices.
protective devices that are not included in this
section. This section contains some general NOTICE
information about the function of typical engine During testing, abnormal operating conditions must
protective devices. be simulated.
Alarms and shutoffs are electronically controlled. The The tests must be performed correctly in order to pre-
operation of all alarms and shutoffs utilize vent possible damage to the engine.
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating Periodic testing of engine protective devices for
temperatures, pressures, or speeds in order to proper operation is recommended maintenance. To
protect the engine from damage. prevent damage to the engine, only authorized
The alarms function in order to warn the operator service personnel or your Caterpillar dealer
when an abnormal operating condition occurs. The should perform the tests.
shutoffs function in order to shut down the engine
when a more critical abnormal operating condition Setpoints for Alarms and Shutoffs
occurs. The shutoffs help to prevent damage to the
engine. Inlet Manifold Air Temperature
Shutoffs may cause unburned gas to remain in the air
inlet and in the exhaust manifold. Table 3 lists information on the operating
temperatures and the shutdown temperatures for
inlet manifold air temperature. The temperatures are
associated with different water temperature
regulators for separate circuit aftercoolers. The
Unburned gas in the air inlet and exhaust system temperatures are also associated with different types
may ignite when the engine is started. Personal of gas engines.
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the Starting the Engine
section.
If an engine protective device shuts off the engine,

always determine the cause of the shutoff. Make the
necessary repairs before attempting to start the
engine.
Become familiar with the following information:
Types of the alarm and shutoff controls
Locations of the alarm and shutoff controls

Conditions which cause each control to function
Procedure for resetting that is required before

starting the engine
28 SEBU7681-22
Operation Section
Electronic Modular Control Panel II+ (EMCP II+)
Table 3
Approximate Operating Temperatures and Shutdown Temperatures for G3500 Inlet Manifold Air Temperature
Opening Temperature for the Approximate Operating

Water Temperature Regulator Temperature Shutdown Temperature(1) Shutdown Temperature(2)
(SCAC)
43 C (109 F) 47 C (117 F) 75 C (167 F) 65 C (149 F)

Standard engine
54 C (130 F) 58 C (136 F) 75 C (167 F) 65 C (149 F)

Standard engine
(1) Engines that operate at less than 50 percent load
(2) Engines that operate at more than 50 percent load
Cogeneration and Bio-Gas Fuel Overspeed

Applications The specific limits are listed in Table 5 . Relay logic
must be provided for shutting off the engine in case
G3500 Engines that are in cogeneration and bio-gas any of the limits are reached. Consult your Caterpillar
applications operate with jacket water coolant dealer for assistance.
temperatures that are higher than normal. The
Table 5
protective system is optional for cogeneration
engines. The protective system is standard for G3500 Engine Shutdown Setpoints
engines that use bio-gas fuel .
Rated Minimum Oil Jacket Overspeed
Table 4 lists the setpoints for cogeneration engines. RPM Pressure Water(1) RPM
Table 4 Temp
High Low
Setpoints For Cogeneration Engines Idle Idle
RPM RPM
Condition Setpoint
1500 276 kPa 103 kPa 117 C 1770
Alarm signal of differential pres- 34.5 kPa (5 psi) (40 psi) (15 psi) (243 F)
sure of jacket water pressure
(1) To prevent overheating, the coolant pressure must be a mini-
Alarm signal of jacket water 113 C (234 F) mum of 27.6 kPa (4 psi).
coolant temperature
i03643502
Alarm signal of engine oil 102 C (215 F)
temperature
Electronic Modular Control
Shutdown temperature of en- 113 C (234 F)
gine oil
Panel II+ (EMCP II+)
Shutdown temperature of inlet 75 C (167 F)
SMCS Code: 4490
air manifold(1)
Note: Your machine may not be equipped with all of
Shutdown temperature of inlet 65 C (149 F) the following controls.
air manifold(2)
(1) Engines that operate at less than 50 percent load
(2) Engines that operate at more than 50 percent load
Engines Without A Caterpillar Remote

Control Panel (Status)
The customer must provide the relay logic for
engines that are not equipped with a Caterpillar
Remote Control Panel (Status). The customer must
provide the relay logic for the following parameters:
Oil pressure (high idle limit)
Oil pressure (low idle limit)

Jacket water coolant temperature (high
temperature)
SEBU7681-22 29
Operation Section
(1) Generator set control + (GSC+) (5) Synchronizing lights module or Custom (7) Voltage adjust rheostat (VAR)
(2) Engine control switch (ECS) alarm module (CAM) (8) Emergency stop push button (ESPB)
(3) Panel lights (PL) (6) Speed potentiometer (SP) or Governor (9) Panel light switch (PLS)
(4) Alarm module (ALM) switch
The Electronic Modular Control Panel II+ (EMCP II+) Engine Control Switch (2) The engine control
is located above the generator distribution housing. switch (ECS) determines the status of the control
The control panel consists of the following panel. In the AUTOMATIC position, the engine will
components: a main panel with indicators, meters start automatically when a remote initiated contact is
and control switches. This control panel may be closed. The engine will be shutdown after the contact
equipped with optional modules in order to match the opens. The engine will be shutdown after a cooldown
customers' needs and requirements. period that is programmable has elapsed. The
cooldown period can be programmed to give a 0 to
The left side of the control panel contains the 30 minute cooldown period before the engine shuts
Generator Set Control + (GSC+). This is the main down.
component of the system. The GSC+ displays the
following information: generator output, fault
conditions and key engine parameters. The center In the MANUAL START position, the engine will start.
section of the control panel contains switches and an In the MANUAL START position, the engine will run
optional alarm module. The right side of the control when ECS remains in the MANUAL START position.
panel may be blank, or the right side of the control
panel may contain the Synchronizing Lights Module In the STOP position, the engine is shutdown by the
or the Custom Alarm Module. fuel solenoid after a programmable cool down time
period has elapsed.
Some components are optional. The optional
components may not be required for your particular In the OFF/RESET position (12 o'clock), the fault
application. lights are reset and the engine shuts down
immediately.
Generator Set Control + (1) The generator set
control + (GSC+) is the main component of the
EMCP II+. See the topic Generator Set Control +
(GSC+) in this section.
30 SEBU7681-22
Operation Section
NOTICE
Generator Set Control + (GSC+)
The engine must be cranking before using the start
aid switch. Damage to the engine is possible if ether Functions and features of the GSC+
is released to the engine but not exhausted or burned
by the engine when cranking.
Panel Lights (3) Panel lights (PL) are controlled by

panel lights switch (9). The panel lights switch is an
ON/OFF switch.
Alarm Module (4) The alarm module (ALM) is
optional. The ALM provides a visual warning. The
ALM provides an audible warning of engine
conditions before these conditions become severe.
Engine conditions that are severe may cause the
engine to shutdown. Engine conditions that are
severe may cause the engine not to start.
Synchronizing Lights Module (5) or Custom
Alarm Module (5) The synchronizing lights module
uses synchronizing lights for paralleling the generator Illustration 22 g00781917
sets. The synchronizing lights module is optional. The location of the GSC+ on the control panel for the
The custom alarm module (CAM) may be installed in EMCP II+
the same opening on the control panel. The CAM
annunciates faults, alarms or other conditions from The left side of the control panel contains the
customer supplied inputs. generator set control + (GSC+). The GSC+ is the
main component of the system. The GSC+ displays
Speed Potentiometer (6) The speed the following information: generator output, generator
potentiometer (SP) is optional. The SP can be used set functions, fault conditions and key engine
with the generator set that has an electronic parameters. The GSC+ accepts information from the
governor. When the governor is equipped with a following sources: operator, speed sensor, engine oil
speed adjusting motor, the governor switch (GS) can pressure sensor, water temperature sensor and
be mounted instead of the SP. The GS is used in optional remote sources. This information is used to
order to raise the engine speed and the frequency.
The GS is used in order to lower the engine speed determine the following parameters: the on/off state
and the frequency. The GS is also an option. of the air for the engine , the on/off state of the fuel
and the on/off state of the starter.
Voltage Adjust Rheostat (7) The voltage adjust
rheostat (VAR) is used to adjust the generator output In the very basic operating conditions, the GSC+
voltage to the desired level. receives a signal in order to run the generator set.
The GSC+ turns on the engine's fuel. The GSC+
Emergency Stop Push Button (8) The emergency turns on the engine's starter. When the engine speed
stop push button (ESPB) is used to shut down the reaches the crank termination speed, the starter is
engine during an emergency situation. If equipped, disengaged. When the GSC+ receives a signal to
the ESPB shuts off the fuel and the ESPB activates stop the engine, the GSC+ shuts off the fuel and the
the optional air shutoff. GSC+ shuts off the ignition.
Panel Light Switch (9) The panel lights switch The functions of the GSC+ are listed below:
turns on or the panel lights switch turns off the panel
lights. The GSC+ controls the normal starting and
stopping of the engine.
Below, you can find the descriptions of the following The GSC+ shows engine conditions and
main modules of the EMCP II+: generator output information on two displays. The
Generator Set Control + (GSC+) displays also show the fault codes and the
programming information for the GSC+.
Alarm Module (ALM)
The GSC+ monitors the system for faults. If a fault
Custom Alarm Module (CAM) occurs, the GSC+ performs a controlled fault
shutdown or the GSC+ provides a fault alarm
Synchronizing Lights Module annunciation. The GSC+ uses indicators and
displays in order to describe the fault.
SEBU7681-22 31
Operation Section
The GSC+ contains programmable features for Fault indicators

certain applications or requirements for the
customer.
The features of the GSC+ are listed below:
Cycle Crank : The GSC+ can be programmed to
crank for adjustable time periods.
Governor Control : When the engine oil

pressure increases past the low oil pressure
setpoint, the GSC+ indicates that the governor
should increase the engine speed from idle rpm to
rated RPM.
Cooldown : When the GSC+ receives a signal to

perform a shutdown, there is a time delay before
the engine will stop running.
Automatic Operation : When the GSC+ is in

automatic mode, the GSC+ can be started by a
remote initiate signal (contact closure). Upon loss
of the signal (contact opening), the GSC+ will
perform a normal shutdown.
Alarm Module Communication : The GSC+ can Illustration 23 g00786766
transmit fault conditions and alarm conditions to Display area of the GSC+
an alarm module (AM). The GSC+ can also (13) Low oil pressure indicator
transmit the fault conditions and the alarm (14) Emergency stop indicator
conditions to a Customer Communication Module (15) High water temperature indicator
(16) Engine overspeed indicator
(CCM). (17) Overcrank indicator
(18) Spare 1 indicator
Powerdown : The EMCP II+ system is designed (19) Spare 2 indicator
to remove power from the GSC+ when the engine (20) Spare 3 indicator
control switch (ECS) is in the OFF/RESET mode (21) Fault shutdown indicator
and when the proper jumper wire is removed. The (22) Fault alarm indicator
(23) Dedicated shutdown indicators
GSC+ allows powerdown when the crank (24) Spare fault indicators
termination relay is off for 70 seconds and the fuel (25) Upper display
control relay is off for 70 seconds. If the wire is not (26) The key for the alarm codes
removed, the GSC+ will remain powered. Refer to
Technical Information Bulletin, TIBU3508 for The fault indicators are used in order to show a fault
additional information on powerdown. that is present. The fault indicators are used in order
to describe a fault that is present. The fault indicators
Fuel Solenoid Type : The GSC+ can be are divided into four groups. The four groups are
programmed in order to work with a fuel system listed below:
that is energized to run. The GSC+ can also be Fault alarm indicator (22)
programmed in order to work with a fuel system
that is energized to shutdown. Fault shutdown indicator (21)
Spare fault indicators (24)

Dedicated shutdown indicators (23)
The yellow fault alarm indicator (22) FLASHES when
the GSC+ detects an alarm fault. The alarm fault
does not cause the engine status to change. The
engine can be started. The engine will continue
operating only if the engine is running at the time of
the alarm fault. Fault alarm indicator (22) is
accompanied by an alarm fault code that is shown on
the upper display (25) when the key for the alarm
codes (26) is pressed.
32 SEBU7681-22
Operation Section
The red fault shutdown indicator (21) FLASHES occurs, the engine overspeed indicator flashes. The
when the GSC+ detects a shutdown fault. The engine engine is shutdown and the engine is not allowed to
will be shut down if the engine is running. The engine start until the fault is corrected.
will not be allowed to start. Fault shutdown indicator
(21) is accompanied by a fault code that is Overcrank The engine does not start within the
immediately shown on the upper display (25). setpoint for total cycle crank time that is programmed
into the GSC+. When the overcrank fault occurs, the
The yellow spare fault indicators (24) FLASH when overcrank indicator FLASHES. The engine is not
the conditions that are associated with that spare allowed to start until the fault is corrected.
fault are active. The three spare faults can be
programmed to show coolant loss, engine oil
temperature, spare fault condition or no assignment. Note: The GSC+ can be programmed to override the
The spare fault condition may be a customer shutdown for low oil pressure and high water
generated switch input. The yellow fault alarm temperature faults. When the operator overrides the
indicator (22) or the red fault shutdown indicator (21) shutdown faults, the GSC+ responds to the faults as
will accompany the spare fault indicators (24). The though the faults are alarm faults. The dedicated
spare fault indicators will tell whether the spare fault shutdown indicator is on continuously, and the
input is programmed to be an alarm condition or a indicator will not be flashing. The engine continues to
shutdown condition. run and the engine can be restarted. When the
dedicated shutdown indicator is ON continuously, the
The red dedicated shutdown indicators (23)
represent the following shutdown faults: low engine setpoint for shutdown has been exceeded, but the
oil pressure, emergency stop, high water GSC+ is programmed to override the shutdown fault.
temperature, engine overspeed and engine The GSC+ does not treat the shutdown fault as a
overcrank. When the GSC+ detects a fault in one of shutdown fault. The GSC+ treats the shutdown fault
these areas, the dedicated shutdown indicator as an alarm fault. At the factory, the GSC+ is
flashes. The engine is shutdown if the engine is programmed to treat a low oil pressure fault and a
running, and the engine is not allowed to start. No high water temperature fault as shutdown faults. The
fault codes are associated with the dedicated operator or the service technician must decide to
shutdown indicators because each indicator has a override these shutdown faults. The operator or the
descriptive label.
service technician must program the GSC+ to treat
Many of the dedicated shutdown faults depend on the shutdown faults as alarm faults.
certain setpoints in the GSC+.
Display
The conditions that are required to activate the
dedicated fault shutdowns and the results of each
dedicated fault are in the following list.
Low Oil Pressure The engine oil pressure drops
below the setpoints for low oil pressure shutdown
that are programmed into the GSC+. There are two
low oil pressure setpoints. One setpoint is used when
the engine is at idle speed. The other setpoint is used
when the engine is at rated speed. When a low oil
pressure fault occurs, the low oil pressure indicator
FLASHES, and the engine is shut down. The engine
is not allowed to start until the fault is corrected.
Emergency Stop The operator presses the
emergency stop push button (ESPB) on the front
panel. When an emergency stop condition occurs,
the emergency stop indicator FLASHES and the
engine is shut down. The engine is not allowed to
start until the condition is corrected.
High Water Temperature The engine coolant
temperature rises above the setpoint for high water
temperature shutdown that is programmed into the
GSC+. When the high water temperature fault
occurs, the high water temperature indicator Illustration 24 g00786776
FLASHES. The engine is shutdown and the engine is Display area of the GSC+
not allowed to start until the fault is corrected.
(25) Upper display
Engine Overspeed The engine speed exceeds the (27) Lower display
(28) The power meter key
setpoint for engine overspeed that is programmed (29) The AC meter key
into the GSC+. When the fault for engine overspeed (30) The engine meter key
SEBU7681-22 33
Operation Section
The display consists of the upper display and the Real power phase C (kW)
lower display. Both displays are used for
programming functions when the display is in the Total apparent power (kVA)
service mode.
Total reactive power (KVAR)
Upper display
Percentage of rated power (%kW)
The upper display (25) shows: AC voltage, current
and frequency. Several options are available on the Power factor (average)
upper display for AC metering. These options can be
viewed one at a time by pressing the AC meter key Power factor phase A
(29) on the keypad. The options are listed below:
Power factor phase B
Average voltage, generator frequency and total
current Power factor phase C
Total energy output (kW/h)
Line to line voltage, generator frequency and line
current for any one phase Total reactive energy output (kVAR/Hr)
Line to line voltage for all three phases Note: All real power values are signed with a + or a
Line current for all three phases . A negative value indicates reverse power.
Note: When total current increases above 9999A , Note: The Real power phase and the power factor
the GSC+ will show current in kA units. phase are not shown when setpoint P032 is set to 1
for delta generator sets.
Line to neutral voltage for all three phases
Note: Total energy output that is greater than
Upper display (25) is also used to show the various 999,999 kW/h will be shown as MW/h in two steps in
fault codes for system faults. order to maintain a resolution of 1 kW/h. The first
step will show MW/h as a whole number up to six
Note: Line to neutral voltages are not shown when places. The second step will show MW/h as a
the setpoint P032 is set to 1 for delta generator sets. decimal to three places.
Lower display The right side of lower display (27) shows the value
of certain engine parameters. The parameters are
The lower display (27) shows values for power listed below:
metering, engine parameters and the relay status.
Engine oil temperature (if equipped)
The left side of the lower display (27) serves as a
power meter for the generator set. The following System battery voltage
functions will scroll automatically:
Engine hours
Total real power (kW)
Engine speed
Total reactive power (KVAR)
Engine oil pressure
Percentage of rated power (%kW)
Engine coolant temperature
Power factor (average)
The value for one of these conditions is shown on
Total energy output (kW/h) display (27) for two seconds. The display then scrolls
to the value for the next condition. A small pointer
The display will stop scrolling when the operator identifies the engine condition that corresponds to
presses the power meter key for less than five the value that is showing. When the engine meter key
seconds. The display will show a particular (30) is pressed, the lower display (27) stops scrolling.
parameter continuously. Additional power meter The lower display continuously shows one particular
functions will scroll, if the power meter key (28) is value. The pointer flashes above the value that is
held for more than five seconds and then released. showing on the display. When the engine meter key
The additional functions are shown below: (30) is pressed for the second time, the lower display
will return to scrolling.
Total real power (kW)
Real power phase A (kW)
Real power phase B (kW)

34 SEBU7681-22
Operation Section
The relay status indicators are on the bottom of the Engine Meter Key (30) This key controls the
lower display (27). When a relay for the GSC+ is viewing of engine parameters on the lower display.
activated, the corresponding indicator is shown on Pressing the key stops the scrolling of engine
the lower display (27). When a relay is not activated, conditions. The value for one particular engine
the corresponding indicator is not shown. condition will show continuously. The pointer flashes
indicating that the scrolling is stopped. The scrolling
Keypad of the engine conditions will resume when the engine
meter key is pressed again.
Lamp Test Key (31) Pressing this key performs a
lamp test on the GSC+ and the optional alarm
module. On the GSC+, the ten fault indicators are ON
CONTINUOUSLY. Every segment of upper display
(5) and lower display (6) is ON. On the optional alarm
module, all of the indicators are ON and the horn
sounds. The function for the lamp test automatically
turns off if the operator presses the key and the
operator holds the key for ten seconds.
The Alarm Codes Key (26) If fault alarm indicator
(22) is FLASHING, pressing this key causes the
upper display (25) to show the corresponding alarm
fault code. If this key is pressed again, the generator
AC output information will be shown on the upper
display (25). If fault alarm indicator (22) is OFF, this
key has no function.
Exit Key (32) This key only functions when the
GSC+ is in Service Mode.
Service Mode Key (33) Pressing this key causes
the GSC+ to enter Service Mode.
Keypad area of the GSC+
Alarm Module
(21) Fault shutdown indicator
(22) Fault alarm indicator
(25) Upper display
(26) Key for the alarm codes
(27) Lower display
(28) Power meter key
(29) AC meter key
(30) Engine meter key
(31) Lamp test key
(32) Exit key
(33) Service mode key
(34) Keypad
Keypad (34) is used to control the information that is

shown on the upper display (25) and lower display
(27). The seven keys have two sets of functions:
normal functions and service functions. The normal
functions of the keys are described in the following
paragraphs.
Power Meter Key (28) This key controls the The location of the Alarm Module (ALM) on the
viewing of power meter information. This information control panel for the EMCP II+
is shown on the lower display. Pressing the key for at
least five seconds causes all the power meter data to The alarm module (ALM) is optional. The alarm
scroll once. The default power meter data then module provides a visual warning and the alarm
resumes scrolling. If the key is pressed for less than module provides an audible warning of engine
five seconds, the display stops scrolling. conditions before the conditions become severe.
AC Meter Key (29) The AC meter key controls the
viewing of the AC parameters on the upper display.
Pressing the key causes the display to show a
different set of parameters.
SEBU7681-22 35
Operation Section
One basic alarm module is used to satisfy the Four red indicators, which are used to display
requirements for the following modules: standby shutdown conditions
NFPA 99 alarm module, standby NFPA 110 alarm
module, NFPA 99 remote annunciator panel and
prime power alarm.
Synchronizing Lights Module
The front of the alarm module consists of the
following indicators:
Four amber indicators, which can indicate High
Coolant Temperature, Low Coolant Temperature
or Low Coolant Level, Low Oil Pressure,
Generator On Load, Charger Malfunction, Low
Engine Oil Level and Low Fuel Level
Four red indicators, which can indicate a Low DC
Voltage, Air Damper Closed, Low Oil Pressure
Shutdown, Overcrank Shutdown, High Coolant
Temperature Shutdown, and Overspeed
Shutdown
An audible alarm and Acknowledge/Silence switch

The location of the Synchronizing Lights Module on
Custom Alarm Module the control panel for the EMCP II+
(35) Synchronizing lamps
(36) Synchronizing switch
The optional synchronizing lights module is mounted

on the right side of the control panel. This module is
not used when the control panel is equipped with the
2301A governor.
The synchronizing lights module contains the
synchronizing lights (35) and the synchronizing
switch (36).
Synchronizing Lights (35) The synchronizing
lights (35) are used as an aid in paralleling units at no
load and under load. Each light is connected to the
side with the load of the generator output circuit
breaker. The lights are used to indicate when the
Illustration 27 g00781924 voltages are in-phase. Close the circuit breaker in
The location of the Custom Alarm Module (CAM) on order to connect the generator with the load.
the control panel for the EMCP II+
Synchronizing Switch (36) The synchronizing
switch has two positions, ON and OFF. When the
The custom alarm module (CAM) is optional. The
switch is in the ON position, the synchronizing lights
custom alarm module provides a visual warning and
are enabled. The generator circuit breaker can be
the custom alarm module provides an audible
closed manually when the synchronizing switch is on
warning of the conditions of the customer supplied
and the lights are synchronized.
inputs before these conditions become severe. The
CAM is equipped with the following items for the
customer: horn, alarm silence switch, lamp test Note: Refer to Operation Section, Parallel
switch and eight switched inputs Operation for information regarding the paralleling of
The front of the alarm module consists of the two generators.
following indicators:
When a reverse power relay is added to a
Four amber indicators, which are used to display synchronizing lights module, the original
alarm conditions synchronizing lights module will change in the
following ways:
The reverse power relay is mounted on the control
panel interior.
36 SEBU7681-22
Operation Section
Sensors and Electrical Components
A reverse power fault is indicated by the Fault Governing of the engine rpm
Shutdown Indicator on the front of the GSC+.
Control of ignition
The reverse power relay is a single phase protective
relay. This relay is energized by power in only one Control of the air/fuel ratio
direction. In a reverse power fault, the relay contacts
close and the engine shuts down. This will take the Start/stop control
generator off the line. The reverse power relay is
equipped with a test switch and adjustments. Monitoring and protection of the engine
i03676293 Governing of the Engine RPM
Sensors and Electrical The ECM receives a signal from the speed/timing
sensor. The ECM maintains the desired engine rpm
Components through electrical control of the engine's throttle.
SMCS Code: 1900; 7400
Control of Ignition
Note: This section contains some general
information about the engine electronic system and Each cylinder has an ignition transformer that is
sensors. For more information, refer to Systems located on top of the valve cover. In order to initiate
Operation/Testing and Adjusting. combustion in each cylinder, the ECM sends a pulse
to the primary coil of the ignition transformer at the
correct time. The time is based on firing order and
Electronic System engine speed. The transformer increases the voltage
which creates a spark across the spark plug
The Caterpillar Electronic System is a complete electrode.
electronic control system for gas engines. The
following benefits are the most significant The transformers are grounded through the valve
advantages of the electronic system: cover. Use caution when a valve cover is removed.
Always disconnect the ignition harness from the
Air/Fuel ratio control
transformer when a valve cover is removed.
Extensive system diagnostics An ignition harness connects each transformer to the
ECM.
Precise control of engine operation
Protection from detonation Control of Air/Fuel Ratio
Timing control of individual cylinders The ECM determines the desired volumetric flow rate
for fuel. The determination is based on the
components: actual engine speed, actual load, MAP,
MAT and internal maps. Next, the ECM sends
information on the desired fuel flow to the fuel
metering valve via the CAN data link. The ECM
adjusts the signal to the fuel metering valve in order
to maintain emissions. The process is repeated
continuously during engine operation.
Start/Stop Control
The ECM contains the logic and the inputs for
controlling the starting and stopping of the engine.
The logic for starting and stopping can be
programmed by the customer. The ECM supplies
positive + battery voltage to the starting motor relay
and the gas shutoff valve.
The engine uses an energize-to-run system. The gas
Junction box shutoff valve must remain energized in order to
supply fuel to the engine. If power is removed from
Most of the functions of the electronic system are the gas shutoff valve, the fuel is shut off. The gas
provided by the Engine Control Module (ECM). The shutoff valve may be controlled by the customer.
ECM is a sealed unit that is located inside a junction
box at the rear of the engine.
Five primary functions are supported by the ECM:
SEBU7681-22 37
Operation Section
Monitoring Engine Operation

Sensors are used in order to monitor engine
operation. Wiring harnesses connect the sensors to
the ECM. The ECM uses the information from the
sensors in order to monitor the engine. The ECM also
uses the information from the sensors in order to
control the engine. The information is also used to
generate event codes, and diagnostic codes. The
codes can be read with a Caterpillar Electronic
Technician (ET).
Event An event is a result of abnormal engine
operation. If abnormal engine operation is detected,
the ECM generates an event code. The ECM can
generate an alarm, a shutdown, or a warning of an
impending shutdown for abnormal engine operation.
These conditions are some examples of events: high
inlet air temperature, low oil pressure and engine
overspeed.
Diagnostic A diagnostic code is a result of a
problem with the operating system or with the
monitoring system. The ECM uses sensors and
internal circuitry to monitor the system components. If
a problem develops in a component or a wiring
harness, the control system will sense the problem.
The control system will notify the operator by creating
a diagnostic code. Some examples of conditions that
activate diagnostics are a short in a circuit for a
sensor, an open circuit, or a noisy signal.
Note: For detailed information on event codes and

diagnostic codes, refer to Troubleshooting.
Sensors
Sensors provide information to the ECM. The
information enables the ECM to control the engine as
efficiently as possible over a wide range of operating
conditions. The information is used for monitoring
engine operation and for protecting the engine.
Illustration 30 shows the locations of the sensors.
38 SEBU7681-22
Operation Section
(1) Engine oil temperature sensor (5) Pressure sensor for filtered oil (9) Manifold air pressure sensor
(2) Jacket water pressure switch (inlet) (6) Manifold air temperature sensor (10) Temperature sensor (Jacket Water
(3) Speed/timing sensor (7) Jacket water pressure sensor (outlet) Coolant)
(4) Pressure sensor for unfiltered oil (8) Flywheel speed sensor (11) Detonation sensor
The functions of the sensors are described below.

SEBU7681-22 39
Operation Section
Engine oil temperature sensor (1) An oil Speed/timing sensor (11) The engine speed/
temperature sensor monitors the engine oil timing sensor is located on the rear end of the left
temperature. A high oil temperature will activate an camshaft. The engine speed/timing sensor provides
alarm or a shutdown. The ECM compares the oil accurate information to the ECM about the position of
temperature to the engine coolant temperature. A the crankshaft and the engine rpm. The ECM uses
high difference between the two temperatures will the position of the crankshaft in order to determine
activate an alarm or a shutdown. ignition timing.
Jacket water pressure switch (2) A pressure
switch is located at the outlet of the oil cooler. The Integrated Temperature Sensing Module
jacket water pressure switch is a limit switch for the
coolant that is entering the block. (ITSM)
Engine speed sensor (3) This sensor only applies The ITSM monitors thermocouples that are located at
to engines that are configured for Island Mode. The the exhaust port of each cylinder. Thermocouples are
Auxiliary Sensing Module uses the signal from this also mounted at the inlets and outlets to the
sensor to accurately determine engine speed. In turbochargers. The temperatures are broadcast over
addition, the Auxiliary Sensing Module determines the Caterpillar data link for use with other modules.
the rate of change of the engine speed. The Auxiliary
Sensing Module uses this information to rapidly The ITSM calculates the average temperature for
respond to changes in engine load. The Auxiliary each bank. Event codes are generated if the
Sensing Module sends information on engine speed following conditions occur:
to the master ECM via the Cat Data Link.
The temperature is higher than the limit that is
Oil pressure sensors (4) and (5) The engine oil programmed.
pressure is measured before the oil filters and after
the oil filters. An alarm or a shutdown can be The temperature of a cylinder deviates
activated by any of the following occurrences: low significantly from the average temperature for all
filtered oil pressure, low oil filter differential pressure of the cylinders.
and high oil filter differential pressure.
Manifold air temperature sensor (6) A sensor for
monitoring the air inlet temperature is located in the
elbow after the number twenty cylinder head.
Excessive inlet air temperature can activate an alarm
or a shutdown.
Jacket water pressure sensor (7) A pressure
sensor is located at the outlet for the engine jacket
water. If the outlet pressure is too low, the ECM will
activate a shutdown.
Manifold air pressure sensor (8) A sensor for
monitoring the air inlet pressure is located in the front
end of the manifold. Excessive inlet air temperature
can activate an alarm or a shutdown.
Engine coolant temperature sensor (9) The
temperature sensor is located in the water
temperature regulator housing. To monitor the
coolant temperature, the element must be in contact
with the coolant. If overheating occurs due to low
coolant level, the sensor will not function properly. A
high coolant temperature will activate an alarm or a
shutdown. A low coolant temperature will only
activate an alarm. The setpoints for the activation can
be programmed with the Cat ET. The engine can be
restarted after a shutdown due to high engine coolant
temperature. However, another shutdown will occur
after one minute if the temperature remains high.
Detonation sensors (10) The detonation sensors
monitor the engine for detonation in each cylinder. To
eliminate detonation, the ECM retards the timing of
the cylinder. If excessive detonation continues, the
ECM will shut down the engine.
40 SEBU7681-22
Operation Section
Engine Diagnostics
Engine Diagnostics S/N: LGS1Up

S/N: NGS1Up
i02896986
S/N: HAT1Up
Configuration Parameters S/N: CWW1Up
SMCS Code: 1000; 1900; 1901; 1902 S/N: CWY1Up
S/N: SB31Up S/N: SLY1Up
S/N: FZA1Up S/N: SXY1Up
S/N: GZA1Up S/N: GZZ1Up
S/N: FZB1Up
Air/Fuel Ratio
S/N: GSB1Up
The correct air/fuel ratio is very important for the
S/N: GZB1Up following considerations:
S/N: TJB1Up Achieving optimum service life for the engine
S/N: FZC1Up Control of emissions
S/N: GZC1Up
Detonation Margin
S/N: TJC1Up
Engine Performance
S/N: F6D1Up
Environmental Regulations
S/N: FZD1Up
If the air/fuel ratio is not appropriate for the fuel and
S/N: NWD1Up the operating conditions, a failure of the engine may
S/N: F6E1Up occur. The service life of the turbocharger, the valves,
and other components may be reduced.
S/N: FZE1Up
Any changes to the air/fuel ratio will affect the
S/N: F6F1Up exhaust emissions. After adjustment, use an
emissions analyzer to measure the exhaust
S/N: FZF1Up emissions. Ensure that the engine is in compliance
with local regulations for emissions.
S/N: F6G1Up
S/N: FZG1Up Site Installation Parameters
S/N: GZG1Up Site installation parameters will have a direct impact
on engine performance and the ability to achieve
S/N: GZH1Up optimum service life for the engine. The following
S/N: GZJ1Up parameters should meet Service Manual,
Application and Installation Guidelinesand Special
S/N: GZK1Up Instruction, Technical Data Sheet Requirementsfor
this product:
S/N: GZL1Up
Fuel Pressure
S/N: HAL1Up
S/N: F6M1Up Fuel Temperature
S/N: GYM1Up Air Supply Temperature
S/N: GZM1Up Inlet Air Restriction

S/N: GZN1Up Exhaust Restriction
S/N: B9P1Up Engine Room Pressure
S/N: RLP1Up
Engine Room Temperature
S/N: GAS1Up
SEBU7681-22 41
Operation Section
Configuration Parameters
Installation Before the Fuel Control Valve Island Mode

The fuel flows from the main gas supply through the The minimum fuel pressure for Island Mode is 20 kPa
fuel filter. Usually, the fuel filter is a component of the (3 psi). The required stability for the steady state fuel
design at the particular site. The customer is pressure for Island Mode is 6.9 mbar (0.1 psi). The
responsible for supplying clean, dry fuel to the transient fuel pressure stability requirement for Island
engine. The fuel filter may be supplied by Caterpillar Mode applications is 48.2 mbar (0.7 psi).
or by the customer. To prevent particles from entering
the engine, a one micron filter is required. The filter Oil Consumption
must be properly sized for the required gas pressure.
For installation of the fuel filter, the recommended The rate of oil consumption is called Brake Specific
location is close to the engine before the engine's Oil Consumption (BSOC). The unit of measure is
gas pressure regulator. Pressure gauges in the gas grams per brake kilowatt hour or pounds per brake
lines on each side of the fuel filter are recommended horsepower hour. The BSOC depends on the engine
in order to monitor the filter's differential pressure. A model, the aspiration, the operating load, and the oil
manual shutoff valve in the gas line before the fuel that is used. For information on calculating the
filter will facilitate servicing of the filter. BSOC, refer to Engine Data Sheet 96.2, LEKQ4028,
Oil Consumption Data.
The filtered fuel flows to the Gas Shutoff Valve
(GSOV). For landfill applications, the GSOV must be Table 6 lists the normal mid-life BSOC for G3500
supplied by the customer. For other applications, the Engines under the following conditions:
GSOV may be supplied by Caterpillar or by the
customer. The solenoid for the GSOV may be Load factor of 100 percent
connected to engine's wiring harness or to a harness
that is supplied by the customer. In either case, the Maintenance is performed according to this
customer may install a switch that can interrupt the Operation and Maintenance Manual,
circuit. Maintenance Interval Schedule.
The control system is configured for a GSOV that is Caterpillar NGEO is used.
energize-to-run. This means that the GSOV must be
energized in order for the engine to run. To enable Table 6
the fuel flow, the ECM provides +Battery voltage to BSOC for G3500 Engines
the solenoid for the GSOV. The valve opens and the
fuel flows to the engine. When the control system Turbocharged Aftercooled Engine 0.426 g/bkw h
shuts down the engine, the voltage is removed from (.0007 lb/bhp h)
the solenoid. The valve closes and the fuel is shut off.
Parallel Utility Applications
The fuel flows through the GSOV to the gas pressure

regulator. The regulator may be supplied by
Caterpillar or by the customer. A regulated pressure
of 7 to 35 kPa (1 to 5 psi) is recommended. Less
pressure may result in reduced power. More pressure
may result in instability. The required stability for fuel
pressure for parallel utility applications is 2 kPa
(0.25 psi).
42 SEBU7681-22
Operation Section
Engine Starting
Engine Starting Inspect the air cleaner service indicator (if

equipped). Service the air cleaner filter element
when the yellow diaphragm enters the red zone, or
i02247953 the red piston locks in the visible position.
Before Starting Engine Cooling System

SMCS Code: 1000; 1400; 1450
Inspect the cooling system for leaks or loose
Note: Certain procedures are required before an connections. Inspect the condition of all the hoses
engine is started for the first time. See Special and pipes for the cooling system. Ensure that the
Instruction, REHS1438, Installation and Initial Start- connections are properly clamped.
Up Procedure for G3500C and G3500E Engines.
Inspect the water pumps for evidence of leaks.
Perform the required daily maintenance and other
periodic maintenance before starting the engine. This Check the coolant level. Add coolant, if necessary.
can prevent major repairs at a later date. See this For information on the proper coolant to use, see
Operation and Maintenance Manual, Maintenance this Operation and Maintenance Manual, Refill
Interval Schedule. Capacities and Recommendations (Maintenance
Section).
Walk-Around Inspection
Driven Equipment
NOTICE
For any type of leak, clean up the fluid. If leaking is If necessary, check the oil levels of the driven
observed, find the source and correct the leak. If equipment. Perform any maintenance that is
leaking is suspected, check the fluid levels more required for the driven equipment. Refer to the
often than recommended until the leak is found or literature that is provided by the OEM of the driven
fixed, or until the suspicion of a leak is proved to be equipment.
unwarranted.
If the engine is equipped with a clutch, ensure that
To obtain maximum service life for your engine, make the clutch is disengaged.
a thorough inspection before starting the engine.
Make a walk-around inspection of the installation. For generator set engines, ensure that the main
Look for items such as oil or coolant leaks, loose circuit breaker is open.
bolts and trash buildup. Remove any trash. Make
repairs, if necessary.
Electrical System
The guards must be in the proper place. Repair
damaged guards or replace missing guards. Inspect the wiring for the following conditions:
Ensure that the areas around the rotating parts are Loose connections
clear.
Wiring that is worn or frayed
Air Inlet System Inspect the gauge panel and the control panel for
good condition. Reset any shutoff or alarm
components.
Unburned gas in the air inlet and exhaust system Fuel System
may ignite when the engine is started. Personal
burned gas, purge the unburned gas from the air NEVER use a flame to check for gas leaks. Use a
inlet and exhaust system. Refer to the topic on gas detector.
purging unburned gas in the Starting the Engine
section. An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
Ensure that the air inlet piping and the air filters
are in place and clean.
Check the fuel lines for leaks with a gas detector.
Ensure that all clamps and connections are
secure.
SEBU7681-22 43
Operation Section
Cold Weather Starting
Inspect the fuel lines for loose fittings and leaks. Air Starting Motor
Ensure that the fuel lines are properly clamped.
Drain moisture and sediment from the air tank and
Ensure that the fuel is supplied to the engine at the from any other air piping.
correct pressure for the engine.
Check the oil level in the lubricator. Keep the
Lubrication System lubricator at least half full. Add oil, if necessary.
Check the air pressure for starting. The air starting

motor requires a minimum of 690 kPa (100 psi).
The maximum allowable air pressure is 1030 kPa
(150 psi). Open the air supply valve.
Electric Starting Motor

Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor engages.
Inspect the wiring, the electrical cables, and the
battery for the following conditions:
Loose connections
Illustration 31 g00760044 Wires that are worn or frayed
Oil level gauge (dipstick)
Corrosion
(1) ADD mark
(2) FULL mark
i01934528
NOTICE
Excessive engine oil will increase oil consumption
Cold Weather Starting
and result in excessive deposits in the combustion SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
chamber. Do not overfill the engine with oil.
NOTICE
Check the engine crankcase oil level. Maintain the Oil pan immersion heaters are not recommended for
heating the lube oil. To ensure the compatibility of the
oil level between the ADD and FULL marks on
components, only use equipment that is recom-
the ENGINE STOPPED WITH OIL COLD side of mended by Caterpillar.
the oil level gauge. For information on the proper
oil to use, see this Operation and Maintenance A jacket water heater is required to maintain a
Manual, Refill Capacities and Recommendations minimum starting temperature of 45 C (113 F). The
(Maintenance Section). engine may be difficult to start if the jacket water
coolant temperature is below 43 C (110 F). The
Check for leaks at the following components: spark plugs may become fouled with moisture
crankshaft seals, crankcase, oil filters, oil gallery condensation if the engine is cranked and the jacket
plugs, sensors and valve covers. water coolant temperature is below 43 C (110 F).
Inspect the tubes, tee pieces, and clamps on the For air starting motors, a larger volume of starting air
crankcase breathers. and/or a higher air pressure may be necessary in
order to start the engine at colder temperatures.
Starting System For electric starting, extra battery capacity may be
necessary.
Note: If the engine is equipped with a system for
external support, prepare the system before starting Consult your Caterpillar dealer for more information
the engine. Ensure that all of the systems for engine on the starting aids that are available for cold weather
support are enabled. Perform all prestart checks for starting.
the control system.
44 SEBU7681-22
Operation Section
Starting the Engine
i02896656 Unsuccessful successive attempts to start the

engine
Starting the Engine Unburned gas may remain in the air inlet and exhaust
SMCS Code: 1000; 1450 system after several unsuccessful attempts to start
the engine. The unburned gas may increase to a
concentration that may ignite during a successive
attempt to start the engine.
Engine exhaust contains products of combustion Perform the following procedure in order to purge the
which may be harmful to your health. Always unburned gas:
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust 1. If the Caterpillar Electronic Technician (ET) is not
to the outside. connected to the engine, connect Cat ET to the
engine.
NOTICE 2. Verify that the value of the Engine Purge Cycle
For initial start-up of a new or rebuilt engine, and for parameter is equal to ten seconds less than the
start-up of an engine that has been serviced, make value of the Crank Cycle parameter.
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the 3. Set the engine control to the START mode. The
fuel supply and/or the ignition to the engine. engine will crank for the Engine Purge Cycle
time. Then, the gas shutoff valve will be energized
and the ignition will be enabled. The engine will
start.
Unburned gas in the air inlet and exhaust system 4. Continue with your previous procedure.
may ignite when the engine is started. Personal
injury and/or property damage may result. Automatic Starting
burned gas, purge the unburned gas from the air
purging unburned gas in the Starting the Engine When the engine is in the AUTOMATIC mode, the
section. engine can start at any moment. To avoid person-
al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode.
Note: Using the EMERGENCY STOP button will
shut off both the fuel and the ignition. If the engine control switch is in the AUTO position,
the engine will automatically start when the remote
Do not start the engine or move any of the controls if start/stop initiate contact closes.
there is a DO NOT OPERATE warning tag or similar
warning tag attached to the start switch or to the
controls. Parameters for the Start/Stop
Ensure that no one will be endangered before the Control
engine is started and when the engine is started.
Driven Equipment
Perform the procedures that are described in this
Operation and Maintenance Manual, Before Starting Start-up is delayed until the switch for the driven
Engine. equipment indicates that the driven equipment is
ready.
Purging Unburned Gas
Purge Cycle
The following events cause unburned gas to remain
in the air inlet and in the exhaust manifold: Note: The engine uses an energize-to-run system.
The gas shutoff valve must remain energized in order
Emergency stop to supply fuel to the engine.
Engine overspeed The purge cycle allows any unburned fuel to exit
through the exhaust before the ignition system is
The engine control is set to the STOP mode and activated.
the gas shutoff valve does not close.
The purge cycle occurs under these conditions:
SEBU7681-22 45
Operation Section
Starting with Jump Start Cables
The gas shutoff valve is de-energized. Table 7

Rated RPM And Low Idle RPM
The ignition is off.
Rated rpm 1200 1500 1800
The engine is cranked.
Low idle rpm 900 1000 1200
The purge cycle occurs before the crank cycle. The
amount of time for the purge cycle is programmable.
i04471308
Cycle Crank Time

Starting with Jump Start
The maximum amount of time for activation of the
starting motor and the gas shutoff valve for starting is
Cables
the cycle crank time. The amount of time is SMCS Code: 1000; 1401; 1402; 1900
programmable.
Rest Cycle
If the engine does not start within the cycle crank Improper jump start cable connections can cause
time, starting is suspended for a rest cycle. The an explosion resulting in personal injury.
amount of time for the rest cycle is equal to the cycle
crank time. Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
Overcrank Time
If the installation is not equipped with a backup
The overcrank time includes the total purge cycle, the battery system, an external electrical source may be
total cycle crank time, and the total rest cycle. These necessary to start the engine.
functions are repeated until termination of the
overcrank time.
NOTICE
If the engine does not start within the overcrank time, Using a battery source with the same voltage as the
the engine control module generates an event code. electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Manual Starting
Do not reverse the battery cables. The alternator can
1. Ensure that fuel is supplied to the engine. be damaged. Attach the negative cable last and re-
move first.
2. Ensure that the driven equipment is ready. For
generator set engines, ensure that the main circuit When using an external electrical source to start the
breaker is open. engine, turn the generator set control switch to the
OFF position. Turn all electrical accessories OFF
before attaching the jump-start cables.
NOTICE
Do not engage the starting motor when flywheel is Ensure that the main power switch is in the OFF posi-
turning. Do not start the engine under load. tion before attaching the jump-start cables to the en-
gine being started.
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 1. Turn the start switch to the OFF position. Turn off
start the engine again.
all accessories.
2. Connect one positive end of the jump-start cable to
3. Start the engine.
the positive cable terminal of the discharged
The crank terminate speed is programmable. battery. Connect the other positive end of the
When the engine rpm exceeds the crank terminate jump-start cable to the positive cable terminal of
speed, the engine control module disengages the the electrical source.
starting motor.
3. Connect one negative end of the jump-start cable
4. Allow the engine speed to stabilize at low idle rpm. to the negative cable terminal of the electrical
Check all of the pressure gauges. Inspect the source. Connect the other negative end of the
engine for leaks and listen for unusual noises. jump-start cable to the engine block or to the
When all systems are normal, the rpm may be chassis ground. This procedure helps to prevent
increased. potential sparks from igniting combustible gases
that are produced by some batteries.
46 SEBU7681-22
Operation Section
After Starting Engine
4. Start the engine.

5. Immediately after the stalled engine is started,
disconnect the jump-start cables in reverse order.
Note: If there is a problem with the alternator or the
battery charger, the engine will not continue to run
after starting, unless the power to the engine control
module is supplied by a separate source.
i02247955
After Starting Engine

SMCS Code: 1000
For new installations and engines that are recently
rebuilt, carefully monitor the engine in order to detect
any unusual engine performance.
After all systems are stabilized and normal, the
engine rpm can be increased from low idle rpm to
rated rpm.
It may be necessary to apply some load in order to
attain normal operating temperatures.
Engaging the Driven Equipment

1. Increase the engine speed to rated rpm.
2. Ensure that the operating parameters are in the
normal ranges for the engine load.
3. Close the main circuit breaker in order to apply the
load.
4. Refer to Special Instruction, REHS1438,
Installation and Initial Start-Up Procedure for
G3500C and G3500E Engines in order to
properly load the engine.
SEBU7681-22 47
Operation Section
Engine Operation
Engine Operation Operating the Engine and the

Driven Equipment
i02136151
Check the gauges and the driven equipment
frequently while the engine is operating under a load.
Engine Operation The engine can be operated continuously at full load.
SMCS Code: 1000
Proper operation and maintenance are key factors in
Partial Load Operation
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation Extended operation at low idle or at a reduced load
and Maintenance Manual in order to minimize will cause increased oil consumption and carbon
operating costs and maximize the service life of the buildup in the cylinders. Carbon buildup results in the
engine. following effects:
Observe the gauges or the Caterpillar Electronic Narrow margin for detonation
Technician (ET) frequently while the engine is
operating. Record the data from the gauges or the Power loss
Cat ET in a log. It is best to record all Cat ET data
from the status screens. Record the time and the Poor performance
date for each event or each diagnostic. Include the
parameters that are listed in Table 8 . Average the Accelerated wear of components
data that is recorded during operation and record the
Caterpillar Engines can be operated at very light
average values for each day. Compare the data to
loads for limited times with no harmful effects. Table 9
the specifications for normal engine operation. lists the limits for hours of operation at various loads.
Comparing the data over time will help to detect
trends in engine performance. After the time limit for reduced load operation
Table 8 has expired, operate the engine for a minimum of
two hours at a load that is more than 70 percent
Engine Performance
of the rated load.
Operator Date
For example, an engine is operating at 20 percent of
Engine serial number Hour meter the rated load. The engine may be operated at this
load factor for a maximum of one-half hour. After the
Load RPM one-half hour, operate this engine for at least two
hours at a load factor of more than 70 percent.
Coolant temperature Oil pressure
Oil filter Air filter To help keep engine maintenance at a minimum,

differential pressure differential pressure follow the guidelines that are listed in Table 9 .
Table 9
Inlet Inlet
manifold pressure manifold temperature Time Limits For Low Load Operation
Exhaust Exhaust Engine Load Time Limit

temperatures pressure
0 to 30 percent 1/2 hour
Secondary transformer voltages Exhaust emissions
31 to 50 percent 2 hours
Throttle position Fuel valve position
51 to 100 percent Continuous (1)
(1) For continuous operation, the manifold air pressure must be
Investigate any significant change in the gauge or in greater than the atmospheric pressure.
the Cat ET readings. Monitor the engine operation
and take action when discrepancies are found.
48 SEBU7681-22
Operation Section
Generator Operation
Generator Operation
i02896671
Generator Operation
SMCS Code: 4450
Loading of the Generator

When a generator is installed or reconnected, be
sure that the total current in one phase does not
exceed the nameplate rating. Each phase should
carry the same load. This allows the engine to work
at the rated capacity. An electrical unbalance can
result in an electrical overload and overheating if one
phase current exceeds the nameplate amperage.
Allowable combinations of unbalanced loads are
shown in Illustration 32 . 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.
Allowable Combinations of Unbalanced Loads
Block Loading and Transient

Capability
The block loading capability (transient response) of a
generator set that is powered by a gas engine is less
than a generator set that is powered by a diesel
engine. Most of this difference is directly attributed to
the inherently different fuel systems of the two
engines. When the governor calls for more power, a
diesel engine reacts by adding fuel directly into the
cylinder. This method permits the diesel engine to
accept 100% block loads with acceptable voltage
dips and frequency changes. When the governor on
a gas engine calls for more power the throttle opens.
This causes a larger flow of the air/fuel mixture to
move through the aftercooler core and the air intake
manifold and into the cylinder. This time delay
reduces the gas engine's capability for accepting
large block loads.
SEBU7681-22 49
Operation Section
Generator Operation
If a block load derating is required, refer to ISO 8528 Note: Normally, Caterpillar generators are designed
Standards or SAE J1349 Standards. for a lagging power factor of 0.8. If operation at less
than 0.7 lagging power factor is desired, consult your
Power Factor Caterpillar dealer in order to check the rating of the
generator.
The power factor represents the efficiency of the
load. The power factor is the ratio of apparent power Excitation Systems
to total power. This ratio is expressed as a decimal.
The power factor represents the portion of the current
which is doing useful work. The portion of current Permanent Magnet Pilot Excited
which is not doing useful work is absorbed in Generators
maintaining the magnetic field in motors. This current
is called the reactive load. Engine power is not Permanent Magnet Pilot Excited (PMPE) generators
required to maintain the reactive load. receive power for the voltage regulator from a pilot
exciter, rather than the main armature. The pilot
In most applications, the power factor of the system exciter consists of a permanent magnet rotor and a
is determined by these components: electric motors, stator. The pilot exciter operates independently from
controls and transformers. Induction motors usually the generator output voltage. Constant excitation
have a power factor that is no larger than 0.8. during a large load application is possible since
Incandescent lighting is a resistive load of about 1.0 irregularities in the output voltage are not fed back
power factor, or unity. Controls can operate at any into the system. Such irregularities can be caused by
power factor. Drivers that have variable frequency or load conditions. The independent operation also
variable speed can operate at any power factor. An allows the generator to better sustain an overload for
uninterruptible power supply can operate at any a short duration.
power factor. In this case, the power factor can be
between 0.4 and 1.0.
Low Idle Adjustment
The power factor of a system may be measured with
a power factor meter or determined by calculations. Typically, the low idle on 3500C generator sets is
Determine the power requirement in kW by 1100 rpm. On 60 Hz units, low idle will be
multiplying the power factor by the kVA that is approximately 66 percent of the full load speed. On
supplied to the system. As the power factor 50 Hz units, low idle will be approximately 80 percent
increases, the total current that is supplied to a of full load speed.
constant power demand will decrease. With equal
loads, a lower power factor will draw more current. A There is no low idle stop on generator sets with
high power factor will result in full engine load that is electronic governors. The low idle is set at the factory
less than the generator's rated amperage. A lower on generator sets that have mechanical governors.
power factor increases the possibility of overloading The low idle is also set at the factory on generator
the generator. sets that run on natural gas. The low idle should only
be adjusted by your Caterpillar dealer if adjustment is
required.
Note: Operating the electric set at low idle speed for
an extended time will cause some voltage regulators
to shut off. The electric set must be completely shut
down. Then, the electric set must be restarted. This
will allow the voltage regulator to again produce an
output.
Standby Generator Sets

Most standby units are automatic. Without an
operator in attendance, standby units will perform the
following functions: start, pick up the load, run and
stop.
50 SEBU7681-22
Operation Section
Single Unit Operation
Standby units will not change the settings for the Bearing Temperature Detectors
governor speed control or the voltage level
automatically. The governor speed and voltage level Bearing temperature detectors are available on
must be preset for the proper operation of that unit. generators with large frames. Bearing temperature
Whenever the generator set is operated manually, detectors measure the temperature of the main
ensure that the settings for the governor speed and bearing. Thus, the temperature of the bearing can be
the voltage level are set correctly for automatic measured or monitored. Bearing temperature
operation. Check all switches for the proper setting. measurements may help to prevent premature
The Start Selector Switch should be in the bearing failure. Two types of temperature detectors
AUTOMATIC position. Emergency Stop Switches are available. Bearing temperature detectors are
should be in RUN position. used with equipment that is provided by the
customer. Contact your Caterpillar dealer for more
Options information.
i04010972
Space Heaters
Most of the SR4B generators are provided with Single Unit Operation
space heaters. These space heaters are installed for SMCS Code: 4450
operation in all climates. The space heaters are
especially for use in high humidity conditions. For
more information on space heaters, refer to Initial Start-Up
Maintenance Section, Space Heater - Check.
Before the initial start-up, perform the megohmmeter
Embedded Temperature Detectors test on the main stator winding. Refer to the Special
Instruction, SEHS9124, Cleaning and Drying of
SR4B generators are available with embedded Electric Set Generators for the procedure.
temperature detectors. The detectors are installed in
the slots of the main armature. The main armature is
also called a stator. The detectors are used with the
Starting
equipment that is provided by the customer. Thus,
the temperature of the main armature winding can be 1. Make all of the preliminary checks listed in this
measured or monitored. Two types of temperature Operation and Maintenance Manual, Before
detectors are available: RTD and thermocouple. Starting Engine topic.
Contact your Caterpillar dealer for more information.
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.
SEBU7681-22 51
Operation Section
Parallel Operation
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.
i02896680
Parallel Operation
SMCS Code: 4450
Initial Start-Up Illustration 33 g00695380
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. When servicing or repairing electric power gen-
eration equipment:
Same phase rotation
Make sure the unit is off-line (disconnected
Same alternating current frequency from utility and/or other generators power serv-
ice), and either locked out or tagged DO NOT
Same voltage adjustment OPERATE. Remove all fuses.
1. Check the phase rotation. a. Connect the light bulbs with rated voltage
between the generator leads and the
The phase rotation of the paralleled units must be corresponding line phase. For example, connect
equal. There are two methods that are used in
order to determine if the phase rotation of the terminal 1 to line 1 across the open circuit
incoming unit is equal to the phase rotation of the breaker.
on-line unit. These methods are listed below.
b. Start the units. Bring the units up to speed. As
Phase rotation meter the units approach the same speed, the lights
will start to blink.
Set of three light bulbs
If the lights blink in sequence, one of the
The procedure for determining the proper phase units is connected backward. In order to
rotation is described below. correct the problem, stop the units. Remove
generator leads 1 and 3 at the circuit
breaker. Exchange these generator leads.
This reverses the direction of phase
rotation. Terminal 2 should always be
connected to line 2. Go to 5.
When the lights flash in unison, the phase

rotation is equal. The first condition of
Initial Start-Up has been met.
2. Adjust the frequency.

The speed of the paralleled units must be equal.
Speed is proportional to the alternating current
frequency.
a. Allow each electric set to run under load for

about 30 minutes.
b. Adjust the governor control in order to give rated
frequency at full load.
52 SEBU7681-22
Operation Section
Parallel Operation
Note: Voltage droop is expressed as the percentage

c. Remove the load and check the high idle speed. of voltage change from no load to full load. Loads of
The high idle speed should be approximately 2 0.8 power factor require a voltage droop of about 5
to 5 percent above full load speed for governors percent. A droop adjustment that causes a 2 percent
that are equipped with droop. If these speeds droop in voltage to a 8 percent droop in voltage is
usually required for satisfactory division of ampere
can not be obtained, contact your Caterpillar
loading.
dealer.
d. For the most consistent results, repeat 2.b and a. Adjust the voltage. Refer to the Initial Start-Up
2.c until the second condition of Initial Start-Up in the Operation Section, Single Unit
has been met. Operation.
3. Adjust the voltage. b. While the engine is running at rated speed, turn
the voltage droop potentiometer clockwise
There are two basically different methods for
reactive power equalization. about 1/2 of full range.
Reactive droop compensation If the driven load has the unity power factor,
set the voltage droop potentiometer on all
Cross current compensation generators at half of full range. Proceed to
3.g.
In the reactive droop compensation, the voltage
regulator causes an individual generator output If the driven load is approximately 0.8
voltage to change in proportion to the reactive power factor, proceed to 3.c.
current. The reactive current is measured with a
current transformer (CT).
c. Readjust the voltage level rheostat until the
The reactive current can be either lagging or voltage is approximately 5 percent above
leading. As the lagging reactive current increases, desired voltage.
the voltage regulator will cause the generator
output voltage to droop proportionally. As the d. Apply full load.
leading reactive current increases, the voltage
regulator will cause the generator output voltage to
e. Readjust the voltage droop rheostat in order to
rise proportionally.
obtain desired voltage with full load at 0.8 power
This method will tend to reduce the reactive factor. The voltage droop of each generator
current for the better KVAR sharing with other must be equal in order to divide the reactive
units. The reactive droop compensation is a load.
standard method on the Caterpillar generator sets.
The following procedure for voltage adjustment is f. Repeat 3.c, 3.d and 3.e for each generator until
for the reactive droop compensation. the following two conditions are met.
In the cross current compensation, the voltage
regulator is forward biased by the difference in The line voltage is equal to the desired level
reactive current outputs of the generators in at full load.
parallel. Cross current compensation is very
similar to the reactive droop compensation. In The voltage at no load is approximately 5
cross current compensation, the secondary percent above the rated voltage.
circuits of the current transformers are connected
in a series string. When one of the generators g. Parallel the generators and apply the driven
carries more reactive current than other
generators, a net difference voltage signal will load. Check the output current of the generator.
offset the generated voltage. This will also reduce If the sum of the amperes of the individual
the reactive current. Refer to the Engine Data generator amperes exceeds the total amperes
Sheet, LEKX8142, Caterpillar Zero Droop Voltage that are going to the load by 10 percent at full
for Parallel Operation for the adjustment load, adjust voltage droop rheostats. This will
procedure.
lead to proportional current sharing between
Note: The adjustment for the voltage level and generators. Some circulating current is
voltage droop determine the amount of circulating permitted at light load. Some circulating current
currents between the generators. The circulating can be expected when generators are cold.
currents between the generators will be reduced
when the voltage adjustments are carefully matched.
Use the same voltmeter to make adjustments on
each unit which will be paralleled.
SEBU7681-22 53
Operation Section
Parallel Operation
7. Generator temperature will be stabilized in

NOTICE
Damage to the generator is possible. Do NOT exceed approximately four hours. After the generator
the rated ampere load on any single generator. temperature has been stabilized, adjust the
voltage droop rheostat of each generator in order
to share the reactive load. Adjust the voltage
h. Make the final adjustments after the generators
droop rheostat of each generator in order to limit
that are parallel have been running at full load
the circulating currents. Less droop increases the
for one hour. Tighten the locknuts on all
reactive current that is carried by the generator.
controls. Install the access cover. The last
Adjusting the voltage droop rheostat in a
condition of Initial Start-Up has been met.
counterclockwise direction will decrease droop.
Adjusting the voltage droop rheostat in a clockwise
Starting Multiple Units direction will increase droop.
Refer to Operation Section, Single Unit Operation.
Speed Droop for the Load Division
Paralleling Multiple Units (If Equipped)
Units may be paralleled at no load or units may be Once the two units have been paralleled, the share of
paralleled with units under load. After the initial the kW load is determined by the governor control
conditions for start-up are satisfied, verify for the setting. If two units of the same capacity and the
following requirements. same governor characteristics have the same
governor control settings, the units will share the load
One of the governors can be an isochronous equally. The total load must not exceed the capacity
governor. Electronic load sharing governors are of the one engine.
an exception.
In order to transfer the load from one engine, follow
Generators must have voltage droop the following procedure.
compensation or cross current compensation. 1. Increase the governor speed control of one unit in
1. Start the unit which will be paralleled. order to increase the load.
2. Turn on the synchronizer lights. 2. Reduce the governor speed control of the other
unit in order to decrease the load on that unit.
3. After the engine has run a few minutes, bring the
engine up to synchronous speed. Synchronous 3. Raise or lower the governor speed control of both
speed means that the frequency of the incoming units in order to change system frequency.
unit will have the same frequency of the unit that is
on-line. The synchronizing lights will begin to blink. Parallel Operation Of Governors
Note: The frequency of the incoming unit should be The different governors that can be used on G3500C
slightly greater than the line frequency. This will allow generator sets are shown below.
the incoming unit to assume part of the load.
4. Adjust the engine speed until the lights blink very

slowly.
5. The lights turn off when the voltages of the two
units are in-phase. At this point, very quickly close
the breaker while the lights are out.
6. Use governor controls in order to share kW load
between engines.
Load Sharing Module (typical example)
54 SEBU7681-22
Operation Section
Parallel Operation
The generator set load sharing module provides the The simplest governor combination for parallel
droop load sharing for generators that are paralleled. generator sets is a speed droop of 3 percent for
The generator set load sharing module provides the each governor. If a constant frequency from no
isochronous load sharing for generators that are load to full load is required, one governor can be
paralleled. The load sharing module has an input for adjusted for isochronous operation. This
the synchronizing parallel module. The module isochronous unit will be called a lead unit .
provides the load sharing that is proportional . More
information is available in the System Operation, In order for all paralleled units to accept the full
Testing and Adjusting, SENR6565, Generator Set share of the load, the following governor
Load Sensor and Generator Load Sharing Module. adjustments are required. The governors should
have the same full load speed. The governors
Function of The Engine Governor should have the same high idle speed in the case
of governors which are adjusted for speed droop
This section describes the function of the engine operation. The controls for the governor should be
governor in relation to load division between parallel set to the high idle position so that the full range of
electric sets. For detailed information on governor the governor is available.
controls and adjustments, refer to the Service Manual
for additional information. Operation of a governor that is isochronous in
It is very important to understand two basic facts parallel with speed droop governors requires
about load division between generator sets which are special techniques.
operating in parallel.
Any number of electric sets can be operated in
1. The power which is supplied to the generator is a parallel. However, only one governor of the group
function of the engine. The engine governor can be adjusted for isochronous operation. The
settings and the positions of the governor controls exception will be some special cases of electronic
determine the amount of power that is delivered by governors with an automatic load sharing
the engine. Therefore, the engine governor governor.
settings and the positions of the governor controls
determine the kW load which is carried by the Stopping
generator. If the governor control setting is
advanced, the engine and the generator will In order to remove a generator from the line, perform
the following procedure.
assume more kW load. Likewise, decreasing the
governor control setting will result in a reduction of 1. Check the load. The load must be less than the
load on the unit. Other units on the line will gain rated capacity of the remaining units.
load or other units will lose load. These other units
2. Be sure that the neutral of one of the remaining
will assume that no change in total load or no
units is grounded.
change in the governor settings of the other units
has taken place. 3. Remove the load from the outgoing unit. Refer to
the Parallel Operation, Load Division - Speed
2. The division of power is not determined by
Droop. The amperage may never go to zero due
generator excitation or terminal voltage. The
to circulating currents.
generator excitation will determine the power
factor of the generator during operation when the 4. Open the circuit breaker.
generator is in parallel with other generators.
5. Allow the engine to cool for five minutes.
Governors that are used with Caterpillar powered 6. Stop the engine.
electric sets can be of two types: governors with fixed
speed droop or governors with adjustable speed
droop. The values of speed droop which are Circulating Currents
commonly used are 3 percent and 0 percent.
Governors with adjustable speed droop can be Understanding the circulating currents becomes very
adjusted so that the settings match the settings of the important when you parallel the units. These
governors with fixed speed droop. If the governor is circulating currents are flowing between generators
adjusted for 0 percent speed droop operation, then that are paralleled. The circulating currents are
the same speed from no load to full load can be caused by voltage differences between the
obtained. generators. The amount of the circulating current can
be determined by subtracting the amperage which is
Summary on Governor Operation going to the load from the total generator amperage.
The preceding discussion of governor operation can

be summarized below.
SEBU7681-22 55
Operation Section
Voltage Regulators
The circulating current may be as high as 25 percent The digital voltage regulator (DVR) is a
of rated amperes with cold generator sets. Such microprocessor based voltage regulator. The
current may not even be considered harmful. The parameters are preset at the factory or the
total generator current should not exceed the parameters can be modified in order to meet the
amperage rating. specific requirements on the site. Certain system
parameters can also be monitored on the display (1)
As the generators warm, the circulating currents will of the DVR. Keypad (5) is used to change the
decrease. The ammeter readings should decrease information that is shown on the display. J1
slightly, but the voltage meter readings should remain connector (6) is used to join the DVR to a personal
constant. computer. Screw terminals (7) are used to join the
DVR to the generator and various customer options.
i01718527
Adjustment Procedure for the

Voltage Regulators Voltage Regulators
SMCS Code: 4467
Refer to the Specifications, Systems Operation,
The voltage regulator controls the generator output Testing and Adjusting, SENR5833, Digital Voltage
voltage. Regulator.
The digital voltage regulator (DVR) can be set up for
a specific application by using the configured
parameters. Parameters are preset at the factory.
Parameters may need to be adjusted in order to meet
the specific requirements of a site. The DVR also
detects faults. When a fault is detected, the DVR sets
the appropriate alarm or caution. Certain system
parameters can also be monitored on the display of
the DVR.
Display (1) and keypad (5) are used to select
parameter values. The display and the keypad are
also used to manipulate the parameter values that
control the operation of the digital voltage regulator.
The display of the digital voltage regulator has four
digits. When one of these digits is a colon, the
number that is showing is a parameter code. When a
colon is not present, the number that is showing is a
parameter value. A decimal point in the display is
used to indicate the precision of the parameter value.
Keypad (5) has three keys. The keys are listed below.
Function key (2)
Scroll down key (3)

Scroll up key (4)
Display (1) has two modes. These modes are the
parameter code mode and the parameter value
Digital Voltage Regulator (DVR) mode. Function key (2) is used to toggle back and
(1) Display forth between the two modes. Scroll down key (3)
(2) Function key and scroll up key (4) are used to change the display's
(3) Scroll down key value. The scroll down key will decrease the
(4) Scroll up key parameter number or the scroll down key will
(5) Keypad
(6) J1 connector
decrease the value. The scroll up key will increase
(7) Screw terminals the parameter number or the scroll up key will
increase the value.
56 SEBU7681-22
Operation Section
Voltage Regulators
Table 10
Parameter Code Parameter Value
:01 0480
0481
0482
0483
:02 0001
0002
0003
0004
:03 0004
0003
0002
:04 0100
0099
0100
0101
The operation of display (1) and keypad (5) is shown

in Table 10 . Pressing function key (2) toggles the
display between the two columns of the table
(parameter code and parameter value). The display
is in the parameter code mode when a colon is
present. If a colon is not present, the display is in
parameter value mode.
When you press scroll up key (3), the number that is
displayed will increase to the next higher number
within the column. When you press scroll down key
(4), the number that is displayed will decrease to the
next lower number within the column. The scroll keys
will not cause the display to change columns.
To configure a parameter code, follow the procedure
below:
1. To select the desired parameter code, press scroll
key (3) or scroll key (4).
2. Access the parameter value by pressing function
key (2).
3. Select the desired parameter value by pressing
scroll key (3) or (4).
4. In order to enter the selected value into the digital
voltage regulator's memory, press function key (2).
SEBU7681-22 57
Operation Section
Engine Stopping
Engine Stopping NOTICE

Do not start the engine until the problem necessitat-
ing the emergency stop has been located and
i02896660
corrected.
Emergency Stopping
The engine will not restart when the button is locked.
SMCS Code: 1000; 7418 To reset the button, pull the button or turn the button
clockwise. The spring-loaded button will return to the
NOTICE OUT position.
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices The control system must also be reset before the
or controls for normal stopping procedure. engine will start. Turn the engine control switch to the
OFF/RESET position.
Pressing the Emergency Stop Button may cause
unburned gas to remain in the air inlet and in the The customer may also provide a remote connection
exhaust manifold. for emergency stopping. For instructions on
connecting a remote emergency stop, see Special
Instruction, REHS1438, Installation and Initial Start-
up Procedure for G3500C and G3500E Engines.
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal Unplanned Shutdowns
Abnormal operating conditions may cause an engine
Before starting an engine that may contain un- shutdown. The fuel will be shut off, but the ignition
burned gas, purge the unburned gas from the air may not be shut off.
purging unburned gas in the Starting the Engine An indication of the cause will be generated by the
section. engine control module. The event code or the
diagnostic code can be obtained with a Caterpillar
Electronic Technician (ET). For more information on
event codes and diagnostic codes, refer to
Emergency Stop Button Troubleshooting.
i02849541
Manual Stop Procedure

SMCS Code: 1000; 7418
NOTICE
Stopping the engine immediately after the engine has
been operating under a load can result in overheating
and accelerated wear of the engine components.
Allow the engine to gradually cool before stopping
the engine.
There may be several different methods of stopping

the engine. Be sure that the engine stopping
procedure is understood. Follow the instructions that
The emergency stop button is in the OUT are provided by the OEM of the control panel.
position for normal engine operation. For an 1. Reduce the load to zero.
emergency stop, press the emergency stop
button. This shuts off both the fuel and the Note: Remove the load at a rate that will avoid
ignition.
detonation. Reduce the load from 100 percent to zero
Ensure that any system that provides external percent within three minutes but not less than two
support to the engine is secured after the engine is minutes.
stopped.
2. For generator set applications, open the main
circuit breaker.
58 SEBU7681-22
Operation Section
After Stopping Engine
Note: Extended idling can cause excessive oil

consumption and related problems.
3. Stop the engine according to the instructions that

are provided by the OEM of the control panel.
If the cooldown feature is utilized, the engine will
operate for a programmed period of time before
the engine stops. This allows the turbochargers to
slow down. After the cooldown, the engine will
shut off.
If the cooldown feature is not utilized, operate the
engine at high idle rpm for a cooldown period
before stopping the engine. If the engine has been
operated at a high load, operate the engine at high
idle until the engine systems stabilize. For
example, wait until the speed of the turbochargers
is reduced. Under normal operating conditions, the
cooldown period should be less one minute.
i02508920
After Stopping Engine

SMCS Code: 1000
Check the engine crankcase oil level. Maintain the

oil level between the ADD and FULL marks on
the ENGINE STOPPED side of the oil level
gauge.
If necessary, perform minor adjustments. Repair

any leaks and tighten loose bolts.
Note the service hour reading. Perform the

maintenance that is scheduled in this Operation
and Maintenance Manual, Maintenance Interval
Schedule (Maintenance Section).
NOTICE
Only use antifreeze/coolant mixtures recommended
in the Refill Capacities and Recommendations sec-
tion of this manual. Failure to do so can cause engine
damage.
Allow the engine to cool. Check the coolant level.

If freezing temperatures are expected, check the
coolant for protection against freezing. The cooling
system must be protected against freezing to the
lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.
Perform all required periodic maintenance on all

driven equipment. Refer to the instructions that
are provided by the OEM of the driven equipment.
SEBU7681-22 59
Maintenance Section
Refill Capacities
Maintenance Section (Table 12, contd)

External
System
Refill Capacities Total

Cooling
System
i05883386
Refill Capacities i04684372
SMCS Code: 1000; 1348; 1395; 7560

Fluid Recommendations
Lubricant Capacities SMCS Code: 1280; 1348; 1395; 7560
The capacity of the engine crankcase includes the Lubricant Recommendations

capacity of the oil filters that are installed at the
factory. Due to significant variations in the quality and in the
Table 11 performance of commercially available oils,
Caterpillar makes the following recommendations:
G3500 Lubrication System
Approximate Refill Capacities Cat NGEO (Natural Gas Engine Oil)
Engine Liters US Gallons Cat NGEO EL350 (Natural Gas Engine Oil)
G3512 307 81
The proper SAE viscosity grade of oil is determined
G3516 424 112 by the minimum ambient temperature during cold
engine start-up, and the maximum ambient
G3520
541 141 temperature during engine operation. To determine
G3520 Landfill
the oil viscosity that is required for starting a cold
soaked engine, refer to the minimum temperature in
Table 13 . To select the oil viscosity for operation at
Coolant Capacities the highest anticipated ambient temperature, refer to
the maximum temperature in the Table. Use the
To maintain the cooling system, the total cooling highest oil viscosity that is available in order to meet
system capacity must be determined. The total the required temperature during start-up.
cooling system capacity will vary between individual
Table 13
installations. The total cooling system capacity
equals the capacity of the jacket water circuit plus the Engine Oil Viscosity
aftercooler circuit plus the external system capacity.
The external system capacity includes the following Cat NGEO Ambient Temperature
components: expansion tank, heat exchanger, Grade of Viscosity
Minimum Maximum
radiator and piping. Refer to the specifications that
are provided by Caterpillar or by the OEM of the SAE 40 5 C (41 F) 50 C (122 F)
equipment. Record the total cooling system capacity
in the following Table: For applications that require starting below 5 C
Table 12 (41 F), oil heaters may be required. For more
G3500 Cooling System information about low temperatures, see the
Approximate Refill Capacities Application and Installation Guide, LEKQ7256,
Fuels, Fuel Systems.
System G3512 G3516 G3520 G3520
Landfill
Jacket 150 L 205 L 344 L 371 L
Water (40 US gal) (54 US gal) (91 US gal) (98 US gal)
Circuit
Aftercool- 30 L 16.5 L 47.5 L 73.7 L
er Circuit (8 US gal) (4.5 US gal) (12.5 US gal) (19.5 US
gal)
(continued)
60 SEBU7681-22
Maintenance Section
For further information about oils, see Special For further information on fuels, see Special
Publication, SEBU6400, Caterpillar Gas Engine Publication, SEBU6400, Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations. Lubricant, Fuel, and Coolant Recommendations.
Fuel Recommendations Coolant Recommendations

Caterpillar gas engines will operate successfully on a During shipping and storage, the engine must be
broad range of gaseous fuels. Pipeline natural gas protected from damage that can be caused by
has been used for many years. Commercial fuel freezing of the cooling system. If the engine is
gases are mixtures of gases. These fuels consist shipped to a site with freezing temperatures and/or if
primarily of hydrocarbons (combinations of hydrogen the engine is stored in a location with freezing
and carbon) and some inert gases. The compositions temperatures, the cooling system must contain
of these gas mixtures have extreme variations. Fuels antifreeze that will withstand the lowest ambient
such as wellhead gas, bio-gas, and manufactured temperature. Frequently check the concentration of
gas are to be reviewed for acceptability. Analyze the glycol in the coolant/antifreeze. Make sure that the
fuel in order to determine the following concentration is adequate in order to prevent
characteristics: freezing. Otherwise, the cooling system is to be
drained.
Composition
Coolant or antifreeze is normally composed of three
Contaminants elements: water, glycol and additives. Each element
must meet specific guidelines.
Heat value
Water
Methane number
Deionized water or distilled water is
Specific gravity recommended for use in engine cooling systems.
If distilled water or deionized water is not available,
Field gas can have varying characteristics of use water with the properties that are listed in Table
combustion. Field gas can contain numerous harmful 14 .
impurities. The impurities can alter the BTU content. Table 14
The impurities can also alter the methane number.
Caterpillar Minimum Acceptable Water Requirements
The impurities include everything from water up to
complex hydrocarbons that can lead to detonation Property Maximum Limit ASTM Test
and severe engine damage. To minimize these
effects, Caterpillar recommends the following 40 mg/L D512,
Chloride (Cl)
guidelines: (2.4 gr per US gal) D4327
1. Evaluate the fuel with the Caterpillar Methane 100 mg/L

Sulfate (SO4) D516
Number Program, LEKQ6378. Consult your Cat (5.9 gr per US gal)
dealer for guidance on fuels below 55 methane 170 mg/L
Total Hardness D1126
number. Fuels below 55 methane number require (10 gr per US gal)
a Special Rating Request(SRR). 340 mg/L
Total Solids (20 gr per US gal) D1888
2. Reduce the oil change interval according to the
results of the oil analysis. Acidity pH of 5.5 to 9.0 D1293
NOTICE
Use of water that does not meet the recommenda-
tions for the cooling system will damage the cooling
system.
Do not use these types of water in the cooling sys-
tem: sea water, softened water that has been condi-
tioned with salt, hard water and tap water.
Only use water that meets the recommendations for
the cooling system.
If you are not sure about the properties of your water,

consult one of the following sources for a water
analysis:
SEBU7681-22 61
Maintenance Section
Caterpillar dealer Table 15

Recommended Coolant/Antifreeze and Service Life of the
Local water utility company Coolant/Antifreeze
Agricultural agent Coolant/Antifreeze Service Life (1)
Independent laboratory Cat NGEC

Three Years
Cat DEAC
Glycol
Commercial Heavy-Duty Cool-
ant/Antifreeze that meets Two Years
NOTICE ASTM D6210
Do not use Extended Life Coolant (ELC) with Cat
Commercial Heavy-Duty Cool-
Gas Engines.
ant/Antifreeze that meets One Year
ASTM D4985
ELC was not formulated for use in Cat Gas Engines.
Cat SCA and Water Two Years
Do not use heat transfer fluids in Cat Gas
Engines. Commercial SCA and Water One Year
(1) The service life of coolant is also limited by use (service hours).
Use only the coolant/antifreeze that is recommended. Refer to the specific engine Operation and Maintenance Man-
ual, Maintenance Interval Schedule.
Preferred Cat NGEC (Natural Gas Engine

Coolant) Additives
Alternatively, use Cat DEAC (Diesel Engine Preferred Cat SCA (Supplemental Coolant
Antifreeze/Coolant) or a commercial heavy-duty Additive)
coolant/antifreeze that meets ASTM D6210 or
ASTM D4985 specifications. Acceptable A commercial SCA that provides
1200 mg/L (70 gr per US gal) or 1200 ppm of nitrites
NOTICE in the final mixture of coolant/antifreeze
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 Note: A 50/50 concentration of Cat NGEC or of
automotive applications. Cat DEAC does not require a treatment with an
SCA at the initial fill. Commercial heavy-duty
Use only the coolant/antifreeze that is recommended. coolant or antifreeze that meets ASTM D6210 or
ASTM D4985 specifications may require a
treatment with an SCA at the initial fill. Read the label
Acceptable In applications that do not require or the instructions that are provided by the OEM of
protection from boiling or from freezing, a mixture of the product.
Cat SCA and water that meets the properties that
are listed in Table 14 is acceptable. To ensure that the correct amount of SCA is in the
cooling system, the concentration of SCA must be
tested on a scheduled basis. Obtain an SOS
Note: The preferred coolant/antifreeze and the coolant analysis (Level 1) or use a test kit to check
acceptable mixture of SCA and water require the concentration of the SCA according to this
different concentrations of SCA. Refer to the Special Operation and Maintenance Manual, Maintenance
Publication, SEBU6400, Caterpillar Gas Engine Interval Schedule.
Lubricant, Fuel, and Coolant Recommendations
Supplemental Coolant Additive (SCA) topic. For further information on coolant, see Special
Publication, SEBU6400, Caterpillar Gas Engine
Table 15 is a list of the coolant/antifreeze that is Lubricant, Fuel, and Coolant Recommendations.
recommended for Caterpillar Gas Engines. The
service life of the coolant/antifreeze that is used in
Caterpillar Gas Engines is also listed. To achieve
this service life, the coolants are to be properly
maintained. The maintenance program includes
SOS coolant analysis.
62 SEBU7681-22
Maintenance Section
Maintenance Recommendations
Maintenance the application of electrical tests
Recommendations Never perform a test over the rated potential. These

tests can damage insulation that is contaminated or
insulation that is in marginal condition. For more
i01135057 information, refer to I.E.E.E. Standard 432-1992 or
consult a Caterpillar dealer.
General Maintenance
Information Space Heaters
SMCS Code: 4450; 7000 The SR4B generator is capable of operating in high
humidity conditions without problems. However,
Note: Read the warnings and read the instructions problems can occur when the generator is idle and
that are contained in the Safety Section of this the surrounding air is warmer than the generator.
manual. These warnings and instructions must be Moisture can form on the windings that will result in
understood before you perform any operation or any poor performance from the windings. Moisture can
maintenance procedures. also result in damage to the windings. Whenever the
generator is not active, ensure that the space heaters
Rotating electric machines are complex structures are in operation.
that are exposed to the following forms of stress:
Whenever the generator is operating, ensure that the
mechanical space heaters are disconnected.
electrical An external source of either 115 VAC or 230 VAC is

required to operate the space heaters.
thermal
environmental
These stresses may be of varying magnitudes. The
insulation systems are very susceptible to damage
that is caused by the stresses that are listed above.
Exposure to these stresses may shorten the effective
life of the insulation system. Therefore, the service
life of an electric machine will largely depend on the
serviceability of the insulation systems. An inspection
program and a testing procedure are recommended.
An inspection program and a testing procedure will
ensure that the equipment is maintained in
satisfactory condition. This will increase field
reliability.
A regular maintenance and inspection program can Space heater connection to external source (H1),
provide an evaluation of the present condition of the (H2), (H3) and (H4) terminals.
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
knowledgeable visual examination of the

equipment
SEBU7681-22 63
Maintenance Section
System Pressure Release
If a 115 VAC source is available, connect both Do not loosen the high pressure fuel lines in order to
heaters in parallel across the source. If a 230 VAC remove air pressure from the fuel system.
source is available, connect both heaters in series
across the source. Refer to Illustration 37 .
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
off the engine.
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050 i05909227
Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Cat dealer regarding welding on a chas-
off the engine. Allow the cooling system pressure cap sis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure. Proper welding procedures are necessary in order to
avoid damage to the engine ECM, sensors, and
associated components. When possible, remove the
Fuel System component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off possible, the correct procedure must be followed.
the engine. When welding on a unit that is equipped with a Cat
Electronic Engine, the following is considered to be
High Pressure Fuel Lines (If Equipped) the safest procedure:
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
Contact with high pressure fuel may cause fluid can cause damage to the drive train, the bearings,
penetration and burn hazards. High pressure fuel hydraulic components, electrical components, and
spray may cause a fire hazard. Failure to follow other components.
these inspection, maintenance and service in-
structions may cause personal injury or death. Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
The high pressure fuel lines are the fuel lines that are to the bearings, the crankshaft, the rotor shaft, and
between the high pressure fuel pump and the high other components.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These Clamp the ground cable from the welder to the com-
fuel lines are different from fuel lines on other fuel ponent that will be welded. Place the clamp as close
systems. as possible to the weld. This will help reduce the pos-
sibility of damage.
This is because of the following differences:
The high pressure fuel lines are constantly Note: Perform the welding in areas that are free from
charged with high pressure. explosive hazards.
The internal pressures of the high pressure fuel 1. Stop the engine. Turn the switched power to the
lines are higher than other types of fuel system. OFF position.
Before any service or repair is performed on the 2. Disconnect the negative battery cable from the
engine fuel lines, perform the following tasks: battery. If a battery disconnect switch is provided,
1. Stop the engine. open the switch.
2. Wait for ten minutes.
64 SEBU7681-22
Maintenance Section
Welding on Engines with Electronic Controls
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
Product Link
from the welder could also severely damage
electrical/electronic components that are located
Cell/Sat Radio
between the welder ground and the weld.
DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
SEBU7681-22 65
Maintenance Section
Generator Start-up Checklist
i03643560

SMCS Code: 4450
Table 16
GENERATOR START-UP CHECKLIST
RATING INFORMATION
Engine Serial Number: ___________________________________ Arrangement Number: ___________________
Generator Serial Number: _________________________________ Arrangement Number: ___________________
GENERATOR NAME PLATE INFORMATION

Voltage: ___________________ Package (prime, continuous, standby): _________________
Amperage: _________________ Kilowatts: ________________________________________
Storage Location:
Generator Alignment:
Main Stator Megohmmeter Reading: Before Storage: After Storage:
Generator dried for 24 hours prior to start-up? (Y/N) Drying method:
SPACE HEATERS Yes No Comments

Space heaters operating properly?
Space heater operated 48 hrs. before start-up?
MEGOHMMETER TEST (SEHS9124) 30 sec. 60 sec. 30 sec. 60 sec. Ambient Comments

reading reading corrected corrected temp.
Beginning of Main Stator

Storage
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Start-up Main Stator
Main Rotor
Exciter Stator
Exciter Rotor
PMG Stator
Regulator Voltage Amps Comments
No Load F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
(continued)
66 SEBU7681-22
Maintenance Section
(Table 16, contd)

GENERATOR START-UP CHECKLIST
Full Load Generator Excitation Name Plate DC Compare with F1 to F2
Information:
F1 to F2 DC
20 to 22 AC
20 to 24 AC
22 to 24 AC
26 to 28 AC
26 to 30 AC
28 to 30 AC
Table 17
GENERATOR START-UP CHECKLIST (CONT.)
ELECTRICAL Yes No Comments

Unit properly grounded
Check diodes
Over current protection
Over voltage protection
Check for loose wiring
Adjust voltage
Adjust frequency
Verify kilowatt transducer (if applicable)
MECHANICAL Data Comments

Bearing temperature readings at full load Front __________ Rear ___________
Stator temperature readings at full load A0 _______ B0 _______ C0 _______
Air gap on main stator Top __________ Bottom __________
Air gap on exciter stator Top __________ Bottom __________
Air gap of PMG Top __________ Bottom __________
Ambient air to generator at full load Temperature ____________________
Supplier air opening to generator Size of Opening _________________
SWITCH GEAR/PARALLEL OPERATION

Manufacturer:
Setting 1 Setting 2 Setting 3 Comments
Circuit breaker type
Overload setting
Reverse power relay
VAR/PF Controller
Load share
(continued)
SEBU7681-22 67
Maintenance Section
(Table 17, contd)

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.
68 SEBU7681-22
Maintenance Section
Maintenance Interval Schedule
i06687407 The generator is disconnected from the load.
Maintenance Interval Schedule When Required

(Prime) Battery - Recycle . . . . . . . . . . . . . . . . . . . . . . . . . 79
SMCS Code: 1000; 4450; 7500
Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . 79
Ensure that all safety information, warnings, and
instructions are read and understood before any Battery or Battery Cable - Disconnect . . . . . . . . . 80
operation or any maintenance procedures are
performed. Coolant Sample (Level 2) - Obtain . . . . . . . . . . . 86
An authorized operator may perform the Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100
maintenance items with daily intervals. An authorized
operator may perform the maintenance items with Generator - Dry. . . . . . . . . . . . . . . . . . . . . . . . . . 102
intervals of every week. The maintenance that is
Generator Lead - Check. . . . . . . . . . . . . . . . . . . 112
recommended for all other maintenance intervals
must be performed by an authorized service Generator Set - Test . . . . . . . . . . . . . . . . . . . . . . 113
technician or by your Cat dealer.
Generator Set Alignment - Check . . . . . . . . . . . 113
The user is responsible for the performance of all
maintenance which includes the following items: Generator Winding - Test . . . . . . . . . . . . . . . . . . 114
performing all adjustments , using proper lubricants,
fluids, and filters and replacing old components with Overhaul Considerations . . . . . . . . . . . . . . . . . . 126
new components due to normal wear and aging .
Space Heater - Test . . . . . . . . . . . . . . . . . . . . . . 129
Failure to adhere to proper maintenance intervals
and procedures may result in diminished Stator Winding Temperature - Test . . . . . . . . . . 133
performance of the product and/or accelerated wear
of components. Throttle Control Valve - Check . . . . . . . . . . . . . . 133
Before each consecutive interval is performed, all Daily

maintenance from the previous intervals must be
performed. Air Tank Moisture and Sediment - Drain . . . . . . . 78
Choose the interval that occurs first in order to Coolant Level - Check . . . . . . . . . . . . . . . . . . . . . 84
determine the correct maintenance interval: fuel
consumption , service hours and calendar time . Engine Air Cleaner Service Indicator - Inspect . . 91
Products that operate in severe operating conditions
may require more frequent maintenance. Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . 96
All of the following will affect the oil change interval: Fuel Filter Differential Pressure - Check . . . . . . 100
operating conditions , fuel type , oil type and size of
the oil sump . Scheduled oil sampling analyzes used Fumes Disposal Filter Differential Pressure -
oil in order to determine if the oil change interval is Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
suitable for your specific engine.
Generator Bearing Temperature - Test/
Refer to this Operation and Maintenance Manual, Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Engine Oil and Filter - Change in order to determine Generator Load - Check. . . . . . . . . . . . . . . . . . . 112
the oil change interval that is suitable for your specific
engine. Jacket Water Heater - Check. . . . . . . . . . . . . . . 121
To determine the maintenance intervals for the Power Factor - Check. . . . . . . . . . . . . . . . . . . . . 127
overhauls, refer to this Operation and Maintenance
Manual, Maintenance Recommendations . Voltage and Frequency - Check . . . . . . . . . . . . 136
Unless other instructions are provided, perform Walk-Around Inspection . . . . . . . . . . . . . . . . . . . 136
maintenance and perform repairs under the following
conditions: Initial 250 Service Hours
The starting system is disabled.
Cylinder Pressure - Test/Record . . . . . . . . . . . . . 90
The engine is stopped.
The generator does not pose an electrical shock
Every 250 Service Hours
hazard.
Battery Electrolyte Level - Check . . . . . . . . . . . . . . .
SEBU7681-22 69
Maintenance Section
Prime
Coolant Sample (Level 1) - Obtain . . . . . . . . . . . 85 Stator Lead - Check . . . . . . . . . . . . . . . . . . . . . . 133

Cooling System Supplemental Coolant Additive
(SCA) - Test/Add . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Every 3000 Service Hours
Engine Oil Sample - Obtain . . . . . . . . . . . . . . . . . 97 Spark Plugs - Inspect/Replace . . . . . . . . . . . . . 129
Fumes Disposal Filter - Drain . . . . . . . . . . . . . . 101 Every 4000 Service Hours

Every 1000 Service Hours Crankcase Blowby - Test/Record . . . . . . . . . . . . 87
Aftercooler Condensation - Drain . . . . . . . . . . . . 78 Cylinder Pressure - Test/Record . . . . . . . . . . . . . 90

Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . 78 Engine Mounts - Inspect . . . . . . . . . . . . . . . . . . . 93
Belts - Inspect/Adjust/Replace. . . . . . . . . . . . . . . 80 Engine Protective Devices - Check . . . . . . . . . . . 98
Crankcase Pressure - Measure. . . . . . . . . . . . . . 88 Ignition System Timing - Check/Adjust . . . . . . . 120
Crankshaft Vibration Damper - Inspect . . . . . . . . . . . Starting Motor - Inspect . . . . . . . . . . . . . . . . . . . 132
Crankshaft Vibration Damper - Inspect . . . . . . . . 88
Engine Crankcase Breather - Clean . . . . . . . . . . 92
Fumes Disposal Filter Element - Replace. . . . . 101
Engine Oil - Change . . . . . . . . . . . . . . . . . . . . . . . 93
Rotating Rectifier - Check . . . . . . . . . . . . . . . . . 128
Engine Oil Filter - Change . . . . . . . . . . . . . . . . . . 94
Turbocharger - Inspect . . . . . . . . . . . . . . . . . . . . 133
Engine Speed/Timing Sensor - Clean/Inspect . . 98
Engine Valve Lash and Bridge - Check. . . . . . . . 99 Every 10 000 Service Hours
Flexible Coupling - Inspect. . . . . . . . . . . . . . . . . 100 Generator Bearing - Inspect. . . . . . . . . . . . . . . . 105
Gas Pressure Regulator Condensation - Between 10 000 and 20 000 Service

Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Hours
Generator Winding Insulation - Test . . . . . . . . . 115
Engine Oil Temperature Regulator - Replace . . . 97
Hoses and Clamps - Inspect/Replace. . . . . . . . . . . .
Overhaul (Top End) . . . . . . . . . . . . . . . . . . . . . . . 123
Inlet Air System - Check. . . . . . . . . . . . . . . . . . . 120
Radiator - Clean . . . . . . . . . . . . . . . . . . . . . . . . . 127 Between 22 000 and 40 000 Service
Valve Stem Projection - Measure/Record . . . . . 135 Hours
Water Pump - Inspect. . . . . . . . . . . . . . . . . . . . . 137 Overhaul (In-Frame). . . . . . . . . . . . . . . . . . . . . . 121
Every 2000 Service Hours Every 24 000 Service Hours or 3

Years
Carburetor Air/Fuel Ratio - Check/Adjust . . . . . . 81
Coolant (NGEC) - Change . . . . . . . . . . . . . . . . . . 81
Compressor Bypass - Check . . . . . . . . . . . . . . . . 81
Generator - Inspect. . . . . . . . . . . . . . . . . . . . . . . 104 Between 45 000 and 80 000 Service
Generator Bearing - Lubricate . . . . . . . . . . . . . . 107
Hours
Overhaul (Major) . . . . . . . . . . . . . . . . . . . . . . . . . 122
Generator Set Vibration - Inspect . . . . . . . . . . . 114
70 SEBU7681-22
Maintenance Section
i06687406 The generator is disconnected from the load.
Maintenance Interval Schedule When Required

(Standby) Battery - Recycle . . . . . . . . . . . . . . . . . . . . . . . . . 79
SMCS Code: 1000; 4450; 7500
Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . 79
Ensure that all safety information, warnings, and
instructions are read and understood before any Battery or Battery Cable - Disconnect . . . . . . . . . 80
operation or any maintenance procedures are
performed. Coolant Sample (Level 2) - Obtain . . . . . . . . . . . 86
An authorized operator may perform the Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100
maintenance items with daily intervals. An authorized
operator may perform the maintenance items with Generator - Dry. . . . . . . . . . . . . . . . . . . . . . . . . . 102
intervals of every week. The maintenance that is
Generator Set - Test . . . . . . . . . . . . . . . . . . . . . . 113
recommended for all other maintenance intervals
must be performed by an authorized service Generator Set Alignment - Check . . . . . . . . . . . 113
technician or by your Cat dealer.
Generator Winding - Test . . . . . . . . . . . . . . . . . . 114
The user is responsible for the performance of all
maintenance which includes the following items: Space Heater - Test . . . . . . . . . . . . . . . . . . . . . . 129
performing all adjustments , using proper lubricants,
fluids, and filters and replacing old components with Stator Winding Temperature - Test . . . . . . . . . . 133
new components due to normal wear and aging .
Throttle Control Valve - Check . . . . . . . . . . . . . . 133
Failure to adhere to proper maintenance intervals
and procedures may result in diminished
performance of the product and/or accelerated wear Daily
of components.
Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . 96
Before each consecutive interval is performed, all
maintenance from the previous intervals must be Fumes Disposal Filter Differential Pressure -
performed. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Choose the interval that occurs first in order to

determine the correct maintenance interval: fuel
Every Week
consumption , service hours and calendar time .
Products that operate in severe operating conditions Air Tank Moisture and Sediment - Drain . . . . . . . 78
may require more frequent maintenance. Coolant Level - Check . . . . . . . . . . . . . . . . . . . . . 84
All of the following will affect the oil change interval: Engine Air Cleaner Service Indicator - Inspect . . 91
operating conditions , fuel type , oil type and size of
the oil sump . Scheduled oil sampling analyzes used Fuel Filter Differential Pressure - Check . . . . . . 100
oil in order to determine if the oil change interval is
suitable for your specific engine. Generator Bearing Temperature - Test/
Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Refer to this Operation and Maintenance Manual,
Engine Oil and Filter - Change in order to determine Generator Lead - Check. . . . . . . . . . . . . . . . . . . 112
the oil change interval that is suitable for your specific
Generator Load - Check. . . . . . . . . . . . . . . . . . . 112
engine.
Jacket Water Heater - Check. . . . . . . . . . . . . . . 121
To determine the maintenance intervals for the
overhauls, refer to this Operation and Maintenance Power Factor - Check. . . . . . . . . . . . . . . . . . . . . 127
Manual, Maintenance Recommendations .
Voltage and Frequency - Check . . . . . . . . . . . . 136
Unless other instructions are provided, perform
maintenance and perform repairs under the following Walk-Around Inspection . . . . . . . . . . . . . . . . . . . 136
conditions:
Battery Electrolyte Level - Check . . . . . . . . . . . . . . .
The starting system is disabled.
The engine is stopped. Every 250 Service Hours
The generator does not pose an electrical shock Coolant Sample (Level 1) - Obtain . . . . . . . . . . . 85
hazard.
SEBU7681-22 71
Maintenance Section
Standby
Cooling System Supplemental Coolant Additive Crankshaft Vibration Damper - Inspect . . . . . . . . . . .

(SCA) - Test/Add . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Crankshaft Vibration Damper - Inspect . . . . . . . . 88
Every 1000 Service Hours Generator Bearing - Lubricate . . . . . . . . . . . . . . 107
Crankcase Pressure - Measure. . . . . . . . . . . . . . 88 Hoses and Clamps - Inspect/Replace. . . . . . . . . . . .
Flexible Coupling - Inspect. . . . . . . . . . . . . . . . . 100
Every 3 Years
Valve Stem Projection - Measure/Record . . . . . 135
Every 1000 Service Hours or 6 Rotating Rectifier - Check . . . . . . . . . . . . . . . . . 128
Months
Engine Oil - Change . . . . . . . . . . . . . . . . . . . . . . . 93
Engine Oil Filter - Change . . . . . . . . . . . . . . . . . . 94
Ignition System Timing - Check/Adjust . . . . . . . 120
Every 10 000 Service Hours
Compressor Bypass - Check . . . . . . . . . . . . . . . . 81 Generator Bearing - Inspect. . . . . . . . . . . . . . . . 105
Generator - Inspect. . . . . . . . . . . . . . . . . . . . . . . 104 Between 10 000 and 20 000 Service

Hours
Every Year
Aftercooler Condensation - Drain . . . . . . . . . . . . 78
Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . 78
Crankcase Blowby - Test/Record . . . . . . . . . . . . 87
Engine Crankcase Breather - Clean . . . . . . . . . . 92
Engine Mounts - Inspect . . . . . . . . . . . . . . . . . . . 93
Engine Oil Sample - Obtain . . . . . . . . . . . . . . . . . 97
Engine Protective Devices - Check . . . . . . . . . . . 98
Engine Speed/Timing Sensor - Clean/Inspect . . 98
Engine Valve Lash and Bridge - Check. . . . . . . . 99
Gas Pressure Regulator Condensation -
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Radiator - Clean . . . . . . . . . . . . . . . . . . . . . . . . . 127
Spark Plugs - Inspect/Replace . . . . . . . . . . . . . 129
Starting Motor - Inspect . . . . . . . . . . . . . . . . . . . 132
Stator Lead - Check . . . . . . . . . . . . . . . . . . . . . . 133
Belts - Inspect/Adjust/Replace. . . . . . . . . . . . . . . 80
72 SEBU7681-22
Maintenance Section
i06688898 Walk-Around Inspection . . . . . . . . . . . . . . . . . . . 136
Maintenance Interval Schedule Initial 250 Service Hours

SMCS Code: 1000; 4450; 7500
When Required Every 250 Service Hours

Battery - Recycle . . . . . . . . . . . . . . . . . . . . . . . . . 79 Battery Electrolyte Level - Check . . . . . . . . . . . . . . .
Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . 79 Coolant Sample (Level 1) - Obtain . . . . . . . . . . . 85
Battery or Battery Cable - Disconnect . . . . . . . . . 80 Cooling System Supplemental Coolant Additive
Coolant Sample (Level 2) - Obtain . . . . . . . . . . . 86 (SCA) - Test/Add . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Engine Oil - Change . . . . . . . . . . . . . . . . . . . . . . . 93 Engine Oil Sample - Obtain . . . . . . . . . . . . . . . . . 97
Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100 Fumes Disposal Filter - Drain . . . . . . . . . . . . . . 101
Generator - Dry. . . . . . . . . . . . . . . . . . . . . . . . . . 102 Every 1000 Service Hours

Generator Lead - Check. . . . . . . . . . . . . . . . . . . 112 Aftercooler Condensation - Drain . . . . . . . . . . . . 78
Generator Set - Test . . . . . . . . . . . . . . . . . . . . . . 113 Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . 78
Generator Set Alignment - Check . . . . . . . . . . . 113 Crankcase Pressure - Measure. . . . . . . . . . . . . . 88
Generator Winding - Test . . . . . . . . . . . . . . . . . . 114 Crankshaft Vibration Damper - Inspect . . . . . . . . . . .
Overhaul Considerations . . . . . . . . . . . . . . . . . . 126 Crankshaft Vibration Damper - Inspect . . . . . . . . 88
Space Heater - Test . . . . . . . . . . . . . . . . . . . . . . 129 Engine Crankcase Breather - Clean . . . . . . . . . . 92
Stator Winding Temperature - Test . . . . . . . . . . 133 Engine Oil Filter - Change . . . . . . . . . . . . . . . . . . 94
Throttle Control Valve - Check . . . . . . . . . . . . . . 133 Engine Speed/Timing Sensor - Clean/Inspect . . 98
Daily Engine Valve Lash and Bridge - Check. . . . . . . . 99
Air Tank Moisture and Sediment - Drain . . . . . . . 78 Flexible Coupling - Inspect. . . . . . . . . . . . . . . . . 100
Coolant Level - Check . . . . . . . . . . . . . . . . . . . . . 85 Gas Pressure Regulator Condensation -

Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Coolant Level - Check . . . . . . . . . . . . . . . . . . . . . 84
Engine Air Cleaner Service Indicator - Inspect . . 91
Fuel Filter Differential Pressure - Check . . . . . . 100
Radiator - Clean . . . . . . . . . . . . . . . . . . . . . . . . . 127
Fumes Disposal Filter Differential Pressure -
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Valve Stem Projection - Measure/Record . . . . . 135
Generator Bearing Temperature - Test/ Water Pump - Inspect. . . . . . . . . . . . . . . . . . . . . 137
Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Jacket Water Heater - Check. . . . . . . . . . . . . . . 121 Every 2000 Service Hours
Power Factor - Check. . . . . . . . . . . . . . . . . . . . . 127 Carburetor Air/Fuel Ratio - Check/Adjust . . . . . . 81
Voltage and Frequency - Check . . . . . . . . . . . . 136 Compressor Bypass - Check . . . . . . . . . . . . . . . . 81
Generator - Inspect. . . . . . . . . . . . . . . . . . . . . . . 104
SEBU7681-22 73
Maintenance Section
Generator Set Vibration - Inspect . . . . . . . . . . . 114 Turbocharger - Inspect . . . . . . . . . . . . . . . . . . . . 133

Generator Bearing - Inspect. . . . . . . . . . . . . . . . 105
Between 10 000 and 20 000 Service
Spark Plugs - Inspect/Replace . . . . . . . . . . . . . 129 Hours
Every 4000 Service Hours Engine Oil Temperature Regulator - Replace . . . 97
Crankcase Blowby - Test/Record . . . . . . . . . . . . 87 Between 22 500 and 24 000 Service

Cylinder Pressure - Test/Record . . . . . . . . . . . . . 90 Hours
Engine Mounts - Inspect . . . . . . . . . . . . . . . . . . . 93 Overhaul (In-Frame). . . . . . . . . . . . . . . . . . . . . . 121
Engine Protective Devices - Check . . . . . . . . . . . 98 Every 24 000 Service Hours or 3

Ignition System Timing - Check/Adjust . . . . . . . 120 Years
Starting Motor - Inspect . . . . . . . . . . . . . . . . . . . 132 Coolant (NGEC) - Change . . . . . . . . . . . . . . . . . . 81
Between 7500 and 8000 Service Between 37 500 and 40 000 Service
Hours Hours
Overhaul (Top End) . . . . . . . . . . . . . . . . . . . . . . . 123 Overhaul (Major) . . . . . . . . . . . . . . . . . . . . . . . . . 122

74 SEBU7681-22
Maintenance Section

SMCS Code: 1000; 4450; 7500

Battery - Recycle . . . . . . . . . . . . . . . . . . . . . . . . . 79 Battery Electrolyte Level - Check . . . . . . . . . . . . . . .
Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . 79 Coolant Sample (Level 1) - Obtain . . . . . . . . . . . 85
Battery or Battery Cable - Disconnect . . . . . . . . . 80 Cooling System Supplemental Coolant Additive
Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100 Engine Oil Sample - Obtain . . . . . . . . . . . . . . . . . 97
Generator - Dry. . . . . . . . . . . . . . . . . . . . . . . . . . 102 Fumes Disposal Filter - Drain . . . . . . . . . . . . . . 101
Generator Lead - Check. . . . . . . . . . . . . . . . . . . 112 Every 1000 Service Hours

Generator Set - Test . . . . . . . . . . . . . . . . . . . . . . 113
Aftercooler Condensation - Drain . . . . . . . . . . . . 78
Generator Set Alignment - Check . . . . . . . . . . . 113
Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . 78
Generator Winding - Test . . . . . . . . . . . . . . . . . . 114 Crankcase Pressure - Measure. . . . . . . . . . . . . . 88
Overhaul Considerations . . . . . . . . . . . . . . . . . . 126 Crankshaft Vibration Damper - Inspect . . . . . . . . . . .
Space Heater - Test . . . . . . . . . . . . . . . . . . . . . . 129 Crankshaft Vibration Damper - Inspect . . . . . . . . 88
Stator Winding Temperature - Test . . . . . . . . . . 133 Engine Crankcase Breather - Clean . . . . . . . . . . 92
Throttle Control Valve - Check . . . . . . . . . . . . . . 133 Engine Oil - Change . . . . . . . . . . . . . . . . . . . . . . . 93
Daily Engine Oil Filter - Change . . . . . . . . . . . . . . . . . . 94
Air Tank Moisture and Sediment - Drain . . . . . . . 78 Engine Speed/Timing Sensor - Clean/Inspect . . 98
Coolant Level - Check . . . . . . . . . . . . . . . . . . . . . 84 Engine Valve Lash and Bridge - Check. . . . . . . . 99
Engine Air Cleaner Service Indicator - Inspect . . 91 Flexible Coupling - Inspect. . . . . . . . . . . . . . . . . 100
Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . 96 Gas Pressure Regulator Condensation -

Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fumes Disposal Filter Differential Pressure -
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Hoses and Clamps - Inspect/Replace. . . . . . . . . . . .
Generator Bearing Temperature - Test/ Inlet Air System - Check. . . . . . . . . . . . . . . . . . . 120
Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Radiator - Clean . . . . . . . . . . . . . . . . . . . . . . . . . 127
Water Pump - Inspect. . . . . . . . . . . . . . . . . . . . . 137
Power Factor - Check. . . . . . . . . . . . . . . . . . . . . 127
SEBU7681-22 75
Maintenance Section






Hours
Overhaul (Top End) . . . . . . . . . . . . . . . . . . . . . . . 123

Hours
Overhaul (In-Frame). . . . . . . . . . . . . . . . . . . . . . 121
Every 24 000 Service Hours or 3

Years

Hours
Overhaul (Major) . . . . . . . . . . . . . . . . . . . . . . . . . 122
76 SEBU7681-22
Maintenance Section

SMCS Code: 1000; 4450; 7500

Automatic Start/Stop - Inspect . . . . . . . . . . . . . . . 78 Battery Electrolyte Level - Check . . . . . . . . . . . . . . .
Battery - Recycle . . . . . . . . . . . . . . . . . . . . . . . . . 79 Coolant Sample (Level 1) - Obtain . . . . . . . . . . . 85
Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . 79 Cooling System Supplemental Coolant Additive
Engine Air Cleaner Service Indicator - Inspect . . 91 Engine Oil Sample - Obtain . . . . . . . . . . . . . . . . . 97
Engine Oil - Change . . . . . . . . . . . . . . . . . . . . . . . 93 Fumes Disposal Filter - Drain . . . . . . . . . . . . . . 101
Fuel Metering Valve - Check . . . . . . . . . . . . . . . 100 Every 1000 Service Hours

Generator - Dry. . . . . . . . . . . . . . . . . . . . . . . . . . 102 Aftercooler Condensation - Drain . . . . . . . . . . . . 78
Generator Lead - Check. . . . . . . . . . . . . . . . . . . 112 Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . 78
Generator Set - Test . . . . . . . . . . . . . . . . . . . . . . 113 Crankcase Pressure - Measure. . . . . . . . . . . . . . 88
Generator Set Alignment - Check . . . . . . . . . . . 113 Engine Crankcase Breather - Clean . . . . . . . . . . 92
Generator Winding - Test . . . . . . . . . . . . . . . . . . 114 Engine Oil Filter - Change . . . . . . . . . . . . . . . . . . 94
Overhaul Considerations . . . . . . . . . . . . . . . . . . 126 Engine Speed/Timing Sensor - Clean/Inspect . . 98
Space Heater - Test . . . . . . . . . . . . . . . . . . . . . . 129
Engine Valve Lash and Bridge - Check. . . . . . . . 99
Stator Winding Temperature - Test . . . . . . . . . . 133
Flexible Coupling - Inspect. . . . . . . . . . . . . . . . . 100
Throttle Control Valve - Check . . . . . . . . . . . . . . 133
Gas Pressure Regulator Condensation -
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Daily
Generator Winding - Test . . . . . . . . . . . . . . . . . . 114
Air Tank Moisture and Sediment - Drain . . . . . . . 78
Engine Air Cleaner Service Indicator - Inspect . . 91
Radiator - Clean . . . . . . . . . . . . . . . . . . . . . . . . . 127
Water Pump - Inspect. . . . . . . . . . . . . . . . . . . . . 137
Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Belts - Inspect/Adjust/Replace. . . . . . . . . . . . . . . 80
Power Factor - Check. . . . . . . . . . . . . . . . . . . . . 127
SEBU7681-22 77
Maintenance Section


Between 7500 and 8000 Service

Hours
Overhaul (Top End) . . . . . . . . . . . . . . . . . . . . . . . 123

Fumes Disposal Filter - Drain . . . . . . . . . . . . . . 101


Hours

Hours
Overhaul (In-Frame). . . . . . . . . . . . . . . . . . . . . . 121
Every 24 000 Service Hours or 3

Years

Hours
Overhaul (Major) . . . . . . . . . . . . . . . . . . . . . . . . . 122
78 SEBU7681-22
Maintenance Section
Aftercooler Condensation - Drain
i01721862
Aftercooler Condensation - When opening the drain valve, wear protective

Drain gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could
SMCS Code: 1063 cause debris to be blown and result in personal
injury.
The air/fuel mixture that is compressed and warmed
by the turbocharger compressor is directed through
the aftercooler core. The air/fuel mixture is cooled in NOTICE
the aftercooler. Care must be taken to ensure that fluids are con-
Condensation can form in the housing of the
aftercooler. A drain plug is provided for draining the
condensation. Be prepared to collect the fluid with suitable contain-
Note: An automatic drain is available for use with bling any component containing fluids.
32 C (90 F) separate circuit aftercoolers. Consult Refer to Special Publication, NENG2500, Cat Dealer
your Caterpillar dealer for details. Service Tool Catalog or refer to Special Publication,
PECJ0003, Cat Shop Supplies and Tools Catalog
for tools and supplies suitable to collect and contain
fluids on Cat products.
and mandates.
1. Open the drain valve that is on the bottom of the

air tank. Allow the moisture and sediment to drain.
2. Close the drain valve.
i04342909
Alternator - Inspect
Illustration 39 g00885207 SMCS Code: 1405-040
Remove the drain plugs (1) from the ends of the Inspect the alternator for the following conditions:
plenum. Drain the moisture into a suitable container.
Reinstall the plugs. Proper connections
i04534752
Clean ports for cooling airflow
Proper charging of the battery
Air Tank Moisture and
Sediment - Drain Observe the ammeter during engine operation in
order to ensure proper battery performance and/or
SMCS Code: 1466-543-M&S proper performance of the electrical system.
Moisture and sediment in the air starting system can Make repairs, if necessary. See the Service Manual
cause the following conditions: for service procedures. Consult your Cat dealer for
assistance.
Freezing
i01942284
Corrosion of internal parts
Malfunction of the air starting system Automatic Start/Stop - Inspect
SMCS Code: 4462
The generator set must be ready to operate under a
load at any time. After performing maintenance on
the generator set, inspect the position of the control
switches. Ensure the following conditions:
SEBU7681-22 79
Maintenance Section
Battery - Recycle
The starting system is enabled. 3. Remove the NEGATIVE - terminal connection on

the battery. Ensure that the terminal can not
The control switches are in the correct position for contact the terminal on the battery.
automatic starting.
4. Remove the POSITIVE + terminal connection on
The switchgear and the automatic transfer the battery.
switches that are associated with the generator
are enabled. Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
i02039199 recycling facility.
Battery - Recycle 5. Remove the used battery.

SMCS Code: 1401-535; 1401; 1401-510; 1401-005; 6. Install the new battery.
1401-561
Note: Before the terminal connections are
Always recycle a battery. Never discard a battery. connected, ensure that the engine start switch is
Return used batteries to one of the following OFF.
locations:
7. Connect the POSITIVE + connection to the
A battery supplier POSITIVE + terminal on the battery.
An authorized battery collection facility 8. Connect the NEGATIVE - terminal connection to
the NEGATIVE - terminal on the battery.
A recycling facility
i06845102
i02710714
Battery - Replace Battery Electrolyte Level -

SMCS Code: 1401-510
Check
SMCS Code: 1401-535-FLV
When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a
Batteries give off combustible gases which can full charge to help prevent the battery from freezing.
explode. A spark can cause the combustible
gases to ignite. This can result in severe personal In warmer climates, check the electrolyte level more
injury or death. frequently.
Ensure proper ventilation for batteries that are in Ensure that the electrolyte level is 13 mm (0.5 inch)
an enclosure. Follow the proper procedures in or- above the top of the separators.
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
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.
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- 1. Remove the filler caps. Maintain the electrolyte
ing is attempted. level to the FULL mark on the battery.
Removing the battery cables or the batteries with If the addition of water is necessary, use distilled
the cover in place may cause a battery explosion water. If distilled water is not available, use clean
resulting in personal injury. water that is low in minerals. Do not use artificially
softened water.
1. Ensure that the engine is stopped. Refer to this 2. Check the condition of the electrolyte with the
manual , Stopping the Engine. Ensure that all 245-5829 Coolant Battery Tester Refractometer.
electrical loads are removed.
3. Keep the batteries clean.
2. Turn off any battery chargers. Disconnect any
battery chargers.
80 SEBU7681-22
Maintenance Section
Battery or Battery Cable - Disconnect
Clean the battery case with one of the following i06581592

cleaning solutions:
Belts - Inspect/Adjust/Replace
A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water SMCS Code: 1357-025; 1357-510; 1357-040
A mixture of 0.1 L (0.11 qt) of ammonia and 1 L Inspection

(1 qt) of clean water
Inspect the alternator belt and the fan drive belts for
Thoroughly rinse the battery case with clean wear and for cracking. Replace the belts if the belts
water. are not in good condition.
Use the 1U-9921 Battery Service Tool to clean Check the belt tension according to the information in
the battery terminals. Use a wire brush to clean the Service Manual, Specifications.
the cable clamps. Clean the items until the
surfaces are bright or shiny. DO NOT remove Slippage of loose belts can reduce the efficiency of
material excessively. Excessive removal of the driven components. Vibration of loose belts can
material can cause the clamps to fit improperly. cause unnecessary wear on the following
Coat the clamps and the terminals with 5N-5561 components:
Silicone Lubricant, petroleum jelly or MPGM.
Belts
i02857256
Pulleys
Battery or Battery Cable - Bearings
Disconnect If the belts are too tight, unnecessary stress is placed
SMCS Code: 1401; 1402-029 on the components. Belts that are too tight reduces
the service life of the components.
Adjusting the Alternator Belt

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. Turnoff any battery chargers. Disconnect any
battery chargers.
3. 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.
4. Tape the leads in order to help prevent accidental
starting. Illustration 40 g01092641
Typical alternator
5. Proceed with necessary system repairs. Reverse
(1) Mounting bolt
the steps in order to reconnect all of the cables. (2) Adjusting nuts
(3) Mounting bolt
1. Loosen mounting bolt (1), adjusting nuts (2) and

mounting bolt (3).
SEBU7681-22 81
Maintenance Section
Carburetor Air/Fuel Ratio - Check/Adjust
2. Turn adjusting nuts (2) to increase or decrease the i02896718

drive belt tension.
3. Tighten adjusting nuts (2). Tighten mounting bolt
Compressor Bypass - Check
(3). Tighten mounting bolt (1). For the proper SMCS Code: 1050-535
torque, see the Service Manual, Specifications
module.
Note: If new drive belts are installed, check the drive
belt tension again after 30 minutes of engine
operation at the rated rpm.
4. Stop the engine.

5. Use the 491-2178 Belt tension meter tool to
check the tension with the alternator guard
installed.
Note: The current guard design allows for inspection
of the belt tension without removal of the guard.
Adjusting the Fan Drive Belt Illustration 41 g01340674

Hydraulically operated valve
1. Loosen the mounting bolt for the pulley.
Check for leaks. If necessary, remove the actuator
2. Loosen the adjusting nut for the pulley. according to the instructions in the Service Manual,
Disassembly and Assembly manual. Inspect the
3. Move the pulley to adjust the belt tension.
throat for wear marks. Check for free movement of
4. Tighten the adjusting nut to the proper torque. the butterfly valve. If necessary, replace the valve.
5. Tighten the mounting bolt to the proper torque. Inspect the gaskets for wear or damage. If
For the proper torque specifications, refer to the necessary, replace the gaskets. Reinstall the
Service Manual, Specifications module. actuator according to the instructions in the Service
Manual, Disassembly and Assembly manual.
Replacement Inspect the coupling for the compressor bypass for
wear and play. If necessary, replace the coupling.
For applications that require multiple drive belts, Excessive wear in the coupling can cause low power
replace the drive belts in matched sets. Replacing or instability in the engine.
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
i03906355
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
Coolant (NGEC) - Change
i02904927
SMCS Code: 1350-044
Carburetor Air/Fuel Ratio - Clean the cooling system before the recommended
maintenance interval if the following conditions exist:
Check/Adjust
SMCS Code: 1266; 1266-535 The engine overheats frequently.
An engine failure may occur if the air/fuel ratio is not Foaming is observed.
appropriate for the fuel and for the operating
conditions. The service life of the turbocharger, of the The oil has entered the cooling system and the
valves, and of the other components may be coolant is contaminated.
reduced.
Coolant analysis indicates that the coolant has
Refer to the Systems Operation, Testing and broken down.
Adjusting for the correct procedure.
82 SEBU7681-22
Maintenance Section
Draining the Cooling System

NOTICE
bling any component containing fluids.
Refer to Special Publication, NENG2500, Dealer
Service Tool Catalog for tools and supplies suitable
to collect and contain fluids on Cat products.
and mandates.
Stop the engine and allow the engine to cool. Ensure
that the engine will not start when the cooling system
is drained.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools Illustration 42 g01445608
Group:
Locations of the vent and drain plugs
Outside Illinois 1-800-542-TOOL (1) Coolant outlet
Inside Illinois 1-800-541-TOOL (2) Aftercooler drain plug
(3) Oil cooler drain plug
Canada 1-800-523-TOOL (4) Engine block drain plug
(5) Drain plug for the adapter
NOTICE
Dispose of used engine coolant properly or recycle. 2. Remove the vent plug from coolant outlet (1).
Various methods have been proposed to reclaim Open drain (2). Remove drain plugs (3), (4), and
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac- (5).
ceptable by Caterpillar to reclaim the used coolant.
Draining the Separate Circuit
Draining the Jacket Water

1. Loosen the cooling system filler cap slowly in order
to relieve any pressure. Remove the cooling
system filler cap.
1. Remove vent plugs (6).

SEBU7681-22 83
Maintenance Section
2. Open coolant drain valve (7). 7. Flush the cooling system with clean water until the
water that drains is clean. Close the cooling
Clean the Cooling System system drain valves. Clean the drain plugs and
install the drain plugs.
NOTICE
Use of commercially available cooling system Cleaning a Cooling System that
cleaners may cause damage to cooling system com- has Heavy Deposits or Plugging
ponents. Use only cooling system cleaners that are
approved for Caterpillar engines.
Note: For the following procedure to be effective,
there must be an active flow through the cooling
1. After the cooling system has been drained, flush system components.
the cooling system with clean water in order to
remove any debris. 1. After the cooling system has been drained, flush
the cooling system with clean water in order to
2. Close the cooling system drain valves. Clean the remove any debris.
drain plugs and install the drain plugs.
2. Close the cooling system drain valves. Clean the
NOTICE drain plugs and install the drain plugs.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. 3. Remove the vent plugs.
4. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
NOTICE Cleaner. Add 0.5 L (1 pt) of cleaner per
If the aftercooler circuit has been drained, the vent
plug must be opened to allow the aftercooler to fill 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
properly. Failure to do this will cause an air lock re- capacity. Install the cooling system filler cap.
sulting in engine damage. Install the vent plugs.
5. Start the engine. Operate the engine for a
3. When the separate circuit is filled, be sure to minimum of 90 minutes with a coolant temperature
remove the vent plug. of at least 82 C (180 F).
4. Fill the cooling system with a mixture of clean 6. Stop the engine and allow the engine to cool.
water and Caterpillar Fast Acting Cooling System Loosen the cooling system filler cap slowly in
Cleaner. Add 0.5 L (1 pt) of cleaner per 15 L order to relieve any pressure. Remove the cooling
(4 US gal) of the cooling system capacity. Install system filler cap. Open the cooling system drain
the cooling system filler cap. Install vent plugs (1). valves and remove the drain plugs. Remove the
5. Start the engine. Operate the engine for a vent plugs. Allow the cleaning solution to drain.
minimum of 30 minutes with a coolant temperature
of at least 82 C (180 F). NOTICE
Improper or incomplete rinsing of the cooling system
6. Stop the engine and allow the engine to cool. For can result in damage to copper and other metal
components.
the jacket water and the separate circuit, loosen
the cooling system filler cap slowly in order to To avoid damage to the cooling system, make sure to
relieve any pressure. Remove the cooling system completely flush the cooling system with clear water.
filler cap. Open the cooling system drain valves Continue to flush the system until all signs of the
and remove the drain plugs. Remove the vent cleaning agent are gone.
plugs. Allow the cleaning solution to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
cleaning agent are gone.
84 SEBU7681-22
Maintenance Section
Coolant Level - Check
7. Flush the cooling system with clean water until the 7. Start the engine. Inspect the cooling system for
water that drains is clean. Close the cooling leaks and for proper operating temperature.
system drain valves. Clean the drain plugs and
install the drain plugs. i04696591
Fill the Cooling System Coolant Level - Check

SMCS Code: 1395-082
NOTICE
It is recommended that the cooling system is filled
from the bottom with the cap removed from the ex-
pansion tank. Climbing equipment may be required to access
this service point. Refer to the Operation and
Maintenance Manual, Mounting and Dismount-
NOTICE ing topic for safety information.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
NOTICE
Overfilling the overflow tank (if equipped) will result in
Note: For information about the proper coolant to damage to the cooling system.
use, and for the capacity of the cooling system, refer
to this operation and maintenance manual, Refill If the cooling system has an overflow tank, maintain
Capacities and Recommendations (Maintenance the coolant level in the tank below 1/2 full in order to
Section). avoid damage to the cooling system.
1. Remove the vent plugs.

2. Fill the cooling system with coolant or antifreeze.
Install the vent plugs. Do not install the cooling
system filler cap yet.
3. Start the engine and operate the engine at low idle
for 10 minutes.
4. Increase the engine speed to high idle until the
thermostat opens and the coolant level is
stabilized.
5. Check the coolant level. Maintain the coolant to the
proper level on the sight gauge (if equipped). If the
machine is not equipped with a sight gauge,
maintain the coolant within 13 mm (0.5 inch) Illustration 44 g00760290
below the bottom of the filler pipe. Refer to Normal position of the coolant in the sight gauge
Operation and Maintenance Manual, Coolant during rated operation
Level - Check.
Observe the coolant level in the sight gauge (if
6. Clean the cooling system filler cap. Inspect the equipped). When the engine is running at normal
gaskets of the cooling system filler cap. If the operating temperature, the coolant should be in the
gaskets of the cooling system filler cap are upper half of the sight gauge. If the coolant level is
damaged, discard the old cooling system filler cap low, add the proper coolant mixture.
and install a new cap.
Add Coolant
Note: For the proper coolant mixture to use, see this
Operation and Maintenance Manual, Refill
Capacities and Recommendations topic.
1. Stop the engine. Allow the engine to cool.

2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.
SEBU7681-22 85
Maintenance Section
Add Coolant
Note: For the proper coolant mixture to use, see this
Operation and Maintenance Manual, Fluid
Recommendations topic and this Operation and
Maintenance Manual, Refill Capacities topic.
1. Stop the engine. Allow the engine to cool.

2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.
Filler cap gaskets
3. Clean the cooling system filler cap. Inspect the

gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
4. Start the engine. Inspect the cooling system for
leaks.
i06064185 Illustration 46 g00103639

Filler cap gaskets
SMCS Code: 1395-082 3. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
S/N: SB31Up gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
S/N: NWD1Up cap. Install the cooling system filler cap.
S/N: GZJ552Up 4. Start the engine. Inspect the cooling system for
S/N: F6M1Up leaks.
i03852509
Climbing equipment may be required to access Coolant Sample (Level 1) -

this service point. Refer to the Operation and
Maintenance Manual, Mounting and Dismount-
Obtain
ing topic for safety information. SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
NOTICE Always use a designated pump for oil sampling, and
Overfilling the overflow tank (if equipped) will result in use a separate designated pump for coolant sam-
damage to the cooling system. pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
If the cooling system has an overflow tank, maintain drawn. This contaminate may cause a false analysis
the coolant level in the tank below 1/2 full in order to and an incorrect interpretation that could lead to con-
avoid damage to the cooling system.
cerns by both dealers and customers.
Observe the coolant level in the sight gauge (if
equipped). When the engine is running at normal For conventional heavy-duty antifreeze/coolant,
operating temperature, the coolant should be in the check the concentration of supplemental coolant
upper half of the sight gauge. If the coolant level is additive (SCA) regularly. The concentration of SCA
low, add the proper coolant mixture. can be checked with an SOS coolant analysis
(Level 1).
86 SEBU7681-22
Maintenance Section
Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible Refer to this Operation and Maintenance Manual,
to the recommended sampling interval. In order to Cooling System Coolant Sample (Level 1) - Obtain
receive the full effect of SOS analysis, you must (Maintenance Section) for the guidelines for proper
establish a consistent trend of data. In order to sampling of the coolant.
establish a pertinent history of data, perform
consistent samplings that are evenly spaced. Submit the sample for Level 2 analysis.
Supplies for collecting samples can be obtained from
your Caterpillar dealer. For additional information about coolant analysis, see
the Special Publication, SEBU6400, Caterpillar Gas
Use the following guidelines for proper sampling of Engine Lubricant, Fuel, and Coolant
the coolant: Recommendations or consult your Cat dealer.
Never collect samples from expansion bottles. i05870232
Never collect samples from the drain for a system.

Cooling System Supplemental
Keep the unused sampling bottles stored in plastic Coolant Additive (SCA) - Test/
bags.
Add
Keep the lids on empty sampling bottles until you
are ready to collect the sample. SMCS Code: 1352-045; 1395-081
Complete the information on the label for the

sampling bottle before you begin to take the
samples. Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact
Obtain coolant samples directly from the coolant with the skin and eyes. Do not drink cooling sys-
sample port. You should not obtain the samples tem coolant additive.
from any other location.
In order to avoid contamination, immediately Note: Caterpillar recommends an SOS coolant

place the sample in the tube that is provided for analysis (Level 1).
mailing.
Submit the sample for Level 1 analysis. Test the Concentration of the SCA
Note: Level 1 results may indicate a need for Coolant/Antifreeze and SCA
Level 2 Analysis.
For additional information about coolant analysis, see NOTICE
the Special Publication, SEBU6400, Caterpillar Gas Do not exceed the recommended six percent supple-
Engine Lubricant, Fuel and Coolant mental coolant additive concentration.
Recommendations or consult your Caterpillar dealer.
Test the concentration of the SCA with the 4C-9301
Coolant Conditioner Test Kit. Follow the instructions
i04318144 that are provided in the kit.
Coolant Sample (Level 2) - Water and SCA

Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
NOTICE
Always use a designated pump for oil sampling, and Test the concentration of the SCA with the 4C-9301
use a separate designated pump for coolant sam- Coolant Conditioner Test Kit. Use the instructions
pling. Using the same pump for both types of sam- that follow:
ples may contaminate the samples that are being 1. Fill the syringe to the 1.0 ml mark with the
drawn. This contaminate may cause a false analysis
coolant.
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers. 2. Dispense the 1.0 mL coolant sample from the
syringe into the empty mixing bottle.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies for
collecting samples can be obtained from your Cat
dealer.
SEBU7681-22 87
Maintenance Section
Crankcase Blowby - Test/Record
3. Add tap water to the mixing bottle in order to bring

NOTICE
the level up to the 10 ml mark. Place the cap on Excessive supplemental coolant additive concentra-
the bottle and shake the bottle. tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
4. Add 2 to 3 drops of the NITRITE INDICATOR heat transfer characteristics. Reduced heat transfer
SOLUTION B to the mixing bottle. Move the bottle could cause cracking of the cylinder head and other
in a circular motion in order to mix the solution. high temperature components.
5. Add one drop of NITRITE TEST SOLUTION A to Excessive supplemental coolant additive concentra-
the mixing bottle. Move the bottle in a circular tion could also result in blockage of the heat ex-
motion in order to mix the solution. changer, overheating, and/or accelerated wear of the
water pump seal.
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of Do not exceed the recommended amount of supple-
mental coolant additive concentration.
drops of NITRITE TEST SOLUTION A that were
required to cause the color change.
3. Add the proper amount of SCA. The concentration
7. Use Table 18 to interpret the results.
of the SCA depends on the type of coolant that is
Table 18
used. To determine the proper amount, see this
Concentration of Maintenance Operation and Maintenance Manual, Refill
Number of Drops SCA Required Capacities topic. To determine the proper coolant,
Less than 25 Less than the recom- Add SCA. see this Operation and Maintenance Manual,
mended concentra- Retest the coolant. Fluid Recommendations topic.
tion of SCA
4. Clean the cooling system filler cap. Install the
25 to 30 The recommended None cooling system filler cap.
concentration of
SCA
i04319789
More than 30 More than the rec- Remove the coolant.
ommended concen-
tration of SCA
Replace with water
only
Crankcase Blowby - Test/
Retest the coolant. Record
SMCS Code: 1317-081
Add the SCA, If Necessary Measure the crankcase blowby of new engines.
Record the data. Continue to measure the blowby
periodically. Comparing the recorded data to the new
data provides information about the condition of the
Pressurized System: Hot coolant can cause seri- engines.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system Note: Crankcase blowby is one of the three factors
components are cool. Loosen the cooling system that help to determine the in-frame overhaul interval.
pressure cap slowly in order to relieve the For more information, see this Operation and
pressure. Maintenance Manual, Overhaul (In-Frame) topic.
After a new engine is used for a short time, the
1. Remove the cooling system filler cap slowly. blowby can decrease as the piston rings are seated.
The blowby will gradually increase as the following
Note: Always dispose of fluids according to local components show wear:
regulations.
Piston rings
2. If necessary, drain some coolant in order to allow
space for the addition of the SCA. Cylinder liners
Note: A problem with the piston rings causes the oil

to deteriorate rapidly. Information regarding the
condition of the piston rings can be obtained from the
measurement of the blowby and the results of oil
analysis.
The blowby of a worn engine may exceed the blowby
of a new engine by two times or more.
88 SEBU7681-22
Maintenance Section
Crankcase Pressure - Measure
A sudden increase in blowby could indicate a broken A damper that is hot is typically due to excessive
piston ring. The following conditions are other torsional vibration. A hot damper can also be due to
potential sources of blowby: the operating environment. See the Service Manual,
Application and Installation Guideline. Monitor the
Worn valve guides temperature of the damper during operation.
A turbocharger seal that leaks The 8T-2821 Temperature Indicator or the
8T-2822 Temperature Indicator are recommended
A rebuilt engine can have a high blowby due to the for monitoring the temperature of the damper. Evenly
following factors: space four of the adhesive indicators around the
outer diameter of the damper.
The piston rings are not seated properly.
Note: If you use an infrared thermometer to monitor
Worn parts such as valve guides were not the temperature of the damper, use the thermometer
replaced. during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
Excessive blowby may indicate the need for an reduce the interval for inspecting the damper and
overhaul. By keeping a record of the results, a
gradual increase in the amount of the blowby will be install temperature indicator strips for more accurate
noted until the amount has become excessive. readings.
To measure the blowby, use the 1U-8860 Large If the temperature of the damper reaches 90 C
Engine Blowby Pickup Group with the 8T-2701 (194 F), reduce the interval for inspecting the
Blowby Indicator. For instructions, see Special damper. If the temperature of the damper reaches
Instruction, SEHS8984, Using the 1U-8860 Large 100 C (212 F), consult your Caterpillar dealer.
Engine Blowby Pickup Group and Special
Instruction, SEHS8712, Using the 8T-2700 Inspect the damper for evidence of dents, cracks,
Blowby/Air Flow Indicator. and leaks of the fluid.
If a fluid leak is found, repair the damper or replace
For assistance, consult your Cat dealer. the damper. The fluid in the damper is silicone.
Silicone has the following characteristics:
i01601829 transparent, viscous, smooth and sticky.
Crankcase Pressure - Measure Inspect the damper and repair or replace the damper
for any of the following reasons.
(Engines with Fumes Disposal
The damper is dented, cracked, or leaking.
Filters)
The paint on the damper is discolored from heat.
SMCS Code: 1074
Measure the crankcase pressure during normal The temperature swatch has been tripped for
operation. temperatures greater than 100 C (212 F).
With a fumes disposal filter that is properly installed, Fluid analysis indicates the silicon fluid has
the crankcase pressure will be within 0.25 kPa degraded from its original viscosity by greater than
(1 inch of H2O) of the atmospheric pressure. 30 percent.
The engine has had a failure because of a broken

i06612601
crankshaft.
Crankshaft Vibration Damper - An analysis of the oil has revealed that the front
Inspect bearing of the crankshaft is badly worn.
SMCS Code: 1205-040 There is a large amount of gear train wear that is
not caused by a lack of oil.
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case.
Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
engine components. A deteriorating damper can
cause excessive gear train noise at variable points in
the speed range.
SEBU7681-22 89
Maintenance Section
Crankshaft Vibration Damper - Inspect
Damper Fluid Sampling

In order to take a damper fluid sample, you will need
to obtain a sample bottle and instructions 436-0477
Sample Set - Oil. The first silicon fluid sample should
be obtained at 15,000 hours. After the first fluid
sample, take regular samples every 4000 hours or at
an interval recommended by the analysis results. The
damper can be sampled a maximum of ten times
over the components life.
Removal and Installation

Refer to the Service Manual, Disassembly and
Assembly or consult your Caterpillar dealer for
information about damper replacement.
i06720204
Crankshaft Vibration Damper -

Inspect
(1500 RPM G3520 engines (if
equipped with an oil fed
damper))
SMCS Code: 1205-040
1. Remove the damper. 4. Clean all parts of the damper. Pay special attention
to the oil supply and venting holes.
2. Remove side plate (3).
5. Replace all accessible rubber seal rings.
3. Separate the inner adapter of the damper (2) from
the spring assembly (1). 6. Replace all disc springs from bolts that have been
removed.
Note: Do not disassemble the damper spring
assembly.
90 SEBU7681-22
Maintenance Section
Cylinder Pressure - Test/Record
7. Check for permissible wear of the Y-seal. Replace 1. Measure for wear. Refer to illustration 49
the seals whenever the damper is disassembled,
2. Measure every spring pack.
or there is evidence of leakage.
3. Place the measuring wedge between the inner
8. Assemble inner adapter (2) and spring assembly
ends of the spring blades and the wedge is
(1).
touching the inner adapter. The measuring wedge
end face and groove bottom must be parallel.
4. Press by hand or use a soft face hammer to force
the wedge along the inner star groove until the
spring tips rest on both groove faces.
The further the wedge can be pressed between the
spring blades, the greater the wear on the inner star
groove and spring blades. If the wedge can be
inserted to the "Not Go" section of the measuring
wedge, replace the damper.
i04319794
Cylinder Pressure - Test/

Record
SMCS Code: 1223; 1223-082-CC; 7450-081
Measure the cylinder pressure of new engines.
Record the data. Continue to measure the cylinder
pressure periodically. Comparing the recorded data
to the new data provides information about the
condition of the engine.
Cylinder pressure can be measured during
9. Check wear of the spring blades. Use of a inspection of the spark plugs. Use the following
measuring wedge is required. If a measuring guidelines for checking the cylinder pressure:
wedge is not supplied, then a wedge is to be
fabricated. Refer to illustration 48 . Remove all of the spark plugs.
Fully open the throttle plate.
Minimize the cranking time to three or four

revolutions which will enable a maximum
consistent cranking speed for the check. Also, the
battery power will be conserved.
A loss of cylinder pressure or a change of pressure in
one or more cylinders may indicate the following
conditions. These conditions may indicate a problem
with lubrication:
Excessive deposits
Guttering of valves
A broken valve
A piston ring that sticks
A broken piston ring

Worn piston rings
Worn cylinder liners
(1) Spring packs
(2) Measuring wedge
(3) Inner star
SEBU7681-22 91
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
If the cylinder pressure has risen by one or more

compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
To measure the cylinder pressure, use the
193-5859 Cylinder Pressure Gauge Gp. Follow the
procedure in the Special Instruction, NEHS0798 that
is included with the gauge group. Record the
pressure for each cylinder. Use the Operation and
Maintenance Manual, Valve Data Sheet (Reference
Materials Section).
Illustration 50 is a graph of typical cylinder pressures
for engines with different compression ratios.
Some engines may be equipped with a different

service indicator.
Observe the service indicator. Clean the air cleaner
element or replace the element when any of the
following conditions occur:
The yellow diaphragm enters the red zone.

The red piston locks in the visible position.
The air restriction reaches 3.75 kPa

(15 inch of H2O).
Test the Service Indicator

Service indicators are important instruments.
Apply vacuum (suction) to the service indicator.
Reset the service indicator.

If the yellow core does not latch at the greatest
vacuum, or if service indicator does not reset easily,
obtain a new service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.
(Y) Cylinder pressure in kPa
(X) Compression ratio
(1) Normal range for cylinder pressure
i01799090
Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040
A service indicator may be mounted on the air
cleaner element or in a remote location.
92 SEBU7681-22
Maintenance Section
Engine Crankcase Breather - Clean
Illustration 52 g00924884 Illustration 53 g00882365
A porous filter is part of the fitting that is used for

mounting of the service indicator. Inspect the filter for 1. Loosen clamps (1). Slide the clamps off tubes (2).
cleanliness. Clean the filter, if necessary. Use Remove the tubes.
compressed air or a clean, nonflammable solvent. 2. Loosen clamps (3). Remove each breather
Note: When service indicator is installed, excessive assembly (4) from the elbow assembly.
tightening may crack the top of the service indicator. 3. Remove O-ring seals from the elbow assembly.
Tighten the service indicator to a torque of 2 Nm Inspect the O-ring seals for good condition. Obtain
(18 lb in).
new O-ring seals, if necessary.
Replace the service indicator annually regardless of 4. Turn the breathers upside-down in order to inspect
the operating conditions.
the condition of the breather elements.
i02895754 Note: Do not replace the breathers in the upside-
down position. If breathers are not replaced properly
Engine Crankcase Breather - water could enter the crankcase and damage to the
Clean engine could result.
SMCS Code: 1317-070 Clean the breather elements with clean,

nonflammable solvent. If the breather elements
Clean the crankcase breather regularly in order to remain contaminated after the cleaning, discard
prevent excessive crankcase pressure that will the breather assemblies and obtain new breather
damage the engine's seals. assemblies. Do not attempt to disassemble the
breather assemblies.
Perform this maintenance when the engine is Allow the breather elements to dry before
stopped. installation.
Note: Lubricate the bore of the elbow assembly with
clean engine oil and install the O-ring seals.
5. Install breather assemblies (4) and tighten clamps

(3). Install elbows (2) and clamps (1). Tighten the
clamps.
SEBU7681-22 93
Maintenance Section
Engine Mounts - Inspect
i03852569 i02017618
Engine Mounts - Inspect Engine Oil - Change

SMCS Code: 1152-040; 1152 SMCS Code: 1348-044; 1348
Hot oil and components can cause personal

injury.
Do not allow hot oil or components to contact
skin.
Typical configuration of mounting bolts for a NOTICE
Ensure that the engine is stopped before performing
Caterpillar genset this procedure. Attach a DO NOT OPERATE tag to
(1) Mounting bolts for the engine the starting controls.
(2) Mounting bolts for the generator
(3) Levelling bolts for the isolators Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the
Misalignment of the engine and the driven equipment bottom of the oil pan. The waste particles are not
will cause extensive damage. Excessive vibration removed when the cold oil is drained. Drain the
can lead to misalignment. Excessive vibration of the crankcase with the oil warm, immediately after the
engine and the driven equipment can be caused by engine is stopped. This draining method allows the
the following conditions: waste particles that are suspended in the oil to be
drained properly. Failure to follow this recommended
Improper mounting procedure will allow the waste particles to be
recirculated through the engine lubrication system
Misalignment of driven equipment with the new oil.
Loose bolts 1. After the engine has been operated at normal
operating temperature, STOP the engine.
Deterioration of the isolators
Ensure that the mounting bolts are tightened to the Note: Drain the oil into a suitable container. Dispose
proper torque. For standard torques, see of fluids according to local regulations.
Specifications, SENR3130, Torque Specifications.
2. Drain the oil by using one of the following methods.
Ensure that the isolators are free of oil and Use the method that corresponds to the
contamination. Inspect the isolators for deterioration. equipment on the engine.
Ensure that the bolts for adjusting the isolator are
correctly adjusted and secured with the locking nut. Note: If a suction device is used in order to remove
Correctly adjusted isolators provide even support for the oil from the oil pan, ensure that the suction
the engine base. Each isolator should impose nearly device is clean. This will prevent dirt from entering
identical force on the base rail. Each isolator should into the oil pan. Be careful not to strike the engine
bear the same portion of the weight of the genset.
oil suction tubes or the piston cooling jets.
Replace any isolator that shows deterioration. For
more information, see the literature that is provided a. If the engine has an oil drain valve, open the
by the OEM of the isolators. Also see the Application valve in order to drain the oil. After the oil has
and Installation Guide for the engine. Consult your drained, close the valve.
Caterpillar dealer for assistance.
b. If the engine has a pump for removing dirty oil,
connect a hose to the outlet of the pump. Place
the hose in a suitable container. Open the valve
for the drain line. Operate the pump until the
crankcase is empty. Close the valve to the drain
line. Disconnect the hose.
c. If the oil drain valve has a quick connect
coupling, attach the coupling. Open the drain
valve in order to drain the crankcase. After the
94 SEBU7681-22
Maintenance Section
Engine Oil Filter - Change
oil has drained, close the drain valve.

NOTICE
Disconnect the coupling. To prevent crankshaft damage and to prevent bearing
damage, manually operate the prelube pump or
d. If the engine does not have a drain valve or a crank the engine with the fuel supply line closed for
pump, remove an oil drain plug. Allow the oil to 15 to 30 seconds. This will ensure that all of the oil fil-
drain. After the oil has drained, clean the drain ters are filled with oil before the engine is started.
plug and clean the fitting for the drain plug.
Install the drain plug. Tighten the drain plug to 5. Close the fuel supply line. Crank the engine until
145 15 Nm (105 10 lb ft). the oil pressure gauge indicates 70 kPa (10 psi).
Open the fuel supply line. Allow the starting motor
Note: Ensure that the dirty oil is thoroughly drained
from the pan. Caterpillar recommends a thorough to cool for two minutes before cranking again.
cleaning of the oil pan with a vacuum and with rags 6. Follow this Operation and Maintenance Manual,
in order to completely remove all of the old oil. This Starting The Engine procedure (Operation
will help prevent inaccurate oil analysis results and/ Section). Operate the engine at low idle for two
or shortened life of the oil.
minutes. This will ensure that the lubrication
3. Replace the engine oil filter elements before filling system and the oil filters are filled with oil. Inspect
the crankcase with new oil. the engine for oil leaks. Ensure that the oil level is
between the ADD and the FULL marks on the
a. For the procedure to change the engine oil LOW IDLE side of the oil level gauge.
filters, refer to the Operation and Maintenance
Manual, Engine Oil Filter - Change topic 7. Stop the engine and allow the oil to drain back into
(Maintenance Section). the sump for a minimum of ten minutes.
8. Remove the oil level gauge and check the oil level.
NOTICE Maintain the oil level between the ADD and the
Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge FULL marks on the ENGINE STOPPED side of
(dipstick). the oil level gauge.
An overfull crankcase can cause the crankshaft to dip i04795253

into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These Engine Oil Filter - Change
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil SMCS Code: 1308-510; 1308
pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption. Replace the engine oil filters when any of the
following conditions are met:
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De- The engine oil is changed.
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of The engine oil filter differential pressure reaches
carbon under the piston rings and wear of the cylin- 100 kPa (15 psi).
der liner.
The engine oil filters have been used for 1000
If the oil level is above the FULL mark on the oil lev- operating hours.
el gauge, drain some of the oil immediately.
Replace the Oil Filter Elements
Note: For the appropriate oil to use, and for the
amount of oil to use, refer to this Operation and
Maintenance Manual, Refill Capacities and
Recommendations article (Maintenance Section).
injury.
4. Remove the oil filler cap. Fill the crankcase
through the oil filler tube only. Clean the oil filler Do not allow hot oil or components to contact
cap. Install the oil filler cap. skin.
SEBU7681-22 95
Maintenance Section
Engine Oil Filter - Change
NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to
the starting controls.
NOTICE
bling any component containing fluids.
Refer to Special Publication, NENG2500, Dealer
Service Tool Catalog for tools and supplies suitable
to collect and contain fluids on Cat products. Illustration 56 g00103713
Mounting base and gasket
and mandates. 4. Clean the sealing surface of the mounting base.
Ensure that all of the old gasket is removed.
5. Apply clean engine oil to the gasket of the new oil
filter.
NOTICE
Caterpillar oil filters are built to Caterpillar specifica-
tions. Use of an oil filter not recommended by Cater-
pillar could result in severe engine damage to the
engine bearings, crankshaft, etc., as a result of the
larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom-
mended by Caterpillar.
6. Place the oil filter in position. Tighten the oil filter

by hand until the gasket contacts the base.
Illustration 55 g01441663 Tighten the oil filter by hand for an additional 1 full
turn (360 degrees). Do not overtighten the oil filter.
1. Remove oil drain plug (1). Drain the oil into a
suitable container. 7. Check the oil level according to the instructions in
this Operation and Maintenance Manual, Engine
2. Remove spin-on oil filters (2) with a Cat filter strap Oil Level - Check.
wrench.
3. Reinstall the oil drain plug. Inspect the Used Oil Filter
Elements
Cut the used oil filter element open with a Cat filter
cutting tool.
Remove the metal wrap. Cut the filter element free
from the end caps. Spread apart the pleats and
inspect the element for metal debris. Due to normal
wear and friction, small amounts of debris may be
found in the oil filter element. An excessive amount of
debris in the element may indicate early wear or a
pending failure. If an excessive amount of debris is
found in the oil filter element, consult your Cat dealer
in order to arrange for further oil analysis.
96 SEBU7681-22
Maintenance Section
Engine Oil Level - Check
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.
i02225089
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
The most accurate check of the engine oil level is
obtained when the engine is stopped. (3) ENGINE STOPPED WITH OIL COLD side
(4) ENGINE AT LOW IDLE WITH WARM OIL side
(5) ADD mark
(6) FULL mark
a. If the engine is stopped, remove the engine oil

level gauge. Observe the engine oil level on
ENGINE STOPPED WITH OIL COLD side (3).
b. If the engine is operating, reduce the engine

speed to low idle. Remove the engine oil level
gauge and observe the engine oil level on
ENGINE AT LOW IDLE WITH WARM OIL side
(4).
The engine oil level should be between ADD
mark (5) and FULL mark (6).
(1) Engine oil level gauge (dipstick) NOTICE
Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge
1. Remove the filler cap (not shown) in order to
(dipstick).
ensure that the crankcase pressure is equal to the
atmospheric pressure. An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
Excess pressure or a slight vacuum will affect oped and also force air bubbles into the oil. These
engine oil level that is measured. bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
2. Ensure that engine oil level gauge (1) is seated. pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylin-
der liner.
If the oil level is above the FULL mark on the oil lev-
el gauge, drain some of the oil immediately.
SEBU7681-22 97
Maintenance Section
Engine Oil Sample - Obtain
3. If necessary, add engine oil. For the correct engine Caterpillar recommends using the sampling valve in
oil to use, refer to this Operation and Maintenance order to obtain oil samples. The quality and the
Manual, Refill Capacities and Recommendations consistency of the samples are better when the
topic (Maintenance Section). Do not fill the sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
crankcase above the FULL mark on the engine obtained during normal engine operation.
oil level gauge. Clean the filler cap (2). Install the
filler cap. The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
4. Record the amount of engine oil that is added. For fluid sampling bottle includes the parts that are
the next engine oil sample and analysis, include needed for obtaining oil samples. Instructions are
the total amount of engine oil that has been added also provided.
since the previous oil change. This will help to
provide the most accurate analysis. NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
i04237495 pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
Engine Oil Sample - Obtain drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
SMCS Code: 1348-554-SM cerns by both dealers and customers.
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil If the engine is not equipped with a sampling valve,
analysis at regularly scheduled intervals. SOS oil use the 1U-5718 Vacuum Pump. The pump is
analysis provides infrared analysis, which is required designed to accept sampling bottles. Disposable
for determining nitration and oxidation levels. tubing must be attached to the pump for insertion into
the sump.
Obtain the Sample and the
For instructions, see Special Publication, PEGJ0047,
Analysis How To Take A Good SOS Oil Sample. Consult
your Cat dealer for complete information and
assistance in establishing an SOS program for your
engine.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to i04688489
contact the skin.
Engine Oil Temperature
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order to Regulator - Replace
help obtain the most accurate analysis, provide the SMCS Code: 1330-510
following information:
The oil temperature regulators divert the engine oil to
Engine model the oil cooler in order to maintain engine oil
temperature.
Service hours on the engine
For instructions on replacing the oil temperature
The number of hours that have accumulated since regulators, see the Service Manual, Disassembly
the last oil change and Assembly module.
The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
98 SEBU7681-22
Maintenance Section
Engine Protective Devices - Check
i02861779
Engine Protective Devices -

Check
SMCS Code: 7400-535
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that are
loose, broken, or damaged. Damaged wiring or
components should be repaired or replaced
immediately.
Calibration Check
Fixed head sensors (if equipped)
NOTICE
During testing, abnormal operating conditions must
be simulated.
The tests must be performed correctly in order to pre-
vent possible damage to the engine.
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible to
determine if the engine protective devices are in
good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices. To prevent damage to the
engine, only authorized service personnel or your
Caterpillar dealer should perform the tests.
Consult your Caterpillar dealer or refer to the Service
Manual for more information. Illustration 60 g00293337
i03900462 The fixed head sensor has a threaded end, and

screws directly into the flywheel housing.
Engine Speed/Timing Sensor - 1. Remove the speed sensor (1) from the housing.
Clean/Inspect Check the condition of the plastic end of the speed
sensors for wear and/or contaminants.
SMCS Code: 1905-070; 1905-040; 1907-070; 1907-
040 2. Clean the metal shavings and other debris from
the face of the speed sensors.
An engine speed/timing sensor is mounted in the
housing of the camshaft at the rear of the engine. 3. Install the engine speed/timing sensor.
The speed/timing sensor provides information about
engine speed and the position of the crankshaft to Slip head sensors (if equipped)
the ECM. There are two possible types of speed/
timing sensors: fixed head and slip head. 1. Remove engine speed/timing sensor (1). Inspect
the condition of the end of the magnet. Look for
signs of wear and contaminants.
2. Clean any debris from the face of the magnet.
SEBU7681-22 99
Maintenance Section
Engine Valve Lash and Bridge - Check
d. Install the sensor. Tighten the locknut to

40 5 Nm (30 4 lb ft).
i03852589
Engine Valve Lash and Bridge

- Check
Illustration 61 g01115363 SMCS Code: 1102-535; 1121-535
3. Check the tension of the slip head. Gently extend

the slip head (2) for a minimum of 4 mm
(0.16 inch). Then push back the slip head. Ignition systems can cause electrical shocks.
Avoid contacting the ignition system compo-
When the slip head has the correct tension, at nents and wiring.
least 22 N (5 lb) of force is required to push in the
slip head from the extended position. Do not attempt to remove the valve covers when
the engine is operating. The transformers are
NOTICE grounded to the valve covers. Personal injury or
The sliphead must be fully extended when the speed/ death may result and the ignition system will be
timing sensor is installed so that the sensor maintains damaged if the valve covers are removed during
the correct clearance with the speed-timing wheel. If engine operation. The engine will not operate
the correct clearance is not maintained, the signal without the valve covers.
from the sensor will not be generated.
For procedures on adjusting the valve bridge and the
Do not install the sensor between the teeth of the engine valve lash, refer to the following publications:
speed-timing wheel. Damage to the sensor would re-
sult. Before installing the sensor, ensure that a tooth Special Instruction, REHS0128, Using the 147-
of the wheel is visible in the mounting hole for the 5482 Indicator Gauge for Valve Lash and Valve
sensor. Bridge Adjustment
The Systems Operation/Testing and Adjusting
4. Install the engine speed/timing sensor. manual for the engine
a. Ensure that a tooth on the speed-timing wheel is The Specifications manual for the engine
visible in the mounting hole for the sensor.
Consult your Caterpillar dealer for assistance.
b. Extend the slip head (2) by a minimum of 4 mm
(0.16 inch). Valve Bridge
c. Coat the threads of the sensor with 4C-5597 Check the valve bridge and adjust the valve bridge, if
Anti-Seize Compound. necessary. Perform the procedure for both valve
bridges for each cylinder.
Note: The slip head is designed to contact a tooth
during the first revolution of the speed-timing After the valve bridge for each cylinder is satisfactory,
wheel. For the maximum allowable clearance measure the valve lash.
between the slip head and the tooth, refer to the
engine's Specifications manual. Engine Valve Lash
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. Improper
valve lash may also lead to valve failure, and result in
catastrophic failure.
100 SEBU7681-22
Maintenance Section
Flexible Coupling - Inspect
If the valve lash is within the tolerance, an adjustment Table 19

of the valve lash is NOT necessary. Dimensions for Usage of Boot (1)
Perform valve lash adjustment if the dimension is not A B
within the tolerance. The valve bridge adjustment
must be performed before making a valve lash 22.1 mm (0.870 inch) 14.1 mm (0.555 inch)(1)
adjustment. (1) The boot must be replaced.
Perform the valve lash setting when the engine is

i03857889
cold. After the engine has been shut down and the
valve covers are removed, the engine is considered
cold. Fuel Filter Differential
Before performing maintenance, prevent the entry of Pressure - Check
foreign matter into the top of the cylinder head and SMCS Code: 1261-535-PX
the valve mechanism. Thoroughly clean the area
around the valve mechanism covers. A fuel pressure gauge that measures fuel filter
differential pressure must be installed in order to
i03523641 determine when the fuel filter requires service. This
gauge and the fuel filter are supplied by the
Flexible Coupling - Inspect customer.
SMCS Code: 3279-040 A fuel pressure gauge that measures filter differential
pressure indicates the difference in fuel pressure
between the inlet side and the outlet side of the fuel
Coupling Boot Maintenance filter. The differential pressure increases as the fuel
filter becomes plugged.
Operate the engine at the rated rpm and at the rated
load. Check the fuel filter differential pressure.
Service the fuel filter when the fuel filter differential
pressure reaches 1.7 kPa (0.25 psi).
For instructions, refer to Special Instruction,
SEHS9298, Installation and Maintenance of
Gaseous Fuel Filters. Consult your Caterpillar dealer
for assistance.
i01724567
Fuel Metering Valve - Check

(Raptor )
SMCS Code: 1741-535
(1) 5N-3272 Rubber Coupling Boot
(2) Wear step
(A) Thickness of a new boot
(B) Replacement thickness
Inspect boot (1) at a minimum of 1500 hour service

intervals. Look for wear steps (2) in boot (1). A
measurement of the wear step can also be taken at
the same time. Use the results of the inspection to
adjust the service interval.
Do not measure the wear step directly due to
displaced rubber material. Measure the thickness at
the highest point of wear. Refer to Table 19 . Replace
boot (1) when the boot is worn to thickness (B).
(1) Fuel metering valve
SEBU7681-22 101
Maintenance Section
Fumes Disposal Filter - Drain
For information regarding the fuel metering valve, 5. Close the condensation trap drain valve.
refer to Installation and Operation Manual,
SEBU7630, Raptor Gas Regulation and Metering Resume normal operation.
Valve/Actuator System for Caterpillar.
i01601766
i01857938
Fumes Disposal Filter
Fumes Disposal Filter - Drain Differential Pressure - Check
SMCS Code: 1074
SMCS Code: 1074

injury.
skin.
Note: Always disconnect power to the fumes

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

filter.
Pressure gauge on top of the filter
Check the differential pressure across the filter

element. Observe the pressure that is indicated by
the pressure gauge on top of the filter. Record the
measurement.
The restriction of a new element is approximately
1.7 kPa (7 inches of H2O).
The normal restriction of the element is
approximately 5.7 to 9.95 kPa
(23 to 40 inches of H2O).
Replace the filter element when the differential

pressure reaches 11.2 kPa (45 inches of H2O).
Replace the element after every year regardless
of the differential pressure.
(1) Drip leg
(2) Condensation trap drain valve
i01749518
2. Open drip leg (1) and drain the fluid into a suitable
container. Fumes Disposal Filter Element
If the filter is installed and maintained properly, no - Replace
more than 28 g (1 ounce) of fluid will be drained. SMCS Code: 1074
If more than one 28 g (1 ounce) is drained, make
sure that the filter is installed according to the
instructions in Special Instruction, REHS0883.
Ensure that the system is operating properly. Hot oil and components can cause personal
injury.
3. Close the drip leg.
4. Open condensation trap drain valve (2) and drain skin.
the fluid into a suitable container.
102 SEBU7681-22
Maintenance Section
Gas Pressure Regulator Condensation - Drain
Note: Always disconnect power to the fumes

collector prior to servicing. The motor is protected by
a thermal protector. If the motor is shut down due to
excessive heat, the motor will automatically restart
when the protector resets.
Cap on the drip leg for the gas supply line to the gas
pressure regulator
1. Close the main gas supply valve.

Illustration 66 g00763796 2. Remove the caps from the drip legs.
(1) Nuts and washers
(2) Cover
3. Allow the moisture to drain into a suitable
(3) Body container. Inspect the drip legs for debris. Clean
(4) Filter element the drip legs, if necessary.
Note: The filter element is mounted above the 4. Clean the caps. Install the caps.
engine. A ladder or a platform will be required for 5. Open the main gas supply valve.
servicing the element.
i03214248
1. Remove three nuts and washers (1) in order to
remove cover (2) from body (3).
Generator - Dry
2. Remove element (4).
SMCS Code: 4450-569
3. Clean the inside of cover (2) and body (3).
4. Install new element (4) into body (3). NOTICE
Do not operate the generator if the windings are wet.
5. Place cover (2) in position and install three nuts If the generator is operated when the windings are
and washers (1). wet, damage can occur due to insulation breakdown.
i01950516
Gas Pressure Regulator Personal injury or death can result from improper
Condensation - Drain troubleshooting and repair procedures.
SMCS Code: 1270-543 The following troubleshooting and repair proce-
dures should only be performed by qualified per-
To collect condensation, drip legs should be installed sonnel familiar with this equipment.
in the following locations:
Refer to Safety Section, Generator Isolating for
Supply line for the gas pressure regulator Maintenance for information regarding the
procedure to safely isolate the generator.
Balance line for the gas pressure regulator
When moisture is present or when moisture is
Supply line to the gas shutoff valve suspected in a generator, the generator must be
dried before being energized.
If the drying procedure does not restore the insulation
resistance to an acceptable value, the winding should
be reconditioned.
SEBU7681-22 103
Maintenance Section
Generator - Dry
Drying Methods Table 20

TOOLS NEEDED
The following methods can be used for drying a
generator: Quantity Part Number Description
1 225-8266 Clamp-on ammeter

Self-circulating air method
(1200 amperes)
Oven method 1 External power
source circuit
Controlled current method
Energize the optional space heaters. Heat can be used in order to dry the generator
windings. This heat can be created by allowing a
controlled current to flow through the generator. No
NOTICE high voltages are generated during the following
Do not allow the winding temperature to exceed procedure. Therefore, insulation breakdown will not
85 C (185.0 F). Temperatures that are greater than occur.
85 C (185.0 F) will damage the winding insulation.
1. Make an external power source. Refer to
Illustration 68 .
Self-Circulating Air Method
2. Disconnect F1+ from the voltage regulator.
Run the engine and disconnect the generator load. Disconnect F2- from the voltage regulator.
This will help circulate air. Operate the generator Disconnect the generator load. Connect the
space heaters. generator output leads T0, T1, T2, and T3
together. Install the clamp-on ammeter to
Oven Method generator output lead T1.
Place the entire generator inside a forced air drying Note: When the line current is measured on multiple
oven for four hours at 65 C (149 F). lead units, measure the current in each conductor per
phase. The currents can then be added.
NOTICE
Use a forced air type oven rather than a radiant type 3. Refer to Illustration 68 . Adjust the rheostat to the
oven.
maximum resistance value. Connect the external
Radiant type ovens can cause localized overheating. power source to wires F1+ and F2-.
4. Start the generator set. Run the generator set at
Controlled Current Method IDLE speed.
NOTICE
Do not exceed the rated phase current that is listed
on the generator nameplate. Exceeding the rated
phase current will easily damage the generator
windings.
5. Monitor the phase current. In order to maintain use

of the circuits for the protection of safety, use the
control panel for the EMCP 3 to gradually
increase the engine rpm. Increase the engine rpm
until one of the following conditions are met:
The rated phase current is obtained.
The full generator set speed is obtained.

External Power Source Circuit 6. If more phase current is necessary, slowly turn the
(1) Battery (12 VDC) rheostat. Turn the rheostat until the rated phase
(2) Rheostat (15 ohm 25 watt) current is reached.
(3) Exciter Field (Stator L1 )
7. On an hourly basis, stop the drying procedure.
Check the insulation resistance. Repeat the above
steps until the insulation resistance is acceptable.
104 SEBU7681-22
Maintenance Section
Generator - Inspect
Guidelines for Space Heaters Carbon
1. Energize the space heaters when the generator is Salt

not operating.
Metal dust
2. Maintain the winding temperature at least 5 C
Dirt that is saturated with moisture
(9 F) over the ambient temperature. In order to
maintain the desired temperature in some These contaminants will develop a conductive path
conditions, a supplemental heat source or which may produce shorts. Cleaning is advisable if
temporary covers may be required. heavy accumulations of dirt can be seen or if heavy
accumulations of dust can be seen. If excess dirt is
3. Check the insulation resistance until the resistance the cause of a restriction in the ventilation, cleaning is
is acceptable. also advisable. Restricted ventilation will cause
excessive heating.
Note: For more information on drying methods, refer
to Special Instruction, SEHS9124, Cleaning and NOTICE
Drying of Electric Set Generators. 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
i06021154 present.
Generator - Inspect If harmful dirt accumulations are present, various

SMCS Code: 4450-040 cleaning techniques are available. The cleaning
procedure that is used may be determined by one of
the items on the following list:
Personal injury or death can result from improper The extent of the cleaning procedure that is being
troubleshooting and repair procedures. attempted
The following troubleshooting and repair proce- The type of enclosure of the generator
dures should only be performed by qualified per-
sonnel familiar with this equipment. The voltage rating of the generator
The type of dirt that is being removed
Cleaning (Assembled Generators)

The high voltage that is produced by an operating
generator set can cause severe injury or death. Cleaning may be required at the point of installation.
Before performing any maintenance or repairs, At this point, complete disassembly of the generator
ensure that the generator will not start. may not be necessary or feasible. In this case, a
vacuum cleaner should be used to pick up the
Place the engine control switch in the OFF posi- following items: dry dirt, dust and carbon. This will
tion. Attach DO NOT OPERATE tags to all start- prevent the spreading of these contaminants.
ing controls. Disconnect the batteries or disable
the starting system. Lock out all switchgear and A small nonconductive tube may need to be
automatic transfer switches that are associated connected to the vacuum cleaner. This will allow the
with the generator. vacuum cleaner to clean the surfaces that are not
exposed. After most of the dust has been removed, a
Refer to Safety Section, Generator Isolating for small brush may be attached to the vacuum hose in
Maintenance for information regarding the order to loosen dirt that is more firmly attached to the
procedure to isolate the generator safely. surface.
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:
SEBU7681-22 105
Maintenance Section
Generator Bearing - Inspect
After the initial cleaning with a vacuum, compressed 1. Remove the bearing bracket. Inspect the following
air may be used to remove the remaining dust and items: bracket bore, bearing outer race and rolling
dirt. Compressed air that is used for cleaning should elements. On standby power units, the bearing
be free of moisture and free of oil. Air pressure must be inspected and the grease must be
should be a maximum of 210 kPa (30 psi) in order to
prevent mechanical damage to the insulation. If the replaced at 3 yr intervals. The sleeve in the
above cleaning procedures are not effective, consult bearing bracket should be inspected for out of
a Cat dealer. roundness, excessive wear, and a bracket step
that is less than 0.0762 mm (0.0030 inch). If there
Cleaning (Disassembled is no sleeve in the bearing bracket, inspect the
bore of the bearing bracket. The bearing should be
Generators) inspected for damage to the outer race, severe
An initial insulation resistance check should be made fretting, and smoothness of operation. When
on the generator in order to confirm electrical possible, the bearing elements should be
integrity. A minimum reading of two megohm would inspected. Some double shielded ball bearings
be expected with severely contaminated generators. prevent visual inspection of the elements of the
A zero megohm reading may indicate an insulation bearing. Other double shielded ball bearings have
breakdown. An insulation breakdown requires more
than cleaning. An insulation breakdown requires a retaining ring. This retaining ring can be
repair. removed to allow access for a visual inspection of
the elements of the bearing.
A high-pressure wash is normally an effective way to
clean windings. This includes windings that have On two-bearing generators, the front bearing can
been exposed to flooding or windings that have been only be removed after the hub is removed. To
contaminated by salt. A solution of hot water and remove the hub, cutoff the hub with a saw. Do not
detergent is used for this method of cleaning. use a torch to remove the hub. Do not pull on the
hub. Pulling the hub will damage the shaft.
A high-pressure wash sprays a high velocity fluid
stream of this solution over the generator that is Note: Bearings that are being removed for failure
being cleaned. This detergent washing is followed by analysis should not be cutoff with a torch.
multiple sprays of clean water. The clean water is
used in order to remove the detergent or the clean 2. All ball bearings should be cleaned. The cavity in
water is used in order to dilute the detergent. the bracket should be repacked, refer to Special
Instruction, REHS4892, Generator Bearing
Allow the generator to dry at room temperature.
Check the insulation resistance. The insulation Service. Pack the ball bearings (one-third to one-
resistance should now be normal. If the insulation half of the volume of the cavity). Refer to Table 21
resistance is not normal, repeat the procedure. It may
be necessary to use solvents if the generator is To reinstall the ball bearings, use an induction
contaminated with oil or if the generator is heater to heat the ball bearings to 107 C
contaminated with grease. (224.6 F) for 10 minutes. Mount the bearings on
the shaft. To reinstall the hub, heat the hub to
Note: For more information on drying methods, refer 400 C (752.0 F) for 3 hours. Mount the hub to
to Special Instructions, SEHS9124, Cleaning and the shaft.
Drying of Electric Set Generators. 3. Ensure that the tube of the grease gun is filled with
grease.
i06612696
4. Remove the bracket drain plug and operate the
Generator Bearing - Inspect generator for 1 hour. Operating the generator will
allow the grease to expand. The expanding grease
SMCS Code: 4471-040
will force the excess grease from the cavity. When
The following maintenance procedure for generator the excess grease is forced from the cavity, the
bearings should be followed: 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.
106 SEBU7681-22
Maintenance Section
Generator Bearing - Inspect
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 4. DO NOT
MIX GREASES.
For additional information, refer to Special
Instructions, REHS 4892, Generator Bearing
Service.
Table 21
Bearing Rotor
Bearing Out- Bearing Inside Bearing Bore in Cavity Shaft
side Diameter Diameter Generator Bracket Bearing Grease Diameter
mm (inch) mm (inch) Part Number Frame Size mm (inch) Shield (Type) mL (oz) mm (inch)
225 mm 105 mm 6V-0410 680(1) 225.003 mm Single 139.12 mL 105.029 mm
(8.8582 inch) (4.1338 inch) (8.8584 inch) (4.7 oz) (4.1350 inch)
to to to
225.034 mm 230.88 mL 105.034 mm
(8.8596 inch) (7.8 oz) (4.1352 inch)
225 mm 105 mm 108-1760 680(1) 225.003 mm Double 148.00 mL 105.029 mm

to to to
225.034 mm 236.80 mL 105.034 mm
(8.8596 inch) (8.0 oz) (4.1352 inch)

to to to
240.033 mm 296.00 mL 110.028 mm
(9.4501 inch) (10.0 oz)(2) (4.3318 inch)
414.40 mL
(14.0 oz)
to
621.60 mL
(21 oz)(3)

to to to
240.033 mm 239.76 mL 110.028 mm
(9.4501 inch) (8.1 oz) (4.3318 inch)

to to to
240.033 mm 239.76 mL 110.028 mm
(9.4501 inch) (8.1 oz) (4.3318 inch)
(continued)
SEBU7681-22 107
Maintenance Section
Generator Bearing - Lubricate
(Table 21, contd)

Bearing Rotor
Bearing Out- Bearing Inside Bearing Bore in Cavity Shaft
side Diameter Diameter Generator Bracket Bearing Grease Diameter
mm (inch) mm (inch) Part Number Frame Size mm (inch) Shield (Type) mL (oz) mm (inch)
to to to
240.033 mm 236.80 mL 110.028 mm
(9.4501 inch) (8.0 oz) (4.3318 inch)
280 mm 130 mm 154-3032 820 280.002 mm Double 421 mL 130.028 mm

(11.024 inch) (5.1181 inch) (11.0237 inch) (14.31 oz) to (5.1192 inch)
to 638.44 mL to
280.032 mm (21.70 oz)(4) 130.051 mm
(11.0249 inch) 472.85 mL (5.1201 inch)
(16.07 oz) to
716.44 mL
(24.35 oz)(5)
(1) Inboard bearing
(2) This bearing is on the same end as the exciter.
(3) This bearing is on the drive end of the generator.
(4) This bearing is on the same end as the exciter.
(5) This bearing is on the drive end of the generator.
i06612714 Note: Add only the amount of grease listed in Table

22 . Do not continue to add grease until purging is
Generator Bearing - Lubricate observed. Purging of grease will not always be
observed.
SMCS Code: 4471-086
5. If grease fittings are permanently installed, ensure
Procedure for Bearing Service that the protective caps for the grease fittings are
installed on the fittings when finished. If a grease
Perform periodic bearing lubrication at the intervals fitting was installed in Step 2, remove the top
that are shown in Table 22 . Use the following grease fitting and install the plug that was
instructions as the suggested procedure to service
removed. If applicable, do not install the plug on
the bearings of the generator.
the bottom grease location yet. Wipe off the
Note: If the generator already has a visible grease excess grease.
point, go to Step 4.
Note: Do not allow grease to drip on the stator
1. Stop the generator set. Remove the required windings of the generator. The stator windings that
external cover plates, grills, and louvers of the are exposed to grease could suffer degraded
generator to access the bearings. insulation. The degraded insulation would cause a
reduction in the life of the windings.
2. Remove the top grease pipe plug and the lower
grease pipe plug. If no grease pipes can be found, 6. Operate the generator set at rated speed for
then locate the insert for the grease pipe. The approximately 1 hour. When running the engine
insert is on the bearing brackets. Remove the more than 30 minutes, the recommended engine
inserts. Install the grease pipes. load to apply is a minimum of 50%. The procedure
will allow the grease to expand. The expanding
3. Install a grease fitting in the top grease pipe. grease will force the excess grease from the
4. Use a Cat 8F-9866 Grease Gun or equivalent cavity. The internal pressure will be reduced as the
grease gun to grease the bearings. Use the excess grease is forced from the cavity. Operate
appropriate type of grease and the quantity that is the generator until no grease is forced out of the
listed in Table 22 . Avoid the use of alternate types cavity.
of grease. Usage of alternate types of grease
could cause premature bearing failure.
108 SEBU7681-22
Maintenance Section
7. Stop the generator set. Inspect the generator

windings, grease tubes, and bearing housings.
Wipe off any excess grease. If a grease pipe plug
was removed in Step 2, install the plug in the
bottom grease pipe. Wipe off any excess grease.
Note: Do not allow grease to drip on the stator

windings of the generator. The stator windings that
are exposed to grease could suffer degraded
insulation. The degraded insulation would cause a
reduction in the life of the windings.
8. Install all the external cover plates, grills, and

louvers of the generator that were removed to
access the bearings.
Table 22
Bearing Bearing Frame Temperature Grease Shaft

Part Number Type Size Maximum(1) Part Number Interval Weight Volume Diameter
5P-2448 315 BC 580 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 75 mm (3 inch)
Ball Bearing 160 mm 590 Instruction, service (1.8 oz)
(6.3 inch) REHS4892, hours or 12
OD Generator months
75 mm Bearing Service
(3 inch) ID
6Y-3955 220 BC 450 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 100 mm
Ball Bearing 180 mm Instruction, service (1.8 oz) (3.9 inch)
OD Generator months
(3.9 inch)
ID
6Y-6488 318 BC 597 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 90 mm (3.5 inch)
Ball Bearing 190 mm Instruction, service (1.8 oz)
OD Generator months
(3.5 inch)
108-1760 321 BC 680 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 105 mm
OD Generator months
(4.1 inch)
ID
Ball Bearing 240 mm 800 Instruction, service (1.8 oz) (4.3 inch)
OD Generator months
(4.3 inch)
ID
(continued)
SEBU7681-22 109
Maintenance Section
(Table 22, contd)

OD Generator months
(3.15 inch)
ID
139-0349 Roller 2900 85 C (185 F) 1p0808 Every 250 2.8 g N/A 127 mm (5 inch)
Roller Bearing 2800 service (0.1 oz)
hours
139-0350 Roller 2900 85 C (185 F) 1p0808 Every 250 2.8 g N/A 127 mm (5 inch)
Roller Bearing 2800 service (0.1 oz)
hours
Ball Bearing 280 mm 1800(2)(3) 95 C (203 F) Instruction, service (1.8 oz) (5.1 inch)
(11 inch) 2600(3) 85 C (185 F) REHS4892, hours or 12
OD 2700(3) 85 C (185 F) Generator months
(5.1 inch)
ID
193-4070 018 BC 498 85 C (185 F) Refer to Special Every 2000 51.2 g 59 mL (2 oz) 90 mm (3.5 inch)
Ball Bearing 140 mm 499 Instruction, service (1.8 oz)
OD Generator months
(3.5 inch)
ID
241-4644 320 BC LC7 95 C (203 F) UNIREX N3 Every 4500 60 g N/A 100 mm
Bearing 215 mm service (2.1 oz) (3.9 inch)
(8.5 inch) hours or 12
OD months
100 mm
(3.9 inch)
ID
243-5220 315 BB LC6100 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 75 mm (3.0 inch)
Bearing 160 mm LC5000
(6.3 inch)
OD
75 mm
(3.0 inch)
ID
253-9789 320 BC 1400 85 C (185 F) UNIREX N3 Grease can- N/A N/A 100 mm
Bearing 215 mm not be added (3.9 inch)
(8.5 inch) to this
OD bearing.
100 mm
(3.9 inch)
ID
253-9792 226BC 1400 95 C (203 F) EA6 Grease can- Grease Grease can- 140 mm
Bearing 230 mm not be added cannot be not be added (5.5 inch)
(9.05 inch) to this added to to this
OD bearing. this bearing.
130 mm bearing.
(5.12 inch)
ID
(continued)
110 SEBU7681-22
Maintenance Section
(Table 22, contd)

261-3545 307 BB LC2000 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 35 mm (1.4 inch)
Bearing 80 mm
(3.1 inch)
OD
35 mm
(1.4 inch)
ID
262-5921 307 BC LC2000 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 35 mm (1.4 inch)
Bearing 80 mm
(3.1 inch)
OD
35 mm
(1.4 inch)
ID
263-0161 309 BC LC3000 95 C (203 F) UNIREX N3 Sealed(4) Sealed Sealed 45 mm (1.8 inch)
Bearing 100 mm
(3.9 inch)
OD
45 mm
(1.8 inch)
ID
281-3091 328 BC 3010(2) 95 C (203 F) EA6 Grease can- Grease Grease can- 140 mm
Ball Bearing 300 mm 3020(2) not be added cannot be not be added (5.5 inch)
(11.8 inch) 3042(2) to this added to to this
OD 3044(2) bearing. this bearing.
140 mm 3045(2) bearing.
(5.5 inch)
ID
311-0843 326 BC 1800(2) 95 C (203 F) EA6 Grease can- N/A N/A 130 mm
Ball Bearing 280 mm not be added (5.1 inch)
(11 inch) to this
OD bearing.
130 mm
(5.1 inch)
ID
311-0844 322 BC 1600 95 C (203 F) EA6 Grease can- N/A N/A 110 mm
Ball Bearing 240 mm not be added (4.3 inch)
(9.4 inch) to this
OD bearing.
110 mm
(4.3 inch)
ID
(continued)
SEBU7681-22 111
Maintenance Section
Generator Bearing Temperature - Test/Record
(Table 22, contd)

341-7383 330 BC 3055(5) 95 C (203 F) Exxon Polyrex Every 1800 51.2 g 14.9 mL 150 mm
Ball Bearing 320 mm 3066(5) EMBase materi- service (1.8 oz) (0.5 oz) (5.9 inch)
(12.6 inch) 3068(5) al is Polyurea. hours or 12
OD months
150 mm
(5.9 inch)
ID
375-3715 328 BC 3010(2) (3) 95 C (203 F) Refer to Special Every 2400 51.2 g 59 mL (2 oz) 140 mm
Ball Bearing 300 mm 3020(2) (3) Instruction, service (1.8 oz) (5.5 inch)
(11.8 inch) 3042(2) (3) REHS4892, hours or 12
OD 3044(2) (3) Generator months
140 mm 3045(2) (3) Bearing Service
(5.5 inch)
ID
(1) Indicates the alarm temperature set point that the bearing should be continuously operated at on the specified generator frame size. Shut-
down set points are typically 10 C (18 F) higher.
(2) 1800 frame generators and 3000 frame generators shipped before 2012 use double-shielded bearings with EA6 grease. There are no
threaded holes in the bearing brackets for the grease tubes that are used to add grease. Therefore, no grease can be added to the bearings.
Beginning in 2012, 1800 frame generators and 3000 frame generators that are shipped will use a single-shielded bearing, Refer to Special
Instruction, REHS4892, Generator Bearing Service grease. The front and rear brackets contain factory installed grease fittings, therefore,
single-shielded bearings must be lubricated periodically. Reference the Parts Manual with package serial number to identify the bearing part
number and to determine bearing lubrication requirements.
(3) All 2600, 2700, 1800, and 3000 frame generators shipped beginning in 2012, use a single-shielded bearing design. Replacement bearings
received from the Parts Division will have a shield on each side of the bearing. The shield facing the outside of the generator must be re-
moved when the new bearing is installed.
(4) Grease cannot be added to this bearing. Refer to the Operation and Maintenance Manual, Generator Bearing - Replace article for informa-
tion concerning the replacement of these bearings.
(5) The generator uses a non-shielded bearing design. Although replacement bearings may have a shield on each side, both shields must be re-
moved when the new bearing is installed. Replacement bearings are shipped as dry bearings and must be packed to 50% grease fill at time
of installation.
Bearing Replacement Note: Generator set alignment is required after the

bearings are replaced.
Refer to the appropriate publication for each specific
generator for bearing replacement procedures. Additional Information
Replace both bearings of a two-bearing generator. Refer to Special Instruction, REHS4892, Generator
Replace any bearing wear sleeves and lip seals Bearing Service for further information.
when the bearings are replaced.
i03873412
Except for the 341-7383 Ball Bearing, replacement
bearings are pre-lubricated. The pre-lubricated
bearings do not require additional grease at time of
Generator Bearing
replacement. The 341-7383 Ball Bearing is shipped Temperature - Test/Record
as a dry bearing. The 341-7383 Ball Bearing must
be packed to 50% grease fill at time of installation. SMCS Code: 4471-081-TA
Old grease must be removed at the time of bearing The monitoring of bearing temperature may prevent
replacement from the bearing bracket cavity. After premature bearing failure. A generator set should
the bearing bracket cavity is cleaned, the bearing never operate above the recommended set points.
Keep records in order to monitor the changes in the
bracket cavity must be packed with new grease from
temperature of the bearing.
one-third to one-half full.
Note: Measure the bearing temperature after the
generator reaches normal operating temperature.
112 SEBU7681-22
Maintenance Section
Generator Lead - Check
Resistive Temperature Detectors The power factor can be referred to as the efficiency
of the load, which can be expressed as the ratio of
(RTDs) kVA to actual kW. The power factor can be calculated
by dividing kW by kVA. Power factor is expressed as
Caterpillar Generators may be equipped with a decimal. Power factor is used to mean the portion
resistance temperature detectors for generator of current that is supplied to a system that is doing
bearings. These detectors are 100 ohm resistance useful work. The portion of the current that is not
temperature detectors. A resistance temperature doing useful work is absorbed in maintaining the
detector may be monitored by equipment that is magnetic field in motors. This current (reactive load)
provided by the customer. Consult with your can be maintained without engine power.
Caterpillar dealer about other methods of measuring
the bearing temperature. Generator sets normally have a low idle setting that is
higher than industrial engines. Low idle will be
Infrared Thermometers approximately 66 percent of the full speed that is
achieved by 60 Hz units. This would be equal to 80
Bearing temperatures can also be recorded with the percent of the full speed that is achieved by 50 Hz
use of an infrared thermometer. Refer to Special units.
Publication, NENG2500, Caterpillar Dealer Service
Tools Catalog for a variety of infrared thermometers. Some generator sets are equipped with Woodward
Follow the instructions that come with your infrared governors and some generator sets are equipped
thermometer. with Cat electronic governors. These generator sets
have no low idle stop. On generator sets with
mechanical governors and generators that are
i05325030
natural gas, the low idle is set at the factory.
Adjustment of the low idle on these machines should
Generator Lead - Check only be done by a Cat dealer.
SMCS Code: 4450-535 Note: Operating the generator set at low idle speed
Check for signs of wear along the generator leads. for an extended time will cause some voltage
Pay particular attention to the leads at the housing for regulators to shut off. The generator set must be
the breaker and the generator terminal box. completely shut down and the generator set must be
restarted. This will allow the voltage regulator to
If the rubber mats or the insulation on the leads show produce an output again.
signs of wear at points of contact with other surfaces,
replace immediately. If your generator set does not
have rubber mats in place, contact your Cat dealer.
i05264201
Generator Load - Check

SMCS Code: 4450-535-LA
During normal operation, monitor the power factor
and monitor generator loading.
When a generator is installed or when a generator is
reconnected, ensure that the total current in any one
phase does not exceed the nameplate rating. Each
phase should carry the same load, which allows the
generator to work at the rated capacity. If one phase
current exceeds the nameplate amperage, an
electrical imbalance will occur. An electrical
imbalance can result in an electrical overload and an
electrical imbalance can result in overheating.
SEBU7681-22 113
Maintenance Section
Generator Set - Test
i01754617 1. Stop the generator. Remove the panels in order to

allow access to the regulator and control terminal
Generator Set - Test strips. Determine the part number for the regulator.
SMCS Code: 4450-081 Record the sensing voltage of the regulator. The
sensing voltage is 120 V 3%, 240 V 3%, or 480
V 3%. If the multimeter has the capability, also
record the frequency.
Personal injury or death can result from high 2. Verify that the generator set is ready to start. Start
voltage.
the generator set and bring the generator set to
When power generation equipment must be in rated speed. Measure the sensing voltage with the
operation to make tests and/or adjustments, high multimeter on terminals 20-22, 22-24, and 20-24.
voltage and current are present. If these voltages match the sensing voltage of the
regulator and if these voltages are nearly equal,
Improper test equipment can fail and present a
high voltage shock hazard to its user. then the output of the generator at the bus bar
should be the correct value.
Make sure the testing equipment is designed for
and correctly operated for high voltage and cur- 3. If the voltages do not match the sensing voltage of
rent tests being made. the regulator, see the service manual for the
regulator for further troubleshooting instructions.
When servicing or repairing electric power gener-
ation equipment: i03956450
Make sure the unit is off-line (disconnected

from utility and/or other generators power Generator Set Alignment -
service), and either locked out or tagged DO Check
NOT OPERATE.
(Generator Sets)
Make sure the generator engine is stopped.
SMCS Code: 7002-024
Make sure all batteries are disconnected.
The genset must be aligned when the genset is
Make sure all capacitors are discharged. 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
Table 23
checked annually.
Tools Needed(1) Properly maintain the alignment between the engine
and the driven equipment in order to minimize the
Part Number Part Quantity following problems:
6V-7070 Digital Multimeter 1
Bearing problems
146-4080 Digital Multimeter 1
Vibration of the engine crankshaft
9U7330 Digital Multimeter 1
(1) Any one of these multimeters may be used.
Vibration of the driven equipment
Refer to the following information for more
The generator set functional test is a simplified test
information about the alignment of the generator set:
that can be performed in order to determine if the
generator is functional. The generator set functional Special Instruction, SEHS7654, Alignment -
test should be performed on a generator set that is
General Instructions
not under load. The generator set functional test
determines if the generator is operating at expected Special Instruction, SEHS7259, Alignment of
voltage and frequency levels. Perform this test at the Single Bearing Generators
regulator and terminal strips. Do not perform this test
at the output connections. Special Instruction, REHS0177, Alignment of the
The generator set functional test consists of the Close Coupled Two Bearing Generators
following steps: Keep a record of the measurement of the alignment.
The record may be used to check the trend of the
alignment. The record may be used to analyze the
trend of the alignment.
114 SEBU7681-22
Maintenance Section
Generator Set Vibration - Inspect
i05264206 i03736530
Generator Set Vibration - Generator Winding - Test

Inspect SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
081
SMCS Code: 4450-040-VI
Check for vibration damage. Vibration may cause the
following problems:
Loose fittings
Loose belts
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 Cat Dealer Service Tools group for Illustration 69 g01388839
information on ordering a vibration analyzer that will PMPE Generator wiring diagram for the family of
meet your needs. 1800 frames
(CR1-C6) Diodes
(CR7) Varistor
(L1) Exciter stator
(L2) Exciter rotor
(L3) Main rotor
(L4) Main stator
(L5) Permanent magnet generator stator
(PM) Permanent magnet
(RFA) Rotating field assembly
(CT1) Optional voltage droop transformer
(T0, T1, T2, T3, T7, T8, T9) Generator terminals
SEBU7681-22 115
Maintenance Section
Generator Winding Insulation - Test
Table 24
Quantity Needed Tool i03736629
1 Low ohmmeter
Generator Winding Insulation -
Measure the resistance of the following windings: Test
(L1), (L2), (L3), (L4) and (L5). The winding that is
being tested must be disconnected from the other SMCS Code: 4453-081; 4454-081; 4457-081; 4470-
components before the resistance can be measured. 081
Note: The winding temperature affects the Recommended Periodic Insulation

resistance. When the winding temperature increases,
the winding resistance increases. When the winding Tests
temperature decreases, the winding resistance
decreases. Therefore, a correct measurement can be
performed only when the winding is at room
temperature. The high voltage that is produced by an operating
generator set can cause severe injury or death.
The following resistance measurements are Before performing any maintenance or repairs,
approximations. If the measured value is not near the ensure that the generator will not start.
listed approximation, the winding is probably
damaged. For a more precise resistance value, Place the engine control switch in the OFF posi-
consult the Technical Marketing Information (TMI). tion. Attach DO NOT OPERATE tags to all start-
Refer to the generator arrangement that is in ing controls. Disconnect the batteries or disable
question. the starting system. Lock out all switchgear and
automatic transfer switches that are associated
The following windings have very little resistance: with the generator.
(L2), (L4) and (L5). The resistance of these windings
will measure near 0 ohms. Use a milliohmmeter to Table 26
measure the resistance of the windings.
Tools Needed
Exciter rotor (L2) Refer to Table 25 .
Part Number Part Name Quantity
Main stator (L4) less than 0.1 ohm 300-8648 Insulation Testing 1
Pilot exciter stator (L5) less than 0.1 ohm Gp
Use a multimeter in order to measure the resistance Periodically, use an insulation tester to check the
of field windings (L1) and (L3). insulation resistance of the generator's main stator
winding. The frequency of this test is determined by
Exciter field (stator) (L1) Refer to table 25 . the generator's environment. Previous insulation
tester readings will also determine the frequency of
Main field (rotor) (L3) approximately 0.35 ohms to this test.
1.2 ohms
Test the main stator windings with an insulation tester
in the following situations:
Note: There should be no continuity between any
winding and ground. There should be no continuity The generator set is started for the first time.
between any winding and another winding.
The generator set is removed from storage.
Table 25
L2 Exciter Main Field for
The generator set is operating in a humid
L1 Exciter Field
Rotor the Rotor environment. Test every three months.
1800 Frame 10.9 ohms 0.05 ohms .9 ohms The generator set is not protected from the
1600 Frame 10 ohms 0.06 ohms .5 ohms
elements in an enclosed area. Test every three
months.
1400 Frame 11 ohms 0.06 ohms .35 ohms
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).
116 SEBU7681-22
Maintenance Section
The generator set has not been run under load for 11. Use the 30/60 Time Resistance Method:
three months. Test the generator set weekly. Use
space heaters around the generator set if the a. Apply voltage.
generator is exposed to a sea water environment
or if the humidity is above 75 percent. Also use b. Observe the readings at 30 seconds. Observe
space heaters if a test result was below 3 the readings at 60 seconds.
megohms.
c. Record the 60 second reading. This reading
Space heaters must be used whenever the generator must be corrected for temperature.
set is not under load. Space heaters must also be
used whenever salt is present or whenever high d. Record temperature.
humidity is present. Using a space heater in this
fashion is the only way to maintain insulation tester e. Record humidity.
readings above one megohm. Use space heaters
only when the generator is not running. f. Remove voltage.
For additional information, refer to Special 12. Evaluate the readings. The actual value of the
Instruction, SEHS9124, Cleaning and Drying of resistance may vary greatly between generators.
Electric Set Generators. For this reason, the insulation's condition must be
evaluated. Base this evaluation on the comparison
Recommended Procedure for the between the 60 second resistance readings and
Insulation Test 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,
Personal injury or death can result from the insulation may have absorbed too much
electrocution. moisture.
Switch the insulation tester to the OFF position.
The megohmmeter is applying a high voltage to This will discharge the insulation tester's leads.
the circuit. Disconnect the insulation tester's leads.
To avoid electrocution, do not touch the instru- Note: The results from the insulation resistance
ment leads without first discharging them. When
finished testing also discharge the generator checks indicate when cleaning and/or repairing is
windings. becoming critical. Generally, insulation resistance will
vary greatly with temperature. Therefore, always test
at the same temperature and humidity. Refer to
1. Take the generator out of service. Illustration 70 .
2. Visually inspect the generator for moisture. If Engine Serial Number
moisture exists, do not perform this insulation test.
Dry the unit first. Refer to Special Instruction, Serial Number for the Generator
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 .
10. Set the voltage to the rated voltage of the
generator.
SEBU7681-22 117
Maintenance Section
118 SEBU7681-22
Maintenance Section
Hoses and Clamps - Inspect/Replace
i06825542 Looseness
Hoses and Clamps - Inspect/ Damage

Replace Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
SMCS Code: 7554-510; 7554-040
Each installation application can be different. The
Hoses and clamps must be inspected periodically differences depend on the following factors:
and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure Type of hose
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. Take Type of fitting material
proper safety precautions before inspecting or
replacing hoses and clamps. Anticipated expansion and contraction of the hose
Note: Always use a board or cardboard when the Anticipated expansion and contraction of the
engine components are checked for leaks. Leaking fittings
fluid that is under pressure can cause serious injury
or possible death. Leaks that are the size of a pin Due to extreme temperature changes, the hose will
hole are included. Refer to Operation and heat set. Heat setting causes hose clamps to loosen
Maintenance Manual, General Hazard Information which can result in leaks. A constant torque hose
for more information. clamp will help to prevent loose hose clamps.
Note: Ensure that the hose is compatible with the Replace hoses that are cracked or soft. Replace
application. hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
Inspect Tubes, Hoses, Bellows, and hose clamps which are loose.
Clamps
Replace the Hoses and the Clamps
Inspect all tubes and hoses for leaks that are caused
by the following conditions. Replace any tube or hose
which exhibits any of the following conditions. Failure NOTICE
to replace a tube or hose which exhibits any of the tained during performance of inspection, mainte-
following conditions may result in a hazardous nance, testing, adjusting, and repair of the product.
situation. Be prepared to collect the fluid with suitable contain-
Hoses which are cracked bling any component containing fluids.
Hoses which are soft Refer to Special Publication, NENG2500, Cat Dealer
Service Tool Catalog or refer to Special Publication,
Outer covering that is chafed or cut PECJ0003, Cat Shop Supplies and Tools Catalog
for tools and supplies suitable to collect and contain
Exposed wire that is used for reinforcement fluids on Cat products.
Outer covering that is ballooning locally Dispose of all fluids according to local regulations
and mandates.
Flexible part of the hose that is kinked or crushed
Armoring that is embedded in the outer covering

Cooling System
Exhaust bellows for leaks or damage
Hoses which exhibit signs of leakage which are

not the result of loose couplings or clamps
Pressurized System: Hot coolant can cause seri-
Inspect all clamps for the following conditions. ous burns. To open the cooling system filler cap,
Replace any clamp which exhibits signs of any of the stop the engine and wait until the cooling system
following conditions. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
Cracking pressure.
SEBU7681-22 119
Maintenance Section
Hoses and Clamps - Inspect/Replace
Personal injury can result from removing hoses Contact with high pressure fuel may cause fluid
or fittings in a pressure system. penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
Failure to relieve pressure can cause personal these inspection, maintenance and service in-
injury. structions may cause personal injury or death.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
NOTICE
Do not bend or strike high pressure lines. Do not in-
1. Stop the engine. stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
2. Allow the engine to cool. hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
3. Before servicing a coolant hose, slowly loosen the recommended torque.
filler cap for the cooling system to relieve any
pressure.
NOTICE
4. Remove the filler cap for the cooling system. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
5. Drain the coolant from the cooling system to a will be disconnected. Fit a suitable cover over any
level that is below the hose that is being replaced. disconnected fuel system components.
Drain the coolant into a suitable clean container.
The coolant can be reused.
Note: High-pressure fuel lines may be installed
6. Remove the hose clamps. between the high-pressure fuel pump and the fuel
7. Disconnect the old hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the high-
8. Replace the old hose with a new hose. pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
9. Install hose clamps which have been inspected or engine stops before you perform any service or
install new hose clamps. Refer to Specifications, repair on high-pressure fuel lines. Waiting for 10
SENR3130, Torque Specifications Hose minutes will allow the pressure to be purged.
Clamps for information about selecting and
installing the proper hose clamps. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
10. Refill the cooling system.
2. Remove the hose clamps.
11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect 3. Disconnect the old hose.
the vacuum valve and seat for debris or damage.
Replace the filler cap if the gaskets are damaged. Note: When servicing fuel system, use cap/s or
cover/s as required to protect the system and
Install the filler cap.
maintain fuel system cleanliness.
12. Start the engine. Inspect the cooling system for
leaks. 4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
Fuel System install new hose clamps. Refer to Specifications,
SENR3130, Torque Specifications Hose
installing the proper hose clamps.
Personal injury can result from removing hoses
or fittings in a pressure system. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Failure to relieve pressure can cause personal engine.
injury.
Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved.
120 SEBU7681-22
Maintenance Section
Ignition System Timing - Check/Adjust
7. Refill the fuel system. Refer to this Operation and 5. Start the engine. Inspect the air lines for leaks.
Maintenance Manual, Fuel System - Prime for
information about priming the engine with fuel. i06024073
8. Start the engine. Inspect the fuel system for leaks.

Ignition System Timing -
Lubrication System Check/Adjust
SMCS Code: 1550-535; 1550-025
Ignition timing for gas engines varies with the gas
Hot oil and hot components can cause personal chemistry. Obtain a fuel analysis in order to
injury. Do not allow hot oil or hot components to determine if the timing for the ignition system is
contact the skin. correct. Evaluate the fuel with the Cat methane
number program that is contained in Gas Engine
Rating Pro (GERP). Alternatively, you may provide
1. Drain the oil from the lubrication system to a level the results of a gas analysis to your Caterpillar dealer
that is below the hose that is being replaced. for assistance in determining the correct timing for
your application.
2. Remove the hose clamps.
Use the Cat Electronic Technician (ET) to adjust the
3. Disconnect the old hose. timing. Adjust the timing according to the instructions
in Special Instruction, REHS1438, Installation and
4. Replace the old hose with a new hose. Initial Start-Up Procedures for G3500C and G3500E
Engines. Consult your Cat dealer for assistance.
install new hose clamps. Refer to Specifications,
i04342943
SENR3130, Torque Specifications Hose
installing the proper hose clamps.
Inlet Air System - Check
SMCS Code: 1058-535; 1071-535; 1087-535
6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, Engine Oil Use of a platform may be necessary to inspect the
Level - Check to ensure that the lubrication following components of the air inlet system:
system is filled with the proper amount of engine
Piping between the air cleaner and the
oil. turbocharger
7. Start the engine. Inspect the lubrication system for
Rubber hoses in the air lines
leaks.
Turbocharger
Air System
Piping between the turbocharger and the
1. Remove the hose clamps. aftercooler
2. Disconnect the old hose. Aftercooler
3. Replace the old hose with a new hose. Connection of the aftercooler to the air plenum
Connection of the air plenum to the cylinder head
install new hose clamps. Refer to Specifications,
SENR3130, Torque Specifications Hose Inspect the components for the following conditions:
installing the proper hose clamps. Cracks
Note: The bellows and the V-clamps that are used on Leaks
the exhaust bellows should never be reused.
Loose connections
Debris
Ensure that all of the connections are secure. Ensure
that the components are in good condition and free of
debris.
SEBU7681-22 121
Maintenance Section
Jacket Water Heater - Check
Make repairs, if necessary. For information regarding A 20 percent loss of cylinder compression
removal and installation of the components, refer to
Service Manual, Disassembly and Assembly. Note: These indications do not require an engine to
Consult your Cat dealer for assistance. be shut down for service. These indications only
mean that an engine should be scheduled for service
i03230758 in the near future. If the engine operation is
satisfactory, an immediate overhaul is not a
Jacket Water Heater - Check requirement.
SMCS Code: 1383-535 Monitor the engine as the engine accumulates

service hours. Consult your Caterpillar dealer about
Jacket water heaters help to improve startability in scheduling a major overhaul.
ambient temperatures that are below 21 C (70 F).
All installations that require automatic starting should Usually, an in-frame overhaul does not require
have jacket water heaters. removal of the engine. Instead, the service is
performed with the engine in place. If the customer
Check the operation of the jacket water heater. requires a minimum disruption in the production of
Check the operation of the circulation pump, if power, the engine can be replaced with a rebuilt
equipped. For an ambient temperature of 0 C model of identical specifications.
(32 F), the heater should maintain the jacket water
coolant temperature at approximately 32 C (90 F). Note: The generator or the driven equipment may
also require service when the engine overhaul is
i03460083 performed. Refer to the literature that is provided by
the OEM of the driven equipment.
Overhaul (In-Frame)
SMCS Code: 1000-020
In-Frame Overhaul Information
An in-frame overhaul includes all of the work that is
Scheduling an In-Frame Overhaul done for a top end overhaul. Additionally, some other
components that wear are replaced. The condition of
Generally, an in-frame overhaul is performed for components is inspected. Those components are
every third top end overhaul. Scheduling an in-frame replaced, if necessary.
overhaul normally depends on the following three Your Caterpillar dealer can provide these services
conditions: and components. Your Caterpillar dealer can ensure
that the components are operating within the
An increase of oil consumption appropriate specifications.
An increase of crankcase blowby The following definitions explain the terminology for
the services that are performed during an overhaul:
A decrease and a variation of cylinder
compression Inspect Inspect the components according to the
instructions that are in Caterpillar reusability
Each individual condition may not indicate a need for publications. Refer to Guidelines for Reusable Parts
an overhaul. However, evaluating the three and Salvage Operations, SEBF8029, Index of
conditions together is the most accurate method of Publications on Reusability or Salvage of Used
determining when an overhaul is necessary. Parts. The guidelines were developed in order to
The engine does not require an overhaul if the help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
engine is operating within acceptable limits for oil
consumption, crankcase blowby, and cylinder required if the existing parts can still be used,
compression. reconditioned, or repaired. If the components are not
in the reusability guidelines, refer to the Service
Periodically measure each of the three conditions. Manual, Specifications module.
The first measurement should occur during the Rebuild The component can be reconditioned in
engine commissioning. This establishes a baseline order to comply with reusability guidelines.
for future measurements. Additional measurements
are scheduled at regular intervals in order to Replace The service life of the part is exhausted.
determine a schedule for the next in-frame overhaul. The part may fail before the next maintenance
interval. The part must be replaced with a part that
The following changes in the three conditions
meets functional specifications. The replacement part
normally require a scheduled overhaul:
may be a new part, a CAT remanufactured part, a
A 300 percent increase in oil consumption rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer.
A 200 percent increase in crankcase blowby
122 SEBU7681-22
Maintenance Section
Overhaul (Major)
Consult your Caterpillar dealer about repair options Other factors must also be considered for
for your engine. determining a major overhaul:
Power output
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the The service hours of the engine
recommendations in Table 27 .
Table 27 Reduced oil pressure
In-Frame Overhaul The wear metal analysis of the lube oil
Clean Oil suction screen
An increase in the levels of noise and vibration
Clean Aftercooler core
Inspect An increase of wear metals in the lube oil indicates
Test that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
Inspect Compressor bypass valve noise and vibration indicates that rotating parts
Rebuild require service.
Replace Exhaust system (landfill)
Fuel metering valve Note: It is possible for oil analysis to indicate a

decrease of wear metals in the lube oil. The cylinder
Oil cooler liners may be worn so that polishing of the bore
Oil pump occurs. Also, the increased use of lube oil will dilute
the wear metals.
Pistons
Monitor the engine as the engine accumulates
Throttle service hours. Consult your Caterpillar dealer about
Transformers and extenders scheduling a major overhaul.
Rebuild Prelube pump Note: The generator or driven equipment may also
Starting motor
require service when the engine is overhauled. Refer
to the literature that is provided by the OEM of the
Turbochargers driven equipment.
Water pumps
Major Overhaul Information
Replace Connecting rod bearings
Cylinder head assemblies

A major overhaul includes all of the work that is done
for top end overhauls and in-frame overhauls.
Cylinder liners Additional parts and labor are required in order to
completely rebuild the engine. In some cases, the
Main bearings engine is relocated for disassembly.
Piston rings For the major overhaul, all of the bearings, seals,
Water temperature regulators gaskets, and components that wear are
disassembled. The parts are cleaned. The parts are
inspected. If necessary, the parts are replaced. The
i03460103 crankshaft is measured for wear. The crankshaft may
require regrinding. Alternatively, the crankshaft may
Overhaul (Major) be replaced with a Caterpillar replacement part.
SMCS Code: 7595-020-MJ Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
Scheduling a Major Overhaul appropriate specifications.
Generally, a major overhaul is performed for every The following definitions explain the terminology for
fifth top end overhaul. The need for a major overhaul the services that are performed during an overhaul:
is determined by several factors. Some of those
factors are the same factors that determine the in- Inspect Inspect the components according to the
frame overhaul: instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts
An increase of oil consumption and Salvage Operations, SEBF8029, Index of
Publications on Reusability or Salvage of Used
An increase of crankcase blowby Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
A decrease and variation of cylinder compression unnecessary expenditures. New parts are not
SEBU7681-22 123
Maintenance Section
Overhaul (Top End)
required if the existing parts can still be used, (Table 28, contd)
reconditioned, or repaired. If the components are not Major Overhaul
Manual, Specifications module. Replace Camshaft bearings
Rebuild The component can be reconditioned in Connecting rod bearings

order to comply with reusability guidelines.
Coupling (tandem engines)
Replace The service life of the part is exhausted.
The part may fail before the next maintenance Cylinder liners
interval. The part must be replaced with a part that
Gaskets and seals
may be a new part, a CAT remanufactured part, a Gear train bushings
rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer. Main bearings
Consult your Caterpillar dealer about repair options Piston rings
for your engine.
Water temperature regulators
If you elect to perform an overhaul without the Wiring harnesses
services of a Caterpillar dealer, be aware of the
recommendations in Table 28 . Your Caterpillar
dealer can provide these services and components. i03906477
Table 28
Major Overhaul
Overhaul (Top End)
SMCS Code: 7595-020-TE
Clean
Inspect
Aftercooler core
Scheduling a Top End Overhaul
Test
Top end overhauls are scheduled according to the
Inspect Camshafts recession of the exhaust valve stems. This
Rebuild measurement provides an accurate indication of the
Camshaft followers
Replace rate of valve wear. This measurement can be used to
Compressor bypass valve predict when a cylinder head requires replacement.
Connecting rods To determine a baseline, measure the projection of

the exhaust valve stems after 100 to 250 service
Crankshaft hours. The baseline is a reference for subsequent
Exhaust system (landfill)
measurements. Continue to measure the projection
periodically.
Fuel metering valve
Plan for the top end overhaul as the valve stem
Gear train projection approaches the maximum limit. Perform
the top end overhaul when the valve stem projection
Inlet air piping
has increased by a total of 2.3 mm (.09 inch). Do not
Oil cooler allow the projection of the exhaust valve stems to
exceed this limit.
Oil pump
Note: Generally, cylinder heads wear out at different
Pistons
rates. In some cases, servicing the cylinder heads at
Throttle valve different times may be the most economic decision.
Transformers and extenders This decision depends on the valve stem projection
of the individual cylinders. However, this decision
Rebuild Prelube pump must include the costs of additional downtime that is
Starting motor caused by this procedure. Perform an economic
analysis in order to determine if cylinder heads
Turbochargers should be serviced as a group or divided into smaller
groups.
Water pumps
Vibration damper
(continued)
124 SEBU7681-22
Maintenance Section
Overhaul (Top End)
Note: The generator or the driven equipment may

also require service when the engine overhaul is Rebuild The component can be reconditioned in
performed. Refer to the literature that is provided by order to comply with reusability guidelines.
the OEM of the driven equipment. Replace The service life of the part is exhausted.
The part may fail before the next maintenance
Top End Overhaul Information interval. The part must be replaced with a part that
A top end overhaul involves servicing the cylinder may be a new part, a CAT remanufactured part, a
heads and turbochargers. Also, some other engine rebuilt part, or a used part. Some worn components
components are inspected. may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
Top end overhauls require more tools than preventive for your engine.
maintenance. The following tools are needed for
restoring the engine to factory specifications:
If you elect to perform an overhaul without the
Torque wrenches services of a Caterpillar dealer, be aware of the
recommendations in Table 29 . Your Caterpillar
Dial indicators dealer can provide these services and components.
Your Caterpillar dealer can ensure that the
Accurate measurement tools components are operating within the appropriate
specifications.
Cleaning equipment Table 29
Rebuilding equipment Top End Overhaul

Caterpillar dealers are equipped with these tools.
Caterpillar dealers can provide a flat rate price for a Clean Aftercooler core
top end overhaul. Inspect Oil cooler core
Test Exhaust manifolds
Unexpected problems may be found during a top end
overhaul. Plan to correct these problems, if Inspect Transformers
necessary. Flexible coupling
Rebuild Prelube pump

Build up in the cylinders from excessive oil
consumption Starting motor
Build up in the cylinders from contamination of the Turbochargers

fuel
Water pumps
Plugging of the aftercooler from coolant that is Replace Cylinder head assemblies
poorly maintained
Spark plugs
Plugging of the aftercooler from contamination of
Water temperature regulators
the inlet air
Degradation of the oil cooler from the hydrogen

sulfide in the fuel Cleaning and Inspection of Components
Deterioration of exhaust manifold components Aftercooler and Oil Cooler
The following definitions explain the terminology for Clean the aftercooler core and the oil cooler core.
the services that are performed during an overhaul: Perform pressure tests on the components. Replace
the components, if necessary.
Inspect Inspect the components according to the
instructions that are in Caterpillar reusability Note: If the cooling system is not properly
publications. Refer to Guidelines for Reusable Parts maintained, cleaning of the aftercooler can be
and Salvage Operations, SEBF8029, Index of difficult. The tank that is opposite of the inlet port and
Publications on Reusability or Salvage of Used the outlet port cannot be removed for cleaning.
Parts. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid Note: This procedure may be used for cleaning both
unnecessary expenditures. New parts are not the aftercooler core and the oil cooler core.
required if the existing parts can still be used,
reconditioned, or repaired. If the components are not 1. Remove the core.
Manual, Specifications module.
SEBU7681-22 125
Maintenance Section
Overhaul (Top End)
2. Turn the core upside-down in order to remove Oil Suction Screen

debris.
NOTICE
Do not use a high concentration of caustic cleaner to Hot oil and components can cause personal
clean the core. A high concentration of caustic injury.
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen- Do not allow hot oil or components to contact
tration of cleaner. skin.
Clean the oil suction screen after the engine oil pan
3. Back flush the core with cleaner. has been drained.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Consult your Caterpillar dealer for Note: Approximately 1 L (1 qt) of engine oil will
part numbers and sizes of containers. remain in the housing after the sump has been
drained. This engine oil will pour out of the housing
Use a 2 to 5 percent concentration of the cleaner when cover (1) is removed. Prepare to catch the
at temperatures up to 93C (200F). engine oil in a pan. Clean up any spills with
absorbent towels or pillows. DO NOT use absorbent
4. Steam clean the core in order to remove any particles.
residue. Flush the fins of the core. Remove any
other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
Personal injury can result from air pressure.

Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
6. Dry the core with compressed air. Direct the air in Illustration 71 g00760655
the reverse direction of the normal flow. (1) Cover

(2) O-ring seal
Note: The test pressure for the oil cooler is 790 kPa (3) Screen assembly
(115 psi). The maximum differential pressure of water
for the aftercooler is 44 kPa (6 psi). The maximum 1. Loosen the bolts from cover (1). Remove cover (1)
differential pressure of air for the aftercooler is and O-ring seal (2). Discard the seal. Remove
5.1 kPa (0.74 psi). screen assembly (3).
7. Inspect the core in order to ensure cleanliness. 2. Wash screen assembly (3) in clean nonflammable
Perform a pressure test of the core. Many shops solvent. Allow the screen assembly to dry before
that service radiators are equipped to perform installation.
pressure tests. If necessary, repair the core. 3. Clean the engine oil sump. Remove the side
8. Install the core. covers in order to gain access to the sump. After
the sump is clean, install the side covers.
For more information on cleaning the cores, consult
your Caterpillar dealer. 4. Inspect screen assembly (3) for good condition.
Obtain a new screen assembly, if necessary.
Install the screen assembly. Install a new O-ring
seal (2). Install cover (1).
126 SEBU7681-22
Maintenance Section
Overhaul Considerations
Transformers Achieve the best cost/value relationship per hour

of extended service life.
The transformers produce a voltage increase. For
good operation, the connections must be clean and Overhaul Intervals
secure. Inspect the transformers for the following
conditions: Top end overhauls are determined by the projection
of exhaust valve stems. In-frame overhauls are
Damaged O-rings determined by cylinder compression, crankcase
blowby, and oil consumption. Major overhauls are
Dirty insulator determined by the in-frame tests, and by results of
SOS oil analysis.
Loose connections
Some other factors that are important for determining
Loose connector the overhaul intervals include the following
considerations:
Moisture
Measure the voltage of the diode for the primary Performance of preventive maintenance
circuit and measure the resistance of the secondary
Use of recommended lubricants
circuit according to Troubleshooting, G3500C
Engines. Consult your Caterpillar dealer for Use of recommended coolants
assistance.
Use of recommended fuels
i01950926
Proper installation
Overhaul Considerations
Operating conditions
SMCS Code: 7595-043
Operation within acceptable limits
Overhaul Information Engine load
An overhaul is replacing the major worn components
Engine speed
of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain Note: To avoid oil problems, engines that are
rebuilt parts or new parts that replace the worn parts.
turbocharged and aftercooled must be operated at a
An overhaul also includes the following maintenance: minimum of 60 percent of rated load.
Inspection of all the parts that are visible during Generally, engines that are operated at a reduced
the disassembly load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
Replacement of the seals and gaskets that are properly operated and maintained.
removed
Overhaul Inspection
Cleaning of the internal passages of the engine
and the engine block Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order to
Most owners will save money by overhauling the perform the required maintenance on the items that
engine at the intervals that are recommended in the are listed. Consult your Caterpillar dealer for
Operation and Maintenance Manual. It is not practical assistance.
to wait until the engine exhibits symptoms of
excessive wear or failure. It is not less costly to wait. To determine the reusability publications that are
A planned overhaul before failure may be the best needed to inspect the engine, refer to Guidelines for
value for the following reasons: Reusable Parts and Salvage Operations, SEBF8029,
Index of Publications on Reusability or Salvage of
Costly unplanned downtime can be avoided. Used Parts.
Many original parts can be reused according to the

guidelines for reusable parts.
The service life of the engine can be extended
without the risk of a major catastrophe due to
engine failure.
SEBU7681-22 127
Maintenance Section
Power Factor - Check
The Guidelines For Reusable Parts and Salvage Overhaul Recommendation

Operations is part of an established Caterpillar parts
reusability program. These guidelines were Caterpillar recommends a scheduled overhaul in
developed in order to assist Caterpillar dealers and order to minimize downtime. A scheduled overhaul
customers reduce costs by avoiding unnecessary will provide the lowest cost and the greatest value.
expenditures for new parts. If the engine parts Schedule an overhaul with your Caterpillar dealer.
comply with the established inspection specifications,
the parts can be reused. New parts are not Overhaul programs vary between dealers. To obtain
necessary if the old parts can be reused, repaired, or specific information about the types of overhaul
salvaged. programs and services, consult your Caterpillar
dealer.
If the parts are not within the inspection
specifications, the parts should be salvaged, i01216962
repaired, replaced, or exchanged. The use of out-of-
spec parts could result in unscheduled downtime
and/or costly repairs. The use of out-of-spec parts
Power Factor - Check
can also contribute to increased fuel consumption SMCS Code: 4450-535-PWR
and reduction of engine efficiency.
The power factor of a system can be determined by a
Your Caterpillar dealer can provide the parts that are power factor meter or by calculations. The power
needed to rebuild the engine at the least possible factor can be calculated by dividing kW by kVA.
cost. Power factor is expressed as a decimal.
Overhaul Programs i04020194
An economical way to obtain most of the parts that Radiator - Clean

are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured SMCS Code: 1353-070
parts are available at a fraction of the cost of new
parts. These parts have been rebuilt by Caterpillar Note: Adjust the frequency of cleaning according to
and certified for use. The following components are the effects of the operating environment.
examples of the remanufactured parts:
Inspect the radiator for these items: damaged fins,
Alternators corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
Connecting rods
Crankshafts
Cylinder heads Personal injury can result from air pressure.
Oil Pumps Personal injury can result without following prop-

er procedure. When using pressure air, wear a
Starting motors protective face shield and protective clothing.
Turbochargers The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
Water pumps nozzle is deadheaded.
Consult your Caterpillar dealer for details and for a

list of the remanufactured parts that are available. Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction of
Your Caterpillar dealer may be offering a variety of the air flow. Hold the nozzle approximately 6 mm
overhaul options. (0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
A Flat Rate Overhaul guarantees the maximum price This movement will remove debris that is between
that you will pay for an overhaul. Flat rate prices on the tubes.
preventive maintenance programs or major repair Pressurized water may also be used for cleaning.
options are available from many servicing dealers for The maximum water pressure for cleaning purposes
all Caterpillar Engines. Consult your Caterpillar must be less than 275 kPa (40 psi). Use pressurized
dealer in order to schedule a before failure overhaul. water in order to soften mud. Clean the core from
both sides.
128 SEBU7681-22
Maintenance Section
Rotating Rectifier - Check
Use a degreaser and steam for removal of oil and Testing a Three-Diode Rectifier
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the Block
core with clean water.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This procedure will help in
the removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to
inspect the core for cleanliness. Repeat the cleaning,
if necessary.
Inspect the fins for damage. Bent fins may be opened
with a comb. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary.
i05072489
Rotating Rectifier - Check

SMCS Code: 4465-535
Check the exciter armature. Ensure that the rotating
rectifier is tight. If a failure of a rectifier is suspected,
proceed to the Testing a Three-Diode Rectifier
Block section.
Three-Diode Rectifier Block (two pieces)
The following procedure tests all three diodes within

a block. Check the positive rectifier block and the
negative rectifier block. If any meter reading does not
fall within the given ranges, replace the rectifier
block.
1. Set the digital multimeter on the diode range.
Remove all leads from the rectifier block.
SEBU7681-22 129
Maintenance Section
Space Heater - Test
2. To test the negative rectifier block, follow these

steps:
a. Place the red test lead on the negative -

terminal. Place the black test lead on the
following rectifier terminals: AC1 (3), AC2 (4)
and AC3 (5). All readings on the meter should
be between 0.4 and 1.0.
b. Place the black test lead on the negative -
terminal. Place the red test lead on the following
rectifier terminals: AC1 (3), AC2 (4) and
AC3 (5). In all cases, the meter should read
OL (overload).
3. To test the positive rectifier block, follow these Illustration 74 g00610396
steps: Space Heater Connection Diagram
a. Place the red test lead on the positive + An SR4 generator can operate in high humidity
rectifier terminal. Place the black test lead on conditions without problems. However, problems can
the following rectifier terminals: AC1 (3), AC2 occur when the generator is idle and the surrounding
air is warmer than the generator. Moisture can form
(4) and AC3 (5). In all cases, the meter should on the windings. Moisture will result in poor
read OL (overload). performance or even damage to the windings.
Whenever the generator is not active, the optional
b. Place the black test lead on the positive + space heaters should be operated.
rectifier terminal. Place the red test lead on the
following rectifier terminals: AC1 (3), AC2 (4) An external source is required to operate the space
and AC3 (5). All readings on the meter should heaters. Both of the sources must be a single phase.
This source can be either 115 vac or 230 vac. When
be between 0.4 and 1.0. the external source is 50 hertz, 200 vac must be
used. Refer to Illustration 74 .
Note: A shorted diode can damage the exciter rotor.
If a diode is shorted, check the exciter rotor. Refer to See your Caterpillar dealer for information on
the Testing and Adjusting, Winding - Test and checking your Caterpillar generator.
Testing and Adjusting, Insulation - Test. Perform
these tests. i04125973
Note: This rectifier block also contains varistor CR7 Spark Plugs - Inspect/Replace
. CR7 can be checked by measuring the resistance
between the positive + rectifier terminal and the SMCS Code: 1555-040; 1555-510
negative - rectifier terminal. The resistance should
be a minimum of 15000 ohms. Note: Condensation can form in spark plugs that
have precombustion chambers and can cause
i03857792
difficulty for cold start-ups. To avoid condensation,
maintain the coolant in the cylinder block at a
minimum temperature of 43 C (110 F)
Space Heater - Test continuously.
SMCS Code: 4450-081-HTR
The service life of the spark plugs is affected by
The space heater is attached to the rear bearing fouling due to deposits from the oil and by peak
bracket. The space heater is located in the voltage. Maintenance of the ignition system is also
generator's exciter end. affected by voltage. Higher voltage is required by
higher inlet manifold air pressure, leaner air to fuel
operation, a higher compression ratio, and
retardation of the timing. Higher voltage reduces the
service life of components such as spark plugs,
wires, and transformers.
130 SEBU7681-22
Maintenance Section
Spark Plugs - Inspect/Replace
The service life of the spark plug is different for

different applications. To help predict the service life
of the spark plug, use Cat Electronic Technician (ET)
to monitor the Cylinder #X Transformer Secondary
Output Voltage Percentage parameter. The value of
this parameter will increase as the spark plug gap
wears over time. Experience at the particular site will
help to determine the proper interval for replacement
of the spark plugs.
If a diagnostic code is generated for the secondary
circuit of the ignition transformer, the spark plug may
need replaced. Misfire and a cold cylinder are other
indications of a worn spark plug. Use Cat ET to
monitor the exhaust port temperatures in order to
locate a cold cylinder.
Removing the Spark Plug
Ignition systems can cause electrical shocks.

Avoid contacting the ignition system compo-
nents and wiring.
Do not attempt to remove the valve covers when
the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
death may result and the ignition system will be
damaged if the valve covers are removed during
engine operation. The engine will not operate
without the valve covers.
(1) Cover
(2) Wiring harness
(3) Transformer
(4) Seal
(5) Spark plug
(6) Valve cover
1. Remove cover (1).

2. Remove wire harness (2) from transformer (3).
3. Remove the two remaining bolts that secure
transformer (3). Remove transformer (3) from
valve cover (6).
4. Inspect O-ring seal (4). If the seal is hard, cracked,
or melted, install a new seal.
Pressurized air can cause personal injury. When

pressurized air is used for cleaning, wear a pro-
tective face shield, protective clothing, and pro-
tective shoes.
SEBU7681-22 131
Maintenance Section
Spark Plugs - Inspect/Replace
Note: Excessive buildup of oil in the spark plug well Insulator (8) is covered with Teflon. If the cover is
is an indication of a damaged lip seal on the cracked or loose, discard the spark plug.
transformer.
Faint marks may extend from shell (9) onto the
5. Debris may have collected in the spark plug well. insulator. The marks may be a result of a corona that
Thoroughly remove any debris. Use compressed forms at the top of the shell. The conductor will
develop a corona when a high voltage potential
air. The maximum air pressure for cleaning ionizes the air. This corona is a normal condition and
purposes must be below 207 kPa (30 psi). Ensure is not an indication of leakage between the shell and
that the area around the spark plug is clean and the insulator.
free of dirt and debris.
Inspect shell (9) for damage. Cracks can be caused
6. Use a 216-1685 deep well socket, an extension, by overtightening the spark plug. Overtightening can
and a breaker bar to loosen spark plug (5). After also yield the metal which loosens the shell. Discard
any spark plug that has a shell that is cracked or
the spark plug has been loosened, use the socket loose.
and extension to remove the spark plug by hand.
Removing the spark plug by hand will help to Inspect the precombustion chamber for deposits.
detect problems with the threads. After the spark Make sure that holes (11) in the precombustion
chamber are not blocked.
plug has been removed, discard the used spark
plug gasket. A light brown deposit or a beige deposit is produced
If the spark plug resists removal by hand, apply by normal operation.
penetrating oil to the threads. To help the oil
penetrate the threads, turn the spark plug back and Deposits that are gray or black may be caused by the
forth until the spark plug is loose. following substances:
If the spark plug could not be removed by hand, Excessive oil

clean the threads with a Spark Plug Seat Cleaner.
This tool scrapes debris from the seat and from the Use of the wrong oil
threads in the cylinder head. Be sure to clean any
debris from the cylinder. A substance that is introduced through the fuel
system or the air system
NOTICE
Do not use a thread tap. A thread tap will remove Poor combustion because of a rich air/fuel mixture
metal unnecessarily. The threads could be stripped
and the cylinder head could be damaged. A spark plug can operate despite a buildup of ash.
Large deposits may retain heat which can cause
premature fuel ignition. Premature fuel ignition can
lead to uncontrollable detonation.
Inspecting the Spark Plug
Cleaning the Spark Plug
Do not use glass beads to clean the spark plug.
The beads could enter the precombustion chamber
through the holes. The beads could clog the holes in
the precombustion chamber.
Use a brass wire brush to clean the spark plug. Be
careful not to damage the Teflon cover.
(7) Terminal post
Installing the Spark Plug
(8) Insulator
(9) Shell Note: Do not use anti-seize compound on spark
(10) Gasket plugs. Most of the heat is transferred through the
(11) Hole in the precombustion chamber threads and the seat area of the spark plug. Contact
of the metal surfaces must be maintained in order to
Inspect the spark plug closely for damage. The
provide the heat transfer that is required.
condition of the spark plug can indicate the operating
condition of the engine.
1. Ensure that the spark plug is clean and free of dirt
Terminal post (7) must not move. If the terminal post and oil.
can be moved by hand, carefully tighten the post into
the threads of the insulator. If the post cannot be
tightened, discard the spark plug.
132 SEBU7681-22
Maintenance Section
Starting Motor - Inspect
2. Always use a new gasket when a spark plug is Inspect the starting motor for proper operation. Listen
installed. If a used spark plug is installed, place a for grinding when the engine is started. Inspect the
new gasket on the spark plug. Orient the tabs of teeth of the starting motor pinion and the flywheel
the gasket toward the precombustion chamber. ring gear. Look for patterns of wear on the teeth.
Look for teeth that are broken or chipped. If damaged
Otherwise, the gasket may not seat properly. If a teeth are found, the starting motor pinion and the
gasket for a spark plug is installed incorrectly, do flywheel ring gear must be replaced.
not increase the torque on the spark plug in order
to improve the seal. Do not reuse the gasket. Electric Starting Motor
Install a new gasket.
Note: Problems with the electric starting motor can
NOTICE be caused by the following conditions: malfunction of
Do not overtighten the spark plug. The shell can be the solenoid and malfunction of the electric starting
cracked and the gasket can be deformed. The metal system.
can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that Inspect the electrical system for the following
is between the shell and the insulator, allowing com- conditions:
bustion pressure to blow past the seal. Serious dam-
age to the engine can occur. Loose connections
Use the proper torque. Corrosion
3. Install spark plug (5) by hand until the spark plug Wires that are worn or frayed
contacts the gasket. Torque the spark plug to the Cleanliness
proper specification. Refer to Specifications,
Spark Plug for the proper torque specification. Make repairs, if necessary.
4. Ensure that the transformer and the extension are Air Starting Motor
clean and free from dirt and oil. Lubricate O-ring
seal (4) with one of the following lubricants:
Dielectric Grease
Personal injury or death can result from improp-
Silicone Lubricant erly checking for a leak.
5. Install transformer (3). Orient the transformer Always use a board or cardboard when checking
toward wiring harness (2). Connect the wiring for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
harness. sue causing serious injury, and possible death.
6. Install cover (1).
If fluid is injected into your skin, it must be
treated immediately by a doctor familiar with this
i04342950 type of injury.
Starting Motor - Inspect Inspect all of the components in the air circuit for the
starting motor. Inspect all of the air lines and
SMCS Code: 1451-040; 1453-040 connections for leaks.
If the starting motor fails, the engine may not start in If the teeth of the starting motor pinion and/or the
an emergency situation. A scheduled inspection of flywheel ring gear are damaged, the air circuit for the
the starting motor is recommended. starting motor must be examined in order to
determine the cause of the problem.
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 Removal and Installation of the
motor pinion does not engage the flywheel ring gear. Starting Motor
The teeth of the starting motor pinion and the
flywheel ring gear can be damaged because of Refer to the Service Manual, Disassembly and
irregular engagement. Assembly module for information on removing the
starting motor and installing the starting motor.
SEBU7681-22 133
Maintenance Section
Stator Lead - Check
Consult your Cat 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
Check the throttle for leaks. If necessary, remove the
insulation throttle according to the instructions in the
Disassembly and Assembly manual. Inspect the
i03852818 throat of the throttle for wear marks. Check for free
movement of the butterfly valve.
Stator Winding Temperature - Inspect the gaskets for wear or damage. If
Test necessary, replace the gaskets. Reinstall the throttle
according to the instructions in the Disassembly and
SMCS Code: 4453-081-TA Assembly manual.
Some generators are provided with optional 100
i03909633
Ohm Resistance Temperature Detectors (RTD).
When the temperature of the stator winding is
suspected to be high, measure the temperature. If Turbocharger - Inspect
the generator is furnished with Resistance SMCS Code: 1052-040
Temperature Detectors, the detectors are installed in
the slots of the main armature (stator). The detectors Periodic inspection and cleaning are recommended
are used with equipment that is available from the for the turbocharger. Fouling of the turbine wheels
factory. This equipment is used in order to measure can contribute to loss of engine power and overall
the main armature's winding temperature. loss of engine efficiency.
i02293325 If the turbocharger fails during engine operation,

damage to the turbocharger compressor wheel and/
Throttle Control Valve - Check or to the engine may occur. Damage to the
turbocharger compressor wheel could allow parts
SMCS Code: 1269-535 from the compressor wheel to enter an engine
cylinder which could damage engine components.
If a decrease in performance is observed or if the
Engine Control Module signals that there is a NOTICE
problem with the manifold pressure, check the Turbocharger bearing failures can cause large quan-
throttle. 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
occurred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
134 SEBU7681-22
Maintenance Section
Turbocharger - Inspect
An inspection of the turbocharger can minimize Note: Deposits of ash and silicone can accumulate
unscheduled downtime. Also, the chance for on the turbine wheel. Turbine wheel will become
potential damage to other engine parts is reduced. unbalanced when the deposits flake off. The
turbocharger cartridge must be replaced when the
Note: Turbocharger components require clearances turbine wheel becomes unbalanced. However,
that are precise. The turbocharger cartridge must be removing deposits from the housing will prevent wear
balanced due to high rpm. on the blades of the new turbine wheel.
The following conditions can cause the turbocharger
to be out-of-balance: 4. Inspect the turbine wheel and the nozzle for
deposits of ash and silicone. If deposits of 1.6 mm
The buildup of deposits (0.06 inch) thickness are found or if the turbine is
in contact with the housing, the turbocharger must
Chipping and/or flaking of deposits be disassembled and cleaned. Removal of the
If the turbocharger must be removed for inspection, deposits can be difficult.
use caution. Do not break deposits from the turbine 5. Inspect the turbine wheel and nozzle vanes for
wheel. Do not attempt to clean the turbine wheel. For
information regarding removal and installation, see damage or bent blades. Do not attempt to repair
the Disassembly and Assembly manual or consult the turbine wheel or nozzle vanes. Replace the
your Caterpillar dealer. For information about repair damaged parts.
of the turbocharger or about replacement of the
turbocharger, consult your Caterpillar dealer. 6. Inspect the bore of the turbine housing for
corrosion and deposits.
1. Remove the exhaust outlet piping and remove the
air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger should be reconditioned. Inspect
the compressor wheel for damage or bent blades.
Do not attempt to repair the damaged blades. Illustration 78 g01955362
Replace the cartridge or turbocharger if the blades Axial clearance
are damaged.
Note: The axial clearance is the free axial
3. Check the compressor wheel for cleanliness. If displacement of the rotor. The rotor is moved back
only the inlet side of the wheel is dirty, dirt and/or and forth with an approximate force between 150 N
moisture is passing through the air filtering (34 lb) and 200 N (45 lb). Tolerances are shown in
system. If oil is found only on the back side of the Table 30 . The deflection of the measuring device
wheel, there is a possibility of a failed turbocharger corresponds to the axial clearance.
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also result from restriction of the inlet air
(plugged air filters). This causes oil to leak past the
seal for the turbocharger compressor.
A restriction in the oil drain tube may result in an
oil leak. Remove and inspect the oil drain tube for
restrictions.
If oil is found on the compressor wheel and/or at
the air inlet, the source is the fuel compressor or
the PCV system.
SEBU7681-22 135
Maintenance Section
Valve Stem Projection - Measure/Record
Table 31
Radial Clearance(1)
TPC47 .635 0.265 mm

(0.025 0.010 inch)
TPC49 .69 0.29 mm

(0.027 0.011 inch)
TPS52 .88 0.27 mm

(0.034 0.010 inch)
(1) The clearances apply to new parts and used parts. Oil films are
not taken into account. The values in the table are valid at an
ambient temperature of 20 C (68 F). The clearances take ac-
count of manufacturing tolerances of the applicable
components.
Illustration 79 g01955369 i03470080

Radial clearance
Valve Stem Projection -
Note: Radial clearance is the maximum deflection at
the hub of the impeller at reciprocal neutralizing of Measure/Record
the radial bearing clearance. Radial clearance is SMCS Code: 1105-082
measured with the measuring device on the hub of
the compressor wheel. Tolerances are shown in Valve Recession The valves and the valve seats
Table 31 . The rotor is tilted with an approximate are worn over time. This causes the valves to recede
force between 150 N (34 lb) and 200 N (45 lb). The into the cylinder head. This condition is called valve
total deflection corresponds to the radial clearance. recession.
The top end overhaul is typically scheduled
Note: Axial clearance and radial clearance must be according to the amount of valve recession. The
measured after the cartridge group has been amount of valve recession should be monitored on
removed, but prior to reinstallation. both intake and exhaust valves. However, it is difficult
to measure the actual valve recession in the cylinder
7. Check the axial clearance and radial clearance. head. A simpler method is used to determine the
valve recession:
8. Clean the turbocharger compressor and turbine
housing with a non-metallic bristle brush and Measure the projection of the valve rotator above
standard shop solvents to remove deposits. the cylinder head.
Blasting the turbine housing and nozzle ring may
Measure the projection of the exhaust valve rotators
be necessary in order to remove deposits. Plastic with a 155-1536 Valve Recession Tool Group.
or walnut shell media can be used for blasting. All Follow the instructions that are provided with the tool
turbocharger components and surfaces must be group.
clean and dry prior to assembly.
Record the measurements on the Operation and
9. Fasten the air inlet piping and the exhaust outlet Maintenance Manual, Valve Data Sheet (Reference
piping to the turbocharger housing. Materials Section).
Table 30
Measure the projection of the exhaust valve
Axial Clearance(1) rotators after 250 service hours. This
measurement is the baseline. The baseline is a
TPC47 0.12 0.04 mm
(0.0047 0.0015 inch) reference for subsequent measurements.
TPC49 0.12 0.04 mm Measure the projection of the exhaust valve

(0.0047 0.0015 inch) rotators at the first 1000 service hours.
TPS52 .14 0.04 mm Plan for the top end overhaul as the projection of
(0.0055 0.0015 inch)
the valve rotator approaches the maximum limit.
(1) The clearances apply to new parts and used parts. Oil films are Perform the top end overhaul when the projection
not taken into account. The values in the table are valid at an of the valve rotator has increased by a total of
ambient temperature of 20 C (68 F). The clearances take ac- 2.3 mm (0.09 inch). Do not allow the recession
count of manufacturing tolerances of the applicable
components. of the exhaust valves to exceed this limit. The
valve head can break. This will cause severe
damage in the combustion chamber.
136 SEBU7681-22
Maintenance Section
Voltage and Frequency - Check
Check the measurement data for a difference in

NOTICE
the valve recession that is greater than 1 mm For any type of leak (coolant, lube, or fuel) clean up
(0.039 inch) for the valves that share a valve the fluid. If leaking is observed, find the source and
bridge. If this measurement is exceeded for two correct the leak. If leaking is suspected, check the flu-
successive measurements, replacement of the id levels more often than recommended until the leak
cylinder head is necessary. is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
i01189996
Voltage and Frequency - NOTICE

Accumulated grease and/or oil on an engine or deck
Check is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
SMCS Code: 4450-535-EL
Check for proper voltage and frequency setting. Ensure that cooling lines are properly clamped.
Check for stability. Check for leaks. Check the condition of all pipes.
Refer to the generator set Serial Plate for correct Inspect the water pump for coolant leaks.
voltage and frequency.
Note: The water pump seal is lubricated by coolant in
i05264229 the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
Walk-Around Inspection parts contract.
SMCS Code: 1000-040 Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
water pump and the installation of water pump and/or
seals, refer to the Service Manual for the engine or
Personal injury or death can result from improper consult your Cat dealer.
troubleshooting and repair procedures.
Inspect the lubrication system for leaks at the front
The following troubleshooting and repair proce- crankshaft seal, the rear crankshaft seal, the oil
dures should only be performed by qualified per- pan, the oil filters, and the valve cover.
sonnel familiar with this equipment.
Inspect the Closed Crankcase Ventilation (CCV)
filter, if equipped. If the restriction indicator is
visible, service the CCV.
Inspect the Engine for Leaks and
for Loose Connections Inspect the fuel system for leaks. Look for loose
fuel line clamps.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these Inspect the piping for the air inlet system and the
checks, costly repairs and accidents can be avoided. elbows for cracks and for loose clamps.
For maximum engine service life, make a thorough Inspect the alternator belt and the accessory drive
inspection of the engine compartment before starting belts for cracks, breaks, or other damage.
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose Belts for multiple groove pulleys must be replaced as
connections, and trash buildup. Make repairs, as matched sets. If only one belt is replaced, the belt will
needed: carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
The guards must be in the proper place. Repair the new belt could cause the belt to break.
damaged guards or replace missing guards.
Drain the water and the sediment from fuel tanks
Wipe all caps and plugs before the engine is on a daily basis in order to ensure that only clean
serviced in order to reduce the chance of system fuel enters the fuel system.
contamination.
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.
SEBU7681-22 137
Maintenance Section
Water Pump - Inspect
Inspect the engine-to-frame ground strap for a

good connection and for good condition.
i01985173
Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
Water Pump - Inspect
level of the batteries, unless the engine is SMCS Code: 1361-040
equipped with a maintenance free battery.
A failed water pump might cause severe engine
Check the condition of the gauges. Replace any overheating problems that could result in cracks in
gauges that are cracked. Replace any gauges that the cylinder head, a piston seizure or other potential
cannot be calibrated. damage to the engine.
Visually inspect the water pump for leaks. If leaking
Inspect the Generator of the water pump seals is observed, replace all of
the water pump seals. Refer to the Service Manual
Refer to Safety Section, Generator Isolating for for the disassembly and assembly procedure.
Maintenance for information regarding the
procedure to isolate the generator safely. Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Service Manual or
A visual inspection should be initially directed at the consult your Caterpillar dealer if repair is needed or
areas that are most prone to damage and replacement is needed.
deterioration. The most prone areas to damage and
deterioration are listed below:
Ground insulation Ground insulation is insulation
that is intended to isolate components that are
carrying current from components that are not
carrying current.
Support insulation Support insulation is made
from one of the following items: a compressed
lamination of fibrous materials, polyester, or felt pads
that have been impregnated with various types of
bonding agents.
There are many different types of damage that can

occur in these areas. Several of the different types of
damage are listed below: Illustration 80 g01028701
Thermal aging Thermal aging can cause the Some water pumps have a filter in the weephole (1).
degradation of insulation or the deterioration of This filter helps prevent dirt from entering the water
insulation. An examination of the coils may reveal pump. Inspect the filter with a flashlight in order to
that the insulation has expanded into the ventilation ensure that the filter is clean. Replace the filter
ducts. This is the result of a loss of bond which will annually or replace the filter when the filter becomes
cause the insulation material to separate. The plugged.
insulation material could also separate from the
conductors on the windings.
Abrasion The surfaces of coils and the surfaces of

connectors may be damaged by abrasion. These
surfaces may also be damaged by contamination
from other sources. An example of these sources
would be chemicals or abrasive substances.
Cracking Cracking of insulation may result from

mechanical stress. The structure that is used to
brace the stator winding will become loose if the
problem is not corrected. Further mechanical
damage or electrical damage may also result.
Erosion Erosion can be caused when foreign

substances rub against the insulation that is on the
surface of the coil .
138 SEBU7681-22
Reference Information Section
Customer Service
Reference Information Latin America, Mexico, Carribean

Caterpillar Americas Co.
Section 701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Customer Service Phone: 305-476-6800
Fax: 305-476-6801
i05133089 Europe, Africa, and Middle East
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
USA and Canada Phone: 22-849-4444
Fax: 22-849-4544
If a problem arises concerning the operation or
service of an engine, the problem will be managed by Far East
the dealer in your area. Caterpillar Asia Pte. Ltd.
7 Tractor Road
Your satisfaction is a primary concern to Caterpillar Jurong, Singapore 627968
and to Cat dealers. If you have a problem that has Republic of Singapore
not been handled to your complete satisfaction,
follow these steps: Phone: 65-662-8333
Fax: 65-662-8302
1. Discuss your problem with a manager from the
dealership. China
Caterpillar China Ltd.
2. If your problem cannot be resolved at the dealer 37/F., The Lee Gardens
without additional assistance, use the phone 33 Hysan Avenue
number below to talk with a Field Service Causeway Bay
Coordinator: G.P.O. Box 3069
Hong Kong
1-800-447-4986 Phone: 852-2848-0333
Fax: 852-2848-0440
The normal hours are from 8:00 to 4:30 Monday
through Friday Central Standard Time. Japan
Caterpillar Japan Ltd.
3. If your needs have not been met still, submit the
SBS Tower
matter in writing to the following address: 10-1, Yoga 4-Chome
Caterpillar Inc. Setagaya-Ku, Tokyo 158-8530
Electric Power North America Japan
Attn: Product Support Manager Phone: 81-3-5717-1150
AC 6109 Fax: 81-3-5717-1177
Mossville, Illinois 61552
Keep in mind: probably, your problem will
ultimately be solved at the dealership, using the
dealership facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a
problem is experienced.
Outside of USA and of Canada

If a problem arises outside of USA and outside
Canada, and if the problem cannot be resolved at the
dealer level, consult the appropriate Caterpillar office.
SEBU7681-22 139
Ordering Replacement Parts
Australia and New Zealand

Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
i01028392
Ordering Replacement Parts

SMCS Code: 4450; 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent speci-
fications including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
Part number
Part name
Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
140 SEBU7681-22
Reference Materials
Reference Materials S/N: LGS1Up

S/N: NGS1Up
i05264255
S/N: HAT1Up
Maintenance Records S/N: CWW1Up
SMCS Code: 1000; 4450 S/N: CWY1Up
S/N: SB31Up S/N: SLY1Up
S/N: FZA1Up S/N: SXY1Up
S/N: GZA1Up S/N: GZZ1Up
S/N: FZB1Up Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
S/N: GSB1Up can be used for the following purposes:
S/N: GZB1Up Determine operating costs.
S/N: TJB1Up
Establish maintenance schedules for other
S/N: FZC1Up engines that are operated in the same
environment.
S/N: GZC1Up
Show compliance with the required maintenance
S/N: TJC1Up practices and maintenance intervals.
S/N: F6D1Up
Maintenance records can be used for various other
S/N: FZD1Up business decisions that are related to engine
maintenance.
S/N: MAD1Up
Maintenance records are a key element of a
S/N: NWD1Up maintenance program that is managed. Accurate
maintenance records can help your Cat dealer to
S/N: F6E1Up fine-tune the recommended maintenance intervals in
order to meet the specific operating situation. This
S/N: FZE1Up should result in a lower engine operating cost.
S/N: F6F1Up Records should be kept for the following items:
S/N: FZF1Up
Fuel Consumption A record of fuel consumption is
S/N: F6G1Up essential in order to determine when the load
sensitive components should be inspected or
S/N: FZG1Up repaired. Fuel consumption also determines overhaul
intervals.
S/N: GZG1Up
Service Hours A record of service hours is
S/N: GZH1Up essential to determine when the speed sensitive
components should be inspected or repaired.
S/N: GZJ1Up
Documents These items should be easy to obtain,
S/N: GZK1Up and these items should be kept in the engine history
S/N: GZL1Up file. All of the documents should show this
information: date, service hours, fuel consumption,
S/N: HAL1Up unit number and engine serial number. The following
types of documents should be kept as proof of
S/N: F6M1Up maintenance or repair for warranty:
S/N: GZM1Up
Keep the following types of documents as proof of
S/N: GZN1Up maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
S/N: B9P1Up
Dealer work orders and itemized bills
S/N: RLP1Up
S/N: GAS1Up Owner repair costs
SEBU7681-22 141
Maintenance Log
Owner receipts
Maintenance log
i03905196
Maintenance Log
SMCS Code: 1000; 4450
Table 32
Engine Model Customer Identifier
Serial Number Arrangement Number
Service
Service Item Date Authorization
Hours
(continued)
142 SEBU7681-22
Valve Data Sheet
(Table 32, contd)
i01745150
Valve Data Sheet

SMCS Code: 1000 S/N: GAS1Up
S/N: SB31Up S/N: LGS1Up
S/N: FZA1Up S/N: NGS1Up
S/N: GZA1Up S/N: HAT1Up
S/N: FZB1Up S/N: CWW1Up
S/N: GSB1Up S/N: CWY1Up
S/N: GZB1Up S/N: SLY1Up
S/N: TJB1Up S/N: SXY1Up
S/N: FZC1Up S/N: GZZ1Up
S/N: GZC1Up
S/N: TJC1Up
S/N: F6D1Up
S/N: FZD1Up
S/N: MAD1Up
S/N: NWD1Up
S/N: F6E1Up
S/N: FZE1Up
S/N: F6F1Up
S/N: FZF1Up
S/N: F6G1Up
S/N: FZG1Up
S/N: GZG1Up
S/N: GZH1Up
S/N: GZJ1Up
S/N: GZK1Up
S/N: GZL1Up
S/N: HAL1Up
S/N: F6M1Up
S/N: GZM1Up
S/N: GZN1Up
S/N: B9P1Up
S/N: RLP1Up
SEBU7681-22 143
Valve Data Sheet
Table 33
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator

Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Inlet Manifold
2 Pushrod Side
Inlet Manifold
3 Pushrod Side
Inlet Manifold
4 Pushrod Side
Inlet Manifold
5 Pushrod Side
Inlet Manifold
6 Pushrod Side
Inlet Manifold
7 Pushrod Side
Inlet Manifold
8 Pushrod Side
Inlet Manifold
9 Pushrod Side
Inlet Manifold
10 Pushrod Side
Inlet Manifold
11 Pushrod Side
Inlet Manifold
12 Pushrod Side
Inlet Manifold
13 Pushrod Side
Inlet Manifold
14 Pushrod Side
Inlet Manifold
15 Pushrod Side
Inlet Manifold
16 Pushrod Side
Inlet Manifold
17 Pushrod Side
Inlet Manifold
18 Pushrod Side
Inlet Manifold
(continued)
144 SEBU7681-22
Reference Material
(Table 33, contd)

19 Pushrod Side
Inlet Manifold
20 Pushrod Side
Inlet Manifold
i04678212 S/N: B9P1Up

S/N: RLP1Up
Reference Material
SMCS Code: 1000; 4450 S/N: GAS1Up
S/N: LGS1Up
S/N: SB31Up
S/N: NGS1Up
S/N: FZA1Up
S/N: HAT1Up
S/N: GZA1Up
S/N: CWW1Up
S/N: FZB1Up
S/N: CWY1Up
S/N: GSB1Up
S/N: SLY1Up
S/N: GZB1Up
S/N: SXY1Up
S/N: TJB1Up
S/N: GZZ1Up
S/N: FZC1Up
The following literature can be obtained through any
S/N: GZC1Up Caterpillar dealer.
S/N: TJC1Up
Coolants
S/N: F6D1Up
S/N: FZD1Up Data Sheet, PEHJ0040, Cat NGEC (Natural Gas
Engine Coolant)
S/N: MAD1Up
Special Publication, PEHJ0191, Cat SOS Fluid
S/N: NWD1Up Analysis
S/N: F6E1Up Special Publication, SEBD0518, Know Your
S/N: FZE1Up Cooling System
S/N: F6F1Up Special Publication, SEBU6400, Caterpillar Gas

Engine Lubricant, Fuel, and Coolant
S/N: FZF1Up Recommendations
S/N: F6G1Up
Fuels
S/N: FZG1Up
S/N: GZG1Up Application and Installation Guide, LEKQ7256,
Fuels, Fuel Systems
S/N: GZH1Up
Application and Installation Guide, LEKQ7260,
S/N: GZJ1Up Low Energy Fuels
S/N: GZK1Up Data Sheet, LEKQ2364, US Stationary Engine
S/N: GZL1Up Regulations/Spark Ignited Emissions
S/N: HAL1Up Data Sheet, LEKQ5404, Fuels Specifications

Changes
S/N: F6M1Up
Data Sheet, LEKQ9360, Internal Combustion
S/N: GZM1Up Engine Fuel Gases
S/N: GZN1Up
SEBU7681-22 145
Reference Material
Special Publication, SEBU6400, Caterpillar Gas Installation and Operation Manual, SEBU7630,
Engine Lubricant, Fuel, and Coolant Raptor Gas Regulation and Metering Valve/
Recommendations Actuator System for Caterpillar
Operation and Calibration Manual, SEBU7631,

Lubricants Tecjet Gas Control Valve
Grease Schematic, RENR5955, G3520C and G3520E
Engine Electrical System
Data Sheet, NEHP6010, Cat Ultra 5Moly
Grease Schematic, RENR5981, G3520C Generator
Electrical System
Data Sheet, NEHP6011, Cat Arctic Platinum
Engines
Data Sheet, NEHP6012, Cat Desert Gold
Generator with wall mount EMCPII+
Data Sheet, NEHP6015, Cat High Speed Ball
Bearing Grease Service Manual, RENR5975, G3500C and
G3500E Generator Sets
Data Sheet, PEHJ0088, Cat Multipurpose
Grease Software Program, LEKQ6378, Methane Number
Program
Data Sheet, PEHP0002, Cat Advanced 3Moly
Grease Special Instruction, REHS1438, Installation and
Initial Start-up Procedure for G3500C and G3500E
Special Publication, PEGJ0035, Grease Engines.
Selection Guide
Special Instruction, SEHS9124, Cleaning &
Oil Drying of Electric Set Generators
Data Sheet, PEHJ0006, Cat NGEO (Natural Gas Special Instruction, GMG00694, Analyzing
Engine Oil) EL350 (SAE 40) Cylinder Condition By Measuring Air Flow
Data Sheet, PEHP0004, Cat NGEO (Natural Gas Special Instruction, REHS0128, Using the
Engine Oil) (SAE 30, SAE 40) 147-5482 Valve Lash Gauge Group For Valve
Lash and Valve Bridge Adjustment
Special Publication, PEHJ0191, Cat SOS Fluid
Analysis Special Instruction, REHS0177, Alignment of the
Close Coupled Two-Bearing Generators
Special Publication, PEHP6001, How To Take A
Good Oil Sample Special Instruction, SEHS7259, Alignment of
Single-Bearing Generators
Special Publication, SEBU6400, Caterpillar Gas
Engine Lubricant, Fuel, and Coolant Special Instruction, SEHS7332, Do Not Operate
Recommendations Tag
Special Instruction, SEHS7633, Battery Test
Miscellaneous Procedure
Application and Installation Guide, LEKQ7250, Special Instruction, SEHS7654, Alignment -

Air Intake General Instructions
Data Sheet, LEKQ4023, Linear Vibration Special Instruction, SEHS8712, Using the
8T-2700 Blowby/Air Flow Indicator
Disassembly and Assembly, RENR5980,
G3500C and G3500E Engines Special Instruction, SEHS8984, Using the
1U-8860 Blowby Pickup Group
Engine Performance, LEBQ6117, G3500
Industrial Special Instruction, SEHS9031, Storage
Procedure for Caterpillar Products
Engine Performance, LEBQ6169, G3500
Generator Set Special Instruction, SEHS9298, Installation and
Maintenance of Gaseous Fuel Filters
146 SEBU7681-22
Decommissioning and Disposal
Special Publication, NEHS0526, Service The American Petroleum Institute Publication No.
Technician Application Guide 1509 can be obtained from the following locations:
local technological society, local library and local
Special Publication, NENG2500, Cat dealer college. If necessary, consult API at the following
Service Tools Catalog address:
Special Publication, PECP9067, One Safe American Petroleum Institute

Source 1220 L St. N.W.
Washington, DC, USA 20005
Special Publication, SEBF8029, Index to Telephone (202) 682-8000
Guidelines for Reusable Parts and Salvage
Operations The International Organization for Standardization
(ISO) offers information and customer service
Special Publication, SEBF8062, Procedure to regarding international standards and standardizing
Inspect and Clean Air Filters activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
Specifications, RENR5977, G3500C and G3500E national standards, regional standards, regulations,
Engines certification and related activities. Consult the
member of ISO in your country.
Specifications, SENR3130, Torque
Specifications International Organization for Standardization
(ISO)
Systems Operation/Testing and Adjusting, 1, rue de Varemb
RENR5978, G3500C and G3500E Engines Case postale 56
CH-1211 Genve 20
Systems Operation/Testing and Adjusting, Switzerland
SENR5833, Digital Voltage Regulator Telephone +41 22 749 01 11
Facsimile +41 22 733 34 30
Troubleshooting, RENR5944, G3516C and E-mail central@iso.ch
G3516E Engines web site http://www.iso.ch
Troubleshooting, RENR5979, G3520C and European classifications are established by the
G3520E Engines Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
Additional Reference Material
CIMAC Central Secretariat
The Engine Fluids Data Book can be obtained from
the following locations: local technological society, Lyoner Strasse 18
local library and local college. If necessary, consult 60528 Frankfurt
EMA at the following address: Germany
Telephone +49 69 6603 1567
Engine Manufacturers Association Facsimile +49 69 6603 1566
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602 i03989612
E-mail: ema@enginemanufacturers.org
(312) 827-8700 Decommissioning and
Facsimile: (312) 827-8737
Disposal
The Society of Automotive Engineers (SAE) SMCS Code: 1000
Specifications can be found in your SAE handbook.
This publication can also be obtained from the S/N: SB31Up
following locations: local technological society, local
library and local college. If necessary, consult SAE at S/N: FZA1Up
the following address:
S/N: GZA1Up
SAE International
400 Commonwealth Drive S/N: FZB1Up
Warrendale, PA, USA 15096-0001 S/N: GSB1Up
Telephone (724) 776-4841
S/N: GZB1Up
S/N: TJB1Up
S/N: FZC1Up
SEBU7681-22 147
Decommissioning and Disposal
S/N: GZC1Up
S/N: TJC1Up
S/N: F6D1Up
S/N: FZD1Up
S/N: MAD1Up
S/N: NWD1Up
S/N: F6E1Up
S/N: FZE1Up
S/N: F6F1Up
S/N: FZF1Up
S/N: F6G1Up
S/N: FZG1Up
S/N: GZG1Up
S/N: GZH1Up
S/N: GZJ1Up
S/N: GZK1Up
S/N: GZL1Up
S/N: HAL1Up
S/N: F6M1Up
S/N: GZM1Up
S/N: GZN1Up
S/N: B9P1Up
S/N: RLP1Up
S/N: GAS1Up
S/N: LGS1Up
S/N: NGS1Up
S/N: HAT1Up
S/N: CWW1Up
S/N: CWY1Up
S/N: SLY1Up
S/N: SXY1Up
S/N: GZZ1Up
When the product is removed from service, local
regulations for the product decommissioning will
vary. Disposal of the product will vary with local
regulations. Consult the nearest Cat dealer for
additional information.
148 SEBU7681-22
Index Section
Index
A Draining the Cooling System ....................... 82
Fill the Cooling System ................................ 84
After Starting Engine ....................................... 46
Coolant Level - Check ............................... 8485
Engaging the Driven Equipment.................. 46
Add Coolant ........................................... 8485
After Stopping Engine ..................................... 58
Coolant Sample (Level 1) - Obtain.................. 85
Aftercooler Condensation - Drain.................... 78
Coolant Sample (Level 2) - Obtain.................. 86
Air Tank Moisture and Sediment - Drain ......... 78
Cooling System Supplemental Coolant
Alarms and Shutoffs ........................................ 27
Additive (SCA) - Test/Add.............................. 86
Setpoints for Alarms and Shutoffs ............... 27
Add the SCA, If Necessary .......................... 87
Testing Alarms and Shutoffs........................ 27
Test the Concentration of the SCA .............. 86
Alternator - Inspect .......................................... 78
Crankcase Blowby - Test/Record .................... 87
Automatic Start/Stop - Inspect ........................ 78
Crankcase Pressure - Measure (Engines
with Fumes Disposal Filters) ......................... 88
B Crankshaft Vibration Damper - Inspect........... 88
Battery - Recycle ............................................. 79 Damper Fluid Sampling ............................... 89
Battery - Replace............................................. 79 Removal and Installation ............................. 89
Battery Electrolyte Level - Check .................... 79 Crankshaft Vibration Damper - Inspect
Battery or Battery Cable - Disconnect............. 80 (1500 RPM G3520 engines (if equipped
Before Starting Engine .............................. 14, 42 with an oil fed damper)) ................................. 89
Air Inlet System............................................ 42 Crushing Prevention and Cutting Prevention.. 13
Cooling System............................................ 42 Customer Assistance .................................... 138
Driven Equipment ........................................ 42 Outside of USA and of Canada ................. 138
Electrical System ......................................... 42 USA and Canada....................................... 138
Fuel System................................................. 42 Customer Service.......................................... 138
Lubrication System ...................................... 43 Cylinder Pressure - Test/Record ..................... 90
Starting System ........................................... 43
Walk-Around Inspection .............................. 42 D
Belts - Inspect/Adjust/Replace ........................ 80
Declaration of Conformity................................ 20
Adjusting the Alternator Belt ........................ 80
Decommissioning and Disposal.................... 146
Adjusting the Fan Drive Belt ........................ 81
Inspection .................................................... 80
Replacement................................................ 81 E
Burn Prevention................................................11 Electrical System............................................. 15
Batteries....................................................... 12 Grounding Practices .................................... 15
Coolant .........................................................11 Electronic Modular Control Panel II+
Oils............................................................... 12 (EMCP II+)..................................................... 28
Alarm Module............................................... 34
C Custom Alarm Module ................................. 35
Generator Set Control + (GSC+) ................. 30
Carburetor Air/Fuel Ratio - Check/Adjust........ 81
Synchronizing Lights Module ...................... 35
Cold Weather Starting ..................................... 43
Emergency Stopping....................................... 57
Compressor Bypass - Check .......................... 81
Emergency Stop Button............................... 57
Configuration Parameters ............................... 40
Unplanned Shutdowns ................................ 57
Air/Fuel Ratio ............................................... 40
Engine Air Cleaner Service Indicator -
Oil Consumption .......................................... 41
Inspect ........................................................... 91
Coolant (NGEC) - Change .............................. 81
Test the Service Indicator ............................ 91
Clean the Cooling System ........................... 83
Engine Crankcase Breather - Clean ............... 92
Cleaning a Cooling System that has Heavy
Engine Diagnostics ......................................... 40
Deposits or Plugging.................................. 83
SEBU7681-22 149
Index Section
Engine Mounts - Inspect.................................. 93 Fumes Disposal Filter Element - Replace..... 101

Engine Oil - Change ........................................ 93
Engine Oil Filter - Change ............................... 94 G
Inspect the Used Oil Filter Elements ........... 95
Replace the Oil Filter Elements ................... 94 Gas Pressure Regulator Condensation -
Engine Oil Level - Check................................. 96 Drain ............................................................ 102
Engine Oil Sample - Obtain............................. 97 General Hazard Information.............................. 8
Obtain the Sample and the Analysis ........... 97 Containing Fluid Spillage............................. 10
Engine Oil Temperature Regulator - Dispose of Waste Properly ...........................11
Replace ......................................................... 97 Fluid Penetration ......................................... 10
Engine Operation ............................................ 47 Inhalation ..................................................... 10
Operating the Engine and the Driven Lines, Tubes, and Hoses ............................. 10
Equipment.................................................. 47 Pressurized Air and Water............................. 9
Partial Load Operation................................. 47 Softwrap........................................................11
Engine Protective Devices - Check................. 98 General Information ........................................ 17
Calibration Check ........................................ 98 General Maintenance Information................... 62
Visual Inspection.......................................... 98 Space Heaters ............................................. 62
Engine Speed/Timing Sensor - Clean/ Generator - Dry.............................................. 102
Inspect ........................................................... 98 Drying Methods.......................................... 103
Fixed head sensors (if equipped) ................ 98 Generator - Inspect ....................................... 104
Slip head sensors (if equipped) ................... 98 Cleaning (Assembled Generators) ............ 104
Engine Starting.......................................... 14, 42 Cleaning (Disassembled Generators) ....... 105
Engine Stopping ........................................ 15, 57 Generator Bearing - Inspect.......................... 105
Engine Valve Lash and Bridge - Check........... 99 Generator Bearing - Lubricate....................... 107
Engine Valve Lash ....................................... 99 Additional Information................................. 111
Valve Bridge................................................. 99 Procedure for Bearing Service .................. 107
Record .......................................................... 111
F
Infrared Thermometers...............................112
Features and Controls..................................... 27 Resistive Temperature Detectors (RTDs) ..112
Fire Prevention and Explosion Prevention...... 12 Generator Isolating for Maintenance............... 15
Fire Extinguisher.......................................... 13 Generator Lead - Check.................................112
Lines, Tubes, and Hoses ............................. 13 Generator Load - Check.................................112
Flexible Coupling - Inspect ............................ 100 Generator Operation ....................................... 48
Coupling Boot Maintenance ...................... 100 Block Loading and Transient Capability ...... 48
Fluid Recommendations ................................. 59 Excitation Systems ...................................... 49
Coolant Recommendations ......................... 60 Loading of the Generator............................. 48
Fuel Recommendations .............................. 60 Low Idle Adjustment .................................... 49
Lubricant Recommendations....................... 59 Options ........................................................ 50
Foreword ........................................................... 4 Power Factor ............................................... 49
California Proposition 65 Warning ................. 4 Standby Generator Sets .............................. 49
Literature Information .................................... 4 Generator Set - Test .......................................113
Maintenance .................................................. 4 Generator Set Alignment - Check
Maintenance Intervals ................................... 4 (Generator Sets)...........................................113
Operation ....................................................... 4 Generator Set Vibration - Inspect...................114
Overhaul ........................................................ 4 Generator Start-up Checklist........................... 65
Safety............................................................. 4 Generator Winding - Test ...............................114
Fuel Filter Differential Pressure - Check ....... 100 Generator Winding Insulation - Test...............115
Fuel Metering Valve - Check (Raptor ) .......... 100 Recommended Periodic Insulation Tests ...115
Fumes Disposal Filter - Drain........................ 101 Recommended Procedure for the Insulation
Fumes Disposal Filter Differential Pressure Test............................................................116
- Check ........................................................ 101
150 SEBU7681-22
Index Section
H Between 10 000 and 20 000 Service

Hours ......................................................... 69
Hoses and Clamps - Inspect/Replace............118
Inspect Tubes, Hoses, Bellows, and
Hours ......................................................... 69
Clamps......................................................118
Replace the Hoses and the Clamps ...........118
Hours ......................................................... 69
Daily ............................................................. 68
I Every 10 000 Service Hours ........................ 69
Ignition System Timing - Check/Adjust ......... 120 Every 1000 Service Hours........................... 69
Ignition Systems .............................................. 14 Every 2000 Service Hours........................... 69
Important Safety Information............................. 2 Every 24 000 Service Hours or 3 Years....... 69
Inlet Air System - Check................................ 120 Every 250 Service Hours ............................. 68
Installation ....................................................... 25 Every 3000 Service Hours........................... 69
Every 4000 Service Hours........................... 69
Every 8000 Service Hours........................... 69
J
Initial 250 Service Hours.............................. 68
Jacket Water Heater - Check ........................ 121 When Required............................................ 68
Maintenance Interval Schedule (Standby)
L Between 10 000 and 20 000 Service
Hours ......................................................... 71
Lifting and Storage .......................................... 23 Daily ............................................................. 70
Every 10 000 Service Hours ........................ 71
M Every 1000 Service Hours........................... 71
Maintenance Interval Schedule.... 68, 70, 72, 74, Every 1000 Service Hours or 6 Months....... 71
76 Every 2000 Service Hours........................... 71
Between 10 000 and 20 000 Service Every 250 Service Hours ............................. 70
Hours ............................................. 73, 75, 77 Every 3 Years............................................... 71
Between 22 000 and 40 000 Service Every 4000 Service Hours........................... 71
Hours ......................................................... 75 Every Week ................................................. 70
Between 22 500 and 24 000 Service Every Year ................................................... 71
Hours ................................................... 73, 77 When Required............................................ 70
Between 37 500 and 40 000 Service Maintenance Log........................................... 141
Hours ................................................... 73, 77 Maintenance Recommendations .................... 62
Between 45 000 and 80 000 Service Maintenance Records ................................... 140
Hours ......................................................... 75 Maintenance Section....................................... 59
Between 7500 and 8000 Service Hours..... 73, Manual Stop Procedure .................................. 57
77 Model View Illustrations .................................. 17
Daily ................................................. 72, 74, 76 Typical Example........................................... 18
Every 10 000 Service Hours ............ 73, 75, 77 Mounting and Dismounting ............................. 14
Every 1000 Service Hours............... 72, 74, 76
Every 2000 Service Hours............... 72, 74, 76 O
Every 24 000 Service Hours or 3 Years...... 73, Operation Section............................................ 23
75, 77 Ordering Replacement Parts......................... 139
Every 250 Service Hours ................. 72, 74, 76 Overhaul (In-Frame)...................................... 121
Every 3000 Service Hours..................... 73, 75 In-Frame Overhaul Information ................. 121
Every 4000 Service Hours............... 73, 75, 77 Scheduling an In-Frame Overhaul ............ 121
Every 8000 Service Hours............... 73, 75, 77 Overhaul (Major) ........................................... 122
Initial 250 Service Hours.................. 72, 74, 76 Major Overhaul Information ....................... 122
When Required................................ 72, 74, 76 Scheduling a Major Overhaul .................... 122
Maintenance Interval Schedule (Prime) Overhaul (Top End) ....................................... 123
SEBU7681-22 151
Index Section
Scheduling a Top End Overhaul ................ 123 Coolants..................................................... 144

Top End Overhaul Information................... 124 Fuels .......................................................... 144
Overhaul Considerations............................... 126 Lubricants .................................................. 145
Overhaul Information ................................. 126 Miscellaneous ............................................ 145
Reference Materials ...................................... 140
P Refill Capacities............................................... 59
Coolant Capacities ...................................... 59
Parallel Operation............................................ 51 Lubricant Capacities .................................... 59
Circulating Currents..................................... 54 Rotating Rectifier - Check ............................. 128
Initial Start-Up .............................................. 51 Testing a Three-Diode Rectifier Block ....... 128
Parallel Operation Of Governors ................. 53
Paralleling Multiple Units ............................. 53
S
Speed Droop for the Load Division (If
Equipped)................................................... 53 Safety Messages............................................... 5
Starting Multiple Units.................................. 53 Automatic Starting (6).................................... 7
Stopping....................................................... 54 Electrical Distribution (5)................................ 7
Plate Locations and Film Locations ................ 20 Electrical Shock (2)........................................ 6
Engine Information (1) ................................. 20 Hot Surface (3) .............................................. 6
Engine Serial Number (2) ............................ 20 Hot Surface (4) .............................................. 7
Generator Identification (3).......................... 20 Lifting the Genset (7) ..................................... 8
Power Factor - Check.................................... 127 Read the Manual (1) ...................................... 6
Product Description ......................................... 18 Safety Section ................................................... 5
Description of the Generator ....................... 19 Sensors and Electrical Components............... 36
Engine Description ...................................... 19 Electronic System ........................................ 36
Intended Use ............................................... 19 Sensors........................................................ 37
Island Mode and Coal Mine Methane (CMM) Single Unit Operation ...................................... 50
application.................................................. 19 Initial Start-Up .............................................. 50
Product Identification Information ................... 20 Starting ........................................................ 50
Product Information Section............................ 17 Stopping....................................................... 51
Product Installation.......................................... 25 Space Heater - Test....................................... 129
Alignment..................................................... 26 Spark Plugs - Inspect/Replace...................... 129
Bearing Inspection....................................... 25 Cleaning the Spark Plug............................ 131
Electrical Measurements ............................. 26 Inspecting the Spark Plug.......................... 131
Location ....................................................... 25 Installing the Spark Plug............................ 131
Protective Devices....................................... 26 Removing the Spark Plug.......................... 130
Receiving Inspection ................................... 25 Starting Motor - Inspect ................................. 132
Storage ........................................................ 25 Air Starting Motor....................................... 132
Unpacking and Storage ............................... 25 Electric Starting Motor ............................... 132
Product Lifting ................................................. 23 Removal and Installation of the Starting
Lifting the Engine Only................................. 23 Motor ........................................................ 132
Lifting the Entire Package............................ 23 Starting the Engine.......................................... 44
Lifting the Generator Only ........................... 23 Automatic Starting ....................................... 44
Product Storage .............................................. 23 Manual Starting............................................ 45
Generator Storage....................................... 24 Parameters for the Start/Stop Control ......... 44
Purging Unburned Gas................................ 44
R Starting with Jump Start Cables...................... 45
Stator Lead - Check ...................................... 133
Radiator - Clean ............................................ 127 Stator Winding Temperature - Test ............... 133
Reference Information..................................... 22 System Pressure Release............................... 63
Reference Information Section ..................... 138 Coolant System ........................................... 63
Reference Material ........................................ 144 Engine Oil .................................................... 63
Additional Reference Material ................... 146
152 SEBU7681-22
Index Section
Fuel System................................................. 63
T
Table of Contents .............................................. 3
Throttle Control Valve - Check ...................... 133
Turbocharger - Inspect .................................. 133
V
Valve Data Sheet........................................... 142
Valve Stem Projection - Measure/Record ..... 135
Voltage and Frequency - Check.................... 136
Voltage Regulators .......................................... 55
Adjustment Procedure for the Voltage
Regulators.................................................. 55
W
Walk-Around Inspection ................................ 136
Inspect the Engine for Leaks and for Loose
Connections ............................................. 136
Inspect the Generator................................ 137
Water Pump - Inspect.................................... 137
Welding on Engines with Electronic
Controls ......................................................... 63
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:
SEBU7681 CAT, CATERPILLAR, their respective logos, Caterpillar Yellow, and the POWER EDGE trade
2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
154 November 2016

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SEBU7681-22 (en-us)

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Engine Stopping .............................................. 57

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

Ignition Systems .............................................. 14 Reference Information Section

Before Starting Engine .................................... 14 Customer Service.......................................... 138

Engine Starting................................................ 14 Reference Materials ...................................... 140

Engine Stopping .............................................. 15 Index Section

Electrical System............................................. 15 Index.............................................................. 148

Generator Isolating for Maintenance............... 15

Product Information Section

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

Product Identification Information ................... 20

Lifting and Storage .......................................... 23

Features and Controls..................................... 27

Engine Diagnostics ......................................... 40

Engine Operation ............................................ 47

Generator Operation ....................................... 48

Foreword Recommended service should be performed at the

Maintenance California Proposition 65 Warning

There are several specific safety messages on this

Make sure that all of the safety messages are legible.

Read the Manual (1)

Hot Surface (3)

Do not operate or work on this engine or genera-

Electrical Shock (2)

Do not connect the generator to a utility electrical

Automatic Starting (6)

Hot surface! Do not touch!

Electrical Distribution (5)

When the engine is in the AUTOMATIC mode, the

General Hazard Information

.Attach a Do Not Operate warning tag to the start

Pressurized Air and Water

Do not wear loose clothing or jewelry that can

Ensure that all protective guards and all covers

Wire that is exposed in reinforced hose

Flexible part of the hose that is kinked or crushed

Containing Fluid Spillage

Refer to Special Publication, NENG2500, Cat Dealer

Never use compressed air for cleaning.

Avoid grinding materials that contain asbestos.

A vacuum cleaner that is equipped with a high

Use exhaust ventilation on permanent machining

Check lines, tubes, and hoses carefully. Do not use

End fittings are damaged or leaking.

Wires are exposed.

Outer covers have embedded armoring.

i01377941 Before starting the engine, ensure that no one is on,

Grounding Practices Illustration 17 g00104545

6. Attach a DO NOT OPERATE or similar warning

Model View Illustrations

(1) Oil filler (6) Throttle (11) Fuel inlet

Intended Use Lubrication System

Product Identification Full load RPM

Information Engine Serial Number (2)

Generator Identification (3)

Generator serial number

Generator set rating

Engine Information (1)

SMCS Code: 1000

EC DECLARATION OF CONFORMITY OF MACHINERY